POST CONTRACT REVIEW SABIC PETROCHEMICAL BV · PDF fileTUBE TECH INTERNATIONAL // REFINERY PROCESS ... robotically-german-refinery ROBOTIC FIRED HEATER ... POST CONTRACT REVIEW SABIC

POST CONTRACT REVIEWSABIC PETROCHEMICAL BVRobotic Fired Heater Convection Bank Tube CleaningF-101L Convection Bank Cleaning

4 MAY 2015 - 10 MAY 2015

ISSUED:

TUBE TECH INTERNATIONAL // REFINERY PROCESS PERFORMANCE IMPROVEMENT SPECIALISTS

SABIC PETROCHEMICAL BV // POST CONTRACT REVIEW

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CONTENTS

SUBJECT PAGE

INITIAL CONTACT: Site Details and Points of Contact 4 Company Profile 5 Examples of previous related contracts 8

SITE SURVEY: Objectives 11

METHOD STATEMENT: 14

RISK ASSESSMENT: 21

PROJECT INITIATED: 28 Conference calls 29

PROJECT MOBILISATION: 30

COMMENT RELATED IMAGES: 37

SOLUTION: 42

PROJECT COMPLETED: 46

FEEDBACK: 53

SABIC PETROCHEMICAL BVF-101L Convection Bank Cleaning

Tel: +44 1268 786999Email: [email protected]: www.tubetech.com


COMPANY OVERVIEW

Tube Tech International’s fired heater / furnace cleaning services are

recognised the world over by refiners and petrochemical companies

alike as the best technology to achieve as new performance.

Fired heater Convection Banks are inaccessible to many mechanical cleaning methods and therefore extremely difficult to clean. Currently the operator can only remove the fouling he can physically see or reach.

Access deep inside and between furnace rows has never been achieved …..until now. Tube Tech’s “As New” cleaning capability using advanced robotics helps in many ways. Namely by reducing energy, CO2 emissions and improving fired heater performance by significantly increasing feed throughput.

For the very first time Tube Tech Robotics is able to clean deep in between all square and triangular pitched tube rows whether finned or studded. This ability delivers an unprecedented return on investment combined with much improved levels of safety, cleanliness and downtime.

Tube Tech’s robotics replaces traditional offline fired heater cleaning techniques which include manually applied chemicals, water jetting, abrasives and dry ice. Two other unique facts are that the Robot can remove extremely hard deposits unlike any global system and it also provides before, during and after visual recordings of the entire job for evidence of our success. Examples of previous related cleaning contracts can be found on pages 8 - 9

SITE DETAILS

COMPANY: SABIC Petrochemical BVSITE LOCATION GEELAN, THE NETHERLANDSSITE SECTOR Olefins 3 Liquid Cracking HeaterITEM TO BE CLEANED F-101L Convection Bank Tube Cleaning

SITE MANAGER Ms Marianne Van Eynde TEL: +31 (4) 67 2245 13 EMAIL: [email protected]

SUPPLIER

COMPANY: TUBE TECH INTERNATIONAL LtdSITE LOCATION United Kingdom

MANAGING DIRECTOR Mike WatsonSALES ENGINEER Christian ChanelTEL: +44 (0)1268 786999 EMAIL: [email protected]

A detailed on-line version of this project can be made available to Sabic approved personnel only via www.tubetech.com. For security purposes please call Tel: +44 1268 786999 to request your password

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TUBE TECH INTERNATIONAL // REFINERY PROCESS PERFORMANCE IMPROVEMENT SPECIALISTS SABIC PETROCHEMICAL BV // OVERVIEW

W: www.tubetech.com E: [email protected]

T: +44(0)1268 786 999

INTRODUCTION

Tube Tech was formed by Mike Watson over 30 years ago.

The vision was to confront the global, pre conceived ideas on how assets were cleaned and inspected. To challenge the procedures and defy the industry mentality that “It’s been done this way for so long, why change?”.

Tube Tech International remove fouling - but what makes us outstanding is our unique approach.

We ask you to think about the commercial, environmental and safety benefits to your company.

