Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Originator: COPI
COPI Group Owner: UO – Engineering – Onshore Sumatra
Area: General
Location: General
System: General System
Document Type: Final Report
Discipline / Sub discipline:
Old COPI Document No.: -
Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 2 of 109
CONTENTS
I. INTRODUCTION
II. METHODOLOGY
2.1 METHODOLOGY OF ENERGY ASSESSMENT
6.2. SYSTEM
6.2.1. Gas Pretreatment
6.2.2. Membrane System
6.2.3. Amine System
Amine Contactor
Amine Regenerator
6.2.4. Dehydration System
6.2.5. Dew Point Control System
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 5 of 109
Gas Chiller
Low Temperature Separator
6.2.6. Condensate Stabilizer
6.2.7. Depropanizer
APPENDICES
1. SCHEDULE OF ENERGY ASSESSMENT/AUDIT
2. MEASUREMENT DATA
3. LABORATORY ANALYSIS
EQUIPMENTS
SYSTEMS
I. INTRODUCTION
As a part of energy management program, in the year of 2007 the Indonesia Business
Unit of ConocoPhillips committed to develop plan regarding various efforts to conserve
sources and to reutilize waste, energy utilization and to reduce emission reduction for
each operating asset. Since 2004, emission level forecasts were generated as part of
environmental performance report that shall be further followed up in actual action
plans. This assessment is intended to guide the company in identifying energy-related
business opportunities and appropriate methods and developing the strategic
framework for realizing them. By performing this assessment / audit, it could also find
emission reduction opportunities in onshore operating asset.
The aim of this assessment is to identify where and how much energy is used in a
facility and for determining energy saving and emission reduction opportunities in
onshore operating asset.
2. Define specific facilities that consume high energy and generate high emission.
3. To observe and evaluate the present situation of those plants in regards with
energy consumption, process efficiency or performance and emission reduction
opportunities.
4. Provide options based on a set of criteria (measures) and select the most
promising options for implementation.
The preparation of the plant survey has been held on 10 – 21 September 2007. The
activity are includes define the boundaries, define data to be collected, define
instruments / meter related to the data to be collected and prepare checklist for
interview.
The Field inspection and data collection has been held on 24 September – 5 October
2007. The activity are includes collection of technical data of main energy-consuming
equipment, operation data, historical data, interview data, and direct measurement
with portable equipment. Principally, the data collected should be enogh to calculate
material and heat balance in each equipment.
During data collecting period at Suban Gas Plant, Grissik Central Gas Plant and Rawa
Oil Plant, not all the data requirement for analysis has been collected. Some of the
data are completed from COPI Office Jakarta and the other data are completed during
2nd field inspection. Direct measurement are done for all fired heater at Suban Gas
Plant and Waste Heat Boiler at Grissik Central Gas Plant.
In order to crosscheck the data gathered are accurate and reliable before carrying out
analyses, it is need to do the data verification. The data verification, has been held on
8 - 10 October 2007 and the discussion regarding the result of data verification has
been held on 23 October 2007.
Data analysis and evaluation has been held on 22 October – 23 November 2007. The
activity of the analysis are includes preparation of calculation methodology, spread
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 8 of 109
2nd field survey has been held on 3 – 7 December 2007 at Suban and Grissik. The
activity during 2nd field survey are includes :
Measurement of flue gas composition and temperature of Heater and
Waste Heat Boiler.
Electrical data records for rotating equipments.
Presentation of draft final report has been held on 18-19 December 2007
The Schedule of Energy Assessment, data has been collected and measured,
laboratory analysis are summarized in the appendices no.1 – no. 4.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 9 of 109
II. METHODOLOGY
The information regarding plant operation has been collected during data collection
period from 24 September to 5 October 2007.
After all the data has been collected, It is need to develop mass balance of each unit
in order to verify the accuracy of flow meter reading. If there are discrepancy between
mass inlet and outlet, ones of the mass flow should be adjusted, and than the data
that has been verified will be used as data basis for development of heat and mass
balance each equipment and system.
The plant model spreadsheet is constructed based on material and energy balance
each equipment, energy efficiency and losses. Process Simulation used to develop
material and energy balance for overall process gas plant.
Especially on the fired heater and waste heat boiler the spreadsheet is constructed
based on the calculation of energy efficiency, losses and emission level of each
equipment. Based on the data that has been collected, performance of each
equipment, efficiency level, energy waste and emission reduction potential of
equipment will be calculated and quantified.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 10 of 109
Based on the energy and emission reduction potential level of each equipment and
refer to technical and financial criteria, recommendation for improvement measure will
be identified.
All of the results of the evaluation / analysis will be discuss, present and reported to
ConocoPhillips.
The reporting of energy assessment / audit wil include preliminary report, interim/draft
final report and final report.
The preliminary report which covers : energy audit methodology, all data
collected, all formula for calculations and preliminary findings.
The interim/draft final report which covers : energy audit methodology, all
data collected, energy performance analysis result, quantity of all energy
waste and emission, energy waste and emission reduction opportunities
and performance monitoring system.
The final report which contains of: executive summary, evaluation result
during audit / assessment, spreadsheet of energy consumption,
spreadsheet of performance monitoring indicators and detail
recommendation report.
All of the calculation are explained regarding the efficiency and performance of each
equipment and process system.
%O2, T stack
AIR
Fluid Flow
T in
Direct Method
Heat Loss Method *
* Refer to Enercon Handbook
a. Direct Method :
The step of calculation of heat loss method in the fired heater are as follows,
a. Measure Ta, Tstack and % O2 in flue gas
b. Calculate combustion air for stoichiometry condition
c. Calculate excess air at % O2 as measure
d. Calculate flue gas flow, kg/h
(flue gas flow = fuel + comb air stoch + excess air)
e. Calculate flue gas loss, kcal/hr
(flue gas loss = flue gas flow x Cp x (Tst – Ta))
LHV of Flue Gas – flue gas loss – Rad & Conv Loss**
Efficiency = X 100%
LHV of Fuel Gas
** Refer to design condition
The efficiency calculated from heat loss method can be used to check the accuracy of
fuel gas flow meter recorded at each fired heater. The step of calculation are as follows
:
calculate heat duty of fired heater based on the different enthalpy of BFW
(steam) inlet and outlet.
calculate the heat release of fired heater based on the calculated efficiency
(ie. the heat duty divided by efficiency).
heat release from the calculation can be used to check the accuracy of fuel
gas flow meter recorded at each fired heater
Efficiency of Waste Heat Boiler also can be calculated in two ways ie. :
Direct Method
Heat Loss Method *
* Refer to Enercon Handbook
a. Direct Method
% O2 , Tstack
Ta (ambient air temp)
Conv. Flue Gas
Rad.
AIR
Fuel Gas
Steam
Acid Gas
WASTE HEAT
BOILER Flow, P, Tsteam
Permeat Gas
Water
Blow Down
Total loss = dry flue gas loss + blow down loss + rad & conv. loss
AIR
FUEL GTG BH
P G ELECTR
IC
Efficiency of Gas Turbine also can be calculated by using heat loss method, which
include heat loss of :
dry flue gas
H2O from combustion of H2
H2O moisture from fuel gas
H2O moisture from air
radiation and convection (refer to design)
compressor
Energy loss
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 15 of 109
Mechanical work
Efficiency =
Heat from fuel gas input
ZRT n Pd n-1
Mechanical Work *= Qx x x (( ) n - 1 ) / (33,000 x 0.77)
MW n –1 Ps
Efficiency of Gas Turbine also can be calculated by using heat loss methode, which
include heat loss of :
dry flue gas
H2O from combustion of H2
H2O moisture from fuel gas
H2O moisture from air
radiation and convection (refer to design)
Energy loss
Mechanical work
Efficiency =
Electric power input
Energy loss
Mechanical work
Efficiency =
Heat from fuel gas input
ZRT n Pd n-1
Mechanical Work * = Q x x x (( ) n - 1 ) / (33,000 x 0.77)
MW n–1 Ps
Gas Chiller
H1
To
To Propane
From Propane
Low Temperatur Acumulator
Separator
Cooling Load* = (GF x Cp g (To – Ti)) + (CF x Cpc (To – Ti)) + (f x CF x Latent Heat)
Cooling Load
COP Actual* =
compressor motor power (actual)
2.2.1.h. Pumps
Energy loss
Mechanical work
Efficiency =
Electric power input
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 18 of 109
Sg = Specific grafity
Ht = Total Head (feet)
Fv = Correction factor related to
viscousity
Ht (psia) = Dp – Sp
Energy
T in h loss T out l
m, p
Electric power
input
T in l T out h
Cooling Load = Q
Q = m (H)
Where
m : Flow rate
H : Enthalpy different
Fouling Factor Performance are calculated based on the value of Overall heat
transfer coefficient (Uo):
Uo = Q / (A Tlm)
Q : actual heat load (Q act)
A : Heat transfer Area
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 19 of 109
VENT
STEAM IN
a. Performance Calculation:
= Q act / Q design
b. Fouling Factor Performance are calculated based on the value of Overall heat
transfer coefficient (Uo):
Uo = Q / (A Tlm)
Q : actual heat load (Q act)
A : Heat transfer Area
Tlm : Log Mean Temperature Different
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 20 of 109
FEED GAS
ADSORBTION
COLUMN
TREATED
GAS
b. Membrane Unit
PROCESS GAS
MEMBRANE
FEED GAS
PERMEATE GAS
LEAN
AMINE
RICH
AMINE
b. Amine Regenerator
ACID GAS
RICH
AMINE
STEAM
AMINE
REGENERATOR
CONDENSATE
LEAN
AMINE
GAS
LP FUEL GAS
FEED
LIQUID LIGHT HC
STEAM
CONDENSATE
STABILIZATION
STEAM
CONDENSATE
CONDENSATE
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 23 of 109
2.2.2.e. Depropanizer
PROPANE
PRODUCT
FEED
LIQUID
DEPROPANIZER
CONDENSATE
PRODUCT
Gas from well head is delivered to CGP with flow line about 1 km length to the
separation unit, HP Production Separator. Because gas produced from HP Production
Separator still contain CO2, H2S and H2O in high concentration, it has to be treated
by CO2/H2S Removal Package and Dehydration Unit to meet the gas delivery
condition requirements.
