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better than a RENTECH boiler. Its no yarn. Each of our boilers is custom-designed by RENTECH
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Select 52 at www.HydrocarbonProcessing.com/RS
PROCESS DESIGN
Dynamic models improve
safety for high-pressure vessels
ENVIRONMENT
Investigation reviews
inert gas usage
SAFETY
Hazard analysis identifies
alarm/control problems
SPECIAL REPORT:
Maintenance
and Reliability
SENTRON LD 5000
Field Tested. Field Proven.
21
10
52
SPECIAL REPORT: MAINTENANCE AND RELIABILITY
53
61
67
PROCESS DESIGN
71
REFINING DEVELOPMENTS
77
DEPARTMENTS
4
10
21
23
101
102
104
106
COLUMNS
9 Editorial Comment
What separates the best-of-class
companies from the rest?
25
29
M. Sawyer
ENVIRONMENT
99 What every refiner should know about
nitrogen generation and delivery
Automation Strategies
The automation challenge
requires new approaches
31
Project Management
Better strategies avoid
project delaysPart 2
J. Hair
SAFETY
95 Minimize false assurances in hazard analyses
Reliability
Make equipment decisions with
up-to-date technical information
Industry Perspectives
News
Forum
Industry Metrics
Events
Marketplace
Advertiser Index
People
37
Global
Russian executives to build
countrys first waste oil refinery
39
Petrochemicals
Ammonia production booms
on cheap natural gas
43
Gas Processing
Asian gas market seeks lower pricing,
infrastructure expansion: Part 1
D. Connaughton
45
Cover Image: In Rotterdam, an entire refinery was shut down, modernized and put back into operation.
Bilfinger is the specialist for these extensive turnarounds. Photo courtesy of Bilfinger SE.
Boxscore Construction
Analysis
Qatars petrochemical sector
surges through new projects
49
Viewpoint
What characteristics define
the worlds best refineries?
www.HydrocarbonProcessing.com
Industry Perspectives
Reflections from a petrochemical giant
Frank Popoff, retired chairman and CEO of the Dow Chemical Co., shared his insight on the petrochemical industry at the
AFPMs 2014 International Petrochemical Conference (IPC).
With a career spanning over 41 years, Mr. Popoff has witnessed
the evolution of the petrochemical industry between two Gulf
coaststhe US and the Middle East.
As a former leader of an international petrochemical company, Mr. Popoff shared some observations on the industry to
IPC attendees. First, expect change in the business cycle; more
importantly, embrace it. Since its inception, the petrochemical
industry has always followed cycles. Unfortunately, companies
still over-invest in new capacity at the top of the business cycle,
thus creating an overcapacity situation. Second, change within
the petrochemical industry is accelerating. Operating companies
are enduring pressures internally and externally that are linked to
underperformance, especially with respect to profits.
Reality vs. perception. Mr. Popoff also remarked that the public
has a disconnected view of the downstream. In the 1950s, the petrochemical industry was viewed as an innovative and high-tech
industry. Fast-forward to present day, the petrochemical industry
is very disconnected from the public and the regulatory agencies.
More importantly, younger people do not consider employment
opportunities in the petrochemical industry. This perception of
the industry must change.
Advice from a veteran. How can the downstream change its
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P. O. Box 2608
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EDITORIAL
Editor
Managing Editor
Reliability/Equipment Editor
Technical Editor
Online Editor
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Contributing Editor
Contributing Editor
Contributing Editor
Stephany Romanow
Adrienne Blume
Heinz P. Bloch
Billy Thinnes
Ben DuBose
Helen Meche
Lee Nichols
Loraine A. Huchler
William M. Goble
ARC Advisory Group
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Periodicals postage paid at Houston, Texas, and at additional mailing office.
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Permission is granted by the copyright owner to libraries and others registered
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President/CEO
Vice President
Vice President, Production
Editor-in-Chief
Business Finance Manager
Part of Euromoney Institutional Investor PLC. Other energy group titles include:
World Oil and Petroleum Economist
Publication Agreement Number 40034765
4MAY 2014|HydrocarbonProcessing.com
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Kinetics Process Improvements, Inc
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2014 Agenda at a Glance:
Wednesday, July 30, 2014
8:45 a.m.
Keynote Presentation
8:45 a.m.
Keynote Presentation
9:15 a.m.
9:15 a.m.
Session 1: Syngas
10:10 a.m.
10:35 a.m.
11 a.m.
11:25 a.m.
10:35 a.m.
11:05 a.m.
12:30 p.m.
Lunch
Session 5: Catalysts
1:30 p.m.
1:55 p.m.
Lunch
12:50 p.m.
2:35 p.m.
3:05 p.m.
Early Bird
(by June 25)
Regular
Admission
Single Attendee
$891
$990
Team of Two
$1,634
$1,815
Group of Five
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Customer:
Challenge:
Result:
EBARA CORPORATION
C O M P R E S S O R S
T U R B I N E S
G L O B A L
S E R V I C E
Select 54 at www.HydrocarbonProcessing.com/RS
Editorial
Comment
vironment (HSE) research program identified the top five human-factor errors.
These factors, sourced from previous organizational accidents listed in HSE databases, are:
1. Managing people
2. Procedures
3. Training and competence
4. Staffing
5. Organizational changes.
As the downstream workforce undergoes a significant shift change when
experienced employees retire, the listed
human factors will have an even higher
impact on an organizations performance.
Staffing and training will carry heightened
concerns as employers plan for a smaller
workforce undertaking vital roles in the
operation of process units and the maintenance of equipment. More important,
what resources will be used to train and
certify plant operators and crafts? As fewer
younger people enter apprentice and craft
training programs, the pool of qualified
and competent employees shrinks.
Maintenance is a key priority for topperforming facilities. Achieving high
49Viewpoint.
What defines
the worlds best refineries?
New process equipment and a higher
refinery complexity index do not
guarantee a place on the worlds best
refineries. Other metrics, such as return
on investment, energy efficiency,
net cash margins, maintenance
practices and more, separate leading
from laggard performance in the
global refining industry.
and
52Maintenance
reliability.
Operating
companies use maintenance programs
to protect their capital investments.
Since equipment failures can result
in expensive unit and plant shutdowns,
or environmental or safety incidents,
best-of-class companies maintain the
mindset that spending to improve
reliability and equipment conditioning
is a great benefit to the organization.
71Process design.
95Safety.
Hazard analysis is
a powerful and effective tool
to evaluate potentially hazardous plant
and process conditions. What are the
best methods to use when identifying
job hazards involving maintenance
and operational tasks? This article
reviews several proven methodologies
to consider when performing
process safety reviews.
Hydrocarbon Processing|MAY 20149
| News
EU-US Energy Council discusses
European energy security
The EU-US Energy Council met recently in Brussels, Belgium.
Following the gathering, the council issued a statement indicating
that developments in Ukraine prove the need for reinforced energy
security in Europe.
The Council underscored that energy relations with Russia must
be based on reciprocity, transparency, fairness, non-discrimination,
openness to competition and continued cooperation to ensure a
level playing field for the safe and secure supply of energy, the
statement said.
Another result of the meeting was that the Council affirmed its
support for Ukraines efforts to diversify its supplies of natural gas,
including through the rapid enhancement of reverse flow capacities
and increased gas storage capacity. The Council also issued
remarks supporting the restructuring and reform of Naftogaz.
News
12
US annual net crude imports 20032013, MMbpd
Other nations
Mexico
Saudi Arabia
Canada
10
8
6
4
2
0
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
News
For over three years, we have left no stone
unturned in trying to find a buyer for the
plant. Our efforts highlight the challenges
and ongoing changes confronting the European refining industry and are in no way
a reflection on the attitude and work ethic
of the Murco team. We will continue to
do all we can to ensure our employees are
supported during this time.
The plant employs 370 staff and between 100 and 150 contractors.
IChemE unveils
new process safety
alliance with Texas A&M
The Institution of Chemical Engineers
(IChemE) and Texas A&M Engineering
have signed an agreement paving the way
for a suite of new process safety products
and services. The memorandum of understanding (MOU) will see both organizations commit to collaboration in process
safety education and strategic leadership.
The Texas A&M Engineering Experiment Station is home to the Mary Kay
OConnor Process Safety Center, which
12
Bilfingers engineering department constantly works to offer the best and innovative solutions to the Hydrocarbon Processing Industry:
JOHNSON SCREENS SHAPED SUPPORT GRID (SSG)
designed to be installed into the bottom head of hydroprocessing
or gas dehydration vessels, allowing better liquid and gas flow,
bed utilization, distribution and an overall more efficient process
than traditional flat surface grid assemblies. Patented design.
