Mobil Cepu Ltd.

an ExxonMobil Subsidiary

Kalimantan
Sulawesi
Papua

Java Indonesia
Cepu

Banyu Urip Project

Central Field Facilities (CFF)
Case Study: Fresh Water and Produced Water Injection from the
Banyu Urip Project

Don Delavan
Process Engineering Lead, Mobil Cepu Ltd.

June 2013

BU Water Management, June 2013

1
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Project Summary Schematic

CFF Capacities
FSO
FSO
• 165 kSTBD oil production
• 300 kbpd total liquid
• 200 kbpd produced water
CFF • 260 kbpd fresh water injection
• 365 kbpd total water injection
• 124 Mscfd subsurface gas handling Shore crossing
• 75 Mscfd gas lift and injection at Palang
• 30 tpd sulfur recovery
• 2.75 Mm3 raw water basin

Export System
• 16 hour crude storage at CPF
• 165 kSTBD crude shipping pumps at CPF
CENTRAL FIELD FACILITIES
• 95 km of 20” buried insulated pipeline
• Steel jacket mooring tower with 360 deg. swivel
IF CPF • 1.7 Mbbl FSO storage capacity

WELLPADS A, B, C
Subsurface
• 2 reservoirs in communication (Oligo-Miocene Carbonate & Serravallian Clastic)
• 3 wellpads with 49 wells (33 producers, 15 injectors, and 1 future use)
• 13 water injection wells for pressure maintenance
• 2 gas injection wells with flow back capability to supplement future fuel gas needs

BU Water Management, June 2013

2
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

CFF – EPC1 (Production Processing Facilities)

• Three Wellpads supporting initial 49 well development program

– 33 producers / 15 injectors
– Flowlines from 3 wellpads to CPF
• Sour oil and gas production and processing
– 45 % CO2 and 1.6% H2S Area “N”
– High pour point crude (33oC) EPC5
– 165 kSTBD oil / 200 kbpd produced water capacity
– ~124 Mscfd gas handling / 75 Mscfd gas injection
• Produced water re-injected with fresh water make-up taken from
Solo River
– Produced and fresh water treatment
– 365 kbpd water injection capacity Area “C”
• Crude heater / stripper for sweetening and stabilization EPC1
• Crude export system facilities
• Amine/Claus/Tail Gas Treating system for fuel gas treatment and
sulfur recovery
• Power generation using gas turbine generators

Area “S”
EPC5

BU Water Management, June 2013

3
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

CFF – EPC5 (Infrastructure Facilities)

Area “N”
• Solo river freshwater intake facility
– Up to 512 kbpd lifting capacity
– ~ 6 km river water pipeline to basin (buried)
Area “N”
• Improved highway access and flyover bridge EPC5
• Parking and security facilities

Area “S”
• 2.75 Mm3 raw water basin
– sized for 2 month dry season at peak production Area “C”
– ~ 2 km raw water pipeline to CPF (buried) EPC1
• Office and administration buildings
• Maintenance and warehouse facilities
• Storage and laydown areas
• Rotator housing, catering and support facilities
• Emergency helipad
• Medical Clinic

Area “S”
EPC5

BU Water Management, June 2013

4
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
North View of Solo River

Solo River and Pumps

CPF

BU Water Management, June 2013

5
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Solo River Pump Station

Solo River Pumps

BU Water Management, June 2013

6
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
South View of CFF and Water Basin

Water Basin
Wellpad
Wellpad

BU Water Management, June 2013

7
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Wellpad

BU Water Management, June 2013

8
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

CFF – Block Flow Diagram

Wellpads Gas
WELLPADS CPF CPF EXPORT

TO GAS INJECTION
GAS COMPRESSION FUEL GAS POWER/STEAM
WELLS & GAS LIFT AGRU
/ DEHYDRATION COMPRESSION GENERATION
SYSTEM

AGE / SRU / TGU THERMAL OXIDIZER

PAD-A
SOLID SULFUR
PRODUCTION AND
SALES

PAD-B

CRUDE OIL CRUDE OIL

Oil
SEPARATION SWEETENING
CRUDE OIL STORAGE
TANKS ONSHORE &
PAD-C OFFSHORE
PIPELINES

CRUDE OIL SHIPPING PUMPS

PRODUCED WATER PRODUCED WATER

SEPARATION DEGASSING FSO
WATER
SKIMMING
Water
TANK

INJECTION WATER MOORING SYSTEM

TO WATER WATER INJECTION SURGE TANKS
INJECTION WELLS FACILITY

RAW WATER
RAW WATER BASIN TREATING

PLANT WATER
RIVER WATER USERS
LIFT PUMPS
CONTACT WATER WASTE WATER
RETENTION TREATING

INFRASTRUCTURE CPF

BU Water Management, June 2013

9
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Water Forecast

BU Water Management, June 2013

10
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Water Treatment Overview

5A
FROM HP PROD
SEPARATOR (FIGURE 2) PRODUCED WATER 5C
TREATMENT SYSTEM
5B (FIGURE 5A)
TO HP PROD SEPARATOR
(FIGURE 2)

