DOCUMENT TITLE : Process Control and Shutdown Philosophy

LTRO-1B Project

CPGL DOC No. : B-84572-RW-PP0-PHY-ST-00-0001

 Table of Contents
Table of Contents ................................................................................................................................ 3 
1  GENERAL ...................................................................................................................................... 5 
1.1  Introduction ............................................................................................................................. 5 
1.2  Objective ................................................................................................................................. 6 
2  ABBREVIATIONS .......................................................................................................................... 7 
3  PROCESS DESCRIPTION ............................................................................................................. 8 
3.1  Brief Description for Rawa Station Facilities ............................................................................ 8 
3.2  Process Description of Letang Wells, Tengah Wells, Letang Tengah Station and LTR
Pipeline ................................................................................................................................. 10 
3.3  Process Description of Existing Rawa Station Facilities ........................................................ 10 
3.3.1  HP System ................................................................................................................. 10 
3.3.2  MP/LP System ........................................................................................................... 10 
3.3.3  Condensate System................................................................................................... 10 
3.3.4  Grissik CGP ............................................................................................................... 11 
3.4  Process Description of New LTRO-1B Facilities ................................................................... 11 
4  CONTROL SYSTEM DESCRIPTION ........................................................................................... 13 
4.1  Existing Rawa Station Control System .................................................................................. 13 
4.2  Control System for LTRO-1A Facilities.................................................................................. 13 
4.2.1  Letang and Tengah Wells .......................................................................................... 13 
4.2.2  Rawa Station ............................................................................................................. 14 
4.3  Control System for LTRO-1B Facilities.................................................................................. 14 
5  OPERATING AND CONTROL NARRATIVE ................................................................................ 15 
5.1  HP Production Separator ...................................................................................................... 15 
5.2  LTR LP Production Separator (20MBD-003) ......................................................................... 16 
5.3  LTR LP Compressor System ................................................................................................ 18 
5.4  Fuel Gas Conditioning System for LTR LP Compression ...................................................... 22 
5.4.1  Fuel Gas Scrubber (60MBF-002) ............................................................................... 22 
5.4.2  Fuel Gas Filter (60MAJ-003A/B) ................................................................................ 23 
5.4.3  Fuel Gas Heater (60HAP-001A/B) ............................................................................. 24 
6  SHUTDOWN PHILOSOPHY ........................................................................................................ 26 
6.1  Shutdown Levels................................................................................................................... 26 
6.1.1  Emergency Shutdown and Depressurize (EDP) ........................................................ 26 
6.1.2  Emergency Shutdown (ESD) ..................................................................................... 27 
6.1.3  Process Shutdown (PSD) .......................................................................................... 28 
6.1.4  Unit Shutdown (USD)................................................................................................. 29 
6.2  Shutdown System ................................................................................................................. 30 
6.2.1  Implementation .......................................................................................................... 30 
6.2.2  Activation ................................................................................................................... 30 
 6.2.3  Function ..................................................................................................................... 30 
6.2.4  Isolation ..................................................................................................................... 30 
6.2.5  Shutdown Valves ....................................................................................................... 31 
6.2.6  Blowdown Valves ....................................................................................................... 31 
6.2.7  Shutdown System Reset ............................................................................................ 31 
6.2.8  Final Element Reset................................................................................................... 31 
6.2.9  Start-Up Overrides ..................................................................................................... 31 
6.2.10  Maintenance Overrides .............................................................................................. 31 
6.2.11  System Segregation................................................................................................... 31 
6.2.12  Alarms Annunciation .................................................................................................. 31 
7  REFERENCES ............................................................................................................................. 32 
APPENDIX A RAWA SHUTDOWN HIERARCHY DIAGRAM 
 approximately 45 MMScfd of gas and approximately 400-500 BPD of condensate. LTRO Phase-
1A have been placed in service in April, 2013.
The LTRO Phase-1B development scenario is to rent reciprocating Compressor - gas engine as
the LTR Low Pressure Compression system to accommodate the depleting of well pressure to
maintain plateu production of 45 MMScfd from Letang, Tengah and Rawa fields and to
maximize the recovery of remaining gas from Letang, Tengah and Rawa before expiration of
PSC in year 2023. The LTRO-1B project scope will also include the installation of new LTR LP
Production Separator which will operate in parallel with the existing HP Production Separator to
handle produced fluid with lower operating pressure and installation of new Fuel Gas
Conditioning system dedicated for LTR LP Compressor.
The LTRO Phase-1B project is scheduled to be placed in service in April, 2020

