PETRONAS TECHNICAL STANDARDS

Corrugated Plate Interceptor (CPI)

PTS 16.39.04
June 2017

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.

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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 4
1.1 SCOPE .............................................................................................................................. 4
1.2 GLOSSARY OF TERM ........................................................................................................ 4
1.3 SUMMARY OF CHANGES ................................................................................................. 6
2.0 GENERAL DESIGN REQUIREMENTS OF CORRUGATED PLATE INTERCEPTOR ............. 7
3.0 SELECTION OF COALESCING PLATE PACK ................................................................ 8
4.0 ANCILLARIES .......................................................................................................... 9
5.0 SPECIFIC HSE REQUIREMENTS .............................................................................. 12
6.0 LOCATION AND LAYOUT FOR CPI INSTALLATION .................................................. 13
7.0 OTHER CONSIDERATIONS .................................................................................... 14
8.0 BIBLIOGRAPHY .................................................................................................... 15
APPENDIX 1: TYPICAL SCHEMATIC OF CPI ........................................................................ 16
APPENDIX 2: FLOW CHART FOR DETERMINING APPLICATION OF CPI ............................... 17
APPENDIX 3: DESIGN CALCULATION TABLE ..................................................................... 18

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1.0 INTRODUCTION

This PTS provides the minimum technical requirements for the design of Corrugated Plate
Interceptor (CPI). This PTS fully adopts API 421, BREF 02/2003 and is supplemented by
requirements based on PETRONAS lessons learnt and best practices.

This PTS was developed to ensure effective removal of suspended oil in industrial effluent and
produced water streams to meet Malaysian Environmental Regulations and Standards in
protecting water quality. By fully complying with the final effluent discharge limit, continuous
plant operation can be sustained. In addition, efficient removal of oil will prevent damages
and hazards due to oil accumulation and fouling of instruments and equipment.

1.1 SCOPE

This PTS specifies the design requirement of CPI for the physical and mechanical separation of
free oil (suspended oil in water).

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition of Terms, Abbreviations &
Reading Guide

1.2.2 Specific Definition of Terms

No Term Definition

1 American Petroleum A conventional oil-water separator following the general

Institute (API) Separator design criteria as defined in API 421 Section 2. Unlike
CPIs, API separators do not employ parallel plate packs
and are subsequently larger than CPIs for a given degree
of separation.

2 Corrugated Plate Interceptor A CPI is a combination of coalescing and gravity type

(CPI) oil/water separator to separate free oil droplets from
water phase based on differential density of oil and
water.

A CPI is divided into compartments where in one

compartment a collection of inclined, corrugated parallel
plates (a plate pack) provides a large horizontal surface
area and reduces turbulence to enhance separation. The
top oil layer is retained by a baffle and removed using oil
skimmers. Appendix 1 shows CPI schematic.

3 Dissolved oil Oily fractions that form a true molecular solution with
water.

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No Term Definition

4 Emulsified oil Oil in the form of smaller oil droplets with a diameter of
less than 20 microns. Emulsified oil forms a stable
suspension in the water and does not form a separate oil
layer.

5 Free oil Oil in the form of discrete oil globules of sufficient size
such that it can rise due to buoyant forces and form an oil
layer on top of the water.

6 Industrial Effluent Any waste in the form of liquid or wastewater generated

from manufacturing process including the treatment of
water for water supply or any activity occurring at any
industrial premises.

7 Oil and Grease Concentration of substances extractable by a method-

defined solvent (e.g. n-hexane) in the water sample,
expressed in mg/L. This parameter is commonly used as
an indication of the amount of oil in a water sample (also
known as oil-in-water). Oil and grease includes (but does
not distinguish between) oily substances in free,
emulsified or dissolved forms.

8 Produced Water Formation water that is brought to the surface during

hydrocarbon production. Produced water contains a
complex mixture of inorganic (dissolved salts, trace
metals, suspended particles) and organic (dispersed and
dissolved hydrocarbons, organic acids) compounds, and
in many cases, residual chemical additives (e.g. scale and
corrosion inhibitors) that are added into the hydrocarbon
production process.

9 Wastewater Treatment Plant Any facility including the effluent collection system,
designed and constructed for the purpose of reducing the
potential of the industrial effluent to cause pollution. A
facility that receives and processes wastewater effluent
to a set quality. It may consist of a series of process units
which are combined to achieve the overall treatment
objective.
Table 1.1: Specific Definitions

1.2.3 Specific Abbreviations

No Abbreviation Description

1 ALARP As Low As Reasonably Practicable

2 BREF Best Available Technique Reference Document

3 CPI Corrugated Plate Interceptor

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No Abbreviation Description

4 FRP Fiber Reinforced Plastic

5 SS Suspended Solids
Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 16.39.04 (June 2017) replaces PTS 16.39.04 (June 2014).

