INTRODUCTION - ptrcon.comptrcon.com/files/ShemenSal-Petro-Ingles1.pdf · INTRODUCTION SHEMENSAL ....

INTRODUCTION

SHEMENSAL. Is a Mexican company incorporated in year 2003,

manufacturer of BLAST ATFM with national and international

distribution Thru its exclusive representative Petroconsultores Inc.

BLAST ATFM is a descaler for process equipment such as heat

exchangers, distillation towers, turbines, offshore installations,

docking facilities, gas lines flow stations and pipeline, gas separators,

radiators, coils, evaporators, condensers, gas sweetening plants, and

the widest range of process equipment.the widest range of process equipment.

In addition, BLAST ATFM is used for cleaning, metal oxidation

removal, removal of incrusted salts such as silica, amines and

carbonates, and is also excellent for stainless steel passivation.

2

• Is a leading Venezuelan Oil & Gas Consulting firm Established

in 2002, Services the Andean and Caribbean Region on Sub

Soil, and Surfaces studies.

• Main Clients include:

• Chevron• Chevron

• Shell

• Suelopetrol

• Repsol

• The company has partnered with Mexican ShemenSal for the

commercialization of Blast ATFM a product that will re-define

Equipment Maintenance in the Oil & Gas industry.3

BLAST ATFM

It is the only product of its kind

that is reusable. It can be used

several times depending from the

type of equipment, process and

application, significantly reducing

maintenance and operating costs.

BLAST ATFM substitutes SAND BLAST, generating white

metal.

BLAST ATFM does not damage seals, paint, gaskets or

thermal insulation. It does not corrode the stainless steel,

bronze or aluminum in treated equipment.4

CLEANING OF TOWER 101-CO-2, GAS PLANT 1 IN PGPB WITH

BLAST ATFM 1

VARIABLES DESIGN BEFORE AFTER

SOUR GAS LOAD

MMCFD262.5 104 262.0

Tower 101-CO-2 of Gas Sweetening Plant 1 started operations in September 16, 2011;

showing low processing capacity and high differential pressure.

The following results were obtained after cleaning with BLAST ATFM:

CP-EN01-FIC61

103.75

MMPCD

GHA A TORRE ABSORCION

70

120

160

101-CO-2: WSG ManagementDesign and Operative Conditions and Cleaning Design and Operative Conditions and Cleaning

ResultsResults:

Actions:

The tower is cleaned with 7,000 liters.

Product is injected at 30 GPM and 3

Hp.

MMCFD

DIFFERENTIAL

PRESSURE MMHG188 154 188

SWEET GAS TEMP. °C 44 55 44

GHA A TORRE ABSORCION

12/07/2012 01:09:05 a.m.10/07/2012 01:09:05 a.m. 2.00 días

20

CP-EN01-PDI16

76.885

MMHG

PRESION DIF. 101-CO-2

12/07/2012 01:09:05 a.m.10/07/2012 01:09:05 a.m. 2.00 días

PRESION DIF. 101-CO-2

0

100

200

300

101-CO-2: Differential Pressure

5

1) PEMEX GAS Y PETROQUIMICA BASICA

TRADITIONAL CLEANING:

Staff is exposed to the risk of accessing confined areas with high pressure

pumps (15,000 psi) and 440v voltage, inside the tower.

Cleaning by absorber tower is performed in 12 days (Shutdown and Startup).

SAFETY AND MAINTENANCE TIME IN TRADITIONAL VS. BLAST

ATFM CLEANING

CLEANING WITH BLAST ATFM:

Staff is not exposed to the risk of accessing confined areas. And no high

pressure pumps are involved.

Cleaning by absorber tower is performed in 5 days (Shutdown and Startup).

6

TRADITIONAL CLEANINGCLEANING WITH

BLAST ATFMSAVINGS

Required time 12 days5 days

7 days

Productivity loss

(142 mmcfd)29.32 MM$

12.02 MM$17.1 MM$

BLAST ATFM Product Cost 1.12 MM$1 0.896 MM$

Total Savings 16.204 MM$

COST-BENEFIT ANALYSIS

Note 1: Initial investment in the BLAST ATFM product was 1.12 MM$ for 7,000 liters, used in the cleaning process of

tower 101-CO-2 of Gas plant 1. Once the product is recovered and filtered, it is equivalent to one fifth (0.224 MM$) of

the initial investment cost, since it may be reused in the cleaning of equipment such as : heat exchangers, Evaporators

and Condensers at least five more times.

7

CLEANING OF TOWER 102-CO, GAS PLANT 1 WITH

SHEMENSAL’S BLAST ATFM.

VARIABLES DESIGNBEFOR

EAFTER

SOUR GAS LOAD

Tower 102-CO if Gas Regenerating plant 1 began operations in September 14, 2011, showing

low processing capacity and high differential pressure.

