Polyester plant precommisioning and start up

2.2 Pre-Commissioning of Paste MixThe individual systems Postesterification and Prepolycondensation respective valves or using blinds, as prior discussed Tightness Test vent groups, incl

- Start-up Procedure

1.1 Definition of Ex

2.2 Pre-Commissioning of Paste Mix

6 Emergency Procedures

1.1 Definition of Ex

plant Cold checks (calibration, leakage tests, control functions)

hot vacuum tests)

plant both parties sign the protocol of Mechanical Completion

By signing this protocol the START-UP TEAM takes over the responsibility the ERECTION TEAM

1.1 Definition of Ex

After the successful performance test the protocol of “plant acceptance

Initial Start-up / Commissioning / Acceptance

Experts for the respective package units.

A NETWORK

The network plan consists of states (targets and completeness of states in percent)

All sections and the states (targets)

The pre-commissioning activities are recorded on ACTIVITY LISTS

The problems which arise are discussed during a meeting among the parties responsible

Network plan

1 Organization of Pre-Commissioning and Start-up:

Precommissioning: Activity List (Ex cerpt)

Cold / Hot Vacuum Check Heating

1.4.1 Field Check ( erection must be completed)

1.4.2 Dry Check ( without water or other liquids, e.g valve calibration, tightness test)1.4.3 Wet Check ( with water and / or EG, e.g level calibration, start of pump circulation)

1.4.5 Trial Run ( start-up of a single section)

1.4.6 Initial Run ( start-up of a single, independent process section such as additive)

The list of activities must be discussed in detail in the start-up team

- Stress free erected equipment and piping (expansion joints, expansion guides)points in the piping systems)

screw pumps)

1.4 Field check and Pre-commissioning

- Leakage test on piping systems, reactors and heat exchangers (HTM evaporators)

- Checking of the signals from the process control system and the main control cabinet (MCC)

- Mechanical check of machines and apparatuses

available The Wet Check is done in cold condition (except steam tracing)

Usually demineralised water (WDR)

glycol (EG)

production building No water must be filled into the HTM (and fuel oil piping systems if existing)

- The calibration of instruments in the field (such as level and flow instruments)

The system must be thoroughly dried, where ever presence of water is not desirable

Heating-up of any system causes thermal expansion of the equipment (piping and apparatuses)and the medium (liquids and gases)

Check the safety armatures and instrumentation before heating-up.

for the distillation tests in the esterification reactor and column systems.

paste mixing and spent EG recycling)

Use the following documents as a guide: “Start-up Preparation Chemical Section

“List of Activities for Start-up”

- Dry Check on HTM system (leakage test)

- Wet Check on HTM system (filling and drying of HTM)

- Trial run of polycondensation reactor systems

- Safety regulations (welding permit)

- etc

“1 Organization of Pre-Commissioning and Start-up

2.2 Pre-Commissioning of Paste Mix

2.3 Pre-Commissioning of Discage Reactor

before starting the work.

Pipes are usually flushed during the field check period with water, steam or air.

2.1.1 Piping

The Pressure Maintenance Test is done at a pressure of max 20 kPa(g)

Do not use a testing pressure higher than 20 kPa(g)

The tower reactor system (section 20)

Leakage Tests:

- Nitrogen and compressed air piping systems: 2000

- Nitrogen circuit of PTA transport system: 4000

- Polycondensation reactor system: 500

(number of flanges, armatures, size of equipment involved)

Alternative method: Ammonia Leakage Test -> see Op Manual V 3, pt 9.6.5

stainless steel approx 17*10-6 m/(m·K), carbon steel approx 12*10-6 m/ m·K)

In the polyester process, where temperatures up to 300°

Thermal stress can generate leakage (gaskets, cracks on welding seams etc.)

