Revamps 2026 Issue

Cracking the code: FCC turnaround lifecycle best practices – Part 2

The common FCC equipment and recommended engineering practices are reviewed, followed by unit start-up and turnaround report generation

Ben Ellebrecht Phillips 66 Wood River Nate Hager Cenovus Lima Herbert Telidetzki Becht

P art 1 of this article, published in PTQ Q2 2026, dis- cussed the expanded role of the process engineer in developing the scope for the FCC turnaround. This has put more onus on the process engineer to define and justify the turnaround scope. Process engineers also pro- vide critical support for shutdown and start-up planning and execution. This adds further complexity to scope devel- opment and introduces potential technical and operational challenges as units approach end-of-run (EOR) conditions. Part 2 will focus on the FCC turnaround itself. With an extended timeframe between turnarounds, the turnaround may be the first opportunity for the process engineer to inspect these vessels. The cycle then continues. FCC general inspection guidelines With vessels now open, this is the opportunity to finally see first-hand what these vessel internals look like. The prior turnaround report and photo file directory, as well as inter - nal drawings, should offer some insight prior to making an entry for inspection. Initial visual inspection via open manways can be helpful in early assessment of the equipment condition, particu- larly the ‘as-found’ condition. Use of drones and remote cameras can also help in assessing the as-found condition. Process engineering should note the amount of catalyst in the regenerator, reactor stripper, and standpipes, with comparison to prior unit shutdowns. Engineers should note the as-found condition of the trays and packing from the manway, particularly fouling and damage. General vessel inspection guidelines It is good practice to plan vessel entry. Review the equip- ment’s internal drawings and note any key dimensions of interest (such as nozzle locations, tray clearances, and weir heights). Prior to the turnaround, it is helpful to have equipment drawings easily available in a directory or with a file link. This is particularly helpful for other process engineers sup- porting the turnaround. In addition, create a file structure for storing pictures prior to the turnaround, including sub- folders for ‘As-found condition’, ‘After cleaning condition’, and ‘Pre and Post Repairs’. It is good practice to download

and sort these photos after inspection or at least at the end of the shift. Naming the best or most important pictures is also helpful. Additionally, have a system for documenting findings and initial recommendations from the inspection or at least at the end of the shift. Online systems such as Microsoft OneNote can be useful for all the supporting engineers to add their comments. Regenerator inspection Due to harsh operating conditions, the FCC regenera- tor should be inspected at every turnaround. Specialised inspectors will normally review the refractory condition both on the regenerator walls and refractory in cyclones It is good practice to plan vessel entry. Review the equipment’s internal drawings and note any key dimensions of interest (such as nozzle locations, tray clearances, and weir heights) and on other internals. In most cases, the issues are from an anchor system failure or erosion in cyclones. However, hot spots may also be caused by erosion from the air grid, spent catalyst distributor, cyclone dipleg outlets, or other purge nozzles. The inspection will also look for mechanical damage, such as cracks in welds, cyclone supports, cyclone body, and air grid nozzles. Process engineering should inspect the pressure tap nozzles for cleanliness, along with the air grid nozzles, thermowells, spent catalyst distributors, cat- alyst cooler distributors, torch oil nozzles, and the regener- ator standpipe inlet (including debris guard) and aeration inlet distributor. Pressure taps, fluidisation nozzles, and thermowells All regenerator pressure taps, including those in the

Revamps 2026