OVERPRESSURE STUDY REPORT

PROJECT : M-8 STATION VLP RELOCATION

COMPRESSOR MODIFICATION
EXISTING FOUNDATION

AFE No. : AFE-222085

CLIENT : PERTAMINA HULU SANGA - SANGA

LOCATION : MUTIARA 8 EAST KALIMANTAN

A2 20/Jan/23 Re-Issued for Approval LKW AW YN/SD RKF BS/RA/MF

A1 11/Nov/22 Issued for Approval LKW AW YN/SD BS MZN

A 16/Sep/22 Issued For Review LKW AW YN/SD BS MZN

Rev Date Description Prep’d Check App’d Project Approval

Doc. No. : MT-AFE222085-RPT-PRC-X-002

Page No. : REV

A2
DOCUMENT TITLE

1 of 26
 OVERPRESSURE STUDY REPORT

RECORD OF REVISION

Rev. Incorporated
Section Page Company Comment Contractor Response
No. (Y/N)
Cover 1 See comment Y Comment incorporated.

no summary section?
Table of pls ensure the format is
3 Y Comment incorporated.
Contents consistent with other
similar reports

pls ensure this section

1.1 4 consistent in all Y Comment incorporated.
AFE222085 documents

pls use name of the

1.2 5 project instead of the Y Comment incorporated.
AFE no.

pls ensure this section

2 6 consistent in all Y Comment incorporated.
AFE222085 documents

Pls check with new

2 6 Y Comment incorporated.
figure

for next revision pls

submit HMB first. Pls
A 3.2 7 submit PFD/ HMB Y Comment incorporated.
together/right after
Simulation

pls add 1 more column

3.2 7 Y Comment incorporated.
for p&id location

The latest datasheet of PSV

to ensure the validity
3.2 7 pls ask for existing
datasheet and attach
is not match with existing
-
P&ID. Hence, ENG used
data on P&ID for references.

pls add brief

explanation what are
3.3 9 the primary protection Y Comment incorporated.
in this project and pls
state the tag no

pls add brief

explanation what are
the secondary
3.3 9 Y Comment incorporated.
protection in this
project and pls state
the tag no

Doc. No. MT-AFE222085-RPT-PRC-X-002 Rev. A2 Page 2 of 41

 OVERPRESSURE STUDY REPORT

Rev. Incorporated
Section Page Company Comment Contractor Response
No. (Y/N)
pls elaborate more,
explain how
4.1 12 overpressure due to Y Comment incorporated.
fire can happen in the
system

pls elaborate more,

explain how
4.1 12 overpressure due to Y Comment incorporated.
blocked outlet can
happen in the system

there is a FG heater,
why tube rupture is not
considered? and are There is no existing PSV on
4.2 12 -
there any other existing FG Heat Exchanger.
possible cause of
overpressure?

only this equipment

that is protected or is it
to protect secton/ The PSV is protected each
A 4.2 12 segment in the Y section in the system, it will
system? if it is to be stated on the table.
protect section pls
state

Since the PSVs are existing,

pls explain how do
the governing scenario is
these scenario are the
4.2 12 - refer to existing PSV’s
governing case for
scenario that stated on
each psv.
P&ID.

pls ensure section/

equipments that need
4.2 12 Y Comment incorporated.
to be protected by psv
are already covered

pls ensure that inlet

line equiv length is
enough (refer to
5.2.1 16 Y Comment incorporated.
attachment it is
assumed 100 ft) and
align with piping.

A1 Record of 2 this comment related to Y Comment incorporated.

Doc. No. MT-AFE222085-RPT-PRC-X-002 Rev. A2 Page 3 of 41

 OVERPRESSURE STUDY REPORT

Rev. Incorporated
Section Page Company Comment Contractor Response
No. (Y/N)
psv type and its actual
data. does the actual
data (type, size & set
Revision
pressure) similar with
p&id that used as
references. pls reverify

Record of pls discuss this during

3 Y Comment incorporated.
Revision hazop

2 7 To Y Comment incorporated.

2 7 And Y Comment incorporated.

since the existing PSV

will be relocated, pls
ensure the PSV data is
3.2 8 Y Comment incorporated.
matched with the
installed PSV (type,
size & set pressure)

from which existing

p&id is this set
pressure? in the MTA-
Set pressure at PSV-
G-10A-517 & 520 rev 6
2885A/B/C has been
3.2 8 the set pressure is 635 -
changed into 635 psig, as
and from psv tag
per existing datasheet.
during site survey it is
alo 635, pls
check/reverify

pls discuss during

Based on HAZOP Study,
hazop the requirement
PSV at 1st Stage VLP
of PSV at 1st stage
3.2 9 - compressor Suction
scrubber since
Scrubber (MT-V-2820A/B/C)
currently there is no
shall be installed.
PSV for that section

pls recheck if this is

pressure of KOD isn't it
constant superimposed
4.2 14 backpressure? Y Comment incorporated.
built up back pressure
is generated due to
fluid flowing

A1 4.3 & 4.4 14 are these data Y Comment incorporated.

Doc. No. MT-AFE222085-RPT-PRC-X-002 Rev. A2 Page 4 of 41

 OVERPRESSURE STUDY REPORT

Rev. Incorporated
Section Page Company Comment Contractor Response
No. (Y/N)
preliminary or already
final? pls add note if
this is still prelim and
update when final data
available

4.4 14 pls update to outlet Y Comment incorporated.

5.1 20 pls recheck Y Comment incorporated.

