BHP F&F Furnace Efficiency Improvements

8/2/2019 BHP F&F Furnace Efficiency Improvements

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FURNACE and FLARE

FURNACE EFFICIENCY IMPROVEMENTS • NOx REDUCTION • FLARE GAS RECOVERY • EFFICIENCY SEMINARS • CEMS

A DIVISION OF BHP ENGINEERING AND CONSTRUCTION, L.P. 715 Oak Park Ave Corpus Christi, TX 78408, USA Voice: (361) 693-6200 Fax: (361) 884-3522

FURNACE EFFICIENCY IMPROVEMENTS

FLARE GAS RECOVERY

EFFICIENCY SEMINARS

NOx REDUCTION

CONTINUOUS EMISSION MONITORING SYSTEM

FEA STRESS ANALYSIS

CORPUS CHRISTI VICTORIA BAYPORT LAGOS

715 OAK PARK AVENUE 11202 US HWY.

59 NORTH, SUITE B 11837 FAIRMONT

PARKWAY Plot 28 Block 93

Awkuzu Street CORPUS CHRISTI

TEXAS 78408 VICTORIA

TEXAS 77905 LA PORTE

TEXAS 77571 Lekki 1

Lagos Nigeria 361-693-6200 361-572-8039 979-429-6807 234-1-270-1581

www.bhpeng.com



CORPUS CHRISTI • VICTORIA • BAYPORT • LAGOS

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FURNACE and FLARE

FURNACE EFFICIENCY IMPROVEMENTS • NOx REDUCTION • FLARE GAS RECOVERY • EFFICIENCY SEMINARS • CEMS

A DIVISION OF BHP ENGINEERING AND CONSTRUCTION, L.P. 715 Oak Park Ave Corpus Christi, TX 78408, USA Voice: (361) 693-6200 Fax: (361) 884-3522

REDUCE ENERGY COST UP TO 5 PERCENT............................................................................3

ENERGY SERVICES ......................................................................................................................4

BENEFITS........................................................................................................................................4

FURNACE and FLARE ................................................................................................................... 5

A. FURNACE EFFICIENCY IMPROVEMENTS ...................................................................... 5

B. NOx REDUCTION.................................................................................................................. 6

C. FLARE GAS RECOVERY...................................................................................................... 7

D. ENERGY LOSS SURVEY...................................................................................................... 8

E. PERSONNEL TRAINING....................................................................................................... 8

F. DATA COLLECTION AND REPORTS................................................................................. 9

CEMS..............................................................................................................................................10

FEA STRESS ANALYSIS............................................................................................................. 12

PROJECT PROFILE - FURNACES ..............................................................................................13




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REDUCE ENERGY COST UP TO 5 PERCENT

Let our combustion experts give you timely, cost effectivesupport and solutions for your combustion equipment problems.

Furnace and Flare Engineers are experienced in design, startup, operation,troubleshooting, and analysis of combustion equipment.

The charts below illustrate the savings possible from small efficiencyimprovements to a medium size heater (100MM BTU/Hr) using fuel valuedat $5 to $10 per MM BTU.

$0

$100,000

$200,000

$300,000

$400,000

$500,000

$600,000

Annual Savings, $/Yr

@5% Improvement

5 6 7 8 9 10

Fuel Cost, $ per MM BTU

S t a c k T e m p e r a tu r e

F u r n a c e

E f f i c i e n c y

5 % E x c e s s A ir 1 0 % E x c e s s A ir




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ENERGY SERVICES

Furnace and Flare offers the services of experienced engineers toimprove the efficiency of your combustion equipment.

A. FURNACE EFFICIENCY IMPROVEMENTS

B. NOx REDUCTIONC. FLARE GAS RECOVERY

D. ENERGY LOSS SURVEYS

E. PERSONNEL TRAINING FOR BETTER OPERATION

F. DATA COLLECTION, CALCULATIONS AND REPORTS

BENEFITS

Most improvements may be implemented with little capital investment,and results can be realized with minimum cost. Improvements to yourcombustion equipment can yield the following benefits.

• REDUCED ENERGY COST

• LOWERED EMISSIONS

• MAXIMIZED EFFICIENCIES

• EXTENDED EQUIPMENT SERVICE LIFE




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FURNACE and FLARE offers the following technical services to improvethe efficiency of your combustion equipment. These services cover thecomplete range of client needs from heater efficiency surveys and operator/ supervisor training to the recovery of products and fuel from flare gas.

A. FURNACE EFFICIENCY IMPROVEMENTS

The following investigation steps will be taken to develop a plan that willoutline corrective action and issue a report of equipment and operatingchanges needed with an estimate of potential savings.

