You are on page 1of 37

TRAINING MODULE

Process Overview, Utility

PT. TPC INDO PLASTIC AND CHEMICALS

TPC Indo Plastic and Chemicals - Training Module

UTILITY RESPONSIBLE

SUPORT PRODUCTION IN ORDER TO MEET THE TARGET.


2

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

UTILITY DUTIES
PRODUCE TREATED WATER ~ CAP. 120 M3/HR PRODUCE DEMIN WATER ~ CAP. 80 M3/HR PRODUCE STEAM ~ CAP. 16 T/HR PRODUCE COOLING WATER ~ CAP. 2,700 M3/HR PRODUCE AI & AS ~ CAP. 1,750 NM3/HR PRODUCE WWR ~ CAP. 45 M3/HR PRODUCE RO WATER ~ CAP. 60 M3/HR

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

OTHER UT SUPPORT
FIRE FIGHTING SYSTEM UNIT VCM TANK & UNLOADING FACILITIES EMERGENCY DIESEL ENGINE GENERATOR POTABLE EDEG CATALYST STORAGE BRINE CHILLING UNIT DEEP WEEL UNIT

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

Utility Plant

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

FACILITY & UTILITY ORGANIZATION


Manager
Engineer

Shift GroupA Operator A 3 Person

Shift Group B Operator B 3 Person

Shift Group.C Operator C 3 Person

Shift Group.D Operator D 3 Person

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

UTILITY PROCESS UTILITY PROCESS


UT.Product Per Day
WWT 912 ( m3 ) RO 1,440 ( m3 ) Demin 1920 ( m3 ) Steam 384 ( m3 ) IW 2880 ( m3 ) AS/AI. 42,000 ( nm3 ) BCU 2,954 ( kW ) CW. 64,800 ( m3 )

UT.Receive Per Day


COAL
1000000 (kg/month ) Fuel. Oil
200 ( M3 )

PDAM water 600 ( m3 )

Nitrogen 3,293 ( Nm3 )

Coal Supplyer Pertamina

PDAM

UAP

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

FIRE FIGHTING SYSTEM UNIT

FIRE FIGHTING PUMP ~ CAP. 1,860 M3/HR Power = 730 kW FIRE WATER TANK ~ CAP. 2,957 M3 PRESSURE LINE CONTROLLER BY JOCKEY PUMP ~ PRES. 10 KG2/M2
8

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

VCM Tank Farm

Capacity : 3,500 m3/ tank Control temp. 40 deg C. by sprinkle shower system VCM import is support by jetty facility. Communication Jetty, DCS and Utility Op. is important during unloading activities.
9

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

COAL FIRED BOILER COAL FIRED BOILER

Type : Coal Fire Boiler Steam Pressure : 17.5 Bar ( normal operation ). 21 Bar ( Design Max ). Steam Flow Rate : 9.5 ton/hr ( normal Op ) 16 ton/hr ( Design Max )
10

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

COAL FIRED BOILER COAL FIRED BOILER

11

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

COAL FIRED BOILER COAL FIRED BOILER

12

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

COAL FIRED BOILER COAL FIRED BOILER

13

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

COAL FIRED BOILER COAL FIRED BOILER

14

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

COAL FIRED BOILER COAL FIRED BOILER

15

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

BOILER OPERATION DATA BOILER :: OPERATION DATA

BOILER ( Boiler Residue ).


Type : Water tube Steam pressure : 19 Kg/cm2 (normal pressure) 23 kg/cm2 (design max. press) Flow rate : 18.9 ton/hr max. normal 9-10 ton/hr The water is feed to de-aerator to release oxygen by inject hydrazine base for control corrosion. And feed to boiler passed economizer. Chemical phosphate based in injected to boiler for control the scaling. The Operation control system utilize PLC allan breadley.
16

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

AIR COMPRESSOR

AIR COMP (2 UNITS) ~ CAP. 1,750 NM3/H WITH PRESS. 7 KG/CM2 IF EMERGENCY, SUUPLY WITH N2 (TANK ~ CAP. 3.5 TON)
17

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

AIR COMPRESSOR FLOW CHART AIR COMPRESSOR FLOW CHART Air Inlet Comp. Screw T. Air Dryer

PA.

USER

User Control EQ.


Internal used TPC Indo only dont distribute

IA
18

TPC Indo Plastic and Chemicals - Training Module

AIR COMPRESSOR UNIT AIR COMPRESSOR UNIT


USER

600 nm3/hr norm.

Inlet Air

AS TANK

Cap. 1750 nm3/hr max.

