Microsoft Power Point - TPC Utility Presentation

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Process Overview,

Utility

PT. TPC INDO PLASTIC AND CHEMICALSPT. TPC INDO PLASTIC AND CHEMICALS

TRAINING MODULE

UTILITY RESPONSIBLE

SUPORT PRODUCTION

IN ORDER TO MEET THE

TARGET.

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TPC Indo Plastic and Chemicals - Training Module

Internal used TPC Indo only – don’t distribute

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

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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

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Utility Plant

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FACILITY & UTILITY ORGANIZATION

Operator A

3 Person

Shift GroupA

Operator B

3 Person

Shift Group B

Operator C

3 Person

Shift Group.C

Operator D

3 Person

Shift Group.D

Engineer

Manager



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UTILITY PROCESSUTILITY PROCESS

WWT912

( m3 )

RO1,440

( m3 )

Demin1920

( m3 )

Steam384( m3 )

IW2880( m3 )

AS/AI.42,000( nm3 )

BCU2,954

( kW )

CW.64,800( m3 )

UT.ProductPer Day

Coal Supplyer

COAL1000000

(kg/month )

Fuel. Oil 200

( M3 )

PDAM

PDAM water

600

( m3 )

UAP

Nitrogen

3,293

( Nm3 )

UT.Receive

Per Day

Pertamina



FIRE FIGHTING SYSTEM UNIT

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• 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

VCM Tank Farm

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• 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.

COAL FIRED BOILERCOAL 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 )

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BOILER : OPERATION DATABOILER : 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.



AIR COMPRESSOR

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• AIR COMP (2 UNITS) ~ CAP. 1,750 NM3/H

WITH PRESS. 7 KG/CM2

• IF EMERGENCY, SUUPLY WITH N2 (TANK ~ CAP. 3.5 TON)

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AIR COMPRESSOR FLOW CHARTAIR COMPRESSOR FLOW CHART

Air

Inlet

Comp.

Screw T.PA.

Air

Dryer

IA

User

Control

EQ.

USER



AIR COMPRESSOR UNITAIR COMPRESSOR UNIT

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Inlet Air

USER

USER

Controller

IA TANKAIR

DRYER

Column B

AIR

DRYER

Column A

AS TANK

Cap. 1750 nm3/hr

max.

600 nm3/hr norm.

200 nm3/hr



EDEG

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• TPC INDO’S EDEG ~ CAP. 2,250 KW (2,812.5 KVA)

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



Exp valveExp valve

EvaporatorEvaporator

CondenserCondenser

CompressorCompressor

Evaporator

EKC

FREONFREON

BRINEBRINE BRINEBRINE

TEVTEV Liquid injectionLiquid injectionSight glassSight glass

Check valveCheck valve Sub coolerSub cooler

Cooling at compressorCooling at compressor

Evaporator controlEvaporator control

CompressorCompressor

Oil

injectionPT.TPC INDO PLASTIC AND CHEMICALS UTILITY SECTION

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

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COOLING FLOW CHARTCOOLING FLOW CHART

IWCW

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

Type = Induced draft tower



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WI Unit

F-9701A F-9701B F-9701C F-9701D

IW FEED

Backwash

TK-9705

DW plant129.3 m3/hr

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



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DEMIN UNIT : OPERATION DATADEMIN UNIT : OPERATION DATA

� DEMIN

1. Operation flow rate ~80 m3/hr

2. cycle time ~ 3,800-4,200 m3

3. Mix bed cycle time ~ 10,000-20,000 m3

4. Each column content : strong & Weak resin

5. Washing column utilize every 6 month for washing

resin and alkali cleaning resin.

6. Conductivity Outlet Anion < 5 us/cm

7. Conductivity Outlet MB < 0.5 us/cm



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CATION ANIONMIX BED

DEMIN

STORAGE

TANK

IW FEED

80 m3/hr

Demin System

CO2

Stripper

Conductivity

Online

Conductivity

Online



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WATER FLOW CHARTWATER FLOW CHART

Raw

water

Sand

FilterIW Cation

USER AnionMix

bed

Storage

tank

HCL

NaOHNaOHHCL



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RO ProcessingRO 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



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��PT. TPC Indo RO Unit Simplified SystemPT. TPC Indo RO Unit Simplified System

Product WaterProduct Water

Reject WaterReject Water

Ph CONTROLPh CONTROL

Ant scaleAnt scale

Normal OperationNormal Operation

Flushing LoopFlushing Loop

FI

Conduct.

ORP pH

lsPI

Feed WaterFeed Water

PLC Controller

Control LoopControl Loop

MembraneMembrane

PrePre--Filter Filter

5 micron5 micronHigh Pressure High Pressure

PumpPumpSand FilterSand Filter Carbon FilterCarbon Filter

39 m3/hr

30 m3/hr

9 m3/hr

Declorinator

DW 1

DW 2



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Principle & MechanismPrinciple & 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



Principle & MechanismPrinciple & Mechanism

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WASTE WATER TREATMENT

• WASTE WATER TREATMENT

CAPACITY = 960 M3/DAY ( MAX )

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• WASTE WATER TREATMENT PROCESS

a. Biological process

b. Chemical process

c. Physical process



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.

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Waste water treatment system

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WWT FLOW CHARTWWT FLOW CHART

Waste

PVCEq tank Cooling Aeration

ClarifierSedimentTWW tank

TK-9707

Sewer

Carbon

ActiveTWW tank



WWT PLANT

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Microsoft Power Point - TPC Utility Presentation