France
Phone +33 5 4902 1600
Fax +33 5 49021616
france.water@bilfinger.com
Select 55 at www.HydrocarbonProcessing.com/RS
News
houses one of the worlds biggest process
safety libraries and is regarded as a leader
in process safety education.
The MOU was signed at the American Institute of Chemical Engineers 2014
Spring Meeting in New Orleans, Louisiana,
by IChemE chief executive David Brown
and Sam Mannan, director of the Mary
Kay OConnor Process Safety Center.
This is good news for IChemE and
good news for Texas A&M, but, impor-
www.intergraph.com/go/spo
Intergraph Corporation. All rights reserved. Intergraph is part of Hexagon. Intergraph, the Intergraph logo, and SmartPlant
are registered trademarks of Intergraph Corp. or its subsidiaries in the United States and in other countries.
14
Select 57 at www.HydrocarbonProcessing.com/RS
INTRODUCING
INSPECT
MECHANICAL INTEGRITY
A N D F I T N E S S - F O R - S E RV I C E S O F T WA R E
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Codewares COMPRESS package is the leading pressure vessel and
heat exchanger design software.
Select 58 at www.HydrocarbonProcessing.com/RS
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28.6 years
03/04/2019
PASS
PASS
News
JRC is being developed by the JTC
Corp., a government agency responsible
for industrial infrastructure development
in Singapore. Located on Jurong Island,
the JRC project will complement and
enhance the existing infrastructure and
support the growth of the chemicals and
energy clusters.
Air Products liquid nitrogen will be
used as a blanketing gas for the oil storage
caverns for safety purposes.
We are honored to have been selected by JTC to take part in and supply this
groundbreaking solution to oil storage
needs, said Leong Wah Fong, managing
director of Air Products Southeast Asia.
Singapores energy and chemical industry is a strategic market for us and we
have built a foundation to serve its needs
through diverse supply modes.
Air Products began serving petrochemical customers on Jurong Island in 1997
through an air separation plant located at
Sakra. To meet the increasing gas demand
in Singapores major chemical hub, the
company has recently announced a pipeline
extension from the area to the newly developed areas in Tembusu to expand coverage.
In addition to the air separation plant
on Jurong Island, the company also has a
fleet of road tankers delivering liquid products, a helium and specialty gas plant in
Senoko and an epoxy additives and a polyamide plant in Gul Crescent.
tal demand, with a 27% share in 2018, owing to the high volume of filters sold both
as original equipment and in the aftermarket. Motor vehicle filter demand will be
supported by a rising number of vehicles
in use and increasingly strict standards for
vehicle emissions. Value growth will also
be supported by the introduction and
increasing adoption of newer products,
such as cabin air filters and other specialty
and high-value vehicle filters. Demand for
17
News
filters in the industrial and manufacturing, consumer, and utilities markets will
all witness above-average growth.
In 2013, fluid filters and internal combustion engine and related filters accounted for 37% and 35% of total filter sales,
respectively. However, air filters, which
represented the remaining 28% of sales in
2013, will achieve the fastest gains through
2018, benefiting from changes in pollution
regulations, improvements in manufacturing activity, rising consumer interest and
rebounding construction spending.
Dresser-Rand wins US
Gulf supplier safety award
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Select 90 at www.HydrocarbonProcessing.com/RS
Forum
technologies, licensed technologies for refining and petrochemicals, water management, process control, process modeling /
simulation, maintenance techniques and
planning and plant management.
The conference will feature several
keynote presentations. Giacomo Respoli,
Vice President of Research and Development Projects of Eni SpA, will discuss the
design of Enis biorefinery and the future
of the downstream. On Day 2, Bakheet
Al-Rashid, CEO and president of Kuwait
National Petroleum, will share his view
on the European refining industry and the
factors reshaping the region.
Forefront of the industry. The HPI is
a global industry; success hinges on companies and their staff finding accurate and
vital information in real time to make informed and profitable decisions. At IRPC
2014, HPI professionals will have the opportunity to network and brainstorm with
executive and leaders that are charting the
course of the global HPI.
Meeting place for the global HPI.
Companies involved in the following areas
will benefit from attending IRPC: refining, natural gas processing, technology
and equipment manufacturing, consult-
ing, construction and engineering, chemicals and petrochemicals, and oil and gas
services and supplies.
Enis Venice biorefinery tour. IRPC
FIG. 1. A tour of Enis Venice biorefinery is a preconference event. This refinery is converting
from a conventional refining complex to biofuel production.
Hydrocarbon Processing|MAY 201421
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Industry Metrics
40
35
30
25
20
15
10
5
0
-5
Feb 14
Jan 14
Dec 13
Nov 13
Oct 13
Sep 13
Aug 13
Jul 13
Jun 13
May 13
80
Mar 14
Jan 14
Dec 13
Nov 13
Oct 13
Sep 13
Mar 13
Aug 13
60
Feb 14
US
EU 16
Japan
Singapore
70
Jul 13
1
0
Jun 13
90
May 13
F M A M J J A S O N D J F M A M J J A S O N D J F
2013
2014
2012
Apr 13
100
Utilization rates, %
Production, Bcfd
Apr 13
Mar 14
WTI, US Gulf
Dubai, Singapore
Arab Heavy, US Gulf
LLS, US Gulf
Brent, Rotterdam
Mar 13
The OPEC Reference Basket for crudes fell $1.23 in March. Changes in
the crude oil markets are attributed to a slowdown in Chinas economy
and reduced crude oil demand by refineries. Non-OPEC supply growth is
expected to outpace global consumption growth and stabilize oil prices.
North America leads in new production stemming from shale oil in the
US and growth in the Canadian oil sands. Global product markets are
expected to receive support from increased diesel and gasoline demand
by OECD nations.
01 Nov
08 Nov
15 Nov
22 Nov
29 Nov
06 Dec
13 Dec
20 Dec
27 Dec
03 Jan
10 Jan
17 Jan
24 Jan
31 Jan
07 Feb
14 Feb
21 Feb
28 Feb
07 Mar
14 Mar
21 Mar
28 Mar
04 Apr
Apr 14
Mar 14
Feb 14
Jan 14
Dec 13
Nov 13
Oct 13
Sep 13
Aug 13
Jul 13
Jun 13
Apr 14
Mar 14
Feb 14
Jan 14
Dec 13
Nov 13
Oct 13
Sep 13
Apr 14
Mar 14
Feb 14
Gasoil, 50 ppm S
Fuel oil, 180 CST, 2% S
Jan 14
Dec 13
0
-2
-10
-20
Nov 13
10
Oct 13
Dubai
Urals
20
Sep 13
Mar 13
Aug 13
2015-Q1
Gasoil, 10 ppm S
Fuel oil, 1% S
Aug 13
2014-Q1
Jul 13
2013-Q1
Jul 13
2012-Q1
Jun 13
2011-Q1
30
20
10
0
-10
-20
-30
Jun 13
2010-Q1
Mar 13
Forecast
2.5
2.0
1.5
1.0
0.5
0.0
-0.5
-1.0
-1.5
96
94
92
90
88
86
84
82
80
78
2009-Q1
May 13
A S O N D J F
2014
May 13
F M A M J J A S O N D J F M A M J J
2012
2013
May 13
Source: DOE
Apr 13
45
Apr 13
W. Texas Inter.
Brent Blend
Dubai Fateh
Apr 13
90
60
Mar 13
105
75
60
50
40
30
20
10
0
-10
120
All paths
lead to
Lewis Pumps
LEWIS PUMPS
Vertical Chemical Pumps
8625 Grant Rd.
St. Louis, MO 63123
T: +1 314 843-4437
F: +1 314 843-7964
Email: sales@lewispumps.com
www.weirminerals.com
Excellent
Minerals
Solutions
Reliability
some ambient air space are located between the pumpage and
the bearings, as illustrated in FIG. 3. Therefore, most of the heat is
radiated to the surrounding air. Also, barrier seals often assist in
further heat removal.
Differences in heat removal. There is obviously a signifi-
cant heat loss along the shaft between the pumpage in the pump
casing and the lightly loaded and thinly oil-coated radial bearing in the bearing housings of API process pumps. Additional
heat will be lost while moving from the radial bearing to the
more highly loaded thrust bearing set. Long-term bearing housing temperatures on liquid oil-lubricated pump bearings have
FIG. 1. Cut-away of an oil-mist reclassifier. Oil mist enters from the left;
as the bore diameter becomes smaller, its velocity increases. The small
oil-mist globules combine into heavier globules, which then coat
the bearings rolling elements.