Since data from flare

pls update this hydraulic is not ready yet,
evaluation using flrae total pressure drop still using
5.2.2 22 N
hydraulic (WPI flare total superimposed back
hydraulic) pressure and piping
pressure drop.

pls reverify, it seems

there is still
misunderstanding
regarding this total
pressure drop calc. pls
calc the total pressure
drop by adding built up Incorporated. Since data
back pressure + from flare hydraulic is not
superimposed back ready yet, total pressure
5.2.2 22 Y
pressure. drop still using total
superimposed back pressure
and piping pressure drop.
For build up back
pressure it shall be
calculated until the
flare. This also to be
updated using WPi
flare hydraulic

Doc. No. MT-AFE222085-RPT-PRC-X-002 Rev. A2 Page 5 of 41

 OVERPRESSURE STUDY REPORT

Table of Contents
1. INTRODUCTION......................................................................................................7
1.1 Background............................................................................................................ 7
1.2 Objectives............................................................................................................... 8
1.3 Abbreviation........................................................................................................... 8
2. FACILITY DESCRIPTION..................................................................................9
3. DESIGN BASIS AND ASSUMPTION.................................................................10
3.1 Software............................................................................................................... 10
3.2 Operating Condition..............................................................................................10
3.3 Design Basis........................................................................................................ 11
4. SIMULATION METHODOLOGY........................................................................14
4.1 Cause of Upset Condition.....................................................................................16
4.2 Scenario Identification..........................................................................................16
4.3 PSV Relief Condition............................................................................................17
4.4 PSV Inlet Data......................................................................................................19
4.5 PSV Outlet Data...................................................................................................19
4.6 PSV Relief Calculation.........................................................................................20
4.6.1 Fire Scenario (Unwetted Vessel)...................................................................20
4.6.2 Closed Outlet Scenario..................................................................................21
4.7 PSV Discharge Area Calculation (Gas/Vapor Relief)............................................22
4.8 PSV Inlet Line Size Criteria..................................................................................23
4.9 PSV Outlet Line Size Criteria................................................................................23
4.10 Back Pressure Coefficient....................................................................................24
4.11 Discharge Coefficient...........................................................................................24
4.12 Noise Height.........................................................................................................24
4.13 Wall Temperature.................................................................................................24
4.14 Settle Out Calculation...........................................................................................24
5. RESULT AND CONCLUSION............................................................................25
5.1 PSV Calculation Result........................................................................................25
5.2 Line Sizing Calculation.........................................................................................26
5.2.1 Inlet Line Sizing Calculation..........................................................................26
5.2.2 Outlet Line Sizing Calculation........................................................................28
6. SUMMARY.......................................................................................................31
7. REFERENCES...................................................................................................32

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 OVERPRESSURE STUDY REPORT

1. INTRODUCTION

1.1 Background
PT. Pertamina Hulu Sanga Sanga (PHSS), as part of their program, intends to
relocate 3 units 5 MMscfd capacity VLP Compressor (C-2800A, C-2800B, C-2800C)
from Mutiara Central Plant to Mutiara 8 Station.
Based on Mutiara-8 plant compression profile from 2022-2038, peak gas production
could reach up to 33 MMscfd. Currently VLP compression system in Mutiara-8 plant
is supported by 3 x 5 MMscfd compressor dan 1 x 5 MMscfd rental compressor that
has contract expire at Q1-2024. At this condition, total VLP compression system at
Mutiara-8 plant is at max 20 MMscfd. Based on LTP Mutiara-8 plant, Mutiara-8 plant
needs additional compressor to fullfil compression system until end of PSC (2038).
Therefore, three compressor (C-2800 A/B/C) will relocate from Mutiara Central Plant
to Mutiara-8 Plant.

Figure 1-1 Area Overview of Mutiara Field

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 OVERPRESSURE STUDY REPORT

1.2 Objectives
Objectives of this document is to provide study on overpressure protection of
Compressor MT-Z-2800A/B/C within M-8 Station VLP Relocation Compressor
Modification Existing Foundation scope of work. This study will examine the
overpressure protection system provided in this facility in order to prevent any
mechanical failure of all components due to the high-pressure exposure.
This report only cover the study of overpressure protection for Compressor MT-Z-
2800A/B/C and system that interfacing with this project including adequacy check of
existing PSV and its inlet and outlet line size at Compressor MT-Z-2800A/B/C
system.

1.3 Abbreviation
BPD : Barrel per Day
MCP : Mutiara Central Plant
MMscfd : Million Standard Cubic Feet per Day
MW : Molecular Weight
P&ID : Piping and Instrumentation Diagram
PCV : Process Control Valve
PFD : Process Flow Diagram
PHSS : PT. Pertamina Hulu Sanga Sanga
PSHH : Pressure Switch High-High
psig : Pound per Square Inch Gauge
PSV : Pressure Safety Valve
RP : Recommended Practice
SDV : Shut Down Valve
VLP : Very Low Pressure

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 OVERPRESSURE STUDY REPORT

2. FACILITY DESCRIPTION
Mutiara-8 plant purpose to receive relocation compressor (C-2800A/B/C) from
A2 Mutiara Central Plant to increase capacity of production. Currently VLP compression
system in Mutiara-8 plant is supported by 3 x 5 MMscfd compressor and 1 x 5
MMscfd rental compressor that has contract expire at Q1-2024. Based on M8 VLP
compression profile in Figure 2 -2, gas rate will be reduce if the compressor C-
2800A/B/C is not relocated.

Figure 2-2 M-8 VLP Compression Profile 2021-2038

Thus to prevent reduce of gas rate, compressor C-2800A/B/C will be installed in to M-
8 station to increase gas rate production which one can fulfill production until 2038.
Based on LTP Mutiara – 8 plant, Mutiara – 8 plant needs additional compressor to
fullfil compression system until end of PSC (2038). Therefore, three compressor (C-
2800 A/B/C) will be relocated from Mutiara Central Plant to Mutiara-8 Plant.

Figure 2-3 VLP Gas Compression M8-Plant After Relocation

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 OVERPRESSURE STUDY REPORT

3. DESIGN BASIS AND ASSUMPTION

3.1 Software
The software used in the calculation are:
 Aspentech HYSYS Process Simulator Ver. 10.0 with Peng-Robinson fluid
properties package to generate fluid properties.
 Aspentech HYSYS Safety Analysis Ver. 10.0 to estimate the PSV relief orifice,
relief area, rated orifice, rated area, inlet line.
 In-house outlet line PSV sizing spreadsheet based on API STD 520 [Ref. 3., 4.]
and API 521 {Ref. 5.] calculation methodology to estimate the outlet line PSV,
mach number, velocity, and momentum.

3.2 Operating Condition

The operating condition of each system is obtained from Process Simulation Report
[Ref. 8.]. The following table summarized the operating condition of each system.

