Online, Non-intrusive Trouble Shooting and Process ... · Online, Non-intrusive Trouble Shooting...
Transcript of Online, Non-intrusive Trouble Shooting and Process ... · Online, Non-intrusive Trouble Shooting...
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Online, Non-intrusive Trouble Shooting
and Process Characterization of FCCU's
using Gamma Ray and Tracer Technology
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Presentation Agenda
• Introduction
• Tracerco Technology
– Gamma Scanning
– Tracer study
• Case study
– Cyclone Blockages
– Feed Nozzle performance
– Stripping Steam Ring Damage
– Catalyst Bed level
– Regenerator Air Grid problems
– Cyclone overloading problems
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What we do…
Provide technologies that enable visualisation of plant
processes to characterise operations and deliver
optimisation to the end user
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How?
Tracerco can comprise any individual element or combination
of the techniques below :
•Unsealed tracer injections to follow various phases
•Gamma scanning to determine levels or detect damage
•Gamma Scanning to assess standpipe density
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Applications of the Technology – FCCU’s
• Riser Density Profile
• Coke Deposits
• Velocity - slip ratios
• Residence times
• Distribution of feed, steam & catalyst
• Residence times
• Distribution
• Cyclone blockages
• Cyclone efficiency
• Vapour underflow
• Catalyst bed level
• Residence times
• Velocities
• Distribution
• Steam underflow
• Catalyst Bed Level
• Dip-Leg Catalyst Levels• Air distribution
• Catalyst distribution
• Cyclone efficiency
• Cyclone blockage
detection
• Catalyst bed level
• Catalyst slugging
• Catalyst density
profile
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Technology Overview
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Cyclone Gamma Scan
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Feed Nozzle Performance
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Tracer Study
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Tracer Study
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Case Studies
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• 6 Internal cyclones.
• Cyclone A was blocked.
• Catalyst level increased as
circulation rate was increased.
Case Studies – Scan of Internal Cyclones to
locate Blocked Cyclone
The unit was operating at
reduced rates due to the
increase in catalyst within the
slurry pump around.
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Separator Study01 October 2018 13
Case Studies – Catalyst Distribution in the Riser
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1371mm Above Feed Nozzles
17 April
3048mm Above Feed Nozzles
18 April
1371mm Above Feed Nozzles
18 April
3048mm Above Feed Nozzles
17 April
Low Rates High Rates
Case Studies – Catalyst Distribution in the Riser
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TruTec™ Scanning
FCC Reactor Stripper –
Catalyst/Vapor Flow Distribution
• Measures steam & catalyst
distribution through the
stripping section
• Identify problem areas for
upcoming turnarounds to
assist in scheduling
maintenance, resulting in
an on-time turnaround
performance
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TruTec™ Scanning
FCC Reactor Stripper –
Catalyst & Vapor Distribution
Catalyst Distribution
Steam Distribution
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Separator Study
01
Octob
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201817
TRACERCO Diagnostics FCCU Study
Stripping Steam Distribution
0
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30 32 34 36 38 40 42 44 46 48 50
Time (seconds)
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dia
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Stripper Top N Stripper Top E Stripper Top S Stripper Top W
Before
Case Studies – Stripper Maldistribution
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Separator Study
01
Octob
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201818
TRACERCO Diagnostics FCCU Study
Stripper Steam Distribution - Top
0
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25 35 45 55 65 75
Time (seconds)
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sit
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Stripper Top N Stripper Top E Stripper Top S Stripper Top W Strip Steam In
After
Case Studies – Stripper Maldistribution
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Separator Study01 October 2018 19
Case Studies – Regenerator Bed Levels
• Three different operating
levels of the Regenerator
• Gamma Scan at each
condition to optimize the
bed level and reduce
catalyst carryover.
Bed Level
Bed Level
Bed Level
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Case Studies – Air Grid Problems
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Case Studies – Blockage causing cyclone
overloading issues
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RTD Distribution Cyclone Inlet Distribution
Case Studies – Blockage causing cyclone
overloading issues
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Conclusion
• Scanning and Tracer injection/detection are the only techniques that allow you to
effectively ‘look inside’ your vessels whilst in normal operating conditions.
• The perfect technology to:
– Troubleshoot operating problems
– Carry out a Process Optimisation Study
– Plan a Turnaround more efficiently
– Carry out a ‘baseline’ study of the unit during Commissioning or after a
Turnaround
– Measure Efficiency gains after a Retrofit
• Tracerco measurement data can also be used to enhance CFD modelling for
more accurate analysis
Thank you and any Questions?
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Resources
Use our Technology Map to find out more!