.

GtTshoreSouth East Asia 82 Cotrfemnce

9-12 February, Singapore

ARUN FIELD
SESSION

Arun Field Development

Phase
by JR Se@e!, Mobil oil Indonesia Inc.
Foflowingd&coveryof the ArssnGas Fiild in 1971and subsequentappnsisuldriflingtoobtain essential
reservoirdata+a development project basedon deiivery of suffkient gas to supply a six train LNG
plant, WS a coincidentcyctingoperation, was planned. H@ wetistreamtemperatures,preasur~ gas
throughputratesand corrosiveC02 COSSISSIL
pirscedpmducirsg,dty, securhyand endrmmend constraintson the designof surfaceweiktream gatheringand processingfacilitiesand led to the sekedon
of the duster developmentconcept.
Producingcapacity,dedicatedto LNG piant demana has resuftedin a two phasefield development
program. Rogram I, consistedof two producingclusterseach containingtwo producbsgtrains and
five high rate gas weik%a central control and power site (point Ala gascyclingsystemconsisting
of three injection com~
eight injecthn weUsand injection lines, and a M-inch condensate
hansmkaion p@iine to the LNG plant. Reduction from the two clustershassuppliedthe threetrain
(first phase)LNG piant. compkted itsfate 1978.and the Artsn Reid cyclingproject. Program 11commencing in 1981, wiif provide for an additional two producing clusters,each consistingof two
producingtraim and six producing wet&as dictated by the LNG plant expansion program.
Tlds paper will provide an overview of the Artm field production mode designconce~ detail the
_
~~
in * _
~
fadtitks fstaR-u* i.e. corroehs, ~tor
probkms have been. or are
carryover and recycUngcompressorUnsitadormand define how these
bein&resoived. fldgwiU inciudea~of_d*Mt
nWMdonsandaddMons
which wiit be rqtsired to accommodateto changingreservoirconditionsduting the tmodueingfifeof the
.4mn Gas Fssd.

The Artsn Field. discowred by Mobil Gil indonesia Inc. in late 1971,
islocatedin the kke block Contract Area in North Aceh Provinceat
the northeastcomer of theIdandof Sunuttra. Repubfic of lndortesia. The discovery well .4run A-1, spudded in August 1971,
encountereda limestone reef containing gas and condensate,The
produced gas contained IS percent carbon dioxide. 0.32 percent
nitrogen.a trae of hydrogensulfideand condensate,with a fiquidto
wellhead gas ratio of 55 BPM MCF.
The follow-up appraisalwell. Arun A-2 drilled during the springof
1972 conhmd the resultsobtained from the discoverywell. The
field boundarieswert definedby drilling elev:n additional welfs,The
nonh+outh trending reef isapproximately 18.5kilometerslongand
5,3 kilometerswide.
Development planning for the Artsn Field began in mid-1972 The
scope of work defining producing facilities required and a bid
packagewere approved in mid- i974. Bsscdon thesea prime contractor was selected for final design, engineering. procutemen~
project management and construction of the initial phase of
development. Markets were developed for sak of the LNG from
Artrn Field. with initiai delivery scheduledfor late-1978. An Indonesiancompany, P.T, Atun Natural Gas Liquik.ation Company,
V,= foti
to Opmte the L?JG Pfarm ownetship behtg 55%0by
Pertamina, 30%0 by Mobd Gil Indonesia, Inc. and 15% by Japan
Indonesia LNG Company.
LNG requiresdedii
p~ng
ttamporration and reseiving
facitttsestim,i irs supply is usuaUycontacted for a specifii delivery
scheduk.A very highde-of
reliabilitymustthereforebedesigned
into the entire system.
lW initial P.T. Arun Piant development provided three trains,
each designedto process300 MMSCFD of gas f~ stock with
provision for fater expansion of *
addtiottal ttains of similar
capacity.Each Arun Fiefd productionseparationunit wasdesigned
with suffiit
capaaty to supplyone LNG piant processtrain. The
initial scopefor the Arun F*M Development prognsmwaato pro-

