HIGH-EFFICIENCY

DESIGN WITH CUSTOM

BACK-END WASTE
HEAT RECOVERY.

HIGH-PERFORMANCE
EMISSION CONTROLS –
FOR THE LOWEST LEVELS
OF CO AND NOX AS
LOW AS 2PPM.

COMPLETE SYSTEMS
CUSTOM DESIGNED
FOR THE MOST
STRINGENT CUSTOMER
SPECIFICATIONS.

RENTECH BOILERS.
AS TOUGH AS TEXAS.
PRODUCTS SOLUTIONS
Heat Recovery Steam Generators Refining and Petrochemical
Waste Heat Boilers Power Generation
Fired Packaged Watertube Boilers Manufacturing & Institutional
Specialty Boilers Food Processing
CHP
WWW.RENTECHBOILERS.COM

Select 53 at www.HydrocarbonProcessing.com/RS
 MARCH 2019 | HydrocarbonProcessing.com

PETROCHEMICAL
TECHNOLOGY
How did asset utilization modeling
save Sadara $1 B in capital costs?

Implement AI to predict the composition

of chemical plant feed

Triple-lane layout for enhanced

cracking coil performance

PROJECT MANAGEMENT
The intelligent 3D model: A game-changer
in digital project execution

BUSINESS TRENDS
Petrochemicals 2025: Three
regions to dominate the surge
in petrochemical capacity growth
 HIGH-EFFICIENCY
DESIGN WITH CUSTOM
BACK-END WASTE
HEAT RECOVERY.

HIGH-PERFORMANCE
EMISSION CONTROLS –
FOR THE LOWEST LEVELS
OF CO AND NOX AS
LOW AS 2PPM.

COMPLETE SYSTEMS
CUSTOM DESIGNED
FOR THE MOST
STRINGENT CUSTOMER
SPECIFICATIONS.

RENTECH BOILERS.
AS TOUGH AS TEXAS.
PRODUCTS SOLUTIONS
Heat Recovery Steam Generators Refining and Petrochemical
Waste Heat Boilers Power Generation
Fired Packaged Watertube Boilers Manufacturing & Institutional
Specialty Boilers Food Processing
CHP
WWW.RENTECHBOILERS.COM

Select 53 at www.HydrocarbonProcessing.com/RS
 MARCH 2019 | Volume 98 Number 3
HydrocarbonProcessing.com

34

SPECIAL FOCUS: PETROCHEMICAL TECHNOLOGY DEPARTMENTS

35 How did asset utilization modeling save Sadara $1 B in capital cost? 4 Industry Perspectives
F. Hayek and M. Moran 8 Business Trends
39 Triple-lane layout for enhanced cracking coil performance 12 Industry Metrics
R. Ramesh and J. Van Der Eijk 83 Show Preview
85 Innovations
47 Development of zeolite catalysts for production of ethylbenzene
87 People
W. Yang and Z. Wang
88 Advertiser Index
50 Implement AI to predict the composition of chemical plant feed 89 Marketplace
O. Giiazov, D. Shalupkin, A. Ermulin and G. Stremousov 90 Events
VALVES, PUMPS AND TURBOMACHINERY
COLUMNS
53 Cut costs and save time servicing valves during refinery turnarounds
7 Editorial Comment
N. Dalal Continuing the advancement of the
petrochemical industry
57 Understand net gas compressor control logic
from a process engineering standpoint 13 Reliability
R. Hong and G.-S. Chang Where asset reliability must begin
in refineries and petrochemical plants
PLANT DESIGN 15 Maintenance
61 Set correct design specifications Mind the small stuff: Tips to manage
for optimized piping and pipe support system particle contamination
S. Maiti 17 Project Management
Intelligent 3D model
PROJECT MANAGEMENT for digital project execution
65 The top three causes of contractor and engineering misalignment 21 Project Management
N. Eichelberger Estimate skid and package dimensions

67 Design considerations for rigging and transportation 23 Europe

Russian petrochemicals industry
of large process columns
on the verge of large-scale growth
B. K. Sharma and A. Bahadur
25 Petrochemicals
MAINTENANCE AND RELIABILITY Which network can fulfil
the petrochemical sector’s
71 Fabrication of clad equipment and piping—Part 2 desire to exploit Industry 4.0?
A. Panchal, R. Carmona, K. Daru, J. Desai, M. Irfan and C. Shargay
27 Fluid Flow
75 Application of ring-type joint gaskets in a refinery Retrofit for reliability
S. Lee, S. H. Lee, S. Jeon and T. Y. Jang with Coriolis flowmeters

79 The critical maintenance team: Do you have one? 29 Executive Viewpoint

Introducing the refinery of the future
G. Thorman
31 Digital
Cover Image: Overview of an ethylene plant. Digitalization:
Why now?

www.HydrocarbonProcessing.com
P. O. Box 2608
Houston, Texas 77252-2608, USA
Phone: +1 (713) 529-4301
Fax: +1 (713) 520-4433
Editors@HydrocarbonProcessing.com

PUBLISHER Catherine Watkins

Industry Perspectives EDITOR/ASSOCIATE PUBLISHER

EDITORIAL
Lee Nichols

Executive Editor Adrienne Blume

Managing Editor Mike Rhodes

What are the opportunities Digital Editor

Technical Editor
Stephanie Bartels
Sumedha Sharma

for the global HPI?

In the February issue of Hydrocarbon Processing, our editors
provided the results of Hydrocarbon Processing’s survey on the
challenges that the downstream processing industry may face
this year. The HPI certainly witnessed its fair share of challenges
in 2018. From new regulatory announcements and enactments
to the continued buildout of new refining, petrochemical and
gas processing/LNG capacity, 2018 epitomized the ever-chang-
ing global HPI marketplace. With several hundred votes, regula-
tions—representing nearly 30%—were viewed as the top chal-
lenge the industry will see in 2019. However, the oversupply of
refined fuels, knowledge transfer and surplus capacity buildout
had strong showings. A final breakdown of votes is listed below:
• Oversupply of refined fuels—20%
• Regulations—28%
• Surplus capacity (e.g., is the industry building
too much?)—16%
• Increasing costs—6%
• Knowledge transfer or lack thereof—20%
• Feedstock availability—2%
• Other—6%.
Now that the industry is aware of the challenges that may
be faced this year, our editors surveyed Hydrocarbon Processing’s
global audience to find out the greatest opportunities the HPI
may witness this year. After several hundred votes, two opportu-
nities emerged as the most popular: An increase in the integra-
tion of refinery and petrochemical operations and an increase in
digital operations. These two categories represented nearly 60%
of total votes cast—an increase in refining and petrochemical
operations and the increased use of digital tools represented
35% and 23%, respectively. In third place, increased process-
ing margins represented 11% of total votes cast. A market share
analysis of total votes is shown in FIG. 1.
35% Increase in refining-petrochemical
operations
23% Increase in digital operations
11% Processing margins
6% Other
5% New demand centers
5% Increased safety measures
5% New technologies
5% Increasing fuels/petrochemicals
demand
5% New capacity builds
FIG. 1. The downstream processing industry’s greatest opportunities
in 2019, as voted by readers of Hydrocarbon Processing.
Visit HydrocarbonProcessing.com to view
Reliability/Equipment Editor Heinz P. Bloch
Contributing Editor Alissa Leeton
Contributing Editor ARC Advisory Group
Contributing Editor Anthony Sofronas
MAGAZINE PRODUCTION / +1 (713) 525-4633
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Assistant Manager, Advertising Production Dasha Ivanova
Manager, Editorial Production Angela Bathe Dietrich
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Graphic Designer Krista Norman
Artist/Illustrator David Weeks
ADVERTISING SALES
See Sales Offices, page 88.
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the results from the latest poll, as well as Publication Agreement Number 40034765 Printed in USA
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results from previous surveys. World Oil ®, Pipeline & Gas Journal and Underground Construction.

4 MARCH 2019 | HydrocarbonProcessing.com
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 Editorial LEE NICHOLS, EDITOR/ASSOCIATE PUBLISHER
Comment Lee.Nichols@HydrocarbonProcessing.com

Advancements in the petrochemical industry

Each year, Hydrocarbon Processing 2050. This growth pattern would mean INSIDE THIS ISSUE
devotes its Special Focus section to the that the petrochemical’s sector’s oil de-
latest advancements in petrochemical
technology, as well as best practices, reli-
mand would increase from 12 MMbpd in
2017 to 18 MMbpd by 2050. 29 Executive Viewpoint.
The President and CEO of
Honeywell UOP provides his insights
ability and safety to ensure efficient and This substantial petrochemical de-
on how the processing plant of the
optimized petrochemical operations. mand forecast is and will be met by a
future must include not only the ability
The petrochemical industry has wit- surge in new petrochemical capacity ad-
to produce low-sulfur fuels, but also
nessed robust growth over the past sev- ditions. According to Hydrocarbon Pro-
petrochemicals.
eral years. Increased demand for petro- cessing’s Construction Boxscore Database,

34 Petrochemicals.
chemicals has been led by developing there are nearly 470 active petrochemical
economies, primarily in Asia. As more projects around the world. The petro- This month’s Special
people move into the middle class, de- chemical sector represents approximately Focus explores the innovative technical
mand for petrochemical-based products 35% of all active projects globally. The approaches being applied in the
increases. This has been the trend for sev- refining and gas processing/LNG indus- petrochemical industry to increase
eral years, with no end in sight. tries represent a market share of 36% and energy process efficiency, optimize
Global demand for petrochemicals 29%, respectively. production and reduce CAPEX.
is forecast to expand exponentially to In total, the Construction Boxscore
at least 2030. The International En-
ergy Agency (IEA) has forecast that
approximately 25% of the increase in
Database is tracking nearly $510 B in ac-
tive petrochemical projects around the
world. Most petrochemical projects are in
53 Valves. Most refineries
perform turnaround activities
every 3 yr–5 yr to maintain and upgrade
oil consumption to 2023—nearly 1.7 three regions: Asia-Pacific ($200B), the plant assets and equipment. Reducing
MMbpd—will be from demand for pet- US($100B) and the Middle East ($90B) the time and cost of servicing valves
rochemicals feedstocks. This consump- (FIG. 1). These three regions represent not during a turnaround is a matter
of using available modern technology,
tion rate is expected to increase substan- only 76% of total active projects, but also
such as smart valves, coupled with the
tially in the longer term. The IEA’s The nearly 79% of announced capital expendi-
right tools and training.
Future of Petrochemicals report forecasts ture in petrochemical capacity additions

61 Plant Design.
that the petrochemical sector will ac- globally. A detailed petrochemicals out-
count for one-third of oil demand growth look of these three regions is provided in This work provides details
to 2030, increasing to nearly half up to this month’s Business Trends section. on why owners and EPC firms must
180 develop a comprehensive and detailed
piping design in downstream
160 processing projects.

65 Project Management.
140
Total active petrochemical projects by region

The author examines

120
the misalignment between owner-
100 operator companies and EPC companies,
as well as several solutions to mitigate
80 cost overruns.

71 Maintenance
60
and
40
Reliability. Part 1 of this
two-part series discussed the various
20 manufacturing processes used for clad
plates and pipes, along with factors
0
Africa Asia-Pacific Canada Western Eastern Europe, Latin Middle East US that affect the decision to use cladding
Europe Russia, CIS America vs. weld overlay. Part 2 discusses
weld procedure qualifications,
FIG. 1. Total active petrochemical projects by region. Source: Hydrocarbon Processing’s
production testing and the clad pipe
Construction Boxscore Database.
manufacturing process.

Hydrocarbon Processing | MARCH 2019 7

 | Business Trends
According to Hydrocarbon Processing’s HPI Market Data 2019, the
Construction Boxscore Database is tracking nearly $510 B in active
petrochemical projects around the world. The global petrochemical
sector continues to expand exponentially as developing nations’
demand for petrochemical/chemical products continues to increase.
This month’s Business Trends details the investments being made in
the global petrochemical industry, with a deeper look at major capital
expenditures in the Asia-Pacific, Middle East and US regions.

Photo: Linde Engineering Division’s polyethylene plant in Al-Jubail Industrial City,

Saudi Arabia. Photo courtesy of The Linde Group.
LEE NICHOLS, Editor/Associate Publisher,
Hydrocarbon Processing

Business Trends

Petrochemicals 2025: Three regions to dominate

the surge in petrochemical capacity growth
The global petrochemical sector continues to expand ex-
ponentially as developing nations’ demand for petrochemical/
chemical products continues to increase. In its “Oil 2018” re-
port, the International Energy Agency (IEA) forecasts that ap-
proximately 25% of the increase in oil consumption to 2023—
nearly 1.7 MMbpd—will be from demand for petrochemical
feedstocks. The IEA’s long-term petrochemical forecast shows
an even greater amount of oil demand from the petrochemical
sector. In the organization’s “The future of petrochemicals” re-
port, the IEA forecast that the petrochemical sector will account
for one-third of oil demand growth to 2030, increasing to nearly
half to 2050. According to the report, production of key plastics
will more than double between 2010 and 2050.
Growing demand centers in the Asia-Pacific region will be
met by billions of dollars of new petrochemical production ca-
pacity in Asia, the Middle East and the US. These three regions
are investing heavily to boost petrochemical processing capac-
ity to satisfy demand.
Many non-OECD countries are witnessing petrochemical
demand rates increasing faster than GDP growth. Several na-
tions will remain dependent on petrochemical imports, while
others are investing to satisfy domestic chemicals demand.
Multiple factors will determine the future of the petrochemi-
cal industry: supply/demand factors, plastics recycling, regu-
lations, feedstock costs, partnerships/mergers/acquisitions,
digitalization, etc. Many nations are investing heavily to satisfy
domestic petrochemicals demand and/or export petrochemi-
cal products to increase revenues.
At the time of this publication, the Boxscore Database was
tracking nearly 470 active petrochemical projects around the
world. A breakdown on active refining project market share
is provided:
• Africa—6% (29 projects)
• Asia-Pacific—34% (158 projects)
• Canada—1% (7 projects)
• Western Europe—5% (22 projects)
• Eastern Europe, Russia and the CIS—12% (55 projects)
• Latin America—6% (28 projects)
• Middle East—13% (63 projects)
• US—23% (106 projects).
In total, the Construction Boxscore Database is track-
ing nearly $510 B in active petrochemical projects around
the world. Asia-Pacific is the leader in capital expenditures
(CAPEX) in the near term. The Boxscore Database is tracking
more than $200 B in active petrochemical projects in Asia. The
US has more than $100 B in active petrochemical projects, fol-
lowed by the Middle East with nearly $90 B in active projects.
These three regions represent not only 76% of total active proj-
ects, but also nearly 79% of announced CAPEX in petrochemi-
cal capacity additions globally. A breakdown of CAPEX in the
petrochemical sector, by region, is provided:
• Africa—$32 B
• Asia-Pacific—$205 B
• Canada—$10 B
• Europe—$48 B
• Latin America—$19 B

New/active projects. According to Hydrocarbon Processing’s

Construction Boxscore Database, more than 280 new petro-
3% Africa
chemical projects were announced from 2016–2018. New pet- 19% US
rochemical project announcements increased from 68 in 2016
to 88 in 2017 to 125 in 2018. This trend represents a year-over-
48% Asia-Pacific
year increase of 29% and 42%, respectively. Most new petro- 10% Middle East
chemical project announcements have been in the Asia-Pacific
region. The region continues to invest a substantial amount of 1% Latin America
capital to increase petrochemical capacity to mitigate imports 6% East Europe, Russia, CIS
and satisfy increasing domestic demand. Over the past 3 yr, the
petrochemical sector has maintained 36%–41% of new project 12% Western Europe
market share, and has been the leader in new project announce-
ments since 2016. Over the past year, Asia-Pacific and the US
2% Canada
have been the leaders in new petrochemical project announce- FIG. 1. Market share of new petrochemical project announcements
ments, accounting for nearly 70% of all new petrochemical proj- by region, December 2017–December 2018. Source: Hydrocarbon
Processing’s Construction Boxscore Database.
ect announcements over the past year (FIG. 1).
Hydrocarbon Processing | MARCH 2019 9
 Business Trends
• Middle East—$88 B
• US—$105 B.
According to the IEA petrochemicals report, nearly all re-
gions, except for Europe, will increase production of primary
chemicals to 2050. The largest capacity growth is seen in the
Middle East and Asia. The Middle East is forecast to increase
production of high-value chemicals, ammonia and methanol
from approximately 70 MMtpy to more than 150 MMtpy by
2050. Nearly all Middle Eastern nations are investing in new
petrochemical production capacity to mitigate the reliance on
crude oil export revenues.
The region has already boosted production capacity, led
by Saudi Arabia, and more investments have been announced.
The Asia-Pacific region’s petrochemical buildout is forecast to
increase by nearly 200 MMtpy to nearly 500 MMtpy by 2050.
China and India will be the leaders in new petrochemical capac-
ity additions; however, multiple Asian nations have announced
capital-intensive projects. Many of these projects will help miti-
gate growing supply and demand gaps and will be built alongside
refining operations. The move toward refining and petrochemi-
cal integration is a primary focus of many operators around the
world, especially in Asia. The ability to share feedstocks allows
producers to produce petrochemical products more efficiently.
Asia-Pacific. To help mitigate imports and to satisfy robust
demand, many Asia-Pacific nations are investing in the expan-
sion and debottlenecking of petrochemical units, as well as the
construction of grassroots petrochemical complexes. These
capital-intensive investments include increased integration
between refining and petrochemical facilities to increase effi-
ciency and value.
At the time of this publication, the Construction Boxscore
Database was tracking nearly 160 active petrochemical projects
in the region. China accounts for nearly half of all petrochemical
projects in the region. India is second in the region, with 15%
market share in active petrochemical projects. When broken
down by activity level, more than 70% of the region’s petrochem-
ical projects are in preconstruction phases, with approximately
43% in the planning/proposed phase:
• Engineering—19%
• FEED—4%
• Planning/proposed—43%
• Study—7%
• Under construction—27%.
China’s Belt Road Initiative calls for the massive develop-
ment of domestic petrochemical production capacity to miti-
gate imports. According to an ICIS report, China plans to add
21 new steam crackers and 10 new refineries in petrochemical
industry parks. This buildout could equate to nearly 27 MMtpy
of new ethylene production by the mid-2020s, reaching more
than 42 MMtpy.
Due to increasing demand for petrochemical products, India
will continue to heavily invest in additional petrochemical pro-
duction capacity. According to IHS, India’s domestic ethylene
capacity has increased from 4 MMtpy in 2014 to 7.2 MMtpy
in 2018. However, with petrochemicals demand forecast to in-
crease substantially, additional capacity will be needed to satisfy
demand and mitigate imports. According to a report by McK-
insey and Co., India’s petrochemicals shortfall could increase to
10 MARCH 2019 | HydrocarbonProcessing.com
25 MMtpy by 2025 if investments in new production capacity
are not made. However, the nation’s operators have announced
plans to invest more than $30 B to boost petrochemical capacity.
Middle East. In response to the decrease in oil prices that oc-
curred from 2014–2016, and to mitigate reliance on oil export
revenues and diversify their product portfolios, nearly all nations
in the Middle East have announced capital investments in new
downstream processing capacity, especially in the production of
petrochemicals. The region has the largest cost advantage in eth-
ylene production, and several countries are building, or planning
to build, mixed-feed crackers, as well as ethylene derivatives, am-
monia/urea and other petrochemical capacity.
Saudi Arabia is the leader in new petrochemical capacity in-
vestments. The Kingdom plans to nearly triple petrochemical
production capacity from 12 MMtpy in 2016 to 34 MMtpy by
2030. The country will accomplish this goal by adding petro-
chemical capacity to existing refineries, as well as building grass-
roots facilities. Several other nations are investing heavily in do-
mestic output. Major projects include:
• Kuwait—Olefins 3-Aromatics 2 project
• Oman—Liwa plastics project
• United Arab Emirates—Ruwais refining and
petrochemical park, including the construction
of Borouge 4
• Qatar—Ras Laffan petrochemical complex (proposed)
• Iran—Mokran petrochemical complex
• Iraq—Nebras petrochemical complex.
US. Due to the shale gas boom, the US has witnessed a renais-
sance in its domestic petrochemical industry. Cheap, readily
available shale gas feedstock has allowed the country to become
one of the world’s lowest-cost ethylene producers. In turn, the
US is building millions of tons of additional ethylene and ethyl-
ene derivatives production capacity.
The Hydrocarbon Processing Construction Boxscore Data-
base is tracking 115 active petrochemical projects in the US.
More than 70% of the country’s petrochemical projects are lo-
cated in Louisiana and Texas. These two states will be instru-
mental in boosting ethylene and ethylene derivatives, methanol
and specialty chemicals capacity into the early 2020s.
By the end of the decade, the US is also forecast to add more
than 10 MMtpy of new ethylene capacity. This boom in ethylene
capacity includes more than 9 MMpty of grassroots facilities, as
well as more than 1.2 MMtpy in ethylene capacity expansion
projects. Most of the country’s grassroots facilities will include
derivative units. In total, US petrochemical producers will invest
nearly $20 B in new ethylene capacity by 2020. A second wave
of new ethane crackers could add more than 5 MMtpy of new
capacity after 2020. In total, capital expenditures for both eth-
ane cracking project waves could top $50 B by the mid-2020s.
The largest ethylene derivative capacity expansion will oc-
cur in the production of polyethylene (PE). By 2020, the US
will add approximately 8 MMtpy of new PE capacity, most of
which will be integrated into new ethane cracking operations;
however, grassroots PE plants are also being built. According
to Platts, PE surplus in the US reached more than 4 MMtpy in
2017 and could increase to 7.5 MMtpy in 2020. This trend will
make exporting US PE a must for producers.
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Industry Metrics

In the US, soaring gasoline stocks and poor fuel oil performance were Global refining margins, 2018–2019*
offset by strong heating oil demand and higher product prices caused by 20
weather-related refinery outages. European product markets weakened WTI, US Gulf
as arbitrage openings pressured margins and outweighed support from a 15 Brent, Rotterdam

Margins, US$/bbl
Oman, Singapore
pickup in diesel and fuel oil demand. In Asia, weakening naphtha and jet/ 10
kerosine markets dragged down margins.
5
An expanded version of Industry Metrics can be found
online at HydrocarbonProcessing.com. 0

Jan.-18

Feb.-18

Mar.-18

April-18

May-18

June-18

July-18

Aug.-18

Sept.-18

Oct.-18

Nov.-18

Dec.-18

Jan.-19
US gas production (Bft3d) and prices (US$/Mft3)
100 7 Global refining utilization rates, 2018–2019*
6 100
80
US EU 16
Gas prices, US$/Mft3

5 95
Production, Bft3

Selected Asia
Utilization rates, %
60 4 90
40 3 85
Monthly price (Henry Hub) 2 80
20 12-month price avg. 75
Production 1
0 0 70
A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J
Jan.-18

Feb.-18

Mar.-18

April-18

May-18

June-18

July-18

Aug.-18

Sept.-18

Oct.-18

Nov.-18

Dec.-18

Jan.-19
2016 2017 2018 2019
Production equals U.S. marketed production, wet gas. Source: EIA.

Selected world oil prices, US$/bbl US Gulf cracking spread vs. WTI, 2018–2019*
50
100 Prem. gasoline Diesel
90 40 Jet/kero Fuel oil
W. Texas Inter.
Cracking spread, US$/bbl

80 Brent Blend 30
Oil prices, US$/bbl

Dubai Fateh
70 Source: DOE 20
60 10
50 0
40 -10
30 -20
20
Jan.-18

Feb.-18

Mar.-18

April-18

May-18

June-18

July-18

Aug.-18

Sept.-18

Oct.-18

Nov.-18

Dec.-18

Jan.-19

Feb.-19
J F M A M J J A S O N D J F M A M J J A S O N D J
2017 2018 2019

World liquid fuel supply and demand, MMbpd Rotterdam cracking spread vs. Brent, 2018–2019*
106 7 30
Implied stock build Forecast
104 6
Stock change and balance, MMbpd

Cracking spread, US$/bbl

Supply and demand, MMbpd

102 Implied stock draw 5

World supply 15
100 World demand 4
98 3 Prem. gasoline Gasoil
96 2 0 Jet/kero Fuel oil
94 1
92 0 -15
90 -1
Jan.-18

Feb.-18

Mar.-18

April-18

May-18

June-18

July-18

Aug.-18

Sept.-18

Oct.-18

Nov.-18

Dec.-18

Jan.-19

Feb.-19

88 -2
2014-Q1 2015-Q1 2016-Q1 2017-Q1 2018-Q1 2019-Q1 2020-Q1
Source: EIA Short-Term Energy Outlook, February 2019 Singapore cracking spread vs. Dubai, 2018–2019*
Brent dated vs. sour grades 20
(Urals and Dubai) spread, 2018–2019*
Cracking spread, US$/bbl

6 10
Light sweet/medium sour

Prem. gasoline Gasoil

crude spread, US$/bbl

4
Jet/kero Fuel oil
2 0
0
Dubai -10
-2
Jan.-18

Feb.-18

Mar.-18

April-18

May-18

June-18

July-18

Aug.-18

Sept.-18

Oct.-18

Nov.-18

Dec.-18

Jan.-19

Feb.-19

Urals
-4
Jan.-18

Feb.-18

Mar.-18

April-18

May-18

June-18

July-18

Aug.-18

Sept.-18

Oct.-18

Nov.-18

Dec.-18

Jan.-19

Feb.-19

* Material published permission of the OPEC Secretariat; copyright 2018;

all rights reserved; OPEC Monthly Oil Market Report, February 2019.

12 MARCH 2019 | HydrocarbonProcessing.com
 HEINZ P. BLOCH, RELIABILITY/EQUIPMENT EDITOR
Reliability Heinz.Bloch@HydrocarbonProcessing.com
Where asset reliability must begin in refineries
and petrochemical plants
Numerous articles on asset reliability have been published
in the decades since 1970. Hundreds of books and conference
presentations deal with reliability topics of interest. Eliciting
feedback from course and workshop attendees at learning cen-
ters for industry in Louisiana and Texas proved valuable; field
forces have confirmed that effective reliability practices greatly
benefit if middle management is “on board” from the inception
of a project. It is too late to optimally involve middle manage-
ment in the quest for reliability after the equipment has begun
arriving at the plant site.
Definitive guidance sought. We had ample opportunity to
pay attention to these concerns, which were voiced by workshop
attendees at McNeese State University in Lake Charles (Louisi-
ana), Lamar University in Beaumont (Texas) and at Texas A&M
University’s Kingsville campus. In the 12 yr since 2006, the com-
ments and feedback from reliability technicians at these promi-
nent locations demonstrated that a variety of reliability manage-
ment approaches exist at different plant sites.
It was evident that diverging approaches brought different re-
sults. At each of the three regional Institutes for Industry Educa-
tion Collaboration (II-ECs), attendees suggested that managers
would also benefit from education in reliability improvement
matters. In particular, we heard that the message of asset reli-
ability having “precursor requirements” should be conveyed to
managers; early involvement by managers is needed to avoid in-
efficiencies and frequent failures later in the plant’s life.
One of our major conclusions and recommendations was for
the training departments of petrochemical plants and oil refiner-
ies to optimize the involvement of managers. Instead of targeting
only the plants’ reliability technicians, these II-ECs would arrange
forums, tutorials or workshop presentations for middle manage-
ment personnel on the theme or topic of “effectively managing
asset reliability in petrochemical plants and oil refineries.”
However, unless managers had been wisely budgeting and
guiding project engineers very early in the business cycle, work-
shop participants later reported facing the impossible task of
imparting reliability to weak designs. Allowing weak designs to
reach the plant meant frequent and expensive efforts to keep
plants running safely. Without wise budgeting and specifica-
tion-based guiding, plants were later plagued by random fail-
ures and costly downtime.
The presenter’s role. In developing and presenting a forum
or workshop on the fundamentals of early management involve-
ment for II-ECs, an experienced presenter will likely focus on
the methods and procedures consistently used by best-of-class
facilities. Both course developers and presenters noted that the
most profitable facilities also excelled in grooming and training
reliability professionals—the future subject matter experts, or
SMEs. An experienced presenter will leave it to his or her listen-
ing or participating middle management audience to examine
and determine where improvement is possible at their respec-
tive facilities. Additionally, competent presenters will be fully
prepared to defend their experience-based claim that the cost of
upgrading to best possible training is negligible, and that the pay-
back is huge. We saw how experienced presenters placed heavy
emphasis on two details of primary importance:
1. The specific training topics and their timed “phases”
in the development of SMEs
2. The respective roles of (a) middle management and (b)
the men and women whose training and development
will culminate in their becoming top-notch professionals.
While it may be true that motivation and the desire to add val-
ue often originate with one’s upbringing, these attributes can also
be learned and/or reinforced by good managers. That said, only
informed managers have the potential of becoming good manag-
ers. Their respective management styles will be highly support-
ive of the techniques and procedures implemented by competent
reliability professionals. Nevertheless, informed managers are in-
tent on giving specific guidance and direction in grooming and
nurturing the talent needed for best-of-class asset performance
and plant profitability. Voicing generalizations is insufficient
when specifics are needed. To restate the two main points:
• Asset reliability in refineries and petrochemical plants
should never be an afterthought. Best-of-class facilities
fully recognize that carrying out the needed steps depends
largely on guidance from above and not as much on later
practices from below.
• It follows that the training departments of oil refineries and
petrochemical plants may ask regional II-ECs to arrange
forums, tutorials or workshop presentations for middle
management personnel on the topic of effectively managing
asset reliability in oil refineries and petrochemical plants.
HEINZ P. BLOCH resides in Montgomery, Texas. His
professional career commenced in 1962 and included
long-term assignments as Exxon Chemical’s Regional
Machinery Specialist for the US. He has taught reliability
on all six continents and authored (or co-written)
735 publications, among them 20 comprehensive
books on practical machinery management for industry.
His latest title, Storage Preservation and Optimized
Lube Application, will soon be released. Mr. Bloch
holds BS and MS degrees (cum laude) in mechanical
engineering and is an ASME Life Fellow.
Hydrocarbon Processing | MARCH 2019 13
Tomorrow’s refinery is flexible, integrated and connected.
It consumes less energy and produces less waste. It readily responds to market
conditions. Plus, it allows you to analyze plant data with UOP proprietary process
information to achieve peak performance and profitability.
Sound impossible? Not with Honeywell UOP. As an operational partner, we’ll help
you create your tomorrow today.

Select 71 at www.HydrocarbonProcessing.com/RS
 T. GOLDMAN
Maintenance Sun Coast Resources Inc., Houston, Texas

Mind the small stuff: Tips to manage

particle contamination
Particle contamination in lubricants
is the primary cause of lubricant-related
equipment failure and hydraulic system
failure, according to industry studies. A
300-gal hydraulic reservoir can contain up
to 8 g of particle contamination. Most par-
ticles are too miniscule for the naked eye
to see, yet are the perfect size to cause abra-
sive wear and disrupt operations.
However, a faulty, long-held, industry-
wide belief remains that using clean fluids
leads to clean machinery. While partly true,
this practice alone will take decades to real-
ize benefits if equipment is not first cleaned.
To reduce particle contamination, improve
fluid cleanliness and maximize equipment
life expectancy, the better approach is to
remove the debris in the equipment before
new clean lubricants are introduced.
There is no better time to remove de-
bris and manage contamination than when
equipment is shut down during scheduled
maintenance or a turnaround. Simple steps
to reduce contamination and increase the
life expectancy of equipment by as much
as seven times are discussed here.
FIG. 1. Since normal operations can create significant amounts of dirt, it is critical to remove
Find your bearings. A thorough analy- storage tank contaminants. Turnarounds and scheduled maintenance are the best times to
conduct these operations.
sis of fluids should be conducted to es-
tablish a baseline and identify areas of
contamination. Fluid samples of criti- water, metal, silicate, paint and water) be- clean tanks and flush lines because the
cal equipment are taken in advance of a cause contamination inevitably happens equipment is down.
scheduled turnaround or maintenance along the lubricant’s journey from the It is critical to remove storage tank con-
event to measure water contamination, manufacturing plant to the equipment taminants because normal operations can
microscopic particulate contamination system or storage tank. create significant amounts of dirt (FIG. 1). If
and even insoluble varnish-forming pre- Particle size and composition are mea- possible, personnel should physically enter
cursors. Technicians typically work close- sured to determine a fluid’s contamina- the tank to clean it. If this is infeasible be-
ly with third-party analytical laboratories tion levels. As particles move through the cause the tank is too small or too difficult
to independently verify the results. equipment’s system, smaller pieces result to reach, then it should be steam cleaned
The tests provide plants with a results- and work into the machines to cause abra- with a tool snaked into the container. The
based schedule, rather than a time-based sion, adhesion, fatigue, erosion and wear. overall goal is to restore the inside of the
schedule that identifies the equipment The most common detriment is abrasive tank to the same clean state as before the
with the most contamination. This sched- wear caused by clearance-sized particles fluid entered.
ule saves time and money, which is crucial interacting with two sliding surfaces. An appropriate analogy is that equip-
during a turnaround. ment and fluids are like mud and ice cream.
Results rarely come back without Clean tanks. Turnarounds and sched- If ice cream is dropped in the mud, nothing
finding areas of contamination (i.e., dirt, uled maintenance are the best times to happens to the mud, yet the ice cream is
Hydrocarbon Processing | MARCH 2019 15
 Maintenance

ruined. If the equipment is not clean, then
the fluid is quickly spoiled.
Filters 101. It is easy to ignore filters, but
they play a critical role. Unchanged filters
wreak havoc on equipment because par-
ticles will eventually bypass the filtration
system and damage equipment. This is a
costly oversight, especially if production
is halted for days to repair the equipment.
Filtration maintenance must be preserved
with a monthly or quarterly program to re-
duce the level of contaminants over time.
The plant’s control room typically
monitors both lube oil and breather fil-
ters on storage tanks, so plants can act fast
once a filtration issue arises.
Certified clean fluids. When tanks are
clean and filters are ready, it is time to use
a certified clean fluid to maintain the sys-
tem’s cleanliness, maximize the life of the
equipment, meet stringent quality control
standards set by original equipment manu-
facturers (OEMs), decrease unscheduled
downtime at the plant and save money. It
costs 90% less to remove particle contami-
nation before fluids are introduced into the
system than to remove particle contamina-
tion after the fluid enters the machinery.
Certified lubricants also reduce the ex-
pense and time required by end users to
prefilter non-certified lubricants to meet
stringent OEM-specified International
Organization for Standardization (ISO)
cleanliness recommendations. Certified
fluid is rigorously tested and verified be-
fore each customer delivery.
Schedule ongoing analysis. After a
turnaround or scheduled maintenance,
monitor fluid cleanliness with regular flu-
id analysis to assess the particle count of
fluids present, and identify any contami-
nation that requires action.
Personnel at plants located on the
Texas Gulf Coast should remember that
water is the primary contaminate and
does the most damage to equipment. Just
a 0.05% increase in water contamination
reduces the expected life of a bearing by
60%. Unfortunately, 0.05% is too little to
detect visually, so unique instruments are
needed to identify water in parts per mil-
lion (ppm). It is important to work with a
supplier with the ability to perform such
testing and consulting.
Takeaway. Most plant equipment is
mission-critical; few non-critical or re-
dundant pieces of equipment exist. To
protect these assets, operators must con-
duct a thorough fluid analysis to establish
a baseline, clean tanks regularly, keep up
with filtration maintenance, use certified
clean fluids and do regular check-ins to
pull samples and track progress.
A contamination management program
not only improves fluid cleanliness, but can
also maximize the life of the equipment
and contribute to cost-containment goals.
For a plant, an effective program translates
to better maintenance, less downtime,
higher productivity and more responsible
stewardship of capital expense.
TROY GOLDMAN is the Product
Integrity Manager at Sun Coast
Resources Inc. The Society of
Tribologists and Lubrication
Engineers recognizes Mr. Goldman
as a Certified Lubrication Specialist.

