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• Meet latest standards and industry best practices
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Economic Justification11
• Pre-BMP:
✓ Fuel gas saving due to heater efficiency improvement
▪ Heater fires FCCU/Visbreaker off-gases
✓ Heater runs for a full 6 year T&I cycle
▪ Saves one decoke shutdown cost & loss of crude throughput
• Post-BMP:
✓ Heater fires 100% low LHV Khuff gas (FCCU/Visbreaker decommissioned)
✓ Higher benefit after BMP due to recovery of C3, C4 & Naphtha which had to be burned in the old heaters to maintain minimum LHV
✓ Heater runs for a full 6 year T&I cycle
▪ Saves two decoke shutdown cost & loss of crude throughput
✓ IIR - 15% with simple payback of 6 years
Challenges
• Selection of location for new heater
✓ Brown field project
✓ Compliance with Bapco safety standard
• Requirement to replace existing crude booster pump
• Providing bypass around Crude/Atmospheric Resid exchanger
• Execution constraints
✓ Many lines - rerouted to create space for new pipelines and supports
✓ 2800 people working simultaneously in congested plant area
✓ Hot tapping 8”x 8” planned for 550# superheated steam line
✓ Demolition of existing 3 heaters (with unit in operation)
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Empowering Progress
Engineering and execution
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Thangaraj Raju
Plant Engineering Department
Project Aspect - Overview
• 5CDU Heaters replacement project followed Chevron Project Development Evaluation Process (CPDEP)
• Scope of project includes:
✓ Vertical cylindrical heater 32 ft diameter, 213 ft height, with 12 burners
✓ CFD Analysis to ensure acceptable firing pattern
✓ Fuel gas knockout drum followed by coalescer & pilot gas knockout drum
✓ Two crude booster pumps
✓ Demolition of existing 3 heaters (with unit onstream)
• Features:
✓ Modular construction of radiant, convection & stack assemblies
✓ Ex-situ refractory dryout
• Front End Engineering Design(FEED) - Engineers India Ltd (EIL)
• Engineering, Procurement & Construction (EPC) - JGC Gulf International Ltd
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Project Execution Plan
• Project schedule - 20 months
• 4 Phases of execution :
✓ Before 5CDU T&I (unit onstream) - 5%
✓ During 5CDU T&I (Nov 2017) - 30%
✓ After 5CDU T&I (unit onstream) - 60%
✓ Short shutdown for commissioning - 5%
• Challenging job due to brownfield project in congested area
• Jobs provisionally planned before unit T&I could not be done due to safety
concerns
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Project Work - During T&I
• Jobs carried out during 22 days of T&I :
✓ Civil foundation supports for pipe rack & pipe supports (100 nos)
✓ Installation of pipe rack 50 metres and its pipe supports
✓ Piping tie-ins >100 nos
✓ Installation of pipelines ~1000 metres on new pipe rack/supports
✓ Hydrotesting, painting & insulation
✓ Welding of reinforcements for fireproofing for pipe rack & pipe supports
✓ Demolition of work station
✓ Re-location of guy wires on existing heater stack
✓ Replacement of UPS
✓ Modification of 2.3KV switch-gear for power supply to new booster pump motor
✓ Underground survey and trial pit for booster pump foundations
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Project Work - During T&I (cont’d) 17
Work In Progress - During 5CDU T&I18
Challenges faced during T&I
• Integration of project schedule with shutdown maintenance T&I schedule
• Difficulty in welding new and old alloy steel pipelines due to magnetization
• Sharing of work space, resources and cranes with Maintenance Department
• Plan integration
• Alternative technique of Phased Array Ultrasonic Testing (PAUT) in place of radiography
• Additional stress relieving machines to cater for 200 alloy steel & NACE weld joints
• Some H2S emission and continuous release of oily water during excavation for foundation of pipe supports
• All the T&I related work for new heater were done with zero incidents
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EPC Work after T&I
• 30%, 60% & 90% 3D Model review
• HAZOP & SIL study
• Heater vendor package finalized and fabrication is in progress
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• Crude booster pump design review due to NPSH issues and relocation of pumps
• Coalescer design modified for maintenance work
Concluding Remarks
• Engineering and T&I activities done safely and successfully without incidents
• Now we need to safely install and commission the new heater on-schedule to meet the key objectives of improving Efficiency, Reliability & Environmental performance
❑ Key Success Factors
✓ Technically strong, experienced, aligned and motivated in-house multidisciplinary team
✓ Concept developed in-house
✓ Vital to involve the right people in the evaluation and decision-making process
✓ Close working relationship with the contractors and vendors
✓ Alignment of Bapco - Project / Maintenance teams and EPC/sub-contractor teams in completing jobs within stipulated time