PETRONAS TECHNICAL STANDARDS DESIGN AND ENGINEERING PRACTICE (CORE) MANUAL, DEOILING INDUSTRIAL WASTEWATER DESIGN & OPERATION OF CORRUGATED PLATED INTERCEPTOR (CPI) PTS 10.05.10.30 FEBRUARY 2009 PETRONASPTS 10.05.10.30 Feb 2009 PTS Circular ‘Mac 2009 — 10.05.10.30 PTS No: PETRONAS © ee Publication Titi Base PTS Version: Deoiling industrial Wastewater Design & Operation of Corrugated Plated Interceptor (cP Release 2 from herein onwards. Document Approval Page 2 ‘This revision of PTS 10.05.10.30 — Deoiling Industrial Wastowator Design & Operation of Corrugated Plated Interceptor (CPI) has been reviewed and found to be satisfactory. No technical changes has been made. ‘The previous version of this PTS (Revision 1, February 2008) will be removed from PTS binder/ e-repository Namo Designation Date ‘Signature Prepared! Ruslan Bin | Technical Manager Reviewed Salleh Water and | ‘Wastewater odfog| Were thocestny (2429/09 ‘Approved by Wan W'Sobi| Principal Engineer | Bin Wan Water and 7 L Abdullah Wastewater R (Process Eng) W504 \Camsumrg® Verified ‘Samsudin: ‘Senior Manager, — Datoviarin | Process Enenecing |2 S/sfoq ) -GTS t Verified Pau Kiew General Manager, \ Huai Engineering GTS | 97,3. 54 Endorsed Pramod Senior General Kumar Manager, GTS Karunakaran Ih 04°05 ie Revision History Date__| Version Description of Updates Reviewer 1981 RO Feb 2008 Ri Reviewed to include more detail and | Si Noreamiah latest technology 7 Binti Nadzmi, Feb 2009 R2 Reviewed and no changes on the Ruslan Bin Md technical part. Changes only to the Saleh PTS numbering rom 5 digits to 8 digitsPTS 10.05.10.30 Feb 2009 Page 3 PREFACE PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,of PETRONAS OPUs/Divisions. They are based on the experience acquired during the involvement with the design, construction, operation and ‘maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, rational and international standards and codes of practice. The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production factties, refineries, gas processing plants, chemical plants, marketing facilties or any ‘ther such facility, and thereby to achieve maximum technical and economic benefit from standardisation, The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be suficently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements, When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. if in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. ‘The right to use PTS rests with three categories of users: 1) PETRONAS and its affliates 2) Other parties who are authorised to use PTS subject to appropriate contractual arrangements, 3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behaif of the said users comply with the relevant standards, Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS. disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or Person whomsoever as a result of or in connection with the use, application or implementation of any PTS, ‘combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS. and/or any company affiiated to PETRONAS that may issue PTS or require the use of PTS, Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company of person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be retumed after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS, The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirementPTS 10.08.10.30 Feb 2009 Page 4 4. INTRODUCTIONS This PTS shall supersede PTS 20.065; DEOILING INDUSTRIAL WASTEWATER DESIGN & OPERATION OF CORRUGATED PLATED INTERCEPTOR (CP)) (1981). This PTS also includes PETRONAS Lessons Learnt and PETRONAS Best Practice for the subject matter as stated above, 2, EXCEPTIONS/AMMENDMENTS. This is a new PTS that shall supersede PTS 20.065: Deoiling industrial Wastewater Design & Operation of Corrugated Plated interceptor (CPI) (1981), 3. PETRONAS LESSON LEARNT Nil 4. PETRONAS BEST PRACTICE Nit 5. REFERENCE 5.1 PTS 20.065, - DEOILING INDUSTRIAL WASTEWATER DESIGN & OPERATION OF CORRUGATED PLATED INTERCEPTOR (CPI) (Rev 0 - 1981) : |PTS 20.265 Feb 2009 Page 5 ‘Table of C Document Approval Revision History. 1. INTRODUCTIONS 7 2. EXCEPTIONS/AMMENDMENTS 3. PETRONAS LESSON LEARNT... Nil 4. PETRONAS BEST PRACTICE. Nil 7 . 5. REFERENCE. 5.1, _ PTS 20.065. - DEOILING INDUSTRIAL WASTEWATER DESIGN & OPERATION OF CORRUGATED PLATED INTERCEPTOR (CPI) (Rev 0 - 1981) Fl 10 Scope %s 20. inodution ‘6 2:1 "Summary of changes é 22 Backgroind 6 23 Of Removal Oijecives. 7 2.0” Applation of CPI 4 40 CP Description wns i 3 41 “Ol Separations. es 3 42 Goalescng Pate Packs 9 43 Removal of Other Materia Se eee 50. Designing a CPI Seer eee cere 5:1 Determination of Wastewater Charactrisies-..n.ssssoonnn an 82. OWeter Soparaton Theory : a 83 Delon Porametre f 54 CPI Sizing .... ts aoe senses i Pehl 85 Selection of Plate Pack Media. sssssssammnssncnenn ens " 88 Ancilaries " 82 Location and Layou or GP insialaon, 2 58 Other Considerations : 2» 58 Package Separator > | 5.10 _ Materials of Construction and Installation ts ae sesveernsere BL ; 60°” Operaton and Malntonance..rnsresnsnsrscscosconsnnnnnnnennnnnennn Na 1 Trash Rack or Bar Sereen 2 62 Inlet Wer. : soeeeetaeee ae 83 Flow Distibuion Baie .---svessnssomevecmonnan i 2 64 Oil Skimmer. vs ee iH - ‘ 22 65 Outlet Weir........ 22 88 Solis Pre-Setioment Compartment See et Heee cree 87 Sols Setioment Compartment 2 52 Pate Packs me) Be nearer. BF 810 _ Waste vanding 2 | 7.0 Performance Monitoring os 4 i 71." “Montorng Planer socscssns ae in iether 7.2 _ Pollution Prevention Plan Selah 7 abi 24 a 80° Performance Improvement ..