ON DEMAND WEBCAST

Bharat Thakkar
Independent Consultant
Thakkar Analytical Services
Deciphering ASTM Moisture Methods in
Hydrocarbon Processing
Many analytical techniques can be used to test moisture levels in crude oil, feedstock and
refined products, however navigating the nuances of ASTM methods for moisture analysis
can be confusing. Attend this webinar to hear Bert Thakkar, Secretary of ASTM’s Committee
D02 on Petroleum Products, Liquid Fuels, and Lubricants discuss ASTM methods and how to
implement them in your lab. Dr. Kerri-Ann Blake, Product Specialist at Metrohm, will provide
Kerri-Ann Blake, PhD expert tips on sample preparation, reagent selection and instrument maintenance that help
Product Specialist you get the most out of your measurements.
Metrohm

View On Demand:
HydrocarbonProcessing.com/Webcasts

Mike Rhodes
Managing Editor
Hydrocarbon Processing

16 MARCH 2019 | HydrocarbonProcessing.com
 R. ROMANO, M. CORTESI, A. MAGAROTTO, C. MINNUCCI
Project Management and A. PINTO, Baker Hughes, a GE company, Florence,
Italy; and R. ZANNORI, A. TITTOBELLO and
G. SEMERARO, TechnipFMC, Rome, Italy

Intelligent 3D model for digital project execution

Digital transformation offers the
chance to reorganize and develop new
models of collaboration that fully leverage
the opportunities offered by digital tech-
nologies and their benefits across the oil
and gas business—particularly for origi-
nal equipment manufacturers (OEMs)
and engineering, procurement and con-
struction (EPC) contractors.
The transformation means that digital
platforms inherently enable new types of
innovation and creativity in a particular
domain, rather than simply supporting
traditional methods.
Digital usage may refer to the simple
concept of “going paperless,” or to the
more wide-reaching achievement of “digi-
tal business maturity,” which affects indi-
vidual processes and joint businesses.
As a consequence, OEM 3D models
are exchanged with 3D models from EPCs
in a neutral format that contains mainly
shapes (FIG. 1), and they are used only for
space management. Meanwhile, all needed
design data for plant design are exchanged
through paper documents and drawings.
In January 2017, the Rome, Italy op-
erating center of a major project lifecycle
services companya and the Florence, Italy
operating center of an international tur-
bomachinery OEM and service compa-
nyb began actively collaborating to achieve
the integration and enhancement of their
own 3D models, under the framework of a
“digital project execution” initiative.
The goal of this cooperation was the
development of a digital methodology
to integrate information and data neces-
sary for plant and equipment design into
an “intelligent 3D model.” This model
would attain an innovative, technically
competitive and efficient project execu-
tion. The two companies recognized the
intelligent 3D model as a key project
deliverable, and jointly defined the con-
tent, the common format, the delivery
timeline and the sharing process for the
detailed design development.
The OEM 3D model has been devel-
oped as a single and authoritative source
of mechanical design information, con-

Oil and gas market challenge. The

scope, nature and complexity of today’s
oil and gas projects present additional
challenges to engineering contractors
and equipment manufacturers to reduce
overall project costs and schedules while
maintaining high engineering integrity
and quality.
These challenges can be addressed by
a new collaborative approach between
the EPC contractor and OEM. This ap-
proach, while maximizing the benefits of
digital transformation, must reshape da-
ta-centric design processes during proj- FIG. 1. OEM 3D models are exchanged with 3D models from EPCs in a neutral format
ect development. that contains mainly shapes.
Digital project execution has the po-
tential to create added value in the design
chain through a “just-in-time” design data
exchange, engineering design integration
and holistic data management.

Intelligent 3D model approach. Tradi-

tionally, EPCs and OEMs develop their de-
signs with specific 3D CAD tools custom-
ized for their different businesses. EPCs
utilize tools to manage bulk materials and
to generate drawings needed for plant erec-
tion, while OEMs utilize mechanical CAD FIG. 2. Specific attributes in the intelligent 3D model include tags for equipment/instrument/
piping line numbering and interface points at battery limits.
software for shop floor machines.
Hydrocarbon Processing | MARCH 2019 17
 Project Management

taining both geometry and all other engi- panyb during the last decade in the model- The intelligent OEM 3D model is
neering data to effectively achieve and im- based definition (MBD) approach. This composed of geometric shapes that rep-
plement a paperless approach that is easily experience links projects to engineering, resent real equipment/components, and
integrated in the EPC plant 3D model, en- manufacturing, supply chain and services. non-geometric design data (attributes)
suring “just in time” data availability. The concept of the annotated 3D mod- associated with each item. The model is
el has been taken as a reference to review visually searchable and easily accessible.
Intelligent 3D model development. the original OEM 3D model content. It The appropriate selection of content
The intelligent 3D model development has been used to optimize existing attri- is the key concept of the intelligent 3D
takes advantage of the experience culti- butes (FIG. 2), including information usu- model, allowing for the successful execu-
vated by the turbomachinery OEM com- ally managed through other deliverables. tion of project design. It also ensures that
the 3D model is not over-designed, which
would limit its manageability.
The intelligent OEM 3D model is
exchanged with the EPC contractor
through a dedicated conversion process.
The format is suitable for “plug-and-play”
insertion into the plant 3D model, creat-
ing a one-to-one correlation between the
two design environments that leaves the
EPC and OEM native files and environ-
ment unchanged. The 3D model is then
shared in a collaboration work space with
a timeline that matches critical milestones
for the project execution (FIG. 3).
The EPC contractor’s detailed de-
sign outcomes are stored directly in the
3D model and are analyzed by the OEM
through the same review tool. This meth-
odology allows the EPC and the OEM
to immediately visualize, in a dedicated
joint session, the model details, the com-
ments and the related follow-up “status”
(i.e. open, closed, etc.) with an overall ef-
ficiency enhancement.
The 3D model is iteratively updated to
track the changes inside the model itself,
FIG. 3. Work process: The 3D model is prepared by the OEM through the addition of design with the advantage of a detailed design
data as attributes (Step 1), then it is shared with the EPC in a suitable format (Step 2). development follow-up inside a single
The EPC inserts the OEM 3D model into its plant 3D model (Step 3). The feedback is performed source of data, until the 3D model final
on a digital tool and transferred to the OEM, and then assessed jointly during a review status is achieved.
(Step 4). Once EPC feedback is agreed upon, the OEM implements the feedback in the 3D
model (Step 5), thereby reiterating the process until the 3D model final release (Step 6).
Case study: Middle East refinery ex-
pansion project. Feasibility tests were
carried out for the a refinery expansion
project in the Middle East. For this specific
project, which was executed by the project
lifecycle services company,a the turboma-
chinery OEM and service companyb sup-
plied two power generation gas turbines,
four electric drive centrifugal compressors
and six reciprocating compressors, for
both makeup and recycle services.
The agreed objective was to achieve an
EPC contractor and OEM design integra-
tion with no data manipulation and auto
placement of the specific models.
To test the new digital project execu-
tion, the turbomachinery OEM compa-
FIG. 4. An intelligent 3D model was used to test the new digital project execution.
nyb provided the project lifecycle services
18 MARCH 2019 | HydrocarbonProcessing.com

companya with an intelligent 3D model
(FIG. 4) with new data and information,
and with a “maturity” indication to de-
fine the reliability of downstream activi-
ties with an analytical approach.
The case study demonstrated the fol-
lowing items:
1. Attributes selected for the project
development can be included
in the OEM 3D model.
2. The inclusion of absolute
geographical coordinates in
the OEM 3D model allowed
its integration with the EPC
model without manipulation.
3. The possibility of managing the
OEM model into the EPC model,
independently from the OEM
CAD native format, allows the
data owner to maintain
responsibility and integrity.
4. All interface points were
recognized by the EPC model
as design “ports,” with specific
mechanical characteristics.
5. The exchange of models,
executed in different project
steps, confirms the reliability
of data maturity management.
6. The entire OEM model
was “searchable” in terms of
characteristics and attributes.
7. Comments and clarifications
during the design phase can
be exchanged through the 3D
model with a complete paperless
approach and more effective
finalization of the system layout.
Test results were promising:
1. Equipment 3D models were
easily manageable due to
limited sizing.
2. A real integration (and cross-
checking) of OEM design data
inside the EPC design data
was realized.
3. The EPC observed a seamless
design execution, with a reduction
in the total number of comments.
4. The OEM and the EPC
appreciated the possibility of
querying the model to obtain
data, as well as the possibility
of developing an agreed-upon
model and effectively verifying
the ergonomics of the plant.
The intelligent 3D model is also the
enabler of a new type of collaboration
between the OEM and the EPC by using
Project Management
virtual reality as a shared environment for
the plant 3D model design review.
The execution of this specific virtual T +49 2961 7405-0
model review allows early detection of info@rembe.de
potential clashes. It also allows for deep
assessment of the maintainability and
operability of equipment in a 1:1 virtual Made
plant, while combining the different com- in
petencies of EPC and OEM engineers. Germany
Takeaway. The results of the case study
demonstrate that traditional “paper”
drawings can be effectively replaced by
the intelligent 3D model and its contents,
leading to significant benefits for the
EPC contractor and the OEM.
A project based on digital execution is
more efficient than conventional design
methods, for a number of reasons:
• Better and faster alignment, since
the EPC data are captured as
designed and updated by the OEM
• Just-in-time data availability based
on maturity and fit-for-purpose Your Specialist for
principle
0 Elimination of misalignments
among drawings, since design PRESSURE
data are included in a unique
digital source
0 Optimization of OEM and
RELIEF
EPC contractor work processes,
avoiding redundancies during SOLUTIONS
engineering development
0 On-time visual recognition of
design issues that could heavily
impact the cost or quality of
the job, if discovered during the
manufacturing/erection phase
0 Reduced time for data retrieval Consulting. Engineering.
• Enhanced exchange of design Products. Service.
solutions between the EPC
contractor and the OEM, which
helps manage schedule constraints
• Immediate reuse of the OEM
3D model by the EPC contractor
© REMBE® | All rights reserved
• Possibility of organizing a
3D model review as an effective
collaborative event among the
EPC contractor, the OEM and
the final customer.
The intelligent 3D model represents
the “power of change” of digital transfor-
mation, enabling OEMs and EPC con-
tractors to investigate innovative collabo-
ration schemes and play unique roles in Gallbergweg 21
the evolving oil and gas market. 59929 Brilon, Germany
F +49 2961 50714
NOTES
a
TechnipFMC www.rembe.de
b
Baker Hughes, a GE Company
Select 151 at www.HydrocarbonProcessing.com/RS
 J. ABID
Project Management Piping/Project Engineer, Islamabad, Pakistan

Estimate skid and package dimensions

In the absence of vendor quotations TABLE 1. Dimensions of existing inlet manifolds (unrefined data)
or detailed engineering, preliminary di-
mensions of skids or packages can be es- Description Length, mm Width, mm Remarks
timated quickly using the ratio method. 6 slot, 4 in. × 6 in.
This method is particularly useful for Class 1500 5,834 3,813 Access = 640 mm
operators, which traditionally have a lim- 6S-4X6-1500
ited database compared to contractors.
9 slot, 4 in. × 6 in.
To overcome this challenge, operators
have created, maintained and organized Class 1500 8,834 3,813 Access = 640 mm
a dimensional database of existing pro- 9S-4X6-1500
cess equipment and skids. 6 slot, 4 in. × 6 in.
The overall dimensions of a skid are Class 600 8,000 3,998 Access = 800 mm
related to key parameters, such as diam-
eter and length of pressure vessel, high- 6S-4X6-600
est flange rating, outer diameter (OD) of 7 slot, 6 in. × 12 in.
pipe, and the number of slots or parallel Class 600 13,000 3,800 Access = 1,500 mm
runs. Skid length ratio is established by 7S-6X12-600
dividing the existing skid length by such
8 slot, 6 in. × 16 in. Access = 800 mm, inlet valve
key parameters. Skid width ratio is estab- in vertical position (less
lished similarly. The average length ratio Class 900 16,027 3,400
width), double isolation valves
and width ratio are calculated to improve 8S-6X16-900 in production header
accuracy and minimize variations. 7 slot, 4 in. × 16 in.
Uneconomical design
The estimated length and width of
Class 600 14,000 4,500 (Unnecessary elbows/
a new skid can be calculated by multi- unutilized space)
plying key parameters with respective 7S-4X16-600
average length ratios and average width
ratios. This concept is illustrated by an
example of estimating the dimensions
of a 10-slot, Class 600, 4-in. inlet × 8-in.
production header conventional inlet
manifold. This method can be applied
to estimate the dimensions of a horizon-
tal vessel skid (based on vessel diameter
and length), a metering skid (based on
L/D ratio and width/run/flange OD) or
cooling water unit plot (based on cooling
tower cell width). An estimate accuracy
of up to +/– 1,000 mm can be achieved
when a dimensional database with con-
sistent criteria (access width, isolation
philosophy, extent of automation/in- FIG. 1. Typical inlet manifold.
strumentation, etc.) is maintained and
updated on a continuous basis.
past records/equipment list (TABLE 1). larly, the key parameter for skid width is
Example 1. To determine the dimen- The skid length depends on the number the highest flange rating of the biggest
sions of the previously mentioned ex- of slots and the OD of the flange (inlet line (i.e., the production header, high-
ample (10-slot, Class 600, 4-in. inlet line), which is highlighted pink in FIG. 1. lighted yellow in FIG. 1). Therefore, the
× 8-in. production conventional inlet So, the skid length ratio is determined by skid width ratio is the “width per flange
manifold), the data here is available from the “length per slot per flange OD.” Simi- OD.” TABLE 1 is rearranged to retrieve re-
Hydrocarbon Processing | MARCH 2019 21
 Project Management

TABLE 2. Dimensions of existing inlet manifolds (refined data)

Length, Number FLG OD Length/ Width, FLG OD Width/
Description mm of slots (Inlet), mm slot/FLG OD mm (prod), mm FLG OD, mm
6S-4X6-1500 5,834 6 310 3.1 3,813 395 9.7
9S-4X6-1500 8,834 9 310 3.2 3,813 395 9.7
6S-4X6-600 8,000 6 273 4.9 3,998 419 9.5
7S-6X12-600 13,000 7 356 5.2 3,800 559 6.8
8S-6X16-900 16,027 8 380 5.3 3,400 705 4.8
7S-4X16-600 14,000 7 273 7.3 4,500 686 6.6
Average length ratio 4.8 Average width ratio 7.8

TABLE 3. Dimensions of existing inlet manifolds (normalized data)1

Adjusted Number FLG OD Length/slot/ Adjusted FLG OD Width/FLG
Description length, mm of slots (inlet), mm FLG OD, mm width, mm (prod), mm OD, mm Remarks
6S-4X6-1500 6,834 6 310 3.7 3,813 395 9.7 Length increase; actual
length was 5,834 mm
9S-4X6-1500 10,234 9 310 3.7 3,813 395 9.7 Length increase; actual
length was 8,834 mm
6S-4X6-600 8,000 6 273 4.9 3,998 419 9.5
7S-6X12-600 11,500 7 356 4.6 3,800 559 6.8 Length decrease; actual
length was 13,000 mm
8S-6X16-900 14,897 8 380 4.9 4,160 705 5.9 Length decrease; actual
length was 16,027 mm
Width increase; actual
width was 3,400 mm
7S-4X16-600 10,256 7 273 5.4 4,500 686 6.6 Length decrease; actual
length was 14,000 mm
Average length ratio 4.5 Average width ratio 8
1
Design basis: Access width = 800 mm; single-isolation valve on inlet lines, test and production header; and isolation valve of inlet lines installed in horizontal position.

fined/statistical data. Note: The average
skid ratios at the end of the table even out
the dimensions from different vendors.
As seen in TABLE 2, considerable varia-
tions exist due to inconsistent access
space, different isolation, etc. It is neces-
sary to adjust/normalize dimensions on a
consistent design basis. This will also help
benchmark skid dimensions (TABLE 3):
The overall length of the skid is deter-
mined by Eq. 1:
Number of slots × flange OD ×
(average length/slot/
flange OD)
where 4 × 273 × 4.5 = 12,334 mm–
12,350 mm.
The overall width of the skid is deter-
mined by Eq. 2:
Flange OD × (average width/
flange OD)
where 419 × 8.0 = 3,359 mm–3,400 mm.
Example 2: Horizontal vessel skid.
Skid width depends mainly on the di-
ameter of the vessel and the number of
major (≥ 3-in.) lines connected to the
vessel. Note: The size/flange rating of
the line(s) do not have a major impact
on the width ratio because, as these pa-
rameters/attributes change, the width
ratio will adjust accordingly. A key pa-
rameter for skid length is the tangent-
to-tangent length of the vessel. As previ-
ously discussed, the basis of design must
(1) be documented for real results. Based on
limited available vendor data, the aver-
age length ratio is 1.5, while the average
width ratio is 1.8.
This method can be applied to es-
timate dimensions of a 2 × 100% hori-
zontal pump skid (based on single-
pump skid dimensions), a metering skid
(2) (based on L/D ratio and width/run/
flange OD) or a cooling water unit plot
(based on cooling tower cell width).
Takeaway. An estimated accuracy of
+/– 1,000 mm can be achieved when a
dimensional database with consistent
criteria (i.e., access width, isolation phi-
losophy, extent of automation/instru-
mentation, etc.) is maintained and up-
dated on a continuous basis.
Furthermore, this concept is based on
limited available data. It is expected that
major oil and gas companies and/or con-
tractors will further develop and bench-
mark data for the benefit of knowledge-
sharing in the oil and gas industry.
JAMSHAID ABID is a Piping/
Project Engineer with more
than 14 yr of experience in
project design, engineering,
installation and commissioning
for onshore oil and gas (greenfield
and brownfield developments)
and ammonia-urea plants in Iraq, Pakistan,
the UAE and Yemen. He holds a BE degree in
mechanical engineering from the University of
Engineering and Technology in Taxila, Pakistan.

22MARCH 2019 | HydrocarbonProcessing.com

 E. GERDEN
Europe Contributing Writer
Russian petrochemicals industry
on the verge of large-scale growth
The Russian government has announced its plan to in-
crease the volume of support for its domestic petrochemicals
industry over the next several years, with the aim of doubling
its production and boosting exports, according to Russian
Minister of Energy Alexander Novak and the press service of
the Russian Presidential Administration.
Planned support is expected to be in the form of additional
subsidies and the creation of favorable tax regimes for produc-
ers. In general, the government plans to create more attractive
and stable conditions for doing business in the Russian petro-
chemicals industry, ensuring stability of the industry’s tax re-
gime for at least 15 yr. A final list of planned support measures
will be announced by the end of 1Q 2019.
According to Novak, the government hopes to attract more
than $40 B of additional investments to the industry by 2030,
with the goal of doubling petrochemicals production capac-
ity within that timeframe. In addition, Russia is planning to
increase the competitiveness of its petrochemicals industry in
the international arena. In the case of tax policy, the govern-
ment plans to introduce a negative excise tax on liquefied hy-
drocarbon gases and ethane in the country.
According to the latest proposal of the Ministry of Energy,
Russia plans to emulate Saudi Arabia, which implemented a
subsidization policy that boosted the petrochemicals indus-
try’s share of national GDP to 14% over the last several de-
cades. This growth is significantly higher than what has been
seen in Russia, where figures do not exceed 1.5% despite the
country’s rich hydrocarbon reserves, which are comparable to
those of Saudi Arabia.
At present, outdated technologies and high depreciation of
fixed assets are two of the major problems of the Russian pet-
rochemicals industry, despite some modernization by leading
producers in recent years.
This has led to a lack of production of key petrochemicals
products in Russia, despite utilization rates of 85%. Most ex-
isting pyrolysis units in Russia were built in the mid-1900s.
The total capacity of ethylene pyrolysis units is estimated at
slightly more than 3 MMtpy, which accounts for approximate-
ly 2% of global production.
According to state plans, capacity should significantly in-
crease over the next few years due to state support. Novak has
said that the implementation of these plans will be part of the
existing energy strategy of Russia for the period to 2030 (e.g.,
Plan 2030). The strategy was approved by the Russian Minis-
try of Energy in 2012 and involves the establishment of six large
petrochemicals clusters in different parts of Russia, including
the Volga, Caspian, West Siberian, East Siberian, Northwest-
ern and Far Eastern regions. Each of these clusters will have its
own olefins complex, a raw materials base and other associated
infrastructure. These clusters will also include enterprises spe-
cializing in the production of finished petrochemicals. Most of
these enterprises will be small- to medium-sized.
Of these clusters, special attention will be paid to the pet-
rochemical facilities being established in the Far East. These
facilities will primarily export to the Asia-Pacific region.
The Eastern Petrochemical Company (EPC)—a petro-
chemical enterprise built by Rosneft—will serve as the basis
for the Far East cluster. The new enterprise will have the capac-
ity to produce more than 10 MMtpy of petrochemicals and will
process oil from the Eastern Siberia-Pacific Ocean pipeline.
At the time of this publication, Rosneft and China’s Sino-
pec are negotiating the construction of a new gas chemical
complex in the Krasnoyarsk Territory. At its initial stage, the
facility will have the capacity to process up to 5 Bm3y of as-
sociated natural gas, with the possibility of expanding to 10
Bm3y. The facility’s feedstock will come from the Yurubchen-
sky oil and gas fields.
The development of the Volga cluster will be another prior-
ity for the Russian government in the field of petrochemicals.
Part of the project includes the construction of a large-scale
ethylene plant at the Nizhnekamsk Petrochemical Plant.
According to state assessments, Plan 2030 will boost
Russia’s ethylene production from 8 MMtpy in 2018 to nearly
13 MMtpy by 2030.
Structure and production. The Russian petrochemicals in-
dustry is primarily dominated by large companies, with the lead-
ing players being Sibur Holding, TAIF Group of Companies,
Rosneft, LUKOIL and Gazprom. Unlike many international
petrochemical giants (Dow, BASF, etc.), none of these compa-
nies are purely petrochemicals. Instead, they are mostly verti-
cally integrated oil companies with petrochemicals businesses.
The Ministry of Energy believes that Russia’s domestic pro-
duction will be enough for the implementation of Plan 2030.
In 2018, oil and gas condensate production in Russia amount-
ed to nearly 600 MMt, of which more than 50% was sent for
processing. In the case of associated petroleum gas, production
reached 83 Bm3 in 2018, of which 40% was processed at do-
mestic gas processing plants. As a rule, the production of raw
materials for petrochemicals facilities is usually carried out
near pyrolysis plants.
Producers hope for state support during the implementa-
tion of petrochemicals projects. These companies are hoping
for state assistance during the establishment of infrastructure
Hydrocarbon Processing | MARCH 2019 23
 Europe

for the new enterprises, as well as for ensuring regular sup-
plies of raw materials for their processing needs. Companies
are ready to actively introduce new technologies to expand the
range of high-value-added products.
Sanctions. Russia has a shortage of production of certain
high-value petrochemical products, particularly special com-
posites and additives. The introduction of new technologies
should help partially solve this problem. However, most of
these new technologies have been traditionally imported to
Russia from abroad, mainly from Western countries, while the
ongoing sanctions against Russia significantly complicate the
further transfer of technology.
While the Russian petrochemical industry was not directly
affected by sanctions from the US and the EU, they still resulted
in restrictions for supplies of various technologies, equipment
and raw materials used in Russian petrochemicals production.
In addition, the existing sanctions have significantly complicat-
ed lending to Russian petrochemicals enterprises by Western
banks. Despite the sanctions, the Russian government has high
hopes for the development of its petrochemicals industry.
producers that the implementation of their ambitious plans to
double petrochemicals production may lead to oversupply.
For example, Dmitry Konov, Chairman of Sibur’s Manage-
ment Board, stated that Russia’s existing petrochemicals ca-
pacities are already competitive in the global market. The main
difficulty is related to the capital intensity of industry projects.
These capital-intensive projects will require significant incen-
tives from the government, which could be problematic, con-
sidering the complex state of the Russian economy.
Dmitry Akishin, Gas and Chemistry Division Head at
Vygon Consulting, believes that Russia has opportunities for
the development of petrochemicals; however, the doubling of
production could be too optimistic for the industry. “To repeat
the path of Saudi Arabia, it is important to have comparable sup-
port tools of domestic petrochemicals production, as in Saudi
Arabia,” said Akishin. “The Kingdom uses a regulated price for
ethane, which is set at $54/1,000 m3 compared to $200/1,000
m3–$300/1,000 m3 in the world market. In addition, it pro-
vides a 30% discount on LPG and allocates about $10 B–$15 B
of annual investments in the development of infrastructure for
the industry through state-owned companies.”

Threat of oversupply? In accordance with Russia’s Ministry
of Energy report, over the past 15 yr, Russia’s petrochemicals
production has ranged from 7%–9%. Despite good prospects
for further production growth, Russia’s leading petrochemicals
analysts have warned national government and domestic oil
EUGENE GERDEN is an international contributing writer
specializing in the global oil refining and gas industry.
He has been published in a number of prominent industry
publications.

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24 MARCH 2019 | HydrocarbonProcessing.com

Petrochemicals
Which network can fulfill the petrochemical
sector’s desire to exploit Industry 4.0?
The global petrochemical industry
has not been short of success. It has ex-
perienced more than 15 yr of strong vol-
ume growth, with no sign of stopping.
Fueled by abundant raw materials and
increasing demand, new petrochemical
plants are being established around the
world, and existing plants are quickly ex-
panding to capitalize on this growth. Hy-
drocarbon Processing’s Construction Box-
score Database is tracking more than 470
active petrochemical projects around the
world. In total, these projects equate to
nearly $510 B in active petrochemical
projects to boost production capacity to
satisfy increasing global demand.
However, as the industry grows, so
does competition. Petrochemical plants
have no choice but to find innovative
ways to rapidly optimize their produc-
tion to get ahead, while maintaining
and increasing safety in all aspects of the
chemical production process.
Cue the Fourth Industrial Revolu-
tion. Also referred to as Industry 4.0,
technologies such as augmented reality
(AR), autonomous robots and real-time
equipment analytics have emerged as
next-generation solutions that can satisfy
a plant’s need for enhanced productiv-
ity, as well as mitigate the constant con-
cern for personnel safety. Many already
see their value. According PWC, 60% of
chemical companies state that Industry
4.0 data and analytics are of high impor-
tance, while 88% believe they will be of
high importance within 5 yr.1
However, these advanced applica-
tions need full Industrial Internet of
Things (IIoT) connectivity to func-
tion—a requirement that Wi-Fi and two-
way radio wide-area network (WAN)
alone cannot fulfil.
Why? Because the information net-
work is the backbone of complex petro-
chemical operations. It is the linchpin on
which the productivity, safety and profit-
G. SMITH
Rajant Corp., Malvern, Pennsylvania
ability of the organization relies. Band-
width and availability are precious, and
downtime is unacceptable.
If plants are to truly take advantage of
the IIoT, their mission-critical applica-
tions must run on a communications net-
work that offers highly reliable, agile and
adaptable connectivity in diverse, evolv-
ing, mobility-driven environments.
Networking challenges in petro-
chemical plants. While it is clear that
the IIoT is a critical part of establishing
Industry 4.0 capabilities plant-wide, de-
ploying a network to support connectiv-
ity demands in a dynamic and inherently
hazardous environment can be difficult.
In the petrochemical industry, balancing
facility and production growth with em-
ployee safety is paramount.
This means that the network must
keep up with several demands. For ex-
ample, many petrochemical plants oper-
ate multiple networks to fulfill separate
communications needs for their person-
nel. The burden of maintaining a Wi-Fi
network for data and a two-way radio
WAN for voice generates significant and
unnecessary added costs and resource
demands for daily operations.
Petrochemical plants also contain an
abundance of explosive and flammable
gases, such as ethylene, propylene, bu-
tadiene and other vapors, which means
that maintaining safety in danger zones
is a top priority for petrochemical plants.
To keep equipment from sparking and
starting a fire, networking infrastructure
generally must be kept in an explosion-
proof box as a precaution, further com-
plicating installation.
Operations carried out in petrochem-
ical plants are mission-critical (from
the moment of deployment to ongoing
plant operations), meaning they require
constant connectivity. Dropping signals,
even for a short span of time, not only
means productivity loss but also puts
plant workers’ safety at risk.
Simply put, plants cannot afford to risk
downtime. With petrochemical plants
undergoing a period of significant expan-
sion, choosing the wrong industrial net-
work solution could mean that a plant’s
investment will be unable to adequately
connect its operations tomorrow.
A new kind of network. To overcome
these hurdles and enable the capabilities
that Industry 4.0 brings, petrochemi-
cal plants require a different kind of
network—an Internet of Things (IoT)-
enabling network that is more flexible
than Wi-Fi networks or two-way radio
WAN. Only then can the petrochemical
industry take advantage of the innova-
tive technologies that maximize pro-
ductivity, enhance safety and give orga-
nizations a leading edge over increasing
petrochemical competition.
One viable solution is for petrochem-
ical plants to deploy a mesh network
topology—a resilient architecture, con-
structed of nodes, that enables a mul-
titude of devices to wirelessly connect
to each other. Each of these devices are
capable of relaying data across the net-
work until that data reaches its target
destination. The technology is gaining
increasing interest due to its ability to
handle the inevitable surge of data that
comes with an increased number of IoT-
connected devices.
Like many other industries, petro-
chemical operations depend on a variety
of vehicles, equipment, heavy machinery
and personnel dispersed across vast, rug-
ged terrain—all of which require reliable,
high-bandwidth and mobile communi-
cations. Every aspect of exploration, ex-
traction and production must always be
carefully monitored and managed to en-
sure continuous operations and cost con-
tainment. A mesh network can provide
Hydrocarbon Processing | MARCH 2019 25
 Petrochemicals
real-time, site-wide communications for
employees, contractors, vehicles, drills,
wellheads, video cameras, smart meters,
sensors, laptops, smartphones and an
abundance of other assets.
It sounds like a dream come true, but
not all mesh networks are created equal.
Plants require fully mobile wireless
broadband connectivity that is simple,
instantaneous and fail-proof in any ap-
plication—a “living” mesh solution that
moves and evolves with changing con-
nectivity demands.
Delivering critical connectivity. This
connectivity is achievable through a
combination of wireless network nodes
and networking software. This software
utilizes any-node to any-node capabili-
ties to continuously and instantaneously
route data via the best available traffic
path and frequency—for any number of
nodes, all with extremely low overhead.
Furthermore, superior mesh networks
can communicate with any Wi-Fi or Eth-
ernet-connected device to deliver low-
latency, high-throughput data, voice and
video applications.
A mesh network can provide a secure
and converged solution, eliminating the
need for petrochemical plants to main-
tain multiple networks by flexibly sup-
porting data, voice and video. Not only
does this solution reduce the total cost
of ownership, but it also simplifies the
work expected of personnel by allowing
them to centralize their communications
to a single device. Depending on the
mesh network provider, certain nodes
are also safe to deploy in any corner of
a petrochemical plant without the need
for mounting in explosion-proof boxes.
Wireless network nodes can be at-
tached to both fixed and mobile assets,
including equipment, vehicles and facil-
ity infrastructure. They can maintain
multiple simultaneous connections be-
tween peers, as well as send and receive
data on multiple frequency bands. Fur-
thermore, they never break connections
to form new ones, meaning connections
are maintained until they are no longer
needed. With high-bandwidth speeds
across multiple mesh node hops, a mesh
network offers extremely low latency for
real-time, plant-wide connectivity, even at
the network edge—making it the perfect
solution for mission-critical operations
that require ubiquitous connectivity.
26 MARCH 2019 | HydrocarbonProcessing.com
Mesh networking software also
autonomously directs traffic over all
meshed connections. By dynamically
load balancing and routing data around
signal blockage from moving assets and
potential interferences, it ensures that
data packets get to their destination via
the fastest path available. By eliminating
the need for a controller node, the net-
work will have no single point of failure.
As petrochemical plants are dispersed
over widespread areas, they are regularly
adding new bandwidth-intensive appli-
cations to support continued growth.
A superior mesh network topology can
rapidly evolve as a plant expands. In fact,
as more nodes are added, more paths to
direct mission-critical data are naturally
formed. With more paths, the network
becomes more resilient.
Petrochemical plants are also poten-
tial targets for high-risk network security
attacks, meaning they require military-
grade data security. A mesh network can
protect a plant from security breaches
due to multi-layered, military-grade se-
curity for network traffic, making it in-
credibly difficult to penetrate. It boasts
multiple cryptographic options, con-
figurable data and media access control
(MAC) address encryption, and config-
urable per-hop, per-packet authentica-
tion between nodes.
Enabling IIoT through a mesh net-
work. A mesh network is an effective
alternative to existing limiting technolo-
gies like Wi-Fi and two-way radio WAN.
Once a petrochemical plant has enabled
IIoT connectivity, a multitude of Indus-
try 4.0 applications can be implemented
to drive optimized production and to
increase employee safety. This means a
plant can immediately exploit advantag-
es, such as radio frequency identification
(RFID) tracking of personnel and con-
tractors, which is enabled through every-
where connectivity and provides real-
time tracking of workers across a plant.
This not only allows operators to moni-
tor personnel’s ongoing safety status, but
also aids in emergency extraction in case
of an incident.
Mesh networks also support band-
width-intensive applications, such as as-
set tracking and optimization, thereby
enabling the monitoring of a plant’s as-
sets in real time, as well as predict equip-
ment maintenance needs and maxi-
mize efficient machine movements on
the production line. Plants can lay the
groundwork for innovative IIoT appli-
cations, such as 24/7, 365-d equipment
autonomy, with plant-wide asset mobi-
lization, which increases petrochemical
output while keeping employees out of
dangerous areas.
In addition, products and equipment
can be protected from theft with real-
time video surveillance. With round-
the-clock views into operations, a plant
can gain insights into plant performance
and events on the production floor. With
AR, productivity of employees can be
enhanced, while also removing them
from potentially hazardous petrochemi-
cal environments. This highlights the
clear benefits of a wireless mesh network
for the petrochemicals market that can
deliver secure, reliable broadband cover-
age anywhere and at any time.
A new era of mesh networking.
Although this list is not exhaustive, it
illustrates how an IIoT-enabling mesh
networking solution can make operations
smarter and employees safer. It also
shows that this new kind of network is
designed to deliver continuous wireless
connectivity to support a myriad of
applications.
What makes mesh networks even
more appealing is that there are no cables
to run, so the IIoT can be deployed cost
effectively in a matter of days or weeks
rather than months. It means petrochemi-
cal plants can maximize this exciting
phase of industrialization sooner than
imagined. The desire to create a truly con-
nected plant facility need not be a distant
pipe dream. Petrochemical plants can-
not afford to ignore the IIoT, and when
it comes to Industry 4.0, a “living” mesh
network is their best alternative.
LITERATURE CITED
1
“Industry 4.0: Building the digital enterprise,”
Pricewaterhouse Cooper, 2016.
GEOFF SMITH began his career
at AT&T Bell Labs developing high-
speed modem technologies. He
led Modem, DSL and Wireless
R&D teams prior to joining Proxim
Wireless in 2000, where he held
senior executive positions managing
R&D, sales and marketing, enabling indoor and
outdoor mobile internet. In 2015, Mr. Smith founded
Wave Mobile Solutions, a DSRC V2X radio company
focused on connected and autonomous vehicles.
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Fluid Flow
Retrofit for reliability with Coriolis flowmeters
Aging infrastructure has become a
much-talked-about issue across the hy-
drocarbon industry. Many long-running
plants have worked almost nonstop for
more than 30 yr–40 yr. They have seen
downturns and years of fast economic
growth. During times of fast economic
growth, instrumentation might have been
pressed into service in ever-smaller spac-
es to accommodate the demands of the
market. Engineers and technicians have
become expert at fitting things into tight
spaces and keeping older equipment run-
ning; however, with shrinking budgets and
an aging workforce that is often not being
replaced, plants are looking for compre-
hensive solutions to the aging problems
that will not interrupt production.
When the price of oil plunged from
$100/bbl to $50/bbl with no sign of re-
covery, hydrocarbon processing plant
managers were forced to reevaluate the
efficiency of the plant and how they could
remain profitable at the $50/bbl price tag.
Investment in quality instrumentation
was key to reducing waste and remaining
relevant against the competition.
While reliability remains the biggest
challenge for any operational system, a
plant manager will look for other factors
when considering updates to the exist-
ing infrastructure: cost, safety and inter-
ruptions to ongoing production are chief
among them. The C-suite and plant man-
agers agree on the need for reliable and
safe equipment.
Two-wire flowmeters. Most hydrocar-
bon plants today run two-wire flowme-
ters. This is how they were originally set
up, primarily because two-wire meters
offer better power consumption and save
on cabling costs.
In the two-wire market, the options
in the past have been limited to differen-
tial pressure (DP), positive displacement
(PD) and turbine meters. While most
plant managers would be thrilled to have
Coriolis meters, that has not been an op-
A. GENTILE
Emerson Automation Solutions, Boulder, Colorado
FIG. 1. As hydrocarbon plants age, plant managers are seeking new solutions and technologies
to help maintain reliability and optimize efficiency.
tion in the two-wire market. As a result,
they have made do with technology that
was less expensive in the initial setup, but
that has proven to be expensive to main-
tain over time.
Add to that the fact that none of those
options are reliable over long-term use
and may require regular maintenance due
to internal moving parts, or they do not
have the range of the Coriolis meter.
This is where Coriolis meters come
into their own by meeting an industry
need with no moving parts that require
regular servicing, combined with consis-
tent reliability over time. The high turn-
down options are also very attractive.
Thanks to advances in technology, such
as the shrinking of processor sizes, a two-
wire Coriolis meter is now a viable option
across the hydrocarbon industry (FIG. 1).
Patching or retrofitting? Plant manag-
ers, engineers and maintenance techni-
cians have needed to be creative to keep
old meters running. Over the long term,
however, a patched system is simply not
feasible or safe—particularly if the tech-
nology is still analog in our increasingly
digital and connected world.
In the past, plants had teams of subject
matter experts tasked with maintaining
specific parts of a hydrocarbon plant. The
trend in recent years, however, has been to
move toward generalists. This means that
fewer people, in a shrinking pool, have
the deep expertise required for long-term
maintenance success. This scenario im-
pacts production in the long term, as un-
planned shutdowns might become more
frequent and could take longer to rectify
when outside technical help is required to
fix a problem, especially if in-house skills
are not readily available.
Ideally, a full retrofit and upgrade
should be undertaken. Many in the C-
suite understand this, but are hesitant to
greenlight such projects. Capital expenses
can quickly overwhelm a budget, especial-
ly when the financial realities beyond the
planning stage of a full upgrade become
apparent. Coupled with the natural hu-
man resistance to change, it is not surpris-
ing that infrastructure continues to age.
Beyond the capital expense and return
on investment (ROI), another important
challenge when considering a retrofit is
that of cabling. In many plants, the cabling
in overhead racks goes back 30 yr–40 yr,
if not longer. More cables are added over
time, but none of the old ones are re-
Hydrocarbon Processing | MARCH 2019 27
 Fluid Flow
moved. To consider removing all the ca-
bling at a late stage would shut production
for days, if not weeks. A solution must fit
the two-wire setup that is already in place.
Plants that have seen significant
growth over the past few decades have
little room to accommodate equipment
that requires more wiring. This makes a
two-wire setup necessary, especially one
that will not require additional straight
pipe runs to be installed.
“Two birds with one stone.” With so
many technicians and engineers retir-
ing and taking decades of knowledge and
skills with them, it is important to recog-
nize that there is very little substitute for
real-world, hard-earned experience over
what is taught in classrooms, books or case
studies. Classroom training in this area is
often missing crucial nuances and vari-
ables found in the real world. For example,
what should a technician do when a meter
is giving an unknown reading, and it is un-
clear if water, entrained gas or something
more corrosive could impact production
as it moves through the system?
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With these questions in mind, it is likely
that all of the open jobs created by the re-
tirement wave will not be backfilled. The
jobs that are filled will likely attract new
graduates who do not yet have the practi-
cal experience to work with existing equip-
ment. These new hires are more accus-
tomed to relying on digital technology for
information. They are digital natives; they
grew up with electronic devices, and they
will expect plant equipment to be digital,
as well—or at least to have a user-friendly
interface. They will expect that a laptop
or handheld device can interface with the
transmitter on the meter to provide the
necessary readings and information about
what is going on inside the process.
The new, two-wire Coriolis meters can
help here. Built-in diagnostic tools that
monitor the meter at all times and send
out alerts of changes, which can be plotted
over time, bring peace of mind. Learning
to use these tools will come more easily to
this next generation of engineers and tech-
nicians. Overall, it is easier to learn how to
use these tools than to learn how to deal
with old meters that might have quirks.
24 — 25 September 2019
Congress Center Wiesbaden, Germany
www.introequipcon.com
Preliminary
programme
available now!
Aging gracefully. For plant managers,
the issue of an aging workforce does not
need to be messy or painful if the right
options, tools and people are chosen.
Shoring up an aging plant can be done in
a way that will give the plant an upgrade,
and at the same time set it up for success
over the next 20 yr.
With careful planning and engineer-
ing, hiring the right talent and freeing up
enough initial capital, an aging hydrocar-
bon plant can realize a significant ROI
when opting for the upfront expense of
installing new, two-wire Coriolis meters
that are now available for much-needed
infrastructure upgrade projects. Built-in
diagnostic tools provide peace of mind
and make these meters more effective in
the long run.
ANTHONY GENTILE is a Marketing
Product Manager with Emerson
Automation Solutions, Micro Motion.
He has 15 yr of experience in the
area of Coriolis flow measurement
and holds a BS degree in chemical
engineering and petroleum refining
from the Colorado School of Mines, as well as an
MBA degree from Regis University.

