Opportunities and Limitations on Remote and Automatic Coke...
Transcript of Opportunities and Limitations on Remote and Automatic Coke...
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Opportunities and Limitations
on Remote and Automatic Coke Cutting
Opportunities and Limitations
on Remote and Automatic Coke Cutting
Rio de Janeiro, 2014-10-01
Dr. Wolfgang Paul
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RUHRPUMPEN Specialist for Pump Technology
Ruhrpumpen - Organisation
Pump Division
Decoking Division
– RP-Argentina
– RP-Brazil
– RP-India
– RP-China
– RP-Egypt
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Coke Cutting System
Short Cutting Time
Reduced failurerate
AutomaticDecoking
Safe and smooth operation
NO STUCK TOOL
Opportunities for Remote / Automatic Decoking
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RUHRPUMPEN Specialist for Pump Technology
Requirements for Rem/Auto Coke Cutting
• Coke Cutting System– Lifting System with enough Power for Automatic Coke cutting
• Hydraulic or electric driven Hoists and Drill Stem Drives
• 5000 kg pull force lifting system
• Control System– Signal channelling from Cutting System to PLC
– Operator Panel with Signal visualization through PLC remote CC
– PLC-program with Automatic Cutting System Program autom. CC
• Drum Vibration Monitoring System and Camera System • Vibration Probes at drum
• Camera Systems for Cutting Deck and Chute observation
• Manual override• Installation and Maintenance
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RUHRPUMPEN Specialist for Pump Technology
Decoking Jet Pump
- Jet Pump unit
- LOU
- Decoking Control
valve
Capacity 295 m³/h
1300 gpm
Head 3158 m
4492 psi
Speed 3923 rpm
Temperature 65 °C
Medium Water with
coke fines
Jet PumpIndia
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RUHRPUMPEN Specialist for Pump Technology
Control system
• Main Control Panel,
Pump area
– Operation of pump unit,
– Lube oil unit
– Panelview
– Condition monitoring
– Maintenance provision
– Status indication by lmps
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RUHRPUMPEN Specialist for Pump Technology
Cutting system: Hoist and DSD
Electrical system• Features
– 1 VFD set for hoists• 1 running, 1 stand by
– 1 VFD set for DSDs• 1 running, 1 stand by
– VFDs, 1 set per coker, • Installed in safe area, or• Cutting deck
– Redundant installation
Pneumatic system• Not recommended
– Un- sufficient power,
– Oil polluted air
– High noise level
– Remote / automatic control• Not reliable
.
Hydraulic system• Features
– Hydraulic power unit
– 1 hyd. hoist/DSD per drum
– 1 Operator panel per drum pair
– Control electric/electronic
– Integrated in PLC system
– Measurement of force, tension
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Weight of Coke
RUHRPUMPEN Specialist for Pump Technology
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RUHRPUMPEN Specialist for Pump Technology
Cutting System Performance
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RUHRPUMPEN Specialist for Pump Technology
Hoist and Rope
• Hoist with integral cartridge gear
– drum with grooves
– Pull force 5 t– slack rope
indicator• locks the
hoist
• Rope– measurement of
tension in the rope
– indication at the operator panel
– avoiding of overload
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RUHRPUMPEN Specialist for Pump Technology
Hoist, Block and Rope• Hoist, electrical
driven, cartridge gear
– Electric driven, 45 kW
– Triple Brake system
– Pull force 5.000 kg,
– slack rope device
– API Baseplate
– Safety cage
• Rope
– 16/18 mm
– measurement of rope tension
– indication at the operator panel
– avoiding of overload
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RUHRPUMPEN Specialist for Pump Technology
Drill Stem Drive
• Drill Stem Drive
– Electric motor
– High load bearing
– Grease lubrication
– Cartridge packing
– Swivel
– Standard version
( down to -20°C)
• Varible Frequency
Converter VFC
– At Cutting deck, or
– At safe area
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RUHRPUMPEN Specialist for Pump Technology
Crosshead with FFA and DSD
Ruhrpumpen Drill Stem Drive
- grease lubricated
- modular design- packing cartridge- one main bearings- hydraulic / electric
Tolerances of installationMain beams
outside-outside 1640 mm
acting width 1400 mm
Tolerances
guide beams/rails +3/- 3 mm
main beams +5/-15 mm
+50/-25 mm special
weight 850 kg
Reduced shock load Vert. main beams
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RUHRPUMPEN Specialist for Pump Technology
