Case Study

Polyethylene (HDPE) Extruder/Mixer Replacement

Challenge:

One of the largest petrochemical facilities in the Midwest was having difficulties meeting demand for their plastic fuel tank (PFT) resin business due to reliability issues. They needed to convert a production line to high density polyethylene (HDPE) and wanted to replace the existing equipment and systems, while utilizing the existing structure.

Solution:

Valdes provided the client with detail engineering of the outside battery limits (OSBL) equipment needed to support a new vendor-supplied mixer/extruder system. The design work provided for various project phases, including demolition, site preparation, engineering schedule, instrument specification, installation, and integration, as well as many details in between.

Valdes assumed responsibility for the project in FEL 3. The project was transferred to Valdes based on strong collaboration between our home office and site teams along with executing projects with an “owner” mentality, with Valdes assuming responsibility for rectifying gaps in FEED, and then assuming full responsibility for FEL 3, Detailed Engineering, and overall Construction Management of the upgrades.

This project utilized CWA & CWP to replace and upgrade the existing extruder system while maintaining operation of the existing system. A new extruder system was installed in an existing unutilized high-bay production building. The building required extensive modifications to accommodate new equipment and area classification. Valdes also engineered and designed a new Substation and MCC which were required as well.

Valdes overcame significant obstacles such as working with an international equipment vendor for the new mixer and executing many activities, both in engineering and in construction, in parallel to deliver our engineering packages on schedule. Moreover, Valdes achieved this while ensuring buy-in from all project stakeholders, including equipment vendors, and the client’s corporate and site-based technical engineering authorities.

Impact:

Valdes has developed their experience using laser scanning and 3D modeling to assess existing conditions and have refined their skills over decades to integrate this process into their design approach. Using these skills, Valdes was able to assess the existing conditions and develop a design for the refinery so that they could move forward with the installation of the new equipment within their existing facility with little interruption.