---wovsssossonenenns 23 | 80° Appendies. nr 26 |PTS 20.265 Feb 2009 Page 6 4.0 SCOPE ‘This manual has been prepared with the following objectives: + to provide engineers and operators with basic understanding of the principles of Corrugated Plate Interceptor (CPI) for removal of oll from wastewater streams at oll, gas and petrochemical storage terminals and processing plants, * to provide guidelines for equipment selection and design including retrofits and upgrades, and * to provide general guidelines on operations and maintenance as well 2s performance monitoring as essential information for evaluation of technologies at design stage, ‘This manual focuses on physical and mechanical separation of suspended oil in water that is also referred as free floating oil, using CPI. 2.0 INTRODUCTION 2.4 SUMMARY OF CHANGES This revision has been essentially only editorial, with no significant technical changes. 2.2 Background Hydrocarbon processing in PETRONAS Group that includes olllwater separation, gas processing, refining and Petrochemical processing, generally produces wastewater streams. Typical pollutants in the wastewater streams of the plants are oil and grease, suspended solids, pH, Chemical Oxygen Demand (COD), Biochemical Oxygen Demand (800), while other less typical but may be present are aromatics, sulfide, ammonia and amine. Heavy ‘metals may also be present depending on the characteristics of the oil or gas and pipeline conditions. ll and grease in the wastewater may be present in various forms - suspended (free phase oil and oil coated solids), emulsified, and dissolved. Coalescing and gravity type oillwater separator such as the Corrugated Plate Interceptor (CPI) as described in this manual is mainly used to remove ol in ts suspended form. The device does not remove or reat emulsified and dissolved ol i | |PTS 20.285 Feb 2009, Page 7 2.3 Oil Removal Objectives The main objective of oll removal is to meet environmental regulations intended for protecting water quality and ensuring aquatic life and human health, Operational objectives that are more of practical and process related reasons are to prevent + upsets of downstream secondary wastewater treatment system such as hindrance of oxygen transfer in aerobic systems and interference of solids settling, and + damages and hazards caused by oll accumulation and fouling of instruments and equipment. 3.0 APPLICATION OF CPI Corrugated Plate Interceptor (CP) is a device commonly found in many PETRONAS facilities. The separator is a simple device with long proven performance, but often its importance as the first ine of defense in preventing damages and upsets to downstream wastewater treatment processes is overlooked. Several factors could potentially affect the safety, efficiency and proper management of the device, thus these factors must be given Careful consideration prior to any installations or modifications, When determining the need for a new CPI or an upgrade of an existing OPI, the necessary steps must be taken to ensure its effectiveness to meet the objectives of wastewater treatment Figure 1 provides a guideline in determining the application of a CPIFigure 1 : Guideline for Determining Application of CPI Wastewater Charactersaton Does ol excouds the eee stad sepastoris not tm? required Needs ony a Froation nit Use cyclone separator, cenlitge separator or ‘other more sukable for finer droplets Use ony ba ype ol separator euch a8 APL Separa Use CPI or ater sutatie package ollwaler separator PTS 20.265 Feb 2009, Page 8PTS 20.265 Feb 2009, Page 9 4.0 CPI DESCRIPTION 4.4 Oil Separation A CPI is a combination of coalescing and gravity type oilfwater separator. It Is a containment specifically designed to provide sufficient quiescent condition that slows down the wastewater velocity, allowing time for free oll droplets to coalesce and rise above the water level as @ separate liquid phase. The tank is divided into ‘compartments where in one compartment an inclined parallel corrugated plate pack provides a greater horizontal surface area and reduces turbulence for the oll to coalesce. The separation occurs at a faster rate, requiring lesser retention time. The top oil layer is retained by a baffle where it is removed using oil skimmers placed just below the oil phase at the end of the tank. The collected oil can either be disposed or reused. Figure 2 shows a typical schematic of a CPI ‘The enhanced separation provided by the corrugated plate pack reduces the overall size of the tank compared to conventional gravity separator. Where gravity separator is only efficient for removal of free oil droplet with diameter size of greater or equal to 150 microns, the CPI is able to remove free oil droplets as small as 60 ‘microns in diameter. 4.2 Coalescing Plate Packs Wastewater flows through the pack of corrugated plates is generally downflow or crossfiow. These flow patterns encourage the wastewater to change directions throughout the media, assisting the smaller cil droplets to remain longer on the surface and coalesce more. Coalescing media is typically made from oleophilic polymeric materials such as polyvinyl chloride (PVC), in the form of corrugated sheets. Oleophilic materials attracts smaller oll droplets to its surface where they coalesce to form larger droplets which slide up to the surface of the media and break free, quickiy rising to the surface of the water. 