Table 3-1 Existing PSV Data

Parameter Unit PSV-2835A/B/C PSV-2865A/B/C PSV-2885A/B/C PSV-2890A/B/C

Equipment 1st Stage VLP Gas 2nd Stage VLP Gas 3rd Stage VLP Gas VLP Compressor
Section to be - Comp. Air Cooler Comp. Air Cooler Comp. Air Cooler Fuel Gas Filter
Protected (MT-E-2835A/B/C) (MT-E-2865A/B/C) (MT-E-2885A/B/C) (MT-F-2890A/B/C)
Previous Sizing
- Blocked Outlet Blocked Outlet Blocked Outlet Fire
Scenario
PSV Type - Pilot Pilot Pilot Pilot
Orifice Design - 3K4 1½G3 1½G3 1D2
A2 Operating
psig 68 192 560 149
Pressure[2.]
Design Pressure psig 230 645 1,287 250
A2 PSV Set
psig 215 600 635 250
Pressure
P&ID Reference MTA-M-10A-116-1/ MTA-M-10A-116-2/ MTA-M-10A-116-2/ MTA-M-10A-125/
- MTA-M-10A-117-1/ MTA-M-10A-117-2/ MTA-M-10A-117-2/ MTA-M-10A-126/
MTA-M-10A-561-1 MTA-M-10A-561-2 MTA-M-10A-561-2 MTA-M-10A-229

A2 Note:
1. Existing PSV data is refer to existing Datasheet [Attachment D]
2. Operating pressure refer to Process Simulation Report. [Ref. 8.]

Doc. No. MT-AFE222085-RPT-PRC-X-002 Rev. A2 Page 10 of 41

 OVERPRESSURE STUDY REPORT

Table 3-2 New PSV Data

Parameter Unit PSV-2820A/B/C

Equipment Section to 1st Stage VLP Gas Comp. Suction

-
be Protected Scrubber (MT-V-2820A/B/C)
Size of Equipment - 3’ (OD) x 6’ (S/S)
A2 Equipment Orientation - Vertical
Operating Pressure psig 90
Design Pressure psig 230
PSV Set Pressure psig 215
MTA-M-10A-116-1/
P&ID Reference - MTA-M-10A-117-1/
MTA-M-10A-561-1

Note:
1. Operating pressure refer to Process Simulation Report. [Ref. 8.]

The fluid properties which are used for the basis of PSV calculation is based on
Process Simulation Report [Ref. 8.]. The data is presented on table below.

Table 3-3 Design Data for Mutiara-8 Plant

Parameter PSV-2820A/ PSV-2835A/ PSV-2865A/ PSV-2885A/ PSV-2890A/
Unit
B/C B/C B/C B/C B/C
Equipment to 1st Stage VLP VLP
1st Stage VLP 2nd Stage VLP 3rd Stage VLP
be protected Gas Comp. Compressor
Gas Comp. Gas Comp. Gas Comp.
Suction Fuel Gas
- Air Cooler Air Cooler Air Cooler
Scrubber Filter
(MT-E- (MT-E- (MT-E-
(MT-V- (MT-F-
2835A/B/C) 2865A/B/C) 2885A/B/C)
2820A/B/C) 2890A/B/C)
A2 Phase - Gas Gas Gas Gas Gas
MW - 20.78 20.78 20.79 20.71 20.79
Density lb/ft3 0.112 0.280 0.586 1.502 0.628
Viscosity cP 0.0117 0.0158 0.0146 0.0162 0.0121
Specific Heat
- 1.273 1.226 1.258 1.269 1.305
Ratio (Cp/Cv)
Compressibility - 0.9937 0.9938 0.9823 0.9706 0.9676

3.3 Design Basis

Design pressure of equipment and piping in the system is determined by the
maximum allowable operating pressure plus safety margin. Although equipment
design pressure is quite far from its normal operation condition, upset condition might
cause higher system pressure than its design. Such overpressure condition should be
prevented to protect from mechanical failure of the equipment.

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 OVERPRESSURE STUDY REPORT

The following basis and assumptions are applied in carrying out the study:
1. Overpressure (PSV) study for selected line sizing based on API RP 14C. [Ref. 2.]
2. PSV sizing methodology based on API 520 & 521. [Ref. 3., 4., 5.]
3. PSV selected size based on API 526. [Ref. 11.]
4. Control valves can be considered to stuck open even though they have already
specified as fail-closed or fail-open indicating the fail-safe position, respectively,
corresponds to the air failure spring return of the valve.
5. PSV inlet line pressure drop shall not exceed 3% of PSV set pressure based on
PSV rated capacity to avoid chattering.
6. The study of flare/vent network system and back pressure analysis around
7. 10% additional margin at piping section is given for settle out calculation.

Refer to API 14C Section 6.2.2.2.4 and 6.2.2.2.5, two level overpressure protections
are required as below:
1. Primary Protection
Primary protection from overpressure should be provided by a PSH sensor to
shut off inflow. If a vessel is heated, PSH sensor should also shut off the fuel or
source or heated. Primary protection for atmospheric components should be
provided by an adequate vent system. The primary protection in this system is
presented below.
Table 3-4 Primary Protection Summary
Equipment to be Protected Primary Protection
1st Stage VLP Gas Comp. Air Cooler
PSHH-2825A/B/C
(MT-E-2835A/B/C)
2nd Stage VLP Gas Comp. Air Cooler
PSHH-2850A/B/C
(MT-E-2865A/B/C)
3rd Stage VLP Gas Comp. Air Cooler
PSHH-2875A/B/C
(MT-E-2885A/B/C)
VLP Compressor Fuel Gas Filter
PAH-2890A/B/C
(MT-F-2890A/B/C)
VLP Compressor Fuel Gas Heater Tube side: PSHH-2860A/B/C
(MT-E-2865A/B/C) Shell side: PAH-2890A/B/C

2. Secondary Protection
Secondary protection from overpressure should be provided by a PSV.
Secondary protection for atmospheric system should be provided by a second
vent. The second vent may be identical to the primary vent, a gauge hatch with a
self-contained PSV or an independent PSV. The secondary protection in this
system is presented below.

