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REGIONAL REPORT
Extensive update of
Middle East refining and
petrochemical industries
ROTATING EQUIPMENT
Thorough review explores
ways to optimize hydrogen
compressor operations
PROCESS ENGINEERING
Improve sizing of emergency
relief devices for olefins units
SPECIAL REPORT:
Maintenance
and Reliability
Proper maintenance and inspection programs
support safe and reliable plant operations
65
40
SPECIAL REPORT: MAINTENANCE AND RELIABILITY
41 Reduce maintenance and production losses
by benchmarking asset performance
M. Naik
45
51
57
DEPARTMENTS
10
19
103
106
108
109
110
News
Industry Metrics
Innovations
Marketplace
Advertiser Index
Events
People
REGIONAL REPORT
65 The Middle Easts strategic expansion of refined products exports
M. Rhodes
ROTATING EQUIPMENT
79 Use new methods to optimize energy efficiency
of hydrogen compressors
COLUMNS
9
Change is redefining
the petrochemical industry
21
25
27
HP staff
Project Management
Build a better bid, or how to achieve
a competitive advantage
in capital projects
31
Global
Uganda proceeds with new refinery
Automation Strategies
Developing the best practices
for operator effectiveness
in the age of collaboration
PROCESS ENGINEERING
91 Improve relief-device sizing under supercritical conditions
Reliability
Reassessing and updating
electric motor bearing lubrication
M. Vila Forteza
PROCESS TECHNOLOGY
87 Improve measurement of heavy oil viscosity
Editorial Comment
33
Petrochemicals
M&A deals rise as investors push
petrochemical leaders to restructure
35
37
Viewpoint
Methanol takes on LNG
for future marine fuels
www.HydrocarbonProcessing.com
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Adrienne Blume
Heinz P. Bloch
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Helen Meche
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Editorial
Comment
27Project management.
37Viewpoint.
Methanol may
be the marine fuel of the
and
40Maintenance
reliability.
Maintenance
report:
65Regional
The Middle East.
The Middle East is transforming its
downstream business to be both
vertically integrated across the value
| News
Shell to become largest LNG player
with 47-B BG Group acquisition
Royal Dutch Shells agreement to purchase BG Group for approximately 47 B
in cash and shares is the oil and gas industrys biggest deal in at least a decade.
Shell saw its 2014 worldwide production drop to the equivalent of 3.08 MMbpd,
the lowest in at least 17 years, while BG boosted reserves in six of the past
seven years, 78% of which were gas, compared with 47% for Shell.
Shell expects the acquisition to accelerate its growth strategy, adding
approximately 25% to the companys proved oil and gas reserves and 20% to
production, each on a 2014 basis. The deal will also provide Shell with enhanced
positions in competitive new oil and gas projects, particularly in Australia LNG
and Brazil deepwater areas.
Shell said that the merged company, led by Shell CEO Ben van Beurden, will
boast a market value twice the size of BP.
News
which has a characteristically poor selfignition quality that utilizes the ME-LGI
principle of pilot injection of MGO or
HFO. Fuel injection is accomplished by
a fuel booster injection valve (FBIV), using 300 bar of hydraulic power to raise the
fuel pressure to an injection pressure of
approximately 600 bar.
To date, MAN Diesel & Turbo has
received orders for seven ME-LGI enginesa mixture of 7S50ME-LGI and
6G50ME-LGI variantsfrom Mitsui
OSK Lines, Marinvest and Westfal-Larsen.
FIG. 1. The Neste Oil maintenance project at its Porvoo, Finland, refinery will cost 100 MM.
FIG. 2. MAN customers and partners take part in the demonstration of its ME-LGI concept.
Hydrocarbon Processing|MAY 201511
News
The first engine will be produced by Mitsui Engineering & Shipbuilding Co. Ltd.
(MES) for a vessel currently under construction by Minaminippon Shipbuilding
Co. Ltd. for Mitsui OSK Lines Ltd. MAN
has previously stated that it is working toward a Tier 3-compatible ME-LGI version
that can meet IMO NOx limits with the
aid of secondary measures. More information about this technology can be found in
the Viewpoint article on page 37.
Reliance commissions
two new plants
Reliance Industries Ltd. has successfully put into operation two plants in Dahej,
Gujarat, India.
The first is a polyethylene terephthalate (PET) resin plant that consists of two
lines with a combined manufacturing capacity of 650 metric Mtpy. The plant has
been built with Invista technology for con-
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Mitsubishi Corp. (26.25%), Mitsubishi
Heavy Industries (MHI) (17.5%), and
Trinidad and Tobagos state-owned National Gas Co. (NGC) (20.0%) and Trinidadbased Massy Holdings Ltd. (10.0%).
The project, scheduled to begin by October 2018 and to be completed by June
2018, would have a capacity of 1 MMtpy
of MeOH and 20 Mtpy of DME. The
MeOH will be sold worldwide, according
to the partners.
Impact of changing
US crude export policy
Wood Mackenzie is examining the
impact a potential policy shift may have
on US export crude oil flows and differentials. Ultimately, while eliminating the
US export ban would narrow the Brent
WTI differential and raise the wellhead
price for US crudes, it would be unlikely
to transform the supply outlook, Wood
Mackenzie suggests.
Wood Mackenzie, which is being acquired by Verisk Analytics, points out
that the quality of a US barrel that might
be exported is not obvious. The greater
narrowing of Brent to Louisiana Light
Sweet (LLS) crude oil would depend on
US exports of light-sweet crude oil to the
growing Asian market, with long-haul
large parcels. Asia would also have the
greatest appetite for crude oils similar
to Mars crude, whereas Europe places a
relatively higher value on condensate, but
would have a limited appetite for US light
barrels because much of its light-sweet
crude oil requirements are satisfied by
production in the North Sea or Mediterranean regions.
Wood Mackenzies outlook suggests
that the best value for Eagle Ford condensate is to split the barrel locally and sell cuts
to a variety of markets. The company suggests that the policy debate needs to move
beyond the generic notion of US crude
14
Select 55 at www.HydrocarbonProcessing.com/RS
News
exports to a more substantive discussion
of potential destinations and types of US
crude oil that might be exported.
WHEN THE
PRESSURE IS HIGH,
TRUST
DELTA SCREENS.
16
News
When the pipelines are complete, Motiva plans to idle the fluid catalytic cracker
(FCC) at its Convent refinery and to reconfigure the existing hydrocracker unit at
its Norco refinery to process 30 Mbpd of
additional gasoil into high-quality diesel.
On a combined basis, the Louisiana Refining System is expected to drive incremental
annual benefits of $350 MM of EBITDA.
www.htri.net
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CTP Grid
www.codeware.com
sales@codeware.com
(941) 927-2670
Founded in 1983, Codeware focuses exclusively
on developing intuitive engineering software.
Contact us to see why companies in over
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28.6 years
03/04/2019
2:PASS
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Industry Metrics
130
Cracking spread, US$/bbl
Mar. 15
Feb. 15
Jan. 15
Nov. 14
Oct. 14
Sept. 14
July 14
June 14
May 14
Aug. 14
Mar. 15
Feb. 15
Jan. 15
Dec. 14
Mar. 15
Feb. 15
Jan. 15
Dec. 14
Nov. 14
Oct. 14
Sept. 14
Aug. 14
Mar. 14
Mar. 15
Feb. 15
-20
2016-Q1
Jan. 15
2015-Q1
Dec. 14
2014-Q1
Nov. 14
2013-Q1
Oct. 14
2012-Q1
Gasoil, 10 ppm S
Fuel oil, 1% S
-10
Mar. 14
2011-Q1
Sept. 14
-0.5
-1.0
Aug. 14
0.0
10
July 14
0.5
June 14
1.0
20
May 14
2.0
1.5
April 14
Forecast
2.5
50
Mar. 15
Feb. 15
Jan. 15
Dec. 14
Nov. 14
April- May- June- July- Aug.- Sept.- Oct.- Nov.- Dec.- Jan.- Feb.- Mar.14
14
14
14
14
14
14
14
14
15
15
15
Gasoil, 50 ppm S
Fuel oil, 180 cSt, 2% S
Oct. 14
Sept. 14
10
-10
-20
Aug. 14
20
10
July 14
30
20
June 14
40
Mar. 14
30
May. 14
Gasoil/diesel, 0.05% S
Fuel oil, 180c
-10
M A M J J A S O N D J F M A M J J A S O N D J F M
2013
2014
2015
96
94
92
90
88
86
84
82
80
78
2010-Q1
0
July 14
Source: DOE
10
June 14
W. Texas Inter.
Brent Blend
Dubai Fateh
70
30
20
May 14
85
April 14
100
April 14
40
40
New projects
Japan
Singapore
115
55
Nov. 14
US
EU 16
Oct. 14
Mar. 14
70
60
50
Sept. 14
M A M J J A S O N D J F M A M J J A S O N D J F M
2013
2014
2015
80
Aug. 14
1
0
90
July 14
June 14
3
Monthly price (Henry Hub)
12-month price avg.
12-month price avg.
Production
May 14
Brent, Rotterdam
100
Utilization rates, %
April 14
WTI, US Gulf
Dubai, Singapore
Dec. 14
0
-5
Mar. 14
80
70
60
50
40
30
20
10
0
Production, Bcfd
15
10
April 14
twitter.com/HunterBuildings
Select 77 at www.HydrocarbonProcessing.com/RS
linkedin.com/company/Hunter-Buildings
Reliability
oil refinery. The author had visited this site in late 2012 or early
2013 to address electric motor lubrication matters. At this refinery, the electrical department was in charge of everything
regarding motor maintenance. The leaders at that location had
taken the position that oil mist was unsuitable for electric motorsan incorrect notion, which is solidly refuted by 27,000
electric motors lubricated and operating elsewhere.
Some of the elsewhere locations include both horizontal
and vertical electric motors in countries around the world. At
a competitors ethylene plant in Texas, oil-mist-lubricated motors range from 1.5 hp to 500 hp. On many of the 107 vertically oriented oil-mist-lubricated motors in the Texas facility,
no motor bearings needed to be replaced over a 37-year period
from 1977 to 2014.
One problem at a major oil refinery located in a northern US
state was that, when solving technical issues, solutions were often based on opinions instead of on solid facts. These opinions
were then passed down to younger staff members, who, without input or mentoring from more experienced individuals,
had no incentive to replace anecdotes with facts. The corporate
engineering group claimed that oil mist could not be cost-justified. Corporate had neglected to factor in the remarkable labor
savings and total life extension of oil-mist-lubricated electric
motors. As a consequence, the refinery specified and purchased
grease-lubricated electric motors. They also stipulated voltage,
speed, service factor, hp, insulation grade and other parameters.
Yet, nobody at this refinery showed any interest in specifying
the bearing style and grease path that are considered equally
important by reliability-focused competitors.
1. Lubrication entry
4. Bearing
5. Inner cap
3. Shaft
Single-shield motor
bearing with shield
facing the grease cavity
partment at this particular refinery did not insist on an expanded specification. Why engage in a career-limiting battle with
entrenched non-readers when all that truly counts are initial
costs and commissioning schedules? The cost-estimating basis
for electric motors at this refinery reflected only the least initial
cost, and each motor supplier wanted to be the lowest bidder.
Case 2. During a 20142015 project for a large petrochemical
6. Bracket
2. Drain
Reliability
Recommended reading
list for oil-mist lubrication
applications
1. Bloch, H. P., Dry sump oil mist lubrication for electric
motors, Hydrocarbon Processing, March 1977.
