Amec Foster Wheeler Presentation for Russia & CIS 2015 ... · Amec Foster Wheeler Presentation...

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!