43. Removal of Other Materials ‘Suspended Solids ‘The quiescent condition and the corrugated plates also causes for the settling of suspended solids including oil ‘coated solids, to the bottom of the tank. As the settled solids or sludge must be regularly removed and disposed to ensure sufficient retention time is available in the tank, provision must be made for withdrawal of the sludge from the tank bottom, Depending on the sludge characteristics, when there is evident presence of heavy metals and radicactive ‘materials, the Malaysian regulations require forthe sludge to be disposed as scheduled waste at a licensed solid waste handling plant, Else the sludge can be disposed at a local landfill, provided with prlor approval from the DOE. j ! :PTS 20.265 Feb 2009, Page 10 sand Sand and other heavier particles will sette at the pre-settling compariment. Similarly to the sludge compartment, this pre-setting compartment is to be sized sufficiently to ensure adequate storage to avoid too frequent cleaning of the compartment. Provision shall also be made for removal of these settled materials, Other Coarse Materials A trash rack or bar screen may be necessary to avoid any coarse debris such as sticks, rags or leaves to be cartied into the CPI that may eventually clog the plate pack. This is especially necessary particularly for plants ‘here the influent is open channel (instead of a closed pipe) where it is more subjected to entrainment of coarse ‘materials. The bar screen chamber shall be located before the inlet of the CPI. | | . Figure 2 : Typical Schematic of Downflow CPI Oil Layer —f | t oll : i me Se ‘Corugated Plate bindPTS 20.265 Feb 2009 Page 11 5.0 DESIGNING A CPI The design of a CPI must be sufficient to remove free oil to ensure that oll and grease concentration in the effluent complies with the regulatory standards. The Malaysian Environmental Quality Regulations requires for absolutely not more than 10 ppm of cil and grease content for Standard B discharge areas while non detectable oil and grease level for Standard A discharge areas. The following provides the design guides for a CPI. 5.1 Determination of Wastewater Characteristics Determining the characteristics of the wastewater (in terms of sources, flow rate and contaminant loading) is ‘essential in deciding and designing for a new installation or upgrading of a CP. However as characterisation may not be possible for plants that are yet to be in operation, data must then be obtained from a similar or typical operating plant, process knowledge, documented MSDS sheets and process flow diagrams, where credible assumptions can be made. Without sufficient information itis difficult to ensure that the CPI is able to perform as intended as the capability for oil separation is affected by various parameters including flow rate, oll and grease loading, pH, temperature, particle size or oil droplet size, solids loading, and specific gravity and viscosity of the «il content Characterisation shall be conducted based on the guidelines issued by the Malaysian Department of Environment (Technical Guidance Document Series No: DOE-IETS-5) with additional parameters as mentioned above. Further reference can also be made to American Petroleum Institute (API) publication AP! 4602, where applicable, for analysis of these parameters, ‘The type of oll present in the wastewater stream is to be determined in the characterisation. Oils in wastewater may exist in various forms; suspended (free phase oil and oil coated solids), emulsified, and dissolved. This manual provides guides only for removal of suspended oil, Different removal methods must be provided if the characterization shows that oll may be present in emulsified and dissolved forms but those methods are not considered in this document, 5.2 OilfWater Separation Theory Viecosily of wastewater, Separation of oll from water is based on the theory that the | td difference in the densities of oi! and water phases will cause oil | v v lobules to rise to the surface. The lesser the diference of the he ole specific gravly ofthe oll and the speci gravity of the water, the ’ slower the oil globules will rise, Forces that act upon the oil droplet and affect its rising rate are the droplet buoyancy (proportional to the droplet volume), drag (proportional to the droplet area) and ‘gravity. The viscosity of the water phase is another factor affecting ¢ rag Bunyaroy coyPTS 20.265 Feb 2009 Page 12 the rising of the oil droplets. The greater the viscosity, the more difficult itis for the oil to rise and slower for it to reach the surface. ‘The rising rate or the vertical velocity of the oil droplet can be derived from Stoke's Lawas below: 2 ,{ Pw- Pe), a( Where; ¥,|s the rising velocity of the design oil droplet, cm/sec gis the acceleration due to gravity, 98 1cm/s® 1, is the dynamic viscosity of wastewater at design temperature, dyne.s/em* ‘pois the density of wastewater at design temperature, g/cm? ‘Peis the density of oil at design temperature, g/cm* ris the radius of the oil droplet, cm & is the diameter of the oil droplet, cm ‘The rising rate of the oil is also related to the surface loading rate of the separator. If the oil rising rate is greater ‘or equal to the surface loading rate, the oil globules will reach the separator surface and can be then removed ‘This is assuming an ideal condition in the separator where there is no short-circuiting, turbulences or eddies. The ‘surface foading rate is the ratio of the incoming flow rate over the surface area