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Delivering Clean Energy Safely

Pump P-2870
Replacement
FINAL PRESENTATION

Ichsan Dwi Nugraha


2314100068

M. Reinaldo Ongky B.A


2314100096

Chemical Engineering Department


Institut Teknologi Sepuluh Nopember

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VICO Indonesia

VICO Indonesia has been operating the Sanga-Sanga


Production Sharing Contract (PSC), which is located in the Kutai
Basin of East Kalimantan and covers an area of approximately
1,700 square kilometers, for more than 40 years. It has
produced more than 12,6 TCF of gas and 0.4 billion barrels of
liquid from the production fields in Badak, Mutiara, Semberah,
Nilam, Pamaguan, Lampake and Beras.

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VICO Indonesia

Semberah Fields was


discovered in 1974 and
is located in the northern
most area of the PSC.
Semberah also contains
multiple oil and gas
reservoirs. All gas and oil
sent from Semberah
Wells is directly
processed at Semberah
Plant-14. Gas is
delivered to Bontang
and oil is delivered to
Tanjung Santan.

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Background

The Problem
On June 2014, external corroded happened on house of pump
P-2870 of Semberah-14 Plant because of the atmospheric
pressure and the humidity condition is high, repainting the
house of pump seemingly impossible because the sand
blasting process could lead into the other damage for another
parts of the house of pump, the marine coating process
already been late because the housing already on the bad
condition.
One of the possible possibility is replace the pump using the
ex-used pump from mini plant C-09

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Pump P-2870

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Pump
Pump is a device that moves fluids, or sometimes slurries, by
mechanical action. Pump can be classified into dynamics pump
and displacement pump.

Dynamic pumps are consist of centrifugal pump (axial flow,


mixed flow, radial flow, and peripheral flow), and special effect
pump (jet, gas lift, hydraulic ram, electromagnetic pump).

Displacement pumps are consist of reciprocating pump (piston,


diaphragm) and rotary pump (single rotor, multiple rotor)

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Pump

The most common types of pumps used in gas processing


plants are centrifugal and positive displacement. Occasionally
regenerative turbine pumps, axial-flow pumps, and ejectors
are used. Modern practice is to use the specific pumps based
on the needed of the operation itself.

Sometimes there are some other things which need to be


considered as the considerations are usually less costly,
require less maintenance, and less space.

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Negative Positive
It can be negative when It can be positive when
liquid level is below the the liquid level is above the
centerline of the pumps. centerline of the pumps

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TDH
Total Dynamics Head is the total equivalent height that a fluid
is to be pumped, taking into account friction losses in the pipe
or the amount of pressure differential created by a pump as it
operates.

The total dynamic head is the total  pressure when water is


flowing in the system. It includes pressure needed to overcome
elevation differences, and friction losses in the pipes in order
to produce a required operation pressure at the outlets.

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Pump P-2870

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Pump P-2870

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Pump P-2870

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Analysis Study on Pump P-
2870

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Analysis Study on Pump
• Positive Suction

2,2 m
API Separator

2,6 m

Box Control

0,7 m

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Analysis Study on Pump
• Positive Suction
OPERATING CONDITIONS
1. Pump Capacity 1371 BPD
40,0 GPM
0,15 M3/min
9085 Kg/hr
2. Operation hours 24 Hours
3. No of operation TOTAL HEAD
1. Discharge Head 113,84ft
pumps 1 Units 2. Suction pressuse 16,44 ft
4. Fluid Name Water 3. Total Head 97,40 ft
5. Normal Temperature 90 o
F
6. Normal Specific Gravity 1,0000
7. Density 62,30 lb/ft3
8. Maximum Vapor
Pressure 0,70 psi
9. Normal
Viscosity 0,86 cP
10. Line Capacity 1.371 BPD
40,0 GPM
11. % Overdesign 20,00 %
12. Capacity
Overdesign 1.646 BPD
48 GPM

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Analysis Study on Pump
• Negative Suction Condition

3m
API Separator

0.3 m

3m

2,6 m

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Analysis Study on Pump
• Negative Suction Condition
OPERATING CONDITIONS
1. Pump Capacity 1371BPD
40,0GPM
0,15M3/min
9085Kg/hr