(hot bolting)

correct sequence (cross­wise) and each bolt has to be marked when the torque has been reached

Liquid circulation systems (HTM, WCL, WCH etc.)

to the equipment

Equipment

leak due to evaporating water)

to make sure that the vessel is clean and empty

Cleaning:

Leakage Tests:

Calibration of Level:

Filters:

than one minute)

cleaning of filter candles)Filters:

pressure as well as circulation where required (Mechanical Catalogue)

mark (arrow)

- Check the position of the agitator shaft (perpendicular)

Agitators:

the reactor (further information is found in the Mechanical Catalogue)Agitators:

Measure the vertical alignment after initial heating and readjust if necessary (tolerance 0.3 %)Columns:

- make sure that any transportation safety units (bolts)General:

manufacturer’s instructions (see Mechanical Catalogue)

- lubrication in accordance with the manufacturer’s instructions (see Mechanical Catalogue)Pumps:

(For high-temperature condition (e.g HTM)

pressure build up or boiling by water in the quench chamber)Centrifugal Pumps:

- sealless pumps (magnetic drive, canned motor)

- open feed and discharge valve, vent, close discharge valve

- check the instrument function (alarm to control room)

- keep the pump running for some hours (as recommended)

to a high value After the bearings are run-in, this temperature will drop slightly)

A small leakage (9 drops per minutes) is necessary and normal (technical tight)Centrifugal Pumps:

Volumetric Pumps (gear pumps, screw pumps)

(positive displacement)

- helical rotor pumps

Volumetric Pumps (gear pumps, screw pumps)

(screw pumps must be filled with EG for lubrication)

(the valves must be fully open)

overheat the motor Use a lubricant liquid such as EG.

accordance with the manufacturer’

after some hours operation (3 - 4 hours are recommended)

to a high level After some hours running this temperature can decrease by a few degree

vertical (perpendicular)

- For start-up procedure and safety instructions follow strictly the instructions in manufacturer’

manual in the Mechanical Catalogue

- For start-up procedure follow strictly the instructions in the manufacturer’

- For commissioning and start-up preparations consult the manufacturer’

Centrifuges and Mills:

- for further commissioning procedure consult the Mechanical Catalogue.

- check the function with standard weights.

adjusting the inlet butterfly valve as well as the vibration motors)

system is balanced

the flanges)

- further commissioning work in accordance with the Mechanical Catalogue

Check that the commissioning work is in accordance with the manufacturer’

described in the Mechanical Catalogue

- make sure that illumination of important equipment, in­

- all MCC’s and CCR’

- ask for the approval of the local authorities

of MCC’s, CCR’

- cable number and are correctly connected and marked in FIELD CHECK REPORT

- all inverters will be adjusted and given a final check by specialists

For communication between the central control room (CCR), the motor control cabinet (MCC)

long as erection work, insulation work and cleaning is going on

- cable connection between the field instruments and the control unit (tag number, nest)

- simulation of the control function

Use water instead of chemicals (except eccentric screw pump test)

disturbance they still remember how to operate the system manually

For initial start-up of the plant all interlocks must be in normal operation.

- filling valves: black

2.2 Pre-Commissioning of Paste Mix

- Pre-Commissioning Paste Mixing and Espree Reactor: Op.Manual, V: 3, pt 8, Doc No IZ-11937

2.2 Pre-Commissioning of Paste Mix

- EG mixing tank with EG mixing pump, EG cooler and Raw Material dosing (PTA)

- the process column system

2.2 Pre-Commissioning of Paste Mix

- Organization of Pre-Comissioning and Start-up: Op.Manual, V: 1A, pt 6, Doc No IZ-11916

2.2 Pre-Commissioning of Paste Mix

Follow the instruction given in the Operating Manual „

and Espree Reactor

Before pressurising the individual systems, make sure that the systems are completely dry

2.2 Pre-Commissioning of Paste Mix

- Postesterification system:

in “open

20E33 and its associated rupture disc has to be open The ball valve must be locked, in “open

- Before pressurising Evaporator system, the blow-off line via safety valve 575-105 must be free