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2.0 GENERAL DESIGN REQUIREMENTS OF CORRUGATED PLATE INTERCEPTOR

2.1.1 The following critical parameters shall be determined in designing a CPI. Where possible,
actual measurements are to be conducted:

i. Flow rate

ii. Oil and grease (dissolved, emulsified and free)

iii. pH

iv. Temperature

v. Particle size or oil droplet size distribution

vi. Suspended solids

vii. Specific gravity and viscosity of the oil

viii. Specific gravity and viscosity of wastewater

2.1.2 CPIs shall be designed for removal of free oil droplets having a minimum droplet size of 60
microns.
2.1.3 All sources into the CPI inclusive of oily water drain and process area drains shall be identified
to determine the flow rate for normal and peak flow.
2.1.4 The horizontal separator area provided shall be determined based on oil droplet rise rate
calculated according to Stokes’ Law. The design of the plate pack shall be such that laminar
conditions are established with Reynolds number of <500 and sufficient retention time is
available for the smallest droplet to traverse the vertical distance between plates.
2.1.5 The requirement for redundancy shall be considered for separation chambers. Each chamber
shall have provision for isolation to enable online cleaning.
2.1.6 Retention time shall be adequately designed to avoid significant odour or septicity, typically
limited to 2 hours.
2.1.7 The CPI design shall ensure that the plate pack cleaning and tank desludging frequency is
optimized. Typically, the cleaning frequency of CPI is semi-annual. However, if inlet solids
concentration is high and/or a large number of CPIs are required, the CPI should include
provisions such as steeper plate inclination, online sludge removal and bottom sludge hopper
to facilitate the cleaning activity and extend the expected cleaning frequency, e.g. once every
1.5 years.
2.1.8 Appendix 1 shows schematic of downflow and crossflow CPI. Appendix 2 outlines the general
flowchart for determination of the applicability of a CPI.

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3.0 SELECTION OF COALESCING PLATE PACK

3.1.1 Plate pack shall be arranged either downflow or crossflow to provide changes in flow direction
with the appropriate spacing and inclination to facilitate coalescence of the oil droplets.

3.1.2 The spacing of the between the corrugated plates in plate pack shall be between 20 to 38 mm
and the inclination of the pack is to shall be 45-60.

3.1.3 A suitable, non-oleophilic plate pack material e.g. FRP, stainless steel which is able to
withstand the expected temperature during operation shall be selected.

3.1.4 The total projected plate area requirement shall be confirmed with manufacturers depending
on the design of the plate pack.

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4.0 ANCILLARIES

4.1.1 The following ancillary equipment shall be provided with the CPI unit.

i. Bar Screen

ii. Influent Section

iii. Inlet Channel and Flow Distribution Baffle

iv. Settlement Chambers

v. Oil Skimmer

vi. Oil Sump

vii. Covers

viii. Outlet Weir

4.1.2 Bar Screen

i. A bar screen (or trash rack) and a bar screen chamber shall be provided before
the inlet of the CPI if coarse materials (i.e. sticks, rags, leaves etc.) are present or
potentially present in the influent stream.

ii. The spacing between the bars should be half the interval of the corrugated plates.

iii. The design should allow for 50% of the screen to be blocked before it is cleaned,
assuming weekly cleaning for the manual screens.

4.1.3 Influent Section

i. When practicable, the inlet into the CPI shall be gravity flow. If pumping is
required, low-shear pumps e.g. screw type pump shall be specified to minimise
oil emulsification.

ii. The incoming flow shall be introduced below the water surface and the piping
shall be sized for minimum pressure drop to avoid turbulence at the surface and
in the tank that might hinder the separation process.

iii. Provision of a straight inlet pipe for a length of at least ten times the size of the
pipe diameter is recommended.

iv. Provision of a holding pit, sump or any other containment with sufficient capacity
to hold the influent flow during maintenance activities such as de-sludging of the
settlement chamber is recommended.