of the separator: sun = 2» 4, Where; SLRs the surface loading rate in m°/m?Mhr Q. is the wastewater flowcate in m"inr 4,8 the separator surface area in m* To achieve rising of oil droplets to the surface, 7, 2 SLR Allowing @ quiescent state and sufficient retention time of the oily wastewater, oil droplets wil rise and at the same time coalesces with other smaller oll droplets, making larger more buoyant oil globules that rise faster. The Inclined plates provide a greater surface area for coalescence to occur, hastening the rising of the globules, 5.3 Design Parameters: ' |PTS 20.265 Feb 2009 Page 13 ‘The critical parameters for designing a CPI are described below. Data on these critical parameters are obtained during wastewater characterization as explained ear. Flowrate Determining the design flowrate can be complicated but itis the key sizing factor that will affect the cost and operability of a CPI, thus careful analysis must be conducted and experienced engineering consultation must be seek Piping diagrams showing all drainage and estimates of peak flow from each source, going into the CPI are to be Provided. Sizing must be based on the combined peak flow rate while for a CPI treating combined storm water and process wastewater the basis must be the sum of both ‘As a good design practice, clean water (non-clly wastewater) including clean non-contaminated stormwater, is to be segregated from the main wastewater collection system that enters the CPI. Depending on the level of ‘contamination the water can either be discharged into the downstream process unit of the wastewater treatment system or even allowed to discharge via the stormwater drainage as site runoff, Another alternative is to contain ‘and reuse for other purposes such as firewater. ‘Stormwater from process areas that is potentially oll contaminated must to be treated at the CPI and a retention basin for the flow before the separator must be determined based on site conditions. It is possible that only the first few hours of the storm flow is treated while treatment may be unnecessary for the remaining flow as the contamination may be diluted or totaly absent. ‘Another good design practice is to consider providing additional capacity to contain spillage if a CPI is located where spills may occur. An estimate of the potential spill volume is to be made if this additional capaciy Is found necessary, Oil Droplet Size Atypical CPI allows for the effective separation of oll droplet with a diameter of greater than 60 microns as the oi droplet size is related to the oil rising velocity to the wastewater surface, Actual measurement ofthe droplets size and the size distribution is required for design. As oll may be present in various sizes, a size distribution analysis provides an indication on the size range and how much oll removal can be achieved In @ CPI, In the absence of actual samples data from a similar plant or assistance form experienced engineering personnel must be obtained | {PTS 20,265 Feb 2009 Page 14 Specific Gravity of Water Phase As explained earlier, specific gravity of the water phase is necessary to design @ CPI. It is different from pure water as contaminants influence the actual water phase density. In the case where actual samples are not available for measurement, an estimate can be made based on the materials that might be present in the wastewater, In the absence of any information specific gravity of pure water may be used. However as this is deemed inaccurate, further optimization is necessary once the unitis in operation and actual data is obtained. Specific Gravity of Oil Phase ‘This Is another critical design parameter as oil separation is highly dependent on the difference of the specific gravity of the oil and water phase. The lesser the density difference, the more difficult itis for the oil to separate from the water phase. Similarly to the water phase, the oil phase density is not the same as pure oll as it may compose of different oils and or attached to other particles. Therefore the specific gravity must be determined from actual measurement. Again, in the absence of such samples data from other similar plants may be cautiously used, Viscosity of the Water Phase The viscosity of the wastewater Is inversely related to the rising velocity, it will affect the ability of the oil to rise to the surface as higher viscosity will hinder mobility. Viscosity is affected by temperature where at lower temperature the viscosity is higher, making it more difficult for oll to rise, while at higher temperature the opposite ‘occurs. Again, itis important that the viscosity of the actuat sample Is determined and usage of data from other facilties is done cautiously. Temperature ‘As specific gravity and viscosity changes with temperature, itis important that the designer is aware of the actual temperature at site and any potential changes during operations,PTS 20.265 Feb 2009 Page 15 8.4 CPISizing In order to allow separation of the oil from the water phase, the sizing of the Interceptor tank must provide a ‘quiescent state and sufficient retention time for the separation to occur. ‘Assuming laminar flow in the interceptor where Stoke's Law is applicable, Reynolds number can then be assumed to be between 500 and 2,000. Reynold's number is an indication of the ratio of inertial forces to viscous forces in the fluid. The following can be derived: rg = Sol ehe She mete Where: Tis Reynol's number, dersioness Tis average velocity of wastewater, emis “Me is the dynamic viscosity of wastewater at design temperature, dyne.sicm* Pwis the density of wastewater at design temperature, gicm? 5s the pate spacing, om is the kinematic viscosity of the wastewater at design temperature, cm’/s ‘Quick/Rough Sizing ‘As a quick calculation for a rough estimation of the CPI size, derivation of the Reynold's number can be used. But the following must be used with caution as it gives only an indication on the size, detail sizing must be completed to determine the required CPI size as shown later in this document. ‘Assuming laminar flow and kinematic viscosity of pure water at design temperature of 40°C and plate spacing of ‘38mm, the probable horizontal surface area (A,) can be derived: where 4 is in m? and Q, is wastewater flowrate in mihr. ~s7.ax 2 1967 8x 2 ‘White the separator length, £, in m, can be estimated by 0.02 * Na Separation Capacity ‘The tank dimension is determined based on the flowrate of the incoming flow, the size distribution of the oil droplets (as explained previously) and the design of the separator plates. Provision of equalization tank prior to the CPI may also affect the sizing. ‘The CPI tank sizing requires the following: * Minimum retention time of 30 minutes based on instantaneous peak flow (or maximum flow), orPTS 20.265 Feb 2009 Page 16 + Retention time of 8 hours based on average flow ~ this is possibie with provision of an equalization prior to the separator however more than & hours may cause significant odour or even septicity. + Minimum of 2 skimming/plate compartments It has been found that approximately 70% of the oll can be separated within the first 40 minutes of retention and that no substantial removal can be expected after two hours of retention time. Design of Plate Pack The required horizontal surface area of the parallel plate separators can be determined using a derivation of the Stoke's Law. Assuming an oll globule diameter of 60 microns: Qn is the design flow in m°/hr ‘Ay/s the horizontal separator area in m? ‘Pols the specific gravity of the wastewater in gfem™ puis the specific oravity ofthe oil in gicm? is the viscosity of the wastewater in dyne.sicm? Me ‘As a word of caution, depending on the design of the plate pack, different manufacturer may require different surface area. Therefore it is of great importance to consult the manufacturer before specify horizontal surface area requirement.PTS 20.265 Feb 2009 Page 17 5.5 Selection of Plate Pack Mei ‘A variety of parallel plate media configurations are commercially available. The two major types are cross flow CPI and downflow CPI. In a cross flow separator, the wastewater enters the plate section from the side and flows horizontally between the plates. In a downflow separator, the wastewater flows down between the parallel plates. The available surface area is affected by the spacing of the plates within the pack and angle of inclination of the plates, Typically the spacing of the plates is 20 to 38 mm and inclination of the pack is 45-60 degree. Tighter spacing provides higher surface area but may cause higher clogging of the pack with solids and may require more frequent cleaning, while greater inclination of 60 degree may be more advantageous if the wastewater contains high solids content as it will hasten solids setting Cleophilic polymeric material such as PVG is inert to most ols and contaminants but can only withstand moderate temperature. Different type of polymer such as polypropylene Is more suitable for higher temperature of up to 185°C. For greater temperatures, metal plates such as stainless steel are used. 5.6 Ancillaries Requirements for Bar Screen When a trash rack (also known as bar screen) is deemed necessary due to the presence of coarse materials (Le. sticks, rags, leaves etc), 2 bar screen chamber is to be provided before the inlet of the CPI. The spacing between the bars should be half the interval of the corrugated plates. Depending on the amount of materials removed and the operating principle, the type of screen installed can either be manually or mechanically cleaned The design is to allow for 50% of the screen to be blocked before itis cleaned, assuming weekly cleaning for the manual screens. Necessary ancilaries must be provided to ensure safe access to the screens for cleaning and maintenance such as trash plate for draining of collected trash and a collection bin beside the chamber. Inlet Conditions, Ideally the inte is of gravity flow as pumped flow causes mechanical emulsification of oil thus adversely affecting the CPI performance. If pumping is required, itis recommended that @ screw type pump is considered as it is capable of minimizing emulsification compared to typical centrifugal pumps. ‘The incoming flow is introduced below the water surface and the piping is sized for minimum pressure drop to avoid turbulence at the surface and in the tank that might hinder separation process. Another feature to avoid inlet turbulence is by providing a straight inlet pipe for a length of at least ten times the size of the pipe diameter. Inlet Channel and Flow Distribution Baffle :PTS 20.265 Feb 2008 Page 18 The incoming flow is to be evenly distributed into all tne compartments of the plate packs by ensuring sufficient flow velocity at the inlet channel with a maximum flow velocity of 20cnvs. The water flow is equally distributed over the cross section of the plate pack by a removable slotted baffle. The top of the baffle is about Gem below the