2.2 Pre-Commissioning of Paste Mix

2.2 Pre-Commissioning of Paste Mix

The individual systems (Postesterification and Prepolycondensation)

respective valves or using blinds, as prior discussed (Tightness Test)

vent groups, including the connected condensers must be ready and steam supply available

2.2 Pre-Commissioning of Paste Mix

pressure increase over a period of 24 hours (consider temperature fluctuation)

- Postesterification system:

- Prepolycondensation system: 20 mbar a

2.2 Pre-Commissioning of Paste Mix

The pressure increase (Leak rate)

Ä

Ä

The cold vacuum test of the two systems (Postesterification and Prepolycondensation)

- Postesterification incl spray system: 54’420 litre 6.6 Pa/h (0.066 mbar/h)

- Prepolycondensation incl spray system: 90’000 litre 4.0 Pa/h (0.04 mbar/h)

2.2 Pre-Commissioning of Paste Mix

- Postesterification system: leakage rate: 6.6 Pa/h ( 0.066 mbar/h)

- Prepolycondensation system: leakage rate: 4.0 Pa/h ( 0.04 mbar/h)-> see Op Manual, Vol 3, pt 8.5.6: Procedure for Ammonia Test

2.2 Pre-Commissioning of Paste Mix

- calibration of instruments in the field (such as level and flow instruments)

available The Wet Check is done in cold condition (except steam tracing)

Usually demineralised water (WDR)

glycol (EG)

production building No water must be filled into the HTM (and fuel oil piping systems if existing)

the Mechanical Catalogue of each equipment

2.2 Pre-Commissioning of Paste Mix

water circulation and check the whole system for leakage

2.2 Pre-Commissioning of Paste Mix

initial start-up with the actual mole ratio in normal operation

2.2 Pre-Commissioning of Paste Mix

The calibration starts with an empty vessel Reset 20FIC127 and start water filling into the reactor

(sensed from hose marking)

- if 1 % level is reached (until 1 % level is reached, fill-in water slowly)

- as soon as the minimum volume (according reactor drawing)

level according to the reactor drawing)

- when the maximum capacity of chamber (water level ~ 100 %)

(0% - 100% monomer level)

Monomer density (temp 265ºC)

2.2 Pre-Commissioning of Paste Mix ing and Espree Reactor

2.2 Pre-Commissioning of Paste Mix

installed on sample valve (SP 1-51)

The calibration starts with an empty reactor vessel Start filling of water into the reactor

2.2 Pre-Commissioning of Paste Mix

(sensed from hose marking)

- if 1 % level is reached (until 1 % level is reached, fill-in water slowly)indicated in the reactor drawing)

- until the maximum capacity of chamber (water level ~ 90%)

calibration curve showing the postesterification’

monomer level (0% - 100% monomer level)

Monomer density (temp 265ºC)

K = water density / monomer density = 1000 / 1100 = 0.909

2.2 Pre-Commissioning of Paste Mix

The calibration starts with an empty vessel Start filling of water into the reactor

2.2 Pre-Commissioning of Paste Mix

- if 1 % level is reached (until 1 % level is reached, fill-in water slowly)

- as soon as the minimum operating volume (according to reactor drawing)

- when the maximum operating volume (according to the reactor drawing)

level (0% - 100% prepolymer level)

Prepolymer density (temp 280ºC)

K = water density / prepolymer density = 1000 / 1100 = 0.909

2.2 Pre-Commissioning of Paste Mix

The level calibration of the EG mixing tank 18S16 (partly calibration only)

e.g 46.3% water level = (46.3 x 1.08)

e.g 45.45% water level = (45.45 x 1.1)

of the plant and the various trial runs such as distillation test)

(preparing of EG/water mixture (80:20)

2.2 Pre-Commissioning of Paste Mix

The level calibration of the EGS collecting tank 37S92 (partly calibration only)

with demineralized water (WDR)

e.g 45.45% water level = (45.45 x 1.1)

water using a pre-calibrated flow instrument (water counter)

