Revamps 2026 Issue

• Sampling of equilibrium catalyst, catalyst fines, and cata - lyst in slurry. • May also include tower scans. This comprehensive test run can be used to update cur - rent unit simulation models. It can also track equipment performance for degradation during the run or equipment issues. The test run is also used as the basis for engi - neering studies and basic stream data. The cycle then continues. Conclusions Given the importance of FCC units in modern refineries and the complexity of operations under demanding economic and environmental parameters, the role of the process engineer has significantly expanded. Today’s engineers must integrate operating data, inspection findings, and operational experience to develop a turnaround scope that appropriately protects the safety, reliability, and profitability needs of the refinery. The practices outlined in this article provide a structured framework and the technical ‘armour’ needed to support necessary scope using data, economics, and historical evi - dence rather than opinion. Equally critical is maintaining continuity across multi-year turnaround cycles. Thorough post-turnaround reporting, clear documentation of as-found conditions, and well-defined recommendations preserve institutional knowledge and prevent each turna - round from becoming a rediscovery exercise. When the issues described in this article are identified,

quantified, and documented, even small or hard-to-inspect problems can be translated into operational recommen - dations and defensible turnaround scope with significant reliability and economic benefit. Ultimately, successful FCC turnarounds are built on disciplined preparation, continuity, and execution – turnaround after turnaround. This article provides guidance only. Each turnaround is different, and plans should be tailored to meet the unique circumstances of each facility.

This article is based on the 2025 AFPM Summit Presentation Cracking the Code: FCC Turnaround Best Practices for Process Engineers .

Ben Ellebrecht is Process Engineer at the Phillips 66 Wood River, Illinois refinery. He is a chemical engineering graduate from the University of Missouri, Science and Technology. Ellebrecht has worked for four years at Phillips 66 as a process design and process engineer for various units. Nate Hager is Process Engineer at Cenovus Energy Lima, Ohio refin - ery. He is a graduate of The Ohio State University in chemical engi - neering. Hager’s past seven years of experience at the Lima refinery cover utilities, FCC, hydrocracking, and hydrotreating. Herbert Telidetzki is FCC and Alkylation Advisor at Becht. He is a chemical engineering graduate from the University of Alberta in Canada. He has more than 35 years of experience in the refining industry. Telidetzki has invested most of his career working on FCCs and alkylation units. Email: htelidetzki@becht.com

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Revamps 2026