What if fouling can be removed at a faster rate in safe, dry, clean conditions, without waste, in-situ, on–line without the need to shut down your plant?

The benefits to a company employing our methods are often astonishing.

We record data, measure and analyse information to establish a clear, detailed picture of how both Client and Contractor can improve the cleaning and inspection procedures further.

Equipped with this data, our driving force is to improve future turnarounds.

The efficiency of clean, decontaminated plant can directly improve the bottom line and we have evidence of client’s with future net savings of 6 and 7 figures.

This focus has led to the development of many bespoke and patentedtechnologies designed to remove and mitigate energy consuming deposits even from inaccessible areas of heat exchangers, fired heaters and other critical processes, regardless of design and deposit severity.

Our approach highlights the value in raising the standards of current, antiquated, off the shelf cleaning methodologies to one of “High Tech”.

With over 60 innovative and patented technologies, Tube Tech International are recognised by many, as world leaders in solving industries’ most challenging fouling issues. And the evidence is having helped clients, to save multiple millions (€ $) in asset replacement and substantially reducing Opex and Capex. operational expenditure and capital expenditure

Fouling Removal areas of speciality

• Robotic Fired Heater / Furnace Convection Banks

• External Shell Side Fouling Removal from Heat Exchangers

• Texas Towers (CCR Platformer Vertical Combined Feed and Effluent Exchangers)

• IRIS Inspection standard Tube Polishing

• Compact Coiled Exchanger Tube Cleaning …… and of course applications where others have tried and failed

However, difficult the problem, or complex the task, we rise to the challenge.

The efficiency of clean, decontaminated plant can directly improve the bottom line and we have evidence of client’s with future net savings of 6 and 7 figures.

By increasing the furnace throughput by 3 tonnes per hour the robotic cleaning of the furnace could see a saving for Sabic of €1.7 Million in the first year.

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“ ”Mike Watson Managing Director Tube Tech International“ ”

EXAMPLES OF PREVIOUS RELATED CONTRACTS:-//

UNITED KINGDOMFRANCEGERMANYCANADATEXASDOMINICAN REPUBLICQATAR

WORLD WIDE EXPERIENCENIGERIA GREECEISRAELSINGAPOREPHILIPPINESOMANSOUTH KOREA

SAUDI ARABIANORWAYMALAYSIASOUTH AFRICAAZERBAIJANAUSTRALIAABU DHABI

IRELANDPAPUA NEW GUINEAANGOLATURKEYMALTASERBIAMOROCCO

FURNACE / FIRED HEATERS TUBES (FINNED CONVECTION SECTION) CLEANED IN SCOTLAND

NEW “Between Fins” Cleaning Technology achieves optimum performance and no refractory damage.www.tubetech.com/furnace-fired-heaters-tubes-finned-convection-section-cleaned-scotland

FURTHER DETAILS ON THE ABOVE CASE STUDIES CAN BE FOUND HERE >>>

ROBOTIC FIRED HEATER CLEANING OF FINNED CONVECTION TUBES

Deposit across 90% of fired heater finned area removedwww.tubetech.com/robotic-fired-heater-cleaning-finned-convection-tubes

FIRED HEATER / FURNACE COILS CLEANED IN TRINIDAD

Innovative Techniques used to Clean Furnace Coilswww.tubetech.com/fired-heaterfurnace-coils-cleaned-trinidad

FURNACE CLEANING OF A GERMAN REFINERY USING ROBOTS – A WORLD FIRST

Furnace cleaning of a heavily fouled convection section using remote technology.www.tubetech.com/world-first-robotic-furnace-cleaning

FURNACE / FIRED HEATERS TUBE DECOKING ON-LINE! AT DISTILLATE SYNTHESIS PLANT IN MALAYSIA – WORLD FIRST!

