Portable Chiller for Naphtha Cooling: Sustains ... · Portable Chiller for Naphtha Cooling: Sustains Hydrocracker at Maximum Throughput In Summer Fatema S. Hashem Technical Services

Portable Chiller for Naphtha Cooling:

Sustains Hydrocracker at Maximum Throughput In Summer

Fatema S. Hashem Technical Services Department

The Bahrain Petroleum Company BSC (c)

Massimo Capra Manager Aggreko Process Services

Aggreko

© Bapco 23-24 January 2017 Empowering Progress

http://bapcoportal/

Portable Chiller for Naphtha Cooling: Sustains Hydrocracker at Maximum Throughput In Summer

Agenda

2 © Bapco 23-24 January 2017 Empowering Progress

• Aggreko • Aggreko in Oil Refineries • The Bahrain Petroleum Company (Bapco) • No.1 Hydrocracking Unit (1HCU) • Operational Challenges - Summer 2016 • Options • Portable Chiller Solution • Concluding remarks


Aggreko


• Power Generation and Temperature Control solutions for rent • Fast deployable solutions • Founded in 1962 in the Netherlands • Global basis - over 190 service centres in over 45 countries. • Employing more than 6,000 people


Aggreko in Oil Refineries


Engineered Temporary Cooling/Power Solutions: • Process Enhancement solutions:

‒ Capture short term Market Opportunities ‒ Solve Seasonal and Environmental issues

• Turnaround solutions: ‒ Provide Utilities continuity ‒ Improve the Time/Cost Schedule


Aggreko Process Services (APS)


Provide Engineered Cooling Solutions meeting customers’ requirements, to achieve: • Safety: participation in Hazop Studies and Management of

Change (MOC) reviews • Environmental compliant solutions • Performance predictability • Reliability • Active customer involvement


Aggreko in Bapco - Summer 2016


• Bapco needed a portable chilled water package • Scoping study:

– Bapco specified: Heat duty, temperatures, technical information – Requirements: 100% reliability, 24/7 operation, standalone package,

continuous support by Aggreko

• Design: – Aggreko submitted optimized solution for review, participated in Hazop, MOC

• Implementation: – Tailor-made portable chiller, installed and commissioned in 3 weeks

Presenter

Presentation Notes

Bapco needed a portable chilled water package for their Hydrocracker Light Naphtha Trim Cooler to ensure that the unit could be sustained at maximum throughput during summer 2016



Aggreko in Bapco - Summer 2016


Portable Chiller


Presenter

Presentation Notes

Ensuring reliability Bapco installed tie-ins and isolation valves Aggreko provided two chillers, compressors, pumps, operating at 50% load, diesel generator, continuous operations, maintenance support Isolation valves installed during night shift at lower ambient temperature, max aircooling, with bypassing the cooler, fast-track before temperatures increased


Aggreko - Measuring Success

• Zero Accidents • No Spills • Assets Availability & Reliability • Added Value for Customer’s Money



The Bahrain Petroleum Company BSC (c)


• 100% owned by the Government of the Kingdom of Bahrain • Formed in 1929 and has been the cornerstone of Bahrain’s

economic development • Refinery started in 1936, has been operating for 80 years • Current refinery capacity 265 MBPD • In 2007, new Low Sulphur Diesel Production (LSDP) Complex

inaugurated • LSDP Complex centred on new heavy vacuum gas oil (HVGO)

hydrocracker (1HCU)


No.1 Hydrocracking Unit (1HCU)


• Processing capacity 50,000 BPD at 80 vol% conversion • Licensed by CLG: 2-reactor system with recycle • 3 yearly catalyst changeout cycle and 6 yearly T&I cycle • Produces a range of high value, low sulphur products: ‒ Naphtha ‒ Kerosene ‒ Ultra low sulphur diesel ‒ Unconverted oil


No.1 Hydrocracking Unit (1HCU)



1HCU Light Naphtha Product



Operational Challenges - Summer 2016


• Higher hydrocracker throughput: more naphtha • Catalyst at end-of-run (EOR): higher reaction temperatures and

more naphtha • Upstream Light Naphtha Air Cooler E7730: high inlet T (catalyst at

EOR), cooler fouling (end of T&I cycle), high ambient temperatures • Light Naphtha Trim Cooler E7731: high seawater temperatures

and low flow • Light Naphtha temperature approaching rundown temperature limit • Potential for a slowdown of hydrocracker

Presenter

Presentation Notes

We recognised the upcoming challenges


Options


• Reduce hydrocracker throughput • Increase the light naphtha end point to reduce TVP • Blend light naphtha and the heavy naphtha routed to storage • Drop part of light naphtha into the heavy naphtha inside the

column • Use of chilled water instead of seawater in E7731 i.e. portable

chiller

Presenter

Presentation Notes

The solution had to be: 1. feasible/ cost effective/ fast-track/short-term/ reliable LPO calculated


Portable Chiller


• Project launched for portable chiller for Light Naphtha cooling • Scope defined: Light Naphtha Trim Cooler heat duty, inlet and

outlet naphtha temperatures and flow

• Mandatory requirements: 100% reliability, 24/7 operation, standalone package with diesel power generator, continuous operations and maintenance support by contractor


Portable Chiller (cont’d)


• Established feasibility based on process, operational and mechanical requirements and cost

• Worked with Aggreko to get a viable solution

• Bapco provided utilities i.e. diesel fuel and flash evaporated distillate (water)

• New piping connections were required which were installed on the run


Portable Chiller (cont’d)


Presenter

Presentation Notes

Ensuring reliability Bapco installed tie-ins and isolation valves Aggreko provided two chillers, compressors, pumps, operating at 50% load, diesel generator, continuous operations, maintenance support Isolation valves installed during night shift at lower ambient temperature, max aircooling, with bypassing the cooler, fast-track before temperatures increased


Performance


• Process specifications and performance before and after chiller

• Chiller worked reliably for 4 months during summer months delivering the required performance

Naphtha Flow (BPH) Cooler Inlet T (F) Cooler Outlet T (F) (Rundown)

June 2016 Before Chiller Installation

300 127 114

June 2016 After Chiller Installation

300 135 82

Max Naphtha Flow 350 138 90


Concluding remarks


• The portable chiller project for Light Naphtha cooling was a great success

• The project was fast tracked: 6 weeks from project initiation to installation

• Achieved 4 months of successful operation during a very hot and humid summer

• Naphtha temperature always below rundown limit • No reduction in 1HCU throughput


Concluding remarks (cont’d)


• Keys to success: ‒ Technically strong, experienced, aligned and motivated in-

house multidisciplinary team ‒ Technically strong, experienced and committed Aggreko

team who worked closely with us ‒ Vital to involve the right people in the evaluation and

decision-making process


Audience Poll


• What was the minimum rundown temperature we were able to achieve with the chiller? ‒ 82 ºF ‒ 100 ºF ‒ 90 ºF ‒ 105 ºF


Thank You


Documents

Portable Chiller for Naphtha Cooling: Sustains ... · Portable Chiller for Naphtha Cooling: Sustains Hydrocracker at Maximum Throughput In Summer Fatema S. Hashem Technical Services