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PERFORMANCE EVALUATION MODELING OF PRE-TREATMENT UNIT IN GAS PROCESSING PLANT

by

Mohamad Rozi Bin Sulaiman (10721)

A project dissertation submitted in partial fulfillment of the requirement for the

BACHELOR OF ENGINEERING (Hons) (Mechanical Engineering)

SEPTEMBER 2011

Universiti Teknologi PETRONAS Bandar Seri Iskandar

31750 Tronoh

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CERTIFICATION OF APPROVAL

Performance Evaluation Modeling Of Pre-Treatment Unit in Gas Processing Plant

By

Mohamad Rozi Bin Sulaiman A project dissertation submitted to the

Mechanical Engineering Programme Universiti Teknologi PETRONAS in partial fulfillment of the requirement for the

BACHELOR OF ENGINEERING (Hons) (MECHANICAL ENGINEERING)

Approved by,

Qd4

(Dr Ainu!

Akmar

Mokhtar)

UNIVERSITI TEKNOLOGI PETRONAS TRONOH, PERAK

September 2011

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CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the original work is my own except as specified in the references and acknowledgements, and that the original work contained herein have not been undertaken or done by unspecified sources or persons.

MOHAMAD

R~BIN

SULAIMAN Date

ii

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ABSTRACT

This paper presents a report for Final Year Project (FYP). The title of the research project is Performance Evaluation Modeling of Pre-Treatment Unit (PTU) in Gas Processing Plant which under manufacturing from mechanical field. The project is conducted at one of Gas Processing Plant which is Pre-treatment Unit (PTU). The project started with identification of critical component for PTU, construction of reliability block diagram (RBD) and reliability analysis based on RBD model. During the completion of the project, the researcher has been assisted by reliability engineer from PETRONAS Gas Berhad in verifying the RBD model. The outcome of this project is a model of reliability that could be used by plant management to evaluate the current reliability of the PTU. Besides, this research can analyze whether that equipment has achieved target plant reliability and identify the sub-component that reduces the overall reliability of the system. This paper includes introduction, literature review, methodology, result and discussion and conclusion. The report will include introduction, literature review and theory, methodology, result and discussion, conclusion and recommendation and reference.

iii

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ACKNOWLEDGEMENT

In the name of Allah, the Most Gracious, the Most MercifuL Praise to Him the Almighty that in his will and given strength, the author managed to complete this final year project within the time required.

First and foremost, the author would like to extend sincere gratitude to Dr. Ainu!

Akmar binti Mokhtar, for her supervision, support, and advice not only in project matter but also for the future life and employment. Her kind support from the beginning of the project until project completion is very appreciated by the author.

Next is to other lecturers of UTP especially from the Mechanical Engineering department, thanks for useful thoughts and assistance that help the author a lot in completing this project.

Last but not least, the author would like to thank his family and supportive colleagues from UTP because always supporting the author.

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TABLE OF CONTENTS

TABLE OF CONTENT LIST OF TABLES LIST OF FIGURES

LIST OF ABBREVIATION

CHAPTER 1: INTRODUCTION 1.1. Background Of Study 1.2. Problem Statement 1.3. Objective Of Study 14. Relevancy OfProject 1.5. Feasibility OfProject

CHAPTER 2: LITERATURE REVIEW AND THEORY 2.1. Reliability Analysis

2.2. Need for Assessing Reliability 2.3. Data for Evaluating Reliability

24. Pre-Treatment Unit In Gas Processing Plant 24.1. The importance ofPTU

2.5. Study to Asses data of Equipment 2.5.1. Reliability Data Collection 2.5.2. Maintainability Analysis 2.6. Functional Block Diagram

2. 7. Construction Of Reliability Block Diagram 2.7.1. Series System

2. 7.2. Parallel System 2.7.3. Redundant System

v

v

viii ix

X

1 1 3 3 4 4

5 5 6 7 7 8 9 9 9 10 10 11 12 13

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CHAPTER3:METHODOLOGY 3 .1. Research Methodology 3 .2. Project Activities 3.3. Time to Failure Model

3. 3 .1. Data Homogeneity 3.3.2. Graphical Test 3.3.3. Mann Test 3.3.4. Laplace Test 3.4. System Familiarization

3.5. Construction ofReliability Block Diagram 3.6. Gantt Chart

3.7. Software's

3. 7.1. BlockSim Software 3. 7.2. Microsoft Excel

CHAPTER 4: RESULTS AND DISCUSSION 4.1 Reliability Block Diagram ofPTU

4 .1.1 General Assumptions

4.1.2 Reliability Block Diagram System I 4.1.3 Reliability Block Diagram System 2 4.1.4 Reliability Block Diagram System 3 4.1.5 Reliability Block Diagram System 4

4.1.6 Reliability Block Diagram (PTU Regeneration) 4.2 Data Collection

4.3 Static Reliability

4.3.1 Static Reliability ofPTU

4.3.2 What-if Analysis for Static Reliability ofPTU 4.4 Reliability ofPTU (OREDA)

4.5 Sensitivity/what-if Analysis

4. 5.1 Improve Reliability of Each Component

4.5.2 Improve System Reliability by Providing Redundancy

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14 14 16 16 17 17 18 18

20

22 26

28 28 28

29 29 30 31 31 31 31 32 32 36 37 38 39 41 43 44

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