vide is welfstream producingcapacity of one and one-half bIilic-I

cubtc feet per day. Gf this totai, 900 M MCFD wouid supply the
requirementsof the thmc-trairt P.T. Anus LNG piam. The 600
M MCFD back-upwcltstreamcapacitymadefcasibietheinstallation
of recyclingfacilities for addkionai condensaterecovery from the
Arun reservoir.
Ahemate meansof developingthe surfacefacilitiesof the .4rtsnField
werestudiedand the clusterconceptwas selected,Major factorsin
the selectionwere:
1. The need to minimize the use of cultivated iand.
2. Centralization of processfacilities and gas compressorplant
would be realized,
3. The flowline length from wellhead to a centralgatheringpoint
for the highpressure,comosiveproducedwellsueamwasgreatiy
reduced,
To meet the initial salescommitmen~ two producing clusters.a
central location for fsld support facilitiesand power generation.
three gas compressors.eight injection wells with connectingpipelines.and gasand condensatetransferlinesfrom the cluswrsto the
central location were constructed,
The clusterdesignprovidesfor sixteenproducingweUs,weUstream
C430iingand separationand control and pipdine facilitiesin a rectangrdar piot680x9@_whidsis
abottttihectaml%a
layout inchsdesspace for gas compressorand a produced water
diaposaipkmt, aswell asfor additional pr~
equipmentnccessa~
for producingthe fsfd in the latter phaseof operatiom. The wefis.
locatedin two rowscf eightlocationseach on 80 meterspacin~ with
160 meter spacing between rows, occupy about ostc-haffof the
clusterarea.
The gas pm
and compressionequipmcm requiresabout onesixth of the chtstcrarea. Located in tha southwst quarter of the
duster are two flare pita to aUow venting of gas and condemate,

l%e overall design concept of the Arun Field provided for four
clustersdesignatedL 11. 111& IV from nocth to south. and the
designatedPoint A.
Central Field Faciity site,

five Producing Wells

Two Pro@ssTtains
Two Injection Compmssors

Point A

Field Common Facilities

Injection Sites

Three 8.9 MW Turbo Generators

Generator Control Buifding
Vehicle Gamge
Mechanical. Electrical& Instrument
Workshops
Warehouse
Utility and Fire Water Systems
Condensate Control. Metenrig and
Readout Equipment

The completion date of the second increment of Phase 1 was

advanced from I January 1979 to 1 July 1978 based on a thtee
rig ddling pro~m. By late June 1978. six producing welfs(three
in each cluster) were on stream with a producibiIit,y.of 1,020
MMSCFD. Six gas injection welfs, with a total injectmy of 648
M MSCFD, and the three injectioncompressorswere in operation.
Point A and the major Field Common Facilitieswerecompleted.
Unstabilizedcondensate production averaged 24.S46 BPD. Gas
deliveriesto the plant averaged 27.4 M MSCFD and gas injection
averaged 375.9 M MSCFD from 519.3 M MSCFD of wclistream
8=

Cluster Ill to Point A

Gas Transfer Line
CondensateTtansfer Line
Electrical TransmissionLines
Communication Lines
Prodttd Water Disposal System
Gas Injection Wells
4. 5.6.7 and 8
Gas Injection Well Roads
Five Gas Injection Lines
Communication Lines.Cluster111to
each Gas Injection WeU Site.