Automatic Cutting Tool
Basic design– Slim tool, OD 13”
– Low lift force
– Low torque
• Switching devices– Manual / Automated
– At the top of the tool
• Valves– Ballshape valves
– No seals
– Pressure operated
• Nozzles, cutting– 0°
– 10°up both cutting nozzles
• Nozzles, drilling– 1 strong centre nozzle
– 3 periphery nozzles
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RUHRPUMPEN Specialist for Pump Technology
Drum Monitoring System
Drum Monitoring
Signals are channelled to PLC System,
Operation Information/Signals for Cutting System
Vibration Noise
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RUHRPUMPEN Specialist for Pump Technology
Operator Shelter with Panel
• Local Operator panel
- Operation of
• Decoking valve
• Isolation valve
• Hoist
• Drill stem drive
– Interactive P&ID
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RUHRPUMPEN Specialist for Pump Technology
Basic design
Operation
remote
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RUHRPUMPEN Specialist for Pump Technology
Remote Operator Shelter
Remote Cutting
System
Frontier, Kansas,
USA 2008
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Remote - Automatic Decoking
Instrumentation drum-shute vibro-system
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RUHRPUMPEN Specialist for Pump Technology
Control and Process visualisation
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RUHRPUMPEN Specialist for Pump Technology
Coke Cutting system
Limitations of Remote / Automatic Coke Cutting
• Coke Cutting System– Weak points of Cutting System cannot be eliminated
– Power of Cutting System cannot be improved
– Safety issues cannot be solved– Except Operators are removed from Cutting deck
– Except Operators are hurt and fatalities are avoided
• Control System– Program is as good as information from site are implemented
– Program is as good as experience from supplier are implemented
– Program is as good as special operation features are implemented– Different Feedstocks can be handled only when procedures are implemented
• Optimization– Optimization is an ongoing process
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RUHRPUMPEN Specialist for Pump Technology
References, running for several years
Germany, 2006 BP remote, automatic
USA, 2009 Frontier remote, manual
Argentina, 2010 Shell remote, manual
USA, 2010 Hunt refining remote, manual
RP has actual 2 orders for remote coke cutting system
3 orders for remote / automatic system
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RUHRPUMPEN Specialist for Pump Technology
BP-Gelsenkirchen
BP-Gelsenkirchen,
Germany
Licencor: FW
Scope
-Cutting system, automatic
-Bottom deheading, semi-auto
-Top deheading, semi-auto
Order: 2003-06
Start up: 2004-05
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RUHRPUMPEN Specialist for Pump Technology
Frontier-Oil
Frontier, Kansas, USA
Licensor: Lummus
EPC: CBI
Scope:
–Cutting system,
–1 pumps, 2 drums
–Order: 2007
–Start up: 2008
– remote cutting system
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RUHRPUMPEN Specialist for Pump Technology
Hunt Refining
Hunt, AL, USA
Licensor: Lummus
EPC: Commonwealth Eng.
Scope:
–Cutting system,
–2 drums, revamped coker
–Electrical cutting system
–Order: 2009
–Start up: 2010
– remote cutting system
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RUHRPUMPEN Specialist for Pump Technology
Hunt Refining
Hunt, AL, USA
Scope:
–Cutting system,
–2 drums, revamped coker
–Electrical cutting system
–Order: 2009
–Start up: 2010
– remote cutting system
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RUHRPUMPEN Specialist for Pump Technology
Hunt Refining
Hunt, AL, USA
Scope:
–Cutting system,
–2 drums, revamped coker
–Electrical cutting system
–Order: 2009
–Start up: 2010
– remote cutting system
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RUHRPUMPEN Specialist for Pump Technology
Remote and Automatic Coke Cutting
Results of Remote and Automatic Coke Cutting
1. Safety
• Increased Safety
• “No Men in the structure during Coke Cutting”
2. Operation / Process
• Increased Stable process– More Data and information to the operator remote
– More Data and information to Control Room remote/automatic
3. More through put => more money
• Stable process, more through put
• Reduced failure rate, reduced downtime, reduced maintenance
• Minimizing of “human factor” with automatic coke cutting
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THANKS FOR YOUR
ATTENTION
RUHRPUMPEN
RUHRPUMPEN Specialist for Pump Technology