1.2 Objective
The objectives of this document are:
 To describe the process control and operating philosophy for New LTRO-1B process
facilities at Rawa Station.
 To describe the shutdown philosophy for New LTRO-1B process facilities at Rawa Station.
To fully understand the operating control narrative of overall Rawa Station facilities, this
document shall be read in conjunction with Doc. No. C-84524-RW-PP0-PHY-ST-00-0004
"Operating and Control Philosophy - LTRO-1A Project" [Ref. 2].
2 ABBREVIATIONS
BPD Barrel per Day
CCR Central Control Room
CGP Central Gas Plant
COPI ConocoPhillips Indonesia
CPGL ConocoPhillips (Grissik) Ltd.
DCS Distributed Control System
EDP Emergency Shutdown and Depressurize
ESD Emergency Shutdown
ESDV Emergency Shutdown Valve
FEL Front End Loading
FIC Flow Indicating Controller
HP High Pressure
HMI Human Machine Interface
LCP Local Control Panel
LI Level Indicator
LP Low Pressure
LTR Letang Tengah Rawa
LTRO Letang Tengah Rawa Optimization
MCC Motor Control Center
MMScfd Millions Standard Cubic Feet per Day
MP Medium Pressure
PCS Process Control System
PI Pressure Indicator
PIC Pressure Indicating Controller
PLC Programmable Logic Controller
PSD Process Shut-Down
PSHH Pressure Switch High-High
PSLL Pressure Switch Low-Low
P&ID Piping and Instrumentation Diagram
PSC Production Sharing Contract
PV Process Value
S/D Shutdown
SCFM Standard Cubic Feet per Minute
SDV Shutdown Valve
SIL Safety Integrity Level
SIS Safety Instrumented System
SP Set Point
TEG Triethylene Glycol
TI Temperature Indicator
USD Unit Shutdown
3 PROCESS DESCRIPTION
3.1 Brief Description for Rawa Station Facilities
The existing Rawa Station Facilities will be modified by LTRO Project in order to maximize the
gas recovery from Letang, Tengah and Rawa wells. The LTRO Project was planned to be
implemented in two phases, Phase-1A with Rawa Station inlet pressure of 450 psig and
Phase-1B with Rawa Station inlet pressure of 215 psig. Currently, the LTRO-1A Project have
been placed in service in April, 2013. The following Table 3.1 summarizes the Rawa Station
facilities after the completion of LTRO-1A and LTRO-1B Project.
Table 3.1 Rawa Station Facilities Summary

Existing Facilities Additional Facilities by

(Before LTRO-1A Project)
 Flowlines and Manifolds
 LP and HP Test Separator
 MP and HP Production
Separator
 Test Tank and Test Tank
Transfer Pumps
 LP and Injection
Compression Systems
LTRO-1A Project
 LTR Manifold
 Letang – Rawa and
Tengah – Rawa Pig
Receiver, and LTR Pig
Launcher
 Gas Dehydration Unit
(including Glycol Contactor
and Regeneration Skid)
(Note-1)
LTRO-1B New Facilities
 LTR LP Production
Separator
 LTR LP Compressor
Package
 Fuel Gas Conditioning Unit
dedicated for LTR LP
Compression

 Gas Dehydration Unit (Note-1)  Condensate Stabilization

 Fuel Gas System Package
 Closed Drain System  Crude/ Condensate Tank
 Flare and Relief System  Instrument Air Package
 Instrument Air System(Note-2) and Instrument Air
Receiver (Note-2)
 Produced Water Tanks and
Produced Water Transfer  Flare Knock Out Drum and
Pumps Flare Knock Out Drum
Pumps
 Closed Drain Drum and
Closed Drain Drum Pumps
 Diesel Fire Water and
Jockey Pumps
Notes:
1. Gas Dehydration Unit installed by LTRO-1A Project was replacing the existing Gas Dehydration Unit.
2. Instrument Air Package and Instrument Air Receiver installed by LTRO-1A Project was replacing the
existing Instrument Air System.

