PT. MEDCO ENERGI KERAMASAN GAS RECEIVING FACILITY
DESIGN BASIS
0
02-05-2008
Approved for Construction
RHM
DNU
SAS
B
11-04-2008
Issued for Approval
RHM
DNU
SAS
REV.
DATE
DESCRIPTION
BY
CHK’D
CHK’D
KELSRI
APPV’D
MEDCO ENERGI
STATUS CODE : A= Issued for Approval ; B= Approved For Construction ; C= As – Built ; I= Issued for Information ; X= Document Cancelled Total Or Partial Reproduction And / Or Utilization of This Document Are Forbidden Without Prior Written Authorization of The Owner
ENGINEERING PROCUREMENT CONSTRUCTION COMMISSIONING
KRS-R-RE-001
PT. KELSRI 0708-R-RE-001
SUBCONTRACT NO. : BF 2691
STATUS
REVISION
B
0
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DESIGN BASIS 0708-R-RE-001
TABLE OF CONTENTS
INDEX
Pages
1. Introduction
4
2. Codes & Standard
4
3. Unit Measurement
4
4. Design Data
5
5. Facilities Description
7
5.1.
Process Facilities
7
5.2.
Utilities
9
6. Design Criteria
9
6.1.
Design Life
9
6.2.
Line Sizing
9
6.3.
Vessel
10
6.4.
Gas Filter
10
6.5.
Relief System
10
6.6.
Flare System
10
6.7.
Compressed Air System
10
6.8.
Utility Water
11
6.9.
Fire Safety System
11
7. Control & Shutdown System
11
8. Attachment
12
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DESIGN BASIS 0708-R-RE-001
1. INTRODUCTION PT Medco E&P Indonesia is planning to supply gas to PLTG Keramasan. The supplied gas will be tied in from existing 6” pipeline from Simpang Keramasan to PLTG Keramasan. For future additional gas supply, 8” pipeline will be installed parallel with the existing 6” pipeline by Pertamina. In order to achieve delivered gas minimum specification, PT Medco E&P Indonesia is planning to install a receiving facility in the downstream of the pipeline. This receiving facility will have functions i.e. separate liquid (condensate and water) from the gas, minimize liquid particle diameter and measure the supplied gas for billing purpose. This receiving facility will be named as Keramasan Gas Receiving Facilities. This document provides information relevant to process design basis for Keramasan Gas Receiving Facilities. 2. CODES & STANDARD The following is a list of general recommended practices, codes and standard shall be used in the detailed engineering design. In addition to these codes and standards, all Indonesian governmental and regulatory agency requirements and regulations shall be applied. The most current version of these codes and standards shall be used. MES
:
Medco Engineering Standard
ANSI
:
American National Standards Institute
ASME
:
American Society of Mechanical Engineers
SNI
:
Standard National Indonesia
NACE
:
National Association of Corrosion Engineers
API
:
American Petroleum Institute
NEC
:
National Electric Code
NFPA
:
National Fire Protection Association
3. UNIT MEASUREMENT US Customary Unit shall be used for all design, drawing and specification. Standard conditions for process calculation are 14.7 psia Page 4 of 11
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and 60°F. In general, the following units and abbreviations shall be used:
Application Area Density Flow Rate (Mass) Flow Rate (Volume) Gas
Liquid
Unit Square Feet Pounds per Cubic Foot Pounds per Hour
Abbreviations ft2 lb/ft3 lb/hr
Million Standard Cubic Feet Per day Standard Cubic Feet per Minutes Barrels per Day Barrels Fluid per Day (Well or Mixed
MMscfd SCFM BPD
Fluid) Barrels Water per Day (water) Gallon per Minute Feet British Thermal Unit Feet Inch Feet Pound Kilowatt Horse Power Pound per Square Inch Pound per Square Inch Absolute Pound per Square Inch Gauge British Thermal Unit per ft per hour Degrees Fahrenheit Seconds Minute Hour Feet per second Barrels (Petroleum) Cubic Feet Gallons (US) CentiPoise
Head Heat Elevation Length Mass Power Pressure Radiation Temperature Time Velocity Volume Viscosity
BFPD BWPD GPM Ft Btu Ft In Ft Lb kW HP Psi Psia Psig Btu/fr2/hr °F Sec Min Hr Fps Bbl ft3 Gal. cP
4. DESIGN DATA 4.1.1.
Site Location Keramasan Gas Receiving Facilities site location is planned at PLTG Keramasan Company’s area, Palembang, South Sumatera, Indonesia.
4.1.2.
Ambient Data a. ambient pressure
: 14.7 psi (1 atm) Page 5 of 11
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b. ambient temperature 4.1.3.