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4.1.4 Inlet Channel and Flow Distribution Baffle

i. The incoming flow shall be evenly distributed into all the compartments of the
plate pack by ensuring sufficient flow velocity at the inlet channel with a
maximum flow velocity of 20 cm/s.

ii. The water flow shall be equally distributed over the cross section of the plate pack
by a suitable mechanism such as a removable slotted baffle. When this is used,
the top of the baffle shall be about 6 cm below the highest position of the oil
skimmer to ensure that oil separated before the baffle can flow to the oil skimmer
at low throughput.

4.1.5 Settlement Chambers

i. Settlement chambers with sufficient solid storage capacity shall be provided at

the lower part of the inlet and separation chambers based on the expected
volume of settled particles. The maximum level shall not restrict the flow velocity
at the inlet channel.

ii. Provision shall be made for withdrawal of the settled sludge from the settlement
chambers.

iii. Bottom hopper is recommended to promote solids movement to the sludge

withdrawal nozzle.

iv. Automatic withdrawal of sludge (e.g. timer based sludge drain valve) is also
recommended.

4.1.6 Oil Skimmer

i. The skimmer shall be designed to efficiently extract the separated oil and the
skimmed oil shall have oil content of at least 90%.

ii. For slotted pipe skimmer, the design shall allow accumulation of the oil layer to a
maximum thickness before the layer is skimmed to prevent under-skimming or
over-skimming. As a general estimate, a thickness range of 2-4 cm can be used.

iii. If pumps are used for extracting the oil layer, they shall be self-priming and
explosion proof.

4.1.7 Oil Sump

i. Skimmed oil shall be discharged into an oil sump from where it is usually pumped
to a slops tank. Higher pump capacity should be used if oil sump has small buffer
capacity.

4.1.8 Covers

i. CPI bays shall be covered unless a hazards risk analysis indicates that uncovered
CPI bays do not pose any significant risk to health, safety or environment.

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ii. Both fixed and floating covers can be used for a CPI.

iii. Where fixed covers are installed, proper venting equipment shall be provided and
blow-off hatches are recommended.

iv. The use of floating covers minimizes the hazards associated with vapor expansion.
Floating covers shall be corrosion proof and lightweight but with sufficient lasting
strength. The weight of the floating covers shall be heavy enough to withstand
surging and swelling of effluent flow.

4.1.9 Outlet Weir

i. The adjustable outlet weir shall be provided to achieve a controlled flow out of
the CPI; preventing turbulence and flow short-circuiting in the tank.

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5.0 SPECIFIC HSE REQUIREMENTS

5.1.1 HSE risks associated with fugitive emissions of air pollutants including VOC, H2S, other toxic
gases and nuisance odours from CPI shall be assessed and mitigation measures such as vapor
collection and treatment shall be taken to reduce the risks to ALARP levels.

5.1.2 Design and selection of equipment for vapor collection and treatment as well as performance
monitoring of these systems shall be in accordance with CAR 2014, Guidance Document on
Fugitive Emission And Control (or equivalent local regulations).

5.1.3 Design of the CPI shall take into account personnel access requirements during operations and
maintenance activities e.g. plate pack removal for cleaning to ensure the protection of
personnel health and safety during such activities.

5.1.4 Performance monitoring of CPI shall be based on IER 2009 or equivalent standards. For CPI
performance monitoring purpose, sampling ports shall be provided at the inlet to the CPI and
exit pipe of each CPI chamber.

5.1.5 Sludge dewatering may be required prior to final disposal. Sludge disposal shall abide by the
local regulatory authority (e.g. SWR 2005).

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6.0 LOCATION AND LAYOUT FOR CPI INSTALLATION

6.1.1 Where possible, a CPI should be located at the lowest level relative to the wastewater
generation areas, and higher than the effluent discharge point to avoid any back-flow into the
CPI from the downstream water body or unit operations and to achieve gravity flow and avoid
pumping. However, since this condition is not always possible, it is recommended that the
incoming flow is by gravity while the discharge can be pumped.

6.1.2 Above ground CPI are preferred. The layout and ancillaries of the CPI shall allow for
accessibility for all operations and maintenance of the CPI and any related equipment e.g., bar
screen, oil skimmer, outlet weir, sampling ports, floating covers.

6.1.3 Site preparation and earthworks for consideration of foundation installation shall follow PTS
11.12.01 and other relevant international standards.

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7.0 OTHER CONSIDERATIONS

7.1.1 If emulsifying agents such as detergents, surfactants and phosphates are present in the
incoming wastewater, installation of a chemical de-emulsification facility shall be considered
upstream of the CPI.