2. Bloch, H. P., Oil mist lubrication: Is it cost-justified?,
Hydrocarbon Processing, October 1990.
3. Bloch, H. P., When to use lifetime lubricated ball
bearings, Hydrocarbon Processing, July 1991.
4. Bloch, H. P., Storage preservation of machinery,
Hydrocarbon Processing, August 1991.
5. Bloch, H. P., Oil mist proven for electric motor
lubrication, Hydrocarbon Processing, August 1994.
6. Bloch, H. P., Implementing modifications on pumps
and motors, Hydrocarbon Processing, September 1994.
7. Bloch, H. P., Identifying electric motor bearings,
Hydrocarbon Processing, November 1995.
8. Bloch, H. P., Lubricationnot an afterthought,
Hydrocarbon Processing, February 1997.
9. Bloch, H. P., Select better bearings, Hydrocarbon
Processing, June 1995.
10. Bloch, H. P. and A. R. Budris, Pump Users Handbook
Life Extension, 4th Ed., The Fairmont Press, Lilburn,
Georgia, 2013.
Again, purchasers with proper lube specifications will avoid
calamity, whereas others will invite distress. An alert reader of
technical texts and information sources will outperform any
non-reader. A company with no budget for technical information, books or training will have more repeat failures than a
company that invests in the knowledge of its maintenance staff
and engineers. Several decades of observation support these
disturbing facts, but talking about the situation could prove
career-limiting for some.
Sealed bearings and smart greases. Assume a refinery
Bearings failed, %
99
95
90
80
70
60
50
40
30
20
AUT 2E45
Polyurea #1
Polyurea #2
10
5
2
1
3 4 5
102
2 3 4 5
103
Bearings grease life, hr
3 4 5
104
Maximizing safety.
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High-quality galvanic isolation for maximum
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Automation
Strategies
tive collaboration requires a high degree of situational awareness, including operational window compliance and a good
overview of the status of procedural automation, process control and any abnormal situations.
New collaboration toolsmany based on Internet Protocol
(IP) and concepts of the emerging IIoToffer significant potential to improve operator effectiveness through increased access
to sensor-based data, new cloud-based data analysis tools and
better collaboration, both within plants and across multi-plant
enterprises. However, many of these tools remain unproven in
demanding industrial environments in which downtime is unacceptable and occasional glitches can have serious repercussions.
Many end users in the heavy process industries still also have
serious concerns about hosting critical data and applications in
the cloud due to the persistent threat of cyber security intrusions.
Information overload is another concern. Present control
systems already provide operators with more raw data and information than they often know what to do with. The newer
information and collaboration tools can only exacerbate the situation. Rather than more data and information, it is important
for operators to quickly and easily access the right information,
in the right context, and in a time frame that makes it useful for
real-time decision support. The operators themselves are often
in the best position to determine this.
Help identify best practices. Clearly, new IT-based technologies and IIoT concepts offer significant future potential to improve operator effectiveness and collaboration. However, many
of these technologies and concepts remain unproven in industrial environments, driving owner/operators to wonder what their
peer organizations are doing in this area.
To help identify best practices, ARC Advisory Group has
launched a confidential web survey on this topic.1 Qualified survey participants will receive a detailed summary. ARC will also
update HP readers in a future column.
1
EDITORS NOTE
For more information, visit www.arcweb.com.
PAUL MILLER is a senior editor/analyst at ARC
Advisory Group and has 30 years of experience in the
industrial automation industry. He continues to follow
the increasing adoption of IT in the OT area and its
various ramifications for industrial organizations.
Visit us at
GPS, Hall D/E,
Booth 7442
Project
Management
RON BECK
Director of Industry Marketing Engineering & Construction, AspenTech
Project Management
eas of uncertainty and risk in the proposed
project, required resources, and realism in
the execution plan to make the appropriate decisions early enough in the project
planning and development process.
Breaking down barriers. As global
work sharing and the size and scope of
projects have increased, managers have
become resistant to changing the highly
structured business processes. To meaningfully address both the bidding and
project execution challenges and risks,
these business processes are now being
evaluated and upgraded. The powerful capabilities of underlying systems, together
with wholesale changes in the engineering workforce, present opportunities for
conceiving, developing and executing
projects in new ways.
Specifically, during the bidding process, the opportunity to tie together
process modeling systems, software to
rate major equipment items, front-end
deliverable collaboration solutions, and
estimating and formal risk analyses will
lead to a competitive advantage and bet-
28
Design
Audit
Farris
Pressure Relief
Management
Solutions
Maintain
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Monitor
Equip
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Global
SHEM OIRERE
Guest columnist
sias defense giant, Rostec, is leading a consortium that includes other Russian firms such as Tatneft and VTB Capital,
the investment arm of Russian bank VTB, along with South
Koreas GS and Telconet Capital Ltd. Partnership.
The Russian-firm-led consortium edged out SK Engineering and Construction Co. to attain the deal. However, the
Ugandan government has retained the Korean firm as an alternate preferred bidder after fears emerged due to sanctions
levied by the US and EU against Russian companies and close
allies of Russian President Vladimir Putin.
The new refinery project marks the end to a prolonged
tug-of-war between the Ugandan government and international oil companies over a controversial tax regime and delayed regulatory requirements to govern the exploration and
production contracts for the countrys estimated commercial
reserves of 3.5 Bbbl. Originally, the government had proposed
a 120-Mbpd refinery.
The primary concerns of the oil companies (in Uganda)
today are receiving approvals on their development plans so
that work can go forward, leading to actual production of
crude oil, says Matthew Tallarovic, director of tax services
for Deloitte East Africa. These approvals for developing the
fields are necessary before an export pipeline or refinery can
actually be viable.
The UKs Tullow Oil, Frances Total SA and China National Offshore Oil Corp. (CNOOC) are developing the oil
fields in Ugandas Albertine Basin. Commercial production of
hydrocarbons is expected in 2018 and will coincide with the
completion of the first phase of the new refinery, which will
process 30 Mbpd.
Concerns that the falling global oil prices could constrain
downstream projects, such as the Ugandan refinery, may not
necessarily be founded. As for Uganda, the refinery will only
be the middle man in the picture, says Tallarovic. As long as
there is demand and an available supply, the refinery works off
Safety Measures
Hard Hat
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Remote Mount
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Workers Off Top of Tank
for Switch Modication
Advanced
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Assures Reliable
Performance
Best-in-Class
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Insulated Gloves
Steel-Toed
Boots
Dual-Point
Option for Two-Alarm
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Safety Harness
echotel.magnetrol.com
Petrochemicals
SHEENA MARTIN
Contributing Editor
agement, however, has not been the primary driving force behind this company
restructuring. Instead, shareholders are
giving their voice, pushing for more attractive, simplified corporate structures
that are agreeable for M&A.
Activist investors are putting pressure on the management of some of
the most prominent chemical majors
to streamline their business portfolio,
said A. T. Kearney partner Joachim von
Hoyningen-Huene.
Activists are primarily facing off with
North American companies at the moment, but increasing fund sizes and a
scarcity of underperforming assets in
the region have also led A. T. Kearney to
forecast stronger shareholder activism in
Europe and Asia.
Targeted companies. In the US, activists have already targeted upstream
companies such as Chesapeake Energy,
SandRidge Energy, QEP Resources and
Hess. In the downstream chemical sector,
activist investors have recently taken aim
at Dow Chemical (FIG. 1) and DuPont.
ily out of line with his demands. Air Products & Chemicals bent to the will of William Ackman in 2013, a credit to the power
that an activist approach can have in swaying a companys leadership and direction.
Ackmans investment group, Pershing Square Capital Managementwhich
holds a 9.8% share in Air Products &
Chemicalsdislodged the company of
its former CEO, John McGlade. In 2014,
board members agreed to enter discussions to hear out Ackmans views on enhancing the companys performance by
changing its corporate culture and improving investment decisions. As of late
March, the companys shares have increased 40% since Ackmans involvement.
DuPont, however, is better positioned
to challenge Peltzs hedge fund, Trian
Fund Management. The hedge fund has
an approximately 2.7% stake in DuPont,
which makes it the fifth-largest company
shareholder.
Ultimately, what all activists have in
common is the goal to strengthen each
companys balance sheet and limit exposure to poorly performing assetsespecially in light of changing breakeven oil
prices. A. T. Kearneys study believes
those factors will put independent oil
companies in prime positions to find
success in the upcoming M&A wave.
All paths
lead to
Lewis Pumps
LEWIS PUMPS
Vertical Chemical Pumps
8625 Grant Rd.
St. Louis, MO 63123
T: +1 314 843-4437
F: +1 314 843-7964
Email: sales@lewispumps.com
www.weirminerals.com
Excellent
Minerals
Solutions
Engineering
Case Histories
since the data are scattered, and probabilities are used. Users
must understand that the equipment service life could be longer
or shorter. However, if the life calculations indicate that a threeyear life is remaining and that only a day run is required, then
this is valuable data to use in the decision-making process.
NOTE
Case 83 was published in HP in March. For past cases, please visit
HydrocarbonProcessing.com.
LITERATURE CITED
Sofronas, A., Analytical troubleshooting of process machinery and pressure vessels,
John Wiley & Sons, 2006.
2
Palmgren, A., Ball and roller bearing engineering, Burbank and Co., pg. 74, 1959.
1
Select 99 at www.HydrocarbonProcessing.com/RS
Viewpoint
4.5
World
3.5
97%
86%
ECA
2022
2021
2020
2019
2018
2017
2016
2015
2014
2013
2012
California
2011
2010
EU in ports
2009
1.5
1.0
0.5
0.1
71%
78%
67%
2008
Viewpoint
the new MeOH-powered ships will be
developed over the next three years.
On March 27, Swedish ferry operator
Stena Line relaunched the Stena Germanica, featuring the worlds first dualfuel MeOH propulsion system. The
240-m-long, 1,500-passenger RoPax ferry features four Wrtsil engines, with
one of the engines converted to MeOH
operation while in dry dock in Polands
Remontowa shipyard in January. Once
the owner is satisfied, the other three
engines will be converted one by one
while the vessel is in service. Running
on MeOH, SOx emissions are expected
to be cut by 99%, NOx by 60%, particulates by 95% and carbon dioxide (CO2 )
by 25%. Funding of 11.2 MM for the
work was provided under the EUs
Trans-European Transport Networks
(TEN-T) program.
Conversion developments. The ef-
FIG. 3. Stena Line will relaunch the Stena Germanica, featuring the
worlds first dual-fuel MeOH propulsion system.
38MAY 2015|HydrocarbonProcessing.com
Zeeco, Inc.
22151 E 91st St.
Broken Arrow, OK 74014 USA
+1 918 258 8551
sales@zeeco.com
Zeeco, Inc. 2015
| Special Report
MAINTENANCE AND RELIABILITY
The service life of an HPI facility is approximately 30 years. During this time, operating
companies use maintenance programs to protect their capital investments. In 2015, the HPI
will spend over $95.2 B globally on various maintenance projects.
Since equipment failures can result in expensive unit and plant shutdowns, as well as in
environmental and/or safety incidents, best-of-class companies maintain the mindset
that spending to improve reliability and equipment conditioning is a great benefit to the
organization. HPI facilities constantly investigate new monitoring and conditioning systems,
along with preventive maintenance and inspection programs.
