motiva port arthur refinery sbu2 commissioning and start-up · 2020-03-03 · restricted presenters...

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Presenters

John Bagley – Motiva Port Arthur

Jim Jenkins – Shell International E&P

Shamara Manora – Motiva Port Arthur

September 2012

Motiva Port Arthur Refinery SBU2 Commissioning And Start-Up

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OVERVIEW

Introduction

New Sulfur Complex Overview

Challenge Statement and Details

Conclusion

2 CONFIDENTIAL

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Sulfur Complex 2 Design Basis

Need To Support 325 MBPD Refinery Crude Expansion

SWS2/3

800 GPM Each Unit

ARU5/6

3900 GPM Each Unit

SRU5/6/7

350 LTD Air Only Each Train

525 LTD Air With Oxygen Enrichment (28%) Each Train

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New Sulfur Complex Overview

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East/West Pipe Rack

(Our Conference Room)

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East/West Pipe Rack


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SWS Configuration

SWS2

– “Clean” – Non-Phenolic Water Service

– Water Segregation From “New Side Only”

– Side Draw For Wash Water Recycle

SWS3

– Phenolic Sour Water Service

– Water Integration With SBU1 (Old Side)

– Stripped Sour Water Recycle


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SWS2

CONFIDENTIAL

CLEAN SOUR WATER DEGASSING

DRUM

CLEAN SOUR WATER

VAPOR RECOVERY

CLEAN SOUR WATER TANK

FINFANS SWS ACID GAS K.O.DRUM HEADER

STR

IPP

ER

TO

WE

R

50#STEAM

WASH WATER

ASTU

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SWS3

CONFIDENTIAL

PHENOLIC SOUR WATER DEGASSING

DRUM

PHENOLIC SOUR WATER

VAPOR RECOVERY

PHENOLIC SOUR WATER

TANK

FINFANS SWS ACID GAS K.O.DRUM HEADER

STR

IPP

ER

TO

WE

R

50#STEAM

WASH WATER

ASTU

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SWS3 Degassing Drum


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ARU Configuration

3900 GPM Each Train

– Dedicated Or Combined Amine Separators

– Rich Flash Drum

– Swing & Surge Tank Capability

– Lean And Rich Transfer Lines With SBU1

– Active Flow Maintained

– AAG Supplied To SBU2 Only

– Dedicated SBU2 Acid Gas Header

– Segregated From SBU1


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ARU

CONFIDENTIAL

SEPARATOR

SEPARATOR

RICH AMINE

LEAN AMINE COOLERS

RE

GE

NE

RA

TOR

TO

WE

RA

RU

5

AM

INE

FI

LTER

S

LEAN AMINE

REFLUXDRUM

50# STEAM

CONDENSATE

ARU6AMINE ACID GASINTERCONNECT

LEAN AMINE SURGE TANK

OVERHEAD FINFAN

CONDENSERS

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Amine Seperators

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Amine Carbon Filter


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SRU Configuration

3 Two Stage Claus Trains

– Dedicated Tail Gas Unit For Each Train

– Oxygen Enrichment (28%)

– 2 Zone Reaction Furnace Configuration

– High Pressure Steam WHB (2 Pass)

– Shell Sulfur Degassing

– Three Compartment Pit Design

– Remote Sulfur Loading


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SRU

CONFIDENTIAL

THERMAL REACTOR

WASTE HEAT BOILER1ST PASS

WASTE HEAT BOILER2ND PASS

WASTE HEAT BOILER STEAM DRUM

600# STEAM HEADER

OXYGEN 1ST SULFURCONDENSER

1ST CLAUSCONVERTER

2ND SULFUR CONDENSER

2ND CLAUS CONVERTER

FINAL SULFUR CONDENSER

SULFUR TANK

SULFUR LOADING RACK

TGTU

1ST CHAMBER

2ND CHAMBER

3RD CHAMBER

AC

ID G

AS

K.O

.DR

UM

AMINE ACID GASINTERCONNECT

SWS GASINTERCONNECT

SW

SK

.O.D

RU

M

ATMOS.

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Thermal Reactor & WHB

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Thermal Reactor

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Converters


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Condensers


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Sulfur Pit


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Pre-Loading Sulfur Pit


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ControTrace – Pit Vent Line


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TGTU Configuration

3 SCOT Units

– Dedicated For Each Claus Train

– “Standard” Temperature SCOT

– 650 PSI Superheated Steam Self Supplied

– Incinerator Waste Heat Recovery

– Robust MDEA Stripper

– Formulated MDEA

– Aqueous Ammonia For Quench Buffer


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TGTU

CONFIDENTIAL

INCINERATOR BURNER

WASTE HEAT

BOILER

STEAM DRUM

600#SUPERHEATED

STEAM

INC

INER

ATO

RS

TAC

K

ATMOS.

