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TRANSCRIPT
Amec Foster Wheeler Presentation
for
Russia & CIS 2015
Bottom of the Barrel Conference
23-24 April, Moscow
Considerations for Improving On-stream Time in Residue Upgrading
Scott Shorey
Director – Business Solutions & Technology
Agenda
Amec Foster Wheeler
Brief Introduction
Residue Conversion
Delayed Coking - SYDECSM
Technology
Factors Affecting On-stream
time
Design & Equipment\
Operations & Training
Training Tools
2
Who is Amec Foster Wheeler?
>40,000
people
US $ 9bn
revenues >50
countries
>150 years
of history
3
► Headquartered in London;
Global Presence
Markets
► Oil & Gas
► Upstream
► Midstream
► Downstream-Refining &
Petrochemicals
► Clean Energy
► Environment & Infrastructure
► Mining
Who is Amec Foster Wheeler?
>40,000
people
US $ 9bn
revenues >50
countries
>150 years
of history
4
Offerings
► Consultancy
► Engineering
► Project management
► Project delivery
► Ongoing asset support
► Specialized power equipment
► Technologies; owned and
applied
5
A global network of talented teams
Residue Upgrading - Delayed Coking Process
► Severe thermal conversion process
► Full conversion of residue to distillates
and coke
► Typically operated for max. liquid yields
► Coker liquid products need further
processing
► Most commonly used residue upgrading
process
► Feedstock flexibility
► Over 5,000,000 BPSD installed capacity
► Conversion and coke formation occur in
the coke drums
► Fired heater design and operation is key
6
Residue Upgrading – High On-stream Time
►What does it take to achieve high
On-stream Time?
► Reliability
► Robust Process
► Design
► Operations
► Flexibility, Adaptability
7
SYDECSM Process – A Few Definitions
► Reliability
► Can be depended on for accuracy and sustained achievement
► Accuracy, constancy, safety
► Robust
► Strong, healthy
► Requiring strength and endurance
► Effective in a broad range of applications
► Flexibility
► Capable of being modified without breaking
► Susceptible to modification or adaptation
► Adjustability
Reliability---Safety---Robust Design---Training
8
Why is On-Stream Time Important?
29/04/2015
50,000 BPSD DCU
• Fired Heaters
• Coke Drums
• Safety Systems
• Automation and Controls
• Operator Training
• Tools
Factors affecting On-stream Time
Fired Heaters
Confidential 11
Terrace-Wall Double Fired Heater
• Individual Pass Control and Firing
• Completely isolated fireboxes on Terrace Wall Designs
• Our philosophy is to set the flow and vary the firing
• Number of passes easily customized; 2, 3, 4, 5, 6…
• Allows greater degree of control for off-design conditions:
• On-line Spalling
• Pigging; Off-line or On-line
• Turndown
Prime differentiator of
Foster Wheeler Design
Confidential 12
Spalling Effectiveness
13
Single fired spall – notice the ‘ratchet effect’ on subsequent clean TMTs
Clean
TMT
Latest On-line Spalling Effectiveness
14
Double fired spall- returns to ‘clean’ TMT
Clean
TMT
• Over 7 years between turnarounds achieved
• Double-fired heater designs with individual convection sections – offers
effective online-spalling and on-line pigging capability
• Fully modularized design for lower installed cost
• SCR technology for NOx control
Terrace Wall Double Fired Heaters
15
• Fired Heaters
• Coke Drums
• Safety Systems
• Automation and Controls
• Operator Training
• Tools
Factors Affecting On-stream Time
Coke drum life improvements:
Design based:
– Single thickness drum wall
– Optimized crotch radius for weld build up hot
box cone/straight wall detail
– Integral forged ring skirt design on cone/
straight wall detail
– Complete mechanical design with full FEA
Operations based:
– Optimized quench & warm-up procedures
– More skin temperatures – monitoring program
– Designed for 7,000 cycles
Coke Drums
17
This program is specifically tailored to monitoring Coke Drum
operations
The goal: maximize useful Coke Drum life through regular
feedback to the client.
Data to be monitored includes:
Feed properties and crude blend
Skin TI data
Unit feed rate and recycle
Steamout, Quench, Warm-up, Coking periods
Heater data (duty, inlet/outlet temperatures)
Coke Drums (Cont.)