In the modern HPI, maintenance and reliability staff should not be viewed as services, but
rather as equal partners of operations in the creation of business value. The May special
report explores innovative methods and programs to keep HPI facilities operating as designed.
Special Report
can help identify a specific type of equipment that is having chronic failures. It
also can identify the bad actor assets of
the equipment type that may be experiencing chronic failures, as well as identify
the most common failure mode for these
chronic issues. Finally, asset performance
benchmarking can help build the case for
a failure elimination program.
The key ingredient of any useful endeavor to determine the remaining life of
machinery is often hidden within the client plants own past failure history. Where
such history exists and where the root
causes of failures have been analyzed, au-
FIG. 4. A bad-actor list identifies the specific assets affected by chronic failures.
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conducted using proprietary asset performance management software for the failures encountered since the installation of
the equipment in January 2004.
The MTBF trend shows a peak in
mid-2006 due to a unit turnaround, during which time the asset was not in operation. Excluding this turnaround, it
was observed that, since its installation
in 2004, the MTBF of the asset has remained the same, with a frequency of 35
days. This scenario had led the company
to believe that filter replacement at this
frequency was normal, and simply a part
of required maintenance.
However, with the help of proprietary
software analysis, it became clear that the
failure rate was too high, justifying investment in a failure elimination program. A
root cause failure analysis (RCFA) was
undertaken using a decision-making model. The main reason behind the frequent
filter plugs was identified as the accumulation of emulsion on the filter surface.
Engineering, operations and maintenance found that the emulsion hardens
over time and completely restricts the
pores on the steel-knit mesh filter element. This caused plugs, which, in turn,
triggered the high differential pressure
alarm. After the root cause was fully understood, a high-pressure backwash system was installed in March 2013 to remove the residue remaining on the filter
after the coalescence operation. A highpressure stream of hot water was run every hour during the low-demand period
of the asset, and the residue was collected
from an outlet at the bottom of the vessel.
opportunity. After the improvement was implemented, an as-
Asset
NOTE
The proprietary software program used to pinpoint
and resolve chronic failures in this case study is
Meridiums Asset Answers.
Hydrocarbon Processing|MAY 201543
KEEP IT ONLINE.
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INDUSTRIES SERVED:
Select 86 at www.HydrocarbonProcessing.com/RS
Special Report
Head
1
3
HBase
lers. The compressor main inlet pressure is 200 psia (13.8 bara),
and the discharge pressure is 315 psia (21.7 bara). For simplicity, the pressure ratio for each impeller is the same:
or:
Rp = (P2 /P1 )1/x
where:
Rp = Pressure ratio across each compressor stage.
X = Number of impellers
P1 = Inlet pressure
P2 = Discharge pressure
For this example:
Rp = (315/200)1/4
Rp = 1.12
Efficiency
Rpx = P2 /P1
3
Base (clean)
Damaged labyrinth seals
2
Flow
Centerline
Shaft
G.E.B.
where:
CLRT = Radial clearance for the new rub-tolerant seals, in.
CLbrg = Radial clearance for the compressor journal
bearings, in.
DEye = Impeller eye diameter at the eye seal, in.
For this example:
CLRT = 0.0025 in. + 14/8,000
CLRT = 0.004 in.
A rule of thumb used by one OEM is that approximately 60%
of the pressure is developed in the impeller. The rest of the pressure rise for a stage is developed in the diffuser, as noted previously. This is a crude rule of thumb, and it is not a precise calculation. This value can vary depending on the stage design and
operating conditions. Accurate values can be obtained from software prediction programs that model the compressor in detail.
Pressure
Cl
V
Diffuser
Impeller
P
V
Qi
Inlet
QL
FIG. 4. Closed impeller with labyrinth seal at impeller eye.
46MAY 2015|HydrocarbonProcessing.com
Velocity
FIG. 5. Velocity/pressure development through a centrifugal
compressor stage.
FIG. 6. The calculated leakage rate for the first-stage impeller with
standard aluminum labyrinth seals is 48 lb/min. The leakage rate
for the first-stage impeller with rub-tolerant seals (0.004 in. clearance)
gives 11 lb/min.
2015 15 - 19 June
Frankfurt/Main
hall 11.1, stand E76
BARTEC ORB
Chicago, IL 60632/USA
sales@bartec-orb.com
www.bartec-orb.com
66
65
Efficiency
64
63
Change out to
rub-tolerant seals
62
61
60
Time
Rub-tolerant seals
BIBLIOGRAPHY
Gresh, M. T., Compressor Performance: Aerodynamics for the User, Flexware, 2011.
Whalen, J. K., et al., Polymer seal use in centrifugal compressors-Two users experiences over 15 years, Proceedings of the Second Middle East Turbomachinery
Symposium, 2013, Doha, Qatar.
TED GRESH is president of Flexware Inc. in Grapeville,
Pennsylvania. He has been involved in the design of highefficiency centrifugal compressor staging, field-testing of
compressors and steam turbines, and troubleshooting field
performance problems for over 40 years. While most of this
time was with Elliott Co., he is presently with Flexware Inc.,
a company focused on turbomachinery engineering consulting
services, training seminars and software for turbomachinery performance
analysis. Mr. Gresh received a BS degree in aerospace engineering from the
University of Pittsburgh. He has published a book on compressor performance,
and holds several patents related to turbomachinery. He is a registered
professional engineer in the state of Pennsylvania.
JOHN K. WHALEN, PE, is the chief engineer for John Crane.
He is a member of STLE, ASME and the Vibration Institute.
Mr. Whalen is also a member of the Turbomachinery Symposium
Advisory Committee and is a registered professional engineer
in the state of Texas. He holds a BS degree in mechanical
engineering from the Rochester Institute of Technology.
He worked for Dresser Rand, where he was involved in large
turbine engineering and rotordynamics. Mr. Whalen joined Centritech Corp.
in 1988 and helped form Turbo Components and Engineering in 1991.
Q
FIG. 8. Compressor efficiency improvement.
281-987-0726
www.dyna-therm.com
SEPARATION AND STEAM DRUM SOLUTIONS SINCE 1961
48MAY 2015|HydrocarbonProcessing.com
(1) D.R. Summers, Three Pass Trays Friend or Foe?, Paper 21a AIChE
Annual Meeting, Nashville, TN, Nov, 2009
(2) H.Z. Kister and M. Olsson, Understanding Maldistribution in 3-Pass
Trays, Distillation and Absorption 2010, Eindhoven, Netherlands,
September 2010
Select 89 at www.HydrocarbonProcessing.com/RS
Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee
of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.
IS CLOSER THAN
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sherwin-williams.com/protective
Special Report
plant, approximately 5.2 MMtpy of steam is required in addition to the 100 MW of steam power used for the steam turbines.
As an example, FIG. 1 is a general process diagram for the ethylene cracking process that is greatly simplified. Ethylene production is used as an example here, as it is a common petrochemical. Ethylene itself has no direct use, but it is a building block for
a wide variety of petrochemical products such as polyethylene,
ethylene oxide, ethylene dichloride and ethylbenzene (styrene).
With regard to the turbomachinery technology, the requirements for steam turbine power are estimated at 100 MW for a
large ethylene plant with a capacity of 1 MMtpy. In the past, the
focus of turbine technology has appropriately fallen on the engineering of large steam turbines. However, in present steamcracking plants, opportunities exist to economically optimize
the steam network using smaller steam turbines (50 kW to
300 kW). Such smaller turbines are installed where PRVs are
located on steam lines, thus effectively recovering wasted energy to generate additional electricity.
Small turbines in steam pressure letdown (replacing
PRVs). The operating principal of pressure letdown turbines
Naphtha
Steam in HPI facilities. Steam systems are used in a wide variety of HPI processes. For example, large steam systems drive
turbines in steam-cracking ethylene plants to power process
gas compressors, refrigerant compressors, pumps and electric
generators.2, 3 In a large ethylene plant, a rough estimate of turbine power requirements is 1 MWh/t of ethylene product.4 For
a 1-MMtpy ethylene plant, this means that approximately 100
MW of steam power is needed from the steam turbines.
In addition to the steam supply used by steam turbines, it
is also used within the steam-cracking process. Steam is mixed
with the hydrocarbon feedstock (e.g., naphtha); the feedstock
and steam are heated in the furnace to a temperature where
hydrocarbon molecules thermally decompose to produce
lighter hydrocarbons. The final product obtained from the
cracking process depends primarily on the feedstock composition, steam-to-hydrocarbon ratio, cracking temperature and
residence time in the furnace. Steam-to-hydrocarbon ratios
typically range from 0.3:1 to 1:1.5 Reports from several large
ethylene plants indicate that the average amount of steam used
for cracking is 5.2 ton of steam/ton of ethylene product with
a steam-to-hydrocarbon ratio of 0.6.4 For a 1-MMtpy ethylene
HP steam
for cracking
Heat exchanger
Cracked
products
Water
Deaerator
Superheater
Boiler
Pump
PRVs
Pyrolysis furnace
HP steam
Process steam
consumption
Condenser
Such pressure-letdown turbines are installed in parallel to existing PRVs so that, during maintenance, the PRVs can be used
instead of the turbine on a temporary basis.
When started, the small turbine automatically takes over
the steam flow control from the PRV. When taken offline, the
PRV automatically resumes control of the steam flow. FIG. 2
shows an installation. Since the available energy was previously wasted in the PRV, the electricity is essentially generated at
a low operating cost. However, the capital cost of the turbine
and economic feasibility studies must be reviewed to determine the viability of installing a small steam turbine.
Design of pressure-letdown turbines. When designing
Steam outlet
PRV
PRV
T2
T3
T4
T5
T6
Pressure
T1
1
2
FIG. 3.The steam expansion on the P vs. h state diagram shows that
the steam flow is entering into the wet vapor region.
52MAY 2015|HydrocarbonProcessing.com
6b
arg
:2
ba
rg
250
n /P
ou
t
=1
200
150
Pi
Power, kWe
trap the heavy wet liquid drops at the larger radius and only
pass the lighter gas, acting somewhat like a centrifuge for the
liquid. This heavy liquid would be trapped in the machine,
causing efficiency losses and even damage to the turbine due
to liquid impacting the turbine impeller blades at the inlet.6
For this reason, the turbine style needed to expand wet
steam is a radial-outflow turbine; due to such a geometry, any
heavy liquid drops will move in the direction of the centrifugal
field, which is in the downstream radial outward direction and
will eliminate possible blade damage. FIG. 5 shows a photo of a
radial outflow turbine wheel made of titanium. Radial-outflow
turbines are slightly less efficient than conventional radial-inflow turbines for single-phase flows, 7 but are needed for additional reliability when expanding a wet steam flow to ensure
that the centrifugal field created in the turbine impeller moves
the heavy liquid drops downstream and out of the turbine.
100
g
bar
g: 4
bar
g
bar
6
=1
arg
P out
g: 4 b
10 bar
=
P in/P out rg
ba
:6
arg
b
= 16
g: 6 barg
P out P in/P out = 10 bar
P in/
= 10
P ou
P in/
g: 2
bar
/
P in
50
0
2,000
3,000
4,000
6,000
5,000
Steam owrate, kg/hr
7,000
8,000
Efficiency, %
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Pressure ratio
3.5
4.0
4.5
5.0
1.0
Power
Isentropic efficiency
0.9
200
0.8
0.6
150
0.5
0.4
100
Efficiency, %
Power, kWe
0.7
0.3
0.2
50
0.1
0
1,000
1,500
2,000
2,500
3,000
Steam owrate, kg/h
3,500
4,000
0.0
4,500
through the turbine is also heat loss to the steam system that
must be compensated. This heat loss is steam-system dependent, and is based on experience. It is estimated as 44,000/yr.
