Gulfpub HP 201106

RENTECH breaks new trails in the
boiler industry with its focus on custom

engineering and design.
Theres no on the shelf inventory at RENTECH because we design and build each and every
boiler to operate at peak efficiency in its own unique conditions. As an industry leader, RENTECH
provides solutions to your most demanding specifications for safe, reliable boilers. From design and
manufacture to installation and service, we are breaking new trails.
JUNE 2011
HPIMPACT
SPECIALREPORT
TECHNOLOGY
Refining margins
under pressure
PROCESS/PLANT
OPTIMIZATION
Update on lubrication
systems
Positive PVC demand
Maintenance, operations
and engineering are
all involved in better
plant performance
Improve energy efficiency

in hydrotreaters
www.HydrocarbonProcessing.com
Reliability has
no quitting time.
Think about ITT.
In oil and gas facilities around the world, ITT delivers pumps, valves, composite piping, switches,
regulators and vibration isolation systems that can handle harsh conditions and keep going.
After all, in the 24/7/365 renery business, the last thing you want is a piece of equipment that
fails. With ITT, your processes stay upand your total cost of ownership stays down. For more
information, and to receive our Oil and Gas catalog, visit www.ittoilgas.com or call 1-800-734-7867.
Conoow | Enidine | Fabri-Valve | Fiberbond | Goulds | ITT Standard | Midland-ACS | Neo-Dyn
Select 86 at www.HydrocarbonProcessing.com/RS
JUNE 2011 VOL. 90 NO. 6

SPECIAL REPORT: PLANT/PROCESS OPTIMIZATION
35
37
41
45
Why technology choice does matter

B. Harkins
Pump rebuilding by expert non-OEMs is effective

Communication and competence are key in finding the best repair shop for major equipment
H. P. Bloch and B. Bluse
Put training back into operator training simulators

This five-step approach is low-cost and offers safer learning experiences
D. C. Glaser
Update your reliability performance to meet process safety

expectations
Better risk assessment can identify root causes for potential catastrophes before they occur
K. Bloch, J. Bertsch and D. Dunmire
55
Rethink planning and schedulings role in refinery optimization
61
Consider closedloop oil-mist lubrication
67
Improve energy efficiency for distillate hydrotreaters retrofit

options
New tools improve prediction of unit feed qualities and yields

M. Swensen and C. Acuff
A growing trend is migrating to this new lubricating system for rotating equipment
D. Ehlert
Energy conservation is a complex analysis on existing units, but benefits are possible
Z. Milosevic and T. Shire
73
Fine-tune ethylene unit startups
95
Use advanced process control to add value for your facility
101
Advanced modeling methods provide useful information on operating main compressor system
and feeds
X. Yang, Q. Xu and K. Li
Optimization programs deliver benefits to existing and new plants

R. Di Nello
Cover China Blue Chemical Co. Ltd.s

2,500- metric tpd methanol plant
is located at Dongfang on the west
coast of Hainan Island near the port
of Bausuo in the South China Sea.
The facility completed successful
start and performance testing in
March 2011. This facility will produce
chemical-grade methanol to supply
both the domestic Chinese market
along with product available for
export. The feedstock is natural gas
from the China National Offshore
Oil Corp.s (CNOOCs) offshore wells.
China Blue is a subsidiary of CNOOC.
The plant utilizes DPTs catalyticrich gas pre-reforming technology
and a DPT steam reformer for
synthesis gas production and Johnson
Matthey Catalysts low-pressure
methanol technology featuring DPTs
proprietary steam raising converters.
The plant is 1 of 13 plants that Davy
Process Technology and Johnson
Matthey Catalysts have licensed,
globally over the past five years.
Photo courtesy of Davy Process
Technology.
HPIMPACT
15
Refining margins
under pressure
to 2015
15
US PVC producers
see healthy exports
17
Oil and gas supports

two million jobs
in Texas
11
HPIN RELIABILITY
How do you size
expansion chambers
(assuming it is
needed)
13
HPINTEGRATION
STRATEGIES
Korean ethylene
plant reaps benefits
from APC
Optimize design for distillation feed

Use these steps for enhanced performance
S. H. Lee and M. J. Binkley
COLUMNS
VALVES 2011SUPPLEMENT
79
Valves 2011
Update on valve technology for processing/refining facilities
DEPARTMENTS
9 HPIN BRIEF 19 HPINNOVATIONS 25 HPIN CONSTRUCTION
32 HPI CONSTRUCTION BOXSCORE UPDATE
106 HPI MARKETPLACE 109 ADVERTISER INDEX
110 HPIN AUTOMATION

SAFETY
Is it possible to
communicate risk
issues successfully?
Houston Office: 2 Greenway Plaza, Suite 1020, Houston, Texas, 77046 USA
Mailing Address: P. O. Box 2608, Houston, Texas 77252-2608, USA
Phone: +1 (713) 529-4301, Fax: +1 (713) 520-4433
E-mail: editorial@HydrocarbonProcessing.com
Publisher Bill Wageneck bill.wageneck@gulfpub.com
EDITORIAL
Editor Stephany Romanow
Process Editor Tricia Crossey
Reliability/Equipment Editor Heinz P. Bloch
Technical Editor Billy Thinnes
Online Editor Ben DuBose
Associate Editor Helen Meche

European Editor Tim Lloyd Wright
Contributing Editor Loraine A. Huchler
Contributing Editor William M. Goble
Contributing Editor Y. Zak Friedman
Contributing Editor ARC Advisory Group
MAGAZINE PRODUCTION
DirectorProduction and Operations
Sheryl Stone
ManagerEditorial Production Angela Bathe
Artist/Illustrator David Weeks
ManagerAdvertising Production
Cheryl Willis
ADVERTISING SALES
See Sales Offices page 108.
CIRCULATION +1 (713) 520-4440
DirectorCirculation Suzanne McGehee
E-mail circulation@gulfpub.com
SUBSCRIPTIONS
Subscription price (includes both print and

digital versions): United States and Canada,
one year $199, two years $359, three years
$469. Outside USA and Canada, one year
$239, two years $419, three years $539, digital format one year $199. Airmail rate outside
North America $175 additional a year. Single
copies $25, prepaid.
Because Hydrocarbon Processing is edited specifically to be of greatest value to people working in this specialized business, subscriptions
are restricted to those engaged in the hydrocarbon processing industry, or service and supply company personnel connected thereto.
Hydrocarbon Processing is indexed by Applied
Science & Tech nology Index, by Chemical
Abstracts and by Engineering Index Inc.
Microfilm copies available through University
Microfilms, International, Ann Arbor, Mich.
The full text of Hydrocarbon Processing is also
available in electronic versions of the Business
Periodicals Index.
ARTICLE REPRINTS
If you would like to have a recent article reprinted for an upcoming conference or for use as a
marketing tool, contact Foster Printing Company
for a price quote. Articles are reprinted on quality stock with advertisements removed; options
are available for covers and turnaround times.
Our minimum order is a quantity of 100.
For more information about article reprints,
call Rhonda Brown with Foster Printing
Company at +1 (866) 879-9144 ext 194
or e-mail rhondab@FosterPrinting.com.
HYDROCARBON PROCESSING (ISSN 0018-8190) is published monthly by
Gulf Publishing Co., 2 Greenway Plaza, Suite 1020, Houston, Texas 77046.
Periodicals postage paid at Houston, Texas, and at additional mailing office.
POSTMASTER: Send address changes to Hydrocarbon Processing, P.O. Box
2608, Houston, Texas 77252.
Copyright 2011 by Gulf Publishing Co. All rights reserved.
Permission is granted by the copyright owner to libraries and others registered with the Copyright Clearance Center (CCC) to photocopy any articles
herein for the base fee of $3 per copy per page. Payment should be sent
directly to the CCC, 21 Congress St., Salem, Mass. 01970. Copying for other
than personal or internal reference use without express permission is prohibited. Requests for special permission or bulk orders should be addressed to
the Editor. ISSN 0018-8190/01.
GULF PUBLISHING COMPANY

John Royall, President/CEO
Ron Higgins, Vice President
Pamela Harvey, Business Finance Manager
Part of Euromoney Institutional Investor PLC.
Other energy group titles include:
World Oil
Petroleum Economist
Publication Agreement Number 40034765
Printed in U.S.A
4
YOUR GLOBAL GASKET PROVIDER
AFTER
450C
ITS ADVANTAGE
THERMICULITE .
Graphite oxidizes at high temps.

So gaskets made with graphite
deteriorate as well. Thermiculite , the

revolutionary sealing material from
Flexitallic maintains its integrity up to 982C.
Preventing leakage and the loss of bolt load that
can be so costlyand ultimately dangerous.
Replace your graphite gaskets. Because when the
heats on, graphite cant serve. Visit: www.exitallic.com,
or call us at USA: 1.281.604.2400; UK: +44(0) 1274 851273.
IRPCASIA: The Conference for the

Global Refining and Petrochemical Industry
On 1921 July 2011 Hydrocarbon Processing will host the 2nd Annual International Refining &
Petrochemical ConferenceAsia. Strategically located in the heart of Southeast Asias refining and
petrochemical industry, and with easy access from all major refining and petrochemical centers, Singapore
is home to IRPC for 2011. IRPCAsia will bring together many of the worlds leading experts in refining and
petrochemical technologies. Like Hydrocarbon Processing, the two-day, two-track conference and exhibition
will focus on presenting leading-edge technology, best practices and solutions for the global hydrocarbon
processing industry.
Silver Sponsor:
REGISTER TODAY:
Suntec Singapore
1921 July 2011
www.GulfPub.com/IRPC
Pricing:
Delegate Fees
Single
USD $995.00
Team of Two
USD $1,790.00
Pack of 10*
USD $9,000.00
VIP team pack of 10 includes: reserved table at lunch, listing as Team Pack Sponsor
on sign at conference and in program.
2011 IRPC ADVISORY BOARD:

John Baric
Dr. Madhukar O. Garg
Licensing Technology Manager

Shell Global Solutions International B.V.
Director
Indian Institute of Petroleum in Dehradun
Eric Benazzi
Marketing Director
Axens
Andrea Gragnani
Director, Refining Product Line
Technip
Dr. Syamal Poddar

Carlos Cabrera
President & CEO
NICE
Director
Poddar & Associates
James Richardson
Dr. Charles Cameron
Head of Research & Technology
BP plc
Director of Southeast Asia

Sd Chemie
Giacomo Rispoli
Antonio Di Pasquale
Vice President, Refining Product Line
Technip
Giacomo Fossataro
Technical and Operation Manager
Walter Tosto S.p.A.
Senior Vice President, Research & Development

eniRefining & Marketing Division
Stephany Romanow
Editor
Hydrocarbon Processing
Michael Stockle
Chief EngineerRefining Technology
Foster Wheeler
For sponsorship and exhibit information, contact your local sales rep or:
Bill Wageneck, Publisher for Gulf Publishing Company
Phone: +1 (713) 529-4301 / Email: Bill.Wageneck@GulfPub.com
For registration and lodging information, contact:
Gwen Hood, Events Manager for Gulf Publishing Company
Phone: +1 (713) 520-4402 / Email: Gwen.Hood@GulfPub.com
I have someone retiring after 33 years on the job.

I have someone taking 33 years of experience with him.
And now someone with just
3 years has to do that job.
With new Human Centered Design technologies from Emerson, its like the experience
never left. Using our deep insights into how your people perform their roles and tasks, Emerson
is designing all of our new products based on the science of Human Centered Design. This lets us
embed the same experience and understanding thats walking through your plant into our control
and monitoring technologies making them the easiest and most intuitive to use. Tasks are
accomplished in fewer steps, and with greater confidence, even when relying on less expertise
and specialization. Its the certainty that jobs are done right, no matter whos doing them. Find the
experience youve been missing at EmersonProcess.com/Experience
The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2011 Emerson Electric Co.
HPIN BRIEF
BILLY THINNES, TECHNICAL EDITOR
BT@HydrocarbonProcessing.com
ConocoPhillips CEO Jim Mulva appeared at a Senate Finance

Committee hearing in Washington, DC, where he outlined the negative effects of
proposed tax policy legislation targeting major energy companies. Other companies
with CEOs testifying were BP, Shell, Chevron, ConocoPhillips and ExxonMobil. The
bill, proposed by several Democratic US Senate members, would repeal tax breaks for
the five largest oil companies, saving US taxpayers approximately $2 billion a year.
Our industry already has the highest effective tax rate in the US, said Mr. Mulva.
Increasing these taxes would cost jobs and raise gasoline and other consumer prices,
while actually unintentionally reducing the governments tax revenue by discouraging
investment by the industrys largest and most financially capable companies.
According to Mr. Mulva, proposals to repeal the Section 199 domestic manufacturing deduction for the five largest oil companies would discriminatorily deny them a
tax deduction available to every other manufacturing industry.
Statoil will withdraw from ownership and management roles with

gas-to-liquids venture company GTL.F1. The Norwegian oil and gas major said it had
played a key role in developing GTL.F1s technology, but, being primarily a user of
technology in its own operations, Statoil does not see licensing of GTL technology as
part of its core business. As a result, Statoils further partnership is no longer essential
for continuing success, the venture firm said. Statoil will have access to the GTL.F1
technology on a preferential commercial basis.
Albemarle has developed a proprietary technology for lithium

extraction from brine. This newly developed technology will allow the company to
recover lithium that is present in the brines at its Magnolia, Arkansas, bromine facility and to utilize it to produce lithium carbonate. The market for lithium chemicals
is expected to grow rapidly, reaching $1.2 billion globally by 2015, primarily from
increased demand for batteries in electrical vehicles. Using this new technology and
brine from its bromine production facility, Albemarle has produced lithium carbonate in a lab setting and is currently operating a pilot plant to optimize the process.
Commercial production could begin as early as 2013.
For the third consecutive year, Air Products received a Pinnacle

Award for chemical transportation safety from Union Pacific Railroad. The award
was recently presented to company representatives at an event held in Houston,
Texas. The Pinnacle Award annually recognizes companies that have implemented
successful prevention and corrective plans and have achieved a rate of zero non-accident releases for shipments of regulated hazardous material. Air Products previously
won this award six times between 1996 and 2006. The Union Pacific award program,
which began in 1996, is open to all Union Pacific chemical and petrochemical customers. Criteria include safe loading techniques, security level of shipments and zero
non-accident releases.
Unrest in North Africa and the Middle East, coupled with the
disaster in Japan, threatens the sustainability of the global economic recovery, but
the momentum of growth is thought to be strong enough in most regions to absorb
the shocks, according to a quarterly analysis report from Ernst & Young. However,
global economic growth projections are being reduced, dropping to around 4%
for 2011. Despite the fact that short-term oil and gas supply and demand remains
relatively balanced, oil prices have gone up in anticipation of supply shocks, the
report says.
We are dealing with a new kind of oil shock, said Marcela Donadio, Americas oil
and gas leader for Ernst & Young. Driven by angst over broad geopolitical concerns,
markets are proactively reacting to a potential supply problem. HP
Natural gas
demand
According to the US Energy Information Administration, the total of
more than 22.1 trillion cubic feet of
natural gas demand in 2010 was the
highest-ever level in the US, exceeding
the previous high point established in
2000 by more than 10%.
With 2010 setting new records for
natural gas demand, Gas Technology
Institute (GTI)an independent, notfor-profit R&D organization serving
the natural gas industrysees the
coming decade as a period of continued robust growth.
The economic and clean-energy
benefits of natural gas are helping
to drive market demand, said David
Carroll, president and CEO of GTI.
The outlook for natural gas demand
remains robust, thanks to the remarkable expansion of natural gas supplies
in recent years and very attractive
end-user prices. We believe that gas
demand will likely reach 2426 trillion
cubic feet by 2020, while also helping
to reduce US carbon emissions.
Future growth in demand will be
led by the power-generation sector,
where natural gas is poised to help
offset an expected wave of older coalfired power-plant retirements. Powergeneration demand in 2010 was at
an all-time high, 40% higher than
demand in 2000.
The natural gas industry is also
experiencing growth in residential
and commercial market sectors. In
2010, residential natural gas demand
was the highest since 2003, while
commercial customers used more gas
than at any time since 1997. While
muted by appliance and building
energy-efficiency improvements, natural gas is well positioned to continue
to efficiently meet building energy
needs as an environmentally friendly
energy source.
Another area in which GTI anticipates major growth in demand is in the
transportation sector, where fleet owners are increasingly turning their attention to natural gas vehicles (NGVs) for
their economic benefits. Current prices
of compressed natural gas for vehicle
use are about $1.95/gallon. HP
HYDROCARBON PROCESSING JUNE 2011
I9
HPIN RELIABILITY
HEINZ P. BLOCH, RELIABILITY/EQUIPMENT EDITOR
HB@HydrocarbonProcessing.com
How do you size expansion chambers

(assuming it is needed)
Expansion chambers (Fig. 1) are
designed to restrict pressure increase in
closed volumes. From basic physics, we, of
course, know that the pressure in a closed
volume increases as temperature goes up.
In case a shaft seal is so tight that it will no
longer allow air confined in bearing housings or gearboxes to flow in and out, the
trapped air would be pressurized as temperature rises. Creating a larger volume for the
trapped air would keep the pressure down.
We find expansion chambers advertised for
use on process pumps and gearboxes. They
can replace breather vents that are commonly found on pump-bearing housings
or gear casings.
Most expansion chambers incorporate
a rolling diaphragm (usually Viton and,
occasionally, Teflon). The diaphragm
divides the interior volume of the chamber
so that ambient air can be aspirated into, or
expelled from, the (up-facing) space above
the diaphragm. The down-facing surface
of the diaphragm is contacted by air (or an
air-oil mixture) that exists in, say, a pumpbearing housing or gearbox interior.
Examining the premise is always
a good first step. About two years ago,
a shaft-seal supplier started discussions with

a wind turbine gearbox manufacturer. The
seal supplier wanted advice on calculating
the size of expansion chambers for gearboxes with dimensions in the vicinity of 3
m x 2 m x 2 m. A worst-case oil-to-ambient temperature difference of 100C was
anticipated by the two parties. Realistically
speaking, temperature differences of 100C
(180F) are rather unusual in a gearbox.
We should always look at the bigger picture and perhaps even challenge the basic
premise.
That said, lets be certain to select the
right lubricant and to accommodate thermal expansion which, on a 3-m-long steel
gearbox, might be somewhere around 0.14
in. We obtained this number by multiplying the coefficient of expansion for steel,
times the length, L (in.), times the anticipated temperature, T, change:
L = 0.0000065 L T
Anyway, heres the academic exercise.
We might elect to work with a base temperature of, say, 100F, which would be (100
+ 460) = 560 Rankine. Continuing in US
units, an increase of 100C (180F) is (180
+ 560) = 740 Rankine.
Charles Law states that the volume
of an ideal gas at constant pressure varies
directly as the absolute temperature; thus,
V 2=V 1 (T 2 / T 1 ) = Constant. For equal
pressure, the new volume, V2 , would have
to be V1 (740/560), or 1.32 times that of
the original air space (or volume) of 1.
Thus, 0.32 volume units would have to be
added to the original air space or volume
unit of 1.
Also, the volume of an expansion
chamber would have to be larger if we had
assumed a lower base temperature, say, 0F.
In that case, the needed volume addition
would be based onV1 (640/460)1and
0.39 volume units would have to be added
to an original air space or volume of 1.
Much of the 3 m-by-2-m-by-2 m overall
gearbox volume will be taken up by the
gears and oil. So, if the remaining air volume had been 30% of the gearbox total,
i.e., 0.3 12 = 3.6 m3, one would have to
add an expansion chamber with a useable
volume of0.32 3.6 = 1.15 m3in the
first instance. In the second instance, the
needed addition would be0.39 3.6
= 1.4 m3.
While this might have answered the
original question, I now imagined all kinds
of different scenarios, including seeing a
1.15 m3 or 1.4 m3 hump on the gearboxes
of future wind turbines. Or perhaps none,
because someone explained intelligent-sealing options to the gearbox manufacturer.
An intelligent-sealing option would be a
balanced seal, or a seal that can take the
pressure increase that comes with a constant volume. Let me explain.
Pressure increase with constant
volume. Suppose we didnt add an
expanding volume to the wind turbine

gearbox and the temperature rose from 0F
FIG. 1
A threaded-type expansion
chamber is sometimes used at
the location where the bearing
housing vent had been installed
originally.
(18C) to 180F (83C). What would be

the pressure increase? Well, we might just
google gas law and observe the before vs.
after conditions indicated by the sub-1 and
sub-2 characters:
P1V1 / n1T1 = P2V2 / n 2T2
The molecular masses, n, probably will
not change, and neither will the volume.
We assume that our installation is at sea
level and atmospheric pressure is 14.7 psia.
Therefore, the absolute pressure will change
in direct proportion to the absolute temperature:
P2 = P1T2 / T1 = 14.7 psia 740R /
560R = 19.4 psia
The P across the seal would be 19.4
14.7 = 4.7 psi. Now, we could design a
seal for that, even if we needed to divert a
slip stream of bearing lubricant to provide a
bit of cooling for the seal. So, we might not
need the expansion chamber, after all? HP
The author is Hydrocarbon Processings Reliability/
Equipment Editor. A practicing consulting engineer with
close to 50 years of applicable experience, he advises
process plants worldwide on failure analysis, reliability
improvement and maintenance cost. He has authored
or co-authored 18 textbooks on machinery reliability
improvement and close to 500 papers or articles. For
more, read his book, PUMP WISDOM, Problem Solving
for Operators and Specialists, John Wiley & Sons, 2011.
I 11
KNOW-HOW DELIVERED
We put tested rening technologies
and processes to work in your
world. From hydroprocessing to
uid
catalytic
cracking
and
Veba Combi-Cracking to resid processing, we offer

proven know-how. So you can improve productivity and
lives. KBR Technology licenses deliver for greeneld
and existing reneries of virtually every type and size.
See HOW we can help you meet mission-critical goals.
Click rening.kbr.com/HP
REFINING
2011 KBR
All Rights Reserved
K11070
6/11
HPINTEGRATION STRATEGIES
DICK HILL, CONTRIBUTING EDITOR
DHill@Arcweb.com
Korean ethylene plant reaps benefits from APC

LG Chem is Koreas first and largest vertically integrated
chemical company. Founded in 1947, the company has emerged
as one of the worlds top 30 chemical makers. LG Chem produces
a variety of chemical products ranging from petrochemicals to
specialty chemicals, as well as electronic materials.
Last year, ARC interviewed Mr. Chang-Hoon Kang, project
manager at the Petrochemicals Divisions Daesan ethylene plant.
Mr. Kang told us that, previously, the plant had problems meeting corporate goals due to a variety of issues such as variability of
feedstock quality. However, using an advanced process controlbased (APC) solution, the engineering team solved the problem
to achieve plant operational stability, increase production, and
decrease energy consumption. In doing so, the benefits more
than paid for the investment.
an online model for composition and severity for the CLP and
multivariable controllers.
Since this was the plants first experience at such a comprehensive change in automation, it had to be established through
proper leadership to help people understand the coming changes.
For example, the changes in the way the operators managed the
process required quick adoption of new methods. Getting the
employees, from operators to engineers, to work together as a
team was an important challenge to overcome early on.
This was to be an integrated approach to automation; so
they had to establish effective connectivity between the existing
distributed control systems (DCSs) and the new APC and optimization solution. In addition, since success relied on accurate
and highly available instrumentation, they had to incorporate
strategies to deal with any instrument failures quickly.
Plant operations needed stability. LG Chems Daesan
ethylene plant is an important asset in LG Chems Petrochemicals unit. The plant was experiencing difficulty in meeting its
corporate operations goals due to a variety of issues. The naphtha
feed typically varies considerably in quality, and the plant has
issues related to furnace decoking, and tank and dryer swings.
Since ethylene crackers are major energy-consuming units, the
dynamics of the process further prohibited any attempts at comprehensive energy management. This all contributed to a process
that was seldom in steady state.
Through a quality improvement program called gaisen, the
company had previously improved the process, more than doubling the capacity from 350,000 tpy to the current world-class
capacity of 760,000 tpy. The underlying problems, however,
continued to cause plant upsets, resulting in total productivity
well below corporate expectations.
To have a chance at meeting corporate goals, the company
realized that it must stabilize operations before it could concentrate on maximizing plant throughput, which is why the company invested to increase the plants capacity in the first place.
Another LG Chem objective was to minimize energy consumption to produce ethylene.
LG Chem realized there was only so much improvement
that could achieved with process and procedure changes. The
company had some success at its Yosu plant using multivariable
control, and the plant manager at Daesan was keen on trying to
adopt this approach. LG Chem chose to work with AspenTech.
Together, the two companies decided that the plant needed to
go further than just applying multivariable control to the 11
ethylene cracker furnaces. The solution needed to be integrated
with the ethylene and propylene recovery areas downstream of
the furnaces. Due to the plantwide scope, inherent feedstock
variations and other disturbances, they decided to incorporate the
Composite Linear Program (CLP) tools with Aspen DMCplus.
LG Chems LGSim ethylene furnace model was used to create
Lessons learned and overall benefits. LG Chem learned

that it was possible to do such a large scope project in a short
period (eight months) and within budget. This was possible partly
due to the team had secured senior managements backing early
in the project scope and partly because the project team included
three members from the supplier and three LG Chem employees.
Including LG Chem personnel on the team continues to help, as
these team members can make the necessary minor adjustments
themselves over the course of the year. If a big issue arises, then
they can organize a task force quickly and, if necessary, call in
AspenTech under their annual maintenance agreement.
LG Chem is very satisfied with the stable operation provided
by the advanced automation. The APC has a 90% service factor
and drives the unit operations to the appropriate constraints.
Management and operating personnel alike are now armed with
key performance indicators and other performance information
to help everyone stay on the productivity path.
LG Chems eight-month effort and $400,000 expenditure
resulted in a 2% increase in ethylene and propylene production.
The stabilization of the plant reduced total energy consumption
by 1.5%. Combined, this represents the equivalent of about $4
million in annual benefits. HP
The author is vice president of ARC Advisory Group, Dedham, Massachusetts,
responsible for developing the strategic direction for ARC products, services and
geographical expansion. He is responsible for covering advanced software business
worldwide. In addition, he provides leadership for support of ARC's automation
team and clients. Mr. Hill has over 30 years of experience in manufacturing and
automation. He has broad international experience with The Foxboro Company.
Prior to Foxboro, Mr. Hill was a senior process control engineer with BP Oil, developing and implementing advanced process control applications. Prior to joining ARC,
he was the US general manager of Walsh Automation, a major engineering consulting firm and supplier of CIM solutions to the pulp and paper, petrochemicals,
pharmaceutical, and other process and manufacturing industries. He is a graduate
from Lowell Technological Institute with a BS degree in chemical engineering.
I 13
By utilizing industry benchmarking with business and operational analysis,

Flowserve can uncover full life cycle cost savings opportunities.
owserve.com/data
Experience In Motion
HPIMPACT
BILLY THINNES, TECHNICAL EDITOR
BT@HydrocarbonProcessing.com
Refining margins under

pressure to 2015
KBC Advanced Technologies recently
published its refining outlook, a report that
analyzes issues facing the global oil refining sector and discusses their impact on the
crude-oil and refined-products markets.
KBC foresees global refining margins continuing under pressure in the medium term
as recovering global demand is met by a continuing wave of new refining capacity construction that will see global refining utilization rates remain around 85% of nameplate
capacity at least through 2015.
The report highlights the key pressures that face refiners, including declining
demand in mature economies; tightening
global standards for marine fuel quality;
increased taxation and regulation of carbon
dioxide emissions; and competition from
biofuels and natural gas liquids (NGLs) from
export-oriented refining countries like India,
Russia and, increasingly, Brazil.
In the Americas, major investment in
a number of Latin American countries,
coupled with increased distillate production
capability in US Gulf Coast refineries, will
see a rise in the export of finished products to
Europe and Africa. Brazil alone is set to add
over 1.2 million bpd of new refining capacity by 2020 as it aims to process most of its
expanding crude-oil production domestically and to export the products.
In Asia, KBC sees both China and India
continuing to add refining capacity. China is
expected to build new capacity in line with
its surging domestic demand for transport
fuels and petrochemical feedstock, driving
global demand for crude oil while still having only a limited impact on product markets. Indias refinersboth public sector and
privatecontinue to advance plans that will
keep the country in strong surplus, eagerly
eyeing export markets in other Asian countries and further abroad.
Middle Eastern refiners are also expected
to add refining capacity above their domestic
requirements, with 1.6 million bpd of firm
new capacity expected by 2016 in Saudi Arabia and the UAE, and more than 1 million
further bpd of potential capacity to be built
elsewhere on the Arabian Peninsula. Iran
and Iraq both continue to plan significant
new additions as well, though geopolitical
realities suggest no clear timeline for these
additions. Surplus output from Middle
Eastern refineries will compete with Asian
products for markets in Asia and Europe,
making operational efficiency, freight costs
and crude-oil pricing key parameters in a
highly competitive market.
European refiners face rising clean-fuels
import competition from the Americas, Asia
and Russia. KBC anticipates a significant
wave of Russian refining upgrading investment driven by recent reforms in Russias
export tariff structure. These upgrades could
see Russias exports swing from relatively lowquality intermediates, like vacuum gasoil and
M-100 fuel oil, to higher-quality finished
products that meet European standards.
With declining export markets for surplus
gasoline, a functioning carbon market from
2013 and a swing to distillate bunker fuels in
the North Sea/Baltic corridor, Europes refiners face the greatest pressure in the global
scenario, although unlike some more bearish
80,000
Thousand, tons
60,000
50,000
US PVC producers
see healthy exports
PVC demand returned to positive growth
in 2010 following the collapse in consumption experienced in 2008 and 2009, according to a new report on market dynamics in
the vinyls chain, published by Nexant.
The global economic slowdown has
taken its toll on the construction sector,
and building activity in Europe and North
America has been dramatically reduced.
China has become the main driver of global
growth. After a decline in Chinese demand
during 2008, the Chinese governments
economic stimulus packages have buoyed
consumption and underpinned positive
growth for the time period of 20092010.
Producers in Western regions have been able
to maintain operating rates due to a large
volume of exports. US producers benefitted
from reduced ethylene feedstock costs, large
5,000
North America
South America
Western Europe
Central Europe
Eastern Europe
Middle East
Africa
Asia-Pacic
40,000
30,000
4,000
Thousand, tons
70,000
analysts, KBC anticipates only limited future

closures, instead anticipating a prolonged
period of relatively low utilization rates.
With over 2 million bpd of refining
capacity earmarked for closure and around
8 million bpd announced for sale, or sold,
since 2009, the refining industry faces an
anxious period of transition over the next five
years, with new entrants attempting to profit
where experienced operators have chosen to
exit. KBC sounds a note of caution in this
years annual refining outlookundoubtedly the refining market is better now than
it was a year ago, but this is not necessarily an
upward trend. Refining will remain a tough
business over the next few years.
North America
South America
Western Europe
Central Europe
Eastern Europe
Middle East
Africa
Asia-Pacic
3,000
2,000
1,000
20,000
0
10,000
0
-1,000
2008
2008 2009 2010 2011 2012 2013 2015 2020 2025

FIG. 1
Regional PVC consumption, 20082025.
FIG. 2
2009
2010
2011
2012
2013
Regional PVC capacity additions, 20082013.
I 15
HPIMPACT
integrated plants and a weak dollar with the
country responsible for over 60% of global
trade in 2010.
Operating rates remained at historical
lows in 2010, with the output of large sections of acetylene-based Chinese capacity
limited in the second half of the year as
government policy on energy conservation
reduced supply of calcium-carbide feedstock.
PVC demand growth is forecast to continue in 2011, but the start-up of additional
capacity in China will see global operating
rates remaining low.
Consumption. In recent years, envi-
ronmental and safety issues, as well as

substitution by polyethylene, have negatively affected PVC consumption. Several
countries have legislated against the use of
plasticized PVC in childrens toys. PVC
consumption in food packaging has also
declined, although more as a result of better cost-performance of other polymers
than its poor environmental and health
perception. In addition, substitution by
polyolefins in cable and wire applications
and certain construction applications have
eased growth in some segments. How-
ever, the cost competitiveness of PVC is

expected to maintain support for consumption growth in the key construction sector
once that industry recovers.
High consumption growth in populous
nations such as China and India will make
Asia the major driver of global PVC consumption growth. While consumption in
the United States has been declining since
2004, growth in Mexico and an expected
recovery in demand in the United States
will support future growth rates in North
America. Western Europe will show the lowest growth, due to the already high per-capita
consumption rate, and low GDP growth
outlook. Growth in Eastern Europe and the
Middle East is running at very high rates
due to oil wealth, while demand in South
America will benefit from high GDP growth
and infrastructure development (Fig. 1).
Supply. Regional capacity development
shows considerable variation due to the
sharply differing consumption outlook
and cost of production in different regions.
Low growth and high energy prices make
investment in North America and Western
Europe unattractive, while the opposite is
Countdown to the International Refining

and Petrochemical ConferenceAsia
1921 July, 2011, Suntec Center, Singapore
Two-days of sessions with

two information-packed tracks:
Safety and Plant Integrity
Refining Process/Product
Development
Environment and Energy Efficiency
Catalyst Technology: Refining/
Petrochemical
Market Trends
Refining/Petrochemical Integration
Petrochemical Processes/Products
Developments
Information and Asset Management
Presenting Companies:
Wood MacKenzie
Shell Global Solutions
Grace Davidson
KTI
KBR
Muse Stancil
Indian Oil Corp.

Yokagawa
Chevron
Engineers India Ltd.
Advisory Board:
Axens
BP plc
eniRefining & Marketing Division
Foster Wheeler
Hydrocarbon Processing
Indian Institute of Petroleum
in Dehradun
NICE
Poddar & Associates
Shell Global Solutions
International B.V.
Sd Chemie
Technip
Walter Tosto S.p.A.
Register for IRPCAsia today at www.GulfPub.com/IRPC.
16
I JUNE 2011 HydrocarbonProcessing.com
true in the Middle East. Capacity development in China is proceeding rapidly due to
the massive demand growth and the relative
attractiveness of coal-based production there.
Other parts of Asia show minimal development due to the lack of competitively priced
feedstock and the abundance of capacity already installed. Some major capacity
developments already underway in North
America have proceeded despite the ongoing
contraction in domestic demand. Much of
this new supply will go to foreign markets.
The capacity development that is underway in China is unprecedented. Capacity
has expanded from 5 million tpy in 2003
to over 15 million tpy in 2009, almost 90%
of total global capacity expansion over the
period (Fig. 2). Despite legitimate environmental concerns, relating both to massive
carbon emissions and mercury pollution, the
development of acetylene-based capacity in
China shows no sign of slowing. The governments effort to restrict the construction and
expansion of less efficient, environmentally
hazardous plants has had little impact on the
overall pace of development, although it has
perhaps prevented some sub-scale projects
from moving ahead.
While coal/acetylene technology has been
progressively replaced by ethylene-based production in other regions, coal-based production in China has been encouraged, as
it does not require imported feedstock or
compete for the limited supplies of ethylene.
The required feedstocks (coal and limestone)
are concentrated in the Western part of the
country, which is comparatively underdeveloped. Industrial activity there is subsequently inexpensive, and provides economic
growth in otherwise isolated areas.
The pace of capacity development in the
Middle East has been slow because of the
lack of local consumers for the caustic soda
byproduct from chlorine production, and
the availability of more attractive investment
opportunities in olefins. The higher longterm global energy pricing environment has
however brought the focus back onto the
ethylene and power cost advantages in the
region, leading to new interest in projects.
Regional demand growth has also considerably outpaced previous expectations, providing a much larger domestic market for new
entrants to sell into.
Demand and trade. Operating rates
have fallen sharply in recent years as capacity has increased while demand has fallen.
Further capacity additions in Asia, Eastern
Europe and the Middle East will see rates
HPIMPACT
Oil and gas supports

two million jobs in Texas
The US oil and natural gas industry supports two million jobs in Texas and 24%
of the states economy, according to a new
study commissioned by API and conducted
by PricewaterhouseCoopers.
API President Jack Gerard said that President Obama and Congress should keep
the studys findings in mind as they debate
greater access to domestic oil and natural gas,
along with higher taxes on energy.
Increasing energy taxes raises costs for

businesses, which may impact consumers,
and it threatens the two million jobs our
industry supports in Texas, Mr. Gerard
said. Higher taxes would also depress
energy production over the longer term,
reducing royalties and income taxes collected by the government.
The new report updates data from a
previous report and shows that, between
2007 and 2009, the economic activity sup-
ported by the industry nationwide actually

increased in size as a percentage of US GDP,
from 7.5% to 7.7%. The industry supports
9.2 million jobs in the US.
The people of the US oil and natural gas
industry are the backbone of our economy,
Mr. Gerard said. They provide most of the
nations energy, spurring job growth across
America. Even during times of economic
recession, the oil and natural gas industry
stands strong. HP
Lets talk numbers
Prize performance, capacity gains

Packinox heat exchangers pack up to 16 000 m2
of heat transfer surface area into one single unit.
That makes them the largest plate heat exchangers
in the world.
The performance benefits of the Packinox design
include closer temperature approach, which gives
rise to lower fuel consumption, and reduced
emissions, plus a lower pressure drop. It all adds
up to gigantic savings on your infrastructure and
installation costs as well as your operating costs.
Those kinds of numbers really make you a winner.
PPI00181EN
fall through 2011, before beginning to

recover in 2012.
The arrival of large volumes of acetylenebased PVC production has changed many
aspects of the global market. The massive
development in capacity has offset imports
of PVC into China, which had been running in excess of 2 million tons per year over
20012004. As the acetylene-based product
set the price in the Chinese market, ethylene-based operators had difficulty selling
into the domestic market due to the rapid
increase in their cost of production, which
was fundamentally based on crude oil as in
other regions. Chinese product was therefore aggressively marketed around the world,
while China continued to import from more
competitive integrated operators in neighboring countries in East Asia. The temporary
reduction in oil prices between 2008 and
2010 eroded the advantage seen by acetylene-based producers, leading to a marked
increase in imports into China. As the capacity build continues, China is expected to
increase production and move to a balanced
position forcing its East Asian counterparts
to look further afield once more.
Exports from North America have risen
sharply in recent years, driven higher by a
combination of large capacity additions,
declining domestic demand and the benefit
of ethane-based ethylene supply. The major
effect has come from the US, where exports
increased from 650,000 tons in 2005 to 2.7
million tons in 2010. The US is forecast to
remain a net exporter but the overall level of
exports will decline as the local construction
market recovers.
The rapid growth of demand in the Middle East has outpaced new capacity development. The current slate of projects will
not be sufficient to meet demand growth,
and therefore the region will remain a net
importer for much of the outlook period.
Most of the import growth to date has been
from East Asia.
17
Value Resources
Automatic Self-Cleaning Filters and Strainers
Gas/Liquid Separators
Disposable Bag and Cartridge Filter Systems
Standard and Custom Fabricated Pipeline
Strainer Solutions
The latest
sustainability
technologies in
liquid filtration
for the oil and
gas industry
Eatons filtration technology

and service capabilities
together with deep
industry experience,
world-class products,
and a global presence
make us highly qualified
to deliver solutions that
enable companies to
evaluate and execute
filtration activities that
improve profitability, retain valuable
product, increase uptime
and productivity, eliminate
media handling, improve
operator safety, and
reduce maintenance.
-ODEL
automatic self-cleaning
strainer, designed for
the continuous removal
of entrained solids from
liquids in pipeline systems, is
available in sizes 2 through 8
in cast construction and
10 through 60 in
fabricated construction.
A wide range of screen
designs is offered from
1/8 perf to 200 mesh as
well as custom designs
and exotic materials.
2EACTO'ARD6is the
ultimate protection for fixed
bed catalytic reactors. This
system uses refinery proven
AccuFlux media to operate
cleaner, more efficient low
flux sizing. Automatic backwashing provides significant
advantages that increase
filtration area by as much as
300% over previous standards.
#LEAR!MINEt
automated
self-cleaning
systems offer
a safe, green,
economical
solution for the
filtration of amine gasses
with no bags or cartridges, no
hazardous waste landfill fees, and
greatly reduced maintenance and
handling costs. ClearAmine provides
an efficient method of removing
harmful solids to extend
equipment life and maximize amine
systems effectiveness.
Download our new Advanced
Filtration Technologies for
Oil and Gas Industries
brochure as well as the others
product brochures you see here.
Call: 800-859-9212 ask for the oil and gas team

Visit: LTRATIONEATONCOMHP
HPINNOVATIONS
SELECTED BY HYDROCARBON PROCESSING EDITORS
editorial@gulfpub.com
Foam provides effective

thermal insulation
BASFs specialty foam Basotect is now
used for the first time to insulate pipes in
a liquefied natural gas (LNG) tank terminal in Gwangyang, Korea. The pipe cover
with Basotect provides energy-efficient
thermal insulation, easy handling and
flame retardancy. LNG is natural gas that
is temporarily liquefied at very low temperatures, to transport or store it more
easily. As the temperature of LNG must
be kept below 162C, efficient insulation
for the pipes is necessary.
According to SKI Insulation, the system supplier of the removable insulation
cover, the pipe cover made from Basotect is more energy efficient as it is 20%
thinner and provides up to 50% better
thermal insulation than conventional
foam insulation. Basotect shows a high
degree of stability at low temperatures,
said Dr. Peter Wolf, Head of Global Business Management Basotect at BASF. In
laboratory tests even at temperatures of
around 200C the material retains its
properties. The high degree of elasticity
and the thermal insulation capacity of
the foam remain unaffected, in contrast
to conventional foam insulation, which
becomes brittle when exposed to such
extreme cold.
Basotect can be installed and handled
in an easy and cost-effective way. SKI
Insulation discovered that the system
material with the lightweight and flexible BASF foam can be easily removed
for regular inspection of pipe integrity
and later reused, unlike rigid conventional foams that are hard to replace. This
translates into reduced maintenance costs.
Additionally, Basotect is a highly flameretardant materialanother key consideration for SKI Insulation as natural gas
burns easily.
Ultra-low NOx burner eliminates

need for ignitor fuel train
Hamworthy Peabody Combustion
announced the introduction of its new
ECOjet ultra-low nitrous oxides (NOx )
burner (Fig. 1). After almost three years
of research and development, including
the use of Hamworthy Peabody Combustions SMARTflow flow modeling, and the
resources of Hamworthy Peabody Combustions World-Leading Advanced Technology Center (14 test furnaces/testing
burner capacities to 300 MMBtu/hr), the
ECOjet emerged, offering ultra-low emissions with little or no flue-gas recirculation.
Every aspect of the burner from air entry to
gas and oil nozzles to swirler was strategically designed, developed and tested.
Ignition is achieved using the highly
reliable, self-cleaning and low maintenance
Chentronics (a Hamworthy Combustion
Group company) high energy direct-spark
ignitor. The burst-mode ignition with
flashing indicator allows the operator to
observe the ignitor condition during operation. This also eliminates the need for an
ignitor fuel train. Gas-electric ignitors are
also available for firing natural gas, propane, coke oven gas, etc.
Easy to install, operate and maintain
Reliable and virtually maintenance-free, self-cleaning high-energy spark

ignition.
Staged gas design provides extremely
stable flames, up to 20:1 burner turndown,
hot standby, available continuous pilot and
precise furnace warmup.
Ultra-low NOx on a full range of gaseous fuels (natural gas, propane, refinery
gas, landfill gas, off-gases)
Low NOx on all liquid fuels (No. 2
through No. 6 fuel oil, ultra-heavy fuels
such as pitch and bitumen)
Applicable to package, industrial,
and utility boilers ranging from single to
multi-burner wall-fired, turbo, and other
boiler types
NOx levels < 30 ppm without flue gas
flue gas recirculation (FGR)
Ultra-low NOx (< 10 ppm) with less
flue gas recirculation than other burners,
greater efficiency and a lower CO2 footprint
Burner ramp rates not limited by
speed
Does not require complicated control
systems
Does not require special fuel or combustion air filtration or straining
Capacities to 400 MMBtu/hr.
Differential pressure sensor

measures up to 2,000 psi
American Sensor Technologies, Inc.
offers the AST5400 wet/wet differential
pressure sensor to measure line pressures
up to 2,000 psi with a turndown ratio of
15:1. This cost-effective sensor brings the
features of differential pressure sensors
to the process industry market at an economical price. The AST5400 differential
pressure sensor can be used to measure
differential pressure across a filter, monitor
level in a sealed or vented tank, or calculate flow across an orifice plate.
Using Krystal Bond Technology, the
AST5400 pressure sensors contain no silicone oil, O-rings or welds. This microelectro mechanical systems (MEMS)
pressure-sensor technology completely
isolates the media to the pressure ports,
thus eliminating contamination risk.
The low strain level on the diaphragm
results in accurate, repeatable measurements. This differential pressure sensor,
with its high line pressure capability, can
be installed into systems without five-way
FIG. 1
Hamworthy Peabody Combustion

ECOjet ultra-low NOx burner.
As HP editors, we hear about

new products, patents, software,
processes, services, etc., that are true
industry innovationsa cut above
the typical product offerings. This
section enables us to highlight these
significant developments. For more
information from these companies,
please go to our website at
www.HydrocarbonProcessing.com/rs
and select the reader service number.
I 19
HPINNOVATIONS
equalization valves, saving users hundreds
of dollars per installation.
The AST5400 sensor replaces systems
that use two gauge pressure sensors to
calculate differential pressure, saving on
installation time and cost. Since the accuracy or inaccuracy of two-sensor systems is
additive, the AST5400 system can easily
increase performance over temperature.
With the advancements in electronics, users of differential pressure switches
can now use a sensor to monitor system

performance and trends in applications
requiring a high turn-down and high
cycle performance. Alarm functions can
be added through most controllers, making the switch obsolete.
With digital compensation, the
AST5400 series offers excellent linearity
and performance over temperature. The
electronics offer a fail-safe condition on
the output signal. If the transducer were
to experience a fault condition, the transducer can be programmed to rail the output signal to 10% below the minimum or
10% above the maximumoutput signal
to notify the user of an issue and protect
the system from undesirable conditions.
The AST5400 series also offers excellent
flexibility, allowing for a variety of wetted
materials and pressure ports.
BEM technology identifies

structural defects
Experience is in Mustangs DNA.

