CKB 20004/CPB 20403
Plant Utilities & Maintenance
Introduction
to Plant Utilities & Maintenance
Objectives
List the utility Systems in chemical plant
Describes the important plant utilities for
each elements.
Describes the scope of plant maintenance
Explain the types of Maintenance Team
Personnel
Plant Utilities
Any chemical plant is
started with plant
utility. It is heart of the
plant serving all kinds
of life blood to the
complex system.
Without them, most
of the equipment
cannot operate.
Scope of Plant Utility
Water
Steam
Condensate Recovery
Fuel Gas
Plant & Instrument Air
Nitrogen
Flare
Feed Stock/Transfer Storage
Product /Transfer Storage
Electrical Supply and Distribution System
Water System
Fire Water
Potable Water
Cooling Water
Utility Water beside
treatment and
disposal of
sewer/waste water.
Water System
Fire water - supply
water to the plant
area distribution
system in the event
of a fire or
hydrocarbon
release.
Hydraulic testing of a hydrant using a Pollard
diffuser equipped with a wireless transmitter
Water System
Potable water -
provides clean
treated water for
safety shower,
eye wash
stations, sanitary
facilities and
personnel
consumption
throughout the
Jeddah Desalinization Plant plant facilities
Water System
Process Overview Potable Water
Supply
Raw water
• Sea water and brackish water
• Surface water from lakes and rivers
• Ground water and spring water
Potable water treatment:
Flocculation , Precipitation .Filtration and adsorption , Removal
of iron, manganese and arsenic , Softening and stabilisation ,
Microfiltration and ultrafiltration, Desalination , Hardening ,
Deacidising and pH adjustment , Oxidation , Disinfection using a
wide range of processes
Potable water distribution
Water System
Cooling water - cool
down the temperature
by using cooling
tower.
Utility water - supplied
to the plant
distribution system
from utility and fire
water tanks.
Water System
Cooling water
Steam System
Generating & supplying
steam at three
pressure/temperature
levels; HP, MP, LP
Condensate is collected
from the steam users by
the HP &LP condensate
return systems.
Condensate Recovery System
HP – collect condensate from HP & MP
system
LP –collect condensate from LP system
Condensate flash drum receive total
condensate system.
Condensate is in form of water - contain no
solid, is hot & not additional treatment.
Return condensate - potential source of
corrosion boiler feed water cycle
Fuel Gas System
Receiving &
supplying of fuel
gas to different
units at two
pressure levels;
HP & LP.
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.
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.
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
Collect hydrocarbon
gases and liquids
released from all areas of
the site.
HP & LP flare systems.
Cold blow down vent
system disposes of
cryogenic vapor/liquid
hydrocarbons.
Used common shielded
Flare
ground flare area.
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.
View of the components of the present invention and interrelationship therein
for generating electricity and potable water.
Shown is a standalone system wherein sunlight is the catalyst energy form used to
create electricity which can be used to energize a structure, home and/or building with
the surplus electricity being fed into the municipal power grid.
view of the solar panels, DC converter and
bank of batteries of the present invention.
view of the electrolytic device
of the present invention.
view of the compressor of the present
invention
Expectation
Define
Describe
Apply
Examine
Evaluate
Precision skill on determine (practical)
Participate in the technical discussion
Problems
Utility operational estimation ? How
do we estimate?
Person responsible?
Mechanism of monitoring?
Physical / Installation cost? How many
percent from capital cost?
What skills are required to become
excellent in facilities expert in
processing plant?
Plant maintenance
concerned with actions taken by the plant
user to maintain an existing system and
facilities or to restore it to an operating
condition.
refers to the methods, strategies, and practices used to
keep an industrial factory running efficiently.
include anything from regular checks of equipment to
optimization of the equipment/functioning properly
to create a productive working environment that is
also safe for workers, including cleaning garbage
bins and toilets.
Plant maintenance
Can divided into two categories:
o Production/operational
Quality, quantity, safety, environment,
cost
o Equipment/system
Reliability, accountability
Scope of Responsibilities
Primary Functions
Maintenance of existing plant equipment
Maintenance of existing plant buildings
and grounds
Equipment inspection and lubrication
Utilities generation and distribution
Alterations and new installations
Scope of Responsibilities
Secondary Functions
Storekeeping, accounting etc
Plant protection (including fire fighting)
Waste disposal
Salvage
Insurance Administration
Senatorial Services/Other services
Benefits
Reduction in unscheduled downtime
More efficient and reliable
Longer equipment life & lower cost of
parts
Lower equipment maintenance cost
Utilization of maintenance staff
Optimized the process
Types of Maintenance Personnel
Planner:
plan all the maintenance work, scale them
with all of the priority (must be experience
with execution methods)
Executor:
run all the work instruction given to them
with a specific task and time frame
Engineer:
deal with engineering modification to
enhance the process or increase the
equipment/system reliability.
The Organization Chart
Factors need to be considered:
Type of operation
Continuity of operations
Geographical situation
Size of plant
Scope of the plant maintenance
department
Work-force level of training and reliability
The Organization Chart
Plant Manager
Quality Stock Control &
Operation Safety Administration
Control Purchasing
Maintenance
Regular System
Maintenance Improvement
Instrumentation
Mechanical Electrical
& Control
The Organization Chart
Plant Manager
Maintenance
Manager
Maintenance Routine Planned Emergency
Engineer Maintenance Maintenance Maintenance
Supervisor Supervisor Supervisor
Maintenance
Control
Supervisor
Ends of Chapter 1
