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Delayed Coking – Operations and Safety

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    4 drums coker
    Participant

    Facilitators: Curtiss Winter, Consultant & Bobby Wright, Stress Engineering

    TOPICS OF DISCUSSION

    Gaskets
    Ownership of Unit
    Training
    Overpressure Scenario
    H2O Hammering
    Foaming-Coke Drum
    Oil Sludge Injection
    Operator Shift Turnover
    Operator Rounds-Schedule

    GASKETS
    – cyclic surface styles of gaskets. What is being used?
    304 flexatalic with inner ring
    grafoil steel gasket
    specialized tonguing, bolts used?
    – leaking during cycles
    –causes?
    ORJ’s styles

    OWNERSHIP OF UNIT
    unit culture
    –active and effective communication
    –accountability is in decline
    – does technology have any effect
    better training, understanding
    operator participation
    – try to have some stable supervisor positions
    – frequent job rotation seems to take away from ownership
    – recognition of staff

    KPIs can help provide feedback

    TRAINING
    – shift turnover
    — need to give important info other than the normal operations.
    – operator rounds
    — hand held computers not an effective way to check equipment
    — 2Xs per shift
    – training
    — basics only in classroom not enough
    more outside time is needed

    NEED TO SET UP NEW EMPLOYEES FOR SUCCESS AT UNIT LEVEL

    OVER PRESSURE SCENARIO
    – cooling H2O rate failure or hot spots…
    – leaving the quench H2O in at the top of the drum by accident
    – fract overhead accumulator off gas pressure controller closes off

    H2O HAMMER
    – cooling a drum by introducting during coling cycle to minimize water hammer
    – valve seating leak

    FOAMING OVER
    – anti foam
    – watching outages
    – switch early
    – causes
    — feed temp- balance
    — pressure
    — velocity of vapors
    – challenges with consistent level indication

    OIL SLUDGE INJECTION
    Pushing to Increase Amount Injected
    -100 micron particulate
    – 1 hour/ 300GPM (500F skin ti 4 feet above cone)
    – exposure to people
    – others are doing this

    OPERATOR SHIFT TURNOVER
    – have a way to document important situations with the unit
    – have 45 minute window for shift exchange

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