Reliability
never exceeded 240F (116C) in pumps at major oil refineries. Operation at these temperatures would require installing a
alves
Best V 67
8
since 1
26MAY 2014|HydrocarbonProcessing.com
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BECAUSE EVERY PART COUNTS.
Dresser-Rand Services cover everything from upgrades, revamps, rerates, product training,
and eld services, right down to the nuts and bolts. And with the largest installed base of rotating
equipment in the industry, Dresser-Rand is ready to deliver comprehensive service solutions for
your centrifugal and reciprocating compressors, steam and gas turbines, and control systems
quickly, efciently and safely. With approximately 49 service centers around the world, our
personnel stand ready to help maximize the reliability, production revenue, and protability of
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Reliability
If we allow specifications to be written or amended by people
who are not informed on new developments and standards,
then the company or employer will soon lag behind others.
Without detailed lubrication knowledge, an employer will lose
more ground to the competition. Of course, a specification update will sometimes make sense and provide benefits for safety
and reliability. Yet, when an unduly tight specification is issued,
then the exact opposite may result.
Vision. When working or purchasing rotating equipment, consider the whole picture and always make informed choices. Not
allowing oil mist to be applied in pumping services over 300F
raises the question: What lube application method will these
user-specifiers choose for the 600F and 740F pumps? Other
than well-proven oil mist, only liquid oil sprayed directly into a
rolling element bearings cages is a suitable option for the reliability-focused engineer. Returning to wet sumps with tricky oil
rings and constant-level lubricators is very maintenance-intensive. An even worse choice is reverting to grease-filled singlepoint automatic lubricators for motors.1 Premium-grade motor
greases separate into soap and oil when pressurized. Lesserquality greases, while not separating as readily under pressure,
will not provide superior protection. Only plantwide oil mist
answers all of these concerns.
As of 2013, well over 130,000 process pumps are successfully lubricated by plantwide oil-mist systems. Also, 26,000
electric motors use oil mist on their bearings, and some of these
have been using oil mist for 35 years without ever replacing or
changing a bearing. Based on decades of successful installations,
applying pure oil-mist systems on electric motor drivers makes
sense and can yield rapid payback.
Nudging some user-specifiers to reliability-focused choices
should be a priority. Perhaps some could be persuaded to attend
a simple vendor-arranged update on plantwide oil-mist systems. Oil mist is highly successful for lubricating electric motors
in the 15 hp500 hp range. Of course, there is no diplomatic
way to remind an indifferent purchaser that making informed
choices is better than selecting equipment based on old anecdotes. By not including electric motor lubrication and standby/
storage protection in cost-justification studies, the uninformed
have locked entire plants into a cycle of avoidable expenditures.
Their BOC competitors have captured the lead by making wise
choices decades ago.
LITERATURE CITED
Bloch, H. P. and A. R. Budris, Pump Users Handbook: Life Extension, 4th Ed., 2013,
The Fairmont Press, Inc., Lilburn, Georgia, p. 296.
2
Bloch, H. P., Pump Wisdom: Problem Solving for Operators and Specialists, John
Wiley & Sons, Hoboken, New Jersey.
1
28
Automation
Strategies
DICK HILL
Vice President, ARC Advisory Group
ers have come a long way over the last several decades. But
technology alone is not sufficient to address the multiple
challenges that todays industrial organizations face. These
challenges span both the project design/construction/commissioning phase for a new industrial facility, and the much
longer operations and maintenance phase, in which ongoing
improvements over the lifecycle of the facilities can play such
a critical part in the business success. In many industrial facilities, this lifecycle can span decades. While it may just represent a small fraction of the total project cost, automation plays
a key role in operations and maintenance.
During the capital project phase, the challenge for the
automation team is often simply to keep their needs off the
critical path, without compromising the end results at startup and commissioning.
During the much longer operations and maintenance
phase of the industrial assets lifecycle (which could be up
to 20 years or more), the automation team must be able to
modify, update and improve the automation assets on almost
a continuous basis, and, do so at minimum cost, with minimum production interruptions, often with shrinking internal
resources. This requires technology users and suppliers alike
to apply whole new approaches.
It (automation) just happens. In his Forum presentation,
Sandy Vassar, facilities I&E manager for ExxonMobil Development Co., used the phrase it just happens to indicate his
teams goal for the automation portion in each of the more
nology suppliers in the audience to partner with technology users to come up with new and innovative solutions to the technology challenge. At the end of the presentation, he stated, We
want our (automation) guys to become the unknown engineers,
because it just happens.
DICK HILL is vice president of ARC Advisory Group in
Dedham, Massachusetts, and is responsible for
developing the strategic direction for ARC products,
services and geographical expansion. He is responsible
for covering advanced software business worldwide.
Mr. Hill has over 30 years of experience in
manufacturing and automation. He has broad
international experience with The Foxboro Co. Mr. Hill
previously worked as a senior process control engineer
with BP Oil and as the US general manager of Walsh
Automation. He is a graduate of Lowell Technological
Institute, with a BS degree in chemical engineering.
Hydrocarbon Processing|MAY 201429
Midstream Solutions
Proven Results
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Project
Management
JOS CORRALES-PREZ
Project Director, Tecnicas Reunidas, Madrid, Spain
Plot plan
MV and MCC
design and requ.
2m
Short circuit
2w
Transformer
requisition
Prelim.
cable list and sizing
2m
Tray layout
1.5 m
Tray levels
1.5 m
Trench layout
3m
Soil resistivity
Soil report
H. area classication
Cable
requisition
1.5 m
Grounding and
lightning
2m
Key
m = months
w = weeks
Best practice
discipline
maps
Review maps
with each
discipline
Review maps
with project
management
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precedence
relations
with project
management
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Project Management
Activity duration and safety buffers. Eliyahu Goldratts
theory of constraints, published in his best seller The Goal: A
Process of Ongoing Improvement, has helped hundreds of factories around the world to achieve dramatic improvements
in delivery times. In his second book, Critical Chain, he extended the same theory to project planning and developed
a new method, which many believe to be the main contribution to project management since the introduction of PERT.
Goldratts method predicts total project duration better than
PERT when resources are limited.
The critical chain method arises from the fabrication environment. The main application has been in projects closely
related to fabrication. Process plant projects are different, and
thus this method needs some tuning. Goldratt says that planned
durations are extremely conservative, but they will not be met
due to the combined effect of the student syndrome and Parkinsons law, as mentioned in Part 1. He recommends to reduce all activity durations by 50% and to introduce, later in the
schedule, a safety time buffer. In the case of process plant projects, a 50% reduction is too much, at least for the first project.
However, a 25% reduction is possible for most engineering and
procurement activities. Construction activities should also be
compressed, but only by 10%.
Duration of equipment and material deliveries is usually estimated from previous projects; it should not be shortened because it is controlled by other factors. Piping deliveries deserve
special attention. Generally, they are part of the critical path and
ago, everyone hoped that 3D CAD systems would reduce piping design and, therefore, total project duration. Many still
wonder why it did not happen. The main reason is that piping
design and vendor information are so intermingled, that cutting only one of them is not enough. Without vendor information, piping design cannot be completed, and isometrics cannot be issued for fabrication.
Project Management
Vendor information is an input for civil design and piping
design, sometimes for the procurement of other downstream
equipment. Therefore, it is crucial for both project duration and
design efficiency. The time required to obtain vendor information may be broken into two periods: placing the purchase order (PO) and waiting for the vendor to prepare the information.
Every project manager knows that early procurement is necessary for timely projects; it guarantees early arrival of vendor
information and timely delivery of long-lead equipment. A recurring problem that delays POs is the time taken to negotiate
price and delivery conditions with vendors. Too frequently,
award decisions are deferred waiting for small discounts; meanwhile, this delays the arrival of much needed information.
After the PO, the time required by the vendor to send approved drawings may take from one to five months for each
piece of equipment, and more for the total project. However,
this period can be reduced if the request is redefined.
Example: Ordering an overhung centrifugal pump. The
perfectionist will request a complete set of certified vendor
drawings. This step can easily require three months because
the fabricator may have to wait for the details of a junction
box supplied by another vendor. A complete set of drawings
is not required. The only details needed to proceed with the
design are:
Civil design requires the footprint with dimensions.
