SLS Secondary Meter System Improvement - Phase 2 DSP

7/17/2019 SLS Secondary Meter System Improvement - Phase 2 DSP

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SLS SECONDARY METER SYSTEM

IMPROVEMENT

Decision Support Package (DSP)CPDEP Pase ! to Pase " Transition Re#uest

$aci%it& Engineering Tea'Re%iai%it& Engineering an Maintenance

Su'atra Ligt SoutAugust !**+



PT. Chevron Pacific Indonesia FET Operations Engineering REM -SLS

CPDEP P,ASE !SI-N.O$$

SLS Seconar& Meter S&ste' I'pro/e'ent

Decision Support Package

CPDEP Pase 0 !

After examining the deliverable, reviewing this Decision SupportPackage and considering the input from DRB Member, agree that

!PD"P phase # is complete and recommend that the team proceedinto !PD"P phase $

Minas, September #%%&

Ari Nugroo

Decision E1ecuti/e

SLS Secondary Meter System Improvement – DSP Phase 2 Page 2 of 13




DR2 INP3T AND SI-N O$$ DOC3MENT

SLS SECONDARY METER SYSTEM IMPROVEMENT

YEAR !**+

DR Me!"er Tea! Signat#re Date

Sudjono Adimulyo Mgr REM SLS

arlo !isnu "M# $E REM SLS

Arief %udiman "M# E&R REM SLS


P$RPOSE DR MEMER RECOME%D&TIO%

E'( $) P*ASE 1

E'( $) P*ASE 2

E'( $) P*ASE 3

E'( $) P*ASE +

$"*ER

PR$E( "$ 'E," P*ASE

PR$E( !I"* $'(I"I$'

RE-LE

*$L(

S"$P

omment on (SP or Project.

See. attac/ment

onditional riteria for proceeding to ne0t P(EP p/ase 3 if any.




E'EC$TI(E S$MM&R)

Introd#ction

"/e $il Production Measurement Secondary Meters System at Sumatra Lig/t Sout/ SLS area located atMinas at/ering S 1 to 4 are currently facing pro5lem6 7/ere t/e electronic device t/at to 5e used tomeasure rate and total flo7 )lo7 "otali8er /as 5een o5solete since 9 years ago# "/e Micromotion (R" )lo7

"otali8er is used to calculate and display t/e )lo7 Rate and "otal :olume 5ase on t/e input transmitted 5yMicromotion (S Sensor and Micromotion R)" )lo7 "ransmitter# %ot/ t/e sensor and )lo7 "ransmitter are stillproduced 5y manufacturer and also t/e R)" performance so far is satisfactory6 accurate and relia5le#

Pro*ect O"*ective

"o prevent t/e lac; of measurement of s/ipped oil production oil data at Minas S level due to t/e inopera5leout of service of )lo7 "otali8er6 t/e replacement project is initiated early 2<<=# "/e ot/er focus items 5esidet/e replacement of "otali8er device are t/e improvement>upgrade of Secondary Meter System performance andfunction 5y adding and automatic printing system and continuous S?! monitoring# %y t/is improvement6 t/erelia5le6 accurate and timely oil production data can 5e ac/ieved 5y applying consistent data collection systemand continuous process measurement# More accurate data 7ill /elp Production and RM" in doing analysis#ontinuous S?! monitoring provided 7it/ alarm 7ill /elp $peration in improving t/e response time if off@spec

oil occurs# "/is 7ill also improve our confidence level on variance discrepancy of oil measurement 5et7een Sand '%S#

Phase-2 Overvie+

P/ase@2 for t/is project 7as started in une 2<<=6 7/ere t/e project team generated several alternatives for t/isimprovement# All alternatives s/ould meet selection criteria# "/e selection criteria include initial cost6constructa5ility6 opera5ility6 maintaina5ility6 relia5ility6 data accuracy and upgradea5ility#

Reco!!endation

Project team recommends alternative B1A6 7/ic/ is to replace e0isting "otali8er 7it/ Emerson )lo7 omputer6add automatic printing capa5ility6 continuous temperature and S?! monitoring#

Project class@2 cost estimate is CSD 394 M E%# P/ase@+ is sc/eduled to start in Septem5er 2<<= 7it/ =

mont/s e0ecution time#

SLS Secondary Meter System Improvement – DSP Phase 2 Page + of 13




Ta",e of Contents

CPDEP P&SE 2 SI% OFF DOC$ME%T...........................................................................................................2

DR I%P$T &%D SI% OFF DOC$ME%T............................................................................................................/

E'EC$TI(E S$MM&R)........................................................................................................................................0&. TE&M RECOMME%D&TIO%........................................................................................................................1

. PROECT DESCRIPTIO%............................................................................................................................1