A selective Amine based on MDEA solvent shall be provided for removal of CO2 &
H2S in feed gas from Gas Scrubber, to meet the sales gas specification. The
system shall also include the regeneration of the MDEA solvent used to absorb
H2S.
Acid Gas Removal Unit is installed with capacity 700 MMSCFD (total 4 trains) Sour
Gas and should be removed CO2 / H2S until meet sales gas specification (3%).
Acid gas released from Acid Gas Removal unit should be routed to The treated gas
scrubber Unit with enough pressure approximately 1400 psig to ensure Acid Gas
have enough pressure for next processes.
A Ethylene Glycol based gas dehydration unit shall be provided to dehydrate gas
from amine unit to achieve the sales gas specification (5-7 Lb/SCF). EG Dehydration
Unit is with capacity 700 MMSCFD (Total 4 trains).
The treated gas will be compressed by GTC (Gas To Compressor) with capacity 235
MMSCFD (There are 4 GTC, each of GTC has 235 MMSCFD Capacity) to increase
sales gas pressure until 1280 psig. The other part of treated gas is delivered to Fuel
Gas Filter as Fuel Gas for Gas Turbine Generator (GTG),Gas Turbine Compressor or
as fuel gas for the CPP gas engine equipment.
The Condensate from Horizontal Separator is routed to Stabilizer Feed Drum for
further separation process from carry over gas. To meet the Condensate Delivery
Condition, the condensate produced is stabilized with Condensate Stabilization Units,
with capacity are 44,349 Lb/hr for train 1 & 82,211 Lb/hr for train 2, and then stored in
the Condensate Storage Tank with capacity is 30,000 BBL. The condensate pumps
will be used to dispatch the condensate to Condensate Truck Loading.
Water collect from separation unit is automatically drained to a common header and
then to be processed in the produced water treatment system.
Blow down system is used for over pressure protection or for reducing the CGP
pressure either in emergency (ESD) or at the operator’s discretion in a shutdown and
blocked condition. The blow down system shall be capable of relieving the entire CPP
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 25 of 109
equipments from the highest possible shut-in pressure down to half times in 15
minutes. The blow down system is arranged with automatic blow down valves which
is fitted at the downstream of the separation units and at the discharge of CNG
Compressor to blow down through the HP Flare vent line.
Localized venting of gas to atmosphere is also provided for piping and vessels via
manual vents and pressure relieving devices, i.e. relief valves.
Fire water will be supplied from the fire water make up pump to a Fire Water Pond.
Fire water is distributed to the fire water main ring by three fire water pumps (two
pumps act as main pumps, and one as jockey) in a duty standby arrangement. Foam
tank and foam pump are provided to protect the condensate storage tank. The CGP
shall be fully equipped with fire and gas detection system.
All electric instruments shall be hard-wired to CGP Control Room and communicated
to Programmable Logic Control (PLC) and Human Machine Interface (HMI) to monitor
and control the process.
The simple process flow of Suban field is shown with block diagram in figure 2.1
Gas to Flare
7
Acid Gas
T 1 T 2 T 3 T 5 T Sales Gas
6
Suban Gas Well Gas Seperation Unit Amine System TEG Dehydration Unit Residual Compressor
T Condensate
8 10
Condensate Stabilizer
11 Liquid water
Gas from Inlet Separator still contains CO2 and H2O in high concentration. The gas
shall be treated in purification unit before the gas is delivered to Grissik Central Gas
Processing plant by Pipe line system.
The Energy source of Suban Gas Plant actually are fuel gas from Scrubber which is
consumed by GTG, GTC and Fired Heater (thermal oxidizer, amine re-boiler heater
and heat medium heater).
Based on 29 September 2007, the fuel gas consumption for each equipment are
shown in table below;
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 26 of 109
TOTAL
C 7.42 MMSCFD
The total fuel consumption at 29 September 2007 (including fuel gas to flare) is
7.42 MMSCFD. There are two type of fuel gas used in Suban Gas Plant ie. : LP
Fuel gas and HP Fuel gas. LP Fuel gas is used to fired heater and HP Fuel gas is
used to GTG and GTC. The heating value (HHV) of LP Fuel gas is around 1,574
Btu/SCF and HP Fuel Gas is around 1,130 Btu/SCF.
Based on the heat balance calculation of Fired Heater, GTG and GTC, the energy
picture on 29 September 2007 which are includes Heat Release, Heat Absorb,
Heat Loss and CO2 emission are as follows :
FLARE
248-FQI-2131B 13,200,110 0 11,898,856 1,472 1,849
248-FQI-2231B 66,000,552 0 59,494,279 1,472 9,243
HEATER
Thermal Oxidizer
225-H-102 38,486,293 0 35,495,414 932 81,738
225-H-202 10,602,175 0 8,303,983 2,012 1,488
Amine Reboiler H-M
Heater
225-H-111 40,771,370 32,203,736 9,055,361 405 5,730
225-H-211 37,035,660 29,160,613 8,988,198 361 5,204
Heat Medium Heater
257-H-101A 8,017,576 5,448,456 2,338,395 486 1,123
257-H-101B 0 0 0 0 0
257-H-201A 10,004,765 7,479,528 2,322,751 543 1,405
257-H-201B 9,088,243 6,758,329 2,473,720 500 1,275
GTG
247-GT-101A 0 0 0 0 0
247-GT-101B 0 0 0 0 0
247-GT-201A 42,371,386 7,714,245 33,163,974 916 5,611
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 28 of 109
Plant Performance :
The production rate at 29 September 2007 is 94,023 BOE which include 517
MMSCFD of sales gas (note : 1 SCF = 6000 BOE) and 7,823 barrel of condensate, and
total heat released including flare gas is 456,657,336 Btu/hr. The performance of
Suban Gas Plant as shown in table below :
PRODUCTION RATE
Sales Gas = 517.20 MMSCFD
= 86,200.00 BOE
ENERGY CONSUME
Excluding Flare 377,456,674.27
Including Flare 456,657,336.12 Btu/hr
ENERGY INTENSITY
Excluding Flare 4,014.51 Btu/BOE
Including Flare 4,856.87 Btu/BOE
It shown that the energy consumption to produce one BOE (= Energy Intensity) at
Suban Gas Plant is 4,014.51 Btu/BOE (Excluding Flare) or 4,856 Btu/BOE (including
flare) . (Note : No design data to compare the Actual Energy Intensity).
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 29 of 109
This condition can not compare with another gas plant, because every plant have its
own characteristic. The important thing is how to reduce energy consumption based
on its own characteristic.
A. DESCRIPTION
Gas from manifold enters the Inlet Separator which will separate gas from the bulk
liquid. The separator are designed for gas flow 160 MMSCFD (for train 1,2) and 214
MMSCFD (for train 3,4), whereas liquid flow are designed about 1973 gallon/min ( for
train 1,2) and 2640 gallon/min (for train 3,4) . Production Separator will be normally
operated at pressure 1188 psig and temperature 240 °F.
B. PERFORMANCE
Main equipment of Separation and cooler system are include : Inlet Cooler 215-E-
101A/B, 215-E-201A/B, 215-E-401A/B and 215-E-301A/B. The performance of
main equipment are as follows.
The above table shows that the actual heat duty of each inlet cooler are less than
design. It means that the actual cooling rate needs less energy than design. The heat
duty on Train #1 and #2 are operated at 60% of design.
The heat transfer rates of exchangers are closed to the design. Based on actual
condition, the performance of cooler is still in good condition.
Losses at inlet cooler are described from cooler outlet temperature. If the outlet
temperature higher than the design outlet temperature, it means the cooling rate is not
good. At this case, the exchangers are still in good condition.
