Tracerco Diagnostics. Services for the Refining and Petrochemical Industries. For further details please contact:

Transcription

1 Services for the Refining and Petrochemical Industries For further details please contact: Process Diagnostics Centre, Pavilion 11, Cowold Way, Belasis Hall Technology Park, Billingham, Cleveland TS23 4EA UK Tel: +44 (0) Fa: +44 (0) Web: Tracerco Limited is a subsidiary of Johnson Matthey PLC, 5th Floor, 25 Farringdon Street, London EC4A 4AB. Registered in England No Tracerco is a trading name of Tracerco Limited. Tracerco is a trading name of Tracerco Limited. TRACERCO is a trademark of the Johnson Matthey Group of companies. XM0150/0/B

2 Contents Flow study 3 Residence study 5 Distribution study Leak study 7 Helium Leak study 9 FCCU study 10 Tower Scan 11 ThruVision Scan 13 Would you like to be able to determine flow relationships through flare lines and piping systems? Are you eperiencing off-spec effluent from your feed/effluent echangers? Do you suspect maldistribution is affecting efficiency in your reactor? The following Tracerco service applications are applied to the investigation of industrial processes to allow plant engineering and operations staff to quickly troubleshoot and resolve operational issues. Better knowledge about the problems you are eperiencing will reduce the cost of making corrections and reduce downtime. performs online investigations using radioisotope and chemical tracers to identify leaking echangers, measure the distribution of feed into catalyst beds, and conduct flare flow studies to measure and locate sources of emissions. Scan 14 Maimizer 16 Tracerco Monitors 18 Flow Study Unit 2 Unit 4 Unit 6 Tracerco Monitor Calibration Services 19 Tracerco Instruments 20 The Tracerco Profiler 21 Tracerco Specialty Applications 22 The measurement of flow around an oil or chemical process is often required where no metering is present to measure flow distribution between main headers and branch headers, or to verify eisting flow measurement devices. The use of the Flow study technology offers a rapid, accurate and cost effective method of determining flows of solid, gas and liquids. The results from such measurements can play a key role in: Predictive maintenance Process optimisation Reduced downtime Tracerco engineers will study the process system to determine the most suitable injection point and detector layout to gain optimum information about the process. Consideration will then be given to the choice of tracer to ensure process compatibility and the required concentration. The tracer material is then injected into the process stream via the identified point. Measurement of the injected pulse through the system is made using a combination of either eternal detectors or sampling with no affect on process operations. D-1 Low Flow Unit 1 Unit 3 High Flow D-1 D-1 D-1 D-1 D-1 Unit 5 Unit 7 Flow Meter Typical systems that can be measured include: Flare line systems Cooling water towers and systems Compressors and turbines Relief valves Effluent streams Process material systems for mass balances 3

3 Pulse Velocity Technique Residence and Distribution Study Reservoir of Radioisotope 1200 Detector #1 Detector #2 Detector #3 Injection Distance 1 Distance 2 Eample Flow Rate The time and distribution of material through miing, reaction or separation vessels can be critical to industrial processes. A Residence study can offer a rapid, on-line, cost effective method of determining these process parameters. A tracer is injected into the inlet of a vessel and its eit is measured using an eternal detector or sampling. This information is used to determine Mean Residence Time and Number of Stirred Tank Equivalents (STE) or the Inverse Peclet Number (IPN) through the vessel. A Distribution study is performed when a ring of detectors is placed around a vessel to determine what percentage of the tracer passes through each segment of the vessel. Residence and Distribution Studies can be used to measure a number of operational parameters on the following equipment: Reactors Oil/Water Separators Packed Bed Distillation Towers Driers FCCU Systems D1 T1 = Velocity Detector Response Detector #1 Detector #2 Detector #3 T1 T Time (s) For eample when a radioactive gas tracer is injected into a vessel, the size of the response from each detector will be directly related to process flow close by its location. For a normally operating system, all of the detectors should see similar amounts of tracer, producing similar responses. However, when tests show that some detectors have much larger responses than others maldistribution is indicated. Residence Time Study Pulse Velocity Technique to Verify or Calibrate a Flow Meter In-Situ Injection point Detector Detector Injection Detector #1 Detector #2 Detector #3 Flow Process vessel In-situ velocity measurement technology used to verify and calibrate meters can be done using the Pulse Velocity technique. These results can serve as an independent verification that data reported for environmental purposes is correct. Response Inlet Pulse Time Response Eit pulse Time 4 5

