FOREWORD This paper was prepared to fulfill one of the requirements for promotion to Senior Engineer Level | in PT Badak NGL. Title of this paper is “ADVANCE PROCESS CONTROL (APC) IMPLEMENTATION IN BADAK LNG PLANT”. | wish this paper will be useful for PT Badak to understand more clearly about how APC is working, optimize APC that already implemented in Train-F, plan implementing in other Trains and explore new benefits in other Plants (Utilities and Storage Loading) | believe if APC already implemented in all Trains and Plants, PT Badak will able to produce LNG and LPG more optimally, efficiently and safely. In this opportunity, | would like to thank to: 1. Mr. Nanang Untung as General Manager / Director PT Badak NGL Mr. Djoko Wibowo as Development Division Manager Mr. Yhenda Permana as Project Department Manager Mr. Darwis as Project Engineering Section Head Mr. Suhadi Isdiyanto as EPDP Coordinator Mr. Bambang Prijadi as Man Power Planning & Organization Section Head All colleagues that already support me to prepare and present this paper. Noe eren | believe this paper is far from perfect, so | will be grateful to receive any comments for improvement. Bontang, 12 May 2009. Page 1 of 114TABLE OF CONTENTS FOREWORD. TABLE OF CONTENTS. ABSTRACT CHAPTER-| INTRODUCTION.. \4, Background 12. Objectives... seseeeetetteettetesees 1.3. Scope of Discussion 1.4. Discussion Method............. CHAPTER-II OPPORTUNITIES AND PROBLEMS. CHAPTER-II| DISCUSSIONS... IlL1, Advance Process Control (APC)... I11.2. Process Scheme of LNG Train.......ccccecsccesnsesesestsesreeaee lIL.3. Operating Strategy and Performance Review... I11.3.1, Production and Scheduling Plans 11.3.2. Amine (Plant-l)......ccccsceeeeeeeereeees I11.3.3, Dryers and Mercury Removal Units (Plant-2) l11.3.4. Scrubber (Plant-3).... 111.3.5. Fractionator (Plant-3) MW3.5.1, Deethamizer......c.ccecccsecseeseterseseeserseerseeen 111.3.5.2. Depropanizer. I11.3.5.3. Debutanizer 11.3.6. Splitter (Train A-D).....ssssssssscessceeeeseeeeeteeetssess 11.3.7. Stabilizer. 111.38. Main Cryogenic Heat Exchanger (MCHE).... UIL.4. Benefit Estimation prior to APC Implementation (Feasibility Study Report at 2001). U11.4.1. Benefit Method. 11.4.2. Prices. Page 2 of 114 27 27 3011.4.3, 11.4.4. ML4.5, 1.4.6. 4.7. 1.4.8. 1.4.9. LNG Maximization. LPG Maximization (C3 and C4)........:ccessesssseeeeernses 1.4.4.1. LPG Extraction. 1114.4.2. LPG Production... Maximize Efficiency. Propane Purity (Refrigerant) Quantified Benefits Summary Other Benefits (not Quantified) Investment. IIL.4.10. Return of Investment. lI.5. APC Pilot Project Implementation at Train-F. M51 M52. IL5.3. 11.5.4. ILS. 15.6. L5.7. 5.8. 5.9. . Plant Survey / Control Tuning Advance Process Control (APC) Technology Selection. Scope of Work........... Project Schedule........ Existing Analyzer Review... Plant Test. Detailed Design Review..............cs++ cecssseseeees sees 1115.7.1. Robust Quality Estimators (ROE of Fractionation Unit... sees sees sees sees . 1I.5.7.2.. MCHE-MR Robust Quality Estimators (RQE) 1I15.7.8. Scrubber Column SMOC........sssesseeeessseeeee . 1.5.7.4. Deethanizer Column SMOC. I115.7.5. Depropanizer Column SMOC........... 1.5.7.6. Debutanizer Column SMOC. 1.5.7.7. Flow Stabilizing SMOC. 1.5.7.8. MCHE-MR SMOC..............::::eeeeee ‘Simulation. DCS Interface Development.............++ . 15.9.1. Scrubber Column SMOC DCS Interface. I5.9.2. Deethanizer Column SMOC DCS Interface....... Page 3 of 114 31 32 32 35 37 39 39 40 a a 42 42 47 48 51 53 56 87 58 60 62 65 67 69 7 73 79 79 80 80