A. DESCRIPTION
The feed gas from Inlet Separator contains CO2 5.42% by mole and small of H2S
content. A typical feed condition is 114 oF and 1163 psia; The products specifications
is designed for the CO2 content is 3.4 % by mole respectively. The acid gas removal
package uses activated methyl-di ethanolamine (MDEA) to remove the acid gases
(H2S & CO2) by means of counter-current mass transfer in an Amine Contactor unit.
The gas from the inlet separator will be fed to the Acid Gas Removal Package. As the
inlet gas is a saturated gas stream, there is a possibility of hydrocarbon and water
condensation prior to inlet of the amine contactor. To minimise liquid carry-over to the
system, a Horizontal filter unit is provided. The horizontal filter unit will have level
control drain-off valves, both on the upstream and downstream of the filter element,
whereby the liquid is sent to the flare system for disposal.
The liquid free gas from the Horizontal filter is then fed to the Amine Contactor,
whereby the gas is in contact with lean aqueous MDEA solution (amine). The
enhanced solubility of the acid gas in lean amine would soluble the acid gas
component, thus stripping it of H2S and CO2.
The rich amine from the contactors flows to the rich amine flash drums. The rich
amine flows under level/flow control through the lean/rich amine exchangers where it
is heated to about 206 oF by heat exchange with the hot lean amine from the two
regenerators. The rich amine feeds the regenerator above the stripping section which
contains stainless steel structured packing. CO2 and H2S are stripped from the rich
solution by heat produced in the regenerator re-boilers.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 31 of 109
B. PERFORMANCE
The heat duty of Amine H-M Heater was only 55 % and 50 % load compare to design
condition.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 32 of 109
The efficiency by using heat loss method are calculated based on the flue gas
composition and temperature measurement by using portable analyzer and
thermometer. No meter of temperature and O2 analyzer in flue gas line.
The flue gas temperature at actual condition is lower than design condition but the
excess air is too high and the operating load is too low. The efficiency at actual
condition is around 85 % compare to design condition which is 89 %. This efficiency
is low compare to design condition, it is caused by higher excess air and lower
operating load.
The above table shows that the heat duty operated closed to the design. The
difference between actual heat duty and design only 10%. The operated temperature
higher than design value.
The performance of heat exchanger can be evaluated from the value of overall heat
transfer rate (U). The U at actual condition is 85 BTU/(Hr/Ft2.F) and 93 BTU/(Hr/Ft2.F)
compare to design value which is 101 BTU/(Hr/Ft2.F..
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 33 of 109
The above table shows that the actual heat duty closed to the design. The difference
between actual and design only +/- 10%. Electric power consumption for motor fan
drivers also close to design with deviance not more than 7%. The fan running at actual
condition also same as design, each exchanger have 2 (two) fans running. This
indicates that the process is in good condition. Temperatures of gas outlet from these
exchangers all meet the specification process condition, 120.7 and 125.7 deg F for
train#1 and #2, and 126 deg F for train#3 refer to the design is 120 and 203.4 deg F
respectively.
The performance of heat exchanger can be evaluated from the value of overall heat
transfer rate (U). The U at operating condition give value of 3.9 and 3.0
BTU/(Hr/Ft2.F) for train#1 and train#2 and 4.5 BTU/(Hr/Ft2.F) for train#3. The design
value is 5.2 and 5.4 BTU/(Hr/Ft2.F).
BTU/HR.FT2.F
The above table shows that regenerator reflux condenser is operated at 55% load for
225-E-101 and 78% load for 225-E-201 compare to design condition. This caused by
the flow rate of acid gas are 62% and 83% compare to design condition.
Actual fan operated for the cooler 225-E-101 is 2 fans running, but the calculated fan
should be operated is 3 fans (2.2). This causes the temperature of the outlet of cooler
is higher than the design. Design value state the temperature is 120 deg F, but this
cooler operated at 135 deg F. The outlet temperature of cooler 225-E-201 is meet to
the design value.
The U (overall heat transfer rate) at actual condition is 1.9 and 2.7 BTU/(Hr/Ft2.F) for
225-E-101 and 225-E-201 compare to design is 3.0 BTU/(Hr/Ft2.F).
ELECTRIC
35.35 35.35 76.00
CONSUMPTION, KW
CALCULATE FAN
2.1 2.1 4.0
OPERATED
The above table shows that the actual heat duty of 225-E-103 and 225-E-203 are
rated at 50% compare to the design. This caused by the flow rate of lean amine only
about 50% - 60% from design capacity.
The flow rate of lean amine affects to the power required of fan cooler driver.
The actual operated fans for 225-E-103 and 225-E-203 are 2 fans compare to 4 fans
for design. This condition affects the performance of cooler, especially with heat
transfer rate.
The value of U (overall heat transfer rate) at actual condition is 1.6 BTU/(Hr/Ft2.F) for
225-E-103 and 1.5 for 225-E-203 compare to design 1.8 BTU/(Hr/Ft2.. This difference
indicated that the performance of coolers are still have good performance.
The flow rate of fluid in Rich-lean amine exchanger is about 40% from design
capacity. This will affect the heat load for these exchangers at 40% for 225-E-103 and
50% for 225-E-203.
LMTD between hot fluid and cold fluid are higher than the design specification. This
case will affect the heat transfer rate for these exchangers. The temperature inlet of
Rich amine is lower compare to the design value. This is indicate the amine contacting
process in the field running on lower temperature than the design specification.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 37 of 109
Two Amine Charge pumps were running at 265 GPM each, and had efficiency of
39.54%. This efficiency is quite low compare with 76.67% efficiency at design
condition. This is due to very low flow rate they handled. The 76.67% efficiency can
be achieved at 1165 GPM.
The sum of fluid flow rate for each pump (530 GPM) is still far below the design flow
rate for one pump. Higher efficiency could be achieved should the fluid flowing is
handled by one pump only.
Two of the three pumps were working to feed Amine re-boiler medium heater, so four
pumps worked to serve two Amine re-boiler medium heater. Each circ.-pump (P-111
A/B) worked at 2211 and 2186 GPM, with 69% efficiency and P-211 A/B worked at
1911 GPM, with 66% efficiency. All pumps are operated close to design efficiency.
The worst case was found at Amine booster pumps, the efficiency of P-101-A/B is only
22 %. The production process utilized two of the three pumps to support Lean amine
charge pumps. Each of these booster pumps pumping out fluid at 225 GPM.
The sum of fluid flow rate (450 GPM) is still far below the design flow rate for one
pump. Higher efficiency could be achieved should the fluid flowing is handled by one
pump only.
A. DESCRIPTION
Hydrocarbon liquid from inlet separator and LTS are sent to the stabilizer feed drum.
Gas from the feed drum is sent under back pressure control to the low pressure fuel
gas system.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 39 of 109
The hydrocarbon liquid from the feed drum is fed under level control to the top tray of
the condensate stabilizer. The stabiliser reboiler is a kettle type shell and tube
exchanger utilizing hot water from Medium Heater at operation.
The condensate product from the stabilizer is sent via the HC condensate cooler
bundle in the refrigerant condenser air cooled exchanger frame and a kettle type
hydrocarbon condenstae cooler by propane refrigerant, gas blanketed, condensate
storage tank.
B. PERFORMANCE
Main equipment of Condensate Stabilizing system are includes : Heat medium heater
257-H-101A/B, 257-H-201A/B; Stabilizer Re-boiler 235-E-101A/B, 235-E-201A/B;
Condensate Cooler 235-E-102, 235-E-102
257-H-101A DESIGN
FUEL,
Flow, MMSCFD 0.12 0.10
FLUE GAS
T out, F 511.20 629.00
O2, % 13.90 3.00
Excess Air, % 179.07 15.27
HOT WATER
, lb/hr 106,647.53 110,000.00
T in, F 310.00 316.60
T out, F 350.00 360.00
P in, Psi N/A 200.00
P out, Psi N/A 200.00
PERFORMANCE
Heat absorption (LHV), MMBtu/hr 5.34 4.76
Heat absorption (HHV), 5.45 4.76
MMBtu/hr
FUEL,
Flow, MMSCFD 0.15 0.14 0.17
FLUE GAS
T out, F 568.80 525.60 629.00
O2, % 8.50 10.20 3.00
Excess Air, % 62.20 86.38 15.27
HOT WATER
, lb/hr 228,820.95 180,110.31 164,900.00
T in, F 300.00 300.00 316.6
T out, F 330.00 330.00 360
P in, Psi N/A 225.00 227.5
P out, Psi N/A 210.00 200
PERFORMANCE
Heat absorption (LHV), MMBtu/hr 7.38 6.66 7.94
Heat absorption (HHV), MMBtu/hr 7.48 6.76 8.00
The above table shows that H-101 A, H-201 A and H-201-B are operated close to
design condition. The efficiency by using heat loss method are calculated based on
the fuel gas heating value, flue gas composition and temperature measurement by
using flue gas analyzer.
Flue gas temperature is lower than design condition but the excess air is very high.
Calculated Efficiency of 257-101-A is 73 % compare to design is 84 % and the
efficiency of 257-201-A/B is around 81 % compare to design is 84 %. The lower
efficiency is caused by higher excess air of the heater.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 41 of 109
The above table shows that actual condition of heat duty of 235-E-201 and 235-E-101
is lower than design. The reboiler of 235-E-201 have capacity higher than 235-E-101
but the heat transfer rate are close to design.
