9801-PRO-DBM-001 Process Design Basis A0. Complete

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PROYEK PEMANFAATAN GAS AIR SERDANG - BERINGIN

PROCESS DESIGN BASIS

0 06-06-2001 Issued for Design ABI JHN DAGB 08-05-2001 Issued for Approval ABI JHN DAGA 06-04-2001 Issued for Review ABI JHN DAG

Rev Date Description Prep’d Chk’d App’d

Total or partial reproduction and/or utilization of this document are forbiddenWithout prior written authorization of the owner


Document No 9801-PRO-DBM-001 Date 06/06/01Revision 1 Page Sheet 2


TABLE OF CONTENTS

TABLE OF CONTENTS........................................................................................................................ 2

I. INTRODUCTION....................................................................................................................... 4

II. GENERAL................................................................................................................................. 5

References......................................................................................................................................... 5

III. DESIGN PHILOSOPHY & DATA..............................................................................................6

5.1 OVERALL SUBSYSTEM GENERAL DATA.............................................................................6

3..1 Design Life and Conditions.....................................................................................................6

3..2 Site Environmental Data..........................................................................................................6

3..3 Climatology.............................................................................................................................. 6

3..4 Earthquake Consideration : Yes, apply zone 1 (0.100).........................................................6

3..5 Environmental Requirement...................................................................................................6

5.1 SKG AIR SERDANG................................................................................................................7

3..1 Feed Gas Flow rate Profile......................................................................................................7

3..2 Gas Composition.....................................................................................................................7

3..3 Pressure................................................................................................................................... 8

3..4 Temperature............................................................................................................................. 8

5.1 PIPELINE 8”.............................................................................................................................. 8

3..1 Gas Flow Rate : 20 MMSCFD...............................................................................................8

3..2 Maximum Operating Pressure : 800 psig..............................................................................8

3..3 Minimum Receiving Pressure (ASD BRG) : 700 psig............................................................8

3..4 Maximum Operating Temperature : 120 oF...........................................................................9

3..5 Gas Composition.....................................................................................................................9

5.1 SKG BERINGIN......................................................................................................................... 9

3..1 Feed Gas Flow rate Profile......................................................................................................9

3..2 Gas Composition................................................................................................................... 10

3..3 Pressure................................................................................................................................. 10

3..4 Temperature........................................................................................................................... 10

5.1 PIPELINE 10“.......................................................................................................................... 11

3..1 Gas Flow Rate : 30 MMSCFD.............................................................................................11

3..2 Maximum Operating Pressure : 800 psig............................................................................11

3..3 Minimum Receiving Pressure (ASD BRG) : 650 psig..........................................................11

3..4 Maximum Operating Temperature : 120 oF.........................................................................11

3..5 Gas Composition................................................................................................................... 11

5.1 CO2 REMOVAL UNIT..............................................................................................................12

3..1 Gas Specification...................................................................................................................12

3..2 Design Basis.......................................................................................................................... 12



5.1 LPG EXTRACTION................................................................................................................. 14

3..1 Inlet Condition........................................................................................................................ 14

3..2 Product Specification............................................................................................................15

3..3 Product Storage.....................................................................................................................15

3..4 Product Loading.................................................................................................................... 16

IV. PROCESS DESIGN.................................................................................................................16

5.1 Gas Compressor Station.......................................................................................................16

5.1 LPG Plant Limau Timur.........................................................................................................16

V. UTILITY................................................................................................................................... 17

4.1 ELECTRICITY......................................................................................................................... 17

4.2 PRODUCT STORE AND DELIVERY......................................................................................17



I. INTRODUCTION

This process design basis defines the general minimum technical requirements of the process detail engineering applicable for the Air Serdang – Beringin Gas Project.

