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Includes Safety, Maintenance, Inspection, Production

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This topic contains 10 replies, has 4 voices, and was last updated by  harrywatson123 1 year, 5 months ago.

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  • #4355

    Anonymous

    THE IDEAL COKER:

    Includes the following considerations:
    – Safety
    – Maintenance
    – Inspection
    – Production

    Turnaround Length in industry is from 5 to 9 years
    _______________________________________________________________

    TRAINING:
    + Simulator in Place
    + Weekly Simulation Problem
    + Monthly Operations Team reviews of Procedures

    DUST FREE
    + Effective Wetting Systems in place for all coke inventories
    + Regular clean-up of coke spilled during transport
    + Coke well-cooled prior to cutting

    ENVIRONMENTAL:
    + Recover all PRV & Blowdown Effluents
    + Water recycled or sent to SWS

    OPERATIONS:
    + Minimal operator presence on the coke drum structure
    + Videocameras
    + Robotics

    MAINTENANCE:
    + PM tracked & optimized
    + Optimal spread between Operations & Mechanical personnel
    + Zero backlog
    + No flush needed to heavy oil pumps

    COKE DRUMS:
    + Coke Drum life is >50 yrs
    + Crack monitoring 100% effective

    HEATERS:
    + Temperature reliably measured without thermocouples
    + Tubes can run up to 1400°F

    …from group 2

  • #7816

    Anonymous

    RESID FEED PUMPS

    • Seal Flush (Once-Through or Closed)
    o Flushless Design?
    Involves circulating system w/ pump and high-temperature barrier fluid
    Do not use rotameter to measure flow rate
    o Seal Replacement minimized
    • Pump location important
    • Ideally = No Flush to Pumps or Instruments
    • Pump Teardown and inspection
    o Metal fatigue checked with magnetic particle and visual inspection

    FURNACE

    • Reliable Pass Flow Indication
    • Wedge @ Hovensa had problems due to tap orientation & w/ transmitter
     considering ultrasonic
    • No coke laydown
     High Mass Flux
     Low residence time
     Improved on-line coke laydown
    • Inspection
     Good Access
     Smart pig a pass on-line
     On-line metal thickness reading
     Eliminate plug header leaks
     100% PMI
     Improved convection tube and fin techniques
    • Burners
     Design for reliable operation
     On-line cleaning
     Ultra Lo-NOX used
    + 0.02 lb/MBTU is coming standard
    + 0.016 lb/MBTU obtained @ Hovensa using a Deka tubular air preheater
     Firing W alls for Burners
    • Big Fire Box
    • Avoid Plugged Tubes / Resultant Tube Failure

  • #7815

    Anonymous

    COKE DRUMS

    Structure Valves
    – Minimum purge steam to Structure valves
    – Valves that reliably operate T/A to T/A
    – Motor Actuators are Reliable
    – No stray valve movements on MOV’s
    – Eliminate effect of vibration on elec contacts
    => Power down between operation using the PLC interlock
    => Shell’s Mike Fynan noted that MOV batteries can lose memory when power is cut, therefore you need to maintain charging to the battery with the circuitry
    => Circuit boards can flex and crack due to vibration and thermal expansion/contraction
    – need to use a hardened circuit board
    – not possible to move circuit board to another location, since need to count turns for position
    – Provide a secure clutch handle to protect MOV when it “torques out”
    – Shell uses the Rotork IQ with the Velan Switch and Valvtron Ball

    Top Deheading
    – All automatic – Closure device, Opening, Stem Position, Closure
    – Auto-switch cutting combo tool
    => Side Note: Delta Slide Valve plus an additional manual flange = Double Block
    or use the new Delta two-point closure design?

    Operations
    – All remote-operated and automatic (valves, deheaders and cutting)
    + Cameras/Acoustics
    – Make shot coke to reduce drain time and cutting

    Design
    – Concrete withstands thermal/cylic stress failure
    – Coke chute ramps are of concrete instead of metal to reduce erosive wear

    Emergency Egress
    – Deluge, Barriers, or Baker Life Chute

    Elevator
    => Dependable!!!
    => Size for turnaround or install separate maintenance elevator

    Maintenance
    – Platforms and Cranes provided as needed
    – All remote-operated and automatic (valves, deheaders and cutting)
    + Cameras/Acoustics
    – Make shot coke to reduce drain time and cutting

  • #7814

    Anonymous

    COKE CUTTING
    Hydraulic power for cutting winches
    – Easier control than pneumatic
    – Better reliability and ongoing maintenance
    – Eliminate oil leaks from rotary joint
    (Side conversation Is it possible to collect oil from the muffler exhaust? None noted)

    Cutting Pumps
    – Options Pacific, Flowserve, Ruhrpumpen
    – Speed Control to remove cutting water discharge valve
    – Use two pumps
    Have double limit switch cut-out on drill stem at top of drum Cutting Pumps
    Hose Inspection that can predict end-of-useful life