NATURAL GAS

AB

SO

RB

ER

TGTU REACTOR

TAILGAS FROM SRU

WASTE HEAT BOILER

QU

EN

CH

TO

WE

R

STR

IPP

ER

REBOILER

RE

FLU

X D

RU

M

SRU ACID GAS

K.O.DRUMCOND.


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Incinerator

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Sulfur Loading Configuration

Remote From SBU2

Jacketed Sulfur Transfer Line

– Approximately 10,000 Feet Of Line

Automated Loading

– Weigh Scale – Auto Stop Fill

– BOL Printed At The Rack

Vapor Scrubbing


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Sulfur Loading Area

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Sulfur from Sulfur Pit

Sulfur Storage Tank

Sulfur Loadout

Truck

Sulfur Truck Weigh Scale

Truck Vapor to Scrubber

Tank Vapor to Scrubber

Caustic Storage/Loadout Vent Scrubber

Vent to Atmosphere

Sulfur Storge/Loadout Vent Blower


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Sulfur Loading Area


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SLR Panel


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Provide a safe, reliable way to dryout the refractory in several vessels within three new sulfur recovery units without plant utilities

(i.e. no natural gas, boiler feed water (BFW), etc.)

Challenge Statement and Details


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Refractory

A refractory material is one that retains its strength at high temperatures and are used in linings for furnaces, boilers, incinerators and reactors.

ASTM C71 defines refractories as non-metallic materials having certain chemical and physical properties that make them applicable for structures, or as components of structures, that are exposed to operating conditions greater than 1,000 °F.

Refractory materials must be chemically and physically stable at high temperatures. Depending on the operating environment, they need to be

– resistant to thermal shock

– be chemically inert to the process (acidic, neutral or basic refractory material)

– have specific ranges of thermal conductivity

– consider coefficient of thermal expansion

The refractory lining in these vessels use a combination of shaped (firebrick) and unshaped/monolithic (castable) refractories.


Refractory

All refractory require anchorage systems such as wire formed anchors, formed metal or ceramic tiles to support the refractory linings.

The anchorage used for refractory on roofs and vertical walls are more critical as they must remain able to support the weight of refractory even at the elevated temperatures and operating conditions.

These units employ a “steerhorn” anchor for support


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Terminology

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Curing - The process of bond formation with water at ambient temperature in cement based castables while

keeping the refractory material wet or the surrounding atmosphere humid for 24-48 hours prior to applying

heat for drying.

Dryout - Dry out is the process for removing both the mechanical water and chemical water from the refractory.

– Free or Physical Water – Excess water not retained in the bond structure that boils off at normal temperatures for

free water.

– Chemically Combined Water - Water that is tied up in the cement bond structure and released in stages at

elevated temperatures.


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Importance of Curing and Dryout

An improperly performed heat-up can trap moisture within the refractory.

– If residual moisture remains in the refractory, this moisture can interact negatively with process chemicals, such as sulfur, that should not be exposed to moisture.

– Water trapped within a refractory leads to a pressure buildup and the potential for dangerous explosive spalling.

A consistent dry-out ensures that a dual-component lining will not form slip planes where surface refractory “droops” or separates from anchored refractory.

All of these problems result in a shortened refractory life, and possibly even damage to costly equipment.

A controlled dry-out gradually forces the migration of free and chemically held water through the refractory lining, removing moisture.

Ceramic bonding occurs when dry-outs are performed at temperatures approximating 1,000°F (538°C). With the application of both heat and pressure, thermal penetration assures cross-sectional ceramic bonding within the refractory. This bond equates to refractory strength. With improved bonding, refractory campaign life should increase.


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Conventional Castables

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Water Ratios (Free vs Chemical)

• Castable = aggregate + cement (bond) + water

• Not all casting water is needed to form final bond

– On average only 25% of the water is needed for bond formation (chemically combined)

– Most of the water needed for placement (free water)

• Bond = many complex compounds develop as the material cures

−These bond structures can significantly impact dryout schedules (RISK)


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CONFIDENTIAL

Water Ratios (Free vs Chemical)

Free water fills and creates porosity

Bond structures formed in curing temperatures below manufacturers' guidelines can result in bond formations that result in:

– Higher % chemical water, lower % free water

– Less free water means less porosity

– More chemical water released at higher temperatures deeper in the lining passing thru lower

porosity material

– SIGNIFICANT increase in dryout time and risk


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CONFIDENTIAL

Free water

• Fills and adds to porosity of the material

• Not combined in bond structure

• Moves at approximately 212°F in lining

• The first hold point is the most critical for cement-bonded refractory for removing the mechanical water and is usually between 220ºF and 400ºF.

