CPD 20002

Plant, Utilities &

Safety

Scope of Plant Utility

System
Objectives

List the utility components in

chemical plant
Describes the important for
each elements.
 Intro

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.
What is the Plant Utility?

Water
Steam
Condensate Recovery
Fuel Gas
Plant & Instrument Air
Nitrogen
Flare
Feed Stock Storage/Transfer
Product Storage/Transfer
Electrical Supply and Distribution
System
Water System

Fire Water
Portable Water

Cooling Water

Utility Water beside

treatment and
disposal of
sewer/waste water.
Boiler Feedwater
 Fire water - supply water to the
plant area distribution system in the
event of a fire or hydrocarbon
release.
Portable water - provides clean
treated water for safety shower, eye
wash stations, sanitary facilities and
personnel consumption throughout
the plant facilities
 Cooling water -
cool down the
temperature by
using cooling
tower.

Utility water - supplied to the plant

distribution system from utility and
fire water tanks.
Boiler feedwater - consists of
demineralised water and
condensate recovery sections.
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 feedwater 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 blowdown vent
system disposes of
cryogenic vapor/liquid
hydrocarbons.
Used common shielded
Flare ground flare area.
Flare System

There are generally two types of

flares that are commonly used in
the manufacturing facilities:
Elevated flares, where the flare tip is
between 20 to 150 meters above
ground.
Ground flares, where the flare tip is
about two to three meters above
ground, which is fenced off with a high
heat shield fencing, which also acts as a
safety zone
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.
Problems;
Utility operational estimation ?
How de 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?
Ends of Chapter 1