For detailed calibration procedure, refer to supplier (sub Vendor’s) instruction manual

2.2 Pre-Commissioning of Paste Mix

Especially for the Espree reactor the four upper guide plates (at ~ 25m)

After heating up, the guide plates must be move to the end position (touching the steel structure)

2.2 Pre-Commissioning of Paste Mix

Sliding faces, which are restricted (i.e by foundation screws or dirt or too much friction)restrict smooth expansion and can cause deformation of equipment (reactor)

FIXED END

SCREW

2.2 Pre-Commissioning of Paste Mix

The atmospheric boiling point of HTM is 256°

the boiling point can be reduced to approx 150 - 200°

- HTM liquid systems (HPD, HSA, HSB, HSC)

- HTM vapour systems (HTV)

- heating above normal HTM boiling temperature i.e under pressure

2.2 Pre-Commissioning of Paste Mix

completely open (MV% = 100%)

small steps (61TIC-… ….: adjust switch-off point of heating plant)

respective plant section to be heated must be slowly increased (preferably 10°C per hour)

than 20°

inform / shut down the heating immediately in case of any abnormality

2.2 Pre-Commissioning of Paste Mix

atmospheric pressure This way EG will evaporate at 196°

temperature (< 10°C below)

Vent immediately when the vent temperature drops again

2.2 Pre-Commissioning of Paste Mix

It should be within the limits of “Mechanical Handbook”

view to tightness and extraordinary occurrences

2.2 Pre-Commissioning of Paste Mix

- Part or all water from the reactors (from level calibration)

- Nominal nitrogen flow in the Espree reactor through the measuring manifold (20FI305)

MANUAL mode Set their set points to 0 bar(g) (atmospheric pressure)

Open the pressure control valves (output of controllers (MV%) = 100%)

2.2 Pre-Commissioning of Paste Mix

- Cooling water (WCL)

position (back to the paste mixer)

- Pressure control valve 20PV100 at bottom of heat exchanger 20E10 is fully opened

2.2 Pre-Commissioning of Paste Mix

- Blind is installed at nozzle N3-10 and N3-11 (feed lance)

- Nitrogen feed through 20FI201 into postesterification chamber: 1.2 kg/h (temporarily)

The condition ready for heating-up must be confirmed by start-up manager and the plant manager

2.2 Pre-Commissioning of Paste Mix

- Drain all water from the stripper column 24T61 (vessel for reflux)(cooling water flows through the cooler)

2.2 Pre-Commissioning of Paste Mix

the valve’

that dirt settles down and damage the valve’

the vent valve (loss of HTM), the emergency drain valve might have a leakage

2.2 Pre-Commissioning of Paste Mix

- Together with the tightness test check the pressure instruments (interlocks!)

expansion during heating)

- Observe level for some time to assure that no drain / filling valve has inner leakage

2.2 Pre-Commissioning of Paste Mix

(MV=100%)

- Open the valve to get a heating rate of 5°

- Increase temperature of the primary system (heating plant) by preferably 10°

max 20°

The temperatures will start to rise from bottom to top (top of evaporator up to vent vessel)

- Slowly (5°C per hour)

(20D23 / 20D33 and 37S90)

maximum temperature of 50°C is allowed

2.2 Pre-Commissioning of Paste Mix

- When the vent temperature reaches a value 10°

- Check the heating state of critical points in the field (portable thermometer)

measuring range can be confirmed now (no calibration necessary)

- The product temperature in the reactors will increase to approx 196°

as long as EG remains in the reactors (atmospheric boiling point)

This is the first stage of hot bolting (200°C)

crosswise with the respective torque meter (see Codes and Standard / IN 40.2003)

(cascade control)

- Increase the temperature of the primary HTM system (61TIC… )

(340 - 345°C) in steps of 10°C per hour