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 Mr Keith Lyles. Electrical components by Mr. Keith Lyles. Compressor internals by Mr. Bob Lorenzi.

1. Overview of the Channelview facility:

H2 Praxairs H2 Pipeline

Fin Fans

Compressor Unit

Electrical Room

99.9% pure H2

H2 For Lyondell compressors

PSA Beds 1st Row

Metering Station

Surge Tank

Filter

PSA Beds 2nd Row

Bomb Resistant Container (BRC)

TAIL GAS

Small amount of H2 to test for traces of impurities

DCS Control Room

H2 Compressed by Lyondell compressors

FEED GAS 95% Hydrogen mixture from Lyondell

Analyzer Unit (N2, O2, CO)

Control Room

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 usable products that are separated by our PSA beds.

II.

Compressed H2: A part of our processed Hydrogen is sent back to Lyondell for compressing using their compressors (Praxair pays separately for this service). But rather than utilizing that compressed H2 directly, Lyondell sends it back to Praxair for us to introduce 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 down for some reason.

Output: Tail Gas: The remaining 5% of the feed gas that is not hydrogen is sent back to Lyondell which they then use as fuel. II. H2 for Compression: By Lyondell compressors. III. 99.9% Pure H2.

I.

2. Electrical Room, Control Rooms and Motors: 1. Electrical Room: Its purpose is to house electrical equipment. Different
electrical equipment that we saw, and their descriptions are as follows:

i.

Electric Switchboard: A device/panel of switches that directs electricity from one source to another. Its role is to divide the main current 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. Switchgear: Combination of switches, fuses and circuit breakers used 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. Transformers : A device that steps-up or step-down voltage. UPS: Uninterruptible Power Supply. The UPS at Channelview was big enough to keep the plant running for 2 hours incase of a power outage. PLC: Programmable Logic Controller used for automation of electromechanical processes.

ii.

iii. iv.

v.

There are specific architectural requirements for the construction of an electrical 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 rating 600V and 5kV. Hence the cable racks and conduits were designed for voltages higher than 600V.

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

3. DCS Control Room: DCS stands for Distributed Control System. The DCS
control room at Channelview was going to be pressurized from inside by using a 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 and
an Induction motor. The one at Channelview running our compressor was a Synchronous motor.

i.

Synchronous motor: Where the speed of motor rotation is equal to the frequency of the power (current) provided. This is done by providing the motor with an excitation current. Mr. Keith showed us the panel where the excitation settings could be changed. Induction motor: The motor is always working at a speed less than the power frequency its running on (lagging motor factor).

ii.

3. Compressor:
The compressor we saw at Channelview was a two stage reciprocating compressor. Reciprocating compressors are positive displacement compressors that have an offset crank shaft driven pistons to compress gases. Some parts of the compressor that were pointed out by Mr. Bob were as follows: 1. Rotating Motor in its enclosure 2. The rotating shaft. 3. Offset Crank Shaft 4. Crosshead (Converts the rotary motion of the shaft into linear motion of the piston) 5. The bed over which the crosshead slides, which is lubricated by 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: