Young sludge Old sludge

Formed when : Formed when :

+ Start up + reduce WAS
+ high BOD or F/M + low BOD or F/M
+ low CRT + high CRT
+ free swimming dominant + Rotifer is dominant

Sludge property Sludge property

Light floc, poor flocculation, Dense and compact floc
and low settle ability, high Which has high flocculation
turbidity and high settle ability

Cause Foaming Cause Denitrification if low

DO, Could be broken out into
pin floc and float on water
surface
Free chlorine is a strong oxidant agent, it come in contact and oxidize resin
under curtain condition by de-crosslink of copolymer matrix which result in
weakening of resin molecule structure and cause them deform and
compact over time

High temperature will alter resin molecule structure by thermal degradation

that result in reduce productivity, capacity and lifetime of resin

Oil, grease will coat the resin surface and make difficult in ion exchange and
cause resin fouling that result in reducing of productivity, capacity and
lifetime of resin
 Domestic water, Back wash,
dewatering Oil content + add some nutrient
+storage
IGF +adjust PH
COD, Oil
Dilution Steam tank + adjust toxicity
Blowdown + Stabilize water
PH Remove oil +Prevent sock load
Spent Neutralization CPI Equalizing
Caustic tank tank tank
COD, PH, Neutralize the Remove oil COD, PH, Oil
Na2S, Oil spent caustic Oil content content,
until pH= 7.5 Toxicity

Check Aeration
Filter Clarifier
Basin Tank
Check condition Remove Settling down sludge Convert organic
like COD, particle, suspended and clean water over compound into
suspended solid, solid, particle flow CO2+H20+sludge by
PH.. Before Particle, Turbidity, settling micro-organism
releasing suspended down velocity, F:M, Sludge
solid, PH, COD sludge blanket depth Age, D.O, PH,
Oil, MLSS
 Off spec if TOC is
more than 10ppm
Oil, Particle,
SS TOC < 10ppm T = 60oC
Suspected
Flash A/C Remove
steam
Drum filter Oil Grease
condensate
Remove Recovery Remove Oil content,
Turbine Vapor heat Heat DP = 2bar
steam
condensate Particle,
SS Remove
Particle,
Clean Mix Bed Cartridge
Deaerator suspended
condensate polisher filter
solid
Remove Remove Ion Particle content,
Oxygen DP = 1 bar,
Cond <0.2 uS/cm
T = 50oC
Oxygen < 0.007 ppm Silica < 0.02ppm
PH =6-8
 Kill
Coagulation bacteria Flocculation
Aluminum Anion
NaOCl
sulfate resin

Clarification Intermediate
Raw water Clarifier
tank
Dissolved gas, sedimentation
suspended solid,
Organic Remove sand,
compound suspended solid
Sludge Tank
Turb <1 NTU Sand Filter
Free cl2: 0.1
Remove sludge -0.5ppm
Belt Press DP < 0.5 bar
Sludge cake
system
Treated
Water tank

Recovery Level control

tank >75%
 DP Remove positive ion, covert
Cl2 < 1ppm CO3 and HCO3 to CO2

Treated water Cation

A/C filter
Tank exchanger

Turb < 1NTU Remove Cl2 and

Cl2: 0.1-0.5ppm suspended solid
High conductivity and organic
compound Remove CO2
degasifier
mechanically

Cond 0.2us/cm
Silica 0.02ppm
PH 6-8
Cond 4us/cm
Mix bed Anion
Silica 0.05ppm
polisher exchanger
PH 6-8
Remove remaining Remove negative ion
Cation and anion Cl, SO4 removed by WBA
SiO2, HCO3 and CO3 removed
by SBA
 Corrosion inhibitor Remove suspended solid
Scale inhibitor Chemical
Fouling inhibitor inject Side stream filter
Killing bacteria

Voting 2oo3 Back

Control water wash
PIC PZT
level
Make up water
Cooling Tower 4.5bar
32oC
If header pressure
Cool down hot lower than 2.58 bars
water returned all plant trip

Process stream
Blow down
42oC The quality of cooling water is maintained by:
water
+ Blow down dirty water
Reduce + Make up clean water
suspended solid + returned clean water from side stream filter
and contaminant + Chemical injection for a treatment
 Gaseous HC, low temp, MeOH as a heating medium
no moisture, water
Dry Cold flare Knock
flare out drum
Liquid HC (C1 –C4) low temp
Flare stack
Cold
blowdown
Gaseous HC, temp >0oC,
have moisture, water HP flare
Liquid
wet
seal
flare

Liquid HC normal or high temp

Warm Wet flare Knock LN will
blowdown out drum automatically
inject to system
Returned when pressure
Gaseous HC, normal liquid less than
Storage
or high temp 0.02kg/cm2
tank
Vent gas from high
pressure tank
Mixture of liquid and
gaseous HC at normal
temp, pressure
Vent gas from Knock out
tank

Returned liquid
drum
* Flare stack

Oxygen
analyzer

MN

gaseous HC at normal
temp, pressure LP Flare
Vent gas from
tank
De-mineralized water, treated
condensate, clean condensate
Boiler Feed Water
Oxygen
scavenger
LS1
Amine Deaerator

Silica < 20 ppb

PH 9.1
DO <7ppb
Conductivity < 7uS/cm 168 bar
Furnace
18.5 bar

De-super heater
Boiler
78 bar
 SHP: 126.5 bar, 520oC Steam
Cracked gas compressor
letdown
HP steam : 41 bar, 400oC

Turbine drives Pump, Generator

MS2 steam : 13 bar, 282oC MS1 steam : 18 bar, 290oC

Dilution Steam generator Flare smokeless
and Furnace purging

LS1 steam : 4 bar, 200oC

deaerator
LS2 steam : 2 bar, 133oC
Heating media
 Safe store compressed Air Remove particle, moisture:
Drain condensate There are 2 Dryers (heatless)
If discharge pressure is down Stabilize outlet pressure + 1 under Drying
to 6 bar, Standby compressor P=8.5 bar Hold pressure for 30 minute + 1 under generation P
IC
automatically start incase upset P=7.5 bar
TI PIC
Air
Compressor PA Drum Dryer

Supply compressed Remove

air for system
HV
The compressor trip if:
+ Discharged Temperature is HH
+ Vibration is HH
+ lube oil level is LL Dew point
+ lube oil temperature is HH Aeration Wet Air Other < -40oC
tank Oxidation User
N2
IA Drum
Safe store compressed Air
Stabilize outlet pressure

PA-IA Hold pressure for 30 minute

incase upset

FFG Control
Valve
 PIC

Nitrogen from Hose Station

3rd party Flare Header
Low pressure
Nitrogen (3-4 bar)

High pressure
Nitrogen (9 bar) Process Blanket
Purging
 Firefighting system
P = 9.5 bar
PIC

Fire Water
Tank
Foam
tank

Water Spray
Hydrant
Gun Nozzle
+Jockey is used to compensate leaking pressure and maintain the pressure in
the system when the system not flowing water.
+ Electric pump will start if the header pressure down to 8.5 bar
+ Diesel Pump will start if header pressure down to 7.8 bar or Electric pump
have problem

Foam is used for Liquid Hydrocarbon: Naphtha, Gasoline, Oil

Steam is Used for Gas area : Cracking furnace area
Inergen is used for Electric area: Substation, DCS room, Laboratory
Portable Fire Extinguisher is used for small Fire