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 OVERPRESSURE STUDY REPORT

Table 3-5 Secondary Protection Summary

Equipment to be Protected Secondary Protection
1st Stage VLP Gas Comp. Suction
PSV-2820A/B/C (New)
Scrubber 9MT-V-2820A/B/C)
1st Stage VLP Gas Compressor
(MT-C-2800A/B/C)
PSV-2835A/B/C (Existing)
1st Stage VLP Gas Comp. Air Cooler
(MT-E-2835A/B/C)
2nd Stage VLP Gas Compressor
(MT-C-2800A/B/C)
A2 PSV-2865A/B/C (Existing)
2nd Stage VLP Gas Comp. Air Cooler
(MT-E-2865A/B/C)
3rd Stage VLP Gas Compressor
(MT-C-2800A/B/C)
Fuel Gas Heat Exchanger – Tube Side
PSV-2885A/B/C (Existing)
(MT-F-2860A/B/C)
3rd Stage VLP Gas Comp. Air Cooler
(MT-E-2885A/B/C)
VLP Compressor Fuel Gas Filter
PSV-2890A/B/C (Existing)
(MT-F-2890A/B/C)
Fuel Gas Heat Exchanger – Shell Side
PSV-2802A/B/C (Existing)
(MT-F-2860A/B/C)

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 OVERPRESSURE STUDY REPORT

4. SIMULATION METHODOLOGY
API RP 520 [Ref. 3., 4.] and API RP 521 [Ref. 5.] set guidelines to determine relief load as well as to size the required orifice area for
PSV.
Safety Analysis Tools in AspenTech HYSYS V.10 is used to calculate PSV relief rate, PSV rated flow, PSV orifice area, and PSV
inlet/outlet line sizing for each governing scenario. Screenshot of HYSYS Safety Analysis Tools is shown on the figure below.

A2

Figure 4-4 Schematic of M-8 Plant Relocation Project

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 OVERPRESSURE STUDY REPORT

A2

Figure 4-5 HYSYS Safety Analysis Tools Screenshot

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 OVERPRESSURE STUDY REPORT

4.1 Cause of Upset Condition

Equipment in the M-8 facilities is protected by PSV from overpressure as result of
analysis of possible failures caused by the following events:
a. External Fire
Fire exposure on equipment can result in overpressure due to vapor generation
(boiling of liquid contents or decomposition reaction) and/or fluid expansion. Fire
exposure can also cause overheating of the vessel walls resulting in a reduction
in material strength.
Unwetted wall vessels are those that have no liquid in contact with the internal
vessel walls. These include VLP Compressor Fuel Gas Filter (F-289A/B/C) that
contain single phase at relieving conditions.
b. Blocked Outlet
The inadvertent closure of a valve on the outlet of pressure equipment while the
equipment is on stream can expose the equipment to a pressure that exceeds
the MAWP.
Even where there are no block valves between stages, interstage PRD(s) might
be required to prevent overpressure in the event of loss of interstage cooling. A
remote-but possible-contingency, however would be on of the downstream
stages. Loss of downstream stage compression would essentially shift all of the
gas compression work to the previous stage. A PRD sized for the blocked outlet
flow conditions at the interstage design pressure is required to prevent
overpressure.
c. Tube Rupture
Complete tube rupture, in which a large quantity of high-pressure fluid flows to
the lower-pressure exchanger side, is a remote but possible contingency. Minor
leakage can seldom overpressure an exchanger during operation, however such
leakage occurring where the low-pressure side is closed in can result in
overpressure. Loss of containment of the low-pressure side to atmosphere is
unlikely to result from a tube rupture where the pressure in the low-pressure side
(including upstream and downstream systems) during the tube rupture does not
exceed the corrected hydrotest pressure.

4.2 Scenario Identification

Possible overpressure scenarios, as listed in API 521, of new installed relief devices
are identified, relief rate scenario is estimated to determine the governing case of the
relief devices. Possible scenario of the new relief devices are summarized below.
Table 4-6 PSV Scenario Identification
PSV Tag No.
Relief Scenario PSV- PSV- PSV- PSV- PSV- PSV-
2820A/B/C 2835A/B/C 2865A/B/C 2885A/B/C 2890A/B/C 2802A/B/C
Blocked Outlet     x x

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 OVERPRESSURE STUDY REPORT

PSV Tag No.

Relief Scenario PSV- PSV- PSV- PSV- PSV- PSV-
2820A/B/C 2835A/B/C 2865A/B/C 2885A/B/C 2890A/B/C 2802A/B/C
In-advertent Valve x x x x x x
Opening
Check Valve Leakage x x x x x x
Control Valve Failure x x x x x x
Electrical or Mechanical x x x x x x
Failure
Loss of Fans x x x x x x
Loss of Heat x x x x x x
Loss of Instrument Air x x x x x x
Cooling/Reflux Failure x x x x x x
Abnormal Heat Input x x x x x x
Heat Exchanger Tube x x x x x 
Failure
Absorbent Flow Failure x x x x x x
Accumulation of Non x x x x x x
Condensable
Entrance of Volatile x x x x x x
Material
Internal Explosion x x x x x x
Chemical Reaction x x x x x x
Hysraulic Expansion x x x x x x
External Fire    x  x
Power Failure x x x x x x
Overfilling x x x x x x
Note:
 : Identified Scenario
x : Not Applicable

4.3 PSV Relief Condition

The relieving pressure is calculated based on API RP 520, Section 5.4.1.1 [Ref. 3.].
The relieving pressure is PSV’s set pressure system of system plus overpressure.
The relieving gas temperature is depending on the mechanism in the overpressure
occurred.
The relieving pressure and corresponding temperature for all scenarios as mentioned
above will be presented on the following table. As per API 520 requirement,
maximum allowable overpressure is 21% for fire scenario and 10% for blocked outlet
scenario.

