switching between cracking and decoking
TRANSCRIPT
1
Switching between
cracking and decoking
Menno VAN DER BIJ - Deputy Manager Instrumentation Department32th Annual European AIChE / Delta Process Academy Seminar
‘Safe start-up of chemical plants’ October 11th, 2016, Domein Martinus / Halle - Zoersel
AMERICAN INSTITUTE OF CHEMICAL ENGINEERS Netherlands / Belgium Section
Pyrolysis Furnaces
2
Switching between cracking and decokingIntroduction
CRAC
KED
GAS
HEA
DER
Deco
ke E
fflue
nt V
alve
Cracking furnace in CRACKING mode of operation
3
Switching between cracking and decokingPossible Hazards
Cracked gas leaking through decoke valve(s) to atmosphere Decoke air routed to furnace, mixing with HC High temperature downstream QOF in case of quench oil
failure Backflow of cracked gas from header to cracking furnace in
case of multiple radiant coil failure Low temperature downstream QOF due to failure of the
emergency water back-up
While in CRACKING mode:
4
Switching between cracking and decokingIntroduction
CRAC
KED
GAS
HEA
DER
Deco
ke E
fflue
nt V
alve
Cracking furnace in DECOKING mode of operation
5
Switching between cracking and decokingPossible Hazards
Cracked gas leaking through cracked gas valve(s) to atmosphere
Hydrocarbon feed routed to furnace, mixing with decoke air DMDS connected to atmosphere Quench oil connected to atmosphere Decoke effluent routed to cracked gas analyzer
While in DECOKING mode (open connection to atmosphere):
6
Switching between cracking and decokingIntroduction
FEEDFEED
PRE-HEATER
DILUTION STEAM
SUPERHEATER
STEAM
HIGH TEMP. COIL
TLE
QUENCHOIL
FITTING
DECOKE CYCLONE
To Atmosphere
CRAC
KED
GAS
HEA
DER
Oil
AIR
To Stack
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
To Fire Box
DMDS
Cracking furnace in HOT STANDBY mode of operation
7
Switching between cracking and decokingPre-conditions for change-over
Hydrocarbon feed lines isolated
Decoke air line isolated
DMDS line isolated
Quench oil line isolated
Decoke air and HC feed lines purged with steam
8
Switching between cracking and decokingHistory
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
Individual operated valves
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
M
Mechanically linked valvesWith 1 electric motor
M
M
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
Electrically linked valves
9
Switching between cracking and decokingPossible Hazards
Overpressure due to simultaneously (partial) closed decoke and cracked gas valve(s)
Backflow of cracked gas to atmosphere while both valves are open
During TRANSFER from cracking mode to decoking modeDe
coke
Effl
uent
Val
ve
Cracked Gas Valve
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
M
M
M
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
Overpressure is possible in all 3 configurations
10
Switching between cracking and decokingSafety Instrumented System requirements
Overpressure due to simultaneously (partial) closed decoke and cracked gas valve(s)
Backflow of cracked gas to atmosphere
During TRANSFER from cracking mode to decoking mode
PREVENT
M
Cracked Gas Valve
M
Cracked Gas Valve
11
Switching between cracking and decokingSafety valve for overpressure protection
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
SP SPLC LC
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
SP SPLC LC
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
SP SPLC LC
To Atmosphere
LC
Cracked Gas Valve
SP SPLC LC
Cracked Gas Valve
SP SPLC LC
Cracked Gas Valve
SP SPLC LC
To Atmosphere
LC
SP = Steam PurgeLC = Locked Closed
12
Switching between cracking and decokingConceptual design
Decoke cyclone
CRAC
KED
GAS
HEA
DER
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
