DeltaValve 2010 Customer Version

The contents of this presentation is PRIVILEGED and

CONFIDENTIAL material of Curtiss Wright Corporation and

should not be disclosed, used by or copied in any manner

by anyone. Any unauthorized use, dissemination of the

information or copying of this presentation is prohibited.

7200 Employees Worldwide

~2 Billion US Dollars in Sales

Offices in Singapore, Korea, UK, France, Germany,

Netherlands, Belgium, Italy, Sweden, Spain, Switzerland,

Canada, USA

Top Unheading

HPU &

Controls

Auto-Switch

Coke Cutting Tool

Bottom Unheading

Isolation Valve

Drill Stem

Enclosure

Isolation Valve

Unheading Evolution

Manual (1950) Swing Away (1990) Enclosed (2001)

Why The Need For Change?

Traditional systems:

• Do not eliminate exposure

• Are expensive to operate & maintain

• Are complex to operate



• Do not safely allow processing of shot-coke

• Can not control a drum dump



• Simply are not safe

• 20 – 30 fatalities and numerous injuriesin past 10 years

Totally Enclosed

DeltaGuard Unheading Device

DeltaGuard® Unheading Device

Pre-Commercialization

• Prototype Fully Tested in Simulated Coker• Bond shear/thrust test

• Thermal test (200F – 1100F)

• Seat leakage test

• Finite Element Analysis• Thermal stress analysis of all critical components

• Thermal Cyclic fatigue study

• Thorough Analysis

• Metallurgy• Mating parts (wear surfaces)

• Switch-deck constraints

Totally Enclosed, Safe,

Simple to Operate, Reliable

COKE DRUM

DELTAGUARD

COKE DRUM

BOTTOM UNHEADING

DEVICE

TRANSITION SPOOL

WITH SIDE ENTRY

FEED

FIXED

CHUTESWITCH

DECK

DISCHARGE

CHUTE

DeltaGuard US Patents

6565714 6964727

6660131 6843889

6989081 7033460

7316762 5816787

7115190 7117959

International Patents

209822 255082

Other US and International

patents pending

Safe Unheading

• Totally enclosed system from top head to coke receiving area

• No exposure to personnel, unheading deck, or to plant equipment

• Isolation of a tary drum

• Isolation or controlof a drum dump

Safe Unheading

• Positive mechanical lockout• All required safety interlocks incorporated• Safe to operate using back-up methods• Remotely operable

Easy Operation

• Satisfy all safety interlocks

• Receive board permission

• Remove positive lockout pin

• Push open/close button

• Remotely operable from– Local control panel

– Control room

Increased Throughput

• Unheading time of 2-4 minutes

• For maximum increase in throughput, the DeltaGuardcan be configured to allow;– Drainage of coke & water through the port (Model GV815)

– Optional-throttling design control of coke and water through the port (Model GV820)

• Elimination of uncontrolled fallouts onto the switch deck eliminates down time for cleanup

Economic Benefits

• No head gasket to replace at each drum cycle

• No feed line coupling gaskets to replace at each drum cycle

• No feed line coupling, or alignment systems to maintain

• No time consuming water flushing required(can be done through the valve)

• No disassembly, cleaning and re-assembly required at each cycle

• No other replacement parts at each cycle

• No maintenance or replacement of tools

First Installation – September 2001

There have been:

• Over 500,000 combined cycles

• No recordable injuries

• No incidents

First Installation – September 2001

Have had:

• No effect on coker quality

• No effect on coker process,(in fact improved coker economics

significantly)

• No effect on coker operations

• No effect on coke drum

drilling operations

• No maintenance expense

• Significantly improved safety

• Eliminates exposures to personnel

• Significant reduction in maintenance

costs at turnarounds


Only One Major Moving Part

• Ensures simplicity and reliability

• Significantly reduces need for spare parts


Seating Technology

• All metal seating

– Nitrided gate and hard chromed seats

• Independent dual seats

– Floating top seat

– Static lower seat

– Double Block & purge/bleed

• Self cleaning

– Constant load keeps gate and seat surfaces together at all times


Steam Purged Body

• Diagnostics Tool

• Regulates Body Temperature

• Creates a Barrier against

Coke migration

C:/Users/wvermeire/Documents/Curtiss Wright/Oil & Gas Systems/DeltaValve/Technical/DVWI 250 Rev 03 Steam Header Design.pdf