Condensate Cooler :
The above table shows that the condensate cooler have heat duty only 25% for 235-
E-102 and 48% for 235-E-202 refer to the design value. This caused by the flow rate
of condensate, and LMTD.
The flow rate for 235-E-102 is 35% and 235-E-202 is only 67% refer to the design.
LMTD value for cooler 235-E-102 and 235-E-202 are 80% from LMTD design. This
affect the value of heat load (Q) of coolers, because the heat load is straight forward
with condensate flow rate and LMTD.
The overall heat transfer rate (U) at actual condition is 1.11 BTU/(Hr/Ft2.F) for 235-E-
102 and 2.12 BTU/(Hr/Ft2.F for 235-E-202 compare to the design is 2.36
2
BTU/(Hr/Ft .F).
A. DESCRIPTION
The propane refrigerant gas from gas chiller via suction scrubber enter the 1st stage
propane compressor. The propane refrigerant gas from the 1st compressor discharge
and from the economizer goes to the propane compressor 2nd stage than the
discharge of 2nd stage goes to the condenser cooler and enter to the accumulator.
Propane refrigerant from the accumulator goes to the economizer (flushing).
Propane gas from the economizer enter the suction of 2nd stage compressor and the
propane refrigerant enter the gas chiller via propane subcooler. The design flowrate
of the 1st stage propane compressor is 38,200 lbs/hr and the 2nd stage of propane
compressor is 52,800 lbs/hr.
There are 3 propane compressor driven by electric motor 1300 KW each and via
refrigerant header supply refrigerant for 4 gas chillers (1 gas chiller for 1 train). At the
actual condition only 2 compressor are in operation.
B. PERFORMANCE
Propane Condenser :
230-E-104 DESIGN
PROPANE :
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 43 of 109
The above table shows that actual condition of heat duty of 230-E-104 is 75%
compare to design. The heat duty impact on the power required for fan driver which is
80% electric consumption respectively.
The U value (overall heat transfer rate) at actual condition is 2.59 BTU/(Hr/Ft2.F) and
3.29 BTU/(Hr/Ft2.F for the design value.
Entirely, the performance of propane condenser is operated at good condition.
Propane Compressor:
The above table shows that the propane compressor operated at 70-80 % load. The
calculated propane flow of stage-1 K-101 A and K-101 C are 30,669 lb/hr and 25,861
lb/hr with the actual power are 1110 KW and 936 KW . The design propane flow of
stage-1 is 38,160 lb/hr with the power is 1,300 KW. It means that the propane
compressor is still operated at normal conditions.
The design COP of the propane compressor is 1.89. COP at actual condition can not
be calculated accurately because no meter for propane flow.
Gas Chiller:
The above table shows the cooling load of gas chiller is 71 % load and two of propane
compressor are operated to handle the refrigeration system.
Performance of each gas chiller can not be calculated, because two propane
compressors serve four gas chillers simultaneously. However total performance still
can be calculated.
The operating condition of four gas chiller almost similar (T gas inlet = 16 F , T out gas
= 5 F). Total COP of gas chiller is 1.79. It’s still close to design condition.
A. DESCRIPTION
The pressure of treated gas after Amine System and Refrigeration System is
decrease lower than 1000 psig. To meet the pressure requirement of sales gas it
needs to compress sales gas by using Residual Gas Compressor. There are 4 gas
compressor 2 x 235 MMSCFD and 2 x 300 MMSCFD driven by gas turbine
generator. At the actual condition only 3 GTC in operation and 1 GTC standby
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 45 of 109
B. PERFORMANCE
Gas Compressor :
The above table shows that the compressor are operated at 80 % load compare to
design condition.
The Energy Intensity (Btu/HP) of 242-K-101, 242-K-301 and 242-K-401 are higher
compare to design value. This condition is caused by the lower operating load of
compressors. To know the performance of compressor, it should be compare with
design performance of gas turbine compressor (see table below).
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 46 of 109
Gas Turbine :
29-Sep-07 DESIGN
242-KT-101 242-KT-201 242-KT-101 /201
A TURBINE
Fuel gas :
flow, MMSCFD 0.59 OFF 1.02
Flue gas :
Temperature, C 1,213 OFF 1,160
O2, % 14 OFF 14
Excess Air, % 191 OFF 185
Eff, % 19 OFF 25
Btu/HP 13,256 OFF 10,115
B COMPRESSOR
Power Required, KW 1,447 OFF 3,471
, HP 1,940 OFF 4,653
29-Sep-07 DESIGN
242-KT-301 242-KT-401 242-KT-301/ 401
A TURBINE
Fuel gas :
flow, MMSCFD 0.73 0.70 1.05
Flue gas :
Temperature, C 1,261 1,237 1,175
O2, % 14 14 14
Excess Air, % 168 174 174
Eff, % 23 23 27
Btu/HP 10,946 11,225 9,401
B COMPRESSOR
Power Required, KW 2,115 1,978 3,409
, HP 2,835 2,651 4,570
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 47 of 109
In the daily operation, the gas turbines efficiency is around 23 %, these efficiency is
less than the design condition (27%). Based on the design performance below, the
performance of gas turbine at low load are close to design figure.
POWER, HP
5,000.00 4,000.00 3,000.00 2,000.00 1,000.00
BTU/KWH
9,400.00 10,000.00 11,000.00 12,500.00 17,000.00
A. DESCRIPTION
Electrical power Generator driven by Gas turbine generator, with the gas supplied
from HP (high pressure) fuel gas system. There are 2 GTGs each 1173 KW from
Suban phase-1 and 3 GTGs each 5820 KW from Suban phase-2.
The Generator specification are 5820 KW of power, 6600 volt, freq 50 Hz, cos Q 0.85.
The large motors (lean amine charge pump, Amne reboiler HM Pump, propane
compressor) are supplied by 6600 volt and the other motors using 400 volts.
B. PERFORMANCE
The main equipment of gas turbine generator are 247-GTG-101A/B and 247-
GTG-201A/B/C
29-Sep-07 DESIGN
247-GT-201A 247-GT- 247-GT- 247-GT-201A
201B 201C
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 48 of 109
TURBINE
Fuel gas :
flow, MMSCFD 0.90 0.9 0.90 1.62
Flue gas :
Temperature, F 916 921 925 946
O2, % 16 16 16 15
Excess Air, % 312 309 308 243
Turbine Eff, % 18.04 18.04 18.01 30
Btu/kwh 16,925 16,926 16,950 11,336
CO2 emission :
Flow, lb/hr 5,611 5,611 5,611 4,446
GENERATOR
Power Output, KW 2,146 2,102 2,178 5,821
PF 0.83 0.83 0.83 0.84
Voltage, V 6,600 6,600 6,600 6,600
Frequency, Hz 50 50 50 50
GTGs are operated less than 40 % load each, total load is around 6,426 KW. This
load actually can be handle by two GTGs with 55 % load each. If any disturbance
occurs, the load shading system will shut off un-priority load, so system black out can
be avoided. The low load of GTG caused low efficiency of gas turbine.
The stack temperature of GTG are close to design condition but the calculated
efficiency is only 18 % compare to design which is 30 %. The decreasing efficiency is
caused by lower operating load which will increased radiation and convection loss.
Compare to the design performance of gas turbine generator (table below) , the
performance GTG at low load are still in good condition
A. DESCRIPTION
Instrument and utility air are supplied by the 1x340 scfm and 1x140 scfm screw type
compressor. The compressed air is filtered and then dried in heatless adsorption type
dries which are on automatic regeneration cycles. The instrument air compressor
packages are provided with local electronic control panels. The instrument air
receiver is normally operated between 110 and 120 psig.
B. PERFORMANCE
DESIGN ACTUAL
DESIGN ACTUAL
The above table shows that the compressor is operated at low load. Actual power of
251-A-101 A is 45.93 KW compare to design 72.6 KW and 251-A-101 B is 28.27 KW
compare to design 44 KW.
Electrical map is derived from single line diagram, and intend to get a closer and clear
point of view to one that need brief description on power consumption at each
process. This map is made simple as possible so, it doesn't show how the electric
system is distributed. Emphasize is given to voltage, and power required for each
equipment. Note that the power mentioned below is the power in normal design
condition.