4 Distribution Study Leak Study GAS OUTLET Leaks on a heat echanger usually result in off-spec material being produced. If the system has a bank of echangers then it is very difficult to identify which one(s) is leaking using client laboratory sampling analysis alone. The use of tracer materials offers a rapid and unambiguous online method of detecting leaks within process vessels. This can greatly reduce plant down time and yield savings in operating costs. A Leak study has a wide range of applications as an aid to process diagnostics and inspection. LIQUID OUTLET COUNTS TIME This is an eample of a Distribution study using an array of radiation detectors at key locations on a vessel. Tracerco has the ability to conduct studies with up to 100 detectors to allow for process conditions to be determined throughout an entire process unit. A highly detailed analysis of process flow through FCC Units and the possibilities for miing or distribution studies in contactors and reactors with a single injection are now possible. The Tracerco team of eperts will work with plant operations to select a suitable radioisotope based on properties of the stream to be studied. Tracers are available in liquid (organic and aqueous), gas and solid forms. Our engineers have years of tracer eperience determining the best methods to collect vital on-line process information to meet your test objectives. These include: Reboiler/condenser leaks in distillation towers Leaks on banks of heat echangers Leaks through bypass valves Vent and relief valve leakage Compressor Ring leakage Ammonia syn gas loop and converter leakage The site requirements include a suitable injection point on the primary inlet line into which the pulse of appropriate tracer can be injected. 6 7

5 0 5 Heat Echanger Leakage Helium Leak Study There are two methods employed to determine leakage, the sampling technique and the eternal detection technique. The first requires a sample point on the downstream line of the secondary stream from which to draw material over a short time period. The samples collected are delivered to a local Tracerco laboratory where they are analysed for tracer content. The second method uses eternal detectors mounted on the lines to monitor the passage of the injected tracer. Any leakage would be indicated as a peak on the detector mounted on the secondary stream eit line. For eample a client had a problem with a feed-effluent echanger system consisting of 5 echangers in series. A diagram showing detector positions is shown below. A sharp pulse of liquid tracer was injected into the feed. The passage through the system was monitored by the odd numbered detectors. The even numbered detectors were the leak detectors. Detector 2 (Green) indicated a leak of 2.5% on the A echanger. Therefore only one echanger needed to be removed from service and repaired. This minimised loss of production and reduced the maintenance epense. Radiation Intensity Injection Detector Echanger Leak Test Leak Detector Time(s) Injection Detector Leaks within process vessels and systems are disruptive to operations and are often small, making detection difficult. The use of the Helium Leak study offers the most stringent of leak test methods available and is applicable to both pressure or vacuum units. For units under pressure the helium is added to the component under investigation at a suitable test pressure. Sampling and measurement at locations within the system into which the helium may leak is then carried out using a helium specific Mass Spectrometer. For vacuum systems the helium is sprayed around the eternal flanges, joints etc. to identify positions of air ingress. Sampling is then conducted usually at the ejector area. Precise location of the leak position allows maintenance efforts to be concentrated in the appropriate area reducing downtime. This yields a saving in operating costs. Offline testing of echanger tubes will identify each leaking tube so it can be repaired or plugged. Heat Echange Leak Detection (offline) Each tube is eamined for the presence of helium Shell-side pressurized with helium gas Leakage Detection Helium mass spec D5 D9 Tube plate Individual tubes blocked with rubber bungs Reactor Feed Pump D1 D4 B A D3 D D8 C D7 E D11 Areas of application include: Heat Echangers Storage Tanks Vacuum Polymerisers Refrigeration Units Product D2 D6 D10 8 9

6 FCCU Study The Fluidized Catalytic Cracking Unit (FCCU) is the economic heart of today s refinery. Small increases in yield can bring significant gains in productivity and revenues. Tracerco Diagnostics FCCU studies have diagnosed operating problems and helped improve the performance of all major components of FCC units. Each project is customised to provide the information needed to optimise or troubleshoot your specific process. All testing is performed while the unit is online and will not interfere with normal unit operations or production scheduling. Data collected can be used to identify operating parameter changes to improve unit productivity, or gauge the accuracy of process modeling and simulation. Tracerco s eperience involves numerous studies performed on units worldwide allowing a better understanding of the integrated processing components of today s FCCU s. Regenerator Reactor Cyclone Operation Cyclone Operation and Distribution Study Catalyst Bed Level Measurement Efficiency of Riser Termination Device Residence Time Cyclone Distribution Study Catalyst Bed Level Measurement and Etent of Bed Dilute - Phase Stripping Section Density Profile Catalyst and Vapour Flow Distribution & Residence Time Reactor Riser A FCCU study utilises our diagnostic capabilities with both sealed source and tracer technologies. These are used to measure the velocity, distribution and residence time of the catalyst or vapour phase through any part of the system. This includes testing to determine the efficiency of riser termination devices, cyclones or distribution devices. A typical study may employ upwards of fifty detectors, inspecting almost the entire system from a common injection point. The tagged process stream can be followed completely through either the reactor vessel or the regenerator. For eample, tracer material injected into the riser can provide: Catalyst and vapour traffic velocities and slip through the riser Determination of efficiency of the riser termination device Flow distribution through the reactor and stripper Cyclone distribution/operating characteristics Reactor/stripper residence times Vapour traffic is usually tagged using an inert gas. The catalyst traffic may be tagged using system native catalyst, E-Cat, Fines, or any specific particle size distribution which has been activated by Tracerco. For additional information on FCCU services provided by Tracerco please reference our FCCU brochure that can be found on our website at or contact an office in your area to request a copy. Tracerco Scanning Services and Tower Scan Application Do you have problems with the operation of your stripper/absorber or fractionation tower? Is this limiting production? Do you want to reduce your operating costs? Do you want to reduce your shutdown time? Tower Scan technology is used to evaluate the mechanical integrity and hydraulic performance Trayed Tower Diagnostics Tray Damage Tray Damage TRACERCO Diagnostics Tower Scan -Ais Active Area Scan Clear Vapor Bar of trayed columns by measuring froth levels on tray decks, liquid backup in downcomers, and clarity of liquid/vapour disengagement zones. Damaged or missing trays, plugged downcomers, feed issues, and tray fouling are eamples of problems with columns that can be diagnosed with a Tower Scan. Tower Scan Features Identified Verify placement of trays Evaluate tray froth heights Foaming and fouling Detect tray damage and flooding Detect mechanical, rate or process related problems Catalyst and Air Distribution Study Riser Density Profile Residence Time Spent Catalyst & Regenerated Catalyst Standpipes Catalyst Slugging Study Catalyst Density Profile Catalyst and Vapour Distribution Catalyst and Vapour Velocities (Slip Ratio) The Tracerco Scanning Services technique s have a proven track record in over forty years of operation in assisting with plant start-ups, pre-shutdown planning and operational trouble-shooting. A Tower Scan is generally performed without any preparation to the tower i.e. no insulation is removed. Tracerco s scanning service has proven to be cost effective by reducing off-spec production and equipment downtime. In today s highly competitive refining, petrochemical, and chemical processing markets, more customers are using Tower Scan information to spot plant bottle-necks and to optimise performance

7 Tracerco Scanning Services and Tower Scan Applications Tracerco Scanning Services and ThruVision Scan Applications ThruVision Scan Orientation Fan Beam Pattern Tower Scan Features Identified Verify placement of packed beds, distributors and collectors Evaluate the quality of liquid phase distribution Detect problems such as fouled or crushed packing, overflowing distributors and collector trays, flooding or foaming ThruVision Scan Features Identified Map or profile liquid maldistribution in packed columns Profile catalyst distribution in fluidised catalytic reactors Identify integrity problems with column and reactor internals (packing, demister pads, catalyst beds, etc.) A Tower Scan is one of the most common and cost effective methods of identifying liquid maldistribution and other problems affecting packed column performance. A Tracerco scan for a packed column is a series of four conventional column scans performed using a 2 2 orthogonal grid scanline orientation. The objective of the scan is to measure the degree of bias (or coincidence) among all four scans under identical scan conditions. A Tracerco Diagnostics Tower Scan of a bed that has uniform liquid distribution throughout will show little variation (implying little density difference) from one scan to another with all four scanlines overlaying one another. Non-uniformity among the scans implies density differences which can normally be attributed to an imbalance in liquid and vapour traffic. A Tower Scan can show discrepancies in liquid level on orifice-type distributors, liquid overflowing vapour risers on chimney trays, or disparities in irrigation rates for spray-type distributors. Scans can also detect evidence of problems such as fouling and crushed or corroded packing which often results in distribution problems. A Tracerco ThruVision Scan is used at one elevation and generates a high resolution cross-sectional density profile inside a process system. This can be a packed distillation column or a fluidised catalyst riser or piping where flow distribution of the process fluids or solids is vital to performance. The technique is most easily eplained by visualising a gamma scan where the source and detector remain at a fied elevation. A series of density measurements are taken by rotating the source and detector around the outer circumference of the vessel on a horizontal plane. Application of Tracerco s ThruVision Scan technology has provided a new window for observing phase distribution inside industrial process units in real time at an economical cost. The ThruVision Scan has been successfully applied to diagnosing the liquid distribution in packed columns and catalyst distribution in fluidised catalytic cracking risers and has made it possible and practical to collect much more vital online process information

8 Tracerco Scanning Services Scan Applications Tracerco Scanning Services Scan Applications The use of Scan technology on piping offers a non-invasive method to eamine the contents of a pipe in a wide range of process industries. The technology uses a small hand held device that is positioned across the section of pipe under investigation. A measurement is taken of signal intensity and a direct interpretation of pipeline contents is made. The most common applications of this technique include the determination of solids build-up within a pipe, slugging of process gas, liquid or solid over a period of time through a transfer pipeline and the confirmation of liquid carry over or gas carry under within a gravity separator. Scan technology offers solutions to a variety of process problems by: Measuring the presence, etent and position of solids within a process pipe Locating an ice/hydrate deposit within a gas flare line Establish the etent, duration and frequency of slugging Measuring liquid/gas interface passage during pipeline purging operations Confirming the presence of liquid carryover or gas undercutting within a vapor/liquid separator Do you have problems with your tank inventory? Are the liquid interfaces where your instruments say they are? Is sludge reducing capacity? These and other process control problems can be addressed using the Scan with neutron backscatter technology. This is a non invasive, rapid, and accurate technique usually performed without any preparation to the vessel. Results are instantly available allowing any process changes to be made. Storage Tank Scan Vapor Foam No hydrogenous material detected Organic Flare Stack Water No hydrogenous material detected above the liquid levels on the inside walls 1-3 Build-up 1-3 Build-up 15ft 3-5 Build-up Deposition Typical Response Vapor Organic Water Deposition Level was detected inches above the bottom tangent of vessel 7-9 Build-up Build-up Skirt This technology has a wide range of applications in industrial processes including: Level and Interface Measurement in Storage Tanks Deposit/Vapour Profile in Pipelines Foam Heights in Tower Downcomers Levels in Tower Distributors/Chimney Trays Interface/Emulsion band in Separators Water Ingress under Insulation Levels in Reboilers/Heat Echangers These are only a few eamples of the use of this fleible and accurate measurement tool. All processes are different so please seek our advice if you have a problem that appears to be suitable for investigation

9 Maimizer Maimizer Would you like to maimise the operational life of your sulfur absorbent? Tracerco has developed a new non intrusive technique for measuring the amount of used and remaining fresh zinc oide absorbent in sulfur removal systems (patent pending). The method builds on eperience with techniques and uses eternal scanning of the absorber vessel to identify a difference associated with the conversion of zinc oide to zinc sulphide. The technique allows consumption of the absorbent to be monitored and the remaining life to be predicted, thus ensuring maimum absorbent utilization. Tracerco s direct eperience with this technique has identified the following benefits: l Non intrusive, online testing l Advice on remaining life l Rapid feedback of results l No need for insulation removal Results of Scanning Sulphur Absorption Profile in a HDS Vessel ZnS I/F ZnO ZnO l Service provision can be linked to absorbent replacement The new scanning method also prevents downstream poisoning if the absorbent has been unepectedly consumed by slugs of sulphur in the feed. This method is suitable for vessels up to 2.438m in diameter with 50.8mm wall thickness. A Hydrogen plant operator obtains a further two years absorbent bed life. The HDS vessel in a refinery hydrogen plant had been operating for seven years. A planned shutdown was due in si months time and the operating company wanted to know eactly how much of the absorbent was still unused. The vessel contained two zinc oide beds, and the scanning results would help the decision whether to change-out the top bed or both beds during the shutdown, or delay the change-out for a further two years. The Maimizer was used to scan the vessel. It identified that the bottom 30% of the bed still consisted of fresh zinc oide absorbent, and an estimated remnant life of three years was calculated. The operator therefore decided to delay the change-out until the net shutdown in two years, and not open up the HDS vessel during the forthcoming shutdown. The scanning results are shown on page 15. An Ammonia customer minimises the amount of absorbent needed during a planned shutdown. The HDS vessel on an Ammonia plant had been running for three years and the zinc oide absorbent bed had a design life of four years. The actual sulphur content of the gas was much less than design, but as a planned shutdown was due, the operating company wanted to know how much of the absorbent had been used. The Maimizer was used to scan the vessel and identified that only the top 12% of the bed had been used. The remaining 88% consisted of fresh zinc oide absorbent. The operator therefore decided to order a small amount of absorbent and replace the top part of the bed during the shutdown. Samples of the absorbent were taken during the discharge and subsequently analysed for sulphur content. The analysis of the samples confirmed the accuracy of the scan measurements. Absorbent density Top bed Bottom bed Elevation (mm)