This results in a net benefit of 110,000/yr for such a turbine.
Overall, such economic assessments need to be made for each
HPI plant, with a clear view of the economic optimization for
the plant operating costs and benefits.
LITERATURE CITED
Moulijn, J. A., M. Makkee and A. E. van Diepen, Chemical Process Technology,
Wiley Publications, 2nd Ed., 2013.
2
Lee, J. J., et al., Reduce revamp costs by optimizing design and operations,
Hydrocarbon Processing, April 2007, pp. 7781.
3
Li, Z., L. Zhao, W. Du and F. Qian, Modeling and Optimization of the Steam
Turbine Network of an Ethylene Plant, Chinese Journal of Chemical Engineering,
Vol. 21, No. 5, pp. 520528, 2013.
4
Verde, L., R. Riccardi, D. Pedretti and A. Nava, Energy Conservation, Ethylene
Plants, Encyclopedia of Chemical Processing Design, Marcel Dekker Publishing, Vol.
18, pp. 171180, 1983.
5
Matar, S. and L. F. Hatch, Chemistry of Petrochemical Processes, Gulf Publishing
Company, 2nd Ed., 2001.
6
Wilson, D. G., The Design of High Efficiency Turbomachinery and Gas Turbine, 1st
Ed., MIT Press, 1984.
7
Aungier, R., Turbine Aerodynamics: Axial-Flow and Radial-Flow Turbine Design and
Analysis, ASME Publishing, 2006.
1
Process Insight:
Figure 1
Figure 2
For more information about this study, see the full article at
www.bre.com/support/technicalarticles
ProMax process simulation software by Bryan Research & Engineering, Inc.
Engineering Solutions for the Oil, Gas, Refining & Chemical Industries
VERSATILE.
Always a leading innovator, ROSEN not only supplies pipeline
customers with the latest diagnostic and system integrity
technologies but also offers exible solutions and all-round
support for plants & terminals.
www.rosen-group.com
Select 61 at www.HydrocarbonProcessing.com/RS
Special Report
parameter, DNL, is defined as D = bearing bore in mm, N = inner ring in rpm and L = load in lb, with values ranging to 1 trillion (1T or 109). An 80-mm electric motor bearing, operating at
3,600 rpm with a load of 600 lb, would have a calculated DNL of
172 MMless than 18% of the allowable threshold value. As of
2014, approximately 26,000 oil-mist-lubricated electric motors
are operating flawlessly in reliability-focused plants. Capitalizing on this favorable experience, the procurement specifications
for both new projects and replacement motors (with rolling element bearings) at many of these plants require oil-mist lubrication in sizes 15 kW and larger.
Although it was well known that synthetic lubes reduce friction, little quantitative work has been done before 1980. Morrison, Zielinski and James quantified how diester fluids reduce
the frictional power losses of industrial equipment; their findings are summarized in TABLES 1 and 2.1 The potential cost savings through power loss reductions are quite substantial. It has
been estimated that industrial machines consume 31% of the
total energy in the US.2 As much as 5% of the mechanical losses
of these machines could be avoided through a combination of
improved equipment design and lubricant optimization.
Motor sealing. Motor sealing and mist drainage are well understood. Although oil mist will neither attack nor degrade
the epoxy insulation on electric motor windings manufactured
Oil sump
Oil mist
MIN 68
0.271
0.192
SYN 32
0.254
0.169
Power loss
Change
per bearing
Total reduction, %
0.017
0.022
0.080
29
0.085
31
0.11
38
58MAY 2015|HydrocarbonProcessing.com
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Select 90 at www.HydrocarbonProcessing.com/RS
70
60
MIN 68
SYN 32
50
40
30
Oil sump
tal regulations (e.g., OSHA or EPA), air quality and environmental concerns reinforce minimizing stray oil-mist emissions. It is
helpful to recall that state-of-the-art oil-mist systems are fully
closed, i.e., they are configured to permit any and all mist not to
escape. The various bearing housings are sealed with the magnetic seals incorporated in the motor end bells, as shown in FIG. 1. Alternatively, advanced rotating labyrinth seals can be installed.4, 5
For many decades, combining effective seals and a closed
oil-mist lubrication system has represented a well-proven solution. The combination not only eliminates virtually all stray
mist and oil leakage, but it facilities nearly 97% recovery of oil
for purification and reuse. These recovery rates enable using
more expensive, superior quality synthetic lubricants.
For many years, polyalpha olefins (PAO) and diester-based
synthetic lubricants embodied most of the properties needed
to extend bearing life and provide the greatest operating efficiency. These oils excel in the areas of bearing temperature and
friction energy reduction. Synthetic lubricants in closed systems
and reusing filtrated lubricant can offer economic benefits.3
Closed systems and oil-mist-lubricated electric motors can
offer reliability-focused users several important advantages:
Compliance with actual and future environmental
regulations
Extended bearing life and reduced electric motor
maintenance budgets
Technical and economic justifications to apply highperformance synthetic oils in plant operations.
PAO and diester-based synthetic lubricants provide
benefits to extend the service life of bearings. As shown in
FIG. 3, synthetic lubricants can reduce bearing temperature
and greatly extend bearing service life. As shown in FIG. 4,
these oils excel in reducing friction. FIG. 5 is a composite plot
of different changes and power reduction percentages. This
figure illustrates the quick return on investment (ROI).
Oil mist
40
FIG. 3. Average temperature rise plot for the ball bearing test.1
35
0.300
0.250
30
Total reduction, %
MIN 68
SYN 32
25
20
15
10
0.200
5
0
0.150
Oil sump
Oil mist
FIG. 4. Power loss plot for the ball bearing test. Two different oils are
used at two different viscosities.1
60MAY 2015|HydrocarbonProcessing.com
Sump: MIN 68
to SYN 32
Mist: MIN 68
to SYN 32
Sump: MIN 68
to mist MIN 68
Sump: SYN 32
to mist SYN 32
Sump: MIN 68
to mist SYN 32
EFFICIENCY MATTERS
RESTORING PLANTS QUICKLY AND SAFELY
WWW.CUDD.COM
Select 161 at www.HydrocarbonProcessing.com/RS
62MAY 2015|HydrocarbonProcessing.com
SUSTAINABLE?
Tier 3 gasoline standard of 10 ppm becomes effective
January 1, 2017 and the EPA implemented a credit averaging,
banking and trading (ABT) program for transition purposes from
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patented non-dispersive caustic treating technologies.
Merichem Company optimized several caustic treating technologies to support
Tier 3 gasoline production. These technologies have been chosen for multiple Tier 3
projects since 2013. Merichems technologies, THIOLEX and REGEN, were chosen
to extract mercaptans from various refinery streams. Merichems REGEN platform
is a key component of the final processing solution that allows treating options to bring
product sulfur levels down to 2 PPMW.
Merichem has licensed over 350 THIOLEX and REGEN units worldwide. To learn more
about how these technologies can benefit you ahead of the Tier 3 transition visit
www.tier3treating.com
Select 84 at www.HydrocarbonProcessing.com/RS
UnitedRentals.com | 800.UR.RENTS
Regional Report
Regional Report
FIG. 1. HPI facilities in Saudi Arabia, including refineries, petrochemical complexes, and ports and terminals.
SAUDI ARABIA
Saudi Arabia holds 16% of the worlds proved oil reserves,
more than half of which are contained in eight fields. The giant
Ghawar field, with an estimated remaining reserve of 75 Bbbl,
has more proved oil reserves than all but seven other countries,
according to the US Energy Information Administration.3 Saudi
Arabia is the largest exporter of total petroleum liquids in the
worldand the second-largest petroleum exporter to the US
and it maintains the worlds largest crude oil production capacity.
Of Saudi Arabias total crude oil production capacity, more
than 70% is considered light gravity, which is generally produced
onshore, with the remaining crude considered to be medium or
heavy gravity, mainly from offshore fields. The country is moving to reduce its share of the latter two grades. Most Saudi oil
production, except for extra-light and super-light crude oil, is
considered sour, as it contains relatively high levels of sulfur (S).
The regions petrochemical capacity is expected to rise from
127 MMtpy in 2012 to over 145 MMtpy by 2018.2 However,
66MAY 2015|HydrocarbonProcessing.com
oline and diesel between 2013 and 2016, Saudi Arabia is constructing multiple clean-fuel projects aimed at reducing the S
content in diesel and gasoline to 10 ppm and lowering the benzene content in gasoline to 1%.
NOC Saudi Aramco has invested in excess of $100 B in the
last decade to support long-term sustainability of oil demand.2
Select 83 at www.HydrocarbonProcessing.com/RS
Regional Report
In the near term, Saudi Aramco will operate 8 MMbpd10
MMbpd of refining capacity, much of which will be directed to
high-demand and growth markets of AP, Europe and the ME.
The NOC is upgrading the countrys domestic refineries to
produce lower-S transportation fuels, and several projects have
been designed to produce near-zero-S fuels by 2016:
Yanbu Aramco Sinopec Refining Co. (YASREF),
a JV between Saudi Aramco (62.5%) and Sinopec
(37.5%), began export operations at its 400-Mbpd
Yanbu Industrial City refinery in January 2015. The
refinery has been designed to process heavy and medium
crude oils and maximize gasoil (GO) and gasoline
production. It includes process units for the separation
and conversion of the feed crude into finished products;
utility and offsite systems to support the refinery
400
300
200
100
0
Saudi Arabia
-100
1Q12
2Q12
3Q12
Iran, I.R.
4Q12
Kuwait
1Q13
2Q13
UAE
3Q13
Others
4Q13
1Q14
2Q14
3Q14
4Q14
877.562.5187 (Toll-free U.S. & Canada) | +1.202.682.8041 (Local & International) | sales@api.org | www.api.org
2015 American Petroleum Institute, all rights reserved. API and the API logo are trademarks or registered trademarks of API in the United States and/or other countries.
68MAY 2015|HydrocarbonProcessing.com
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KUWAIT
Despite its relative size (18 Mkm2), Kuwait has the thirdlargest refining capacity in the ME and consumes only a small
portion of its total crude production. The national oil company,
Kuwait National Petroleum Co. (KNPC), is investing more
than $31 B in projectsthe Clean Fuels Project (CFP) and
the New Refinery Project (NRP)to overhaul the countrys
refining sector and diversify its oil-heavy economy. The countrys petroleum export revenues account for nearly 60% of its
GDP and approximately 94% of export revenues, which were
estimated at $92 B in 2013, according to EIA data.5
Once completed, these ambitious modernization/expansion projects will place the country as the third-largest exporter
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Regional Report
The CFP and NRP projects will produce high-quality, low-S
fuels for export to various markets around the globe, and they
are part of Kuwaits goal to increase its total domestic refining
capacity to 1.4 MMbpd of refined fuels by 2020.2
Expanding olefins cracking capability. Petrochemical Industries Corp. (PIC), a subsidiary of Kuwait Petroleum Co., is
developing the countrys third olefins cracker, Olefins 3. The
first olefins cracker began operations in the Al-Shuaiba Industrial Area in 1997 as part of a petrochemical complex owned
and operated by PICs joint venture, Equate. In 2009, it was
joined by a second cracker, owned by the Kuwait Olefin Company (TKOC) and operated by Equate.
