INSTALLATION, COMMISSIONING

and START-UP PROCEDURE

MTDF-BBS-MS-0275-3320-A5010-1001

CPI SEPARATOR

Matindok Gas Development Project

Banggai, Central Sulawesi
Indonesia

FOR

CONSORTIUM WIKA-TECHNIP
PT BANYU BIRU SEJATI
Bumi Satria Kencana, Blok C No. 9
Tel. 021-8841762 Fax. 021-8856176
e-mail : ptbanyubiru@gmail.com
Jln. KH Noer Ali, Bekasi 17144

2015

TABLE OF CONTENT

1) Introduction

............................. 3

2) Scope

............................. 3

3) General Information

............................. 4

4) Installation Procedure

............................. 7

5) CPI Separator in Picture

............................. 8

6) Technical Specification

............................. 12

1. INTRODUCTION

This Installation, Commissioning and Start-up Procedure details works required for :

CPI (Corrugated Plate Interceptor) Separator installation in the job site

Commissioning the installed CPI Separator

Start-up the CPI Separator after successfully commissioning

These works must be successfully executed before the CPI Separator is put into normal
operation.

2. SCOPE
This protocol is applied to the Corrugated Plate Interceptor CPI Separator for Matindok
Gas Development Project in Banggai, Central Sulawesi Indonesia. The unit is used to
separate oil from water in oily feed water.
Air
Vent
Sight
Glass

Water
Outlet
Mancag
e

Oil
Outlet

Ladde
r

CPI Pack
Module
Supporting
Legs
Solids
Outlet

Supporting
Legs
Figure 1. Parts of CPI Separator

Solids
Outlet
Skid/Ba
se

3. GENERAL INFORMATION

3.1

Safety
Before performing CPI Separator installation in the job site, every personnel must
wear personal protective equipment (PPE) properly. Clean the area where CPI
Separator to be installed from solid materials that may cause accidents, such as
used concrete materials, metal sheet, nails, and other sharp objects. Make sure the
CPI Separator foundation is free from stagnant water, oil and lubricant that may
cause injury or accident during work in progress.

3.2

Corrugated Plate Interceptor (CPI)

Corrugated plate interceptor or CPI is a special designed waste water treatment
equipment where oil and water separation will take place. It is made from fiberglass
reinforced polymer (FRP). The CPI is made from some corrugated plates which are
arranged into one pack with a specific distance between them and then installed in a
stainless steel frame. There are 25 sheets of corrugated plates for every single CPI
pack. The supplied CPI Separator has 4 packs or modules.

Figure 2. Typical CPI Pack/Module

Figure 3. CPI Pack/Module in a stainless steel frame

3.4

Configuration
The CPI Separator consists of 5 nozzles namely :
1. Inlet - where feed water or raw waste water entering the CPI Separator
2. Primary Solids Outlet - for removing sludge periodically
3. Secondary Solids Outlet - for removing sludge periodically
4. Water Outlet - where treated effluent flows through the outlet piping and
collected temporary in a collection pond prior to final discharge
5. Oil Outlet where floating oil accumulation overflows through oil piping and
collected temporary in a collecting pit prior to final discharge by trucking
6. Air Vent.
(Please see Figure 1)

CPI Pack

Figure 4. CPI Separator Configuration

All of CPI pack are placed with a slop of 45 degree from the ground. There are 4 pack of
CPI which can be removed from the chamber one by one for cleaning with high pressure
water during maintenance period only.
3.5 Brief Process Description
The separation process of oil from feed water or raw waste water in CPI Separator is as
follow (Please see Figure 4).
(1) Feed Water containing free oil is introduced into the CPI Separator via gravity or
pump at a specific total head.
(2) The CPI Separator distributes the incoming feed water flow and creates the
necessary laminar flow for proper oil and water separation.
(3) The corrugated plates will provide the necessary surface area to successfully
separate oil from water and solids into their various distinct phases.
(4) The lighter liquid or oil flows upwards and discharges via oil skimmer.
(5) The heavier liquid or water flows downward and discharges via water discharge
outlet as treated effluent.

4. INSTALLATION PROCEDURE
Installation in terms of CPI Separator here is the establishment of the above foundation
followed by the installation of CPI Separator and the accessories required, such as skid,
ladder, mancage, platforms and handrail.
When the CPI Separator and the accessories are available in the site warehouse and the
foundation is ready for use, the installation can be started. The terms of installation for this
procedure is the erection of CPI Separator on the foundation followed by the site
assembly of the accessories, such as ladder, mancage, platform and handrail. The skid as
the CPI Separator support on the foundation can be installed firstly on the foundation and
followed by CPI Separator installed on it.
Anchor bolt positions for the skid should be located correctly prior to skid installation.
There are four anchor bolts required. The skid then is installed once all the anchor bolts
are ready in their positions.
4.1 Reference Drawings
The installation of CPI Separator should refer to the following drawings :

a) MTDF-BBS-MR-0275-3320-A2001-1001 : General Arrangement Drawings

b) MTDF-BBS-MR-0275-3320-A2008-1001 : Stairs, Ladders and Platform Drawings
c) MTDF-BBS-MR-0275-3320-A1115-1001 : Shop Drawings/Skid Drawings
d) MTDF-BBS-MR-0275-3320-A1109-1001 : Nozzle Detailed Drawings
e) MTDF-BBS-MR-0275-3320-A0101-1001 : Process Description
CPI Separator is delivered to the job site without ladder and platform installed on it. The
ladder and platform must be mounted to the CPI Separator with bolts and nuts in the job
site. The bolts and nuts for this application is already provided and shipped to the job site.
Therefore wed do need welder since no welding required during CPI Separator installatio.
4.2

Tools
Installation of the CPI Separator and accessories in the job site will need, but not
limited, the following tools :
a) Scaffolding
b) ladder
c)

Chain hoist

d) Tripod for chain hoist (if necessary)

e) Rope or steel sling
f)

Wrenches which the size matching with the size of bolts and nuts required

g) Gasket
h) Crane or Backhoe to lift CPI Separator, ladder and platform during installation

5. CPI SEPARATOR IN PICTURES

5.1 CPI SEPARATOR

Viewed from below

Viewed from above

Viewed from the side

10
5.2 SKID

5.3 LADDER

Ladder-1
Mancage

Safety Rail

Ladder

11

Ladder-2
Base Plate
5.4 PLATFORM AND HANDRAIL

Platform Support

Platform

Handrail

12

6. TECHINCAL SPECIFICATION
CPI SEPARATOR
Quantity

: 1 (one) unit

Rated Capacity

: 30 gpm

CPI Material

Tank Material

***