FCC fundamentals:

turnaround best practices

Basic procedures and activities are presented for the unit engineer
and other support personnel, designed to ensure a successful and safe
FCC turnaround
Ziad S Jawad
Shaw Energy & Chemicals Group

he term turnaround was coined

as oil refining itself was just
being developed. Large barrels
were used to heat and process crude oil,
and periodically these barrels had to
be turned as the metal exposed to the
heating element degraded; hence, the
term turnaround. Today, a turnaround
has a much more involved meaning.
Wikipedia describes turnaround as
follows:
In petroleum refining and chemical
manufacturing, a term meaning a
scheduled large-scale maintenance
activity wherein an entire process unit is
taken off stream for an extended period
for comprehensive revamp and renewal.
This operation involves a lot of
preparation, and many precautions are
taken because this is a dangerous
operation (especially at startup).
This article presents a collection of
best practices and examples of pitfalls to
avoid, which, if taken into account in
advance or incorporated into the
planning and work scope, will help to
guarantee a safe and successful
turnaround. This is the third article in a
series entitled FCC fundamentals,
designed to help unit engineers and
other support personnel maximise a
scheduled FCC shutdown. Just as in the
early days of refining, thoughtful
planning and execution will result in an
efficient turnaround, saving time and
money, and ensuring a long and
profitable run. Above all, advance
preparation is critical for the safe
execution of the plan, as, in the end,
finishing the job safely is the factor of
most value.

Advanced turnaround
preparation

As with most difficult tasks, advanced

preparation is the key to successful
completion. Unit engineers should be
engaged early in the preparation stages,
including the development of capital
projects, work scope and shutdown/
startup plans. It is important to baseline
normal operations pre- and post-

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turnaround with an equipment

evaluation that includes a complete
pressure survey and material balance.
This will help to quantify the success of
the turnaround, in addition to being a
valuable tool when providing input to
the work scope. Keep in mind that
work scope recommendations must be
accompanied by solid justification.
The unit engineers time during the
turnaround is valuable. There tends to
be a waiting period, followed by several
activities that require immediate and
simultaneous attention. The result
could be missed inspections or concerns
that are not addressed. The execution
of the turnaround work must not be
delayed. To avoid these situations,
prepare an inspection plan in advance
of the shutdown. Include checklists
and assemble all required mechanical
drawings. Table 1 shows a checklist for
a distillation tower. This checklist can
be duplicated for each tray in the tower.
The purpose is not to capture everything
that could possibly be inspected, but to
ensure a thorough inspection and help
document the findings. Keep a master
copy, either electronic or paper, and
make copies to capture findings and
notes during each trip inside the unit.
An attrition source checklist is specific

to FCC and includes a list of aeration or

steam connections and associated
restriction orifice diameters for quick
verification during the shutdown.
Steam/air rings and cyclones are other
possible candidates to thoroughly
inspect when searching for potential
attrition sources, including checklist
items.
Similar to checklists, equipment
drawing packages can be prepared well
in advance of the turnaround and
tailored to specific inspection tasks.
Keep a master copy of the drawings
that reflect existing equipment and
new equipment to be installed. The
master should be kept in the office,
where additional copies can be
reproduced for use during the
inspection. One example is a separate
drawing package for the equipment
accessible via each manway on the
reactor or regenerator. Knowing the
scaffolding plan in advance is also
helpful. During the inspection, it is
usually busy, noisy, dirty and dark.
Simplify the task by cutting out
important parts of the drawings. Group
these parts on a smaller piece of paper
and highlight important items for quick
reference when inside the vessel. For
example, mechanical drawings of the

Checklist for a distillation tower

Tray 19 top tray. Only monel tray in the column.
Weir height 3 5/8 (+/-1/8)
Downcomer clearance N/A


OK? Item





Comments

Are the downcomers clean and free of debris?

Are all the valves in place? Are there any bent or loose valves?

Is there any significant coke build-up under the valves?

Is the tray level? Are there any bulges caused by pressure

surges or flashing water?

Is the weir height correct?

Is the reflux nozzle in place? Is there any pluggage? (flow test)

Are there any holes or seal leaks that could allow liquid to

bypass the tray? (flashlight test)

Are the nuts and bolts tight?

Table 1

PTQ Q2 2009 19

Figure 1 Initial inspection of a cooling water channel box

reactor stripper can be simplified on
one or two pages, showing steam rings
and important dimensions. Main
fractionator drawings can be simplified
to just a few pages, showing odd, even,
draw or feed trays each on their own
sheet. These should accompany a
checklist and can also be used to take
inspection notes.

Shutdown and startup

procedure

The job of managing the FCC catalyst

inventory, which is particularly
important, immediately preceding and
following a turnaround, is commonly
assigned to the unit engineer. At
shutdown, the capacity of the hoppers
must be adjusted to allow enough room
for all of the catalyst in inventory to be
unloaded. Similarly, enough catalyst
must be available at startup to completely
inventory the unit and sustain any
losses until the next fresh shipments
arrive. These tasks can be tricky at times
due to losses during shutdown and
startup and usually involve selling or
disposing of equilibrium catalyst before
shutdown and purchasing it during the
shutdown.
The FCC shutdown procedure usually
begins several days before the actual
point of feed out; early activities include
the discontinuation of the use of
additives or addition of fresh catalyst.
Similarly, the startup procedure does not
end at feed in, but continues for several
days until the unit is completely lined
out and operating normally. The unit
engineer should be familiar with all of
the shutdown and startup procedure
steps and, at times, work closely with
operations to assist with the development
or optimisation of these procedures.
One possible task is the evaluation of
special procedures such as washing or

20 PTQ Q2 2009

decontamination procedures. Part of

this task is the selection of speciality
solvents or other cleaning agents. There
are several products that are useful when
attempting to properly clean for entry to
the main fractionator or gas plant
equipment. These products are very
effective for vessels in dirty or sour
services and accelerate the steam-out
time considerably. The chemical vendor
should be contacted as well regarding
recommended procedures, setup and
the safe use of the chemical.
Technical support during critical steps
of the startup procedure is invaluable.
Operational problems must be quickly
resolved and constant troubleshooting
is usually required. Another important
task is the monitoring of catalyst levels
during loading to minimise stack
emissions or carryover to the main
fractionator. New equipment startup
will not be familiar to operations support
personnel, and additional technical
support is almost always required.
Unit shutdown and startup are
excellent learning opportunities for the
FCCU engineer. Time should be taken to
sit on the board during this period and
learn more about unit operations. The
unit will experience many transient
operating conditions that are not normal
and only seen as the unit shuts down or
starts up.

Unit inspections

Once the mechanical blinds are installed

and the manways begin to open, the
process engineers role gets busy again.
Although there is a lot going on, safety
should always be the first concern. The
key to safety during a turnaround is
awareness of your surroundings. There is
a lot of welding, chipping, and the
movement of large items using cranes
and other refinery support equipment.

Safety areas are usually roped off, but

these areas can be mislabelled or the
barriers may be inadvertently removed.
Other safety items to be aware of include
the breathing environments in enclosed
areas and the possibility of falling debris.
Be sure to know and follow the refinerys
standard operating procedures such as
lock-out/tag-out and safe scaffolding.
Perform regular cleanliness audits and
report any problems. Slips and trips are
common injuries, as well as eye irritation
caused by foreign material, dirt and
dust. Obtain proper PPE and other safety
supplies in advance. These supplies are
discussed in detail later.
Inspections occur in many phases
and usually are performed in parallel
with other inspection groups. Process
engineers must work side by side with
personnel from mechanical and pressure
equipment integrity, as well as the
maintenance and refractory quality
control inspectors. Inspections usually
begin with the initial opening of the
manways, through which the first
glimpses inside the unit are available.
Keep in close contact with maintenance
personnel,
so
that
important
opportunities for initial findings are not
missed. Figure 1 shows the initial
inspection of a cooling water channel
box. If the removal of the cover plate
was not observed, this debris may not
have been noted. The root problem,
which was a failed upstream basket
strainer, may have been overlooked.
There could be several inspections inside
a vessel before it is fully cleaned and
prepped for maintenance.
One of the most important parts of a
turnaround is the initial discovery phase.
How quickly a problem is identified has
an impact on the success of the
turnaround. Once vessel entry is
available, time is critical. There is limited
time to conduct the initial inspection,
identify problems, and design and
implement engineering solutions. If too
much time elapses, the proper solution
may not have a chance to be
implemented. Often, many vessels are
available at the same time and the unit
support engineer has to prioritise which
item gets attention first. It is during this
period that assistance from third-party
inspectors is useful.
Contact technology providers in
advance and keep them informed of the
scope and projected dates. More than
likely, they will offer to visit during the
shutdown and provide a trip report as a
courtesy or part of their normal service
agreement. The quality of these reports
will vary from company to company. It is
not reasonable to place high expectations
on these reports without working out a
commercial arrangement for their visit,
but they can add valuable insight. Allow
only a few key vendors on-site with an
attempt to relay some expectation on the

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quality or content of the service report. It

is also best to obtain assistance from
colleagues as the point of contact for the
administrative details of the visit. This
will allow the unit engineer to focus
more attention on inspections and the
final report with the vendor.
Additionally, it may be prudent to
select one or two of the previously
mentioned vendors and inquire about
their inspection services. An acceptable
amount of support is one third-party
inspector per area to assist on initial
inspection and design solutions. For
example, identify a group of gas plant
distillation towers that will be available
for entry at the same time. Speciality
tray manufacturers usually have a
separate service group that can perform
an initial inspection and provide a
detailed inspection report, which will
include design solutions. These
inspections can help to minimise
turnaround duration, in addition to
providing a much more detailed report
(every bolt, support, distributor and weir
height). Once the third-party inspections
are complete, follow-up inspections by
the unit engineer can be more general
and used to track findings and repair
solutions. To maximise the effectiveness
and minimise downtime of the thirdparty inspectors, their support can also
be staged over multiple areas in the
refinery such as FCC and alkylation
units. Pre-placed parts trailers from
suppliers are also worth considering as a
cost- and time-saving option by
streamlining the procurement process.
Shaws Energy & Chemicals Group
can provide many levels of this type of
assistance for the converter and gas
plant sections, from full support with
process, mechanical and construction to
a single-person visit. Companies with a
well-established reputation in the
industry can produce measurable results
in the form of a faster, more efficient
turnaround, as well as soft benefits such
as improved reliability and operability
during the length of the run, based on
root cause analysis.
Other vendors to consider are
suppliers of catalyst, cyclones, fired
heaters and slide valves, as well as
chemical suppliers. As previously noted,
these vendors should be limited to one
per area or staged to prevent multiple
vendors reviewing the same piece of
equipment, which can be confusing and
waste time. Use only one vendor for the
initial inspection for a specific piece of
equipment.
Vendors that are not selected for an
on-site visit may be able to review
inspection reports, photographs and
mechanical drawings. Have a separate
contractor for hole watch duties and
avoid using extras from an existing craft.
There are certified, well-trained
subcontractors who specialise in these

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Figure 2 Damaged cyclone dipleg outlet valve

types of safety duties and, in the end,
they often prove to be less expensive.
Minimising down time can save money
and time, and will improve the
effectiveness of turnaround activities.
Following the inspections for
discovery is the maintenance phase of
the shutdown. The process engineer is
required to follow all of the turnaround
maintenance items as well as the
installation of new equipment and
share, with the entire team, the
responsibility for guaranteeing that the
equipment will run efficiently and
reliably for the subsequent run. There
must be close coordination with the
equipment engineering company or
technology licensor.
Most other disciplines have a much
more focused agenda during the
shutdown than the process engineer,
who can review all of the mechanical
disciplines reports and provide quality
assurance/quality control feedback.
Attendance at daily status and progress
meetings is a must. Process engineers
should ask questions, since they will be
considering things from a different
perspective and learning as well.
Capturing and recording findings in a
daily journal is recommended as a
method of gathering data to support
plans for the next turnaround, which
can never be too early. Shaw provides a
TIC/TAC (total installed cost/total
avoided cost) analysis, which is a riskbased appraisal of the process and
mechanical configuration to assist the
refiner in developing the scope of work
for the next turnaround. Integral to this
review is the historical information and
inspection findings from previous
turnarounds.
Final inspection and closure is another
important responsibility. The process
engineer or FCC asset manager should
always be the last person to sign off on a
manway closure to guarantee everything
is properly repaired, cleaned and
reassembled correctly. All individual

pieces of equipment accessible from the

manway should be verified as well. The
following are some guidelines and
suggestions for specific pieces of
equipment.

Cyclones

The initial and final inspections of FCC

reactor and regenerator cyclones are
critical. FCC operations are sometime
unstable. Dense bed levels are difficult
to monitor accurately and, as units are
pushed beyond design limits, cyclones
are often the first to show signs of
problems. If either set of cyclones are
consistently operated beyond their
design limits, some level of repairs
should be anticipated and replacement
parts should be on-site in advance. The
cyclone inlet, barrel, cone, dipleg,
transition areas between cyclones in
series and supports should all be checked
for signs of wear and erosion. Often, a
third-party refractory inspector will
perform a detailed inspection as well.
The dipleg outlet valve should
receive a thorough initial and final
inspection. Coke or erosion caused by a
variety of issues can cause serious
operational problems. Flapper and
counter-weighted valves should move
freely. Each should be tested individually
by fully opening and allowing them to
swing closed. It is extremely important
to consider catalyst or debris that may
fall when performing this procedure.
Be aware of people working below
when opening these valves, because a
significant amount of catalyst may be
discharged. The flapper should hit the
shroud equally at all points when fully
opened. When closed, there should be
no more than a 1/16th of an inch gap,
usually in only one region.
Notice the shrouded valve in Figure
2. This flapper did not hit freely and, as
a result, part of the shroud failed. Given
time, the rest of the shroud will also fail,
followed by the flapper itself. Also note
that the valve in the picture is wired