Blocked serpentine furnace coils cleared in one day.www.tubetech.com/furnace-fired-heaters-tube-decoking-line-distillate-synthesis-plant-malaysia-world-first

FURNACE / FIRED HEATERS TUBES ( USX/TLX ) CLEANED IN RECORD TIME

Combined high pressure water jetting, rotary mechanical de-scaling and ultrasonic systems.www.tubetech.com/furnace-fired-heaters-tubes-usxtlx-cleaned-record-time

FURNACES / FIRED HEATER CONVECTION BANK CLEANED ROBOTICALLY ON GERMAN REFINERY

Furnace cleared using remote mechanical operation.www.tubetech.com/furnaces-fired-heater-convection-bank-cleaned-robotically-german-refinery

ROBOTIC FIRED HEATER CONVECTION BANK CLEANING IN TRINIDAD

90% improvement over traditional cleaning technologies.www.tubetech.com/robotic-fired-heater-convection-bank-cleaning-trinidad

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SABIC PETROCHEMICAL BV // SITE SURVEY

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SITE SURVEY OBJECTIVES

1 x Convection Bank consisting of 8 banks.

7 banks were 9240mm long.

1 bank was 19160mm long.

Deposit anticipated to be light, friable scaleadhered to the outside periphery of theconvection tubes.

Banks to be as clean as possible i.e. minimum 80% production standard.


T: +44(0)1268 786 999


AVERAGE PLANT LOSSES PER FIRED HEATER

Quantity of banks on a mid

size petrochemical plant

20

Energy going through a fired heater

60-70%CA.

Typical heater energy

cost per annum*

€400 per tonne

A 2% increase in

heater efficiency =

$1.68mp.a.

* Based on 40-70% refinery energy costs due to heating Source: EUROPIA and US DoE

SABIC PETROCHEMICAL BV // SITE SURVEY

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Top access

view

Manually assessing deposit hardness

Typical access for

robot

Images taken of fouling at different levels


T: +44(0)1268 786 999

SABIC PETROCHEMICAL BV // METHOD STATEMENT


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TUBE TECH INTERNATIONAL // POST CONTRACT REVIEW


T: +44(0)1268 786 999

PROCEDURE FOR CONVECTION SECTION CLEANING ON FURNACE

THIS METHOD STATEMENT IS EXCLUSIVE TO TUBE TECH LIMITED AND MUST BE KEPT PRIVATE AND CONFIDENTIAL. (PLEASE REFER TO CONFIDENTIALITY CLAUSE (FOOTNOTE).)IT IS IMPORTANT THAT THIS METHOD STATEMENT IS READ IN CONJUNCTION WITH SABIC SITE SAFETY RULES

As per the specification, work would commence using dedicated Fired Heater Convection Section Robotic Crawler Water Jetting Unit coupled to TTiL Wysper™ jetting pump, with variable volumes and pressures (maximum 15,000-psi) suitable to clean the application.

1. Arrive at site, complete site induction, plant specific induction, equipment check (diesel pumps, compressors and 110v equipment) and obtain all necessary permits to work.

2. Client to provide clear access to the application and adequate standing area for control stations. Access to the convection section areas will be gained via the three purpose built doors on the side of the unit (shown on Viva specific drawing).

3. Overview of work area. Application should be accessible by flat standing; this is both safely large enough for access both in and out, in the event of an emergency. Client to ensure adequate protection and containment in lower section of unit and create a ‘swimming pool’ bund ie lined scaffold erection with suitable effluent run off.

4. Check all equipment (including hoses), to ensure all certified equipment is in date; everything is suitable for purpose and is undamaged.

5. The necessary safety guards and control valves should be fitted to all mechanical equipment and all preparation should be carried out to an acceptable level.

6. Set up in a safe manner, all safety signs and notices are to be displayed in the appropriate prominent positions and area is barriered off to a safe distance, prior to commencement of any work.

7. Insert camera system into access points to establish where and level of deposits. Record data.

8. Each of the three levels has a door leading to top of each tubed section, this is to be used as insertion point for Robotic Crawlers.METHOD

STATEMENT

9. From door access points. 2 x Robotic crawlers to be inserted on chosen level (one handed ‘Right’, the other ‘Left’),

these are to clean in opposing directions and once a full cleaning cycle is completed in these directions they will change level and repeat until all levels completed.

