TRAINING MODULE

Process Overview,
Utility

PT. TPC INDO PLASTI

C AND
ASTIC
C H E MI CA L S

TPC Indo Plastic and Chemicals - Training Module

FACILITY DUTIES
SECURE ALL OUTSIDE SERVICES
TO INSIDE COMPANY.
@ PDAM WATER
@ INDUSTRIAL ESTATE FACILITY
@ GOVERNMENT INSPECTION
@ ENVIRONMENT CONCERN
@ JETTY/ UNLOADING FACILITIES
2

Internal used TPC Indo only dont distribute

UTILITY RESPONSIBLE
SUPORT PRODUCTION
IN ORDER TO MEET THE
TARGET.

TPC Indo Plastic and Chemicals - Training Module

UTILITY DUTIES

PRODUCE TREATED WATER ~ CAP. 120 M3/HR

PRODUCE DEMIN WATER ~ CAP. 80 M3/HR
PRODUCE STEAM ~ CAP. 18.9 T/HR
PRODUCE COOLING WATER ~ CAP. 2,700 M3/HR
PRODUCE AI & AS ~ CAP. 1,750 NM3/HR
PRODUCE WWR ~ CAP. 40 M3/HR
PRODUCE RO WATER ~ CAP. 30 M3/HR

Internal used TPC Indo only dont distribute

OTHER UT SUPPORT

CATALYST STORAGE
BRINE CHILLING UNIT
EMERGENCY DIESEL ENGINE GENERATOR
POTABLE EDEG
FIRE FIGHTING SYSTEM UNIT
DEEP WEEL UNIT
VCM TANK & UNLOADING FACILITIES

Internal used TPC Indo only dont distribute

Utility
Plant

Internal used TPC Indo only dont distribute

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

FACILITY & UTILITY ORGANIZATION

Manager
Engineer
Daily Staft

Shift GroupA
Operator A
3 Person

Shift Group B

Shift Group.C

Shift Group.D

Operator B
3 Person

Operator C
3 Person

Operator D
3 Person

Internal used TPC Indo only dont distribute

UTILITY PROCES
S
ROCESS
UT.Product
Per Day
WWT
912
( m3 )

RO
720
( m3 )

Demin
1920
( m3 )

Steam
453.6
( m3 )

IW
2880
( m3 )

AS/AI.
42,000
( nm3 )

BCU
2352
( m3 )

CW.
64,800
( m3 )

UT.Receive
Per Day
COAL
1000000
(kg/month )

Fuel. Oil
200
( M3 )

Coal Supplyer

PDAM water
600
( m3 )

PDAM

Nitrogen
3,293
( Nm3 )

UAP

Pertamina
8

Internal used TPC Indo only dont distribute

VCM day
tank

Internal used TPC Indo only dont distribute

WATER
TER FLOW
FLOW CHAR
HART
Raw
water

Sand
Filter

IW

Cation

HCL
USER

Storage
tank

Mix
bed

HCL
NaOH

Anion

NaOH
10

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

WI Unit
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
129.3 m3/hr

Backwash

DW plant

IW FEED

F-9701A

F-9701B

F-9701C

F-9701D

TK-9705

11

TREATED
WATER

12

TPC Indo Plastic and Chemicals - Training Module

Demin System
80 m3/hr
IW FEED

CATION

CO2
Stripper

ANION

MIX BED

Conductivity
Online

DEMIN
STORAGE
TANK

Conductivity
Online
13

TPC Indo Plastic and Chemicals - Training Module

DEMIN UNIT : OPER

ATION DATA
OPERA
ATA

DEMIN
1. Operation flow rate ~80 m3/hr
2.

cycle time ~ 4,400-4,800 m3

3.

Mix bed cycle time ~ 13200-14400 m3

4.

Each column content : strong & Weak resin

5.

Washing column utilize every 6 month for washing

resin and alkaly cleaning resin.

6.

Conductivity Outlet Anion < 0.5 us/cm

7.

