Replacement of Reactor Internals - RFTL

JULIO R. ZEVALLOS GUERRA

Belongs to Petroperu Corporation

It is located in the north of Peru, in Piura department.

It was created in 1917.

CCC was built in 1974, under UOP license.

Main plants are: Distillation Unit (65000 B/D) FCC Unit (19000 B/D) Vacuum Unit (29000 B/D) Gas Recovery Unit

XI Catalytic Cracking Complex Turnaround

It is divided in 4 Units:

Engineering: Equipment Inspection

Coordination and Cost: Maintenance Planning

Plant Maintenance: Maintenance Execution

Shops: Welding, Tool machines, Pump repair


It is turnaround of Catalytic Cracking Complex

Includes following plants: FCC, Vacuum, Merox, Gas Recovery, Utilities, CO Boiler, Salt Water Facilities

Organization includes 20 zones, such as:

Repair of CO Boiler

Replacements on reactor

Repair of rotating equipment

Repair of fractionating column

Repair of vacuum furnace


Replacement of FV4 reactor cyclone with two cyclones

Replacement of the stripper, adding 1 more plate.


CYCLONE:

Bad mechanical condition: Heavy damage on anti erosion protection of the cyclone

Efficiency lost

Accumulation of catalyzer on the bottom of fraction column

Need of bigger cyclone for present operation conditions


STRIPPER:

Bad mechanical condition of Baffles and stripper plates.

Damage of anti-erosion protection of Baffles.

Mechanical failure of steam distributor.

Low efficiency on stripping of hydrocarbon gases, due to higher load of FCC unit.


To improve the catalyst separation of hydrocarbon gases from the reactor, by saving catalyst, avoiding contamination of the fraction system and to process higher load of FCC unit.

Minimize dragging hydrocarbons to the regenerator.

To improve the thermal balance.

To reduce loss of hydrocarbons.

Overcome mechanical problems.

Increase operational reliability and flexibility


REACTOR

REGENERATOR

RISER

STRIPPER


There were programmed some previous works, mainly fabrication of parts of riser and temporary structures.

In addition to Petroperus personnel, we contracted some services:

ITEM SERVICE DESCRIPTION CONTRACTOR

1 Contracted personnel Minar

2 Rolled of plates Demem

3 Non Destructive Testing Qualitest

4 Installation of anti erosion protection Saterfi

5 Heat treating of Stripper and riser Inspectra


Team 1 Team 2

PS01 External structure PC01 Bottom support for riser

PS02 External structure for head PC02 Structure for riser head

PS03 Internal structure bottom part PC03 Structure for riser

PS04 Internal structure medium part PC04 Balance Hoist riser segment

PS05 Internal structure top part PC05 Steam distributor superior # 1

PS06 Structure for gas line PC06 Steam distributor superior # 2

PS07 Top platform PC07 Steam distributor inferior

PS08 Hoisting rocker arm for head PC08 Baffles of Stripper

PS09 Bracket tools PC09 Baffles of Riser

PS10 Cyclone support PC10 Riser Segment

PC11 Scaffolding for Stripper

Following parts were manufactured in Petroperus shops:


PS01 External structure


PS05 Internal structure top part


PC10 Riser Segment


PC05 Y PC06 Steam distributors


Control of execution


Replacement of internals were programmed to do during the CCC turnaround.

In addition to Petroperus personnel, we contracted some services:


ITEM SERVICE DESCRIPTION CONTRACTOR

1 Welding service Minar

2 Heat treating Inspectra

3 Non Destructive Testing Qualitest

4 Installation of scaffolding R&H

5 Topography Vulcano

6 Installation of anti erosive protection Saterfi

COLOR CODE

GREY : REMAINS

GREEN : REUSED

RED : REPLACED

BLUE : NEW

CYCLONE

REGENERATOR

FV3

HEATER FH1

REACTOR

FV4

RISER

VALV. FK2

VALV. FK1

ORIFICE

CHAMBER

FV16

VALV.