: 75 – 100 °F
Inlet Gas Data Data of inlet gas for Keramasan Gas Receiving Facilities is referred to “PFD” for Looping Pipeline Simpang Y Keramasan, “supplied by Pertamina, dated February 23, 2007 (see attachment) and listed bellow: a. Pressure
: 450 psig
b. Temperature
: 73 °F
c. Composition
: (dry basis)
COMPONENT METHANE ETHANE PROPHANE I-BUTANE N-BUTANE I-PENTANE N-PENTANE N-HEXANE N-HEPTANE N-OCTANE NITROGEN CARBON DIOXIDE 4.1.4.
UNIT % MOL % MOL % MOL % MOL % MOL % MOL % MOL % MOL % MOL % MOL % MOL % MOL
VALUE 85.36 5.64 2.81 0.38 0.45 0.18 0.13 0.03 0.00 0.00 0.00 5.00
Design Capacity Based on “Notulen Rapat Pembahasan Draft Amandemen PJBG Pusat Listrik Keramasan” dated April 19, 2007, committed gas deliverability is 22.3 BBTUD (see attachment). Design capacity of Keramasan Gas Receiving Facilities is MMscfd of Gas and 250 BPD of liquid.
4.1.5.
Sales Gas Specification Specifications of sales gas for Keramasan Gas Receiving Facilities is referred to “Specifikasi Gas Bumi untuk Pusat Listrik Keramasan sesuai PJBG” (see attachment) and listed bellow:
COMPONENT METHANE ETHANE PROPHANE BUTANE C5+ N2 CO2
UNIT % MOL % MOL % MOL % MOL % MOL % MOL % MOL
VALUE MINIMUM MAXIMUM 74 100 5 5 5 2 1 10 Page 6 of 11
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H2S KADAR AIR TEMPERATURE NILAI KALOR KOTOR TEKANAN DI TITIK PENYERAHAN
ppm lb/MMSCFD °C BTU/SCF psig
20 950 280
2 10 40 1200 350
5. FACILITIES DESCRIPTION 5.1. Process Facilities Keramasan process facilities consist of Gas Scrubber, Gas Filter, Metering System, Condensate System and Flare System. a. Gas Scrubber Keramasan Gas Receiving Facilities receives gas from the existing 6” diameter and 3.3 km length Simpang Keramasan – Keramasan pipeline with incoming pressure of 450, approximately. The pressure of gas will be reduced to 300 – 370 psig using pressure control valve before enter to gas scrubber. Gas enters gas scrubber for gas-liquid separation process. The function of this gas scrubber is to remove entrained liquid from the gas stream. The gas product will pass through the top this vertical separator with mist extractor and the design pressure is 700 psig and 160°F.
b. Gas Filter Gas from the top of gas scrubber will enter gas filter. The function of this filter is to achieve the diameter requirement. The filtration efficiency is 99% removal droplet @ 0.5-micron maximum solid & liquid. The gas outlet gas filter is sent to the metering system for further handling. Design pressure of gas filter is 700 psig @ 160°F. c. Metering System The gas outlet filter is then measured at a gas metering system before transferred to PLTG Keramasan. The metering system used for this measurement is custody metering system type complete with gas chromatography and moisture analyzer. The metering installation shall follow AGA-3 requirement and the gas chromatography shall follow AGA-8 requirement. Design pressure of Gas Metering is 700 psig @ 160°F. d. Condensate System Page 7 of 11
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This system consists of condensate drum and recovery pump. Liquid product from gas scrubber, gas filters and others will be sent to KO Drum before transferred and stored to condensate drum. After the liquid maintain a specific level at condensate drum, the liquid is then pumped to an unloading truck using recovery pump. e. Drain System Closed drain system shall be provided to collect the entire hydrocarbon inventory for disposal. Low point drain connections are provided at Gas Scrubber, Filter, and Condensate Tank. Closed drain system consist of closed drain line, header and pond. An open drain system is also provided to collect the wash water in the facilities areas. These are routed to the rainwater collection that completed with control box. f.
Flare System Flare system is provided for safe disposal of waste hydrocarbon vapour which are generated during plant upset, emergency and shut down condition. Flare system consist of a flare header, flare KO drum (horizontal type, without mist extractor), flare KO drum pump, and multiple-jet enclosed flare complete with a flare ignition system. Flare gas is released to flare header through Pressure Control Valve (PCV), or blow down during emergency.
0
Flare gas is then sent to flare K.O. drum for liquid-gas separation. Liquid product, drain, is transferred to condensate system using flare KO drum pump.
