samac smh

Polymethyl Methacrylate (PMMA) Pelletizing Extruder Line Overhaul

by with No Comment Turnarounds and shutdowns completed

Client: Saudi Methacrylates Company (SAMAC – SABIC / Mitsubishi Chemical JV)
Location: Jubail Industrial City, Kingdom of Saudi Arabia
Facility Unit: Polymethyl Methacrylate (PMMA) Resin Plant

Equipment: High-Torque Co-Rotating Twin-Screw Extruder, Melt Pump Assembly & Underwater Pelletizer

Services: High-Precision Extruder Overhaul, Barrel Segment Alignment, Screw Element Reconditioning, Die Plate Resurfacing

Project Overview

SMH Arabia completed a full-scope mechanical overhaul of the primary PMMA pelletizing extruder train during a planned unit outage at SAMAC’s acrylic resin manufacturing complex in Jubail. To eliminate polymer contamination, barrel scoring, and melt-pressure fluctuations, the engineering team executed complete disassembly, dimensional metrology, and precision field alignment across the twin-screw extruder barrel, melt pump, cutter head assembly, and drive motor.

Core Engineering & Mechanical Scope

  • Extruder Barrel & Screw Element Overhaul: Extraction of twin-screw shafts, non-destructive testing (LPI/MPI) for thermal stress micro-cracks, screw segment re-configuration, and bimetallic barrel liner bore measurement.
  • Melt Pump & Cutter Head Refurbishment: Complete mechanical servicing of high-pressure polymer melt gear pumps, replacement of high-temperature mechanical seals, cutter hub re-balancing, and precision die plate face resurfacing.
  • Extruder Drive Gearbox Servicing: Gear tooth contact pattern analysis (backlash checking), internal bearing replacement, shaft oil seal renewal, and lube oil flushing.
  • Laser Shaft Alignment & Metrology: High-precision laser alignment across the main motor, heavy gearbox, melt pump, and extruder drive shaft to correct thermal growth offsets.
  • Pre-Commissioning & Dynamic Testing: Cold/hot runout checks, uncoupled solo motor runs, baseline vibration monitoring, and dynamic balancing of rotating cutter assemblies at the SMH central workshop.

Key Outcomes & SEO Highlights

On-Time Outage Delivery: Executed full mechanical refurbishment strictly within SAMAC’s scheduled shutdown window under ISO 9001, 14001, and 45001 compliance.

Resin Melt Quality & Flow Rate: Restored steady melt-pressure delivery, eliminating melt fracture and ensuring uniform PMMA pellet size.

Mechanical Integrity: Reduced drive train vibration levels well within original OEM baseline limits.

samac smh

Turnaround & Maintenance Excellence: Extruder Overhaul for PDH-PP Plant

by Turnarounds and shutdowns completed

Industry: Petrochemical & Polymer Manufacturing

Target Equipment: Extruder Package (PDH-PP Unit)

Location / Partner: SAMAC / SMH Technical Team

Overview

SMH successfully executed the major overhaul of the core Extruder unit for the PDH-PP Plant at SAMAC. Leveraging specialized mechanical expertise and proven turnaround management protocols, SMH ensured seamless reliability, precise alignability, and extended operational lifespan for critical rotating machinery.

Core Competencies & Services Delivered

  • Mechanical Overhaul & Refurbishment: Complete strip-down, inspection, and precision overhaul of high-capacity Extruder trains.
  • Turnaround & Shutdown Execution: Timely execution meeting strict plant availability and safety standards.
  • Precision Alignment & Dynamic Inspection: Critical component tolerance checks, drive assembly alignment, and wear assessment.
  • Quality & Safety Compliance: Zero-incidents execution following rigorous QA/QC and industrial safety protocols.

Key Outcomes

  • Enhanced mechanical reliability and throughput efficiency for polymer processing.
  • Reduced risk of unplanned downtime via proactive asset maintenance.
  • Delivered on-schedule handover within targeted turnaround windows.