During mechanicalcommissioningand start-up of the Arun Field

facilities at Cluster III and Point A. three signiktnt problem
areas were encountered:

l%e second incrementof Phase 1. to be on+tream by I January

1979,consistedof
Cluster H

Point A

Field Common Facilities

Gas Injection Wells 1, 2 and 3

Gas Injection Well Roads
Three Gas Injection Lines
Communication Lines, Cluster 11to
each Gas [niecdon WeU Site

lle first Cfuster 111producing well was spuddedon 4 September

1976, Cluster 111production started on J3 May 1977, and gas
injedon started in July 1977 to GIW- 1 and GI W-6. Cottdensate
production to the pipeline started on 16 May. initiaf receiptat the
condemate
tanker
compkted
LNG plant on 21 May and thefirst
loading on 17 Gctober 1977. At year end 1977. Cluster 111bad
prtxxssed38,624 BSCF of dry gasof which 14.763BSCF wasllared.
22264 BSCF injected into the Arun -oir.
1.209 BSCF consumed as fuel and 0.388 BSCF for the pipelineto the LNG plant.
During this period. 217!.S66 BBLS of unstabilizedcondensatewas
producedand 1,749.562BBLS of stabilizedcondensatewasstoredor
shipped k~ P.T. Am, At years end. three cluster 111weifswere
on stream with a producibitit~ of 570 M MSCFD. and three gas
injection wellswith an injecmty capacity of 372 MMSCFD were
tied in.

Phaae I of the Arun Fttld Development consisted of two incrernenta.the first to be on stream I May 1977, comprising

Cluster
111

[njeetion Sites

when necesary, from the pro= fa~lti.

and from the Producing
wells. Afso located in the same area is a mud pit for surpluswell
drihtg fluids and a large fire water teservoir. llw entire cluster
is sutToundedby a securityfence and a dike+mbanktnent antipoffutionditch.

1. Hydraulic Well Control System

2, Wellstream Cookr Leaks and Efficiency Losses

five producing We%

Two Prtxxss Ttztits
Gne Injection Compressor

3. Third Stage RecycleValve Vibration on the Gas Compressors

Gti!er probkms which were found to be significant wenx

Administration Buildhtg
Drilfing Tools Shop
Air Strip, Fuel and Passenger
Servitxs
Gas ControL Metering and Readout
Equipment

1. Choke Cavity Erosion and G-ring Failures

2, Separator Flare Lkte Vibration
3. Flare Pit WaU and Igttitor Failures
4. Compressor(king

seal Oil Ring and bbyrinth Seal Failures

5, CompressorControl Instrumentation Inadequacies

Cluster 11to Point A

Gas Transfer Line
CondensateTransfer Line
Electrical TransmissionLines
Communication Lines
Injection Gas Tmsfer Line, Cluster
1110 Cfuster 111.
Pro+cd Water Disposal System

6.

Data Acquiskion System Faults

7. PressureReduction Valve Corrosion-Erosion

8. Turbo-compressorDrive Coupling Contamination
9. Turbo-generator Gperation Reliability
10. Turbo-gerierator Fuel Gas Reliability

Production Statistics For The Arun Field From 1977Through 1980 Are As FOUOWS:
PRODUCTION
Wellstream Gas

Dry Gas

Gas Injection
Unstb. Cond.
Stb. Cond.

I
j BSCF

I!w
45.19r

1979

229.184

1%.014

I$k?a

460.323

486.528

391.055

418.015

iI

BSCF

38.624

: BSCF

22264

MBBLS

2!71.6

MBBLS

1,749.6

Gas Delivery to LNG Plant BSCF

~...
~

W7a

.388

124.8

11,112
9,606

53.&t7

168.352
25,!X0

124.531
~w

20,789

22454

212174

2$7,(57

11. Corrosion-Erosionin Flowline Components

12. PandTtt fkposits in Oaa Separator Mist Extractor
13. liquid Carr;over from Oas Separator
Tltapmblems atniwJluliolM areraviewad brfatly:
Hydmsdic Wail CosstroiSystem
The X%sastreevalws on theckssterproductionwellsamoperatedby
hydraulic fluid pressure.llte original hydratdic fluid used was a
synthetii lubricantfor aviation and industrialjet engines,chosenfor
its high temperature stabiity. R was found, however. that this
hydraulicfluid mad rapid V ring and sealmaterialdetetioratiorsi
which resultedin leakageand line plugging Changingthe materials
of these W rings and seals helped. but the problems was not
completely solved until the hydraulic fluid was replaced with an
inhibited turbine oil.