Executive Viewpoint
Introducing the refinery of the future
Businesses that develop and com-
mercialize process technology are in a
unique position to identify and evaluate
global trends in our industry. For more
than 100 yr, our company has advised
its customers in the application of new
technologies to improve their profit-
ability in an ever-changing global energy
marketplace. In most cases, this consulta-
tion commences many years before our
clients are ready to make final investment
decisions. This is what forms the basis
for a clear, long-term view of the trends
emerging across the industry.
One important long-term concept
is what we define as the “refinery of the
future.” It is based on a philosophy that
refineries must be designed to facilitate
an evolution of product slates and deliver
sustainable competitiveness in terms of
the overall cash cost of production, capi-
tal efficiency, responsiveness to regula-
tion and competition and the agility to
manage molecules for the greatest profit-
ability. The refinery of the future also is
designed for the flexibility to cost-effec-
tively address changes in market condi-
tions in the short term, as well as 10 yr or
20 yr down the line.
Today’s refiners face an array of new
challenges, the greatest of which are the
need to continue making investments to
produce clean-burning fuels, react to mar-
ket dislocations and adapt to the widely
forecasted plateau in demand for trans-
portation fuels. Each of these challenges
will affect product mix and investment
strategies for refiners in the future. In ad-
dition, the need to address operator turn-
over and inexperience in an environment
of increasing complexity—from feedstock
to products—is another crucial challenge.
For many, the stricter rules intending
to eliminate the use of high-sulfur bun-
ker fuel presents a pressing challenge.
Simultaneously, many countries are mov-
ing away from burning fuel oil for power
generation and heating. These trends
are quickly closing the market for heavy,
J. GUGEL, PRESIDENT AND CEO
Honeywell UOP, Des Plaines, Illinois
high-sulfur fuels and creating mounting
pressure for significant upgrades in refin-
ing capabilities. More than ever before,
these upgrades must be made with a clear
view of future market conditions.
Meanwhile, high-growth economies,
with rapidly growing middle classes, will
increase their consumption of transpor-
tation fuels, and many of them are also
investing in a new domestic refining in-
frastructure capable of producing cleaner-
burning fuels. Existing refiners that tradi-
tionally have supplied fuel products into
these export markets will find demand in
those markets being met by newly estab-
lished domestic refiners. As a result, mil-
lions of barrels of export refining capacity
could be at risk of being stranded—that
is, unless the assets that produce them can
be adapted or repurposed.
With overall fuel volumes forecast to
peak around 2035, most refiners—even
those in markets where fuels are grow-
ing—are looking for paths to better man-
age their molecules so they can enter
product categories that offer growing
volumes, as well as greater profitability.
Many of these refiners plan to expand into
petrochemicals, where global demand
is growing 40% faster than gross domes-
tic product, and several times faster than
transportation fuels.
This strong demand for petrochemi-
cals is being driven by dozens of coun-
tries such as China, India and Indonesia,
where nearly 3 B people will graduate into
the middle class by 2050. These consum-
ers will fuel demand for more synthetic
fibers, packaging, automobiles, new food
options and pharmaceuticals and count-
less other consumer goods.
To satisfy this growing demand, the
refinery of the future must have the abil-
ity to upgrade crude oil into high-qual-
ity cleaner-burning fuels, in addition to
higher-value petrochemicals. The tech-
nologies that enable both production of a
clean fuels slate and an efficient pathway
to “crude-to-chemicals” from cost-advan-
taged feedstocks are essential to the long-
term profitability of refiners.
In the past, refineries that converted
15%–25% of their production into pet-
rochemicals were considered highly inte-
grated. Our company recently licensed a
world-scale complex that is in construc-
tion, and that will efficiently convert
more than half its crude intake into petro-
chemicals. Even at this level, 50% is by no
means the technological limit. It is simply
the level of petrochemicals production
that satisfied the customer’s targeted
product slate, which includes production
of clean fuels.
Refineries such as this—integrated
with substantial petrochemicals produc-
tion—are likely to be among the most
consistently profitable over the long run.
In fact, refineries that produce only petro-
chemicals are clearly on the horizon.
As important as any other factor, the
refinery of the future will be a digitally
connected facility. It will be equipped
with cloud-based connected plant ser-
vices that analyze plant performance
data with proprietary models to provide
recommendations that improve process
optimization and operational reliability,
minimize energy consumption and emis-
sions, eliminate waste products and bet-
ter manage water. It also can bridge gaps
in experience caused by retirements and
personnel attrition, providing insights
and guidance to plant operators.
Since joining UOP in 1992,
JOHN GUGEL has held roles in
business management, sales,
marketing, project management and
engineering. He most recently
served as Vice President and General
Manager of Honeywell UOP’s
process technology and equipment business. Prior to
this, he was Vice President and General Manager of the
company’s gas processing and hydrogen business. In
previous roles, he served as Global Director of
Honeywell UOP’s refining business Mr. Gugel earned
Bch and MS of Science degrees in civil and
environmental engineering from the University of
Wisconsin, and an MBA from Northwestern University’s
Kellogg School of Management.
Hydrocarbon Processing | MARCH 2019 29
Select 70 at www.HydrocarbonProcessing.com/RS
 D. MICKLEM
Digital KBC, a Yokogawa Company, Houston, Texas
Digitalization: Why now?
The process industries are under threat. Their products
are encountering substitution while market demand is stag-
nant; their means of production are challenged by alternative
technologies; local communities do not like dangerous, noisy,
smelly or highly visible assets on their doorsteps; regulators
are making it costlier to operate; retiring employees are de-
pleting the industry knowledge pool; and tech industries are
attracting potential new talent.
Faced with such an environment, investment choices are
limited and capital is scarce; physical infrastructure is aging
and inflexible. Operational technology (OT) is required to
last a quarter of a century—many process operations are con-
trolling their plants with systems installed in the 1990s with
only superficial upgrades since that time. Such technology is
limited in scope; therefore, the plant’s ability to manage its as-
sets holistically, rather than as individual standalone units, is
impaired. This makes them particularly vulnerable.
The focus of most plants has been “operability”—making
sure that each asset is available and runs reliably and safely.
Little time is left to devote to driving excellence; the OT infra-
structure and tools to get the most out of the entire plant are
not readily accessible, and the organization is not prepared to
manage a change in focus.
Plants that are committed to the medium and long term
must have robust strategies to counter these threats and to
guarantee their relevance and competitiveness. Digitalization
is one of the key strategies that a plant can adopt to address
these challenges by spending a modest amount of capital yet
generating quick and effective results, sustainably.
Didn’t the industry “digitalize” in the 1980s? The 1980s
went through a digital revolution as old pneumatic and elec-
tronic instruments and controllers were upgraded to digital
technologies. However, that was digitization, not digitalization.
Digitization is simply a change of format from analog to digital,
but essentially business as usual.
Conversely, digitalization has a far greater outcome-orient-
ed ambition. It is the scalable application of digital technologies
and the alignment of organizational capabilities that an energy
or chemical process operation should have and master, with
digital information at the core to achieve excellence.
What do operations leaders think? Many in the down-
stream industry are confused or irritated by digitalization. Over-
all, information technology (IT) vendors are to blame. They
push the idea that digitalization is an IT issue yet cannot ex-
plain its relevance to an operational audience. They flood their
offerings with new buzzwords but fail to articulate a compelling
value proposition when challenged with operational reality.
Despite this, digitalization cannot be ignored, and plants
must look past the confusion to uncover their own unique val-
ues and outcomes.
The author’s company recently commissioned a survey of
100 operations leaders across the oil refining and petrochemi-
cals industry to understand how they are responding to mar-
ket conditions and setting themselves on a more sustainable
path. One of the three major trends identified was the influ-
ence of technology on the industry. Respondents showed a
strong desire to obtain a digital blueprint for the future, yet
felt underprepared within their organizations for the adoption
of technologies such as the cloud, the Industrial Internet of
Things (IIoT) and artificial intelligence (AI).
Why digitalize? The same research also showed that digi-
talization leaders can access as much as 800% higher human
productivity in operations, compared to industry laggards. Al-
though still in its infancy, digitalization is clearly already hav-
ing a massive impact. The potential business impact is truly
transformational.
Digitalization allows plant personnel to manage day-to-
day performance safely and reliably, so that the facility can
respond to swings in market dynamics, operate at a true op-
timum, squeeze the gap between potential and realized prof-
itability, create more utility for its end customers/consumers
and outmaneuver competition.
It also enables a process operation to extend its problem-
solving ecosphere beyond the plant: to engage the support,
brainpower and technologies of the plant’s key partners, cus-
tomers and suppliers, each of which can bring specific exper-
tise and experience to augment the plant’s own capabilities
and resources.
Digitalization can turn a distracted organization that is
bogged down in reacting to day-to-day issues and inundated
with data, information and advice into an agile, well-oiled ma-
chine that proactively anticipates issues and organizes to pri-
oritize and solve them before they escalate.
Digitalization—now is the time. When performed correct-
ly, digitalization creates revenue, improves business perfor-
mance (not just processes), solves problems that could not be
solved before, empowers personnel and makes them more ef-
fective. It builds a culture with digital information at the core.
Now is the time to digitalize. Digitalization has been en-
abled by rapid growth in technology capabilities and the ac-
ceptance of new business models. Most in the industry are
only just beginning their digitalization journey, but some are
already embracing digitalization and are pushing themselves
ahead of the rest. Digitalization creates and sustains competi-
Hydrocarbon Processing | MARCH 2019 31
 Digital

tive advantage, and those who are not digitalizing now are be-
ing left behind—they will be consumed in the marketplace.
Digitalization actions to take now. The following are steps
companies should be taking to advance digitalization within
their organizations.
Table stakes. Plants should be properly readied to embark
on their digitalization journey. Appropriate infrastructure
should be in place, data should be trustworthy, and people
should be prepared and accepting. Legacy technology should
be assessed against present objectives to determine if it stays
(maybe in an upgraded form) or goes.
Investments should be holistic and scalable in nature—
they should consider the impact of any change in one area
on the end-to-end plant economics. They should be smart
enough to identify problems and recommend solutions, not
to just present information without context.
Problem-solving can extend beyond the plant through the
use of the cloud. Suppliers, customers and third-party experts
can be engaged as stakeholders in the desired outcome, no
matter where they are located.
Digitalization solutions should be easy to use and main-
tain. As much as practical, solutions should be automated so
the human becomes an implementor and supervisor of strat-
egy, rather than a number-cruncher and tactician.
Playing for competitive advantage. Plants should start
any one of several ‘quick-win’ digitalization projects now. The
right project depends on where the plant is on its digitaliza-
tion journey. It is important for plant operations leaders to
mobilize the workforce to embrace a culture of digitalization
and convince executives that their investments are bringing
noticeable and measurable returns.
An exciting digital future. The digital future will look
quite different: decision-making will be streamlined, and
conclusions will be drawn with more certainty; operational
execution will be largely automated; and people will be em-
powered with a wider scope of accountability, resulting in
greater job satisfaction.
The digitally wise will operate plants with a massively re-
duced number of unexpected events; excellent levels of reli-
ability, safety performance and environmental compliance;
and extraordinary efficiency. Assets will operate with agility
and flexibility. Competition will have been left behind.
DUNCAN MICKLEM is the Executive Vice President of
Strategy and Marketing at KBC, a Yokogawa Company.
He is responsible for business planning; corporate
strategy, including investment prioritization/capital
allocation, mergers and acquisitions (M&A); and
marketing. Mr. Micklem started his career in the
engineering industry with AMEC. After moving to KBC,
he held business management roles focused on business development,
strategy, restructuring and planning. Mr. Micklem holds degrees in
biology and geography from the University of Exeter, UK and an MBA
degree from Cass Business School in the UK.

September 19, 2019 | The Houstonian | Houston, Texas

Deadline for Nominations is May 2, 2019!

Nominations are being accepted in the following categories:
• Automation technology
• Catalyst technology
• Cybersecurity program/software
• Refining technology
• Petrochemical technology
• Gas processing/LNG technology
• Flow control technology
• Best Health, Safety or
Environmental contribution
• Instrument technology
• Modeling technology
• Digitalization
• AR/VR/AI advances
• Project/asset milestones
• Licensor of the year
• EPC of the year
• Asset monitoring technology
• Consulting firm of the year
• Executive of the year
• Lifetime achievement
• Most promising engineer

For more information on sponsorship opportunities at the 2019 HP Awards, please contact
your sales representative or Hortensia "Tish" Barroso, Business Development Manager at
Hortensia.Barroso@GulfEnergyInfo.com or by phone at +1 (713) 520-4404.

VISIT HY DROCARBONPROCESSI NG.COM/AWARDS FOR MORE INFORMATION

32 MARCH 2019 | HydrocarbonProcessing.com
Get more from your operation.
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Select 76 at www.HydrocarbonProcessing.com/RS
 | Special Focus
PETROCHEMICAL TECHNOLOGY
Demand for petrochemicals is forecast to surge into the 2020s.
Developing economies in Asia and other regions will lead in new
petrochemical demand centers. The Asia-Pacific, Middle East and US
regions will head the charge in building new petrochemical capacity to
satisfy regional and global demand. The global petrochemical sector
is seeking more flexibility and efficiency so that it can quickly adapt
to future market changes. This month’s Special Focus explores the
innovative technical approaches being applied in the petrochemical
industry to increase energy process efficiency and optimize production.

View of the construction of SIBUR’s polyethylene plant site in Tobolsk,

Tyumen region, Russia, in July 2017.
 Special Focus Petrochemical Technology
F. HAYEK and M. MORAN, Sadara Chemical Co.,
Jubail Industrial City, Saudi Arabia

How did asset utilization modeling

save Sadara $1 B in capital cost?
Sadara is a JV between Saudi Aramco and Dow Chemical.
The two companies invested $20 B to build the world’s largest
petrochemical complex ever constructed in one phase (FIG. 1).
This project included new process units that had never been
built before in Saudi Arabia, or in any of the countries of the
Gulf Cooperation Council (GCC). In addition, some of the
complex’s units process risky and challenging chemicals,
whereas others operate at world-scale rates. With such a large
investment in a complicated, highly integrated site, it was im-
portant that the money be well spent to earn the rate of return
investors expect.
As most engineering and construction companies are
more interested in minimizing the initial investment, oper-
ating companies such as Sadara have a different objective:
They want to balance the initial capital investment against the
production and the conversion costs necessary to make their
products over the life of the assets. FIG. 1. A view of the Sadara petrochemical complex. Photo courtesy
of Sadara.
During the design phase, it is important to factor in or dis-
cern how different equipment and process units will affect
availability and asset utilization, so that the plant can meet quired to answer the specific business/technical questions un-
business production targets within cost constraints. This ac- der consideration. Sadara uses three different “levels” of RAM
tion is more difficult than it sounds, since even an experienced models: RAM1, RAM2 and RAM3.
engineer has difficulty predicting actual production in a large,
highly integrated site, given different unit availabilities, com- RAM1 site model. RAM1 is the highest-level model and is
plex process unit configurations, equipment failure and repair, a single model built for the entire site. Constructing the ini-
seasonal effects, fluctuations in supply and demand, and inter- tial model required incorporating process unit configurations,
mediate storage capacity. This is a classic optimization prob- tankage sizes, import/export capabilities and turnaround
lem that requires the right methodology and tools. For that schedule estimates, as well as power, utilities and infrastruc-
reason, Sadara used reliability, availability and maintainability ture information. As opposed to the RAM2 models used at the
(RAM) modeling as a key part of its design approach. plant level, the RAM1 model uses simple uptime/downtime
estimates for each major process unit.
Overview of asset utilization modeling. RAM model- Initial RAM1 model performance data was based on his-
ing is a Monte Carlo mathematical methodology that al- torical data from Sadara’s parent companies, and from world-
lows a user to evaluate different design scenarios, assuming wide refining and petrochemical best practices. Over time,
a given process/equipment configuration, pipe flow, tank these initial data estimates will be replaced with actual Sadara
management and equipment failure/repair characteristics. operating data.
Model outputs are asset utilization, availability and the costs Process units, tanks and other major assets are modeled as
to achieve that asset utilization over a given time period. It simple blocks with little underlying supporting detail. What
is important to note that, since Monte Carlo modeling is a is important in these models are the interconnections and de-
probabilistic mathematical technique, model outputs are also pendencies between the units.
probabilistic (e.g., outputs are probability distributions, rath- In the initial phases of the Sadara program, RAM1 mod-
er than specific discrete values). els were crucial for determining which process units would be
RAM models can be built to any degree of detail. However, built and the ultimate storage configuration. Production rev-
in practice, these models should be built only to the detail re- enue determined from the RAM1 model was then balanced
Hydrocarbon Processing | MARCH 2019 35
 Petrochemical Technology
Site model (RAM 1)
97% 98% 96%
Unit 1 model Unit 2 model Unit 25 model
(RAM 2) (RAM 2) (RAM 2)
FIG. 2. The output of the RAM1 model sets the target availabilities
for each of the underlying 26 process unit models.
against the costs to build, operate and maintain these units, as
determined from engineering estimates. However, the RAM1
model remains evergreen, and is updated as new business in-
put becomes available.
Primary outputs of the RAM1 model are “utilized hours,”
along with storage and import/export capabilities over a 20-
yr time frame. The term “utilized hours” is best understood as
the percentage of time that the unit must be available at full
production. Simply put, it becomes the yearly asset mechani-
cal reliability (AMR) percentage over that 20-yr time horizon.
Overview of asset utilization modeling. The output of
the RAM1 model sets the target availabilities for each of the
underlying 26 process unit models (FIG. 2).
RAM2 plant models. Whereas there is only one RAM1 model,
there are RAM2 models built for each of the 26 process units and
utilities. RAM2 models are much more detailed than the RAM1
model. Blocks are added for each major equipment item, us-
ing typical failure and repair characteristics for that equipment.
The model is then run, and adjustments are made that add or
subtract redundancy, using more/less reliable equipment (obvi-
ously with cost differences) until the RAM1 and RAM2 model
outputs converge. Outputs from the RAM2 models include the
asset utilization of the plant, the total number of failures for all
equipment and the percentage of production losses that each
equipment caused, in addition to tank full/empty events.
Of importance is the Pareto chart of equipment vs. asset uti-
lization loss for every piece of equipment in the unit—often
called the “sensitivity” level. These charts can often be used to
determine what equipment performance could be improved to
increase overall asset utilization. They are frequently used by
reliability engineers to identify potential projects that would
increase asset utilization for that unit. Tanks’ empty/full events
suggest whether the tanks are properly sized, or if they need to
be increased to improve asset utilization or decreased to save
capital cost.
RAM3 models. RAM3 models are smaller, and usually more
specific, models that are often built to answer a specific ques-
tion. They have frequently been used for spare parts optimi-
zation or case studies. The information needed to conduct a
spare parts optimization analysis includes failure and repair
characteristics, replenishment time, the cost of spare parts and
spare parts production sensitivity. Model outputs are the mini-
mum/maximum stocking levels that guarantee production is
never lost because of spare parts unavailability, and that spare
parts are not overstocked.
36 MARCH 2019 | HydrocarbonProcessing.com
RAM modeling benefits. Sadara has received RAM modeling
benefits from numerous sources. The following are some of the
more common benefit areas, such as the ability to determine:
• When redundancy is needed or when the system
96.5% is over-designed
Unit 25 model • How reliable a given piece of equipment should be
(RAM 2) • When, where and how much tankage is needed
• Which equipment improvement projects make the most
sense economically
• Optimal quantities of spare parts for given equipment
• Effectiveness of preventive and predictive maintenance
(PPM) and turnaround frequency/duration
• Load-shedding strategies when unplanned events occur.
One benefit often received is the determination of whether
redundancy is needed or not. Sometimes added capital cost can
save a future loss of production, resulting in huge benefits. Con-
versely, there may be times when redundancy is not needed and,
in these cases, redundancy can result in capital spent unwisely,
along with possibly a lifetime of unnecessary maintenance costs.
At Sadara, in two separate instances, entire trains were eliminated.
Determining the reliability of a piece of equipment or a com-
ponent within a given piece of equipment is not a trivial matter.
RAM modeling makes it possible to accurately determine the
cost/benefit of improved reliability or to select between vendors.
This was used extensively during the RAM modeling effort.
Tankage is usually desired for operational flexibility reasons.
However, it often cannot be justified economically. RAM mod-
eling allows operators to pinpoint precisely how much tankage
is needed—if any at all—between process units, raw materials
storage or finished product storage. If RAM modeling had not
been used, the Sadara complex would have been built with more,
and larger, tankage than necessary.
RAM modeling is also very good at determining the sensitiv-
ity of equipment, which leads to asset utilization losses. Once
known, the cost for projects to eliminate or reduce those losses
can be calculated to determine which projects make the most
sense financially. This aspect of RAM modeling remains an im-
portant part of Sadara’s reliability program on an ongoing basis.
Spare parts optimization has become an important part of
Sadara’s asset management effort. In the Middle East, this is es-
pecially important in the Gulf region, since lead times are much
longer than along the US Gulf Coast. Spare parts optimization
strikes a balance whereby no production is lost due to the un-
availability of spare parts or the overstocking of spares.
PPM and turnaround schedules are often set to maintain
certain equipment to keep them in running condition and to
prevent unplanned outages. Once a PPM or turnaround has
been completed, the model resets the age of these maintained
equipment parts to a specific value, as determined by equip-
ment experts. This way, credit can be given to the renewed parts
by adjusting their age. This process results in a more accurate
availability and asset utilization estimate for future model runs.
Setting load-shedding strategies is of great importance to
handle process interruptions. It helps maintain focus on as-
sets based on their importance to safety, production and asset
performance.
Takeaways. By utilizing RAM modeling, Sadara saved more
than $1 B in capital spending, while simultaneously increas-
 Petrochemical Technology

ing production capabilities and achieving business objectives.

These benefits accrued from the elimination of process trains,
decreased capital equipment spend, a more robust electrical
grid and supporting components, the addition or elimination
of redundancy where appropriate, adjustment of tank sizes and
spare parts optimization.
The real validation that RAM modeling was beneficial has
been the operational results. After the plant had been fully
commissioned and all units were operating for several months,
the overall plant availability was slightly greater than 97%. No
doubt this was due to many factors. However, it is unlikely that
such a high availability could have been achieved without the
extensive use of RAM modeling.
While it played a very important role during the design Tailor-made solutions for
phase, RAM modeling continues to be an essential component
of Sadara’s asset management program. For example, reliability
cost-effective gas treatment
engineers use RAM2 models as a source of ideas on how a pro- and sulphur recovery plants
cess unit’s availability can be improved by targeting equipment
projects based on sensitivity results.
In 2018, Sadara successfully completed its performance Over 500 projects developed
test, the creditors reliability test (CRT), an exercise required
by the company’s financial lenders to demonstrate the com- for onshore, offshore, upstream
pany’s ability to operate its market-facing plants and supply and downstream installations
chain at 90% of design capacity or better for a period of 60
consecutive days. From October 19 through December 17,
Sadara engaged in its first official run of the CRT, monitored
by the lenders’ representative. All plants and supply chain fa-
cilities passed their tests safely on the first official try. New
industrial companies very rarely pass lenders’ reliability tests
on the first official attempt, and Sadara was the first Saudi Ar-
amco JV ever to do so. This is a validation of the overall as-
set management approach that was taken on the project, and
there is no doubt that RAM modeling played an important
role in achieving that important milestone.
At the very least, asset utilization modeling should be an es-
sential part of every capital project. Models created during the
design phase can then be leveraged to answer future operation- Licensor of SRU and supplier of
al and maintenance issues based on a rigorous analysis rather stick-built process plants and
than on a gut feeling. Used this way, asset utilization models modular or skid-mounted units for:
complement the process simulation models that process engi-
neers already maintain for each unit. • Gas treatment
• Gas field development
FAREED HAYEK is a Senior Reliability Simulation Engineer
at Sadara Chemical Co., specializing in RAM modeling and • Gas dehydration with solvents or adsorbents
spare parts optimization. Previously, Mr. Hayek was a • NGL recovery and stabilisation
reliability and improvement engineer at Dow Chemical
in Freeport, Texas. Prior to that, he was a senior reliability
• Gas sweetening
and maintainability engineer at NASA for the International • Sulphur recovery and tail gas treatment
Space Station (ISS) and the Space Shuttle programs.
He received the Space Flight Awareness Honoree award for reliability and Custom solutions to fit your needs
maintainability support of the ISS. He holds ASQ CRE and CMRP certifications.
Mr. Hayek earned a BS degree in mechanical engineering from the University
of Jordan, an MS degree in computer engineering from the University
of Houston, and is a PhD candidate in industrial engineering at Mississippi
State University.

MARTY MORAN is a Senior Reliability Engineer at Sadara

Chemical Co. He is trained as a chemical engineer and has
more than 35 yr of experience in process industries. He has
concentrated his career on using advanced computer
technology in the areas of asset management/reliability,
advanced process control and plant optimization. Mr. Moran
holds a US patent for multivariable control. Prior to joining www.siirtecnigi.com - marketing@siirtecnigi.com
Sadara, he worked for AspenTech, Meridium, Continental Controls and Setpoint.

