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Mastering the art and science of FCCU constructability issues

AltairStrickland has been managing andexecuting turnarounds and revamps

since its inception in 1976. While refin-eries have become more complex andmore congested, footprints have prettymuch remained the same. This compli-cates project execution and raises multipleconstructability issues. Add in the concernfor quality, safety, schedule and budgetand youve got a multidimensional scope.AltairStrickland has always stressed that

preplanning is a key to the door of suc-cess. J im Robinson, one of the founders ofAltairStrickland, and Whitney Stricklandaddressed several areas of constructabilityat the first annual catcracking.com semi-nar that was held in League City, Texas,recently. Here is a sampling of some of theissues they addressed.

The first area they addressed was equip-ment installation through door sheets. Toset the stage they cited an FCCU revampcase history of an air grid installation. Thecomplete revamp scope was extensive andincluded: Installation of regenerator lower conesection. Replacement of regenerator air grid. Replacement of feed section on riser. Replaced reactor trickle valves. Flue gas line repairs. Knife gate valve repairs.

Extensive refractory work. Miscellaneous maintenance work.

The main constructability issues con-cerned the installation of the regeneratorin the lower cone section and replacing therisers feed section. The FCCU still had the

original plate type air grid. The originalscope called for installing the trunk of thegrid into the existing cone section, how-ever, there was no access for welding or forweld inspection if the trunk grid was to beinstalled in this manner.

AltairStrickland went the extra mile.They carefully made a mock-up of theequipment so they could demonstratethe problem; this prompted the ownerto procure a new cone section. Still, the

installation was difficult. The structuralsteel came up to the tangent line, therewere several big beams that could not beremoved, there was an upper constraintlayer of dip leg bracing and some tricklevalves had to be removed. The beams were redesigned withnotches to allow as much height as pos-sible. Two air hoists on trolleys were usedas part of the rigging so the equipmentcould be taken from the crane and ledthrough the door sheet.

Beams were needed to support the doorsheet and rigging devices. The cone sec-tion was installed with the lower part ofthe trunk. The air grid was brought in sothe two back lateral arms could be installedfirst followed by installation of the twofront lateral arms. Each piece of air gridweighed about 26,000 pounds and the conesection weighed in at 28,000 pounds.

Another door sheet installation alsoinvolved regenerator cyclones. In thiscase the project was a major RFCCUrevamp in Canada. AltairStricklandwas initially contacted to plan, manage

and execute the project, but due to anunexpected financial situation and unionissues, A ltairStricklands role changedand they became a consultant to theowner and the union contractor. This wasthe plants first major revamp since theRFCCU had been commissioned in 2000.Robinson and six AltairStrickland super-

visors participated in the consultation. The complete scope included: Removal and replacement of thefirst stage regenerator along with pri-mary and secondary cyclones (six each). Removal and replacement of exter-nal risers (two each). Removal and replacement of regen-erated catalyst slide valves (two each). Removal and replacement of regen-erated catalyst standpipes (two each) andwye sections (two each).

Removal and replacement of therough cut cyclones (four each) completewith overhead vaporlines and crossovers(three sisters). Removal andreplacements of sec-ond-stage regenera-tor withdrawal wells(two each) completewith overhead linesand nozzles.

Installation oferosion-resistantrefractory on reactorfirst stage cyclone

inlets. Coke anchors added to the reactorcyclones. Removal and replacement of reactorfirst stage cyclone dip legs and dust-bowls complete with trickle valves. Installation of two new 36-inch manways on the reactor.

The fi rst issue to be addressed wasthe impracticality of the existing doorsheet support beam design. A third-par-ty engineering company had originallydesigned beams that were way too heavyand unwieldy. AltairStrickland workedwith the owner and their engineeringcontractor to design a beam that waslighter in weight, but still provided theneeded support. Next, the AltairStrickland teamhelped design a removal and installa-

tion system so the cyclones could be

ON THE FRONT COVER

FCCU REVAMP CASE STUDY

Equipment installation through door sheets

FCCU REVAMP CASE STUDY

Door sheet installation involving

regenerator cyclones

Beams were needed to support the doorsheet and rigging devices. The cone section wasinstalled with the lower part of the trunk. The airgrid was brought in so that the two back lateral

arms could be installed first followed by installationof the two front lateral arms. Each piece of air gridweighed about 26,000 pounds and the cone sec-tion weighed in at 28,000 pounds.

Like a virtual tour, AltairStrickland uses its AutoCADTM capabilities to walk clients through tricky removal/installation projects.

AltairStrickland had input into thedesign of a more practical door sheetsupport beam.

AltairStrickland participated in thedesign of a rail system to aid cycloneremoval/installation.

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more easily removed and new cyclonesinstalled. There were several dimension-al constraints that had to be considered.First was the placement of the opening.

