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

One Team One Direction VICO Indonesia

One Team One Direction VICO Indonesia
 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.

One Team One Direction VICO Indonesia

 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

One Team One Direction VICO Indonesia

 Pump P-2870

One Team One Direction VICO Indonesia

 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)

One Team One Direction VICO Indonesia

One Team One Direction VICO Indonesia
 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.

One Team One Direction VICO Indonesia

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

One Team One Direction VICO Indonesia

 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.

One Team One Direction VICO Indonesia

 Pump P-2870

One Team One Direction VICO Indonesia

 Pump P-2870

One Team One Direction VICO Indonesia

 Pump P-2870

One Team One Direction VICO Indonesia

 Analysis Study on Pump P-2870

One Team One Direction VICO Indonesia

 Analysis Study on Pump
• Positive Suction

2,2 m
API Separator

2,6 m

Box Control

0,7 m

One Team One Direction VICO Indonesia

 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 16,44ft
4. Fluid Name Water 3. Total Head 97,40ft
5. Normal Temperature 90 oF

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

One Team One Direction VICO Indonesia

 Analysis Study on Pump
• Negative Suction Condition

3m
API Separator

0.3 m

3m

2,6 m

One Team One Direction VICO Indonesia

 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 Pressure -5,66
4. Fluid Name Water 3. Special Margin 0,00
5. Normal Temperature 90 oF 4. Differential Pressure 42,69
6. Normal Specific Gravity 1,0000 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 %
12. Capacity Overdesign 1.646 BPD
48 GPM

One Team One Direction VICO Indonesia

 Available Pump on Mini Plant C-09

One Team One Direction VICO Indonesia

 Available Pump on Mini Plant C-09

One Team One Direction VICO Indonesia

 Available Pump on Mini Plant C-09

One Team One Direction VICO Indonesia

 Available Pump on Mini Plant C-09
Perbandingan TDH
Existing dan TDH Baru
160

150
TDH (ft)

140

130

120

110

100

90

80
0 10 20 30 40 50 60 70 80 90 100
Flow rate (GPM)
One Team One Direction VICO Indonesia
 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.

One Team One Direction VICO Indonesia

 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.

One Team One Direction VICO Indonesia

 Available Pump on Mini Plant C-09

Larger Impeller
Diameter

One Team One Direction VICO Indonesia

 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

One Team One Direction VICO Indonesia

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

One Team One Direction VICO Indonesia

 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

One Team One Direction VICO Indonesia

 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

One Team One Direction VICO Indonesia

 Calculation of The Distance from the Flame
Center to the Object

Burn
Pit

Pump
D = 64,6919 ft = 19,731
m

One Team One Direction VICO Indonesia

 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.

One Team One Direction VICO Indonesia

 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.

One Team One Direction VICO Indonesia

 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.

One Team One Direction VICO Indonesia

m Semberah V-2420
Well MP Separator
WATER PROCESSING FLOW DIAGRAM
V-2430
MP Separator
Water Clarifier
injection
V-3580
HP Separator Injection

V-2010
Semberah LP Separator T3500
Well
V-2740 Oily Water
V-2080 Water Holding Tank
LP Separator
Break Cap. 1.200 Bbls
Drum
H-2280
Heater Treater
Burn Pit
V-2770
K.O. Drum
om 13 Plant H-2310
Process Heater Treater

P-2870
om 14 Plant
Process H-2320 Water Clarifier
Heater Treater
injection
Injection
To T-2030A/B

oduce API
-40 Separator
psig T-3510 WEMCO CPI
P-3520 A
To Burn Pit
oduce
dak Sample
point P-2850 A/B
psig
Sample
point
Legend :
P-3520 B Normally Closed
Normally Open

One Team One Direction VICO Indonesia

 From Semberah
Well
V-2420
MP Separator
WATER PROCESSING FLOW DIAGRAM
V-2430
MP Separator
Water Clarifier
injection
V-3580
HP Separator Injection
From Semberah
Well V-2010
LP Separator T3500
V-2740 Oily Water
V-2080 Water Holding Tank
LP Separator
Break Cap. 1.200 Bbls
Drum
H-2280
Heater Treater
Burn Pit
V-2770
From 13 Plant K.O. Drum
Process H-2310
Heater Treater
From 14 Plant P-2870
Process
6" HDPE

H-2320 Water Clarifier

Heater Treater injection
To T-2030A/B
Injection

Water Produce
To S-40 API
50-60 psig Separator
T-3510 WEMCO CPI
P-3520 A
Water Produce
To Burn Pit
To Badak
80-120 psig Sample
P-2850 A/B
Sample point
point

Legend :
P-3520 B Normally Closed
Normally Open

One Team One Direction VICO Indonesia