• STACK GAS ANALYSIS

• HEATER DRAFT PROFILE

• HEATER TEMPERATURE PROFILE

• OBSERVATION OF FLAME PATTERN

• MECHANICAL CONDITION OF EQUIPMENT

• PROCESS FLOW AND TEMPERATURE PROFILE

• TUNING THE FURNACE FOR OPTIMUM EFFICIENCY




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B. NOx REDUCTION

Troubleshooting and installation of modern burners is important foroptimum fuel efficiency and LoNOx performance. FURNACE and FLAREhas the experience to solve your burner problems.

• BURNER REGISTER OPERATION• BURNER FLAME PATTERN DIAGNOSTICS

• TURNAROUND MAINTENANCE SUPERVISION

• BURNER TIP ALIGNMENT AND TOLERANCE ADJUSTMENTS

• AIR PREHEAT AND DUCT SYSTEM DIAGNOSTICS

• FUEL FILTRATION SYSTEMS DESIGN




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C. FLARE GAS RECOVERY

FURNACE and FLARE can assist you with any flare system problemsfrom relief valve sizing to tip replacement to product recovery from flaregas.

• PSV SIZING WITH INLET AND OUTLET PIPE SIZING PER API 520

• RELIEF SYSTEM DESIGN AND HYDRAULIC CALCULATIONS

• KNOCKOUT DRUM AND SEAL DRUM DESIGN

• FLARE TIP DIAMETER AND ELEVATION ESTIMATION PER API521

• FLARE GAS RECOVERY SYSTEM DESIGN AND INSTALLATION




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D. ENERGY LOSS SURVEY

The energy transmission and exchanger train will be investigated todevelop a plan of action to reduce steam and heat transfer losses.

• STEAM SYSTEM SURVEYS

• BOILER EFFICIENCY INVESTIGATION

• HEAT EXCHANGER EFFICIENCY INVESTIGATION

E. PERSONNEL TRAINING

FURNACE and FLARE can provide tools and understanding youroperators and supervisors need to continuously monitor and adjust yourcombustion equipment for optimum efficiency.

• BURNER AND HEATER SEMINARS

• BOILER OPERATION AND TROUBLESHOOTING

• NOx FORMATION CHEMISTRY

• HAND'S ON PROBLEM SOLVING




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F. DATA COLLECTION AND REPORTS

All aspects of furnace and boiler operation can be captured for resolutionof efficiency problems or stack gas compliance investigation. Reports willbe issued in a timely manner.

• TIMELY REPORT OF FINDINGS

• SUGGESTIONS FOR ENERGY SAVINGS

• COST ESTIMATES FOR ANY EQUIPMENT CHANGES

• RESULTS OF EQUIPMENT MECHANICAL CONDITION

• PHOTOGRAPHS OF EXISTING EQUIPMENT

• CALCULATIONS INCLUDED WITH RAW OPERATING DATA




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CEMS

(Continuous Emission Monitoring System)

BHP provided all phases of engineering including front end engineering, budgeestimates, detailed engineering, installation, inspection and start up. Theanalyzer projects included:

• Sample System• Analyzer Specifications & Purchase• Analyzer / Control System Interface Design

The following is a list of recent CEMS projects with cost range up to$500,000.

BHP Heater Analyzer ProjectsYear Client Project Description Analyzed

2005 CITGO #4 Platformer Heater CEMS NOx, O2

2003 CITGO SRU Claus Air Demand Analyzers H2S, SO2

2000 CITGO SRU Tail Gas Incinerator CEMS SO2, O2

1998 CITGO #2 FCCU CEMS NOx, CO, O2

2005 FHR MIO Crude Boiler CEMS NOx, CO, O2

2004 FHR #2 Parex Heater CEMS NOx, CO, O2

2004 FHR Toluene Heater CEMS NOx, CO, O2

2003 FHR Thermal Oxider CEMS H2S

2002 FHR MSTDP Heater CEMS NOx, CO, O2

2001 FHR BTX Heaters CEMS (4 Stack System) NOx, CO, O2

2003 Valero Three Rivers Fuel Gas H2S Analyzer H2S

Plus numerous other on-line process analyzer projects.




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Continuous Emission Monitoring System

FHR BTX Heaters CEMS (4 Stack System) NOx, CO, O2

Dual Stream Monitoring Single Stream Monitoring

Firing Efficiency Analyzer O2 & Combustibles

Manual Operation Automatic Operation




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FEA STRESS ANALYSIS

Before Revision

Over Stress

After Revision

Over StressRemoved

Stress contour viewsof heater stack for aheater upgrades

project

Structural design capabilities utilizing FEA improves structural design

economy & saves T/A time.




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FURNACE and FLARE

FURNACE EFFICIENCY IMPROVEMENTS • NOx REDUCTION • FLARE GAS RECOVERY • EFFICIENCY SEMINARS

A DIVISION OF BHP ENGINEERING AND CONSTRUCTION, L.P. 715 Oak Park Ave Corpus Christi, TX 78408, USA (361) 693-6200

PROJECT PROFILE - FURNACES

Furnace and Flare Engineers have completed many projects to upgrade Heaters andBoilers for LoNOx requirements and improve energy conservation.

