flowserve conference remote & automated coke...

© Flowserve Corporation (2012) 1

2012 Decoking ConferenceFlowserve

Remote & Automated Coke Cutting

Andrew WorleyGlobal Product Manager Coke Cutting Systems


2012 Decoking Conference

• Flowserve Overview• Coke Cutting Process Evolution• Coke Drum Monitoring

• Audio• Video• Vibration

• Remote Coke Cutting • Automated Coke Cutting

Agenda: Remote & Automated Cutting



1938 Process patented by Shell

1938 Original Jet pumps & valves by

1940 enters the market

1947 First Pacific Pump Decoking Installation

1979 First Combination Cutting Tool (Axial)

1980 First Simple Automated System Commissioned

1985 Pacific & Worthington merge

1992 Pump Divisions of Ingersoll-Rand & Dresser form joint venture

1994 First 4000 psi (27600 kPa) Jet pump

1995 On Deck Remote System Commissioned

2000 acquires IDP

2004 First Autoshift ™ Cutting Tool

2008 First 5000 psi (34473 kPa) Jet pump with 6235 psi (42989 kPa) MAWP

2010 Fully Automated System Shipped

2011 Off Deck Remote System Commissioned

2013 Fully Automated System Scheduled for Commissioning

Hydraulic Coke Cutting Systems History

Flowserve has built over 200 coke cutting systems

over the past 70 years with drum diameters

exceeding 32 ft



Coke Cutting Evolution




Manual Cutting – Old systems

• Personnel located on cutting deck• Operate winch and rotary joint

controls




Current Local Cutting Standard Cutting

• Electronic Joystick• All equipment PLC

Controlled• HMI with full system

information



Coke Drum Monitoring


2012 Decoking ConferenceCoke Drum Monitoring

Systems to help operator monitor progress

Audio

Video

Vibration


2012 Decoking ConferenceCoke Cutting Monitoring - Audio

MIC

MIC

Audio Server

Speaker

Operator Shelter• Allows the

operator to hear the jet hit the drum

• More direct than standing at the cutting deck

• Can be routed to on deck or off deck operator shelters


2012 Decoking ConferenceCoke Cutting Monitoring - Video


2012 Decoking ConferenceVideo Design Considerations

Flexibility

• Cameras options– Fixed– Pan & tilt capability , degrees– Zoom capability– Infra Red Cameras – Weather equipped Lens wiper capable Heater defroster blower De-icing feature


2012 Decoking ConferenceLocation in the Delayed Coking Unit

Location of the equipment is key• Clear field of access• Protected from

outside disruptions• Adequate utility

availability• Junction box• Cabling

connections



• 4 Vibration probes mounted on coke drum

• Signals routed to Flowserve IPS Apex™ for analysis

• Signals displayed on the HMI

Coke Drum MonitoringCoke Cutting Monitoring – Drum Vibration



Vibration systems


• Can be displayed on stand-alone HMI or integrated with control system

Coke Cutting Monitoring – Drum Vibration



Vibration systems


• Can be displayed on stand-alone HMI or integrated with control system




System Architecture




Vibration Strip

Charts

Instantaneous Vibrations




Field Information

Push Button

Controls




Drum Cleanliness

will be indicated

here




2. Remote Coke Cutting



Move operator from the cutting deck to a remote location

BenefitsIncreased SafetyPersonnel no longer exposed to:

• High-pressure water• Hot spots or steam eruptions• Hydrogen sulfide vapors• Mechanical hazards

Remote Coke Cutting



Equipment required• AutoShift™ cutting tool• Remote winch and rotary joint operation• Remote operator enclosure• Automatic Guide Plate or Tool Enclosure• Vibration/acoustical devices• Video equipment

Information requiredData sent remotely to operator

• Cutting tool position and rotational speed• Cable tension and AutoShift mode• Drum status• Video Feedback for Pit, Winch, & Top of Drum

