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Metso’s new intelligent valve technology for Shell Eastern Petrochemicals’
Houdini project 

12.10.2010  + + +  Shell’s largest petrochemicals investment to date, the so-called Houdini project in Singapore, was managed with the strong intention to use the latest technology, intelligence and diagnostic potential on the pneumatically operated on/off valves. As the technology leader, Metso was awarded the umbrella contract for all pneumatically operated on/off valves in the new parts of the plant. 

Metso’s contribution to the project includes some 1,350 valve assemblies with new technology. All pneumatically operated on/off valves in the project are equipped with Neles ValvGuard VG9F intelligent safety valve controllers, as mandatory, instead of conventional solenoid valves and limit switches. This new technology-based pneumatically operated on/off valve set-up was applied for the first time on such scale anywhere in the world. 

Mr. Peter Beerepoot (Shell ECC Project, Manager Process Automation Group and Instrumentation) is very satisfied with the decision to use ValvGuard throughout the Houdini project. “Yes, there is always a risk in using a new product on such a scale, but we were convinced of the advantages the valve controller offered. Houdini was a complex project, but the end result speaks for itself. We started the plant up with no major hiccups in just 29 days, which was most satisfactory.” Shell announced the Houdini project’s successful completion in May 2010.

New technology on global scale

The new plant is set up for the FOUNDATION Fieldbus using the FDT/DTM technology. Metso’s delivery scope includes Neles ball valves, high-performance triple eccentric disc valves, V-port segment valves, eccentric rotary-plug valves and pneumatic cylinder actuators, as well as Jamesbury ball valves, butterfly valves and pneumatic actuators. Metso also included some 3rd party valve products in order to provide a “Total Project Approach” from one vendor. 

The total delivery comprises 528 on/off valves, 653 emergency shut-down (ESD) valves, 93 control valves, including low db and anti-cavitation Q-trim models, 33 high rate and low rate de-pressurizing valves and 51 manually operated valves. Sizes range from 0.5”-72”. Pressure ratings range from ANSI Class 150, 300 and 600 to 1500. The temperature range is from high to cryogenic. The project fully follows Shell’s specifications, including fugitive emission requirements. 

All pneumatically operated on/off valves for the Shell Houdini project are equipped with Neles ValvGuard VG9F intelligent safety valve controllers, which is mandatory, rather than using conventional solenoid valves and limit switches. This enables the plant to carry out full diagnostics on all on/off valves via the DCS asset management system. The Neles ValvGuard VG9F is connected to the safety system and the FOUNDATION Fieldbus DCS system for full diagnostics and configuration. VG9F intelligent safety valve controllers are also mounted on all pneumatically operated on/off valves outside the Metso range. 

Project support all over the world

At the Shell Houdini project, Metso site teams of around 20 people are working at full speed to support the commissioning and start-up activities. For such projects, Metso provides global key-account management support and in-house engineering support for EPC contractors. Additionally, support for package-unit suppliers’ projects is provided all over the world, as well as project execution support and site project management services.

Houdini project 

Shell Eastern Petrochemicals Complex (SEPC) project in Singapore is the company’s largest petrochemicals investment to date and its second world-scale petrochemicals project within Asia in four years. The project was announced successfully completed in May 2010.

According to the Houdini project plan, each of the new chemical production units has started up. The world-scale ethylene cracker complex started up in March 2010, and one of the world’s largest monoethylene glycol plants started production in November 2009. The project also includes modifications to the Shell Pulau Bukom Refinery, enabling it to process a wider range of crudes to supply feedstock to the cracker. A new ethylene jetty and cryogenic terminal enable the import and export of ethylene.

Metso is a global supplier of sustainable technology and services for mining, construction, power generation, automation, recycling and the pulp and paper industries. We have 27,000 employees in more than 50 countries.  

For more information please visit www.metso.com
or contact Oscar Bronsveld < oscar.bronsveld@metso.com >

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