Steam Purged Body

• Steam purged body

• Diagnostics Tool

• Regulates Body Temperature

• Creates a Barrier against

Coke Migration

• Supports Coke Containment

System

DeltaGuard® Unheading DeviceInternal Coke Containment System

DeltaGuard® Unheading DeviceSeating Technology – Throttling Design

• Internal Coke Containment System

– Keeps coke fines from

entering the bonnet

– Reduces steam

consumption

DeltaGuard® Unheading DeviceSeating Technology – Throttling Design

5 Year TurnaroundChevron, Salt Lake City

Gate Lower Seat

DeltaGuard® Unheading DevicePin and Lock-out Tower

DeltaGuard® Unheading DeviceDimensional Data

530 mm

2.4m

6m

2.6m

32,660 kg


Maintenance

• Quick assembly and

disassembly with coke drum

• Minimal part requirements for

complete seat and seal

replacement

• Re-buildable on switch deck

during shutdowns

Transition Spool

DeltaGlide™

DeltaGlide™

Maintenance

• Smooth installation

• Balanced load

• Constant alignment

• On deck serviceable

DeltaGlide™

DeltaGuard® Top Unheading Device

Traditional Top Unheading Device


Based on DeltaGuard Bottom

Unheading Device Technology

• Double, live-loaded, dynamic,

metal seats

• Designed to keep coke out of

body cavity

• Steam purged body

• Low steam consumption

• Adaptable to all top head

diameters

• Hydraulically actuated

• On-site maintenance


560 mm

1.52 m

2.8 m

1.3 m

5,625 kg

Dimensional Data

HPU & Controls

Hydraulic Power Unit

• Simple, reliable and

redundant hydraulic system

• Minimal hydraulic system

requirements for valves,

fittings and piping

• One hydraulic cylinder

• One hydraulic line in and out

HPU & ControlsSystem Block Diagram (2 drum DCU)

HPU & ControlsPump Control

HPU & Controls

Cooling Water System

Drill Stem Guide / Blow-out Diverter

Drill Stem Guide / Blow-out Diverter

System Benefits:

• Totally contained cutting tool

• Protect against steam burns

• Protection from blow-outs/eruptions

• Interlocks incorporated

• Natural integration of Hydraulics/Controls with

bottom unheading system

• Proven technology

Auto-Switch Coke Cutting Tool

Isolation Valves

GV 850 Isolation ValveModel VT , VN

GV 850 Isolation Valve• Total Isolation Valve Solution

– Linear goggle Blind Principal

– Live Loaded, Self Cleaning Metal Seats

– Fully Bi-Directional Double Block and Purge Isolation

– Top Entry (field serviceable)

– Electro Hydraulic Actuator

– Manual De-Clutchable Override

GV 850 Isolation Valve

• Total Isolation Valve Solution

– Zero Non Turnaround Scheduled Maintenance

– Condition Diagnostics

– Optional Maintenance Jib

Live Loaded, Self Cleaning Metal Seats

• Double Live Loaded, Ultra Heavy Duty Metal Seals with Proven Reliability

• Seal Tightness Not Sensitive to Body Deflection

• Valve Torque / Thrust / Operation Not Sensitive to Body Deflection

• No Change In Seal Performance Over Time

Actuation• Electric Actuation

– Limitorque SMB CVA Series– Rotork– Customer Preference

• Electro Hydraulic / Continuous position indication / Manual De-clutchable Override

• Hydraulic Actuation• Manual Actuator if Requested

GV 850 Isolation Valve Models• VT (Sealed Body Cavity)

– For use in; • hydrocarbon liquids near

coking temperature

• solids laden hydrocarbon liquids

• dirty hydrocarbon vapor streams

• on/ off, throttling service

• VN (Open Body Cavity)

– For use in; • steam , water

• clean hydrocarbon liquids below coking temperature

• clean hydrocarbon vapor streams

• on /off, throttling service

GV 850 DCU Services by Model Number (DV Recommendation)

• GV850 VT– OH Vapor to Blow down

• XV 1023

– OH Vapor to Fractionator

• XV 1060

– Coke Condensate

• XV 1028

– Drain to Coke Pad

• XV 1029

– Manifold Isolation Valve

• XV 1038

– Wax Tailings/Steam

• XV 1050

– HC Liquids / Vapor Bypass to Fractionator

• XV 1065

• GV850 VN– Coke Drum Vapor discharge (PSV

Discharge)