%#1# P*ASE@1 RE:IE!##################################################################################################################################4%#2# P*ASE@2 (EISI$' *IERAR*-.############################################################################################################4

C. &LTER%&TI(E E(&L$&TIO% &%D SELECTIO%.......................................................................................3

#1# SELE"I$' RI"ERIA A'( E'ERA"E( AL"ER'A"I:ES############################################################################=#2# AL"ER'A"I:E "RA(E$))########################################################################################################################

D. PROECT (&L$E......................................................................................................................................45

E. P&SE-2 PROECT COST &%D SCED$LE..........................................................................................45F. P&SE-2 RESO$RCE &%D CPDEP TOOLS............................................................................................44

S"A))I' ? RES$CRES.##################################################################################ERROR6 OO7M&R7 %OT DEFI%ED.

. P&SE-/ FOR8&RD PL&%......................................................................................................................42

PLA' )$R P*ASE@3###########################################################################################################################################12R$A( MAP########################################################################################################################################################12





&. Tea! Reco!!endation

"/e project team recommends selecting alternative B1A6 7/ic/ is to replace )lo7 "otali8er 7it/Emerson )lo7 omputer6 add automatic printing capa5ility and continuous temperature and S?!monitoring#

. Pro*ect Description

B.1. Phase-1 Review

"/e assessment performed during P/ase 1 /as found t/at t/e )lo7 "otali8er part of Minas SecondaryMeter System is o5solete 7/ile t/e ot/er part is still performing good# "/ere is also an opportunityidentified to improve t/e functionality and capa5ility of current Secondary Meter System to meet t/e$perational reFuirement#

%ased on a5ove assessment result t/ere is an opportunity . "o provide relia5le SLS Secondary Meter5y upgrading t/e e0isting measurement system in order to /ave accurate and timely data of oilproduction#

"o analy8e t/e opportunity6 project team framed t/e pro5lem# "/e 5oundaries of t/is project are.

In scope. Secondary Meter System at Minas and Petapa/an S

MMI Monitoring at Minas and Petapa/an S

S?! on@line continuous monitoring at Minas and Petapa/an S

$ut scope. S?! S La5 "est Measurement

Primary Meter

*ydrocar5on measurement

Energy omponent (ata Entry Procedure

Proving of Secondary Meter

B.2. Phase-2 Decision Hierarchy :

iven. $5solete part anticipation plan

Accurate6 relia5le and timely oil production measurement

onsistent data collection

Maintenance flo7 process

)ocus .

"ec/nology > alternative selection and proven implementation (ata accuracy and availa5ility

Scope of replacement and upgrade

Plan for Maintenance responsi5ility and spare part management

"actical. lass 3 Scope and ost Estimate

P(EP P/ase 3 (elivera5les

(raft of Preliminary Engineering Spec and (ra7ing

Project E0ecution Plan and ontracting Plan





$@34 preparation and approval

C. &,ternative Eva,#ation and Se,ection

C.1. Selection Criteria and Generated Alternatives

"/e project team generated five 9 alternatives to replace )lo7 "otali8er and improve SecondaryMeter capa5ility# "/e alternatives 7ere categori8ed on 3 t/ree groups for easy understanding andcomparison# "/e alternatives 7ere compared and evaluated 5ased on selection criteria# "/e 7eig/tfactor and selection criteria detail information are as follo7s.

SLS Secondary Meter System Improvement – DSP Phase 2 Page = of 13




Several alternatives 7ere generated and evaluated# )ollo7ings are t/e alternatives.

&,ternative 9 4 &: ; C are grouped in order to clearly descri5e t/at all of t/ese 3 alternatives areusing t/e similar 5rand > manufacturer 7it/ e0isting flo7 sensor and flo7 transmitter6 7/ile t/e ot/eralternatives Alt 2 and 3 are using devices from different manufacturer#

&,ternative 94& 7ill replace t/e totali8er unit 7it/ )lo7 omputer Emerson product6 7/ic/ /ascapa5ility to perform t/e 5atc/ control and manage printer 5eside t/e flo7 computation# "/e )lo7omputer 7ill calculate and display rate and total volume including maintain /istorical data# )lo7omputer 7ill also 5e as a printer manager 7/ic/ 7ill manage t/e manual or automatic tic;et printingas per pre@set time# )lo7 omputer 7ill also receive signal input from S?! monitor and temperaturetransmitter and display t/ese process parameters6 save /istorical data and also generate alarm ofunspec oil /ig/ 7ater cut# )lo7 omputer 7ill communicate 7it/ e0isting MMI Station 7/ic/ 7illdisplay and stored all of t/e data at $perator ontrol Room# "/e compati5ility and integrity of ne7device 7it/ t/e e0isting device sensor and flo7 transmitter is 7arranted as all devices are from t/esame manufacturer and 7ill 5e tec/nically supported 5y manufactureGs representative# In t/isalternative6 only one device is reFuired to calculate flo76 manage automatic printing jo56 monitor and

