Buffer Basin Cleaning; Combination Between Operation Excellence and Environmental Compliance With 3R (Reduce, Reuse, Recycle) Approach

Abstract

Abstract In 2012, Total E&P Indonesie (TEPI) decided to conduct cleaning of Buffer Basin. Buffer Basin is an open concrete basin connected to downstream of API Separator (integrated system in New Oily Water Treatment/ NOWT, Senipah Terminal). Originally, Buffer Basin was designed to handle fluctuation/ excessive flow of incoming oily water from process (e.g. from separator and storage tank draining). The biggest impact of isolating buffer basin is stopping liquid production of all TEPI sites. This generates long discussion and trial before the implementation. Consequently, accumulations of sludge/ sand were affecting not only the quality of the discharged produced water but also the health of people/ personnel due to the massive generation of BTEX (Benzene, Toluene, Ethyl Benzene, and Xylene). The key factor of Buffer Basin cleaning was the successful re-activation of old OWTU to temporarily bypass the incoming oily water treatment. During this temporary period, no process shutdown was experienced which may impact occurrence of production loss. The oily water treatment operating cost was reduced by approximately 50% due to reduction on chemical injection. The quality of disposed water to environment is still below permit requirement. Meanwhile, cleaning the Buffer Basin itself was challenging due to huge amount and various properties of sludge/ solid, highly impacted by weather, hazardous material exposure, etc. The sludge was treated using Sludge Oil Recovery (SOR) process resulting in 4 derivatives/ products (recovered oil, solid, emulsion, and oily water). To comply with environment regulation, upon relevant Government Bodies approval, TEPI in cooperation with licensed Contractor used 3R (Reduced, Reuse, Recycle) approach to manage the waste. The solid waste was processed to become fire resistant bricks which can later on be used as heat insulation. The emulsion was used as synthetic fuel and become energy source for making the bricks. The water was treated in oily water treatment unit prior disposal to environment. Recovered oil was sent back to TEPI's storage tank. The project was completed and all the challenges were overcome.