the compressorcaselabyrinth sealsand shaft oil sealson the high

pressuremachinewere experienced.It wasdeterminedthat abrasive
wear on the labyrinth seak and shaft sleeves was caused by
foreign material in the supply gas, This problem wss controlled
by utilizing a finer meshcompressorsuctionscreenand by changing
the seai labyrinth material to forged alundnium, Minor modifications that have overcome early major probkrtts include retaining
screwsin the shroud ring to prevent movement, the use of four
inner oil seal rings rather than two rings to redue seal leakage,
and a complete redesignof the tilt pad seal assembly.The thrust
disc mounting was changed. The method of assemblingthe labyrinths was modiikd and rotor assemblyis now done in a vertical
position to improve concentriaty and centerline integity of the
labyrinthsand diaphrams during assembly.Its the last three years.
the three high pressure (7100 IMa) injection compressorshave
operatedat or near designconditions.

Weiktream Cooler Leaks and Efficiency Lames

During early operation of the Cluster 11welktream coolets it was
not possibleto operate at designeffkierrcy. It was d-vmd
that
ovetsize weephoks in the stiffener plates.the panition plates.and
very fine cracks in tube end seals wells were allowing 20To to
35% of the wellstreamto bypass.The condition was remedied by
calling on the manufacturer to weld closethe wecpholcsand completely seal the panition platesin each of the wellstteamcoolersin
Clusters 11and HI.
Third Stage Recycle vibration
0ss the first gas injection compressor installed. severe vibration
was experiencedin the third stage reqde valve piping.
l?te vibration was a result of a piping corttlgusationincapabkeof
handling the velocny. pressuredrops and turbulenceof full recycle
flow. The 3-inchthird stagerecyclevalvewas replacedwith a 4-inch
valveand extensivedownstreampiping revisionsmadeto comet the
vibration probkm.
Choke Cavity Erosion and O Ring Fzhrea
The flowline chokesare mukipte orttlccval= usinga rotating disc
to provide adjttstabk flow settingsand shut+ff. During the eariy
period ofopemdon the Butsa-N
Orin~deteriorated
art:
failed under pressure.corrosion+rosionoaurred in the inkt cavity
and in the outlet spool of the flowline chokes, and the front disc
earners were subjectto breakagedue to high torque during choke
operation. These problems were solved by changing the O ring
material to teflort,changingthe metallurgyof the choke body to 410
stainlesssteel. and reducing the holes in the choke disc from 2inches to I Ikj-inchesto reduce the high torques during choke
operation. The outlet spool was changed to lrsconel(4)0 overtild
internally with Stellite.
Separator Flare Line Vibration
During clusterstart-up and de-buggin%high volumesof gas were
delivered from the separatorsto the the pits. At thesehigh rates
there was substantialseparator flare line vibration. The problem
was controlled by additional supportsand bracingof the separator
tlare line.
Flare Pft Wall at:d Igniter Ilaiissrea

111wells.
the wellstream
During high rate clean-up of the Cluster
was diverted dtrectly into the tlare pits, where the gasand liquids
enter through spargerssubmergedone meter under water to reduce
surfacetemperatures.The heat generatedduring extended periods
of high rate flaring resrdtedin severecrackingof theconcreteIitdng
spalling of the rock retaining wads. and takrre of the supports
and igniters which extend out above ik? water surface.
Flare pit design modifications for Cluster 11 included poured in
*
concretewalk with a concreteapron over the retainkg walk.
A modi!kd igniter systemhas beendesignedand will beinstalledin
the (3tstw 11and 111flare pita when new ignitota are bved.
CampremtY