To say that Mustang has automation and control experience is an
understatement. Most of its management team has worked in the industry
for more than 30 years. They are supported by specialists, managers and
engineers averaging close to 20 years of systems expertise and industry
project knowledge. Mustang offers vendor independence, alliances with the
most recognized technology producers and global experience in:
Main Automation Contracting
Systems Integration
Project Management
Functional Safety
Advanced Process Control
Abnormal Condition Management
Human Machine Interface

Alarm Management
Network Security
Manufacturing Execution Systems
Environmental Data Management
Look to Mustang. We have built-in experience to get projects done right.
Automation and Control

People Oriented...Project Driven
automation@mustangeng.com
www.mustangeng.com
20
InfraMetrix LLC announced a new buried infrastructure diagnostic service that

utilizes broadband electromagnetic (BEM)
eddy current technology. InfraMetrix is
the only US firm licensed to offer BEM
for water, sewer and gas utilities. Unlike
ultrasonic and magnetic flux leakage testing, BEM is truly a non-invasive technology. BEM will identify evidence of ferrous pipeline wall loss or other structural
defects, enabling fast remedial action.
BEM, first developed in Australia, is
a technology that can be used internally
or externally, and will provide an accurate
profile of the pipe wall and detect metal
loss down to 125 in. BEM produces wallthickness contour maps that illustrate
remaining wall thickness at surveyed sections. Estimates of annual rate of wallthickness loss and remaining useful life are
easily determined with BEM data.
BEM offers two major advantages over
other pipeline inspection technologies.
First, it does not require direct contact
with the metal, and can determine the
thickness of the surveyed pipeline through
coatings and linings without their removal.
Second, it eliminates service disruptions
because pipes can be inspected without
disrupting service.
Bill DiTullio, president of InfraMetrix,
stated, The rate of deterioration of buried ferrous water, sewer and gas pressure
pipelines is not solely a function of age and
material, but rather the cumulative effect
of the environment that surrounds these
assets. As a result, desktop studies alone are
insufficient for making capital expenditure
decisions. At the opposite end of the spectrum, it is not practical or even necessary
to perform an internal inspection of the
entire network to locate where the greatest
risk of failure exists. I believe that BEM
provides the most cost-effective solution
for planning capital investments, especially when capital resources are limited.
BEM provides a quick and cost-effective
You Get More Than Just a Process Gas Compressor

Lubricated up to 1000 bar, non-lubricated up to 300 bar
For longest running time: We recommend our own designed,
in-house engineered compressor valves and key components
Designed for easy maintenance
We are the competent partner with the full range
of services worldwide
Your Benet:
Lowest Life Cycle Costs
Rod load up to 1500 kN / 335000 lbbs

Power up to 31000 kW / 42100 hhp
Curious? Visit www.recip.com/api618

HPINNOVATIONS
in Process Unit Decontamination
New Directions
assessment of the risk of failure of buried

metal pipelines, and a program of desktop
investigations and making the best use of
funds for assessing the risk of failure and
threat to public health and safety.
InfraMetrix was recently awarded a
number of BEM survey contracts in the
US and abroad. The owner and utility
companies are now able to save thousands of dollars using BEM technology,
they will be able to assess the condition
of the pipeline while it remains in service.

Module facilitates optimal

management for gas turbines
Dresser-Rand, a global supplier of
rotating equipment solutions to the oil,
gas, petrochemical, and process industries
announced the availability of its Envision
Gas Turbine (GT) Performance Module.
The module is designed to assist opera-
WHO SHOULD
ATTEND:
CURRICULUM:
Global Best Practices
OPERATIONS
Process
Superintendent
Operations/Unit
Engineer
Plant Manager
Waste Water Manager
Operations Manager/
Supervisor
Safety Personnel +
Asset Protection
Decontamination
Trends+Methodologies
Planning + Logistics
Chemistries
Efuent Management
Economic Benets
MAINTENANCE
RELIABILITY
Maintenance
Manager/Engineer
Turn Around
Manager/Engineer
Turn Around
Planner/Coordinator
Asset Manager
ENGINEERS
Tech Service
Engineer
Process Engineer
Construction
Manager
Utility Manager
ENVIRONMENTAL
& SAFETY
PROFESSIONALS
Decontamination Trends &

Global Best Practices Seminar
Discover The Latest
Held in Cologne, Germany | October 24-28th 2011
Space is limited so register now at www.deconu.com
Sponsored by Zyme-Flow
Sponsorship and exhibitor opportunities available
)RUPRUHLQIRUPDWLRQFRQWDFWDVKOH\EDUEHU#]\PHRZFRP
22
tors and field service personnel in their dayto-day operation of General Electric aero
derivative gas turbines. This is accomplished
by gathering and analyzing real-time data to
calculate thermodynamic performance. The
outputs of the GT Performance Module are
ISO reference corrected and humidity corrected, specifically for the General Electric
LM series gas turbines.
The GT Performance Module facilitates the optimal management of gas
turbines. Its development was based on
decades of packaging experience with the
GE LM2500 to accurately calculate turbine performance as if it were on a DresserRand factory test stand, said Dan Levin,
general manager, Dresser-Rand Control
Systems. It facilitates the effective planning for operational and maintenance
activities ahead of a planned shutdown.
Dresser-Rands GT Performance Module provides two direct benefits to the GE
LM2500 gas turbine generator set. First,
it lowers operating costs. The real-time
monitoring of gas turbine performance
can help ensure a generator set operates at
peak efficiency. Recognizing indications
of performance degradation early allows
for prompt corrective action to prevent
excessive energy/fuel usage and reduced
turbine life. Second, it provides predictive
maintenance capabilities that are crucial
in identifying performance degradation
from irregularities like turbine compressor fouling, imbalanced fuel nozzles, compressor rotating stall, expander efficiency
degradation and exhaust pressure drop.
Users can assess the engines performance relative to OEM-determined predictions, Levin said. With this information, operational and maintenance activities
can be planned in advance of a scheduled
shutdown. Users can also reduce the impact
on production and decide what corrective
actions are needed before servicing the turbine. This is crucial for the optimal functioning of General Electric aero derivatives.
The GT Performance Module also adds
value by allowing for the optimization of an
engines maintenance schedule. With lower
costs from fewer maintenance intervals and
the increased turbine runtime, the total
cost savings from maintenance optimization could be significant.
One of the modules key advantages is
providing comprehensive information in
various forms when and where its needed.
Users can select from multiple graph formats or create trends from stored data.
E50001-E440-F170-V1-4A00
There is a prerequisite for effective

solutions and efficient operation.
Intelligent tools for highest life cycle performance from Siemens
Solutions for the oil and gas industry
The economical setup of oil and gas

assets requires a perfect interplay of
planning, engineering, installation, and
operation. To achieve this, progressing
of all relevant data and transparent processes are essential. Siemens offers highly qualified software tools and consulting
services to optimize all stages along the
plant life cycle.
From initial planning with the Oil and Gas

Manager through engineering and life
cycle management with COMOS to faster
and better decision-making with XHQ,
Siemens supports planners, builders, and
operators along the whole oil and gas
value chain.
For career
opportunities
within Siemens
Oil and Gas, visit
jobsearch.
siemens.biz
Please drop by at Siemens booth No. 13

at the IDOC 2011 in Abu Dhabi, UAE, on
May 23rd to 25th.
www.siemens.com/oilandgas
)BWJOHUIFJODPSSFDUMJRVJEMFWFM
DBOCFEFUSJNFOUBMUPZPVSQSPDFTT
#SFBUIFFBTZXJUIUIF'JTIFS '06/%"5*0/ GJFMECVTMFWFMDPOUSPMMFS
'JTIFS '*&-%76& %-$G EJHJUBM MFWFM DPOUSPMMFST BSF B CSFBUI PG GSFTI BJS GPS
MJRVJEMFWFMBQQMJDBUJPOT5IFZNFBTVSFQSPDFTTMFWFMTXJUIBDDVSBDZBOESFMJBCJMJUZ
TP UIFSFT OP VODFSUBJOUZ 1MVT UIFZ FOTVSF DPOTJTUFOU MPPQ QFSGPSNBODF XJUI
UIF BCJMJUZ UP EZOBNJDBMMZ SFTQPOE UP EFOTJUZ DIBOHFT JO ZPVS QSPDFTT *OUVJUJWF
HSBQIJDBM EJTQMBZT SFBMUJNF BDDFTT UP IJTUPSJDBM PQFSBUJOH MPHT BOE FBTJMZ
DPOHVSFEQSPDFTTVJETBEESFBMWBMVFUPMFWFMDPOUSPMTZTUFNT%-$GEJHJUBM
MFWFM DPOUSPMMFST BSF TVSF UP NBLF B TQMBTI BU ZPVS GBDJMJUZ -FBSO NPSF BU
XXX'JTIFSDPN%-$G
5IF&NFSTPOMPHPJTBUSBEFNBSLBOETFSWJDFNBSLPG&NFSTPO&MFDUSJD$P'JTIFS$POUSPMT*OUFSOBUJPOBM--$%9.9 )
HPIN CONSTRUCTION
HELEN MECHE, ASSOCIATE EDITOR
HM@HydrocarbonProcessing.com
North America
KBR has been awarded a $65 million
contract by Chevron Products Co. to execute a base-oil expansion project at Chevrons refinery in Pascagoula, Mississippi. The
construction project includes building a new
lubes hydrocracker and a lube dewaxing/
hydrofinishing unit. Work is expected to
begin in May 2011, and upon completion,
the facility is expected to be one of the largest premium base-oil plants in the world.
Shell has successfully started production from its Scotford Upgrader Expansion project in Canada. The 100,000-bpd
expansion takes upgrading capacity at Scotford to 255,000 bpd of heavy oil from the
Athabasca oil sands. This marks the first
commercial production from the upgrader
expansion. The Scotford Upgrader processes oil sands bitumenheavy oilfrom
the Muskeg River Mine and Jackpine Mine
for use in refined oil products.
Westlake Chemical Corp. has an
expansion program that includes increasing
the ethane-based ethylene capacity at Lake
Charles, Louisiana, and evaluating expansion options and the upgrading of ethylene
production facilities at Calvert City, Kentucky, to capitalize on new low-cost ethane
and other light feedstocks being developed in North America.
Each of the companys two light feedstock ethylene crackers in Lake Charles will
be expanded as part of this program. These
expansions will commence as planned
maintenance turnarounds occur in order to
provide ethylene for existing internal derivatives units and the merchant market. The
first cracker expansion will increase capacity
by approximately 230240 million lb/yr,
while also increasing feedstock flexibility.
It is expected that this project will be completed by late 2012 and a second expansion
concluded by the end of 2014.
PetroAlgae Inc. has an agreement with
Haldor Topse and its US subsidiary, Haldor Topse, Inc., to provide technology
and catalysts to upgrade oils produced from
PetroAlgaes biomass through refinery coking
processes and pyrolysis into drop-in renewable fuels, including diesel and jet fuels.
Under the agreement, the two companies will work together to apply Haldor
Topse catalysts, equipment and licensed
technology to upgrade oils derived from
PetroAlgaes biocrude.
URS Corp. has been awarded a contract
by BP Products North America Inc. to
provide construction and maintenance services, including electrical, mechanical, piping, instrumentation and civil works to the
Whiting Refinery in Whiting, Indiana. The
three-year contract has a maximum value of
$150 million for URS.
CB&I has a project, valued in excess
of $45 million, for storage tanks at an oil
sands project near Fort McMurray, Alberta,
Canada. CB&Is scope of work includes the
engineering, procurement, fabrication and
construction of 12 cone-roof tanks at the oil
sands project. CB&Is contract is scheduled
for completion in 2013.
Technip has an engineering, procurement and construction-support services contract with Canadian Natural
Resources Ltd., worth approximately 100
million, for the Horizon project in Fort
McMurray, Alberta, Canada. The contract
covers the expansion of the existing delayed
coking unit, completed by Technip in 2008.
It confirms Technips leading position in the
refining of nonconventional hydrocarbons
such as refining bitumen.
Technips operating center in Rome,
Italy, will execute the contract which is
scheduled to be completed in 2013. Detail
engineering, procurement and supply of
materials and equipment will be delivered
on a lump-sum basis, while the construction management will be charged on a
reimbursable basis.
Bayer MaterialScience is set to invest
some $120 million into its Baytown,
Texas, site. The Baytown site, which celebrates 40 years of manufacturing success
this year, is the companys largest manufacturing facility in the US, and it is a
keystone of Bayer MaterialSciences global
manufacturing strategy.
The planned $120 million investment
includes:
Methylene diphenyl diisocyanate (MDI)environmental upgrades,

reliability improvements and minor
debottlenecking
Toluene diisocyanate (TDI)
improved process technology, environmental upgrades, and energy-efficiency
and reliability improvements that will
increase productivity
Polycarbonatereliability upgrades
and quality improvements for advanced
optical applications.
South America
Technip, in consortium with Tom
Engenharia, was awarded a lump-sum
turnkey EPC contract by Petrobras for
five new units at the Presidente Bernardes
Refinery in Cubato, state of So Paulo,
Brazil. This contract covers EPC, commissioning, pre-operation and assisted operation of five new process units, including a
diesel hydrotreater and a hydrogen plant, as
well as all associated utilities.
The project, which is scheduled to be
completed by the end of 2013, will produce
low-sulfur-content diesel to comply with
new Brazilian environmental regulations.
Oxford Catalysts Group PLCs gasto-liquids (GTL) demonstration plant has
arrived in Fortaleza, Brazil, following the
timely completion of its construction in
Asia last year. The integrated GTL dem-
Trend analysis forecasting

Hydrocarbon Processing maintains an
extensive database of historical HPI project information. The Boxscore Database is a
35-year compilation of projects by type, operating company, licensor, engineering/constructor, location, etc. Many companies use the historical data for trending or sales forecasting.
The historical information is available in
comma-delimited or Excel and can be custom
sorted to suit your needs. The cost depends on
the size and complexity of the sort requested.
You can focus on a narrow request, such as
the history of a particular type of project, or
you can obtain the entire 35-year Boxscore
database or portions thereof. Simply send
a clear description of the data needed and
receive a prompt cost quotation.
Contact: Drew Combs
P.O. Box 2608, Houston, Texas, 77252-2608
713-520-4409 Drew.Combs@GulfPub.com
I 25
HPIN CONSTRUCTION
New methanol facility online in China
China Blue Chemical Co. Ltd. and Davy Process Technology
(DPT), a Johnson Matthey Co., announced the successful startup, performance test and plant acceptance of a 2,500-metric
ton/day methanol plant in Hainan Island in the South China
Sea in March 2011. The methanol facility is located at Dongfang. It is the worlds largest operating coal-based methanol
plant, and the methanol is used for olefin production.
This facility will produce chemical-grade methanolUS
AA grade and the Chinese GB388 standard methanolto
supply both the domestic Chinese market along with product
available for export. The feedstock is natural gas from the China
National Offshore Oil Corp.s (CNOOC) offshore wells. China
Blue is a subsidiary of CNOOC.
The plant utilizes DPTs catalytic-rich gas pre-reforming
technology and a DPT steam reformer for synthesis gas production and Johnson Matthey Catalysts low-pressure methanol
technology featuring DPTs proprietary steam-raising converters.
The success of this plant, which was completed in 31
months from start of the contract, is due to the excellent team
work and cooperation between Davy Process Technology and
Johnson Matthey Catalysts as technology licensors and catalysts suppliers, China Blue Chemical Co. Ltd., the owner and
operator, and Chengda the Chinese Design Institute, which
performed the detailed engineering and construction management. The plant is 1 of 13 plants that Davy Process Technology
and Johnson Matthey Catalysts have licensed globally over the
past five years. HP
Davys Radial Flow Steam-Raising Converters.
onstration plant incorporates the Groups

proprietary microchannel reactor and
catalyst technologies for the key steam
methane reforming and Fischer-Tropsch
steps of the GTL process. The demonstration is fully funded and managed by the
Groups partners Toyo Engineering Corp.
and MODEC, Inc., in collaboration with
Petrobras, which is hosting the demonstration at its Lubnor refinery in Fortaleza.
The GTL plant will be reassembled
at the demonstration site, and will then
progress to the pre-commissioning and
commissioning stages. These are expected
to be completed within four months. The
demonstration plant is scheduled to start
up in September, subject to successful commissioning and availability of the required
utilities from Petrobras. Following startup,
the demonstration will operate for approximately nine months.
Braskem has launched the cornerstone of its new PVC plant located in
Marechal Deodoro in the state of Alagoas,
Brazil. Construction of the new plant has
already begun and should create around
2,500 direct jobs until completed. With
an investment estimated at R$1 billion,
26
which is the highest ever made by Braskem

in a single project, the new industrial unit
is scheduled to start operations in the first
half of 2012.
The new plant will have an annual production capacity of 200 kilotons. Braskem
already has a PVC unit in Alagoas, and this
project will bring its annual PVC production capacity in the state to 460 kilotons.
The new plant will reportedly make Alagoas the largest producer of PVC in Latin
America, which should help strengthen the
PVC manufacturing complex that already
exists in the state.
Europe
Evonik Industries has started up a new
facility to produce high-purity isobutene at
its site in Antwerp, Belgium. The new plant,
which involved investment of tens of millions of euros, can produce up to 110,000
metric tpy of isobutene, and it forms part of
the sites integrated C4 production platform.
The investment has tripled Evoniks production capacity for isobutene.
A subsidiary of Foster Wheeler AGs
Global Engineering and Construction
Group has received a pre-FEED con-
tract from Statoil Petroleum AS for the

Snhvit Future Development Project at
Statoils Melkya-based liquefied natural gas (LNG) facility on Melkya Island
approximately 450 km north of the Arctic Circle, Hammerfest, Norway. Statoil
has informed Foster Wheeler that further
releases of pre-front-end engineering
and design (pre-FEED) work to Foster
Wheeler under the existing contract are
likely to be made during 2011, depending
upon the development option(s) selected
by Statoil.
Foster Wheelers scope of work will
include concept design activities to support the finalization of the development
concept and the plant capacity for the
expansion of LNG production at the
Melkya LNG facility, as well as energy
optimization investigations. Foster Wheelers involvement through this contract will
continue through 2011.
Bayer Material Science is to expand
production of polycarbonate at its
Krefeld-Uerdingen site in Germany
through an investment of about 90 million. The plants annual capacity is to
gradually reach 400,000 tons over the
HPIN CONSTRUCTION
next four years in stepped increases. The
current nameplate capacity is 330,000 tpy.
In addition to the polycarbonate
expansion at the site, Bayer MaterialScience is also rebuilding chlorineproduction facilities to increase energy
efficiency. The new facilities will utilize
state-of-the-art membrane technology
and the innovative companys oxygen
depolarized cathode (ODC) technology.
Compared with the membrane technology, ODC will reportedly reduce both
electricity use and indirect CO2 emissions
up to 30%.
wholly owned subsidiary of Albemarle

Corp.), have selected Samsung Engineering to provide engineering, procurement and construction services for the
SOCC aluminum alkyls manufacturing
facility in Jubail, Saudi Arabia.
Samsung will immediately begin the
detailed engineering in Seoul, Korea.
The manufacturing facility will be constructed in Jubail Industrial City, Saudi
Arabia, at the Specialty Chem site, with
a mechanical completion date projected

for the third quarter of 2012. The SOCC
facility will initially manufacture 6,000
metric tpy of tri-ethyl aluminum, the key
co-catalyst used in polyolefin production.
International Petroleum Investment
Co. (IPIC) is proceeding with the implementation of a 200,000-bpd refinery at
Fujairah, UAE, at an estimated cost of
$3 billion.
Japan Far East Gas Co., Ltd., a company newly established by ITOCHU
Corp., Japan Petroleum Exploration Co.,
Ltd. (JAPEX), Marubeni Corp., INPEX
Corp. and ITOCHU Oil Exploration
Co., Ltd. (CIECO) has signed an agreement on the implementation of a joint
study for the natural gas utilization project
in the Vladivostok area with Russias stateowned gas company Gazprom.
The joint study consists of pre-frontend engineering and design (pre-FEED)
for the construction of a liquefied natural
gas (LNG) plant with production capacity
of 10 million tpy, a preliminary feasibility study on the compressed natural gas
(CNG) pilot project, and a preliminary
study on a gas chemical complex project.
The joint study is scheduled to be completed by the end of 2011.
Middle East
Merichem Co. has a licensing and
equipment-supply agreement with a leading supplier of direct reduced iron (DRI)
facilities to install a LO-CAT hydrogen sulfide treatment system at a new grassroots
facility in the Mideast. The 1.43 metric-tpd
LO-CAT unit, provided through the Merichem Gas Technologies business unit, will
be integrated into the overall DRI processing facility, with a proposed startup date
during the fourth quarter of 2012.
The LO-CAT unit will be treating
70,000 Nm3/hr of natural gas with a H2S
removal efficiency of 99.9%, far exceeding
current environmental standards. This will
be the seventh LO-CAT unit to be installed
in a DRI facility worldwide.
Saudi Organometallic Chemicals
Co. (SOCC), a joint venture equally
owned by SABIC affiliate Saudi Specialty Chemical Co. (Specialty Chem)
and Albemarle Netherlands B.V. (a
27
HPIN CONSTRUCTION
The Fujairah Refinery project, a strategic initiative of the government, will be
located near the new Abu Dhabi crude-oil
pipeline Main Oil Terminal and the UAE
deepwater export terminals in Fujairah. It
will be designed to process UAE crudes
such as Murban, Upper Zakum and Dubai.
A number of financing optionsincluding, but not limited to, project financing
are under consideration.
The project management consultancy
(PMC) contract for the front-end engineering and design (FEED) phase of the Fujairah Refinery was awarded to Shaw Stone
& Webster in April 2011. The project is
now in pre-FEED, with project completion
anticipated to occur by mid 2016.
A subsidiary of Foster Wheeler AGs
Global Engineering and Construction Group has a contract with Bahrain
National Gas Co. (BANAGAS) to undertake a feasibility study for the modifications and expansion of the BANAGAS
liquefied petroleum gas (LPG) facilities
in Bahrain. The expansion will allow the
plant to increase its gas throughput, which
is planned to reach 285 million scfd of
associated gas and 18 million scfd of refinery offgas by 2014.

Foster Wheeler will develop options
for modifications to, and expansion of,
the existing facilities in line with the new
throughput objectives. Foster Wheeler
will then undertake a techno-economic
evaluation to select the preferred option(s)
for implementation. The study is scheduled for completion in the third quarter
of 2011.
plex that will support economic growth

and job creation in Egypt through the
development of the countrys petrochemical master plan, said Mohamed
Hafez, chairman and chief executive
officer of Egyptian Polystyrene Production Co. The construction of the first
phase of the styrenics complex, including
a 200,000 metric-tpy polystyrene unit, is
nearing completion.
Asia-Pacific
Badger Licensing LLC has a contract
to provide proprietary technology and
basic engineering for a 300,000 metric-tpy
ethylbenzene/styrene monomer (EBSM)
plant for Egyptian Polystyrene Production Co. (EStyrenics). The plant will be
located within the El Dekila port site in
Alexandria, Egypt. The contract covers
technology licensing and the front-end
engineering and design (FEED) package,
along with operations training and commissioning support.
Badgers technology and engineering services will provide the foundation
for this EBSM plant, representing the
second phase of a larger styrenics com-
Lummus Technology, a CB&I company, has a contract from Kazakhstan Petrochemical Industries Inc. LLP (KPI)
for the license and basic engineering of a
propane dehydrogenation unit and a polypropylene plant. The two units, each with
a design capacity of 500,000 metric tpy,
are planned as part of KPIs gas-processing
complex to be built in the western Atyrau
region, Kazakhstan.
The propane dehydrogenation unit will
make use of the CATOFIN technology
for converting propane to propylene. The
polypropylene plant will use the Novolen
advanced gas-phase polypropylene technology. This will enable KPI to produce
Make confidence
part of your process
Get Aggrekos dependable temporary
utilities, and expect success in all of
your operations.
From turnaround projects to emergency outages,
Aggreko has the equipment you need to maintain
productivityno matter what. Whether your job
calls for rental generators, HVAC or more, Aggreko
delivers the industry standard of quality every time.
With over 50 locations across North America, plus
our 24/7/365 service, Aggreko is standing by with
the resources you can depend on in your processes
so you can always focus on results.
Solutions
28
Rental Generators
Temporary HVAC
Turnaround and Rightsizing
Contingency Planning
Call 888.245.6386, or visit us online

at aggreko.com/northamerica
Scan this QR code*

to learn more about the
new low-power valves.
* Requires QR code reader.
The best of both worlds.

Introducing new low-power valves from ASCO. Our solenoid valves are now available with
the worldbeating reliability you expect, but at the lowest power rating everonly 0.55 watt!
So you can install more devices on a process plant bus network. Or use them in remote locations
with solar/battery sources. And unlike integrated valves, you can choose from a wide range of
easily available models, with larger orifices to handle higher flows without clogging. Many
ASCO low-power solenoid valves come with the ASCO Today same-day shipping program for the
fastest delivery on the planet.

The ASCO trademark is registered in the U.S. and other countries. The Emerson logo is a trademark and service mark of Emerson Electric Co. 2011 ASCO Valve, Inc.
800-972-ASCO (2726) | www.ascovalve.com/LowPower | e-mail: info-valve@asco.com
HPIN CONSTRUCTION
a broad range of polypropylene products
to meet the needs of both local and export
markets. Both technologies provide high
reliability and easy operability.
Haldor Topse has been awarded
the contract for the second out of four
substitute natural gas (SNG) projects
approved by Chinas National Development and Reform Commission. The
plant will be commissioned by the Hui
Neng Group, a major coal mining company in the Inner Mongolia region. The
plant will produce SNG based on syngas
from coal gasification, and, onsite the
SNG will be converted into liquefied
natural gas (LNG). Topse will be the
licensor for the methanation section and
will supply license, engineering design,
catalyst and service.
The Hui Neng SNG plant has a total
planned capacity of 1.6 billion Nm3 per
This bench top analyzer tops all others in its price range for
features and performance. Its equipped with an intuitive user
interface, full-color touch screen and on-board Windows XP
computer. Ethernet electronics that permit remote access for
calibration, diagnostics or service support. Plus, the Phoenix II
has a large sample compartment that accommodates spinners
and special holders yet requires little or no sample preparation.
It all adds up to the lowest cost of ownership, backed by
AMETEKs reputation for reliability and world class customer
support. Visit: ametekpi.com
30
year of SNG production to LNG, and the

first execution phase is 400 million Nm3
of SNG per year. The plant will be operational by the end of 2013.
Air Products has signed an agreement
with JGC Corp. to supply its proprietary
propane pre-cooled mixed-refrigerant process and MCR main heat exchanger for a
two-million-tpy LNG project in Luwuk,
Central Sulawesi, Indonesia. The DonggiSenoro LNG project, a joint venture
between Indonesias state-owned oil and
gas company, Pertamina, along with Mitsubishi Corp., Korea Gas Corp. and PT
Medco Energi Internasional, is targeted
for a 2014 startup.
Supporting Chinas efforts to increase
the use of biogas for renewable energy
production and in motor vehicles, GE is
supplying its ecomagination-approved Jenbacher biogas engine technology to power
Chinas largest ethanol production plant
under construction in the city of NanYang,
Henan Province. Owned by Henan Tianguan Group, China, the new ethanol production plant will produce 500,000 m3/d
of biogas, based on organic material from
cassava plants.
A 36-MW onsite power plant, featuring GEs Jenbacher engines, is being built
in multiple phases to support the ethanol plants operations. Both new facilities
are being built adjacent to the companys
existing ethanol production facility, which
uses a biomass digester system to convert
cassavainstead of graininto ethanol
in China.
GEs Jenbacher engines and associated
equipment were scheduled to be delivered
to the project site starting in April 2011.
After completion of engine installation
and commissioning, the biogas power
plant is scheduled to begin operating in
July 2011.
Axens and The Shaw Group Inc.
have been selected to license a next-generation catalytic cracking technology that
will reportedly help refiners maximize
propylene production and other high-value
refinery products. The advanced technology, High Severity Fluidized Catalytic
Cracking (HS-FCC), will reportedly produce higher yields of propylene and other
light valuable products than conventional
FCC units. The technology developers
selected Shaw and Axens to promote and
license the technology worldwide.
FLOWCUBE SENSOR TECHNOLOGY

The HS-FCC technology has evolved
during a 15-year development effort that
combines the innovation of five separate
entities. During Phase 1, Japans JX Nippon Oil & Energy Corp. (JX) and Saudi
Arabias King Fahd University of Petroleum and Minerals (KFUPM) formed
a research venture. JX, which leads the
technology developers, provided technical research and KFUPM provided the
location for initial laboratory testing
facilities.
During Phase 2, Saudi Aramco joined
JX and KFUPM to continue developing the technology. The expanded team
designed, built and operated a 30-bpd
demonstration unit at Saudi Aramcos
Ras Tanura refinery. JX has embarked on
the third phase of development including scaling-up of a demonstration unit
to a 3,000-bpd pre-commercial demonstration unit that is being built at JXs
refinery in Mizushima, Japan. Shaw and
Axens provided engineering services for
the unit, which is expected to be operational in 2011.
The Linde Group will build and operate a large hydrogen and synthesis gas
plant in the Chongqing Chemical Park
in Western China in a joint enterprise
with Chongqing Chemical & Pharmaceutical Holding Co. (CCPHC). The
project has a total investment value of
around 200 million. Linde holds 60%
of the shares in the joint enterprise with
CCPHC.
In future, the new onsite plant will
provide the production facilities of BASF
and CCPHC based in Chongqing with
carbon monoxide, hydrogen and synthesis
gas. The new plant, which will be supplied by Lindes Engineering Division, is
expected to come onstream in the third
quarter of 2014.
Samsung Engineering was awarded
a high-density polyethylene plant contract for $229 million from ONGC Petro
Additions Ltd., a subsidiary of Indias
national oil company Oil & Natural Gas
Corp., Ltd. The plant will be built in the
special economic zone of Dahej, located
in the state of Gujarat, India, and is set
to produce 340,000 tpy of high-density
polyethylene. Samsung Engineering will
handle the engineering, procurement,
construction and commissioning on a
lump-sum turnkey basis, with the completion date set for August 2013. HP
OF
CO
C
OM
MBUST
BU
USTION
S T IIO
ON S
SAFE
SA
AF
FET
ETY
BREAKTHROUGH
UGH
IN MEASUREMENT
ME
ENT
ASSURANCE
To know that your combustion gas measurement is fully
operational, is the only way to safely run your red heater process.
Introducing the NEW SERVOTOUGH FluegasExact 2700.
The worlds rst combustion gas analyzer with an integrated,
in-line ow sensor.
FLUEGAS EXACT 2700 KEY BENEFITS:
WORLDS FIRST INTEGRATED,
IN-LINE FLOW SENSOR
LOW MAINTENANCE
AND LONG SENSOR LIFE
OXYGEN AND COMBUSTIBLES

IN ONE ANALYZER
HIGHLY RELIABLE AND

REPEATABLE MEASUREMENTS
CALIBRATION VERIFIES
SAMPLE SYSTEM INTEGRITY
IMPROVE PERSONNEL AND

PROCESS SAFETY
No one understands your requirement for reliability and accuracy

more than Servomex. For over 50 years weve been innovating,
developing and supporting our customers with expert technology,
advice and service.
FOR MORE INFORMATION, TALK TO THE EXPERTS, VISIT:
WWW.COMBUSTION-EXPERT.COM
31
HPI CONSTRUCTION BOXSCORE UPDATE

Company
City
Plant Site
Project
Capacity Unit Cost Status Yr Cmpl Licensor
PetroChina Daqing
PetroChina
UPC Technology Corp
HPCL
Essar Oil Ltd
Cosmo Oil Co Ltd
Petron Corp
Petrovietnam
Daqing
Guangdong
Nanchong
Mumbai
Vadinar
Sakai
Bataan
Dung Quat
Daqing
Jieyang
Nanchong
Mumbai
Vadinar
Sakai
Bataan
Dung Quat
Ethylene
Refinery
Phthalic Anhydride
Cracker, FCC
Refinery
ETBE
Refinery
Refinery
Canadian Nat Resources

SNC-Lavalin
Husky Energy Inc
Edmonton
Fort McMurray
Fort McMurray
Edmonton
Fort McMurray
Fort McMurray
Bitumen Refinery
SAGD
OTSG
AIOC
Evonik Industries AG
Socar
HKM
Enel SpA
Statoil
Polskie LNG
Offshore
Antwerp
Kulevi
Duisburg
Porto Empedocle
Melkoya Island
Swinoujscie
Chirag
Antwerp
Khobi Dstrict
Duisburg
Porto Empedocle
Melkoya Island
Swinoujscie
FPSO
Isobutane
LNG Terminal
Coke Oven Plant (2)
LNG Terminal
LNG
LNG Terminal
Santos
Coatzacoalcos
La Cangrejera
Poza Rica
Salamanca
Veracruz
Camisea
Paramaribo
Santos
Coatzacoalcos
La Cangrejera
Poza Rica
Amor Refinery
Tuxpan
Camisea
Paramaribo
LNG Floating (FLNG)

Ethylene Cracker
Paraxylene
Cryogenic Gas Plant
Sulfur Recovery Unit
Terminal, Petroleum
Nat Gas Liquids
Refinery
Bandar Abbas
Baghdad
Al Jubail
Jubail
Saudi Aramco
Homs
Fujairah
Bandar Abbas
Baghdad
Al Jubail
Jubail Ind City
Yanbu
Homs
Fujairah
Kenai
Whiting
Norco
Kenai
Whiting
Norco
Engineering
Constructor
ASIA/PACIFIC
China
China
China
India
India
Japan
Philippine Repub
Vietnam
RE
600 tpy
EX
400 bpd
TO
60 Mtpy
RE
28 Mbpd
EX
375 bpsd
RE 140000 l/d
EX
180 bpd
EX
6.5 MMtpy
2000 U 2012
8700 P 2013
20 P 2013
C 2011
382 U 2012
C 2011
1800 U 2014
3000 P 2016
Shaw S&W
PDVSA
UOP
ABB Lummus
Simon Carves |TCE

Vogelbusch
CB&I|FW|Axens|UOP
Tecnicas Reunidas|PDVSA
Gazprom|Technip|JGC
Belco
Essar
Daelim
Tecnicas Reunidas|JGC|Technip
CANADA
Alberta
Alberta
Alberta
5000 bpd
5000 bpd
60 bpd
50 U 2014
U 2011
U 2012
North West Upgrading

SNC-Lavalin
Snamprogetti
SNC-Lavalin
KTI|Snamprogetti
EUROPE
Azerbaijan
Belgium
Georgia
Germany
Italy
Norway
Poland
183000
110
10
2.32
8
EX
4.3
5
bpd
m-tpy
m-tpy
m-tpy
Bcmy
Mtpy
BNm3/y
3000 E
C
U
U
1200 E
843 F
U
2013
2011
2015
2013
2015
2012
2014
2.7
1
228
200
80
500
520
15
MMtpy
MMtpy
Mtpy
MMcfd
tpd
Mbbl
MMscfd
Mbpd
F
2500 F
U
307 U
43.4 U
14 U
143 U
575 U
2013
2015
2012
2012
2011
2011
2012
2013
Refinery
Crude oil pumping station RE
Ethylene Vinyl Acetate
Coker
Yanbu
Coker
Crude Unit, Atmospheric
Refinery
120
2.5
200
103
771
115
200
bpd
Mtpy
t/a
Mbpd
tph
bpd
bpd
U
E
385 E
U
E
M
3000 F
2015
2012
2013
2013
2014
2013
2016
Natural Gas Plant

Refinery
Renewable Diesel
64 Bcfy
410 bpd
137 Mgpy
EX
EX
KBR
Linde|Statoil
Saipem|Techint
Uhde
Tractebel Eng
FW|Linde
Techint|Saipem
Braskem SA
Chiyoda|SBM Offshore
Technip|IDESA
LATIN AMERICA
Brazil
Mexico
Mexico
Mexico
Mexico
Mexico
Peru
Surinam
Petrobras Netherlands B.V.

