The 50-50 joint venture Sinopec Sabic Tianjin Petrochemical Co. Ltd (SSTPC) requested in 2019 the design and manufacture of several critical ball valves, some of them with the AMPO RCM valve condition monitoring system, with the aim to monitor the valves operation parameters which are really critical on the polycarbonate process.
Tianjin polycarbonate plant was developed by SABIC’s world-class advanced polycarbonate license, which was previously and successfully implemented on Sabic Cartagena plant in Spain. This complex has a production capacity of 260,000 polycarbonate tonnes per year.
SOLUTION:
AMPO POYAM VALVES produced and successfully delivered for this project diverse highly engineered isolation ball valves with double acting actuators and equipped by the AMPO RCM valve condition monitoring system, which is a predictive maintenance system patented by AMPO. The valves were installed on the most critical production lines of the polycarbonate complex.
This AMPO RCM (Remote Condition Monitoring) system developed by AMPO POYAM VALVES monitors valves’ torque/position and detects possible future failures that may occur in the valves installed at the plant, so that they can prevent unexpected plant shutdowns and increase efficiency. Moreover, the system ensures that the valves are continuously connected, so that AMPO supplies monitoring and analysis of the situation of the valves.
Several AMPO POYAM switch plug valves were installed at Salt Lake City refinery years ago and Marathon Petroleum requested a safety and ergonomics upgrade for the operation of an AMPO POYAM switch plug valve.
Salt Lake City refinery began operations in 1908 and is now the largest refinery in Utah with a total crude oil refining capacity of 66,000 barrels per calendar day (bpcd). The Salt Lake City refinery processes crude oil from Utah, Colarado, Wyoming and Canada to manufacture gasoline, distillates, heavy fuel oil, natural gas liquids and petrochemicals and propane.
SOLUTION:
AMPO rebuilt the existing switch plug valve automatizing valve operation with an electric actuator and double security interlocks for safety increase.
AMPO POYAM VALVES evaluates and offers complete valve actuation control systems customized specifically for functional requirements, optimizing CAPEX and OPEX. We are moreover part of an integrated supply chain network with world-renowned actuator manufacturers, which allows us to offer the widest range of proven-in-use VALVE ACTUATION CONTROL system solutions. The VALVE ACTUATION CONTROL SYSTEMS go through comprehensive Factory Acceptance Testing (FAT) to deliver the most reliable valve actuation control systems on the market.
AMPO POYAM VALVES offers more than just valves by its INTEGRATED SMART SOLUTIONS (ISS) development services.
The development of an Emergency shutdown integrated system for Queensland Alumina Limited. (Turnkey project)
SOLUTION:
AMPO POYAM VALVES supplied in 2023 an emergency shutdown integrated system for Queensland Alumina Limited (QAL), one of the largest alumina refineries in Australia. The system was tailored designed by our in-house Ph.D level “INTEGRATED SMART SOLUTIONS (ISS)” experts in tight collaboration with our AMPO SERVICE team, who takes care of aftermarket and develops custom made engineered solutions for worldwide end users/operators of the mining and energy sectors. The system consisted of six 20” 600 lbs slurry angle valves, six Hydraulic Power Units (HPU) and Programmable Logic Controllers (PLC) as well as six oil accumulators.
Located in Gladstone, Queensland, the East coast of Australia, this SIL1 rated emergency shutdown integrated system will be shortly installed in the flash tank area of the alumina refinery, after the digestion unit. This smart system assures valve closure in case a command is received from the plant Emergency Shutdown System (ESD). Hydraulic accumulators guarantee valve closure even if electric power is down. This control system has maximum priority and overrides any other order.
The dual control system also has a Programmable Logic Controller (PLC) for valve positioning. DCS (Distributed Control System) controls the valve position using an optical fibre communication system and can be controlled in 1% increments.
The emergency shutdown system also includes a condition monitoring system to monitor critical parameters such as oil level, temperature, pressure and valve position, which are transmitted to the plant DCS (Distributed Control System) using the beforementioned optical fibre communication system. Electrical enclosure also includes vortex coolers to assure long service life under high temperature conditions. The enclosure is moreover IP65, keeping system isolated from outside contamination.
These ISS systems have already been delivered and will be shortly installed in Queensland Alumina refinery, where we will work hand in hand with the customer during the set-up process, referring our valve and ISS specialists from AMPO to Australia.
With the achievement of this new milestone, AMPO strengths its INTEGRATED SMART SOLUTIONS (ISS) development services, offering more than just valves. AMPO POYAM VALVES’ technology expertise and integration capabilities allow AMPO to design and develop complete bespoke integrated systems, both free standing or skid modular solutions.