10 Tracerco Monitors Tracerco provides an award winning range of monitor products and services accredited to ISO9001:2008 and EN 13980:2008 international standards. Our range is designed to be lightweight, easy to carry and operate in the most demanding of environments. Our radiation contamination monitors conform to Standard EN 60325:2004 and our radiation dose rate monitors to EN 60846:2004. Radiation Monitors We offer a number of monitors which includes a range of intrinsically safe monitors, which are suitable for use in a potentially eplosive environment. Our range includes hand held, personal and probing monitors. Tracerco Monitors - Intrinsically Safe T201 Radiation Contamination Monitor, T202 Radiation Dose Rate Monitor and T404 Personal Electronic Dosimeter (PED) Tracerco Monitors - Non-Intrinsically Safe T401 Contamination Monitor, T402 Dose Rate Monitor Tracerco Monitors Tracerco Monitor Calibration Services Monitor Calibration, Retest, Servicing & Repair Current legislation requires that all radiation monitors used in service are subject to regular inspection and testing. Tracerco provides a professional service for the repair, testing and re-calibration of gamma dose rate and alpha/beta contamination monitors to ensure compliance. Radiation monitors are retested, and where necessary calibrated, in accordance with required standards. Key features of our service are: Typical turnaround within 3 days Epress service available upon request Fast turn-around on repairs Calibration of contamination monitors available against a range of isotopes including Ra-226 and Pb-210 Full range dose rate calibration facility to 100 msv/hr Testing of instruments to saturation dose rates in ecess of 100 msv/hr Calibration and repair of neutron monitors by approved third party facilities Intrinsically Safe Monitors Tracerco PED 18 19

11 Tracerco Instruments Tracerco Instruments The Tracerco Profiler Nucleonic gauges that utilise the unique properties of radioisotopes to provide measurement and control are widespread throughout industry. Tracerco Instruments provide a wide range of specialist measurement solutions, measuring key parameters such as level, density and interface. These instruments are all non-wetted devices, allowing them to be used in the harshest of process conditions such as high temperatures, slurries or corrosive materials. Typical Level Measurement System Benefits of Tracerco Instruments: Mechanical failure eliminated No fouling issues Easy to retrofit Greater control Reduced maintenance costs Tracerco has developed an award-winning instrument, The Tracerco Profiler, that is used in the oil and gas industry to measure the vertical distribution of various materials contained in separation process vessels. The Tracerco Profiler has now been designed to withstand the elevated operating temperatures typically eperienced within a Desalter vessel. The instrument is non contact, has no moving parts and requires minimal maintenance. The vertical measurement of the various phases in the Desalter provides information on the etent of inter phase miing that can be monitored to optimise fluid throughput while providing costs savings on chemical additives. If you would like to learn more about any of the Tracerco Instruments contact a technical advisor today for additional information or to schedule an onsite presentation. Typical Applications for The Tracerco Profiler Include: Oil/water/gas Separation vessels Heavy Oil Separation vessels Vertical cyclonic separators Desalters HP/LP Production & Test Separators Electrostatic coalescers/treaters, Degassers Multiphase settling tanks Inclined plate separators - Oil sands Primary separation vessels - Oil sands Froth Tanks - Oil sands Deepwater sub-sea phase separators Optimus Hyperion for Density Gas Tracerco PhaseGauge Benefits of The Tracerco Profiler Increased production throughput Real time process optimisation Reduce shutdowns and chemical additive costs Improves asset environmental compliance Low maintenance Foam Oil The Tracerco Profiler for Desalters Emulsion Water Sand Tracerco PhaseFinder Tracerco InterfaceGauge 100% Density 2 Tracerco TankGauge Oil Emulsion Water 20 21

12 Tracerco Speciality Applications Tracerco works with some of the worlds leading companies to assist them with special applications to solve non-standard measurement and monitoring problems. Relying on our vast knowledge and eperience with nuclear and chemical-based process measurement and monitoring systems, Tracerco provides custom instrumentation and process monitoring such as acquiring real time process density data for special process or research projects, custom designed nuclear instrumentation to tailor fit applications, or unique chemical tagging techniques for process characterisation. operating temperatures typically eperienced within a Desalter vessel. This patented specialist measurement instrument is used by refineries to measure phase interface position optimising separation performance and provide cost savings on chemical additives. Our eperienced application specialists will work closely with you to develop project parameters, to perform onsite job walks, and to design and eecute eperiments testing the technical feasibility all to find the best solution for your special application. A good eample is The Tracerco Profiler. This instrument is commonly used in the upstream oil and gas industry to measure the vertical distribution of various materials contained in separation process vessels. At the request of a major North American oil refiner Tracerco redesigned The Tracerco Profiler instrument to withstand the elevated 22