Plant, Utilities & Maintenance: .: Karte 01

CPB 20004
Plant, Utilities &

Maintenance
.: Karte 01 :.
Introduction to Plant Utility
& Maintenance
Chemical Processing Plant :-
Palm Oil Mill :-
Food Processing Factory:
Plant Management :-
Plant / Physical structure
Manpower System
Plant Maintenance
Plant Utilities
Introduction to
Plant Utilities
What is the Plant Utility?
Chemical Processing Plant also requires various other services
called Utilities for smoothly carrying out the processes. Utility
is neither a reactant nor a product, But Utilities are required
for maintaining adequate conditions of a manufacturing unit.
The term utilities can also refer to the set of services provided
by these organizations consumed by the public/plant:
electricity, natural gas, water, sewage, telephone, and
transportation
Scope of 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
Utility # 1. 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.
Utility # 2. 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.
Utility # 3. 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
Utility # 4. Fuel Gas System
 Receiving &
supplying of
fuel gas to
different units at
two pressure
levels; HP & LP.
Utility # 5. 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.
Utility # 6. 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.
Utility # 7. 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.
Utility # 8. 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 ground flare area.
Utility # 8. 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
Utility # 9. 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.
Utility # 10. Product Storage & Transfer
• Consists of receiving, storing

& supplying of different
product.
• Stored before it transfer to
jetty to export.
Introduction to
Plant
Maintenance
What
is
Maintenance?
Maintenance
 (Oxford) The process of preserving a condition or situation or the state of being preserved
 (Merriam Webster) the upkeep of property or equipment
 (Kamus Dewan) ‘membuat kerja-kerja serta mengurus supaya berjalan

lancar (bkn sesuatu usaha dsb)’
Plant Maintenance
Plant maintenance ~ refers to the methods, strategies, and practices used to keep
an industrial factory running efficiently.
~ include anything from regular checks of equipment to make sure they are
functioning properly, to cleaning garbage bins and toilets.
The general aim of plant maintenance is to create a productive working

environment that is also safe for workers.
PLANT MAINTENANCE
• 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
POOR GOOD
Maintain to keep in good

working order
Maintenance the act

of maintaining
What is Repair
Repair
 (Oxford) The process of restoring (something damaged, faulty, or worn) to
a good condition
Repair
to mend, to make up for something wrong

Maintenance vs Repair
Maintenance is the routinely scheduled services, inspections and part
replacements that manufacturer recommends based on the age or
mileage of your equipment.
Repairs are services that are required or necessary when something on

equipment is not working properly or may have worn to the point where
a replacement is required to maintain the performance of the equipment.
Maintenance vs Repair
Maintenance & Asset Management
Maintenance & Asset Management
√ √ √
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CPB 20004

Plant, Utilities &

Plant / Physical structure

 Utility Water beside

 Consists of receiving, storing &

 Collect hydrocarbon gases and liquids

• Consists of receiving, storing

 (Merriam Webster) the upkeep of property or equipment

 (Kamus Dewan) ‘membuat kerja-kerja serta mengurus supaya berjalan

The general aim of plant maintenance is to create a productive working

Maintain to keep in good

Maintenance the act

to mend, to make up for something wrong

Repairs are services that are required or necessary when something on

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