400 V
215-EM-301/401/A/B 1-2
Inlet cooler fan
22 KW x8
B. Amine System
6.6 KV
400 V
225-P-102A/B/C 225-PM-103A/B 225-PM-203A/B
Lean Amine booster pump A/B/C Regenerator reflux pump A/B Regenerator reflux pump A/B
112 HP x3 3.73 HP x2 3.73 HP x2
11 KW x8 14.7 HP 14.7 HP
C. Dehydration system
400 V
229-PM-302/402/A/B
Glycol Injection pump
26.8 HP
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 51 of 109
6.6 KV
230-KM-101 A/B/C
Propane compressor A/B/C
1306 KW x3
400 V
400 V
106 HP 11 KW x2 29.5 HP 40 HP x2
400 V
242-EM-301/401 A-D
Residue gas compr. After cooler
15 KW x8
400 V
400 V
Based on the site survey founded that many metering and instrument are not work
properly. Findings and recommendations of metering and instrumentation at
Suban Gas Plant are as follows :
link to DCS
2. Heater
Based on the calculation bellows are the efficiency, heat absorb and CO2
emission of fired heater at Suban Gas Plant
Finding :
The heat duty of Amine H-M Heater is only 50 % and 44 % load compare to
design condition. The Gas Plant are operated at 517 MMSCFD of sales
gas or 74 % load compare to design condition. This condition means that
the design of fired heater is too large.
Recommendation :
Design Amine H-M Heater is too large, so the heater can be handle for
revamping until 125 % Amine Capacity.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 55 of 109
Amine H-M Heater is the main energy consuming equipment in the amine
system, so its performance should be monitored daily. Hence, it needs
temperature and O2 meters at flue gas line to support the monitoring
activity.
Amine H-M Heater should be operated close to the design excess air (15%)
to achieve better efficiency,
Based on the calculation, bellows are the efficiency, heat rate, BHP and CO2
emission of GTG at Suban Gas Plant:
Finding :
Three GTGs load are low in daily operation ( less then 40%),.the average
efficiency is around 18 % (design = 30 %)
Heat rate of three GTGs are around 16.9 MBtu/KWH compare to design
11.3 MBtu/KWH
Recommendation :
Power require and energy intensity of residue gas compressor are as follows :
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 56 of 109
Finding :
Max capacity of KT-401 and KT-301 are 235 MMSCFD each, with suction
press 950 psi and discharge 1280 psi
Max capacity of KT-201 and KT-101 are 300 MMSCFD each, with suction
press 950 psi and discharge 1200 psi
Based on the design flow rate, 3 GTCs can handle 770 MMSCF
7. Propane Compressor
Finding :
8. Gas Chiller
Finding :
Inlet flow of refrigerant to gas chiller come from one header, so difficult to
evaluate COP for each gas chiller
Heat duty of four gas chiller is 11.8 MMBTU/hr compare to design is 16.52
MMBTU/hr. The motor power of propane compressor is 2046 kW
9. Pump
Finding :
Amine charge pumps and Amine booster pumps were running in low efficiency. This
is due to very low of fluid rate they handled. Should two split of flow that flowing
through “Amine booster pumps is merged together to flow through one pump only(530
GPM), its total flow still far below the rate of design (1165 GPM).
The similar case was found at Amine booster pumps. Two pumps were running to
handle 225 GPM rate each.
Recommendation :
Higher efficiency could be achieved should the fluid flowing is handled by one pump
only (If total rate of flow not exceed flow rate at design).
10. Cooler
Findings :
Power required to drive motors of fan coolers are below 1% due to their heat
duties. This condition indicate that the power consumption of these coolers are in
good condition except Treated gas cooler and Condensate cooler.
Recommendations :
Need to check again the performance of Treated gas cooler and Condensate
cooler, especially motor driver of fan coolers.
Findings :
The performance of heat exchangers still in good condition, except for Stabilizer
Reboiler 235-E-201, because the dirty factor more than design specification.
Based on heat balance calculation, energy losses from high temperature flue gas at
Suban is coming from Stack of Thermal Oxidizer, GTG and GTC.
a. Energy Losses :
Total losses from flue gas is around 201 MMBtu/hr with average temperature 1,177
deg F. Actually, by utilizing economizer with stack temperature around 500 deg F, this
Flue gas losses can be used to generate saturated steam about 120,000 lb/hr.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 61 of 109
b. Potential Saving :
Based on the evaluation, shows that the potential saving are coming from :
Utilized flare gas that will reduced fuel consumption about 0.8 MMSCFD
, US $/Year 123,750.00
, US $/Year 990,000.00
, US $/Year 1,113,750.00
CO2 emission at suban gas plant is 127,901 lb/hr. its come from combustion of
fuel gas at flare gas, heater, GTC and GTG.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 62 of 109
Total 8860
Findings :
Existing daily report just only for production activity, it does not cover the
data for plant performance evaluation purposes
Important data for plant performance not covered in daily log sheet
Recommendation :
The Central Gas Processing – Grissik plant was designed firstly for processing gas
from four field in the Corridor Block, South Sumatra: Dayung/Sumpal and GLT
(Gelam/Letang/Tengah) field. The quality gas from Dayung field has high CO2
content (31 %) and the gas quality from GLT has high condensate content.
The source of inlet gas to be processed in CGP has changed after the Suban Gas
Plant was operated. Partly of Suban Gas sales line also was processed in CGP if the
specification of Suban Gas Sales was nearly out of specification, especially on the
CO2 content. So, the mixed gas from Suban plant and CGP plant will meet
specification at the gas sales pipeline.
The simple process flow of CGP-Grissik Plant is shown with block diagram in figure
1.1 below:
FlareGas
T
11 Permeate Gas Acid Gas
5 6 Suban Gas
Sales bypass
T 1 T 2A T 4 T 7 T 9
The flow diagram of CGP Grissik plant that obtained from basic design and field
survey can be described below:
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 64 of 109
Based on overall process, the processing load of CGP plant during field survey activity
is 54.6% of capacity design. This condition is caused by shut down condition for
repairing of the Amine Regenerator 25-C-202.
The HP fuel gas supply for the plant is obtained from the Back-up sales gas line and
Suban taping gas line via the pressure control valve. Gas heated by steam, under
back pressure control, goes to the high pressure fuel gas scrubber which is operated
at about 260 psig. The high pressure fuel gas supplies fuel the gas turbine and partly
sent to Bentayan field.
The LP fuel gas from the stabilizer feed drum and stabilizer overhead is supplied for
TEG regeneration heater, gas pretreatment heater, fuel gas for WHB incenerator and
flare purge gas, flare stack pilot, tank blanket.
The HP fuel gas is supplied to GTG and to the LP fuel gas, when the LP gas demand
exceeds the available LP fuel gas supply.
CGP Grissik plant used three (3) type of energy for the process, utility and offsites
facilities. The types of energy that used are : LP Fuel gas, steam from WHB and
electricity from GTG.
Based on 2 October 2007, the amount of fuel gas coming from scrubber is 5.910
MMSCFD. The distribution of fuel gas as shown in table below;
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 65 of 109
There are two type of fuel gas used, LP Fuel gas which is consumed by fired heater
and HP Fuel gas which is consumed by GTG. The heating value of LP Fuel gas is
around 1,060 Btu/SCF and HP Fuel is around 1,484 Btu/SCF
Based on heat balance calculation in WHB and GTG, the energy picture based on 2
October 2007 which includes total energy input/heat released, heat absorbed, heat
loss and CO2 emission as shown in table below,
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 66 of 109
FLARE
90,840,020 0 84,736,763 1,562 12,421
HEATER
Regen Gas Heater
21-H-101 8,473,864 5,794,116 2,487,229 430 1,377
21-H-201 0 0 0 0 0
Glycol Heater
41-H-101 1,196,695 922,279 256,466 430 191
41-H-201 1,196,695 922,279 256,466 430 191
41-H-301 0 0 0 0 0
WHB
46-B-101 165,049,729 120,492,608 41,432,959 376 158,802
46-B-201 0 0 0 0 0
GTG
47-GTG-101A 37,103,706 7,084,939 19,478,242 949 4,569
47-GTG-101B 40,880,730 7,415,749 18,133,682 967 5,034
47-GTG-101C 0 0 0 0 0
TOTAL 344,741,441 142,631,970 166,781,807 468 182,585
Plant Performance :
PRODUCTION RATE
Sales Gas = 186.50 MMSCFD
= 31,083.33 BOE
ENERGY CONSUME
Excluding Flare 256,621,725.71 Btu/hr
Including Flare 347,461,746.16 Btu/hr
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 67 of 109
ENERGY INTENSITY
Excluding Flare 7,940.68 Btu/BOE
Including Flare 10,751.56 Btu/BOE
Total heat input to WHB, GTG,Regeneration Gas Heater and Glycol Heater is
253,901,420 Btu/hr and total heat released including flare gas is 344,741,441 Btu/hr.
The production rate is 32,317.33 BOE which include 186.5 MMSCFD sales gas and
1,234 Barrel of condensate, means the energy consumed to produce one BOE
(energy intensity) is 7,940.68 BTU/BOE (Excluding flare) and 10,751.56 BTU/BOE
Including flare).
A. DESCRIPTION
The Gas Pre-Treatment Unit has been designed to operate at 2 x 50% each train with
a total gas throughput capacity of 230 MMSCFD and designed to remove heavy
hydrocarbons (C6+) from 380 ppm to 39 ppm.
The overall process works on the principles of Adsorption, Regeneration and, Cooling
and, is commonly referred to a Thermal Swing Adsorption (TSA) process. Each train
has 4 Adsorber Towers. Under normal operation each train has 2 Adsorber towers in
operation mode,one Adsorber Towers in Regeneration mode and one Adsorber
Towers in cooling mode.