Capacity design of the existing facilities can be seen in following Table 3.2.
Table 3.2 Design Capacity of Existing Rawa Station Facilities
Equipment Tag
Equipment Designed Capacity
Number
Existing Facilities (Before LTRO-1A Project)
HP Production Separator 5000-V-70 38 MMscfd, 1575 BPD (estimated)
23 MMscfd, 1200 BOPD, 6000
MP (LP) Production Separator 3033-V-60
BWPD (estimated)
LP Compressor Package 5000-PK-101 10-15 MMscfd
Gas Injection Compressor 46 MMscfd
5000-V-80
Suction Scrubber
Gas Injection Compressor 46 MMscfd,
5000-PK-100
Package Suct : 500 psig, Disch : 1450 psig
 Equipment Tag
Equipment Designed Capacity
Number
Gas Injection Compressor After
5000-E-110 12.4 MMBTU/hr
Cooler
Glycol Contactor 5000-C-100 46 MMscfd
Glycol Regeneration Package 5000-C-100 TEG circulation rate 8 USgpm
Test Tank 5000-T-10 500 bbl
Produced Water Tank 5000-T-11/16 2 x 500 bbl
120 USGPM and 60 USGPM,
Test Tank Transfer Pump 5000-P-007/034
diff head 100 psi
135 USGPM,
Produced Water Transfer Pump 5000-P-001A/B
diff head 50 psi
Additional Facilities by LTRO-1A Project
Condensate Stabilization
20-SZZ-001 600 BPD Crude/Cond
Package
Crude /Condensate Tank 21-ABJ-001 1520 BBLS (Net Working Capacity)
Flare K.O. Drum 43-MBD-001 72 MMSCFD
Flare K.O. Drum Pump 43-PBA-001 A/B 26.4 USGPM (rated)
Closed Drain Drum 62-MBD-001 124 bbls
Closed Drain Pump 62-PBA-001 A/B 17.6 USGPM (rated)
Portable Pit Pump 43-PBA-002 17.5 USGPM
Diesel Fire Water Pump + Day
71-PBA-011/12 1000 USGPM
Tank
Electrical Jockey Pump 71-PBA-013 125 USGPM
Well Water Pump 71-PBA -014 100 USGPM
Instrument Gas K.O. POT 3M-MAK-100~106 0.86 SCFM
Corrosion Inhibitor Injection 3M-PBE-100~106 /
Tank = 1000 L
Package 42-SZZ-001
Instrument Air Receiver 67-MBF-100 72 SCFM
Instrument air Compressor and
67-CA-001 100 SCFM
Drier package
Glycol Contactor 27-MAF-201 46 MMSCFD
Glycol Regeneration Package 27-SZZ-001 TEG Circulation rate of 15 USGPM

Capacity design of the new LTRO-1B facilities can be seen in following Table 3.3.
Table 3.3 Design Capacity of LTRO-1B Facilities

Equipment Tag
Equipment Designed Capacity
Number

LTR LP Production Separator 20MBD-003 Gas: 26 MMscfd, Liquid: 959 BPD

LTR LP Compressor Package
83-A-201A/B 26 MMScfd
A/B
Fuel Gas Scrubber 60MBF-002 1.5 MMScfd

Fuel Gas Filter 60MAJ-003A/B 1.5 MMScfd

Fuel Gas Electric Heater 60HAP-001A/B 19 kW

3.2 Process Description of Letang Wells, Tengah Wells, Letang Tengah
Station and LTR Pipeline
Wellfluids from Letang and Tengah Wells are flown to Rawa Station through dedicated
multiphase flowline. Tengah wellfluid from Tengah Well No.1 and Tengah Well No.3 are
combined and transported in a single multiphase line and be commingled with Tengah Well
No.5. The wellfluids from the three Tengah wells are sent to Rawa Station by 6” – 15 km pipeline
(Tengah Well – Letang Tengah Station) and directed to the existing 10” – 4 km pipeline (Letang
Tengah Station – Rawa Station).
During LTRO-1A project, Tengah Pig Launcher (3K-KAH-101) was installed to serve the Tengah
multiphase line near Tengah Well No. 5, and Tengah Pig Receiver (3K-KAQ-101) was installed
in the Letang Tengah Station. The existing Letang Pig Receiver (95-V-101) was reconfigured to
be used as the Tengah – Rawa Pig Launcher.
Letang well fluids are flown to Rawa Station using the existing 10” – 6.5 km Letang – Letang
Tengah Station multiphase line. This line are routed to Rawa Station at km. 6.