2. Operation hours 24 Hours


DIFFERENTIAL PRESSURE
1. Discharge Pressure 37,03
3. No of operation pumps 1 Units 2. Suction
4. Fluid Name Water -5,66
Pressure
5. Normal Temperature 90 oF 3. Special Margin 0,00
6. Normal Specific Gravity 1,0000 4. Differential Pressure 42,69
5. Head 98,87
7. Density 62,30 lb/ft3

8. Maximum Vapor Pressure 0,70 psi

9. Normal Viscosity 0,86 cP

10. Line Capacity 1.371 BPD

40,0 GPM

11. % Overdesign 20,00 %


One12. Capacity
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Available Pump on Mini Plant
C-09

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Available Pump on Mini Plant
C-09

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Available Pump on Mini Plant
C-09

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Available Pump on Mini Plant
C-09
TDH (ft)

Flow rate
(GPM)
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Orifice
An orifice plate is a device used for
measuring flow rate, for reducing pressure
or for restricting flow (in the latter two
cases it is often called a restriction plate).
The orifice plate bore can be made in many
configurations to handle various flow
measurement jobs. The flowing conditions
should be checked to see which of the
configurations is suitable for each
measurement job.

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Impeller

An impeller is a rotor used to increase the


pressure and flow of a fluid. Impeller is a
rotating component of a centrifugal pump
which transfer energy from the motor that
drives the pump to the fluid being pumped
by accelerating the fluid outwards from the
center of rotation.

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Available Pump on Mini Plant
C-09

Larger
Impeller
Diameter

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Negative Suction Condition
Calculation of The Distance from the Flame
Center to the Object or Point being considered

in most cases, equipment can safely tolerate


higher degrees of heat density that those defined
for personnel. Any items vurnerable to
overheating problems are involved, such as
construction materials that have low melting
points, heat-sensitive streams, flammable vapor
spaces, or electrical equipment, then the effect of
radiant heat on them may need to be evaluated

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Negative Suction Condition
• Calculation of The Distance from the Flame
Center to the Object or Point being considered

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Calculation of The Distance from the
Flame Center to the Object
• Basis Perhitungan (Oil/Cond)
Flowrate actual yaitu 230 BCPD = 2707,54 lb/hr
Hc dari oil = 17.158,3 Btu/lb
• Basis Perhitungan Gas
Flowrate actual yaitu 5,15 MMSCFD = 10791,41
lb/hr
Hc dari oil = 20.062 Btu/lb

Q1 (Oil) = Flowrate x Hc = 4,6 10^7 btu/hr


Q2 (Gas) = Flowrate x Hc = 2,2 10^8 btu/hr
Q = Q1 + Q2 = 2,6 10^8 btu/hr

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Calculation of The Distance from the
Flame Center to the Object
• Basic Calculation of The Distance of Pump
directly to The Burn Pit
Q = 9,78.10^8 btu/hr
=1
F = 0,1 (Gas dan Pembakaran ideal)
K = 500 btu/hr

D = 64,6919 ft = 19,731 m

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Calculation of The Distance from the
Flame Center to the Object

Burn
Pit

Pum
p
D = 64,6919 ft =
19,731 m

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Conclusion
• The pump P-2870 can be replaced by using pump
available in C-09 mini plant using positive suction
and negative suction. But, it is necessary to place
the pump with the distance about 19 m far from the
burn pit for safety reason.

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Recommendation
• In order to avoid a similar case in the future, it is
recommended to perform the following:
1. Replace the pump P-2870 using available pump from
C-09 miniplant with positive suction immediately
but we need to focus on prevent atmospheric
pressure and the humidity conditions.
2. Replace the pump P-2870 using available pump from
C-09 miniplant with negative suction immediately
but we need to focus on placing the pump +/- 19 m
away from the burn pit for safety reason.
3. Paint the house of the new pump and skid with good
surface preparation.

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References
• American Petroleum Institute. 1997. Guide for
Pressure-Relieving and Depressuring System.
• Gas Processors Suppliers Association. 2004.
Engineering Data Book.
• Geankoplis, Christie J. 2003. Transport Process and
Unit Operations. New York: Prentice Hall Book
Company
• Karassik, Igor. 2001. Pump Handbook. New York: Mc
Graw Hill Book Company
• Wibisono, Nugroho. 2008. Orifice and Restriction
Orifice.

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