The Dayung gas from inlet separator is sent to the membrane unit to remove CO2,
lowering the CO2 content of the gas from about 30.5 mole% to less than 15.0%.
The Membrane CO2 separation unit was designed to process the Dayung gas to
reduce the CO2 content of the gas from 31% to 15%. The remainder of the CO2 in the
Dayung gas is then removed in the Amine-treating Unit, allowing the gas to meet the
sales gas pipeline specification for CO2, which has a minimum value of 5%. As the
Dayung gas flows through the semipermeable polimide membranes, approximately
63% of the CO2, 60% of the H2S, and 8% of the Methane is separated into the
permeate gas stream. The permeate Gas, consisting of about 80% CO2 and 20%
Methane, is sent to the Waste Heat Boilers as fuel gas.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 68 of 109
B. PERFORMANCE
The main equipment at Gas Pretreatment (TSA) system are Regenerator Gas Heater
and Regen Gas/Gas Exchanger
2-Oct-07 DESIGN
1 FUEL,
Flow, MMSCFD 0.16 OFF 0.31
2 FLUE GAS
T out, F 430.00 OFF 430.40
(Estimated)
O2, % 14.00 OFF 14.00
(Estimated)
Excess Air, % 185.64 OFF 185.64
3 PERFORMANCE
Heat absorption (LHV), 5.75 OFF 11.06
MMBtu/hr
Heat absorption (HHV), 5.80 OFF 11.16
MMBtu/hr
Regen gas heater is operated at 60% load compare to design condition and the fuel
consump is 0.16 MMSCFD
The stack temperature and oxygen content are estimated close to design condition
with the efficiency is 74.65 %
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 69 of 109
The above table shows that the heat duty operated only about 0.475 MMBTU/hr for E-
101 and 4.67 MMBTU/hr for E-102, although the design heat duty is 7.5 MMBTU/hr for
E-101 and 8.26 MMBTU/hr for E-102. This heat duty value produce capacity only
about 6.34 % for E-101 and 56.54 % for E-102 compare to design capacity.
This condition caused by the feed gas to TSA unit only 26 MMSCFD (110,283 lb/hr)
for adsorption and 20 MMCSFD (87,483 lb/hr) for cooling condition compare to the
design capacity for gas process adsorption is 115 MMSCFD (20% capacity).
The different between design and operation are the LMTD value. Actual LMTD is
62.74 oF for E-101 and 44.17 oF for E-102 compare to design is 61.9 F for E-101 and
55.43 oF for E-102.
The performance of heat exchanger can be evaluated from the value of overall heat
transfer rate (U). The U at operating condition give value about 3.12 BTU/(Hr/Ft2.F)
for 21-E-101 and 44.17 BTU/(Hr/Ft2.F for 21-E-102, while the design value is 6.26
BTU/(Hr/Ft2.F) for 21-E-101 and 55.43 BTU/(Hr/Ft2.F) for 21-E-102.
A. DESCRIPTION
The gas treating process consists of three identical amine contactors, two normally
treating about 114 MMSCFD of Dayung gas each (referred design base) and the third
treating about 129 MMSCFD of Gelam, Letang, Tengah (GLT) gas. The amine units
are designed to produce treated gas containing less than 2% CO2 and 4 ppmV H2S
consequently the bypasses allow the sales gas still to meet its specification of 5%
CO2 and 8 ppmV of H2S.
Amine unit feed gas stream enters the bottom of an amine contactor where it is
counter-currently contacted with lean 50 wt% UCARSOL solution with main
composition is MDEA solution. CO2 and H2S are absorbed by the lean amine and the
treated gas exits the top of the tower. The amine contactor contains stainless steel
structured packing.
The design lean amine circulation rate to the Dayung gas contactors is about 1640 US
gpm and the design lean amine circulation rate to GLT gas is about 1621 USgpm
based on maximum allowable rich amine loading of 0.49 mole (CO2+H2S)/mole
UCARSOL (MDEA solution).
The rich amine from the contactors flows under level control to the rich amine flash
drums. Gas from the flash drums flows under back pressure control to the waste gas
incenerators. The rich amine flows under level/flow control through the lean/rich amine
exchangers where it is heated to about 206 oF by heat exchange with the hot lean
amine from the two regenerators.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 71 of 109
The rich amine feeds the regenerator above the stripping section which contains
stainless steel structured packing. CO2 and H2S are stripped from the rich solution by
steam produced in the regenerator reboilers which consist of 4 (four) kettle type shell
and tube heat exchanger for each regenerator.
B. PERFORMANCE
The main equipment of amine system are Regenerator Reflux Condenser 25-E-
101/202, Amine Reg. Reboiler 25-E-102A-D /202A-D , Lean amine cooler 25-E-
103/203, Rich / Lean Amine Exchanger 25-E-104A/B, 25-E-204A/B; Amine
Charge Pump 25-P-102A/B/C; Amine Booster Pump 25-P-101B/C
The above table shows that the actual heat duty is closed to the design. The
difference between actual heat duty and design value only 5%, although the flow rate
regenerated rich amine higher than design, the temperature outlet of amine reboiler
less than design (actual is 249.5 deg F and design value is 262 deg F).
The overall heat transfer rate (U) at actual condition is 132 BTU/(Hr/Ft2.F) compare
the design is 173 BTU/(Hr/Ft2.F. This condition caused by the LMTD of actual is
higher than design value.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 72 of 109
The above table shows that the heat duty actual of 25-E-103 and 25-E-203 are
operated at 50% to the design. This caused by the flow rate of lean amine to be
cooled also only about 50% - 60% from design capacity.
The flow rate of lean amine does not affect to the power required of fan cooler driver,
so the power required to motors also higher than calculated value. At this case, the
actual fan be operated closed to design (11 fans for 25-E-103 and 12 fans running for
25-E-203). This condition related with performance of cooler, especially with heat
transfer rate. The U (overall heat transfer rate) at operating condition give value about
2 BTU/(Hr/Ft2.F) for operated and 3 BTU/(Hr/Ft2.F for the design value. This difference
indicated that the performance of cooler lower than the design performance.
The above table shows that the heat duty operated of exchanger 25-E-104A/B is
higher than design value. The difference is about 25% higher than design.
The above table shows that regen reflux condenser and amine regenerator re-boiler
are operated close to design condition. It has difference of heat duty about 11% than
the design value. This caused by the flow rate of acid gas to be removed also only
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 74 of 109
13% less than the design capacity (operated is 20.6 MMSCFD, and the design value
is 23.25 MMSCFD).
Power required of motor fan driver also proportional with the exchanger heat duty. At
this condition the actual operate 11 fans, and the calculated result is also same fans to
be operated.
Caused by the flow rate capacity of cooler load, the overall heat transfer also follow
with this condition. The U (overall heat transfer rate) at operating condition give value
about 3.57 BTU/(Hr/Ft2.F) and 4.19 BTU/(Hr/Ft2.F for the design value.
Only one Amine charge pump (Charge pump C) was running very close to design
condition. It’s efficiency reached 86.89% with flow rate of 2862 GPM, This pump is
designed to running with 83.53% efficiency at 2487 GPM flow rate. The pump was
running actually in even higher efficiency than the design condition. Attention should
be addressed to this situation since the pump draw consumed electric power of 2240
HP. It just below it's maximum power rating: 2250 HP.
Two of the Amine booster pumps were running. They were Amine Booster pump B
and C. Their efficiencies are 69.03% at 1556 GPM and 65.19% at 1306 GPM
respectively. At the other side, we have data from design condition when each pump
handles 2871 GPM. At this design condition, we got 81.94% efficiency. These two
pumps were running in good condition and within the range of operation.
A. DESCRIPTION
Propane refrigerant gas from gas chiller at 75 psig, compress by propane compressor
(single stage screw compressor). The compressor discharge at about 252 psig goes
to the propane condenser where it is totally condensed at about 122 oF. The propane
condenser is an air cooled heat exchanger.
The condensed propane goes to the propane accumulator and then to the gas chiller
via the level control valve. The refrigerant chills the sales gas from 57 F to 45 F and
then goes to LTS to separate the gas from the condensate.
B. PERFORMANCE
The main equipment at Refrigeration System are Exchanger (Gas chiller 30-E-102),
Propane compressor 30-K-101A/B and Gas/Gas Exchanger.
The above table shows that the refrigeration system operated at low load and the
propane chiller are operated at 40 % load (39 MMSCFD ) at actual power 110 KW
compare to design condition. The COP at actual condition is 2.24 compare to design
value is 2.79
Only one compressor is operated to handle the refrigeration system. The operating
conditions are as follows;
o
SUCTION TEMPERATUR ( F) 35.00 30.00
o
CONDENSING TEMPERATUR ( F) 127.00 120.00
PROPANE FLOW LBS/H 14,000.00 7,191.72 (Calculated)
At the actual condition, the refrigerant flow is 7191 lb/hr at actual power 110 KW and
COP = 2.87. Compare to design condition, the refrigerant flow is 14,000 lb/hr at
power design 260 KW and COP = 3. It means that the performance of compressor is
still in good condition.