mSeaIOH

Rhsgand bbyrkstIt SeAFaBssm

On start up of the tlrst compressorinatahdon, sesiotsakstks in

CompressorControl Instnsrnentationhmdquacks
Alarnts and trips occurreddue to water in the control room trench
shottingout control wiring at defectivesplices.and dueto outmoded
temperaturecontrol and protectioncardsin the speedtrorticcontrol
panels.AU control wiring was replaced,ekvated racksin the cable
trenchinstalled.and a drain sumpcortstructed.The outmodedcards
in the speedtroniccontrol panelswerereplacedwith cardshavingthe
latest revisions.Following control systemrecalibration.the systems
have operatedwith a high degreeof reliability.
Data Acquisition System
l%e DAS cott:inuouslygathersinformation on weUproductionand
f~ties petforma~ of the chster in which the systemis instaUcd.
Considerablerecalibrationof enddevicesand debuggingof the data
collectionequiprnentwas requiredfollowingstart-up. Venturi meter
constants for inter-stage compressionflow, critical information
reflecting compressor flow. critical information reflecting compmssorperfomxmce. were found to be erroneous.All compressor
venturi tubeshave now been replacedwith orifkx plates.The flow
transmittersfnr the inejctioncompressm require weekly recalibration becauseof gmdual drift. AU flow and pressuretransmittersare
now schcdts!edfor mplacemetstwith improved devices.
Resatwe RedsscdonValve Cosrdots-ENssinn
The pressurereducingvalve in each flowline isa high pressure.low
tkibel. plug and seat ring design with an expanding labyrinth
-ge.
ne 316 staittkSSsteel plug and seat ring have a stellite
seatingsurfacato provide a tight seatingarea resistantto erosion.
Corrosion+rosion of the 316 stainless steel area immediately
upstreamand downstreamof the plugstellitedareaand immediately
downstreamof the stellite on the seat ring was soonevidentas the
valvespassedsignifkasttvolumesof gasin theclosedposition.Valves
in seMee over six months were subjectto body cavity erosionat a
rapid rate. l%e metallurgy was modified by the manufacturer to
providea body of II/ 13chromium with the internal contour spray
coated with stcllite.llte plugand seatringof316 stairtksssteelwere
also spray coated with steliiteover their entire surfaces.

Tush) - Cmspramr

Dsive Coupling Contadnation

During rebuild of a Cluster111compressorin October 1977,thetwo

lubricatedgear-typedrivecouplingsbetweenthe gear box of thetwo
machineswereinspectedand considcrabksludgebuild-up of a black
plasticnaturewasobsemd in the upstreamand downstreamendsof
the couplings lxtwm the gear box. It was determined that the
coupling with the sludge build-up had not been connectedto the
_W-mfiti_atit-tk-*~
thetwo compressorsdid not have anti-siudgehoks for tcrttovalof
sludge build-up from the coupling. Thecmtplirt~ for all comp~
was modiied to incorporatethe anti-sludgedesignand all
couplingswere connectedto fdtsationsystem
Turbo -

Cenemtor OpasatismRaMaWty

During the fti year ofturbine-generatoroperationthe powerPian&

rkxsignedfor very high reliability, OpemtedE3rbeiow the squired
standard. During this perio4 two generatotswere on line sharinga

load varying from 2 NIW initiaily to about 5 MW (eachgeneratoris

site rated at 8.95 MW). A third unit operated on standby. Forty
turbine failures(trips) wem experiencedthe first year. The causeof
trips were Ematic Speed ControL 15 trim, Human Error. 9 trips
Fake Vibration Indication, 7 tripx Fake Fire Aiarrn, 4 trip$ Other,
5 trips. he speed control was tmnedied by repiacing defective
printedcircuite.ontrolcards.llte fake tire aiarmswerecorrectedbya
redesign of the fire deteeuonsystem.
Turbo -

