Presenters:
Michel Boutin: Machinery Engineer
Shell Scotford Refinery
Brad Hatton: Machinery Engineer
Shell Scotford Refinery
Definition Plan 54
Plan 54
AP I Plan 54
C lean
E xternal
S ource of
P ressurized
B arrier Fluid
Overview - Scotford
Overview (cont)
System pressure is maintained by a
main pressure control valve on the skid.
Pressure control to each pump is by a
local control valve.
Flow control is maintained by a
restriction orifice.
Cooling of barrier fluid is by an Air
Cooled Heat Exchanger
Skid Details
Pump Details
Process P &ID
Operating History
System was chemically cleaned and
flushed during commissioning
Used milk pads at each seal to check
for cleanliness
Found three failed seals upon start up
Flow indicators showed high flows and
one was leaking to grade
100
80
70
60
50
40
30
20
10
0
03/05/2006 12:00:00 AM
224.96 days
10/16/2006 12:00:00 AM
Set points
Alarms were set on the flows to each
seal
High Flow was set@ 90% of instrument
range (2X Normal flow)
Low Flow was set @ value from Seal
Supplier
Low Pressure Alarm set at 70 kPag (10
psig) above stuffing box pressure.
Troubleshooting
Detecting small leaks on the inner seal
is next to impossible. Trending on the
flows helps but small leaks are not
detectable.
Leaks on the secondary seal will show
barrier fluid on the pump
Trouble shooting guide for Operations
was generated
Troubleshooting (cont)
Learnings (cont)
We did not flush through each seal and had
to install a temporary jump-over to avoid
flushing debris thru the seal.
The reservoir does not have a weir or baffle
plate. Suction to pumps is located on the
bottom. Future projects should have it on the
side or use a stand pipe inside.
No Source of heat for the fluid. Relying on the
heat generated by the seals.
Learnings (cont)
100
80
70
60
50
40
30
20
10
0
10/01/200612:00:00AM
70.04days
12/10/200612:00:00AM
20E14CP2:PC20411.MEAS
31.6277
kPag
20E14CP2:PC20411.OUT
0.0000
%
20E14CP2:PC20411.SPT
31.6277
kPag
20E14CP2:PDI20472.PNT
-0.1155
kPa
3000 100
2500
2000
1500
1000
500
0
0
0
0
12/05/2006 12:00:00 AM
E2014 BARRIER COOLR TO HDR
E2014 BARRIER COOLR TO HDR
E2014 BARRIER COOLR TO HDR
S2022A/B BARRIER FILTERS
24.00 hours
12/06/2006 12:00:00 AM
20E14CP2:PC20411.MEAS
1408.6914
3000 100
2500
kPag
20E14CP2:PC20411.OUT
2000
0.0000
%
20E14CP2:PC20411.SPT
1408.6914
kPag
20E14CP2:PDI20472.PNT
6.1878
kPa
1500
1000
500
0
0
0
0
12/05/2006 8:00:00 AM
E2014 BARRIER COOLR TO HDR
E2014 BARRIER COOLR TO HDR
E2014 BARRIER COOLR TO HDR
S2022A/B BARRIER FILTERS
2.00 hours
12/05/2006 10:00:00 AM
Major Findings
No way to tell when there is water in the
system.
No easy way to drain water from the
system.
Circulation pump selection is acceptable
for a clean system, but did not take in
account for off design conditions.
EHT was not considered in the project
20P05CP2:PC20551.MEAS
1801.4902
20P05CP2:PC20551.OUT
31.4801
0.6
1500
20P05CP2:PC20551.SPT
1800.0000
20P05CP2:FI20549.PNT
0.5514
20P05CP2:FI20554.PNT
0.4921
1000
500
0
0 0
0.3 0.3
05/14/2007 3:12:32.363 PM
P2005A/B BARRIER FLUID
P2005A/B BARRIER FLUID
P2005A/B BARRIER FLUID
P2005A BARRIER FLUID
P2005B BARRIER FLUID
7.04 days
05/21/2007 4:12:32.363 PM
100
80
70
60
50
40
30
20
0
08/28/2007 11:40:57.985 AM
V2026 BARRIER FLUID DRuM
14.04 days
09/11/2007 12:40:57.985 PM
P2008A/B Vacuum
1200 100
20P08CP2:PC20561.M EAS
238.2031
kPag
20P08CP2:PC20561.OUT
1000
68.2035
%
800
20P08CP2:PC20561.SPT
232.0000
kPag
20P08CP2:FI20559.PNT
600
400
-0.0002
Am3/h
20P08CP2:FI20564.PNT
-0.0004
200
0
0
0
0.2 0.2
08/28/2007 11:44:26.677 AM
P2008A BARRIER
P2008A BARRIER
P2008A BARRIER
P2008B BARRIER
FLUID
FLUID
FLUID
FLUID
0
14.04 days
09/11/2007 12:44:26.677 PM
Am3/h
20P08CP2:XI20734.CIN
1
20P08CP2:XI20735.CIN
0
100
80
70
60
50
40
30
20
10
0
08/07/2007 12:00:00 AM
90.04 days
11/05/2007 12:00:00 AM
EHT @ P-2014A
Orifice Location
Piping @ P-2005
End of Presentation