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 OVERPRESSURE STUDY REPORT

Table 4-7 Relief Condition of PSV

Parameter Unit PSV-2820A/B/C PSV-2835A/B/C PSV-2865A/B/C PSV-2885A/B/C PSV-2890A/B/C PSV-2802A/B/C
1st Stage VLP Gas 2nd Stage VLP Gas 3rd Stage VLP Gas VLP Compressor
3rd Stage VLP Gas VLP Compressor
Comp. Suction Comp. Suction Comp. Suction Fuel Gas Heat
Equipment to be protected - Comp. Air Cooler Fuel Gas Filter
Scrubber Scrubber Scrubber Exchanger
(MT-E-2885A/B/C) (MT-F-2890A/B/C)
(MT-V-2820A/B/C) (MT-V-2845A/B/C) (MT-V-2870A/B/C) (MT-E-2860A/B/C)
Blocked
Scenario - Fire Blocked Outlet Blocked Outlet Blocked Outlet Fire Tube Rupture
Outlet
PSV Set Pressure[1.] psig 215 215 600 635 250
Superimposed Back
psi 4 4 4 4 4
Pressure
Allowable overpressure % 21 10 10 10 10 21
Relief Pressure psig 260 237 237 660 660 303
Relief Temperature °F 4,307 130 268 284 284 613

Note:
1. PSV set pressure is taken from existing P&ID. [Ref. 10.]
2. Superimposed back pressure is taken from operating condition at Knock Out Drum (V-8160)

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 OVERPRESSURE STUDY REPORT

4.4 PSV Inlet Data

The inlet line of PSV data are taken from Isometric Drawing. The following table
summarizes data for inlet line PSV.
Table 4-8 PSV Inlet Data
Total Length
PSV Tag No. Location Line Number
(m)
X”-HG-1B-80366/
1st Stage VLP Gas Comp. Suction
PSV-2820A/B/C X”-HG-1B-80367/ 30.969
Scrubber (MT-V-2820A/B/C)
X”-HG-1B-80368
PSV-2835A/B/C 3”-HG-1B-80318/
2nd Stage VLP Gas Comp. Suction
3”-HG-1B-80334/ 31.230
Scrubber (MT-V-2845A/B/C)
A2 3”-HG-1B-80360
1½”-HG-3B-80323/
3rd Stage VLP Gas Comp. Suction
PSV-2865A/B/C 1½”-HG-3B-80339/ 36.373
Scrubber (MT-V-2870A/B/C)
A2 1½”-HG-3B-80355
1½”-HG-3B-80327/
3rd Stage VLP Gas Comp. Air Cooler
PSV-2885A/B/C 1½”-HG-3B-80343/ 40.503
(MT-E-2885A/B/C)
1½”-HG-3B-80359
2”-HG-1B-80099/
VLP Compressor Fuel Gas Filter
PSV-2890A/B/C 2”-HG-1B-0522/ 10.363
(MT-F-2890A/B/C)
2”-HG-1B-0528

Note:
1. Inlet PSV-2820A/B/C to be calculated at section 5.2.1. The other PSV line size is existing line that will be
verified at section 5.2.1.

4.5 PSV Outlet Data

The outlet line of PSV data are taken from Isometric Drawing. The following table
summarizes data for inlet line PSV.
Table 4-9 PSV Outlet Data

Total Length
Line Number Description
(m)
X”-F-1B-80043/
X”-F-1B-80044/ Outlet Line PSV-2820A/B/C 3.681
X”-F-1B-80145
4”-F-1B-80028/
4”-F-1B-80023/ Outlet Line PSV-2835A/B/C 2.605
4”-F-1B-80128
4”-F-1B-80029/
4”-F-1B-80024/ Outlet Line PSV-2865A/B/C 2.628
4”-F-1B-80129

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 OVERPRESSURE STUDY REPORT

Total Length
Line Number Description
(m)
4”-F-1B-80030/
4”-F-1B-80025/ Outlet Line PSV-2885A/B/C 2.360
4”-F-1B-80130
4”-F-1B-80031/
4”-F-1B-80026/ Outlet Line PSV-2890A/B/C 3.951
4”-F-1B-80132
6”-F-1B-80040 Flare Sub-Header Line 89.080
16”-F-1B-80050 Inlet Knock Out Drum (V-8160) 201.593

Note:
1. Inlet PSV-2820A/B/C to be calculated at section 5.2.1. The other PSV line size is existing line that will
be verified at section 5.2.1.

4.6 PSV Relief Calculation

4.6.1 Fire Scenario (Unwetted Vessel)

For unwetted vessel, those in which the internal walls are exposed to a gas, vapour
or super-critical fluid, or are internally insulated regardless of the contained fluids, the
relief rate are calculated by using the equation as follows;

Where,
M : Molecular weight
A’ : Exposed surface area of vessel, ft2
Tw : Maximum wall temperature of vessel material, °R
P1 : Relieving Pressure, psia
T1 : Relieving Temperature, °R
Maximum wall temperature of vessel as per API STD 521 section 5.15.2.2.2 [Ref. 6]
for carbon steel is recommended as 593°C (1100°F).
The vessel surface is assumed entirely exposed to fire. The exposed area calculation
includes 2:1 elliptical head area, and vessel shell area. The dimension of vessel is
obtained from Piping and Instrumentation Diagram (Attachment C).
The equipment is simplified as follows for area calculations.

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 OVERPRESSURE STUDY REPORT

Di

Ellipsoidal Head Cylindrical Ellipsoidal Head

Section Section
Section
AEL AEL
Area from nozzles connections is omitted. The vessel surface is calculated using the
following equation;

ԑ = 0.866 (for ellipsoidal 2:1 type head)

The area of unwetted vessel and other equipment that only contain gas are
summarized on the following table.
Table 4-10 Summary of Dimension for Unwetted Equipment
Equipment Tag No. Description Size
A2 MT-V-2820A/B/C 1st Stage VLP Comp. Suction Scrubber 36” OD x 72” P/S
MT-V-2845A/B/C 2 Stage VLP Comp. Suction Scrubber
nd

MT-V-2870A/B/C 3rd Stage VLP Comp. Suction Scrubber

MT-F-2890A/B/C VLP Compressor Fuel Gas Filter 16” OD x 48” P/S

The discharge areas for pressure-relief devices on vessels containing super-critical

fluids, gases or vapours exposed to open fires can be estimated using the following
equation.

Where,
A = effective discharge area of the valve, in2
A’ = exposed surface area of the vessel, ft2
P1 = upstream relieving absolute pressure, psia
Whilst, F’ can be determined using the following equation:

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 OVERPRESSURE STUDY REPORT

Where,
Kd = coefficient of discharge. For preliminary sizing, Kd=0.975 is used.
Tw = recommended maximum wall temperature of vessel material, °R
T1 = gas absolute temperature at upstream relieving pressure, °R

4.6.2 Closed Outlet Scenario

The relief rate for closed outlet scenario is the total incoming stream and vapor
flowrate plus that generated at relieving conditions per API 521 [Ref. 3.].