Piping design needs the exact location of inlet
and outlet flanges.
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Global
HAL FOSTER
Guest Columnist
arm, Kirishineftehimexport, was impressed with Mr. Yermolaevs determination and resourcefulness. Three years later, Mr.
Smirnov asked Mr. Yermolaev to join the Kirishi refinery business
as assistant to the general director.
In his new job, Mr. Yermolaev also met Mr. Ramzaitsev, who
would become his business partner. At the time, Mr. Ramzaitsev
was running the oil company Urals Moscow, which had a close
relationship with the Kirishi refinery. Upon Mr. Smirnovs recommendation, Mr. Yermolaev became the head of Urals Moscows
new representative office in Kirishi in 1993.
The early 1990s were a chaotic time in Russia as a market
economy took shape. Former state-owned corporations were
split into pieces, consolidated or bankrupted at a rapid pace. New
Global
businesses were formed. Many of those went bankrupt as well.
As was the pattern elsewhere in the regions, a handful of
companies came to dominate the business world in the Kirishi area. They included Urals Moscow; Kirishinefteorgsintez,
the company that ran the refinery; Kirishineftehimexport; and
Help-Moscow, a distribution firm. Surgutneftegas later bought
the Kirishi refinery.
However, even dominant companies ran into problems. Urals
Moscow began slipping in the late 1990s, and eventually was dissolved. Mr. Ramzaitsev formed Urals Energy Public Co. Ltd. in
the early 2000s to capitalize on some of Urals Moscows former
business, and Mr. Yermolaev quickly joined him.
The catalyst for the Kirishi-2 refinery was the Russian governments decree in the early 2000s that all oil companies, including Urals Energy Public, needed their own refineries. The
order was aimed at resolving a refinery shortage in the country.
Urals Energy Public began working on the refinery in 2006.
During the global economic downturn of 20082010, Mr.
Ramzaitsev was forced to sell Urals Energy Public. However, he
and Mr. Yermolaev remained committed to Kirishi-2, forming a
partnership to make it become a reality. The partnership has acquired most of the land that will be needed, along with a 13-km
rail spur from the refinery to a main rail line. The rail link, an
expensive but strategic purchase, will allow the refinery to transport its refined products to St. Petersburg for shipment overseas.
The refinery will also help satisfy domestic supply, which is
presently lacking in northern Russia. The Northwestern Federal
Diesel,
Mtpy
Residual oil,
Mtpy
432.3
1,064.2
1,162.6
Kirishinefteorgsintez
2,387.8
5,129.2
7,159.4
Total
2,820.1
6,193.4
8,322
187
457
1,185
252.7
242.8
1.4
Production by company
Lukoil
Ukhtaneftepererabotka
Demand by region
Arkhangelsk
Vologda
Kaliningrad
175.5
231.6
122.2
Leningrad
1,900.9
1,841.3
2,089.5
Murmansk
151.9
234.8
1,268.5
Novgorod
117.2
152
11.3
170
246.8
15
106.4
119.4
256.8
Pskov
Republic of Karelia
Komi Republic
152.2
586
183
Total
3,213.8
4,111.7
5,132.7
Discrepancy between
production and
consumption volumes
393.7
2,081.7
3,189.3
HAL FOSTER is a journalist and journalism professor. He was a writer, editor and
manager at San Francisco Chronicle, Los Angeles Times, Omaha World-Herald,
Portland Oregonian and Seattle Post-Intelligencer. He was also a journalist in
Japan for nine years. After obtaining a PhD in journalism and mass communication
at the University of North Carolina in 1988, Dr. Foster taught at Sam Houston State
University in Texas; Auburn University in Alabama; the University of Alaska;
and the Kazakhstan Institute of Management, Economics and Strategic Research.
He was a Fulbright professor of journalism in Odessa and Lviv, Ukraine.
Additionally, Dr. Foster has taught seminars in media management, business
journalism and other topics in Ukraine and Kazakhstan, and he has done onsite
consulting for independent newspapers in Ukraine, Bosnia and Poland.
38
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Boxscore Construction
Analysis
No. of
LNG trains
Total capacity,
MMtpy
Qatargas 1
10 (each train =
3.2 MMtpy)
Japan, Spain
Qatargas 2
Asia, Europe, UK
Qatargas 3
7.8
Asia, Europe
Qatargas 4
7.8
Asia, Europe
RasGas 12
6.6
Asia
RasGas 35
Asia, Europe
RasGas 67
Main markets
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200
No product-level data
Other petroleum products
Liqueed petroleum gas
Residual fuel oil
Distillate fuel oil
Kerosine
Jet fuel
Motor gasoline
180
160
140
120
100
80
60
40
20
0
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
Detailed and up-to-date information for active construction projects in the refining,
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48MAY 2014|HydrocarbonProcessing.com
JON D. STROUP
Viewpoint
on the worlds best refineries list, a refinery must show excellent performance
across a broad range of metrics and perform them consistently. To be in this elite
group, the refinery must achieve strong
performance over a minimum of three
consecutive studies (six years) in metrics
such as return on investment, energy inten-
Large-sized average
capacities, thousand bpd
Crude
186
Crude
447
Vacuum
63
Vacuum
169
Coker
11
Coker
48
Hydrocracker
28
Hydrocracker
34
Reformer
35
Reformer
67
FCC
40
FCC
114
Diesel HT
68
Diesel HT
128
Sulfur, ltpd
154
Sulfur, ltpd
626
Complexity
11
Complexity
14
Average age, yr
27
Average age, yr
21
Crude sulfur
1.2
Crude sulfur
1.7
Crude gravity
34
Crude gravity
32
Viewpoint
145
135
Cost, $/bbl
125
2012
LG
115
95
2010
85
75
Large-sized
Return on investment
Process utilization
Energy
Maintenance
Non-maintenance personnel
Efficiency indicators
Operational availability
MD
105
Mid-sized
Competitiveness
1
Source: HSB Solomon Associates
Quartile
misconception is that the worlds best refineries are new and very complex sites.
Results from the study proved that many
of the top-performing refineries are not
the most complex. New does not guarantee lead performance; most of the topperforming refineries are in the middle
of the pack with respect to age.
The last misconception is the belief
that the best performers are in the first
quartile in every major category. This is
not the case, as shown in FIG. 2. It is essential for an organization to have sufficient resources to operate and maintain
its refinery, along with the resources necessary to seek out and implement continuous improvement. From the 2012
study, the worlds best performers are
not in the first quartile when it comes to
non-maintenance personnel.
To-do list. How can you get your refinery
on the worlds best refineries list? Here
are some recommended action items:
Improve operational and mainte-
I n t r o d u c i n g P r o R o x a n d S e a R o x .
The new Global assortment for
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| Special Report
MAINTENANCE AND RELIABILITY
Scheduled maintenance and turnarounds are opportunities to increase plant safety
and environmental performance. By enhancing the mechanical integrity of HPI
facilities, operating companies can achieve and maintain higher uptime and equipment
availability; all are factors that contribute to higher profitability. Best-of-class
companies hold the mindset that reliability programs provide great benefits. Investing
in new monitoring and conditioning systems, along with preventive maintenance and
inspection programs, can optimize unit and total facility performance.
Photo courtesy of Bilfinger SE.
Special Report
Hydraulic assembly
Impeller/propeller
Suction inlet
Seal rings
inlet nozzle may save money initially, but they often create flow
disturbances, which tend to reduce pump life.
Pump performance expressed as head and flow. Pump
performance is always described in terms of head, H, produced
at a given flow capability, Q , and hydraulic efficiency, , attained at any particular intersection of H and Q. Head is usually plotted on the vertical scale or vertical axis (the left of the
In FIG. 4, the point of zero flow (where the curve intersects the y axis) is called the shutoff point. The point at which
operating efficiency is at a peak is called the best efficiency
point (BEP). Head rise from BEP to shutoff is often chosen
around 10%15% of differential head. This choice makes it
easy to modulate pump flow by adjusting control valve open
area based on monitoring pressure. Pumps operate on their
curves, and knowledge of what pressure relates to what flow
allows technicians to program control loops.
Reliability tip: Operation at locations too far from BEP
HQ
NPSH r
NPSHr
90
80
Effi
c
50
Efficiency, %
60
ien
cy,
%
Head
70
40
30
Power
GR. 1.O
Power SP.
