successful installation and commissioning of the …
TRANSCRIPT
SUCCESSFUL INSTALLATION AND COMMISSIONING OF THE MOST POWERFUL HYPER COMPRESSOR WORLDWIDELDPE Webinar, April 2021Alexandru Roman – Burckhardt CompressionKevin Liao - Formosa Plastic Corporation
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Outline Project introduction Compressor Package Overview, technical data Formosa Plastic Corporation USA - introduction Construction and installation key milestones Installation highlights, key points K8+8 Hyper compressor pre-commissioning and commissioning
highlights First operation experience with K8+8 Hyper Compressor BC support for Maintenance & Reliability Readiness
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FPC, TX, USA LDPE Plant ExxonMobil Tubular License
Projected Production: 400 kTA
PP: BCAG 8B6C, Hyper: K8+K8
Hyper Compressor Rate: 160 T/hr.
5 Reactor Ethylene Feed
6 Injection points
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PP Compressor Overview – 8B6C-2.108_1
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K8+8 Overview
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K8+8 – Technical Data Motor power: 34.5 MW 1st Stage discharge pressure – 1530bar 2nd Stage discharge pressure – 3100bar
Motor-Compressor coupling spec:- Rigid coupling - 2nd Stage- Torsionally rigid coupling - 1st Stage
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Formosa Plastics Corporation, U.S.A. Founded in 1978 Headquarter: Livingston, New Jersey. Manufacturing complex:
Baton rouge, LouisianaPoint Comfort, Texas
Annual revenue: ~USD$ 5 billions US Employee: 2,900
Point Comfort, Texas: now including LDPE
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FPC Taiwan Mailiao Plant
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Formosa and BCAG Hyper
(1) K6
(1) K8, (1) K6(2) K8, (1) 8B6C
Mailiao EVA plant: (1) K8 on 160kTA tubular line, (1) K6 on 72kTA autoclave line Ningbo EVA plant: (1) K6 on 72kTA autoclave line Point Comfort LDPE: (2) K8 (K8+K8) on 400kTA tubular
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Purge/Primary TimelineHyper Timeline
PP/Hyper Construction Milestones
2020/11 C2 runs to 44,000psig, making polymer
2016/7 Site construction break-ground
2017/4
2018/8
2018/10
2018/11
2020/1
2020/9
Hyper frames arrived for humidity controlled storage.
Motor assembly begins, 2nd stage frame and foundation bolts installed.
Motor rotor and 1st stage frame rough set. Roof over. Leveling and grouting in progress.
Hyper oil mist system operational. Oil piping flushing scope proposed. On-site installations continues
Hyper 5-minute mechanical run (5 minutes)
Hyper nitrogen run, commissioning
2018/7
2019/72019/10
2020/6
Motors assembly begins
Motor and frame rough set. On-site installation begins
PP pre-commissioning begins
PP Nitrogen run; HP blowing
Compressor overhaul
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Hyper Compressor Installation Highlights Foundation base plate alignment Oil mist system 1st stg frame - motor – 2nd stg frame alignments
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Hyper Foundation Highlight Upper base plate alignment precision: 0.05mm across 1m
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Oil Mist System (On-site preservation) Corrosion prevention by low pressure, atomized (2 micron) oil droplets inside of compressor frame
and cylinders , creates lubricant film on internal surfaces
While installation and alignments in progress
(48) mist points on PP/Hyper
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Hyper compressor alignment highlights Centerline misalignment: ±5.8mm / ±2.0mm
Flange face parallel: ± 0.9mm
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Picture gallery
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K8+8 Hyper compressor pre-commissioning and commissioning highlights Mechanical Test Run Nitrogen test run Ethylene test run - Operation experience with K8+8 Hyper Compressor Prognost data
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Nitrogen Test Run – operating range
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First start up with Ethylene - a correct approach
4.5 hours – Ramp up3h@ 3000barMTR
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Prognost System data – operation experienceTroubleshoot
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Prognost System data – 1st Stage Plungers Run-out
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Prognost System data – 2nd Stage Plungers Run-out
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All intermediate CRS Vibrations
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BC support for Maintenance & OperationReliability Readiness On site operation and maintenance training:▪ cylinder lubrication adjustment before and during operation:
➢ cylinder lubrication corrective measures based on plungers behavior
➢ cylinder lubrication delivery rate
▪ maintenance training - general practice and documentation
▪ specific maintenance procedures for PP and Hyper compressor
▪ workshop (clean room) maintenance procedures for compressor parts, special storage condition
Spare part management training Prognost system training
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BC support for Maintenance & OperationReliability Readiness