highest postion ofthe oil skimmer in order that at low throughput, ol separated before the baifle can flow to the oll skimmer. Settlement Chambers ‘The settlement chambers are at the lower part of the inlet channel and the CPI chamber and used for storage of Particles that settles easier such as sand. Sulficient storage capacity is estimated based on the expected volume of settled particles, The maximum level shall not restrict the flow velocity atthe inlet channel. ll Skimmer The skimmer is the most important ancilary equipment that ensures the CPI's objective of oll removal is met Without proper design and selection skimmer, the CPI will fa. Accumulation of the oll layer is allowed to a maximum thickness before the layer is skimmed. This is to prevent under-skimming or over-skimming as both wil ‘cause problems to the CPI performance, Under-skimming is of a lesser concer, as long as the thick layer of ol does not pass under the baffle separating the oil layer from the effuent channel, On the other hand over- ‘skimming may cause greater problems as excessive skimming may lead to drawing of the water layer as wel ‘This drawing may cause turbulence and mixing at the water layer where separation occurs, eventually causing oil ‘emulsion and hindering oll separation, The maximum oll layer thickness at the water surface can be established based on the difference in specific gravity of ol and water and on the dliference in level between the edge of the skimming device and the level of water at the outlet weir, As 2 general estimate, a thickness range of 2-4cm can be used. There are different types of skimmers available for consideration, each having its own advantages and isadvantages. Selection is to be made depending on the conditions and requirements at site, The different skimmers are: + Slotted pipe skimmer + Rotary drum skimmer + Floating oll skimmer + Dise skimmer For slotted pipe skimmer, the overflow edge of the skim pipe is to be installed horizontally and in the highest position at the same level in all bays of the CPI by adjusting the thickness of the packing between the horizontal fianges, il SumpPTS 20.265 Feb 2009 Page 19 ‘Skimmed ol is discharged into an oil sump from where it is pumped to 2 slops tank. Due to the compact CPI design, the oll sump has a relatively small buffer capacity, especially for facilities with high oil loading. This however can be compensated by using a higher pump capacity. For instance, in refinery processes, two level controlled pumps at 10m*/h capacity can be considered Covers CPI bays are typically covered even though this may impose safety hazards to operations and maintenance as the tank is then considered a confined space, However the cover is necessary to reduce evaporation and spread of odours that may impose greater hazards to the surrounding areas. Airborne sand and dust may also cause problems to the CPI, Hazards to operations must be mitigated by enforcing proper procedures and regulations. Fixed covers are typically permanent steel reinforced concrete, or non-supporting foamialuminum sandwich ‘cover. However fixed covers limit the space for expansion of vapors that may be present between the oll surface ‘and the cover, This requires for explosion minimizing conditions limiting to installation of explosion proof electrical equipment and low level work-act recommended to minimize damage in the event of an explosion. There is a possibility that these vapors can be ly. Proper venting equipment is to be provided while blow-off hatches are collected and recovered for other suitable uses by using conventional recovery equipment. The use of floating covers minimizes the hazards associated with limited space for vapor expansion. The covers must be of corrosion proof and lightweight but with sufficient lasting strength. Four types of covers are available for consideration: + foamed slabs i.e polyurethane foam encapsulated with floerglass skin (density is to be more than 73kgim") + polyethylene balis + steel pontoons Outlet Weir The design of the outlet weir is to achieve a controlled flow out of the CPI preventing turbulence at the separation phase and the oil layer at the surface as well as flow short-circulting in the tank. Thus it also depends on the type ‘and focation of the oil skimmer for instance if a fixed skimming pipe is use the weir is to be § cm below the ‘overtlow edge of the skim pipe, A maximum throughput must then be set to avoid short-circuting of the flow through the tank. An adjustable weir allows flexibiliies and robustness to cope for flow changes during ‘operations. The position of the weir is also related to the discharge point and location of the receiving water-body (subsequent unit operations. Others: + Ifthere is any automatic control elements itis to be in accordance to NEMA standards + If pumps are used for extracting the oil layer itis to be self priming and explosion proof | |PTS 20.265 Feb 2009 Page 20 * Effluent sampling ports must be provided at the exit pipe of each CPI chamber 5.7 Location and Layout for CPI Installation The location of the CPI depends on the overall plant layout as well as the site topography. It is typically at the lowest evel relative to the wastewater generation areas, while it s always higher than the effluent dlscharge point {0 avoid any back-flowing into the CPI from the downstream water body or unit operations. This is the ideal Condition to achieve gravity flow and avoid pumping. However this concition is not aiways