This project consist of two sub-system :

1. Sub-system I :

- Gas Compressor Station Air Serdang (SKG ASD) 20 MMSCFD capacity

- Gas Compressor Station Beringin (SKG BRG) 10 MMSCFD capacity

- Gas Dehydration Unit Air Serdang (DHP ASD) 20 MMSCFD capacity

- Gas Dehydration Unit Beringin (DHP Beringin )

- Gas Pipeline Transmission 8” 32.4 km from SKG ASD to SKG BRG

- Gas Pipeline Transmission 10” 27.5 km from SKG BRG to LPG Plant Limau Timur

- CO2 Removal Plant Limau Timur (CO2 LMT) 30 MMSCFD capacity

2. Sub-system II :

- LPG Extraction Plant Limau Timur (LPG LMT) 30 MMSCFD Feeding capacity with storage 600 Ton Capacity.

- LPG Storage Tank and Loading System Pulau Layang Plaju 1000 Ton capacity

OVERALL PROCESS SCHEME



II. GENERAL

References

As minimum, the most recent edition or revision of the following industry standards and codes shall be used or referred to in the design, material selection, fabrication, installation, inspection, testing, marking and shipment of the mechanical equipment.

API RP 14C Analysis, Design, Installation and Testing of Basic Surface Safety System for Offshore Production Platforms

API RP 14E Design and Installation of Offshore Production Platform Piping System (particularly for line-sizing criteria)

API RP 2000 Venting Atmospheric and Low Pressure Tanks

API RP 520 Sizing, Selection, and Installation of Pressure Relieving Devices in Refineries

API RP 521 Pressure Relief and Depressurizing System

API RP 750 Management of Process Hazards

API Spec 12J Oil and Gas Separators

GPA 2172 Publication for calculation of gross heating value, relative density and compressibility factor for natural gas mixtures from compositional analysis

API RP 551 Process Measurement Instrumentation

API RP 554 Process Instrumentation and Control

- Indonesia Government Regulation No. 11/1979

- Engineering Data Book Gas Processors Suppliers Association (GPSA).



III. DESIGN PHILOSOPHY & DATA

5.1 OVERALL SUBSYSTEM GENERAL DATA

3.1 Design Life and Conditions

Overall equipment both in Sub-System I and Sub-System II shall be designed for 20 Years.

3.2 Site Environmental Data

- Site Elevation : SKG ASD : +/- 150 ft above MSL SKG BRG : +/- 150 ft above MSL LPG LMT : +/- 150 ft above MSL

- Ambient Temperature : 80 oF to 100 oF (90 oF Normal)

- Plant Safety :

Process Plant has many hazards that need to be considered in the design of the facilities. Process design shall consider various hazards including but not limited to:

Handling and disposal of process fluids and chemicals Noise levels in excess of 85dB (A) Hot surfaces in excess of 60°C (140°F)

3.3 Climatology

- Wind Condition : Wind Direction : NE (North-East) Wind Velocity : 19.2 ft/s

- Rain fall Average Rainfall per years : 1640 mm Average Number of rainy days : 109 days Average Number raining in hours : 2 hours Maximum rainfall daily : 2 inch/hr

- Humidity Relative Humidity : min 60 % - maximum 95 %

- Air Pressure Average Air pressure yearly : 1009.2 mbar

3.4 Earthquake Consideration : Yes, apply zone 1 (0.100)

3.5 Environmental Requirement

CONTRACTOR shall comply with all Indonesian laws, rules and regulations.

As a minimum CONTRACTOR shall meet the following pollution limits or the Indonesian Law values if more stringent:



AIR EMISSION LIMITS (Continuous 24 Hour Average Emission Limits)

Reference for Indonesian Emission Standards shall be the latest version.

Peraturan Menteri Negara Lingkungan Hidup Nomor 4 tahun 2000 (Water pollution: Indonesia Government Regulation (permen Negara Lingkungan Hidup No. 4 tahun 2007))

Air Polution: Keputusan Menteri Negara Lingkungan Hidup No. 129, Tahun 2000 tentang baku mutu Emisi Sumber Tidak Bergerak

Reference for Indonesian Safety Standards shall be the last version

Safety: Indonesia Government regulation No. 11/1979 & Pertamina safety Regulation Noise: Indonesia Government Code No. SE-01/MEN 1978 Storage Tank:

Indonesia Government Regulation No. 11/1979 Ketentuan umum Pemadam Kebakaran Api dan Keselamatan (KUPAK)