Generator
Fuel Gas RebbUty

l%e power pkwtt fuel gas systemaa originally installed required

seveml modificationsto ensure fuel supply during power failures.
and capability to handle any liquid carryoversin thesupply:~tem.
Two of the threeturbinesare dual fuelunitswhilethethird untttsgas
fuel only. l%e fuel gassupplyisobtainedfrom the main gassupplyto
the LNG plant at Point A. The fuel gas eleetrieai controls were
changedfrom Vac to Vdc supply.
A died driven air compressorwas installedto provideemergeney
instrumentair. Condensatecarryoverwasgre+ reducedby raising
the fuel gas temperature. insulating the fuel Itnes. relocating the
[empetitturecontroller from the K.O. drum to the fuel gasskidand
by the installation of a filter separator. No fuel gas supply failures
from carryoverhaveoecumd sincecompletionof themodifications.
Corrosion -

Erosion of Flowline Components

Corrosion<rosion of the gas production well floaviinecomponents

has been a setio~ problem in the Arun Field sincemid-1978. [n
additimt to corrosionO(the tlowlinechokeand thepressurereducing
vahe as discussedpreviously. the flowiine meter runs and irriet
manifoids. both locatedadjacentto the wclktream coolers,and the
Ilowline itself have also been subjeetto corrosion<rosion. Ail of
these components were carbon steel material. selected on the
assumption that under the temperature itnd pressureoperating
conditions. the H !S and CO! -W components in the welktream
would intetwt with the carbon steelto form a protectivecorrosion
resistantbarrierof iron siderite.The initial remedialactiontaken was
to overlay the corrosion<rosionareas in tl% fiek! witi 308 or 316
stainlesssteel.This work was statted in mid-1978.
The corrosion+rosioncontinuedto migratebeyondthe overiayand
a continual overlay operation was setup in late-1978to overlay the
entire meter run. the flow crosses.the inlet header, the check and
block valves.and so much of the 6 iigamentsas possibleon the inlet
manifold. In 1980 he deeisionwas made to fabricate 410 stainless

steelreplacementinlet manifolds meter runsand the entire flowline

from the tee block of the well to the meter run.

Paraffin Deposits in Gas Separator ,Mist Extractors

After one year of service.a Cluster 111separatorwasinspected.The
fist phasegasseetionwalk and %anetypemistextractorswerefound
coated to a depth of about I / 16 inch with a yellow pamlllt
substance.The seeondphasecondensatesectionwails were free of
the parafftn build-up but the coakseer pads were coated from the
bottom to the midpoint. The third phase water section had no
evideof the paraffin. A dewaxittg procedure proved most
successfulfor removal of the pamffin deposits. The procedure
consistsof a gradual increaa in temperatureof the weiktream by
control at the welistreamcoolers.until a separatortemperatureof
190 to 200 F is reached and then maintained for a three-hour
period. foUowed by a gradual temperature reduction to the 72 to
8@ F operating temperature.
This procedure,performedon a monthly basis.hasbeensuccessful
in
preventingthe paraffin buildup,
Separator %lodillcations
The throughput rates,excceding320 %IMCFD of gas.it was found
that the separatorscarried over liquid. This introducedthe potential
for liquid build-up in the 42 inch gas pipeline. and for possibie
pipelinecorrosion.or subsequentliquid siu@tg. whichcouldcreate
processupsetsat the LSG Plant.
The prima~ causeof the separatorcarryover wasdeterminedto be
capacitylimltatiortsof the mistextractorswhicharesituatedat either
end of the @ wctions of ik separators.
The separatorswere modified with redesigned mist extmctors of
-mater capacity. extemkms of the down+omers and changesin the
internal baffles. Following modifications.the sep~ratorswereeach
tested to a 4tM M %ICFD of welistreitmthroughput rate without
evidenceof carryover.
In summary. it may be said that the Arun Field Development
required 3 considerableamount of prototype equipment to meeta
combination of unusualtemperature-pressure-volume
and corrosive
weiistream conditions. Some of the problems which beeame
apparent such as corrosion were major. however. the facilitiesas
designedhave performed with a high level of dependabilityto meet
demand requirementsof the LNG Plant.

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