Design of High Rate Blender Hydraulic Power Pack Unit on Stimulation Vessel – Study Case Stim Star Borneo for Offshore Operations at Delta Mahakam Area – East Borneo

Application of Hydraulic Power technology in world industry today is still continue to increased. Not only in Industrial it’s self, but in  Marine, Onshore and Offshore also use these technologies. Requirement of service in well services - Offshore Delta Mahakam region makes PT. Halliburton Indonesia as a Service Company increase his fleet service. The Type Stimulation Vessel Fleets - Stim Star Borneo is planned to improve the service unit of High Rate Water Pack (HRWP) with High Pressure Pump unit plus Gravel Pack Sand (GP) and High Rate Blender Unit. Blender High Rate is a unit tubular mixing blender driven by hydraulic power, motors blender, sand screw, pump suction and discharge pump that’s is installed unity. For that The authors will plan  system, calculation and specifications of Hydraulic Power Pack Unit for High Rate the Blender. Calculations start from of Operasional Requirement Conditions, and continued with Design Block Diagram, P & ID, and also calculations of systems such as Head, RPM, Pipe Diamater, Pipe Thickness, Main Hydraulic Pump, Reservoir Tank and Cooler. Where The Requirement of Hydraulic Main Pump Power is 950 kW with Electric Motor as prime mover 950 kW. The final result of the design is show as Layout and Detail drawing in attachment.


2.3.Drafting Design Systems
Drafting Design System includes Block Diagram and P & ID diagrams.This is done because the calculation system and design should be consistent.Where the Block Diagram explaining the work process flow diagram Hydraulic Power Pack, which describes the unit -the unit that become manual hydraulic pump unit.While P & ID is a more specific system design that describes the flow or pipe system, instrument -instrument and unit -including the number of units and specifications as the reference for the calculation system.

Calculation sytem and Specifications
The Data Design / Draft drom previous Design and Operational Requirement, needs to have the calculation of those system.Where the calculation of this system include:

Design Block Diagram, P & ID, Specifications System and Equipment
Search units available in the market in accordance with the specifications and catalog ang available.

Making Design Layout and Cost Analysis
System designs that already mee the requirement will be created its Design Layout plotted on the General Arrangement Stimulation Vessel -SSB in accordance with the specifications and the size of the catalog according to standard drawing.Then in doing analysis calculation installation costs.

Conclusions and recommendations
Conclusions and Recommendations are made based on all aspects of the discussion of this research.

Operasional Data and Desain
Operational planning design Hydraulic Power Pack Unit is in accordance with the Regional Operational Delta Mahakam block in East Kalimantan.Data is obtained from PT.Total E & P Indonesia and PT.Halliburton Indonesia -Balikpapan, the process that could happen on the system are: a.Fluid Mixing Process : HRB is used to manufacture a mixture of gel fluid or process fluid b.Circulating Mixing Process : HRB is used on mixing fluid.In those process is inside fluid tanks and then return the pump to the process fluid tanks.This is done to maintain the mixture composition and process fluid in ideal conditions.c.Direct Discharge or Direct Mixing Discharge : ie unit Pump Suction and Discharge HRB used as a reservoir discharge path which is then directly connected to the suction pipe High Pressure Pump.On the other conditions are also designed HRB used in a condition to Tab Fluid International Journal of Marine Engineering Innovation and Research, Vol. 1 (2), Mar. 2017. 98-105 (pISSN: 2541-5972, eISSN: 2548-1479) 100 Mixing Blender then in mixing and pumped to the High Pressure Pump Suction pipe discharge

Desain System
Before the Design System it is necessary to perform the manufacture of the block diagrams and P & ID's draft preliminary calculations needs head loss and the need for cooling equipment.

Calculation System 3.3.1 Calculation of Unit Head and RPM User
The need for pumps (User Units) in accordance with the operational needs (offshore operation) needs to be in accordance with the previous calculation data that has been calculated and designed.Because there are changes, which include changes in the needs of Q (flow rate) and the Head of each pump of the conditions existing before the calculation of the adjustment.From the table above it can be seen that the two pump units, the number 1 and 2 should be an adjustment Flow rate and the Head, this adjustment is done by a decrease in RPM units according to the catalog specification unit / reference.

RPM Motor Hydraulic Adjustment Calculation
Because no adjustment Flow rate (Q) and Head accordance with the operational condition then this will also affect the speed (RPM) on the hydraulic motor unit that is connected directly to the pump (Direct Driver).

Pipe diameter calculation unit User
Based on previous calculation, the calculation of the diameter of the pipe can be done.From the Data Flow Rate (Q) the above table it can be calculated diameter of the pipe using the formula: Where : Q = Flow rate, 4.8, m 3 /s V = Flow Velocity Rekomendation flow velocity : 1. Velocity of pressure lines = 7 -20 ft/sec or 2.13 -6.1 m/s 2. Velocity of suction lines = 2 -5 ft/sec or 0.61 -1.5 m/s using V = 6 m/s so that each Unit Discharge Pipe Users can be determined using ANSI Standard Pipe

Pipe diameter calculation Hydarulic Main Pump
Where the main hydraulic pump to supply to a hydraulic motor driver using one pump driven Electric Motor.Due to a series of pipeline pump as paralalel, then Q for this pipeline is the total of Q entire lifeline.

Figure. 1 .Figure. 2 .
Figure.1.Stimullation Vessel -SSB a) Calculation of Unit Head and RPM user b) Adjustment Calculation RPM Motor Hydraulic c) Calculation of Diameter Pipe Unit Users d) Calculation of Diameter Pipes Main Hydraulic Pump e) Calculation mateial and minimum thickness of pipe f) Calculation of Main Pump Head g) The need Hhydraulic Main Pump h) Electric Motor Supplies (Driver) i) The need Reservoir Tank j) The need Cooler

Figure. 4 .
Figure.4.Blok Diagram Operasional and Equipment 3.2.2P & ID (Piping and Instrument Diagram) Piping and Instrument Diagrams (P & ID) is designed in accordance with the Block Diagram.Where this diagram will be the reference for the calculation of required equipment and instrument both specifications, the type and number of units required.

Figure. 5 .
Figure.5.Piping and Instrument Diagram (P&ID) Qt1 = Qsuct.centr.+ Qdisch.centr.+Qsand screw1 +Qsand screw2+Qagitator +Qla1 +Qla2 + Qdry add.1 + Qdry add.2So the result Qt1 = 0.01967 m 3 /s or 70.79 m 3 /h Pipe as needed : So the diameter = 64.62 mm or 2.54 inch use Pipe Diameter 2½" Inch Standart ANSI 3.3.5Pipe Material Calculation and Minimum Thickness Pressure / high pressure 5070 psi in accordance with the specifications Pressure Control Valve to be used and in accordance with the specifications Hydraulic Motor.Operation pressure = 5070 Psi Using the Reference Year ASME B.31.In 2012 we can see the minimum thickness of each pipe to be used.With Formula Lame's or Barlow's, the minimum thickness is as follows:Where ; t = thickness, in inch P = Design pressure in psi D = Outside Diameter Pipa, inch S = Allowable stress, psi Grade material used is in accordance with ASME B31 or SAE standards as recommended material.Using material no.2 = Steel C-1021 So that the minimum thickness calculation is as follows :

TABLE . 1
. PUMPING SCHEDULE ZONE 1 DATA Of the three operational conditions above can be obtained following data:

TABLE 6 .
THE CALCULATION OF THE MINIMUM THICKNESS OF THE PIPE AND SCHEDULE