Facility Improvement Program

for
New Purchasing Produced Water Treatment Unit

at

MALEO PRODUCER PLATFORM

MADURA STRAIT OFFSHORE

Maleo Producer Platform Department

PT. Radiant Utama Interinsco

Date Approved:
_______________________
June/2015

Design Brief - Sheet 2 of 11

Facility Improvement Program for

New Purchasing Produced Water Treatment Unit
At Maleo Producer Platform

Submitted by:
Wahyu Priyo K
Wahyu Priyo K. [Engineering Team]

Date: June, 22nd 2015

Reviewed by:
Heryanto Kusharyono
Heryanto Kusharyono [Field Operation Manager]

Date: June, 22nd 2015

Approved by:
Agung Ady Saputra
Agung AS [Reliability, Maintenance & Integrated Planning]

Date: June, 22nd 2015

Approved by:
Radityo Yakti
Radityo Yakti [General Manager]

Date: June, 22nd 2015

Design Brief - Sheet 3 of 11

Table of Content

1. INTRODUCTION
2. PROJECT BACKGROUND
3. PURPOSE

4. PROCESS DESIGN
5. PRODUCED WATER TREATMENT SELECTION
6. CONCLUSION

Design Brief - Sheet 4 of 11

Study Engineering Report

1.

Introduction
Maleo Producer Platform (MPP) is a processing gas facility owned and operated by
RUI operation and maintenance. Since 2006, MPP has been operating to process gas
from Maleo 3, 4, 5, and 6 which are wells owned by Santos. In 2014, maleo Producer
Platform obtain new sources of gas wells, called Peluang.

2.

Project Background
Hydrocarbon liquids (condensate) are present in natural gas pipeline and facility.
Condensate is a by-product in the processing of natural gas. Its presence would be a
waste if the platform does not provide a facility for processing. Maleo Producer
Platform based design is a platform to process dry gas. This platform is designed only
for treatment or eliminates the water content of the gas with low condensate content.
There in an increase in production with the inclusion of Peluang wells caused the
problem in the produced water. There is an increase of the condensate concentration
in the produced water. It requires special treatment to maximize the separation of
condensate and water. Due to high levels of condensate content in water can cause
environmental problems if it discharged to the sea. There are several ways can do to
lower the concentration of oily water. Current to prevent condensate discharged into
the ocean, has been done the skimming process in produced water degasser.
Installation of a new separator is another way to improve the separation of
condensate in water.
The new equipment has been installed to reduce oily water concentration. Hi-Flow
Unit is a temporary equipment to maximize the separation between oil and water. It
is works by using solid media (canister filter) to increase the size of the oil droplet so
the separation can be better. The existence of this equipment is quite helpful to
reduce the oil content in produced water. But it is not able to maximize the
separation during the corrosion inhibitor was injected and then mixed in produced

Design Brief - Sheet 5 of 11

water. The canister filter is very sensitive to the addition of chemicals so that can
interfere with the performance of this unit.

Separation
Unit

WHP

Booster
Compression
Unit

Export
Compression
Unit

Liquid
Storage

Liquid to
Onshore
by Vessel

Dehydration
Unit

Gas
Metering

Gas to Pipeline

MOPU
MOPUFacility
Facility

Figure 1 Maleo & Peluang Flowchart

From Peluang
WHP

Deliquidiser

LC

Analyser

SALES GAS

LC

HCDP

H2O

H2S

GC

Scrubber
TGC #1
(23-VG-210)
LC

After
Cooler #1

FC
PC
PC

Maleo 3

Maleo 5
Maleo 4

TEG Cooler
(38-HA-333)

(23-HA-212)

Test Manifold

Maleo 4

Test
Sep

NO
NC

NC

20-VA-101

PT
25-CB-200A/B
LC
LC

20-CB-100

Scrubber
Booster
Comp

After Cooler
Booster

(23-VG-310)

(23-HA-312)

TGC #1

TEG
Contactor

(23-KA-211)

38-VB-300

LC

Raw Gas Cooler

Booster
Compressor

(25-HA-201)

(23-KA-311)
Scrubber
TGC #2

Lean Glycol

(23-VG-210)

Inlet Manifold

Inlet
Sep
20-VA-102

To TEG
Regeneration

After
Cooler #2

LC

(23-HA-222)

TGC #2

LC

Rich Glycol

To TEG
Regeneration

(23-KA-221)

Gas Line
Produced Water Line

Produced Water
Degasser

Condensate

(44-VD-103)

TEG Line

Hi-Flow Unit

Waste Tank

Subsea

Subsea

Disposal Caisson

Figure 2 Simplified P&ID of Maleo Producer Platform

3.

Purpose
The purpose of additional equipment to maximize separation process of oil in
Produced Water until the content of oil in produced water to comply with KLH
Regulation. (Under 35 ppm)

Design Brief - Sheet 6 of 11

4.