20
10
0
Flowrate, BEP
FIG. 4. Typical H-Q performance curves are sloped as shown. The BEP
is marked with a small triangle; power and other parameters are often
displayed on the same plot.
54MAY 2014|HydrocarbonProcessing.com
A published pump curve is valid only for this particular impeller pattern, geometry, size and operation at the speed indicated by the manufacturer or entity that produced the curve.
Curve steepness or inclination has to do with the number of
vanes in that impeller. Curve steepness is also affected by the
angle each vane makes relative to the impeller hub.
Select 86 at www.HydrocarbonProcessing.com/RS
20
40
Specic speed, Ns
60
500
1,000
2,000
3,000
Radial-vane
Francis-vane
120
200
300
6,000
10,000
15,000
SI
US
Axial ow
H
1,500
1,000
Pivot line
Q
500
10,000
10,000
Ns
10,000
5,000
4,000
5,000
4,000
5,000
4,000
200
3,000
3,000
3,000
150
2,000
2,000
2,000
1,500
1,500
100
1,000
1,000
1,000
800
500
400
300
500
80
70
60
50
40
30
20
15
10
1,500
rpm
300
Flowrate, gpm
Head/stage, ft
400
150
100
80
30
20
15
600
500
400
300
200
200
60
50
40
10
100
1 With Q and N,
determine pivot point
2 With pivot point and H,
determine Ns
N Q
Ns = ____
H
5
FIG. 6. A pump-specific speed nomogram allows for quick estimations.
56MAY 2014|HydrocarbonProcessing.com
Mixed ow
800
700
600
CONNECT
with professionals while learning from the best
2014
2
20
01
0
14
1
4
S E P T E M B E R 22-25
Houston, Texas
info@turbo-lab.tamu.edu
or visit PUMPTURBO.TAMU.EDU
FIG. 7. Double-flow impellers are used for higher flows and relatively
equalized (balanced) axial thrust.
58MAY 2014|HydrocarbonProcessing.com
9
9
9
9
Low life-cycle-costs
High reliability
HERMETIC-Pump
/6+6
Type CAMTV 52
Capacity:
120 m/h
Head:
1400 m
Motor power:
370 kW
9
9
9
9
HERMETIC-Pumpen GmbH
info.hp@hermetic-pumpen.com www.hermetic-pumpen.com
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Select 92 at www.HydrocarbonProcessing.com/RS
Special Report
early as the 1950s, the first widely used alloy for reformer tube
application was HK40, which was basically an Fe-based alloy
composed of: 25% Cr to ensure creep and oxidation resistance,
20% Ni to maintain an austenitic structure, and 0.4% C. The
high carbon content, as compared to similar wrought alloy,
coupled with high-quantity Cr, leads to the formation of Cr
carbides. Two main categories of carbides coexisting in heatresistant austenitic SS are:
62MAY 2014|HydrocarbonProcessing.com
mal stability of carbides but also to prevent the formation of undesirable phases such as sigma phase, G-phase, etc. The solid-solution strengthening is also a key to ensure good creep properties,
and it can only be achieved by a precise balance of all elements.
Such a statement implies that very wide ranges of chemical
compositions (e.g., a 6% range for Ni content as observed in
some published data) are clearly unrealistic to ensure specific
creep properties with reasonable ranges between minimum
(95% confidence interval) and average strengths. The wide
ranges are published to protect the know-how, which is arguable.
Equally unrealistic are specifications or suppliers claiming
to control undesirable elements, e.g., Bi to 5 ppm. Standard
production control apparatus for chemical composition can-
BP,
BP,
al creep tests are conducted. Design conditions require predicted lifetimes of at least 100,000 hr, and, more often, 200,000 hr
or 300,000 hr of testing is preferred. Knowing that 100,000 hr
represents more than 11 years of reformer tube service, the
usual extrapolation practices (e.g., according to Dutch Stoomwezen code) allow a factor of 3 between the actual data and
extrapolated creep curves.
Accordingly, these curves need to be based on some testing
of at least 33,000 hr in addition to the usual short-term (100 hr)
creep tests. Of course, such very long-term properties at very
high temperatures are the most difficult to verify. Due to this
reason, third-party testing by independent laboratories for at
least mid-term (> 1,000 hr) durations is so important to assess
the relevance and seriousness of a creep curve.
The Larson Miller curves enable gathering within a given
range of temperatures the various stress/lifetime obtained by
testing. A Larson Miller curve that is more like a line rather
Maximum temperature, C
1,300
25-35 Nb MA
1,250
Base case
Same
Decreased
25-35 Nb-MA dimensions
OD
1,200
1,150
1,100
1,050
MC in HP
MC in HP-Nb
MC in XM
Increased
ID
OD
144.6
144.6
142.2
144.6
ID
121
121
121
122.6
Thickness
11
11
9.8
10.2
Weight
606
606
547
573
Length
13,500
13,500
13,500
13,500
Catalyst volume
100
100
100
103%
Calculated life, hr
100,000
210,300
100,000
100,000
50
50
HP Micro minimum
25/35 Nb-Ma-R minimum
HP mod minimum
HK-40 minimum
870
890
910
930
950
970
Temperature, C
990
1,010
1,030
Stress, MPa
Stress, MPa
HP Micro
25/35 Nb-Ma-R
HP mod
HK-40
HP-40
5
850
1,050
64MAY 2014|HydrocarbonProcessing.com
5
850
870
890
910
930
950
970
Temperature, C
990
1,010
1,030
1,050
in the high LMP range is limited and safety margins are continuously reduced due to cost optimization, a conservative
approach is needed. No matter how detailed and severe the
quality controls can be (e.g., eddy current, x-rays, mechanical
testing, etc.), no NDT is perfect. In an industry where a clear
trend to larger and more concentrated plants exists, a single
failure can have severe consequences.
Therefore, optimizing the equipment to the ultimate design by making first-hand savings may be a very short-sighted
approach. It is actually safer to stick to actual and proven data
and to avoid obvious extrapolations. Reliability of key components is necessary for long-term investments and should not
be only driven by price.
Stress, MPa
32
33
34
35
36
LMP = T(K)(22.96 + log(Tf)/1,000 with Tf in hours
37
38
EFFICIENCY MATTERS.
WWW.CUDD.COM
NOMENCLATURE
Bismuth
Nb
Boron
Si
Carbon
Ta
Cerium
Sn
Chromium
Ti
Hafnium
W
Iron
V
Lead
Y
Manganese
Zr
Nickle
Niobium
Silicon
Tantalum
Tin
Titanium
Tungsten
Vanadium
Yttrium
Zirconium
ACKNOWLEDGMENTS
The authors thank H. Van Wortel and H. Van de Veer from TNO for their fruitful discussions.
NOTES
25/35 Nb-MA R (Manaurite XMR grade), specifically designed for its high
creep resistance and therefore dedicated to steam-reformer applications by
Manoir Industries.
b
Thermodynamic calculations were done using ThermoCalc software.
c
Manoirs creep curves were done on five different heats.
a
LITERATURE CITED
Sourmail, T., Precipitation in creep resistant austenitic steels, Materials Science
and Technology, No. 17, pp. 114, 2001.
2
Kaya, A. A., Microstructure of HK40 alloy after high-temperature service in
oxidizing/carburizing environment, II Carburization and carbides transformation, Materials Characterization, No. 49 pp. 2334, 2002.
3
Almeida, L. H., et al., Microstructural characterization of modified 25Cr-35Ni
centrifugally cast steel furnace tubes, Materials Characterization, No. 49, pp.
219229, 2003.
4
Cueff, et al., Influence of yttrium-alloying addition on the oxidation of alumina
formers at 1173K, Oxidation of Metals, pp. 439455, 2002.
5
Shao, et al., Effect of cerium addition on oxidation behaviour of 25Cr20Ni
alloy under low oxygen partial pressure, Journal of Rare Earths, no. 30, pp.164
169, 2012.
6
Chen, et al., Effect of rare earth element yttrium addition on microstructures
and properties of 21Cr-11Ni austenitic stainless steel, Materials and Design, no.
32, pp. 22062212, 2011.
7
Lifshitz, et al., The kinetics of precipitation from supersaturated solid solutions, Journal of Physics and Chemistry of Solids, No. 19, pp. 3550, 1961.
8
Mohri, T., et al., Application of advanced material for catalyst tubes for steam
reformers, AIChE Ammonia Symposium, October 1992.
1
66
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and Development and Projects, eni S.p.A
10:1510:45 a.m.