3.3 Process Description of Existing Rawa Station Facilities

3.3.1 HP System
The Modified Rawa Station receives well fluids from all three fields; Letang, Tengah and Rawa
fields. The existing production from Rawa field is provided as either HP or LP, whilst Letang and
Tengah production are both be HP. Letang and Tengah production arriving in Rawa Station are
received in a new LTR Manifold prior to onward commingling with Rawa HP production in the
existing HP Production Manifold at approximately 450 psig.
Fluids from HP production header are separated into gas and liquid in the existing HP
Production Separator (5000-V-70). The liquid outlet from the HP Production Separator (5000-V-
70) is combined with the liquid streams from the existing Injection Compressor Suction Scrubber
and LP production from Rawa LP wells.
The scrubbed gas are compressed with the existing Injection Compressor Package (5000-PK-
100) up to estimated pressure of 1286 psig and cooled down to around 120 oF in the existing
Injection Compressor After Cooler. The cooled gas then dehydrated in Glycol Contactor (27-
MAF-201). Water content of the gas are reduced to less than 10 lb water/ MMscf gas. The
dehydrated gas then exported to Grissik CGP via 12”-54 km gas trunkline. During LTRO-1A, the
LTR Pig Launcher was installed at Rawa Station, and LTR Pig Receiver was installed at Grissik
CGP for Trunkline pigging facility.
3.3.2 MP/LP System
Fluids from LP production header are separated out to gas, condensate and water in the existing
MP Production Separator (3033-V-60). The condensate then routed to the Condensate
Stabilization Package to achieve an RVP and TVP as specified, and subsequent storage in
Crude/Condensate Tank and an existing Test Tank. Crude/Condensate product is pumped to
the Ramba Station by the existing Test Tank Transfer Pumps. The produced water then directed
to the existing Produced Water Tanks prior pumping to Ramba Station for reinjection into the
disposal wells.
The separated gas from the existing MP Production Separator (3033-V-60) is compressed by
the existing LP Compressor Package (5000-PK-101) which comprises two stage reciprocating
compressor with interstage cooling. Compressed gas then commingled with the outlet gas
stream from the existing HP Production Separator (5000-V-70) and routed to the Injection
Compressor Suction Scrubber for removal of liquid carryover to Injection Compressor (5000-PK-
100).
3.3.3 Condensate System
The Condensate Stabilization Package (20-SZZ-001) contains a Condensate Pre-Heater (20-
HBG-001), a 1st Stage Condensate Separator (20-MBD-001) equipped with an internal heater
(20-ZAP-001), a 2nd Stage Condensate Separator (20-MBD-002), two Condensate Pumps
namely 20-PBA-001A/B (duty/standby) and one Condensate Cooler (20-HAL-001). The
condensate from the existing MP Production Separator (3033-V-60) is sent to the Condensate
Pre-Heater (20-HBG-001) to pre-heat the condensate using hot condensate from the 2nd Stage
Condensate Separator (20-MBD-002). The 1st Stage Condensate Separator (20-MBD-001) is
Philosophy / Strategy / Description B-84572-RW-PP0-PHY-ST-00-0001 – Rev 1
Process Control and Shutdown Philosophy – LTRO-1B Project
ConocoPhillips (Grissik) Ltd. Page 11 of 33

equipped with an internal heater (20-ZAP-001) to further heat up the pre-heated condensate.
The additional heat is intended to vaporize light components to achieve the required condensate
product shipping specification with the maximum RVP of 12 psia and TVP of 13 psia. This heater
consists of 2 (two) stage, with the 1st stage automatically handle the normal duty and the 2nd
stage is manually adjustable to handle the peak duty during pre-heater maintenance.
The 1st Stage Condensate Separator (20-MBD-001) is a three phase separator. The flash gas
from this separator is sent to the existing Flare System, the hot condensate is routed to the 2nd
Stage Condensate Separator (20-MBD-002), and the produced water is sent to the existing
Produced Water Tanks. The 2nd Stage Condensate Separator (20-MBD-002) is two phase
separator. The flash gas from this vessel is also sent to the existing Flare System and the hot
condensate is intended to be diverted to the Condensate Pre-Heater (20-HBG-001) for cooling
while additional cooling is further achieved in the Condensate Cooler (20-HAL-001). Stabilized
condensate product is pumped by the Condensate Pumps (20-PBA-001A/B) for storage in new
Crude/Condensate Tank (21-ABJ-001) or the existing Test Tank (5000-T-10).
3.3.4 Grissik CGP
The incoming gases from Rawa Station are combined with the gas from Gelam Station and
routed to the existing GLT Slug Catcher (15-M-101). This slug catcher provides gas and liquid
separation. The existing slug catcher is an above ground finger type designed with hydrocarbon
liquid capacity of 241 barrels.
The LTR Pig Receiver was installed at the downstream of Rawa Station gas trunkline and used
during pigging operations from the Rawa Station to Grissik CGP. Flare and drain lines from the
Pig Receiver is routed to the existing Grissik CGP flare and drain systems.