• XV 1001, 1006

– Utility steam MOV

• XV 1039

– Quench Water MOV(purged)

• XV 1040

– Atmospheric Vent Valve

• XV 1041, 1042

– Quench Oil HCGO

• XV 1053, 1054

GV850 VT• VT

– Double, Metal, Self Cleaning Seats

– Live loaded

– Fully Sealed Body Cavity at all Times

• Seats extend into lower bonnet

• Seat extensions cover both surfaces of gate over full stroke

• Seat extensions are fully live loaded and purge pressure assisted

• Seat extensions are ground and polished to valve seat tightness

• Zero Cross Valve leakage with Purge

• Designed for continuous Static Purge.

GV 850 VT

GV 850 VN• VN

– Double, Metal, Self Cleaning Seats

– Live Loaded

– Fully sealed Body Cavity while in Open and Closed Positions Only

– Seat Seals are live loaded and Purge Assisted

– Zero Cross Valve Leakage with Purge

– Static purge while in fully open and closed positions.

– Flowing purge during stroke

GV 850 VN

Top Entry / In Line Serviceable

• All Internal parts accessible while installed

• Easy Disassembly and Re-assembly

• No Special Tools or Equipment

• Optional Maintenance Jib

Top Entry / In Line Serviceable

Purge Steam Consumption Rates

Size Factory Test Results Steam Header

Sizing

Recommendations

10” .3 lb/hr 150 lb/hr

12” .36 lb/hr 180 lb/hr

18” .54 lb/hr 270 lb/hr

24” .72 lb/hr 360 lb/hr

30” .9 lb/hr 450 lb/hr

36” 1.1 lb/hr 540 lb/hr

Diagnostics

• Static Steam Pressurized Body and Bonnets– VN, Low Purge Steam in Open or Closed Positions

– VT, Low Purge Steam at all times

– Header sizing guideline;• 10 lbs/hr/inch of port Diameter/valve

• Steam Pressure and Flow Sensors– Real Time Verification of Positive Isolation

– Positive Confirmation of Seat / Gate Condition

Zero “Non Turnaround Scheduled” Maintenance

• No Maintenance of Packing

• No Maintenance of Seat Seals

• No Maintenance of Gate

Sizes/End Connections

• Sizes: 3” to 48”

• ANSI Class 150, 300, 600

• FF, RF, RTJ, Weld End

Isolation ValvesValve Sizes and Connections

• Sizes From 3” to 48”

• 150#, 300# and 600#

• FF, RF, RTJ, Weld End

• No Maintenance

Inventory

Certifications

• ASME Sec VIII Div 1 & 2

• U-Stamp Designation

• MAWP 1062 kPa (154 PSI) @ 504°C (940°F)

• FEA-Finite Element Analysis

• CRN# -ABSA

• PED certification including ATEX &

CE markings

• GOST-R certification

Installation, Commissioning & Start-up

Field Services

Services Provided:

• Installation and commissioning supervision

• Warranty and repair

• Major rebuilds

• Site audits

• On-going maintenance

• Training

Field Services

DeltaValve Service Center:

– TapcoEnpro Facility – Barnsley, UK

– TapcoEnpro Facility – Houston, USA• Extensive history of valve repair

• Proven safety record

• Large scale operation

Units Sold (2001)

Salt Lake City

2 Bottom Unheading Valves

http://www.chevron.com/

Units Sold (as of January 2010)