0
5.2. Utilities Utilities for Keramasan Receving Facilities consist of compressed air system, electricity power, fresh water and fire safety system. a. Compressed Air System Compressed air system is used to produce clean, oil free and dry air for instrument air, utility air and diaphragm pump driven. This system consists of air compressors, air dryers and air receiver. Ambient air is compressed using air compressor to produce compressed air. The compressed air is then dehydrated in the air dryer. The air dryer is used to separate Page 8 of 11
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condensed moisture from the compressed air. Dry air is then stored at air receiver for instrument air, utility air and air pump driver purpose. b. Electric Power Main electric power will be provided by PT. PLN (Persero). Emergency electric power will be provided by the power plant contractor, PT. Asta Keramasan Energy. UPS shall be provided for temporary power supply to the metering system in case of power loss. c. Utility Water Water is used for utility purpose. A deep well be used for fresh water source and shall be provided with water tank and plumbing system. d. Fire Safety System Fire safety system shall be provided for both light and heavy fire fighting. Fire safety system for light fire case is provided by portable gas fire extinguishers. Fire safety system for heavy fire case is provided by fusible loop. This loop is connected with ESD system. When heavy fire case occurs in Keramasan Gas Receiving Facilities, fusible loop will trigger ESD system to shut down the facility.
6. DESIGN CRITERIA 6.1. Design Life The facility is designed for a 15-year design life. 6.2. Line Sizing Process line sizing and criteria shall refer to International API Standards, RP 14E, Recommended Practice for Design and Installation of Offshore Production Platform Piping Systems and PT. Medco E&P Indonesia Engineering Standard MEP-P-ES-001, Standard Specification for Piping Material Specification. 6.3. Vessel
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Vessel Sizing and design criteria shall refer to International API Standards, RP 12J, Specification for Oil and Gas Separator. Vessel sizing and criteria shall also refer to PT. Medco E&P Indonesia Engineering Standard MEP-R-ES-001, Standard Specification for Vapor Liquid Separator. For special case, K.O. Drum sizing shall also refer to API 521, Guide for Pressure-Relieving and Depressuring Systems. 6.4. Gas Filter Gas filter sizing and criteria shall refer to PT. Medco E&P Indonesia Engineering Standard MEP-R-ES-003, Standard Specification for Fuel Gas Separator and Filter. 6.5. Relief System Relief gas system including relief valve and blow down calculation and criteria shall refer to International API Standards RP 520, Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries; Part I – Sizing and RP 521, Guide for Pressure-Relieving and Depressuring Systems. 6.6. Flare System Flare system criteria including the ignition system shall refer to international API STD 521, Guide for Pressure-Relieving and Depressuring Systems. Flare system and API STD 537, Flare Details for General Refunery and Petrochemical Service.
6.7. Compressed Air System Criteria of all equipments included in instrument air system such as air compressor, air filter, air dryer and air receiver shall refer to standards as follow: a. API STD 618, Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services. b. API STD 619, Rotary Type Positive Displacement Compressors for Petroleum, Chemical, and Gas Industry Services. c. MEP-M-ES-004, Standard Specification for Instrument Air Compressor Package. d. MEP-I-ES-001, Standard Specification for Engineering and Design of Instrument System. Page 10 of 11
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e. API 550 & Vendor Catalogue for Air Demand Calculation. f.
ANSI/ISA – 7.0.01 – 1996, Quality Standard for Instrument Air.
6.8. Utility Water Utility water criteria shall refer to local standard, i.e. PDAM Standard. 6.9. Fire Safety System Fire safety system and fire fighting equipment shall refer to PT. Medco E&P Indonesia Engineering Standard MEP-F-ES-001, Standard Specification for General Fire and safety and MEP-F-ES-003, Standard Specification for Portable & Auxiliary Fire Fighting Equipment. 7. CONTROL & SHUTDOWN SYSTEM Control, alarm and shutdown system will use pneumatic system. New pneumatic panel will be provided for alarm and shutdown system. Shutdown level shall developed with initial outline of the expected hierarchy:
Unit Shutdown
Process Shutdown (PSD), which will shut off process inflow and outflow of the facility and initiate gas inventory depressurizing.
Emergency Shutdown (ESD), which will intake process shutdown and blowdown gas from system to annunciate fire/emergency alarm.
B
PSD will be triggered by push/pull button. ESD will be triggered by ESD push/pull Button and fusible loop.
8. ATTACHMENT A.
PFD for Looping Pipeline Simpang Y Keramasan
B.
Notulen Rapat Pembahasan Draft Amandemen PJBG Pusat Listrik Keramasan dated April 19, 2007.
C.
Spesifikasi Gas Bumi untuk Pusat Listrik Keramasan sesuai PJBG.
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