Remote Coke Cutting



Modular Cutting Shack Design – Inside

Video camera Display

Cutting System Permissives

and Operations Status Lights

Coke Cutting Operating Controls

Photo courtesy M.Moloney, ExxonMobil

Speaker

Remote Coke Cutting – First On Deck Site



Video camera Display

Cutting System Permissives on HMI

Coke Cutting Operating Controls

Speaker

Remote Coke Cutting – 2011 Installation



Drum Information through Vibration MonitoringWinch & Rotary Joint InformationSystem Pressure Information

•Progress monitored on customizable display screens

0

0

40

3000

15

6080

04700

Remote Coke Cutting - Boring



0

0

40

4000

8

04700

6080100

Drum Information through Vibration MonitoringWinch & Rotary Joint InformationSystem Pressure Information

•Progress monitored on customizable display screens

Remote Coke Cutting - Boring


2012 Decoking ConferenceKey Learnings & Successful Practices

Video is essential ‘kit’ for a coke handler. Site requires a system which is reliable and will provide at least four views simultaneously. (Open head, winch drum, chute, and crane location.)

Consider “serious controls” on human presence on the cutting deck during unheading and decoking. Routine human presence may come to be viewed as necessary, and reduce the benefit of the effort.

HMI graphics need to be simple to use, consistent, and well understood by the coke handler.



Consider hydraulic or electric winches.

ALL RIGHTS RESERVED

Take care in arranging commissioning activities and resources, especially if remote decoking is being commissioned in conjunction with other complex changes. Missing a step or double-booking a resource can easily cost you hours or days.

Key Learnings & Successful Practices



Automated Coke Cutting


2012 Decoking ConferenceAutomated Coke Cutting

History• 1980s – Simple Boring & Time Based Cutting

• mid 2000’s – BP Gelsenkirchen – On deck, time based, with some vibration feedback

• 2010 - Fully automated systems• Embedded intelligence and advanced algorithms to

process signals and control the cutting process• Automatic coke cutting with continuous feedback• Operator consulting only required for exceptions



PLC cuts coke. Operator needed for abnormalitiesEquipment required

• AutoShift™ cutting tool• Remote winch and rotary joint operation• Remote operator enclosure• Automatic Guide Plate or Tool Enclosure• Vibration Drum Monitoring

Information required Data received by PLC and transferred to IPS APEX

• Cutting tool position and rotational speed• Cable tension and AutoShift mode

Data received directly by IPS APEX• Drum status

Automated Coke Cutting- Equipment



Basic operation

Use vibration sensors mounted on the coke drum to provide feedback on the state of cleanliness of the drum wall

Sensors provide interactive feedback on the cutting status that can optimize the cutting time

Program is customized based on site-specific cutting practices and configured with end user





• APEX Cutting Algorithm• Preprogrammed Algorithm• Manual Backup



Improved cutting personnel safety• Automated cutting system integrated with PLC interlocks• Minimize probability of operator mistake• Eliminates shortcuts sometimes taken by cutting personnel• Standardized cutting procedures reduce risk of aggressive cutting

practices

Process efficiency and consistency• Advance the cutting program as soon as possible based on

vibration feedback• Consistent cutting times with standardized cutting procedure

Automated Coke Cutting- Benefits



Improved equipment reliability • Less damage from ramming tool into coke bed during boring• Less chance of damage from aggressive cutting techniques• Can monitor performance of jet pump and other decoking equipment

for predictive maintenance

Data recording for process optimization / troubleshooting• Data recorded and can be compared w/process data to optimize

cycle times• Ability to access data for troubleshooting in case of any failure event• Ability to monitor performance of jet pump and other decoking

equipment for predictive maintenance

Automated Coke Cutting- Benefits



Andrew Worley [email protected]

Thank You

Remote & Automated Coke Cutting

flowserve conference remote & automated coke...

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Flowserve Conference Remote & Automated Coke Cutting · © Flowserve Corporation (2012) 3 2012 Decoking Conference 1938 Process patented by Shell 1938 Original Jet pumps & valves