Notable Burner and Heater Projects:

Refinery LoNOx Burners - Burner Installed Cost $1.3 millionCITGO Refining Company - Corpus Christi, TX

Provided engineering with PFD's, P&ID's, Electrical One-lines, Instrument Loopdrawings, Tie-ins, and mechanical specifications to retrofit the # 5 Platformerfurnace with LoNOx burners.

Refinery LoNOx Burners - Burner Installed Cost $1.5 millionCITGO Refining Company - Corpus Christi, TX

Provided engineering with PFD's, P&ID's, Electrical One-lines, Instrument Loopdrawings, Tie-ins, and mechanical specifications to retrofit the # 4 Platformerfurnace with LoNOx burners.

Refinery LoNOx Burners - Burner Cost $1.0 millionFlint Hills Resources - Corpus Christi, TX

Provided engineering with PFD's, Tie-ins, P&ID's, Electrical One-lines, InstrumentLoop drawings, and mechanical specifications to retrofit the West Crude furnacewith LoNOx burners. This project included new fuel gas coalescing filters, airpreheater, burner controls and air ducts.

Co-Gen Auxiliary BurnersValero Refining - Corpus Christi, TX

A Duct Burner system was added to the existing Cogeneration/Steam GenerationUnit in the East Plant to provide supplemental firing to increase steam generation.Provided initial process evaluation, scope definition, complete engineering,equipment specification and selection, construction management and start-upassistance for this project.




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6-Oil System ReactivationEquistar Chemicals, LP - Corpus Christi, TX

Complete detail design for the reactivation of the 6-Oil facilities for the “A” Boilersat the Equistar Corpus Christi Plant, including mechanical /piping,instrument/electrical and Triconex programming update. This project converted 4

boilers from natural gas to heavy waste oil fuel firing.

Waste Liquid Boiler and Turbo-Gen. Set - Total Project Cost $5.0 MillionCelanese Chemical

Provided project management and complete project design for full discipline WasteLiquid Boiler and 600# Steam Turbo-Generator Set.

SRU Waste Heat Boilers and Superheater - Total Project Cost $1.6 Million

Valero Refining - Corpus Christi, TXProvided complete detail process and project engineering including mechanical,I&E, structural, and piping design. This project was performed on a crash basis.Partial issues of drawings were required to expedite construction. Assisted inconstruction inspection.

Gas Oil HDS Unit Revamp - Total Project Cost $8.0 MillionValero Refining - Corpus Christi, TX

Provided a 25% increased flow rate to the Gas Oil Treater Stabilizer Heat withheat integration, improved preheat capabilities and energy conservation. This

increased product recovery was achieved while meeting desired productspecifications.

Major new equipment included a reactor, heater, trayed vessel, drums, air-cooledexchangers, shell & tube exchangers, numerous pumps and instrumentation.

Provided initial process simulations and evaluations, scope definition, definitiveproject estimate, complete engineering, equipment specification and selection,construction management and start-up assistance for this project.

The pre-outage construction portion of this project was accomplished in sixweeks, while the unit outage portion o the effort was accomplished in twenty days.Peak workforce for this project was 300 men.




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Refinery LoNOx Burners - Burner Installed Cost $450,000Valero Refining –Three Rivers, TX

Provided engineering with PFD's, P&ID's, Electrical One-lines, Instrument Loopdrawings, Tie-ins, Piping isometrics and mechanical specifications to retrofit theVacuum Unit furnace with LoNOx burners.


Provided engineering with PFD's, P&ID's, Electrical One-lines, Instrument Loopdrawings, Tie-ins, Piping isometrics and mechanical specifications to retrofit thetwo (2) furnaces in the #1 Reformer Unit with LoNOx burners.


Provided engineering with PFD's, P&ID's, Electrical One-lines, Instrument Loopdrawings, Tie-ins, Piping isometrics and mechanical specifications to retrofit theHF Alky Unit furnace with LoNOx burners.

Furnace Efficiency Improvements- Installed Cost $750,000Valero Refining –Three Rivers, TX

Provided engineering with PFD's, P&ID's, Electrical One-lines, Instrument Loop

drawings, Tie-ins, Piping isometrics, FEA analysis of existing and modifiedstructure, structural steel drawings and mechanical specifications to retrofit the #1Reformer Unit furnace with added convection section with steam coils andaddition stack high to provide required draft to recover waste heat.

Furnace Efficiency Improvements - Installed Cost $ 2,500,000Valero Refining –Three Rivers, TX

Provided engineering with PFD's, P&ID's, Electrical One-lines, Instrument Loopdrawings, Tie-ins, Piping isometrics, FEA analysis of existing and modifiedstructure, structural steel drawings and mechanical specifications to retrofit three

(3) #1 Crude Unit furnace with added convection sections with steam coils andaddition stack high to provide required draft to recover waste heat.

BHP F&F Furnace Efficiency Improvements

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