10. Check/ensure all parties have the opportunity to stop work and have good communication

1st man by stopping Robotic Crawler at the control station 2nd man by hand signal (visual instruction) or voice (via radio) to either 1st or 3rd man 3rd man by stopping pump

1st man operator - visual & verbal (radio) communication with guide/safetyman and/or pump man

2nd man guide/safetyman - will be positioned in visual & verbal (radio) communication with operator and/or pump man

3rd man pumpman - will be stationed at the pump and be in constant visual/verbal contact with the safetyman and operator

Test and run up all equipment, bringing pump upto optimum pressure – set pressure

Test equipment (i.e.) a) Convection Section Cleaning Robotic Crawlers b) HP Water Jetting Pump Unit (client supplied) c) Compressor (client supplied) d) Camera

11. Repeat stage 9 & 10 for level ‘B’ & ‘C’.

12. Pump to be started and Robotic Crawler to complete cleaning cycle. Debris to be checked and camera recorded.

Cleaning cycle consists of: a. Lower cleaning arm into pre-set position b. Clean along tube length c. Raise/lower cleaning arm when in vicinity of baffle/support plate d. Once full run is complete lower arm to next tube level and continue as above e. Manually lift Robotic Crawler over to next tube run using ’pizza-tray’ lift tool and

continue as above until all rows complete

13. Clearing will continue as per above until deposit removed as per questionnaire.

14. Once completed camera inspection to confirm and record.

15. CLIENT TO VISUALLY INSPECT PIPES TO ACCEPTABLE STANDARD (PLEASE NOTE OBJECTIVE)

Regular supervision of the job site is to take place and tool box talks will occur on a regular basis.

SABIC PETROCHEMICAL BV // METHOD STATEMENTTUBE TECH INTERNATIONAL // POST CONTRACT REVIEW


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6. SAFETY

A. CLIENTS WORK PERMIT SYSTEM TO BE UTILISED. ALL PERMITS TO BE CHECKED BY SUPERVISOR. PERMIT TO WORK SYSTEM TO BE KNOWN AND UNDERSTOOD BY ALL OPERATORS.

B. THE ENGINEER IS TO BE PROVIDED WITH THE FOLLOWING, PRIOR TO COMMENCEMENT OF WORK OR UPON REQUEST:-

COMPANY HEALTH & SAFETY SHEETS DAILY OR WEEKLY SAFETY REPORT SHEETS AND JOB REPORT SHEETS. COSHH REPORTS (WHERE APPLICABLE)

C. ALL SUPERVISORS TO BE FULLY COMPETENT WITH EQUIPMENT AND TO HAVE SATISFACTORY EXPERIENCE FOR THIS TYPE OF WORKS AND SIMILAR WORKS.

D. HOUSE KEEPING TO BE CARRIED OUT DAILY.

E. TOOL BOX TALK TO BE GIVEN TO ALL PERSONNEL WORKING ON THE APPLICATION, PRIOR TO COMMENCEMENT OF WORK AND AT OUR WORKS.

KEY POINTS: Permit procedure COSHH (where applicable) P.P.E. Scope of work Assembly point Evacuation procedures/Emergency procedures. Safe place of work Care and attention Housekeeping

ALL CONTRACTUAL OPERATIONS TO BE CARRIED OUT IN ACCORDANCE WITH SAFETY REGULATIONS, INCLUDING COSHH AND SAFE WORKING PROCEDURES.

7. PLANT TO BE USED

2 X HP WATER JETTING PUMP UNITS (CLIENT SUPPLIED2 X CONVECTION SECTION CLEANING ROBOTIC CRAWLERS (PLUS SPARE)1 X COMPRESSOR (CLIENT SUPPLIED)

8. PERSONNEL PROTECTIVE EQUIPMENT

A. EXTERNAL OPERATORS/SAFETY/GUIDE MEN: HARD HATS, WET SUITS (IF REQUIRED), FIRE RETARDANT DUST PROOF HI-VIS OVERALLS, BOOTS

WITH HARD CAPS, EAR DEFENDERS, GLASSES (LEP) OR GOGGLES AND GAUNTLETS.