Conductivity Outlet Anion < 0.5 us/cm

Internal used TPC Indo only dont distribute

141
4

DEMI
N

TPC Indo Plastic and Chemicals - Training Module

COOL
COOLING FLOW
FLOW CHAR
HART
Type = Induced draft tower

IW

CW
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 Zinc-lite program treatment
The sludge doze non oxidizing 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
Internal used TPC Indo only dont distribute

161
6

COOLIN
G

TPC Indo Plastic and Chemicals - Training Module

BOI
ATION DATA
BOILER : OPER
OPERA
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.
Internal used TPC Indo only dont distribute

181
8

BOILER : OPER
PERATION DATA
DATA

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 )

BOILER
BOILE
R

20

TPC Indo Plastic and Chemicals - Training Module

AIR COM
OR FLOW
COMPRESS
RESSO
FLOW CHAR
HART
Air
Inlet

Comp.
Screw T.

PA.

Air
Dryer

User
Control
EQ.

IA

USER

21

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

AIR
OR
AIR COMPRESS
RESSO
UNIT
NIT

600 nm3/hr norm.

USER

AS TANK

Inlet
Air

USER

Cap. 1750
nm3/hr
max.

200
nm3/hr
AI
R
DRY
ER
Colu
mn
A

Internal used TPC Indo only dont distribute

AIR
DRYER
Column
B

IA TANK

TPC Indo Plastic and Chemicals - Training Module

Controller

Internal used TPC Indo only dont distribute

22

AS/A
I

Internal used TPC Indo only dont distribute

232
3

TPC Indo Plastic and Chemicals - Training Module

WWT FLOW CHAR

CHART

Waste
PVC

Carbon
Active

Eq tank

Cooling

Aeration

TWW tank

Sediment

Clarifier

TWW tank

TK-9707
Sewer

WASTE WATER TREATMENT

WASTE WATER TREATMENT
CAPACITY = 960 M3/DAY (
MAX )
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.

WASTE
WATER

Waste water treatment system

WWT
Internal used TPC Indo only dont distribute

PLANT

29

Internal used TPC Indo only dont distribute

TPC Indo Plastic and Chemicals - Training Module

Catalyst
Storage
Function : maintain temp. min 20 deg C
Size : 10 m x 9.3 m
The energy requirement : 10,000 Kcal/hr
Using R22
Volumetric house = 558 m3
Total surface area = 186 m2
The system is consist :
- semi hermetic compressor
- Air cooled condenser
- Fan blower
- Oil separator
- Air Cooler

TPC Indo Plastic and Chemicals - Training Module

All the operation control utilizing PLC allan breadly

30

INITIATOR STORAGE

Internal used TPC Indo only dont distribute

313
1

BRINE CHILLING UNIT

VCM Recover
Control Temp. 0 deg C. at constant rate 89 m3/hr.
Catalyst
Control temp. -20 Deg C at constant rate 8.4 m3/hr
Energy Requirement : 30,530 Kcal/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

TPC Indo Plastic and Chemicals - Training Module

BRINE
CHILLING

Tank
Farm
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.

TPC Indo Plastic and Chemicals - Training Module

TANK
FARM

PT. TPC Indo RO Unit Simplified System

PLC Controller

DW 2

DW 1
Membrane
ls

Feed
eed Water

PI

39 m3/hr
ORP
San
Sand Filt
ilter

Carbo
n Filt
arbon
ilter

pH

Pre-Fil
-Filtter
5 micron

Conduct.
FI

Produ
ct Water
Produc

30 m3/hr
Hig
High Pressu
Pressure
Pu m p

Reject
ect Water

9 m3/hr
Ph CONTROL

Ant sca
scale

Normal Operation
Flushing Loop
Loop
Contr
ontrol Loop
Loop

Declorinator

Internal used TPC Indo only dont distribute

36

RO Processing

Reverse Osmosis ( R.O.) is the process that water molecule

are forced through a semi-permeable membrane by hydraulic
pressure from high
Internal used TPC Indo only dont distribute

373
7

concentration to low concentration

Internal used TPC Indo only dont distribute

383
8

TPC Indo Plastic and Chemicals - Training Module

Principle &
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

TPC Indo Plastic and Chemicals - Training Module

UTILITY UT SIDE FLOW

FLOW CHAR
HART
O
PDAM
Admin,UT,PVC,ME
Fuel Oil

Boiler

Coal

Boiler CFB

Nitrogen

Process user

PLN

PVC/UT

40

Internal used TPC Indo only dont distribute