Process Design

4.1

Produced Water Design Basis

Properties

Value

Unit

Flow rate

Up to 5

M3/day

Pressure

50

Psig

Temperature

40

Kinematic viscosity

3.031 (@ 37.8C )

cSt

Density

0.8227 (@ 15C)

Kg/m3

Inlet oil concentration

Up to 10.000

ppm

Oil droplet size

Up to 10

Liquid phase

Emulsified

Produced water from Maleo and Peluang was collected in Produced water degasser.
Produced water will be pumped out to Caisson when the high signal of Degasser
reached (89 % level). Pump running as many as four to five times in a day with each
run as much as 1 m3 of produced water is pumped. Produced water should be
treated before going to caisson to maintain the oil in water content is 35 ppm or less.
4.2

Produced Water Treatment Criteria

Reduced the oil content to 35 ppm or less

Small foot print and low height

Easy to maintenance

No chemical treatment

No heat treatment

Preferably mechanical treatment

Design Brief - Sheet 7 of 11

4.3

Space Available
Available are is a truncated trapezoid-shaped: 1.83 m 10.06 m 4.88 m 9.45 m
and deck spacing is approximately 3.05 m.
10.06 m
4.88 m
Vertical space ~ 3.05 m
1.83 m
9.45 m

Figure 3 Space available for Produced Water Treatment

Design Brief - Sheet 8 of 11

4.4

Tie-in Point
To Caisson

Produced
Water
Treatment
8m

Unit

5m

5m

Degasser

BA-01-224

44-LCV-009

44-PA-100
Degasser Pump

4.5

Degasser condition
Degasser is equipment to accommodate separation liquid of all process equipment.
In this equipment the separation process is occur between the oil and water based
on the difference in density.
Inlet of Hi-flow unit will be tie-in at the discharge of degasser pump and the outlet
will be tie-in at the downstream of LCV-009. Hi-flow unit have operating pressure at
2-5 Bar. And the discharge pressure of degasser pump is 3,5 bar. Hi-flow will be in
placed on main deck area. The distance between hi-flow and tie-in point is 30 meters
with elevation is 5 meters. The connection using the flexible hose flange-end Sch. 80
#150 ANSI RF. The differential of elevation affect pressure drop of fluid/produced
water which pumped from degasser to Hi-flow unit.Tthe pressure drop of liquid
should be determined.

4.6

Calculation of pressure drop

a) Discharge pressure pump is 350 Kpa.
The pressure known from local pressure indicator.
b) Pressure drop from tie-in point to Hi-Flow inlet.
P = gh/1000

Design Brief - Sheet 9 of 11

Where is:
P = pressure drop (kPa)
= liquid density (998,11 kg/m3)
g = gravity (9,8 m/s2)
h = elevation differetial (5 m);
P = 998.119.85 / 1000
P = 48.9 kPa
c) Pressure drop of Hi-Flow unit is 20 kPa.
d) Pressure drop at LCV-009.
P = (1.363SGQ^2)/Cv^2
Where is:
P = pressure drop (Kpa)
SG = specific gravity of liquid (0,998 kg/m3)
Q = liquid flow rate (0,7 m3/h)
Cv = flow coefficient with 15 % open (26.6);
P = (1.3630.9980.7^2)/26.6^2
P = 0.09 kPa
e) Pressure drop of main piperack to Caisson.
P = gh
P = 998.119.89 / 1000
P = 88.02 kPa
Based on calculation above, the total pressure drop is
Ptotal = (48.9 + 20 + 0.09 + 88.02) kPa
= 157.02 kPa

Design Brief - Sheet 10 of 11

So, the pressure at pipe end to disposal caisson is

Ptotal = 350 157.02
= 192.98 kPa
5.

Produced Water Treatment Selection

5.1

Osorb Technology by ProSep

Osorb Media is a revolutionary, re-generable, organically-modified silica adsorbent
utilized for the treatment of oilfield water and gas streams. Osorb Media is both an
adsorbent and an absorbent, utilizing physical bond to capture hydrocarbons and
organics, while forming no permanent chemical bonds between the media and the
sorbates. This lack of permanent bonding enables regeneration and repeated reuse
of the media in addition to recovery of the contaminants held in the medias matrix.
Table 1 Specification of Osorb Skid

Description

5.2

Unit

Length

1,900 mm

75"

Width

1,600 mm

63"

Height

2,800 mm

110"

Footprint

3 m2

32 ft2

Maximum Flow Rate

33 m3/hr

5,000 bwpd

Design Pressure

FV - 15 barg

FV- 217 psi

Design Temperature

-20 to 100C

-4 to 212F

Structure Weight

3,450 kg

7,606 lbs

Hi-Flow Unit by Cetco

Hi-Flow is a new generation polymeric media that has been developed over the past
few years. The media removes the free oil and grease from the water by utilizing a
combination of mechanisms. The majority of the oil is removed by coalescence but
the media also has some absorption and adsorption properties. The process is very
simple, as any free or dispersed oil in water is removed when the water flows through
the elements filled with the media.

Design Brief - Sheet 11 of 11

Table 2 Specification of Hi-Flow Unit

5.3

Description

Unit

Design Flow rate

412.5 BWPD (2.7 m3/h)

Operating Temperature

24 degC

Operating Pressure

1-2 barg

Dimension

254 mm ID X 940 mm LG

Design Temperature

70 degC

Design Pressure

20.7 barg

No of canister

Empty Vessel weight

350 kg each

Material of Construction

SS 316L

Advantages and Disadvantages

Osorb Technology by Prosep

Hi-Flow Unit by Cetco

Not sensitive with chemical injection

Sensitive with chemical injection

Adsorption method

Adsorption and coalescing method

Producing silica adsorbent waste

Producing filter waste

High effort to regenerate/replace the

More easily to regenerate/replace the

adsorbent
Heavy weight (3.5 ton/vessel skid)

adsorbent/filter
Skid weight about 1 ton/vessel skid