pt. pratiwi putri sulung
DESCRIPTION
Chevron. PRESENTATION TO. PT. PRATIWI PUTRI SULUNG. Co-Gen Duri. Introduction. Located in Texas, U.S.A. Michael W. Kort M.E.Eng., his expertise is the Oil/Gas Facilities pipeline equipment and is stationed in Indonesia. - PowerPoint PPT PresentationTRANSCRIPT
PT. PRATIWI PUTRI SULUNG
Co-Gen Duri
PRESENTATION TO
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Introduction
Located in Texas, U.S.A.
Michael W. Kort M.E.Eng., his expertise is the Oil/Gas Facilities pipeline equipment and is stationed in Indonesia.
North Star Intl. doing business with Q. B. Johnson Manufacturing Inc. Oklahoma, U.S.A.
North Star Intl. doing business with Luxor Manufacturing Inc. Texas, U.S.A.
North Star Intl. doing business with Alabaster Corp. Bioremediation, Texas, U.S.A.
North Star Intl. doing business with PT. Pratiwi Putri Sulung, Jakarta, Indonesia.
PT. Pratiwi Putri Sulung, their expertise manufacturing and construction of Metering Stations.
Air-Operated Valve (AOV-1) Air-Operated Valve (AOV-1) Facility Improvement Facility Improvement
at NDC Fuel Gas Plantat NDC Fuel Gas Plant
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NDC letdown stationNDC letdown station
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Background
1. Current Condition :• Inadequate redundancy for system control of Emergency Shutdown Valve. • Had been in service / operation for 7 (seven) years since NDC Plant
commissioning in 2000 and never been serviced. • Single piping (no bypass for Emergency Shutdown Valve) without any facility for
maintenance.• No Predictive/ Preventive maintenance can be applied. • No double block & bleed valves.• Pressure Safety Valves (PSVs) are directly release to atmosphere at the fuel gas
plant with inadequate requirement based on PSV Audit Chevron standard.
• 2. What are we going to do? :• We are going to provide alternative line facility of gas supply with no
operation interruption (on line condition). Thereby increasing plant reliability.
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Background (cont.)
3. How will we do it? : By installing the by pass line for Emergency shutdown valve. By installing the alternative system control for redundancy. By installing the double block & bleed valves. By performing the PSV audit and modify relief system as necessary.
4. Why is this important? : This AOV-1 valve is the weakest point where it can fail anytime and shutdown the
entire plant.
5. How it will contribute to GPO business objectives? It becomes very critical for both NDC Plant Safety & Commercial Operation. In case
of failure, NDC will loss of electricity & steam production and may impact on loss of generation at the grid & steam supply to CPI operation.
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LEDEEN PNEUMATIC AOV
10” GROVE VALVE B5
10” GROVE VALVE B516” GROVE
VALVE B5
BLEED VALVE
Business Driver
– To avoid potential revenue loss of To avoid potential revenue loss of US$ 224,000.00/ dayUS$ 224,000.00/ day due to loss due to loss of fuel gas supply (from MCTN side)of fuel gas supply (from MCTN side)
– To avoid potential revenue loss of approximately US$ 9MM/ day (from CPI To avoid potential revenue loss of approximately US$ 9MM/ day (from CPI production)production)
– To improve safety and reliability of NDC plant operation To improve safety and reliability of NDC plant operation
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Boundary Conditions
• 1. In Scope:• Area of scope for fuel gas supply facility at NDC letdown
station & HCT pigging facility at North Duri • Design, construct, and commission of new modification of
incoming fuel gas • Hydro-test, NDT, and X-ray are required and documented • New operation and maintenance procedures• Total appropriated budget (materials & man powers)• Instrumentation system• Civil work (pipe support) • Venting line modification• Double block & bleed arrangement
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Uncertainties
Identified Technical Uncertainties– The qualified contractor to execute the installation.
– New bypass line design may require a big area including underground line thru the road crossing.
– Budget value approved by management is less than estimated
– Material availability and delivery of the Air Operated Valve (AOV)
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MR 1
M2B M2A
Preliminary Overall Plan
Preliminary Assessment– The AOV-1 is located downstream of the CPI HCT interface to isolate the
system from the supply line. – This valve is remotely manually controlled through the DCS to open or close
the fuel gas supply line. The DCS monitors the pressure downstream of the regulating station by pressure transmitter, and under normal operating conditions, adjust the two 8 inch control valves (PCV-23A & PCV-23B) to maintain the operating pressure. During start-up of the first CT, the smaller 3 inch regulating valve is used to maintain system pressure.