4.7 PSV Discharge Area Calculation (Gas/Vapor Relief)

The relieving area is calculated based on API RP 520 [Ref. 4.] gas/vapor critical flow
equation. The equation is presented as follows:

Where,
A = Required effective discharge area of the device, in²
W = Mass flow rate, lb/hr
C = Function of the ratio of the ideal gas specific heat (k=Cp/Cv) of the gas or
vapour at inlet relieving temperature.
Kd = Effective coefficient of discharge
Kb = Capacity correction factor due to backpressure
Kc = Combination correction factor for installation with a rupture disk upstream
of the PSV
P1 = Upstream relieving pressure, psia
T1 = Gas absolute temperature at upstream relieving pressure, R
Z = Compressibility factor
The coefficient C is calculated as an input parameter to determine the relief rate of
the relief area of PSV.

Where.
k = Ratio of the specific heats
Based on API RP 520, the recommended value assumed for the factors are as
follows.

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 OVERPRESSURE STUDY REPORT

Effective coefficient of discharge (Kd)

• Kd= 0.975, when a pressure relief valve is installed with or without a rupture disk
in combination
• Kd= 0.62, when a pressure relief valve is not installed and sizing is for a rupture
disk

Back Pressure Facto (Kb)

• For balanced vessel, Kb is obtained from manufacturer.
• For conventional and pilot vessels, Kb equal to 1.

Combination Correction Factor (Kc)

• Kc= 1.0, when a rupture disk is not installed.
• Kc= 0.9, when a rupture disk is installed in combination with a pressure relief
valve.

The PSV effective discharge area is calculated using formula for gas/vapor critical
flow which is verified by the following equation:

Where:
Pcf= Critical Flow Pressure (psia)

When the backpressure (Pb) is less than the critical flow pressure (Pcf), the flow is
identified as critical flow.

4.8 PSV Inlet Line Size Criteria

The line size criteria for PSV inlet is pressure drop loss limited by 3% of PSV set
pressure as per API 520 Part 1 Section 5.4.1.1 [Ref. 3.]. The pressure loss should be
calculated using the rated capacity of the pressure relief valve to avoid valve
chattering.

4.9 PSV Outlet Line Size Criteria

The outlet line calculated is performed in accordance to API 521 Section 5.5 [Ref. 5.].
The following criteria outlet line as shown below:
 Minimum line size is 2” and however the outlet line shall not be smaller than the
outlet flange of the relieving device;
 Velocity and ρv2:
 The recommended maximum Mach number is 0.7 calculated at rated flowrate.
This criteria is applied to avoid pipe vibration and noise generation caused by
excess velocity in the lines.
 Calculated ρv2 should be < 134,590 lb/ft.s2 (< 200,000 kg/m.s2). High ρv2
(momentum) value may cause problems in piping system such as vibration and
acoustic fatigue. This value is also used as a limiting factor to prevent erosion.

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 All relief valve Static Back Pressure (SBP) shall not exceed the Maximum Allowable
Back Pressure (MABP). MABP is determined by valve type used, as follows:
Table 4-11 Maximum Allowable Backpressure Criteria
PSV Type MABP
Conventional < 10% of PSV set pressure
Balanced-Bellows < 30% of PSV set pressure
Pilot < 50% of PSV set pressure

According to API Std. 521, lines downstream relieving device for individual pressure
relief valves are sized on the basis of the rated capacity.

4.10 Back Pressure Coefficient

Line calculation shall be carried out in order to maintain back pressure lower than the
maximum indicated by API so as to maintain Kb = 1. For this reason, in PSV
calculation, Kb value is assumed equal to 1.

4.11 Discharge Coefficient

According to API 520 section 5.6.3 an estimated value of 0.975 (for gas phase) and
0.65 (for liquid phase) have been assumed in order to provide correct design of PSV.

4.12 Noise Height

Based on API 521 Section 5.8.10.3, the sound pressure level or noise level is at 30 m
(100 ft) or 98.97 dBA.

4.13 Wall Temperature

Maximum wall temperature of vessel as per API STD 521 Section 4.4.13.2.4.3 for
carbon steel is recommended as 593°C (1,100°F).

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5. RESULT AND CONCLUSION

5.1 PSV Calculation Result

PSV calculation sheet is presented in Attachment A. The selected PSV is taken from HYSYS Safety Analysis. The result of the relief
load and PSV sizing is summarized in the following table:
Table 5-12 Existing PSV Calculation Result

PSV PSV Existing Orifice

Calculated Existing
Pset Prelief Trelief Relief Rated
PSV Tag No. PSV Type Relief Scenario Orifice In/Out Flange Remarks
(psig) (psig) (°F) Rate Rate in Type
Size (in2) Rating
(lb/hr) (lb/hr)
PSV-2835A/
Pilot Blocked Outlet 215 237 268 11,431 26,070 0.81 1.84 3K4 150# / 150# Adequate
B/C
PSV-2865A/
Pilot Blocked Outlet 600 660 284 11,299 19,132 0.30 0.50 1½G3 300# / 150# Adequate
B/C
PSV-2885A/
Pilot Blocked Outlet 635 699 281 11,114 20,212 0.28 0.50 1½G3 600# / 150# Adequate
B/C
PSV-2890A/
Pilot Fire 250 303 613 183 1,581 0.01 0.11 1D2 150# / 150# Adequate
B/C
A2 PSV-2802A/
Conventional Tube Rupture
B/C
A2
From the table above, Tube Rupture case is selected as governing case for PSV-2890A/B/C.
Table 5-13 New PSV Calculation Result

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 OVERPRESSURE STUDY REPORT

PSV PSV Existing

Calculated
PSV Pset Prelief Trelief Relief Rated Calculated In/Out
PSV Tag No. Relief Scenario Orifice Size
Type (psig) (psig) (°F) Rate Rate Orifice Flange
(in2)
(lb/hr) (lb/hr) Rating
Fire 215 260 4,307 264 616 0.05 1D2 150# / 150#
PSV-2820A/B/C Pilot
Blocked Outlet 215 237 130 11,431 12,603 0.71 1½H3 150# / 150#

From the table above, Blocked Outlet case is selected as governing case for PSV-2820A/B/C.