Peraturan Khusus Depnaker

5.1 SKG AIR SERDANG

3.1 Feed Gas Flow rate Profile

YEAR LP Gas HP Gas

2002 5 5

2003 5 5

2004 5 5

2005 5 5

2006 5 5

2007 5 5

2008 5 5

2009 5 5

2010 5 5

2011 5 5

Total 10

3.2 Gas Composition

COMPONENT HP Gas (% mole) LP Gas ( % mole)

Carbon Dioxide N/A N/A

Nitrogen N/A N/A

Methane N/A N/A

Ethane N/A N/A



Propane N/A N/A

i-Butane N/A N/A

n-Butane N/A N/A

i-Pentane N/A N/A

n-Pentane N/A N/A

n-Hexane (+) N/A N/A

Total N/A N/A

Water Content Inlet (lb/mmscf)

N/A N/A

Water Content Inlet (mix) lb/mmscf

100

Water Content Outlet (lb/mmscf)

7

3.3 Pressure

Variable LP Gas HP Gas

Inlet Pressure (psig) 30 850

Outlet Pressure (psig) 800 800

3.4 Temperature


Inlet Temperature (oF) 130 130

Outlet Temperature (oF) 120 120

5.1 PIPELINE 8”

3.1 Gas Flow Rate : 20 MMSCFD

3.2 Maximum Operating Pressure : 800 psig

3.3 Minimum Receiving Pressure (ASD BRG) : 700 psig

3.4 Maximum Operating Temperature : 120 oF

3.5 Gas Composition



COMPONENT HP Gas (% mole)

Carbon Dioxide N/A

Nitrogen N/A

Methane N/A

Ethane N/A

Propane N/A

i-Butane N/A

n-Butane N/A

i-Pentane N/A

n-Pentane N/A

n-Hexane (+) N/A


N/A


100


7

5.1 SKG BERINGIN

3.1 Feed Gas Flow rate Profile

YEAR LP Gas HP Gas

2002 10 10

2003 10 10

2004 10 10

2005 10 10

2006 10 10

2007 10 10

2008 10 10

2009 10 10

2010 10 10

2011 10 10

Total 20



3.2 Gas Composition

COMPONENT HP Gas (% mole) LP Gas ( % mole)

Carbon Dioxide N/A N/A

Nitrogen N/A N/A

Methane N/A N/A

Ethane N/A N/A

Propane N/A N/A

i-Butane N/A N/A

n-Butane N/A N/A

i-Pentane N/A N/A

n-Pentane N/A N/A

n-Hexane (+) N/A N/A

Total N/A N/A


N/A N/A


100


7

3.3 Pressure


Inlet Pressure (psig) 30 70

Outlet Pressure (psig) 700 700

3.4 Temperature


Inlet Temperature (oF) 130 130

Outlet Temperature (oF) 120 120

5.1 PIPELINE 10“

3.1 Gas Flow Rate : 30 MMSCFD



3.2 Maximum Operating Pressure : 800 psig

3.3 Minimum Receiving Pressure (ASD BRG) : 650 psig

3.4 Maximum Operating Temperature : 120 oF

3.5 Gas Composition

COMPONENT HP Gas (% mole)

Carbon Dioxide N/A

Nitrogen N/A

Methane N/A

Ethane N/A

Propane N/A

i-Butane N/A

n-Butane N/A

i-Pentane N/A

n-Pentane N/A

n-Hexane (+) N/A


N/A


100


7

5.1 CO2 REMOVAL UNIT

3.1 Gas Specification

The design of Amine CO2 Removal capacity is 31.4 MMSCFD and feed gas composition shown Table – 1 is obtained from Titis Sampurna specification

TABLE – 1Composition of Natural Gas



COMPONENT COMPOSITION (MOLE %)

