TAR Vessel Entry Best Practices: Decrease Costs and ... refineries and petrochemical plants must...
Transcript of TAR Vessel Entry Best Practices: Decrease Costs and ... refineries and petrochemical plants must...
Mr. Tom McQueary - President ZymeFlow Decon Technology
TAR Vessel Entry Best Practices: Decrease Costs and Increase Safety
Evolution of decontamination
Best practices for vessel entry
Case study
Conclusion
Brief company introduction
Q&A
Agenda
Most basic method to prepare equipment for entry
Steam hardens deposits creating more mechanical work
Tower bottoms and trays many times require several shifts to break up hydrogen deficient deposits
Pyrophorics hidden under hardened deposits
Steam Out
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Typical refinery cleaning: remove organic scale, de-oil, passivate, and/or remove sludge
Chemicals and/or manual cleaning with equipment
Additional equipment required for setup, effluent treatment, and disposal
Secondary step required to decontaminate (LEL/VOC, benzene, H2S, FeS)
Traditional Chemical Cleaning
Traditional cleaning example
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Long maintenance outages reducing refinery margins
Increasing environmental and safety regulations
Unexpected fouling/coking from spot market feedstock
Emergency shutdowns
Pyrophorics risks
Unanticipated contaminants
Evolution of Decon: Forces of Change
State of the industry requires more efficient and safe technologies including turnarounds and maintenance
Decontamination
Making industrial equipment safe for entry by destroying, neutralizing, making harmless, or removing hazardous unwanted contaminants
ALL refineries and petrochemical plants must perform some form of decontamination every time a unit is brought down for personnel entry, hot work, and inspection
Hydrogen Sulfide
Harmful Gases (LEL/VOC)
Benzene Pyrophoric iron sulfide
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ZymeFlow Decontamination
H2S
Removed
Residual
Oil
0 ppm
LEL
FeS
0% Neutralized
Benzene
0 ppm
Preparing process units for safe entry in 8-12 hours.
Simultaneous Treatment
Residual Solids
Conditioned
Distillation Cleaning
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Oxidation
Zyme-Flow UN657 proprietary chemistry blend including surfactant and mild oxidizer
Vapour-Phase® patented method adding Zyme-Flow chemistry with steam to simultaneously eliminate contaminants
Penetrates sludge, scale, and surfaces to free hydrocarbon, benzene, and LEL
Oxidizes hydrogen sulfide (H2S) and pyrophoric iron sulfide (FeS)
Contaminants and chemistry measurable throughout the process
Evolution of Decon: Zyme-Flow Process
Time/Resources Simultaneous treatment of
contaminants
8-12 hours Minimum equipment footprint No secondary treatment needed
for effluent Safety Non exothermic Non reversible oxidation of H2S
and pyrophoric iron sulfide No exposure or corrosion
concerns
Environment Effluent can be sent directly to
oily water sewer Open to atmosphere much
faster No bi-products
Evolution of Decon: Zyme-Flow Process
• Water is added to tower bottom (about 20% level)
• Steam injected into the bottom drain, or as close as possible
STE
AM
• Zyme-Flow® and Rezyd-X® added to water and temperature raised to above 100°C
Zyme-Flow® Rezyd-X®
STEAM
Best Practice H2S Benzene Pyrophoric Scale LEL
Boil Out with Vapour-Phase®
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100°C
STEAM Zyme-Flow®
Rezyd-X®
• Solution continues to boil in the bottom of the tower during Vapour-Phase
• Injection of Zyme-Flow during the steaming phase will last 8-12 hours
STE
AM
Best Practice H2S Benzene Pyrophoric Scale LEL
Boil Out with Vapour-Phase®
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Full PetroChemical Turnaround Kuwait
Case Study
Kuwait Petrochem Plant Decon
• Vapour-Phase and Boil-Out applications used in combination with Zyme-Flow UN657 as
the main chemistry and Rezyd-X on areas containing heavy sludge • Critical path quench water column prepared for entry with a Vapour-Phase application
using Zyme-Flow UN657 • Combination of Zyme-Flow UN657 and Rezyd-X in a Boil Out application used on bottom
section of quench water column
Engineered Solution
• Attempted to circulate an alternate chemical which failed to fully decontaminate the units and produced large amounts of liquid waste
Past Procedure
• Previous shutdown produced large amounts of liquid waste and sludge • Kuwait’s new regulations do not allow liquid waste to be taken off site
Concern
• Decontaminate 42 pieces of equipment in 5 days, including critical path quench water
system
Challenge
Benzene, LEL, and H2S in all units reached zero
No pyrophoric activity
Critical path quench system decontaminated in less than 12 hours
Significantly reduced steam and effluent disposal
Plant implementing the procedure as a Best Practice for preparing process equipment and tanks for entry
Kuwait Petrochem Plant Results
“This is an excellent and unique performance, not only did ZymeFlow® help to enter the vessel safely, but also reduced the waste significantly.” -Turnaround Team
Click to edit Master title style New regulations forced the change to more efficient technology, ZymeFlow Decon tested and proven
Results beyond regulation compliance
Saved time including five (5) days off critical path
Greatly improved personnel safety
Significantly reduced water and waste/effluent disposal
Zero pyrophorics or gas incidents
Achieved full TAR in 30 days
Kuwait Petrochem Plant Summary
Using steam only methods continue to pose safety risk and extend turnaround time
Many chemical treatment options are available but must be evaluated carefully
Indirect and opportunity costs need to be considered
Proper selection of the decontamination method can directly affect turnaround success
Conclusion
Decontamination specialists for over 25 years
200+ TAR and emergency outage projects/year
Experience in over 50 countries
Wide range of specialty blended chemistries
Various application options including Vapour-Phase®
Zero recordable injuries in 25 year history
Worldwide Leader in Decontamination
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www.ZymeFlow.com
© 2016 United Laboratories International, LLC. All Rights Reserved.
Conclusion & Questions
Please contact: Meghan Kidwell Global Marketing Manager