store temperature and S?! including communication /andling 7it/ e0isting monitoring system MMI#&,ternative 94 7ill replace t/e totali8er unit 7it/ Micromotion M:( 2<<<# %y installing t/is device6 t/ee0isting R)" )lo7 "ransmitter 7ill not 5e used6 as t/e M:( is a com5ination of )lo7 "ransmitter and)lo7 "otali8er# )or automatic printing jo56 t/e separate independent R"C>ompact PL also can use)lo7 omputer as used in Alternative B1A 7ill 5e reFuired as printer manager and 5atc/ controller#)lo7 omputer 7ill collect6 store and display t/e flo7 data from M:( 2<<<6 and also from S?!monitor and temperature transmitter6 including alarm generation# )lo7 omputer 7ill also manage t/ecommunication 7it/ e0isting MMI station# As Alternative B1A6 t/e compati5ility and integrity of t/esystem is 7arranted and convinci5le# "/e difference compared to Alternative 1A is t/at6 on t/isalternative6 t7o devices 7ill 5e reFuired to perform all of t/e reFuired function descri5ed /ere#

SLS Secondary Meter System Improvement – DSP Phase 2 Page H of 13




&,ternative 94C 7ill 5e Fuite similar to alternative B1%6 5ut t/e device used /ere is Micromotion Altus3=<< instead of M:( 2<<<6 7/ere t/e Altus 3=<< is designed for 'et $il omputer /ig/erspecification t/an M:(# )lo7 omputer is still reFuired as Alternative B1% to perform all of t/ereFuired function# "/e compati5ility6 integrity and num5er of device are same 7it/ Alternative B1%#*o7ever6 on t/is alternative6 t/e flo7 transmitter and flo7 totali8er /ave /ig/er specification compareto Alternative B1%#

&,ternative 92 7ill 5e almost similar to alternative B1A6 5ut t/e )lo7 omputer is using ot/er 5rand >different 5rand 7it/ e0isting devices sensor and flo7 transmitter# "/us6 compati5ility and integrity oft/e 7/ole metering system is not guaranteed and /ig/ possi5ility to 5ecome in accurate andunrelia5le# It 7ill also potentially difficult to /ave t/e provider responsi5le for t/e 7/ole measurementsystem as t/ey mig/t not ;no7>understand /o7 t/e sensor and flo7 transmitter 7or;# *ardcommissioning 7or; and lo7 confidence on opera5ility6 relia5ility and data accuracy are potentialpro5lem if t/is alternative selected#

&,ternative 9/ 7ill utili8e e0isting PL and MMI Station at at/ering Station to 5e used as )lo7"otali8er# All measured process parameter flo76 S?! and temperature6 7ill 5e 7ired to PL andmonitored at e0isting MMI station# MMI 7it/ !onder7are application 7ill 5e modified to manage t/eautomatic printing jo5# Additional analog input module and /ig/ speed counter module are reFuired to

receive transmit signal from R)"6 S?! monitor and temperature transmitter# Some pro5lemspotentially occur if t/is alternative is selected6 suc/ as. li;e Alt B26 compati5ility and integrity of t/esystem is Fuestiona5le6 and6 t/e difficulties to purc/ase additional PL module as some of e0istingPL in Minas S is no longer produced# "/e ot/er pro5lem mig/t occur during commissioning andstart up# "/ese conditions may lead to pro5lem on opera5ility6 maintaina5ility and relia5ility#

C.2. Alternative vs Selection Criteria

"/e follo7ing ta5le s/o7s t/e trade off of eac/ alternative on eac/ criteria of selection6 as t/e consensusta;en 5y project team.

SLS Secondary Meter System Improvement – DSP Phase 2 Page of 13




%ased on t/e evaluations a5ove6 conclusions for SLS Secondary Meter System Improvement is.• Alternative B1A 7as voted as t/e 5est alternative using t/e 7eig/ted selection criteria

• *ig/est confidence level on $pera5ility6 Maintaina5ility6 Relia5ility and (ata Accuracy

• Integrity and ompati5ility 7it/ e0isting part>device is convinced

• Relatively Lo7 Initial ost6 smoot/ commissioning and start up

In parallel 7it/ alternative generation a5ove6 project team /as decided to use e0isting P( Meter atPetapa/an S and add one of t/e alternatives a5ove#

"/e 7atercut %S?! meter to 5e installed as part of t/is project6 7ill 5e t/e same or close specificationand 5rand 7it/ %S?! meter used in SL'# It supposed to measure accurately on <@9 7ater cut range and/ave /ig/ accuracy# "/e consideration is t/at t/e fluid c/aracteristic at t/e point of measurement at SLS issimilar 7it/ t/ose in SL'# "/e 7ater cut meter used in SL' also reported /ave very good performance onaccuracy6 opera5ility as 7ell as its relia5ility#

It is also recommended 5y Project team and get 5uy in from (E>(R% to e0ecute t/e procurement and

installation for t/e project partially replacement of totali8er and additional of printing device during P/ase+ using (irect Appointment6 7it/ t/e follo7ing reasons.