COFFEE BREAK
TRACK 1: REFINING
Session 3: Biofuels
Session Chair: Ajit Sapre*, Group President, Research
and Technology, Reliance Technology Group
11:2511:45 a.m.
11:45 a.m.
12:05 p.m.
Hydrocracker light naphtha recycle operation Suliman Albassam, Process Engineer, Saudi Aramco
10:4511:05 a.m.
11:0511:25 a.m.
12:0512:25 p.m.
12:251:25 p.m.
LUNCH
TRACK 1: REFINING
1:251:45 p.m.
TRACK 2: PETROCHEMICALS
TRACK 2: PETROCHEMICALS
MICHAEL SILVERMAN
Senior V.P., Downstream Technology
& Chief Technology Officer
Ivanhoe Energy
RAMANA MURTHY
Specialist, Process
Kuwait National Petroleum Company
CARLO ZAFFARONI
Ph.D. P.E., Industrial Water
& Process Director, Europe
CH2MHILL S.r.l.
FIORENZO GUITINI
Downstream Service
Engineering Manager
GE Oil & Gas
BRUCE R. BEADLE
Engineering Specialist
Saudi Aramco
VERONIQUE REICH
Principal Process Engineer
Technip E&C Ltd
VISHWANTH DASARI
Inspection Engineer
Indian Oil Corporation
Limited (IOCL)
1:452:05 p.m.
TRACK 1: REFINING
Refinery / ethylene plant integration through refinery offGas (ROG) - Nick Rogers, Ethylene Technology Consultant,
and Veronique Reich, Principal Process Engineer,
Technip E&C Ltd
2:052:25 p.m.
2:252:45 p.m.
The future of heavy oil - Michael Silverman, Senior V.P.Downstream Technology & Chief Technology Officer,
Ivanhoe Energy
2:453:05 p.m.
Petrochemicals: An opportunity for refiners Stefano Zerinder, Senior Consultant Global Refining
& Petrochemical Feedstocks, ICIS Consulting
3:053:35 p.m.
COFFEE BREAK
TRACK 1: REFINING
TRACK 2: PETROCHEMICALS
3:353:55 p.m.
3:554:15 p.m.
Innovative advancements in delay coking equipment David Anderson, Refinery Market Manager, DeltaValve,
a Curtiss-Wright Company
4:154:35 p.m.
4:354:55 p.m.
4:555:15 p.m.
5:15 p.m.
CLOSING REMARKS
CONTINENTAL BREAKFAST
9:159:30 a.m.
9:3010:15 a.m.
KEYNOTE ADDRESS: Reshaping of rening landscape in Europe - Bakheet Al-Rashidi, CEO and President, Kuwait Petroleum International
10:1510:45 a.m.
10:4511 a.m.
COFFEE BREAK
TRACK 1: REFINING
TRACK 2: PETROCHEMICALS
1111:20 a.m.
Quality team as a support function for maintenance in plant turn-around - Tuomas Ouni,
Expert, Phenol and Hydrocarbon Technologies, Borealis Polymers Oy
11:2011:40 a.m.
Increasing of the gasoline productivity at Azzawia refinery using pyrolysis gasoline Jamal B. Rashed and Ezeddine Muftah, Researcher, Libyan Petroleum Institute (LPI)
Understanding corrosion under insulation (CUI) coatings, reliable and simple, but choose
correctly - Miles Buckhurst, Global Concept Director HPI, Jotun AS.
11:40 a.m.12
p.m.
Causes and prevention of corrosion on the interior surface of metal jacketing used on
mechanical insulation - Jim Young, Technical Director, ITW Insulation Systems
1212:20 p.m.
Refineries need to adapt: imbalances between crude oil quality and refinery configuration
offer opportunities to improve refinery profitability - W. Paul Ruwe, Group Manager, and Peter
Bartlett, Group Manager, Jacobs Consultancy, Inc.
Stress corrosion cracking in SS 316 steam coil - Vishwanth Dasari and Bijay K. Muduli,
Inspection Manager, Indian Oil Corporation Limited (IOCL)
Improved turnaround Management - a sure shot formula for profitability Sudhakara Babu Marpudi, Sohar Refinery, Oman Refineries and Petroleum
Industries Company
FCC special valves: best practices to increase performance, reliability and service
life - Mauro Natalini, Deputy Manager- Valve Engineering, Remosa Valves
12:2012:40 p.m.
12:401 p.m.
12 p.m.
LUNCH
TRACK 1: REFINING
TRACK 2: PETROCHEMICALS
Increasing profitability via hydroprocessing flexibility and know-how Robert Wade, Staff Engineer, Advanced Refining Technologies
Commercial experience of operating FCC unit with low catalyst-to-feed ratio and the
reduced REO content in the catalysts - M.I. Levinbuk, Chief Researcher, Topchiev Institute
of Petrochemical Synthesis, RAS
2:403 p.m.
Symphony, the next generation family of higher performance reforming catalysts Xavier Decoodt, Head of Reforming Hydrogenation Catalysts and Absorbents, Axens
33:20 p.m.
Filtrex s.r.l. ACR filtration technology ensures longer catalyst life and cycle lengths of key
refinery process units - Riolo Nicola, Business Director, FILTREX S.r.l.
An overview of energy management system (ISO 50001) with its implementation plan C.H. Rama Krushna Chary, Environment Engineer, Kuwait Oil Company
22:20 p.m.
2:202:40 p.m.
3:203:50 p.m.
COFFEE BREAK
TRACK 1: REFINING
3:504:10 p.m.
4:104:30 p.m.
TRACK 2: PETROCHEMICALS
Upgrading a CDU main fractionator with innovative mass transfer components Guiseppe Mosca, Refinery Global Application Manager, Sulzer Chemtech
4:30 p.m.
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(2)
where:
P = Pressure
i
= Stress intensification factor (SIF)
MA = Moments due to primary loads (sustained loads)
TABLE 1. Measured vs. allowable alignment tolerance at
opened ange joint in aboveground piping
Item
ASME PCC-1
tolerance, in.
Measured
tolerance, in.
Gap, max./min.
0.03125
0.85
0.0625
0.96
0.25
(1)
where DA and DB are the displacements, and KA and KB represent the stiffness measurements.
DA and DB were computed using Eq. 1, and the displacement stress at both A and B were evaluated. Section B, shown
in FIG. 2, was found to have maximum stresses. For this reason,
detailed analysis was restricted to this section.
1.3
(0.16, 1.05)
Toughness ratio, Kr
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.1
0.2
0.3
0.4
0.5
1.1
0.0
0.0
(3)
1.2
1.0
0.6 0.7
Load ratio, Lr
0.8
0.9
1.0
68MAY 2014|HydrocarbonProcessing.com
1.1
1.2
1.3
(6)
(7)
(8)
(9)
(10)
of flange leakage.
Equivalent pressure method. The axial force and moment
at the flange at operating conditions are converted to an equivalent pressure in this method. Stress-analysis software performs
this calculation, and its computation is shown in Eq. 11:
Equivalent pressure Pe = (16M 3.14G 3) +
(4Fa 3.14G 2) + P
(11)
Composite Repairs and Prevention For External Corrosion, Mechanical Damage, Defects, Etc.
www.ClockSpring.com
Clock Spring is a registered trademark of NCF Industries, Inc. All rights reserved. Manufactured under license from NCF Industries, Inc.
The Clock Spring symbol is a trademark of Clock Spring Company, L.P.
(12)
ML = (C 4) (SbAb Fa Hp A G PG )
(13)
where:
Gasket area = A G = 0.785 (Do2 Di 2) = 0.785 (18.252
16.632) = 44.36 in.2
Total bolting force = Sb Ab = 35,000 psi 20 = 35,000
20 = 700,000 lb
Hydrostatic force = Hp = 0.785 G 2 P = 0.785 17.442 500
= 119,380 lb
Axial force in the flange = Fa = 23,463 lb (from operating case)
PG = 4,000 psi, or the minimum recommended operating gasket seating stress for a spiral-wound gasket. (Note: This
stress is larger than the gasket factor multiplied by the
design pressure, which is used for the flange design.)
Gasket reaction = A G PG = 44.36 4,000 = 177,440 lb.