PIC is looking to place the cracker at the new Al-Zour refinery, which would lower costs as it would potentially utilize
the refinerys feedstock. The project will contain a 1.4-MMtpy
TABLE 1. Kuwaiti reneries current capacities and future
expansion plans
Present capacity,
Mbpd
Planned capacity,
Mbpd
Mina Abdullah
270
454
Mina Al-Ahmadi
466
346
Shuaiba
200
Al-Zour
615
936
1,415
Facility
cracker and produce ethylene derivatives like 1 MMtpy of polyethylene and 400 Mtpy600 Mtpy of polypropylene.
Initial feasibility studies conducted in 2010 put the total cost
of the project at nearly $5 B; with changing market conditions,
that price has ballooned to $7 B$9 B. The project remains in
the early planning stages, and will likely push back the initial
completion date of 2018. The feedstock source is still being analyzed, but it will include ethane, offgases, propane and combinations of LPG, naphtha and condensate.
OTHER ME NATIONS
Iraq. To alleviate shortfalls in refined fuels and to meet increas-
ing domestic demand, Iraq has laid plans to double its refining
capacity to 1.5 MMbpd by 2017. The plan includes $20 B in
investments to construct several new refineries with a total capacity of 740 Mbpd. Due to fighting with ISIS and continued
economic and political instability, the majority of these projects, except for the Karbala refinery that is presently under construction, have been delayed indefinitely. The Kirkuk refinery
plan was revived in late 2014 after continuous delays, and the
Iraq oil ministry announced it will rebid the Nassiriya refinery
contract in 2015. Shells $11-B petrochemical complex in the
southern oil hub of Basra is being called Nibras, Arabic for beacon of light, and it envisions an ethane cracking unit that would
produce ethylene to make plastics. The project is expected to be
completed in 2020 or 2021.
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Shell is developing the huge Majnoon oil field near Basra
that is pumping approximately 200 Mbpd. Shell also signed a
$17.2-B deal last year to collect natural gas from Iraqs southern
oil field production. The gas has traditionally been flared, and
Iraq has long had ambitions to collect and use the gas to meet
domestic energy demand.
Qatar. While several large projects have been canceled recently,
Qatar is still investing in its refining and petrochemical sectors.
74MAY 2015|HydrocarbonProcessing.com
Regional Report
distillation and sulfur recovery units, a residue fluidized catalytic
cracker (RFCC) and a carbon black delayed coker (CBDC) unit,
which will have a production capacity of 40 Mtpy of carbon black
and 30 Mbpd of crude. It will consist of two trains with a designed processing capacity of 700 Mt of anode green petroleum
coke. The $10-B project is expected to be completed in 2015.
Iran. Despite being hampered by economic sanctions, approxi-
mately 360 Mbpd of new condensate splitting capacity is expected to come onstream in three phases, starting at the end of 2015
or early 2016. This project is likely to transform the country
from a gasoline importer to an exporter.2 A signed 2013 agreement to begin exporting natural gas to neighboring Iraq has been
delayed due to security concerns and fighting between Islamic
State militants and Iraqi troops.
Completion of the pipeline would initially allow delivery of
4 MMcmd of gas to feed three power plants in Baghdad and Diyala. That volume could rise to 35 MMcmd. Iran has huge gas reserves and exports small quantities to Turkey, but it has been unable to increase production fast enough to meet its own demand.
Northern Iran relies heavily on gas imports from Turkmenistan,
especially for winter heating.
The Liwa Plastics project is being built to enhance both fuel and
plastics production in Oman, and it includes the construction of a
gas extraction plant in Fahud. Total costs for the complex, extraction plant, infrastructure and other facilities could top $5 B. Plastics production will increase from 200 Mtpy to 1.4 MMtpy from
20132018, while fuels production will grow from 7.3 MMtpy to
11.3 MMtpy from 20132018.4 The project will be constructed
in tandem with the Sohar refinery expansion and upgrade project.
Global engineering firms are eyeing the mega-refinery
scheme at the Duqm Refinery and Petrochemical Integrated
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Complex on Omans Al-Wusta coast. Duqm Refinery and Petrochemical Industries Co. LLC (DRPIC), an equal JV of Oman
Oil Co. (OOC) and International Petroleum Investment Co.
(IPIC), respectively the energy investment arms of the Sultanate of Oman and the UAE Emirate of Abu Dhabi, is jointly
developing the refinery project with an investment of approximately $6 B. Plans for an associated petrochemical complex in
the second phase could add a further $9 B to the total project
cost. One of the projects main goals is to facilitate the export
and import of hydrocarbon products in a region still underdeveloped compared with the north of the country. The project
will be integrated at the Petkim petrochemicals site on the Aegean coast. It will process medium-sour crudes (Azeri light,
Kerkuk and Urals oil) into low-S transportation fuels, meeting
Euro 5 specs. The products will be mainly sold to the domestic
market and will provide feedstock for the Petkim Petrochemical
complex, part of Socars downstream activities and its most important production unit outside Azerbaijan. The $5-B project,
which is expected to be commissioned in
2018, is a JV between Azerbaijan state oil
firm SOCAR and Turkey Enerji AS.
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LITERATURE CITED
Organization of the Petroleum Exporting Countries,
Monthly Oil Market Report, March 2015.
Nichols., L. and S. Romanow, Hydrocarbon Processings
HPI Market Data 2015, Global Construction and
Investment and Refining.
US EIA, Saudi Arabia Analysis Brief, September
10, 2014.
Hydrocarbon Processings Construction Boxscore
Database, April 2015.
US EIA, Kuwait Analysis Brief, October 24, 2014.
www.ConstructionBoxscore.com
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Rotating Equipment
M. VILA FORTEZA, Repsol SA, Petronor, Spain
pressor manufacturers and specialized companies have developed sophisticated software for continuous monitoring of reciprocating compressors. The related analyses are obtained in real
time and can be overlapped to do more complex studies when
required. Newer monitoring systems can survey more online parameters that allow the engineers the ability to assess the compressors status and successfully anticipate failures that formerly
could not be detected. The primary justification to install a monitoring system is based on early fault detection and protection of
the machine against breakdowns. Without such systems, it would
be very difficult to detect a catastrophic or high-cost failure.
2%7%
3%10%
0.5%1%
1%3%
Bypass energy
losses
12%50%
Rotating Equipment
Gas composition. The PV diagram will vary according
to the process gas compositionthus, the energy used in the
compression cycle will also vary. It is essential to know the gas
composition when assessing energy efficiency to achieve consistent conclusions and formulate effective actions.
Suction temperature. The hotter the gas entering the cylinder, the hotter the discharged gas after compression. The cooling
system may become ineffective and not qualified for actual working conditions. Also, the colder the gas entering the compression
chamber, the denser the gas will become, and more pumped mass
per volume unit is achieved, thus increasing compressor capacity.
Valve design. When the process conditions differ considerably from the original design, the performance of the valves
could decrease significantly. It is easy to install new valves to
meet new process conditions or to modify the existing ones. The
efficiency and performance of the compressor can be improved.
Cylinder, packing and frame lubrication. It is important
to control the oil viscosity, pressures, temperature and other
oil properties because they do affect the mechanical efficiency
of the machine.
Clearance volume. In a reciprocating compressor, the clearance volume is a residual space at the end of the stroke between
the head end or crank end when the piston is located at TDC
or BDC, plus other remaining spaces inside the compression
chamber. Clearance volume typically ranges between 4% and
16% of the swept volume, and it can essentially decrease or increase flow capacity. A higher clearance volume can result in
lower volumetric efficiency and lower compressor capacity.
It is very important to understand the impact of clearance
volume on the capacity of the machine. Compressor capacity
can be modified by changing the uncompressed volume of gas
inside the cylinder. Fitting the machine capacity to the flow required by the process will allow minimizing the quantity of gas
through the recirculation valves and energy consumption.
Compression ratio. Depending on the original process
conditions, the compressor is designed to work efficiently over
a specified range of temperatures and pressures. When varying
Safety analysis
Vibration
Wear monitoring
Data
Safety
acquisition protection
Performance optimization
Temperature
Lubrication monitoring
Other
VISU
Component tracking
Head end
1
Displacement
Pressure
Discharge valves
100% capacity
50% capacity
(suction valves held
open crank end)
0 capacity
(suction valves held
open both ends)
80MAY 2015|HydrocarbonProcessing.com
Rotating Equipment
entropy (TS) diagram of the cycle. Good heat transfer through
the cylinder walls is important, as the polytropic exponent (actual parameter compression process) is reduced. This effect
involves a lower ratio of the polytropic work and isothermal
compression and, therefore, a greater compression efficiency.4
API 618 has good information and recommendations on the
design of cooling systems. Other valuable literature references
are listed at the end of this article.
CAPACITY CONTROL
In reciprocating compressors, the major energy inefficiency
source is the capacity control of the machine. Flow control of the
pumped gas according to the specific needs of the process has
been broadly developed as the cost of energy and CO2 emissions
have increased. There are different capacity-control methods
used for reciprocating compressors. Some have been used for
years, and the control range is very limited. More modern technologies have been developed that offer higher flexibility and,
therefore, significant energy savings. The range of working loads
and the compression ratio will often determine the control system selected. All working cases and loadings of the machine must
be verified by the OEM to obtain the optimal capacity control
in terms of energy savings and reliability. Several typical capacity
control systems in reciprocating compressors are described here:
Gas recirculation to the suction line. The simplest method
to control gas flow to the process is the recirculation of excess
compressed gas to the compressor suction. Through an automatic valve, normally commanded by the suction pressure set
point, excess gas is recirculated to the suction line. Although a
simple method, recirculation of compressed gas is very inefficient, because a certain amount of gas that has been compressed
is expanded again when it returns to the compressor inlet pipe to
be recompressed. Depending on other factors, the compressed
gas must be cooled before going back to the machine; sometimes
additional coolers may be necessary.
The gas recirculation valve to the inlet pipe is usually installed on compressors, regardless if it is used as a primary capacity control system. This method helps other flow-control
systems to ensure finer control, or it can be used for emergency
flow recirculation if the main control system fails.
Throttling of suction gas valve. Another simple technique
to control reciprocating compressor capacity is to use pressure reduction at the inlet pipe through a manual or controlled
valve. This method will reduce the volumetric efficiency by
lowering the gas density, thus the mass of compressed gas (capacity) decreases.
The major disadvantage of this method is that a significant
decrease in suction pressure is necessary to achieve effective
flow control of the machine. Also, due to the suction pressure
reduction, the compression ratio increases, and the discharge
gas temperature can substantially increase as well as the rod
loadings. In some cases, it may not be a noticeable decrease in
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ISO 9001:2008
Hydrocarbon Processing|MAY 201581
Rotating Equipment
power consumption due to the higher compression ratio and
discharge temperature.
Unloaders on suction valves. This method is the most
widely used to control the load on double-acting reciprocating
compressors (FIG. 3). Load control is achieved by loading or unloading the suction valves with pneumatic actuators, which are
usually operated manually, depending on the required capacity.
The unloaded valves are open during the compression cycle,
so that the gas moves in and out of the compression chamber
through the suction valve. This flow is not sent downstream,
thus reducing the capacity of the machine and energy consumption proportionally to the amount of gas that is not compressed.