possible, stil itis important that the Incoming Is by gravity flow to avoid turbulence that reduces CPI efficiency while the discharge can then be pumped The layout of the CP! must allow for accessibility for all operations and maintenance of the tank and any related equipment such as the oil skimmer. For instance it must allow for safe access to clean or replace the plate pack and also for desludging works. Below or above ground tanks are possible however in many cases above ground tanks are preferred for the following reasons: + Prevention of groundwater contamination + Easier accessibility for maintenance and leak detection + Reduce installation cost as below ground tank requires double walled with leak detection + A prefabricated above ground unit (such as a steel basin) can be considered as an option. This wil reduce installation time and can make it mobile (for temporary or mult-sites usage) 5.8 Other Considerations Emulsifying Agents ‘The presence of detergents, surfactants and phosphates in the incoming wastewater may cause a CPI failure, ‘These or other emulsifying agents are specially formulated to increase the dispersion of oll into small droplets in the water and thus the reason they are used to remove oil from equipment and piping system, These agents Increase the separation time required in the CPI. Low emulsifying soaps and detergents are an alternative to reduce the separation time, Care must also be taken when there are other basic compounds such as caustic that cemulsifies oil Presence of Contaminants Contaminants such as heavy metals that are in particulate form may settle at the sludge compartment. Solvents or fue! may be encapsulated by particles and also settled as sludge. Sludge that contain such contaminants that can be toxic and hazardous Is categorized as scheduled waste that must be disposed as regulated by the focal authority. Sludge samples must be analysed to determine its toxicity prior to final disposal. 6.9 Package SeparatorPTS 20.285 Feb 2009 Page 21 There are conditions when a typical CPI may not be feasible. These conditions may vary, perhaps due to site constraints, retrofiting or supplementing existing unit, non-typical oily wastewater characteristics (le. pressurized stream, very high oll content andlor high solids), limited installation time, and/or as temporary treatment. In any of these conditions package CPIs may be worth considering. Package separators of similar design principles with a typical CPI are available in the market in standard sizes for specific applications. They are effective if selected and applied correctly. For added quality assurance, those manufactured and tested based on European Standards BSEN 858 Parts1 and 2 may be considered where applicable. 5.40 Matorials of Construction and Installation In selecting materials for construction of the interceptor, factors to be considered are corrosion, leakage, structural strength and buoyancy. These factors depend upon the site and climatic conditions and the wastewater characteristics itsett ‘The following are some guides in interceptor materials selection and installation: + Most interceptors are constructed of either reinforced concrete or fiberglass while stee! are used more commonly for above ground installations. + Underground separators are subjected to relevant standards on underground tanks for flammable and ‘combustible liquids. * The structure shall be made watertight such as bituminous coatings, joint gaskets, and pipe connection gaskets/seals whichever applicable. Separators should be leak tested according to relevant standards, * The interceptor tank and the plate pack shall be made of corrosion proof either from acid or alkali attacks cr other corrosive materials such as sea water (when applicable). Typically the material used is able to withstand wastewater pH of less than § or greater than 9 for short periods only. In the case when the ‘wastewater contains specialized corrosive compounds such as aromatic hydrocarbons that may attack the plastic plates or fibre glass tank, a materials specialist must be consulted for the right materials selection. + Adequate access is to be provided for safe maintenance and cleaning works, ‘Where applicable for materials selection and testing, reference can be made to European Standard BSEN 858 Parts 1 and 2 or other available relevant standards.PTS 20.265 Feb 2009 Page 22 6.0 OPERATION AND MAINTENANCE Being a simple device, with minimum moving parts, the operation and maintenance of a typical CPI is minimal Depending on the characteristics of the wastewater such as the oil droplet size, pH, temperature, hydraulic loading, oi! concentration, and solids loading, the operations and maintenance of the device mainly requires as described below. 6.1 Trash Rack or Bar Screen ‘The screen Is to be safely cleaned regularly using a suitable tool. The frequency of cleaning depends on the volume of materials collected but generally the design is for weekly cleaning. The removed materials are to be collected in a tray and emptied in a trough or drum located beside the screen chamber. 