Braskem/IDESA JV
Pemex
Pemex Gas
Pemex
Pemex
PlusPetrol Peru
Staatsolie
BY
EX
Linde
Pemex
PlusPetrol Peru
CB&I Lummus
ICA Fluor|Linde
Tecna
Sener
Tecna
Aker Solutions
Technip
Tecna
Tecna
Saipem
MIDDLE EAST
Iran
Iraq
Saudi Arabia
Saudi Arabia
Saudi Arabia
Syria
UAE
Persian Gulf Star

SCOP
GS E&C
SATORP
Homs Refinery Co
IPIC
FW|UOP
APS Eng Co Roma

GS E&C
Chiyoda|Samsung Eng
Techint
Chiyoda|Samsung Eng
Techint
Shaw S&W
UNITED STATES
Alaska
Indiana
Louisiana
Phillips 66 Nat Gas Co

BP Products
Valero Energy Corp
EX
EX
20 A
3800 U 2011
241 U
BOXSCORE DATABASE
Bechtel
Bechtel
URS Corp - Washington Div|Fluor URS Corp - Washington Div|Fluor
UOP|Dresser-Rand
ONLINE
THE GLOBAL SOURCE

FOR TRACKING HPI
CONSTRUCTION ACTIVITY
For more than 50 years, Hydrocarbon Processing
magazine remains the only source that collects and
maintains data specically for the HPI community,
publishing up-to-the-minute construction projects
from around the globe with our online product,
Boxscore Database. Updated weekly, our database
helps engineers, contractors and marketing personnel
identify active HPI construction projects around the
world to:
Generate leads
Market research
Track trend analysis
And, decide future budget planning.
Now, weve made our best product even better!
Enhancements include:
Exporting your search results to Excel so you can
compile your research
Delivering the latest updated projects directly to
your inbox each week
Designing customized construction reports for your
company using our 50 years of archived projects.
For a Free 2 -Week Trial, contact Lee Nichols at
+1 (713) 525-4626, Lee.Nichols@GulfPub.com,
or visit www.ConstructionBoxscore.com
32
I JUNE 2011 HYDROCARBON PROCESSING
Oil Refinery | Sven Persson | Annealing operator | India
Are your heat exchangers

as good as new after ve
years in a sour environment?
As part of a renery expansion project, a large Indian oil company set out to
extend the life of heat exchangers in the new coker unit. This meant dealing with an
extremely corrosive environment caused by substantial amounts of hydrogen
sulphide, ammonia and cyanide.
Because of the high content of hydrogen sulphide and the subsequent risk of
hydrogen induced cracking, the engineering company involved in the plant design
specied Sanicro 28 stainless steel tubes. This grade is a safe choice when
the process ow is rich in acids, chlorides and hydrogen sulphide. When the
new renery unit was started in 2005, Sanicro 28 tubing had been installed
in10 heat exchangers.
Five years later, when the heat exchangers were opened for inspection and testing,
the tubes showed no signs of corrosion.
CHALLENGE
YOUR EXPECTATIONS
w w w. s m t . s a n d v i k . c o m / o i l re f i n e r y
HPI VIEWPOINT
Why technology choice does matter
Brian Harkins is a director for KBRs Technology business unit. In his current role, he is
responsible for growing KBRs technology portfolio. Mr. Harkins has been actively involved in
the technology sector for process industries
for more than 25 years in roles that span sales,
marketing, business development, technology
management, mergers and acquisitions (M&A),
project management, consulting and technology implementation.
Prior to joining KBR, he held positions at Setpoint, Aspen Technology,
Inc., and Invensys Process Systems. Mr. Harkins has a chemical engineering degree from Rice University and has been active in presenting
and publishing in the industry over his career.
TABLE 1. The Top Ten list of factors that significantly

influence decision-making on process technology
Market demand forecasts
Market pricing forecasts
Total installed costs (TIC)
Operating cost estimates
Energy use estimates
Feed tolerance (range of usable feeds)
Yield, including byproduct or co-product
Facility flowsheet impact
Total cost of ownership (TCO)
Licensor experience
These days, the idea of optimizing comes up everywhere. We

personally optimize our time, our retirement portfolio, our route
to work, our diets, our energy use at home, and a host of other
things. In the business world, we are no less prolific, optimizing
work processes, supply chains, processes, flow-sheets, energy use,
control performance, turnaround schedules and more. So when
we suggest that technology decisions also have an optimum outcome, are you really surprised?
In the current market, decisions about technology investmentseverything from process licensing to wireless phonesare
influenced by a host of factors. A wireless phone might be superseded by a newer one with better capabilities in just a few months,
as are computers, software, televisions and even cars.
Because of these influences, we have become somewhat conditioned to the concept of technology being fast-paced and everchanging. We are sometimes lulled into the false perception that
everything can be replaced with something newer and better. As
a result, we dont often give much credence to the timelessness
of the decisions that we must make about process technology.
After all, we will have a chance to upgrade at the next major
turnaround, wont we?
drives the decision to buy and build a process dominates the thinking process. Yes, engineering and construction companies routinely
look forand findways to improve the capital picture without
compromising the end product, and yes, with computer modeling
and simulation, these decisions are much more accurate, and costs are
(on a relative basis) much lower than they have ever been.
The other half of the equation is how the process operates.
Before a final decision is made, a view of the net present value
(NPV) is taken to see how the operating side of the equation influences the economic picture. This calculation is full of uncertainty.
Licensors succeed if they can meet or exceed any guarantees they
offer in the license grant. Thats the easy part. What is significantly
harder to foresee is the long-term operating impact of the licensing
decision. How much will it cost to operate? This is a function of
energy consumption, feed costs, catalyst and additives, maintenance
of associated equipment, repairs and upgrades, and so on. Add to
this the quality requirements that may change over time, and what
the available operating range of the unit is within safety margins.
Now youve got enough variables to make what was once a very
simple decision a very complicated one.
DECISION-MAKING PROCESS
Pricing pressures. As pressure to reduce purchase price has
What can be equally as startling is the rigor and challenge

that operating companies apply to their decisions about process
technology. For such large capital expenditures, they study the
market, get consulting help to evaluate their options and assess
their current operations to see how the addition of a new unit will
upset the equilibrium they currently have and how they will deal
with that. There are a series of gates and checkpoints where the
estimates are tightened; new data is compared to previous projections; and management is asked to affirm or overturn their earlier
decision to proceed. Getting to Gate 1 of these decision processes is
often, in itself, a 24-month effort. This slow, methodical approach
to decisions about process technology is designed to ensure that
a decision made to invest in a new process fits the operation, and
the business, for the long haul. Or is it?
increased in our personal lives, weve gotten savvier to total cost of

ownershipdriven by after-market costschange fees for airline
reservations, software support and upgrade fees and maintenance
programs for cars. Every one of them comes with a cost-benefit
decision of its own. For everything from phones to homes, the
money we spend using them over their lifetime dwarfs the money
we spend buying them at the beginning. If only we had clarity
of those costs when we made the initial decision! Add to that the
challenge of accurately predicting that crude prices will be around
$100/bbl in 2011 and gas will remain cheap, and whether or not
the company down the street will also build, and your decision
certainty, for all of your analysis, is essentially gone.
How do we do this in the world of big dollar capital decisions? Our decision analysis carries weighting on the choice of
licensor that includes the ongoing costs for maintenance and
Factoring in cost. The decision to buy a particular process begins

with a focus on total installed cost, because the capital cycle that
HPI Viewpoint continued on page 108

I 35
CRYO-PLUS
Get More Valuable Liquid from your Gas Streams
Linde Process Plants, Inc. provides engineering, design,
fabrication and construction of cryogenic plants for the
extraction of hydrocarbon liquid from natural gas, refinery
and petrochemical gas streams. Recovered liquid components can include ethylene, ethane, propylene, propane,
isobutane as well as other valuable olefinic and paraffinic
hydrocarbons. Combine your CRYO-PLUS plant with a
Linde PSA to recover high purity hydrogen from refinery
and petrochemical off-gas streams.
Why choose Lindes CRYO-PLUS

Proprietary technology with a proven
track record in:
Refinery Off-Gas
Petrochemical Off-Gas
Natural Gas
Robust, adaptable and flexible design,
and operation
Typical payout times of six (6) months
to two (2) years
A member of The Linde Group

Linde Process Plants, Inc.
6100 South Yale Avenue, Suite 1200, Tulsa, Oklahoma 74136, USA
Phone: +1.918.477.1200, Fax: +1.918.477.1100, www.LPPUSA.com, e-mail: sales@LPPUSA.com
PLANT/PROCESS OPTIMIZATION
SPECIALREPORT
Pump rebuilding by expert

non-OEMs is effective
Communication and competence are key in finding
the best repair shop for major equipment
H. P. BLOCH, HP Staff and B. BLUSE, Hydro Inc., Chicago, Illinois
tarting with the late 1980s, considerable consolidation and re-shuffling

has affected the pump industry.
Some of the big name pump producers,
the legacy manufacturers, have vanished
from the scene. As their process pumps age
and undergo repairs, component geometry
needs to be restored. New and improved
metallurgies must be selected. Asset optimization requires upgrading the weak-link
components and optimizing hydraulic efficiencies. Traditional restoration and merely
doing routine maintenance by quick fixes
are rarely the wisest course of action.
That said, this overview and a recent case
history deal with pumps in the 100-kW and
larger size categories. It is in these sizes that
the loss of legacy brand experience makes
itself felt. Some original equipment manufacturers (OEMs) are no longer staffed with
primarily experienced personnel, and there
are repercussions. At times the now often
less knowledgeable OEM employees are, in
some instances, ill-equipped to work with
the owner-operator of these pumps. In contrast, a few competent pump repair shops
(CPRSs) are diligently nurturing CPRSowner/user cooperation.
However, smart owner-operators realize
that essential non-OEM capabilities must
be defined. Surveys are made to define prerepair and anticipated post-repair mechanical reliability and hydraulic efficiency
achievements. Such surveys represent the
first stage in a critically important sequence
of interactions between the CPRS and the
pump owner or customer. All culminate in
combining expert repairs with substantial
upgrading so as to reduce the risk of incurring repeat failures.
Coker jet pump: Upgrades for
Pacific 3-in. S-A-TB. A major US East
Coast refinery was experiencing repeated

problems with its steam turbine-driven
coker pump. Within the first six months
of the year, the pump had failed several
times. Refinery personnel communicated with a number of pump shops and
then met with a CPRS aftermarket engineer. The aftermarket engineer had years
of applicable experience with the Pacific
product line and was able to explain opportunities beyond simple restorative repairs.
The meeting participants also learned that
the CPRS had special expertise in the BFI
product linemore specifically, the former
Pacific pumps, 8 in. and above. This aided
the refinerys decision to send the pump to
the CPRS.
An initial receiving inspection revealed
that the pump was in very poor condition.
While the refinery was under pressure to
get the pump back in service as soon as
possible, the CPRS engineers convinced
the customer to allow time to correct additional serious problems that were uncovered. In the words of the CPRS lead engineer on this project, they were determined
to get it right and to deliver to the refinery the best-running pump possible while
meeting the critical delivery requirements
of the customer.
FIG. 1
Erosion damage on impellers

(photo courtesy of Hydro, Inc.).
Problem specification. After being
repaired by a variety of pump shops

through the years--both OEM and nonOEM, the pump had many non-compliance issues, such as:
The impellers exhibited erosion damage, cavitation damage and vane-tip damage (Figs. 1 and 2).
The pump shaft originally supplied
by the OEM had a run-out of 0.0045 in.
at the balance sleeve (Fig. 3).
Axial misalignment of hydraulic components reached as much as 0.096 in.
The various running clearances had
all touched off and had opened to approximately 0.030 in.
FIG. 2
Vane-tip damage on diffusers

(photo courtesy of Hydro, Inc.).
FIG. 3
Run-out at balance sleeve on

pump shaft .0045 in. (photo
courtesy of Hydro, Inc.).
I 37
Stepping up performance
next generation BRIM technology
W WW.T OPSOE.CO M
Are you looking to step up plant performance?

Topses next generation BRIM catalysts offer refiners the opportunity to increase
performance through an increase in catalyst activity.
Using the original BRIM technology Topse has developed several new catalysts, resulting
in higher activity at lower lling densities.
The next generation BRIM catalysts display
-
high dispersion
high porosity
high activity
We look forward to stepping up your performance!
FIG. 4
BORSIG
Completely rebuilt coker jet pump (photo courtesy of Hydro, Inc.).
Total indicator readings (TIRs), or

run-outs, of as much as 0.007 in. were
found on the wearing ring and bushing
locating diameters
Flow at the impeller exit was not completely discharging into the diffuser.
The axial gap between diffuser and
axial face was too large; it ranged from
0.006 in. to 0.050 in.
There was excessive clearance between
the pump head and the casing.
Solutions and upgrades mapped
out. Expert CPRS entities work as a team
with the customer. Doing so constitutes a

mutually beneficial technology transfer
essentially a mentoring relationship. The
CPRS assisted with the development of a
comprehensive scope of work. An agreement was reached on a well-defined project
plan to deliver a top-quality repair for this
critical pump. The repair plan included:
Re-establishing the centerline compliance of the rotor
Re-establishing of the design axial
clearance between diffusers and the axial
face of the covers
Manufacturing a new shaft with maximum TIR of 0.001 in.
Manufacturing new wear parts with a
maximum TIR of 0.0015 in.
Balancing the assembly to the universally accepted 4W/N criteria.
In addition to restoring the fits and tolerances of the rotor to their optimum specifications, the CPRS also proposed several
upgrades to which the customer agreed. All
were designed to improve the reliability and
performance of this pump:
A split-ring design eliminates multiface contact, which creates TIR and assembly problems
Interference fit covers helps maintain
concentric running clearances
Machined diffuser blades and invest-
ment cast impellers to increase efficiency

A larger shaft to provide improved
rotor stability.
The results of this all-encompassing
effort are worthy of note. The CPRSrepaired pump (Fig. 4) was installed and
is, in the words of the customer, now
their best running pump. It exhibits
very low vibration and is producing the
same performance at 4,000 rpm as the
pump in its previous condition at 4,400
rpm. Both the customer and the CPRS
have every expectation that this pump will
run better and last longer, saving many
thousands of dollars in repair costs and
downtime for the refinery. The payback
for combining repairs and upgrading was
remarkable in this instance, and similar
approaches are easily justified for virtually every legacy pump in an hydrocarbon
processing facility. HP
Heinz P. Bloch is a consulting
engineer residing in West Des Moines,
Iowa (hpbloch@mchsi.com). He has
held machinery-oriented staff and line
positions with Exxon affiliates in the
US, Italy, Spain, England, The Netherlands and Japan in
a career spanning several decades prior to retirement
as Exxon Chemicals Regional Machinery Specialist for
the US. Mr. Bloch is the author of 18 comprehensive
texts and close to 500 other publications on machinery
reliability improvement. He advises process plants worldwide on equipment uptime extension and maintenance
cost reduction opportunities. He is also the reliability
and equipment editor for Hydrocarbon Processing. He
is an ASME Life Fellow and maintains registration as a
professional engineer in Texas and New Jersey.
Bob Bluse currently works with

Hydro Inc. in Chicago Illinois, as vice
president of Business Development.
With more than 30 years in the pump
aftermarket services business in various positions and with multiple pump companies, his
experience is proven in helping customers and companies alike provide a higher level of operational performance and increased revenue.
Leading
Technology for
Innovative
Solutions
Quench Coolers
Process Gas Waste Heat
Recovery Systems
Reciprocating Compressors
Centrifugal Compressors
Membrane Technology e.g.
Emission Control Systems
Industrial Boilers and
Power Plant Technology
Services
BORSIG GROUP
Egellsstrasse 21
D-13507 Berlin/Germany
Phone: +49 (30) 4301-01
Fax:
+49 (30) 4301-2236
E-mail: info@borsig.de
www.borsig.de
From Singapore to Saskatchewan

And everywhere in between.
www.CBI.com
CB&I has worked in more than 100 countries around the world, on all
seven continents. We have the global experience and local knowledge to
safely deliver superior results in all kinds of environments. From concept
to completion, CB&I gets the job done.
Safely. Reliably. Globally.
Engineering Solutions . . . Delivering Results

SPECIALREPORT
Put training back into

operator training simulators
This five-step approach is low-cost and offers safer learning experiences
D. C. GLASER, Simulation Solutions, Inc., Shrewsbury, New Jersey
great deal of effort and expense goes into the technical

development of an operator training simulator (OTS)
without a commensurate effort in planning for its implementation as a training tool. Because of this, OTS benefits are
not fully realized, and, after limited initial use (often for a new
plant startup), an OTS falls into disuse. A proven systematic
five-step approach for implementing OTS over the long term is
described in detail, along with testimonials from OTS users. The
five steps include: identification, normal operations, startup and
shutdown, troubleshooting, and optimization. The use of OTS
to develop applied skills such as cooperation, communication
and supervision is also covered.
Simulators have been used to train plant operators for the past
45 years. Some well-known benefits of OTS are:
Low cost compared to actual hands-on training.
Virtual environment provides a safer learning experience
for new operators.
Students are exposed to many situations in s short period
of time.
The current problem with simulator training, especially
with respect to plant operations, is that most of the effort and
use is geared toward engineering benefits as opposed to training
benefits (Fig. 1).
In many cases, an OTS is used for only a few select exercises
such as startup, shutdown and limited troubleshooting. Simulator instructors are usually provided with little support and adequate time to prepare training objectives, lesson plans, training
exercises and evaluation criteria. They are often under prepared
(Fig. 2). This means that many of the capabilities and possible
training exercises are never used or presented to the trainee.
Typically, instructors are senior operators put in charge of training newer operators, even though they may have no prior experience as an instructor. The International Atomic Energy Agency
(IAEA), in its publication, Development of instructors for nuclear
power plant personnel training (IAEA-TECDOC 1392) makes a
strong case for qualified simulator instructors, and states, A simulator setting requires an instructor to have wider competence than
that needed for classroom training.1 In this same document, the
IAEA stresses, The attitude and professional demeanor of trainees
and instructors should reflect the professionalism expected in the
main control room. To provide support in learning these areas,
simulator instructors should have an appropriate qualification.
The five-phase identification, normal operations, startup and
shudowns, troubleshooting and optimization (INSTO) learning
module combines using the simulator with instructor and student
laboratory exercise manuals to reinforce concepts and provide
virtual process practice. It equips instructors with the tools necessary to train effective and competent operators. Feedback from
clients has been great: The instructor and student manuals are
very useful because we have a product you can load and go, was
one comment.
Startup
Shutdown
Troubleshooting
Simulator instructors
Training objectives
Reading and
rounds sheets
Simulator
Normal
operations
Lesson plans
Training exercises
Performance objectives
Simulator models
Engineering benets
Operator training
results
Startup
scramble
Optimization
DCS or emulated HMI
FIG. 1
Engineering benefits vs. operator training.
FIG. 2
Operator
evaluation
Operator training simulator iceberg.
I 41
SPECIALREPORT
Methodology. INSTO is an immersive method for training operators to fully know and understand a process, making
them experts on the equipment, procedures, mechanisms and
general operation. The goal and result of this type of training is a
more intuitive and capable operator that can seamlessly transition
from normal operations to troubleshooting system faults while
minimizing economic and human costs. Safety is a central theme
throughout, with the harshest grading resulting from unsafe practices performed by the student.
INSTO. This is a process for training that aligns itself to nearly
any simulation program, from generic process simulators and
modules to fully customized replications of live plants.
IdentificationFamiliarization with the process being
operated is of utmost importance, as is knowing exactly where
various instrumentation and equipment are located on both
the digital control system (DCS) in the control room as well as
on site out in the field. Students are given piping and instrumentation diagrams (P&ID), DCS screen shots, and images
representing a field operators view they are asked to correlate
between the three. Testing is done by asking the students to
label blank forms of the process with the correct tag names
and descriptions of pumps, valves, equipment and any other
instrumentation represented.
Normal operationsKnowing how a process or plant
works when everything is operating correctly helps operators
Number of day-to-day operator

initiated panel/DCS moves
Level of plant automation

and plant/console system
reliability/increase in
communication requirements
1970
1990
2000
2010
Evolution of a console operators job.
Gr
ad
e
High skill level

7, 8, 9, 10
Grading
Event
Does not inform others of

indication of abnormal
conditions
Informs others of indications

of abnormal conditions or
alarms
Informs others of relevant

information immediately,
clearly
Makes
recommendations
Does not inform others of

recommendations, intensions
or actions taken
Informs others of
recommendations,
intentions/actions taken
Communicates
recommendation,intensions/
actions clearly
Seeks information
Does not ask for information

when needed
Seeks feedback that impt

information provided is rcvd
and understood
Seeks feedback that all

information given is
received/understood
Conrmation
feedback sought
Does not verify that

information received is
understood
Veries receipt of information
Does not review information

at shift handover
Studies shift handover

information with minimal
questioning
Fails to log important

information
Logs Information
Is often too argumentative or

assertive
Displays Positive Support

Behavior
Medium skill level

4, 5, 6
Gr
ad
e
Event
Low skill level

1 , 2, 3
Gr
ad
e
Grading
Informs others
5
Proper shift handover
6
Logging
Team support
Always veries that

info/instructions are
rcvd/understood
Studies shift handover info
and questions as necessary
for relevance
Logs clearly all relevant
information
Team building and

maintaining
Conict solving
Flexibility
4
Consideration of others
Support of others
Always supports team actions
Low skill level

1, 2, 3
Creates conict with
group by poor attitude
and actions
Criticizes other team
member's incorrect
actions w/out
Medium skill
level
4, 5, 6
Avoids unnecessary
conict
Recognizes team conict and

constructively resolves to
stregthen them
Corrects other team

members' errors
without criticism
Recognizes team members' errors

and corrects them in a way to
ensure that the team benets
Lacks Flexibility
Adapts to change
Encourages constructive change

where necessary
Ignores
accomplishments of
ther team members
Recognizes
accomplishments of
other team members
Recognizes accomplishments of
team members and reinforces them
Ignores other team

member's
conversations
Listens to other team

members'
conversations and
corrects error quickly
Involved in all team communication

and corrects all errors quickly
Subtotal
Subtotal
Overall score
FIG. 4
42
High skill level

7, 8, 9, 10
Communication grading sheet.
Overall score
FIG. 5
Cooperation grading sheet.
Gr
ad
e
Cooperation
Communication
Gr
ad
e
FIG. 3
1980
Gr
ad
e
1960
develop a deeper understanding of process dynamics. This system

behavior knowledge under normal operating conditions helps
operators to more readily identify when the process deviates from
normal conditions. Students are given worksheets with tag names
and asked to make predictions as to what a step change at one
control point will cause to occur at other critical control points.
Once predictions are made, the student runs the simulation making controller step changes and recording the actual changes at
the various controllers and indicators. Making predictions and
comparing them to actual results better reinforces the process
dynamics to the student than simply reading about the process
or getting no exposure to dynamics at all.
Startup and shutdownAlthough relatively infrequent
events compared to normal operations, they can cause a number of accidents and problems in the field. The process is in an
unsteady state and it behaves differently than normal until it
reaches design conditions. During these times, temperatures,
pressures, tank/drum levels and flow rates can be significantly
higher or lower than normal operations, and having operators
prepared for these conditions is important for plant safety as
well as efficiency of startup and shutdown. Students are asked to
complete exercises such as startup or shutdown scrambles, as well
as simulating startups and shutdowns using procedures designed
for interaction between console operators and field operators.
TroubleshootingA major function of plant operators is
to quickly recognize and remedy situations when the process conditions deviate from their normal set points unexpectedly. These
types of events occur if there is equipment failure, change in the
utilities provided, or operator error either in the control room
or out in the field. Operators are trained using the simulator to
recognize faults in the process and quickly determine a resolution
to either return the system to steady state or move forward with
a shutdown procedure until the proper repairs have been made.
Students are asked to predict the effects of particular failures on
various controllers, indicators and equipment. Once predictions
are made, the fault is simulated for comparison against the students initial predictions.
OptimizationOptimization usually involves the engineers and process design rather than the actual operators. Once
operators are trained well enough on a particular process and have
a deep understanding of it, it is possible for them to make suggestions to improve the effectiveness of the process. Working with the
process every day and being fluent in all of its working intricacies,
it is possible that the operator could see a way to squeeze out a
Not Mozart, Yet a

Classical Genius
little more product, make more efficient use of inputs, or make

the process a little safer or more efficient.
Cooperation, communication and supervision. Due
to advances in todays DCS, automation and controls, and
safety instrumented systems (SISs), the number of day-to-day
operator initiated moves has decreased substantially. However,
the amount of communication has increased to the point where
it is reported that, during steady-state operation, in most
cases, communication time is equal to or exceeds time spent
inspecting and adjusting the instruments.2 Fig. 3 highlights
these changes.
It has also been reported that, console operators do not
conduct their business in isolation from others. Collaboration
between process supervisors, other console operators, field operators, engineering staff and technicians is dynamic and crucial.3
Therefore, it is important to evaluate communication and
cooperation skills training as part of team exercises on the simulator. A set of grading sheets has been developed for use by the
instructor to help evaluate and document these skills (Figs. 4
and 5).
Using simulators with dual capabilities for training both
console operators and outside operators to provide realistic
training to new supervisors is also possible. Complex exercises,
such as plant startup or shutdown can be used to evaluate a
supervisors abilities in over a dozen areas such as understanding a framework for command and control, providing instructions, giving effective assistance, maintaining a disciplined
atmosphere, prioritizing team actions, being aware of operator
overload, and calling for the implementation of emergency
plans when needed.
Future uses of operator training simulators.
Changes in regulations, such as the ISA 18.2 standard on alarm

management, will have an impact on operator training related
to layers of protection and threshold requirements for an operator response prior to the SIS taking over. The trend is definitely
toward more rigorous operator training. Systematic training
via an OTS is essential and will play an expanding role in the
refining and petrochemical industries. HP
1
2
Just
like
Mozarts
compositions
SAMSONs Series 240 Valves are
world renowned and appreciated.
Tuned like organ pipes, the Series 240
suits all pressures and ows, from adagio to allegro. Yet, the valves denitely
work piano so nobody will be roused
by a sudden beat of the drum. And, just
like in an orchestra, the number of instruments is your choice. With positioners, solenoid valves and limit switches,
further virtuoso performers are waiting
to come in.
LITERATURE CITED
Development of Instructors for nuclear power plant personnel training,
IAEA, IAEA-TECDOC-1392, June 2004.
Communication Differences between Dedicated Inside and Outside
Operators, Newsletter, Beville Engineering, Inc., 1991, http://www.beville.
com/article.asp?ArticleName=W4.txt.
Ortloff, Dr. R. C., Training Approaches for Using Simulators to Teach
Process Control Technology, Control Engineering, December, 2010, http://
www.controleng.com/index.php?id=483&cHash=081010&tx_ttnews[tt_
news]=40524.
Donald C. Glaser is the president of Simulation Solutions,

Inc. His company has been the leader in providing process controlbased dynamic simulations and related programs for use in training
process operators since 1980. These simulators have been used in
over 230 locations in 28 countries on six continents. Mr. Glaser has
spent his entire career developing operator training simulators (OTS). His company was
the first to bring dynamic simulation to the personal computer, and now is the first to
market a simulator that includes a virtual reality 3D training station for outside operators, field operators and supervisors. Mr. Glaser has incorporated a systematic training
approach into OTS. He has authored many articles on training applications of dynamic
simulation and has delivered numerous hands-on training courses. Mr. Glaser has
a BS degree in chemical engineering from Lafayette College, Easton, Pennsylvania.
SAMSON AG x MESS- UND REGELTECHNIK

Weismllerstrae 3
60314 Frankfurt am Main x Germany
A01007EN
We supply the instruments,

you be the conductor.
Phone: +49 69 4009-0 x Fax: +49 69 4009-1507

E-mail: samson@samson.de x www.samson.de
Efuent Wa
Water Quality
Before
After
solve processing
problems with
heavy crudes.
well share
our experience.
Joe Nguyen, Research Scientist
Solving problems when you process heavy crudes means having a

partner with the right knowledge.
Visit us at www.bakerhughes.com/xeric
When an upgrader processing 100% heavy crudes had a signicant

amount of desalter oil carryunder, we had the solutionBaker Petrolite
and nd out how our unique combination

of experience, knowledge, and the new
XERIC 7000 heavy oil demulsier.

Baker Petrolite XERIC heavy oil program
Baker Petrolite XERIC 7000 heavy oil demulsier program

signicantly reduced oil losses by more than 70% while maintaining
desalter operational stability and the desired salt, water, and solids
removal performance.
www.bakerhughes.com
2011 Baker Hughes Incorporated. All Rights Reserved. 31714
can improve your heavy crudes

processing performance.
SPECIALREPORT
Update your reliability performance

to meet process safety expectations
Better risk assessment can identify root causes
for potential catastrophes before they occur
K. BLOCH and J. BERTSCH, Flint Hills Resources, LP, St. Paul, Minnesota;
and D. DUNMIRE, Western ROPE, LLC, Long Beach, California
rocess hazard analysis (PHA) and mechanical integrity (MI)

programs are two essential elements used in the Process
Safety Management (PSM) Standard to prevent or to minimize the consequences of catastrophic toxic, reactive, flammable
or explosive chemical releases. In instances where process containment is essential for maintaining process safety, equipment that
does not meet reliability expectations is more likely to be involved
in a PSM failure. When a PSM failure occurs, the equipment
maintenance history often exposes the failure as an accident that
was waiting to happen.
The MI program and related safeguards must control the consequences of equipment failure process safety hazards identified
during a PHA to an acceptable level. A quantitative approach to
evaluating equipment failure risk can be used to determine the reliability needed to adequately prevent or minimize potential process
safety consequences. Additional safeguards are needed when the
MI program alone cannot realistically achieve an acceptable level
of equipment performance. This article explains how one refinery
uses a quantitative approach to satisfy PSM objectives on potential
releases represented by process pump mechanical-seal failures.
EQUIPMENT RELIABILITY IMPACTS PROCESS SAFETY
OSHAs PSM Standard (CFR 1910.119) details the requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive, flammable or explosive chemicals. PHA teams assemble to identify and evaluate hazards that
represent the potential release of dangerous materials as described
in subpart e of the PSM StandardCFR 1910.119(e). As part
of the PHA process, action items are assigned to manage the
consequences of identified hazards to an acceptable level. It is not
uncommon for historical PHAs to be evaluated in response to an
accidental release of potentially hazardous process materials. This
evaluation is triggered to understand how previous PHA teams
assessed the hazard. It is, therefore, possible to interpret any failure
that results in the accidental release of potentially hazardous process materials as a PHA team failure. More precisely, it indicates
that the previous PHA teams may have failed to adequately identify, evaluate and control the hazard. Its potential consequences
were, therefore, left for discovery by the process safety failure that
exposed them.
Many, if not most, process safety failures are preceded by lower
consequence repeat failures. These low consequence failures can
form a failure rap sheet documented in the equipment work

order (WO) history of a plants computerized maintenance management system (CMMS).
When a process safety failure is investigated, a persistent history
of failures stands out as an obvious warning of greater risks that
should have been identified and controlled. However, prior to the
process safety failure, these lower consequence failures can easily
be seen as a normal part of equipment operation and maintenance.
This type of normalization of deviance received much attention
within NASA after the loss of 14 astronauts and two space shuttles.
Evidence of it can also be found in the hydrocarbon processing
and manufacturing industries. Consider the following examples of
catastrophic releases caused by centrifugal pump failures.
CASE HISTORIES
Several case histories demonstrate the need for responsive risk

mitigation efforts.
Alkylate pump fire. A fire and explosion occurred at a large
New Mexico refinery on April 8, 2004.1 The fire ignited upon the
catastrophic release of flammable process liquid following a centrifugal pump mechanical-seal failure. The failure caused six injuries as well as extensive property damage and business interruption.
The fire resulted due to loss of process containment from
one of a set of three centrifugal pumps in alkylate recirculation
service. Alkylate is a mixture of light hydrocarbons typically in
the C4 (butane) to C8 (octane) range. Process material leaking
from the pump at 350F autoignited upon contact with air. This
failure was attributed to misapplication of energy control after
the pump was removed from service to address a process fouling
problem. More specifically, the release occurred when mechanics
that were scheduled to replace a defective mechanical seal began
disassembling the pump on location.
The three alkylate-recirculation pumps at this facility had
a recurring history of seal failures. In its formal report, the US
Chemical Safety Board (CSB) designated this incident as an MI
program failure. In the report, the CSB cites 23 WOs issued to
address seal failures in the three pumps in a 12-month period
leading up to the catastrophic process release. (Note: A summary
table was published in Hydrocarbon Processing, May 2010, p. 9).
The CSB makes the valid argument that an effective mechanical
integrity program would have investigated and resolved the probHYDROCARBON PROCESSING JUNE 2011
I 45
SPECIALREPORT
lems that were repeatedly causing the (alkylate) pumps to fail.

Instead, the investigation showed that any opportunity to prevent
the failure through reliability improvement was substituted with
breakdown maintenance. In other words, maintenance was
used to address the problems caused by pump failures rather than
addressing the underlying causes that would have resulted in
satisfactory pump performance, sufficient to reduce the risk for a
process safety failure.
The potential for a process safety failure increases during shutdowns for maintenance.2 This case history illustrates how energycontrol defects experienced during routine maintenance activities
can interfere with safe work execution. For this reason, multiple
safe-work practices like lockout-tagout and confined space entry
policies are often used to mitigate additional risk when equipment
is shut down for maintenance. But it is not unusual for process
safety failures to occur on equipment in continuous operation when
these additional safety precautions typically do not apply. The next
case history illustrates how similar MI defects can be involved in
process safety failures regardless of the equipments operating mode.
No. 2 fuel-oil pump fire. A fire occurred in a distillate
hydrotreating unit operated by a large US Midwestern refinery

on Nov. 15, 2004 (Fig. 1). The fire ignited upon the catastrophic
release of flammable process liquid following a centrifugal pump
mechanical-seal failure, as shown in Fig. 2. The failure resulted
in one OSHA-recordable injury along with extensive property
damage and significant business interruption.
The fire ignited when the No. 2 fuel oil, a diesel-range hydrocarbon mixture with carbon-chain lengths ranging between C10
and C20, leaked from the pump through a failed mechanical seal.
Similar to the pump failure described previously, the 600F process material leaked out above its autoignition temperature (about
500F) and caught fire immediately upon contacting oxygen.
The injury occurred during the emergency response to the fire.
The first responder began applying water to the pump fire without
first increasing his personal protective equipment (PPE) level. At
some time during the response, an injury resulted from smoke
inhalation. However, within two hours, the fire was extinguished
and the emergency situation was brought under control without
any further safety consequences.
Reviewing the maintenance record of the pumps involved in this
event revealed a long history of thrust bearing failures and seal leaks
FIG. 1
46
No. 2 fuel-oil pump emergency response.
(see Table 1) similar to the pumps examined in the first case history.
Likewise, the cause of the fire was determined to be a catastrophic
mechanical-seal failure. However, the physical evidence collected
at the unit after the fire indicated that seal damage was a secondary
effect and had been preceded by catastrophic thrust-bearing failure.
The primary failure had caused uncontrolled shaft movement in the
axial (thrust) direction, which then destroyed the mechanical seal.
Eventually, the investigation team was able to link together
the probable causes of unstable hydraulics at the pump installation. The failure mechanism was introduced by operating the
No. 2 fuel-oil pumps in continuous parallel service. Originally,
the pumps were designed for single-spare operation. However,
through years of growth and unit debottlenecking efforts, the
pumps were continuously operated in parallel to overcome rundown piping pressure constraints. In the parallel operation, the
pumps rotating elements came under constant stress. Before the
fire, this failure mechanism was adequately managed by condition monitoring and frequent repairs. But, eventually, a fire in
an operating unit and an OSHA-recordable injury settled any
debate over the potential consequences for accepting poor pump
reliability in this service. Although this particular installation had
been examined twice previously by PHA teams in accordance with
OSHA regulations, the hazard remained hidden until the process
safety failure exposed it.
Although these two separate failures occurred in different
facilities, in different services, at different times, and under different process operating conditions, the common thread of belowexpectations reliability runs between them. In both cases, it is
easy to look back on events as an accident waiting to happen.
Unfortunately, in neither case was the MI program able to prevent
repeat failures that eventually resulted in an unacceptable, nondiscretionary process safety failure.
In both cases, the owner-operators of the unreliable equipment
were in full compliance with OSHA 1910.119(e) governing the
use of the PHA program to detect hazards that could result in the
potential release. However, in both cases, the PHA program failed
to identify and adequately control the hazards that ultimately
resulted in the failure. Additionally, the MI program (OSHA
1910.119(j)) was unable to achieve a level of equipment reliability
sufficient to offset any PHA defect. The MI program is just as
important for the PSM standard to achieve its objective as any of
its other elements.
FIG. 2
No. 2 fuel-oil pump failure.
Conservative, but reasonable? Typical PHA team members
do not take lightly their responsibility to identify hazards. Rendering
their services in PHA meetings requires a considerable amount of
time away from their normal responsibilities. They participate with
the intention of adding value by detecting, assessing and controlling
any hidden hazards to protect themselves and their fellow workers.
They, therefore, take their PHA performance very seriously and are
committed to learning from their mistakes. By learning, they can
add more value in future PHA meetings. Should PHA teams or
team members be criticized (publicly, privately or interpersonally)
for having failed to avoid an incident? It is common practice for the
teams to err on the safe side in future PHA meetings.
In some cases, this conservative response may be appropriate.
For example, it is both reasonable and important to expect drastic
changes when a facility learns of an operation that is contrary to
industry policies or standards. Conversely, it would not be realistic
to view all potential hydrocarbon releases equally. Yet, this is what
some teams do upon recognizing their failure to generate action
items sufficient to mitigate the potential risk of a process safety
failure in previous PHA meetings. Merely piling on more action
items may or may not add value.
Addressing them may create an illusory image of improving
workplace safety while not really making progress on mitigating
hazards that truly represent unacceptable risk.
Recent events in process safety failure show how dangerous it
can be to develop initiatives around safety items that represent
little or no incremental value. This situation was brought to British Petroleums (BPs) attention after the refinery explosion at its
Texas City, Texas, facility on March 23, 2005.3 It is not that BP
was not concerned about, nor investing in, process safety improvements. The unfair truth about process safety is that there is no
reward for hard work. To avoid a process safety failure, the effort
must be properly directed. A safety program will fail if it focuses
employee attention on the wrong things. The illusion of a safe
workplace is destroyed when a catastrophic failure exposes a persistent, unacceptable risk as an accident waiting to happen. Working on the wrong things creates a distraction from the greater and
more realistic process safety threats that should be resolved first.
RISK BASICS
Although the argument could be made that safer pump operation results from upgrading with more robust seals, bearings and
monitoring systems, doing so is probably not the most deliberate
way to achieve process safety. In many cases upgrades offer no
incremental improvement unless they address a deficiency that
causes the pump to perform below justified life-cycle expectations.4 Indiscriminately upgrading pumps can consume a considerable amount of resources with the intention of making a system
safer, while creating a distraction from other process safety hazards
that often represent even greater risk.
Risk is a function of frequency and consequence. Not all centrifugal process pump failures represent the same risk. For example,
a hydrocarbon pump operating in the middle of a congested
process unit may not represent the same potential consequences
as a pump moving similar process liquids in a remote location
away from an operating unit. Likewise, the high-temperature
gasoil (GO) fraction that leaked in the second case history may
not represent the same potential consequences as a leaking GO
fraction cooled below 300F, downstream from a rundown cooler.
The point here is that assessing the potential consequence of
a catastrophic pump failure is not a binary process. A risk assess-
SPECIALREPORT
ment (RA) is not performed by simply asking whether or not the