AIR
FEED
STEAMFSLL
FI
Oil
L
DMDS
PSHH PDSLLPI
PAHPDI
PDALPressure transmitter
Differential pressure transmitter
Note: Switch-over can be manually from local panel or DCS or fully automatic through the safeguarding system
13
Switching between cracking and decokingConceptual design
CRAC
KED
GAS
HEA
DER
Deco
ke E
fflue
nt V
alve
14
Switching between cracking and decokingPressure profile
PAHH
PAH
PDAL
PDALL
dP = 0 Bar
Closed
Open DEV
CGVDEV
CGV
Decoke Effluent Valve DEV Cracked Gas Valve CGV
Differential pressure
T1 T2 T3 T4 T5 T6 T7 T8
CRACKING TO DECOKING: STEP 1De
coke
Effl
uent
Val
ve
PAHH
PAH
PDAL
PDALL
dP = 0 Bar
Closed
Open DEV
CGVDEV
CGV
Decoke Effluent Valve DEV Cracked Gas Valve CGV
Differential pressure
T1 T2 T3 T4 T5 T6 T7 T8
CRACKING TO DECOKING: STEP 2De
coke
Effl
uent
Val
ve
PAHH
PAH
PDAL
PDALL
dP = 0 Bar
Closed
Open DEV
CGVDEV
CGV
Decoke Effluent Valve DEV Cracked Gas Valve CGV
Differential pressure
T1 T2 T3 T4 T5 T6 T7 T8
CRACKING TO DECOKING: STEP 3De
coke
Effl
uent
Val
ve
PAHH
PAH
PDAL
PDALL
dP = 0 Bar
Closed
Open DEV
CGVDEV
CGV
Decoke Effluent Valve DEV Cracked Gas Valve CGV
Differential pressure
T1 T2 T3 T4 T5 T6 T7 T8
CRACKING TO DECOKING: STEP 4De
coke
Effl
uent
Val
ve
PAHH
PAH
PDAL
PDALL
dP = 0 Bar
Closed
Open DEV
CGVDEV
CGV
Decoke Effluent Valve DEV Cracked Gas Valve CGV
Differential pressure
T1 T2 T3 T4 T5 T6 T7 T8
CRACKING TO DECOKING: STEP 5De
coke
Effl
uent
Val
ve
Cracked Gas Valve
15
Switching between cracking and decokingConceptual design
CRAC
KED
GAS
HEA
DER
Deco
ke E
fflue
nt V
alve
M
16
Switching between cracking and decokingDifferential pressure transmitters replaced
Decoke cyclone
Cracked Gas Valve
PI
PDI
PDSLL
PDAL
PAH PSHH
Pressure transmitter
17
Switching between cracking and decokingImproved reliability Safety Integrity Level
CRAC
KED
GAS
HEA
DER
Deco
ke E
fflue
nt V
alve
18
Switching between cracking and decokingEmergency isolation
Closing the cracked gas valve after a multiple coil rupture
Initiate furnace total shutdown:
> Close feed and DMDS valves
> Close decoke air valve
> Close fuel gas valves
Close quench oil valve (if applicable)
Overpressure protection remains active
Steam purge of HC and decoke air lines bypassed
19
Switching between cracking and decokingEmergency isolation
Maintaining overpressure protection and preventing backflow of cracked gas to decoke drum only possible with electrically
linked valves
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
Deco
ke E
fflue
nt V
alve
Cracked Gas Valve
M
M
MDe
coke
Effl
uent
Val
ve
Cracked Gas Valve
20
Switching between cracking and decokingConclusionsAdvantages of electrically linked valves compared to
mechanically linked valves
Easier to install
Easier to maintain pressures within safe limits
Less dependent of dilution steam flow fluctuations
Possibility for EMERGENCY ISOLATION after coil rupture
while maintain overpressure and back flow protection
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Switching between cracking and decokingConclusions
Advantages of 4 gauge pressure transmitters compared to 2 dP-transmitters + 2 gauge transmitters
Continuous comparison of transmitter availability
Higher availability and reliability
Less process connections = less steam purges
No potential backflow over instrument equalization valve
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Switching between cracking and decokingConclusions
Advantages of overpressure protection with pressure transmitters compared to safety valve
Overprotection always available
Higher reliability – no blocked PSV inlet
No key-interlocks required
23
Switching between cracking and decoking
QUESTIONS ?
Thank you