M M WATER SUPPLY
5D TO PLANT

RAW WATER
TREATMENT SYSTEM
(FIGURE 5B)
5E

RIVER WATER INTAKE (1) RAW WATER BASIN

RIVER WATER LIFT PUMPS (3) LAKE WATER LIFT PUMPS (5)

INJECTION WATER
SURGE TANK TO WATER
INJECTION WATER
(2) INJECTION WELLS
RAIN BLACK REJECT PUMPS (4)
WATER WATER WATER

INJECTION WATER
BOOSTER PUMPS

WASTE WATE 5I
TREATMENT SYSTEM
(FIGURE 5C)

BU Water Management, June 2013

11
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
CFF – Water System

Produced Water Treatment

• 4 x 25% hydrocyclones (407 m3/hr or 61 kbpd each) for oil separation
• Produced water degassing system which flashes and remove sour gas
• Produced water skimming vessel to remove any residual oil
• Injection water specifications: <50 ppm oil and <20 micron particles

Raw (Solo River) Water System

• 3 x 50% Solo River water intake pumps (1870 m3/hr or 282 kbpd each)
• 2.75 Mm3 raw water basin (2-month dry season capacity)
• Raw water treatment system: clarifiers, media filters, and de-aeration (2200 m3/hr or 332 kbpd total inlet)
• Treated raw water utilized as feed for: plant water, potable water, firewater, boiler feed water and injection
water make-up
Water Injection System
• 4 x 33% booster and injection pumps (887 m3/hr or 134 kbpd each, 1800 psig discharge pressure)
• Treated produced water and raw water are injected into the reservoir for pressure maintenance

BU Water Management, June 2013

12
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Produced Water Treatment

TO CRUDE OIL STRIPPER
CONDENSER

5J

AVRC SUCTION ATMOSPHERIC

SCRUBBER (1) VFD VAPOR RECOVERY
COMPRESSOR (2)

PRODUCED WATER 5A
FROM HP PROD
SEPARATOR (FIGURE 2) AVRC SUCTION SCRUBBER
CONDENSATE PUMP (2)

HYDROCYCLONES
PRODUCED
(4)
WATER
PRODUCED WATER DEGASSING
PRODUCED WATER
DEGASSING VESSELS (2) COLUMN
SKIMMING TANK
(1)
(1)

5C TO INJECTION
WATER SURGE
PRODUCED WATER TANK (FIGURE 5)
COOLER (2)

5H
FROM RECYCLE
OIL PUMPS (FIGURE 5C)

TO HAZARDOUS
SKIM OIL SEPARATORS (1) WASTE DISPOSAL
SLOP OIL TANK
(1)
5B
TO HP PRODUCTION
SEPARATOR (FIGURE 2)
SLOP OIL TANK PUMPS (2)
SKIM OIL SEPARATOR SKIM OIL SEPARATOR OIL
WATER PUMPS (2) PUMPS (2)

BU Water Management, June 2013

13
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Hydrocyclones

180 liners

BU Water Management, June 2013

14
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
High Rate Solid Contact Clarifier (HRSCC)
Lime and Polyelectrolyte
Hypochlorite FeCl3

Stilling Flash Multi Media

Chamber Mixing HRSCC
Chamber Feed Sump

Sludge To River Water Pipeline

Blowdown
Collection
Sump

BU Water Management, June 2013

15
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
High Rate Solid Contact Clarifier (HRSCC)

BU Water Management, June 2013

16
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Multi Media Filters

BU Water Management, June 2013

17
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Multi Media Filters

Concrete Filling
BU Water Management, June 2013
18
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Multi Media Filters

Concrete Filling
BU Water Management, June 2013
19
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Cartridge Filters