5.2 Line Sizing Calculation

5.2.1 Inlet Line Sizing Calculation

Line sizing calculation sheet is presented in Attachment A. the adequacy check of existing line is taken from HYSYS Safety Analysis
as shown on table below.
Table 5-14 Inlet Line Adequacy Check

Line Number Total Allowable Existing

Flowrate[1
PSV Pset Pressure Pressure Inlet
Description Case .]
Remarks
Type (psig) Drop Drop[2.] Flange
(lb/hr)
(psi) (psi) Rating
3”-HG-1B-80318/
Inlet Line Blocked
3”-HG-1B-80334/ Pilot 215 11,431 4.62 6.45 150# Adequate
PSV-2835A/B/C Outlet
3”-HG-1B-80360
1½”-HG-3B-80323/
Inlet Line Blocked Not
1½”-HG-3B-80339/ Pilot 600 11,299 82.25 18.00 300#
PSV-2865A/B/C Outlet Adequate
A2 1½”-HG-3B-80355
1½”-HG-3B-80327/ Inlet Line Blocked Pilot 635 11,114 84.02 19.05 600# Not
1½”-HG-3B-80343/ PSV-2885A/B/C Outlet Adequate

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 OVERPRESSURE STUDY REPORT

Line Number Total Allowable Existing

Flowrate[1
PSV Pset Pressure Pressure Inlet
Description Case .]
Remarks
Type (psig) Drop Drop[2.] Flange
(lb/hr)
(psi) (psi) Rating
1½”-HG-3B-80359
2”-HG-1B-80099/
Inlet Line Tube
2”-HG-1B-0522/ Pilot 250 686 0.03 7.50 150# Adequate
PSV-2890A/B/C Rupture
2”-HG-1B-0528

Note:
1. Required relief rate is used for pilot operated PSV.
2. Based on 3% line losses criteria.

Based on table above, can be concluded that some existing inlet line of each PSVs are not adequate to accommodate compressor
relocation project from MCP to M-8 Plant. Proposed line size is presented on table below.
Table 5-15 Proposed Line Size for Inlet Line Existing PSV

Allowable
Total Pressure Selected
Pset Flowrate Line Size Pressure
Line Number Description SCH Drop Remarks Size
(psig) (lb/hr) (in) Drop[2.]
(psi) (in)
(psi)
A2
1½”-HG-3B-80323/ 1½ 80 82.25 NOT OK
Inlet Line
1½”-HG-3B-80339/ 600 11,299 2 40 15.38 18.00 OK 2
PSV-2865A/B/C
1½”-HG-3B-80355 3 40 1.97 OK

1½”-HG-3B-80323/ 1½ 80 84.02 NOT OK

Inlet Line
1½”-HG-3B-80339/ 635 11,114 2 40 15.72 19.05 OK 2
PSV-2885A/B/C
1½”-HG-3B-80355 3 40 2.01 OK

Note:

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 OVERPRESSURE STUDY REPORT

1. Required relief rate is used for pilot operated PSV.

2. Based on 3% line losses criteria.

Line sizing result of inlet line new PSV-2820A/B/C is summary on table below.

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 OVERPRESSURE STUDY REPORT

Table 5-16 Inlet Line for New PSV-2820A/B/C Sizing Result

Line Number Total Allowable

Line Selected
PSV Pset Flowrate Pressure Pressure
Description Case Size SCH Remarks Size
Type (psig) (lb/hr) Drop Drop[2.]
(in) (in)
(psi) (psi)
A2
X”-HG-1B-80366/ 2 40 28.39 NOT OK
Inlet Line
X”-HG-1B-80367/ Fire Pilot 215 11,431 3 40 3.63 6.45 OK 3
PSV-2820A/B/C
X”-HG-1B-80368 4 40 0.89 OK

Note:
1. Required relief rate is used for pilot operated PSV.
2. Based on 3% line losses criteria.

5.2.2 Outlet Line Sizing Calculation

Outlet line PSV for MT-Z-2800A and MT-Z-2800B will be tapping to existing flare line at M-8 Plant. The PSV outlet line is performed
using line PSV sizing spreadsheet. The detail calculations of PSV outlet line are presented in the Attachment B. Adequacy check
result of outlet line PSV at MT-Z-2800A/B is presented on table below.
Table 5-17 Outlet Line Adequacy Check

Line Number
Calc.
Max. Remarks
Flowrate[1 Total Calc. Max. Calc. Max.
PSV Pset Press.
Description Case .]
Press. ρv2 ρv2 Mach Mach
Type (psig) Drop[2.]
A2 (lb/hr) Drop[3.] (lb/ft.s2) (lb/ft.s2) No. No. Press. Mach
(psi) ρv2
(psi) Drop No.

4”-F-1B-80028/ Outlet Line Blocked

Pilot 215 11,431 4.462 22 25,483 134,590 0.68 0.70 OK OK OK
4”-F-1B-80023 PSV-2835A/B Outlet

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 OVERPRESSURE STUDY REPORT

Line Number
Calc.
Max. Remarks
Flowrate [1
Total Calc. Max. Calc. Max.
PSV Pset .] Press.
Description Case Press. ρv2 ρv2 Mach Mach
Type (psig) Drop[2.]
A2 (lb/hr) Drop[3.] (lb/ft.s2) (lb/ft.s2) No. No. Press. Mach
(psi) ρv2
(psi) Drop No.

4”-F-1B-80029/ Outlet Line Blocked

Pilot 600 11,299 4.169 300 24,959 134,590 0.67 0.70 OK OK OK
4”-F-1B-80024 PSV-2865A/B Outlet
4”-F-1B-80030/ Outlet Line Blocked
Pilot 635 11,114 4.152 313 24,185 134,590 0.67 0.70 OK OK OK
4”-F-1B-80025 PSV-2885A/B Outlet
4”-F-1B-80031/ Outlet Line Tube
Pilot 250 686 4.002 125 69 134,590 0.03 0.70 OK OK OK
4”-F-1B-80026 PSV-2890A/B Rupture
Note:
1. Required relief rate is used for pilot operated PSV.
2. Based on 50% set pressure.
3. Calculated total pressure drop is total superimposed back pressure and piping pressure drop.

Based on the table above, can be concluded that the existing outlet line of each PSVs are adequate to accommodate compressor
relocation project from MCP to M-8 Plant. Since the existing outlet lines are adequate, the outlet line size for PSV-2835C, PSV-
2865C, PSV-2885C, and PSV-2890C will follow the existing outlet PSV line size.
A2 The new PSV-2820A/B/C outlet line calculation is summarized in the following table.