"/e "otali8er replacement is considered as part replacement6 not t/e 7/ole metering system

replacement6 compati5ility 7it/ t/e e0isting system sensor and transmitter is reFuired "/e alternative selected during P/ase 2 is supporting t/e system compati5ility

"/e integrity of t/e metering system is strongly reFuired to 5e maintained

Smoot/ commissioning and installationJ provider>vendor 7ill 5e responsi5le for 7/ole metering

system6 not only t/e replaced part# Ensure strong tec/nical support and 7arranty

%ased on t/e a5ove reason6 direct appointment to P" ontrol System6 an Indonesia rep for EmersonMicromotion product6 is reFuested#

D. Pro*ect (a,#e

"/e economic value of t/is project is /ard to define as t/e project is mostly t/e replacement of t/e o5soletepart# Event/oug/ it is /ard to define6 5ut t/e major advantage of t/is project can 5e descri5ed 5elo7.

Operationa, E<ce,,ence

Improve accuracy and consistency of data .

o "imely

o

ompre/ensive and continuous rate6 S?!6 temperatureo Reduce discrepancy due to estimation6 un@continuous S?!

Improve t/e utili8ation of data for analysis6 and Fuality of decision on reservoir

management onsistently maintain spec of s/ipped oil K <#9 .

o Early 7arning if un@spec

o Reduce additional effort to treat un@spec s/ipped oil

Organi=ation Capa"i,it>

SLS Secondary Meter System Improvement – DSP Phase 2 Page 1< of 13




Simplify $perator duty manual to automatic6 alarm6 compre/ensive data

lear maintenance responsi5ility optimum B of device to 5e maintained6 proofing jo5

E. Phase-2 Pro*ect Cost and Sched#,e

lass@2 cost estimate for t/is project is

%o Description ?#antit> $nit $nit Price S#" Tota,

1 )lo7 omputer6 Printer and Enclosure = unit 1<62H9#<< =169#<<

2 %S?! Monitoring = unit 1+6912#+3 1<169H4#H

3 Po7er6 ontrol ? Instrument a5les6 Accessories6 unction %o0 = lot 969=H#1+ 36<+=#<<

+ Pulse enerator for Petapa/an S 1 unit 26<<<#<< 26<<<#<<

9 Programming R"C and MMI = lot 1<6<<<#<< =<6<<<#<<

4 Installation and omissioning = lot 969<<#<< 3H69<<#<<

= "raining and (ocumentation 1 lot 16<<<#<< 16<<<#<<

/20:[email protected]@

/2:042.A5

/B1:B04.@3

S$ TOT&L

45 Contigenc>

TOT&L

Project Sc/edule.

F. Phase-2 Reso#rceDecision E<ec#tive

Ari 'ugro/o @ SLS Production Manager

Decision Revie+ oard.

Sudjono Adimulyo @ SLS REM Manager

arlo A# !isnu @ SLS REM@)E" "eam Manager

Arief %udiman @ SLS REM<@E&R "eam Manager


Q2-07

Q3-07

Q4-07

Q1-08

Q2-08

Q3-08

P/ase 1

P/ase 2Approval

S#rve> ;Pre. Eng

P/ase 3 Approval incl#$@34

Proc. of F,o+ Co!p

Proc. of S;8 !onitoring

Inst. of F,o+ Co!p

Inst. of S;8Monitoring

1st unit PIS 7>o S?!

mon#

ompletely PIS

lose $ut ?Loo;5ac;




Pro*ect Cha!pion

'anang uniarto @ )E"@REM SLS

Pro*ect Tea!

Suparman @ )E"@REM SLS asmir inting @ )E"@REM SLS

%a;at Su;artono @ E&R@REM SLS

u;u/ ertasafari @ Production SLS

!a7an Ira7an @ I"@Csptream "ec/ omputing

Reso#rces (edi urnia @ *"

(eddie Rac/aju @ Production SLS

(anny Andryanto @ Production SLS

(ani Satria (/arma @ Production SLS

. Phase-/ For+ard P,an

Plan for Phase-

omplete survey to get fi0ed scope and lass 3 ost Estimate

Preliminary (esign Spec and (ra7ing

ontracting Plan and R approval

(SP P/ase 3 and $@34

Road !a"




Documents

SLS Secondary Meter System Improvement - Phase 2 DSP