USER

200 nm3/hr
AIR DRYER Column A AIR DRYER Column B

IA TANK

Controller

19

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

EDEG

TPC INDOS EDEG ~ CAP. 2,250 KW (2,812.5 KVA)

20

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

BRINE CHILLING UNIT

VCM Recover Control Temp. 0 deg C. at constant rate 67.5 m3/hr. Catalyst Control temp. -20 Deg C at constant rate 8.4 m3/hr Energy Requirement : 332 kW/hr There is consist screw compressor, condenser and Evaporator FW2100 is PLC for control the Compressor operation. EKC is PLC for control the Evaporator operation

21

Internal used TPC Indo only dont distribute

Condenser Condenser

Evaporator control

Compressor Compressor

Exp valve Exp valve

EKC

Evaporator Evaporator

FREON

Evaporator

BRINE

BRINE

Cooling at compressor

Compressor Compressor

Check valve

Sub cooler

Oil injection
PT.TPC INDO PLASTIC AND CHEMICALS

TEV

Sight glass Liquid injection


UTILITY SECTION

TPC Indo Plastic and Chemicals - Training Module

CATALYST STORAGE

Total storage house volume = 558 m3


Total floor area = 186 m2.

The refrigeration duty is 10,000 kcal/hr (2 UNITS) Control temp. -20 Deg C Energy Requirement : 9.5 kW/hr
23

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

COOLING FLOW CHART COOLING FLOW CHART


Type = Induced draft tower

IW

CW Basin

Process PVC

Cooling water is supplied to process by circulation pump 2.700 m3/hr max. Chemical add for prevent fouling and corrosion with 3D Trasar program treatment The sludge doze biocide and biodispesant agent is provide intermittent to control microbiological and organic growth up. Cycle concentration control 5. with corrosion rate max. 3 mpy Larson skold index max. 30 LSI (Lange liar saturation index) is control between 0 2 Ryznar Stability index control between 5 - 7
Internal used TPC Indo only dont distribute

24

TPC Indo Plastic and Chemicals - Training Module

WI Unit
The treatment cap. Is 129.3 m3/hr normal. Max 173.2 m3/hr The treatment is reduce SS up to 1 ppm max. Back wash frequency 1 time/day and flow rate 68 m3/hr. WI plant is supply the water to demin plant, PVC plant and Cooling make up 129.3 m3/hr
IW FEED

Backwash

DW plant

F-9701A

F-9701B

F-9701C

F-9701D

TK-9705
Internal used TPC Indo only dont distribute

25

TPC Indo Plastic and Chemicals - Training Module

DEMIN UNIT OPERATION DATA DEMIN UNIT :: OPERATION DATA

DEMIN 1. Operation flow rate ~80 m3/hr


2. 3. 4. 5. 6. 7. cycle time ~ 3,800-4,200 m3 Mix bed cycle time ~ 10,000-20,000 m3 Each column content : strong & Weak resin Washing column utilize every 6 month for washing resin and alkali cleaning resin. Conductivity Outlet Anion < 5 us/cm Conductivity Outlet MB < 0.5 us/cm
26

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

Demin System
80 m3/hr
IW FEED

CATION

CO2 Stripper

ANION MIX BED

DEMIN STORAGE TANK

Conductivity Online

Conductivity Online
27

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

WATER FLOW CHART WATER FLOW CHART Raw water Sand Filter IW Cation

HCL

USER

Storage tank

Mix bed

Anion

HCL NaOH
Internal used TPC Indo only dont distribute

NaOH

28

TPC Indo Plastic and Chemicals - Training Module

RO Processing

Reverse Osmosis ( R.O.) is the process that water molecule are forced through a semi-permeable membrane by hydraulic pressure from high concentration to low concentration
Internal used TPC Indo only dont distribute

29

TPC Indo Plastic and Chemicals - Training Module

PT. TPC Indo RO Unit Simplified System


DW 2
PLC Controller

DW 1
Membrane ls Conduct. FI Product Water ORP pH PI

39 m3/hr

30 m3/hr
High Pressure Pump Reject Water

Feed Water

Sand Filter

Carbon Filter

Pre-Filter Pre5 micron

9 m3/hr
Ph CONTROL

Normal Operation Ant scale Flushing Loop Control Loop

Declorinator

30

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

Principle & Mechanism


1. Big blue Housing 2. Pressure Switch 3. Pump 4. Solenoid Valve 5. Pressure Gauge 6. Conductivity 7. Flow meter 8. Vessel Membrane 9. Filmed RO Membrane 10. Valve 11. Check Valve 12. Piping 13. Control Electric Box
31

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

Principle & Mechanism

32

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

WASTE WATER TREATMENT


WASTE WATER TREATMENT CAPACITY = 960 M3/DAY ( MAX ) WASTE WATER TREATMENT PROCESS a. Biological process b. Chemical process c. Physical process
33

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

a. Biological Process Treatment It designed to reduce the BOD/ COD, Organic matter and Suspended solid by utilzing the functions of microorganism. b. Chemical Process Treatment Coagulation & Flocculation system is applied for removing in organic suspended solid from waste water. c. Physical/ Mechanical Treatment For guaranties the water effluent in low turbidity, SS and chloride content. It designed utilize the Filter Press and Carbon Active Filter.

34

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

Waste water treatment system

35

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

WWT FLOW CHART WWT FLOW CHART

Waste PVC

Eq tank

Cooling

Aeration

TWW tank

Sediment

Clarifier

Carbon Active

TWW tank

TK-9707 Sewer
36

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

WWT PLANT

37

Internal used TPC Indo only dont distribute