Carbon Dioxide 13.46

H2S 0.00

N2 1.04

Methane 63.82

Ethane 8.20

Propane 9.36

i-Butane 1.08

n-Butane 1.74

i-Pentane 0.42

n-Pentane 0.36

n-Hexane + 0.38

H2O 0.14

Total 100

3.2 Design Basis

ITEM : Amine CO2 Gas Removal Package

LOCATION : Limau Timur, South Sumatera

AREA CLASSIFICATION :CL. 1. Div.2. Group C/D area in accordance to API-RP 500

DESIGN MAX. WIND PRESSURE :300 kgf/sqm (please consider the shape factor (k) of the equipment)

EARTHQUAKE CONSIDERATION : Yes. Apply zone 1 (0.100)

SKID FOUNDATION : Concrete Slab

TREATING FLUID : Ucarsol AP 810, concentration 45% wt. in water

MAX. ACID GAS LOADING : 0.498 mole CO2/mole Amine

ELECTRICAL SUPPLY :380 VAC, 3-phase, 50 Hz, u/t max. 200 kW drivers above 200 kW gas-engine to be applied.

INSTRUMENT POWER :

220 VAC, 1-phase, 50 Hz

Air supply 80-100 psig

FUEL GAS : Natural gas (water saturated) @ plant inlet



conditions approximate 1050 btu/scf

UNIT PROCESS GUARANTEE BY VENDOR:CO2 content < 5.4 %mole, under all inlet conditions (3-cases)

INLET GAS PROPERTIES

Case 1 Case 2 Case 3

Total Flow Rate, MMSCFD 29.75 30.93 31.4

Specific Gravity 0.88 0.87 0.86

Operating Pressure, psia 665 665 665

Operating Temperature, F 90 90 90

Contaminants: CO2 & H2S CO2 & H2S CO2 & H2S

5.1 LPG EXTRACTION

The Hydrocarbon Liquids Recovery Unit (HRU) will be manufactured to form part of the Limau Timur Gas Plant for the South Sumatera Gas Utilization Project. The HRU will be designed to extract the optimum amount of natural gas liquids by separation and refrigeration system to produce 192 TPD of commercial grade LPG, 27 MMSCFD of pipeline quality natural gas, and 1316 bbls/day of hydrocarbon condensate.

3.1 Inlet Condition


Design Case, %moleCO2 13.46H2S 0N2 1.04C1 63.82C2 8.2C3 9.36iC4 1.08nC4 1.74iC5 0.42nC5 0.36C6+ 0.38H2O 0.14

100

OUTLET GAS PROPERTIES

Delivery Pressure 665 psia

Maximum CO2 content <5.4 %mole max

Maximum Liquid Carryover in Gas Stream 0.1 (assuming no foaming)