Select 152 at www.HydrocarbonProcessing.com/RS

 37
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 Special Focus
Triple-lane layout for enhanced
cracking coil performance
Ethylene is a precursor to many chemi-
cals, fibers and plastics that are used in
daily life. At most petrochemical sites, the
ethylene plant is the mother unit that feeds
a number of downstream units. Nearly all
ethylene is produced in specially designed
furnaces by thermally cracking ethane and
longer-chain hydrocarbons.
Cracking furnaces are complex equip-
ment and consume a large portion of the
capital and operating costs of an ethyl-
ene plant. They also require significant
operator attention and maintenance. It is
essential to have a well-running furnace
section to ensure smooth and profitable
operations at the plant and site. Frequent-
ly shutting down furnaces for decoking or
maintenance costs money, disrupts down-
stream sections and prevents the plant
from meeting its production targets.
This article describes the development
of a proprietary triple-lane radiant coil
layouta that can be used in cracking fur-
naces to obtain markedly longer furnace
run lengths, higher capacities and better
yields. This concept was first implement-
ed in 2012 at a Middle East cracker as part
of a furnace modernization project with
the aim of increasing the capacity, reliabil-
ity and availability of existing furnaces.
Since then, this concept has been applied
at two other projects. Key results that
demonstrate the performance and ben-
efits of the technology are provided here.
Cracking furnace design and op-
eration. Ethylene plants, also referred
to as steam crackers, consist of five main
sections:
• Furnace section
• Quench section
• Cracked gas compression
• Recovery and purification
• Refrigeration.
Petrochemical Technology
R. RAMESH and J. VAN DER EIJK, TechnipFMC
Process Technology, Zoetermeer, The Netherlands
The furnace section is where the feed
is cracked at high temperature to convert
it to ethylene, propylene and other co-
products. Modern plants typically have
5–10 cracking furnaces. These cracking
furnaces are an intricate assembly of many
individual pieces of equipment and must
be custom designed to match the feed
quality, cracking severity, run length and
other parameters.
Key considerations. Cracking, or pyrol-
ysis, is a complex, non-catalytic phenom-
enon that involves numerous reactions,
intermediate species and final products.
In its most basic form, it may be thought
of as dehydrogenation and carbon-carbon
bond rupture. The reactions are endo-
thermic, so heat is needed to initiate and
sustain them. The pyrolysis product is a
mixture of components that includes:
• Hydrogen
• Methane
• Monoolefins (e.g., ethylene,
propylene, butenes)
• Diolefins (e.g., butadiene,
propadiene, isoprene)
• Acetylenes (e.g., acetylene,
methylacetylene, vinylacetylene)
• Naphthenes (e.g., cyclopentene,
methyl cyclohexane)
• Aromatics (benzene, toluene,
xylenes)
• Tars.
Three main parameters determine py-
rolysis yields and selectivity to ethylene
and propylene:
1. Cracked gas temperature—
This refers to the coil outlet
temperature (COT) and the gas
temperature profile as it flows
through the cracking coil. Each
feedstock is associated with an
optimum COT that would provide
the best conversion and yields.
This is a function of
the feed characteristics and
required products and usually
lies between 800°C (1,472°F)
and 880°C (1,616°F).
2. Cracked gas pressure—
Low hydrocarbon partial pressures
favor selectivity toward ethylene.
For this reason, the coil
operating pressure is kept as
low as practically possible.
To obtain still lower hydrocarbon
pressures, a controlled amount
of process steam, known as
dilution steam, is co-fed with the
hydrocarbons. This not only lowers
the hydrocarbon partial pressure,
but also reduces coke deposition.
3. Residence time—A multitude
of side reactions can consume
the formed ethylene and degrade
it to lower-value, long-chain
hydrocarbons. These reactions
can be kept to a minimum by
designing the coil to have a very
short residence time and by
quickly cooling the gas after it
leaves the coil.
Coking and furnace run length are two
other key considerations in furnace design
and operation. Coke is an undesirable by-
product of pyrolysis that accumulates on
the inside of the radiant coil. It is a matrix
of severely dehydrogenated long-chain
molecules that are formed by complex in-
teractions between the gas phase compo-
nents and the tube wall material. Coking
rates vary with location, and they generally
increase from coil inlet to outlet and peak
wherever the wall temperature is higher.
Coke forms a barrier for heat transfer
and increases coil pressure drop by reduc-
ing the cross-sectional area left for gas flow.
Hydrocarbon Processing | MARCH 2019 39
 Petrochemical Technology
These two phenomena lead to higher tube
wall temperatures and a higher gas pres-
sure profile. While one accelerates coking
rates, the other leads to a drop in the yield
of desired products. This can be remedied
by periodically taking the furnaces offline
and cleaning them. Cleaning consists of
decoking the radiant coil by blowing a
mixture of steam and air (controlled coke
burn) or steam only (coke gasification).
Run length is the number of days
that a furnace can operate between con-
secutive decokes. It depends on crack-
ing conditions and often varies between
35 d–75 d. Furnaces that coke heav-
ily will have shorter run lengths and will
need to be decoked more frequently. This
has several impacts:
• Lower furnace availability
for cracking
• Lower ethylene production
• Higher energy cost and increased
emissions
• Shorter coil life
• Increased load on operators
and maintenance staff.
FIG. 1. Schematic of a cracking furnace.
FIG. 2. Typical coil layouts used in cracking
furnaces.
40 MARCH 2019 | HydrocarbonProcessing.com
Furnace designs can be optimized to
increase capacity, run length and yield/
selectivity. The design changes needed to
achieve one of these goals usually come at
the expense of others. For example:
• A furnace can be designed
for a long run length by selecting
a coil with a high surface area.
However, this is likely to increase
the residence time, which is
unfavorable for olefins yields.
Conversely, a short residence
time coil is likely to have less
surface area—and, therefore,
an inferior run length—but it
will give a higher yield.
• One way to reduce total plant
CAPEX is to select fewer, larger
furnaces rather than numerous,
smaller furnaces. However, at a
certain point the maximum practical
furnace dimensions are reached.
If more capacity is pushed into
the furnace when it is at its limit,
run lengths become shorter
and the availability will decrease.
FIG. 3. Radiant section with horizontal coils
(pre-1970s).
Furnace description. Cracking fur-
naces can be functionally and physically
divided into three zones: radiant section,
convection section and transfer line ex-
changers (TLEs) (FIG. 1):
• The convection section recovers
waste heat from the flue gas leaving
the firebox. It is made up of several
banks of tubes for preheating
hydrocarbon feed, dilution steam,
boiler feedwater and superheating
the saturated very-high-pressure
(VHP) steam produced in the
TLEs. Alternatively, combustion air
can also be preheated (not shown
in FIG. 1). Depending on the design,
the cooled flue gas is vented to
atmosphere by a fan or natural draft.
• The radiant section comprises
the cracking coils and the firebox,
including the burners.
• TLEs are waste heat boilers placed
at the outlet of the radiant coils
to rapidly cool the cracked gas
and kill secondary reactions.
They use the recovered heat to
produce saturated VHP steam.
Convection section. The convec-
tion section is usually located above the
firebox at a small offset to it. The tubes
are laid horizontally with the flue gas
in vertical crossflow between them; the
tubes themselves may be bare or finned.
The services of the different heat transfer
banks shown in FIG. 1 include:
• Feed preheater (FPH)
• Economizer (ECO)
• Dilution steam superheater (DSSH)
• Mixed heater 1, feed + dilution
steam (HTC-1)
• Steam superheater 1 (HPSSH-I)
• HP steam superheater 2 (HPSSH-II)
• Mixed heater 2, feed + dilution
steam (HTC-2).
Radiant section. The firebox is a rect-
angular, refractory-lined volume within
which the radiant coils are suspended
vertically, and burners are placed in the
bottom and/or in the side walls. The
coils are arranged in one or two lanes. In
a single-lane layout, the coils are arranged
on the firebox center line. In a dual-lane
layout, they are on both sides of the cen-
ter line. Each coil consists of one or more
pipes that are connected to each other in
a series parallel arrangement.
FIG. 2 shows examples of coil layouts
that are used in cracking furnaces. Ex-
ample A in this figure has four passes in

series, with one pipe in each pass. Ex-
ample B depicts a two-pass coil with two
parallel pipes in the inlet pass and a third
larger pipe in the outlet pass. Example C
amalgamates some features of A and B: it
is a four-pass coil with two parallel pas-
sages in the first two passes. Example D is
a two-pass coil with one pipe in each pass;
it is commonly referred to as a U coil. The
number and type of coils and their geo-
metric details, such as diameter, length,
wall thickness, etc., are intrinsic features
of the furnace design. Burners are located
along the box length and on both sides of
the coil lane(s). They may be located in
the firebox floor or in the side walls.
Within a coil, cracking starts once
the gas mixture crosses threshold tem-
perature and proceeds as the gas flows
through the coil. The cracked gas leaving
the radiant coils is cooled in the TLEs.
This is done to halt the cracking reactions
when the gas is cooled below a threshold
temperature.
TLEs. TLEs may be double-pipe ex-
changers or conventional multi-tube
exchangers. Both types are placed verti-
cally, with cracked gas in the inner pipe
(tube side) and boiler water/steam in
the outer pipe (shell side). The shell is
connected to an overhead steam drum
by downcomers and risers. The cooled
cracked gas from the TLEs is combined
and sent to the furnace outlet and then to
the cracked gas header.
Evolution of single-lane and dual-
lane layouts. Prior to the 1970s, crack-
ing furnaces were usually equipped with
horizontal coils that had several passes
and residence times of a few seconds.
The furnaces were also small, with ca-
pacities of a few thousand metric tpy of
ethylene. FIG. 3 depicts how the radiant
section would look when viewed from
the top and from the end walls.
The 1970s saw rising feedstock and en-
ergy costs, but also booming demand for
ethylene derivatives. This led to sweeping
changes in the ethylene industry:
• Larger plants
• Fewer and larger cracking furnaces
• Greater emphasis on yields and
energy efficiency.
The relatively short horizontal coils
were phased out, and taller vertical coils
took their place. This allowed larger fur-
naces with taller fireboxes and shorter res-
idence times. The increased box height al-
Petrochemical Technology
lowed more heat absorption in the radiant layout, a detailed study was undertaken
section and better box efficiency. FIG. 4 to develop the next-generation radiant
shows two examples of a radiant section coil, a triple-lane layout. The advantages
with vertical coils: The one on the left is of a triple-lane layout over contemporary
an inline coil and the one on the right is a layouts can be explained from first princi-
staggered coil. Staggered coils require less ples. The analysis has been based on a U-
box length but have higher peak tube wall coil in dual lanes, but the conclusions can
temperatures and, as a result, more coking be extended to any other existing layout.
and shorter run lengths.
The next new trend was split coils. A refresher on heat radiation. Radia-
These permitted an increase in coil surface tion is the principal mode of heat transfer
area without a proportional rise in coil vol- in the firebox of a cracking furnace. The
ume. In other words, the heat absorption refractory sidewalls and burner flames are
by the process could be increased without discrete heat sources. However, they can
incurring too much penalty on yields. On be idealized as a single, composite radiat-
another front, the market saw several new ing plane with a uniform temperature. This
radiant coil materials with higher allow-
able temperatures. These could be used
to increase heat flux and pare down resi-
dence time to the millisecond range.
Ethylene plants continued to grow
larger and larger, and the market became
increasingly competitive during the last
decades of the 20th century and in the
first decades of this century. Producers
wanted even larger furnaces to keep capi-
tal and operating costs down. FIG. 5 dem-
onstrates this trend.
The application of process intensi-
fication resulted in the dual-lane layout
shown in FIG. 6. This is a better configu-
ration than the staggered layout, as shad-
owing is less pronounced and the peak
to average differential is smaller, which
enabled designers to obtain a higher fur-
nace capacity from the same firebox vol- FIG. 4. Firebox with vertical coils
ume. Due to the success of the dual-lane (1970s–1990s).
FIG. 5. Growth in furnace capacities in the past 50 yr.
Hydrocarbon Processing | MARCH 2019 41
 Petrochemical Technology
plane occupies the length and height of the
box. Therefore, a firebox would have two
hot radiating planes along its length, one
on each side of the box. The heat transfer
rate from the hot radiating plane to a tube
wall can be calculated using Eq. 1:
Q 12 = σ × A2 × F12 × (T14 – T24) (1)
where
Q 12 = Net heat absorbed by a tube
A2 = Tube surface area
T1 = Temperature of the hot
radiating plane
T2 = Tube wall temperature
F12 = View factor from the radiating
plane to the tube wall
σ = Stefan-Boltzmann constant.
FIG. 6. Dual-lane U coil (since 1999).
FIG. 7. Shielding effect.
42 MARCH 2019 | HydrocarbonProcessing.com
The “view factor” is a term that em-
bodies the spatial relationship between
the radiant and absorbing surfaces and
their emissivities. The view factor is:
• 1 when a radiant beam strikes
an absorbing surface normally and
both surfaces are ideal black bodies
(i.e., their emissivities are 1)
• 0 when the beam strikes a
surface tangentially
• Between 0 and 1 when the
impinging angle is between 0°
and 90°, and when the surfaces
are not black bodies.
The heat flux and temperature of the
absorbing surface go hand in hand with
the view factor: both reach a maximum at
locations where the view factor peaks and
come down as the factor falls off. Such
a direct relationship exists between the
first two parameters and the view factor
that the latter may be considered a proxy
for them. This forms the basis for subse-
quent paragraphs where the different coil
FIG. 8. Radiation on tube in dual-lane layout.
FIG. 9. Lowest and highest tube metal
temperatures in dual-lane layout.
layouts are evaluated by comparing their
view factors.
FIG. 7 illustrates the effect of shielding.
Since radiation occurs in straight lines, a
body that is in a shadow created by an-
other object does not receive any heat
directly from the primary heat source. It
will, however, receive radiation from the
gas volume that surrounds it and with
which it has a direct line of sight.
Heat flux and wall temperature in
a dual-lane layout with U coils. In a
dual-lane layout, both lanes have the same
number of inlet tubes and outlet tubes and
the same degree of exposure to the radi-
ating planes. Each row receives radiation
from the radiating plane that is adjacent to
it and from the plane on the other side of
the box. The space between the two rows
is called the inter-lane space and is cooler
than the radiating plane. FIG. 8 is a top
view of a dual-lane layout showing the ra-
diation impingement on a tube from both
radiating planes. It shows how one side of
the tube gets the full brunt of radiation,
while the other side is partly shielded by
the tubes in the adjacent row. As a result,
the side facing the inter-lane space has a
smaller view factor and a lower tube metal
temperature (TMT) than the side facing
the refractory. This is shown in FIG. 9.
A dual-lane furnace fitted with U coils is
used to illustrate this phenomenon. In such
a coil, the inlet pass and the outlet pass have
the same orientation to the radiating plane
and the other tubes, so they have the same
view factors. FIG. 10 shows view factors
computed around the tube circumference
for such a coil: It is 1 at the point directly
facing the burners/refractory wall, and ap-
proximately 0.75 on the opposite side. The
wall temperature and heat flux will have
the same asymmetric trend as the view fac-
tor due to the close relationship between
them. These results imply that the tube
surface area is not optimally used. The
portion that is facing the refractory wall
must transfer more heat (therefore, it is
hotter), while the area facing the inter-lane
space must transfer less (cooler). It must
be recognized that the coking rate and run
length are related to the peak wall tempera-
ture. An incentive exists to reduce this peak
value. The challenge of developing a new
layout that would improve the circumfer-
ential heat distribution and thereby shave
off the peak was undertaken. A description
of the resulting triple-lane layout follows.
 Petrochemical Technology

Advantages of triple-lane layout.
The triple-lane concept turns the problem
on its head: rather than trying to reduce
shielding and its effects, it uses them to
reduce peak wall temperatures.
FIG. 11A shows U coils arranged in dual
lanes. The red circles are the inlet tubes
and the yellow circles are the outlet tubes.
The furnace run length is effectively de-
termined by the peak wall temperature
in the outlet tubes on the side facing the
refractory wall. The team recognized
that the peak wall temperatures could be
lowered if the outlet tubes could be re-
positioned so as not to face the radiating
plane. However, this is not possible when
there are only two lanes. It does become
feasible if the number of lanes is increased
to at least three and the outlet tubes are
placed in the central lane. FIG. 11B illus-
trates this configuration.
In this new arrangement, the outlet
tubes are surrounded by the relatively
cooler inter-lane gas. As a result, the cir-
cumferential variations in the view factor,
wall temperature and heat flux of these
tubes become fewer, while the overall
FIG. 11. (A) U coils in dual-lane layout; (B) U coils in triple-lane layout.
view factor is still high. FIGS. 12A and 12B
are a comparison of view factors in a two-
lane and a triple-lane U coil layout. The
change from dual lane to triple lane has a
moderating effect on the view factors of
the hottest, most critical part of the coil,
namely the outlet tubes. They adopt a
nearly circular profile and the maximum AUMA Assistant App
value is only about 0.75, compared to 1 in
the dual lane.
Plant operators
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FIG. 10. View factors in dual-lane U coil layout.
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FIG. 12. (A) View factors for dual-lane U coil; (B) View factors for triple-lane U coil.

Select 153 at www.HydrocarbonProcessing.com/RS

anzeige_drittel_seite_hydrocarbon_processing_auma_usa.indd
08.02.2019
1 09:15:20
 Petrochemical Technology

As a result, the outlet pass has a signifi- capacity and better selectivity. Implementation of triple-lane concept
cantly lower peak wall temperature and • In all cases, the furnace end-of-run in major project. This section describes
the circumferential profile becomes more criterion for tube wall temperature the successful implementation of the triple-
uniform. This reduces coking and pressure was fixed at 1,080°C (1,976°F). lane concept in a furnace revamp project
drop in this pass. The total heat duty of the TABLE 1 summarizes the results. executed in 2011–2013. This project was
outlet pass decreases while the inlet pass • The annual ethylene output is delivered to a global olefins manufacturer
increases. The heat fluxes change along a good overall indicator of the for its plant in the Middle East. This unit
the length of the coil, as shown in FIG. 13. improvement achieved, as it has 10 furnaces cracking an external liquid
The higher heat flux in the inlet tubes has factors into the roles played by feed. All units were revamped. The original
no adverse effects. In fact, shifting a part feed capacity, yield and furnace furnaces were designed to crack gas con-
of the duty to the less hot inlet tubes is ad- availability. All the triple-lane cases densate and were equipped with one-pass
vantageous, as it lowers the maximum wall have a higher annual ethylene cracking coils arranged in a single lane.
temperature in the outlet pass. output than the base case, but for The plant had been experiencing se-
A design exercise was performed to different reasons. In the longer run vere problems with the coils for many
test this hypothesis. Two furnaces were length case, the responsible factor is years due to:
designed for the same feed quality/rate, the higher furnace availability due • Very short coil run lengths
cracking severity and other operating to the fewer number of decokes per • Frequent blockage and rupture
conditions: one had a U coil in a dual- year, while in the higher-capacity due to coke.
lane (base case) arrangement, and the case it is due to the larger feedrate. This had major consequences on site
other had the same coils in a triple-lane • The exact improvement that can be operations:
arrangement: obtained will depend on how it • The average coil lifespan was
• The base case was designed was originally designed and how approximately 1.5 yr, far less than
for a run length of 60 d. it is operating. In general, the the industry standard of about 6 yr.
• In the triple-lane case, three poorer the present operation, the As the plant had more than 1,500
alternative designs were made greater the relative improvement radiant coils, this meant that many
for longer run length, higher that can be achieved. coil repairs and replacements were
required every year. The result:
TABLE 1. Performance of dual-lane vs. triple-lane layouts O High furnace downtime
for inspection and repair
Triple-lane design
O Abnormally high spending
Dual-lane Longer run Higher Better
design length case capacity case selectivity case
on coil materials
O Heavy workload for inspection
Feedrate, tph 40 40 45 40
and maintenance crew.
Total coil length, m Base Base Base 89% base • Furnace availability and reliability
Max tube wall temp. 1,080 1,080 1,080 1,080 were poor due to the short run
at end-of-run, °C lengths and the high inspection and
Run length, d 60 80 60 60 maintenance frequency. The annual
Ethylene yield, wt% dry Base Base Base 101.4% base ethylene production output suffered.
Propylene yield, wt% dry Base Base Base 101.4% base The client embarked on a furnace
Relative annual ethylene Base Base + 0.8% Base + 12.5% Base + 1.4%
modernization project to solve the exist-
production, tpy ing deficiencies and improve the plant’s
Relative run length, % 100% 133% 100% 100%
capability beyond its original capacity. Its
objectives were ambitious:
Relative capacity, % 100% 100% 113% 100%
• Modify the furnaces to reduce
coking and extend run lengths
TABLE 2. Revamp project performance gain with triple-lane layout • Improve furnace availability and
Scenario Before revamp After revamp reliability to bring them on par
Coil type Single-pass U coil
with industry standards
Layout Single-lane Triple-lane
Coil surface Internally finned Bare coil
Coil surface area, bare area, m2 Base Base + 50%
Feed capacity, tph Base Base + 26%
Furnace run length, d Base Base × 2.7
Ethylene production, Mtpy Base Base + 31%
Ethylene + other high value chemicals, Mtpy Base Base + 33%
Specific energy consumption, GJ/t Base Base – 13%
Coil life, yr Base > Base × 4 FIG. 13. Heat flux along coil length.

44MARCH 2019 | HydrocarbonProcessing.com

 Petrochemical Technology
• Increase capacity by at least 25%.
Furthermore, the client insisted that
the longer run lengths would need to be
realized at the increased capacity.
A detailed two-phase study was con-
ducted. The first phase consisted of
computer simulations of the present op-
eration. The second phase consisted of
selecting the best revamping option. Both
phases relied on the extensive use of a
proprietary software for steam cracking
yield prediction and complete furnace
simulation of gas or liquid feedstocks.b
After studying various revamp options,
it was apparent that a U coil arranged in
three lanes offered the best solution. This
coil type, which has been applied in many
liquid cracking furnaces, would be better
than other alternatives because:
• It would allow more tubes to be
placed in the existing firebox,
resulting in higher gas flow area
(i.e., capacity) and more surface
area (lower heat flux and lower
tube wall temperatures).
• It would shield the outlet pass
from peak temperatures/heat flux
and reduce coking.
The site works for this revamp project
were staggered over a period of 1 yr, with
one or two furnaces being modified at any
given time. This avoided the need for a
lengthy plant shutdown and allowed the
client to more quickly realize the benefits
of the upgrades.
TABLE 2 summarizes the pre-revamp
and post-revamp performance of the fur-
naces. The performance data for both situ-
ations are based on actual operational data,
rather than design data. For reasons of
confidentiality, the changes are shown on
a relative basis rather than absolute values.
The differences in furnace geometry
and performance before and after the re-
vamp project include:
• The 50% rise in surface area during
the revamp was more than enough
to compensate for the 26% growth
in feed capacity. As a result, the
revamp design had a lower average
heat flux over the coil, despite
an increase in total firing.
• The main advantage of the
triple-lane design is its lower
peak wall temperatures in the
outlet pass. Together with the
drop in average heat flux, this
was responsible for lower coking
rates and longer run length.
• The 31% rise in ethylene product
rate is greater than the feed
capacity increase. The delta is
mainly due to the better furnace
availability and the higher average
coil selectivity over the furnace run
length (average between furnace
start of run and furnace end of run).
Takeaway. Radiant coil designs have
evolved over the past few decades to meet
greater industry demands. This jour-
ney has been characterized by numer-
ous small steps, as well as several vital,
groundbreaking innovations. Key mile-
stones include the introduction of verti-
cal coils, inline dual-lane coils, staggered
coils and dual-lane coils.
The triple-lane concept is the latest
development in this lineage. It has sever-
al merits over preceding and competing
developments:
• Reduces peak tube metal
temperatures
• Is a simple and elegant way
to improve run length, capacity
and selectivity
• Can be applied in revamps and
new furnaces
• Is suitable for all cracker feeds,
from ethane to VGO.
The first plant has been operating suc-
cessfully for more than 6 yr, and another
for 3 yr. In addition, a third project is in
the execution phase.
NOTES
a
Triple-Lane Coil Layout is a proprietary technology
of TechnipFMC
b
SPYRO is TechnipFMC’s proprietary software for
steam cracking yield prediction and complete fur-
nace simulation of gas or liquid feedstocks.
RAJARAM RAMESH is Technology Manager of the
ethylene product line at TechnipFMC’s operating
center in the Netherlands. He is responsible for
maintaining and fostering TechnipFMC’s conceptual
design, process engineering and execution capabilities
and applying these to debottlenecking, expansion
and modernization of complete ethylene plants.
Mr. Ramesh has 35 yr of experience in process design,
process engineering and technology development.
JOHAN VAN DER EIJK is Process Manager at
TechnipFMC’s operating center in the Netherlands.
He leads the process design department and has
25 yr of experience in process engineering with
a specialization in the petrochemical industry.
His experience includes work on proposals, studies,
grassroots, revamp and development projects as
process lead engineer, as well as participation in
training, root cause analysis, test runs, startups and
troubleshooting. Since 2008, he has been a part
of the TechnipFMC Experts Network as an Expert
(and since 2014 as Main Expert) in ethylene,
with expertise in cracking furnaces.
Select 154 at www.HydrocarbonProcessing.com/RS
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Evolution of the Downstream

Subjects covered will include:
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Refinery Tour: Includes Neste’s Kilpilahti refinery (limited to 50 registrants)

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Host Sponsors Data Sponsor Mini-Tech Session Hotel Key Card Sponsor
 Special Focus Petrochemical Technology
W. YANG and Z. WANG, Sinopec Shanghai Research Institute
of Petrochemical Technology, Shanghai, China

Development of zeolite catalysts

for production of ethylbenzene
Zeolites, an important type of catalyt-
ic material, are widely used in industrial
catalysis. The research, development and
industrialization of novel zeolites play
key roles in the evolution of the chemi-
cal industry. The use of the FAU-type
zeolite, zeolite Y, greatly improved the ef-
ficiency of oil refining, while the use of
SAPO-34, a related CHA-type zeolite,
helped realize the industrialization of the
methanol-to-olefins process.1
At present, hundreds of natural and ar-
tificial zeolites have been found and syn-
thesized, and 245 types of frameworks
have been approved by the Structure
Commission of the International Zeolite
Association (IZA-SC) (TABLE 1).2 Zeo-
lites of approximately 19 types of frame-
works have been industrialized.3 Most of
these zeolites are used as catalysts for the
production of basic organic chemicals.
Ethylbenzene, one of the most im-
portant chemicals, is frequently used for
the production of styrene, which is used
to produce polystyrene, ABS resin, SAN
resin and other products. Ethylbenzene
is manufactured through the alkylation of
benzene catalyzed by an AlCl/HCl sys-
tem at the early stage. Although effective,
it is a somewhat controversial process
due to the corrosive nature of its catalyst
system. The zeolite-catalyzed alkylation
process is environmentally benign, which
produces little waste during operation.
Zeolites of five types of structures (MFI,
MEL, FAU, *BEA and MWW) listed in
TABLE 2 have been used as the active com-
ponents of catalysts.4 They act as impor-
tant factors in the progress of the produc-
tion process of ethylbenzene.
In this article, zeolites of the five frame-
work types are introduced, and their use as
active components of catalysts for the pro-
duction of ethylbenzene is summarized.
MFI-type zeolite. This zeolite is one of
the most important. The material of the
MFI structure is ZSM-5, an aluminum
silicate zeolite. Two kinds of ten-member
ring (10-MR) channels exist: one straight
elliptical pore system (5.3 Å × 5.6 Å)
along the [010] axis, and one zig-zag cir-
cular pore system (5.1 Å × 5.5 Å) along
the [100] axis. Due to its unique pore
structure, great stability and adjustable
acidic property, ZSM-5 zeolite is widely
used in the chemical industry.

TABLE 1. Zeolite framework types a

ABW ACO AEI AEL AEN AET AFG AFI AFN AFO AFR AFS AFT AFV AFX
AFY AHT ANA APC APD AST ASV ATN ATO ATS ATT ATV AVL AWO AWW
BCT BEC BIK BOF BOG BOZ BPH BRE BSV CAN CAS CDO CFI CGF CGS
CHA -CHI -CLO CON CSV CZP DAC DDR DFO DFT DOH DON EAB EDI EEI
EMT EON EPI ERI ESV ETL ETR EUO EWS EZT FAR FAU FER FRA GIS
GIU GME GON GOO HEU IFO IFR -IFT -IFU IFW IFY IHW IMF IRN IRR
-IRY ISV ITE ITG ITH ITR ITT -ITV ITW IWR IWS IWV IWW JBW JNT
JOZ JRY JSN JSR JST JSW KFI LAU LEV LIO -LIT LOS LOV LTA LTF
LTJ LTL LTN MAR MAZ MEI MEL MEP MER MFI MFS MON MOR MOZ MRT
MSE MSO MTF MTN MTT MTW MVY MWF MWW NAB NAT NES NON NPO NPT
NSI OBW OFF OKO OSI OSO OWE -PAR PAU PCR PHI PON POR POS PSI
PUN PWO PWW RHO -RON RRO RSN RTE RTH RUT RWR RWY SAF SAO SAS
SAT SAV SBE SBN SBS SBT SEW SFE SFF SFG SFH SFN SFO SFS SFW
SGT SIV SOD SOF SOR SOS SSF SSY STF STI STT STW -SVR SVV SWY
SZR TER THO TOL TON TSC TUN UEI UFI UOS UOV UOZ USI UTL UWY
VET VFI VNI VSV WEI -WEN YFI YUG ZON *BEA *CTH *-EWT *-ITN *MRE *PCS
*SFV *-SSO *STO *-SVY *UOE
a
A hyphen preceding a three-letter code indicates that the framework is interrupted—i.e., not all T atoms are four-connected. An asterisk indicates that the material
of the framework type is partially disordered.

Hydrocarbon Processing | MARCH 2019 47

 Petrochemical Technology
For production of ethylbenzene, the
vapor-phase process of ethylation of ben-
zene with pure ethylene was first indus-
trialized in 1980 using MFI zeolite-based
alkylation catalysts.5 The ethylbenzene
technology also adapts to fluid catalytic
cracker (FCC) offgas feed after modifi-
cation. The dilute-ethylene process has
a pretreatment system for feedstock and
was first commercialized at Shell’s Stan-
low refinery in the UK with an annual
ethylbenzene capacity of 160,000 metric
tpy in 1991. A larger industrial plant was
later built in the Netherlands with a ca-
pacity of 450,000 metric tpy.
With MFI-type zeolite as an active
component of catalyst, three series of va-
por-phase alkylation catalysts were devel-
oped and industrialized by a prominent
research institute in China.6,7,8 AB-12,
SEB-12 and DF-AS are the three most
representative catalysts. Pure ethylene,
dilute ethylene, ethanol and coal-based
crude ethylene [a byproduct of the meth-
anol-to-propylene (MTP) process, with
TABLE 2. Commercialized zeolites for the production of ethylbenzene
MFI MEL
Framework
image
Along (010) Along (100)
Ring size 10 10
(No. of T atoms)
Channel 3D 3D
dimensionality
FIG. 1. Zeolites of MWW-type framework.
48 MARCH 2019 | HydrocarbonProcessing.com
a high ethylene content of 75%–95%] are
all suitable feedstocks.
MEL-type zeolite. The type material of
MEL structure, ZSM-11, has a pore system
similar to that of MFI-type zeolite. MFI-/
MEL-type zeolite, which is a co-crystalline
zeolite of MFI and MEL, exhibits special
catalytic performance in the vapor-phase
alkylation of benzene with FCC offgas.
Based on the co-crystalline zeolite, alkyla-
tion catalysts with the brand names of DL-
0802A and DL-0802B were industrialized
by a chemical physics institute in China.9
The pretreatment of feedstock is simpler
than that of the dilute ethylene process.
FAU-type zeolite. This zeolite posseses
a three-dimensional (3D) pore system
with 12-membered ring (12-MR) pore
openings. The basic structural units of
FAU zeolite are the sodalite cages, which
form supercages that are large enough to
accommodate spheres with a 1.2-nm di-
ameter. Faujasite, zeolite X and zeolite Y
FAU *BEA MWW
Along (111) Along (100) Projection
Along (001)
12 12 10
(With cage) (With cage and
side pocket)
3D 3D 2D
are all FAU-type zeolites. Different from
faujasite, the counteraction of zeolite Y is
Na+. Moreover, the Si/Al molar ratio of
zeolite Y is higher than that of zeolite X.
Zeolite Y is mainly used as a catalyst in the
FCC process in petroleum refineries.
In 1990, a liquid-phase process was
commercialized for the production of eth-
ylbenzene, catalyzed by the zeolite Y-based
catalyst.10 The catalyst is also used in the
transalkylation reactor to convert polyeth-
ylbenzenes into ethylbenzene in the liquid
phase. In the alkylation reactor, the feed
ratio of benzene to ethylene is about 7,
and the catalyst lifetime is approximately
1 yr. This liquid-phase ethylbenzene pro-
cess was licensed to several industrial cli-
ents, and their total ethylbenzene capacity
is approximately 2.8 MMtpy.
AEB-1H is a transalkylation catalyst
developed and industrialized by a pe-
troleum research institute in China. The
catalyst uses FAU zeolite as the active
component.4 In 2014, industrial experi-
mentation with a new transalkylation cat-
alyst (EBC-2) based on modified zeolite
Y was successfully performed.
*BEA-type zeolite. Zeolite of *BEA-
type framework possesses a 3D, 12-MR
pore structure consisting of perpendicu-
lar straight channels (6.6 Å × 6.7 Å). The
interconnections create narrow helicoidal
channels with an effective pore diameter
of 5.6 Å × 5.6 Å. The *BEA-type zeolite
is highly active in the liquid-phase alkyla-
tion of benzene with ethylene, and shows
higher conversion of ethylene and selec-
tivity to ethylbenzene than FAU zeolite.
A process for the production of ethylben-
zene was developed and commercialized
in 1996 using a modified *BEA zeolite-
100
Catalytic performance, %
80
60
40
20
0
MWW *BEA FAU
Conversion of ethylene, %
Selectivity to ethylated benzenes, %
Diethylbenzene/ethylbenzene, %
FIG. 2. Catalytic performance of zeolites
of different framework types. Ethylation of
benzene at 220°C (428°F) and 3.4 MPa with
a benzene/ethylene feed ratio of 4.

