PTQ Q2 2026 Issue

in the turnaround can be helpful, particularly if issues are noted. Key items should include: • Feed removed from unit. • Catalyst removal stopped/note main levels and pressures. • Main fractionator liquid removal complete. • Installation of the reactor overhead blind or closing of the reactor overhead valve. • Shutdown of the air blower. • Shutdown of the wet gas compressor. • Start of chemical cleaning. • Opening of equipment. When extensive work is expected in the FCC regenerator and reactor system, catalyst removal can significantly add to the critical path timeline. Ensuring good removal during the shutdown can reduce the time spent vacuuming cata- lyst from the unit. It may be helpful to use a contractor to aid in catalyst removal from difficult areas, such as standpipes and risers, while the unit is still warm (prior to steam con- densation causing wet catalyst in these areas). Flare management can cause shutdown delays in hydro- carbon-freeing equipment. Especially when multiple units are being shut down, it can be difficult for operations to set the correct priority for de-inventorying. Having a flare management plan can set the correct priority. Liquefied petroleum gas (LPG) streams can be particularly difficult to manage, as they tend to vaporise slowly and sporadically. Issues should be noted in the turnaround report, particu- larly delays from flare management. Final conclusions As companies manage environmental and economic con- straints, the role of the process engineer has expanded beyond traditional scope definition. Today’s engineers must integrate operating data, inspection findings, and opera - tional experience to develop a turnaround scope that pro- tects safety and reliability while also balancing profitability and cost control. The practices outlined in this article pro - vide a structured framework to defend the necessary scope using data, economics, and historical evidence. Part 2 will focus on process engineering inspection guidelines, start-up monitoring strategies, and post-re- start best practices designed to protect the investment made during the turnaround. It will address how to verify equipment performance against expectations, detect early signs of fouling or damage, and establish baseline data for the next run cycle. Together, these practices close the loop between inspection, execution, and long-term operational performance, ensuring that each turnaround strengthens the foundation for the next. Ben Ellebrecht is Process Engineer at the Phillips 66 Wood River, Illinois refinery. He is a chemical engineering graduate from Missouri University of Science and Technology. Nate Hager is Process Engineer at the Cenovus Energy Lima, Ohio refin - ery. He is a graduate of The Ohio State University in chemical engineering. Herbert Telidetzki is FCC and Alkylation Advisor at Becht. He is a chemical engineering graduate from The University of Alberta, Canada and has more than 35 years of experience in the refining industry.

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