- Gas Phase


Total Flow Rate, MMSCFD 27.22 28.26 28.66

Operating Pressure, psia 665 665 665

Operating Temperature, F 120 120 120

Composition, %mole

CO2 5.45 5.22 5.15

H2S 0.00 0.00 0.00

N2 1.15 1.31 1.40

C1 69.84 71.79 72.92

C2 8.98 8.22 7.79

C3 10.24 9.23 8.60

iC4 1.18 1.10 1.05

nC4 1.90 1.84 1.79

iC5 0.46 0.45 0.45

nC5 0.39 0.39 0.40

C6+ 0.41 0.45 0.45

H2O saturated saturated Saturated

Table 3.7.1 Feed Gas Condition

- Condensate Phase

Condensate

Flow, USGPM @ 60 F 91.02 58.86 51.44

Mass flow, lb/hr 25,899 16,890 14,728

Pressure, psia 665 665 665

Temperature, F 90 90 90

Composition, %mole

CO2 6.56 7.10 6.45

H2S 0.00 0.00 0.00

N2 0.10 0.13 0.12

C1 16.10 17.75 16.26

C2 7.6 6.57 6.52

C3 22.57 12.82 19.12

iC4 5.14 5.33 4.67

nC4 10.86 11.65 10.43

iC5 5.15 5.72 5.21

nC5 5.39 6.19 5.77

C6+ 20.44 25.62 25.35

H2O 0.10 0.10 0.10

Table 3.7.2 Feed Condensate Condition

3.2 Product Specification




Gas

Flow Rate, MMSCFD 26.02 27.29 27.50

Pressure, psig 600 600 600

Temperature, F 120 max 120 max 120 max

Btu/scf 950 min 950 min 950 min

LPG

Flow, TPD 191 143 137

Vapor Pressure @100 F, psig 120 max 120 max 120 max

Ethane content, %volume 0.2 min 0.2 min 0.2 min

C3/C4 Content, % volume 97.5 max 97.5 max 97.5 max

Pentane plus, % volume 2.00 max 2.00 max 2.00 max

Stabilized Condensate

Flow, bbls/day 1.316 1.275 1.130

Vapor Pressure @100 F, psia 8 max 8 max 8 max

3.3 Product Storage

- Storage at Limau Timur

LPG : Pressurized cylinder

Capacity : To cover 3 days on spec LPG Production

Volume : 3 x 200 metric tones LPG

Condensate : Atmospheric Tank – 1 Nos

Capacity : 2 days production

Volume : 1 x 3000 std bbls

- Storage at Pulau Layang

LPG : Pressurized Sphere

Capacity : To cover 5 days on spec LPG Production

Volume : 1 x 1000 metric tones LPG

3.4 Product Loading

- At Lmau Timur LPG Plant

LPG Product

Transportation : By Truck 8 & 15 MT

Loading Time : 0.5 - 1 Hours



Condensate Product

Transportation : By Truck, 15000 liter

Loading Time : 0.5 - 1 hours

- At Pulau Layang

Transportation : By LPG Tanker

Loading Time : Hold Hours

IV. PROCESS DESIGN

5.1 Gas Compressor Station

5.1 LPG Plant Limau Timur

The process design case is defined based on the feed gas throughput given in attached document based on the design case, process simulation has been performed utilizing HYSYS software.

All product streams quantities are based on an Inlet gas volume of maximum 28.66 MMSCFD with a gas composition as shown in Table 3.7.1 (excluding water).

The resulting specification products from these quantities at the Fractionation Plant are as follows:

LPG : 190 Metric tonnes/day

Condensate : 1500 Barrel/day

LPG extraction plant consist of :

- Liquefaction with propane refrigerant chiller- Fractionation with Low Temperature Separator (Demetanizer), Deetanizer Column, and

Debutanizer Column.

To ensure that no hydrate formed during the process of liquefaction then used Mono Ethylene Glycol (MEG) as a hydrate inhibitor

V. UTILITY

This section describes the utility needs and availability at Pemanfaatan Gas Air Serdang Beringin Project for both sub-system. All required utilities must be self provided and this also includes for disposal of waste products.Utilities for this plant will be self provided by the utility in both Sub-system.

4.1 ELECTRICITY



Electric power for all users at the both sub-system will be provided by gas engine driven generators. The engines will be reciprocating type with minimum 10 % operating horse power margin over the generator maximum demand case. The feed to the engines will be fuel gas. At start-up plant fuel gas will be provided from a upstream of plant after inlet separator at each sub-system

The power generation system comprises of:

Normal Condition: 2 Nos (2 x 100%) gas engines of rating (refer to load list) kW / 400 V, 50 Hz

4.2 PRODUCT STORE

LPG Production will be stored in LPG Storage vessel. LPG storage should be able to store the on-spec LPG product for three (3) days, whereas the off-spec product will be stored in others storage ( off-spec LPG storage).

Condesate production will be stored in Condensate Storage Tank. condensate storage should be able to store the on-spec condensate product for seven (7) days.

LPG product will be transfer by LPG truck line to Pulau Layang LPG Storage in Palembang. LPG Storage in Pulau Layang should be able to store the LPG product for seven (7) days. From Pulau Layang, LPG product will be delivered by LPG Tanker.

Condensate product will be transfer to Pertamina by truck line or by Pipeline.

The specification of Loading of LPG and condensate be described below :

- LIMAU TIMUR

LPG Transportation : By LPG Truck 8 MT & 15 MTLoading Time : 0.5 – 1 hours

CondensateTransportation : by Truck 15000 liters or by pipeline

- PULAU LAYANG Transportation : By LPG Tanker Loading Time : 4 hours


9801-PRO-DBM-001 Process Design Basis A0. Complete

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