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 OVERPRESSURE STUDY REPORT

Table 5-18 Outlet Line for New PSV-2820A/B/C Sizing Result A2

Line Number Calc.
Allowable Remarks
Line Total Calc. Max. Calc. Max. Selected
Pset Flowrate Press.
Description Size SCH Press. ρv2 ρv2 Mach Mach Size
(psig) (lb/hr) Drop[2.] Press. Mach
(in) Drop (lb/ft.s2) (lb/ft.s2) Number Number ρv2 (in)
(psi) Drop Number
(psi)

X”-F-1B-80143/ 3 40 5.179 57,563 134,590 1.01 0.70 OK OK NOT OK

Outlet Line
X”-F-1B-80144/ 300 11,431 4 40 4.596 150 19,412 134,590 0.58 0.70 OK OK OK 4
PSV-2820A/B/C
X”-F-1B-80145 6 40 4.435 3,769 134,590 0.26 0.7 OK OK OK
Note:
1. Based on 50% set pressure.
2. Calculated total pressure drop is total superimposed back pressure and piping pressure drop.

5.3 Settle Out Calculation

Settle out pressure during shutdown is presented below.
Table 4-19 Settle Out Calculation
Parameter Unit Value

Settle Out Pressure psig 206

Settle Out Temperature °F 200

Set Pressure PSV psig 215

MAWP psig 230

Overpressure - No, Settle Out pressure < Set Pressure

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6. SUMMARY
Based on results above, can be concluded that:
1. Existing PSVs from MCP are adequate to accommodate relief rate due to
relocation to M-8 Plant.
2. Existing inlet line of PSV-2835A/B/C and PSV-2890A/B/C from MCP are adequate
to accommodate relief rate due to relocation to M-8 Plant.
3. Existing inlet line size of PSV-2865A/B/C and PSV-2885A/B/C from MCP shall be
increased since it’s not adequate due to relocation to M-8 Plant. The proposed line
size for those inlet line PSV is summarized on table below.
Table 6-20 PSV Calculation Result

Proposed
Existing Line PSV Tag No. Line Size
(in)
1½”-HG-3B-80323/
1½”-HG-3B-80339/ PSV-2865A/B/C 2
1½”-HG-3B-80355
1½”-HG-3B-80323/
A2 1½”-HG-3B-80339/ PSV-2885A/B/C 2
1½”-HG-3B-80355

4. Existing outlet line of PSVs at M-8 Plant are adequate to accommodate relief rate
due to relocation from MCP.
5. New PSV sizing and its inlet & outlet line are summarized in the following table.
Table 6-21 PSV Calculation Result

PSV
Calculated
Relief Selected Pset Relief Selected
PSV Tag No. Orifice
Scenario PSV Type (psig) Rate Orifice
Size (in2)
(lb/hr)

PSV-2820A/B/C Blocked Outlet Pilot 215 11,431 0.71 1½H3

Table 6-22 Inlet & Outlet PSV Line Size Calculation Result

Selected Pipe Size (in)

PSV Tag No. Equipment Tag Number
Inlet Outlet

1st Stage HP Gas Compressor

PSV-2820A/B/C 3 4
Suction Scrubber (MT-V-2820A/B/C)

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7. REFERENCES
1. Project Design Basis, Doc. No. MT-AFE222085-RPT-GEN-X-001.
2. API RP 14C “Recommended Practice for Analysis, Design, Installation, and Testing
of Safety Systems for Offshore Production Facilities,” 8th Edition, May 2018.
3. API STD 520 Part I “Sizing, Selection, and Installation of Pressure Relieving
Devices,” 10th Edition, October 2020.
4. API STD 520 Part II “Sizing, Selection, and Installation of Pressure Relieving
Devices,” 7th Edition, October 2020.
5. API STD 521 “Pressure Relieving and Depressuring System,” 7th Edition, June
2020.
6. Norsok Standard Process Design P-001, 5th Edition, September 2006.
7. Piping Material Specification, Doc. No. STD-E-110-17:2019, PHSS-ES-5090.
8. Process Simulation Report, Doc. No. MT-AFE-222085-RPT-PRC-X-001.
9. Site Survey Report, Doc. No. MT-AFE222085-RPT-GEN-X-003.
10. Piping and Instrumentation Diagram:

Drawing Number Description

P&I Diagram VLP Compression MT-Z-2800B
MTA-M-10A-116 Sheet 1
Mutiara M-8 Gas Station
P&I Diagram VLP Compression MT-Z-2800B
MTA-M-10A-116 Sheet 2
Mutiara M-8 Gas Station
P&I Diagram VLP Compression MT-Z-2800A
MTA-M-10A-117 Sheet 1
Mutiara M-8 Gas Station
P&I Diagram VLP Compression MT-Z-2800A
MTA-M-10A-117 Sheet 2
Mutiara M-8 Gas Station
P&I Diagram VLP Compression MT-Z-2800B
MTA-M-10A-125
Mutiara M-8 Gas Facility
P&I Diagram VLP Compression MT-Z-2800A
MTA-M-10A-126
Mutiara M-8 Gas Facility
P&I Diagram VLP Compression MT-Z-2800C
MTA-M-10A-561 Sheet 1
Mutiara M-8 Gas Station
P&I Diagram VLP Compression MT-Z-2800C
MTA-M-10A-561 Sheet 2
Mutiara M-8 Gas Station
P&I Diagram VLP Compression MT-Z-2800C
MTA-G-10A-229
Mutiara M-8 Gas Facility

11. API STD 526 “Flanged Steel Pressure Relief Valves,” 6th Edition, April 2009.

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ATTACHMENT – A: PSV CALCULATION RESULT BY SAFETY ANALYSIS

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8. ATTACHMENT – B: PSV LINE OUTLET SIZING BY SPREADSHEET

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9. ATTACHMENT – C: PIPING & INSTRUMENTATION DIAGRAM

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10. ATTACHMENT – D: EXISTING PSV DATASHEET

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11. ATTACHMENT – E: SETTLE OUT CALCULATION

Doc. No. MT-AFE222085-RPT-PRC-X-002 Rev. A2 Page 39 of 41