INSTALLATION, COMMISSIONING and START-UP PROCEDURE

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

CPI SEPARATORMatindok Gas Development Project

Banggai, Central SulawesiIndonesia

FOR

CONSORTIUM WIKA-TECHNIP

PT BANYU BIRU SEJATIBumi Satria Kencana, Blok C No. 9

Tel. 021-8841762 Fax. 021-8856176 e-mail : ptbanyubiru@gmail.com

Jln. KH Noer Ali, Bekasi 17144

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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

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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.

Figure 1. Parts of CPI Separator

Sight Glass

Oil Outlet

Supporting Legs

Solids Outlet

Solids Outlet

Skid/Base

Supporting Legs

Ladder

Mancage

Water Outlet

Air Vent

CPI Pack Module

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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

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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)

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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.

CPI Pack Module

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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

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5. CPI SEPARATOR IN PICTURES

5.1 CPI SEPARATOR

Viewed from below

Viewed from above

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Viewed from the side

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5.2 SKID

5.3 LADDER

Ladder-1

Mancage Safety Rail Ladder

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Ladder-2

Base Plate

5.4 PLATFORM AND HANDRAIL

Platform Support Platform Handrail

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6. TECHINCAL SPECIFICATION

CPI SEPARATOR

Quantity : 1 (one) unit

Rated Capacity : 30 gpm

CPI Material :

Tank Material :

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