Therefore:
ML = (21.25 4) (700,000 23,463 119,380
177,440) 12 = 168,104 in.-lb
70MAY 2014|HydrocarbonProcessing.com
(14)
Process Design
J. RENFRO, Honeywell Process Solutions,
Houston, Texas; G. STEPHENSON, Honeywell
Process Solutions, London, Ontario, Canada;
E. MARQUES-RIQUELME and C. VANDU,
Shell Global Solutions International BV,
The Hague, The Netherlands
PROTECTION SYSTEMS
A common method of protecting process equipment against
excessively high pressure or temperature is the emergency depressurization (also known as a blowdown) by means of relief
devices such as relief valves and orifices, rupture disks and safety
valves. Other depressurization equipment include separation
vessels, heat exchangers, distillation columns and compressors.
Emergency depressuring removes the potentially dangerous contents of the process equipment and transfers them to a safe and
lower-pressure location. It also decreases the force exerted by the
fluid on the walls of equipment by reducing the pressure quickly
and diminishes the risk of event escalation due to a fire or a leak
of an explosive or toxic gas.
During depressurization in a typical two-phase separator, the
vessels inlets and outlets (both gas and liquid) are closed by using isolation valves. The depressurization valve is opened, and
the gas is disposed of via a restriction orifice or fixed choke into
the flare (or vent) system. Instead of using a restriction orifice
friendly depressuring utilities available. However, their predictions are conservative due to simplifications made in the
mathematic models. The business impact from conservative
predictions is that new plants are over designed with stainless
steel (SS), and existing plants must be modified against high
costs and deferred production. If SS is selected where carbon
steel (CS) would have been adequate, equipment costs could
be twice as high or more.3
Hydrocarbon Processing|MAY 201471
Process Design
Accurate dynamic depressurization calculations are required to ensure the selection of the most cost-effective materials for safe and reliable operating services. For existing facilities, reassessment of the temperature during depressuring can
lead to changes in operating conditions or changes in process
equipment to ensure safe operation.
There are many process safety requirements that must be
considered when designing new process equipment and units
or assessing the operation of existing assets. One of these requirements is avoiding brittle fracture of the metallic materials used in process equipment. Having reliable and consistent
predictions of fluid and minimum wall temperatures during
depressurization is fundamental to demonstrating compliance
with this requirement. This article discusses the use of a rigorous non-equilibrium vessel model containing detailed heat
fd = Rd D 0.5
fk = Rk D 0.5
Rd
Knuckle
Rk
Dish
72MAY 2014|HydrocarbonProcessing.com
Process Design
Values of the dish radius and knuckle radius factors are well
known for many standard torispherical head styles. However,
some standard head styles, such as the Standard F&D and Shallow F&D head styles, have a fixed knuckle radius. In this instance, the knuckle radius factor cannot be determined until the
diameter of the vessel is specified. Custom-head types can be
modeled as long as fd and fk can be calculated.
Vessel orientation and outlet calculations. The vessel
model allows the configuration of either a vertically or horizontally oriented vessel, as well as different locations of the depressurization outlet. The depressurization outlet is defined by a
nozzle, which is configured through specification of the nozzle
diameter and center height from the bottom of the vessel. FIG. 3
shows the different vessel orientations and depressurization
nozzle locations that are supported.
The depressurization nozzle can be at the top or bottom or
on the side of the vessel. The depressurization nozzle allows accurate modeling of fluid removal from the vessel. The overall
composition in the nozzle is determined by mixing outflows
from the zones in the vessel. The outflow for a zone is the fraction of the nozzle cross-sectional area covered by the fluid in the
zone times the total outflow, which is established by the restriction orifice connected to the depressuring nozzle.
Restriction orifice model. The restriction orifice model
73
Process Design
from a fire through radiation impingement on the outer surface
of the vessel and heat conduction through the vessel wall.
TABLE 1. Spadeadam experiment S12
Item
Value
CH4
66.5 mol%
C2H6
3.5 mol%
C3H8
30 mol%
Temperature
20C
Pressure
120 bar
Diameter
1.13 m
Tan-tan height
2.25 m
Orientation
Vertical
Head type
2:1 semi-elliptical
Wall thickness
50 mm
Orice diameter
10 mm
Back pressure
1.013 bar
External temperature
20C
140
25
Blowdown utility prediction
Experimental values
120
5
Temperature, C
Pressure, bar
100
80
60
-5
-15
40
-25
20
0
-35
0
500
Time, sec
1,000
1,500
500
Time, sec
1,000
1,500
20
15
15
10
5
Temperature,C
5
Temperature, C
25
-5
0
-5
-10
-15
-15
Blowdown utility prediction vapor zone
Experimental values liquid zone
Experimental values vapor zone
Blowdown utility prediction liquid zone
-20
-25
-35
15
-25
500
Time, sec
1,000
1,500
74MAY 2014|HydrocarbonProcessing.com
-30
500
Time, sec
1,000
1,500
Benet From
Our Expertise
Process Design
temperature, the energy content in the vessel wall and insulation is underestimated. In either case, the predictions of the
temperature profile in the vessel wall and insulation and conditions of the fluid holdup will be attenuated during depressuring. Although not strictly correct, a steady-state wall initialization method can provide the most realistic initialization of the
temperature profile. With this method, the initial temperature
profile in the vessel wall and insulation is calculated by solving
the steady-state heat conduction equation with the convective
boundary condition applied at the inner surface of the wall and
the outer surfaces of the insulation.
MODEL IMPLEMENTATION
The dynamic vessel model calculations described here are
incorporated into a new dynamic depressurization simulation
utility; it was developed to overcome serious deficiencies identified in earlier existing tools, such as:a
Numerical stability. Some tools can stall during calculations, especially for depressurization cases in which the
fluid is narrow boiling, the conditions within the vessel
are close to the critical conditions of the fluid, or abrupt
phase changes occur during depressurization.
Systems with a water phase. Although theoretically some
tools can model a water phase, in practice, the solution of
three-phase systems presents many numerical challenges.
Limited number and type of components
Limited selection of thermodynamic methods
Limited capability to set the style of the heads of the vessel
Calculation of the initial conditions is not rigorous.
The model was implemented using an equation oriented
(EO) simultaneous formulation solution to handle the complexity of interactions of the different model mechanisms. Using
an EO simultaneous solution formulation allows extension to
future optimal design problem formulations in an efficient way.
A01147EN
Process Design
a dynamic depressuring as part of the simulator. This added
flexibility addresses the value in the selection of construction
materials for vessels as well as orifice sizing. It overcomes serious deficiencies identified in earlier commercially available
tools. The model can provide a high degree of solution accuracy
and is robust for three-phase systems. The model consistently
predicts liquid formation when it occurs experimentally and
demonstrates stable solution behavior in systems with many
components. The utility offers a large number of accurate thermodynamic models and can be used to model vessels with any
torispherical head style. It also performs rigorous calculation of
initial phase equilibrium and vessel conditions.
a
NOTES
The dynamic vessel model calculations described previously have been incorporated in a new dynamic depressurization utility of the UniSim Design process
simulator, named the Blowdown Utility.
LITERATURE CITED
Complete literature cited is available at HydrocarbonProcessing.com.
JEFF RENFRO is an engineering fellow of Honeywells Automation and Control
Solutions business. At Honeywell, he has worked with advanced process control,
MES and simulation groups as a solution architect and consultant. Dr. Renfro is a
member of the UniSim Design development team. He has also worked for Shell
Development Co., Dynamic Matrix Control Corp., Dynamic Optimization Technology
and Products, and PAS. During his career, he has supported the OPERA, DMO and
NOVA optimization and modeling systems, and served as both a consultant and
implementer for their online applications. Dr. Renfro holds a BS degree in chemical
engineering from the University of Texas and a PhD in chemical engineering from the
University of Houston.
Energy People
Making Energy
Facilities Work -Better
76MAY 2014|HydrocarbonProcessing.com
Refining Developments
J. SEXTON, J. HIGHFIELD and N. LARSEN,
Marathon Petroleum Company, LP, Catlettsburg,
Kentucky; and S. ISMAIL and D. NEUMAN,
BASF Corp., Florham Park, New Jersey
Refining Developments
TABLE 1. Comparison of total catalyst and heating costs during the three cases
Case number
Base
Base
Base
Base
Base
Base
Feed temperature, F
Base
Base
Base
Operational mode
Riser/reactor operation
Base
Base
Base
Base
Base 2.10
Base 0.66
Base
Base + 91
Base + 22
Zero
High
Zero
Base
Base + $1.20
Base + $0.10
Activity, FACT%
Base
Base + 1.0
Base + 1.0
Nickel, ppmw
Base
Base 33
Base 21
Vanadium, ppmw
Base
Base 336
Base 210
Base
Base 1.40
Base + 0.35
Base
Base
Base
Regenerator conditions
Regen bed temperature, F
Fresh catalyst and torch oil
Fresh cat + co-catalyst makeup, tpd
Torch oil costs
Total cost of heating the unit, $/bbl
Equilibrium catalyst
Conversion
Standard fresh feed conversion, vol%
Cutpoint temperature, F
4/1/12
Co-catalyst converter
8/1/12
12/1/12
FCC repairs
Steady state
Controlled shutdown
Power failure
Steady state
Torch
oil
4/1/13
ity and porosity with a large total surface area at 410 m2/g. It
has a high Z/M ratio with maximum rare earth on the zeolite,
thus the catalyst is stable even at high regenerator temperatures. The matrix provides a tailored porosity to allow the
diffusion of heavy hydrocarbons into the particle, resulting
in selective cracking.
