Revamps 2026 Issue

• Tracking instrumentation issues. • Feed into the unit and lining-out units.

Process engineering will aid the operations unit in moni- toring and troubleshooting process issues. Engineering can help with trend analysis to provide early warning of poten- tial issues. Engineering support often helps track turna- round progress and should document key issues that may require procedural changes or mechanical upgrades. Note times and any issues for key activities for the turnaround report, including: • Start of the air blower. • Start/shutdown of the air heater. • Start/completion of refractory cure. • Start/completion pulling main fractionator blind. • Start/completion of catalyst addition. • Start of torch oil. • When a product is on spec and routed to product storage/ downstream processing (sometimes from slop to cutter to finished product or downstream processing). • Start of catalyst circulation. • Feed into the unit. • Note significant issues during the start-up. Post-turnaround process activities After some time to recuperate, it is time to complete the turnaround report. The most important part is the findings from the turnaround. This should include recommendations on: • Changes in unit monitoring (process, testing). • Changes in shutdown and start-up practices and procedures. • Recommended equipment replacement or repair, par- ticularly for possible upgrades that will require engineering. • Issues that were found but not resolved and will require additional follow-up. The report should include a summary noting the as-found condition compared with the prior turnaround, a summary of repairs, and any operational or mechanical upgrades rec- ommended for each piece of equipment reviewed during the turnaround. A summary photo is also helpful, with other photos kept in a turnaround directory. It is helpful to have an outline developed prior to the turn- around, with summary notes added during the turnaround. The final report is normally distributed for review/comment to the process engineering team and then issued for future reference. Post-turnaround benchmarking test run A post-turnaround test run to bench mark the unit opera- tion shortly after the unit has been restarted and the oper- ation is stable is also recommended. The post-turnaround test run should include comprehensive data collection on the unit process data, including: • Collect a full pressure and temperature survey of the unit. • Survey or standpipes for pressure build-up. • Include cooling water flows to exchangers (enlist the help of a chemical vendor). • Full set of samples for analysis (recommend collecting two sets spread apart).

Figure 9 Fractionator inlet coke build-up

noted for repair. Proper clearance is needed to ensure that any coke formation on the hinges is cleared during oper- ation. As with trickle valves, it may be prudent to replace these valves if wear and damage have been noted: • For existing valves, recommend replacing/altering when clearances exceed 1/8in. • New trickle valves should be able to meet less than 1/16in clearance. . Reactor stripper and distributors The reactor stripper should uniformly distribute catalyst and steam over the stripper diameter. Damage and plugging to the shed trays, disc/donuts or stripper packing should be noted and addressed in the turnaround. Plugging distribu- tion holes in the tray decks should be noted and cleared. Damage to the stripping steam distributor nozzles or steam distribution should be noted and repaired (see Figure 7 ). Note if any nozzles were plugged and update the draw- ing (verify the change in nozzle velocities because of the nozzle plugging). Frequent nozzle damage should be inves- tigated for high or low velocities and possible replacement for the next turnaround. Distributors should be checked for poor operating range as part of the pre-turnaround prepa- ration. Monitoring distributor nozzle velocities during the run is also good practice. The reactor overhead line can be subject to erosion and coke build-up (see Figure 8 ). As part of the inspection, note any coke build-up in the reactor overhead line. Note any damage to refractory lining, particularly around elbows. Significant coke build-up should be removed. Sites can consider using high-pressure water to dislodge coke. Coke in the fractionator inlet should also be noted and removed (see Figure 9 ). Start-up process activities Start-up is usually an extensive effort between operations, process engineering, and mechanical support. With round- the-clock coverage, effective communication is needed between shifts. Process engineering is active during key parts of the start-up, in particular: • Tracking the refractory dry-out (if needed) and general unit heat-up. • Tracking catalyst addition rates and levels. • Torch oil addition. • Initial catalyst circulation and reactor heat-up.

Revamps 2026