B. ALL OPERATORS: WHEN WORKING AT HEIGHT, IN ADDITION TO ITEMS LISTED IN A. AND B., ALSO SAFETY HARNESSES.METHOD

STATEMENT

SAFE WORKING METHOD STATEMENT

1. MOBILISATION OF PLANT, MEN AND MATERIALS

A. TRANSPORTATION OF MEN AND MATERIALS FROM SITE TO ACCOMMODATION TO BE ON A DAILY BASIS.

B. ALL HIRED PLANT, WHEN APPLICABLE, WOULD BE DELIVERED DIRECTLY TO SITE. TRANSPORT WOULD BE BY TRAILER, UNLESS OTHERWISE ADVISED.

2. JOB DESCRIPTION SEE QUESTIONNAIRE

3. ACCESS

ACCESS TO APPLICATION WILL BE VIA WALKWAY/SCAFFOLD TO TUBE PLATE, PREVIOUSLY OPENED BY CLIENT PERSONNEL.

4. MANPOWER PER SHIFT

A.1 X SUPERVISOR 3-4 X OPERATORS

B.SITE INSPECTED BY AUTHORISED PERSONNEL.

5. COMMUNICATIONS

THROUGHOUT THE DURATION OF THESE WORKS, GOOD COMMUNICATION TO BE MAINTAINED WITH THE CLIENT AND AUTHORISED PERSONNEL AT ALL TIMES.

DIAGRAM A

ACCESS DOORS MOUNTED ON SIDE OF FURNACE CONVECTION SECTION.

A = TOP

SABIC PETROCHEMICAL BV // METHOD STATEMENT

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9. SUMMARY ALL WORK TO BE CARRIED OUT STRICTLY IN ACCORDANCE WITH THE SPECIFICATION AND SAFETY REQUIREMENTS, AS LAID DOWN BY THE CLIENT, AND AS DETAILED IN THE AGREED PROGRAMME OR WORKS.

10. EMERGENCY TELEPHONE NUMBERS DAY TIME: +44 1268 786 999OUT OF HOURS NUMBERS : MIKE WATSON +44 7825 888 000MARTIN BYFORD +44 7825 888 111SCOTT DONSON +44 7825 888 222 11. DISCLAIMERTUBE TECH CANNOT BE HELD RESPONSIBLE FOR CLAIMS OF LOSS/DAMAGE OR INCONVENIENCES RESULTING FROM ADVISE PASSED ONTO A THIRD PARTY VIA OUR CLIENTS.

12. CONFIDENTIALITY CLAUSE

The existence of this Method Statement and its terms are confidential. Tube Tech Ltd retain ownership and all rights to the information contained in the said Statement.

The Client shall not copy, reproduce, use for any unauthorised purpose or part with possession of the Method Statement made available by Tube Tech Ltd or conduct any unauthorised examination of the Method Statement and shall promptly return the said Statement to Tube Tech Ltd, on request, at any time.

Breach of any of the aforementioned terms shall entitle Tube Tech Ltd to institute legal proceedings.

E & OEThe above information is supplied based on information known at the time of posting and should be taken as a guide only, as events during contract may change the contents herein.

An updated Method Statement can be supplied on request.

RISKASSESSMENT



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SABIC PETROCHEMICAL BV // RISK ASSESSMENT

RISK ASSESSMENTTASK

STEPS

Setting up Equipment

Jetting

darTT™

RotaFlex™

SD/LD Drill

WHAT ARE THE HAZARDS?

1, 2, 3, 5, 6, 8, 9, 10, 11, 12, 15, 18, 20, 22, 23, 24,

26, 27, 28, 29

In addition to set-up:13, 14, 17, 19, 21, 25

In addition to set-up:4, 13, 14, 16, 17, 19, 21, 25

In addition to set-up:4, 13, 14, 17, 19, 21, 25,

In addition to set-up:7, 13, 14, 17, 19, 21, 25,

WHAT CAN THE HAZARDS DO?

Injury to personnel, damage to plant &

equipment


equipment


equipment


equipment


equipment

INITIAL RISK H/M/L

M

M

M

M

M

REMAINING RISK H/M/L

L

L

L

L

L

HOW CAN I LOWER THE RISK?BY DOING WHAT?