6.2 Inlet Weir ‘When the bay of the CPI is to be emptied, flow over the weir can be prevented by placing a grooved wooden board over the weir plates, 6.3 Flow Distribution Baffle ‘When there is more than one compartment of plate packs operating in parallel, there is a baffle configuration that distributes the incoming flow into the different bays. Depending on the design, the slots of the baffle are to be cleaned periodically to avoid any clogging that may restrict the flow into the packs. To emply a bay, the flow \ 38mm ial Lf ens » me 2000 /\ 0.0065 100 cm m 0.92 g 1000 mm JK em > » = 8.05 m 3. Calculating the length of parallel plates Vertical_ length, & Vertical velocity. rising rate, ¥,, Retention time, , 5, wnere, = 4 atincine plats angle of fi = 60° cos B Sy tus, = cos 0.5 Px As Length of Plata, Bat ang since 4, = 2S ePe. 4, Meet Nat thus, 1, = Mined Bot ,Cos B 0.0065 sy om? \ s y 1 L,, = (2000 —— cons Seem) [SEE 6 I om.s he 992 a 0217 em | es Bh 4. Calculating the Horizontal Surface Area ay, 4y 4, = 1000_m® s {0 om _|__hr i] fe (0.0217 om | om = | 3600s Ay = 1280 mi? Caution: Due to the variation of plate pack design, consult vendor before finalizing specification for surface area,PTS 20.265 Feb 2009 Page 29 APPENDIX 2 : DESIGN CALCULATION TABLE ecg 1 Flowrate, Oy Design temperature, 7), Oil droplet siz diameter, 5 Density of wastewater, 2, Density of ol, 2, Dynamic viscosity of wastewater, 1, Kinematic viscosity of wastewater, vi Flow Reynolds Number, Nic Rising rate of oil droplet, Vo Separator surface area, 4, Horizontal separator area, dy Surface Loading Rate, SLR Plate spacing, S, Plate inclination, Length of parallel plate, Zp Chamber retention time, ¢, Sludge holding capacity, Pause m/min mm degree m min ne design capacity 40 0.006 0.992, 0.92 0.853 x 107 0.858 x 107 2,000 calculated calculated calculated calculated 38 48 calculated 30 estimated Conor peak flow (maximum flow) capacity at operating temperature expected operating temperature minimum diameter of oll droplets for separation by CPI at T,, of 40°C at, of 40°C at 7, of 40°C. at Ty, of 40°C ‘assuming laminar flow based on Stoke's Law based on Oy, based on 4, and piate inclination where Yp > SLR for separation Various spacing between 20-38mm various incline 48.60 degree typically to achieve laminar flow based on instantaneous peak flow (maximum flow) based on settled particles where maximum level not to restrict wastewater velocity|. Clean ber sorean Inet weir Flow dstrbuton baffle Skim oil if manual) (Clean outlet weir ‘Adjust outet weir Clean skimmer (f automatic) 8. Solids pre-settement compartment 9. Solids settement ‘compartment 0. Plate pack foe ‘weokiy or when required when CP! bay is to be emptied periodically petiodically based on oll ‘accumulation weekly when there is change in flow weekly periodically periodically periodically PTS 20.265 Feb 2009 Page 30, APPENDIX 3 : OPERATIONS AND MAINTENANCE CHECKLIST remove trashidebris Pace a grooved wooden board over the weir plates. To empty a bay, the flow distribution can be roplaced wih sto! sheet, dveting flow gong nto the bay to be leaned, ‘Skim cil and maintain ol ayer thickness of 2-4em Remove debris Change the wer plate height check, ean and maintain al equipment ie. pumps, bel etc. based ‘on equipment manual, settings to maintain ol thickness layer of 2- 4am, Remove accumulated sand and other partes. Use sludge sampling device to determine level. If destudging is ‘equred, stp the fow through the CPI to prevent ol carryover in the effluent. Clean plate packs with high pressure water jt Cad ‘Typical design allows 50% of screen tobe blocked before cleaning. To prevent flow over the weir when the CPI bay o be emptied To avoid any logging that may restrict the ow nto the pack ‘Over and under skimming will cause CPI inefficiency To prevent clogging of weir. Weir height to contl effluent fow and prevent shar-cruitng of fow. (Over and under skimming will cause CPt ineficiency When maximum level of sand is reached and exceeded, retention time wil be reduced and eficiency ofthe CP will also be reduced Remove the studge before the evel reaches the plate assembly to prevention reduoed retention ime and plate logging, ‘ter a period of operation the plate amy be clogged.PTS 20.265 Feb 2009, Page 31 APPENDIX 4 : CPI MONITORING PROGRAMME CCC a nT Cenc) Ree) Critical Level [Equipment Pate Condition dally Observation rot plugged packing plugged Istudge level m weekly on-site measurement as per design high sludge level reaching plates Retention Time min rmonthiy* calculated > 40 min but <2 hr <4 mins Joievel at top layerskimmer daily Observation thin or no cil accumulation high cil accumulation inlet JOitand Grease mg. ally Lab analysis as per design ‘exceed 10ppm or design value lFiow mine continuous. oncine as per design ‘exceed design fow lrss mg. daily Lab analysis as per design exceed design velue [Temperature °c daily on-sitelon-ine <40°C >60°C Specific Gravity of of ler? monthly? Lab analysis as per design ‘exceed design value i droplet size micron rmonthiy? Lab analysis > 60 microns < 80 microns il viscosity ayne.siom* rmonthiy* Lab analysis ‘8 per design ‘exceed design velue sual jar observation daily ‘onsite, imhoff Cone some settioable solids and thin layer of ol__thick layer of oil and solids (dark colour) utlot il and Grease gil daily Lab analysis 2 per desion| dail lFiow= mor continuous ‘onstine 28 per design excaed design flow [visual jar observation daily on-site no visible ol layer and settable sols thick ayer offre ol and setleable solids [Specific Gravity of ot giom? wookly Leb analysis loi croptet size ‘micron monthiy* Lab analysis < 60 microns > 60 microns [Temperature °o. daily on-site/ontne <40°C. >0°C [Sludge (removed from sludge hopper) ITs when removed Lab analysis ISpectc Gravity of when removed Lab analysis, “ orwhen there are changes of oi characierisiscs optional