PVCDCSUPGRADEPROJECT–BENCHMARKACHIEVEMENT.ppt

PVC DCS UPGRADE PROJECT – BENCHMARK ACHIEVEMENT PRESENTED BY: Rashesh M Shah Project Leader 10-11th May 2004 About Petrokemya About PVC Plant About PVC Process Existing Systems Why to Upgrade? How to Upgrade? What to Upgrade? System Sizing System Configuration Major Challenges Strategies to meet Challenges Major Surprises Significant Achievements Acknowledgements About Petrokemya Petrokemya is wholly owned SABIC company producing Petrochemicals and Polymer Resins Petrokemya facilities have Olefins (Olefins-1, 2 and 3), PVC/VCM, Polystyrene and Polyethylene Plants in addition to Utilities and Steam Generation Petrokemya facilities have Installed capacity of about 5.15 Million Tons Petrochemicals per Year About PVC Plants PVC Plant operates Trains - A and B installed in 1986 with capacity of 100,000 MTY each PVC Plant operates Trains - C installed in 1991 with capacity of 100,000 MTY PVC Plant operates E-PVC installed in 1995 with capacity of 24,000 MTY PVC Plant (Train-A and B) De-Bottlenecking was completed in 2003 to have additional 40% capacity About PVC Process PVC manufacturing is a BATCH process Basic Raw Material is VCM which is produced by Ethylene and Chlorine Petrokemya manufactures K67, K70 and K57 grades of S-PVC products Petrokemya manufactures P701, P702 and P703 grades of E-PVC products Application for K67 is General purpose (pipe, conduits, Furniture etc.) Application for K70 Flexible purpose (mainly electrical cable) Application for K57 Tough plastic (pipe fittings etc.) Application for E-PVC is fine coating (Vinyl Flooring, Wall Tiles, Artificial Leather etc.) Existing Systems Foxboro SPEC200 based Analog Control System for Continuous Control HIMA PLC for Discrete Control and Plant Shutdown MODCOMP Classic II/75 Process computers for Batch Application and Data Collection Foxboro INTERSPEC for Analog Signal Interface to MODCOMP Process Computers Existing Systems 09 Foxboro SPEC200 I/O Rack and Marshalling panels (Each 4.0 M Wide) 16 HIM