Mobil-Badger 2nd Mobil-Badger 3rd
pure ethylene pure ethylene
vapor-phase vapor phase
MFI MFI
1980 1990
Lummus/UOP EB One
ethylene
liquid phase
FAU
FIG. 3. Development of zeolite catalysts for the production of ethylbenzene.
based alkylation catalyst, EBZ-500.11
*BEA-type zeolite-based ethylation
catalyst for the production of ethylben-
zene has also been industrialized.12 The
active components of liquid-phase alkyla-
tion catalysts with the brand names of
AEB-2 and AEB-6 developed and com-
mercialized are *BEA-type zeolites, as
well. A series of AEB catalysts are running
in several industrial plants.13
MWW-type zeolite. MWW is a general
term for a series of zeolites formed by the
stacking of basic layers of MWW-type
structure, such as MCM-22, MCM-56,
ITQ-2, MCM-36 and IEZ-MWW.14 The
differences between them are the number
of layers, the stacking manner and/or the
spacing between adjacent layers (FIG. 1). In
a typical MWW framework, two indepen-
dent pore systems are accessible via 10-MR
windows: one is defined by 2D sinusoidal
channels with elliptical ring cross-sections
of 4.1 Å × 5.1 Å, and the other contains
12-MR cages of 7.1 Å × 7.1 Å × 18.2 Å re-
stricted by 10-MR openings of 4.5 Å × 5.5
Å. In addition, pockets like semi-cages are
located on the crystal surfaces.
In the liquid-phase alkylation of ben-
zene, MWW-type zeolite shows activity
that is comparable to FAU zeolite, but less
active than *BEA-type zeolite. The advan-
tage of MWW-type zeolite is that the se-
lectivity to ethylbenzene is higher (lower
diethylbenzene/ethylbenzene molar ra-
tio, shown in FIG. 2). Alkylation catalyst
using the MWW-type zeolite, MCM-22,
was developed and commercialized in
1995 and 1997, respectively.15 The ethyl-
benzene technology can be easily adapted
for dilute-ethylene feedstock (ethylene
accounts for more than 70%).
UZM-8 is another MWW-type zeolite
that is efficient in the liquid-phase alkyl-
Mobil-Rathen EBMax
pure/dilute ethylene
liquid phase
Sinopec
MWW pure ethylene
vapor/liquid phase
MFI/*FEA
2000
Lummus/UOP EB One
and Eni SpA
pure ethylene
liquid phase
*BEA
ation of benzene and provides improved
product yield.16 A new liquid-phase al-
kylation catalyst with the trade name of
EBZ-800TL has been developed.
Lately, a new MWW-type zeolite
named SCM-1 with a crystal thickness
of approximately 5 nm was synthesized
in a dual-amine system.17 The zeolite
is more efficient in the liquid-phase al-
kylation of benzene with ethylene than
MCM-22. Using SCM-1 as the active
component, a new alkylation catalyst
with the brand name of EBC-1 has been
developed and commercialized.
Directions for future developments.
The process for the production of ethyl-
benzene is only one of the petrochemical
processes that use zeolite catalysts, and
it involves only five zeolites of the 245
types of known frameworks. The devel-
opment of alkylation catalysts reflects
the progress of zeolite science and tech-
nology (FIG. 3). The strong possibility of
discovering and industrializing zeolites
with higher efficiencies is the reason why
attempts to synthesize zeolites with nov-
el frameworks are still flourishing after
more than 70 yr of fruitful development.
Another direction for the develop-
ment of zeolite catalyst is its green prepa-
ration process, as wastewater is produced
during synthesis and ion exchange. It
would be of great interest to manufacture
zeolite catalyst in more effective ways to
reduce environmental pollution.
LITERATURE CITED
1
Shi, J., Y. Wang, W. Yang, Y. Tang and Z. Xie, Chem.
Soc. Rev., Vol. 44, 2015.
2
IZA Structure Commission, “Database of zeolite
structures,” accessed February 1, 2019, online:
http://asia.iza-structure.org/IZA-SC/ftc_table.php
3
Vermeiren, W., and J.-P. Gilson, Top. Catal., Vol. 52,
2009.
4
Yang, W., Z. Wang, H. Sun and B. Zhang, Chin. J.
Petrochemical Technology
Lummus/UOP EB One
pure ethylene
Sinopec liquid phase
ethylene MWW
vapor phase Novel
MFI/*FEA zeolites?
2010 Sinopec
DICP-Sinopec- dilute ethylene
CNPC 3rd vapor phase
FCC-offgas Sinopec MFI Sinopec
vapor phase dilute ethylene pure ethylene
MFI/MEL vapor phase liquid phase
MFI MWW
Catal., Vol. 37, 2016.
5
Chen, N. Y., and W. E. Garwood, Catal. Rev. Sci. Eng.,
Vol. 28, 1986.
6
Sun, H., W. Yang, B. Liao and J. Zheng, Chem. React.
Eng. Tech., Vol. 22, 2006.
7
Zhang, Y., Q. Tian and X. Ma, Pet. Refinery Eng., Vol.
42, 2012.
8
Yang, W., H. Sun, W. Liu, B. Zhang, Z. Shen, M. Huan
and H. Zhang, US Patent No. 8,519,208, 2013.
9
Wang, Q., S. Zhang, G. Cai, F. Li, L. Xu, Z. Huang and
Y. Li, US Patent 5,869,021, 1999.
10
Wight, C. G., US Patent 4,169,111, 1979.
11
Gajda, G. J. and R. T. Gajek, US Patent 5,522,984,
1996.
12
Bellussi, G., G. Pazzuconi, C. Perego, G. Girotti and
G. Terzoni, J. Catal., Vol. 157, 1995.
13
Huang, Z., S. Tian, Y. Xu, W. Wang, F. Zhang and
X. Wang, US Patent 5,600,050, 1997.
14
Wang, Y., Y. Liu, L. Wang, H. Wu, X. Li, M. He and
P. Wu, J. Phys. Chem. C, Vol. 113, 2009.
15
Armor, J. N., Appl. Catal. A, Vol. 222, 2001.
16
Jan, D.-Y., J. A. Johnson, R. J. Schmidt and M. P.
Koljack, US Patent 8,518,847, 2013.
17
Wang, Z. Y. Luo, B. Zhang, H. Sun, Y. Tang and W.
Yang, 25th North American Meeting of the Catalysis
Society, Denver, Colorado, June 4–9, 2017, poster.
WEIMIN YANG, Professorate
Senior Engineer, obtained his
BSc degree and PhD in physical
chemistry from Nanjing University
in Nanjing, China. He is President
of Sinopec Shanghai Research
Institute of Petrochemical
Technology (SRIPT) and Director of the State Key
Laboratory of Green Chemical Engineering and
Industrial Catalysis. He won Second Prize of the
National Award for Technological Invention, and the
China Patent Gold Award. Dr. Yang also won the
Industry Innovation Award of the Ho Leung Ho
Lee Foundation and was honored with the title of
National Outstanding Scientific and Technological
Worker. He has published 147 papers and has been
granted 261 Chinese patents and 28 overseas patents.
ZHENDONG WANG is a Senior
Engineer and Supervisor of the
Prospective and Fundamental
Research Department at SRIPT.
He joined the company in 2012
after he received his PhD in
physical chemistry from East
China Normal University. Dr. Wang’s major areas
of expertise are the high-throughput synthesis
of novel zeolite and the development of a green
process for the preparation of zeolite catalysts.
Hydrocarbon Processing | MARCH 2019 49
 Special Focus Petrochemical Technology
O. GIIAZOV, Chemical Technologies Inc., New York, New York;
and D. SHALUPKIN, A. ERMULIN and G. STREMOUSOV,
Chemical Technologies LLC, Saint Petersburg, Russia

Implement AI to predict the composition

of chemical plant feed
An important indicator of the techno- error in determining the concentration of The use of the latest developments in
logical processes at chemical plants is the components may exceed permissible val- the technologies of artificial intelligence
composition of the main flows, including ues for many petrochemical processes. At (AI) and machine learning has great po-
feed, products and intermediate flows. It the same time, analysis of the composition tential to reduce the cost of work to de-
is believed that, at present, the accuracy of of process flows is not usually provided for termine the composition of process flows
determining the composition by modern all potentially important flows, due to rela- while increasing the quality of the results.
methods of analysis is quite high, but the tively high investment and operating costs.
Existing methods for determin-
TABLE 1. Concentration of components according to the results of the ing process stream composition. A
analytical laboratory common method for determining the
Composition of depropanizer column feed flow, wt% concentration of components in process
Time, n-Butane + Sum
streams is inline chromatography analy-
min Propadiene Propylene Propane i-Butane Butene of C5 Aromatics C6+ sis. Analysis is carried out during a speci-
fied cycle of the analyzer, which can span
0 4.79 33.82 33.74 7.44 3.94 7.81 6.25 2.21
30 min–60 min.
5 3.6 32.04 32.2 8.02 2 6.32 4.43 11.39 Generally, the accuracy of determin-
10 3.07 32.53 30.95 7.55 2.73 7.89 4.23 11.05 ing the composition by means of such an
15 3.59 34.06 33.44 8.05 3.89 7.72 5.82 3.43 analyzer is not adequately high. This is
20 3.85 32.23 31.77 8.07 2.02 5.55 6.4 10.11 due to a decrease in sensitivity to the con-
25 4.8 32.56 30.98 8.42 3.44 6.83 5.2 7.77
centrations of components, which hap-
pens due to the high frequency of mea-
30 3.54 34.97 29.1 8.3 3.09 6.38 4.99 9.63
surements—one analysis per 30 min–60
35 4.08 32.8 30.17 8.44 2.53 5.67 5.02 11.29 min. In due course, each chromatograph-
40 3.01 34.66 30.7 8.07 3.95 5.69 6.42 7.5 ic analyzer must be disconnected from
45 3.25 34.5 33.8 7.12 3.09 7.71 6.73 3.8 the industrial plant and calibrated.
50 3.03 33.3 32.48 8.78 3.8 5.8 4.54 8.27 The main tool and resource for deter-
mining the most accurate composition of
55 4.16 32.73 29.62 7.6 3.68 5.13 5.43 11.65
the process flow is an analytical labora-
60 3.52 34.62 31.25 7.22 2.78 6.18 5.52 8.91 tory. As a rule, the frequency of analysis
65 4.95 33.14 29.42 8.69 2.86 5.72 5.46 9.76 ranges from 12 hr–24 hr. The sampling
70 4.55 35.99 29.06 8.11 3.65 6.13 5.03 7.48 and analysis procedures, including fix-
75 4.26 33.32 30.7 7.19 3.15 7 6.55 7.83 ing the exact time of sampling, must be
80 3.42 32.13 30.6 7.38 2.48 7.97 5.59 10.43
regulated so that the results of laboratory
analyses have an applied value in the con-
85 4.56 35.31 30.6 7.11 2.79 5.05 4.41 10.17
dition of varying process flows.
90 3.26 35.17 29.7 8.87 2.87 6.01 6.31 7.81 Despite a more precise determination
95 3.46 33.44 31.97 8.17 3.45 6.26 4.88 8.37 of the composition of the samples, the an-
100 4.54 34.59 29.34 7.3 2.08 7.52 6.54 8.09 alytical laboratory cannot always be con-
105 3.99 34.72 33.94 7.38 2.91 5.51 5.51 6.04 sidered as a “gold standard,” because the
results may have some systematic error—
110 4.51 32.66 32 8.86 3.78 5.18 5.87 7.14
or, in other words, a confidence interval,
115 3.81 33.35 30.22 7.5 3.31 7.94 4.34 9.53 which is the average value of the error of
120 4.63 35.99 29.94 8.57 3.82 5.43 4.49 7.13 the results of the analytical laboratory.
50 MARCH 2019 | HydrocarbonProcessing.com
 Petrochemical Technology

The authors encountered such an error
while carrying out a full-scale experiment
on the feed flow at a depropanizer column.
They took several samples in a row from a
process flow with a short time interval and
at a stable process regime. The analysis
results were not identical, but they were
within the confidence interval character-
ized by a certain systematic error.
Full-scale experiment. To determine
the confidence interval of the analytical
laboratory, a test was carried out at the
depropanizer column for the separation
of C3 hydrocarbons. The feed pipeline
was sampled within 2 hr in a row (from
Implementing AI to determine feed
flow composition. Alongside the results
of chromatographic analyses, petrochem-
ical and oil refineries measure and record
other technological parameters. These
data are used to monitor and control the
process blocks and the plant as a whole.
The volume of these measurements is
large and, at present, this data contains
the potential for additional optimization
of units without the use of hardware or
TABLE 2. Values of confidence intervals of the analytical laboratory
for different components
Composition of the feed flow of the depropanizer column, wt%
constructive intervention in the plant.
By using statistical methods of data
analysis based on AI and machine learn-
ing, it is possible to determine parameters
that are not measured directly or indirectly
by the sensors of a depropanizer column.
The calculation is based on thermody-
namic and statistical dependencies, which
could be found in changing the param-
eters of the plant. This allows for the cal-
culation of additional process parameters,

Propadiene
12:00 to 14:00), with an interval of 5

n-Butane +

Aromatics
Propylene

Sum of C5
i-Butane
Propane
min. The content of components in the

Butene
analytical laboratory were subsequently

C6+
analyzed. The tests results are shown in Parameter
TABLE 1. Quantile 5% 3.04 32.16 29.15 7.13 2.03 5.14 4.35 3.5
According to the presented data, be- Quantile 95% 4.8 35.85 33.79 8.84 3.93 7.93 6.55 11.37
tween 5-min measurements, the results Confidence interval, wt% 0.88 1.85 2.32 0.86 0.95 1.4 1.1 3.93
of the analysis of the analytical laboratory
for each component, on average, have the 44
following variations:
Analytical lab with errors
• Propadiene = 0.88 wt%, 43
which is 22.4% of the average
component concentration 40
• Propylene= 1.85 wt%,
38
which is 5.5% of the average
Mass, %

component concentration 36
• Propane = 2.32 wt%,
which is 7.5% of the average 34
component concentration
32
• n-Butane + i-Butane = 0.86 wt%,
which is 10.8% of the average 30
component concentration 02 June 03 June 04 June 05 June 06 June 07 June 08 June 09 June 10 June 11 June 12 June
2018 2018 2018 2018 2018 2018 2018 2018 2018 2018 2018
• Butene = 0.95 wt%,
which is 30.4% of the average FIG. 1. Values of the analytical laboratory results for the propane, along with the
component concentration confidence interval.
• Sum of C5 = 1.4 wt%,
which is 21.7% of the average 44
component concentration Analytical lab with errors
• Aromatics = 1.1 wt%, 43 Chromatograph
Virtual analyzer current time
which is 20.2% of the average
40
component concentration
• С6+ = 3.7 wt%, which 38
Mass, %

is 47.6% of the average

component concentration. 36
According to the results of the analy-
sis of components in the process flow, 34
at a 5-min sampling period, a high-value 32
scattering is noticeable. For this case, the
values of the confidence intervals are pre- 30
sented in TABLE 2. 02 June 03 June 04 June 05 June 06 June 07 June 08 June 09 June 10 June 11 June 12 June
2018 2018 2018 2018 2018 2018 2018 2018 2018 2018 2018
FIG. 1 shows the values of the analytical
laboratory results for propane, along with FIG. 2. Results of the calculation of the mathematical model were within the confidence interval
of the analytical laboratory.
the confidence interval from TABLE 2.
Hydrocarbon Processing | MARCH 2019 51
 Petrochemical Technology
based on the values of the process sensors.
At the same time, to calculate such new
parameters, physical access to the process
flows is not required. Physical access is
necessary only to organize access to the
database, which contains the actual values
of the parameters of the chemical process.
In addition to determining parameters
that are not measured, it is possible to
create a digital analog of an existing chro-
matographic analyzer. At the same time,
it is possible to add new functions—for
example, the prediction of the concentra-
tion of components in the process flow
for some limited future horizon (i.e., pre-
dicting changes in composition).
For the depropanizer column, a math-
ematical model and software based on AI
technologies were developed to calculate
44
43
40
38
Mass, %
36
34
32
30
02 June 03 June 04 June 05 June
2018 2018 2018 2018
FIG. 3. Predicted values of the concentration of the propane received with the help of a
mathematical model.
FIG. 4. Interface displaying calculation results, a table of values of the components concentration
and a schematic diagram of the unit.
52 MARCH 2019 | HydrocarbonProcessing.com
the concentration of components in the
feed flow of the unit.
As shown in FIG. 2, the results of the
calculation of the mathematical model—
which was applied to the calculation of the
composition of the feed of the unit with-
out physical access to the process flow—
were within the confidence interval of the
analytical laboratory.
At the same time, mathematical models
for the prediction of the composition of the
depropanizer column feed flow in a future
horizon of 30 min were developed. FIG. 3
shows the predicted values of the concen-
tration of the propane received with the
help of such a mathematical model. The
values do not exceed the limits of the confi-
dence interval of the analytical laboratory.
The accuracy of parameter value cal-
Analytical lab with errors
Chromatograph
Virtual analyzer + 30 min
06 June 07 June 08 June 09 June 10 June 11 June
2018 2018 2018 2018 2018 2018
culation by mathematical models could
be compared to the accuracy of parameter
value determination by physical measur-
ing instruments. As such, the replacement
of expensive in-service sensors that use
digital analogs based on mathematical
models can be considered.
The mathematical model can be lo-
cated on any digital medium with an op-
erating system, screen and access to the
database of the petrochemical plant. This
greatly simplifies the process and the cost
of integration, since it does not require
any changes to the internal information
structure of the chemical manufacture.
For the depropanizer column, math-
ematical models were installed on a por-
table tablet computer with a pre-installed
set of algorithms and the possibility of
installation of mathematical models. Cal-
culation of the additional parameters of
the chemical plant in the automatic mode
was achieved on the basis of the measured
values of technological parameters.
Connection to the depropanizer col-
umn database was made via USB protocol.
Mathematical models were used to calcu-
late the values of technological parameters
in real time. The values were calculated
for the current point of time and for 15
min and 30 min in advance. The calcula-
tion results are displayed on the interface
12 June (FIG. 4), which contains a graphic display
2018 area, a table of values of the components
concentration and a schematic diagram
of the unit. Indicated flows for which the
calculation of values was performed are on
the schematic diagram. Integration took
one working day and did not require ad-
ditional financial costs.
Takeaway. This example can be scaled
for other petrochemical processes and for
other industries. It is possible to simulta-
neously implement such analyzers for dif-
ferent process flows of a plant, allowing
the manufacturer to receive a complete
picture of operations and improve the ef-
ficiency of plant management.
OLEG GIIAZOV is the Director of Chemical Technologies
Inc. in New York, New York.
DMITRY SHALUPKIN is the Chief Technical Officer of
Chemical Technologies LLC in Saint Petersburg, Russia.
ARTEM ERMULIN is the Technical Leader for Chemical
Technologies LLC in Saint Petersburg, Russia.
GEORGII STREMOUSOV is a Senior Process Engineer at
Chemical Technologies LLC in Saint Petersburg, Russia.
 Valves, Pumps and
Turbomachinery
N. DALAL, Emerson Automation Solutions,
Marshalltown, Iowa

Cut costs and save time servicing valves

during refinery turnarounds
Most refineries perform turnaround
activities every 3 yr–5 yr to maintain
and upgrade plant assets and equipment.
How the timeline is planned, and how
the scope is defined and executed, varies
from refinery to refinery. Minimizing the
amount of time and expertise needed is
always critical to the success of the turn-
around to meet budgetary constraints and
deadlines. Each day a process unit is down
for a turnaround, the refinery is not mak-
ing profits, and the cost increases.
A 460,000-bpd Gulf Coast refinery de-
termined that it was servicing too many
control valves (FIG. 1) for maintenance
during each turnaround. Refinery per-
sonnel and management questioned why
so many control valves were being pulled,
and how that number could be reduced.
To find the answers to these and other
questions, the refinery turned to its con-
trol valve vendor and service provider.
After running tests and determin-
ing if the valves actually needed to be
pulled, the control valve scope for the
site’s turnaround was reduced from 309
valves to 218, resulting in a cost savings
of $577,000. The reduction in scope in-
cluded removing the need for scaffolding,
extra labor, cranes, etc.
Reducing the time and cost of servic-
ing valves during a turnaround is a matter
of using readily-available modern tech-
nology, such as smart valves, coupled with
the right tools and training. These strate-
gies reduce the number of labor hours re-
quired for valve servicing, the number of
valves pulled and the cost of purchasing
parts or valves, leading to cost and time
savings by eliminating unnecessary work.
Determining valves that require
service. Analyzing data from valve smart
positioners using built-in diagnostic tools
can reduce the number of control valves
that require service by identifying which
valves are working well. Refinery staff
or the control valve vendor can leverage
smart positioners and diagnostic software
to determine valve health and need for
service (FIG. 2).
For those valves requiring service,
these tests can provide information as
to the nature of the required work and
facilitate planning. This information can

FIG. 2. A technician can run valve diagnostic

FIG. 1. A refinery may have hundreds or thousands of valves that are serviced, repaired or tests using a handheld device, a laptop or
replaced during a turnaround. from the control room.

Hydrocarbon Processing | MARCH 2019 53

 Valves, Pumps and Turbomachinery

often include the parts needed for ser-
vice, which allows ordering in advance
and avoiding any expedited fees from the
valve vendor. Unplanned work is one of
the main problems routinely encoun-
tered during turnarounds, leading to cost
and schedule overruns. Reducing this
work is critical.
Using initial installation baseline test
data when the valve was installed, the con-
trol valve vendor can determine if a valve
must be pulled for maintenance. The di-
agnostic tools in the smart positioner can
show alert records stored in the device, as
shown in FIG. 3. If the control valve assem-
bly is performing incorrectly, alerts such
as travel deviation, drive signal problems
and supply air irregularities can reveal
issues with a valve and assist in repair
FIG. 3. This scan indicates an issue with
the control valve, whether it needs more
troubleshooting and if the valve must be
removed from the line for maintenance.
activities. In the case of the Gulf Coast
refiner mentioned here, the site used the
signature series data to determine which
valves needed repair, and the servicing
of healthy valves was removed from the
turnaround control valve scope of work.
With the valve in bypass mode, a tech-
nician can run a series of tests. For exam-
ple, one vendor’s valve diagnostic software
executes a 25-step functional performance
test that starts at 50% and changes in
0.25%, 0.5%, 1%, 2%, 5% and 10% incre-
ments in both directions. Data is acquired
to determine the minimum signal required
to get the valve to respond, and an assess-
ment is made of valve tuning (FIG. 4).
Another diagnostic generates a “valve
signature” plot (FIG. 5) showing the in-
tegrity of the valve and actuator assem-
blies. The input (actuator net pressure) is
plotted on the “y” axis, while the output
(travel) is plotted along the “x” axis. By
plotting data in this fashion, any increase
or decrease in force is shown as a verti-
cal change on the graph. In this case, the
slope indicates that the actuator contains
a spring, and the green line represents the
computer’s best fit between all data points.
For control valves that show no alerts,
have an acceptable valve signature test
and have no stroking issues, pulling the
valve for maintenance is unnecessary.
In the case of the Gulf Coast refiner,
using smart positioners and diagnostics
(FIG. 6) eliminated 49 control valves from
those requiring maintenance during the
turnaround.
Tracking valves. At the start of each
turnaround, a site turnaround team de-
velops a list of control valves that require
service. At the Gulf Coast refiner, 309
control valves were put on the list; how-
ever, valves are sometimes put on the list
for no other reason than they have always
been on the list.
This often happens because refiner-
ies have trouble tracking the status of all
valves. Written documents and emails
from the maintenance and operations
departments and the control valve ven-
dors get lost or misplaced, so the site
turnaround team simply lists all valves for
servicing. To address this issue, a refin-
ery and its valve vendor can use modern,
cloud-based technologies.
For example, a refinery can work in
conjunction with its valve vendor using
SharePoint or another collaboration tool
to track valve repair status, assign prior-
ity to valves, list parts prices, and store
photos, repair reports and repair histo-
ries. Whenever anyone at the refinery or
the vendor’s service technician performs
maintenance, repairs or replacements on
a valve, the necessary paperwork can be
stored in this collaboration tool.
With such data, the site turnaround
team can see individual valves that have
been serviced, and when, and determine
whether they require service during the
turnaround.
Witnessing from a distance. In many
cases, a refinery will order replacement
valves or repairs to existing valves as part
of a turnaround, and plant personnel will
need to witness control valve hydrostatic,
seat leak and factory acceptance testing at
the control valve vendor. The shop per-
forming the function could be 45 min
away, or it could be hours away by car or

FIG. 5. A “valve signature” plot showing the

integrity of the valve and actuator assemblies;
the input (actuator net pressure) is plotted
FIG. 4. Dashboard of smart positioner shows that the control valve cannot get to the on the “y” axis, while the output (travel)
commanded setpoint, so it is signaling the need for more troubleshooting. is plotted along the “x” axis.

54 MARCH 2019 | HydrocarbonProcessing.com
 Valves, Pumps and Turbomachinery

plane. Scheduling such trips can cause de- fic delays often added to trip time. The vite to join a video conference for a sched-
lays on reassembly and shipment of the control valve service provider sent an in- uled time. The video conference took 30
valve, as the control valve vendor waits for
witnesses to arrive for acceptance tests.
Using modern technology, refinery
personnel can use live video conference
software, such as WebEx, to view the test-
ing without leaving the office, saving costs
for the refinery and the vendor and avoid-
ing schedule delays.
Video conferencing allows refinery
personnel to be at the service shop vir-
tually, rather than in person. The control
valve service provider sends a link to a vir-
tual meeting, and then uses multiple high-
definition cameras to show the test to re-
mote users, (FIG. 7). With audio available,
the refinery expert can ask the shop tech-
nician to show a closer view of equipment
on the control valve. If necessary, the valve
vendor’s shop technician can remove the
camera from the stand and physically hold
the camera closer to the assembly.
This method was used for a turn-
around for another Gulf Coast refiner.
The site personnel were only about an FIG. 6. A healthy operating valve, as the actuator pressure vs. travel is smooth, with full
hour away from the service shop, but traf- saturation at both ends of the travel.

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Hydrocarbon Processing | MARCH 2019 55

 Valves, Pumps and Turbomachinery
FIG. 7. With video conferencing, refinery personnel can witness control valve hydrostatic, seat
leak and factory acceptance testing remotely, saving travel time and expense.
min to run through the test, without site
personnel needing to leave their office.
This allowed the test to be performed ex-
actly at the scheduled time, and reduced
plant personnel time from 2.5 hr or more
to 30 min.
Bring in the valve vendor. Most major
control valve vendors and service provid-
ers have experience with shutdown, turn-
around and outage engagements across
different end users and industries. En-
gaging these experienced teams can help
a refinery increase clarity on the control
valve scope and timeline for repairs, dis-
cover opportunities to reduce cost, and
bring control valves back to an OEM state
by using certified parts installed with fac-
tory procedures performed by trained
factory technicians.
56 MARCH 2019 | HydrocarbonProcessing.com
Discussions can begin as early as
24 mos–60 mos before a planned turn-
around to define the scope and unit
scheduled for maintenance. Typically, the
process involves:
• Operational planning (24 mos–
60 mos prior): Future projects are
planned at a high level with key
stakeholders for a future successful
turnaround that is on time and safe.
These key customer stakeholders
are maintenance, engineering,
reliability and safety leaders.
• Alignment (12 mos–24 mos prior):
The initial scope definition is
generated, and preliminary
schedule milestones and budgets
are defined. The project goals and
objectives are also defined, work
lists are prioritized and a scope
freeze date is determined.
• Work scope definition (12 mos–
18 mos prior): Customer kickoff
meeting held with the valve and
service vendor to define a list of
assets to be addressed. A walkdown
of these assets is executed to capture
all relevant data. Diagnostic tools
are used to validate if the asset
can be repaired immediately, or
if it needs further inspection.
• Detailed planning (4 mos–12 mos
prior): The customer has agreed
to the proposal and scope.
Critical valve spares with long
lead times must be put on order,
along with stocked items. The need
for extra labor should be planned
and scheduled. Mobile service
centers must be booked, and other
final approvals from the customer
should be secured.
• Pre-planning (2 mos–6 mos prior):
All resources are aligned for the
execution. This step prepares for
execution, risk reduction and
all communication plans, safety
checks, procedures and signoffs to
commence shutdown.
• Execution: Once the unit is
brought down safely, cleaned and
is safe to approach, the work can
begin. Daily meetings, reports and
communication are key. Safety is
also key during this stage because a
de-energized plant can be dangerous.
Training on new technology for site
personnel is performed here.
• Post evaluation: The unit is back
online, and the plant is producing
product. Key stakeholders review
the execution, measuring the
effectiveness of the strategy and
benchmarking maintenance and
reliability comparisons for future
turnarounds.
Takeaway. Use smart positioners and di-
agnostics to determine if a control valve
needs service. A control valve vendor can
assist with all other turnaround needs, in-
cluding defining the control valve scope,
testing control valves and valve repair.
NEIL DALAL is a Refining Senior
Sales Engineer for Emerson Flow
Controls Products based in
Marshalltown, Iowa. He holds a BBA
degree in marketing and an MBA
degree from the University of Iowa.

Understand net gas compressor control logic
from a process engineering standpoint
In a refinery or petrochemical plant,
certain equipment can create “gray areas”
between process engineers and instru-
ment engineers. The two-stage recipro-
cating compressor control, typical of a
naphtha reformer, is one of these. The
following article describes the interpreta-
tion of that control from the standpoint
of a process engineer.
The purpose of this article is to under-
stand four points:
1. The selection control
2. The exact meaning of controller
action, controller output and
control valve fail position
3. Why a high selector is preferable
to a low selector in two-stage
reciprocating compressor control
4. The overall scheme and logic
of a two-stage reciprocating
compressor control.
What is selection control? As can be
seen in FIG. 1, selection control is used
when more than two controllers try to
manipulate one control element or control
valve. In most cases, one of the controllers
is assigned to the control valve during nor-
mal operation, and the other assumes con-
trol during abnormal or upset condition.
In the case of FIG. 1, the flow control-
ler (FC) is supposed to control the valve
to maintain the flow of positive displace-
ment pump discharge, while the pressure
controller (PC) takes control if the pro-
cess variable (pressure) is above a certain
limit as a kind of abnormal condition.
This is why selective control is sometimes
called override control.
What is controller output? Many pro-
cess engineers, especially early in their ca-
reer, misunderstand that controller output
Valves, Pumps and
Turbomachinery
R. HONG and G.-S. CHANG, GS Engineering
& Construction, Seoul, South Korea
directly corresponds to process variable. put (25%) is not directly the same as the
As shown in FIG. 2, they may wrongly as- process variable level (50%), but rather the
sume that controller output (or the signal same as the control valve opening of 25%.
to the control valve) should be 60% if the Another reason why controller output
level is 60%. The following example shows does not correspond to process variable is
why this understanding is incorrect. that controller output (OPn) is based on
FIG. 2 shows a simple diagram for a not only error (ε, calculated by controller
surge drum with level control, where the with the difference between setpoint and
entire feedstream is flowing out of the process variable) but also on the previous
drum bottom. During normal operation, output (OPn–1). It can be represented as
the feed flowrate and product output rate shown in Eq. 1:
are 100 m3/hr and the level is controlled
at 50%, while the level controller (LC) 1. Normal operation
output is 50% and the control valve open-
ing is 50% (assuming the control valve In 100 m3/hr
50%
characteristic is “linear” where the flow- LC
rate through the control valve is propor-
tional to its opening).
Imagine this system goes to 50% turn- 100 m3/hr Out
down operation and stabilizes after tran- 50% opening
sient conditions. In this 50% turndown
2. Turndown operation
operation, the feed flowrate and product
output flowrate are 50 m3/hr and the level
is stabilized at 50%, while the LC output is In 50 m3/hr
50% 25%
25% and the control valve opening is 25%. LC
By observing this 50% turndown opera-
tion, it can be seen that the controller out-
50 m3/hr Out
High selector
25% opening
>
FIG. 2. Diagram for a surge drum with level
control during normal operation and turndown
operation.
PC FC
FC
FIG. 1. Selection control is used when more FIG. 3. Flow controller action should be
than two controllers try to manipulate one reversed since the controller output must
control element or control valve. decrease when flow increases.
Hydrocarbon Processing | MARCH 2019 57
 Valves, Pumps and Turbomachinery

OPn = OPn–1 + E (1) troller output is necessary to understand
the overall concept of control logic.
This is a usually preferred option,
since the integral term among propor- What is controller action? Controller
tional/integral/derivative controllers action can be “direct” or “reverse,” based
may not be used or may be negligibly on whether the controller output should
small in some cases, even though the be increased or decreased when the pro-
same function can be obtained by the cess variable increases. As shown in FIG. 3,
integral term. The exact meaning of con- the flow controller action should be “re-
versed” since the controller output must
Minimum bypass decrease (closing the control valve) when
flow increases (enlarging the error from
the flow setpoint).
FC
Another example is shown in FIG. 4.
The flow of pump discharge is checked,
and its flow controller changes the open-
ing of the control valve in the minimum
bypass (recirculation) line. Should this
controller be “direct” or “reverse?” The
FIG. 4. The flow of pump discharge is purpose of this control is to keep the min-
checked, and its flow controller changes imum flow in the common line to protect
the opening of the control valve in the the pump. If the flow decreases under its
minimum bypass line. setpoint, then the control valve in the by-
Air
Air
Fluid
Fail-close, air-to-open Fail-open, air-to-close
FIG. 5. Diagram of fail-close and fail-open positions for valve.
Vent to ATM to flare
PV-0
FC
S-1 S-2
> >
PC PC
PC-1 PV-1A PC-2 PV-2A
FO FO
PV-1B PV-2B
FO FO
First stage Second stage
Reciprocating compressor
*inlet/interstage/outlet KO drums, interstage/outlet coolers are not shown
FIG. 6. Diagram of fail-close and fail-open positions for valve.
58 MARCH 2019 | HydrocarbonProcessing.com
pass must be opened more, which means
the controller action must be reversed.
Understanding control valve fail
position and its effect. Regardless
of whether the fail position of the valve
is fail-close (FC) or fail-open (FO), the
electrical signal increases the air pressure
(against spring force) to control the valve
actuator through the current-to-pressure
(I/P) positioner. The signal opens the
control valve more in an FC case and vice
versa in an FO case. FIG. 5 aids in under-
standing why the control valve works this
way—except in a special case where the
valve plug is located under its seat and
moves up when it closes.
Whether the control valve must be FC
or FO depends on which position is safer
or leads the system into a more desirable
condition when air fails. Typical FO ser-
vices are pump minimum bypass, com-
pressor kick, liquid to fired heater, column
reflux/pumparound, etc.
In FIG. 3, assume the fail position of
the control valve is FC, as it is normal.
Increased process variable (flow) will de-
crease the controller output (reverse) and
then decrease the control valve opening,
which corrects the flow to match its flow
setpoint. If the control valve is FO, then
the increased process variable (flow) will
decrease the controller output (reverse)
and then increase the control valve open-
ing. This enlarges the error between the
process variable and its setpoint. If the
control valve in FIG. 3 must be FO, then
the controller action must be direct.
Another method for FO control valves
is the DCS output option, as outlined in
the next section.
Why use high selector instead of low
selector? A recycle valve is a popular and
economic method to control the flow of a
positive displacement compressor (FIG. 6)
PC since the flow of this kind of compressor is
PC-3 PV-3
fixed. With this recycle control, part of the
FC compressor discharge should always be re-
cycled to its suction to match the compres-
sor performance to the system demand.
In the case of upset condition, when
more gas is supplied from an upstream
system than is needed in a downstream
system, the process fluid (gas) must go
somewhere. Ultimately, it comes down
to vent or flare. Since the pressure is con-
trolled by the recycle control valve and
the last means (vent) is PV-0 at first-stage
 Valves, Pumps and Turbomachinery

suction, the signals that make the recycle
control valve open wider must be se-
lected in the selectors. With this in mind,
several reasons exist why a high selector
is better than a low selector.
First, during startup, it is common to
manually operate control valves. Intuition
says that increasing the controller output
increases the control valve opening. To
do this, the signal to the FO control valve
must be reversed logically inside the DCS
after calculation or adjustment, which is
referred to as the DCS output option.
Secondly, using high selectors is easier
to understand and seems correct, because
a higher signal (to the high selectors)
means a larger valve opening. This makes
FIG. 7a much simpler, without any addi-
tional reversing effect required between
the selectors and the control valves.
Reversing signals. Several means exist
to reverse the signal from the controller to
the control valve, as can be seen in FIG. 7:
1. The controller can be direct or
reverse, but to simplify the problem
it is better to set it as direct.
2. Reversal between the controller normally not recommended.
and the selector. 7. Reversing the function of the
3. Note that PY-1A and PY-2A smart I/P positioner can be done.
are reversing signals, because No reversal is assumed in this case.
the PV-1A/B opening is reverse 8. Control valve fail position. The
to the PC-1 output, and the PV- FO control valve has a reversing
2A/B opening is reverse to the effect by its own mechanism where
PC-2 output. the air is introduced into the top
4. Reversal between the selector of the actuator against the spring.
and the DCS output option— An increased signal (increased
no reversal in this case. air pressure) decreases the valve
5. DCS output option—reversal opening. This is canceled by the
only for FO valves. DCS output option (No. 5)
6. Reversing at the I/P positioner in the preceding list.
by switching the instrument The number of reversals from the se-
air connections is possible, but lectors to the control valves should be
TABLE 1. Relationship between pressure and valve opening
Pressure ↗ ↗ ↗
Controller PC-1 (direct) PC-2 (direct) PC-3 (direct)
Controller output
↗ ↗ ↗
Valve opening
↗ ↘ ↗ ↘ ↗ ↗
Valve PV-0 PV-1A/B PV-2A/B PV-3

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Hydrocarbon Processing | MARCH 2019 59

 Valves, Pumps and Turbomachinery

even if a high selector is used, and odd if
a low selector is used. Two reversals from
the selector to the control valves are in
FIG. 7: one is a DCS output option and the
other is the FO control valve itself, so use
of a high selector is validated.
The odd number of reversals with a
low selector would have the same effect,
but with an even number of reversals with
a high selector; however, this would make
the logic more complicated.
When the process variable (pressure)
increases at the suction of the first stage
(PC-1) and the interstage (PC-2) with
direct controller action, the signals from
First-stage suction
PC-1
Direct
50~100%
X X
PY-1B PY-1A
0~100%
PY
Output option Output option
direct reverse
FC
PV-0 PV-1A
Vent First-stage recycle
100
Opening, %
PC-1 to PV-1A/B and from PC-2 to PV- to open PV-2A, and then PV-2B,
2A/B must be reversed so that the valve to recycle more to the interstage.
opening decreases with increasing pres- The action takes effect only
sure, as shown in the red box in FIG. 7. when the signal from PC-3 to
S-2 (selector) is higher than
Understanding the control logic. the signal from PC-2 to S-2.
A description of each controller (PC-1, 2. In the case of higher pressure at the
PC-2 and PC-3) from the second-stage interstage, PC-2 tries to decrease
discharge back to the first suction is the opening of PV-2B, and then
as follows: PV-2A, to receive less from the
1. In the case of higher pressure at second-stage discharge. The action
the second-stage discharge, PC-3 takes effect only when the signal
increases the opening of PV-3 from PC-2 to S-2 is higher than
to send more product. When the signal from PC-3 to S-2. When
PV-3 is fully opened, PC-3 tries the PC-2 controller output reaches
50% while trying to fully close PV-
Interstage Second-stage discharge 2A/B, PC-2 tries to open PV-1A,
PC-2 PC-3 and then PV-1B, to recycle more to
Direct Direct
the first-stage suction. The action
takes effect only when the signal
from PC-2 to S-1 is higher than
0~50% 50~100% 0~50% 50~100% 0~50%
X X X X the signal from PC-1 to S-1.
PY-2B PY-2A PY-3B PY-3A 3. In the case of higher pressure at
the first-stage suction, PC-1 tries
100~0% 0~100% 100~0% 0~100% 100~0% to decrease the opening of PV-1B,
> >
S-1 S-2
and then PV-1A, to receive less
from the interstage. The action
takes effect only when the signal
from PC-1 to S-1 is higher than
0~50% 50~100% 0~50% 50~100% the signal from PC-2 to S-2. When
X X X X
PY PY PY
the PC-1 controller output reaches
50% while trying to fully close PV-
0~100% 0~100% 0~100% 0~100% 1A/B, PC-1 opens PV-0 to vent to
atmosphere or a flare.
Output option Output option Output option Output option It is also important to check the rela-
reverse reverse reverse reverse
tionship between the process variable
FO FO FO FO FC (pressure) vs. the valve opening follow-
ing the logic shown in FIG. 7 to make sure
PV-1B PV-2A PV-2B PV-3 that the control valves operate correctly. If
First-stage recycle Second-stage recycle Second-stage recycle Product
the results are in alignment with those in
TABLE 1, then the design is correct.

