PT. PRATIWI PUTRI SULUNG

transcript

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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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

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. 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

OPEN OPEN

CLOSED

PARTIALLY SHUTDOWN

INSTALL VALVE

CLOSED 1 INSTALL

PREFABRICATED SPOOL

OPEN OPEN

CLOSED CLOSED

INSTALL BLIND FLANGE

DOUBLE BLOCK

PARTIALLY SHUTDOWN

CLOSED

CLOSED CLOSED

OPEN OPEN

REMOVE

CLOSED2 INSTALL

PREFABRICATED SPOOL

INSTALL VALVE

DOUBLE BLOCK

PARTIALLY SHUTDOWN

CLOSED

OPEN OPEN

PARTIALLY SHUTDOWN

REMOVE BLIND FLANGE

CLOSED

RE-INSTALL

CLOSED

PARTIALLY SHUTDOWN

3 INSTALL PREFABRICATED

CLOSED

OPEN OPEN

CLOSED

INSTALL VALVE

PARTIALLY SHUTDOWN

CLOSED

OPEN OPEN

PARTIALLY SHUTDOWN

CLOSED

OPEN OPEN

CLOSED

INSTALL VALVES

DOUBLE BLOCK

CLOSED

TRANSFER FLOW

NORTH AREA IS FINISHED

REMOVE

INSTALL BIND FLANGE

CLOSED CLOSED

OPEN OPEN

CLOSED

PARTIALLY SHUTDOWN

CLOSED

INSTALL VALVE

CLOSED

OPEN OPEN

CLOSED

DOUBLE BLOCK

REMOVE

PARTIALLY SHUTDOWN

CLOSED

PARTIALLY SHUTDOWN

AOV 2 CLOSED

DOUBLE BLOCK

CLOSED

CLOSEDCLOSED

CLOSED

OPEN OPEN

CLOSED

INSTALL VALVE

PARTIALLY SHUTDOWN

RE-INSTALL

CLOSED

OPEN OPEN

CLOSED

OPEN OPEN

CLOSED

PARTIALLY SHUTDOWN

CLOSED

OPEN OPEN

CLOSED

IS IN FULL SERVICE

PREFABRICATED PIPELINE 16”

PREFABRICATED PARTS FABRICATED BY PPS AND HYDRO-TESTED AND X-RAY

AND REPORT (DOCUMENTED)

IS IN FULL SERVICE

PIG RECEIVER

4”FLARE

IS IN FULL SERVICE

PIG RECEIVER

IS IN FULL SERVICE

MR 1 NO

INSTALL VALVE

PIG RECEIVER

NC NCNC

IS IN FULL SERVICE

PIG RECEIVER

IS IN FULL SERVICE

MR 1 NO

INSTALL VALVE

PIG RECEIVER

IS IN FULL SERVICE

NOMR 1

PIG RECEIVER

IS IN FULL SERVICE

NC MR 1 NO

PIG RECEIVER

IS IN FULL SERVICE

MR 1 NO

NC NCNC

24”18

IS IN FULL SERVICE

MR 1NO

NCNCNC

16” 16”

NO6 INSTALL PREFABRICATED

AOV II

ALTERNATIVE 1, EXCISTING PIPELINE AOV 1 IN SERVICE NEW PIPELINE AOV 2 OUT OF SERVICE

IS IN FULL SERVICE

NEW PIPELINE INSTALLED

ALTERNATIVE 1, EXCISTING PIPELINE AOV 1 OUT OF SERVICE NEW PIPELINE AOV 2 IN SERVICE

IS IN FULL SERVICE

NEW PIPELINE INSTALLED

DRAWINGS

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Thank you for your kind

ATTENTION

PT. PRATIWI PUTRI SULUNG

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