Leading The Unheading Revolution - Refining...
Transcript of Leading The Unheading Revolution - Refining...
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Leading TheUnheading Revolution
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A Heritage of FirstsA History of Innovations
Glenn Curtiss Orville WrightWilbur Wright
Aviation’s Pioneers
First Flight December 17, 1903
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Unheading Evolution
Manual (1950) Swing Away (1990) Enclosed (2001)
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First Installation: September 20, 2001
500,000+ cycles 500,000+ cycles No recordable injuriesNo recordable injuriesNo incidents No incidents
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Research & Development
– Understanding of the serve-service nature of the delayed coking process– Switch & cutting deck space constraints – Metallurgical testing analysis – Selection of materials of construction– Selection of material hard surfacing– Coke bond/shear strength– Actuator/drive train thrust requirements– Evaluated single-disk, dual-disk, and rotating-disk valve design
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SASOL-CarboTar PETROZUATA
CoffeyvilleResources
ENI - Gela Raffinaria
Petronas
RepsolUfaneftikem
PEMEX
Nippon Oil
PetroCanada
Husky
CNRL
TOTALTOTAL
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Worldwide Coker MarketEstimated Coke-drums: 750
Bottom Unheading Devices Sold:United States: 152Outside USA: 100Total: 252
Top Unheading Devices Sold:United States: 59Outside USA: 72Total: 131
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1.75’ / 533mm
8’ / 2.4m
28’ / 8.5m
72000 lbs / 32660 kg
DeltaGuard Bottom Unheading DeviceDimensional Data
US Patents6565714 69647276660131 68438896989081 70334607316762 58167877115190 7117959
International Patents209822 255082
Other US and International patents pending
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Revolutionary Design• All metal seating
– Nitrided gate and hard chromed seats
• Independent dual seats– Double block & purge/bleed – Floating top seat– Static lower seat– Protected in open/closed positions
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Revolutionary Design• Self cleaning
– Constant load keeps gate and seat surfaces together at all times
– No chance of particulate being trapped between the gate and seats
• Single-gate design– Device remains sealed even with
HPU or actuator shaft failure – No complex internal components
(balls, wedges, etc.) which may wear, clog, or fail
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Revolutionary Design
• Steam Purged Body– Regulates body temperature– Creates a barrier against
coke migration– Diagnostic tool– No need to continually turn
steam off and on for each cycle
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• Proven Internal Coke Containment System– Keeps coke fines from
entering the bonnet– Reduces steam
consumption
Revolutionary Design
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Design Specifications• ASME Sec VIII Div 1 & 2• U-Stamp Designation• MAWP 1062 kPa (154 PSI) @ 504°C (940°F)• FEA-Finite Element Analysis - mechanical Integrity • CRN# -ABSA• PED certification including ATEX & CE markings• GOST-R certification • Cooling box - shorter valve length• Face to face - 614mm (20 1/8”)• One major moving part - reliability• Double block & purge/bleed-dual seating technology • One HPU requirement - for bottom & top unheading and related equipment• Materials of construction - major components
- Body= 5C cast ( A 217 C 5 )- Bonnet= 2 ¼ chrome fab (A 387 Gr22)- Gate= A 387 Gr 5 with Nitriding- Seats= F182 Gr5 with hard chrome- Shaft= 17-4 PH1100
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Safe Unheading• Totally enclosed system from the top
of the coke-drum to the drain pit, rail car or sluice way
• Eliminate exposure risk to personnel, equipment, and the unheading deck
• Remotely operated from control room
• Safe secondary backup actuation• Positive mechanical lockout• All safety interlocks incorporated• Isolation of a tarry drum• Isolation or control of a drum dump
The DeltaGuard® Advantage
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Easy Operation• Push button controls • No feed line to disengage • Discharge chute permanently
attached to device • No intermediate chute to raise
The DeltaGuard® Advantage
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• No head or feed line coupling gaskets to replace
• No water flushing• No drum flange surfaces, tools or
deck to clean between cycles • No replacement parts after
each cycle• No maintenance or replacement
of tools• Device has one major moving part
Reliable, Low Maintenance