The co-catalyst is designed to fundamentally change unit
performance faster than what can be achieved via a base catalyst change-out and, to a greater extent, than conventional
operational changes. The flexibility provided by co-catalysts
allows refiners to quickly respond to changes in operational
issues, take advantage of changing economics, address feedstock changes, or simply improve the conversion of the existing base catalyst to maximize profitability.
The use of a co-catalyst as a torch-oil replacement strategy at Catlettsburg was the first application of its kind. MPC
understood that the co-catalysts high activity would provide
consistent additional coke, based on previous experiences.
A risk assessment determined that there was little downside
exposure by using the co-catalyst system.
Results. The FCCU at Catlettsburg has a large catalyst inventory compared to other units with similar feedrates. Therefore, the co-catalyst was used at the high end of the usage
rates. MPC chose to utilize the co-catalyst at a 1:1 ratio with
the existing fresh catalyst formulation. Notwithstanding the
high ratio of co-catalyst to fresh catalyst, the actual addition
of the co-catalyst to the unit reached 30% of the inventory just
before the planned shutdown to repair the unit. The co-cata-
Refining Developments
TABLE 2. Comparison of operating conditions during the three cases
Case number
Base
Base
Base
Base
Base
Base
Feed temperature, F
Base
Base
Base
Operational mode
Riser/reactor operation
Base
Base
Base
Base
Base 2.1
Base 0.66
Regenerator conditions
Regen pressure, psig
Base
Base
Base
Base
Base + 91
Base + 22
Base
Base + 423
Base + 28
Base
Base + 0.2
Base + 0.1
Base
Base
Base
Base
Base + 0.01
Base
Base
Base
Base + 19
Base
Base + $1.20
Base + $0.10
Activity, FACT%
Base
Base +1.0
Base + 1.0
Nickel, ppmw
Base
Base 33
Base 21
Vanadium, ppmw
Base
Base 336
Base 210
CRC, wt%
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base 1.34
Base + 0.35
Base
Base 0.10
Base + 0.17
Conversion
Standard fresh feed conversion, vol%
+
C3 Liquid, vol%
Refining Developments
TABLE 3. Comparison of yield slates during the three cases
Case number
Operational mode
Unit net prot, $/bbl
Base
Base $0.83
Base $0.52
Riser/reactor operation
Combined feedrate, bpd
Base
Base
Base
Base
Base
Base
Base
Base 2.1
Base 0.66
Base
Base + $1.20
Base + $0.10
Fresh catalyst
Fresh cat + co-catalyst makeup, tpd
Total cost of heating the unit, $/bbl
Equilibrium catalyst
Activity, FACT%
Base
Base +1.0
Base + 1.0
Nickel, ppmw
Base
Base 33
Base 21
Vanadium, ppmw
Base
Base 336
Base 210
CRC, wt%
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base + 0.52
Base + 0.03
Propane, vol%
Base
Base + 0.01
Base + 0.16
Propylene, vol%
Base
Base 0.26
Base + 0.03
nButane, vol%
Base
Base 0.07
Base 0.02
Isobutane, vol%
Base
Base 0.45
Base + 0.33
Base
Base 0.04
Base 0.11
Base
Base 0.10
Base +0.61
Base
Base 0.64
Base 0.09
Base
Base + 1.00
Base 0.50
Base
Base + 0.34
Base + 0.15
Base
Base 0.10
Base + 0.17
C3 liquid, vol%
Operating data
Process check
Final report
Scrubber
water
FCC
simulation
models
Heat balance
and protability
samples
Comprehensive
detail an ongoing systematic evaluation of
H2 balance
targets are on track
Feed analysis
benchmarking
the FCCU. The reports are a framework
for conversations regarding the matching
FIG. 3. Information flow to support refinery operations to create maximum value.
of an optimal catalyst solution to meet the
changing needs of the refinery. FIG. 3 gives
a graphical summary of the work flow or activities involved in
sufficient catalytic coke that the refinery could reduce the torch
ensuring that quality discussions are possible.
oil injection rate. The transition from torch oil to co-catalyst
MPCs Catlettsburg refinery personnel worked with the catconverter was rapid. By the end of September, the torch oil inalyst company to evaluate the benefits of co-catalyst vs. torchjection was reduced to virtually zero. Additionally, total catalyst
oil injection. An FCC simulation using a commercially available
additions (base catalyst plus co-catalyst) were reduced by over
FCC model was done.4 Using the data from a period in which
30%. Finally, application of the co-catalyst provided operating
flexibility and allowed MPC to schedule a controlled shutdown.
the refinery was running well under steady-state conditions, a
Base Case model was constructed. It is well known that there
are many interacting variables affecting the performance of the
Post-audit results. As part of its relationship with its catalyst
FCCU. An analysis was undertaken to answer questions such as
supplier, MPC Catlettsburg regularly provided the catalyst sup80MAY 2014|HydrocarbonProcessing.com
Refining Developments
to harvest a higher selectivity of desired products. Dry gas was
the impact of co-catalyst on the constant feed, ROT and other
significantly lower by 0.5 vol%, while propylene and butylene
operating conditions. All comparisons were done on the basis
yields matched or exceeded the Base Case. The gap created
of constant ROT and matched the actual operating conditions
in gasoline yield, between Cases 1 and 2, with torch oil, was
such as regenerator temperature, C/O ratio, and the yield slate.
closed when the co-catalyst replaced the torch oil in Case 3.
Case 1 or steady state is the Base Case, as shown in TABLE 2.
Decant oil (bottoms) was also reduced. However, LCO yield
Case 2, denoted by the torch-oil case, simulated the operatwas lower because of the high activity of the cracking of the
ing conditions when the refinery was experiencing the probprimary intermediates into gasoline and light olefin products.
lems when one of the interstage standpipes between the two
From TABLE 3, the unit net profit decrease with the cosections of the regenerator was partially blocked. In this case,
the sustained unit operation was achieved by injecting torch
catalyst was $0.31 better than the case with torch oil. Again,
oil and increasing catalyst addition. An empirical method was
the simulation model does not take into account the costs for
agreed upon to simulate the torch oil injection, and it was utilized to match the
actual catalyst-addition rates and refinery operating conditions. The empirical
Conv3
approach was a heuristic method to simulate lowering of catalyst activity by artiConv4
ficially increasing the sodium in the feed
to match the activity. As torch oil was not
a regular feature of the operation, it was
Conv5
not included in the economics calculaRemaining Wall Thickness
tion performed by the simulation model.
Conv6
Finally, the co-catalyst, or Case 3,
was a simulation where there was no
Conv7
torch oil in the unit and the FCCU was
running smoothly with the base catalyst
and co-catalyst alone.
Conv8
From the simulation output of TABLE
2, the major constraint is the heat balance management. Initially, this necessitated using torch oil to overcome
the constraint. But, the torch oil also
severely deactivated the FCC catalyst
and required increasing the catalyst-addition rate to maintain the equilibrium
Transfer the risk of unplanned downtime, loss of
activity of the circulating catalyst.
To maintain the equilibrium activity
production or a catastrophic failure in your red heaters.
at the desired level, the refinery initially
Quest Integritys Furnace Tube Inspection System (FTISTM) is the globally proven
used increased catalyst during the torchtechnology that delivers 100% coverage of your serpentine coils. Combined with
oil period. Then, when the co-catalyst
our LifeQuestTM Heater software to provide tness for-service and remaining life
was introduced, conditions changed.
compliant with the API-579 standard, Quest Integrity delivers a solution that helps
The volume of torch oil was reduced
transfer your integrity and maintenance risk into reliability.
initially and finally eliminated while still