WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in a Single Source
First Quarter 2011 Plant Maintenance/Reliability/Safety
HYDROCARBON PUBLISHING COMPANY Translating Knowledge into Profitability
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TABLE OF CONTENTS 1Q2011 Review Plant Maintenance/Reliability/Safety 21. Plant Maintenance/Reliability/Safet ............................................................................................. 1 21.1 MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES ............................................................................................. 1 21.1.1 Introduction .............................................................................................................................................. 1 21.1.2 Market Conditions .................................................................................................................................... 1 21.1.2.1 Industry Challenges and Technology Drivers ......................................................................... 1 21.1.2.2 Economic Impact of Maintenance, Reliability, and Safety Issues .......................................... 3 21.1.3 Technology Directions, Competition, and Future Outlook ....................................................................... 5 21.1.3.1 Technology Vendors Focus on Turnkey Offerings ................................................................. 5 21.1.3.2 Unit-by-Unit Reliability and Safety Issues ............................................................................. 5 21.1.3.3 Latest Developments in Refinery Maintenance, Reliability, and Safety ................................. 6 21.1.4 Conclusion ................................................................................................................................................ 8 21.2 STATE-OF-THE-ART TECHNOLOGY ....................................................................................................................... 8 21.2.1 Optimization of Plant Reliability with Asset Management ....................................................................... 8 21.2.1.1 Reliability Centered Maintenance ........................................................................................... 9 21.2.1.2 Risk-based Inspection ........................................................................................................... 10 21.2.1.3 Root Cause Analysis ............................................................................................................. 10 21.2.1.4 Reactive Maintenance vs. Predictive Maintenance ............................................................... 11 21.2.2 Intelligent Field Devices ......................................................................................................................... 11 21.2.2.1 Standard Communication Protocols ...................................................................................... 11 21.2.2.2 Incorporating Wireless Technologies into Refineries ........................................................... 12 21.2.3 Inspection and Monitoring ...................................................................................................................... 13 21.2.3.1 Non-destructive Testing ........................................................................................................ 13 21.2.3.2 Laboratory Evaluation........................................................................................................... 15 21.2.4 Identifying Gaps in Reliability and Maintenance Practices via Benchmarking ..................................... 15 21.2.4.1 AP Networks ......................................................................................................................... 15 21.2.4.2 Solomon Associates .............................................................................................................. 16 21.2.5 Commercially Available Automation, Control, and Asset Management Technologies .......................... 17 21.2.5.1 AP Networks ......................................................................................................................... 17 21.2.5.2 ABB Automation .................................................................................................................. 18 21.2.5.3 AspenTech ............................................................................................................................ 19 21.2.5.4 Emerson Process Management.............................................................................................. 20 21.2.5.5 Flowserve .............................................................................................................................. 22 21.2.5.6 Honeywell Process Solutions ................................................................................................ 22 21.2.5.7 Invensys Operations Management ........................................................................................ 24 21.2.5.8 KBC ...................................................................................................................................... 25 21.2.5.9 Metso..................................................................................................................................... 26 21.2.5.10 Rockwell Automation ........................................................................................................... 27 21.2.5.11 Yokogawa ............................................................................................................................. 28 21.3 PLANT OPERATIONS AND PRACTICES .................................................................................................................. 28 21.3.1 Case Study: Improving Plant Turnaround Strategy ............................................................................... 28 21.3.2 Impact of Materials Science on Refinery Reliability ............................................................................... 29 21.3.3 Refinery Process Safety Management ..................................................................................................... 31 21.3.4 Case Study: Implementing PSM Metrics ................................................................................................ 32 21.3.5 Maintenance, Reliability, and Safety Issues for Individual Processing Units ........................................ 33 21.3.5.1 Crude Blending, Treating, and Desalting .............................................................................. 33 21.3.5.2 CDU/VDU and Crude Preheat Train .................................................................................... 35 21.3.5.3 Fluid Catalytic Cracking ....................................................................................................... 38 21.3.5.4 Hydrocracking....................................................................................................................... 41
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TABLE OF CONTENTS 21.3.5.5 Hydrotreating......................................................................................................................... 43 21.3.5.6 Catalytic Reforming .............................................................................................................. 44 21.3.5.7 Isomerization ......................................................................................................................... 46 21.3.5.8 Coking and Visbreaking/Thermal Cracking .......................................................................... 47 21.3.5.9 Solvent Deasphalting ............................................................................................................. 50 21.3.5.10 Alkylation .............................................................................................................................. 51 21.3.5.11 Gas Plant and Flare Gas System ............................................................................................ 52 21.3.5.12 Product Treating, Sulfur Plant, and Amine Systems ............................................................. 54 21.3.5.13 Hydrogen Plant ...................................................................................................................... 56 21.3.5.14 Lube Oil Production .............................................................................................................. 57 21.3.5.15 Utilities Systems and Auxiliary Equipment/Processes .......................................................... 58 21.4 REFERENCES ........................................................................................................................................................ 61
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