30-E-101 DESIGN
The above table shows that gas/gas exchanger at the dew point control system have
heat duty only 30% refer to the design value. This caused by the flow rate of gas also
only 35%. The temperature profile of gas also not have high different between
operated and design value.
Caused by the flow rate capacity of gas to the gas/gas exchanger, the overall heat
transfer also follow with this condition. The U (overall heat transfer rate) at operating
condition give value about 0.23 BTU/(Hr/Ft2.F) and 0.30 BTU/(Hr/Ft2.F for the design
value.
A. DESCRIPTION
The hydrocarbon liquid from the feed drum is fed under level control to the top tray of
the condensate stabilizer. The stabilizer is a 32 inch ID reboiled stripping column
containing 18 stainless steel valve trays.
The stabiliser reboiler is a kettle type shell and tube exchanger utilizing about 3404
lb/h of 140# steam at normal operation. During normal operation about 1738 bbl/day
of 10 psi RVP condensate are produced. The condensate product from the stabilizer
is sent via the HC condensate cooler bundle in the refrigerant condenser air cooled
exchanger frame.
B. PERFORMANCE
The main equipment at Condensate Stabilizing system are Stabilizer Re-boiler 35-E-
102, and Condensate cooler 35-E-101
35-E-102 DESIGN
STEAM SIDE (SHELL)
Pressure, psig 117.00 150.00
Temp sat'd steam, F 330.00 330.00
Flow rate (35-FIC-006), Lb/hr 803.00 3,751.35
CONDENSATE SIDE (TUBE)
Temp Condensate to re-boiler, F 278.00 261
Delta T 66.00 69.40
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 78 of 109
The above table shows that actual heat duty of 35-E-102 is only 20 % compare to
design condition because the flow rate of feed liquid to the stabilizer is only 20 % - 25
% compare to design.
Due to the flow rate of stabilizer re-boiler is only 20% than the design, the U (overall
heat transfer rate) at operating condition give value about 6.52 BTU/(Hr/Ft2.F)
compare with the design value, 30.73 BTU/(Hr/Ft2.F
The arrangement of cooler in this area is designed to serve three stream cooling fluid,
i.e : Propane condenser, Propane overhead condenser and condensate stabilizer.
Only one fans cooler installed to cool them. At the plant survey, the propane overhead
condenser was off.
Heat Load total at actual condition of two condenser (30-E-105 and 35-E-101) are 3.8
MMBTU/hr compare with the design value is 5.7 MMBTU/hr. This heat load gives
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 79 of 109
A. DESCRIPTION
The water saturated gas from the three amine trains is dehydrated by contacting it
with lean triethylene glycol (TEG) in the three, identical glycol contactors. The design
water content of the dry gas is 10 lb H2O per MMSCFD. The dehydrated GLT gas is
recombined with the GLT amine unit bypass gas, sent through the dewpoint unit and
then to sales. The Dayung/Suban gases from two of the glycol contactors and the
Dayung/Suban amine unit bypass gas are sent directly to Sales.
Lean glycol is fed to the top of the glycol contactor at a rate of about 30-USgpm. A coil
is provided in the top of the tower to cool the glycol from about 210 oF to less than 150
oF by heat exchange with the dried gas leaving the contactor. The glycol flows
downwards through the structured packing in the column counter-currently contacting
and absorbing water from the gas flowing upwards through the packing.
The rich glycol accumulates on the chimney tray and is sent under level control to the
glycol regeneration skid. The dry gas exits the top of the contactor with the
Dayung/Suban gasses going to sales and the GLT gas going to the hydrocarbon dew-
point control unit.
The three glycol regeneration skids are identical. There are no connections between
the glycol regeneration skids or between the glycol lines in each train.
B. PERFORMANCE
The above table shows that Rich/Lean Glycol Exchanger are operated close to design
condition. Its heat duty is only 5% differ than the design value, although the flow rate
of glycol at the operation only 70% - 80% than design capacity. This condition is
caused by the difference of LMTD between operated and design value. The operating
condition gives temperature outlet of Lean glycol lower than design value.
Due to the flow rate capacity of cooler load, the U (overall heat transfer rate) at
operating condition give value about 70%-80% than the design value.
2-Oct-07
41-H-101 41-H-201
1 FUEL,
Flow, MMSCFD 0.02 0.02
2 FLUE GAS
T out, F 430.00 430.00
O2, % 7.00 7.00
Excess Air, % 45.77 45.77
3 PERFORMANCE
Heat absorption (LHV), MMBtu/hr 0.91 0.91
Heat absorption (HHV), MMBtu/hr 0.92 0.92
The heat duty of Glycol heater is 0.91 mmbtu/hr (calculated from process site).
Assuming the oxygen content of flue gas is 7%, the calculated efficiency is 84.91%.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 81 of 109
A. DESCRIPTION
Permeate gas from membranes, rich amine flash drum gas, and acid gas from the
amine reflux accumulators are combined and sent to the waste gas incenerator. In the
incenerator, the waste gas is incenerated by burning fuel gas at a sufficient high
temperature to ensure the complete destruction (oxidation) of the H2S and
hydrocarbons. The minimum exit gas temperature at the top of the stack is 450 oF to
ensure that the allowable ground level SO2 concentration is not exceeded.
150 psig saturated steam is produced by two heat recovey boilers with each capacity
of 230,000 lb/h. Normally, two boilers are operated to supply necessary steam for all
users in CGP.
B. PERFORMANCE
The main equipment of Waste Heat Boiler system are Waste Heat Boiler 46-B-
101/201, and BFW pump 46-P-102A/B/C.
2-Oct-07 DESIGN
46-B-101 46-B-101/102
1 INLET GAS,
Fuel Gas Flow, MMSCFD 1.55 1.77
Acid Gas Flow, MMSCFD 20.23 48.11
Permeat Gas Flow, MMSCFD 8.35 68.39
2 FLUE GAS
T out, F 376.00 416.00
O2, % 7.00 2.62
Excess Air, % 45.77 13.17
3 BFW
lb/hr 200,392.00 245,000.00
T in Economizer, F 200.00 251.00
T out Evaporator, F 347.00 375.00
4 PERFORMANCE
Heat Release (LHV), MMBtu/hr 149.52 822.94
Heat Release (HHV), MMBtu/hr 164.41
The above table shows that the WHB are operated at only 50 % load compare to
design condition, and the calculated efficiency is 80%. The temperature in flue gas are
lower than design condition and the excess air is higher than design.
Like Amine booster Pumps, the two BFW pumps were running within the specification,
and the efficiency reached is accepted. This BFW pump is designed to run with
63.53% efficiency at 528 GPM flow rate. Actually, two pumps were running at same
rate of flow (380 GPM) with 60.48% efficiency.
A. DESCRIPTION
Electrical power is generated and distributed to provide the prower requirements for
the gas plant and offsites. Electrical power Generator driven by Gas turbine generator,
which gas supplied from HP (high pressure) fuel gas system. Three gas turbine are
provided with two generator running and one on the standby mode. The design
capacity of generator is 4500 kW each unit. The actual capacity on the field survey
only about 2100 kW each turbine generator (45% of design capacity) and running two
of three generators.
Generator specification is power 4688, voltage 4160, freq 50 Hz, cos Q 0.85. The
large motor (lean amine charge pump, WHB Blower, propane compressor) supply by
6600 volt and the other motors using 400 volts.
B. PERFROMANCE
2-Oct-07 DESIGN
47-GT-101A 47-GT-101B 47-GT-101A/B/C
TURBINE
Fuel gas :
flow, MMSCFD 0.89 0.92 1.31
Flue gas :
Temperature, F 0 0 900
O2, % 16 16 16
Excess Air, % 296 281 267
Turbine Eff, % 21 21 30
Btu/kwh 16,571 16,077 11,559
CO2 Emission
lb/hr 4,870 5,034 7,914
GENERATOR
Power Output, KW 2,158 2,265 4,688
PF 0.81 0.83 0.84
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 84 of 109
The above table shows that GTG operated at 50 % load compare to design condition.
The heat rate of 47-GT-101A is 16,571 Btu/kwh, greather than design 16000 Btu/kwh
but 47-GT-101B 16,077 Btu/kwh close to design.
A. OPERATION
Instrument and utility air are supplied by the two 340 scfm, screw type compressor
connectod in a lead-lag configuration. The compressed air is filtered and then dried in
heatless adsorption type dries which are on automatic regeneration cycles. The
instrument air compressor packages are provided with local electronic control panels.
The instrument air receiver is normally operated between 110 and 120 psig. The utility
air take-off is equipped with a shut off valves to prevent utility air usage from drawing
down the instrument air pressure.
B. PERFORMANCE
There are three compressors Atlas Copco GA 75 , 51-A-101A /B/C with design
capacity is 340 SCFM, the performance of each equipment are as follows,
The above table shows that the compressor is operated at low load. The
performance can not be evaluate accurately because no flow meter of air
Electric map for Central Grissik Plant is like the one for Suban Gas plant. It is derived
from single line diagram, and intend to get a closer and clear point of view to one that
need brief description on power consumption at each process. It Emphasize the
voltage, and power required for each equipment.