pump contains hydrocarbon. The consequences of a catastrophic
pump failure are a function of several critical factors. Some factors
include the type of process material, leak rate, failure location and
temperature. Additionally, assessing the failure frequency can be
aided by determining what is in the CMMS before a process safety
failure triggers an investigation. This information makes it possible to detect an accident waiting to happen before it happens.
What does good look like? The two case histories given
here illustrate scenarios where a high frequency of seal failures

preceded a catastrophic chemical release that defeated PSM
objectives. These are considered MI program failures because
the MI program did not drive the equipment-failure frequency
sufficiently low to mitigate the risk for a process safety failure.
Remember: Risk is a function of frequency and consequence.
Therefore, driving the risk for a safety process failure down to zero
(the goal of a zero-injury workplace) simply involves reducing
the equipment-failure frequency to zero. Unfortunately, this can
only be achieved by shutting down equipment for which failure
may result in PSM consequences. Even the most reliable equipment represents risk as long as it is operating.
Although most companies would immediately shut down
equipment found operating unsafely, few industrial enterprises
would voluntarily shut down a machine to guarantee their zeroinjury workplace goal. After everything is shut down, nobody
gets hurt at work because nobody goes to work. It is more satisfying to set an acceptable risk tolerance and understand what exactly
needs to be done to achieve it. By assigning risk and consequence,
it becomes possible to establish equipment-reliability targets
based on the relationship between risk, consequence and failure
frequency. This is a much more rewarding alternative to achieving
safe equipment operation. It represents an approach that helps
facilities manage their MI program with performance expectations
that are aligned with equipment failure risk tolerance.
STANDARDIZED APPROACH TO RISK
An RA tool was constructed to evaluate the risk represented

by process releases resulting from catastrophic pump failures. The
guideline was developed to be consistent with, and borrows heavily from, the approach defined in API Publication 581 Risk-Based
TABLE 1. No. 2 fuel oil pump failure history
Failure
Date
Problem
Aug. 18, 1993
Leaking head
Sept. 3, 1993
Failed coupling
Jan. 27, 1994
Failed coupling
Feb. 22, 1994
Leaking head
Nov. 22,1994
Cavitating noise
April 27, 1998
Leaking seal
May 29, 1998
Failed coupling
Nov. 20, 1998
Failed thrust bearings
April 6, 1999
Leaking seal
10
March 30, 2000
Leaking seal
11
Aug. 3, 2000
Leaking seal
12
Feb. 20, 2002
Failed coupling
13
Oct. 21, 2002
14
Sept. 9, 2003
I 47
SPECIALREPORT
Risk-based
pump analysis
FIG. 3
Catastrophic pump-seal failure risk assessment method

overview.
Consequence category description
3
Medium
Airline
fatalities
US work
Driving
related fatalities,
fatalities US manufacturing
US high
risk (mining,
heavy
construction)
Generic
renery pump
risk prole
2
Low
b
c
1
Near
miss
10-2
1/100
Catastrophic pump failure frequency/consequence plot.
Inspection (RBI) Base Resource Document.4 RBI is a widely

accepted method currently practiced across the refining industry.
Although API 581 applies primarily to fixed equipment, the
approach has many parallels that apply to failure RA for rotating
machines. Accordingly, the standard RBI components are supplemented with data, methods and tools more specific to centrifugal
pumps when needed.
A standardized RA approach reduces the inconsistency that
different PHA teams may encounter at different times. More
importantly, a standardized approach adds value by connecting
the reliability of a specific pump installation to process safety risk
tolerance. The benefit comes from determining a realistic target
for the MI program to achieve, instead of motivating reliability
professionals to achieve their safety goals with nonspecific targets
like work harder, or do better or fail less. Setting a tangible
reliability target allows a responsible decision to be made as to
whether or not risk tolerance can be achieved through the MI
program alone. If the MI program cannot realistically achieve the
desired level of risk control, then additional layers of protection
must be added to manage the risk to an acceptable level.
In some cases, the MI program may adequately drive risk to
an acceptable level without requiring any additional safeguards
or improvements. At such a time, the PHA team has a basis to
conclude that no further actions are needed to mitigate the potential hazards associated with a catastrophic pump failure. In short,
the existing safeguards have been evaluated and are considered
adequate. The process of evaluating the potential risk associated with catastrophic pump failures begins with determining
an acceptable level of risk. This prevents the PHA process from
defeating its purpose by creating action items that consume avail48
FIG. 5
Likelihood
analysis
Risk analysis
Risk-based pump analysis.
Method overview. Fig. 3 shows the basic process used to

evaluate the risk represented by a catastrophic centrifugal pump
seal failure. The analysis begins with a technical pump risk assessmentrisk-based pump analysis ( RBPA). This step is performed
according to the consequence analysis and likelihood analysis
methods described in API 581 Sections 7 and 8. Afterward, a
quantitative layer of protection analysis (LOPA) is used to compare the specific pump risk against an acceptable risk tolerance.
This makes it possible to develop a reliability plan to operate the
pumps within risk tolerance.
Catastrophic pump-seal failure and consequences.
10-7
10-6
10-5
10-4
10-3
1/10,000,000 1/1,000,000 1/100,000 1/10,000 1/1,000
Failure per year frequency
FIG. 4
Consequence
analysis
able resources that should be working on resolving more important process safety risks.
5
Extreme
4
High
Risk-based
reliability plan
OSHA data from 1992 to 2009 contains a record of 36 catastrophic releases of highly hazardous chemicals that resulted in
fatalities.5 These incidents are responsible for 52 fatalities and
250 employee injuries. Ninety-eight of these injuries were severe
enough to require hospitalization. One of these incidents involved
a process release that occurred while steaming-out a pump casing.
The pump casing split open, resulting in a hot oil release that
immediately exploded (Jan. 19, 2005, Kern Oil Refinery, Bakersfield, California). The conditions present during this failure are
similar to those that the CSB documents in the first case history.
However, none of the fatal incidents contained in the OSHA
database resulted from a pump-reliability issue.
It would not be responsible to conclude that a catastrophic
pump seal failure could not result in a fatality based on these historical statistics. The second case history illustrates the potential
for pump-failure mechanisms to be directly involved in a process
safety incident capable of causing severe consequences. Although
there is insufficient data for a straightforward fatality frequency
calculation, enough statistical information exists to estimate a
minimum frequency based on site-specific data and industry averages. A frequency/consequence diagram, such as the one shown in
Fig. 4, can be constructed using this information along with these
facts and assumptions:
A total estimated 2009 refining capacity of 17.67 million
bpd6
The relationship of approximately one fire for every one
thousand repairs, as cited by an industry reliability authority. 7,8
This was corroborated by a large US refinery in 2009.
According to this analysis, the frequency for a fatality (highest
severity consequence) is estimated to be lower than 1x10-6 (1/1
million) years. This frequency suggests that a fatality caused by a
pump-reliability issue is probably more likely than an airline fatality but less likely than other typical US workplace fatality causes.9
Based on the industry workplace fatality statistics contained in the
OSHA database, this relative ranking seems reasonable.
This information makes it possible to define risk tolerance.
Risk tolerance (or literally tolerance to risk) implies that the
choice has been made to operate equipment in a responsible man-
ner rather than shutting it down to mitigate
a process safety failure risk. Risk tolerance
will vary between different organizations. It
is a decision that should be made under the
direction of legal counsel and supported by
industry statistics.
Risk-based pump analysis. Fig. 5
shows the primary steps involved in the
RBPA. In the RBPA, results from the consequence analysis are combined with the likelihood analysis to determine the risk associated
with a catastrophic pump failure. Comparing actual operating risk against a designated
risk tolerance makes it possible to assess risk
reduction options that may adequately control the process safety hazard. To be effective, the risk reduction options must directly
address the factors governing process safety.
SPECIALREPORT
Risk-based pump analysis

Consequence
analysis
Likelihood
analysis
Determine the release

area for a:
t.BKPSMFBL
t'VMMCPSFMFBL
Determine the
t3FQSFTFOUBUJWFnVJE
t"TTPDJBUFEQSPQFSUJFT
&TUJNBUFUIFSFMFBTF
JOWFOUPSZ
FIG. 6
Risk
analysis
Determine the scenario

release type (continuous
or instantaneous):
t.BKPSMFBL
t'VMMCPSFMFBL
Calculate release rates:

t.BKPSMFBL
t'VMMCPSFMFBL
Calculate and plot the

impact area for each
scenario:
t.BKPSMFBL
t'VMMCPSFMFBL
Consequence analysis steps.
Consequence analysis. The consequence analysis is covered extensively in API

581 RBI Base Resource Document Section 7. It is used to calculate the release area that would develop upon a loss of process
containment caused by a catastrophic equipment failure. In this
case, the RBI principles of API 581 Section 7 are being applied
to potential releases caused by a catastrophic pump failure. Fig.
6 outlines the recommended approach for working through the
consequence analysis using the methods described in API 581
Section 7.
The analysis should be based on a representative fluid and
should assume that typical refinery pump service is constantly
changing and the process material properties being evaluated
may be best described as an estimate of average operating conditions over a time period. API 581 breaks process fluids down to
a discrete number of representative fluids. This level of detail is
sufficient for the consequence analysis.
The flow area for a major leak is represented by an annular
area between the shaft sleeve and the closest fixed dimension of
the pump casing or packing gland. The OD of the shaft sleeve and
the ID of the closest fixed dimension of the pump casing or packing gland are determined from the seal manufacturers detailed
drawing as illustrated in Fig. 7. These dimensions are then used
to calculate a major seal failure leak rate.
Likelihood analysis. The likelihood analysis is described
in detail by API 581 RBI Base Resource Document Section 8.

Its purpose is to generate an initiating event frequency for both
the major and full bore leak scenarios. The likelihood analysis
described in this study makes use of generic initiating event frequencies (IEFg ) that are based on the empirical data shown in Fig.
8. This figure is based on catastrophic pump failure data placed
into the public domain by multiple sources.1018 This information
covers a wide range of leak rates from minor leaks (low severity)
to full bore leaks (high severity). The middle area of the chart
represents the major leak range.
The likelihood analysis is performed by 1) selecting an appropriate IEFg based on the analysis represented in Fig. 9 then 2)
adjusting the IEFg based on the specific pumps actual reliability
history (MTBFa see Eq. 1) compared with the standard reliability of a generic refinery process pump (MTBFg ). This adjustment
Packing gland
Major leak
Pump case
Throat bushing
Shaft sleeve
Shaft
Seal chamber
Rotating seal
Stationary seal
Major leak
ow path
Sleeve OD
Fixed ID
FIG. 7
Simplified seal sketchMajor leak flow path.
is made according to Eq. 2, which produces the initiating event

frequency for a specific pump installation (IEFa ).
MTBFa
IEFa
Years of pump repair history
Repairs for all pumps in the functional group

IEFg u
MTBFg
MTBFa
(1)
(2)
Risk analysis. The risk analysis takes place as the LOPA that
assesses the pump operating risk against the designated risk tolerance. Its purpose is to determine if a pump installation meets its
reliability expectations. This is true if the frequency of mitigated
consequences is less than the designated risk tolerance. If the
frequency of mitigated consequences is more than the designated
risk tolerance, then guidance should be suggested to improve
performance to meet process safety objectives.
I 49
SPECIALREPORT
Probability of personnel in affected area. The probability of personnel in the affected area, Pp, is a function of the
size of the affected area, Aa, and the amount of time personnel are
likely to be in this area. There are causes of catastrophic pump

failures that increase the probability of personnel being in the
affected area at the time of the event. An example may be an
abnormal process condition (such as flow loss) where the console
operator calls for the outside personnel to respond. There are also
causes that are random in nature where the probability of personnel in the affected area is based on the average amount of time
that people are in the area on any given day.
Failure cause distribution estimates for centrifugal pumps in
US process plants indicate that approximately 12% of failures
are caused by improper operation.1019 Some of these causes
result from chronic poor operating practices that reduce pump
reliability. They may have been normalized over time and do not
result in an operator response. An example may include cavitation
noises caused by low NPSHa operation or long-term flow outside
of recommended reliability limits.20 An estimate of 10% of the
causes of major releases that result in increased occupancy of the
affected area is assumed for this analysis. The remaining random
occupancy that does not increase the probability of personnel in
the affected area would therefore be 90%.
An estimated random occupancy of 1 hr/day/1,000 ft2 is
assumed for normal process areas. This estimate should be modified if there is evidence of higher or lower occupancy. Remote
areas that are not frequented with multiple rounds a shift will be
less. Affected areas that include known high-occupancy zones will
be greater. Any basis for choosing a different random occupancy
should be documented. This random occupancy is further simplified to a probability of 0.04/1,000 ft2. By combining cause generated occupancy with random occupancy an overall probability of
personnel in the affected area can be determined by Eq. 3.
100
Reference line
2
5
10
5
4
Release area, in.2
1
1
3
1
0.1
3
2
3
1
0.01
0.001
10-5
1/100,000
FIG. 8
10-4
10-3
10-2
1/10,000
1/1,000
1/100
Event frequency per year
10-1
1/10
Generic centrifugal pump leak area/frequency.
Pp = 0.10 + Aa (0.04/1,000 ft2)

Establish safe design objectives (based on LOPA results)
t.5#'
t*OEFQFOEFOUMBZFSTPGQSPUFDUJPO
Identify, evaluate and select alternatives (for meeting safe design objectives)
Identify alternatives
'.&"
NBKPSMFBLGBJMVSF
NPEFT
t"1*
t$VSSFOUEFTJHOQSBDUJDF
t#FTUQSBDUJDFQFFSSFWJFX
3$'"
TFBMCFBSJOH
GBJMVSFT
Design review
t"WBJMBCMFUFDIOPMPHZ
Evaluate and select alternatives
Implement risk-based reliability plan (to meet safe design objectives)

3FMJBCJMJUZTUSBUFHZ
QMBO
FIG. 9
50
1SPKFDUQMBO
Creating a risk-based reliability plan.
"VEJUQMBO
'BJMVSFBOBMZTJT
QMBO
(3)
Probability of ignition. API 581
reports probability of ignition, P i , for

five potential outcomes in tables. The
proper table in API 581 Section 7 should
be selected based upon the process leak
assessment made during the consequence
analysis.
Risk-based reliability plan. The output from the RBPA feeds into a process for
managing the risk of a process safety failure.
The frequency of mitigated consequences,
Fm, is the product of the frequency of the
specific pumps initiating event frequency,
IEF a, the total probability of failure on
demand for each independent layer of protection, PFDt , the probability of personnel
in the affected area and the probability for
ignition as calculated in Eq. 4. If the frequency of mitigated consequences, Fm, is
higher than the designated risk tolerance,
then a risk-based reliability plan must be
developed to manage the risk for a process
safety failure. This can be accomplished
by either increasing the pumps reliability, MTBF, or by applying safeguards sufficient to mitigate the consequences of a
catastrophic pump failure to an acceptable
TABLE 2. HVGO pump WO history
Date
Problem
Cost
Dec. 13, 2006
Need to replace inboard and outboard bearings
$1,445
April 9, 2007
Replace inboard and outboard pump bearings
$1,974
March 31, 2008
Inboard seal leak
$4,771
Nov. 1, 2008
Inboard pump seal leaking
$3,853
April 7, 2009
Outboard bearing leak
$3,487
$15,530
level. The basic process used to develop a risk-based reliability

plan is shown in Fig. 9.
Fm = IEFa (PFDt )(Pp )(Pi )
(4)
The LOPA results designate a target MTBF for meeting a designated risk tolerance. MTBF improvements have a number of
advantages. For example, they reduce both maintenance costs and
the potential to introduce some major leak failure modes during repairs like the one described in the first case history. MTBF
improvements are typically preventive instead of reactive. However,
it may be difficult to quantify the expected MTBF improvement
available through failure analysis and investigation. Failure analysis
skills, training and methods are involved in developing an effective
set of corrective actions to increase MTBF. This depends greatly
upon the failure investigators individual capabilities.
Machinery engineers must be consulted to determine if the
MTBF improvement is realistically achievable. Consideration
should be given to proven technology and both industry and per-
FIG. 10
Catastrophic HVGO pump seal failure consequences.
sonal experience with the process requirements. MTBF improvements can be applied together with additional safeguards to meet
the overall risk tolerance criteria. If MTBF alternatives are selected
as a part of the strategy to meet the risk tolerance, MTBF becomes
a part of the process safety risk management for the pump group
under consideration. It should be managed with the same diligence
and priority as defined by safe operating limits.
Case history in preventive risk mitigation. An investigation was used to determine the cause for a series of recurring seal
and thrust bearing failures on two heavy vacuum gasoil (HVGO)
service pumps operating side-by-side in a refinery vacuum crude
SPECIALREPORT
unit. The maintenance history of these pumps is shown in Table 2.

The investigation determined that high frequency vibration caused
by vortex cavitation suction recirculation (VCSR) was responsible
for the low MTBF. Based on this diagnosis, an action item was created to increase the pumps NPSH margin ratio to reduce the cavitation forces responsible for excessive stress on the thrust bearings.
Addressing this action item would require either redesigning or
replacing the pumps at considerable expense. Based on the resulting maintenance expenses, other competing reliability improvement projects offered a greater return on investment. Therefore,
it was decided that the risk of catastrophic HVGO pump failure
should continue to be managed by repairs. The repairs were to be
triggered by condition monitoring until the higher priority reliability improvement projects could be completed.
The potential consequences of HVGO leaks in, vacuum crude
unit service are not comforting (Fig. 10). A leak of sufficient size
would likely autoignite upon contacting air. The consequence for
a catastrophic pump failure represents a potential PSM incident
in addition to property damage and business interruption. But
condition monitoring seemed to be an acceptable approach to
managing the risk for a catastrophic HVGO pump failure based
on previous operating history.
Upon developing the RBPA guidance, the HVGO pumps were
reevaluated to verify that the reliability strategy was in agreement
with refinery risk tolerance. The analysis showed that the pump
group was one protective layer short at its present MTBF, and its
reliability would have to be increased to at least six years MTBF to
operate within refinery risk tolerance. This immediately changed the
basis for the project from a reliability improvement opportunity to
a process safety risk mitigation project. The priority of the HVGO

pump project was elevated and an execution date was scheduled.
Disclaimer and conclusions. The guideline and method-
ology discussed in this article attempts to be generally applicable

to all centrifugal pumps. However, good engineering judgment
must prevail while applying this guideline. The approach can be
modified as appropriate following a recommended peer-review
and documenting the technical basis for deviations.
Tolerating repeat failures on machinery that contains potentially
hazardous process materials can have disappointing consequences.
However, it is not uncommon for equipment failures to be accepted
without comparing actual reliability performance against a designated risk tolerance. In cases where breakdown maintenance is the
option selected to manage the risk for catastrophic process releases,
a definitive and objective basis is needed to expose a potentially
unacceptable process safety hazard before an incident occurs.
A standard RA method can be developed to evaluate pump
reliability on the basis of managing its failure frequency sufficiently
low to realistically avoid a process safety incident. However, the
MI program by itself may not sufficiently elevate equipment reliability to a level where process safety consequences can confidently
be prevented. Risk tolerance ultimately determines the complete
plan needed to fully address a process safety risk. In many cases, a
complete plan represents a combination of reliability (MI program)
improvements and safeguards (layers of protection).
The RBI method described in API 581 Sections 7 and 8 provides a sound engineering basis to do risk analysis on equipment whose failure may represent process safety consequences.
Need to predict emissions from a scrubbing

column and display real-time data? Were on it.
We make your challenges our challenges.
To see how CHEMCAD has helped advance engineering
for our customers, visit chemstations.com/demos8.
David Hill, CHEMCAD Support Expert
Engineering advanced
2011 Chemstations, Inc. All rights reserved. | CMS-322-1 5/11
52
This information can be supplemented with site specific failure
data and industry statistics to develop RA criteria for centrifugal pumps operating in the petroleum and chemical processing
industries. Practicing this approach to process safety is expected
to provide more satisfying and effective results than dedicating
resources to random safety improvements that may ultimately fall
short in avoiding a process safety failure. HP
Italian design
A masterpiece
ACKNOWLEDGMENT
This is an updated and refreshed version of the original paper presented at
the American Institute of Chemical Engineers 2011 Spring Meeting, 7th Global
Congress on Process Safety, Chicago, Illinois, March 1316, 2011.
LITERATURE CITED
Oil Refinery Fire and Explosion, 2004-08-I-NM, U.S. Chemical Safety and
Hazard Investigation Board, October 2005.
2 Safe Ups and Downs, 1st Ed. (booklet), Standard Oil Co., 1960.
3 The Report of the BP U.S. Refineries Independent Safety Review Panel,
January 2007.
4 Risk Based Inspection (RBI) Base Resource Document, API Publication
581 1st ed., May 2000.
5 OSHA National Emphasis Program Directive, CPL 03-00-004, June 7,
2007, http://www.osha.gov/ (accessed December 26, 2010).
6 Refining Capacity Report, January 1, 2009, National Petrochemical &
Refiners Association, August 2009.
7 Bloch, H. P., Understanding canned motor pumps, Lubrication Management
and Technology, September/October 2008.
8 Bloch, H. P., Pump statistics should shape strategies, Maintenance
Technology, October 2008.
9 Layer of Protection Analysis Simplified Risk Assessment, Center for
Chemical Process Safety of the American Institute of Chemical Engineers,
2001.
10 OREDA, Offshore Reliability Data, 4th and earlier eds., SINTEF, 2002.
11 HSE, Offshore Hydrocarbon Releases Statistics and Analysis, 2002, HSR
2002 02, 2003.
12 Mannan, S., Lees Loss Prevention in the Process Industries, 3rd ed., 2005.
13 Cox, A.W., F.P. Lees, and M.L. Ang, Classification of Hazardous Locations,
Institute of Chemical Engineers, 1990.
14 DNV (for DTI in UK), White Rose DA Volume 5 Part Two (Concept Safety
Analysis), July 2000.
15 HSE, Offshore Technology Report OTO 1999 079, January 2000.
16 Spouge, J., New Generic Leak Frequencies for Process Equipment, Process
Safety Progress, Vol. 24, No.4, December 2005.
17 Guidelines for Quantitative Risk Assessment, Purple Book, CPR18E, SDU,
Committee for the Prevention of Disasters (CPR), The Hague, 1999.
18 Flemish Government, LNE Department, Handbook Failure Frequencies
2009 for drawing up a Safety Report, May 5, 2009.
19 Bloch, H. P. and F. K. Geitner, Machinery Failure Analysis and
Troubleshooting, Vol. 2, 1999.
20 Schiavello, B., Cavitation and Recirculation Troubleshooting Methodology,
Proceedings of the 10th International Pump Users Symposium, 1993.
1
Kenneth Bloch is a PHA/Loss control engineer at Flint Hills Resources Pine Bend
Refinery in Rosemount, Minnesota. He is responsible for detecting and addressing
potential process safety failures. He specializes in root-cause analysis and catastrophic
equipment failure investigation. He publishes articles about equipment failure analysis,
life-cycle extension and reliability improvement, and speaks regularly at the API/NPRA
Operating Practices Symposium, NPRA National Safety Conference, and AIChE Loss
Prevention Symposium. Mr. Bloch holds a BS degree (honors) from Lamar University
in Beaumont, Texas, as well as, API -510, 570, and 653 inspection certifications.
Jeremy Bertsch is a reliability center manager at the Flint Hills Resources Pine
Bend Refinery in Rosemount, Minnesota. He is responsible for providing reliable
production and excellent operating team performance for the process units within
his department. Mr. Bertsch has over 15 years of refinery experience, primarily within
the rotating equipment and reliability engineering disciplines. He holds a BS degree
in mechanical engineering from the South Dakota School of Mines and Technology
in Rapid City, South Dakota.
Doug Dunmire is a refinery consultant with Western ROPE. His work includes
development of risk analysis and management tools for refining clients. Mr. Dunmire
holds a BS degree in chemical engineering from the University of California Davis.
Creativity is the art we

apply to achieve superior
design and developments
in technology.
For over 70 years we have designed and supplied
cost-effective technology, process plants and equipment for the oil & gas and refining industry around
the world. With our expertise we provide tailormade solutions from studies and revamps to skidmounted units and complete turnkey plants.
Oil & gas treatment
separation, dehydration and HC dew point control,
LPG and NGL recovery, sweetening,
mercaptan removal
Acid gas treatment & sulphur recovery
acid gas enrichment, Claus, ammonia Claus,
oxygen-enriched Claus, tail gas treatment,
sulphur degassing
Advanced process controls
Special process equipment
SIIRTEC NIGI Engineering Contractors

Via Algardi, 2 20148, Milan (Italy)
Tel: +39-0239223.1 Fax: +39-0239223.010 Web: www.sini.it
Contact: marketing@sini.it
SPECIALREPORT
Rethink planning and schedulings

role in refinery optimization
New tools improve prediction of unit feed qualities and yields
M. SWENSEN, Valero Energy Corporation, San Antonio, Texas;
and C. ACUFF, M3 Technology, Houston, Texas
lanning and scheduling are the core business functions

whereby refiners adjust the entire manufacturing process to
improve profits and achieve better results. Whether its used at
a small refinery or a large one, planning and scheduling can have a
major impact on profitability. A case in point is Valero Energy Corporations 14 refineries with crude and feedstock throughput ranging
from 90,000 barrels per day (bpd) to over 300,000 bpd. Improved
planning and scheduling can have a positive impact within the refinery as well as across the companys supply chain. With todays crude
prices pushing past $100/bbl, a small per barrel impact can be very
significant. Regardless of size and economies of scale, the specifics
of planning and scheduling are applicable throughout the industry.
This article will cover the challenges, solutions, results and benefits
of planning and scheduling in refinery optimization.
Planning and scheduling/blending defined. The pro-
duction planning system provides the strategic direction regarding

which crudes to purchase and in what proportions, the need for
additional feedstocks, the operating rates and conditions of each
process unit, and the optimal product slate. A linear program (LP)
is the primary tool used to vary all of these parameters to optimize
refinery profitability over the planning period, taking into account
projected market prices, unit operating constraints and availability, and expected demand for products in various channels of
trade. The planning tool assumes a continuous, steady supply of
crude and feedstocks, and a continuous demand for products and
stable refinery operations over the period. It does not model the
build or draw of inventories. Based on these assumptions, the LP
produces the optimal period-average operating plan.
In reality, refineries do not operate on averages. Crude and
feedstocks arrive in batches, and product is shipped in batches.
While the refinery runs continuously, individual units may run
differently for periods of time for various reasons. Planning is not
event based, which is why scheduling is needed. Scheduling takes
all of these discrete events into account with the goal of implementing the operating strategy developed in the planning process.
Scheduling provides dynamic responses to changes as they
occur (called event-based capabilities). Scheduling details out the
events as they will occur in the refinery, including such things as
the timing of receipts and the tanks into which crude and feedstocks will be received. The scheduling tool predicts the resulting
tank composition and qualities. The schedule reflects details
such as how various intermediate streams will be routed within
the refinery, operating rates, parameters and yields on each process unit for each day. It also includes timing of batches, recipes
required to produce different product grades and the detailed
product shipment schedule into the future.
Scheduling also makes use of offline built-in optimizers for
maximizing profit for crude and product blending. The blend
optimizer can be used to optimize a single crude or gasoline blend,
or it can be used to develop optimum recipes for a sequence of
blends through time (multi-period optimization). In the case of
products blending, the optimizer maximizes profitability as well as
minimizes quality giveaway, all while meeting target specifications
and managing inventory balances of component tanks.
In short, scheduling/blending is the development of the detailed,
executable plan to implement the operating strategy developed in
the planning process, running the refinery up against identified
physical or economic constraints to maximize profitability.
Solution for Valeros diverse refining operations.
Beginning with just one refinery in 1997, Valero has grown

through acquisitions and mergers to become North Americas
largest independent refiner, with 14 refineries having a combined
production capacity of more than 2.6 million bpd. Valeros refining network stretches from the US West Coast, Mid-Continent
and Gulf Coast to Canada and the Caribbean. Such a diverse set
of assets produces many unique challenges. For example, crude
supply can be ratable, locally produced crude or foreign imports.
Refineries might be landlocked or have direct access to waterborne
movements. Storage tanks can include a mixture of offsite/thirdparty terminals and onsite refinery tanks. Tank stratification or
partial mixing and the use of running-gauge tanks can have a big
impact on operations. Tracking pipeline line-fill volumes and
compositions can be essential in some situations and unnecessary
in others. Product blending facilities range from batch blending and run-down blending to configurations with individual
component tanks, online analyzers, and online batch quality
control. Product specifications include California Air Resources
Board (CARB) grades, unique one-time export grades, Reformulated Blendstock for Oxygenate Blending (RBOB) and other
grades such as Conventional Blendstock for Oxygenate Blending
(CBOB) and conventional grades.
In mid-2008, Valero initiated a project to improve and standardize refinery scheduling and blending tools, as well as work
processes. After completing software selection, end-user alignHYDROCARBON PROCESSING JUNE 2011
I 55
SPECIALREPORT
ment, and implementation plan development, the first refinery

implementation kicked off in early March 2009. The main focus
of the project was the deployment of refinery scheduling and a
multi-blend optimizer software as a new standard crude, feedstock and product scheduling/blending platform. The new tool
would replace multiple non-standard, non-integrated spreadsheets at each refinery. The scheduling/blending platform captures
the uniqueness of each refinery and its associated logistics while
allowing for central support of models and reports, development
and sharing of best practices, and data mining/reporting from a
Alkylate
Product
tanks
1st blend
header
Component
tanks
Product
tanks
Reformate
2nd blend
header
Product
tanks
Component
tanks
3rd blend
header
Naphtha
Product
tanks
Process
units
FIG. 1
Manifold
Manifold
Rundown blending optimization with three blend headers.
Drying Technology
database-backed scheduling system. As of early April 2011, implementation is nearing completion across all Valeros US refineries.
Refinery optimization is a collaborative effort. At
Valero, many groups and individuals participate in the optimization of a refinery, including the refinery planner, refinery
schedulers (e.g., crude, process unit, distillate/other products,
and gasoline blenders/schedulers), crude and feedstock planning,
product planning, transportation, supply and trading, refinery
operations, and refinery oil movements.
In the past, scheduling systems were restricted to a scope of
inside the fence of the refinery. Today, scheduling systems
span across the supply chain, terminals, refineries and organizational groups. This enables a collaborative effort, better visibility
and additional points of adjustment for improving economics.
Adjustments are seen by multiple groups, enabling faster response
and awareness.
Scheduling integrates data, technology and people. The more
feedback and comparison that is enabled, the more effective the
optimization becomes. For example, the planning models process unit sub-models are shared with the scheduling system. The
scheduling system compares simulated unit performance vs. actual
unit performance. The refinery scheduler can apply biases to
compensate for sub-model inaccuracy. The planning group then
receives feedback on sub-model accuracy, and this information
is then used to tune submodels, ultimately benefiting both the
planning and scheduling tools.
Timely updates of shipments and receipts (i.e. nominations)
from the supply and trading group are reflected in the refinery
scheduling system for the crude, feedstocks and products schedulers. Supply and trading receives feedback on actual arrival/departure times, demurrage events, quantities and material properties.
Refinery operations and oil movements receive daily operating
orders from the refinery schedulers, including direct import of
receipts, shipments, blends and tank transfers into oil movement
tracking systems. In short, scheduling is the hub that coordinates the
contributions of many to optimize the refinery.
Rundown blending optimization. Fig. 1 shows the schematic for rundown blending optimization. Rundown blending
involves multiple process unit streams as continuous feed components into blend headers. The blend headers may also pull feed
from typical component tankage. As depicted, at any point in
time, three blend headers receive feed from any of the component
Primary
crude
blending
terminal
DR
r HY
N
CARBO
You
er

56
Renery
Marine
liftings
Simulation scope includes terminal activities,

pipeline batches, renery, and distribution
FIG. 2
Refinery supply-chain logistics.
Finished
product
tank
farm
Pipeline D
Distribution
terminal
u nd
www.newton-s.com
Pipeline C
Pipeline B
Secondary
crude
terminal
n
o
i
t
a
c
i
f
eci
p
s
r
te
O L .. .
Wa
CONTR
ep
Ke
Pipeline A
Pipeline E
tanks and process unit rundown streams. Rundown streams must
be completely consumed in the three blends, since there is no other
possible destination for these streams. Volume of each blend can be
fixed or allowed to vary. The blend optimizer solves the group of
three blends together to meet specifications for each grade, minimize quality giveaway and maximize profits. The optimizer can
also optimize sequential groups of blends in a multi-period optimization. While Fig. 1 shows three blend headers, the solution is user
configured for any number necessary for the site. While depicted
with gasoline blending, it can also be configured to optimize diesel
or fuel-oil blends that are often managed as rundown blends.
Refinery supply-chain logistics. Managing supply and
demand is a requirement for achieving overall refinery optimization. Without doing so, a refinery can be constrained on blend
feedstocks, production rates, or shipment of finished product. At
Valero, the refinery supply-chain network includes a variety of
docks, terminals, tank farms, refineries and pipelines. Fig. 2 shows
the supply-chain scope for a marine-based refinery with multiple
pipelines and terminal assets. These assets along with the production capability of the refinery are visually shown in a model making it easy to see the possible inventory limitations, throughputs
and constraints across the refinery supply chain network.
Pipelines A, B, C, D and E reflect real logistical challenges to
maintaining balance across the network. Each pipeline has unique
linefill, minimum/maximum rate constraints, multiple inlets/outlets, and default throughput rates. Crude pipeline chains, such as A
and B, can work sequentially with or without the secondary crude
terminal. Likewise, the product pipeline chain has the flexibility to
provide product to a secondary distribution terminal or to a common carrier pipeline (E). The solution is to simulate the pipeline
batches, terminal activities and refinery production/consumption
across the supply-chain network to see the big picture of where
each asset stands. Volume and properties for each pipeline batch
and pipeline segment are available at any point in the simulation.
SPECIALREPORT
implementation of a more robust tool as well as the improvement

of associated work processes. Several observed benefits were noted:
Data from the process historian, lab information system,
movement systems and commercial nomination schedule system
are integrated using web services and the suppliers integration tool
Tracking of crude properties in each tank and in the crude
feed blends provide prediction of unit feed qualities and yields:
o At one Valero refinery, crude total acid number (TAN)
was increased an average of 0.2 points by better predicting the
TAN of a particular side draw.
o At another refinery, use of the blending tool for crude
Crude and product blend comparison
Deviation analysis
Actual blend results
Blend
performance
multi-dimensional
comparison
Scheduled blends
Destination facility
Component facilities
Recipe
Heel(s)
Volumes, properties
Blend #1
Blend #2
Single blend
optimizer
FIG. 3
Blend #3
Blend #4
Blend #5
Multi-blend
optimizer
Blend #6
Long-term blend
optimization using
aggregate tankage
Single- and multi-blend performance analysis.
Blend performance analysis. To use either the single blend

optimizer or the multi-period blend optimizer, the blending/
scheduling tool must accurately predict the properties and qualities of product batches. Constant vigilance is required to ensure
that blend property prediction correlations are properly tuned.
In Fig. 3, scheduled blends that have been optimized using the
blending tools single- and multi-blend solvers are transferred to
refinery operations for execution. Once the blends are executed,
results are brought back into the blending tool for comparison
and analysis. The goal is to measure the deviation (i.e., between
predicted and actual product qualities) in order to tune the blending correlations.
Inspect what you expect! Blend performance analysis provides
an easy way to compare scheduled vs. actual results. For example,
the actual recipe can be applied to the scheduled component qualities. Or the effects of the scheduled recipe can be analyzed with
the actual component qualities (instead of simulated qualities).
Comparisons include simulated vs. actual for: (1) blend recipe, (2)
component quality, (3) destination tank quality including heel,
and (4) batch quality, excluding heel. Deviations are automatically
calculated across the multiple dimensions. This makes tracking
down the root cause for the deviation much faster.
Benefits across the organization. Benefits from the sched-
uling/blending project have materialized, both as a result of the

57
SPECIALREPORT
blend optimization allowed better utilization of all process units

during the higher-demand summer gasoline season
o At yet another refinery, the blending tools virtual blend
feature allows optimized crude recipes to include crude cargoes
that are yet to be received into tankage.
Cargoes of lower-quality intermediate feeds no longer result
in surprises for unit operations because receipts can be simulated
before being used.
o Rate on one resid cracking unit would typically fall by
6,0008,000 bpd when impacted by lower quality feeds. Now,
due to better scheduling and blending of feeds, the production
rate impact is typically only 2,0003,000 bpd.
At a West Coast refinery, schedulers used to work with three
separate tools: a legacy DOS-based blend optimizer, a spreadsheet
scheduling tool, and the CARB predictive spreadsheet model,
The blend otimizer can use passing CARB as a product quality
specification. Now all three tools are combined into one.
Common gasoline blend property predictions are available
by integrating Valeros proprietary blend equation library into
both the planning tool and the scheduling/blending platform.
o Combined with the blending tool, it optimizes profitability while still managing inventories was accomplished.
o During Reid vapor pressure transition, one Gulf Coast
refinery had always required purchases of a high-cost blend stock.
They were able to manage the most recent transition with no purchases needed.
Tracking and managing dock availability and utilization
allows better management of inventories and minimization of
inventories.
o One scheduler at a marine-based refinery noted that they

used to be able to tell oil movements whether a ship could be
brought to the dock tomorrow, but can now tell them what time
tomorrow to bring it in.
Valero expects to capture more benefits going forward with
the completed scheduling/blending platform implementation.
Valero will leverage best practices with the improved scheduling/
blending platform and corporate commercial scheduling tools.
The integrated refinery scheduling/blending tool has become the
foundation for better communication, and it serves as the conduit
for all information related to planned plant operations as well as
for crude, feedstock and product movements. HP
Mark Swensen is director of supply-chain optimization for
Valero Energy Corp. He has been with Valero for nine years. Mr.
Swensens other roles at Valero include strategic planning, mergers
and acquisitions, Latin American business development, and alternative energy business development. Before Valero, his employment
included business strategy consulting and roles as process engineer and startup/commissioning engineer. Mr. Swensen earned a BS degree in chemical engineering from
Brigham Young University and an MBA degree from the Darden School of Business at
the University of Virginia.
Craig Acuff is the business development director with M3 Technologys SIMTO (scheduling and simulation) and M-Blend (single/
multi-period blend optimization). Mr. Acuff has 24 years of experience and has been involved with implementing refinery systems for
achieving business process improvements, along with assisting many
end users with making the transition to best practices. Mr. Acuff earned a BS degree
in mathematics from Oklahoma State University and an MS degree specializing in
computer science from the University of Central Oklahoma.
LIVE WEBCAST
presents . . .
Thursday, June 23, 2011

11 a.m. ET / 10 a.m. CT
Dont Pay At the Pump: Four Smart Steps Reneries Can

Take to Lower Production Costs
While consumers are used to buying gasoline at the pump, many reneries are paying at the pump in a negative way that
drives up production costs. Optimizing the efciency of API pumpswhich account for 60 percent of the motor energy used
in typical rening operationsis one of the simplest ways to boost reliability and save energy on production, so that you can
sell more to customers.
In this webcast, Mike Pemberton, an energy efciency expert for ITT Goulds Pumps, will give practical advice supported by
specic examples from rening operations for Chevron, Shell and other major companies. Attendees will learn:
How to select the right-sized pumpand why many are oversized, with some undersized
Tips for identifying the 10 percent of pumps that offer the fastest payback from optimization
Facts and fallacies about smart controls
How asset management is helping smart reneries to boost bottom-line performance
This webcast will deliver news you can use for anyone who oversees pumps, energy utilization and reliabilityincluding
renery managers, process engineers, production supervisors, reliability engineers and purchasing.
ITT Speaker: Mike Pemberton

REGISTER at
think simplicity
The Sensepoint XCD hazardous gas monitor

from Honeywell Analytics conveys the safety
status of your site at a glance through its
tri-color traffic-light display. XCDs flexible
advantages and ease of use increase safety
and save your company money. It also saves
you from worry, putting you in an easy chair.
Sensepoint XCD offers the easiest and fastest way to get ROI and added value from a gas
monitoring system. It installs simply and works out of the box, as a standalone system
or networkable device. Advantages include many flexible product features such as oneman, non-intrusive operation, highly-configurable sensors and electronic board, simplified
calibration, and versatile magnetic switches that adjust to scale, range, relay operation,
alarm set point and other requirements. Bottom line is, XCD respects your bottom line
while upgrading your companys safety system with state-of-the-art protection.
To learn more, call 1-800-538-0363

or visit www.XCDbyHoneywell.com
2011 Honeywell International Inc. All rights reserved.
2011 Thermo Fisher Scientic Inc. All rights reserved. Copyrights in and to the Matches and Blowtorch photographs are
owned by a third party and licensed for limited use only to Thermo Fisher Scientic by maxx images and SuperStock.
Imagine one gas analyzer that does the work of ten.
Introducing Thermo Scientific Prima PRO, the online gas

analyzer that uses high-speed mass spectrometry to increase
yield, conserve energy, and enhance process safety.
In fact, a single Prima PRO can do the work of ten gas
chromatographs to dramatically lower your cost of ownership
and raise the bar on product quality.
This powerful yet easy-to-use, simple-to-maintain system
offers automatic tuning and calibration and produces higher
resolution for a number of process variables. So you have a
better understanding of process dynamics and can implement
Thermo Scientic Prima PRO
more effective operating procedures. Plus, Prima PRO is built to
Named 2010 Innovative Product of the Year

by the International Society of Automation
(ISA) Analysis Division for superior
performance and ease-of-maintenance.
deliver 99.9% uptimemaking it a safe, reliable choice.

