Objectives: Understand importance of utility and maintenance
system in industry/plant
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Plant Utilities All chemical plant is started with plant
utility Without utility system, most of the equipment cannot
operate.
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Scope of Plant Utility Water Steam Condensate Recovery Fuel Gas
Plant & Instrument Air Nitrogen Flare Feed Stock
Storage/Transfer Product Storage/Transfer Electrical Supply
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Water System Fire Water Fire Water Potable Water Potable Water
Cooling Water Cooling Water Utility Water Utility Water
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Steam System Generating & supplying steam at three
pressure/temperature levels; HP, MP, LP Generating & supplying
steam at three pressure/temperature levels; HP, MP, LP Provide
industry with powerful source of energy Provide industry with
powerful source of energy
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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.
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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.
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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
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Plant & Instrument Air System Supplied by air compressors.
Supplied by air compressors. Compressor driven is by using steam
turbine or motor driven. 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. Air is filtered, compressed & dried before supply to
plant air distribution throughout the plant complex.
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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
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pipe PIG-pipeline inspection gauges
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Feed Stock Storage & Transfer Consists of receiving,
storing & supplying of different feeds (eg. butanes, methanol)
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.
As an intermediate product or imported from off-sites by ship or
pipeline, are all stored in the utility area.
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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.
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Product Storage & Transfer Consists of receiving, storing
& supplying of different product. Stored before it transfer to
jetty to export.
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Electrical Supply & Distribution Electrical system is the
main component to run the equipment. Electrical system is the main
component to run the equipment. Most plant in Malaysia get
electricity from TNB Most plant in Malaysia get electricity from
TNB Some plant will generate their electricity by their own
generator. Some plant will generate their electricity by their own
generator.
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Plant Manager Operation/ Production QA & QC Administration
Purchasing & Logistic Safety Maintenance Regular Maintenance
System Improvement MechanicalElectrical Instrumentation &
Control EXAMPLE OF ORGANIZATION CHART
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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
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BREAKDOWN???? SHUTDOWN????
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example downtime\12-18 March 2012 (2).xls example
downtime\12-18 March 2012 (2).xls example downtime\5-11 March 2012
(1).xls example downtime\5-11 March 2012 (1).xls example
downtime\downtime ACM (2).xls example downtime\downtime ACM (2).xls
example downtime\Time latest (1).xls example downtime\Time latest
(1).xls
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Method Strategies Practices 1.Regular check 2. Make sure system
well function 3. Safe