NOTE
a
The graphs at the bottom of FIG. 7 show that the
control outputs of the x-axis start from the right (0%)
PV-0 PV-1A PV-1B PV-2B PV-2A PV-3 and move to the left (100%), thereby arranging the
0
compressor suction on the left and the second-stage
Control output, PC-3 discharge on the right.
100% 50% 0%
Control output, PC-1
RANGKI HONG is a senior process engineer on the
100% 50% 0% plant basic engineering team at GS E&C. He has 22
yr of wide experience in engineering and design of
various refinery and petrochemical processes, and
specializes in utilities and offsites basic design.
He holds a BS degree in chemical engineering
from Korea University in Seoul, Korea.

PV-1B PV-1A PV-2A PV-2B GEUN-SOO CHANG is a principal process engineer

and leader of the plant basic engineering group
at GS E&C. He holds an MS degree in chemical
Control output, PC-2
engineering from Seoul National University. He has
contributed to basic engineering, commissioning
FIG. 7. Overall control logic for the controller to the control valve. and troubleshooting for numerous EPC projects for
refinery and petrochemical plants.

60 MARCH 2019 | HydrocarbonProcessing.com

Set correct design specifications
for optimized piping and pipe support system
During the planning and engineering execution of petro-
chemical, oil and gas, and power projects, it is essential that the
owner and engineering, procurement and construction (EPC)
contractor mutually develop a comprehensive and detailed pip-
ing design specification. This specification should not only ad-
dress the grey areas of governing piping codes of construction,
such as ASME B31.3 or ASME B31.1, etc., but also ensure full
compliance to code-intended design aspects, design optimiza-
tion, material productivity, reliability and maintainability with
a focus to project-specific objectives and criteria adhering to
local regulations.
An overly conservative design specification that stipulates
stringent criteria above and beyond ASME B31.3/31.1 not only
affects cost and material productivity, but also seriously jeopar-
dizes the reliability and functionality of the piping system; con-
nected equipment; supporting steel structures; pipe supporting
devices such as struts, snubbers, etc.; and process performance
of the associated equipment. When developing a piping design
specification or addressing flexibility analysis guidelines, focus
must be maintained on severity levels of the piping system, the
criticality of the connected equipment and environmental load-
ing (wind, seismic, snow) and their consequences on the piping
system and equipment, ensuring that guidelines of B31 pressure
piping code and its interpretations are met.
On the contrary, a poorly drafted piping design specifica-
tion leaves many ambiguities among designers. Therefore, the
opportunity to properly optimize the piping and pipe support
system according to project objectives is eventually lost.
A blanket consideration or a copy-and-paste job using the
same design specification for multiple different projects is det-
rimental to achieving the project’s specific objective of reliable
and optimized design.
A piping design specification must be comprehensively
drafted with care, keeping in mind project requirements, gov-
erning codes of construction and project objectives to ensure
the safety of critical equipment, long-term reliability, maintain-
ability, cost optimization, material productivity and, most im-
portantly, full compliance to construction codes.
This article highlights examples and case studies for pip-
ing and pipe support design where an overly conservative
approach or even a complete absence of proper approach/
guidelines can create potentially serious design issues, leading
to long-term reliability problems for piping systems and as-
sociated critical equipment.
Plant Design
S. MAITI, Wood Group, Kolkata, India
Many areas are not explicitly addressed in B31 pressure piping
codes. Sometimes these code requirements are ignored or over-
looked, which can lead to potential “loose ends” from a design
perspective. Eventually, these aspects are left to the designers’
choice or to good engineering practices. These design aspects sig-
nificantly impact the optimization of piping and pipe support sys-
tem optimization, safety and reliability. Some of these issues are
discussed here, based on recently executed projects. It should be
noted that complete design reliability is not limited only to these
factors. In fact, numerous other factors affect the design reliability
of piping and pipe support systems, but are not discussed here.
Installation temperature. The reference temperature for cal-
culating thermal expansion of the piping system while comput-
ing support or equipment nozzle reaction forces and moments is
the installation temperature. This data should come from project
specifications and has a significant impact on pipe support ther-
mal load, equipment nozzle loading, etc. Many pipe stress speci-
fications conservatively stipulate the minimum design metal
temperature (MDMT) of pipe material, as installation tempera-
ture can lead to an unnecessary requirement of piping flexibility
and additional supports with a loss of performance and oppor-
tunity for a reliable piping system. Piping support reaction and
equipment nozzle reaction are computed and qualified based on
the installation temperature, whereas the expansion stress range
will be based on minimum ambient temperature to maximum
temperature (design), as per the B31.3 code.
Pipe support design/equipment nozzle load checking.
When piping systems are subjected to occasional load, such as
seismic or wind, those are to be added with normal operating
cases (operating temperature/pressure) rather than with de-
sign cases (design temperature/pressure). Combining design
temperature with a seismic/wind load case and evaluating pipe
support load/equipment nozzle load almost sounds like two
occasional cases in conjunction, which B31 code does not rec-
ommend. Conservative piping stress specifications that allow
this kind of combination result in heavy structural design/foun-
dation, special requirements for additional pipe support and
complex pipe routing, and unnecessary special reinforcement
for equipment nozzles.
Allowable nozzle load and nozzle flexibility. With the ad-
vent of modulated finite element analysis (FEA) tools,a it is easy
Hydrocarbon Processing | MARCH 2019 61
 Plant Design
250
Resulting moment, kilonewton-meter
200
150
100
50
0 stiffness of 2 E6 is required for this case to achieve convergence
0.E+00 1.E+06 2.E+06 3.E+06
Strut stiffness, lb/in.
FIG. 1. A stiffness sensitivity analysis of a strut used near the
coke drum of a delayed coker unit.
to estimate nozzle flexibility and use that information in pipe
stress calculation rather than considering an infinitely stiff anchor
(as high as E12 lb/in.), which gives an impractical result. This
result leads to a complex pipe routing with increased flexibility
and special supports. To maintain the simplicity of routing and
pipe support, the use of equipment nozzle stiffness through FEA
calculation or other means, such as WRC 297, is recommended.
In most cases, stress specification dictates the allowable
load for the vessel/exchanger, and the pipe stress engineer lim-
its the equipment loading within those parameters. However,
in a high-seismic zone, when operating and seismic cases are
combined for the qualification of allowable nozzle loading of
pressure vessels, then it is beneficial to take advantage of ASME
VIII, Division 2 elastic analysis. Here, the thermal load and pri-
mary load, such as pressure and seismic inertia load, are treated
differently. This provides the analyst with leverage to qualify the
pressure vessel shell nozzle junction analysis.
For rotating equipment, especially for pumps, rather than
using the same allowance for both operating and operating
+ occasional (+ occ), a factor such as 1.33 or 1.5 can be used for
the combined case of operating + occ. However, this approach
should agree with the equipment vendor and owner/client.
This will simplify pipe support by reducing special supports,
such as snubbers, and improve reliability. However, piping sys-
tems must comply with code requirements of occasional stress-
es and position retention requirements during a seismic event.
Handling two-phase flow. Two-phase flow, with or without
slug, is a potential source of vibrations and can pose a serious re-
liability issue if not addressed in the design phase. These vibra-
tions not only reduce the fatigue life of a piping and support sys-
tem, but also create maintenance problems, such as dislocation
of the supports from steel. The best prevention is to maintain a
minimum natural frequency of the piping system, such as 6/7
Hz, as required. However, proper analysis must be carried out to
achieve this frequency. Rather than just adding a few guides and
stops in the piping stops, a finite stiffness supporting analysis
must be adopted to achieve a realistic result. A good stress speci-
fication must explicitly dictate the stiffness requirement of the
modal analysis, as well as the frequency criteria for two-phase
flow lines to arrest potential vibration issues.
Use of pipe supports. The rigid strut support, which often
plays the role of reliable pipe support with a friction gap of less
62 MARCH 2019 | HydrocarbonProcessing.com
than zero for high-temperature piping, is highly recommended
to be simulated with the appropriate stiffness of the strut itself,
as well as the associated structural part with which the strut is
connected. If possible, for critical application, a stiffness sensi-
tivity analysis should be performed to determine a minimum re-
quired stiffness to ensure proper functionality of the strut. FIG. 1
is an example of a strut used near the coke drum of a delayed
coker unit to direct the thermal expansion away from the coke
drum. The stiffness sensitivity analysis shows that a minimum
4.E+06 5.E+06 6.E+06
of the loading imposed on the coke drum nozzle.
A similar approach is applicable for a snubber, which is de-
signed to take only an occasional load and not a thermal one.
While conducting a dynamic analysis, snubber stiffness is an
input to pipe stress analysis software. However, for equivalent
static analysis, analysts must be careful to choose the stiffness
and ensure that connected structural stiffness is maintained well
above the snubber stiffness to ensure its functionality and main-
tain the position of the piping system during a seismic event.
Allowable loading for pipe support standard. The pipe
support standard used for any project must have allowable load-
ing for standardized pipe support members and attachments.
The weld size and type of weld should also be clearly defined
in the support standard as minimum requirements. Selection
of support member and attachment based on pipe size only is
not recommended. In the absence of allowable loading of pipe
support, further structural evaluation is required for selecting
the appropriate pipe supporting element. Any deviation from
this approach is a clear case of non-compliance of B31 code and
must be avoided to attain reliability and structural integrity of
the pipe-supporting element.
Unlisted code mechanical components. A good stress
specification also recognizes where special analysis may be re-
quired to ensure design reliability of the piping or support com-
ponents, particularly for unlisted code items like the stress in-
tensification ratio for pipe diameter thickness exceeding 100 for
components like bends, lateral tees or Y pieces. FEA is recom-
mended for these applications, especially where large-diameter
piping with high pressure and temperature are associated. This
is also relevant for equipment nozzle qualifications for top, bot-
tom, side or hill-side nozzles for towers, vessels, etc. FEA is rec-
ommended, using ASME VIII, Division 2 elastic analysis stress
categorization, since WRC bulletins such as 107 and 297 are
not applicable for these calculations. Numerous unlisted code
items or design scenarios require thorough analysis depending
on application, but those cases are not discussed here.
Allowable excursion of pressure/temperature. Process
engineers often define short-term escalations of pressure/tem-
perature as design pressure/temperature. Subsequently, pipe
material and stress engineers carry out pressure design analy-
sis and select piping component ratings based on this elevated
pressure/temperature.
Process engineers responsible for the preparation of line
lists and line parameters must consult with stress and mate-
rial engineers for possible impacts on materials, especially for
high-temperature and pressure-alloy steel piping. They should

evaluate whether B31.3 Clause 302.2.4 can be applied for a
short-term occasional case, and they should define this as an
upset case in the line list and line parameters. Application of
this clause will have an impact on the pressure design of the
piping system, as well as subsequent impacts on the flexibility
analysis, equipment nozzle loading, pipe support loading, etc.
Design basis can highlight a mention of this excursion
clause, alerting the designer to choose an optimized design
within the ambient current code of construction.
Use of more applicable data for SIF and flexilibility factor
(B31J). In 2001, the B31 mechanical design committee (MDC)
initiated a project for evaluating more applicable data of SIF (i)
and flexibility factors (K) as a defined appendix of B31 pressure
piping. In 2017, B31J was approved by the American National
Standards Institute (ANSI) and has provided a more refined data
set for SIF and flexibility factors for piping components.
Designers should be aware of the criticality of the piping
system—its high pressure and temperature, displacement and
thermal cycle, the fact that it is fatigue prone, etc.—and act
accordingly by using B31J for more realistic results for code
stress calculations.
Takeaway. The design aspects presented are a few rudimen-
tary considerations for design work, but their implications are
significant. Based on the type of petrochemical plant and re-
lated application, numerous considerations affect piping and
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Plant Design
pipe support design. Since it is impossible and unrealistic to
cover all aspects of a stress procedure/specification in a single
document, the following general guidelines must be consid-
ered while drafting a piping stress procedure:
• A design specification is vital to ensure the reliability and
safety of the piping system, which cannot be left loose.
It must be drafted properly and implemented without fail.
• The specification should be project-specific and compliant
to local regulations, such as PED, IBR, etc., as well as
international standards like B31 pressure piping codes.
• Attention must be paid to simplifying pipe support
systems, rather than unnecessary complication
through an unrealistic and impractical analysis.
• Root cause analysis (RCA) of the ongoing reliability of
piping and pipe support systems must be studied and
documented. The RCA outcomes must be effectively
implemented, and design specifications must be
recalibrated to prevent such occurrences.
NOTES
a
NOZZLE PRO
SOUMITRA MAITI is Principal Engineer—Piping at Wood Group
India in Kolkata, India. He has more than 13 yr of experience in
piping stress analysis and pipe support engineering in the oil
and gas, power and steel sectors. He previously worked for GE
Energy, Tata Consulting Engineers Ltd. and L&T-Sargent & Lundy
Ltd. He graduated with a degree in mechanical engineering from
Jadavpur University in Kolkata, India.
Hydrocarbon Processing | MARCH 2019 63
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The top three causes of contractor
and engineering misalignment
When contractors, engineers and operations teams at down-
stream processing plants do not work together at optimal effi-
ciency, it can present serious problems. If these teams are not
aligned, and if information is not properly shared, it can get in
the way of safety, productivity and cost control.
Fiatech, which is now part of the Construction Industry In-
stitute, estimates that the typical engineering, procurement and
construction (EPC) firm will budget less than 0.3% of the total
project cost for information handover. However, Fiatech also
found that an additional expense of 2%–4% of the total project
cost is required by the owner-operator to manually correct and
enter required information into operations and maintenance
(O&M) systems. For example, on a $400-MM project, approx-
imately $1 MM might be budgeted by the EPC firm, but the
owner-operator must invest an additional $8 MM–$16 MM in
“hidden” data entry and validation costs. The study’s good news
is that 60% of those hidden costs can be avoided through peri-
odic, structured and automated information exchanges between
EPC and O&M systems. This means that $5 MM–$10 MM of
operational costs can be saved on a $400-MM capital project.
The reader might wonder why this is so hard and why the
hidden costs are so great. The author’s team has analyzed these
challenges and observed that, across a range of process indus-
tries, hidden costs can emerge from three main sources:
1. Different work styles, personalities and motivations
between EPC and O&M systems
2. An over-reliance on email and file transfer protocol
(FTP) communications
3. Drawing libraries that do not reflect what is built.
Different work styles, personalities and motivations. Mul-
tiple types of people with different responsibilities and outlooks
must collaborate seamlessly to avoid wasting money in handoffs.
The first person involved is the on-time, on-budget con-
tractor. The contractor who is building a new unit or manag-
ing a turnaround is motivated to complete the job on time and
on budget. Contractors are not overly interested in how project
or design documentation is applied for operational use, espe-
cially given that those documents represent as little as 20% of
project documents. In addition, contractors do not have the
time, motivation or resources to check that they are working
from the most up-to-date information. Their priority is to get
Project
Management
N. EICHELBERGER, Accruent,
Omaha, Nebraska
the job done on time, on budget and with reasonable quality.
Since they work with computer-aided design (CAD) drawings,
they can improvise to complete the work. However, this creates
problems the next time the system is worked on by a different
contractor. Simply put, contractors are less likely to detail the
as-built version beyond what is required for them to get paid.
The second person involved is the engineer. Hydrocar-
bon plant engineers are responsible for designing solutions that
meet codes and specifications, and that are safe, resilient and
durable. These engineers are experts at creating detailed draw-
ings with CAD systems, and they typically have sound pro-
cesses. They know the systems, understand how everything is
supposed to work and which fail-safe mechanisms are needed
to do so. Plant engineers are typically practical people who de-
pend on record keeping and precision. They require data and
accurate records to deal with problems at both the macro (plant
efficiency) and micro (component performance) levels.
Engineers plan and build the processing plants. They are re-
sponsible for keeping plan drawings and CAD files up to date.
They apply scientific principles to design and implement sys-
tems that perform the right duties and comply with regulations,
thus ensuring that systems are safe for workers. They collaborate
within and across disciplines to make an overall system work.
Their blind spot may be a tendency to work “by the book” and
“off the drawings” instead of “in the real world.”
The third person involved is in production and is respon-
sible for maintaining the license to operate. Operational
personnel must optimize production and protect their licenses
to operate. This includes maintaining documentation such as
operating procedures, certificates, specifications, manuals, and
piping and instrumentation diagrams (P&IDs). All too often,
operations personnel do not ensure that the right requirements
are in place for data handover. While procurement can hold the
contractor accountable for delivering to the letter of the agree-
ment, the structure and format of the data may not be in the for-
mat needed by operations personnel. The result can be a hando-
ver of PDFs that cannot be edited and updated. Consequently,
when the next change is needed, the design documents must be
recreated from scratch, which costs money and time.
Over-reliance on email and FTP communications. When
we asked audience members in a recent webinar how they com-
Hydrocarbon Processing | MARCH 2019 65
 Project Management
municate engineering information, 44% responded that they
use email. Unfortunately, email is not dependable for managing
the information flow for hydrocarbon plant projects.
Email allows transmission of engineering drawings as attach-
ments. When these files are transmitted correctly, there is no
problem. Unfortunately, email is subject to human errors, such as:
• Omitting the attachment
• Attaching a file size that is too large to send
• Attaching the wrong design file or version
• Failing to attach all documents.
FIG. 1. Maintenance workers in the field.
Only One Foot Required.
Roth Low NPSH pumps
require a Net Postive
Suction Head (NPSH)
of only one foot of
liquid for full curve
performance.
Roth chemical processing pumps
include a standard chemical duty, low
NPSH, seal less magnetic drive, and
low NPSH multistage pump options to
pump an extensive array of chemicals
including liquefied gases.
1-888-444-ROTH • www.rothpump.com
Select 155 at www.HydrocarbonProcessing.com/RS
66 
In one of our company’s surveys, it was found that 28% of
engineers use FTP communications to share engineering infor-
mation. While this process addresses file size issues, it also intro-
duces the risk of sending an incorrect file. Overall, it is easy to
make mistakes and share the wrong information with the wrong
people when depending on FTP communications.
Other problems with using FTP communications for sharing
engineering information are:
• Version control—Was the correct version sent?
Does that recipient know if an updated version
of the drawing becomes available?
• Access, especially in the field—Many phones do not
have an app for sharing, opening, accessing or sharing
information via FTP communications.
As new team members are added, providing access to the
right files becomes a challenge. If information lives in emails,
new team members must then receive all the right emails or a
new batch of files via FTP communications. Information has
been shared, but this does not mean that the correct information
is available to the right people in a work order system.
‘As-built’ is not reflected in the drawings. When changes
occur in a plant, whether they are made by the operator or con-
tractor, they are often not documented in the master engineer-
ing drawings. With O&M personnel, this happens because they
are busy executing work orders and do not have time to update
the documentation. When performing their work in the field,
maintenance workers must have up-to-date information for the
sake of safety and compliance (FIG. 1).
Each engineer depends on team members to keep master in-
formation complete and accurate. This process is crucial when
work is handled concurrently across disciplines or departments.
If maintenance personnel or contractors have made changes that
are not reflected in the master documents, this may lead to er-
rors that can impact plant performance, reliability and/or safety.
Engineers may encounter delays, quality control issues and the
need for rework when changes are not reflected in the current
drawings and when master documents are not kept up to date.
The solution: A master documentation system. An engi-
neering information management (EIM) system for documents
can contain the costs and risks of misalignment between all par-
ties. EIM systems provide a centralized, easy-to-access, single
source of truth. The best EIM systems provide a mobile inter-
face that allows contractors and maintenance personnel to up-
date and view as-built plans, with notifications when documents
change and/or need approval. Operators can have direct access
to the relevant technical documentation when viewing work or-
ders, equipment specifications or job plans by tapping directly
into the current CAD drawings or building management system.
This attention to detail keeps contractors and engineers on the
same page and provides an audit trail for compliance to hold
each party accountable.
NATHAN EICHELBERGER is the Senior Vice President for Accruent.
He has more than 24 yr of experience in technology leadership.
Mr. Eichelberger has built his technical career developing
collaborative relationships to achieve the best solutions for teams
and customers. His career has included work at Gateway
Computers and LANDESK/Ivanti Software prior to joining Accruent.
 Project
Management
B. K. SHARMA and A. BAHADUR,
Fluor Daniel India Pvt. Ltd., Haryana, India

Design considerations for rigging and

transportation of large process columns
Design guidelines for rigging and
transporting large process columns are
outlined in this article, along with the
various aspects that should be considered
during the initial design phase of equip-
ment. Attention to these points will mini-
mize changes in equipment and avoid
cost and schedule overruns.

Lifting weight consideration. The

lifting weight for a fully dressed column
should include the weight of the column
(with the ladder and platform); internal
attachments like trays, packing and insula-
FIG. 1. Shackle dimensions can be taken from the Crosby shackle table, based on the WLL.
tion; and piping, which is installed on the
columns before lifting.
The standard design of trunnion and
lifting/tailing lugs should be carried out in
accordance with good engineering prac-
tices. Alignment with other attachments
used for lifting, such as spreader beams,
slings and shackles, should be considered.
The design of lifting/tailing lug shack-
le dimensions can be taken from the
Crosby shackle dimensions table (FIG. 1),
or an equivalent, based on the working
load limit (WLL). All below-the-hook
components (i.e., lugs and trunnions)
should meet the criteria provided in FIG. 2. Clashing of the shackle shown with the
ASME B30.20/BTH-1.1 marked part of the tailing lug stiffener.
Shear stress ≤ 0.45 × Fy, bending stress
≤ 0.66 × Fy and bearing stress ≤ 0.75 × Fy
should be evaluated for tailing/lifting lug sling diameter. The distance between the
design (Fy = minimum yield values from keeper plates should be 30% more than the FIG. 3. A possible solution: the tailing lug is
ASME Section 2, Part D). The proof load size of the sling diameter to allow for sling moved an additional 75 mm away from the skirt.
of shackles is generally equal to the WLL compression and deformation.
of a shackle multiplied by 2. The ultimate The sleeve is generally provided to
load capacity = 5 × WLL. avoid friction between the sling and the is better for large, heavyweight columns.
trunnion. The sleeve is a thin plate that acts Tailing lug clashing must also be
Suggested options for trunnion as a bearing surface between the trunnion checked for all lifting positions during the
configuration. The keeper plates on the and the sling, thereby reducing friction. rigging operation. FIG. 2 and FIG. 3 illus-
sleeve should be at least the size of the Providing a sleeve on the trunnion design trate the interference between the shackle
Hydrocarbon Processing | MARCH 2019 67
 Project Management
and tailing lug stiffener during the last
phase of the tailing operation.
Rigging analysis. The reaction force act-
ing on the tailing lug must be calculated by
analyzing the various lifting angles, from
horizontal (0°) to vertical (90°). The an-
gle that results in the highest value, W2Y, is
considered for the detailed design. An im-
pact factor of 2 will be considered, unless
a different value is selected for the project
specification (FIG. 4).
For large and heavy vessels, a finite el-
ement analysis (FEA) of the lifting case
should be performed to investigate the
structural behavior of the vessel for differ-
ent lifting conditions. If the FEA is used
to evaluate columns for lifting, then an
FIG. 4. Vessel loading diagram during lifting.
FIG. 5. Stiffeners shown in skirt base block.
68 MARCH 2019 | HydrocarbonProcessing.com
elastic analysis is preferred, as per ASME.
It is good engineering practice to apply an
impact factor of 1.5 or 2, as per the speci-
fication requirement; to limit the mem-
brane (local or primary) stress to 0.9 ×
Fy; and to limit the membrane plus bend-
ing stress to 1.1 × Fy. These limits should
be applied to the pressure boundary, the
skirt and the base ring.
A buckling analysis also must be per-
formed to protect columns from collapse
due to the loads acting on them. This anal-
ysis may result in an increase of mid-shell
course thickness for thin, tall columns.
Sometimes the lifting trunnion and tail-
ing lug location must be selected to reduce
mid-span bending (i.e., to minimize the ef-
fective bending arm of the process column
accordingly). Also, the skirt base block
must be stiffened with additional supports
to prevent deformation during the lifting
of a large process column (FIG. 5).
If the total induced combined stress
[i.e., bending stress (σb/Sb) + tensile
stress (σt/St)] is < 1 on the skirt base
block, then there is no need to provide
additional struts. If the total induced com-
bined stress = > 1, then additional struts
must be provided for the skirt base block
stiffening (FIG. 5). The tensile stress = 0.6
× Fy, and the bending stress = 0.66 × Fy
FIG. 6. Large-bore piping shown on columns.
TABLE 1. Accelerations to be considered for column transportation
Case
Sea transport
Road transport on SPMT to erection site
*Acceleration values shown are examples and may differ based on logistics and client specifications/requirements.
(where σb = induced bending stress, Sb =
allowable bending stress, σt = induced ten-
sile stress and St = allowable tensile stress).
Extent of pre-dressing. The extent of
pre-dressing must be defined for a large
column. For example, the piping that must
be installed on a column in horizontal con-
dition, prior to lifting, must be determined.
This information must be readily available
so that pre-installed piping supports can be
analyzed in advance, which could eliminate
the deformation of pipes during lifting.
Other major services to be considered
include deluge lines, steam-out lines, drain
lines for level gauges or transmitters, and
fuel gas lines. Information on these items
are needed for lifting considerations, as
well as for transporting the fully dressed
column from the laydown area and mov-
ing it to the final site with a self-propelled
modular trailer (SPMT).
Large-bore-pipe pre-dressing lifting
should be analyzed (FIG. 6). Additional
supports should be installed for the pip-
ing on the column. A lifting study should
consider the possibility of fouling of the
sling or lifting tackles on the fully dressed
column as a result of attachments like lad-
der and platform (L&P) extensions, pipe
extensions, external support clips, etc.
Acceleration to be considered
Transverse Longitudinal Vertical
±0.76 g ±0.4 g 1 g/±0.46 g
±0.1 g ±0.3 g 1 g/±0.05 g
 Project Management

Sections of platforms or pipes that may
foul can be identified and installed after
column erection.
A suitable section on an L&P extension
can be identified and marked on the draw-
ings so that those portions are installed af-
ter vertical installation of the column. This
will help avoid clashing with slings and lift-
ing tackles during lifting. An advance lifting
study should be performed for large/heavy
process columns to avoid later changes.
Transportation scheme. A transporta-
tion study should be performed to iden-
tify possible clashing during shipping,
along with the dressing condition. Gener-
ally, these columns will be placed on the
transportation saddles during shipping
and dressing.
The transportation saddle design
should consider both sea acceleration and
road transport acceleration values, as these
values will be used for both dressing and
transport with the SPMT to the final lifting
location at the site. TABLE 1 shows the typi-
cal accelerations to be considered for the
different cases. Adequate lashing points on
the transportation saddles must be identi- BRIJESH KUMAR SHARMA is a Mechanical Engineer
at Fluor Daniel India Pvt. Ltd. He holds a BE degree
fied by a logistics consultation for fastening in engineering from the Sant Longowal Institute
during shipment by sea or road (FIG. 7). of Engineering and Technology in Longowal, India.
Takeaway. The importance of good con- AVADHESH BAHADUR is a Mechanical Engineer
ceptual and preliminary designs in the de- at Fluor Daniel India Pvt. Ltd. He holds an MTech
degree in engineering from the Indian Institute
velopment of safe and cost-effective lift- of Technology in Kanpur, India and is a member
ing and transportation procedures have of the Institute of Mechanical Engineers (UK).
been examined here, with the following
key takeaways:
• During the initial phase, it is
necessary to design the lifting
attachments (trunnion, lugs, etc.) for
ease of construction and installation.
• Incorrect selection of rigging
arrangement and lifting tackles
(e.g., inadequate size of sling,
shackles and spreader beams) may
lead to damage of components,
structural failures or personal injury.
• Such failures may have major
impacts on the project cost and
schedule.
LITERATURE CITED
1
American Society of Mechanical Engineers,
“B30.20/BTH-1: Below-the-hook lifting devices,” FIG. 7. Lashing points shown on transport
New York, New York, 2013/2017. saddles for fastening during shipment.