    COKE HANDLING

    Bridge Cranes are remote operated
    IDEA => Use cutting air, instead of cutting water?
    Gravity Drain Pad
    Remove economic majority of coke fines
    Fines trap out prior to water reaching maze using railroad rails with coke stacked up against them
    Drain cut tank bottoms to pad, instead of maze
    Toyo vertical shafts pumps for pumping from Pit –> Maze

  • #7813

    Anonymous

    MAIN FRACTIONATOR

    Bottoms Recirculating System with Strainers
    HCGO product has coke strainer
    Zero Recycle (Trap out above FZ)
    Spray Wash Zone above flash zone
    Dual level indication on bottom
    Trays that resist steam -> water explosion
    – operators are trend to fixed valve trays instead of floating valve trays
    NH4 CL salt handling
    – avoid tray corrosion/salt deposition
    CN corrosion controled in OVHD system
    – Vessel Cracking
    – Water Wash of fin fans
    Chemical cleaning employed to allow rapid equipment entry
    – Quick turn, Zymeflow
    – Liquid vs Vapor Phase effectiveness
    – Should allow entry within 24 hours (C6 H6 Removal is key in napththa circuits)

    WET GAS COMPRESSOR
    Few use Wheel Wash
    – Fouling of wheels noted to be low

  • #7812

    Anonymous

    Blowdown System

    Hot Contactor
    Strainers needed to remove coke fines
    Proper temperature control
    – Desuperheater on inlet
    – Heater on Contactor
    Bypass for temperature control
    During steam and water quench use a throttling valve to control pressure and prevent foamover

    Fin Fan Condensers
    Fin Fan LGO wash of tubes
    Block Valves for isolation and cleaning

    Settler
    Oil/Water Separation
    – Add demulsifier at times
    External wash depends on location of bundles
    Recycle of light oil to hot contactor is employed by Conoco

    WarmUp Condensate
    Gravity flow from coke drums to hot contactor is the best design
    Do not use a warm-up drum

  • #7337

    Anonymous

    [quote]ORIGINAL: Guest

    COKE DRUMS

    Structure Valves
    – Minimum purge steam to Structure valves
    – Valves that reliably operate T/A to T/A
    – Motor Actuators are Reliable
    – No stray valve movements on MOV’s
    – Eliminate effect of vibration on elec contacts
    => Power down between operation using the PLC interlock
    => Shell’s Mike Fynan noted that MOV batteries can lose memory when power is cut, therefore you need to maintain charging to the battery with the circuitry
    => Circuit boards can flex and crack due to vibration and thermal expansion/contraction
    – need to use a hardened circuit board
    – not possible to move circuit board to another location, since need to count turns for position
    – Provide a secure clutch handle to protect MOV when it “torques out”
    – Shell uses the Rotork IQ with the Velan Switch and Valvtron Ball

    Top Deheading
    – All automatic – Closure device, Opening, Stem Position, Closure
    – Auto-switch cutting combo tool
    => Side Note: Delta Slide Valve plus an additional manual flange = Double Block
    or use the new Delta two-point closure design?

    Operations
    – All remote-operated and automatic (valves, deheaders and cutting)
    + Cameras/Acoustics
    – Make shot coke to reduce drain time and cutting

    Design
    – Concrete withstands thermal/cylic stress failure
    – Coke chute ramps are of concrete instead of metal to reduce erosive wear

    Emergency Egress
    – Deluge, Barriers, or Baker Life Chute

    Elevator
    => Dependable!!!
    => Size for turnaround or install separate maintenance elevator

    Maintenance
    – Platforms and Cranes provided as needed
    – All remote-operated and automatic (valves, deheaders and cutting)
    + Cameras/Acoustics
    – Make shot coke to reduce drain time and cutting
    [/quote]

  • #6410

    Desh 562001
    Member

    Any established data on Naptha Injection for Impeller cleaning, frequency of wheel wash and problems encountered during such cleaning operations? Do you have wet gas compressors with on-line naptha injection installed?
    Experts advise is requested.

  • #6409

    Desh 562001
    Member

    What is the experts opinion on installation of a common HPU for Coke Cutting (hydraulic winch & rotary joint for the cutting tool) and Top & Bottom Deheading Systems?
    Some of the installations use a common HPU for both. Rather than have seperate HPUs its better to optimise on one.
    Experts’ advise is requested.

  • #6406

    Claus Graf
    Participant

    We have used both arrangements on recent DCU projects.
     
    When we have designed systems with one (1) HPU, because of the different flow rates required, the electric motor is coupled to two (2) hydraulic pumps, each one with its own valve manifold.
     
    When using two (2) HPU’s, the decoking system HPU is installed on the cutting deck.
     
    Regards,
     
    CG

  • #30805

    harrywatson123
    Participant

    This phase is meant to provide a primary advent to layout principles that can be utilized in barrier and landscape layout. It can even encompass dialogue on how and what people see when traveling on highways. Issues to be addressed encompass distance and movement, line, shape, scale, balance, rhythm and series and orientation. Each of those factors should be taken into consideration and punctiliously selected with a view to create a layout that is like minded with its environment.

