CPB 20004 Plant Utilities & Maintenance chapter 1 Introduction to Plant Utilities & Maintenance

Objectives: Understand importance of utility and maintenance system in industry/plant

Plant Utilities All chemical plant is started with plant utility Without utility system, most of the equipment cannot operate.

Scope of Plant Utility Water Steam Condensate Recovery Fuel Gas Plant & Instrument Air Nitrogen Flare Feed Stock Storage/Transfer Product Storage/Transfer Electrical Supply

Fire Water Potable Water Cooling Water Utility Water Water System 1. Fire water - supply water to the plant area distribution system in the event of a fire or hydrocarbon release. 2. Potable water - provides clean treated water for safety shower, eye wash stations, sanitary facilities and personnel consumption throughout the plant facilities 3. Utility water - supplied to the plant distribution system 4. Cooling water - cool down the temperature by using cooling tower. Cooling towers are heat removal devices used to transfer process waste heat to the atmosphere.

Steam System Generating & supplying steam at three pressure/temperature levels; HP, MP, LP Provide industry with powerful source of energy

Steam system problem…..

Condensate Recovery System Condensate is the liquid formed when steam passes from the gaseous to the liquid state. Process involving the recovery and reuse of condensate discharged from a steam system to save energy and resources. In a heating process, once steam has transferred its latent heat to the product being heated, it turns into condensate. Recycling this condensate by returning it to the boiler system is a common form of condensate recovery. 1.Condensate is the liquid formed when steam passes from the gaseous to the liquid state. 2. Condensate recovery is a process involving the recovery and reuse of condensate discharged from a steam system to save energy and resources. In a heating process, once steam has transferred its latent heat to the product being heated, it turns into condensate. Recycling this condensate by returning it to the boiler system is a common form of condensate recovery. 3. Condensate recovery can use as: boiler feed water, reducing water treatment and use in cleaning process.

Condensate is in form of water - contain no solid, is hot & not additional treatment. Condensate recovery can use as: boiler feed water, reducing water treatment and use in cleaning process.

Fuel Gas System Many fuel gases are composed of hydrocarbon (e.g. methane) Sources of potential heat energy or light energy that can be readily transmitted and distributed through pipes from the point of origin directly to the place of consumption Methane is important for electrical generation by burning it as a fuel in a gas turbine or steam boiler 4. Fuel gas- Many fuel gases are composed of hydrocarbons (such asmethane or propane), hydrogen, carbon monoxide, or mixtures thereof. Such gases are sources of potential heat energy or light energy that can be readily transmitted and distributed through pipes from the point of origin directly to the place of consumption. Methane is important for electrical generation by burning it as a fuel in a gas turbine or steam boiler. 

Plant & Instrument Air System Supplied by air compressors. Compressor driven is by using steam turbine or motor driven. Air is filtered, compressed & dried before supply to plant air distribution throughout the plant complex. 5.Plant & instrument air-blower to trasport product from one section to one section

Nitrogen System For catalyst regeneration, methanol storage tank purging, & for instrument air in the port storage area. Use for reactor dry out, catalyst loading, & purging during start-up & shutdown. Purging & clearing of pipelines. Nitrogen-use in food industry;  nitrogen fumigation as pest control 6. Nitrogen-use in food industry;  nitrogen fumigation as pest control

PIGGING PROCESS… pipe PIG-pipeline inspection gauges

Feed Stock Storage & Transfer Consists of receiving, storing & supplying of different feeds (eg. butanes, methanol) As an intermediate product or imported from off-sites by ship or pipeline, are all stored in the utility area.

Flare System In industrial plants, flare stacks are primarily used for burning off flammable gas released by pressure relief valves during unplanned over-pressuring of plant equipment During plant or partial plant start up and shutdowns, flare stacks are also often used for the planned combustion of gases over relatively short periods. 7. Flare-In industrial plants, flare stacks are primarily used for burning off flammable gas released by pressure relief valves during unplanned over-pressuring of plant equipmentDuring plant or partial plant startups and shutdowns, flare stacks are also often used for the planned combustion of gases over relatively short periods.

FLARE SYSTEM…….

Product Storage & Transfer Consists of receiving, storing & supplying of different product. Stored before it transfer to jetty to export.

Electrical Supply & Distribution Electrical system is the main component to run the equipment. Most plant in Malaysia get electricity from TNB Some plant will generate their electricity by their own generator.

PLANT MAINTENANCE

EXAMPLE OF ORGANIZATION CHART Plant Manager Operation/ Production QA & QC Safety Administration Purchasing & Logistic Maintenance Regular Maintenance System Improvement Mechanical Electrical Instrumentation & Control

PLANT MAINTENANCE Plant maintenance is an important service function of an efficient production system It helps in maintaining and increasing the operational efficiency of plant facilities Maintenance is the procedure of finding the faults in any equipment/machine and also removal of fault It may be before the breakdown or after the breakdown

BREAKDOWN???? SHUTDOWN????

example downtime\12-18 March 2012 (2).xls example downtime\downtime ACM (2).xls example downtime\Time latest (1).xls

Plant maintenance step Method Strategies Practices 1.Regular check 2. Make sure system well function 3. Safe

Responsibility ENGINEER SUPERVISOR TECHNICIAN OPERATOR