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1、EXPERTISEBEYONDCONTROLSETHYLENEPLANTMODIFICATIONPROJECTCaseStudyACCCCaseStudySITUATIONAnowner/operatoroftheethyleneprocessingunitforoneofthemainpetrochemicalindustryplantsinBashkortostan,Russia,waschallengedwithupgradingtheirfacilitytobecomemoreefficient,reliableandsafe.Theprocessing
2、unitwassuccessfullyoperatingCCC’ssinglerackSimplexSeries4Controlsystemsince2001onitscomplicatedturbomachinerytrains.Eachtrainwascomposedofacompressordrivenbyasteamturbine.Afive-sectionM1machinewasdesignedtocompressthepyrolysisstreamtoapressureof38kg/cm2.TheM1wascomprisedofthreerecycl
3、elines,eachwithadedicatedantisurgevalveandwasrecentlyreplacedduetodamage.Athree-sectionturbocompressor,theM5,waspartofaclosedcircuitethylenerefrigerationcycleusedforfumeexhaustandcompressionofethylenevaporstoapressureof20.6kg/cm2.TheM5,similartotheM1,alsoincludedthreerecyclelinesanda
4、nantisurgevalveineachline.EachsuctionlineoftheM5wasequippedwithathrottlevalve.AlsopartofthecomplexturbomachinerytrainwastheM6turbo-compressorthatworkedwithintheclosed-circuitpropylenerefrigerationcycleandwasusedtocompressthepropylenevapors.TheM6consistedoftwocasings,thefirstofwhichin
5、cludedtwosuctioninletswithassociatedinletthrottlevalves.Ithadasteamturbinedrivewithanautomaticintermediatesteamextractionpressure/flowandwasequippedwiththreerecyclelinesandantisurgevalves.Afteraten-yearsuccessfuloperationrun,thecontrolsystemandallcontrolledturbomachineryhardwarerequi
6、redsubstantialmodificationstokeepitsafe,reliableandproductive.Tofacilitatethis,theoperator’sparentcompanychoseCCCforasecondtimeinanopenbidfortheircontrolsolutions.2SOLUTIONCCCconsultedwiththeclienttodevelopacustomizedsolutiontofittheirspecificneeds.Afterlengthydiscussionswithengineer
7、s,operators,andprojectpersonnel,itwasdeterminedthatafullydeterministic,multi-taskingoperatingsystemwouldprovidethemostcomprehensivesolution.ThreeVanguardDuplexchassis,oneper•compressorwereinstalled.Thescopeofworkincluded:•PanelmodificationsandfinalcheckoutofthecontrolpanelsfortheM1,M
8、5andM5compre
