Process Industries

Reichhold Projects

Since 1997, GP has been providing services to Reichhold (www.reichhold.com) plants located throughout North America. These services have ranged from mechanical integrity to reactive relief system analysis and are described below.

• Conducted runaway reaction evaluation of Seneca high pressure co-polymerization reactor and specified new cyclone-style knock-out vessel to separate liquids following high pressure relief actuation. This 8,000 gallon KO tank is in service and has successfully protected two reactor trains (part of 100% expansion of plant).
• Conducted runaway reaction (DIERS) and isothermal calorimetry testing and utilized this data in the evaluation (for new service) of two reactor relief systems in Houston. Sized relief devices to protect these reactors, and carried out the specification and detailed mechanical design of the relief headers, complex pipe supports, and shared cyclone style knock-out vessel (30,000 gallons). Oversaw system installation.
• Directed additional DIERS and isothermal calorimetry testing programs for acrylate polymerization safety improvement, including two-phase relief sizing and knock-out vessel functionality and integrity evaluations.
• Assisted Reichhold in developing customized tools for relief adequacy screening for atmospheric storage tanks.
• Assisted Reichhold in developing and presenting a comprehensive relief technology class for their North American production facilities.
• Wrote template mechanical integrity procedures for Reichhold Corporate that have been adopted by all the major Reichhold facilities. GP also provided training to key plant personnel on the implementation of the procedures. This work included evaluation of best practices at nine sites.
• Implemented customized mechanical integrity (MI) programs at three Reichhold facilities.
• Conducted Fitness-for-Service engineering evaluations of storage tanks, reactors and other vessels at five Reichhold facilities. These evaluations utilized API 653, API 620, or ASME B&PV Code criteria, as appropriate, and included finite element analysis of non-standard tank configurations.
• Provided training and certification of maintenance personnel in visual and ultrasonic thickness inspection at plants in Bridgeville, PA, Houston, TX, Newark, NJ and Jacksonville, FL.
• Produced a corporate welding manual to assist plants in standardizing the welding methods used in critical processes. This included commonly used Welding Procedure Specifications and welder qualification guidelines, in accordance with ASME B&PV Code, Section IX.