266 Bottom

Unheading Valves

131 Top

Unheading Valves

160 Isolation Valves

Customers

First Customer – Chevron Salt Lake City, Utah, USA

• Installation Sept 20, 2001

• No maintenance expense & no outages

• Eliminates personnel exposure and risks

• Fabricated design

• Transition spool bolted to drum

• 24 hr cycles

• ROI-Immediate maintenance & operational

savings-refinery specific

• Valve supported by structure,not by drum

• Continue to produce sponge coke

• 2 installed out of 2

Customers

Second Customer – Chevron Pascagoula, Mississippi, USA

• Installation February 2003



• Fabricated design

• Transition spool connected to drum

• Reduced to 12 hr cycles

• ROI-Immediate maintenance & operational

savings-refinery specific

• ROI-Increase throughput

• Valve supported by structure, not by drum

• Produce shot coke

• 6 out of 6 bottoms & 6 tops installed

Customers

Fifth Customer – BP Texas City, Texas, USA

• Installation April 2004



• Cast design

• Transition Spool integral to the drum

• 14 hr cycles

• ROI-Immediate maintenance &

operational savings-refinery specific

• ROI-Increase Throughput

• Valve supported by structure,

not by drum

• Produce of Shot Coke

• 6 installed

Customers

Sixth Customer – Citgo Lake Charles, Louisana, USA

• Installation July 2004



• Cast design

• Transition Spool Integral to the drum

• 18 hr cycles

• ROI-Immediate maintenance &

operational savings-refinery specific

• ROI-Increase Throughput

• Valve supported by structure, not by drum

• Produce shot coke

• 4 installed

• remaining 4 currently being installed

Case Study 2

Shell Wilmington RefineryWilmington, California

Refinery Delayed Coker Unit Background

• 4 drum coker unit

• DeltaValve enclosed unheading system

• Foster Wheeler process licensed technology

Case Study 2


Incident Background (May 2006)

• Main transformer failure and lost power to

some major equipment on the delayed coker

unit

• Not able to get heater trip system reset and get

heat back into the coke drums

Case Study 2


Incident Background (May 2006)

• One coke drum has been charged for about 19

hours and the other drum had been charged for

about 7 hours

• Continued to put feed into the coke drums for 2

hours at about 230C (too cold for any coking

reactions to occur)

• Eventually operators stopped feed into the

coke drums, but the amount of cold feed was

too much

Case Study 2


Event Procedure

• Successfully introduced steam and quench

water into both drums to cool the internal

materials

• Proceeded to unhead the first drum (19 hours

charging)

• Material in this drum was a slurry of coke

particles and cool tarry material, similar to the

consistency of road asphalt.

• Successfully emptied the first coke drum

Case Study 2


Event Procedure

• Certain the second drum (7 hour feed) was

going to be mostly tar. Cause for significant

concern and extra precaution.

• Waited for second drum tar to cool sufficiently.

• Attempted to drain quench water through feed

line. Unsuccessful, tar plugged the line.

Case Study 2


Event Procedure

• Added fire-water sprays into the coke pit as a

precautionary measure (concerns of a hot tar

flash fire.)

• Evacuated coke structure.

• Slowly opened the DeltaValve by remote

operation from an enclosed unheading shelter.

Case Study 2


Outcome

• Hot water and liquid tar came from the bottom

of the coke drum through the valve.

• Dumped approximately 5000 barrels of tar into

the coke pit.

• Successfully unheaded the tarry drum without

incident.

Case Study 2


Final Result

• No injuries

• No risk to personnel

• No damaged equipment

• No detrimental environmental impact

• No downtime

(estimated savings of up to $10 million)

Case Study 2


“We are obviously thrilled with the performance of our DeltaValve unheading system, and we know the

cost of the system was justified economically just by this one event. The safety benefits of being able

to remotely un-head the drum and reclose it are, of course, priceless.

The industry has come a long way in terms of coker safety and DeltaValve has made an immense

contribution to that progress.”

Eric Brown

Crude, DCU Production Specialist

Tesoro (Shell ) Wilmington

Why Install the DeltaGuard®?

Safe Unheading• Totally enclosed system, eliminates exposure risks

Return on Investment• Immediate reduction of operating/maintenance expense

Refinery specific- ~ $200K+per drum per year

• Ability to process alternative crudes

• Increased production due to reduce cycle times

• Drum is drained directly through the device

Easy to Operate• Push button-open/close

Reliable Design• One major moving part

Experience (Proven Technology)

• 7 + years of maintenance free operation

• Over 500,000 combined cycles

• No safety incidents

Some of Our Customers

http://www.repsolypf.com/eng/todosobrerepsolypf/conozcarepsolypf/identidadvisual/identidadvisual.asp?FormatoID=4507&PaginaID=64360&Nivel=51

http://www.bp.com/home.do?categoryId=1&contentId=2006973

http://www.lukoil.com/

Thank Youand

What can we do for you?

DeltaValve 2010 Customer Version

Documents

Transcript of DeltaValve 2010 Customer Version