To learn more, visit www.thermoscientific.com/primapro,
email us at sales.process.us@thermofisher.com or call
1 (713) 2720404 or 1 (800) 4377979.
Moving science forward

SPECIALREPORT
Consider closedloop
oil-mist lubrication
A growing trend is migrating to this new
lubricating system for rotating equipment
D. EHLERT, Lubrication Systems Co., Houston, Texas
il-mist lubrication systems have been used for many

years. Properly applied, they also represent a proven and
environmentally clean technology for lubricating rotating
equipment in the hydrocarbon processing industry (HPI). Fullscale oil-mist lubrication for many pumps and motors in the HPI
dates back to the mid-1960s. Several US refiners started installing
large-scale plantwide oil-mist systems in the late 1960s and early
1970s. Two large US Gulf Coast refineries were among the first
to adopt oil mist for their hundreds of pumps and motors; they
continue to do so today, almost 50 years later.
At present, there are an estimated 70,000 machines lubricated
by oil mist. Only a small number of US refiners have not (or not
yet) adopted oil mist as the primary means of lubricating rotating
equipment with rolling element bearings.
The overall reliability of properly designed oil-mist systems is
nothing short of astounding. At the heart of these systems is a mixing nozzle called an oil-mist generator. Because it has no moving
parts to wear out, experience shows it to be 99.99999% reliable.1
Whenever problems were reported, the real cause of reliability issues
was either the oil and/or the distribution systems arrangement.
Lube-oil challenges: A look at history. There were many
challenges with oil mist in the early years. Some users failed to
realize that lubricant base stocks are very important contributors
to long-term successful systems operation and equipment lubrication. The oil used in the system must be free of paraffin.2 In this
case, the paraffin contains wax or waxy substances that tended
to coalesce and plug the systems reclassifiers whenever ambient
temperatures fell below 5C (40F). Reclassifiers are orificed fittings, as shown in Fig. 1, that create turbulence in the laminar
oil-mist flow. This turbulence causes the small dry mist globules
(also somewhat erroneously called particles) to impinge on
each other and to grow in size. The large globules then form the
wet mist needed for bearing lubrication. The difference in dry
mist and wet mist is merely in the size of the particles; dry mist is
essentially composed of particles less than 3 microns in diameter.
Clean, dry air is used as the carrier that allows the small atomized
oil globules to be transported throughout the distribution system.
Wet mistglobules larger than 3 micronsare heavy enough to
form a thin liquid film on the bearings rolling elements. It is this
oil film that provides bearing lubrication.
With unsuitable oils, wax crystals adhere to the orifice face.
As more wax collects, it eventually plugs the orifice. The back
pressure will then rise and eventually trip the high-mist pressure
alarms provided with well-engineered plantwide systems. At this
point, all lubrication to the rotating equipment can be lost, and
the system has to be dewaxed to restore lubrication. Fortunately,
this loss of oil mist rarely means that equipment failure is instantaneous. It has been proven that equipment such as centrifugal
process pumps and their motor drivers will continue to operate
for about 8 hours without additional lubrication being supplied
by the oil-mist system.1
An ambient temperature change is not always the culprit for
waxing issues. Reclassifiers can plug-up in ambient temperatures
as high as 37C (98F). Mineral oils that have not been properly
dewaxed can plug the system even during the warm US Gulf
Coast summer months.
However, plugging problems disappeared two decades ago,
and no longer exist with properly selected lubricants. This is
when many facilities that use oil mist on a plantwide scale opted
to use wax-free naphthenic-based mineral oils, or have converted
to synthetic oils. These facilities enjoy additional benefits with
modern lubricants. The incremental cost for synthetic oils is offset
by the reduced oil consumption inherent to oil-mist systems and
by reliably operating equipment with high-process temperatures.
Installation challenges. Proper installation of the piping distribution system is important to the overall success of an
oil-mist system. Incorrect installation practices created many
problems associated with early oil-mist distribution systems. The
mixing ratio for oil mist is approximately 200,000 volumes of air
per 1 volume of lube oil.
Because the mist consists of oil globules carried by air and
oil-mist globules behave like any other weighted particle or mass,
Oil mist reclassication
Mist ow
dry oil mist
Wet mist
Velocity and turbulence

converts dry mist to wet mist
FIG. 1
Cross-sectional view of an oil-mist reclassifier.
I 61
SPECIALREPORT
gravity ultimately controls where globules go. Several factors can

cause the oil-mist globules to fall out of suspension. Among these
factors are abnormally high- or low-flow velocities, excessive
impingement on the pipe wall, and oil pools that may have been
allowed to accumulate in carelessly configured pipes.
High velocity is caused by flow restrictions in the pipe; greatly
reduced flow diameters essentially duplicate reclassifier action.
Pipe flow may be restricted in main headers whenever a low point
or trap is formed in the pipe. If liquid oil accumulates in low
points or traps, flow velocity can increase and cause the oil globules to coalesce along the pipe wall in flow-restricted regions.
Low velocity can also result if the pipe header extends beyond
the distance over which oil mist will safely remain in suspension.
Oil mist will remain suspended in the carrier air for approximately
five minutes after it is first generated at the point of mixing in the
oil-mist generator (OMG). Travel times in excess of five minutes
allows gravity to predominate and cause more oil globules to fall
out of suspension. Moreover, the velocity must be calculated
throughout the entire header system during the design phase. This
will ensure sufficient velocities at each point of application. Even
the most distant application point in the system, be it a pump or
motor, must be reached.
While impingement on the pipe wall is often caused by
increased mist velocity, high rates of impingement can also result
from poor installation practices. Sharp turns cause mist particles
or oil globules to swing wide in the flow, similar to a car taking curves at a high rate of speed. As a particle of mass moves
2-in. header sagged between beams
Oil drained from

header into equipment
Reclassifer was
mounted inline
Pumps
FIG. 2
Old style oil-mist system installation.
Header pipe sloped
Manifolds w/
reclassiers
Pump
Pump
Drains to oil
collectors
FIG. 3
62
Modern one-way oil-mist system.
through a sharp turn, impingement on the wall occurs and liquid

drops fall to the bottom of the header. Internal pipe shavings or
sections of pipe that are incorrectly joined together can also create
impingement points that disturb mist flow.
Pools of oil act as a sponge and can pull oil globules out of
suspension as they slide across the surface. More oil may then
accumulate, and the region of reduced cross-sectional pipe diameter will cover a progressively larger surface. A larger surface then
collects even more particles.
While it is true that the shortest distance between two points
is a straight line, misapplication of this rule can likely cause a few
self-inflicted problems in early oil-mist installations. Laying the
pipe header flat in the pipe rack and arranging smaller connecting
pipe to connect from the bottom of the header to the equipment
was an error in judgment. Laying the header flat would allow it
to sag between the common 6-m (20-ft) spans of the pipe racks.
Small lines connecting from the bottom of the header to the
equipment created a perfect drain for accumulated oil, Fig. 2.
Many early oil-mist systems had the reclassifiers mounted
inline with the low point of the drop pipe or drop tubing to the
pumps or electric motor bearings. They, therefore, functioned as a
restriction in the flow when a small volume of coalesced oil would
drain down from the header. This restriction became a greater
hindrance in the cooler months; the viscosity of liquid oil would
increase and low-system pressure could not push it through the
reclassifiers. In modern systems, small-diameter take-off pipes are
connected to the top of the header piping, and the problem has
long since vanished.
Oil drainage into and through the equipment often created
serious housekeeping issues. From the first systems through the
mid- to late-1970s, such drainage was of little concern. However,
in the early to mid-1980s, more emphasis was placed on plant
cleanliness, and the recovery of spent oil gained in importance.
Early history of one-way systems. The 1980s brought
cleaner systems that enhanced lubricant application and equipment reliability. Proper sloping and support of the header pipe
to prevent low points and allow the liquid oil to flow back to
the OMG were among the first improvements made. This had a
major impact on housekeeping because it reduced oil consumption and no longer allowed excess oil to reach the equipment base.
De v i c e s we re
developed for collecting the oil
draining from each
piece of equipment.
Bearing isolators
became popular
also in the 1980s;
these helped to
contain stray mist
in the bearing housing and to direct it
and the coalesced
oil into a collection
device.
Oil mist flowing
through the rolling
elements and creatFIG. 4 Mist-distribution manifold.
ing a positive pressure in the bearing
Advances in oil-mist lubrication. We may have to aban-
don our old notions of oil-mist technology. It certainly would

be inappropriate to say that we have tried oil mist and it didnt
work. Additional advances were made in oil-mist lubrication
technologies and applications between 1985 and 1995.4 In particular, oil-mist generator designs were greatly improved in the
mid-1980s and again in the late-1990s. Control systems evolved
from electromechanical to solid state. More operating parameters
were monitored, and displaying individual control room alarms
became the new norm.
Along with the overall OMGs, several other system components were improved. Modern oil-mist distribution manifolds
FIG. 5
Mist-distribution system.
were reconfigured into an assembly that had six reclassifier ports,

a viewing chamber and a push-button drain, as shown in Fig. 4.
The viewing chamber was a great improvement over the original
block-style manifold, which terminated in a snap drain at the bottom. With no way of seeing accumulated oil on top of the snap
drain, this drain at best represented a minor advantage over the
inline reclassifier. Unless the snap drain was opened, oil would
build up above the level of the reclassifiers and block the oil-mist
flow to the equipment.
Improvements to the mist distribution manifold, and with
routing drop pipes or drop tubing with a continuous downward
slope, led to redesigned spent oil collection devices. Among early
collection containers one often found discarded plastic milk jugs
with rubber stoppers.5 Unless attended to, the stopper would
shake loose, allowing rain water to fill the jug, thus floating out
the oil from the jug. This evolved to a cast-aluminum container
with a vent, overflow port, sight glass, six equipment drain points
and a drain valve.
A major refinery in Thailand, using one-way systems, was
among the first to no longer discard spent oil. They realized
Two comparable reneries with 600 pumps
16
Oil consumption, thousand of gallons
housing was clearly recognized as a superior means of lubrication.

It was established beyond any doubt that pure oil mist preserved
equipment in the idle or standby mode. Forward-looking plants
included oil-mist lubrication on electric motor drivers ranging
from fractional hp to as large as 1,000 kW.
Fig. 3 illustrates the installation that provided superior performance as compared to the older installations. This arrangement
also made pure oil mist more popular and desirable; it came to
be known as a one-way system where the oil mist was generated,
distributed and disposed of after lubricating the equipment. The
thought was that oil that had contacted a bearing was contaminated and no longer suitable for use.
As of perhaps 1990, there was more discussion on environmental impact. Concern increased for soil, water supplies, our
atmosphere, and protection of the earths ozone layer. One of
the big topics was volatile organic compounds (VOCs). Moves
were underway to disallow oil mist because, in old-style one-way
systems, stray mist was emitted from equipment seals and drains.
Ultimately, oil mist was classified as an aerosol, similar to hair
spray and other household aerosols. Moreover, oil mist is not a
vapor or VOC due to the oils used in the systems.3
Improved installation procedures made oil-mist systems far
more reliable. In turn, this improved the reliability of the equipment so lubricated. A survey of the US and Canadian refining
industry in the late 1990s indicated that there were more than
1,100 large-scale oil-mist systems in operation at that time.
SPECIALREPORT
Oil consumption reduced 71% with oil mist

Without oil mist
With oil mist
14
12
10
8
6
4
2
0
2000
2001
FIG. 6
Oil consumption reductions possible with oil-mist system

in a refinery.
FIG. 7
Side view of closed-loop oil-mist unit.
I 63
SPECIALREPORT
the OMG. At the

OMG, the oil is
stripped from the air
stream and returned
to liquid oil state by
the demisting device.
The liquid oil that
drains into the small
collection container
(Fig. 5) is manually
pumped into the
return header from
where it then gravityfeeds into the demisting device collection tank, as shown
in Fig. 8.
The driving force
for the returning
excess mist is the
same air flow that
delivers the oil mist
FIG. 8 Large scale oil-mist system with
FIG. 9 Layout of early closed-loop system.
to the point of lubridemisting collection tank.
cation and creates a
positive pressure in
considerable savings from reduced oil consumption and from
the bearing housing. This positive pressure keeps out atmodispensing with manual lubricant collection, as shown in Figs. 5
spheric contaminants, moisture and blowing sand from running
and 6. Samples of collected oil indicated that the common conas well as standby equipment. There is continuous flow of air
taminants were wear particles and water. Both are easily removed
and positive pressure throughout the entire system. Meticulous
with simple filter carts and modern oil purifiers.
care was given in the development of the closed-loop system to
After further developments in bearing housing sealing techensure that the positive pressure in the bearing housing was not
nology and advancements in oil-mist accessories, closed-loop oilcompromised. The same 0.15-psi to 0.25-psi pressure is mainmist systems became the next step in the improvement chain. Oil
tained in the bearing housings with the closed-loop system as
mist provided excellent lubrication reliability to rolling element
with the one-way system.
bearings in pumps, other general purpose machines and electric
The oil is collected in the demisting tank and is automatically
motors. Excess oil quantities and undesirable soil contamination
pumped into the OMGs bulk-oil supply through a 10-m filter.
were now kept in check. With the oil mist being contained in the
Oil sampling is recommended at the demisting tank to ascertain
bearing housing and the coalesced (liquefied) oil collected below
oil quality is not lost. Many HPI facilities take oil samples from
the equipment, the feasibility of returning and reusing oil onsite
fresh new oil direct from their suppliers to monitor oil quality.
was revisited. The savings noted by the Thai refinery supported
Monthly oil sampling is recommended for the returning oil.
the development and use of a closed-loop oil-mist system.
The bulk oil is pumped through another 10-m filter prior to
refilling of the misting chamber tank.
Closed-loop oil-mist systems. A closed-loop system may
As with the one-way system, the collection container in the
be a compact unit on a single pump (Fig. 7) or a large-scale sysclosed-loop system allows for human intervention whenever the
tem serving a complete process unit. Closed-loop systems commechanical seal of a process pump fails. Should that happen,
prise a distribution header along with a parallel return header.
product could penetrate the bearing housing seal and seep into
The return header accommodates the returning excess mist and
the housing. However, and in this case, only 3.7 l (1 gal) of oil
liquid oil after passing through the equipment. Additional comwould need to be disposed of vs. 378 l (100 gal).
ponents of the closed-loop system are the return manifold, the
The closed-loop system allows for a more expansive distribucollection container with a hand pump, and a demisting device.
tion system than the one-way system when equipment is located
The return manifold and collection container with hand pump
at or near the process units battery limits. A flow booster or
facilitate returning the excess mist and liquid oil. The demisting
bypass is installed at the end of the distribution header and
device incorporates a motor-driven fan that creates high turburouted to the return header. This device maintains the normal
lence within a filter medium. This device causes wetting out
flow of approximately 7.3 mps (24 fps), which is the rate needed
or coalescing of excess mist and returning it to the liquid state;
to prevent the oil-mist globules from falling out of suspension.
only clean air then exits the system.
Note: There is somewhat skewed correlation with the previously
Large-scale systems allow collected oil in the mist manifolds
mentioned 5-min. (300-sec) maximum safe travel time to the
and liquid oil downstream of the bearing housings to migrate to
most distant point to be lubricated. Prudence and an abundance
the collection container below the equipment. The excess mist
of safety factor normally limits maximum header distances to
continues to flow through the collection container; it moves
within a highly conservative radius of only 600 ft from the oilon to the return manifold, into the return header and back to
mist generator.
64
Benefits. A well-engineered closed-loop oil-mist system provides the same benefits as the one-way system. These include a
continuous flow of fresh lubricant, positive pressure in the bearing housing, energy savings and very low maintenance requirements. Additional benefits include reduced oil consumption
that helps justify the incremental cost of synthetic oils, less open
container handling of spent oil collected, reduction of stray mist/
oil into the environment and the capability to extend the piping
system to greater distances. Closed-loop oil-mist systems have
been documented as being a best available technology (BAT) for
lubrication of rotating equipment.6
Installations. The first closed-loop systems (Fig. 9) were
installed in the early 1990s. They are still in operation and are
delivering highly reliable resultsjust as expected of any oil-mist
system. A recent survey revealed that closed-loop oil mist was
being used in 11 countries around the world with an approximate
total of 155 closed systems in service.About 13% of all large-scale
oil-mist systems are the closed type. One of the most prominent users of closed-loop oil mist is an oil refinery in Western
Australia.7 This refinery has in operation 15 large-scale closedloop and numerous compact systems. Their oldest systems have
been online at least 10 years, imparting equipment reliability as
expected. Aside from the US and Australia, there are closed-loop
systems operating in Canada, India, the Middle East, Southeast
Asia, South Korea and Taiwan.
The most intriguing and highly successful applications of
closed-loop oil-mist systems comprise air-cooled heat exchanger
(ACHE) fan shaft bearings and motor bearings. Years ago, oneway oil-mist systems were tried in ACHEs. It was noted that
early one-way systems created significant housekeeping issues due
to the excess mist escaping from the shaft and motor bearings.
Recent technology utilizes redesigned shaft bearings, as shown in
Fig. 10, that will contain the oil mist and allow it to be captured
and recycled.8 The older one-way systems lacked the ability to
capture, control and recycle excess oil mist.
A motor (Fig. 11) has also been developed exclusively for
ACHEs and oil-mist lubrication. In this system, the oil mist is
routed through the bearings, and an outlet is provided for recovery of excess mist and coalesced oil collected from the motor
internal volume or stator housing.
SPECIALREPORT
FIG. 10
Redesign closed-loop oil-mist system with redesigned

shaft bearings.
FIG. 11
Motor developed exclusively for ACHEs and oil mist

lubrication.
Options. The trend to use oil mist is growing throughout the
world as a closed-loop system. With over 155 closed-loop systems

among the well over 1,200 full-scale systems in successful service,
oil-mist technology continues to be adapted to applications that
where once considered off limits for oil mist.
Equipment connections are the same for either system, oneway or closed-loop, and no additional modifications or adaptations are required. Closed-loop systems are easily retrofitted to
existing equipment, as was (and occasionally still is) the now
decades-old one-way system. Careful consideration must be
given to the oil type used, and sound installation procedures are
critical to achieving positive results from any oil-mist system.
Fortunately, every detail of these successful installations is well
known and well documented in books, articles, supplier procedures and user standards. HP
LITERATURE CITED
Complete literature cited is available online at HydrocarbonProcessing.com.
Don Ehlert is manager of EPC Sales at Lubrication Systems Co.,

a Colfax Co., located in Houston, Texas. His current responsibilities
include providing technical training and sales presentations. He is
also responsible for quotation assemblies for both domestic and
foreign engineering companies and end users. Mr. Ehlert also
provides technical support to oil-mist users worldwide. Since joining LSC in 1984,
he has filled positions in equipment assembly, field maintenance, field installation,
field management, sales and sales management. He has been instrumental with the
development of oil-mist related products and accessories for special applications. Prior
to joining LSC, Mr. Ehlert had spent time in the US Navy, providing maintenance and
operation support for aircraft on hydraulic and flight-control systems.
I 65
Spray
Nozzles
Spray
Analysis
Spray
Control
Spray
Fabrication
Why Leading Refineries

and Engineering Firms Rely
on Us for Injectors and Quills
Retractable Injector, Slurry

Backflush Quill, Water
Wash Quill (bottom to top)
Dual Nozzle
Injector
Computational Fluid
Dynamics (CFD)
Manufacturing quality and flexibility.

Need a simple quill or multi-nozzle injector? Insertion length of a
few inches or several feet? 25# or 2500# class flange? High-pressure,
high-temperature and/or corrosion-resistant construction? Special
design features like a water-jacket, air purge or easy retraction for
maintenance? Tell us what you need and well design and manufacture
to your specifications and meet B31.1, B33.3 and CRN (Canadian
Registration Number) requirements.
CFD shows the change in drop size based

on nozzle placement in the duct.
D32
(m)
220
165
Z = 0.6 m
Nozzle spraying
in-line with duct
Proven track record.

Weve manufactured hundreds of injectors for water wash, slurry
backflush, feed and additive injection, SNCR and SCR NOx control,
desuperheating and more. Customers include Jacobs Engineering,
Foster Wheeler Corp., Shaw Group, Conoco Phillips Co., Shell, Valero
and dozens more.
Learn More at spray.com/injectors
Visit our web site for helpful literature on key considerations in
injector and quill design and guidelines for optimizing performance.
110
55
0
Design validation with process modeling.

Let us simulate the injection environment to identify potential
problems. We can model gas flow, droplet trajectory and velocity,
atomization, heat transfer, thermal stresses, vibration and more
to ensure optimal performance.
Nozzle spraying
at 45 in duct
1-800-95-SPRAY | spray.com |
Specify and order standard nozzles spray.com/ispray
SPECIALREPORT
Improve energy efficiency for

distillate hydrotreaters retrofit options
Energy conservation is a complex analysis on existing units,
but benefits are possible
Z. MILOSEVIC and T. SHIRE, KBC Process Technology Ltd., Walton-on-Thames, UK
istillate hydrotreaters are large

energy consumers. As more stringent sulfur specifications are introduced, refiners must increase energy usage
for hydrotreating purposes. As much as
10% of a refinerys total energy consumption is attributed to hydrotreating products. Furthermore, these units can be
quite energy inefficient. This case study
examines the economics of retrofitting
distillate hydrotreaters options that can
improve energy efficiency: 1) increasing
the surface area of feed preheat exchangers,
and 2) installing a hot separator. The study
also addresses the economics of using alternative heat exchange techniques, such as
twisted tubes, plate exchangers and printed
circuit exchangers.
When benchmarked against such targets, many hydrotreaters show BT indices of

500%. In other words, these units consume
five times more energy than that of the best
design unit. The BT unit used for comparison would be one with the same throughput, feed quality and severity of operation
as the actual unit.
Challenged energy performance.
The poor energy efficiency of an average

hydrotreater is primarily due to insufficient heat integration, resulting in the loss
of high-grade waste heat to water and air
coolers. The effectiveness of heat integration is normally assessed by using pinch
analysis techniques and its targeting part.2
Fig. 1 shows a conventionally designed
diesel hydrotreater. In this particular case,
the BT index was estimated at 550%. Part

of this inefficiency is immediately attributed to the units electric power consumption, which is generated at suboptimal total
efficiency (24%). If an assumption is made
that all motive power is generated at the BT
efficiency (80%), so that the effect of using
inefficiently generated power is annulled,
the remaining BT index would be 450%.
This unit is heat-integrated to some
extent: the reactor effluent preheats the
gasoil (GO) feed in exchanger E-1, before
preheating the stripper feed in exchanger
E-3. The unit is hot fed at 160C. If the
unit were cold fed, there would normally
be another feed/effluent exchanger downstream of E-3 and before the air cooler.
In many existing hydrotreaters, the feed
preheat temperature is considered low, bear-
Energy hogs. Distillate hydrotreaters are
one of the main energy consumers within a

refinery. New environmental rules mandate
even lower sulfur levels for transportation
fuels. Thus, refiners have few options but
to increase hydrotreating severity to remove
sulfur-containing compounds from refined
products and product streams. Unfortunately, many existing hydrotreating operations waste energy.
Room for improvement. The energy
efficiency of a process unit, or of an entire
refinery, can be benchmarked and compared against a selected reference value.
Various methods are used: some are statistical; some are based on historical performance; and others apply a more solid
engineering basis.
Some options apply a best technology
(BT) benchmark, whereby the energy efficiency of an existing unit is compared with
the best design target.1 The ratio of the
actual and the targeted consumption yields
a BT index for the process unit.
F-1
Qf = 24.7 GJ/h
= 87%
337C
FG
Diesel
stripper
8 barg
313C
V-6
Wild naphtha
200C
385C
E-3
260C
MP steam tph
E-1
172C
97C
HPLT
Gasoil feed
110 tph 160C
E-4
168C
RGC
FIG. 1
H2
makeup
Diesel
E-5
E-2
168C
Treat gas 19C
Flow diagram of a conventional distillate hydrotreating unit.
I 67
SPECIALREPORT
ing in mind that it is preheated using very hot

reactor effluent. In the unit as shown in Fig.
1, the feed is preheated to 313C, although
the reactor effluent is available at 385C.
Surely, the approach between the two temperatures could have been engineered to be
lower, say to 40C, instead of the actual 72C.
385C
Qf = 24.7 GJ/h
Feed
168C
313C
260C
Obviously, if the sizes of exchangers E-1

and E-3 are increased, more heat could be
transferred between the hot stream (effluent) and the cold stream (feed). This would
increase the feed-preheat temperature and
reduce the furnace duty, at a constant furnace outlet temperature.
385C
E-3 moved
and area
added
Feed
168C
Qf = 11.7 GJ/h
337C
E-1
E-1
228C
E-3
200C
Stripper feed
97C
New
HPHT
218C
Stripper feed
E-2
HPLT
HPLT
40C
E-2
40C
Retrot-hot separator
Original design
FIG. 2
Flow diagram of the original and retrofit for distillate hydrotreating unit.
Asset Longevity
Plant & Pipeline Performance
Quest Integrity Group is a dynamic company built on a foundation of leading edge science and technology that has innovated
and shaped industries for nearly 40 years.
Our asset integrity and reliability management solutions are
comprised of technology-enabled advanced inspection and
engineering assessment services and products that help companies in the rening and chemical, pipeline, syngas and power
industries increase protability, reduce operational and safety
risks and improve operational planning.
(888) 557-3363
(888) 893-7030
www.QuestIntegrity.com
Sales@QuestIntegrity.com

68
The other major inefficiency is the

absence of a hot separator. The effluent is
condensed in the air cooler upstream of the
high-pressure and low-temperature (HPLT)
gas/liquid separator. This heatstill available at a high temperature of 172C, and
quite valuableis lost to the atmosphere.
It would be more energy efficient to partly
condense the effluent at 172C in a hot
separator, send the hot liquid directly to
the stripper, only cool the remaining gas
against air and send the smaller stream to
the existing cold separator.
The problem of improving the
energy efficiency in a grassroots distillate
hydrotreater was addressed elsewhere.3 It
is proposed that a hot separator, combined
with enhanced heat transfer between the
feed and effluent, can lower unit energy
consumption to practically a BT value. At
such conditions, the feed would be at a
temperature high enough to be sent directly
to the reactor. The furnace would not be
used in normal operation, as all remaining heat would be supplied by the reaction
exotherm. The proposed enhanced heat
transfer is to be accomplished by using
plate-type heat exchangers. Such a solution
is feasible, and a number of units have been
designed, built and operated in this way.
Retrofits prove more difficult.
However, in retrofit situations, which are

primarily considered in the present analysis,
it is observed that many hydrotreaters are
too small and are below the critical size for
plate-type exchangers to be retrofitted economically. The problem is further aggravated
if the unit is hot fed, which is otherwise a
desirable feature of energy efficient designs.
With all this in mind, there are two
options, not mutually exclusive, for
improving the energy efficiency of an existing, medium-sized hydrotreater:
1. Add an exchanger area to E-1 and
E-3 so that more reactor-effluent heat can
be recovered by the GO feed
2. Install a hot separator and modify
the exchanger network, as required.
As may be intuitively expected, the first
option is likely to be less capital intensive,
but offering lower energy savings. The presented study addresses the economics for
both options, and provides conclusions that
may direct selection.
Option 1: Increase area of E-1 and
E-3. Both exchangers E-1 and E-3 have
large temperature approaches (72C and

60C, respectively) and offer the opportunity to economically install additional
Anytime, Anywhere
Anchor-Loc 3 insulating fiber
modules keep your project on

schedule with consistent, reliable
performance anywhere in the world.
Anchor-Loc 3 insulating fiber modules are

specifically designed and manufactured for the
global market, providing a winning combination
of performance, reliability and consistency you
can count on anywhere in the
world. This new generation
Insulating Fiber Modules

of Anchor-Loc modules is
designed to meet a wide range of application
requirements in a variety of heat processing
vessels. They provide continuous S-folded
blanket construction for improved thermal
performance in high temperature applications
and are available in various fiber chemistries,
temperature grades and densities to meet the
most demanding requirements. Anchor-Loc 3
modules offer:
Consistent design & quality assurance

Anchor-Loc 3 module design features construction from a continuous fold of spun blanket,
stainless steel alloy hardware and center mount
attachment. The design allows for consistent
furnace layout, ease of installation and dependable service life. All components meet or exceed
established industry standards assuring the
same high quality worldwide.
Fast, cost-effective delivery

The Unifrax sales team provides design
recommendations, engineering layout and
product sourcing options, ensuring a costeffective furnace lining solution wherever
youre located in the global market.
Universal specifications
For more information and a list of our

worldwide manufacturing locations, visit
the Unifrax website, call 716-278-3800 or
email anchorloc3anytime@unifrax.com.
Anchor-Loc 3 modules are produced in each

of our global manufacturing centers using the
same raw material specifications, dimensional
tolerances and assembly procedures, providing
product uniformity and consistency worldwide.
www.unifrax.com
SPECIALREPORT
surface area. Table 1 lists four projects to

be evaluated.
Based purely on its simple payback,
Project Ainstalling twisted tubes
appears to be the most attractive. This
project could on average save 5.2 GJ/h
(from start-of-run to end-of-run). Twisted
tubes are easy to install. They may cost a
fraction more than a new shell, but they
allow duty increase without increasing
systems pressure drop, thus keeping the
recycle compressors power unchanged.
Although the shortest of the four options
listed in Table 1, the payback for Project A
is not very attractive at 4.5 yearsa return
that may not be justifiable unless other

benefits may result.
The cost to add the first new shell (Project B) is high due to extensive piping modifications. However, once the first shell is
installed, the incremental cost of adding
more exchanger area is reduced. Following this logic, Projects C and D have been
consideredadding 2 and 3 new shells,
respectively. At 4.6 years, Project C shows a
slightly improved payback time than Project
B. The payback on the incremental area is
4.3 years.
As expected, each additional new shell
recovers less heat, as the temperature driv-
TABLE 1. Retrofit options to increase energy efficiency in diesel

hydrotreaters
Saving GJ/h,
Value,
Investment, Payback, Furnace
process
thousand /yr million
yr
duty, GJ/h
Project
24.7
Base case
Install twisted tubes in E-1 and E-3
5.2
380
1.7
4.5
18.8
33% area increase

(1 new shell in each exchanger)
5.2
335
1.6
4.8
18.8
67% area increase (2 new shells)
7.9
490
2.3
4.6
16.3
100% area increase (3 new shells)
9.2
537
2.9
5.5
15.5
Note: The fuel cost used to calculate the savings is 6/GJ. The CO2 reduction benefit is added to the fuel-saving benefit at CO2
price of 20 /ton, making the total fuel cost 7.3 /GJ.

70
ing forces in the exchanger are reduced.

Project D (a third new shell in each
exchanger) only recovers an additional
1.3 GJ/h, while the savings are mostly
outweighed by the increase in compressor
duty. Project D, alone, has an incremental
payback of 14 years.
The fact that these modified exchangers show a temperature cross, and have
relatively large duties with (now) tighter
temperature approaches, indicates a possible application of plate-type or similar
exchanger designs.
Option 2: Install hot HP separator.
An alternative approach to saving energy

is installing a second separator. The bulk
of the liquid downstream of exchanger
E-1 would be sent directly to the stripper,
rather than being cooled to 40C and then
reheated in the reactor effluent/stripper
feed exchanger E-3.
In the example hydrotreater (Fig. 1),
this option is particularly attractive as the
pinch occurs precisely in exchanger E-3. A
hot separator eliminates the need for this
exchanger, thus larger energy savings are
possible than what is achievable by adding
surface area alone (as in Option 1).
Since E-3 becomes redundant, it can
be reused as an additional feed/effluent
exchanger. There are no other changes in
the exchanger network. The stripper bottom
stream continues to preheat the stripper feed
from the cold separator and the treat gas. If
the unit were cold fed, there would be an
option to use more of the stripper bottoms
heat and perhaps the gas stream from the hot
separator to preheat the cold feed. The proposed revised flowsheet is shown in Fig. 2.
Table 2 summarizes the economics of
two available hot separator options. The
first option includes installing a new separator, and reusing E-3 as a further reactor feed/effluent exchanger (this includes
replacing the shells for an increased pressure rating). The second option considers
the incremental benefit of adding more area
to E-3 and adding a recycle-gas heater to
recover additional energy.
The investment cost associated with
installing a hot separator is higher than the
cost of simply adding exchanger area to the
feed-preheat train. However, the savings
are larger and the return on investment is
improved.
The second option shown in Table 2
adding more area to E-3offers an attractive incremental payback of 2.4 years. Once
the decision is made to install a hot separator, it may be more cost-effective to increase
the size of the feed/effluent exchangers at
the same time.
Due to the higher separation temperature and increase in hydrogen solubility,
installing a hot separator incurs two important process-related consequences:
1. Reduced hydrogen content in the
recycle gas. A 5% reduction in hydrogen
(H 2) concentration is expected for the
example hydrotreater. This will shorten
the catalyst life and reduce the cycle length
from about 3 years to 2.2 years. Assuming
a catalyst volume of 120 tons, at 16 /kg,
the extra catalyst replacement cost would
be around 230,000/yr. Alternatively, the
catalyst life could be restored to three years
by increasing the purge and H2 makeup.
About 1,500 Nm3 of additional H2 will be
needed for each 100 m3 of feed. Which of
the two alternatives will be selected depends
on the hydrogen cost. Shorter cycle length
would also incur a production loss of 12
days/yr and some added maintenance costs.
2. Increased H2 loss to fuel gas. This
additional loss is estimated at 175 kg/h.
In this particular case, this additional loss
is estimated at 175 kg/h, losing around
275,000/yr as a difference between the
cost of H2 (900/ton) and its values as
fuel (6/GJ). This loss is, however, much
reduced if the purge gas is recycled to the
H2 manufacturing plant.
The additional processing cost reduces
the benefits of installing a hot separator
from 885,000/yr to a value between
375,000/yr and perhaps 550,000/
yr, depending on the purge gas routing.
This net benefit can be lower or slightly
higher than the 490,000/yr achievable by
revamping the preheat train only. The extra
processing cost renders the hot separation
unattractive in this particular retrofit. Similar results have been reported elsewhere.4
The conclusion, however, may change if
the effects of unit debottlenecking and/or
throughput increase become substantial.
Those benefits would be greater with the
hot separator than with just revamping the
feed preheat train, and may again swing the
project economics in hot separators favor.
Minor processing issues. Other,
minor process issues to be addressed are:
Wash-water and stripper operation. In the present study, it was possible
to maintain the wash-water consumption
and stripper conditions at present values,
so that there would be little or no change
to the downstream operation. This needs to
be verified for each particular case.
Additional pressure drop from send-
SPECIALREPORT
tant temperature controlling mechanism is

removed. With the feed heater in operation,
the reactor outlet temperature can be controlled simply by turning down the heater
and reducing the feed temperature.
However, with the furnace on minimum
firing or on standby, other controlling
mechanisms can be used. These include a
quench-gas flow to the reactor bed, bypassing the feed/effluent exchanger, using a feed
cooler or installing an additional heat consumer (e.g., a steam generator) in the reactor effluent loop.
ing the feed through E-1, although any P

increase would be, to a large extent, offset
by the lower flowrate through the cooler,
upstream of the cold separator.
A process study may also address
moving exchanger E-3 upstream of the
feed pump, to avoid the need to increase
the pressure ratingincluding the effect of
high temperature on pump operation and
cavitation.
Control outlet temperature. As
the furnace duty is reduced by the listed
revamp projects, a question may arise
concerning control of the reactor outlet
temperature (which is affected by the feed
temperature and reaction exotherm).
Improved heat integration greatly
reduces the duty of the feed furnace, in some
cases to zero. It can be argued that an impor-
Alternative technology. To enhance
the heat transfer in a large shell-and-tube

heat exchanger with tight temperature
approach and a significant temperature cross, large additional area must be
installed. The materials of construction and
TABLE 2. Hot separator project economics

Saving GJ/h,
process
Project
Base case
Hot separator
Separator + add area to E-3
Value,
thousand /yr
Investment,
thousand
Payback, Furnace duty,

yr
GJ/h
24.6
8.8
640
2,710
4.2
14.2
13.0
885
3,310
3.7
9.6
Note: The separator investment cost (2.71 million ) is calculated as follows: hot drum: 1.6 million (D = 2.1 m L = 9.6 m,
55 bar stainless); piping: 200,000 ; modifying and re-rating E-3: 910,000 .
Straight to the Target!
Measure oxygen where it really matters:

Directly in your process
Why depend on a complicated gas sampling
and conditioning system when you can
measure oxygen directly in your process
and at lower cost of ownership?
Measure in-line with
METTLER TOLEDO Process Analytics.
www.mt.com/O2gasUS
71
SPECIALREPORT
pressures involved add to the costs for such

revamps. To lower this cost, alternative
exchanger technologies can be considered.
Such options include:
Plate/frame. The plate-and-frame type
of exchangers offer high heat-transfer coefficients, and are fairly straightforward to
mechanically clean. However, the pressure
requirements of hydrotreating units may
make some of these exchangers unsuitable
in this application. Plate exchangers have
been proven in large grassroots designs.
For the particular unit considered here, the
duty was too small to justify replacement.
Printed-circuit heat exchangers
(PCHE). These exchangers use diffusionbonded stainless steel plates, with channels
for the fluid etched in them. The channel
geometry leads to high heat-transfer coefficients, while the design is suitable for
high pressures. PCHEs are compact, can
be produced in small sizes and offer several
advantages:
Fits in plot area of existing exchangers
Tighter temperature approach can be
economically achieved
Lower overall pressure drop
Improved project economics. In the
present study, results found are:
Option 1adding exchanger

area. Slightly higher benefits are obtained
(670,000/yr vs. 537,000/yr, due to the
lower pressure drop of PCHE), at 40%
lower investment (2.1 million vs. 2.9 million), offering a 3 year payback (vs. 5.5 years)
Option 2using PCHE in
conjunction with hot separator. Again,
slightly higher benefit (930,000/yr vs.
885,000/yr) are obtained, but at lower
investment cost (2.8 million vs. 3.3 million), and faster payback (3 yr vs. 3.7 yr)
Potential disadvantages of using PCHE
are:
Mechanical cleaning is not possible
(although materials of construction and
low liquid volume are suited for chemical
cleaningsimilar to plate exchangers)
Small passages (slightly smaller than
in plate exchangers) raising fouling issues
Insufficient experience. PCHE have
many offshore applications, but are rarely
used in downstream industry.
Options. Of the two options available for
revamping a hot-fed hydrotreater, 1) adding area to feed/effluent exchanger, and 2)
installing a hot separator with some addition of heat exchange area, the hot separa-
MICROTHERM SlimFlex
Microtherm on a roll what could be simpler?
tor option (with exchanger area addition),

offers larger energy savings (13 GJ/h vs. 7.9
GJ/h of furnace process duty), and larger
potential energy benefits (885,000/yr
vs. 490,000/yr). Hot separator requires
a higher investment cost (3.3 million vs.
2.3 million), but offers a more favorable
return (3.7 yr vs. 4.6 yr).
With a hot separator, the unit energy
efficiency, as measured by the BT index,
would improve from 450% BT to around
240% BT. Installing a hot separator incurs
additional processing cost due to reduced
H2 concentration in the recycle gas. This
affects the catalyst life and cycle length, and
increases H2 loss to fuel gas. These factors
substantially impact project economics;
they can render the hot separation option
economically unattractive in retrofit situations. In grassroots designs, however, it is
expected that the hot-separator configuration would be chosen.
The analysis and the project economics are based on energy benefits only. In
many cases, improved heat recovery debottlenecks the feed furnace and enables an
increase in unit throughput. Both revamp
options are open to this additional potential
benefit. If the unit capacity can be increased,
the refiner may find that the yield-related
benefits outweigh the energy ones, and they
more than compensate for the H2 purity loss
in case of the hot-separator installation. HP
ACKNOWLEDGMENTS
The authors thank Dharmesh Panchal and Joris
Mertens for their valuable suggestions during the
preparation of this article.
36 (914mm) wide rolls in .2 (5mm) and .4 (10mm) thicknesses
LITERATURE CITED
Complete literature cited is available online at
HydrocarbonProcessing.com.
Multiple times more efficient than conventional insulations