This system does not permit a fine control of the load, and
the quantity of load steps that can be achieved depends on the
Control gas
connection
Fixed volume pocket
ance volume present in the cylinders of a reciprocating compressor will change the volumetric efficiency. Any change in the
clearance volume of the cylinder will affect the maximum load
capacity of the compressor.
Previously, compressors were designed with clearance
pockets that provided one or two additional steps of loading
on each cylinder, depending on its location (crank end, head
end or both). Later, with the development of electronics, some
manufacturers have designed hydraulic control systems that enable automatic clearance volume with continuous fine adjustments during the compression cycle (stepless-capacity control
systems) at rates from 50% to 100%. FIG. 4 shows a manually
actuated valve that allows one additional load step in the head
end of the cylinder, along with another valve that is hydraulically actuated to permit stepless-capacity control.
FIG. 5 shows a new control system in which the hydraulic unit
is not needed because the capacity control is achieved due to a
reference gas, typically the process gas compressed by the machine. The clearance pocket can be mounted in both cylinder
ends, and it is possible to achieve a regulation range from 70%
to 100%. This system works with a standard valve, and is easy to
install and maintain.
P
Dr
Compressor
cylinder
Dr
Energy savings
compared to recycle
valve control
Cr
Cr
C
V
TDC
BDC
TDC
BDC
6
Piston
ring
Cylinder
A
Piston
b
ba
82MAY 2015|HydrocarbonProcessing.com
Gap
Rotating Equipment
Reverse flow capacity control systems. Capacity-control
systems based on a reverse flow effect present an interesting
evolution. While using the traditional unloaders on the cylinder effect where the valve works is unloaded during the whole
cycle, the reverse-flow systems allow the valve to work only
during a part of the compression cycle, thus obtaining a stepless-capacity-control system. This system was developed in the
1990s; it has evolved and is considered very reliable (FIGS. 6
and 7). Several manufacturers have developed their own capacity-regulation system based on the same principle. They all
offer good energy savings because the capacity control ranges
from 20% to 100% capacity.
Ks
GFA
P01
2
RT01
PS2
P01
PS2
P01
83
Rotating Equipment
Once Ks is calculated, the valve efficiency can be calculated:
EFA = GFA Ks with: GFA = OP Lift
where:
Ks = Flow coefficient
Lift = Stroke from the closed to the open position
= Measured mass flowrate
P01 = Total pressure upstream of the valve
Ps2 = Static pressure downstream
T = Total temperature upstream
= Ratio of heat capacities
p = Pressure drop across the valve
= Valve diameter
EFA = Effective flow area
GFA = Geometric flow area
OP = Opening periphery
7
6
5
4
3
2
1
0
Energy savings
10
20
30
40
50
Supply pressure, bar
60
70
Packings. About 3% to 10% of the energy used by reciprocating compressors is generated by friction losses in the packings.
Another 0.5% to 1% of energy loss is due to leaks in the packings and piston rings. The packings also have a high influence on
reliability, as they are subjected to significant wear. Preventing
leaks to the environment and flares has been addressed by new
designs developed by OEMs in energy efficiency and reliability.
Packing does influence energy consumption for compressors.
It is estimated that each standard ring set tangential/radial may
represent an average energy consumption of about 5 kW. This
power value multiplied by all the rings installed on the machine
is not negligible. Manufacturers have developed new designs to
minimize friction between rings and the piston rod. A new design
(FIG. 11) uses a single-ring design with a pressure balancing groove
that reduces friction losses up to 40% over standard packings.a
Packings are responsible for most gas leaks, and have environmental and economic impacts (FIG. 12). To dilute and minimize
leakage of process gas, low-emission packings have been installed
Energy loss, %
Loss by friction, kW
ID = Inner diameter
OD = External diameter.
The efficiency of the valve increases by increasing the EFA
parameter, so it can be deduced from the listed equations that
valve efficiency will improve by increasing within certain limits
one or more of these parameters:
Opening periphery (OP) is the length of the perimeter of
the gas passage on the seat. It can be calculated for a ring valve as
the sum of the OD and ID of all rings inside the valve.
Lift is the maximum stroke from the closing to opening positions of the rings or plate inside the valve.
Ks is the ratio between the ideal nozzle throat area (EFA)
and the GFA.
BCD ring
RT ring
Average leakage
Average leakage
Service life
(Set of one radial cut ring and one tangential cut ring)
84MAY 2015|HydrocarbonProcessing.com
pgas
poil > pgas
Rotating Equipment
equipped with inert gas injection (usually nitrogen). This design
is well-proven and validated by the successive revisions of the
API 618 about reciprocating compressors. FIG. 13 shows a packing system equipped with nitrogen injection.
Another advanced design aims to achieve zero leakage and
minimize friction losses, as shown in FIG. 14.b In this case, pressurized oil is injected into the packing at a pressure slightly higher
than the gas pressure, so the leak is avoided. Oil consumption is
minimal, and, due to oil flow friction losses, the temperatures
reached in piston rod and packing rings are lower than those that
are obtained in other designs.
CONCLUSIONS
There is an important improvement margin in terms of energy
efficiency related to reciprocating compressors. Some modifications and best practices can be implemented easily and with very
little investment. Some improvements can be obtained simply
by adjusting the loading of the compressor to the real needs of
the process, thus avoiding unwanted gas recirculation. The daily
work of checking process conditions and machine capacity is critical to improving compressor efficiency and performance. The
reliability engineer must be aware of new developments to take
advantage of solutions and practices that are efficient in terms of
energy and to minimize gas leakages and recirculations.
NOTES
A new design with reduced friction is the Balanced Cup Design (BCD) made by
HOERBIGER.
b
XPerSeal, developed by HOERBIGER.
a
LITERATURE CITED
Dimoplon, W., What Process Engineers Need to Know About Compressors,
Compressor Handbook for the Hydrocarbon Industries, Gulf Publishing Company,
1979.
2
Vila Forteza, M., Eficiencia energtica y actualizacin tecnolgica de compresores centrfugos en la actual coyuntura econmica, Revista Mantenimiento,
No. 267, September 2013.
3
Bloch, H. P. and J. J. Hoefner, Reciprocating Compressors Operation and
Maintenance of Reciprocating Compressors, Gulf Publishing Company, 1996.
4
EFRC Website, http://www.recip.org/173.0.html.
5
Faulkner, H. B., An investigation of instantaneous heat transfer during compression and expansion in reciprocating gas handling equipment, Massachussets
Institute of Technology, 1983.
6
Stachel, K. and M. Wenisch, Improved control concepts for reciprocating compressors in refining processes, ERTC 18th Annual Meeting, November 2013,
Budapest, Hungary.
7
Hanlon, P. C., Ed., Compressor Handbook, McGraw Hill, 2001.
8
Liu, Y. and Y. Yongzhang, Prediction for the Sealing Characteristics of Piston
Rings of a Reciprocating Compressor, International Compressor Engineering
Conference, 1986.
9
Leonard, S. M., Increasing the Reliability of Reciprocating Compressors on
Hydrogen Services, NPRA Maintenance Conference, May 2023, 1997.
10
Kosla, A. and A. Babbini, Fluid dynamic design of a new generation of reciprocating compressor valves, GE Technology insights, 2013.
11
Lindner-Silwester, T., and C. Hold, The BCD packing ringa new high performance design HOERBIGER Ventilwerke GmbH & Co KG. 7th Conference of
the EFRC, October 2010, Florence, Italy.
12
XPerSeal Customer Presentation 2013, HOERBIGER.
13
Machu, E. H., Valve Throttling, Its Influence on Compressor Efficiency and Gas
Temperatures, International Compressor Engineering Conference, Paper 805,
1992.
1
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Process Technology
F. SADEGHI, S. SADEGHI and U. SUNDARARAJ,
University of Calgary, Canada
tra-heavy oil that does not flow unless heated or diluted with
a light crude oil or natural gas condensate. It has a high viscosity (10,000 cP) under reservoir conditions. Extraction of
bitumen as a source of crude oil has recently received more attention because of high oil prices and the introduction of new
profitable technologies for extraction and processing. Production, transportation and refining of crude oils, in general, are
significantly dependent on the viscosity.
Viscosity is a significant factor for designing separation
processes. For example, oil, water and gas are separated in a
three-phase separator. Separation of water from oil is highly
(1)
The terminal velocity, Vt , or settling velocity, of water droplets is inversely proportional to viscosity, , and proportional
to the gravitational constant g. Here, Dp is the droplet diameter, 1 , is the water density and 2 is the oil density. Decreasing
the viscosity tenfold could improve (i.e., decrease) the settling
velocity tenfold and result in much lower residence time and,
consequently, smaller separator size.
Oil viscosity also affects sizing of pipelines because pressure loss in pipelines depends directly on fluid viscosity. For
example, hydraulic calculations show that an increase in viscosity from 1 mPa.s to 10 mPa.s will increase the pressure drop by
10%50% (depending on roughness/friction factor) in turbulent flow,2 resulting in significant costs for pumping equipment
and energy/power to operate. The same increase in viscosity
could reduce the terminal velocity for a water droplet size in a
separator by 10 times (Stokes law), which would be reflected in
a much longer separation vessel.
To facilitate transportation, the viscosity of bitumen can be
reduced either by heating to a higher temperature or by adding
a diluent, or both. Generally, a diluent is added at regular distances along pipelines carrying heavy crude to reduce the viscosity, thus facilitating the flow. This diluted bitumen is called
dilbit, and the method is considered an effective way to transport highly viscous oil.
Naphtha or gas condensates are the usual diluents in dilbit.
The viscosity of bitumen is reduced to meet the pipeline specifications of 19API and 350 cSt at minimum temperature (i.e.,
8C within the pipeline).2 One study examined the dilution of
bitumen using methyl tert-butyl ether (MTBE) inhibited asphaltene deposition, which can occur when paraffinic hydrocarbon
is used as diluent.3 A liquid viscosity model was used to calculate
viscosity of components as a function of temperature, and then
used the mixing rule to determine blend viscosity as a function
of composition. A distillation test was also performed to assess
separation of diluents from bitumen, and it was found that the
bulk of diluents could be removed without difficulty.
Another article studied different mixing rules for heavy and
light oils.4 It was found that prediction using pure mixing rules
yielded a viscosity with high error. Their analysis showed that
the accuracy of the model in predicting viscosity diminished
as the API decreased. The effect of viscosity and water droplet
size in water/oil emulsion systems was also investigated.5 They
Hydrocarbon Processing|MAY 201587
Process Technology
showed that asphaltenes play an important role in stabilizing
water droplets in the mixture. As a result, a smaller average particle size and higher viscosity were reported with increasing asphaltene content in the emulsion.
An article developed a correlation for predicting the viscosity of heavy oil/diluent systems.6 They proposed a model
that showed good agreement with experiments, especially for
mixtures with higher viscosity ratios (ratio of 20 or above).
The required input for their model was density and viscosity
of the heavy and light components. They used a modified version of the Arrhenius equation and reported a good agreement
between the predicted and experimental data. However, some
limitations were noted for the proposed model, i.e., it was valid
only for mixtures with high-viscosity ratios and should be used
TBP, C
209.8
10
192
323.2
20
200
10
358.9
30
204
Vol. wt%
15
387.2
40
207
412.5
50
209
25
434.5
60
213
30
458.8
70
218
35
483.8
80
226
40
509.7
90
239
45
537.6
567.3
55
597.1
60
626.5
was carried out in a modified gas chromatograph with methodology based on ASTM D7169. The properties of the bitumen
and diluent used in this study are listed in TABLES 1 and 2.