• The mechanical water is turned into steam and forced out of the refractory by the heat

Chemically combined water

• Used in development of bond as temperature increases

• The upper hold points remove the chemical water and form the final bond within the refractory for maximum strength.

• Some of the water is released at various temperatures, examples might be:

400°F

600°F

800°F

1,000 °F

Heat-up must be

designed to accommodate

type & thickness


Heat-Up Guidelines

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Complex Linings

Sections of linings that would normally require different dryout schedules

– Changes in lining composition (number of layers)

– Significant change in lining thicknesses (even if the same materials)

– Changes in material or refractory product form (ie. Cement castable, chem-bonded

castable, refractory plastic, etc.)

Normally increases the dryout time to account for all of the critical release points


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Lining As Installed

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Unit size:

• 12’6” ID Shell X ~48’ long

Water behind 9” brick:

• 20,500 pounds, or

• 2500 gallons


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Thermal Profiles

9˝HOTFACE

BRICK

3˝DENSE

CASTABLE

3˝INSULATINGCASTABLE

STEELSHELL

1500 ˚F (815 ˚C)1400 ˚F (760 ˚C)1300 ˚F (704 ˚C)1200 ˚F (649 ˚C)1100 ˚F (593 ˚C)1000 ˚F (538 ˚C)

900 ˚F (482 ˚C)800 ˚F (427 ˚C)700 ˚F (371 ˚C)600 ˚F (316 ˚C)500 ˚F (260 ˚C)400 ˚F (204 ˚C)300 ˚F (149 ˚C)200 ˚F (93 ˚C)100 ˚F (38 ˚C)

0 ˚F (-18 ˚C)

Inside Gas VesselTemperature ºF Hot Face ºF Intermediate ºF Backup ºF Shell ºF

200ºF 193 184 149 115250ºF 239 226 174 125300ºF 285 267 199 133350ºF 332 309 223 141400ºF 378 350 247 149450ºF 424 391 270 156500ºF 470 432 293 162550ºF 516 473 316 168600ºF 562 514 339 1751000ºF 931 839 520 223

Mean Temperatures of Refractory Layers

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Refractory cement has elements that trap many microscopic air pockets in the mix that provide a high degree of insulation.


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Required Utilities & Preliminary Tasks

Instrument Quality Air

Combustion Air

Fuel Supply

Boiler Feed Water

Process Safety Interlocks and Safety Equipment

Complete Boil-Out of New Boilers

Obtaining and managing all these utilities and process parameters was a joint effort between five companies


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Instrument Air Supply

Provide instrument air at 90 psig and a dewpoint of -40 degF for instrumentation and regulator control

Ensured all instrumentation was lined up and energized


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Combustion Air

Electric Combustion Air Blower

– Blowers had a rated capacity of 100,000 ft³/hr

– Primary and Secondary CAB were installed

– Set up of blowers ensured that heat is distributed evenly regardless of a vessel’s geometry.

– Blowers contained a step-down transformer to supply current to the system’s flame failure device. Thus a fan

failure would shut down the burner system.


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Fuel Supply

Provided propane from two 1990 gallon LPG tanks

Liquid propane was converted into gas via four 80 gph direct fired vaporizer units working in parallel

A gallon of liquid propane will become ~36 cubic feet of vapor

A direct fired vaporizer uses a direct flame to vaporize liquid LPG inside a heat exchanger/pressured vessel.

Requiring no electricity, the direct fired vaporizer utilizes LPG itself as its source of energy and provides a constant supply of LPG to the process unit


Fuel Supply

= 234,000 ft3/train

= 151,200 ft3/train

= 27,000 ft3/train

= 72,000 ft3/train


Fuel Supply

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Fuel Supply


Boiler Feed Water


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Dryout Equipment Apparatus

The combustion set consisted of a burner, combustion air blower and flame safety control cabinet. All were

interconnected with gas and air hosing.


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Dryout Burner Apparatus

The refractory was heated in accordance with manufactures heat up schedule using a supplemental burner as the heat source.

The burner was mounted onto the equipment within a sufficient distance away from the tube and wall surface to prevent any flame impingement or overheating.

The burner assembly included an integral or an independent observation port to view the flame throughout the dry-out process.

Thermocouples were installed to calculate the average gas temperature throughout the dry out process. Thermocouples were installed at multiple points as directed by the manufacture of the refractory.

A vent was installed in the rear of the equipment to allow for proper venting of the flue gasses.

Boilers had adequate liquid level to prevent WHB tubes, tubesheets, drums, etc from being damaged from over-expansion of these components


Thermal Reactor and WHB Pass 1/2


Thermal Reactor and WHB Pass 1/2

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2nd Sulfur Condenser & SCOT WHB

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Second Sulfur Condenser

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SCOT Reactor WHB

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Incinerator Dryout Apparatus

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Incinerator

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SCOT Reactor and Claus Converters

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Claus Converters and SCOT Reactor

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Burner Management Plan

Burner

– A high velocity, excess air burner

– Rated capacity of 10MM BTU/hr with a high turndown ratio approaching 100/1.

