Banyu Urip Facility which started up in 2015 was designed to process 185,000 BPD crude oil. Previous studies indicated surface facilities were constrained compare to reservoir deliverability. Debottlenecking activities including wash water injection into the production separator increased production 8% higher of the design capacity. Recent plant capacity test confirmed additional cooling would be required to increase production 19% higher than design capacity. Additional cooling capacity was installed downstream of the Crude Oil Stripper which successfully increased production to the new higher crude production.
This paper will share the comprehensive assessment of increasing capacity of the Banyu Urip production facilities including the additional cooling capacity and other facilities aspect affected by increasing crude production. The additional crude cooling capacity was achieved by the installation of an air cooler; however, the concept selection process also evaluated other brownfield constraintssuch as equipment spacing, constructibility, demand on supporting utlities and safety systems.
Early screen was performed to identify the equipment area taking into account the impact to operability, maintenability, and process performance. Due to the brownfield nature of the project the ideal location for symetrical arrangement of the new equipment was not avaible, therefore a screening level hydraulic analysis was require to validate the location was suitable for the process contidtions (i.e. pressure drop, velocity, etc.). The final location proved to perform as designed by by delivering the required cooling to support the increase capacity higher by 19% of design capacity.