Correct PPE for the task. Correct tools for the task. Use mechanical lifting to move heavy loads when possible, split load when possible. Operatives to use correct manual handling techniques. Use banks-man to direct vehicle movement in confined areas, extra care to be taken when vehicles are reversing in plant area, banks-man to site mobile plant and equipment in plant area. All mobile plant to be earthed to local steel work (if required), chalwyn valve & spark arrester to be in place (if required). Fire-cover set-up (client arrangement) & operators aware of positioning.

In addition to set-up:All operatives to be aware of working area conditions and to orientate themselves before work commences. Any hazards identified to be dealt with and recorded. All operatives involved in the task must be trained & competent in the use of equipment. All operators will wear correct PPE for the task. Emergency evacuation routes to be in place prior to work commencing.




SABIC PETROCHEMICAL BV // RISK ASSESSMENTS

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TASK STEPS

Camera Inspection

Pigging or Drift™

HydroWhip™

Confined Space

Height

WHAT ARE THE HAZARDS?

In addition to set-up:4, 21, 25

In addition to set-up:7, 13, 14, 17, 21, 25

In addition to set-up:7, 13, 14, 17, 19, 21, 25

Additional:32

Additional:30 or 31

WHAT CAN THE HAZARDS DO?


equipment


equipment


equipment

Injury to personnel


equipment

INITIAL RISK H/M/L

M

M

M

M

M

RISK ASSESSMENT Continued

REMAINING RISK H/M/L

L

L

L

L

L

HOW CAN I LOWER THE RISK?BY DOING WHAT?




All operatives to be aware of conditions inside vessel and to orientate themselves with internal layout before work commences, any hazards are to be dealt with and recorded. All operatives working in confined space must be trained & competent. Gas test to be carried out & recorded. Air suits or B.A. (if required). Harnesses to be worn (if required).

Harnesses to be worn (if required & practicably reasonable) & attached to a suitable anchor point via safety rope or lanyard.


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Manual Handling1. Moving heavy loads by lifting, pulling or pushing2. Moving awkward shapes or uneven loads3. Awkward body position while moving loads4. Repetitive movement of loads5. Twisting the body to move the load6. Difficult condition e.g. uneven surfaces7. Considerable force required to operate stationary equipment

Work with Tools, Equipment or Machinery8. Use of hand tools9. Use of portable powered tools (electrical, pneumatic, hydraulic)10. Use of fixed power tools/machines11. Use of mobile powered machinery

Release of Energy12. Potential to drop heavy weights13. Potential to release hot/cold substances14. Potential to release substances at pressure15. Potential to release flammable substance16. Potential for electric shock >12017. Potential to produce projectiles and particles18. Potential to release stored energy (springs, etc)19. Vibration20. Potential for sudden movement of equipment or tools

Work in Hazardous Conditions21. Difficult access to work location22. Uneven surfaces23. Sharp edges24. Abrasive surfaces25. Hot/Cold surfaces26. Hot/Cold/Wet conditions27. Excessive noise28. Operation required even in severe weather conditions29. Exposure to vehicular movements

Hazardous Locations30. Work at height (inside equipment or structures)31. Work at height (outside equipment or structures)32. Work in ‘Confined Spaces’33. Work in excavations greater than 1-metre34. Work directly above water

Other ConsiderationsIs there a procedure for this task? Yes/No

Location on site? __________________

Sequence of events to be agreed as work progresses

Is there any special information, instruction or training in addition to normal craft skills and experience required for this task? Yes/No

If yes, please specify:

a. Certified jetting/mechanical descaling technicianb. ‘Confined Space’ trainingc. Special equipment training (cherry picker, forklift, etc)d. Safety Passporte. Rope accessf. Breathing apparatus

Mitigation Measures - specifya. Fire Cover:b. Split Control:c. Other:

List Actions to be covered by special emergency procedures

AS PER SITE INDUCTION

Personal Protective Equipment

List special equipment in addition to site minimum:

Eyes Hands FeetFace Limbs Fall ArrestHead Body RespiratoryHearing

HAZARD LISTA careful assessment of any manual handling must be made; mechanical assistance for heavy weights or awkward locations must be provided. See site safety services or your risk manual for guidance.