Very low thermal conductivity over full temperature range
Capable of sustained exposure to 1832 F (1000 C)
Fully hydrophobic throughout the material to repel water
Dr. Zoran Milosevic is a senior
Fast and simple to cut and shape directly from the roll
Microtherm - Truly the Best Performance at High Temperatures
MICROTHERM
Aerogel
Calcium Silicate
Ceramic Fiber
Mineral Wool
0.000
0.020
0.040
0.060
0.080
0.100
Tim Shire is a senior consultant

0.120
0.140
Thermal Conductivity (W/m-K) at 600 C Mean
C1676
ASTM Standard
for Microporous
0.160
Data Per ASTM
Testing Standards
www.microthermgroup.com
Microtherm Inc.
+1 865 681 0155
Microtherm NV
+32 3 760 19 80
Nippon Microtherm +81 3 3377 2821

72
staff consultant with KBC Process

Technology Ltd., and an internationally
renowned authority on energy optimization and profit improvement of oil
refineries and petrochemical plants. He is best known
through his work on profit improvement and energy conservation. He has over 40 published papers and articles
on energy efficiency, refinery/petrochemicals profitability
improvement, and energy economics. Dr. Milosevic has
given numerous training courses in energy economics,
refinery energy efficiency and Pinch technology.
with KBC Process Technology Ltd,

working in the Energy Optimization
group. He manages energy and water
optimization studies in refining, petrochemicals and gas processing industries in the Far East.
Mr. Shire holds BS and MS degrees in chemical engineering from the University of Cambridge.
SPECIALREPORT
Fine-tune ethylene unit startups

Advanced modeling methods provide useful information
on operating main compressor system and feeds
X. YANG, Q. XU and K. LI, Lamar University, Beaumont, Texas
Operating line with

maximum rotation speed
lim
it l
ine
ogy is an extension of the previous works.5,6 It integrates the modeling activities in four interactive stages, as shown in Fig. 2. At the
first stage, model development starts with setting up a steady-state
(SS) simulation model. During the modeling, pressure node and
flow node models will be modeled and connected, respectively.
The SS is based on the mass and energy balance. The developed
SS model should be validated by plant design data, and supports
from industrial expertise are usually necessary.
Once the system SS is satisfied, it is transferred to a pressuredriven DS environment at the second stage. Process control information and new operating data from the plant DCS historian
and/or industrial expertise are required to do the dynamic model
validation. After validation, the DS model is generally reliable for
the startup simulation.
Before the dynamic model is applied for the startup simulation, it should be adjusted to running at the initial startup state,
where the system is commissioned to a warm-up status. In the
rge
among which the CGC is the major unit that is used to compress
the cracked gas to a designated high pressure (HP) for downstream
separation operations. The CGC system is the heart of an ethylene plant. Failure of this unit can lead to severe accidents and
significant economic losses. Commonly, a centrifugal compressor has four operating limits: surge limits, stonewall limits, and
minimum and maximum speed limits. These limits comprise the
map for the operating envelope. Compressor operations should
be well controlled within this operating envelope to ensure safety.
Fig. 1 shows a typical compressor operating envelope. During
the startup period, the entire ethylene plant runs from an initial
low-loading status to normal operation. In this process, plant
equipment experience big changes in temperature, pressure and
flowrates that easily upset the CGC. Therefore, CGC failures
occur frequently during ethylene plant startups. These failures do
cause increased downtime, excessive flaring, equipment damage,
and even, fatal accidents. Thus, a quick and smooth startup of the
compression system is essential.
General methodology. Developed rigorous DS methodol-
Su
Background. Ethylene plants are heavy users of compressors,
operating policies.4 DS is used to not only simulate original plant

startup procedures, but also to optimize the startup procedure in
a proactive way.
Head
he cracked-gas compressor (CGC) system is one of the

most important and valuable operating compressor systems
within ethylene plants. Any deterioration of the CGC unit
can result in significant operating difficulties within the entire
plant; thus causing severe economic losses. In this example, a rigorous pressure-driven dynamic simulation (DS) model is used to
examine and to improve the CGC operating performance during
plant startup. A real-case study demonstrates the efficacy of this
proposed methodology.
Modeling startups. In the absence of virtual tests, many

Operating line with
plants are using a trial-and-error approach to address this issue
minimum rotation speed
to gain expensive and sometimes painful experiences.1 Since the
startup operation is a dynamic process, DS models have been
developed and applied to improve the CGC startup operation.
Inlet volume owrate
DS is widely used as operation training simulators.2 As it is
FIG. 1 Compressor operating envelope.
capable to model complex processes, DS is very popular in supporting a variety of engineering and operational tasks for the oil
and gas processing industries.3 For instance,
DS can be used for examining potential
operational risks, performing design optiDS modeling
DS modeling
SS modeling
for initial
and
and
mizations, identifying production limitstate of startup
validation
validation
ing constraints and validating dynamic
responses.1 DS can also be used to predict
FIG. 2 General methodology framework.
the operating point trajectory under various transient scenarios, and thus evaluate
all
St
line
w
one
Startup
simulation and
optimization
I 73
SPECIALREPORT
KB31
Turbine
KB54
FC1
FC2
1st Stage 2nd Stage 3rd Stage
PC2
4th Stage
5th Stage
PC1
TC1
TC2
D1
LC1
Heavy naphtha
cracked gas
TC3
D2
D3
LC3
TC4
D4
LC4
LC5
LC2
TC5
TC6
D5
LC6
Condensate
Stripper
Recycled
feed from
downstream
Caustic/water
wash tower
Light naphtha
cracked gas
D6
LC7 LC8
LC9
TC9
TC8
TC7
LC
10
Dryer
D7
LC
11
LC
12
LC
13
FC3
FC4
KB21
FIG. 3
Flowsheet of the five-stage CGC system.6
1,200
Flowrate, thousand lb/hr
1,000
3rd stage discharge rate
800
5th stage discharge rate

Light-naphtha cracked gas
600
Recycle from
400 downstream process
KB21
Heavy-naphtha cracked gas
200 KB51
0
0
FIG. 4
8
Time, hr
10
12
14
16
Original startup procedure.6
last stage, alternative plant startup procedures will be virtually

tested. The optimal startup procedures will be identified, where
various startup operations should be effectively and efficiently
synchronized to improve the startup performance, in terms of
safety, environmental and economic concerns. Onsite industrial
expertise will always be required to verify the effectiveness of
modeling results at every stage.
CGC process description. In a typical ethylene plant, the
feedstock is sent to furnaces for thermal cracking. The furnace

effluent is then forwarded to the quench tower, where the cracked
gas is cooled and partially condensed. The quench-tower overhead
vapor is sent to a five-stage CGC system for compression to a set
pressure for downstream separation. The CGC system consists
of a series of compressors, drums, pumps and heat exchangers.
A reported CGC system is selected for study in this article.6 As
shown in Fig. 3, in flash drums, cracked gas is separated into two
phases: oil-liquid and vapors, or three phases: oil-liquid, water
and vapor. In the two-phase drums, liquid is knocked out or recy74
KB51
cled back to the previous stage drum, and vapor goes to the next
stage. In the three-phase drums, the hydrocarbon (HC) liquid is
knocked out of the system, and water is fed back to the previous
stage drum. Meanwhile, the vapor stream is sent downstream.
A caustic/water wash tower for carbon dioxide (CO2) removal
is positioned between the third-stage discharge drum and the
fourth-stage suction drum. The condensate stripper accepts the
HC-liquid feed from the fifth-stage suction drum. After this
feed stream is heated and distillated, top products go back to the
fourth-stage suction drum and bottom products flow out of the
system. The dryer drum is located after the fifth-stage discharge
drum. Vapor from this drum is sent to the downstream cold box;
and light HCs are sent back to the fifth-stage suction drum, while
heavy HCs are circulated to the fifth-stage discharge drum.
Fig. 3 also shows the major control information for the CGC
system. The first-stage suction-drum pressure is controlled by
regulating the turbine driving speed. The five compressors have the
same rotation speed, since all the compressors share the same shaft
and are driven by a steam turbine. There exist two minimum flow
loops for surge protection: the low-pressure recycling stream, KB31,
from the third stage to the first stage; and the HP recycling stream,
KB54, from the fifth stage to the fourth stage. KB31 is manipulated
by a flow controller to control the third-stage discharge flowrate,
and KB54 is designated to control the fifth-stage discharge flowrate.
During the plant startup, a light feedstock (mainly methane,
ethane, ethylene and propylene) will be used to warm up the plant
system. The entire plantincluding the CGC system, cold box
and recovery sectionsare operating at stable conditions with
no fresh feed. Meanwhile, all products from the downstream
processes are totally recycled back to the input of CGC.
Since the light feedstock has a smaller molecular weight, surge
can occur on the first-stage compressor. To avoid this condition,
a large volume of gas will be sent to the CGC system. If the light
feedstock flows through the CGC system with less condensation,
this large volume of gas can cause a stonewall problem in downstream stages. Therefore, recycling stream, KB21, from the second
discharge drum to the first-stage suction drum is done to prevent
the third stage from stonewalling.
2.6
Original startup
trajectory
2.5
2.4
2.3
New startup
trajectory
2.2
2.1
Safety
2.0
envelope
1.20 1.15
1.10 1.05
1.00 0.95
0.90 0.85 0
Volume, 107 ft3/hr
1,000
FIG. 7
900
Optimization of CGC startup operation. Fig. 4 shows

a practical plant startup procedure, which includes dynamic
changes of the flowrates for cracked-gas feed, controlled compressor outflow and various recycle streams.6 Note: The startup
operation begins at the first hour, and the cracked-gas feed from
the heavy -naphtha cracking furnaces ramps up at two different
rates for each of the first two furnaces within 30-minute durations. The feed from the light-naphtha cracking furnaces are also
Head, 104 ft
CO2 contained in the cracked gas must be removed by the

caustic tower. While recycling streams KB31 and KB54 do
not flow through the caustic tower. To get the caustic tower in
service, cracked gas is introduced, KB51, is established. This
allows stabilizing the caustic tower and cleaning up the cracked
gas before it enters the cold box. However, this flow loop has a
considerable pressure drop when the gas enters the first suction
drum, resulting in a big temperature drop. To avoid this problem, KB51 is taken out directly from the fifth-stage compressor
before the compressed gas is cooled down.
When modeling a CGC system, one simplification is made
to speed up the computation, i.e., lumping heating/cooling
duties of heat exchangers into duties of the closest downstream
drums. Thus, the temperature control loops in Fig. 3 are applied
to manipulate the flash-drum cooling duty instead of the heatexchanger duty. This simplification reduces the modeling complexity and computational load without sacrificing the simulation accuracy. To optimize the startup performance of the CGC
system, various startup operations should be effectively and
efficiently studied. In this article, various flowrates (feed, KB21,
KB51, KB31 and KB54) are investigated, which provides the
opportunities to improve the startup operations.
SPECIALREPORT
15
5
10
Time, hr
Startup comparisonthe first-stage compressor.
New 3rd stage discharge
800
New 5th stage discharge
Simplify your operations with

Novozymes wastewater solutions
Original 5th stage discharge
700
600
Original 3rd stage discharge
500
0
FIG. 5
8
Time, hr
10
12
14
16
Novozymes provides cost-effective

solutions for improving biological treatment.
Discharge flowrates of the third and fifth compressors.
Key benets include:

4,700
s Increased throughput of high-strength waste material

s Improved treatment during turnarounds
s Improved settling
s Stabilized nitrification
s Reduced toxicity
Maximum speed limit=4,653 rpm
4,650
4,600
New compressor speed
4,550
Original compressor speed
4,500
4,450
4,400
Minimum speed limit = 4,419 rpm
4,350
For more information on Novozymes

bioaugmentation products or to place an order:
4,300
0
FIG. 6
Compressor speed.
8
Time, hr
10
12
14
16
Web: www.novozymes.com/wastewatersolutions
Tel: 1-800-859-2972
E-mail: wastewater@novozymes.com
75
SPECIALREPORT
2.7
2.6
2.5
2.4
2.4
2.2
New startup
trajectory
2.0
15
Safety
envelope
1.4
6.0
FIG. 8
5.5
5.0
Volume, 106 ft3/hr
2.2
Original startup
trajectory
2.0
10
5 Time, hr
4.5
2.3
2.1
1.8
1.6
New startup
trajectory
2.6
Head, 104 ft
Head, 104 ft
Original startup
trajectory
1.8
4.0
Safety
envelope
1.9
1.6
Startup comparisonthe second-stage compressor.
FIG. 10
1.5
1.4
1.3
1.2
Volume, 106 ft3/hr
1.1
15
10
1.0 0 5
Time, hr
Startup comparisonthe fourth-stage compressor.
2.7
2.5
New startup
trajectory
New startup
trajectory
2.6
2.5
2.4
Head, 104 ft
Head, 104 ft
2.4
2.3
Original startup
trajectory
2.2
2.1
2.3
2.2
Original startup
trajectory
2.1
2.0
Safety
envelope
2.0
1.8
1.9
2.8
FIG. 9
2.6
2.4
2.2
Volume, 106 ft3/hr
2.0
1.8
10 15
0 5
Time, hr
Startup comparisonthe third-stage compressor.
incremented in two ramps for each furnace but without any idle
waiting between two furnaces.
The performance of the previous (reported) startup procedure, as shown in Fig. 4, can be systematically evaluated through
dynamic simulation. One observation is that the pressure of the
first-suction drum drops quickly at the beginning of startup
when the fresh feed is introduced. As a result, the operating
speed is pushed to the lower limit. One explanation for this
development is that when the cracked gas from heavy naphtha
enters; the recycled flowrate of stream KB31 should be reduced
to maintain a constant flowrate for the third-stage compressor
discharge. However, the flowrate cuts back too quickly. As this
stream is at a higher pressure than the cracked gas input, this
flowrate cut causes significant pressure reduction in the firststage suction drum. To maintain pressure, the compressor speed
must decrease correspondingly. A similar cutback occurs for the
recycling stream of KB54.
Based on this analysis, the starting time or the flowrates of
the two recycle streams (KB31 and KB54) should be adjusted.
As KB31 and KB54 are manipulated to control the discharge
76
Safety
envelope
1.9
8.0
FIG. 11
7.5
7.0
6.5 6.0 5.5 5.0

Volume, 105 ft3/hr
4.5
4.0
10 15
05
Time, hr
Startup comparisonthe fifth-stage compressor.
flowrates of the third-stage and fifth-stage compressors, adjustments are actually accomplished by tuning the setpoints of the
outlet flowrate for the third-stage and fifth-stage compressors.
Fig. 5 provides the detailed adjustments compared with the
previous setpoints.
The adjusted startup procedure was tested based on the rigorous DS. It shows that the compressor performance would improve
(see Fig. 6). With the previous startup procedure, the compressor
speed approached 4,440 rpm between the second and the fifth
hour, which is too close to the lower limit speed (4,419 rpm).
This swift change should be mitigated. With the new startup procedure, the compressor speed variance was significantly reduced,
thus enabling a smoother startup for the CGC system.
To compare the dynamic performances of two startup strategies, the operating status for the five-stage compressors is tracked
and shown in Figs. 711. Note: Over time, the operating envelope
in Fig. 1 forms a closed wall, which cannot be touched by the
operating point at any time. As shown, at each compression stage,
the operating trajectories of both startup procedures are running
within the closed wall, which means the two startup procedures
Safe
Single - step decontamination thats safe for people,

your plant and the environment.
Safe for personnel, plant equipment and the environment, Zyme-Flow is non-toxic,
non-hazardous and biodegradable. Its patented formulation delivers fast and highly
effective results. So, less time is needed to prepare equipment for entry while safety
concerns associated with cleaning, degassing and environmental compliance are
simply eliminated. Its the naturally safe solution that does it all in a single step.
Get Tough. Get Zyme-Flow
For information call Dee Bryant at 832.775.1565
dee.bryant@zymeow.com | zymeow.com
Zyme-Flow is a mark of United Laboratories

International, LLC. 2011 United Laboratories
International. All Rights Reserved.
Worldwide Leader in Renery

Decontamination
Zyme-Flow tough. From routine decontamination to heavy oil.
SPECIALREPORT
6
are feasible. However, the operating trajectory of the new startup

procedure undergoes smoother changes than the original procedure. Meanwhile, the maximum changes of the new startup
trajectories are also smaller than those from the original startup
procedure. Therefore, the new startup plan will operate the compressors in a safer condition and sustain more disturbances than
the original procedure. Note: Such dynamic-performance evaluations provide the most valuable insights to the CGC system,
which can only be accomplished via rigorous DS.
Options. CGCs are the most important facilities in ethylene
plants, whose failure can cause severe accidents and/or tremendous economic loss. Rigorous DS is an efficient and effective
way to improve CGC operation performance, especially during
a plant startup. HP
1
2
3
LITERATURE CITED
Singh, A., K. Y. Li, H. H. Lou, J. R. Hopper, H. Golwala and S. Ghumare,
Flare minimization via dynamic simulation, Int. J. Environ. Pollution, 2007,
pp. 29, 19.
Luyben, W. L., Plant-wide dynamic simulators in chemical processing and
control, 1st Ed., CRC, Boca Raton, Florida, 2002.
Rutherford, P., W. Persad and M. Lauritsin, Consider dynamic simulation
tools when planning new plant startup, Hydrocarbon Processing, October
2003, p. 75.
Patel, V., J. Feng, S. Dasgupta, P. Ramdoss and J. Wu, Application of
dynamic simulation in the design, operation, and troubleshooting of
compressor systems, Proceedings of the 36th Turbo-Machinery Symposium.
Houston, Sept. 10, 2007, p. 95.
Xu, Q., X. Yang, C. Liu, K. Li, H. H. Lou and J. L. Gossage, Chemical plant
flare minimization via plant-wide dynamic simulation, Ind. Eng. Chem. Res.,
2009, Vol. 48, No. 7, p. 3505.
Yang, X., Q. Xu, C. Zhao, K. Li and H. H. Lou, Pressure-driven dynamic

simulation for improving the performance of a multistage compression
system during plant startup, Ind. Eng. Chem. Res, Vol. 8(20), p. 9195, 2009.
Xiongtao Yang is a Ph.D student in Dan F. Smith Department

of Chemical Engineering at Lamar University. He has four years
experience on process equipment and control in power and petrochemical industries. He holds BS degrees from the Beijing University
of Chemical Technology in process equipment and control. His
research interests include process control, process simulation and optimization, process safety analysis and feasibility studies on flare minimization in chemical industry.
Qiang Xu is an associate professor of Dan F. Smith Department of

Chemical Engineering at Lamar University. He holds BS, MS and PhD
degrees all in chemical engineering from Tsinghua University, China.
His research interests include process modeling, scheduling, dynamic
simulation and optimization, industrial pollution prevention and
waste minimization, and chemical process safety and flexibility analysis. His research
work on proactive flare minimization and environmentally benign manufacturing has
been extensively supported by Texas Commission on Environmental Quality, Texas
Air Research Center, Texas Hazardous Waste Research Center, DOD and industries.
Kuyen Li is a Professor of Dan F. Smith Department of Chemical

Engineering at Lamar University. He received his BS and MS degrees
from Cheng Kung University of Taiwan and PhD from Mississippi
State University, all in chemical engineering. His research interests
include air-pollution control by dynamic simulation and advanced
oxidation, advanced remediation methods for contaminated soil and sludge, and
industrial wastewater treatment by biological and advanced oxidation method. His
research work has been strongly supported by the US EPA, Texas Commission on
Environmental Quality, Texas Air Research Center and industries.
save
the date
1 SEPTEMBER 2011
Omni Riverway, Houston
Is social media taking over your corporate marketing
strategy? Or are you having a difcult time implementing
social media into your marketing program? Marketing in
the Oileld 2011 will help you simplify your social media as
well as maximize your results.
We will provide practical advice on how to balance and
prioritize your digital media to-do list towards achieving
the most impact and return on your time and investment.
View the agenda, see who is on

the advisory board and register:
www.GulfPub.com/MITO
78
Special Supplement to
VALVES
2011
CONTENTS
Fugitive emissions from valves: Update V81
Corporate Proles
Curtiss-Wright Flow Control V85 Maxon V87 Onis V89 TrimTeck V91 VYC Industrial V92
DeltaValves fully automated coke-drum unheading device permanently connects to the bottom of a coke-drum,
creating an enclosed system from the top of the drum to the discharge pit. With the push of a single button from
a remote location, safe and reliable coke-drum unheading can be achieved.
Catalyst valve
problems?
We Have Solutions!
The Hemiwedge Valve was designed to take on the severe conditions
of catalyst handling. If you thought there was no alternative to
traditional valve designs, we have great news!
The STATIONARY CORE in the Hemiwedge Valve protects the

seating surfaces from the solids ow, resulting in greatly increased
service life over conventional metal seated ball valves.
In some instances, where traditional metal seated ball valves were
lasting 2-3 months, the Hemiwedge Valve has tripled or quadrupled
the service life of the valve . . . and is still going strong!
Let Hemiwedge Valve solve your

challenging valve problems.
Call today for more information at
936-539-5770 or visit Hemiwedge.com
Hemiwedge Valve
1011 Beach Airport Rd. | Conroe, TX 77301
Tel: 936-539-5770 | Email: info@hemiwedge.com
VALVES 2011
Fugitive emissions from valves: Update

J. WILWERDING, SAGE Environmental Consulting, L.P., Denver, Colorado
Fugitive emissions awareness and mitigation have come a long way in the last
50 years, especially in the US. Initial fugitive emission studies of sources in the Los
Angeles basin were done by Bernie Steigerwald in 1958. In the 1970s, the US Environmental Protection Agency (EPA) embarked on a substantial effort to quantify
these emissions and develop a standard sniff test to identify hydrocarbon leaks
using portable hydrocarbon analyzers (known as EPA Reference Method 21). The
1980s saw promulgation of the first significant regulations requiring synthetic
organic chemicals manufacturing (SOCMI) industries and petroleum refineries to
institute find them and fix them work practice programs. These programs were
referred to as leak detection and repair (LDAR) programs.
LDAR program benefits. After several years of facility effort to

sort out how to implement new LDAR programs, EPA began its first significant
enforcement initiatives surrounding the monitoring requirements during the 1990s.
Various EPA offices purchased hydrocarbon analyzers to do their own, independent
reviews of a facility LDAR program. These reviews culminated into an Enforcement
Alert from EPA, informing petrochemical industries of widespread disagreement
between EPA- and industry-determined leak percentages (the percentage of equipment with leaks). The reviews alleged that industry failed to implement Method 21
correctly, and the agency estimated approximately 80 million pounds of undetected
and unreported hydrocarbon emissions were being released annually in the US.1
Although proving a concrete violation that monitoring was conducted incorrectly was legally difficult (only one LDAR enforcement case has ever gone to trial
in the US2 ) demanding stiff penalties, often in the millions of dollars, was not.
Under the Petroleum Refining Initiative in the early 2000s, fugitive emissions
became a marquee compliance issue for EPA with the petroleum refining industry.
To avoid litigation, US refiners agreed to implement LDAR best-management
practices, eventually referred to as Enhanced LDAR Programs or ELPs.
The ELPs reduced the repair action thresholdleak definition, in parts per
million (ppm) total organic hydrocarbons,increased leak monitoring frequency
and required LDAR program training, procedures, and third-party audits. By 2008,
reported fugitive emissions of toxic hydrocarbonsa subset of overall volatile
organic compound (VOC) emissionsfrom the petroleum refining sector had
dropped by 42% compared to the start of the decade.3 While differences in
emissions accounting methods may have contributed to the observed decrease,
as shown in Fig. 1, ELPs are believed to be responsible for the largest part of the
reduction. Reviews of toxic fugitive emission reductions from valves and pumps,
the two equipment types impacted by most refinery ELP requirements. Reviews
of toxic fugitive emission reductions from valves and pumps at one major refinery
showed capacity-adjusted emissions dropped roughly 80% after the requirements
took effect in 2003, as shown in Fig. 2.4
Bolstered by the success of these Enhanced LDAR Programs, EPA continued
to pursue best practice agreements with the rest of the refining industry (approximately 20% since 2008), and began negotiations with several companies in the
Chemical Manufacturing Industry (CMI) for alleged LDAR noncompliance with
hazardous organic NESHAP (HON) regulations.5 The CMI sector, partially regulated
under SOCMI regulations from the 1980s, became subject to these substantially
increased requirements in the mid-1990s. The petroleum refining ELPs in the
2000s aimed to achieve the same emission reduction levels as HON regulations
had achieved for toxic air pollutants almost a decade earlier.
EPA was confronted with a dilemmawith already low repair-action thresholds and more frequent monitoring required under HON, what could be considered
best practice and an enhancement in the CMI sector? Where could emissions
still be reduced? In some cases, leak definitions were further lowered (e.g., from
500 ppm for valves and connectors to 250 ppm, and from 2,000 ppm for pumps
to 500 ppm). Requirements for QA/QC and third-party audits were increased.
However, overall emissions reductions from these enhancements were known to
be significantly lower compared to the refining sector.
Older models present problems. Working closely with several

industry partners, EPAs understanding of the fugitive emissions problem began to
change. Find it and fix it work practice programs were limited in their ability to
control fugitive emissions by the underlying process equipment technology. Older
equipment, designed and manufactured with larger tolerances, would always leak
more. Some packing and seal designs were inherently less effective at controlling
Two
line caption
emissions.
Only by replacing these seals, packing, or equipment with advanced
designs could long-term leak rates be reduced.
Responsible party dilemma. This understanding of how to control
fugitive emissions accompanied a paradigm-shift in who at the site is best-suited
to address the problem. The plant environmental department usually drove the
LDAR program, because the requirements came from EPA and not from the Occupational Safety and Health Administration (OSHA), where process safety was the
driver. However, the environmental department, being largely removed from the
everyday operation and maintenance of the plant, was least-equipped to affect a
direct change on equipment leaks. They could do monitoring and request repairs,
but as long as the regulatory timeframes were met, not much more would be done.
Maintenance and reliability personnel, however, could take the monitoring information and identify bad-actor equipment, and establish clearer meantime-to-failure criteria so that equipment could be refurbished or replaced prior to
failure. Maintenance could do root-cause analyses to identify equipment applications that were leak-prone so that other equipment types could be selected, and
could determine which repair types were most successful and cost-effective over
the long term. They could combine equipment manufacturer information with
leak-performance data (see Table 1) to determine which vendors produced the
best equipment for their processes. All of this information could be forwarded to
the procurement department to ensure the best, most cost-effective equipment
was purchased for the facility.
Fugitive emissions, million/lb
Leak-free involves monitoring and new equipment

technology
25
Petroleum NAICS TRI fugitive emissions to air

20.79
20
15
12.1
10
5
0
2000
2008
FIG. 1. Petroleum NAICS TRI fugitive emissions to air, million lbs.
HYDROCARBON PROCESSING VALVES 2011
I V-81
VALVES 2011
TABLE 1. Leak percent of active inventory by manufacturer

Manufacturer
2005
A
96/12,8520.7%
B
30/2,6731.1%
C
108/6,7371.6%
D
59/2,3142.5%
E
0/310.0%
F
2/593.4%
G
1,196/18,9666.3%
H
1/432.3%
I
24/4095.9%
J
96/1,4336.7%
K
91/1,4066.5%
L
52/6777.7%
M
81/1,2196.6%
2006
156/13,8741.1%
57/3,5441.6%
182/7,1272.6%
69/2,8472.4%
3/319.7%
1/611.6%
609/16,9833.6%
3/456.7%
28/4506.2%
121/1,5957.6%
92/1,4826.2%
54/7387.3%
110/1,2448.8%
2007
161/15,9691.0%
45/4,5111.0%
193/7,9542.4%
70/3,5272.0%
2/4170.5%
3/714.2%
287/10,7082.7%
2/484.2%
30/4836.2%
108/1,8016.0%
132/1,6558.0%
67/8577.8%
136/1,32210.3%
2008
155/19,7060.8%
53/6,1250.9%
211/9,4452.2%
79/4,3811.8%
1/5040.2%
2/822.4%
193/8,8092.2%
1/541.9%
37/5716.5%
109/2,2044.9%
119/1,8606.4%
95/1,0479.1%
118/1,5227.8%
2009
135/21,7260.6%
63/6,5691.0%
139/9,9371.4%
79/4,7361.7%
1/5720.2%
5/865.8%
275/8,3293.3%
2/523.8%
35/6175.7%
132/2,4225.5%
155/1,9478.0%
100/1,0789.3%
207/1,67812.3%
Average leak rate at 500 ppm, %

0.86
1.11
2.04
2.09
2.11
3.50
3.61
3.77
6.09
6.14
7.00
8.23
9.17
Valve and pumps capacity

adjusted TRI emissions, lbs/1,000
bpy of rening capacity
Today. So, where is the hydrocarbon processing industry in 2011 regard5.0

4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
FIG. 2. Valve and pump capacity adjusted TRI emissions, lbs/1,000 bpy of
refining capacity.
500
> 500 ppmv
Leakage, ppmv
400
300
200
100
0
0
250
500
750
1,000
Cycle number
1,250
1,500
FIG. 3. Yarmouth Research API 622 Test Report.
In short, EPA determined, that while fugitive emissions may be the line
where facility operations impact the community and the environment, they
were merely the symptom of a larger problem outside the control of the environmental department. Fundamental, lasting change in equipment leaks could
only be achieved by an integrated approach between maintenance, reliability,
operations, procurement and environmental personnel. And this change would
need to be technology-based.
V-82
I VALVES 2011
HydrocarbonProcessing.com
ing US fugitive emissions control? To enhance LDAR requirements further, the

latest EPA ELPs include requirements for equipment-leak root-cause surveys,
preventative maintenance tracking systems, implementation of innovative repair
techniques for equipment which cannot be isolated, and replacement of valve
and connector equipment with low-leaking technologies.6,7 Low-leaking
valve technologies are generally defined as equipment that has been designed
to prevent leaks above 100 ppm for a period of five years, as demonstrated by
testing or written manufacturer guarantee. Installing low-leaking equipment is
required unless the technology is commercially unavailable.
Companies subject to these new technology requirements are just now seeing some sticking points. First, what does a manufacturer guarantee really get
you? Usually, valves are upgraded by installing new packing, unless its more
cost-effective to replace the entire valve. With labor costs typically at 90% of
the total re-pack cost, requirements to deliver another $20 packing set, even if a
site can demonstrate that all of the conditions of original installation were met,
arguably does little to discourage companies from offering such a guarantee.
Second, testing results may be used to document that low-leaking technology has been installed, as long as the test has been conducted according to
generally accepted good engineering practices. Test protocols can vary widely,
between 500 mechanical actuations and no thermal cycles, to 5,000 mechanical actuations and 10 thermal cycles.8 Tests can be helium or other inert-gas,
volume-based leak tests, as with ISO 15848A/B or with hydrocarbon, ppm-based
to simulate Method 21 screening values, with ISO 15848-1. After numerous
discussions with various organizations to standardize testing requirements
around a particular protocol, EPA has recently backed away from endorsing any
protocol due to safety and liability concerns.
Third, facilities must demonstrate that a particular technology is commercially unavailable to avoid having to install low-leaking equipment. Determination of availability may be based on numerous factors, including safety,
process suitability, and even process-licensing restrictions.9 However, facilities
must usually demonstrate at least three vendors were contacted and could
not meet the 100-ppm/5-year technology standard to invoke the exemption.
Facilities still wonder, however, how hard EPA expects them to look for a
suitable manufacturer. And what cost premium might this technology impose
when identified?
Good news. Both costs and availability are headed in the right direction.
According to David Reeves, senior specialist for Bolting and Sealing Technology
at Chevron, the company has now identified five valve packings which will meet
the stringent ChevronTexaco testing protocol/standard (up from one just a few
years ago). Additionally, costs for some of these technologies are similar and
sometimes less than costs for similar equipment.10
VALVES 2011
TABLE 2. Leak rate comparison for normal-to-monitor

(NTM) valves vs. difficult-to-monitor13
Facility
3
3
4
4
6
6
7
7
11
11
12
12
Overall
Overall
500 ppm
Leak definition, %
Valves Average Max
Min
DTM
4.06
7.74
0.44
NTM
3.16
5.13
1.02
DTM
0.78
1.22
0.38
NTM
2.10
3.37
1.19
DTM
1.43
2.48
0.69
NTM
2.02
2.36
1.23
DTM
0.29
0.53
0.15
NTM
1.55
1.99
1.14
DTM
2.45
3.61
1.39
NTM
2.04
2.44
1.58
DTM
0.75
1.04
0.47
NTM
0.90
1.02
0.78
DTM
1.63
2.77
0.59
NTM
1.96
2.72
1.16
10,000 ppm
Leak definition, %
Average Max
Min
0.79
2.02
0.00
0.41
0.61
0.14
0.46
0.73
0.11
0.63
1.06
0.33
0.22
0.42
0.00
0.34
0.55
0.21
0.31
0.43
0.23
0.00
0.00
0.00
0.25
0.38
0.07
0.25
0.31
0.16
0.10
0.20
0.00
0.18
0.23
0.13
0.36
0.70
0.07
0.30
0.46
0.16
As EPA continues to impose new ELPs on the last refineries and companies
in the CMI sector, some facilities are looking to retire their agreements with EPA.
While no facilities have been successful to date, many are lined up with documentation demonstrating they are in substantial and material compliance with
the provisions of their consent decree. EPA has not weighed in officially on what
those terms mean, however. Does that mean 51%, 90% or 99.9% compliance?
With over a million LDAR compliance events are done annually at many sites,
there is a big difference in these numbers. Even a 99.9% compliance level could
still mean over 1,000 possible violations.11
Outside the enforcement process that is driving these ELP agreements, EPA
continues to sharpen the pencil on LDAR. Drill and tap repair, once thought to
be an extraordinary repair technique by EPA and industry, has become a quasiregulatory requirement for leaking valves that otherwise cannot be repaired
without shutting down the process unit.12 Refinery or SOCMI process units newly
built, reconstructed or modified after Nov. 7, 2006 must meet ELP-like repairaction thresholds (500 ppm for valves and 2,000 ppm for pumps). SOCMI units
must monitor connectors.
The future. EPA is currently developing additional, universal standards

for LDAR, and is hoping in the process to clarify many long-standing concerns
with various federal LDAR requirements. One of these is optical imaging (OI),
which many had hoped would revolutionize LDAR in the US by improving leakscanning speeds and reducing costly repairs to small leaks. Because the final
EPA rule language allowing OI as an alternate detection methodology is still
coupled to the traditional Method 21 monitoring, much of the cost-effectiveness failed to materialize, resulting in few sites using this alternate method.
However, EPA may now allow facilities to use OI for elevated equipment that
is difficult-to-monitor (DTM) see Table 2. Since scaffolding and man-lift costs
to do DTM monitoring safely (Table 2) can cost millions of dollars per year, use
of OI could result in significant cost-savings, since typically only about 1% of
DTM valves leak annually.13
With changes like these, the future of LDAR in the US is looking brighter.
Most companies will tout how much cleaner their plants are now, despite
grumblings about EPA compliance enforcement. Hopefully, well one day get to
that magic pot of gold at the end of the rainbow, where all are happy, industry
and environment together. HP
LITERATURE CITED
1
EPA Enforcement Alert, October 2009.
FIG. 4. Hydrocarbon optical imaging camera (Photo courtesy of FLIR

Systems, Inc., model GasFindIR GF320).
2
Murphy Oil USA vs. United States, January 2002 and Hovensa Refining
consent decree, January 2011.
3 US EPA Toxic Release Inventory reporting results.
4 Evaluating fugitive emissions compliance database systems to demonstrate
Substantial and Material Compliance as a Means of Terminating USEPA
LDAR Consent Decrees, Charles Bennett and John Gray, Marathon Petroleum
Company LLC, Joe Wilwerding and Shane Kling, SAGE Environmental
Consulting, L.P., NPRA 2010 Environmental Conference.
5 Hazardous Organic National Emission Standards for Hazardous Air Pollutants
6 Hovensa consent decree, January 2011.
7 Ineos-Lanxess consent decree, July 2009.
8 ChevronTexaco Method, Valve World, June 2005.
9 Murphy Oil USA consent decree dated January 2011, Appendix E.
10 David Reeves, Chevron Refining, ISA LDAR Symposium, 2010.
11 Folsom, E., Northern Tier Energy, and J. Wilwerding, SAGE Environmental
Consulting, LP, LDAR, BWON Tanks Conference, 2011.
12 US Federal Register, Vol. 17, No. 215, Nov. 7, 2006.
13 Harris, B., Sage Environmental Consulting, LP, ISA LDAR Symposium, 2010.
Joe Wilwerding, SAGE Environmental Consulting, LP, is a

chemical engineer with over 13 years of continuous regulatory
and industrial environmental experience in the petroleum refining,
oil and gas, and chemical sectors regarding LDAR, greenhouse
gas (GHG), emissions inventory, BWON, MACT and other Clean
Air Act compliance programs. He has written technical papers and presented at
numerous national environmental conferences on LDAR and GHG issues, and has
performed frequent training of government and industry personnel on compliance
implementation in these areas.
Mr. Wilwerding previously functioned as a primary national technical expert for
fugitive emissions and LDAR programs at the US EPA, and was involved with numerous regulatory and policy position documents regarding fugitive emissions, including
the 2006 NSPS Subpart VV revisions, the alternate work practice for leak detection,
EPA internal LDAR enforcement strategy documents, and EPAs LDAR Best Practice
Guide. Mr. Wilwerding worked at the EPA National Enforcement Investigations Center for 11 years, performing CAA audits around the US at large petroleum refining,
petrochemical and manufacturing facilities. He provided litigation and negotiation
technical support on single/multimedia compliance cases, and helped negotiate
national/global consent decrees with petrochemical companies regarding fugitive
emissions best management practices and enhanced LDAR programs.
SAGE Environmental Consulting, LP (www.sageenvironmental.com) is a leading
provider of air pollution consulting services to the refining and petrochemical industries.
I V-83
CORPORATE PROFILE: CURTISS-WRIGHT FLOW CONTROL

