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Type PR Online Assurance Program: Success Story

Ebulator details

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340 views2 pages

Type PR Online Assurance Program: Success Story

Ebulator details

Uploaded by

varun sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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success story

Type PR Online Assurance Program


The Challenge: Today, refiners utilize the ebullated bed hydrocracking process to convert heavy residues and
petroleum bottoms into saleable distillate products, thus maximizing plant throughput and
equipment performance. Recently, a world class refinery experienced three upsets of their
ebullated bed process within a period of five years. Because the refinery was operating with an
unspared pump, as is customary in this service, the upsets resulted in 60 days of unplanned
downtime, with significant production losses.
The Solution: The Flowserve Type PR Online Assurance program has been implemented at refineries in order to help
diagnose these recurring problems within the ebullated bed hydrocracking unit. Utilizing the Flowserve
Technology Advantage™ platform, the Type PR Online Assurance program combines equipment
performance data acquisition with expertise and advanced diagnostics. This makes it possible for
plant operators to not only detect system problems, but to take corrective actions to optimize the
ebullated bed process. At the heart of this system is IPS APEX™, an intelligent monitoring, diagnostic
and control device developed by Flowserve engineers.

After the installation was complete, the PR Online Assurance program quickly identified the problems
and allowed plant personnel to take the necessary actions to improve overall unit performance.

The Type PR “Ebullator” reactor recycle pumping system • Gas holdups: Catalyst bed partially fills with trapped
operates in extremely demanding conditions. High- gasses, reducing flow through the unit.
temperature, high-pressure feed is mixed with hydrogen
Left undetected, these problems can result in decreased
and reacted within a catalyst bed that is “ebullated” by the
efficiencies, damaged equipment and the loss of millions
Type PR system. This system includes the ebullating pump,
of dollars in costly downtime.
variable frequency drive and oil injection pumps.
In the typical ebullated bed conversion process, refiners
can potentially be faced with a wide variety of problems.
Some of the more common problems encountered are:
• Carryover events: Solids in the catalyst bed enter
the suction of the Type PR downcomer and impeller,
causing an obstruction in the flow.
• Catalyst bed compression: Catalyst bed becomes filled
with solids, causing a dead-head condition within the
reactor vessel.
• Impeller jam: Large solids in the system lodge in the
impeller inlet, causing it to stall.
• Improper lubrication: Oil condition deteriorates, or
incorrect oil grade is used.
• Reverse rotation: Motor incorrectly wired at
commissioning
Type PR Reactor Recycle Pump Installation

Experience In Motion
success story

Recommendations: Results:
As a solution to these harmful conditions, Flowserve has developed the After the last pump repairs were made and the Type PR Online
PR Online Assurance Program, offering 24/7 monitoring of the reactor Assurance system installed, the refinery was able to:
recycle pump. Together with IPS APEX data acquisition and diagnostics,
• Optimize system efficiency
this system:
• Maximize productivity
• Acquires data from the pump and other components via its onboard, • Reduce or eliminate downtime
sensor-based monitoring and control system • Minimize maintenance costs
• Analyzes data, diagnosing any problems using advanced algorithms • Execute timely implementation of upgrades
developed by Flowserve engineers specifically for the PR ebullator • Perform all of the above for minimum investment
pump
Through the application of advanced technologies and with
• Warns plant personnel of current or developing problems within the
the cooperation of product and industry experts, users of the
ebullated bed system or any of its components
Type PR Online Assurance program can proactively manage every
Data is then transmitted to the Technology Advantage Web portal. This facet of the life cycle cost of ebullated bed process equipment.
user-friendly tool allows plant personnel to monitor the ebullated bed unit In doing so, customers can look beyond traditional equipment
operations via a secure system accessible from anywhere in the world. and aftermarket purchase agreements for alternative, value-based
business relationships.

Technology Advantage Web Portal

Bulletin FSG-SS-011a (E) Printed in USA. February 2012.


© Flowserve Corporation

USA and Canada Latin America


To find your local Flowserve representative: Flowserve Corporation Flowserve Corporation
5215 North O’Connor Blvd. Martín Rodriguez 4460
Suite 2300 B1644CGN-Victoria-San Fernando
For more information about Flowserve Corporation,
Irving, Texas 75039-5421 USA Buenos Aires, Argentina
visit www.flowserve.com or call +1 937 890 5839. Telephone: +1 937 890 5839 Telephone: +54 11 4006 8700
Telefax: +54 11 4714 1610
Europe, Middle East, Africa
Flowserve Corporation Asia Pacific
Parallelweg 13 Flowserve Pte. Ltd.
4878 AH Etten-Leur 10 Tuas Loop
The Netherlands Singapore 637345
Telephone: +31 76 502 8100 Telephone: +65 6771 0600
Telefax: +65 6862 2329

flowserve.com

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