– The turndown capability enabled precise temperature control at full combustion air rates ensuring minimum

gradients throughout the heat cycle.

– The high velocity provided a turbulent atmosphere within the vessel or duct eliminating stagnant areas and

minimizing temperature differentials.

Combustion Air Blower

– Blowers had a rated capacities of 100,000 ft³/hr.

– Blowers contained a step-down transformer to supply current to the system’s flame failure device. Thus a fan

failure would shut down the burner system.

– Set up to ensure that heat is distributed evenly regardless of a vessel’s geometry.


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Flame Safety Control Cabinet

– The control cabinet contained various valves that control the gas flow rates to the burner

– Automatic safety valves shut down the system when

– Flame failure device, with scanner built into the burner, was unable to detect flame. The combustion sets were

equipped with Fire-eye brand flame failure system. The flame scanner was built deep into the burner body so that

burners in close proximity would not influence the interlock.

Temperature Recorder

– The system consisted of 24-point recorders, producing a continuous permanent chart of all thermocouples.


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Thermocouples

– Used Type K (chromel-alumel) made of 1/8" stainless steel sheath and 18-gage thermocouple wire.

– Ensured the proper length was used to ensure a satisfactory position inside the vessel.

– All were connected via type K compensating wire and routed as not to interfere with traffic during the dryout

process.

– Skin thermocouples were installed via a capacitor discharge unit to the shell.

Redundant Equipment (e.g. a spare combustion set) was provided as well.


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Boil Out

The internal surfaces of a new boiler contain deposits of residual oil, grease and protective coating inherent in manufacturing procedures.

It is important that these deposits be removed from the heating surfaces since this contamination will lower the heat transfer rate and possibly cause overheating of pressure vessel metal.

These deposits can generally be removed by an alkaline boil-out

Boil-out chemicals are highly caustic. Caustic Soda Ash will produce a violent flash if introduced to water too rapidly. Employees handling the chemicals must wear protective equipment, I.E. Goggles, gloves, aprons, etc.. and an emergency shower should be nearby. Typically a mild acid like vinegar serves as an antidote.

Boiler Feed Water is needed and a proper steam drum level needs to be maintained

Fire the boiler at the proper temperature as indicated by water treatment specialist(s)

Continue the boil out for at least 60 hours until the blowdown is clean.

When blowdown is clean, remove the heat source, and allow the unit to cool gradually.

Drain the boiler when water temperature drops below 200°F.

Remove the inspection covers, flush the system with treated water at least three to four times.

Inspect pressure parts internally. If any remnant oil is found, repeat the boil-out procedure.

Take the necessary precautions to protect boiler internal surfaces from corrosion by utilizing the appropriate lay up


Timeline


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Ensuring Safety Always

Steam Drum Low Level Interlock

Steam PRVs with Silencer on new equipment

Temporary boiler high pressure steam shutdown and fire detection shutoff

Temperature controls

Air to Gas Ratio Controls

LPG Tank location, PRVs, effluent line design and pressure testing

LEL monitoring


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Lessons Learned

Of the 27 vessels in need of dryout, there was one vessel that needed refractory repairs

Partially dryout was not favorable due to the potential of alkali hydrolysis

No more than a few weeks (usually not more than 3 or 4) should pass after installation until dryout should begin. Providing some kind of air movement (such as a dehumidifier or dryer of some kind) would extend that time somewhat.

Heat transfer calculations and resulting skin temperatures for various hot face temperatures allowed the engineering team to decide on the max heat-up temperature during dry-out for the various vessels

The hold temperatures for dryout are based on the thermal conductivity amongst the refractory and the water of hydration temperature throughout the refractory. For example, the 4th water of hydration temperature for the 3” insulating castable in the Thermal Reactor is reached around 825-850F. This requires getting the intermediate castable layer to above 1000F. Thus, the target dry-out temperature at the hot face has to be 1500F.


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Conclusion

New Sulfur Complex

– Two – 3900 gpm capcaity ARUs

– Two – SWS (Phenolic and Clean)

– Three – 507 LTPD SRU Trains

Need Refractory Dryout in a Tight Startup Schedule with limited plant utilities

Provided ways to get

– Instrument Quality Air

– Boiler Feed Water

– Burner Assembly

– Boil Out, Curing and Dryout


A Disciplined Plan, Purposely Executed, as ONE Site, with Full Transparency, and NO Freelancing…....And Before You Know

it, We’re Running an Entire Refinery!!!

Questions?


motiva port arthur refinery sbu2 commissioning and start-up · 2020-03-03 · restricted presenters...

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