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TABLE OF CONTENT
1. BACKGROUND ........................................................................................................... 3
2. DISCUSSION ............................................................................................................... 3
3. WHAT IF BADAK LNG DOES NOTHING? .................................................................. 4
4. PROPOSED SOLUTIONS ........................................................................................... 4
5. JUSTIFICATION .......................................................................................................... 5
6. PROJECT TIME FRAME .............................................................................................
57. PROJECT COST
ESTIMATION .................................................................................. 5
8. COST BENEFIT ANALYSIS ........................................................................................ 7
9. CONCLUSIONS............................................................................................................ 8
10. RECOMMENDATIONS ................................................................................................ 9
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1. BACKGROUND
2. DISCUSSION
G3-AT-24 berperan penting untuk memastikan komposisi butane pada plant 24.
(blablabla)…………
GC-AT-24 menggunakan produk dari Siemens, Optichrom Advanced, yang telah obsolete
sejak 2011. Alat ini telah digunakn sejak tahun …..
Air compressor 39-K-21 has a crucial role to maintain the processes in Plant 39H. It increases
pressure of atmospheric air until 8.8 kgf/cm 2 by three compression stages before transferring it to
moisture separator column 39-C-16.The failure of 39-K-21 will disturb the process in Plant 39H and at
the end will trigger theDistributed Control System (DCS) toshut downthe plant.
The existing 39-K-21 air compressor uses Elliott Digital Controller (EDC) as its control system
(seeFigure 1). The control system has been implemented for 39-K-21 since 1998. But in 2007, FS
Elliott as the Manufacturer announced that the system had been obsolete and its spare parts would
only be available until March 2010 (see Attachment-2). Therefore, its spare parts are not available in
the market today. If someday thecontroller fails because of either internal or external damage,
themaintenance crew will find some difficulties to fix the problem due tospare partsunavailability.
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Consequently, Plant 39H needs to beshutdownfor much longer period. The control system
replacement must be implemented to ensure availability of parts and other supports from
manufacturer as well as to increase reliability and performance of overall 39-K-21 system. The
engineering details for control panel assembly of the existing control system can be found in
Attachment-3.
Based on the record, Plant 39Hexperienceda trip in May 28 th, 2014 due to lightning
strikes.Fortunately, thelightning strikes did not harm the control system of 39-K-21because of the
protecting devices.However, the lightning strike caused a signal isolator for an I/O channel burned
and could not be fixed. The spare of signal isolator to replace the broken one was not available in the
site at that time and the supplier also needs few months to order new signal isolator. So during that
period, the I/O channel was not protected bysignal isolator. This experience implies that control
system accessories such as signal isolators, circuit breakers, relays, etc. are also
important.Therefore, in order to increase the reliability and performance of new control systemas well
as to ensure the availability of spare parts in case of emergency, the control system accessories such
as signal isolators, relays, circuit breakers, etc. also needs to be replaced.
The control system of air compressor is connected with several field instruments in 39-K-21.
In order to make sure that the process in Plant 39H can be operated safely, reliably, and efficiently,
the 39-K-21 field instrumentations and accessories must also be replacedalong with the control
system. The instrumentations that considered to be evaluatedfor replacementif necessary are control
valves, pressure transmitters, temperature transmitter,vibration transmitters and sensors, current
transmitter, level switch, pressure switch, and I/P converters. The list of those instrumentations can be
found in Attachment-4.
If BadakLNG does nothing, it might let the unsafe condition in Plant 39H. The controller could
be failed anytime due to components aging and lead a total shutdown of Plant 39H. The reparation
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also might be very difficult because now most of the spare parts are uncommon. This condition does
not only inflict damage to the plant but also potentially cause a financial loss since the Plant 39H
produces liquid nitrogen which is demanded to support the LNG production in Badak LNG. So in that
situation, in order to cover the needs of nitrogen, Badak LNG must buy liquid nitrogen from the third
party which is expensive.
4. PROPOSED SOLUTIONS
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5. JUSTIFICATION
If someday the controller of 39-K-21 is failed or broken due to components aging, it shall be
difficult for Badak LNG to repair it since now the spare parts are not available in the market anymore.
As a result, Plant 39H cannot be operated for a long time until the controller repaired or replaced by
the new one.
Another reason is also that if Plant 39H must be off-service, Badak LNG has to buy liquid
nitrogen (LIN) from third party, which a potential financial loss.
This project will be executed after all the materials are available at the warehouse. The
estimation of project schedule is shown in Table 1.
The estimated cost of this project is approximately US$ 400,000.00. The detailed cost estimation of
this project is shown on the Table 2.
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This document is the property of PT Badak NGL. It must not be stored, reproduced or disclosed to others without written authorisation from the PT Badak NGL.
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The evaluation is based on the technical and the economical considerations as well as the
availability of the replacement parts in the market. In order to meet with producer requirement that all
proposed Capital Projects 2015 must be completed with Cost and Benefit Analysis, the following
methods are used to evaluate the project feasibility:
In order to perform the above investment evaluation, the following parameters are taken
based on the data and the information provided by multi parties:
1. It is estimated that the lifetime of the system is 10 years. Therefore all commercial or benefit
will be divided by this lifetime period.
2. The investment value of the controller and field instruments replacement is about US$
400,000.
3. Project investment lifetime is assumed to be 10 years.
4. Interest rate is about 8%.
5. Current bank “hurdle rate” is 12%.
6. The income is taken by the example of the cost needed to buy the liquid nitrogen when Plant
39H shut down due to39-K-21controller failure. Based on the experiences when Plant 39H
shut down,Badak LNG must buy approximately 20 m3 liquid nitroged (LIN) per day to cover
nitrogen demand and maintain plant processes. Assumed in one year, the failed controller
needs 30 days to be repaired, so Badak LNGmust buy LIN from the third party as much as 20
m3/day x 30 days = 600 m3. The price of liquid nitrogen is assumed US$ 0.4 per liter. So, in a
year Badak LNG must pay 600 m3 x US$ 0.4/liter x 1000 liter/m3 = US$240,000.
7. The outcome cash flow refers to the following assumption:
a. Preventive maintenance of controller and field instruments are about US$25 per year.
b. Replacement of one damaged transmitter in about 4 years is about US$4,000/4 =
US$1,000.
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The calculation sheet generated by Microsoft Excel is used to find the Cost and Benefit
Analysis Parameters of this project investment which is economically justified. Several parameters
values are shown in Table 4.
9. CONCLUSIONS
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10. RECOMMENDATIONS
It is recommended to replace the controller and its related field instruments of 39-K-21. The
replacement project consists of some work scopes as follows:
1. Replace the existing 39-K-21 controller (EDC) with more reliable control system.
2. Replace the existing control system accessories andfield instrumentsof 39-K-21.
ATTACHMENT LIST
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List of Valves,Transmitters, Sensors, and I/P Converters of 39-K-21
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