Operative Conditions:102-CO: Sour Gas Load

Actions:

It was cleaned with 9,000 liters of BLAST ATFM

at a ratio of 50 GPM

SOUR GAS LOAD

MMCFD525 380 500

DIFFERENTIAL

PRESSURE MMHG88 116 57

102-CO: Differential Pressure

8

IDENTIFICATION: REGENERATION TOWER

TAG No.: 102-CO

LOCATION: GAS SWEETENING P. 1

INITIAL REPORT OF THE VISUAL INSPECTION TO TOWER

102-COM GAS PLANT 1.

INSPECTION DATE: FEBRUARY 18, 2013

9


BLAST ATFMSAVINGS


7 days

Productivity loss (230 mmcfd) 2 123.97 MM$51.65 MM$

72.32 MM$

BLAST ATFM Product Cost 1.54 MM$1




Note 1: Initial investment in BLAST ATFM was 1.42 MM$ for 9,000 liters, used in the cleaning process of

tower 102-CO, Gas plant 1.

Note 2: The production loss of 230 mmcf is obtained from the 930 mmcf usually processed by the Work

Center minus the 700 mmcf processed during Gas Plant No. 1 shutdown.

10

CLEANING OF TOWER 101-CO1, GAS PLANT 1 OF PGPB

WITH SHEMENSAL’S BLAST ATFM1

VARIABLES DESIGN BEFOREAFTER

09/17/12

SOUR GAS LOAD

MMCFD420 MMSCFD 325 451

Gas Sweetening Tower 101-CO1, Sweetening Gas plant 1 started operations in September 05, 2012,

showing low processing capacity and high differential pressure.

Operative Conditions:

Actions:

It was cleaned with 9,000 liters of BLAST ATFM at

50 GPM.

MMCFD

DIFFERENTIAL

PRESSURE

MMHG

125 mm Hg 182 188

11


CLEANING OF TOWER 101-CO1, GAS PLANT 2 OF PGPB WITH BLAST

ATFM 1.

VARIABLES DESIGN BEFOREAFTER

15/02/13

SOUR GAS LOAD

MMCFD420 MMSCFD 278 392

Tower 101-CO1 of Gas Sweetening Plant 2 started operations in November 15, 2012, showing low

processing capacity and high differential pressure.

Operative Conditions:

Actions:

The tower was cleaned with 9000 lt of BLAST ATFM

at 50 GPM

DIFFERENTIAL

PRESSURE MMHG125 mm Hg 146 170

* The Plant was inoperative from Oct 8 to Nov 14

12



BLAST ATFM SAVINGS


7 days

Production Loss (120 MMSCFD) 2 73.76 MM$30.73 MM$

43.03 MM$

Product Cost BLAST ATFM 1.42 MM$

Savings per Tower 41.61 MM$


IN TOWER 101-CO1, GAS PLANT 1 AND

IN TOWER 101-CO1, GAS PLANT 2

Savings per Tower

Total Savings from both Towers

41.61 MM$

83.22 MM$

Note 1: Investment in BLAST ATFM is 1.42 M$ per 9,000 liters.

.

Note 2: Production gain of 120 MMCF. It is obtained as an average of the improvement in Gas 1 (126 MMCF) and Gas 2 (114

MMCF) production increase.

13

GASKET REMOVAL, CLEANING AND ATTACHMENT IN

ABSORBER TOWER DA-4401-B

14

GASKET REPLACEMENT PROCESS FOR ABSORBER TOWER

DA-4401-B, GAS SWEETENING PLANT 3

As we can see, the gasket of absorber

tower DA-4401B was dirty, reason why the

tower’s differential pressure was high and

the design load could not be processed,

but after the cleaning the gasket recovered

its design condition, correcting in that way

the high differential pressure and tower

channeling problem.

First

The gasket of absorber tower DA-4401-B shows excessive

mud, hydrocarbons and corrosion.

Second (bottom) section of absorber tower DA-4401-B

completely filled with the new gasket IMTP-40 KOCH-

GLITSCH

channeling problem.

The behavior test was performed in

October 8 to 10, in order to evaluate the

operation of gas sweetening plant No. 3,

increasing the processing capacity from 80

to 120 mmcfd (in this test the plant

recovered its design capacity).

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GASKET TRANSPORTATION TO THE API PLANT BY TRUCK

16

BEFORE AFTER

17

HEAT EXCHANGERS CLEANING WITH BLAST ATFM

Those Heath Exchangers out of service due to incrustation were selected.

BEFORE

18

HEAT EXCHANGERS CLEANING WITH BLAST ATFMThe pipes were immersed for 24 hrs.

CLEANING

PROCESS

19

The result was satisfactory, since it was detected that BLAST ATFM cleaned the

bundle of pipes well.

Heath Exchangers were in operative conditions.

HEAT EXCHANGERS CLEANING WITH BLAST ATFM

CLEANING RESULTS20

Lean amine plate coolers EA-201 and EA-202 of the Gas Sweetening plant operated with

decreased efficiency, with differential input and output MDEA temperatures being observable.

