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PT. PRATIWI PUTRI SULUNG

Chevron. PRESENTATION TO. PT. PRATIWI PUTRI SULUNG. Co-Gen Duri. Introduction. Located in Texas, U.S.A. Michael W. Kort M.E.Eng., his expertise is the Oil/Gas Facilities pipeline equipment and is stationed in Indonesia.

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PT. PRATIWI PUTRI SULUNG

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  1. Chevron PRESENTATION TO PT. PRATIWI PUTRI SULUNG Co-Gen Duri

  2. Introduction Located in Texas, U.S.A. Michael W. Kort M.E.Eng., his expertise is the Oil/Gas Facilities pipeline equipment and is stationed in Indonesia. North Star Intl. doing business with Q. B. Johnson Manufacturing Inc. Oklahoma, U.S.A. North Star Intl. doing business with Luxor Manufacturing Inc. Texas, U.S.A. North Star Intl. doing business with Alabaster Corp. Bioremediation, Texas, U.S.A. North Star Intl. doing business with PT. Pratiwi Putri Sulung, Jakarta, Indonesia. PT. Pratiwi Putri Sulung, their expertise manufacturing and construction of Metering Stations.

  3. Chevron Air-Operated Valve (AOV-1) Facility Improvement at NDC Fuel Gas Plant NDC letdown station

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  8. Chevron Background 1. Current Condition : • Inadequate redundancy for system control of Emergency Shutdown Valve. • Had been in service / operation for 7 (seven) years since NDC Plant commissioning in 2000 and never been serviced. • Single piping (no bypass for Emergency Shutdown Valve) without any facility for maintenance. • No Predictive/ Preventive maintenance can be applied. • No double block & bleed valves. • Pressure Safety Valves (PSVs) are directly release to atmosphere at the fuel gas plant with inadequate requirement based on PSV Audit Chevron standard. • 2. What are we going to do? : • We are going to provide alternative line facility of gas supply with no operation interruption (on line condition). Thereby increasing plant reliability.

  9. Chevron Background(cont.) • 3. How will we do it? : • By installing the by pass line for Emergency shutdown valve. • By installing the alternative system control for redundancy. • By installing the double block & bleed valves. • By performing the PSV audit and modify relief system as necessary. • 4. Why is this important? : • This AOV-1 valve is the weakest point where it can fail anytime and shutdown the entire plant. • 5. How it will contribute to GPO business objectives? • It becomes very critical for both NDC Plant Safety & Commercial Operation. In case of failure, NDC will loss of electricity & steam production and may impact on loss of generation at the grid & steam supply to CPI operation.

  10. LEDEEN PNEUMATIC AOV BLEED VALVE 10” GROVE VALVE B5 16” GROVE VALVE B5 10” GROVE VALVE B5

  11. Chevron Business Driver • To avoid potential revenue loss of US$ 224,000.00/ daydue to loss of fuel gas supply (from MCTN side) • To avoid potential revenue loss of approximately US$ 9MM/ day (from CPI production) • To improve safety and reliability of NDC plant operation

  12. Chevron Boundary Conditions • 1. In Scope: • Area of scope for fuel gas supply facility at NDC letdown station & HCT pigging facility at North Duri • Design, construct, and commission of new modification of incoming fuel gas • Hydro-test, NDT, and X-ray are required and documented • New operation and maintenance procedures • Total appropriated budget (materials & man powers) • Instrumentation system • Civil work (pipe support) • Venting line modification • Double block & bleed arrangement

  13. Chevron Uncertainties Identified Technical Uncertainties • The qualified contractor to execute the installation. • New bypass line design may require a big area including underground line thru the road crossing. • Budget value approved by management is less than estimated • Material availability and delivery of the Air Operated Valve (AOV)

  14. MR 1 M2A M2B

  15. Chevron Preliminary Overall Plan Preliminary Assessment • The AOV-1 is located downstream of the CPI HCT interface to isolate the system from the supply line. • This valve is remotely manually controlled through the DCS to open or close the fuel gas supply line. The DCS monitors the pressure downstream of the regulating station by pressure transmitter, and under normal operating conditions, adjust the two 8 inch control valves (PCV-23A & PCV-23B) to maintain the operating pressure. During start-up of the first CT, the smaller 3 inch regulating valve is used to maintain system pressure. • This valve is manually gear operator and it has been provided to operate the valve if the instrument air system is non operational or the actuator has malfunctioned. • Downstream of AOV-1 valve is a pressure reducing / regulating station, which is designed to maintain the fuel gas system pressure at 425 psig and protected from over pressure in event of a control valve failure by two 10 inch pressure relief valves (PSV-26 & PSV-27).