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 Maintenance
and Reliability
A. PANCHAL, Reliance Industries, Mumbai, India;
R. CARMONA, Fluor Daniel, Philippines; K. DARU,
Fluor, Sugar Land, Texas; J. DESAI, Fluor Daniel
Pvt. Ltd., New Delhi, India; M. IRFAN, Fluor Arabia
Ltd., Saudi Arabia; and C. SHARGAY, Fluor
Enterprises, Aliso Viejo, California

Fabrication of clad equipment and piping—Part 2

For pressure vessels, heat exchangers
and piping in corrosive services, the ma-
terials in contact with the process are of-
ten required to be high alloys to provide
a reliable service life. When the design
conditions call for thick walls, the use
of carbon or low-alloy steel (LAS) clad-
ding—or overlaying with a high alloy—is
often a significant cost savings compared
with the use of solid high alloys. Part 1,
published in the February issue of Hydro-
carbon Processing, discussed the various
manufacturing processes for clad plates
and pipes, along with factors that affect
the decision between using cladding vs.
weld overlay. Part 2 will discuss weld pro-
cedure qualifications, production testing,
the welding of internal attachments and
the clad pipe manufacturing process.
Considerations: Cut-back and thick-
ness. The following provides consider-
ations for when cut-back impinges on the
backing material’s required thickness. As
discussed in Part 1, ASME code (Section
VIII, Div. 1 and Div. 215) allows cladding
or overlay to be considered in strength
calculations. However, additional provi-
sions must be taken into account, and
even when the primary cladding or over-
lay layer is not being used as “credit” in
meeting the minimum thickness require-
ments, there are cases where the cut-back
depth impinged on the backing material
design thickness. Therefore, some of the
back cladding is being used as part of the
code design thickness. One impact is that
this affects the weld procedure specifica-
tion (WPS) qualification requirements,
and specifically whether it needs to be
qualified per ASME Section IX,16 Para.
QW-217(a) or (b), which are described
further in this article. FIG. 9. illustrates
the steps in analyzing UCL-23 require-
ments.
Condition 1: Cladding and back
cladding not considered for strength
purposes. As shown in FIG. 9, if the avail-
able backing material thickness at the un-
dercut (Tbc) is greater than the minimum
required thickness (Tr) under all loadings
before corrosion allowance is added, then
the cladding or back cladding is not be-
ing used for strength purposes (e.g., Tbc
≥ Tr). The welding procedures for such
weld detail can be qualified either per
QW-217(a) or (b) per Section IX. When
both options are acceptable, most proce-
dures are qualified per QW-217(b).
Condition 2: Back cladding needed
for strength purposes. If the remaining
backing material thickness is not enough
to meet minimum ASME requirements,
then appropriate thickness equal to
Tuc consisting of back cladding CRA
filler metal may be utilized for strength.
The method of including cladding for
strength purposes is given in ASME
Code Par. UCL-23(c). This practice has
also been confirmed by Code Interpreta-
tion VIII-80-17.17 According to the code,
an equivalent undercut thickness equal
to Tuc × Sc/Sb (allowable stress for clad-
ding at the design temperature/allow-
able stress for the base metal at the de-
sign temperature) may be considered for
strength (e.g., Tuc × Sc/Sb + Tbc must be
≥ Tr). This case will require welding pro-
Outside
Tbc
Tuc a
Inside
FIG. 9. Sketch of a back-cladded weld.
Note: Tbc is the base metal thickness at
the back-cladding area; Tuc is the intentional
undercut thickness at the back-cladding
area; and a is the cut-back length.
cedures for alloy weld overlay to be quali-
fied per QW-217(a), as qualification per
QW-217(b) is not allowed.
According to the code, if the cladding
is by weld metal overlay cladding, then
the allowable stress of the wrought mate-
rial—the chemistry of which most close-
ly approximates that of the back cladding
at the design temperature—can be used
for Sc. If back-cladding overlay is con-
sidered for strength (e.g., the base metal
thickness is not adequate for strength as
per UCL-35(c) of the ASME Code VIII,
Division 1), then the final radiography of
the base metal welds must be performed
after the disposition of the back cladding
weld overlay.
Weld procedure qualification. If clad-
ding or back cladding is used for strength
purposes, then the welding procedure
(e.g., the WPS) shall be qualified in ac-
cordance with ASME Section IX, QW-
217(a), which requires that:
Hydrocarbon Processing | MARCH 2019 71
 Maintenance and Reliability
• The procedure qualification record
(PQR) test coupon should be
made using clad coupons, which
are the same p-number base metal
and cladding as the production
welding, and should use the same
welding process and filler metal
combination as will be used in
production welding.
• The essential and nonessential
variables—per Section IX,
QW-251.1—and the referenced
tables should apply for each welding
process used in production.
• The qualified thickness range for
the base metal and filler metal(s)
should be based on the actual test
coupon thickness and QW-451,
except that the minimum thickness
of the filler metal joining the
Attachment directly Attachment welded
welded on cladding on weld overlay
FIG. 10. A lightly loaded internal attachment is
shown directly welded to the cladding (left).
The cladding has been stripped back (right),
a weld overlay has been applied and the
attachment is welded to the weld overlay.
FIG. 11. Clad pipe manufacturing process.23
72 MARCH 2019 | HydrocarbonProcessing.com
cladding portion should be based
on a chemical analysis performed
in accordance with Table QW-
453. Tensile and bend tests are
required, which should be made
using specimens that contain full
thickness of cladding through a
reduced section of the specimen.
If cladding and back cladding are not
used for strength purposes, the welding
procedure shall be qualified using ASME
Section IX, QW-217(a) or (b), and (b)
allows two separate qualifications—one
for the base metal welding and an overlay
WPS/PQR to qualify the back cladding.
It also requires that:
• The essential variables and
testing requirements for butt-
weld qualifications should apply
for joining the base metal portion
of weldment. The PQRs, which
support the base metal portion of
the WPS, need not be made on the
test coupons made with clad metal.
• For the back cladding, which is
qualified using a corrosion-resistant
overlay PQR, QW-217(b) refers to
QW-251.4 for the special welding
essential variables. QW-251.4 then
refers to the set of tables defining
the essential and nonessential
variables, which are tables QW-252
through QW-267. Separate tables
are provided for corrosion-resistant
overlays for each welding process.
QW-251.4 then refers to the set
of tables defining the essential
and nonessential variables
(e.g., tables QW-252 through
QW-267). Separate tables are
provided for corrosion-resistant
overlays for each welding process.
• Using the shielded metal arc
welding (SMAW) process and
Table QW-233.1, the amperage
for the corrosion-resistant overlay
is an essential variable. The table
defines QW-409.22 as essential,
and QW-409.22 states that an
increase in the amperage for the
first layer of more than 10% of that
qualified requires requalification
of welding procedure.
• For overlay qualifications, the
required PQR testing is shown in
ASME Section IX, Table QW-453.
The testing includes penetrant tests,
bend tests and chemical analysis.
The chemical analysis is typically
determined by extracting chips
from the deposited overlay at a
predetermined depth above the
weld interface—which is explained
in ASME Section IX, Figure
QW-462.5(a).
Production testing. In addition to the
nondestructive examination (NDE) re-
quired by the design code, such as ASME
Section VIII, some owners specify pen-
etrant or magnetic particle testing and
chemical analysis of production overlays
and back claddings. One example of the
chemical analysis testing for back cladding
would be to require sampling at two or
three locations per the long seam and cir-
cumferential seam, as well as at each nozzle
weld. This testing is required to be done at
a specified depth below the surface that
is in contact with the process. A portable
positive materials identification (PMI)
analyzer is typically used. The chemi-
cal analysis is generally required to meet
the specified levels of the major elements
for the undiluted weld chemistry. The
chipped or ground-down test locations of
the production overlays are later restored
(e.g., repaired) using the same overlay
weld procedure followed by an NDE.
If the backcladding alloy far exceeds
the cladding alloy, such as when Ni-based
welding filler metals are used to back clad
welds between 410S SS clad plates, the
criteria for the chemical analysis testing
 Maintenance and Reliability

can be reduced. For example, it is com-
mon to increase the limit on the maxi-
mum iron in the Ni-based back cladding
weld from a maximum of 5% to 10%.
Another possible test on weld overlays
or back claddings made with austenitic
SS is the ferrite number (FN). The pur-
pose of the test is that, if the weld metal
has a high ferrite phase content, it may
be susceptible to sigma embrittlement,
as ferrite can transform to sigma from
high temperature exposure. Hence, test-
ing for the maximum ferrite number is
generally required if the equipment is
required to be PWHT or is operating at
a high temperature. A minimum ferrite
is also beneficial, as it minimizes the risk
of hot cracking during welding. A typical
required range of 3 FN–10 FN is used for
most SS grades, except for 347 SS, which
typically has a stricter limit of 5 FN–10
FN.11,18 Ferrite measurements must be
taken before PWHT, if PWHT for the
backing material is being done.
Welding internal attachments to
cladding or overlay. Welding internally
welded attachments on clad equipment
has always been a topic of great interest
and debate. It is unclear when internal
attachments can be attached directly on
cladding, when cladding should be re-
moved, and the area weld overlaid before
internal attachments can be welded.
Only lightly loaded attachments are
typically welded on the cladding. In the
case of heavily loaded alloy-welded at-
tachments, the cladding at the attach-
ment location is removed first and the
weld overlay is applied. The heavily load-
ed alloy attachment is then attached to
the overlay (FIG. 10). Generally, when an
attachment is to be welded onto the clad-
ding, the bond of the cladding with the
base metal is verified by straight-beam
ultrasonic testing (UT) to confirm that
there is no disbondment at the attach-
ment location.
For vessels with applied linings, the
lining should be stripped back to allow
the attachment to be welded directly to
the backing, unless testing or analysis of
the cladding is shown to be adequate to
carry the load. The attachment shall en-
sure adequate corrosion protection. At-
tachments may be attached directly to
the cladding (vessels constructed from
integrally clad material or weld overlay)
if the primary and secondary stress at the
weld attachment between the support
plate and cladding are acceptable for the
cladding material to the respective code.
As per API RP 582, RP 934-A19 and
RP 934-C,20 which are specifically for
LAS reactors and equipment, internal at-
tachment welding on cladding or overlay
can be performed after PWHT provided
a PQR, or a mockup test shows a satisfac-
tory result of absence of a newly formed
HAZ in the base metal. Whenever the
cladding or overlay is at least 4.8-mm
thick, the risk of forming an HAZ has
been shown to be very low with most
commonly used weld procedures.11,21
Fabrication and welding of clad
ASME B31.3 piping. The manufactur-
ing of large-sized clad pipes (nominal pipe
sizes of 8 in.–36 in.) is typically done by
rolling clad plates and welding the lon-
gitudinal joint from both the inside and

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Hydrocarbon Processing | MARCH 2019 73

 Maintenance and Reliability
outside (FIG. 11). API specification 5LD22
also provides the requirements for clad-
ding where the backing materials are the
pipeline grades of CS.
Special beveling is required to allow
the CS or LAS root pass to be made from
the outside (Step 6). The inside is then
back cladded with CRA (Step 7). This re-
quires a special welding arm that is long
enough to reach into at least half the pipe
length. The CS or LAS weld is then com-
pleted from the outside (Step 8). Heat
treatment is also typically done, which is
not shown in FIG. 11.
As per the ASME Piping Code 31.3,
Paragraph 323.4.3, fabrication by welding
of clad piping must meet ASME Section
VIII, Division 1, Par. UCL-30–UCL-52,
and the piping code (whichever require-
ments are stricter). For the welding of cir-
cumferential butt welds, some welds will
have access available to the inside surface,
and some will not. Welds between the
pipe and flanges are an example of a circ
weld with access to the inside surface. For
these welds, the same cut-back, beveling,
welding, back cladding and other steps
done for vessel welding can be done for
these pipe welds.
For the circ welds that do not have
access to the inside surface, an appropri-
ate CRA filler metal is used for the entire
weld (e.g., through both the cladding and
backing layers). In many cases, Ni-based
filler metals are used.
The pipe fittings and flanges are typi-
cally overlaid in the clad piping systems.
The overlay procedures must be properly
qualified, and the production overlays are
generally tested using penetrant or mag-
netic particle testing, along with chemi-
cal analysis sampling. The discussion on
vessel flanges and nozzles is also applica-
ble to these components. Branch connec-
tions especially need careful procedures
and NDE with clad piping fabrication, as
it is essential that no areas of CS or LAS
are left exposed. When set-on weldolets
or sockolets are used for the branches, it
is essential that the bore of the hole made
through the main pipe is overlaid.
Small-diameter piping is impractical
to get as clad or overlay. Hence, an ap-
propriate solid alloy is often used for the
systems where the larger-diameter piping
is overlaid.
Takeaway. The use of cladding and
weld overlay are excellent techniques to
74 MARCH 2019 | HydrocarbonProcessing.com
provide corrosion-resistant properties,
while most of the thickness is a less-ex-
pensive, non-alloyed base metal. Howev-
er, there are various possible issues with
code compliance and proper fabrication,
which should be specified and addressed
at the start of the design to ensure reli-
able service.
REFERENCES
15
API Specification 5LD, “Specification for CRA Clad
or Lined Steel Pipe,” American Petroleum Institute,
Washington, DC, March 2009.
16
Nishimoto, K., T. Aizawa, S. Takimoto and W.
Kawakami, “Recent technology development and
manufacturing experiences of clad steel pipe for
natural gas transportation pipelines,” Japan Steel
Works ( JSW) Technical Review, No. 20.
17
Harris, M. K., Welding Health and Safety: A Field
Guide for OEHS Professionals, AIHA Press, American
Industrial Hygiene Association, Fairfax, Virginia,
2002.
18
API Technical Report 942-B, “Material, fabrication
and repair considerations for austenitic alloys subject
to embrittlement and cracking in high temperature
565°C to 760°C (1050°F to 1400°F) refinery ser-
vices,” American Petroleum Institute, Washington,
DC, November 2017.
19
API Recommended Practice 934-A, “Materials
and Fabrication of 2¼Cr-1Mo, 2¼Cr-1Mo-¼V,
3Cr-1Mo, and 3Cr-1Mo-¼V steel heavy wall
pressure vessels for high temperature, high pres-
sure hydrogen service,” American Petroleum
Institute, Washington DC, May 2008 (addendum
March 2012).
20
API Recommended Practice 934-C, “Materials and
fabrication of 1¼Cr-½Mo steel heavy wall pressure
vessels for high temperature, high pressure hydro-
gen service operating at or below 825°F (441°C),”
American Petroleum Institute, Washington DC,
May 2008.
21
ASME PCC-2, “Repair of pressure equipment and
piping,” American Society of Mechanical Engineers,
New York, New York, February 2015.
22
API Specification 5LD, “Specification for CRA clad
or lined steel pipe,” American Petroleum Institute,
Washington, DC, March 2009.
23
Nishimoto, K., T. Aizawa, S. Takimoto and W.
Kawakami, “Recent technology development and
manufacturing experiences of clad steel pipe for
natural gas transportation pipelines,” Japan Steel
Works Technical Review, No. 20.
ANILKUMAR PANCHAL is a
Mechanical Design Engineer with
the Technical Services Group at
Kuwait Integrated Petroleum
Industries Company (KIPIC). When
this article was written, he was
employed with Reliance Industries
Ltd. Mr. Panchal has worked on butyl rubber,
gasification, ethane cracker, chlorinated PVC and
refinery revamp projects. He is a certified chartered
engineer and professional engineer in India, and has
prior work experience at L&T Heavy Engineering,
Bechtel India, Jacobs Engineering and Reliance
Industries. Mr. Panchal holds a BS degree in
mechanical engineering from Lalbhai Dalpatbhai
College of Engineering (LDCE) in Ahmedabad,
India, and an MS degree in industrial process
equipment design from Sardar Vallabhbhai National
Institute of Technology (SVNIT) in Surat, India.
RYAN KATIGBAK CARMONA is
a Mechanical Engineer specializing
in the area of static equipment
engineering and design. His key
interests are material selection
and the design of static equipment
like columns, reactors and vessels,
as well as the structural design of equipment
platforms. Mr. Carmona has a BS degree in mechanical
engineering from Batangas State University in the
Philippines.
KUNTAK DARU is a Technical
Director in Mechanical Engineering
at Fluor Corp. He has more than
30 yr of experience in the
engineering, designing and
specifying of static equipment
in the refinery, oil and gas,
petrochemical and chemical industries. He now
serves as a mechanical coach for Fluor in the
Asia-Pacific region, where he oversees the regional
work and the training of personnel in static equipment
design. Mr. Daru has produced five publications in his
field, and holds a BS degree in mechanical engineering
from SVNIT in Surat, India.
JIGNESH DESAI is a Senior Design
Engineer for Materials and Welding
in the Mechanical Engineering
department at Fluor Daniel Pvt. Ltd.
in New Delhi, India. He has more than
20 yr of experience in equipment
and piping engineering (metallurgy,
welding, fabrication, coating and testing) in the field of
refining, gas processing, petrochemical and power
plant projects. He has produced five publications in his
field, and earned a BS degree in metallurgical
engineering from the Faculty of Technology and
Engineering at the Maharaja Sayajirao University of
Baroda in India. Additionally, his professional
qualifications include International Welding Engineer
from the International Institute of Welding, NACE
Protective Coating Specialist–2 Advanced, and Lead
Auditor QMS ISO 9001-2008 from IRCA.
MUHAMMAD IRFAN is a Mechanical
Engineer specializing in the area of
static equipment engineering. He
has participated in various green
and brownfield upstream/
downstream projects for the oil and
gas/refining/petrochemical sectors.
His specialty is in the mechanical design of pressure
vessels, columns and reactors, and in the thermal
design of shell-and-tube heat exchangers. He has a
thorough understanding of ASME, API, TEMA and
NBIC design codes and standards. He is actively
involved in giving technical trainings to junior
members of his organization. Mr. Irfan has a BS degree
in mechanical engineering from NED University of
Engineering and Technology in Karachi, Pakistan.
CATHLEEN SHARGAY is a Senior
Fellow and Technical Director in the
Materials and Welding Engineering
group at Fluor Enterprises in Aliso
Viejo, California. Over the span of her
35-yr career, she has specialized
in corrosion, metallurgical damage
mechanisms, materials selection and fabrication for the
refining, power and other process industries. She has
produced more than 60 publications in her field. Ms.
Shargay has a BS degree in metallurgical engineering
from Stevens Institute of Technology.

Application of ring-type joint gaskets in a refinery
In refineries and petrochemical plants,
ring-type joint (RTJ) flanges have been
applied to high-pressure processes or sen-
sitive areas that are susceptible to leaks.
In an RTJ flange, the bolt tightening load
should be calculated and applied carefully
to achieve good sealing performance and
to avoid flange deformation with over-
tightening. However, a deviation exists
between theoretical bolt load values and
actual application—many maintenance
personnel have experienced leak incidents
by applying only the theoretical bolt load
value, leading them to apply a higher bolt
load value than its criteria requires.
In most cases, the root cause of the
leak incident was not a bold load crite-
rion, but concerns about applying this
value remain. Field personnel generally
believe that a higher tightening load is
more effective to achieve good sealing
performance in a flange joint. While this
technique is not technically incorrect, ex-
cessive tightening can lead to increased
flange deformation damage.
The RTJ flange is normally used to
design a heavy wall item with low-alloy
materials, so it is difficult to repair or re-
place within a short turnaround period.
Additionally, repair costs are expensive.
This article explores adequate and prac-
tical criteria to maintain the sealing per-
formance of flange joints and to minimize
flange deformation.
A test spool was manufactured with
flange damage cases, and finite element
method (FEM) analyses were carried out
to check performance. The work deter-
mined that the bolt load criteria could be
adjusted effectively and successfully ap-
plied to the maintenance work of the resi-
due desulfurization process. No leaks were
Maintenance
and Reliability
S. LEE, S. H. LEE and S. JEON, SK Energy,
Ulsan, South Korea; and T. Y. JANG, SK Innovation,
Daejeon, South Korea
detected, and no re-tightening was needed gasket is advantageous
during startup and normal operation. for sealing performance.
• Ring gaskets can be reusable;
Challenges. RTJ flanges require great however, in practice, gaskets
care in handling, such as bolt tightening have been used without
or the cleaning of the sealing face, and are detailed inspection.
used in some high-pressure petroleum To remedy these issues, simulation
processes [over the American Society test spools reflecting variation cases were
of Mechanical Engineers (ASME) Class made, and the sealing performances of
1500 rating], or in petrochemical pro- each bolt load were confirmed. In addi-
cesses containing hydrogen (H2). tion, FEM analysis under similar con-
Normally, the recommended bolt load ditions was conducted and compared.
value is based on the flange design value Based on this, the management plan for
determined during the initial design, so an RTJ flange was derived and applied to
the bolt load value is different even though a residue hydrodesulfurization (RHDS)
the same bolt size and material are used. process turnaround work. The applica-
Despite the theoretical bolt load crite- tion result was successful.
rion, maintenance technicians may apply
an excessive bolt load to prevent leaks. SIMULATION TEST
This has consistently resulted in flange Test spools with artificial defects were
deformation or damage to the gasket seal- fabricated under the following condi-
ing face, leading to leaks. While many tions. Artificial defects were applied to
maintenance personnel are aware of this, one flange in each pair of flanges (FIG. 1
such errors continue to be prevalent. Af- and TABLE 1).
ter interviewing numerous maintenance • Simulation test condition: Flange
personnel, the following shared view- test spool (FIG. 1)
points emerged: O Flange: 8-in., Class 2500 ×
• Bolts should be tightened more Schedule 160 standard flange,
strongly than their given bolt load A105 Tp321
to improve sealing performance. O Gasket: Tp347 octagonal type,
• Applying graphite tape on the ring R-51
TABLE 1. Damages reflected (refer to FIG. 1, shown as red colors)
Flange 1 Flange 2 Flange 3 Flange 4 Flange 5
Damage A at No 1-mm 2-mm 3-mm 1-mm
inner groove depth* depth* depth* depth*
Damage B at No No 1.3-mm depth 0.7-mm depth 1-mm depth** +
outer groove at four points at four points 1.3-mm depth
at four points
Gasket New New New Used New
* Around entire circle ** Around a half circle
Hydrocarbon Processing | MARCH 2019 75
 Maintenance and Reliability

O Bolt: A193-B16 • Bolt tightening Simulation test results. For all flanges
• Pressurizing condition O The initial bolt load value was with various damages, no leakage was de-
O Pressure was increased slowly 20% of the yield strength (YS), tected when applying up to 40% of the YS,
to 300 bar and then maintained which gradually increased by as detailed in TABLE 2.
for 1 hr. If leaks occur during 10% when the leaks occurred • Flange 1: Leakage occurred
pressurization, then the bolt load and stopped when it reached when 20% of the YS was applied
is increased by 10%. 50% of the maximum YS. and pressure reached 250 bar.
When the bolt load was increased
TABLE 2. Simulation test results to 30% of the YS, no leak was
detected, even at 300 bar.
Flange 1 Flange 2 Flange 3 Flange 4 Flange 5
• Flange 2: No leakage occurred at
Graphite Old gasket 300 bar at 20% of the YS. However,
Flange No compound on gasket – used –
as a result of this, it is difficult to
Pressurizing 20% of YS, 20% of YS, 20% of YS, 20% of YS, 20% of YS, conclude that the effect of graphite
to 25 bar no leak no leak no leak no leak leak
wrapping on the gasket was effective.
~ 200 bar 20% of YS, – 20% of YS, 20% of YS, 30% of YS, • Flange 3: Leakage was evident
no leak leak no leak no leak at 200 bar at 20% of the YS,
~ 250 bar 20% of YS, – 30% of YS, 20% of YS, 30% of YS, but no leakage occurred at 300 bar
leak leak leak no leak at up to 40% of YS.
~ 300 bar 30% of YS, 20% of YS, 40% of YS, 30% of YS, 30% of YS, • Flange 4: Leakage occurred
no leak no leak no leak no leak no leak when the YS reached 20% and
the pressure reached 250 bar.
TABLE 3. FEA modeling case When the YS was increased to 30%,
no leakage was detected at 300 bar.
Flange 1 Flange 3 Flange 4 Flange 5
Yield • Flange 5: A leak occurred at 25 bar
strength With Damage A With Damage A and B under tightening at 20% of the YS,
20% Case 1-1 Case 2-1 Case 3-1 Case 4-1 but no leakage was detected at
Bolt stress 30% Case 1-2 Case 2-2 Case 3-2 Case 4-2 300 bar at 30% of the YS.
40% Case 1-3 Case 2-3 Case 3-3 Case 4-3
FEM analysis. The stresses on the con-
50% Case 1-4 Case 2-4 Case 3-4 Case 4-4
tact surface while increasing the bolt load
60% Case 1-5 Case 2-5 Case 3-5 Case 4-5 for the four cases were analyzed: no dam-
age, 2-mm damage, 3-mm damage, and
damage of 1-mm inside and 1-mm out-
side. For FEM modeling (TABLE 3), Flang-
es 1, 3, 4 and 5 with only Type-A damage
were considered. The bolt load was gradu-
ally increased from 20% of the initial YS to
60% of the YS. As shown in FIG. 2, the R-
type gasket has four sealing lines at the top,
bottom, right and left. A flange and groove
details are shown in FIG. 3.

FIG. 2. The R-type gasket has four sealing

FIG. 1. Test spool and flanges for simulation test. lines at the top, bottom, right and left.

76 MARCH 2019 | HydrocarbonProcessing.com
 Maintenance and Reliability

Analysis result. The FEA determined
that the upper flange has the largest stress
concentration in the center part of the
gasket and the inside groove, and the seal-
ing line of four faces is formed. As the bolt
load increased, the stress in the two seg-
ments (A and C in FIG. 4) of the inside of
the four contact surfaces increased. The
FEA results for Flange 1-1 indicated no
damage. The four points were stressed
almost evenly, but Areas A and C experi-
enced slightly increased stress while the
bolt load increased.
Flanges 1-3 and 1-4 experienced dam-
age in Area A only, and a similar tendency
was observed. The inside groove face of
the upper flange and the outside groove
face of the lower flange experienced
stress, and the sealing line was formed
(FIG. 5). For Flange 2-3, the damaged
Area C with gap was not contacted. It is
believed that stresses are concentrated in

FIG. 3. Flange and groove details.

 PRESSURE VESSELS
HEAT EXCHANGERS

 PROCESS
TECHNOLOGY
FIG. 4. FEA results for Flange 1, which is not damaged. Four points have stressed almost evenly,
but Areas A and C indicate slightly higher stress levels while the bolt load increases.  BALL VALVES

www.borsig.de
BORSIG GmbH
Phone: + 49 030 4301-01
Fax: + 49 030 4301-2236
E-mail: info@borsig.de
Egellsstrasse 21
13507 Berlin
Germany

FIG. 5. FEA results for Flange 3.

Select 156 at www.HydrocarbonProcessing.com/RS

 Maintenance and Reliability

TABLE 4. Calculated stress in four areas

Flange 1 Flange 3
Area Case 1-1 Case 1-2 Case 1-3 Case 1-4 Case 1-5 Case 2-1 Case 2-2 Case 2-3 Case 2-4 Case 2-5
A 143.9 215.6 287.1 358.7 430.2 249.4 373 494.8 616.7 737.2
B 145.7 218.1 288.1 347.8 409.3 118.1 177.7 236.1 295.5 354.5
C 143.8 215.4 287.1 358.7 430.2 Non-contacted
D 146 218.5 287.8 347.7 409.6 264.4 387.5 506 630.4 759.1

TABLE 5. RTJ bolt load application guide per groove deformation

Groove damage Normal
(deformation gap) flange ~ 1 mm
Bolt load YS × 35% YS × 40%
FIG. 6. FEA results for Flange 5. In the stress distribution along the bolt stress, large and
complicated stress distributions can be seen due to the unbalanced groove deformation.
Areas A and D and that the sealing line is
formed through these areas. When more
bolt load is applied, a possibility exists for
the forming of a sealing line in Area B due
to plastic deformation.
A sealing line is also formed on the
outside groove surface of the upper flange
and on the outside groove surface of the
lower flange. Only the inside groove sur-
face of the lower flange is not formed with
1 mm~2 mm 2 mm~3 mm 3 mm
YS × 45% YS × 50% Flange
replacement
tributions can be seen due to the unbal-
anced groove deformation. It is assumed
that only elastic deformation occurs,
but plastic deformation actually occurs,
which is expected to result in sealing in
more areas than FEA results.
It was decided to apply different bolt
load values according to the groove de-
formation amount (TABLE 5). As a result
of application to 68 flanges in the high-
distortion of grooves. Even in the
severe damage case, applying 40%
of YS was enough to cause sealing.
3. A relatively high stress is
applied to the inside grooves
in a normal flange.
4. If at least two contact surfaces
each act as an inside and outside
sealing point, leakage is eliminated
since these two contact surfaces
form the sealing line.
5. It can be determined that the bolt
load standard value is basically
35% of the bolt YS, regardless
of the degree of deformation,
and it would be increased by 5%
according to the degree of the
groove deformation.
6. A thinly applied compound
is recommended to act as a
lubricant during the placing
process. Gasket reuse and graphite
wrapping are not recommended
since their effect cannot be ensured
for long-term usage.
SANGMO LEE is the Pressure Vessel Specialist at
SK Energy and has more than 24 yr of experience
providing technical support for numerous large
projects. He earned a BS degree from the University
of Ulsan and holds a Professional Engineer certificate
for welding and metallurgy.
SEHO LEE is a Stationary Equipment Engineer at
SK Energy in South Korea. He has more than 7 yr
of petrochemical industry experience, specializing
in pressure vessel and flange leak troubleshooting
and maintenance. He graduated with a BS degree
in mechanical engineering from Inha University
in South Korea.

the sealing line due to the damage. The
three points (A, B and D) that are con-
tacting in Flange 3 are approximately 1.7
times more stressed than Flange 1, which
is contacted with four points (TABLE 4).
For Flange 5, the formed stress appears
to be very unstable. Stress is distributed
unevenly on the gasket and the flange of
the normal and damaged parts, which
leads to an unstable sealing line (FIG. 6).
In the stress distribution along the bolt
stress, large and complicated stress dis-
pressure sections of the RHDS unit, no
leakage has been detected in startup and
normal operations.
Takeaway. The following results were
obtained:
1. RTJ flanges showed excellent
sealing performance in the
simulation tests and FEA results.
2. Sufficient sealing performance
can be obtained with a bolt load
applying 20% of YS, if there is no
SEOKRYONG JEON is the Leader of the stationary
equipment engineering team. He has more than 24 yr
of experience in reliability and project management
for refinery and petrochemical plants. He earned an
MS degree in metallurgical engineering at Hanyang
University in South Korea.
TAE YOUNG JANG is a Senior Researcher at the
SK Innovation Institute of Technology Innovation
in Daejeon, South Korea. He has more than 11 yr of
petrochemical industry experience, specializing in
computational fluid dynamics and finite element
analysis. He received an MS degree in mechanical
engineering from the Korea Advanced Institute
of Science and Technology (KAIST).

78 MARCH 2019 | HydrocarbonProcessing.com

The critical maintenance team: Do you have one?
Larger plants typically have planners and maintenance super-
visors onsite, as well as operations personnel. But are they formed
as a team? Do they make decisions as a team? Does the alignment
of the maintenance workflow process and computerized mainte-
nance management system (CMMS) support the team?
It is common to see pieces of the above. However, their
performance is too often fragmented, with some areas/depart-
ments doing well while others underperform. Telltale negative
signs include:
• Maintenance planners reporting to area maintenance
supervisors and receiving no centralized best planner
practice leadership
• Maintenance supervisors with a focus on the emergencies
of the day and with little time allocated for helping
plan and schedule the next week’s schedule
• Planners who specialize in emergency parts acquisition
and who are, in effect, junior maintenance supervisors
• Operations customers who come to maintenance from
numerous positions with conflicting requests and a
universal demand of “fix it now”
• A workflow process that has gaps and workaround
avenues, often frequently modified to meet ever-changing
conditions and perceived needs
• A poorly used or constructed CMMS that hinders, rather
than helps, work management
• Management staff members who are frustrated with
poor metric results that indicate high levels of emergency
work, raising costs and declining reliability—e.g.,
key performance indicators (KPIs) have become key
indicators of poor performance.
In 2006, a small group of maintenance consultants looked at
available practices to correct some of the shortfalls common in
the field of work management. What they found included lim-
ited training courses for planners, along with supervisors receiv-
ing only leadership pep talks, and operations personnel with no
maintenance training at all.
The consulting group began with planners. The traditional
4-hr planner training session was significantly expanded to near-
ly a full week. Note: This training was not focused on how to use
a CMMS. Rather, planners were assumed to know their CMMS,
including the important area of securing parts. Their previous
knowledge would now feed a key component of the much larg-
er work management process. What started as a training effort
grew into a certification, awarded only after the classroom train-
Maintenance
and Reliability
G. THORMAN, Independent Consultant,
Osceola, Wisconsin
ing and testing, coached field implementation of new skills and
a final audit were successfully completed. Planners came away
from this training with an all-inclusive perspective of what the
planning and scheduling role should be.
However, components were still missing, since planners do
not operate in a silo. The work they plan is typically requested
and scheduled by operations personnel. The maintenance su-
pervisor then executes the work and captures the results, return-
ing the work orders to planners for closure. A successful work
management plan requires all of these entities to be cohesive
and group focused. This training is not just focused on roles, but
also on the team. This led to the team being aptly identified as
a natural work team using a well-defined process. Each of the
three entities received not only training for their respective roles,
but also training on how to operate as a team, followed by indi-
vidual field coaching, along with an audit of role performance
and the desired certification.
Contributing to the training’s success was its verification
through a closed-book test, which became the portal to confirm
the training and prove that the candidates were ready to apply
their new tools in the field. Candidates who did not meet the
minimum score received personal coaching before retaking the
test. As with many of life’s endeavors, the testing became quite
competitive. Scores were kept confidential, but candidate chat-
ter usually revealed who got the highest scores—all of which
added to the excitement of the process. The ending audit and
certification as gold, silver or bronze in the field of maintenance
planner, maintenance supervisor or operations maintenance co-
ordinator were equally competitive.
Over the years of natural work team training, few candidates
have withdrawn from the process, and few candidates who have
been driven to succeed and reach certification have failed. Since
the process is made up of teams, team awards are also given based
on the lowest certification of any of the team’s members. This
promotes achievement of team members for the team’s benefit.
If a natural work team training process is being considered,
the following are several details of the process design.
Prelude to training. The week before the process begins is
crucial, as it sets the expectations and deliverables. Typically,
a review of the candidates and management’s goals begin with
1-hr presentations to key personnel, at times including the en-
tire site. The presentations cover topics such as training, coach-
ing, and the final audits and certifications (FIG. 1). They also de-
Hydrocarbon Processing | MARCH 2019 79
 Maintenance and Reliability

Classroom Written In-field Process Results and

Assessment
training exam coaching audit certification

Individuals Group Individuals Individual/group Organization Customer

• Assess P&S • 3 d–4 d • Based on classroom • 10 wk–20 wk • 1 d–3 d per work • Each member receives
organization •Single-point lessons training document • Daily and weekly team member a certificate for the level
• Evaluate planner, (100+) • Go/no-go for scheduling meetings • 35 technical topics and reached
supervisor and • Exercises certification implementation eight management • Meeting with P&S client
coordinator • Start work on • Documentation • Team backlog review topics project leader and
capabilities team meetings, not allowed • Scheduling tool • Score provided for each individual planners to
• Evaluate training weekly agenda, • 75% required to pass; • P&S performance topic for the group present results
and coaching needs, backlog review, retests are allowed indicators average and individual • Identify with client
aligned with current scheduling tool, • Certificate • Transfer of best needs for retraining,
plant-desired practices KPI development, practices recoaching or additional
• Define performance etc. support
measurements
• Conduct white board
exercise to capture - Audit score ≥ 80%
existing maintenance Gold
workflow processes - Audit score ≥ 70%
• Introduce with Silver
kickoff presentations - Audit score ≥ 60%
Bronze
Not certified - Audit score < 60%

FIG. 1. The work team certification process.

tail the “why” of such a process being implemented and how the
entire plant benefits. If a union is involved, a presentation is of-
fered to help the union better understand what the certification
benefits are for its members (often if there are hourly planners).
In addition, union craftsmen will learn how a certification pro-
cess allows them to experience better-organized jobs with less
emergency job pull-offs. The pre-week session includes a white-
board exercise diagramming the work process flow. Partici-
pants—including maintenance and operations personnel—can
see the gaps and workarounds that often exist in the work pro-
cess flow. These gaps then become notable points during the
classroom training and underscore the need for a robust work
management process managed by trained participants.
Classroom training. The training portion of the project is a
lengthy process averaging more than 30 hr of instruction. Topics
range from how work orders originate and who approves them,
to what is involved in planning, scheduling and execution, and
the completion and closure process. The topics are pre-aligned
with site protocol and adjusted as necessary. If conflicts with
best practices exist, the site may decide on changes or adjust
the training program before it begins. Typically, the program’s
best practices are within 90% of what the site already expects.
The training contains textbook-supplied material in a single-
point lesson (SPL) format, along with videos, spot review ques-
tions and prizes for candidate winners. Exercises cover specific
knowledge topics, including how to calculate a backlog or build
a Gantt chart (TABLE 1). Candidates have never considered the
classroom training boring since the topics always include spe-
cifics to each role (e.g., planner, supervisor, coordinator) while
still benefitting the entire group. The training is for both indi-
vidual roles and completing team objectives.
80 MARCH 2019 | HydrocarbonProcessing.com
Testing. Each test covers elements from the role-specific train-
ing (e.g., the planner test is different from the supervisor test
and the maintenance coordinator test). Typically, the test takes
1 hr–2 hr to complete. A calculator is recommended for deter-
mining backlogs in a man-weeks question. The test results are
not disclosed and are rated as pass/fail—a passing score is 75%.
For candidates who fail to meet the minimum score, retests are
allowed. The test is the portal through which candidates must
successfully pass to begin implementing their new skills, roles
and responsibilities.
Implementation and coaching. The newly certified candi-
dates are ready to implement the skills they have proven they
learned by passing the test. Teams begin by conducting man-
dated daily and weekly scheduling meetings. Coaches often run
the first meetings to ensure that correct protocol is followed, and
then attend the additional meetings to observe and resolve de-
viations. One example is the maintenance supervisor’s report on
the status of a job scheduled for the day. “Almost done,” “nearing
completion” and “about halfway” are unacceptable responses to
a job’s status. The supervisor’s report is expected to use more
precise terms that include percentages (e.g., 0%, 25%, 50%, 75%
or 100%). This process allows the team to understand the status
of the job and to move to the next phase of decision-making if a
job has not been completed. Repetition of this process is key to
sustainability. Other coaching takes place with supervisor crew
line-outs, planner preparation of job packets, coordinator selec-
tions of jobs for the schedule, etc. All coaching will help candi-
dates prepare for audits and final certifications.
Audits. At the end of the implementation and coaching stage,
the coach becomes the auditor and advises that all observable
 Maintenance and Reliability