– This valve is manually gear operator and it has been provided to operate the valve if the instrument air system is non operational or the actuator has malfunctioned.
– Downstream of AOV-1 valve is a pressure reducing / regulating station, which is designed to maintain the fuel gas system pressure at 425 psig and protected from over pressure in event of a control valve failure by two 10 inch pressure relief valves (PSV-26 & PSV-27).
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Preliminary Overall Plan (cont’d)
Design Alternatives
1. Fully shutdown (Alternative 1)
2. Hot-tap tie-in at NDC facility (Alternative 2)
3. Partially shutdown with temporary plug at NDC facility (no hot-tap) - (Alternative 3)
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Strategic Table
Strategic Theme
Partially shutdown with NO temporary plug at NDC facility (no hot-tap) (Alternative 3)
Tie-in connectionThe bypass line from pig receiver point at HCT plant will feed-in 16" pipeline into the of gas led-
down station.
The bypass line will be fabricated outside and feed-in 14" branch line into the existing elbow of gas led-down station. Hot tap equipment will be required for this temporary plug. Small modification on the pig receiver is required.
It will need partially shutdown of NDC gas letdown plant.
ImplementationThe bypass line will be fabricated outside and feed-in 16" branch line into the existing of gas led-down station. Small modification on the pig receiver is required.It will need partially shutdown of NDC gas letdown plant.
EXISTING UNIT
AOV 1
NO ISOLATIONNO DOUBLE BLOCK
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PIPE AND EQUIPMENT
Prefabricated and Hydrotested and X-ray and Documented by; PT. Pratiwi Putri Sulung.
Installation and construction by; PT. Pratiwi Putri Sulung, supervised by Michael W. Kort
PREFABRICATED PARTS FABRICATED BY PPS AND HYDRO-TESTED AND X-RAY
AND REPORT (DOCUMENTED)
PURPOSE FOR QUICK INSTALLATION
1
2
3
4
5
6
7
:
1. CLOSE Valve A and B
A BClose Close
Relieve Valve
2. Open Relieve Valve3. Inspect for leaks at the Valves,
by a Gas Detector 4.This will tell you, OK or NG 5. If Ok, remove obstacles
Down Stream of the Valves6. If NG, install a Stopple after
you can remove obstacles Down Stream of the Valves
VALVE INSPECTION
Relieve Valve
PARTIALLY SHUTDOWN
REMOVE
CLOSED
AOV 1
OPEN OPEN
CLOSED
PARTIALLY SHUTDOWN
INSTALL VALVE
CLOSED 1 INSTALL
PREFABRICATED SPOOL
AOV 1
OPEN
OPEN OPEN
CLOSED CLOSED
INSTALL BLIND FLANGE
DOUBLE BLOCK
PARTIALLY SHUTDOWN
CLOSED
CLOSED CLOSED
AOV 1
OPEN
OPEN OPEN
REMOVE
AOV 1
OPEN
CLOSED2 INSTALL
PREFABRICATED SPOOL
INSTALL VALVE
DOUBLE BLOCK
PARTIALLY SHUTDOWN
CLOSED
CLOSED
CLOSED
OPEN OPEN
PARTIALLY SHUTDOWN
REMOVE BLIND FLANGE
CLOSED
AOV 1
OPEN
RE-INSTALL
OPEN
OPEN
CLOSED
CLOSED
CLOSED
PARTIALLY SHUTDOWN
3 INSTALL PREFABRICATED
CLOSED
AOV 1