3.4 Process Description of New LTRO-1B Facilities

The new LTR LP Production Separator (20MBD-003) and LTR LP Compressor (83-A-201A/B)
will be installed to accommodate declining of Rawa Station inlet pressure. The LTR LP
Production Separator (20MBD-003) will operate in parallel with the existing HP Production
Separator (5000-V-70).
The gas outlet from HP Production Separator (5000-V-70) and new LTR LP Production
Separator (20MBD-003) will be commingled and routed to LTR LP Compressor system. While
the liquid from these two separators will be commingled and routed to the existing MP
Production Separator (3033-V-60). The LTR LP Compressor system consist of 3x33% package
units, engine driven reciprocating gas compressor.
The gas outlet from LTR LP Compressor Packages commingled with gas compressed by
existing LP Compressor (5000-PK-101) enters the existing Injection Compressor Suction
Scrubber (5000-V-80) for further compression by the existing Gas Injection Compressor (5000-
PK-100).
A new fuel gas system dedicated for LTR LP Compressor system will be provided. The fuel gas
system will consist of 1x100% Fuel Gas Scrubber (60MBF-002), 2x100% Fuel Gas Filters
(60MAJ-003A/B) and 2x100% Fuel Gas Heaters (60HAP-001A/B). The normal fuel gas source
will be drawn from the suction of Gas Injection Compressor (5000-PK-100), the start-up source
will be drawn from the suction of LTR LP Compressor (83-A-201A/B), and the alternate source
for back-up will be drawn from Glycol Contactors outlet.
The Figure 3.1 show the schematic diagram of LTRO-1B main process system.
Figure 3.1 – Schematic Diagram Main Process System LTRO-1B Project
4 CONTROL SYSTEM DESCRIPTION
4.1 Existing Rawa Station Control System
Two different Control Systems have been applied in the existing Rawa Station Plant before
LTRO-1A Project, as shown in Table 4.1 below.
Table 4.1 Control System in Existing Rawa Station Facilities (Before LTRO-1A Project)

Control
No. System Description Remarks
Equipment
Pneumatic  Majority of the process control
Local Control uses Local Pneumatic Control
 Pneumatic Local Panel for the
control of the Glycol Contactor
Pneumatic and Regeneration Package.
1.
Control Pneumatic This Pneumatic Local Panel is
Local Panel used for local pneumatic
alarms and common
shutdown signals to the
package.
Local Control  LP Compressor Package is
Panel for LP controlled by Local Control
Compressor Panel located near
Package compressor using Allen
(5000-PK-101). Bradley PLC.
Electronic
2. Unit Control  Gas Injection Compressor
Control
Panel for Gas Package is controlled by Unit
Injection Control Panel using Allen
Compressor Bradley PLC located in the
Package Control Room with a panel
(5000-PK-100). mounted HMI.

No integrated and automated safety and control system is available in the existing Rawa control
system before LTRO-1A Project.

4.2 Control System for LTRO-1A Facilities

4.2.1 Letang and Tengah Wells

The following control systems have been applied to Letang and Tengah Wells.

 Production from each well is controlled by the manual choke valve.

 The local flow recorder measures production flowrate.
 The well shall be shut down by the existing automated master valve and wing valve which
is activated by high/low pressure switches as well as a fusible plug. The Wellhead Control
Panel was provided to accommodate control system.
4.2.2 Rawa Station
The control system at Rawa Station after LTRO-1A Project is divided into 2 main electronic
systems as described on Table 4.2 below.
Table 4.2 Rawa Station Control System after LTRO-1A Project

System Description

 Distributed Control System (DCS) was installed to accommodate the

process control of LTRO-1A facilities. The LTRO-1A facilities is
controlled and monitored by the PCS.
 The Process Control System accommodates the LTRO-1A facilities
Process Control
and upgrade existing Pneumatic Local Control. The existing pneumatic
System (PCS)
control such as level control, pressure control, flow control, etc were
replaced with electronic devices as well as adding I/P positioner to the
existing control valve as final control elements

 Safety Integrated System (SIS) is connected to LTRO-1A glycol and

instrument air system.
 SIS system that enhance the shutdown system for the LTRO-1A
Safety Integrated facilities as well as the existing facilities was in placed.
System (SIS)  There was no modifications to the existing Fire & Gas Systems
 Additional flame and gas detectors in the Compressor Shelter was
connected to the LTRO-1A SIS
 Logic and graphics is provided in the SIS

4.3 Control System for LTRO-1B Facilities

The control system for LTRO-1B facilities will follow the control system for the existing LTRO-1A
facilities.