Revamps 2023 Issue

Safety is a primary concern for IGS, and a robust safety programme was implemented to ensure a safe working environment for all personnel involved. The company maintains a zero-inci- dent safety philosophy and actively promotes a culture of safety among its employees. Daily toolbox talks, safety observations, unit walk-downs, and job safety audits were conducted to mitigate potential hazards and main- tain safety standards throughout the project. IGS’s safety track record included a total recordable incident rate (TRIR) of 0.0 in 2022, well below the indus- try average. The company adheres to OSHA best practices and local safety regulations to ensure compliance and

Convection section cleaning evaluation results for reformer heater

Parameter

UOM

Before

After

Stack temperature

°C %

208

168

Fuel efficiency Absorbed duty

88.32

90.38

Gcal/hr

13.8 122

14.8 122

BFW inlet temperature

°C

BFW mass flow

kg/hr

22,203

23,886

Mass circulation through Steam generator Steam drum pressure

tonne/hr kg/cm²g

150 36.2

Blowdown amount

Total amount of produced Superheated steam

21,146

22,748

kg/hr

Superheated steam Temperature

°C

360

362

Table 2

Case study conclusions The successful cleaning of the convection section in the refinery’s HGU unit marked a significant step towards restoring the unit’s performance. The removal of fouling from the finned tubes facilitated enhanced heat absorption and a reduction in stack temperature, thereby improving overall thermal efficiency. This achievement represents a noteworthy milestone in the refinery’s ongoing expansion project and contributes to its long-term operational success. The removal of fouling from the finned tubes facilitated enhanced heat absorption and a reduction in stack temperature, thereby improving overall thermal efficiency IGS also provided technical recommendations for future maintenance and improvement, including the application of Cetek refractory coating to prevent refractory fouling. The conclusion of the project underscores the collaborative efforts between the oil refinery and IGS, as well as the pos - itive working relationship among all team members. The combined IGS and Tube Tech approach reflects the increased demand for thoroughly conducted feasibility studies, even for small projects. Moreover, it is essential to quantify the influence (if any) of all IGS products on fired heater performance. Scott Donson is VP, International Business Development and Technical Operations, Integrated Global Services. He has a wealth of experience within the petrochemical industry, having spent more than 20 years at Tube Tech, and 30 years in the industry in total. His expertise is in heat exchanger cleaning services, representing Tube Tech Industrial.

maintain a safe work environment. IGS follows stringent quality control standards to meet customer requirements. The project was executed in accordance with the IGS qual- ity control standards, and a quality control package (QCP) was agreed upon before the start of work. Results A performance test run was then conducted to evaluate the unit’s condition after the cleaning process. The unit’s capacity was successfully raised to 100% on April 16 and maintained for 24 hours. The test procedure for evaluat- ing the unit’s performance after cleaning was based on the HPU’s latest probation test, ensuring consistency and com- parability. Data from various sources, including DCS data, laboratory analysis results, outside field/local data, and electrical data, were collected during the test to accurately assess the unit’s performance. The performance test for the HGU was conducted from April 16 at 11:00 to April 17 at 11:00, lasting 24 hours. The main feedstock for the unit was natural gas, supplemented by a small portion of recycled hydrogen. The composition of the natural gas feed, as well as mass flow rates for differ - ent streams, was recorded. The laboratory analysis results showed changes in the feed composition and products dur- ing the probation test. Various operating parameters of the unit, such as temper- atures, pressures, steam-to-carbon ratio, and steam drum pressure, were monitored during the probation test. The unit’s performance was compared to previous tests, reveal- ing improved performance in terms of duty recovered by the convection section and a reduction in stack temperature. The evaluation of the probation test results indicated that the cleaning of the convection section had led to a 14% increase in duty recovered from flue gases compared to the previous test in December 2021. The reformer inlet temperature also increased from 437°C to 501°C, contributing to improved thermal effi - ciency. The lower stack temperature and increased effi - ciency resulted in cost savings of approximately $220,000 annually.

Revamps 2023