BU Water Management, June 2013

20
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary
Deaerators

BU Water Management, June 2013

21
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Raw Water Treatment

M
SULFUR PELLETIZING UNIT

FROM LAKE 5D
RAW WATER CLARIFIERS
WATER LIFT CRUDE DESALTING UNIT
(2)
PUMPS (FIGURE

DEAERATED WATER TANK PLANT WATER TO FW MAIN

MEDIA FILTER FEED PUMPS (1)
(6) WATER DEAERATORS
FILTER FEED SUMP (1) (2)
PLANT WATER TO WELLPADS

M MULTI MEDIA WATER

FINE FILTER (10) PLANT WASH
CPF PLANT WATER
WATER PUMPS (4)

HP SEPARATOR INLET
CLARIFIER BACKWASH WATER TRANSFER PUMPS
(5)
WATER PUMPS (2)

BLOWDOWN COLLECTION
<20 ppb O2
<3 micron TSS 5E TO INJECTION
WATER SURGE
TANK (FIGURE 5)
SOLID DISPOSAL

FILTERED WATER PERMEATE WATER TO BFW TREATMENT UNIT

TANK (1) REVERSE TANK (1)
OSMOSIS UNITS
(2)
TO CHEMICAL DOSING UNIT
FILTERED WATER PERMEATE WATER
AND POTABLE WATER TANK
PUMPS (2) PUMPS (2)

TO DIESEL CENTRIFUGE
TO HYPOCHLORITE
GENERATION PACKAGE

5G
REJECT WATER
TO INLET POND
(FIGURE 5C)

5F REJECT WATER TO
NEUTRALIZATION
SUMP (FIGURE 5C)

BU Water Management, June 2013

22
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Waste Water Treatment

FROM HYPOCHLORITE
GENERATION PACKAGE

FROM BFW TREATMENT SKID

FROM CONDENSATE
POLISHING UNIT M
CAUSTIC ACID UTILITY AIR

REJECT WATER 5F
FROM RO UNITS
(FIGURE 5B)

NEUTRALIZATION SUMP (1)

NEUTRALIZATION PUMP (1)

NEUTRALIZATION PIT TREATMENT UNIT (1)

FROM MISCELLANEOUS
OPEN DRAINS

FROM RO UNITS 5G
(FIGURE 5B)

5H
TO SLOP OIL TANK
(FIGURE 5A)

M M 5I TO INJECTION
WASTE WATER WATER SURGE
TREATMENT UNIT (1) TANK (FIGURE 5)
RECYCLE OIL PUMPS
CPI SEPARATOR (1)
(2)
INLET
POND RETENTION POND
(1) (1)
WASTE WATER
PUMPS (2) CPI WASTE WATER FEED
PUMPS (2) OPEN DRAIN WATER
SUMP PUMPS (2)

BU Water Management, June 2013

23
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Questions

BU Water Management, June 2013

24
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

CPF Layout

BU Water Management, June 2013

25
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Wellpad Layout

BU Water Management, June 2013

26
 Mobil Cepu Ltd.
an ExxonMobil Subsidiary

Crude Oil Separation / Sweetening

TO HP FUEL GAS USERS

HP FUEL GAS
SCRUBBERS (2)

FUEL GAS
FROM WELLS
COMPRESSORS (2)
AGRU TO LP FUEL GAS USERS
4A AGE 4C
FROM WELLS
SRU
TEST TGU
SEPARATORS (2) (FIGURE 4)
TO GAS INJECTION WELLS
HP INLET
HP
GAS COOLER (1)
3E SCRUBBER
CAP GAS FROM TO GAS LIFT WELLS
(1)
WELLS (FIGURE 3)
GAS CRUDE OIL STRIPPER
3A COMPRESSION 5J
OVERHEAD CONDENSERS (2) FROM PW DEGASSING
(FIGURE 3)
AND AVRC (FIGURE 5)
3D

FROM WELLS 3C

CRUDE OIL
FEED STRIPPERS (2)
HP PRODUCTION HEATERS (2)
SEPARATORS (2)

LP PRODUCTION
SEPARATORS (2)
STEAM

5A FEED/BOTTOMS
EXCHANGERS (2)
TO WATER 5B STRIPPER BOTTOM
INJECTION WELLS PUMPS (4)
WATER
CRUDE OIL TO OIL EXPORT
TREATING
STORAGE TANKS PIPELINE
(FIGURE 5)
CRUDE OIL (4)
DEHYDRATORS (2) CRUDE OIL STRIPPER
COOLERS (2)
CRUDE OIL CRUDE OIL
BOOSTER SHIPPING
CRUDE PUMPS (3) PUMPS (3)
DEHYDRATOR WATER RERUN
TRANSFER PUMPS (4) PUMPS (2)

BU Water Management, June 2013

27