BACKGROUND

“Compabloc CP75-V500” Coolers

EA-201-A MDEA Water

Input temperature 100°°°° C 28°°°° C

Output Temperature 56°°°° C 45°°°° C

EA-201-B MDEA Water


CLEANING OF ALFA LAVAL’S COMPABLOC COOLER

Coolers were installed in 2009 and received a single preventive maintenance in 2010.



EA-202-A MDEA Water



EA-202-B MDEA Water


Output Temperature 56°°°° C 45°°°° C 21

RESULTS

MDEA

Temperature

Before

Cleaning

After

CleaningDifferential

EA-201-A

Input 100°°°° C 100°°°° C

Output 56°°°° C 43°°°° C - 13°°°° C

EA-201-B

Input 100°°°° C 100°°°° C

Output 58°°°° C 45°°°° C - 13°°°° C

EA-202-A

Input 100°°°° C 100°°°° C

Output 57°°°° C 48°°°° C - 9°°°° C

EA-202-B

Input 110°°°° C 100°°°° C

Output 66°°°° C 54°°°° C - 12°°°° C 22

The cost of the plate coolers’ maintenance performed through direct management allowed

92% estimated savings, compared with the costs that have been incurred by the Companies.

BENEFITS

Item Contract 1 ATFM Additive

Labor$784,402

$15,830

Product 3 $45,600 2

Total Cost $784,402 $61,025

Expected savings 92%Expected savings 92%

1 Reference quotation 0061210050 from the Alfa Laval company.2 Works under direct management using ATFM brand antioxidant descaling additive.3 The product volume used by each plate cooler was 300 Lts.

The maintenance of the 4 existing

equipment is envisaged, in order to maintain

heath transfer at suitable levels, with annual

savings of 2.9 MM$.

Type Cost

Hired $3,137,608

Direct management $244,100

Annual savings $2,893,508

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BENEFITS

BLAST ATFM

�Biodegradable

�Operator-friendly

�Reusable

�Reduces plant downtime by reducing cleaning downtime.

�Increases equipment productivity, considering per day production, before

and after the cleaning.

�Reduces equipment maintenance costs.�Reduces equipment maintenance costs.

�Extends the equipment’s useful life, reducing new equipment and spare

parts investment cost.

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FOR USED PAINT, IT IS LIMED AND WHEN THE BLAST ATFM PRODUCT IS

APPLIED, IT FILLS PORES AND BRIGHTENS THE PAINT, BEING APPLICABLE

ON:

• SPHERES

• HORIZONTAL AND

• VERTICAL TANKS

EXTERNAL CLEANING

BEFORE AFTERBEFORECPG SPHERES CLEANING IN POZA RICACPG SPHERES CLEANING IN POZA RICACPG SPHERES CLEANING IN POZA RICACPG SPHERES CLEANING IN POZA RICAMANUAL CLEANINGMANUAL CLEANINGMANUAL CLEANINGMANUAL CLEANING CLEANING WITH CLEANING WITH CLEANING WITH CLEANING WITH BLAST ATFM BLAST ATFM BLAST ATFM BLAST ATFM ADDITIVE ADDITIVE ADDITIVE ADDITIVE REQUIRED TIME 45 DIAS 2 DAYSRAW MATERIAL COST $210,000.00 $90,000.00LABOR COST $225,000.00 $10,000.00TIME SAVINGSTIME SAVINGSTIME SAVINGSTIME SAVINGS 43 DAYS43 DAYS43 DAYS43 DAYSMONEY SAVINGSMONEY SAVINGSMONEY SAVINGSMONEY SAVINGS $335,000.00$335,000.00$335,000.00$335,000.00 25

CONSERVATION AND MAINTENANCE OF SPARE PARTS IN GENERAL

• FLANGES

• ELBOWS

• VALVES

• CARBON FILTERS

• STUDS

• LIQUID ABSORBER TOWER

RINGS AND GASKETS.

EXTERNAL CLEANING

BEFORE AFTER

BEFORE AFTER

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BLAST ATFM PRODUCT RECYCLING PROGRAM

Cleaning is carried out in regenerator tower DA-4402, using just buckets, sisal brush and wash out water.

BEFORE AFTER

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BLAST ATFM PRODUCT RECYCLING PROGRAM

BEFORE AFTER

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Contact• Luciano Piccinini

• Director

• Tel. (58) 414 381 7769

• [email protected]

• Guido Italiani

• Director

• Tel. (58) 414 323 8140

• [email protected]• [email protected]

• Freddy Salcedo

• Vice - President

• Tel. (41) 990 67204

• [email protected]

• www.petroconsultores.com

• info @Petroconsultores.com

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INTRODUCTION - ptrcon.comptrcon.com/files/ShemenSal-Petro-Ingles1.pdf · INTRODUCTION SHEMENSAL ....

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