VALVES 2011
CWFC offers comprehensive products

and services for the oil and gas industry
Curtiss-Wright Flow Controls (CWFCs) Oil & Gas Systems Division supplies
a diverse portfolio of products and services to the oil and gas industry, including
reactors, fractionating towers, separator, orifice chambers, diverter and butterfly
valves, fully automated coke drum unheading systems, as well as integrated control
systems, engineered valves, safety relief valves, and service and repair, and more. As
demand for global fuel requirements grow, processing capacity must also increase
and CWFCs products provide the oil and gas industry with significant savings while
providing technology solutions that foster plant flexibility, reliability, enhanced
production and compliance with safety and environmental regulations.
The business units and their brands which comprise CWFC Oil & Gas Systems
provide critical technology for severe service processing. Each business unit with
its brand has its own focus and market niche, and when combined with the other
business units offer an extremely diversified range of products and service for the
oil and gas industry.
DeltaValve is the world leader in full automated coke drum unheading solutions.
Their systems are available for the bottom and top of the coke drum, and completely
isolate personnel and equipment from coke drum fallout and other hazards associated with the unheading process. Other innovative products include DeltaValves
drum top blowout diverter/ drill stem guide, auto-switch coke cutting tool, and a
complete line of isolation valves designed specifically for the dirty service associated
with the delayed coker.
TapcoEnpro International (TEI) provides products and services to improve the
safety, reliability and efficiency of your Fluidized Catalytic Cracking Unit (FCCU).
With 14 active patents and the largest installed base of single source FCCU valves
and actuators worldwide, TapcoEnpro technology and innovation provides a complete package of state of the art, critical service, high temperature valves; fast acting
hydraulic actuators; digitally controlled hydraulic power units; heavy wall reactors
and pressure vessels and other FCCU components..
Total Automation Solutions (TAS) is a turnkey supplier and manufacturer of
integrated automation and controls technology, products and services. TAS integrates quality OEM automation and control products with the optimum team of
automation and control engineering resources to supply custom manufacturing,
automation management and maintenance services, automation systems design,
and PLC Programming Services
Valve Systems and Controls (VSC) can manage the entire front end of your project, from conceptual thinking to product specifications, from budgets to timelines,
and can supply any or all of the products and services required. VSC can also provide
highly skilled service technicians for repair, retrofitting, preventive maintenance and
training on valve systems anywhere in the world, regardless of manufacturers or
systems integrators.
GroQuip has, since 1972, been safely delivering quality as a supplier of engineering information, products Safety Relief Devices, and services to customers with
pressure processes. Their customers have strict regulatory compliance mandates
(OSHA-PSM; EPA-RMP; BOEMRE; etc.). Largely, the customers are in Chemical
Processing Industry (CPI); Hydrocarbon Processing Industry (HPI); Upstream Exploration and Production; Midstream Gas Processing, Fractionating, Pipelining; and
Downstream Refining.
Farris Engineering has been a leader in the design and manufacture of a wide
range of spring-loaded and pilot-operated pressure relief valves for more than 60
years. Used as safety devices, they prevent over pressurization of vessels, pipelines,
and processing equipment. Farris Engineering is a recognized leader in the hydrocarbon processing, refinery, petrochemical, gas production and processing markets.
Farris Engineering Services provides patented, web-based iPRSM software, a

powerful engineering calculation and documentation repository tool, assists processing plants in meeting the pressure related requirements for PSM compliance.
Together with iPRSM, our Farris Engineering Services team provides comprehensive
pressure system design and audit services, providing processing facilities with a safe
and hazard-free work environment.
Sprague Products includes air driven hydraulic pumps, gas boosters, and power
units supported with a complete line of valves and pump accessories. The Sprague
S-216 and PowerStar line of pumps offer various liquid pressures up to 33,500 psi
(2311 bar). Spragues pneumatic gas boosters are a cost effective way to compress
air/gas to meet high pressure requirements. The pneumatic gas amplifier design
offers greater efficiency as well as being modular for increased versatility.
Solent & Pratt is based in Bridport, Dorset, United Kingdom, and is a world
leader in the manufacture of high performance triple offset butterfly valves for
severe service applications. These valves are used within the petroleum, petrochemical, chemical and process industries.
Contact information
16315 Market Street
Channelview, Texas 77530
Website: www.cwfc.com
I V-85
CORPORATE PROFILE: MAXON

VALVES 2011
Extend process uptime

without sacrificing safety
Comparison of Probability of Failure on Demand (PFD)
Maxon Series 8000 Safety Shut-off Valves

and PSTrend partial stroke testing technology
Rugged is much more than a buzzword. The Series

8000s claim of ruggedness is field-proven and comes from design and construction features which put Series 8000 in front of run-of-the-mill shut-off valves. Chief
among them is the unique metal-to-metal seating that actually wears IN,
not out, with each cycle. Equipped with strong springs to assure ultra-fast closing.
A wide choice of special materials for body and trim provide excellent application
flexibility. Series 8000 even meets tough Class VI leakage standards normally
reserved for soft-seated valves. No wonder Maxon valves enjoy a stellar reputation
for safety, reliability, and long service life!
PFD:
0.05
Probability of Failure on Demand (PFD)
Maxons Series 8000 safety shut-off valvesglobally-recognized for their rugged design and longevityare heightened with new features designed to keep
them your first choice for safety, reliability, and maximized system up-time.
for Valves With and Without Partial Stroke Testing (PST)
without
0.045
PST
0.04
Degraded
SIL 1
Performance
Range
0.035
0.03
0.025
PFD: with
PST
0.02
0.015
0.01
SIL 2
Performance
Range
0.005
0
0
10
12
Years of Operation
When youre hot, youre hot.when youre cold,

youre not. Series 8000 valves are made for reliable performance in extreme
conditionssearing heat and bitter coldproviding sure closing at temps to
50C (58F). They also meet API 6FA standards where valves must maintain
leakage requirements when exposed to flame temperatures of up to 760980C
for thirty minutes.
If theres any doubt remaining, consider Series 8000s global endorsements
which include FM, CSA, EN, ATEX, Hazardous Locations, Fire Safe, and carries safety
assessment to IEC 691508, making them SIL-3 capable.
You can see clearly now. The redesigned visual indicator (open/
closed) is larger and announces valve position in high-contrast, bright colors, with
a dramatically increased viewing angle. An added bonus: the new visual indicator
can be easily retrofitted to any existing Series 8000 valve.
How about adding some smarts? Todays motorists benefit
from their autos advanced diagnostics, warning systems and 100,000-mile tuneup
intervals, but furnace, fired-heater and boiler operators, for example, often operate
unaware. They want and need knowledge of their equipments condition, and they
desire longer periods of uninterrupted safe operation.
Lets be honest: even the highest-quality valves are subject to stressors which
increase the probability of failure on demand and negatively affect SIL (safety
integrity level) over long periods of service.
PSTrend, a PLC-based system, is designed in such a way that it partially strokes
the valve diskwithout interrupting burner management system functions.
The patent-pending PSTrend functional logic then trends results from periodic
testing, looking for indications of degrading valve performance, allowing operating
personnel to plan ahead for service or replacement of faulty valves.1
But wont frequent testing cause premature wear?
Maxon Series 8000 utilizing metal-to-metal seats (that wear in, not out, with use)
can actually benefit from frequent testing. This self-cleaning feature makes corrective action possible for a degrading valve by simply increasing the test frequency,
fully leveraging 8000s wear in, not out characteristics.
This graph suggests that maintenance would be required within 2 years

for an untested valve versus 6 years for one with monthly PST testing.
Maxonyour
complete system
solution provider.
S e r i e s 8 0 0 0 va l v e a n d
PSTrends unique benefits
are fully leveraged when
theyre an integral part of a
Maxon-designed combustion
system which can include fuelefficient SMARTLINK digital
ratio controls and the latest in burner technology. This combination will make a
positive impact on your companys bottom line by allowing you to run safer and
more efficiently over longer periods of time.
1 As
a matter of good practice, all safety instrumented functions should be analyzed

by a functional safety expert for your specific application.
Contact information
Sales and manufacturing facilities located worldwide including
Muncie, Indiana USA, Brussels, Belgium, Shanghai, China
Email or consult website for your nearest location
Email: info@maxoncorp.com
Website: www.maxoncorp.com
I V-87
Need to Blind?
Use an Onis Blind

Onis Line Blinds replace spectable blinds,
slip blinds, and gure-8 blinds.
100% Positive Isolation.
Line Blinds
Safe.
Fast.
Reliable.
One Person, Zero Tools,

Blinded in Minutes.
www.onislineblind.com
888-664-7872
CORPORATE PROFILE: ONIS

VALVES 2011
Onis Line Blinds are not valves;

they are blinds... Safe. Fast. Reliable.
Onis Line Blinds replace spectacle blinds, slip blinds, and figure-8 blinds with
an inline blind that can be operated by one person, in a few minutes without using
any tools. Onis Line Blinds reduce maintenance costs, increase production time,
improve safety by reducing exposure, and minimize emissions during blinding.
Onis Blinds provide 100% POSITIVE ISOLATION by an operator in minutes. Onis
has been in operation for over 32 years, and the manufacturing facility (Lambesc,
France) is ISO 9001-2008 certified. Each Onis Blind is custom built to the specific
data for each application.
How Onis Blinds Work. For all Onis Line Blinds, the pipe separation is
performed the exact same as spreading pipes preparing to swing a figure-8. With
an Onis Blind, the effort by the operator is minimal, to move a great deal of weight
(any pipe) a very small distance to move the slide.
The pipe must be depressurized, as the Onis Blind is not a valve. A lever (or a
gearbox, depending on size/pressure/ temperature) is turned, and the forged Onis
bodies are separated and the pipe is spread. The slide is moved on rollers from
the full-bore to blinded position. The lever (or gearbox) is closed to recompress
the bodies.
Onis Vannobturator 6 150# Hydrogen service (Double-Blockand-Bleed with a Blind)
Advantages of Onis Blinds:
Onis Specifics. Onis Blinds physically spread the pipe. There are only 4
Increase production time

Reduce plant maintenance costs
Operators can blind lines anytime
Improve safety by reducing exposure time
Reduce emissions during blinding
Gaskets can be changed outside of process
Zero tools or cranes needed to blind
Can be automated (operated from control room)
Product Range:
Sizes: to 50
150# to 2500# Flanges
Pressure: Vacuum to 6100 psig
Temperature: 152F to 1,400F
Onis FCCU Blinds, Onis Quick Filter, and Twin Onis Blinds
Onis Blinds are custom built to customers requirements: ASME Section VIII
Div-1, B 16.5, B16.48, B31.3, NACE, API-607
gaskets on the slide and zero internal (backseat) gaskets or moving parts that are
hard to change in the field. The advantage of this feature is that all gaskets can be
inspected, and changed if needed, without opening the line. For example, a few
days before operators need to blind a line, anyone can easily inspect the gaskets,
and if they need replacing, the gaskets can be removed and replaced while the
production line is still in operation. For Dangerous mediums there is no need to
use additional PPE while replacing gaskets. When the line is blinded, the full-bore
gaskets are accessible and available to easily change and provide a new seat when
the line is returned to service.
All Onis moving parts are outside of the process, and there is no reduction of
flow from the pipe and no place for product build-up. Additionally, all Onis Blinds
have slide covers, grease fittings (to ensure bushing longevity), and lock-out/ tagout latches. The bodies of Onis blinds are made from solid forgings and are not
welded flanges. Onis blinds can be built for hydrotesting additional when specified
by the customer.
Onis offers manufacturers one year warranty (additional upon request). Installation support and on-site training for operators and maintenance personnel are
available. Thank you for considering Onis Line Blinds.
Where Onis Blinds are used. Onis Blinds are currently used in
refineries, chemical plants, pipelines, and compression stations. The Onis Blind can
be used in any service (i.e. H2S, Nitrogen, Decoke/Feed lines, diesel, natural gas,
benzine, chlorine, HCN, and more). Onis Blinds can be used to isolate reactors, heaters, pumps, and furnaces. Onis Blinds are used in offshore applications and their
minimal operation time offer-many advantages. Onis Blinds are ideal for blinding
critical processes quickly for emergencies or approaching hurricanes.
Who uses Onis Blinds. Onis Blinds are currently used by ExxonMobil,
Shell, BP, ConocoPhillips, Petrobras, Pemex, General Electric, DuPont, LyondellBasell,
Certianteed, Dow, Total, Chevron, Honeywell, PetroChina, and BASF (and many
more). Onis Blinds are ideal for any company that must blind frequently or needs to
minimize exposure to improve safety.
Line Blinds
Contact information
Onis Inc., One Riverway, Suite 1700
Houston, Texas, 77056
Phone: 713-840-6377/888-664-7872
Fax: 832-201-7767
Email: sales@onislineblind.com
Website: www.onislineblind.com
I V-89
Get the Information You Need to Compete in 2011

Order the Full Version of tthe HPI Market Data 2011
The HPIs most comprehens

comprehensive and trusted forecast of capital,
maintenance and operating expenditures for the local and
global HPI, the HPI Market Data 2011 includes over 75 pages
of expanded coverage and detailed analysis for:
HPI Economics
Equ
Maintenance and Equipment
Natural Gas/LNG
Petrochemicals
Refining
En
Health, Safety and Environment
f
Includes a BONUS CD featuring:
More than 10 years of trends on global construction
activity and spending from previous forecasts.
Box
HPI Construction Boxscore
Updates 2009 and 2010.
Hydro
20 articles from Hydrocarbon
Processing picked by the
ke trends and issues.
editors to highlight key
ORDER YOUR COPY TODAY and make

strategic decisions in 2011 and beyond!
Online: www.GulfPub.com/2011hpi
Call: +1 (713) 520-4426
ARE YOU TAKING FULL ADVANTAGE OF HYDROCARBON PROCESSING?
Subscriber Only Benefits
Discover all the benefits of being

a premium subscriber and gain full access
to HydrocarbonProcessing.com
Twelve monthly issues in print or

digital format and premium access to
HydrocarbonProcessing.com, including:
All the latest issues and Process
Handbooks
HPs extensive archive containing
8 years of back issues
A subject/author index of print articles
with links to articles available online
Monthly e-newsletters providing
an early preview of upcoming special
editorial features and exclusive content.
Published since 1922, Hydrocarbon Processing
provides operational and technical
information to improve plant reliability,
profitability, safety and end-product quality.
The editors of Hydrocarbon Processing
bring you first-hand knowledge on
the latest advances in technologies
and technical articles to help you do
your job more effectively.
SUBSCRIBE TODAY!
Log on to www.HydrocarbonProcessing.com
or call +1 (713) 520-4440.
Subscribe online at www.HydrocarbonProcessing.com or call +1 (713) 520-4440
As a Hydrocarbon Processing premium

subscriber, you will receive full access to
WorldOil.com as well as World Oil magazine
in your choice of print or digital format.
Start your subscription today.
CORPORATE PROFILE: TRIMTECK

VALVES 2011
Process control solutions

to optimize plant performance
Trimteck has over thirty years of experience engineering, manufacturing, and
marketing high quality, cost-effective flow control solutions and equipment for
critical processes, and our products are currently helping customers improve quality, optimize throughput, and reduce emissions and energy costs across an array
of industries in more than 42 countries. Our application engineers and global
certified representatives are committed to personalized customer service and have
an extensive line of products and technologies to draw upon when designing and
specifying a solution. Moreover, our organizational focus on implementing highly
efficient engineering, sourcing, manufacturing, and distribution processes enables
Trimteck to guarantee world-class quality, competitive pricing, and rapid delivery
to anywhere in the world.
In our view, top-guided, piston-cylinder actuated linear control valves have
demonstrated their superiority over typical cage-guided, diaphragm actuated
models. This is due to, among others, the comprehensive and precise fluid control
that can be achieved, as well as the ease and simplicity with which they can be
serviced in-line. Our mission has been to make such solutions more affordable
with the aim of reducing lifecycle costs. With that, we offer a comprehensive line
of Optimux control valvesand an array of actuators, positioners, severe service
trims, and other accessoriesthat our application engineers and representatives
use to solve even the most complex flow control problems quickly and economically.
Our Products:
Control Valves
OpGL Globe Control Valve
OpDX Butterfly Control Valve
OpVEE V-Notch Control Valve
OpEXL Eccentric Plug Valve
OpTE Triple Eccentric Butterfly Valve
OpTB Trunnion Ball Control Valve
Actuators
OpTK Piston Cylinder Actuator
OpRPA Rack & Pinion Actuator
Positioners
HPP4500 Smart Positioner
HPP4000 Explosion Proof Positioner
HPP2500 Alphateck Pneumatic Positioner
Contact information
12461 NW 44th Street
Coral Springs, FL 33065
Phone: +1-954-753-5545
Fax: +1-954-753-5561
Email: info@trimteck.com
Web: www.trimteck.com
I V-91
CORPORATE PROFILE: VYC INDUSTRIAL

VALVES 2011
VYC Industrial, s.a., simple perfection

Without wishing to be conceited, but with a natural satisfaction, we can safely
say that the future of VYC industrial, s.a. is assured, both at home and in the highly
competitive international market, thanks to our firm will to progress and the exceptional people who make up our company.
What counts the most today is to have and to generate trust and confidence
between our customers and ourselves. This trust and confidence is born and maintained because we create attractive products, offer competitive prices and provide
the necessary information and services.
For all these reasons, the VYC mark, for our customers, is a symbol of full assurance on products of high prestige, acknowledged for their SIMPLE PERFECTION.
Since 1914, VYC has been designing and manufacturing valves for the regulation and control of all types of fluids, specially steam. Never standing still, we are
committed to ongoing research and innovation.
The materials used to manufacture our products are strictly inspected and
controlled. This, together with our advanced manufacturing system, permits us to
comfortably meet the increasingly high demands of our customers.
Other controls and inspections are performed by such classification societies
as Lloyds Register of Shipping, American Bureau, Bureau Veritas, Germanischer
Lloyd, E.C.A. and others.
Contact information
Avenc del Dav, 22 Pol. Ind. Can Petit
08227 TERRASSA (Barcelona) SPAIN
Phone: +34 93 735 76 90
Fax : +34 93 735 81 35
info@vycindustrial.com
www.vycindustrial.com
V-92
VALVES 2011 HydrocarbonProcessing.com
na
hi
Qua
l
Re
ub
on
isi
Superv
ity
li c of C
Processing Solutions
that Fit
Conference Partner:
$O&K(
November 1-3, 2011
Media Partner:
Javits Convention Center New York City
See It in Action
in the Exhibit Hall:
Learn About It
in the Classroom:
Over 250 Exhibitorsand counting

Process Control & Automation Center
Presentations in the New Product
Technology Theater
The AIChE Northeast Regional

Conference at the CHEM SHOW
Special Track: Nanotechnology
Workshops and Conference
Dont Miss the #1 Process Equipment & Technology Event

FREE Advance Registration: www.chemshow.com
Endorsed by:
Produced and managed by:
George R. Brown Convention Center . Houston, Texas
Unparalleled Opportunities
In-depth Short Courses

Solution-based Case Studies
Innovative Discussion groups
Hands-on Tutorials
Pioneering Lectures
Outstanding Exhibit Floor
CEU Credits Available
Meet your PE Requirements with the

NEW! Engineering Ethics Tutorial and Earn CEUs!
Co-located with:
Exhibits Open Free to the Public
Tuesday & Wednesday

2:30 P.M. - 7:00 P.M.
Thursday
9:30 A.M. - 12:00 P.M.
For more information or to join our mail list, email or call now 979.845.7417 inquiry@turbo-lab.edu
Sponsored by:
The Turbomachinery Laboratory Texas A&M University
3254 TAMU College Station, TX 77843-3254
P: 979.845.7417 F: 979.845.1835
inquiry@turbo-lab.edu http://turbolab.tamu.edu
SPECIALREPORT
Use advanced process control

to add value for your facility
Optimization programs deliver benefits to existing and new plants
R. DI NELLO, Honeywell Process Solutions, Phoenix, Arizona
dvanced process control (APC) has been an evolving

field of study since the 1950s. The hardware platforms
and algorithmic software that form the foundation of
this field have changed throughout the years. But the goal of
APC has remained the same: to improve the economic and
operating performance of a process unit. APC has become
increasingly important in improving the competitive position
of a processing unit, a plant and even a company within a
crowded marketplace.
documents provide some additional insight into the cost and

effort involved in these early advanced control projects.2
Table 1 lists information on two early advanced control projects,
including pricing at the time of implementation, as well as what
the cost would be today. As shown, the hardware infrastructure cost
comprised nearly 6% to 7% of the total project cost. Unfortunately,
records dont reveal the total labor costs, but the 15-month project
duration provides an idea of the total effort involved.
Benefit analysis. The typical APC project begins with a ben-
Origin of APC. To understand where APC is today and how
to optimize APC for maximum value, one should first examine

where it began. The first reported implementation of advanced
control using a digital computer in the process industries took
place in 1959 at Texacos Port Arthur, Texas refinery.1 The unit
involved was a small catalytic polymerization unit using a solid
phosphoric acid catalyst to convert olefins, such as propylene, to
trimers and tetramers. The product is typically used as a gasoline
blending component.
The reported benefits included improved propylene conversion from 83% to 92% with a catalyst savings of $75,000/yr.
The project implementation costs were not as well documented,
but hardware infrastructure costs were reported to be approximately $300,000. The hardware included not only the RW-300
computerthe first digital computer for automatic process
unitsbut also transducers and wires, among other elements,
to interface with pneumatic instrumentation. Surviving proposal
efits analysis. These studies provide the economic basis for determining whether it is justifiable to proceed with a project. They
also provide a baseline against which the actual APC performance
can be judged. A study may be done by internal staff at a plant,
or by an outside consultant. This will usually depend on internal
staff availability and knowledge of APC technology. In some cases,
APC vendors can provide these studies as part of the proposal
offering. In any case, the studies should address these points:
Study scope of work
Procedure
Benefit estimation methods
Process description
Economic basis
Benefit calculations
Instrumentation requirements
Computing requirements
Proposed APC scope of work.
TABLE 1. Advanced process control historical costs

Year
Unit
Scope
Price
Price, 2009
1959
H2SO4 alkylation
(dual train)
RW-300 computer hardware including necessary transducers to interface with instrumentation

Control programming and analysis including reactor and distillation sections (DeC3, DeIC4, DeC4)
Total cost
$215,099
$88,200
$303,299
$1,565,506
$641,926
$2,207,432
1964
FCCU
340 computer hardware including AI inputs, analog filters, input/output equipment, pneumatic set point
stations for activation of pneumatic controllers. Installation and introductory and system programming
courses also included.
Control programming and analysis including reactor/regenerator section and main fractionator to:
1. Determine coke burning rates, air rates, catalyst circulation rate, heater duty rate, yields, main
fractionator loading
2. Determine constraining condition on unit
3. Determine optimum operating conditions of unit
4. Implement dynamic regulation program to hold unit at optimum operating point
Instrumentation and wiring costs
Total cost
$259,770
$1,777,662
$97,880
$669,814
$38,600
$396,250
$264,148
$2,711,624
I 95
SPECIALREPORT
Scope of work. The study scope of work should identify the

processes that are included in the study. If some processes or areas
were dropped, reasons should be provided. Additionally, the goals
of the study should be clearly outlined.
Study procedure. The study procedure should describe the
process for doing the work. It would include a description of the
data collected and why it was chosen. The report should reveal
how any anomalies in the study data, such as process upsets and
instrument failure, were handled.
Benefit estimation methods. A detailed description of benefit
estimation methods should also be provided. It should include
benefit sources, such as production increases (throughput and/or
yield), product recovery, transition improvements and energy savings. The calculation methods must be clearly outlined, and there
are a number of methods that can be applied. The more common
ones include best operator, statistical and simulation. Each
estimation method has strengths and weaknesses. Overall, reasons
should be provided for applying any particular method.
FIG. 1
Set of tuning solutions at different closed-loop settings.
Process description. As part of the study, process description

should be included. The description should be brief, but detailed
enough to allow a reviewer to determine if the writer has sufficient
understanding of the process to provide a correct analysis.
Economic basis. A detailed economic basis should be provided. The basis can take a number of forms, depending on the
process involved and amount of available information. For example, if the unit under study produces a directly saleable product,
such as ammonia, from a purchased feedstock like natural gas,
then it is relatively simple to determine the cost and value of
those streams.
Conversely, if the unit is in the middle of the processing train,
determining the monetary values of intermediate products is
more complex. It usually requires developing intermediate pricing
from a planning model of the entire facility. This is the case for
oil refineries or many petrochemical facilities. In a few instances,
the actual economic data is so sensitive that it may not be provided. When this occurs, relative values are assigned to the various
streams so that any process optimization is directionally correct, but benefits are provided in physical units only. Finally, any
assumptions about plant onstream factors and APC availability
factors should be documented.
Benefit calculations. The actual benefit calculations should be
provided in detail when possible. Any assumptions, engineering
units and other factors should be included so that calculations
can be easily reproduced or modified. If simulations are used to
develop benefits, the model details should be described in sufficient detail so that model validity can be assessed.
Instrumentation. Any deficiencies in instrumentation should
be identified, and recommendations should be made for corrections before the APC work begins. Typical areas explored include:
Saturated valves
Controllers in manual mode
Poor tuning performance
Missing measurements.
Computing requirements. This requirement is necessary to
host the APC and should be identified. Both hardware and software needs should be identified.
Proposed APC scope of work. Finally, the proposed APC
scope of work should be provided so that a comparison can be
made to determine if the proposed APC is designed to capture
the identified benefits. Additionally, an initial modeling pass
should be made for any proposed inferential calculations. This
will help validate that an inferential calculation is possible with
the available data. It is an especially important point if the majority of the identified benefits rely on this particular measurement.
If the initial modeling pass is questionable and the benefits rely
heavily on this measurement, an online analyzer may be necessary
to fully capture the identified benefits. The cost of any online
analyzer is significant and must be included in the total project
cost. A project schedule and table of responsibilities should be
prepared, as well.
Next step. Once the APC study is completed, the next step
FIG. 2
96
View of the set point and load change response curves at

the 10 tuning solutions.
is to schedule and complete any identified corrections in the

base-level instrumentation. Aside from new instrumentation,
much, if not all, of this work should be done, whether or not
the APC project moves ahead. Correcting saturating valves,
bad measurements, poor tuning, improper distributed control
system (DCS) configuration, incorrect DSC scaling, out-ofdate or incorrect operator schematics, poorly designed control
strategies and other odd behaviors is part of continuing control
system maintenance.
Control-loop performance. At present, it is considered best
practice to have in place a program to periodically assess control-loop performance, and to prioritize and perform identified
maintenance. Automated tools can help monitor control-loop
performance and identify poorly performing or interactive loops.
Additionally, tuning tools with advanced control techniques
can help provide proportionalintegralderivative (PID) tuning
parameters. Some tools provide a range of tuning performance so
that the user can compare different closed-loop speeds of response
and select the appropriate settings for the application. These tools
go beyond simple hand tuning and can provide:
Rapid consistent tuning
Historical record of tuning
Multiple tuning scenarios from a single tuning session
Evidence of poor measurement or final element behavior
Tuning in either open or closed loop or a hybrid form starting in open loop and moving to closed loop as tuning parameters
become available.
Figs. 1 and 2 show the results from a tuning tool.4 Fig. 1 provides a set of 10 tuning solutions at different closed-loop settling
times. Fig. 2 provides a view of setpoint and load change response
curves for any of the 10 tuning solutions. Users can select a tuning solution for the desired control performance, and multiple
sets can be selected for use with advanced PID algorithms. This
allows faster speed of response when the error is outside a userdefined band, as well as a slower speed when the error is inside the
band. Level surge control is a typical application. Fig. 3 shows the
results of a tuning session for a crude pre-flash column bottoms
level. Incoming crude is manipulated to maintain the column
bottom level.
Another advanced control technology innovation is the availability of model-based control at the DCS level. Single-input,
single-output (SISO) model-based control is now available as
a control algorithm selection instead of PID.5 Not every loop
requires a model-based control algorithm, but some loops can
benefit. Specifically, this includes loops where control performance would be improved if the operator were allowed to enter
a range instead of a set point for control regulation. Some level
loops and analyzer loops also fall into this category.
SPECIALREPORT
Full model nonlinear multiple input multiple output6

Full model linear multiple input multiple output7
Reduced model linear multiple input multiple output8
Nonlinear models. The full model nonlinear multiple input
multiple output (MIMO) controller uses both very general
nonlinear-state space models and dynamic first principles-based
models to provide both control and optimization. The models are
complex and require a good understanding of process dynamics,
kinetics and thermodynamics. Because of the complexity and cost,
this control technology is selected for processes such as polyethylene, polypropylene and other polymer processes, which experience
grade transitions and other disturbances that are highly nonlinear.
EU High
100.00
100.00
100.00
37820.0
RAXIS
Crude ow before tuning
48 HOUR RT HM RT HM
Crude ow after tuning
Eng.
units
EU High
0.00
0.00
0.00
0.00
FIG. 3
% High
100.0
Percent
scale
Level loop
Level loop under test
Level loop stabilized in
Level loop
before tuning
manual
after tuning
% Low
0.0
Tuning session for a crude pre-flash column bottoms level

controller.
Consider a surge-level loop. Using a SISO model-based

algorithm, an operator is able to directly enter an allowable range
for the level instead of a set point. The optimal scenario involves
the level slowly moving to a desired value, and an operator can
accomplish this by using the algorithms optimization feature. For
example, an operator can enter a range of 40% to 75%, along with
a targeted value of 60% for the optimizer to slowly move toward.
Analyzer control is another class of loops that can benefit from
SISO model-based control. The complex dynamics, as well as the
typical minimum or maximum limits instead of setpoints, make
this advanced algorithm a preferable choice over PID. Again, the
optimizer can slowly drive the process to a minimum, maximum
or target value. Distillation columns producing commercial-grade
propane or butane may benefit from this control algorithm, as can
air demand control for sulfur recovery units.
Once the base-level instrumentation deficiencies are addressed,
the APC project can begin. The typical APC project uses some
type of multivariable controller. While there are a number of
algorithms available,3 they can be divided into three categories:
97
SPECIALREPORT
Linear models. The full-model linear MIMO controller is
applied to highly interactive industrial processes or processes with

significant dead-time and complex dynamics. These processes
are fairly linear over the normal operating window. The models
using this technology are linear empirical models of various
forms developed by step-testing the process. The step-testing
method can be single-variable open loop to multivariable closed
loop. This control technology is selected for most refining and
petrochemical processes. The controller provides both control
and optimization. Model gains can be updated online, providing
some nonlinear capability.
Other methods. The reduced-model linear MIMO controller is designed for remote processing facilities and facilities where
multivariable control has not been considered due to limitations on plant testing, lack of skilled internal resources and vastly
changing regulatory dynamics. Step testing is not required. Only
an estimate of the steady-state gain between independent and
dependent variables is needed. The controller provides both control and optimization. This control technology is based on the
processes under consideration (linear or nonlinear), degree of
control required (complete dynamic model or step testing not
allowed), available plant support or preference, and cost.
Detailed design. With the control technology selected, the
next step is finalizing the detailed design of the controller. The

starting point is typically the design provided in the benefits study
document or the proposal. The full-model linear MIMO controller is the most commonly selected technology. This design is
updated during detailed discussions with operations, process engineering and control staff. Identifying the independent variables
and the optimizers objective function are critical. Any omissions
can result in increased project costs and schedule delays. Adding
dependent variables usually have less of an impact on project cost
and schedule.
In many cases, inferential measurements and supporting calculations are needed. These calculations are typically developed
using statistical tools.10 These tools should allow the development
of linear, nonlinear, dynamic and user-defined models. Linear
models are the most commonly used, however, when the form of
the equation is known from engineering principles. In this case, a
user-defined model is appropriate. These calculations are usually
done before controller model development. Most of these calculations are important to the overall success of the APC project, and
they need to be carefully developed and evaluated.
If step testing is required for model development, current testing and identification tools should be used to lower the required
effort and effect on the process. The best tools9 provide full automated testing. This allows the user to design the test in either
open or closed loop, or a mix of both. Independent variables can
be moved sequentially or in a multivariate approach. The tool
performs MV movement, data collection and online identification
with rankings that allow the user to assess model quality as the
testing progresses. If needed, the user may adjust testing parameters to improve quality. The goal is to produce as close to a final
model matrix as possible at the end of step testing.
Online efforts. Once the model matrix is finalized, the con-
troller is ready to be placed online. The commissioning procedure usually involves activating one independent variable at a
time. The associated dependent variables are observed to ensure
that they remain within limits. MV limits should be widened
98
as appropriate. Various dependent variables should be placed in

conflict with other dependant variables to confirm that the desired
control give-ups are observed. The dependent variable unbiased
predictions should be observed over time to verify prediction quality. Independent variable trends should be observed to identify
and correct any oscillatory behavior. Operations staff should be
directly involved so that a detailed understanding of the controller
is developed.
Once the initial commissioning is completed and the operators
are comfortable with the controller, the plant support staff should
continue to monitor performance using key performance indicators. Operating conditions change over time, and the controller
may require additional adjustments as conditions vary. This is very
important for the long-term success of all APC projects. Plants
that provide support staff and place an emphasis on controller
performance using monitoring tools see a higher long-term success rate for their APC projects.11, 12
The development of APC has provided technology that is
used at a number of levels within the plant control area hierarchy.
From loop tuning to optimization, APC-inspired technology is
providing benefits to the process industries. Plants can select and
deploy the appropriate technologies to achieve the desired results
for their sites. Design and commissioning methodologies have
been streamlined for quality and cost effectiveness.
The nominal price of a turnkey APC project on a typical
refining process unit is $250,000 to $500,000, which is substantially less than prices seen in earlier projects. Implementation
schedules have been reduced from 15 months to an average of
four to six months. The availability of online APC applications
is 95% to 98%. The hardware infrastructure is typically a servergrade computer using OPC to communicate to the digital-control system, and it usually contributes approximately 5% to 10%
to the overall price of a project today. The return on investment
of a project is typically realized in less than 12 months. Overall,
APC provides more value today for the process industries than
it has in the past, and future innovations in technology, project
methodology and support will continue to enhance the delivered
value of APC. HP
LITERATURE CITED
Stout. T., A view from the Past, National Petrochemical & Refiners
Association, CC-98-149, 1998.
2 Personal copies (1959) (1964).
3 Qin, S. J., and T. A. Badgwell, A Survey of Industrial Model Predictive
Control Technology, Control Engineering Practice, Vol. 11, 2003, pp. 733
764.
4 Honeywell, Scout Suite OperTune, OPR-R310-003, December 2009.
5 Honeywell, Profit Loop Users Guide, November 2008.
6 Honeywell Profit NLC.
7 Honeywell, Profit Controller Designers Guide, RM11-410 R320, November
2008
8 Honeywell, Profit Controller Express, PN-09-25-ENG, June 2010.
9 Honeywell, Profit Stepper Users Guide, AP09-910; R320, November 2008.
10 Honeywell, Profit Sensor Pro Users Guide, PS11-100; R320, November
2008.
11 Honeywell, Profit Expert Users Guide, AP09-900, R320, November 2008.
12 Umakant, J., Syncrude Model for Sustaining APC Benefits, Honeywell
Strategic Users Forum, June 2010.
1
Ron Di Nello is a consultant with Honeywell Process Solutions. He has more than
35 years of refining, petrochemical and chemical industry experience. His current
focus is advanced process control applications including conceptual studies, cost/
benefit analysis, functional designs, master plans and regulatory, advanced, and
predictive control, including dynamic and steady state optimization. Mr. Di Nello
holds a BS degree in chemical engineering from the University of New Mexico and is
a registered professional engineer in Texas.
AD: www.graficadueprint.com
2010 Costacurta S.p.A.-VICO
SINCE 1921...
AND WE
STILL LOVE IT
For more than eighty years, we at Costacurta have been
constantly and resolutely committed to the development
and manufacture of special steel wire and plate
components used in many different industrial processes.
Every day at Costacurta, we work to improve the quality
of our products and services and the safety of all our
collaborators, paying ever-greater attention to the
protection of the environment.
Within the wide range of Costacurta products you will
also find some, described below, that are used specifically
in the oil, petrochemical and chemical industries:
- RADIAL FLOW AND DOWN FLOW REACTOR INTERNALS;
- GAS-LIQUID AND LIQUID-LIQUID SEPARATORS;
- ARMOURING OF REFRACTORY, ANTI-ABRASIVE AND
ANTI-CORROSIVE LININGS.
For more information visit our website or contact the
division 'C' components for the oil, petrochemical
and chemical industries at tcrc@costacurta.it.
Costacurta S.p.A.-VICO
via Grazioli, 30
20161 Milano, Italy
tel. +39 02.66.20.20.66
fax: +39 02.66.20.20.99
Radial Flow and Down Flow reactor internals
Management systems
certified by LRQA:
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
www.costacurta.it
GIVE YOUR ORGANIZATION THE TOOLS TO ACHIEVE

GREATNESS IN THE OIL & GAS INDUSTRY
Gulf Publishing Company Site License Programs

WorldOil.com | WorldOil.com/RigStar | HydrocarbonProcessing.com | ConstructionBoxscore.com
Lee Nichols: Phone: +1 (713) 525-4626, Fax: +1 (713) 525-4631, E-mail: Lee.Nichols@GulfPub.com
SPECIALREPORT
Optimize design for distillation feed

Use these steps for enhanced performance
S. H. LEE and M. J. BINKLEY, GTC Technology US LLC, Irving, Texas
hen designing distillation columns, engineers focus

on selecting the required number of trays or packing
height and column diameter to achieve target performance. As a result, distillation column feed condition is often
overlooked. Improper feed design can hinder performance and
influences unit economics.
This article will illustrate useful distillation column feed design
optimization methodologies. A case study is demonstrated in
detail and highlights how optimum feed design enhances distillation column performance.
Technical considerations for feed location. Selecting
optimum feed location is critical to maximizing distillation column performance. Improper feed location of a distillation column
can downgrade column performance; the degree of separation is
decreased at the same reflux/boil up ratio or the higher reflux/
boil-up ratio is required to maintain the degree of separation.
An ideal feed location is feeding to a section of the distillation
column where column internal liquid traffic composition is similar to feed stream composition. In this case, it can minimize the
composition gradient between feed stream and distillation internal
fluids. In distillation column operations, it is often seen that feed
compositions are changed from original design conditions. In the
case of significant deviation, discrepancy between column internal
liquid composition and feed stream composition can increase, and
results in non-optimum feed location. Therefore, evaluating the
feed location is an essential step for a successful distillation unit
revamp or optimization.
However, it is very difficult to sample and analyze the column
internal liquid traffic composition in most of the distillation
columns that are commercially operated. Instead, process simulation modeling has been widely utilized to predict internal liquid
composition and determine the optimum feed location in the
actual industry design. As feed optimization through simulation
modeling is convenient and does not require additional costs
for field measurements and laboratory analysis, it seems to be a
very convenient procedure on the surface. Nevertheless, reputable simulation software itself does not promise the reliability of
simulation modeling. Inherent gaps between actual conditions
and theoretical simulation modeling should not be ignored.1 The
appropriate simulation flow sheeting methodology is necessary
to bridge between actual conditions and the simulation model.
It is common for improper simulation modeling to give misleading results regarding the optimum feed-point location and cause
poorer column performance than expected.
Key ratio plotting is a useful tool to evaluate optimum
feed location in simulation modeling. This key ratio is usually
expressed as the mole fraction ratio of light keys to heavy keys in

a semi-logarithmic scale chart. A benefit in using the chart is that
retrograde distillation due to non-optimum feed location can be
visually identified. Optimum feed location can be graphically
selected through the chart. Meanwhile, it should not be overlooked that key ratio plotting only shows binary key component
behaviors. Light non-key behaviors are not recognized in this plotting.2 Relying on key ratio plotting is dangerous in determining
optimum feed location. Reviewing non-key component composition profiles through the column and various sensitivity analyses
is also required to ensure optimum feed location.
Arranging multiple feed locations to a single distillation column is one of the solutions for a column in which feed compositions are frequently varied. Actual feed location can be switched to
suit varying feed composition. Switching methods can be arranged
either by manual block valves or automatic control valves. This
design is usually feasible in a trayed distillation column. It is difficult to arrange multiple feed locations in most packed column
cases unless an extra bed is inserted to allow an alternate bed.
Feed temperature. Feed temperature is one of the major
factors in influencing the overall heat balance of a distillation
column system. Increased feed enthalpy can help reduce the
required energy input from the reboiler at the same degree of
separation. Installing a feed pre-heater is a very common process
option to minimize reboiler heat duty. If the feed preheater can
be integrated with other valuable process streams (as a heating
medium), overall energy efficiency of the distillation system can
be improved further. A simple heat integration in the distillation
block is heating feed streams using the bottom product.
However, increasing feed temperature does not always
improve the overall energy efficiency of a distillation unit. Excessive feed temperature increments can cause a significant amount
of flash of heavy key and heavy non-key components at the
distillation column feed zone. In this case, a higher amount of
reflux stream is necessary to maintain required overhead distillate purities. This augmented reflux ratio thus requires a higher
boil-up ratio. Overall energy efficiency is eventually aggravated.3
Therefore, carefully reviewing feed temperature and phase is critical to minimize the distillation units overall energy consumption.
Identifying feed condition at a reliably measured feed temperature should be conducted to evaluate optimum feed conditions.
Sensitivity analysis is a required step as well.
Internal feed-distributor design. The importance of the
internal feed distributor cannot be ignored in distillation column feeding optimization. The equilibrium stage basis simulator
I 101
SPECIALREPORT
predicts distillation column performance based on ideal mixing

between feed and column internal traffic. This means that the
feed distribution quality is not reflected in the equilibrium stage
calculation result. Therefore, feed distribution quality should be
evaluated separately to ensure that simulated distillation column
performance predictions are met.
In real distillation column operation, feed distribution quality influences overall performance. Non-optimized feed fluid
distribution can cause non-uniform concentration across a distillation column cross-sectional area and result in downgrading
FIG. 1
Feed distributor and four-pass top tray with two off-center

downcomers.
performance. The importance of feed distribution is emphasized

when a distillation column has multi-pass trays and/or packing.
In multi-pass trays, it is essential that uniform internal liquidto-vapor (L/V) ratio in each section shall be maintained.4 Also,
the feed distribution ratio shall be matched to the tray L/V ratio
as closely as possible for best performance. Otherwise, poor feed
distribution can cause an imbalanced L/V ratio in each pass. In
an imbalanced L/V ratio, the reduction of tray efficiency can be
observed and non-uniform froth height generation can reduce
overall column capacity.
Non-optimum tray layout selection can increase the difficulty of feed distribution. A typical example is when the distillation columns top tray is configured with two off-center positioned
downcomers in four-pass-tray geometry. In this geometry, an
internal feed/reflux distributor has to be fed to one center and two
side inlets. With a conventional distributor design, this almost
guarantees that the split of liquid flow was not proportional to
the vapor from each pass. Poor feed/reflux distribution to the tray
inlet panel causes an uneven L/V ratio in each active area.
If the top tray is converted to the tray with two sides and
one center downcomers, feed/reflux distribution problems can
be resolved. However, this conversion requires complete layout
changes of all trays in the column, which may not be feasible in
a revamp solution. Since it requires high modification costs, it is
not a feasible solution in most cases.
Alternatively, this feed maldistribution can be fixed by an
enhanced feed distributor design. Installing controlling orifices can
split liquid flow to match the tray pass liquid ratio. Fig. 1 displays
the feed distributor for four-pass trays with two off-center downPlatinum sponsor:
REGISTER EARLY & SAVE

www.WGLNetwork.com
Ernst & Young proudly presents the
HOUSTON
HOUSTON
2011 WOMENS
Silver sponsors:
1516 November 2011 Hyatt Regency Downtown Houston, Texas USA
Register today for the 8th installment of the Womens Global Leadership Conference
in Energy & Technology and take advantage of the Early Bird pricing!
www.WGLNetwork.com
Regular
Early Bird
(before 11 September 2011)
Single attendee: .................................. USD $800