Hazardous Substances

Does this task involve potential exposures to hazardous chemicals, products of other substances?

Yes/No

If yes, check to confirm that a COSHH assessment has been carried out

Other Comments/Requirements

Tube Tech International Ltd accept no responsibility for any errors or omissions within this document. Any claims for loss, damage, inconvenience resulting for advice passed on by a third party via our clients will not be accepted

The above measures will be implemented before work starts. The content of this risk assessment has been communicated to employees and contractors who will be present at the workplace

Signed _______________________________________

Name _______________________________________

Date ___________________

(Person responsible for co-ordinating the preventive and protective measures for the task) H

AZ

AR

D L

IST


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V E C T O R F R E E B IE S : F ing e rp r int s

SABIC PETROCHEMICAL BV // CONFERENCE CALLS

CONTACT: Stephanie Van Deuren TITLE: Furnace Team LeadCOMPANY: Sabic TEL: (4)67 2248 66 EMAIL: [email protected]

CONTACT: Marianne Van Eynde TITLE: Research EngineerCOMPANY: SabicTEL: (4)67 2245 13 EMAIL: [email protected]

CONTACT: Jos Renet TITLE: Maintenance SupervisorCOMPANY: Sabic TEL: (4)64 7621 23 EMAIL: [email protected]

CONTACT: Jan Voorhurst TITLE: Senior Executor COMPANY: Reym B.V.TEL: (4)64 5106 47 EMAIL: [email protected]

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CONTACTS


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PROJECT START

PROJECT MOBILISATION


T: +44(0)1268 786 999


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SABIC PETROCHEMICAL BV // PROJECT MOBILISATION

4TH MAY 2015

Project

1 april 2014

CAMERA-INSPECTIERAPPORT

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TUBE TECH INTERNATIONAL // REFINERY PROCESS PERFORMANCE IMPROVEMENT SPECIALISTS SABIC PETROCHEMICAL BV // IRIS INSPECTION

33W: www.tubetech.com E: [email protected]

T: +44(0)1268 786 999

Inspection report from Convection Bank OLE 4 Oven 50, a neighbouring furnace was likely to be indicative of F-101L Convection Bank

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SABIC PETROCHEMICAL BV // COMMENT RELATED IMAGES

POST CONTRACT REPORT OBSERVATIONS & IMAGES


T: +44(0)1268 786 999


COMMENT RELATED IMAGES

IMAGES OF ADDITIONAL OBSERVATIONS MADE ON SITE BY TUBE TECH PERSONNEL


T: +44(0)1268 786 999


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SOLUTION



T: +44(0)1268 786 999

FIRED HEATER ROBOTS FIT THROUGH INSPECTION HATCHES TO CLEAN INTERMEDIATE TOP AND BOTTOM BANKS.

SABIC PETROCHEMICAL BV // SOLUTION

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T: +44(0)1268 786 999 45

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10TH MAY 2015

SABIC PETROCHEMICAL BV // PROJECT COMPLETED


T: +44(0)1268 786 999


Increased capacity and steam production.

Energy efficiency increase.

Before cleaning the stack temperature was 150% higher

than the design stack temperature,

while after cleaning it decreased almost

back to design (100%).

Energy efficiency distribution over all furnace sections and convection banks.

Increased heat transfer over the convection section tubes.

Cleaning avoided overheating of convection bank tubes in the low temperature sections and avoided damage to the flue gas fan.

RESULTS & BENEFITS

This best practice tailor-made cleaning plan will result in the highest chance of success and more benefit obtained from an effective cleaning action.

Reduced risk of damaging the convection section tubes.

Furnace is back to design

operating stack temperature.

Duty going to the ECO bank increased.

Reduced stack temperatures and less loss to the atmosphere.

Inspection provides more insight in the location and degree of fouling within the convection section tubes.

Reduced risk to flue gas fan that would otherwise have to withstand higher temperatures.