Viscosity measurements were conducted using oscillatory
and rotational rheometers. Measurements were performed using Couette geometry (inner cylinder diameter = 27 mm; gap
= 2 mm) at an elevated temperature and cone-plate geometry
for heavy oil at low temperature (disk diameter = 25 mm; gap =
47 micron; angle = 1). The blend was prepared by adding
10 wt% kerosine to bitumen.
TBP, C
20
50
Diluent (kerosine)
distillation curve: ASTM D86
65
652.9
70
676.4
Density at 15C
75
694.8
80
711.4
Diluent (kerosine)
998 kg/m3
Density at 15C
756 kg/m3
Viscosity at 30C
510 Pa.s
Viscosity at 30C
0.00161 Pa.s
Viscosity at 80C
2.09 Pa.s
3.0
600
A) 30C
Bitumen
500
B) 80C
2.5
Bitumen
2.0
*, Pa.s
*, Pa.s
400
300
1.5
200
1.0
100
0.5
Blend
0
0.01
Blend
0.1
10
100
1,000
0.0
0.01
88MAY 2015|HydrocarbonProcessing.com
0.1
10
100
1,000
Process Technology
tioned distinctive microstructures, which are highly dependent
on thermo-mechanical conditions, are responsible for the linear
and nonlinear rheological behavior of heavy oil materials.
The results obtained from viscometry are compared to simulation results in TABLES 35. In TABLE 3, the simulation results
based on inputting only the distillation curve of the heavy oil
into the simulation software are presented. There is a significant
difference between these simulation results and the viscometry results in TABLE 3. Changing the thermodynamic property
package did not improve the simulation results. In fact, for both
thermodynamic packages, the simulation tool greatly underestimated the viscosity for bitumen and for the blend.
In another simulation, the density of oil and its distillation
curve were loaded into the simulation software, and the results
are shown in TABLE 4. It is observed that viscosity prediction
slightly increases in this case, but there is still a considerable
discrepancy between the simulation and experimental values.
Therefore, it is concluded that including density in the simulation does not significantly improve the prediction of viscosity.
In another attempt, the density and viscosities of heavy oil
at two temperatures (30C and 80C), along with the distillation curve, were loaded into the software and simulation results were compared to experimental measurements in TABLE 5.
600
Bitumen, 30C
500
*, Pa.s
400
300
200
100
Blend
Bitumen, 50C
0
0.01
0.1
10
100
1,000
100
Modulus, Pa
0.01
0.0001
20
Bitumen, G'
Blend, G'
Bitumen, G"
Blend, G"
30
40
50
60
Temperature, C
70
80
90
FIG. 3. Elastic modulus (G) and loss modulus (G) of bitumen and
the blend.
Hydrocarbon Processing|MAY 201589
Process Technology
TABLE 3. Viscosity of the components and the blend
(without loading bulk properties of heavy oil in simulation tool)
Rheology
, Pa.s
Kerosine
30C
50C
Simulation tool
80C
30C
50C
80C
0.0014 0.00072
Heavy oil
510
34.96
2.09
2.307
0.4
0.076
Blend 10%
39
4.5
0.5
0.3738
0.11
0.032
30C
50C
Simulation tool
80C
30C
50C
80C
Heavy oil
510
34.96
2.09
3.374
0.5256
0.088
Blend 10%
39
4.5
0.5
0.5135
0.1379
0.037
30C
50C
Simulation tool
80C
30C
50C
80C
Heavy oil
510
34.96
2.09
510
33
2.1
Blend 10%
39
4.5
0.5
10.28
1.73
0.2773
Although the predicted results for heavy oil are very close to
the experimental values in this case, the values for the blend
are still quite different, as the simulation tool underestimates
the viscosity values by at least 50%.
One study 2 examined the viscosity of bitumen blend with
diluents and showed that Cragoes equation provided the best
prediction of the blend viscosity compared to other methods
such as mixing rule, API and Mehrotras methods.8 Cragoes
equation is shown here (Eq. 2):
1
x
x
D
O
+D
+
+m
ln
ln O
ln
c
c
c
(2)
and 10 wt% blends with kerosine were measured and the results
were compared with the empirical simulation data. The effect
on reducing viscosity by adding 10 wt% of kerosine as a diluent
into bitumen was equal to the effect obtained upon increasing
temperature from 30C to 50C.
Bitumen viscosity at lower temperatures (such as 30C) exhibited shear-thinning behavior. At higher temperatures (such as
50C and 80C) or for blends containing 10% diluent, viscosity was almost Newtonian, i.e., independent of shear rate. Temperature sweep tests revealed the existence of a structural phase
90MAY 2015|HydrocarbonProcessing.com
FARHAD SADEGHI, PhD, P.Eng, is a senior process engineer with Fjords Processing
(formerly AkerSolutions) in Calgary, Alberta, Canada.
SOHEIL SADEGHI is a PhD student at the department of chemical and petroleum
engineering, University of Calgary, Alberta, Canada.
UTTANDARAMAN SUNDARARAJ, PhD, P.Eng, FEC, is a professor at the
department of chemical and petroleum engineering, University of Calgary,
Alberta, Canada.
Process Engineering
D. SMITH AND J. BURGESS, Smith & Burgess,
Houston, Texas
ibility factor of the fluid is greater than 0.8, then the ideal gas
ratio of specific heats may be used to determine the expansion
coefficient. If the compressibility factor is less than 0.8, then
the expansion coefficient should be based on the isentropic
expansion coefficient. This article shows that the listed guidance can over-predict the capacity of the relief device near the
critical point for light gases. The authors suggest that, when
the fluid critical volume is 2 or lower, a direct integration
method is required to accurately estimate relief-device capacities. If the critical volume is greater than 2 and the compressibility factor is less than 0.8, then using the nozzle equation
with the isentropic expansion factor is acceptable.
Background. The accurate sizing of relief devices is very important. Operating facilities processing such fluids near the
critical locus want to ensure that plant equipment is adequately protected from overpressure and that relief devices are not
oversized. In general, the potential consequence for undersizing relief devices is severe, and is the focus of relevant industry codes and standards.1, 2 Relief-device sizing equations
are based on a modified nozzle flow equation (e.g., Eqs. 27 in
API 520, Part 1) and assume that the expansion of the fluid/
gas (the nozzle capacity) can be predicted by Eq. 1 (for US
customary units):1
C 520 k
2
k
1
k
1
k 1
(1)
v
P
P
v
CP
T CV
G
P
P1
vt2
v dP
t
P dP
P1
max
(3)
max
Integration , %
Ideal k , %
Isentropic , %
30
20
10
0
-10
(2)
-20
-30
-40
-50
0.40
0.50
0.60
0.70
0.80
0.90
1.00
Process Engineering
Since equations of state have known issues with predicting
the physical properties needed to size relief devices near the
critical loci of the fluid, all physical properties in this evaluation were calculated using the National Institute of Standards
and Technologys REFPROP property package, version 9.1.
Results. The results of all the relief-device sizing estimates
are shown in FIG. 1 as a function of the compressibility factor.
What is noted for these light hydrocarbon gases is that using
the modified nozzle equation with the expansion factor based
50
Integration , %
40
30
20
10
0
-10
-20
-30
-40
-50
0
10
12
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IRPC
HP Staff
HPIRPC.com
technical tracks to cover the broad spectrum of HPI topics and disciplines. The
tracks are refining/biofuels, petrochemicals and gas processing/LNG.
The refining track will address the
processing of heavy oil into clean transportation and marine fuels. Presentations
will address new technologies to handle
present-day crudes and improved flexibility methods in refining operations.
The petrochemicals track will focus on
olefins and aromatic operations and on
future product and feedstock trends. The
gas processing track will include presentations on gas treating, LNG commercialization and more.
Other technical sessions are dedicated
to energy efficiency, process optimization, corrosion mitigation/prevention
methods, safety, petrochemical/refinery
integration, environmental performance,
advanced catalytic technologies, licensed
A truly
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IRPC CONFERENCES:
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for top petrochemical project; Saudi Aramco and Total Refining and Petrochemical (SATORP) Co. for top refining project;
and Sasol North Americas GTL project in
Lake Charles, Louisiana, for top LNG/gas
processing project. The engineering, procurement and construction companies for
these projects will also receive awards for
their participation. The SATORP, Sadara
Chemical and Sasol GTL projects were selected from 12 HPI projects by an online
survey conducted by HP. These projects
were identified by HP readers as having
the highest impact on the global and regional downstream industry.
The industrys leading edge. The HPI
is a global industry; success hinges on
companies and their staff finding accurate
and vital information in real time to make
informed and profitable decisions. At
IRPC 2015, HPI professionals will have
the opportunity to network and brainstorm with executives and leaders that are
charting the course of the global HPI.
The meeting place for the global
downstream. Companies involved in
the following areas will benefit from attending IRPC: refining, natural gas processing, technology and equipment manufacturing, consulting, construction and
engineering, chemicals and petrochemicals, and oil and gas services and supplies.
Individuals and company officials active
in the following role types will also benefit from attending IRPC: operations and
supply management, business development, engineering, research and development, project management, construction
and design, and more.
For more information about the 2015
International Refining and Petrochemical
Conferenceorganized by Gulf Publishing Company and dmg::events Middle
East, the organizers of ADIPECplease
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94
TERMINALS AND
STORAGE REPORT
2015
Special Supplement to
Safety and
environmental
updates for HPI
storage tanks
T97
CORPORATE PROFILES
CB&I T101
COVER PHOTO
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CESSING
ENVIRONMENT
SEPTEMBER 2014
HydrocarbonProcessing
Scavengers control
e oil
toxic compounds in crud
PETROCHEMICAL
DEVELOPMENTS
Ammonia production
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REFINING DEVELOPMEN
SPECIAL REPORT:
Refining
Developments
Subscribe Today!
Log on to HydrocarbonProcessing.com or call +1 (713) 520-4440.
Storage tanks are a key part of any HPI distribution operation, according to Li-Chuan Liu of the Logistical Engineering University, China. Notably, tank-bottom plates are very
vulnerable to corrosion, which compromises the integrity of
the tank wall and bottom. Result: Leaks and even complete
failure of the tank are linked to corrosion attacks.
Leaks and containment failures are high-risk events that
impact plant safety and the environment, said Liu. Such
events result in a direct loss of revenue. Contamination of soil
and water can potentially lead to punitive action from federal
and state environmental agencies.
Fires and explosions due to the accidental release of flammable materials are the main catastrophic events from storage
leungchopanShutterstock.com
HYDROCARBON PROCESSING|MAY 2015|TERMINALS AND STORAGE REPORT
T97
huyangshuShutterstock.com
The American Petroleum Institute (API), through its various committees, has developed standards and best practices to
help downstream companies safely operate their facilities and
pipelines. API standards are reviewed on a regular basis. API
standards for aboveground storage tanks (ASTs) are Standards
620, 625, 650 and 653 (TABLE 1), and are developed using API
procedures and standards development. The AST standards
are reviewed on an 18-month basis. Changes in several AST
standards took effect in 2014: API 650 was issued in September 2014 with participant in the API Monogram Program;
the final release was in March 2015. For API Standards 653,
625 and 620, the revisions were issued in November 2014.
system that is best for all sites. Each leak-detection method has
unique characteristics. For example, vapor-detection devices
work rapidly and are most effective in porous soils, while liquid
detectors are only appropriate. Identifying the best leak-detection system depends on many factors including cost, facility
configuration, groundwater depth, soil type and other variables.