TABLE 1. Gantt chart exercise example

Hours
Task Duration, hr 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Beginning of project 0
Equipment site cleaning 4
Remove conveyor hoods 4
Remove conveyor belt 2
Remove discharge hopper 2
Replace head pulley 2
Remove loading hopper 3
Replace tail pulley 2
Replace defect rollers 4
Install new conveyor belt 4
Perform belt joint 8
Install discharge hopper 2
Install loading hopper 3
Install conveyor hoods 4
Proceed to no-load testing 2
Process to load testing 2
Critical path
What is the total length of the job? 31 hr  What are the tasks determining the critical path? 2, 3, 4, 7, 8, 10, 11, 15, 16

actions and decisions will be part of the final score and certi-
fication ranking for each candidate. A lengthy form becomes
the checklist to certification by the auditor. Each candidate ar-
ranges an audit period with the auditor, where detailed ques-
tions are asked and documentation is requested by the audi-
tor to verify compliance. The formal audit requires a 1 hr–2
hr individual time slot. Upon completion of the informal and
formal audit, a score will determine if the candidate passes.
Candidates who are dissatisfied with their ranking may request
personal remedial coaching and re-auditing, as allowed and ap-
proved by management. Candidates who want to secure previ-
ously approved multiple-role certifications are given separate
audits for each role.
Certifications. Once all audits have been completed and
scored, candidates are ready to celebrate. Team award plaques
are presented to those teams that achieved recognition. This
team award is coveted, as it reflects how well the individuals
scored as a team, emphasizing that the success of an individual
is only a part of the success of the team. The success of a team is
summarized by how well the group works together for the ad-
vancement of the plant’s entire maintenance and reliability goals.
Sustainability. Because of normal plant personnel turnover,
renewal sessions are often conducted every 2 yr–3 yr with new
candidates. This allows the process to remain embedded with-
in a site’s core group and to become part of its culture. Com-
pleting these sessions usually takes half the time of the original
session, as existing certified members become ad-hoc coaches
and supporters for the new candidates. Renewal sessions are
often accompanied by rechecks of how the overall process is
doing at the site. This status of the process is captured in a man-
agement audit report that highlights any areas that may require
reinforcement. Metrics tend to reflect if the process has con-
tributed to overall plant improvement objectives.
Takeaways. This certification process should contain the fol-
lowing:
• Plant management that is 100% behind the effort
• Principles of best-practice maintenance work
management protocols
• A degree of competition among the candidates,
for which success is then measured by both testing
and scoring
• Certification success that is regarded with a sense
of pride by both management and candidates
• Continuous and random management observations
that help make the process sustainable
• Certification renewal sessions to re-certify existing
personnel and also certify new personnel.
Any plant can implement this process by adhering to these
outlined steps and by developing the appropriate materials.
Past results have consistently shown changes and improve-
ments in workplace cultures and the advancement of positive
relations between maintenance and operations teams. Metrics
and continuous improvement measurements underscore the
benefits of having dedicated teams for planning and schedul-
ing critical maintenance.
GLYN THORMAN has 30 yr of experience in maintenance and
reliability consulting, and was a member of the original NWT
Certification Process team. He has implemented this process at
many facilities to bring their maintenance and operations
perspectives together create a cohesive team solution.
Hydrocarbon Processing | MARCH 2019 81
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 Show Preview LNG2019
A. BLUME, Executive Editor

LNG2019 Shanghai to explore

sustainable energy future
1–5 April 2019
Shanghai, China
• 19th iteration of LNG
conference to take place
in Shanghai, China,
1–5 April 2019
• More than 240 speakers and
250 exhibitors confirmed
• Anticipated attendance
of more than 11,000
delegates from more than
80 countries and
550 organizations
• Conference program
to feature presentations
and key insights by company
leaders, government officials
and industry experts
• Evening networking events
encourage delegates to enjoy
food and entertainment
with colleagues and new
connections
• Experience traditional
Chinese culture within
the modern environment
of Shanghai
The 19th International Conference
and Exhibition on Liquefied Natural Gas
(LNG2019), presented by the Interna-
tional Gas Union (IGU), Gas Technology
Institute (GTI) and the International In-
stitute of Refrigeration (IIR), is the pre-
mier LNG event conducted by the indus-
try for the industry.
Since 1968, the LNG series has grown
into a significant global LNG event, with
the key aim of conducting a strategic, tech-
nical and commercial event for the LNG
industry. The event is held every 3 yr, al-
ternating between exporting and import-
ing countries. In 2019, Shanghai will host
the 19th edition. LNG2019 is supported
by the Shanghai Municipal People’s Gov-
ernment and hosted by the China LNG
Association, the China Gas Society, the
Chinese Association of Refrigeration and
the China Gas Association.
Among the prominent speakers con-
firmed for the opening ceremony of
LNG2019 are the chairmen of China’s
three major oil companies—China Na-
tional Offshore Oil Corp. (CNOOC),
China National Petroleum Corp. (CNPC)
and Sinopec.
Conference program to focus on sus-
tainable energy. In launching the theme,
“LNG for a sustainable energy future,”
LNG2019 focuses on the industry’s chal-
lenge of answering an increasing demand
for reliable and cleaner sources of energy,
with the primary question being: How
does the industry adapt to this changing
landscape? LNG2019 will highlight the
strategic, commercial and technical solu-
tions and discussions taking place within
the industry to create a sustainable and en-
vironmentally considerate energy future.
In the plenary sessions, industry lead-
ers will share experiences, discuss market
challenges and opportunities, and con-
sider the future of LNG. Plenary speakers
will feature representation from leading
global energy companies, government
ministers and other senior-level experts
from outside the industry.

www.lng2019.com

FIG. 1. The Shanghai World Expo Exhibition and Convention Center (SWEECC) welcomes LNG2019.

Hydrocarbon Processing | MARCH 2019 83

 Show Preview: LNG2019

During the spotlight sessions, senior
industry panelists will share their views,
successes and case studies while discuss-
ing the complexities of the industry’s
most topical subjects. At the LNG fo-
rums, expert panelists will explore the
challenges and potential within specific
areas of the LNG industry, sharing case
studies and encouraging the audience to
join the conversation.
Paper sessions will focus on global
industry developments across the entire
LNG value chain. Finally, the research
and innovation showcase will provide a
global platform for the LNG industry’s
latest technical developments. Authors
will present their findings during an inter-
active showcase.
In addition, evening networking func-
tions will allow delegates to network and
make new contacts. A welcome recep-
tion will be held at the Shanghai World
Expo Exhibition and Convention Center
(SWEEC) (FIG. 1) on 1 April, and a net-
working reception will be hosted by Gaz-
prom at the SWEEC on 4 April.

Host city. Home to 23 million people,

Shanghai (FIG. 2) is the largest city in
China. Shanghai is a renowned global
economic hub for finance, trade and ship-
ping. Famous for its impressive skyline,
historic buildings and museums, the city
blends traditional Chinese culture with a
modern environment.

Attending LNG2019. To learn more

about LNG2019’s conference agenda,
speakers, exhibition, host city and China
FIG. 2. Shanghai, the host city for LNG2019, is famous for its impressive skyline, visa information, and to register, visit
historic buildings and museums. www.lng2019.com.

om
essing.c
carbonProc
| Hydro
RY 2019
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84 MARCH 2019 | HydrocarbonProcessing.com
MIKE RHODES, MANAGING EDITOR
Mike.Rhodes@HydrocarbonProcessing.com
Thermal mass flowmeter
for hydrocarbon tank
vapor recovery systems
Engineers tasked with finding a green
solution to waste gas emissions from hy-
drocarbon storage tanks during loading
and unloading operations will find that the
ST100 series thermal flowmeter from Flu-
id Components International (FCI) sup-
ports tank vapor recovery systems, which
help reduce greenhouse gas emissions.
The loading and unloading of hydro-
carbon products at tanker terminals, oil
and gas refineries and chemical plants cre-
ates vapors that must be vented to avoid
hazardous tank overpressure conditions
that can cause a rupture. While gas relief
valve venting reduces the tank overpres-
sure condition, it increases a plant’s carbon
footprint and damages the environment.
Tank vapor recovery systems solve
this dilemma. They gather the excess gas
vapor from tanks and send it to electric
generating stations, where it is fed to large
turbine engines that drive electricity gen-
erating systems. Vapor recovery requires
highly accurate and reliable gas flowme-
ters designed for rugged operating condi-
tions with high turndowns to accommo-
date fluctuations in gas vapor delivery.
FCI’s ST100 thermal mass flowmeter
series can be calibrated to measure the
mixed, dirty hydrocarbon gases result-
ing from tank loading and unloading op-
erations. Featuring a thermal dispersion
technology air/gas flow sensor with op-
tional pressure measurement, this meter
combines repeatable measurement with
feature- and function-rich electronics. It
provides direct gas mass flow measure-
ment and requires no additional sensors
or flow calculating devices. Its no-mov-
ing-parts design also virtually eliminates
wear, breakage and maintenance.
The basic insertion-style ST100 flow-
meter measures air/gas flow from 0.25 ft/
sec–1,000 ft/sec (0.07 m/sec–305 m/sec)
with an accuracy of ± 0.75% of reading, and
± 0.5% of full scale. A wide variety of pres-
sure ranges can be specified, from 0 psig–
1,000 psig (0 barg–70 barg), depending
on the specific model selected to support
the most demanding applications.
When specifying the ST100 meter,
users have multiple communication op-
tions. They can choose from: 4-20 mA
analog, frequency/pulse or certified digi-
tal bus communications, such as HART,
Foundation Fieldbus, Profibus PA or
Modbus RS485. Should a production
field or plant’s communication needs
change, a new, replaceable card can be
swapped out in the field.
Designed with a graphical, multi-
variable backlit LCD display, the so-
phisticated readout of the ST100 meter
(FIG. 1) continuously displays all process
measurements and alarm statuses for easy
onsite viewing by technicians, and it can
query for service diagnostics.
The meter’s electronics include a user-
selectable and programmable data logger.
Readings are stored in a removable, inter-
nal micro-SD card. The micro-SD card
has a 2-GB capacity capable of storing
approximately 21 MM readings. The re-
cording time base is user-selectable, with
a maximum rate of 1 reading/sec. The
logging feature is selectable via the front-
panel menu or via the serial port and con-
figuration software tools.
The feature-rich ST100 meter utilizes
constant power thermal mass flow sensing
technology that measures flow with 100:1
turndowns in ranges from 0.006 ft3/min–
1,850 ft3/min (0.01 m3/hr–3,140 m3/hr).
The transmitter/electronics are integrally
mounted with the flow body or can be re-
mote mounted to 1,000 ft (305 m) away.
The transmitter enclosure is NEMA4X/
IP67-rated and available in painted alumi-
num or stainless steel.
ST100 meters are agency approved for
hazardous environment installations. FCI
products undergo rigorous agency testing
and obtain approvals on the entire instru-
ment, not just the enclosure. Approvals
available for the ST100 flowmeter include:
FM, FMc, ATEX, IECEx, EAC/TRCU,
CPA, NEPSI, InMetro and CE.
Select 1 at www.HydrocarbonProcessing.com/RS
Innovations
FIG. 1. FCI’s ST100 thermal mass flowmeter
series.
New standards for global
purge solutions
Pepperl+Fuchs, a world leader in pro-
cess automation, has introduced an ad-
vanced Bebco EPS purge and pressuriza-
tion system, designed for Class I or II/
Division 2 and Zone 2/22 locations. This
innovative and compact manual or auto-
matic system delivers all the features need-
ed for reliable hazardous location protec-
tion within a small, streamlined solution.
The 7500 series Ex pzc/Type Z purge
and pressurization system can be fully
automatic or manual and purges a com-
mon enclosure of hazardous gas or dust
to maintain positive pressure. It effec-
tively reduces the classification within the
protected enclosure to a non-hazardous
area. The 7500 carries ATEX and IECEx
certifications and is UL listed. It operates
within an extremely small footprint of
only 5.8 in. × 3.8 in. × 1.9 in.
The 7500 Series includes intelligent
automatic monitoring and control of en-
closure pressure with dilution and con-
tinuous flow functionality. The system
makes automatic adjustments and pro-
vides an alarm output for reliable pro-
tection. It is designed in marine-grade
chromate aluminum, making it rugged
enough to withstand the harsh conditions
of many process industries. The 7500
uses universal AC/DC power and is avail-
able as both a panel mount and an exter-
Hydrocarbon Processing | MARCH 2019 85
 Innovations
nal mount. The large touchscreen enables
quick and easy setup while also providing
status LEDs, a bar graph for pressure and
multiple program selections.
Select 2 at www.HydrocarbonProcessing.com/RS
Accurate, reliable
system for bulk level and
density measurements
Tracerco has added to its range of ad-
vanced nucleonic instrumentation with
the launch of Hyperion. Designed using
innovative scintillator-based technology,
Hyperion is a non-contact, no-moving-
parts measurement solution that pro-
vides accurate and reliable bulk level and
density measurements, enabling custom-
ers in the oil, gas, petrochemical, refining
and mining industries to solve their most
challenging process measurement and
control problems.
Externally mounted to eliminate pos-
sible leak paths, this robust solution is
unaffected by adverse process condi-
tions, such as high pressures, extreme
temperatures, fouling or corrosive fluids.
Hyperion also automatically compen-
sates for the effects of ambient tempera-
ture changes, allowing for sustained ac-
curacy and virtually no age-related drift
in its measurements.
Housed in 316L stainless steel as a
standard, Hyperion is rugged, ensuring
FIG. 2. Sulzer’s portable Mixpac Mixcoat Spray
pneumatic dispense system.
FIG. 3. Elfab’s new ASME-certified Flow Lab
test rig.
86 MARCH 2019 | HydrocarbonProcessing.com
that vibrations or dust settling have no
impact on its operation. Internal sealing
also safeguards the condition of Hyper-
ion, even in the event of water ingress.
With an enhanced self-diagnostics
capability and built-in condition moni-
toring, the system can monitor health
status and relative humidity, predict
component failures and provide an end-
of-life estimation. This allows operators
to diagnose potential errors in the mea-
surement, providing a proactive and cost-
effective approach to the planning of any
maintenance on equipment.
Hyperion is Tracerco’s latest addition
to its nucleonic instrumentation portfo-
lio and will provide production, safety
and environmental benefits.
Select 3 at www.HydrocarbonProcessing.com/RS
Spray protective coating
dispensing system
Sulzer Mixpac USA Inc., a leading in-
novator of two-component adhesive dis-
pensing systems, has released its MIX-
PAC MixCoat Spray, a member of the
innovative MIXPAC MixCoat cartridge-
based, two-component dispensing sys-
tem family. The portable Mixpac Mix-
coat Spray pneumatic dispense system is
designed for small-volume applications,
touch-up and repairs, including pipeline
repair and field joint coating.
Mixcoat Spray (FIG. 2) is an excellent
choice for complex, quick-set coating
structures, such as 100% solid polyure-
thanes and polyureas. It is widely used
for offshore and water/wastewater mar-
kets, secondary containment for tanks,
spray-on truck bed liners, sealing mem-
branes, sealing foundations and con-
crete pipelines.
The complete MixCoat Spray sys-
tem includes cartridges containing the
packaged coating material, a mixer that
ensures consistent coating mix and the
pneumatic operated spray. With a light-
weight, ergonomic design, the MixCoat
Spray is ideal for one-handed use. Un-
like other cumbersome dispersion op-
tions, MixCoat Spray dials and settings
are located on the handle, eliminating
the need for additional hoses and gaug-
es. Sulzur’s MixCoat Spray provides the
ability to use 1:1, 2:1, 3:1 and 4:1 ratios.
This self-contained system requires
only a pressurized air connection. The
integrated air flow and dual-stage trigger
makes the system unique and user-friend-
ly. The dual-stage trigger allows atomizing
air to flow first to the nozzle and then to
initiate material flow from the cartridge.
Mixcoat Spray is also compatible
with both single-line and dual-line flex
hoses for detailed spray projects. It is the
only cartridge system that can be used
to spray polyureas with a flexible hose,
making it possible to spray inside small
spaces, such as manhole applications.
This equipment is an ideal alternative for
smaller spray projects that would nor-
mally require the use of costly dispens-
ing equipment that require lengthy setup
and cleanup times.
Select 4 at www.HydrocarbonProcessing.com/RS
ASME-certified flow lab
Elfab, a leading manufacturer of pres-
sure safety solutions, has enhanced in-
house testing capabilities with its new
ASME-certified Flow Lab. Elfab is the
first rupture disc company outside the US
to gain this certification, improving its po-
sition to attract global business to the UK.
The Flow Lab (FIG. 3) test rig is de-
veloped and assembled by Elfab’s engi-
neering team. American Society of Me-
chanical Engineers (ASME) certification
allows Elfab to carry out capacity testing,
and the company now has authorization
to apply the UD stamp to a wide range of
rupture discs for systems built to ASME
pressure vessel codes. The UD stamp is
a legal requirement for many pressure
relief products sold to the US and other
regions worldwide.
The Flow Lab enables Elfab to estab-
lish a rupture disc’s resistance to flow (Kr
value) and its minimum net flow area
(MNFA). This data is used by pipeline
and process engineering designers, and
the new facility will see Elfab certifying
products to both ASME and ISO4126-6
(Annex D) standards.
Elfab’s ASME acceptance followed a
rigorous review of the test facility by the
National Board of Boiler and Pressure
Vessel Inspectors, with flow testing and
certification tests being witnessed by an
approved National Board Team Leader.
In-house testing using the Flow Lab
has commenced with recertification of a
range of discs requiring 6-yr certification
renewal. New product certifications be-
gan in 2019.
Select 5 at www.HydrocarbonProcessing.com/RS
MIKE RHODES, MANAGING EDITOR
Mike.Rhodes@HydrocarbonProcessing.com
MFG Chemical has
promoted Barry Lassiter
to VP of operations, where
he will be responsible for
MFG’s three plants in the
Dalton, Georgia area and
the recently acquired 26.7-
acre plant in Pasadena,
Texas. Barry joined MFG
in 2014 following nearly
40 yr with Dupont and
Invista. Joe Welch joined
MFG in 2018 with 22 yr
of experience in leading
environmental, health and
safety (EHS) initiatives
in both the public and
private sectors. Mr. Welch
will now assume Mr.
Lassiter’s previous role
as Director.
ValvTechnologies Inc. has
named Mark Abbott as
Director of engineering,
where he will have
global management
responsibility for all
of ValvTechnologies’
engineering groups and
activities worldwide. He
will lead R&D, product
development and design,
manufacturing, production
and application
engineering, and will
spearhead engineering
process continuous
improvement and product
standardization programs.
Mr. Abbott joined
ValvTechnologies in 2016
as Product Engineering
and Design Manager.
He previously served as
Engineering Manager
within Schlumberger’s
Completions Division, led
Flowserve’s Durco product
design team, and worked
as a Research Engineer
and a Senior Drilling
Engineer for ExxonMobil.
People
Operational Sustainability Michael Lordi has been Merichem Co. has Connell Bros. Co. LLC, a
LLC (OS) has hired appointed CEO of Elliott appointed Cyndie M. company of Wilbur-Ellis
Thelma Kipe as VP for Group, succeeding Fredrick to the position and a leading marketer
customer and product Yasuyuki Uruma, who of Senior VP and General and distributor of specialty
management. Ms. Kipe has retired after 47 yr Manager of Merichem chemicals and ingredients
brings three decades with Elliott Group and Process Technologies. Ms. in Asia-Pacific, announced
of experience in Elliott’s parent company, Fredrick’s responsibilities a strategic rebranding of
implementing, designing, Ebara Corp. Mr. Lordi include leadership of the company under the
supporting, selling and joined Elliott in 1987 the business unit sales, new name, Connell. Azita
interfacing with software as Sales and Marketing marketing, product Owlia has been named
for industrial users to Manager for Elliott’s tube execution, R&D and President and CEO of
the OS team. She joins tool business. He has financial performance. Connell. Prior to joining
OS after nearly 20 yr at since held increasingly She is replacing Ronald Connell, Dr. Owlia served
Rolls-Royce in various responsible roles covering Buras, who served as as a Senior VP at Bayer
roles, including managing every aspect of Elliott’s Executive VP and General MaterialScience, now
the company’s VisiumKMS business, most recently as Manager of this business known as Covestro. Dr.
EHS software. She also VP of industrial products, for the last 7 yr. Ms. Owlia joined the company
previously worked for VP of Global Service Fredrick has more than in 2011 as VP of North Asia.
Radian and Oracle in and COO. 25 yr of experience in
project management and downstream, midstream
customer support roles. and technology licensing. Valor Mineral Management
ROSS has promoted VP She previously spent LLC has added Ed McCabe
of corporate operations 6 yr with SNC-Lavalin, and Greg McCabe to its
The International Society Joseph Martorana to the working as the VP board of advisors. Ed
of Automation (ISA) position of Executive VP. of engineering and McCabe is the President of
announced that Paul Mr. Martorana has more operations, and General McCabe Energy Inc. and
Gruhn, PE, CFSE and than 26 yr of leadership Manager of its engineers has been active in the oil
ISA Life Fellow, is its experience in the process and construction division. and gas business of the
2019 Society President. equipment manufacturing She has also held roles Permian Basin for more
He will lead the ISA industry, and has been with Exterran and than 35 yr, operating and
board of directors, a driving force in the Conoco. She previously managing numerous oil
which is responsible for management and global served in management and gas properties. Greg
governing, setting policy growth of the ROSS group and engineering roles for McCabe is an experienced
and establishing the of companies. Merichem for 14 yr prior geologist with more
strategic direction of the to her role at Exterran. than 32 yr of oil and
organization. Mr. Gruhn gas experience. He is a
is a Global Functional Brendan Warn has been principal of numerous
Safety Consultant with appointed Senior VP The EnergyNet board of oil and gas-focused
aeSolutions. He serves as of investor relations directors has appointed entities, including McCabe
a Co-Chair and long-time of Total, succeeding Chris Atherton as CEO of Petroleum Corp., Manix
member of the ISA 84 Mike Sangster. Prior to the company, succeeding Royalty, Masterson
standard committee joining Total, Mr. Warn William W. Britain, who Royalty Fund and G-Mc
(on safety instrumented was Managing Director founded the company Exploration.
systems) and continues and UK Head of Equity and has served as CEO
to develop and teach ISA Research at BMO Capital since 1999. Mr. Britain
courses on safety systems. Markets. He has more will remain Chairman of Jeffrey Jianfeng Lou,
He also developed than 13 yr of experience the board. Mr. Atherton Senior VP of battery
the first commercial in equity research across most recently served materials for BASF (China)
safety system modeling three investment banks, as President of the Co. Ltd. will, as President,
program. Mr. Gruhn has including Macquarie company and has held assume responsibility for
written two ISA textbooks, Capital and Jefferies Intl. varying roles of increasing the Division Advanced
numerous chapters in in London. Previously, Mr. responsibility since he Materials & Systems
other books and dozens Warn was an Associate joined the company Research, succeeding
of published articles. Director at Evans & Peck. in 2002. Harald Lauke.
Hydrocarbon Processing | MARCH 2019 87
ADVERTISER INDEX  /  HydrocarbonProcessing.com
The first number after the company name is the page on which an advertisement appears. The second number is the Reader Service Number. There are two ways readers can obtain product and service information:
go to www.HydrocarbonProcessing.com/RS, follow the instructions on the screen, and your request will be forwarded for immediate action, or go online to the advertiser's website listed below.

Company Page RS# Company Page RS# Company Page RS#

Website Website Website

AFPM RMC 2019 ....................................70
Atlas Copco ............................................5 (61)
www.info.hotims.com/73417-61
AUMA Riester GmbH & Co., KG ...............43 (153)
www.info.hotims.com/73417-153
Axens ..................................................92 (51)
www.info.hotims.com/73417-51
Borsig ................................................. 77 (156)
www.info.hotims.com/73417-156
DOME Exhibitions .................................64
General Atomics ...................................30 (70)
www.info.hotims.com/73417-70
Gulf Energy Information
Construction Boxcore Database .......... 91
Energy Web Atlas .............................. 73
Events—HP Awards ........................... 32
This Index and procedure for securing additional information is provided as a service to Hydrocarbon Processing advertisers and a convenience to our readers. Gulf Energy Information is not responsible for omissions or errors.
Events—IRPC Americas ......................63
Events—IRPC EurAsia.........................46
Events—WGLC ...................................38
HP Circulation ............................. 82, 84
HP Marketplace ................................89
HP Webcast—Metrohm USA Inc. ......... 16
HP Webcast—AVEVA ..........................24
HP Webcast—Honeywell UOP ............ 55
Honeywell UOP ................................... 14 (71)
www.info.hotims.com/73417-71
IREC 2019 .............................................28
Johnson Screens,
a brand of Aqseptence Group ...............6 (92)
www.info.hotims.com/73417-92
Linde Engineering North America ......... 33 (76)
www.info.hotims.com/73417-76
McDermott Technologies ......................20 (75)
www.info.hotims.com/73417-75
Merichem Company...............................11 (84)
www.info.hotims.com/73417-84
Metrix .................................................45 (154)
www.info.hotims.com/73417-154
NACE International ...............................69
NISTM ..................................................59
Ohmstede Industrial Services Inc. ........26A
REMBE ................................................ 19 (151)
www.info.hotims.com/73417-151
Rentec Boiler System ..............................2 (53)
www.info.hotims.com/73417-53
Roth Pump Company............................66 (155)
www.info.hotims.com/73417-155
Siirtec Nigi ........................................... 37 (152)
www.info.hotims.com/73417-152

RUSSIA/FSU INDONESIA, MALAYSIA, SINGAPORE, THAILAND

Lilia Fedotova Peggy Thay
Anik International & Co. Ltd. Publicitas Singapore Pte Ltd
Phone: +7 (495) 628-10-333 Phone: +65 6836-2272
Catherine Watkins, Publisher E-mail: Lilia.Fedotova@GulfEnergyInfo.com E-mail: Singapore@GulfEnergyInfo.com
Phone: +1 (713) 520-4421
TURKEY, WESTERN EUROPE JAPAN
E-mail: Catherine.Watkins@
HydrocarbonProcessing.com Hamilton Pearman Yoshinori Ikeda
www.HydrocarbonProcessing.com Phone: +33 608 310 575 Pacific Business Inc.
E-mail: Hamilton.Pearman@ Phone: +81 (3) 3661-6138
SALES OFFICES—NORTH AMERICA GulfEnergyInfo.com E-mail: Japan@GulfEnergyInfo.com
EASTERN UNITED STATES, EASTERN CANADA UNITED KINGDOM/SCANDINAVIA KOREA
Merrie Lynch YB Jeon
Patrick Djuma
Phone: +1 (617) 357-8190 Storm Associates Inc.
Phone: +44 20 3409 2243
Mobile: +1 (617) 594-4943 Phone: +82 (2) 755-3774
E-mail: Patrick.Djuma@GulfEnergyInfo.com
E-mail: Merrie.Lynch@GulfEnergyInfo.com E-mail: Korea@GulfEnergyInfo.com
GULF COAST, SOUTH TEXAS SALES OFFICES—OTHER AREAS
MEXICO, CENTRAL AMERICA, SOUTH AMERICA
Austin Milburn AFRICA, MIDDLE EAST Marco Antonio Monteiro
Phone: +1 (713) 525-4626 Tanya Mbaluli Mobile: +55 21 99616-4347
E-mail: Austin.Milburn@ Twiga Media Partner E-mail: Brazil@GulfEnergyInfo.com
HydrocarbonProcessing.com Phone: +254 722 376 972
MIDWEST, NORTH TEXAS E-mail: Mbaluli@GulfEnergyInfo.com CLASSIFIED SALES
Josh Mayer CHINA—HONG KONG Laura Kane
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Iris Yuen
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Phone: +86 13802701367 (China)
WESTERN UNITED STATES, WESTERN CANADA Phone: +852 69185500 (Hong Kong) DATA PRODUCTS
Rick Ayer E-mail: Iris.Yuen@GulfEnergyInfo.com
J’Nette Davis-Nichols
Phone: +1 (949) 366-9089
INDIA Phone: +1 (713) 520-4426
E-mail: Rick.Ayer@GulfEnergyInfo.com
Manav Kanwar E-mail: Jnette.Davis-Nichols@
SALES OFFICES—EUROPE Phone: +91-22-2837 7070/71/72 GulfEnergyInfo.com
ITALY, EASTERN EUROPE Mobile: +91-98673 67374
E-mail: India@GulfEnergyInfo.com REPRINTS
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Mediapoint & Communications SRL Jill Kaletha, Foster Printing at Mossberg & Co.
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E-mail: Fabio.Potesta@GulfEnergyInfo.com E-mail: JKaletha@Mossbergco.com

88 MARCH 2019 | HydrocarbonProcessing.com
 MARKETPLACE / L.Kane@GulfEnergyInfo.com / +1 (713) 412-2389

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Hydrocarbon Processing | MARCH 2019 89

ALISSA LEETON, CONTRIBUTING EDITOR
Alissa.Leeton@HydrocarbonProcessing.com
MARCH
ABB Customer World,
March 4–7, George R. Brown
Convention Center,
Houston, Texas
www.new.abb.com
Eastern Mediterranean Gas
Conference (EMGC), March 6–7,
Gulf Energy Information Events,
Nicosia, Cyprus
EMGasConference.com
(See box for contact information)
CERA Week, March 11–15,
Hilton Americas–Houston,
Houston, Texas
ceraweek@ihsmarkit.com
ceraweek.com
AFPM Annual Meeting,
March 17–19, Marriott Rivercenter,
San Antonio, Texas
(See box for contact information)
AFPM International Petrochemical
Conference, March 24–26,
Grand Hyatt San Antonio,
San Antonio, Texas
(See box for contact information)
Corrosion 2019, March 24–28,
Music City Center,
Nashville, Tennessee
P: +1 281-228-6413
Lesley.Martinez@nace.org
nacecorrosion.org/
CIPPE, March 27–29, New China
International Exhibition Center,
Beijing, China
P: +86 1058-2365-55
cippe@zhenweiexpo.com
www.cippe.com.cn/en/
AIChE Spring Meeting,
March 31–April 4,
Hilton New Orleans Riverside,
New Orleans, Louisiana
P: +1 800-242-4363
www.aiche.org
APRIL
International Conference
& Exhibition on Liquefied
Natural Gas (LNG2019),
April 1–5, Shanghai World
Expo Exhibition & Convention
Center, Shanghai, China
+44 20-7978-0775
info@lng2019.com
www.lng2019.com
90 MARCH 2019 | HydrocarbonProcessing.com
International Aboveground
Storage Tank Conference,
April 2–4, Rosen Shingle
Creek Hotel, Orlando, Florida
Janelle@nistm.org
www.nistm.org
Pipeline Opportunities
Conference, April 9,
Gulf Energy Information Events,
JW Marriott, Houston, Texas
(See box for contact information)
GPA Midstream Convention,
April 14–17, Marriott Rivercenter,
San Antonio, Texas
gpamidstreamconvention.org
Reliable Plant Conference
& Exhibition, April 16–18,
Huntington Convention Center,
Cleveland, Ohio
conference.reliableplant.com
ENTELEC Conference & Expo,
April 23–25, George R. Brown
Convention Center, Houston, Texas
www.entelec.org
MIOGE, April 23–26,
Crocus Expo, Moscow, Russia
www.mioge.ru/en-GB
Sour Oil & Gas Advanced
Technology (SOGAT),
April 28–May 1, Abu Dhabi, UAE
www.Sogat.org
MCAA Industry Forum,
April 29–May 1, Loews Ventana
Canyon Resort, Tuscon, Arizona
P: +1 757-258-3100 ext. 201
themcaa.org
MAY
Offshore Technology Conference,
May 6–9, NRG Park,
Houston, Texas
P: +1 972-952-9494
meetingsotc@otcnet.org
www.otcnet.org
API Spring Refining and
Equipment Standards Meeting,
May 6–9, Grand Hyatt San
Antonio, San Antonio, Texas
(See box for contact information)
Aspentech Optimize, May 13–16,
Hilton Americas, Houston, Texas
P: +1 781-221-6400
info@aspentech.com
www.aspentech.com
ACHEMAsia, May 21–23,
National Exhibition
and Convention Center,
Shanghai, China
www.achemasia.de
AFPM Reliability & Maintenance
Conference & Exhibition,
May 21–24,
Gaylord Texan, Grapevine, Texas
(See box for contact information)
JUNE
ILTA, June 3–5,
George R. Brown Convention
Center, Houston, Texas
P: 703-875-2011
www.ilta.org
IRPC EurAsia, June 5–7,
Gulf Energy Information Events,
Helsinki, Finland
HPIRPC.com/Europe
(See box for contact information)
Valve World Americas,
June 19–20, George R. Brown
Convention Center, Houston, Texas
P: +1 416-361-7030
s.bradley@kci-world.com
www.valveworldexpo
americas.com
AUGUST
Maintenance & Reliability
Forum (MaRS), Aug. 7–9, Moody
Gardens Hotel & Conference
Center, Galveston, Texas
P: 832-876-3226
CCedro@hunterbuildings.com
www.smrphouston.org
ECC Conference, Aug. 28–31,
The Broadmoor, Colorado
Springs, Colorado
www.ecc-conference.org
SEPTEMBER
Turbomachinery & Pump
Symposia, Sept. 10–12,
George R. Brown Convention
Center, Houston, Texas
P: 979-845-7417
info@turbo-lab.tamu.edu
Gastech, Sept. 17–19,
George R. Brown Convention
Center, Houston, Texas
www.gastechevent.com
Events
HP Awards, Sept. 19,
Gulf Energy Information Events,
Houston, Texas
HydrocarbonProcessing.com/
Awards
(See box for contact information)
IRPC Americas, Sept. 25–26,
Gulf Energy Information Events,
Houston, Texas
HPIRPC.com/Americas
(See box for contact information)
OCTOBER
AFPM Operations & Process
Technology Summit,
Oct. 14–16, Marriott Rivercenter,
San Antonio, Texas
(See box for contact information)
Chem Show, Oct. 22–24, Javits
Convention Center, New York,
New York
P: 203-221-9232
info@chemshow.com
chemshow.com
GasPro Webcast, Oct. 24,
Gulf Energy Information Events,
Houston, Texas
(See box for contact information)
Women’s Global Leadership
Conference, Oct. 29–30,
Gulf Energy Information Events,
Royal Sonesta, Houston, Texas
WGLconference.com
(See box for contact information)
Hydrocarbon Processing/
Gulf Energy
Information Events
P: +1 713-520-4475
Melissa.Smith@
GulfEnergyInfo.com
EnergyEvents@
GulfEnergyInfo.com
American Fuel
& Petrochemical
Manufacturers (AFPM)
P: +1 202-457-0480
info@afpm.org
www.afpm.org
American Petroleum
Institute (API)
P: +1 202-682-8195
registrar@api.org
www.api.org
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