Avoids costly replacement

Extra capacity increases the economics, reliability and sustainability of the furnace.


49Tel: +44 1268 786999Email: [email protected]: www.tubetech.com

OUTCOME

UTILISING REMOTE VISUAL VIDEO INSPECTION PROBES INDEPENDENT INSPECTION TEAM CONFIRMED ALL FOULING REMOVED FROM EVERY TUBE ROW.

THE FURNACE IS AGAIN ABLE TO ACHIEVE A CAPACITY OF 45 T/H AND THE STEAM PRODUCTION IS 4 T/H HIGHER AS BEFORE CLEANING.


ROBOTIC CLEANING OVERCOMES RESTRICTED ACCESS.

STEAM CRACKING FURNACE CONVECTION SECTION ACHIEVES NEAR 100% CLEANLINESS

HEAT DUTY OF CONVECTION BANKS INCREASED BY 11% AND THE % STACK LOSS REDUCED -16% THANKS TO ROBOTIC CLEANING.

CUSTOMER BENEFITS EXPERIENCED

Before After % increase

FPH MW 5.84 6.11 5%ECO MW 1.74 2.63 51%UMP MW 8.29 8.82 6%SSH I MW 3.18 3.86 21%SSH II MW 2.79 3.38 21%LMP MW 12.51 13.44 7%

Total MW 34.35 38.24 11%

% of total firing absorbed in CS % 52.75% 53.99% Total firing MW 65.13 70.83 9%% loss stack % 7.35% 6.18% -16%

SABIC PERFORMANCE RESULTS

RECOMMENDATIONTLE’S (TRANSFER LINE EXCHANGERS) CAN BE A LIMITING FACTOR DUE TO THE FOULING BEING SO DIFFICULT TO REMOVE USING TRADITIONAL HIGH PRESSURE WATER. TUBE TECH RECOMMEND A BESPOKE TLE DRILLING AND POLISHING TECHNOLOGY TO ALLOW INSPECTION USING ULTRASONIC IRIS TECHNOLOGY.

TO REMOVE COKE BLOCKAGES FROM FURNACE TUBES TUBE TECH’S HIGH SPEED, REMOTE CONTROL DENSE WYSPER JET IS RECOMMENDED.



T: +44(0)1268 786 999


THE FUTURE



T: +44(0)1268 786 999

FEEDBACK

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SABIC PETROCHEMICAL BV // FEEDBACK

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”

SABIC PETROCHEMICAL BV // FEEDBACKTUBE TECH INTERNATIONAL // REFINERY PROCESS PERFORMANCE IMPROVEMENT SPECIALISTS

“”

The root cause of the decreasing performance of the furnace was reduced heat transfer in the convection section due to external fouling. After robotic cleaning by Tube Tech International, the heat duty of each convection bank increased by 11% and the % stack loss reduced by 16%. The quality of high pressure steam generated was improved. Thorough cleaning avoided damage to the low temperature sections and flue gas fan. The external cleaning was a success and will bring many benefits in the coming years.

Marianne Van Eynde Research Engineer, Sabic Geleen

“”

A $1,000,000.00 to $2,000,000.00 dollar estimated saving is how much Ethylene Fired Heater clients can expect to save. Our Robots unlock this previously unattainable saving by removing more fouling than ever thought possible compared to conventional methods.Every fired heater project has its unique challenges whether due to limited access, unknown fouling levels even design changes omitted from client drawings. All credit to our R+D team and site operators who proactively overcame every obstacle.

Christian Chanel International Sales, Tube Tech International


T: +44(0)1268 786 999

POST CONTRACT REVIEWSABIC PETROCHEMICAL BVRobotic Fired Heater Convection Bank Tube CleaningF-101L Convection Bank Cleaning

4 MAY 2015 - 10 MAY 2015

ISSUED:


Documents

POST CONTRACT REVIEW SABIC PETROCHEMICAL BV · PDF fileTUBE TECH INTERNATIONAL // REFINERY PROCESS ... robotically-german-refinery ROBOTIC FIRED HEATER ... POST CONTRACT REVIEW SABIC