  16. Chevron Preliminary Overall Plan (cont’d) Design Alternatives 1. Fully shutdown (Alternative 1) 2. Hot-tap tie-in at NDC facility (Alternative 2) 3. Partially shutdown with temporary plug at NDC facility (no hot-tap) - (Alternative 3)

  17. Strategic Table Strategic Theme Partially shutdown with NO temporary plug at NDC facility (no hot-tap) (Alternative 3) Tie-in connection The bypass line from pig receiver point at HCT plant will feed-in 16" pipeline into the of gas led-down station. The bypass line will be fabricated outside and feed-in 14" branch line into the existing elbow of gas led-down station. Hot tap equipment will be required for this temporary plug. Small modification on the pig receiver is required. It will need partially shutdown of NDC gas letdown plant. Implementation The bypass line will be fabricated outside and feed-in 16" branch line into the existing of gas led-down station. Small modification on the pig receiver is required. It will need partially shutdown of NDC gas letdown plant.

  18. Chevron EXISTINGUNIT AOV 1 NO DOUBLE BLOCK NO ISOLATION

  19. PIPE AND EQUIPMENT Prefabricated and Hydrotested and X-ray and Documented by; PT. Pratiwi Putri Sulung. Installation and construction by; PT. Pratiwi Putri Sulung, supervised by Michael W. Kort

  20. PREFABRICATED PARTS FABRICATED BY PPS AND HYDRO-TESTED AND X-RAY AND REPORT (DOCUMENTED) PURPOSE FOR QUICK INSTALLATION 3 2 1 6 5 4 7

  21. VALVE INSPECTION Relieve Valve A B Close Close : 1. CLOSE Valve A and B 2. Open Relieve Valve 3. Inspect for leaks at the Valves, by a Gas Detector 4.This will tell you, OK or NG 5. If Ok, remove obstacles Down Stream of the Valves 6. If NG, install a Stopple after you can remove obstacles Down Stream of the Valves Relieve Valve

  22. PARTIALLYSHUTDOWN REMOVE CLOSED CLOSED AOV 1 OPEN OPEN

  23. PARTIALLYSHUTDOWN INSTALL VALVE CLOSED INSTALL BLIND FLANGE 1 INSTALL PREFABRICATED SPOOL CLOSED CLOSED DOUBLE BLOCK AOV 1 OPEN OPEN OPEN

  24. PARTIALLYSHUTDOWN REMOVE CLOSED CLOSED CLOSED AOV 1 OPEN OPEN OPEN

  25. PARTIALLYSHUTDOWN INSTALL VALVE CLOSED CLOSED 2 INSTALL PREFABRICATED SPOOL DOUBLE BLOCK CLOSED CLOSED AOV 1 OPEN OPEN OPEN

  26. PARTIALLYSHUTDOWN REMOVE BLIND FLANGE RE-INSTALL CLOSED CLOSED CLOSED CLOSED AOV 1 OPEN OPEN OPEN

  27. PARTIALLYSHUTDOWN 3 INSTALL PREFABRICATED CLOSED INSTALL VALVE CLOSED CLOSED INSTALL VALVE CLOSED CLOSED AOV 1 OPEN OPEN OPEN

  28. PARTIALLYSHUTDOWN CLOSED CLOSED CLOSED 4 INSTALL PREFABRICATED CLOSED CLOSED AOV 1 OPEN OPEN OPEN

  29. PARTIALLYSHUTDOWN CLOSED CLOSED CLOSED DOUBLE BLOCK CLOSED CLOSED AOV 1 OPEN AOV 2 OPEN OPEN CLOSED CLOSED INSTALL VALVES