The DeltaGuard® Advantage
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The DeltaGuard® AdvantageExperience–Proven Technology• 7 year installation base • Over a half million combined unheading cycles• Zero maintenance between turnarounds • Zero recordable injuries• Continuous coker operation
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The DeltaGuard® AdvantageReturn on Investment• Immediate reduction of operating
and maintenance costs • Unheading and reheading time of
2 - 3 minutes• Increased production due to reduced
cycle times • Drum water can be drained directly
through device • Optional throttling design - control of
coke and water through port• Compatible with shot coke
production • Elimination of uncontrolled fallout• Ability to safely process alternative
crudes, namely shot coke
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Reliance InstallationJamnagar, India
• Installation June 2008• Fabricated bonnet design• New drum with single feed entry• 8 bottom valves & 8 top valves
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Valero InstallationSan Nicolas, Aruba
• Installation March 2006• Cast body/bonnet design• Bolt-in transition spool• 4 bottom valves
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Husky InstallationLloydminster, Canada
• Installation June 2007• Cast body/bonnet design• Bolt-in transition spool• 2 bottom valves
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Petrobras InstallationDuque de Caxias, Brazil
• Installation April 2008• Cast body/bonnet design• New drum with single feed entry• 4 bottom & 4 top valves
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5 Year TurnaroundChevron, Salt Lake City
Gate Lower Seat
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DeltaGuard Hydraulic Power Unit• Simple, reliable and redundant
hydraulic system
• Minimal hydraulic system requirements for valves, fittings and piping
• One hydraulic cylinder
• One hydraulic line in and out
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Remotely operable from local control panel or control room
DeltaGuard Control Station
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DeltaGlide Transport System with power-lift
DeltaGuard Installation:• The DeltaGlide provides ease of installation and maintenance.
• Optional power-lift raises/lowers DeltaGuard® and DeltaGlide™ from the drum flange to the structure.
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DeltaGuard Maintenance:• Maintains component alignment
during disassembly • Provides sufficient runway for
complete parts removal and re-installation on the switch deck
DeltaGlide Transport System with power-lift
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DeltaGlide Transport System
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DeltaGlide Installation
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DeltaGlide Installation
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DeltaGlide Installation
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Full DCU Product LineTop Unheading
Bottom Unheading
DeltaGlide™
Drill Stem Guide
HPU &Controls
Transition Spools
Auto-SwitchCoke Cutting Tool
Isolation Valve
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DeltaGuard® Top Unheading Device• Same proven technology used in the bottom unheading device• Proven top unheading safety and reliability• Patented seating technology• 131 units sold
193’’ / 4.9m
28” / 0.71m
12000 lbs5443 kg
64” / 1.63m
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Drill Stem Guide and Enclosure
• Maximum top head safety when used with the DeltaValve® auto switch coke cutting tool
• Customized for site specific requirements• Standard design provides;
– Drill stem guidance– Continuous cutting tool containment– Blowout protection-relief capacity and
routing
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Auto-Switch Coke Cutting Tool
• Provides automatic shifting of coke cutting and boring modes
• Pump pressures to 5500 psi (37.92 MPa)• Switching set pressures between
200-300 psi (1.38 – 2.07 MPa)• Complete CFD nozzle optimization for
combinations of pump pressures to 5500 psi (37.92 MPa), flows to 2000 gpm (7570 lpm), and drum diameters to 32 feet (9.75 m).
• Remote verification of drilling mode• Prototype-current testing Chevron Salt Lake &
Valero Pt Arthur
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Isolation Valves• Based on proven DeltaGuard® sealing technology• Continuous performance from turnaround to
turnaround • Heavy-duty linear electric/hydraulic drive train• Dual, metal, self cleaning seats• Live loaded• Steam purged body and bonnets• Extremely low steam usage • Double block and purge• ANSI 300# design• Top entry design• In-line repairable