7.1.2 For quality assurance, package CPI separators shall be manufactured and tested based on BS
EN 858 Part 1.

7.1.3 In selecting materials of construction and installation of CPI, the following shall apply:

i. CPIs shall be constructed of either reinforced concrete or steel while fiberglass

shall only be considered for above-ground installations.

ii. Non-oleophilic plate pack material (e.g. FRP, stainless steel) which is able to
withstand the expected temperature during operation shall be selected. The CPI
chambers interceptor tank and the plate pack shall be made of corrosion resistant
materials, resistant to acid or alkali attacks or other corrodents such as sea water
where applicable). In the case when the wastewater contains specialized
corrosive compounds such as aromatic hydrocarbons that may attack the plastic
plates or fibre glass tank, Technical Authority for Materials & Corrosion shall be
consulted.

iii. Where applicable for materials selection and testing, reference can be made to
BS EN 858 Part 1.

7.1.4 Underground CPIs shall be designed based on relevant standards on underground tanks for
flammable and combustible liquids.

7.1.5 The structure of the CPI shall be made watertight by using joint gaskets and pipe connection
gaskets/seals, whichever applicable. CPIs shall be leak tested according to the relevant
standards.

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8.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS STANDARDS

Index to PTS PTS 00.01.01

PTS Requirements, General Definition Of Terms, Abbreviations & PTS 00.01.03

Reading Guide

Site Preparation and Earthworks PTS 11.12.01

MALAYSIAN ACTS, REGULATIONS AND GUIDELINES

Environmental Quality Act 1974 (Clean Air) Regulations 2014 CAR 2014

Environmental Quality Act 1974 (Industrial Effluent) Regulations 2009 IER 2009

Environmental Quality Act 1974 (Scheduled Wastes) Regulations 2005 SWR 2005

Guidance Document on Fugitive Emission And Control

INTERNATIONAL STANDARDS

American Petroleum Institute, “Design and Operation of Oil Water API 421, 1990
Separators”

British Standard, “Separator systems for light liquids” BS EN 858-1, 2002

European Commission Integrated Pollution and Prevention and Control BREF 02/2003,
Reference Document on Best Available Techniques in Common 2003
Wastewater and Waste Gas Treatment/Management Systems in the
Chemical Sector

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APPENDIX 1: TYPICAL SCHEMATIC OF CPI

Rotatable Slotted
Pipe Skimmer

Effluent
Oil Layer Outlet
Nozzle
Adjustable
Effluent Outlet Weir
Inlet
Nozzle
Separation
Flow
Chamber
Distribution Effluent
Inlet Baffle
Chamber Chamber

Plate
Pack

Sludge Settlement Chamber

Sludge Withdrawal Nozzle

Figure 1: Schematic of Downflow CPI

Adjustable
Outlet Weir

Oil Skimmer

Flow
Distribution
Baffle Separation Chamber

Effluent
Chamber
Effluent Plate
Inlet Pack
Nozzle
Inlet
Effluent
Chamber
Outlet
Nozzle

Anti Short-
circuiting Baffles Sludge Settlement
Chamber

Sludge Withdrawal Nozzle

Figure 2: Typical Schematic of Crossflow CPI

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APPENDIX 2: FLOW CHART FOR DETERMINING APPLICATION OF CPI

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APPENDIX 3: DESIGN CALCULATION TABLE

Typical
Parameter Units Remarks
Value

1. Flowrate, Qw m3/hr design peak flow (maximum flow)

capacity capacity at operating
temperature
0
2. Design temperature, Tw C 40 expected operating
temperature

3. Oil droplet size in diameter,  cm 0.006 minimum diameter of oil

droplets for separation by CPI

4. Density of wastewater, w g/cm3 0.992 at Tw of 400C

5. Density of oil, o g/cm3 0.92 at Tw of 400C

6. Dynamic viscosity of dyne.s/cm2 0.653 x 10-2 at Tw of 400C

wastewater, w

7. Kinematic viscosity of cm2/s 0.658 x 10-2 at Tw of 400C

wastewater, w

8. Flow Reynolds Number, NRe - <500 assuming laminar flow

9. Plate spacing, Sp mm 38 various spacing between 20-

38mm

10. Plate inclination, 0 degree 45 various incline 45-60 degree

11. Length of parallel plate, Lp m calculated typically to achieve laminar

flow

12. Chamber retention time, tr min 30 based on instantaneous peak

flow (maximum flow)

13. Sludge holding capacity, Vsludge estimated based on settled particles

m3
where maximum level not to
restrict wastewater velocity