  30. PARTIALLYSHUTDOWN CLOSED OPEN OPEN TRANSFER FLOW OPEN OPEN NORTH AREA IS FINISHED AOV 1 OPEN AOV 2 CLOSED CLOSED INSTALL BIND FLANGE CLOSED REMOVE

  31. PARTIALLYSHUTDOWN CLOSED OPEN OPEN OPEN OPEN AOV 1 OPEN DOUBLE BLOCK AOV 2 CLOSED 5 INSTALL PREFABRICATED SPOOL CLOSED INSTALL VALVE CLOSED

  32. PARTIALLYSHUTDOWN CLOSED OPEN OPEN OPEN OPEN AOV 1 OPEN AOV 2 CLOSED CLOSED CLOSED CLOSED CLOSED REMOVE

  33. PARTIALLYSHUTDOWN CLOSED OPEN OPEN OPEN OPEN AOV 1 OPEN INSTALL VALVE AOV 2 CLOSED CLOSED 6 INSTALL PREFABRICATED SPOOL DOUBLE BLOCK CLOSED CLOSED CLOSED INSTALL VALVE CLOSED

  34. PARTIALLYSHUTDOWN CLOSED OPEN OPEN OPEN OPEN AOV 1 OPEN AOV 2 CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED RE-INSTALL

  35. PARTIALLYSHUTDOWN CLOSED OPEN OPEN OPEN OPEN AOV 1 OPEN AOV 2 CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED 7 INSTALL PREFABRICATED

  36. IS INFULLSERVICE CLOSED OPEN OPEN OPEN OPEN AOV 1 OPEN AOV 2 OPEN OPEN CLOSED OPEN OPEN CLOSED

  37. IS INFULLSERVICE NO NO NO NC NO NO NO AOV 1 NO NO NO NO AOV 2 NC NC NC

  38. PREFABRICATED PIPELINE 16” 4 PREFABRICATED PARTS FABRICATED BY PPS AND HYDRO-TESTED AND X-RAY AND REPORT (DOCUMENTED) 6 5 3 1 2

  39. IS IN FULL SERVICE 16” 18” MR 3B NC 12” M12 NO MR 1 4” MR 3A NC MR 2A MR 2B 18” 24” NC NC PIG RECEIVER 4” FLARE

  40. IS IN FULL SERVICE MR 3B NC NC MR 1 NO MR 3A NC MR 2A MR 2B 18” 24” NC NC PIG RECEIVER 1 INSTALL PREFABRICATED TEE

  41. IS IN FULL SERVICE MR 3B NC MR 1 NO MR 3A NC MR 2B MR 2A 18” 24” NC NC PIG RECEIVER NC INSTALL VALVE

  42. IS IN FULL SERVICE MR 3B NC NO MR 1 MR 3A NC MR 2B MR 2A 18” 24” NC NC PIG RECEIVER NC 2 INSTALL PREFABRICATED SPOOL

  43. IS IN FULL SERVICE MR 3B NC MR 1 NC NO MR 3A NC MR 2B MR 2A 18” 24” NC NC PIG RECEIVER NC NC INSTALL VALVE

  44. IS IN FULL SERVICE MR 3B NC NC NO MR 1 NC MR 3A MR 2A MR 2B 18” 24” NC NC PIG RECEIVER NC 3 INSTALL PREFABRICATED SPOOL NC

  45. IS IN FULL SERVICE MR 3B NC NO NC MR 1 MR 3A NC MR 2A MR 2B 18” 24” NC NC PIG RECEIVER 4 INSTALL PREFABRICATED SPOOL NC NC

  46. IS IN FULL SERVICE 5 INSTALL PREFABRICATED SPOOL NC MR 3B NO MR 1 NC MR 3A MR 2B MR 2A 18” 24” NC NC NC NC

  47. IS IN FULL SERVICE NC NO NO NO NO AOV I 16” NO 16” AOV II NO NO 16” NO 6 INSTALL PREFABRICATED SPOOL 16” NO NC NC NC MR 3B NC NO MR 1 NC MR 3A 18” MR2B MR2A 24” 24” NC NC NC NC

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