The power mentioned at each equipment is the power in normal design condition.
A. Amine System
4.16 KV
25-P-102 A/B/C
Amine Charge pump A/B/C
2250 HP x3
480 V
4.16 KV
30-K-101 A/B
Propane Compressor A/B
350 HP x2 480 V
480 V
35-PM-102 A/B
Condensate shipping pump A/B
75 HP x2
D. Dehydration System
480 V
4.16 KV
46-K-101/201
Inc. Blower train A/B
400 HP
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 87 of 109
480 V
480 V
H. Utility System
480 V
Based on the site survey founded that many metering and instrument are not work
properly. Findings and recommendations of metering and instrumentation at
Grissik Central Gas Plant are as follows :
line analyzer = 14 %)
Need to install
sampling line of flue
gas for each GTG
Finding :
WHB is operated at high excess air (77 %) compare to the design figure
which is 27 % excess air. The efficiency is 80 %
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 89 of 109
Recommendation :
3. Heater
Finding :
4. GTG
Findings :
GTG are operated at lower load is around 50 % compare to design, but the
performance ( heat rate ) are still close to design at low load
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 90 of 109
5. Propane Comp
Findings :
Based on the actual data, the refrigeration load is only 50 % compare to design
condition, but the COP is 2.87 compare to design COP is 3. It means that the
compressor is still in good condition
6. Gas Chiller
Findings :
the temperature indicator inlet and outlet are still in good conditions
7. Air cooler
Findings :
Power rated required for drive motors of fan coolers are below 1% - 2% due
to their heat duties, except for Lean Amine 25-E-203 and Condensate
cooler (25-E-101). This case indicate that power consumption of these
coolers more waste energy (less efficiency).
Recommendations :
Need to check the cooler system of Lean amine cooler, because at the
plant survey, they have high power consumption although the capacity of
heat load only a half than design.
8. Heat Exchanger
Findings :
Findings :
The Thermal swing adsorber (TSA) system running on good condition,
because the C6+ concentration at the feed gas to membrane is 29 ppm
compare to the design is 39 ppm.
The membrane system separation only give separation rate is 32%
compare to the design 50% of CO2 feed, so the CO2 content in gas to
contactor still high than design value.
Recommendation :
Need to check again the membrane module system to upgrade the
separation rate.
Findings :
The absortion rate capacity of amine contactor is only 38% refer to the
design capacity rate. This case caused by the flowrate of gas processing
capacity of lean amine only 40% than design.
Recommendation :
a. Energy Losses :
Based on heat balance calculation, energy losses from high temperature flue gas
(more than500deg F) at Grissik is coming from Stack of GTG. Total losses is
57,821,543 Btu/hr.
GTG
247-GT-201A 30,471,332 949
247-GT-201B 27,350,211 967
247-GT-201C 0 0
TOTAL 57,821,543 958
Actually, by utilizing economizer with stack temperature around 500 deg F, this
Fluegas losses can be used to generate saturated steam about 28,000 lb/hr.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 95 of 109
b. Potential Saving :
Based on the evaluation, shows that the potential saving are coming from :
Utilized flare gas that will reduced fuel consumption to 1.0 MMSCFD
CO2 emission at suban gas plant is 182,886 lb/hr. its come from combustion of
fuel gas at flare gas, heater, WHB and GTG. Optimized operation and utilized
flare gas can reduce CO2 emission around 5 %
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 96 of 109
CO2 reduction,
lb/hr
utilized flare gas 8,507.79
Total 8,507.79
Findings :
Existing daily report just for production activity it does not cover data for
plant performance evaluation purpose
Important data for plant performance not cover in daily log sheet
Recommendation :
There are wells at ConocoPhillips South Sumatra area that contents oil in significant
amount and high gas concentration. Rawa plant is designed to process this oil, and re
inject the gases to the injection wells.
High-pressure oil & gas came firstly from wells entering the plant via manifold, before
entering the production processes. The first process is High-pressure separator (HP
separator). Oil, MP Gas and Water is separated in this process. MP gas (450 psig)
leave the top separator and water leave the bottom of the separator and then store it
in the production water tank before send to Central Ramba.
Oil & LP gas mixture goes to medium pressure (MP) separator. In MP Separator, Oil
& HP gas is separated. Oil is stored to the crude oil tank before ship to Plaju. LP Gas
(50 psig) compressed by LP Gas compressor (gas engine) to raise it the pressure until
450 psig.
MP gas from HP separator mix with MP Gas from LP Compressor and then the HP
Compressor driven by gas turbine to rise the pressure until 1200 psig. Water content
in HP Gas is reduced by glycol system before injected to the wells. The design of HP
Compressor is 45 MMSCFD and about 1 MMSCFD of process gas used for fuel.
The simplified process flow diagram of Rawa field is shown at diagram in figure 1.1
MP Gas 5
HP Compressor
Oil wells 2
1
Injection
To wells
HP Separator MP Separator Gas Scrubber
Glycol
System
3 4
Data from production records taken from 1-10 Aug 2007 at table 1 shows that oil
extracted from wells is about 300-320 barrels/day (0.001%) and water produced is
1500-1600 (0.003%). About 21 MMSCFD gas derived is re injected to injection wells
while the other product, i.e. fuel gas, is sent to Ramba station.
The Energy Source of Rawa oil Plant is LPgas used for gas turbine compressor (LP
and HP) and Glycol Regenerator which comes from LP Separator. LP Compressor
driven by gas engine to increase the LP Gas pressure from 60 psi to 450 psi and HP
Compressor driven by gas turbine to increase the MP gas from LP Compressor and
HP Separator to 1200 psi.
Fuel flow meter only for total consumption. There is no flow meter for each
consumers. The total consumption is 0.7 – 1.1 MMSCFD
Rawa oil processing plant doesn't have electric power generation systems inside the
plant itself. Electric power derived from Ramba power plant via medium voltage lines,
11KV, 3, 50 Hz. Incoming power line then is stepped down by a transformer to
380V/220V, 3, and in turn, this voltage system is applied to all the electrical
equipments and machines inside the plant. There is no KW Meter in main panel. The
estimate load is about 150 KW.
For emergency purposes, there is a diesel fueled electric generator (380V, 3, 50 Hz)
that has capacity of 505 KVA. This generator set needed extra maintenance due to
this machine is of the old type, and have been used over a long period of time.
HP Compressor 5000-PK-100
Injection gas flow at actual condition is 39.20 MMSCFD (87 % load) compare to
design (45 MMSCFD) and power require is 2860 HP compare to 3525 HP
21-Dec-07 DESIGN
HP Turbine 5000- HP turbine 5000-
PK-100 PK-100
A TURBINE
Fuel gas :
flow, MMSCFD 0.85 0.89
Flue gas :
Temperature, C 1,062 900
O2, % 15 16
Excess Air, % 234 279
Eff, % 22 27
Btu/BHP 11,460 9,392
CO2 emission :
Flow, lb/hr 2,217 2,450
B COMPRESSOR
Power Required, KW 2,134 2,630
, HP 2,860 3,525
Turbine is operated at 72 % load (2860 HP) compare to design (3525 HP) and heat
rate is 11.460 Btu/HP compare to the design heat rate is 10500 Btu/HP.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 100 of 109
LP Compressor 5000-PK-101
A. Instrumentation
no control monitoring system that can be used to monitor the operation of the
compressor from control room.
B. Compressor
LP compressors shut down frequently and causing increase of flare gas from 1
MMSCFD to 4-9 MMSCFD.
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 102 of 109
Function : converting energy from fuel gas to mechanical energy to produce electricity
Key Performance Indicator :
Efficiency which is consist of gas turbine efficiency and generator
efficiency
Variable should be Measured :
Fuel gas flow (input)
Fuel gas heating value (LHV)
Generator Output
Oxygen content in flue gas
Flue gas temperature
Spread sheet :
Function : converting energy from fuel gas to mechanical energy to compress sales
gas
Key Performance Indicator :
Efficiency which consist of gas turbine efficiency and compressor
efficiency
Energy Intensity which is representing by fuel gas divided by
mechanical energy to compress sales gas
Variable should be Measured :
Fuel gas flow (input)
Fuel gas heating value (LHV)
Oxygen content in flue gas
Flue gas temperature
Suction and discharge pressure of sales gas
Flow of sales gas
Spread sheet :
6.1.7. Pumps
6.2. SYSTEM
6.2.1. TSA System
Spread sheet :
Spread sheet :
Functions : to reduce acid gas (CO2 & H2S) content of treated gas
Final Report ID-N-GN-00000-00000-00068
Energy Management Audit / Assessment for PSC Corridor
ConocoPhillips Indonesia Page 107 of 109
A. Amine Contactor
B. Amine Regenerator
A. Gas Chiller
Composition of condensate
Flow of steam
Operating Temperature and Pressure of column
Spread sheet :
See Appendix no.6.17
6.2.7. Depropanizer