This was critical so that equipment couldbe removed and installed without hit-ting the flue gas line. The system usedHillman rollers and plating. AltairStrickland used its in-houseAutoCAD capabilities to walk theowners and contractors through a virtualremoval/installation. They also provid-ed precise instructions/drawings on lugplacement and refractory chipping forthe rigging of the air hoists.

There were two other areas of con-cern to AltairStrickland. They were ofsuch concern that the team made actualmodels to make sure a welder couldaccess the crossover on the bottom of

the primary and secondary cyclones.The models revealed a definite problem.The stiffening ribs on the crossovers didnot allow for a man to enter and workproperly. The original equipment vendorwas contacted, but reported back that itwas not possible to remove the stiffen-ing ribs. Undaunted by the news, theteam devised another solution; duringthe preturnaround period, the stiffeningribs were removed and the area was weldprepped. This allowed needed access

during the installation.

In another case history,AltairStrickland had worked often at thisrefinery since the late 1970s. Because ofthe refinerys age and tight footprint itis difficult to maneuver. There is onlyone way in or out of the FCCU. The

owner had contacted AltairStricklandone year prior to the turnaround startdate and AltairStrickland decided to usea crawler crane, but just one month priorto the turnaround, the crawler becameunavailable. The scope included: New regenerator shell, head andcyclones. New combustor. New stripper. New cat hopper.

Removal and installation of fin fancoolers. Tie-ins for a new scrubber. All new lines under the combustor.

This FCCU revamp involved thereplacement of nearly 80 percent of theequipment in the structure. Major structure modifications dur-ing predown and turnaround schedule. Because the crawler was suddenlyunavailable, AltairStrickland revised theentire plan utilizing the TC24000 fromDeep South Crane. The new plan wasextensive and included having the tail-ing rig constantly move in and out ofthe space where the precipitator nowsits so equipment could be removed andnew equipment installed. Jig stands wereset up on the road perpendicular to theunit to allow the regenerator head andcyclones to be fabricated on site. Thearea was so tight the crane boom had tobe assembled over the pipe rack.

A new client approachedAltairStrickland for an FCCU revamp.In this case, the scope included: New head and cyclones in theregenerator. Installation of a new reactor. Tie-ins to the FCC for a new scrubber. Flue gas cooler work. Major structure work. The client envisioned installing the

combustor riser distributor cap beforeinstalling the head and cyclone assem-blies. AltairStrickland presented pre-liminary drawings showing the conceptwould not work with the secondarytrickle valves on. Instead, they proposedthe cap be installed with the head andcyclone assembly. The client agreed.

The project was completed successfullyand the satisfied client has since awardedAltairStrickland other jobs.

When AltairStrickland was hired,this new client already had selecteda crane they wanted to use to lift the600,000-pound reactor. The crane theyhad in mind required a major freewaybe shut down during the heavy lifts.AltairStrickland studied all aspects ofthe lift and suggested a 660-ton crawlercrane could perform the job without thehassle and expense of shutting down thefreeway. The client agreed and the liftcame off without a hitch.

Another project involved the instal-lation of a new reactor, new regeneratorcyclone pairs, dust bowls and diple-gs. Although in this instance the clientthought it necessary to use multiple jigstands, AltairStrickland used their 3-DAutoCAD to show only one jig standwas needed for a new reactor in which allplatforms, most of the piping, and instru-mentation could be installed. Another j igstand was used for the regenerator dur-ing the turnaround. The client was wellpleased with the outcome. However, itshould be noted that AltairStrickland has

many parts and pieces ready made for

jig stands that can accommodate varioussizes of regenerators and reactors. Adapting to the unexpected is anAltairStrickland added specialty. To seea video of their presentation at the firstannual catcracking.com seminar, go towww.altairstrickland.com, or to learnmore about AltairStricklands full rangeof services, contact Whitney Strickland

at (281) 478-6200.

AltairStrickland1605 S. Battleground

La Porte, TX 77571

www.altairstrickland.com

281-478-6200

FCCU REVAMP CASE STUDY

Solutions to problematic crane installations

Due to the lack of space, AltairStrickland hadthe crane boom assembled over the pipe rack.

FCCU REVAMP CASE STUDY

Major equipment installation

FCCU REVAMP CASE STUDY

Crane considerations

FCCU REVAMP CASE STUDY

Jig stand usage

This photo shows the new reactor stripper.

The tailing rig was a Manitowoc M230 that had tobe moved in and out of a very small area to allowequipment to get in and out of the FCCU.

For another client, AltairStrickland did a 3-Dsurvey of the construction area then modeled it inAutoCADTM, which revealed a better way to lift the690,000-pound FCC reactor.

Because of their specialization, AltairStricklandhas many parts and pieces ready made for jigstands that can accommodate various sizes of

regenerators and reactors. But in this case, theyrecommended only one for the reactor and anotherfor the regenerator.

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