    Distance and motion affect what motorists see when riding via the throughway corridor. Speed alters the peripheral cone of imaginative and prescient and the space to the motorist’s factor of focus. Figure 1 illustrates the vision cone for 3 vehicular speeds. In general, as velocity increases, the cone of vision narrows and the focal distance will increase. Likewise, at slower speeds, peripheral imaginative and prescient is elevated and the focal distance is in the direction of the observer. Vision cones delineate the location within which gadgets are typically in attention. Objects outside those cones become blurred.

    Lines are created with the aid of joining two points. Lines are essential to a few dimensional bureaucracy. The man or woman of paperwork is expressed by using lines. Smooth, flowing, horizontal strains may additionally propose calm and serenity, even as bold, vertical, angular lines might also advocate power and tension. The maximum outstanding line created with the aid of a noise barrier is the top profile (Figure 2). Lines may be created on the floor of the barrier wall the use of numerous substances and texture patterns. Lines may also be implied. For example, a row of street bushes can also seem to shape a stable line.

    Form depicts quantity in 3 dimensions –duration, width, and intensity. A barrier wall itself is a three dimensional shape. This is typically called high quality form. The horizontal wall configuration may be designed to create spaces which can be normally known as bad areas or forms (Figure 2).

    Scale establishes a body of reference. It is a relative size. People usually relate to their surroundings the use of the human body or different factors of acquainted dimension because the reference dimension. Noise barrier partitions can be 15′ tall or more. Such a wall might seem big and overpowering located adjacent to a again lot line considering that residential fences are greater generally 4 to eight’ tall (Figure 2). The perceived scale of barrier walls may be reduced thru the usage of landscaping and/or inside the layout of the wall itself (e.G. Materials, configuration, etc.).

    Balance creates order and team spirit via accomplishing a sense of equilibrium. Two simple forms of balance encompass: symmetry and asymmetry (Figures 3a and 3b). Symmetry consequences when factors are organized similarly around a crucial axis, developing a mirror-photo effect. Symmetry is considered to be a formal kind of balance. Asymmetry is more casual, missing a critical axis. Elements are juxtaposed in this type of manner that they counterbalance every other with out growing a reflect photo.
    Rhythm and sequence establish consistent, recognizable styles (Figures 4 and five). Repeated patterns create a feel of familiarity and comfort. They additionally offer a feel of progression, until continued indefinitely. Rhythm and series can be created the use of both the barrier wall and/or landscaping.

    Orientation refers back to the dominant visible route installed through layout (Figure 6). Horizontal orientation is related to distinctly flat and expansive landforms. This form of orientation tends to direct the attention ahead, reducing the apparent height of a barrier wall with the aid of emphasizing its courting to the horizon. Vertical orientation is associated with upward attaining paperwork together with skyscrapers. This kind of orientation tends to direct the eye upward, increasing the obvious top of a barrier wall.

    Barrier Design

    This phase is split into subsections pertaining to layout problems unique to barrier structures, panorama remedy, and integrating barriers and landscape.

    Parts of the Barrier Wall

    Walls consist of three simple elements: the cap, the body, and the base (Figure 9). The cap offers a pinnacle aspect to the wall — giving it a specific finished appearance. The body is the dominant a part of the wall. The base refers to where the frame meets the floor. It affords a sense of connection with the landscape.

    The profile line created by the top of the wall defines the overall individual and form of the wall. The pinnacle profile can be designed to mirror, comparison, or remain impartial to the environment. Figure eight illustrates and instance of a peaked top profile imitating a steepled skyline, and a horizontal, wavy pinnacle profile contrasting the vertical varieties of the urban downtown skyline.

    Wall Configuration

    The configuration of a barrier wall may be altered via converting its horizontal alignment. Figures nine and 10 illustrate two commonplace wall configurations: serpentine and castellated. Both of those cut up the road of the wall growing a greater 3-dimensional shape. This effects in a more visually exciting wall. In addition, the “bad” space created by using the undulations can feature as planting pockets. While these configurations potentially growth the structural electricity of the wall, in addition they boom the fee. How a whole lot the price would increase depends on specific details which includes substances and the diploma and quantity of undulations.

    Materials and Textures

    The most commonplace substances for constructing noise limitations are precast concrete, metal, and wood. Brick is likewise used, but handiest to a restrained quantity because of higher value (Figure eleven). Several floor finishes and textures are available to offer a massive kind of alternatives for barrier wall layout. Appendix B lists the common barrier wall materials and numerous floor finishes and textures currently to be had.

    The man or woman of the barrier wall is without delay related to the materials and textures used within the layout. In general, timber seems inherently greater suburban and rural than concrete or metal, which seem tougher and extra city. However, despite the fabric used, the individual of the wall may be substantially modified by means of the sort of floor treatment used on the wall body.

    Surface texture and patterns may be implemented to lend any favored person. How texture and styles are perceived depends on the speed of the observer (Figure 12a, b, c). At high speeds, textures come to be blurred and styles may not be discernible. Coarse textures and simple, formidable patterns ought to be used in high speed conditions. On the opposite hand, the residential facet of noise limitations is generally experienced through slower moving observers. People on foot or riding at gradual speeds are capable to differentiate finer textures and more problematic and complex styles by the DURAFLEX DISTRIBUTION NZ.

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