Team of two: .................................... USD $1,450
Small Group of 5: ............................. USD $3,000
Leadership Pack of 10*: .................. USD $5,750
...................................USD $680
................................USD $1,325
................................USD $2,875
................................USD $5,250
Wine tasting sponsor:
* Discounts and Recognition for Groups of 10 or more: Purchase a Leadership Pack and receive
10 delegate passes at a discounted rate and a listing in the program as a Leadership Pack sponsor.
For sponsor opportunities contact,

Hadley McClellan, Director of Events
+1 (713) 520-4475, Hadley.McClellan@GulfPub.com
EVENT
102
External feed-line configuration. Inappropriate external
feed configurations also influence distillation column performance. If feed flow is split and introduced to the distillation
column through multiple locations, all multiple-branch pipes
shall be symmetrical. Otherwise, feed flows are not introduced in
uniform manners and column performance is influenced. Unless
external feed-line balancing is strongly specified in process design
materials, such as piping and instrumentation diagrams (P&IDs)
and process data sheets, this line balancing may be overlooked
during the final piping design.
External feed-line geometry is also a critical issue when twophase fluid is formed in the feed stream line. Certain distillation
columns, such as refinery multi-product fractionators, are inherently designed with two-phase feed conditions. Quite a few energy
saving projects specify two-phase feed conditions.
As is well-known in the industry, a two-phase feed condition
necessitates more complex design steps than a single-phase feed
condition. Undesirable two-phase flow patterns are prone to
causing unit troubles including entrainment, flow instability,
temperature and/or pressure fluctuation, hammering and pipe or
equipment erosion.5 It is generally known that a slug flow regime
should be avoided at two-phase feed inlets. A highly aerated slug
can act like frothy surge and can cause not only column instability but also severe hydraulic pounding and distillation equipment
damage.6 For a particular vacuum tower inlet, a mist flow regime
can create liquid entrainment in the flash zone.7 At high twophase flow velocities, most of the liquid components are turned
to mist droplets and distributed into the vapor phase. This liquid
mist is prone to be entrained in the vacuum tower flash zone and
impacts distillate product yield and/or qualities.
Understanding two-phase flow patterns and proper piping
geometry is required to avoid unit troubles. However, it is very difficult to identify two-phase flow patterns in an accurate manner.
There is no reliable calculation method to predict void fractions
for pressure drop and fluid residence time yet. Due to a lack of a
universal model, two-phase flow pattern prediction is varied upon
Impurities
Other process streams
Feed
Water
Steam
Solvent recovery
column (SRC)
Hydrocarbon solvent
FIG. 2
Original process configuration.
45
40
Reux rate, gpm
comers. Since controlling orifices are positioned inside distributor

arms, these features are not revealed in Fig. 1. A drawback of this
design is creating an additional pressure drop through the feed/
reflux distributor, thus influencing pipeline hydraulics. Therefore,
it is necessary to check whether a sufficient driving force is still
maintained at a higher feed distributor pressure-drop scenario.
A packed column is more vulnerable than a trayed column
with regard to feed distribution. Like multi-pass trays, a troughstyle liquid distributor with multiple primary troughs (parting
boxes) requires uniform incoming liquid distributions to multiple
primary troughs. Otherwise, uniform liquid distribution cannot
be maintained at the liquid distributor component irrigating the
next packed bed.
Proper internal feed distributor sizing is also necessary to
achieve uniform feed distribution. High feed fluid velocity can
allow more fluid flow at the end of the distributor. Pressure drop
among the entry header, lateral arm and discharge hole needs to
be optimized. It is usually recommended that progressive pressure
drop increments through the feed distributor provide adequate
feed distribution. In case of a packed tower trough-style distributor, high inlet liquid velocity can cause liquid splashing, allowing
liquid flows outside the primary trough(s) of the gravity distributor. Slightly submerged guide-tube installation with properly sized
discharge holes can help prevent liquid splashing.
SPECIALREPORT
35
30
25
20
1
FIG. 3
3
4
5
Feed stage, from column top to bottom
Reflux rate vs. feed stage at same solvent product purity.
the model chosen. Graphical and empirical methods are widely

used as well. Design practices regarding piping geometry and fitting methods are available in the industry.
Case study. The case study demonstrates how column perfor-
mance is improved by distillation column feeding optimization.

The solvent-recovery column function is to separate water and
impurities from spent hydrocarbon solvent and to supply regenerated solvent back to the main process unit. Using contaminated
solvent as the feed stream, a reflux stream combines with the feed
line and is pre-heated prior to entering the column at one single
point located at the columns top. Water and other impurities are
stripped from the hydrocarbon solvent, and purified solvent is
produced at the bottom of the column and recycled back to the
main process unit. The original solvent-recovery column configuration is described in Fig. 2. As capacity of the main process unit
is expanded, the capacity of the solvent-recovery column should
also be increased to supply enough solvent to the main process
unit. However, the solvent columns maximum capacity was lower
than the required capacity.
An engineering firm that conducted the main process unit
expansion work originally evaluated the solvent recovery column capacity expansion. The expansion study concluded that
the existing column diameter was not large enough to handle
the required column internal traffic and implementing a larger
I 103
SPECIALREPORT
TABLE 1. Solvent-recovery column performance
comparison
Key ratio, light key/heavy key
1
Top-stage feeding
Third-stage feeding
Fifth-stage feeding
0.1
Unit
Pre-revamp
operation
Post revamp
operation
Feedrate
GPM
BASE
+ 35%
BASE
68
Feed temperature
Feed phase
Water and other impurities
in bottom solvent
Reflux ratio (to feed)
0.01
Reboiler steam consumption

per feed
0.001
1
FIG. 4
3
5
7
Stage number, from column top to bottom
Key ratio plot.
Impurities
Other process streams
Feed
Steam
Water
Solvent recovery
column (SRC)
Hydrocarbon solvent
FIG. 5
Modified process configuration.
diameter column with other periphery equipment modifications

was suggested. Since this modification plan required a high capital
expenditure and a long shutdown period, this modification scenario was not accepted in the given overall project schedule and
budget. A more feasible modification scenario was desired to meet
the project schedule as well as the performance targets.
An alternative set of unit evaluation and optimization studies
was conducted by another party. The evaluation started with the
identification of the root cause, which is an essential step for unit
optimization. Operating condition data as well as design documents and materials, were gathered. A preliminary study was done
based on operating conditions. The study revealed that the maximum design and simulated duties of the feed pre-heaters were not
matched in a reasonable manner. Simulated pre-heater duties at
measured feed temperatures were much higher than the maximum
calculated heat exchangers duties. Meanwhile, all design material
data were consistent: P&ID and equipment data sheets showed
the same heat-exchanger duties. To confirm the feed pre-heating
system design, a field survey was conducted and compared with
the design materials. Surprisingly, the field survey disclosed that
104
Case parameter
Two-phase
Liquid
wt ppm
BASE
Volume basis
BASE
48%
lb steam/gallon
BASE
12%
all design materials were not updated to the real equipment configurations. There were five heat exchangers positioned in the
actual feed pre-heating circuit, while the P&ID only showed three
exchangers. Through clarifications with the technical/operating
staffs, it was found that two more heat exchangers were added to
increase feed temperature, but design document materials were
not updated. The belief was that higher feed temperature always
improves the energy consumption in a distillation unit.
To evaluate the column performance in detail, rigorous simulation modeling was conducted based on operating conditions.
The purpose of modeling was to identify the bottleneck point and
to construct a base model for revamping. Obtaining pertinent
operating data is necessary for reliable simulation modeling. A
review of operating data showed that daily operating conditions
were not suitable for simulation modeling. As measured stream
volumetric flowrates were not standardized, mass-balance closure
could not be reviewed. Also, gathered temperature and pressure
data were not consistent. A dedicated test run was required to
gather reliable operating data. A set of operating data was obtained
at the rate just before the maximum operating point in a snap-shot
basis. Overall mass and component balance closure data were
compiled. Each instrument position was checked and confirmed
through a field survey.8
Before performing rigorous simulation modeling, the thermodynamic package was reviewed in the selected commercial process simulator. It was found that the binary interaction parameter
and alpha functions were not available between key components
in the selected thermodynamic packages data base. In this case,
most of the commercial simulators automatically choose the ideal
gas law between components and report results. It is difficult to
recognize this assumption unless detailed thermodynamic parameters are reviewed among components. For reliable simulation
modeling, binary interaction parameters and alpha functions
that were regressed through experiment data were applied in
the selected liquid activity coefficient model. Through various
sensitivity analyses, tray efficiency of the column was quantified.
Rigorous simulation results indicated that two-phase feed was
formed at the operating feed temperature. This feed temperature was
much higher than the original design feed temperature. The increment of feed temperature was intended to maximize feed preheater
duty and reduce overall energy consumption. However, undesirable
two-phase feed caused an excessive hydrocarbon solvent amount in
the column overhead system. To maintain product purity specifications of the bottom product, the reflux rate needed to be increased.
A higher reflux rate generated more vapor/liquid traffic inside the
column and limited column capacity. To destroy this vicious cycle,
the feed temperature should be decreased to maintain the liquid feed.
A case study was conducted to check whether the existing feed
point was optimum. Required reflux rates were simulated with
various feed points at the same bottom solvent purity. These results
are displayed in Fig. 3. This figure shows that adding a rectification section helps to minimize the reflux rate at the same product
purity and the feeding at Stage 3 shows the minimum reflux rate.
Partial key ratio plots are highlighted among stages 1 and 5. Fig.
4 shows key ratio plot changes as the feed point is elevated down.
Monitoring key ratio behavior with various feed points shows that
retrograde distillation was observed at the Stage 5 feeding.
The solvent recovery unit was modified according to the feedoptimization study. The feed tray was relocated from the top tray
to the tray matching the third theoretical stage. The reflux stream
was no longer combined with the feed stream and was introduced
to the top tray independently. The feed temperature was reduced
to maintain liquid-phase feed condition. New feed temperature
was set at a temperature slightly lower than the simulated bubblepoint temperature. In spite of the slightly sub-cooled feed, this
temperature maintains a stable liquid-phase feeding against a
minor feed composition variation. The internal feed distributor
was designed and installed at the new feed location. Since the feed
stream contains some fouled materials, the discharge hole size was
optimized to prevent potential plugging. It was also found that
the control valve flow was reaching the critical flow zone. A new
control valve was installed to prevent the choked flow. Modified
process schemes are depicted in Fig. 5.
Table 1 summarizes the solvent columns pre- and post-modification operating data. The maximum feed rate of the column
is increased by 35%. The metered reflux rate is significantly
SPECIALREPORT
improved without sacrificing bottom product purity. The new

reflux ratio is only 52% of the previous amount. The reboiler heating medium (steam) consumption per feed is reduced by 12%. HP
1
2
3
4
5
6
7
8
LITERATURE CITED
Lee, S. H., et al, Optimizing crude unit designs, Petroleum Technology
Quarterly, 2Q, 2009.
Kister, H. Z., Distillation design, McGraw-Hill Company, 1992.
Lee, S. H., et al., Minimizing energy consumption in distillation units AIChE
Spring national meeting, April 2009.
Bolles, W. L., Multipass flow distribution and Mass Transfer Efficiency for
Distillation Plates, AIChE Journal, Vol. 22, No. 1, January 1976.
Daniels, L., Dealing with two-phase flows, Chemical Engineering, June 1995.
Kister, H. Z., Distillation operation, McGraw-Hill Company, 1990.
DeGance, A. E., et al, Chemical Engineering Aspects of Two-Phase Flow,
Chemical Engineering, March 1970.
Kister, H., et al., Sensitivity analysis is key to successful DC5 simulation,
Hydrocarbon Processing, October 1998.
Soun Ho Lee is the manager of refining application for GTC

Technology US LLC in Irving, Texas, and specializes in process design,
simulation modeling, distillation equipment design and field troubleshooting for refining and aromatic applications. Mr. Lee holds a
BS degree in chemical engineering from Sogang University, Korea.
Michael J. Binkley is manager of product development for

the GTC Process Equipment Technology (PET) group in Irving, Texas.
He is a registered professional engineer in Texas with 42 years of
experience in mass transfer and separations equipment development and applications. Mr. Binkley has invented several separations
equipment advancement-related patents, as well as numerous product trademarks.
He earned a BS degree in chemical engineering from Texas Tech University.
EMERGENCY
SERVICE
800-231-0077
ACS Industries can set you free.
UNHAPPY with long lead times for response and product delivery?
Dont trap yourself into thinking only one source is able to handle your
requirements. ACS can replace almost any existing tray, regardless of
original manufacturer. With 70 years experience,
we use advanced 3-D modeling and CAD/CAM to
design and make a wide variety of trays and internals.
YOU ARE FREE to choose the highest

quality and best price, delivery, and
engineering support. Call ACS Industries
for all your trays and internals.
105
HPI MARKETPLACE
&MJNJOBUF
7BMWF$BWJUBUJPO
s0LACEONEORMOREDIFFUSERSDOWNSTREAM
OFAVALVETOELIMINATECAVITATION
s%LIMINATENOISE
s%LIMINATEPIPEVIBRATION
s2EDUCEVALVElRSTCOSTS
s2EDUCEVALVEMAINTENANCE
SURPLUS GAS PROCESSING/REFINING EQUIPMENT

25 MMCFD x 1100 PSIG PROPAK REFRIGERATION PLANT
28 TPD SELECTOX SULFUR RECOVERY UNIT
1100 BPD LPG CONTACTOR x 7.5 GPM CAUSTIC REGEN
NGL/LPG PLANTS: 10600 MMCFD
AMINE PLANTS: 603300 GPM
SULFUR PLANTS: 10180 TPD
FRACTIONATION: 100025,000 BPD
HELIUM RECOVERY: 75 & 80 MMCFD
NITROGEN REJECTION: 25100 MMCFD
MANY OTHER REFINING/GAS PROCESSING UNITS
We offer engineered surplus equipment solutions.
Bexar Energy Holdings, Inc.

Phone 210-342-7106 s Fax 210-223-0018
www.bexarenergy.com s Email: info@bexarenergy.com
WABASH SELLS & RENTS
#53ERVICES,,#
BOILERS & DIESEL GENERATORS
0ARKVIEW#IR%LK'ROVE6LG),

0HONE sRCRONFEL CUSERVICESNET
WWWCUSERVICESNET
FAST EMERGENCY SERVICE
800-704-2002
Call 713-520-4449 for details about
www.wabashpower.com
Hydrocarbon Processings
FAX: 847-541-1279
847-541-5600
Recruitment

106
Advertising Program
Use a combination of print,
recruitment e-newsletter, plus
Website to reach our total audience
circulation of more than 100,000!
HPI MARKETPLACE
0IPE3TRESS
0ROCESS3IMULATION
0ELLETIZING$IE$ESIGN
(EAT4RANSFER!NALYSIS
&INITE%LEMENT!NALYSIS
#OMPUTATIONAL&LUID$YNAMICS
6ESSEL%XCHANGER-ACHINE$ESIGN
2OTOR$YNAMICS3TRUCTURAL$YNAMICS
3PECIALISTSINDESIGNFAILURE
ANALYSISANDTROUBLESHOOTINGOF
STATICANDROTATINGEQUIPMENT
WWWKNIGHTHAWKCOM
(OUSTON4EXAS
4ELss
&AXss
NOISE
CONTROL ENGINEERING
CA
Co PE-O
mp PE
lian N
t!
HTRI Xchanger Suite an integrated, easy-to-use suite of tools that
delivers accurate design calculations for
shell-and-tube heat exchangers
jacketed-pipe heat exchangers
hairpin heat exchangers
plate-and-frame heat exchangers
spiral plate heat exchangers
fired heaters
air coolers
economizers
tube layouts
vibration analysis
Interfaces with many process simulator and physical property

packages either directly or via CAPE-OPEN.
HFP Acoustical Consultants

Houston TX
Calgary AB
(888) 789-9400
(888) 259-3600
(713) 789-9400
(403) 259-6600
E-mail: info@hfpacoustical.com
Internet: www.hfpacoustical.com
Heat Transfer Research, Inc.

150 Venture Drive
College Station, Texas 77845, USA
HTRI@HTRI.net
www.HTRI.net
Flexware
Turbomachinery Engineers
Engineering Services
Its vaporized water.

Its transparent gas.
Steam.
Its Nationwide Boiler.
Call us about your Turbomachinery questions and problems. We

would be more than happy to you help with:
A. Turbomachinery training courses
B. Troubleshooting of Turbomachinery mechanical problems & root
cause failure analysis.
C. Rotordynamic analysis.
D. Overhaul assistance Inspection and test witness services.
E. Commissioning & startup.
F. Compressor & turbine performance analysis.
G. Compressor and turbine gas path design.
H. Compressor and turbine efficiency enhancements and rerates.
I. Sleeve seal leakage problems
J. Temporary technical employees
www.flexwareinc.com
sales@flexwareinc.com
1-724-527-3911
To learn more call

1-800-227-1966 or visit
www.nationwideboiler.com
Integrity. Dependability.
Real Customer Service.
Rentals | Sales | Leasing

I 107
HPI MARKETPLACE
HPI VIEWPOINT
continued from page 35
operations. We also look at the range of operations a particular

process and licensed configuration can support. Some handle a
wider range of feeds at a cost of efficiency. Others can produce significantly different products at a cost of throughput. Or the price
for different outcomes is more energy consumption. Certainly modeling assessments can give us sensitivity cases for our justification.
Modeling to support these questions is where a licensor and their
specific experience can helpbut not until you choose because
these models represent their secret sauce.
What are we left with? We have to look at the track record
and reputation of the licensor. Is it an established business? Does it

have a long-term track record of supplying licenses? Does it have a
real understanding of complex processes? Is it continuing to evolve
and innovate? Most importantly, does it have the wisdom to offer
capabilities that can meet a wide range of market conditions? Is it
willing to take calculated risks on market trends? Does it fundamentally speak to the challenges of the business (thats your business, by
the way) in the market? Much of a successful decision on process
licensing shows up after all the dust has settled. When the unit is
up and running and things change (and they always change) then
the ability of the unit to respond to that change is where the value
of the decision manifests. So, ultimately, look for someone who can
deliver successful implementations year after year, one success at a
time. While processes may look alike, the ultimate result is how they
stand the test of time. Maybe the best indicator is that, if the success
of the licensor is measured in your success, then you can confidently
show your company you can deliver! HP
SALES OFFICESEUROPE
FRANCE, GREECE, NORTH AFRICA, MIDDLE
EAST, SPAIN, PORTUGAL, SOUTHERN
BELGIUM, LUXEMBOURG, SWITZERLAND,
GERMANY, AUSTRIA, TURKEY
Bill Wageneck, Publisher
Phone: +1 (713) 529-4301
Fax: +1 (713) 520-4433
E-mail: Bill.Wageneck@GulfPub.com
SALES OFFICESNORTH AMERICA

IL, LA, MO, OK, TX
Josh Mayer
Phone: +1 (972) 816-6745, Fax: +1 (972) 767-4442
E-mail: Josh.Mayer@GulfPub.com
AK, AL, AR, AZ, CA, CO, FL, GA, HI, IA, ID,
IN, KS, KY, MI, MN, MS, MT, ND, NE, NM,
NV, OR, SD, TN, TX, UT, WA, WI, WY,
WESTERN CANADA
Laura Kane
Phone: +1 (713) 520-4449, Fax: +1 (713) 520-4459
Mobile: +1 (713) 412-2389
E-mail: Laura.Kane@GulfPub.com
CT, DC, DE, MA, MD, ME, NC, NH, NJ, NY,
OH, PA, RI, SC, VA, VT, WV,
EASTERN CANADA
Merrie Lynch
Phone: +1 (617) 357-8190, Fax: +1 (617) 357-8194
Mobile: +1 (617) 594-4943
E-mail: Merrie.Lynch@GulfPub.com
DATA PRODUCTS AND CLASSIFIED SALES

Drew Combs, Gulf Publishing Company
Phone: +1 (713) 520-4409, Fax: +1 (713) 525-4631
E-mail: Drew.Combs@GulfPub.com
108
Catherine Watkins
Tl.: +33 (0)1 30 47 92 51
Fax: +33 (0)1 30 47 92 40
E-mail: Watkins@GulfPub.com
ITALY, EASTERN EUROPE

Fabio Potest
Mediapoint & Communications SRL
Phone: +39 (010) 570-4948
Fax: +39 (010) 553-0088
E-mail: Fabio.Potesta@GulfPub.com
RUSSIA/FSU
Lilia Fedotova
Anik International & Co. Ltd.
Phone: +7 (495) 628-10-333
E-mail: Lilia.Fedotova@GulfPub.com
UNITED KINGDOM/SCANDINAVIA,
NORTHERN BELGIUM, THE NETHERLANDS
Michael Brown
Phone: +44 161 440 0854
Mobile: +44 79866 34646
E-mail: Michael.Brown@GulfPub.com
SALES OFFICESOTHER AREAS

AUSTRALIAPerth
Brian Arnold
Phone: +61 (8) 9332-9839, Fax: +61 (8) 9313-6442
E-mail: Australia@GulfPub.com
CHINAHong Kong
Iris Yuen
Phone: +86 13802701367, (China)
Phone: +852 69185500, (Hong Kong)
E-mail: Iris.Yuen@GulfPub.com
BRAZILSo Paulo
Alfred Bilyk
Phone/Fax: 11 23 37 42 40
Mobile: 11 85 86 52 59
E-mail: Brazil@GulfPub.com
INDIA
Manav Kanwar
Phone: +91-22-2837 7070/71/72
Fax: +91-22-2822 2803
Mobile: +91-98673 67374
E-mail: India@GulfPub.com
JAPANTokyo
Yoshinori Ikeda
Pacific Business Inc.
Phone: +81 (3) 3661-6138
Fax: +81 (3) 3661-6139
E-mail: Japan@GulfPub.com
INDONESIA, MALAYSIA, SINGAPORE,

THAILAND
Peggy Thay
Publicitas Singapore Pte Ltd
Phone: +65 6836-2272
Fax: +65 6634-5231
E-mail: Singapore@GulfPub.com
PAKISTANKarachi
S. E. Ahmed
Intermedia Communications
Phone: +92 (21) 663-4795
Fax: +92 (21) 663-4795
REPRINTS
Rhona Brown, Foster Printing Service
Phone: +1 (866) 879-9144 ext. 194
E-mail: RhondaB@FosterPrinting.com
FREE Product and Service InformationJUNE 2011

HOW TO USE THE INDEX: The FIRST NUMBER after the company name is the page on which an
advertisement appears. The SECOND NUMBER, appearing in parentheses, after the company
name, is the READER SERVICE NUMBER. There are several ways readers can obtain information:
1. The quickest way to request information from an advertiser or about an editorial item is to go to www.
HydrocarbonProcessing.com/RS. If you follow the instructions on the screen your request will be forwarded for
immediate action.
2. Go online to the advertiser's Website listed below.
3. Circle the Reader Service Number below and fax this page to +1 (416) 620-9790. Include your name, company, complete
address, phone number, fax number and e-mail address, and check the box on the right for your division of industry and
job title.
Name ________________________________________________________
Company ________________________________________________________
Address ______________________________________________________
City/State/Zip ____________________________________________________
Country ______________________________________________________
Phone No. _______________________________________________________
FAX No. ______________________________________________________
e-mail ___________________________________________________________
This Advertisers Index and procedure for securing additional information is provided as a service to Hydrocarbon
Processing advertisers and a convenience to our readers. Gulf Publishing Co. is not responsible for omissions or errors.
This information must be provided to process your request:

PRIMARY DIVISION OF INDUSTRY
(check one only):
A
B
C
F
G
H
J
P
-Refining Company
-Petrochemical Co.
-Gas Processing Co.
-Equipment Manufacturer
-Supply Company
-Service Company
-Chemical Co.
-Engrg./Construction Co.
JOB FUNCTION
(check one only):
B
E
F
G
I
J
-Company Official, Manager

-Engineer or Consultant
-Supt. or Asst.
-Foreman or Asst.
-Chemist
-Purchasing Agt.
ADVERTISERS in this issue of HYDROCARBON PROCESSING

Company
Website
Page
RS#
ACS Industries Inc. . . . . . . . . . . . . . 105 (174)

Aggreko . . . . . . . . . . . . . . . . . . . . . . 28 (156)
www.info.hotims.com/35904-156
Alfa Laval Packinox . . . . . . . . . . . . . . 17 (152)

Ametek Process Instruments . . . . . . . 30 (157)
(58)
Borsig GmbH. . . . . . . . . . . . . . . . . . . 39 (160)

(74)
(55)
(59)
Chemshow . . . . . . . . . . . . . . . . . . .V-93
(62)
(57)
(96)
Eaton Filtration . . . . . . . . . . . . . . . . . 18 (100)

(94)
Emerson Process Management . . . . . . 8

Emerson Process Management
(Fisher Controls) . . . . . . . . . . . . . . . 24
(87)
(71)
(91)
(86)
Samson GmbH . . . . . . . . . . . . . . . . . 43 (177)

Sandvik Steel AB . . . . . . . . . . . . . . . . 34
(89)
(81)
M3 Technology . . . . . . . . . . . . . . . . 105 (175)

Siemens AG. . . . . . . . . . . . . . . . . . . . 23
Siirtec Nigi SpA . . . . . . . . . . . . . . . . . 53 (179)

Spraying Systems Co . . . . . . . . . . . . . 66
(66)
(76)
Trachte USA . . . . . . . . . . . . . . . . . . . 97 (176)

TrimTeck . . . . . . . . . . . . . . . . . . . . .V-91
Turbomachinery Laboratory . . . . . . .V-94
VYC Industrial . . . . . . . . . . . . . . . . .V-92
Mustang Engineering . . . . . . . . . . . . 20 (153)
(70)
Mettler-Toledo . . . . . . . . . . . . . . . . . 71 (170)
Microtherm . . . . . . . . . . . . . . . . . . . . 72 (171)
(98)
Unifrax . . . . . . . . . . . . . . . . . . . . . . . 69
(95)
(97)
Maxon, A Honeywell Company . . . .V-86
(79)
Total Automation Solutions . . . . . . . . 51 (162)
(69)
Quest Integrity Group LLC . . . . . . . . . 68 (168)
Thermo Fisher Scientific . . . . . . . . . . . 60

(60)
Linde Process Plants . . . . . . . . . . . . . 36
Prosim . . . . . . . . . . . . . . . . . . . . . . . 57 (166)
ITT Industries . . . . . . . . . . . . . . . . . . . 2
(52)
Shenyang Rainda Chemical Co., Ltd. . . 4 (151)
Honeywell Analytics. . . . . . . . . . . . . . 59
Onis . . . . . . . . . . . . . . . . . . . . . . . .V-88
Servomex Ltd. . . . . . . . . . . . . . . . . . . 31 (158)
Hemiwedge Valve . . . . . . . . . . . . . .V-80
RS#
KTI Corporation . . . . . . . . . . . . . . . . . 54
Eidos Sap SRL . . . . . . . . . . . . . . . . . . 33
Gulf Publishing Company

Construction Boxscore . . . . . . . . . . . 32 (159)
HPI Marketplace . . . . . . . . . . 106108

HPI Market Databook . . . . . . . . . .V-90
Site License . . . . . . . . . . . . . . . . . . 100
Haldor Topse A/S . . . . . . . . . . . . . . . 38
Page
Koch Glitsch . . . . . . . . . . . . . . . . . . 27 (155)
Chemstations Inc. . . . . . . . . . . . . . . . 52 (161)
Curtiss-Wright Flow Control . . . . . .V-84
Novozymes Biologicals . . . . . . . . . . . 75 (172)
KBR . . . . . . . . . . . . . . . . . . . . . . . . . 12
Costacurta SpA Vico . . . . . . . . . . . . . 99
(83)
Flowserve Pumps . . . . . . . . . . . . . . . 14
(67)
Bently Pressurized Bearing Co . . . . . . 70 (169)
CB&I . . . . . . . . . . . . . . . . . . . . . . . . . 40
Newton's . . . . . . . . . . . . . . . . . . . . . 56 (165)
HP Subscription . . . . . . . . . . . . . . .V-90
HP Webcast. . . . . . . . . . . . . . . . . . . 58 (167)
Cameron . . . . . . . . . . . . . . . . . . . . . . 10
(93)
(53)
Burckhardt Compression Ag . . . . . . . 21
Flexitallic LP . . . . . . . . . . . . . . . . . . . . 5
EventsWGLC . . . . . . . . . . . . . . . 102 (178)
Baldor Electric Company . . . . . . . . . 111
Company
Website
(64)
Baker Hughes Inc . . . . . . . . . . . . . . . 44
RS#
EventsIRPC Asia . . . . . . . . . . . . 67
EventsMarketing in the Oilfield . . 78 (173)
Axens . . . . . . . . . . . . . . . . . . . . . . . 112
Page
Asco Valve Inc. . . . . . . . . . . . . . . . . . 29
Company
Website
(68)
(99)
Zyme Flow . . . . . . . . . . . . . . . . . . . . 77
(71)
Zyme Flow . . . . . . . . . . . . . . . . . . . . 22 (154)

For information about subscribing to HYDROCARBON PROCESSING, please visit www.HydrocarbonProcessing.com

I 109
HPIN AUTOMATION SAFETY

WILLIAM GOBLE, CONTRIBUTING EDITOR
wgoble@exida.com
Is it possible to communicate
risk issues successfully?
A safety project has a better chance of being approved if the
person making the payback decision understands the concept
of risk cost. If there is a likelihood of a $1,000,000-cost event
happening once every 100 years, then the risk cost/yr is $10,000.
A project gets approved when the cost of the safety project is less
than a reduction in risk cost. However, one big problem is that
risk cost is well not understood by many people, and the concept
is hard to explain. Often, the risk is estimated to be noncredible, therefore the risk cost is extremely low. Therefore, no risk
cost reduction, no payback. One time when I tried to explain
risk cost, I was asked, Who do I pay the $10,000 to each year?
Many a good safety project has been shot down because the concept of risk cost was not well communicated.
Risk communication is not easy. Once when trying to
justify the importance of a safety system project, I got a quick

decision. I have been at this plant for 30 years, and we have
not had any explosions. So why should we spend money on
a safety system now. I explained the probability of accident
statistics and the low likelihood of an event. I used terms like
once every 100 years. That did not work as the response was, I
wont be here in 100 years. I explained that given the rare event
statistics, experiences at one plant are not enough to judge the
risk. I explained the very high consequence cost. But, it was soon
clear that the message was not working, and the project would
have little chance of success. Risk communication is not easy, and
often, there is a failure to clearly communicate the benefits and
consequences involved.
A recent family attempt to communicate risk cost and reduce
risk went very poorly. For some time now, my company car has
been a Toyota Prius. I enjoy the good gas mileage. However, I
have seen reports and have even had an e-mail discussion with
someone who had experienced a sudden unintended acceleration (SUA) incident in this vehicle type. Although the news
reports tended to sensationalize the situation, based on some
rough statistics from the Internet, the risk seemed small and,
even, tolerable. After my Internet reading, I did find several
suggestions on how to deal with the problem should it occur. So,
I thought that supplemental training on consequence mitigation techniques for all possible drivers of the car would reduce
risk further.
Getting rid of the risk. I explained to all drivers of the Prius
including some members of my family how they should attempt
to put the car into neutral and try to shut down the car by holding
the ignition button for three seconds. In the Internet research, I
saw that one of the drivers experiencing an SUA incident claimed
that neither the transmission control nor ignition switch worked.
110
I JUNE 2011 HYDROCARBON PROCESSING
Given this claim and realizing that both the transmission control and ignition switch appear to be contact inputs to the control
computer, I thought there was additional consequence reduction
needed. So, I explained that if the car did not stop accelerating,
the driver should steer the car into an obstacle like a ditch, a field
or a guardrail before gaining further velocity. This was not my
idea. One of the drivers who experienced an SUA incident drove
the car into desert sand where it stopped. It makes sense to me,
the engineer. Lower levels of kinetic energy result in less damage.
But, I went too far.
The listeners facial expressions turned to fear and anger. The
result of my risk mitigation training was an immediate demand
to get rid of the Prius. A discussion about the small probability of
an incident lacked any impact. I could not make any risk-based
argument to get agreement to keep the car. The sensational TV
news report did not help either. So, now I have a new company
car with a conventional mechanical transmission and no reputation for unintended acceleration.
Communicating clearly. There have been times where risk
communication is successful. One company was working on a

procedure to establish quantitative tolerable risk criteria as part
of its risk management program. During training on this subject, I heard Dr. Eric Scharpf ask if anyone knew someone, who
had been involved in an automobile accident. Most everyone
answered affirmatively. Then he asked about other normal everyday life-risk issues. Yes, people have known someone involved in
an automobile accident, yet, they choose to continue driving.
That is a voluntary risk. A mental process within each person
judged the risk vs. the reward and concluded that the reward was
worth much more than the risk.
Expressing the likelihood and consequence of these voluntary risks put things into perspective. That helped put a quantitative calibration factor into the tolerable risk criteria that we
were working to establish. The whole program was successful,
and this company now has a good risk-management procedure
in place.
Now if I had only remembered to use that same approach
before doing my SUA risk mitigation training sessions. HP
The author is a principal partner of exida.com, a company that does consulting, training and support for safety-critical and high-availability process automation. He has over 25 years of experience in automation systems, doing analog and
digital circuit design, software development, engineering management and marketing. Dr. Goble is the author of the ISA book Control Systems Safety Evaluation
and Reliability. He is a fellow member of ISA and a member of ISAs SP84 committee on safety systems. Dr. Goble can be reached by e-mail at: wgoble@exida.com.
Tower Power
The new Baldor RPM AC Cooling Tower Direct
systems, the RPM AC Cooling Tower motor and
Drive Motor sets a new standard in cooling
VS1CTD Cooling Tower drive offers improved
tower motors. Designed exclusively for cooling
reliability while greatly reducing maintenance
tower applications, the RPM AC motor mounts
costs and energy consumption.
directly to the cooling tower fan, eliminating
Energy Efficient
Unmatched Quality
Superior Reliability
high-maintenance gearboxes, drive shafts and
Check out our website for case studies,
couplings. Combined with Baldors VS1CTD
installation photos and additional information
proprietary adjustable frequency drive, this slow
about the revolutionary new RPM AC Cooling
speed, high torque combination operates at
Tower technology from Baldor. We are truly
variable speeds to maximize system efficiency
changing the future of cooling tower technology!
Quiet Operation
baldor.com/CoolingTower
Made in the USA
Low Maintenance
and minimize noise. Perfect for new installations

or for retrofitting older, less efficient cooling tower
2011 Baldor Electric Company
479-646-4711
Your objectives
in focus
Make the most of todays and tomorrows
challenges with leading-edge solutions from Axens
- Clean and alternative fuel technologies
- Petrochemicals
- Energy efficiency
- High performance catalysts & adsorbents
- Revamps
Single source technology and service provider

ISO 9001 ISO 14001 OHSAS 18001
www.axens.net

Gulfpub HP 201106

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Gulfpub HP 201106

Diunggah oleh

Hak Cipta:

Format Tersedia

RENTECH breaks new trails in the

boiler industry with its focus on custom

Positive PVC demand

Improve energy efficiency

JUNE 2011 VOL. 90 NO. 6

SPECIAL REPORT: PLANT/PROCESS OPTIMIZATION

Why technology choice does matter

Pump rebuilding by expert non-OEMs is effective

Put training back into operator training simulators

Update your reliability performance to meet process safety

Rethink planning and schedulings role in refinery optimization

Consider closedloop oil-mist lubrication

Improve energy efficiency for distillate hydrotreaters retrofit

New tools improve prediction of unit feed qualities and yields

Fine-tune ethylene unit startups

Use advanced process control to add value for your facility

Optimization programs deliver benefits to existing and new plants

Cover China Blue Chemical Co. Ltd.s

Oil and gas supports

Optimize design for distillation feed

110 HPIN AUTOMATION

Associate Editor Helen Meche

Subscription price (includes both print and

GULF PUBLISHING COMPANY

YOUR GLOBAL GASKET PROVIDER

Graphite oxidizes at high temps.

deteriorate as well. Thermiculite , the

IRPCASIA: The Conference for the

2011 IRPC ADVISORY BOARD:

Dr. Madhukar O. Garg

Licensing Technology Manager

Dr. Syamal Poddar

Director of Southeast Asia

Senior Vice President, Research & Development

I have someone retiring after 33 years on the job.

ConocoPhillips CEO Jim Mulva appeared at a Senate Finance

Statoil will withdraw from ownership and management roles with

Albemarle has developed a proprietary technology for lithium

For the third consecutive year, Air Products received a Pinnacle

HYDROCARBON PROCESSING JUNE 2011

How do you size expansion chambers

a shaft-seal supplier started discussions with

expanding volume to the wind turbine

(18C) to 180F (83C). What would be

Veba Combi-Cracking to resid processing, we offer

Korean ethylene plant reaps benefits from APC

Plant operations needed stability. LG Chems Daesan

Lessons learned and overall benefits. LG Chem learned

By utilizing industry benchmarking with business and operational analysis,

Refining margins under

analysts, KBC anticipates only limited future

2008 2009 2010 2011 2012 2013 2015 2020 2025

Regional PVC consumption, 20082025.

Regional PVC capacity additions, 20082013.

HYDROCARBON PROCESSING JUNE 2011

ronmental and safety issues, as well as

ever, the cost competitiveness of PVC is

Countdown to the International Refining

Two-days of sessions with

Indian Oil Corp.

Register for IRPCAsia today at www.GulfPub.com/IRPC.

I JUNE 2011 HydrocarbonProcessing.com

Oil and gas supports

#SFBUIFFBTZXJUIUIF'JTIFS '06/%"5*0/ GJFMECVTMFWFMDPOUSPMMFS