18
DrumLife Coke Drum Monitoring
• Fired Heaters
• Coke Drums
• Safety Systems
• Automation and Controls
• Operator Training
• Tools
Factors Affecting On-stream Time
Interlocks
► Switch Valve
► Inlet Isolation Valves
► Vapor Isolation Valves
► Utility Isolation Valves
► Coke Drum Relief
► Vent Valves / Ejectors
► Heater Operations
► Coke Cutting System
► Top / Bottom Un-heading
Devices
Safety Systems - Coker Interlocks
20
• Fired Heaters
• Coke Drums
• Safety Systems
• Automation and Controls
• Operator Training
• Tools
Factors affecting On-stream Time
Two primary categories:
1. Eliminate (or at a minimum better manage) personnel on the coker
structure primarily through automation
– Follows the philosophy of the “Safest risk is the one that is never taken”
– Remote Unheading
– Remote/Automated Cutting
– Total Automation
2. Reduce potential exposure to hazards through design and operating
procedure improvements
– Cutting Tool Enclosures
– Quench procedures to reduce potential of hot spots
– Coke drum pressure reduction prior to venting/draining/unheading
– Coker Interlocks
Safety – Categorization & Automation
22
Goal is to relocate operator from the cutting deck to a remote
location
Objective of system is to provide the operator all necessary
information in a remote location
Utilizes vibration, acoustic, and video monitoring
– Typically 5 vibration sensors required for remote cutting (4 on drum shell, 1 on
cone, and 1 on coke chute)
– Video cameras
– Audio equipment/microphones (optional)
Benefits include improved safety through reduced potential for
exposure to cutting deck hazards and improved operator
information
Remote and Automated Coke Cutting
23
Remote Cutting
Systems have been developed
to allow automated coke
cutting
Benefits include improved
safety, process efficiency
through standardized cutting
procedures with consistent
cutting times, and improved
equipment reliability
Remote and Automated Coke Cutting
24
Automated Cutting
A fully automated system consists of the following:
Coke drum batch controller system
– Resides in the SIS and each coke drum has >40 defined steps
– Sequencer moves the appropriate valves and provides a process confirmation
of that move
– Secondary confirmation
– Monitors positions of all applicable valves and process variables
– Halts, alarms, and flags any deviations.
– If the step number is lost for a some failure, system will move into
initialization mode, analyze and evaluate the position of the valves and
suggest the appropriate step to initiate
Total Automation
25
Structure
Automated system is only as good as its ability to deal with upset
situations
– Early switch, plugged line, quench flexibility, anti-foam flexibility, failed pressure
test, decoking issues
– Operator must have the flexibility address issues within normal confines of the
sequence
– Especially important during draining and decoking when most upsets occur
System design must also allow for other upset/abnormal
operations
– Bypass Drum
– Cold Start
Total Automation
26
Upsets
BP Whiting DCU Project
27
Whiting, Indiana, USA
102,000 BPSD DCU
6 coke drums
Total automation concept
Modular design
FW providing all engineering
Houston led
Procurement
Modular fabrication
Construction management
Innovative DCU Design and Project Execution
• Fired Heaters
• Coke Drums
• Safety Systems
• Automation and Controls
• Operator Training
• Tools
SYDECSM Technology – Factors affecting On-stream Time
Complex process technology and innovation are far out pacing the
capacity of traditional technical training.
Coking is a unique process with unique challenges to manage:
– Batch process
– Extreme temperatures
– Highly viscous feed
– Coke-cutting and handling
Delayed-coking requires a unique training program that can assimilate
new innovation, tenured experience, fundamental process principles and
create knowledge that will improve operator competency
Operator Training
Confidential 29
Delayed-Coking – Unique Challenges:
Operator Training
30
•Traditional Training Isn’t Cutting It…
Operator Training
31
•Traditional Training Isn’t Cutting It…
• Fired Heaters
• Coke Drums
• Safety Systems
• Automation and Controls
• Operator Training
• Tools
SYDECSM Technology – Factors Affecting On-stream Time
Standardized SYDEC training program to establish core
competency in Delayed Coking
– Web-based (available from all computers 24/7)
– Available when the employee is ready, not when a trainer is available
– Consistent training for all personnel – the message is always the same
– Learning tool (not your typical testing software)
– Animated Graphics
– Terminology Library
Training Tools
Confidential 33
KnowledgeWebTM
We continue to evolve using a Lessons Learned procedure:
Conceptual Basic Detail Construction Start-up
To further improve safety, reliability, operability and cost and on-
stream time.
Lessons Learned
34
35
Amec Foster Wheeler: SYDECSM Process
Innovative design leads to superior technology and
operations
Large coke drum
design expertise
Unique fractionation
design
Designed in
safety and
reliability
Maximum liquid
product yields
Specialty Coke
production
Proprietary
Terrace-WallTM
double-fired
furnace
Market Leader Operations
Support
Thank You!