OPEN
CLOSED
CLOSED
CLOSED
OPEN OPEN
CLOSED
INSTALL VALVE
INSTALL VALVE
4 INSTALL PREFABRICATED
PARTIALLY SHUTDOWN
CLOSED
AOV 1
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN OPEN
PARTIALLY SHUTDOWN
CLOSED
AOV 1
OPEN
AOV 2
CLOSED
CLOSED
CLOSED
CLOSED
OPEN OPEN
CLOSED
CLOSED
INSTALL VALVES
DOUBLE BLOCK
AOV 1
AOV 2
OPEN
CLOSED
TRANSFER FLOW
NORTH AREA IS FINISHED
REMOVE
INSTALL BIND FLANGE
CLOSED CLOSED
OPEN
OPEN OPEN
OPEN
CLOSED
PARTIALLY SHUTDOWN
PARTIALLY SHUTDOWN
AOV 1
OPEN
AOV 2
CLOSED
5 INSTALL PREFABRICATED
SPOOL
INSTALL VALVE
CLOSED
CLOSED
OPEN
OPEN OPEN
OPEN
CLOSED
DOUBLE BLOCK
REMOVE
PARTIALLY SHUTDOWN
AOV 1
AOV 2
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
OPEN
OPEN
PARTIALLY SHUTDOWN
AOV 1
OPEN
AOV 2 CLOSED
6 INSTALL PREFABRICATED
SPOOL
DOUBLE BLOCK
CLOSED
CLOSED
CLOSEDCLOSED
CLOSED
OPEN
OPEN OPEN
OPEN
CLOSED
INSTALL VALVE
INSTALL VALVE
PARTIALLY SHUTDOWN
RE-INSTALL
AOV 1
AOV 2
CLOSED
OPEN
OPEN
OPEN OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
7 INSTALL PREFABRICATED
AOV 1
AOV 2
OPEN
CLOSED
OPEN
OPEN OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
PARTIALLY SHUTDOWN
AOV 1
AOV 2
OPEN
CLOSED
OPEN
OPEN OPEN
OPEN
CLOSED
CLOSED
OPEN
OPEN
OPEN
OPEN
IS IN FULL SERVICE
IS IN FULL SERVICE
NO
NO
NO
NO
NO
NO
NO
NO
NO
NC
NC
NC
NO
NC
AOV 1
AOV 2
PREFABRICATED PIPELINE 16”
PREFABRICATED PARTS FABRICATED BY PPS AND HYDRO-TESTED AND X-RAY
AND REPORT (DOCUMENTED)
2
1
3
4
5
6
IS IN FULL SERVICE
PIG RECEIVER
NO
NCNC
NC
NC
MR 1
MR
2A
MR
2B
M12
24”
18”
16”
12”
18”
4”
4”FLARE
MR 3B
MR 3A
IS IN FULL SERVICE
NO
NCNC
NC
NC
MR 1
24”
18”
MR
2A
1 INSTALL PREFABRICATED
TEE
NC
MR
2B
PIG RECEIVER
MR 3B
MR 3A
IS IN FULL SERVICE
24”
18”
MR 1 NO
MR
2A
MR
2B
NC
NC
NC NC
NC
INSTALL VALVE
PIG RECEIVER
MR 3B
MR 3A
MR 1
MR
2A
MR
2B
NO
NC
NC
NC NCNC
24”
18”
2 INSTALL PREFABRICATED
SPOOL
IS IN FULL SERVICE
PIG RECEIVER
MR 3B
MR 3A
IS IN FULL SERVICE
MR 1 NO
MR
2A
MR
2B
NC
NC
NC
NCNC
NC
NC
24”
18”
INSTALL VALVE
PIG RECEIVER
MR 3B
MR 3A
IS IN FULL SERVICE
NOMR 1
MR
2A
MR
2B
NC
NC
NC
NC NC
NC
NC
24”
18”
3 INSTALL PREFABRICATED
SPOOL
PIG RECEIVER
MR 3B
MR 3A
IS IN FULL SERVICE
NC MR 1 NO
PIG RECEIVER
NC
NC
NC NC
NC
NC
MR
2A
MR
2B
4 INSTALL PREFABRICATED
SPOOL
24”
18”
MR 3B
MR 3A
IS IN FULL SERVICE
5 INSTALL PREFABRICATED
SPOOL
MR 1 NO
NC
NC
NC NCNC
NC
MR
2A
MR
2B
24”18
”
MR 3B
MR 3A
IS IN FULL SERVICE
MR 1NO
NC
NC
NC
NCNCNC
NC
24”
16”
18”
16” 16”
16”
24”
NC
NC
NC
NO
NO
NO
NO
NO
NO
NO
NO
NO6 INSTALL PREFABRICATED
SPOOL
MR 3A
MR 3B
MR
2A
MR
2B
AOV I
AOV II
ALTERNATIVE 1, EXCISTING PIPELINE AOV 1 IN SERVICE NEW PIPELINE AOV 2 OUT OF SERVICE
IS IN FULL SERVICE
NEW PIPELINE INSTALLED
NC
NCNC
NCNC
NC
NO
ALTERNATIVE 1, EXCISTING PIPELINE AOV 1 OUT OF SERVICE NEW PIPELINE AOV 2 IN SERVICE
IS IN FULL SERVICE
NEW PIPELINE INSTALLED
NC
NCNO
NONO
NC
NC
DRAWINGS
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