Although there are many methods for detecting oil leaks
from storage tanks, it may not be easy to discover the leak.
With the increasing capacity and size of storage tanks, the level
changes from a very slow leak may be too small and not measurable by automatic or manual gauging until a substantial volume of product has been released, said Liu.
Very small level changes due to oil leaking from large storage tanks can occur at an extremely low rate, thus, the leak may
not be detected by gauging alone.
A photo ionization detector (PID) can be used to test oil vapor concentration in a tank foundation, the sensitivity to ppm
levels, which is fine leak detection, according to Liu. The re-
T98
Intergraphs TANK is a comprehensive, easy-to-use software package for the design, analysis and evaluation of oil stor-
age tanks. It provides quick and accurate designs for new tanks
and evaluation of existing tanks.
Data collection. The menu-driven interface of TANK allows for the quick definition of input and functions for the accurate analysis of oil storage tanks to API standards. Increased
flexibility allows combination of data for analyses or to desired
reports. In addition, unit files are completely user-definable, so
engineers are not bound by program default settings.
Analysis options and codes. TANK performs calculations in accordance with the latest API Standards 650 and 653.
Analysis can also take into account wind, seismic and settlement conditions, plus calculate air venting requirements to
API 2000 Section 4.3.
Output and reports. After completing an analysis, you can
view the results in a tabular report or as a graphic diagram with
associated data. For convenience in verifying the results, the
output reports reference code sections used where applicable.
Material databases. TANK has many databases integral to
the package, which make it easy to select standard data for accurate analysis. A number of US and international structural
steel databases are provided. API materials are available.
EVENTS
T99
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T101
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The bracket itself is mounted with a single bolt hole at the top of the bracket. Once
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Calibrator simplifies
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A new, handheld pressure calibrator
that delivers deadweight tester accuracy
in an onsite instrument (FIG. 3) is offered
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The HPC40 series calibrator is designed for process control applications,
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Innovations
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Hydrocarbon Processing
104MAY 2015|HydrocarbonProcessing.com
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Innovations
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Thermo Fisher Scientific has released
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A solution developed by Systec Controls for such applications makes use
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www.info.hotims.com/56796-171
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www.info.hotims.com/56796-99
www.info.hotims.com/56796-155
(78)
www.info.hotims.com/56796-172
Dyna-Therm ............................................................ 48
Flexitallic LP .............................................................. 5
ILTA ......................................................................... 78
Inpro / Seal Company ............................................... 70
(172)
www.info.hotims.com/56796-161
(154)
www.info.hotims.com/56796-93
Axens ......................................................................112
DeltaScreens .............................................................16
Company
Website
www.info.hotims.com/56796-173
www.info.hotims.com/56796-164
RS#
www.info.hotims.com/56796-154
www.info.hotims.com/56796-163
Page
Website
www.info.hotims.com/56796-162
Company
(91)
www.info.hotims.com/56796-91
(94)
www.info.hotims.com/56796-94
This Index and procedure for securing additional information is provided as a service to Hydrocarbon Processing advertisers and a convenience to our readers. Gulf Publishing Company is not responsible for omissions or errors.
AK, AL, AR, AZ, CA, CO, FL, GA, HI, IA, ID, IN, KS,
KY, MI, MN, MS, MT, ND, NE, NM, NV, OR, SD, TN,
TX, UT, WA, WI, WY, WESTERN CANADA
Ryan Akbar
Phone/Fax: +1 (713) 520-4449
Mobile: +1 (832) 691-6053
E-mail: Ryan.Akbar@GulfPub.com
CT, DC, DE, MA, MD, ME, NC, NH, NJ, NY, OH, PA,
RI, SC, VA, VT, WV, EASTERN CANADA
Merrie Lynch
Phone: +1 (617) 357-8190, Fax: +1 (617) 357-8194
Mobile: +1 (617) 594-4943
E-mail: Merrie.Lynch@GulfPub.com
CLASSIFIED SALES
Gerry Mayer
Phone: +1 (972) 816-3534, Fax: +1 (972) 767-4442
E-mail: Gerry.Mayer@GulfPub.com
DATA PRODUCTS
Lee Nichols
Phone/Fax: +1 (713) 525-4626
E-mail: Lee.Nichols@GulfPub.com
108MAY 2015|HydrocarbonProcessing.com
SALES OFFICESEUROPE
FRANCE, GREECE, NORTH AFRICA,
MIDDLE EAST, SPAIN, PORTUGAL,
SOUTHERN BELGIUM, LUXEMBOURG,
SWITZERLAND, GERMANY, AUSTRIA, TURKEY
Catherine Watkins
Phone: +33 (0) 1 30 47 92 51
Fax: +33 (0) 1 30 47 92 40
E-mail: Watkins@GulfPub.com
Jim Watkins
Phone: +33 (0) 1 30 47 92 51
Fax: +33 (0) 1 30 47 92 40
Cell: +33 (0) 6 76 35 11 52
Jim.Watkins@GulfPub.com
RUSSIA/FSU
Lilia Fedotova
Anik International & Co. Ltd.
Phone: +7 (495) 628-10-333
E-mail: Lilia.Fedotova@GulfPub.com
UNITED KINGDOM/SCANDINAVIA,
NORTHERN BELGIUM, THE NETHERLANDS
Michael Brown
Phone: +44 161 440 0854
Mobile: +44 79866 34646
E-mail: Michael.Brown@GulfPub.com
CHINAHong Kong
Iris Yuen
Phone: +86 13802701367 (China)
Phone: +852 69185500 (Hong Kong)
E-mail: Iris.Yuen@GulfPub.com
BRAZILSo Paulo
Alfred Bilyk
Phone/Fax: 11 23 37 42 40
Mobile: 11 85 86 52 59
E-mail: Brazil@GulfPub.com
INDIA
Manav Kanwar
Phone: +91-22-2837 7070/71/72, Fax: +91-22-2822 2803
Mobile: +91-98673 67374
E-mail: India@GulfPub.com
JAPANTokyo
Yoshinori Ikeda
Pacific Business Inc.
Phone: +81 (3) 3661-6138, Fax: +81 (3) 3661-6139
E-mail: Japan@GulfPub.com
KOREA
Young-Seoh Chinn
JES Media, Inc.
Phone: +82 (2) 481-3411/3, Fax: +82 (2) 481-3414
E-mail: Korea@GulfPub.com
REPRINTS
Rhonda Brown, Foster Printing Service
Phone: +1 (866) 879-9144 ext. 194
E-mail: RhondaB@FosterPrinting.com
Events
MAY
2015 Offshore Technology
Conference (OTC), May 47,
Reliant Park, Houston, Texas
P: +1 (972) 952-9494
meetings@otcnet.org
2015.otcnet.org
AFPM National Occupational
and Process Safety Conference,
May 1213, Hyatt Regency Austin,
Austin, Texas
(See box for contact information)
The 13th World LNG Series:
Americas Summit, May 1215,
Four Seasons Hotel, Austin, Texas
P: +44 20 7978 0061
LNGAmericas@thecwcgroup.com
lngamericas.cwclng.com
Hazards 25In association
with Mary Kay OConnor Process
Safety Center, May 1315,
Edinburgh, Scotland, UK
P: +44 (0) 1788 534489
hazards25@icheme.org
www.icheme.org
Fourth Annual Asia Pacific
Small & Mid-Scale LNG Forum
(APAC LNG), dmg events,
May 1315, Singapore Marriott
Hotel, Singapore
www.apaclng.com
(See box for contact information)
Canada LNG Export Conference
& Exhibition, dmg events,
May 1921, Calgary, Alta., Canada
www.canadalngexport.com
(See box for contact information)
AFPM Reliability & Maintenance
Conference & Exhibition,
May 1922, Austin, Texas
(See box for contact information)
Industrial Valve Summit (IVS),
May 2728, Bergamo, Italy
P: +39 3316117476
press@industrialvalvesummit.com
www.industrialvalvesummit.com
JUNE
International Refining and
Petrochemical Conference (IRPC)
2015, Gulf Publishing Company
Events, May 31Jun. 3, Jumeirah at
Etihad Towers, Abu Dhabi, UAE
HPIRPC.com
(See box for contact information)
JULY
OCTOBER
AUGUST
AIChE 60th Annual Safety in
Ammonia Plants and Related
Facilities Symposium,
Aug. 30Sep. 3, Boston, Mass.
(See box for contact information)
National Association of
Corrosion Engineers (NACE),
Central Area Conference,
Aug. 31Sep. 2, St. Louis, Mo.
P: +1 (281) 228-6223
firstservice@nace.org
www.nace.org
SEPTEMBER
EUROCORR 2015European
Corrosion Congress, Sep. 610,
Stadthalle, Graz, Austria
P: +43 (0) 3842 402 2290
eurocorr2015@asmet
eurocorr2015.org
GasPro Americas (GasPro),
Gulf Publishing Company
Events, Sep. 911,
Hyatt Regency Houston,
Houston, Texas
GasProcessingConference.com
(See box for contact information)
LNG 360 Americas Conference
and Exhibition, dmg events,
Sep. 911, Houston, Texas
www.lng360latamcar.com
(See box for contact information)
American Institute of
Chemical Engineers (AIChE)
P: +1 (203) 702-7660
customerservice@aiche.org
www.aiche.org
American Society of
Mechanical Engineers (ASME)
P: +1 (973) 882-1170
customercare@asme.org
www.asme.org
dmg events Global Energy
P: +1 (403) 209-3555
Calgarysales@dmgevents.com
www.dmgevents.com
People
Hammond Manufacturing
Co. Ltd. has added
Andreas Sobotta as VP of
North American sales and
marketing. Mr. Sobotta
was most recently a
national sales manager
with Davis Controls; VP
of marketing with Festo;
business unit manager
with Siemens; and cogeneral manager/director
of sales and marketing
at Phoenix Contact.
Thomas Hinckley
has joined Fishbone
Safety Solutions as
VP of operations, with
responsibilities that
include ensuring that
the companys industry
resources and systems
are in place and working
at maximum efficiency.
110MAY 2015|HydrocarbonProcessing.com
Servomex, a leader
in gas analysis, has
appointed Luca Marinelli
as general manager for
ServomexAmericas,
based in Houston, Texas.
He most recently served
as general manager for
Europe, the Middle East,
Africa and India (EMEA&I).
Mr. Marinelli succeeds
Martin Cox, who returns to
Servomex in the UK with
global responsibility for
business development as
market sector manager
Sensing Technologies.
Register Early
and Save 15%
Early Bird Pricing Ends June 23rd
Safety/environment
Pipeline infrastructure/storage
Legislative and regulatory compliance
(domestic/international)
Business and market perspectives
Economics and nance
2. Participate as a speaker
3. Sponsor/Exhibit
Speaker/Sponsor/Exhibitor Inquiries:
Contact Melissa Smith, Events Director, at +1 713-520-4475 or Melissa.Smith@GulfPub.com
Now in its third year, the LNG 360 Americas Conference and Exhibition
will continue to offer a platform to LNG producers, major international
consumers, members of the government, EPCS, project investors, shippers
and all other key industry stakeholders to share insights and strategies,
spearheading LNG partnerships and projects within the Americas.
For questions or speaker inquiries: Monica Ansary, Senior Producer
Energy, dmg::energy events, at MonicaAnsary@dmgevents.com
or +44 0 203 772 6075
LNG360Americas.com
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