Module 17 – Utilities & Support Systems

Objective:
By the end of this module, a trainee will be able to:

1. Understand the role of utilities in a petrochemical plant.

2. Identify common utilities and their functions.

3. Recognize operator responsibilities in monitoring and using utilities.

4. Understand basic troubleshooting and safety considerations for utility systems.

5. Appreciate how utility performance affects plant operation and product quality.

17.1 – Introduction to Utilities & Support Systems

Definition:

• Utilities = services and resources that support the operation of process units.

• Examples: steam, cooling water, instrument air, nitrogen, electricity, and fuel gas.

Importance:

• Utilities enable reactions, separations, and equipment operation.

• Reliable utilities prevent process upsets and downtime.

• Operators must monitor availability, pressure, temperature, and flow.

Analogy:

• Utilities = “electricity, water, and air conditioning in a building; everything depends on them.”

17.2 – Steam Systems

Purpose:

• Provide heat for reactors, distillation, and process equipment.

• Used for tracing and cleaning in pipelines and vessels.

Operator Role:

• Monitor steam pressure, temperature, and flow.

• Check for leaks and condensate return.

• Coordinate with maintenance for trap or valve issues.

Safety Considerations:

• High-pressure steam can cause burns.

• Steam leaks must be reported immediately.

Analogy:

• Steam = “hot water in central heating; too much or too little affects comfort (or process).”

17.3 – Cooling Water Systems

Purpose:

• Remove heat from reactors, condensers, compressors, and exchangers.

• Maintain proper equipment temperature for safe operation.

Operator Role:

• Monitor temperature, flow, and pressure.

• Check for scaling, fouling, and leakage.

• Report abnormal temperature rise or flow drop.

Safety Considerations:

• Avoid exposure to high-temperature water or chemical treatment additives.

Analogy:

• Cooling water = “radiator in a car keeping the engine from overheating.”

17.4 – Instrument Air Systems

Purpose:

• Supply clean, dry, oil-free air to:

  • Control valves

  • Pneumatic instruments

  • Actuators

Operator Role:

• Monitor pressure, dryness, and dew point.

• Check for leaks and air compressor health.

• Ensure backup air sources are available for critical loops.

Safety Considerations:

• High-pressure air can be dangerous if released improperly.

• Moisture in air can cause instrument failure or corrosion.

Analogy:

• Instrument air = “pneumatic system in a factory powering machines.”

17.5 – Nitrogen Systems

Purpose:

• Blanketing or purging vessels and pipelines to prevent:

  • Fire/explosion

  • Contamination

• Often used for line isolation or safe maintenance.

Operator Role:

• Monitor flow, pressure, and inventory.

• Follow SOPs for purging and blanketing operations.

• Ensure safe handling of high-pressure cylinders or piping.

Safety Considerations:

• Nitrogen is asphyxiant; ensure proper ventilation.

• Avoid confined space hazards.

Analogy:

• Nitrogen = “protective cover preventing oxygen from causing fire.”

17.6 – Other Utilities

• Electricity

Power pumps, compressors, lighting

Monitor voltage, breakers, and load alarms

• Fuel Gas

Provide heat in fired heaters or boilers

Monitor flow, pressure, and safety interlocks

• Cooling Air

Cool instruments or small equipment

Ensure fan operation and duct integrity

• Deionized Water

Used in condensers, scrubbers, and chemical processes

Monitor quality, flow, and tank levels

Operator Tips:

• Know the critical utilities for your process unit.

• Observe trends and report anomalies promptly.

• Participate in preventive maintenance rounds for utilities.

Analogy:

• Utilities = “support staff in a company keeping operations running smoothly.”

17.7 – Operator Troubleshooting for Utilities

Common Issues:

1. Steam pressure drop → poor heating → check traps, leaks, or boiler supply.

2. Cooling water flow low → high exchanger temperature → check pump, valves, debris.

3. Instrument air pressure low → control loops fail → check compressors, dryers, leaks.

4. Nitrogen flow interrupted → unsafe purging → check cylinder supply, valves, regulators.

Operator Approach:

• Observe trends and alarms.

• Verify source and distribution integrity.

• Report to maintenance and follow SOP for safe correction.

17.8 – Quiz / Knowledge Check

1. Name four utilities commonly used in a petrochemical plant.

2. Why is instrument air important?

3. What is the operator’s role in monitoring steam and cooling water?

4. How is nitrogen used for safety in plants?

5. Give an analogy for utilities in everyday life.

6. What should an operator do if cooling water flow drops suddenly?

17.9 – Media Sites Integration

• Videos:

  • Conceptual utility system overview (steam, cooling water, air, nitrogen)

  • Panel and field monitoring demonstration

  • Minor troubleshooting animation

• Diagrams / Infographics:

  • Utility distribution schematic

  • Steam, cooling water, and air circuits

  • Nitrogen purging diagram

• PDF Downloads:

  • Utility monitoring checklist

  • Operator observation log for utilities

  • Conceptual troubleshooting guide

• Interactive:

  • Embedded quizzes

  • Scenario exercises: utility failure and operator response

17.10 – Summary & Key Takeaways

1. Utilities support all process operations; reliability is critical for safe and efficient operation.

2. Operators monitor steam, cooling water, instrument air, nitrogen, and other utilities.

3. Early detection of anomalies prevents process upsets and safety hazards.

4. Follow SOPs for startup, shutdown, purging, and minor troubleshooting.

5. Conceptual understanding of utility systems helps operators coordinate with maintenance and control room.