FK4

VALV.

FK3

GAS

LINE

GAS TO MAIN

COLUMN

GAS TO CO

BOILER

STRIPPER


REGENERATOR

FV3

HEATER FH1

REACTOR

FV4

RISER

VALV. FK2

VALV. FK1 VALV.

FK4

VALV.

FK3

GAS

LINE

GAS TO MAIN

COLUMN

STRIPPER

GAST TO CO

BOILER


COLOR CODE

GREY : REMAINS

GREEN : REUSED

RED : REPLACED

BLUE : NEW ORIFICE CHAMBER

FV16

REGENERATOR

FV3

HEATER FH1

REACTOR

FV4

RISER

VALV. FK2

VALV. FK1 VALV.

FK4

VALV.

FK3

GAS

LINE

GAS TO MAIN

COLUMN

STRIPPER

GAS TO CO

BOILER


COLOR CODE

GREY : REMAINS

GREEN : REUSED

RED : REPLACED


FV16

REGENERATOR

FV3

HEATER FH1

REACTOR

FV4

RISER

VALV. FK2

VALV. FK1 VALV.

FK4

VALV.

FK3

GAS

LINE

GAS TO MAINI

COLUMN

STRIPPER

GAS TO CO

BOILER


COLOR CODE

GREY : REMAINS

GREEN : REUSED

RED : REPLACED


FV16

REGENERATOR

FV3

HEATER FH1

REACTOR

FV4

RISER

VALV. FK2

VALV. FK1 VALV.

FK4

VALV.

FK3

GAS

LINE

STRIPPER

GAS TO CO

BOILER


COLOR CODE

GREY : REMAINS

GREEN : REUSED

RED : REPLACED


FV16

There are 92 joints to weld, distributed as follows:

47 during previous works. 45 during replacement.

Welding type Electrode

Alloy steel SMAW (Arc welding) E8018-B2

GTAW (TIG) ER80S-B2

Carbon steel SMAW (Arc welding) E7018

Clad (Inox) GMAW (MIG) OK.AUTROD-1679

Hex mesh and S-bar SMAW (Arc welding) E410 Ni-Mo

Electrodes required:


Materials to weld are Chrome Molybdenum alloys (1 Cr, Mo).

ASTM-387 GR.11

ASTM-335 GR. P11

ASTM-234 GR. WP11

Welding these materials is rather difficult due to Chrome content. Petroperus welders have to be trained in this welding type in order to get required skill.

Replacement is done according to following technical standards:

API 31.3 for pipes in petroleum refineries

ASME Secc. VIII for pressure vessels

UOP Standards


WPS - Welding procedures specifications


Heat treating cycle


Riser heat treating



LIFTINGS WEIGHT

(Tn)

1 Dismounting of gas pipeline 2.0

2 Dismounting of top platform 2.0

3 Dismounting of head with cyclone 9.5

4 Dismounting of top end of riser 9.5

5 Dismounting of riser segment 7.0

6 Dismounting of stripper baffles 0.4

7 Dismounting of steam distributor 0.4

8 Installation of Steam Distributor 0.2

9 Installation of new stripper baffles 0.4

10 Installation of riser segment 7.0

11 Installation of internal temporary structure 4.0

12 Installation of top end of riser 9.5

13 Installation of internal upper structure 4.0

14 Installation of new cyclones 7.7

15 Installation of Head with Plenum chamber 4.0

16 Installation of top platform 2.0

17 Installation of gas pipeline 2.0


CRANE

It is a principal concern during a plant turnaround

Work is done according to safety procedures in Petroperus safety handbook

Work permits are used for:

Works with heat or fire

Works in restricted areas

Works at height

Personal protective equipment is used for different jobs


RISER BAFFLES

STRIPPER

BAFFLES


Documents

Replacement of Reactor Internals - RFTL