9. channelview tour report

7/31/2019 9. Channelview Tour Report

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Channelview, Texas Lyondell PSA Site (USA-841)

On our trip to Channelview, we were introduced to 3 aspects of the plant:

Overview of all system components of the plant by Mr. David Yanda and MrKeith Lyles.

Electrical components by Mr. Keith Lyles.

Compressor internals by Mr. Bob Lorenzi.

1. Overview of the Channelview facility :

Figure 1: Basic Channelview Layout

Mr David Yanda explained how we get 2 input gases from Lyondell and send out

3 output gas flows.

Input:

I. Feed Gas: Which is 95% Hydrogen and 5% other usableproducts that are separated by our PSA beds.

BombResist a

nt

Conta

iner(B

RC)

FEED GAS

95% Hydrogen mixture fromLyondell

H2

For Lyondellcompressors

Control Room

Analyzer

Unit

(N2, O2, CO)

DCS Control

Room

Metering

Station

PSA Beds

2nd Row

Surge

Tank

Electrical

RoomCompressor

UnitFin

Fans

PSA Beds

1st Row

TAIL GAS

H2

PraxairsH2 Pipeline

H2

Compressedby Lyondell

compressors

99.9%pureH2

Small amount of H2 to test for

traces of impurities

Filter


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II. Compressed H2: A part of our processed Hydrogen is sentback to Lyondell for compressing using their compressors (Praxairpays separately for this service). But rather than utilizing that

compressed H2 directly, Lyondell sends it back to Praxair for us tointroduce it into our main Hydrogen Pipeline network. This is done

to ensure increased reliability because our pipeline ensures

providing them with Hydrogen even if their compressors shut downfor some reason.

Output:

I. Tail Gas: The remaining 5% of the feed gas that is nothydrogen is sent back to Lyondell which they then use as fuel.

II. H2 for Compression: By Lyondell compressors.

III. 99.9% Pure H2.

2. Electrical Room, Control Rooms and Motors:

1. Electrical Room: Its purpose is to house electrical equipment. Differentelectrical equipment that we saw, and their descriptions are as follows:

i. Electric Switchboard : A device/panel of switches that directselectricity from one source to another. Its role is to divide the maincurrent supply into smaller currents for further distribution, to

provide switching and metering.The switchboard at Channelview was distributing power

to the transformer, UPS, instruments and other control equipment,the compressor motor and two smaller fin-fan motors.

ii. Switchgear : Combination of switches, fuses and circuit breakersused to control, protect and isolate electrical equipment.The switchgear at Channelview was a High Voltage

switchgear, because it was operating a 1250 horse power motor for

rotating the compressor.

iii. Transformers : A device that steps-up or step-down voltage.

iv. UPS : Uninterruptible Power Supply. The UPS at Channelview wasbig enough to keep the plant running for 2 hours incase of a poweroutage.

v. PLC : Programmable Logic Controller used for automation ofelectromechanical processes.

There are specific architectural requirements for the construction of anelectrical room and the power cables going out to the plant as specified by

NEC (National Electrical Code) article 110 Part II (600V and below) and Part

III (600V and more). At channel view we saw 2 major power cables of rating600V and 5kV. Hence the cable racks and conduits were designed for voltages

higher than 600V.


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2. Control Room: The control room at Channelview was a very small one. Theplant will be un-manned after commission and will be remotely monitoredthrough the Sierra Pines control room.

3. DCS Control Room: DCS stands for Distributed Control System. The DCScontrol room at Channelview was going to be pressurized from inside by usinga positive pressurized unit (PPU). This is done for saving the electrical

equipment from damage by corrosive effects of gaseous contaminants,humidity, shock and electrostatic discharge.

4. Motors: Mr. Keith explained the difference between a Synchronous motor andan Induction motor. The one at Channelview running our compressor was aSynchronous motor.

i. Synchronous motor: Where the speed of motor rotation is equal tothe frequency of the power (current) provided. This is done byproviding the motor with an excitation current. Mr. Keith showed

us the panel where the excitation settings could be changed.

ii. Induction motor: The motor is always working at a speed less thanthe power frequency its running on (lagging motor factor).

3. Compressor:

The compressor we saw at Channelview was a two stage reciprocatingcompressor. Reciprocating compressors are positive displacement compressors that

have an offset crank shaft driven pistons to compress gases. Some parts of thecompressor that were pointed out by Mr. Bob were as follows:

1. Rotating Motor in its enclosure

2. The rotating shaft.

3. Offset Crank Shaft4. Crosshead (Converts the rotary motion of the shaft into

linear motion of the piston)

5. The bed over which the crosshead slides, which is lubricatedby oil in order to reduce friction between the constantly

moving metal parts.

A picture I found online that looks similar to the compressor we saw is as follows:


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9. channelview tour report

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