PTQ Q2 2009 21

Figure 4 Shaw/Axens proprietary FIT system

Figure 3 Refractory block protector upstream of thermowell
shut. It is common for these valves to be
wired shut during the turnaround, used
for mounting lights or stringing wire, or
even used to rig heavier equipment. All
of these practices should be discouraged
and, at the very least, each dipleg outlet
must be thoroughly checked as final
access is removed.
Another important check on cyclone
diplegs is commonly referred to as a
ball check. The procedure usually
involves dropping a heavy ball that is
attached to a chain from the plenum
down through the dipleg to verify there
are no obstructions. Any blockage
would most certainly result in an
unplanned shutdown to inspect and
clear. This check should be conducted
after all work is complete, and should
be followed by final inspection and
closure of the plenum.

Riser thermocouples and FIT

The interior of an FCC feed riser is a very

erosive environment and a difficult

service for thermowells. To complicate

matters, it is common for a thermocouple
to continue to provide output once it
has failed in this service. To help protect
these instruments, the well should be
fabricated from erosion-resistant material
such as cast Stellite. A refractory block
protector should also be provided
upstream (Figure 3). Retractable designs
that can be replaced online are also an
option. In general, all erosion-resistant
parts are brittle, so special care must be
taken.
The FCC feed injection system is
continuously
exposed
to
this
environment. Its reliable operation is
not only critical to the profitability, but
excessive reactor coke formation due to
nozzle tip erosion can result in an
unscheduled shutdown. Shaw E&Cs
proprietary feed injection system has an
industry-proven record for reliable
operation. Its design includes a
removable feed nozzle for tip inspection
and replacement. The nozzle tips can be

Figure 5 Torch oil nozzles and the accompanying thermocouple should be inspected,
taking note of their location and thermocouple instrumentation tag

22 PTQ Q2 2009

inspected in place, although it is much

easier to pull the nozzles shortly after
shutdown rather than waiting, if and
when it is needed. During the removal
procedure, timing and technique are
important. Waiting too long following
shutdown and not following the correct
extraction techniques could make
removal difficult. External piping can be
easily removed for the inspection of the
target bolt, steam and oil orifice. The
Shaw/Axens proprietary FIT system is
shown in Figure 4.

Torch oil nozzles

Units are typically designed with

multiple torch oil nozzles, but it is
possible to obtain the desired bed
temperature with only one nozzle. Using
fewer nozzles than designed will result
in elevated local high temperatures.
More than likely if a torch nozzle has
failed, it is the result of a thermal
excursion during startup. Proper torch
oil procedures begin well before feed in.
Torch oil nozzles and the accompanying
thermocouple should be inspected, as
well as the associated piping, taking
note of their location and thermocouple
instrumentation tag, as shown in Figure
5. During the startup procedure, begin
with one nozzle at a time. Have an
operator posted at the isolation valve
and continuously monitor the associated
thermocouple. If a rise in temperature is
not observed in one minute after flow
initiates, shut off the oil and double
check the piping. Then increase the bed
temperature to approximately 800F and
retry. Never continue hydrocarbon flow
without verification of the associated
temperature increase. Once the
combustion of the torch oil is verified,
quickly repeat the procedure for all of
the available torch oil nozzles.

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Instrumentation taps
and piping

A complete pressure balance should be

performed well in advance to assist the
initial turnaround scope development.
It is possible to add new pressure taps for
new projects or even for existing
equipment if identified far enough in
advance. This is also a good time to
identify problems with the piping and
tap setup. It is best to use a new pressure
gauge with a reasonable range or
preferably a single or digital gauge when
doing surveys. During the shutdown,
capital improvement and maintenance
projects should be followed closely in
the field to verify that new taps and
piping are correctly installed.
Poor piping may make it difficult or
impossible to measure the pressure and
troubleshoot the unit. Replacing broken
gauges may be impossible on-line.
Shutdown may be the only time to
correct these problems, so be sure to
check purge and aeration tap restriction
orifices, and correct any piping
problems.
It is best to follow a standard piping
detail for instrument purge. A local
pressure gauge should be on the same
leg as the impulse line, with a separate
block valve for the local gauge. Figure 6
shows a typical example. If the line is
3/4 inch or larger piping, it is best to
reduce it down to 1/2 inch, so a smaller
valve can be used. Reducing the size will
make it easier to get the measurement
quickly. A pressure survey should not be
time consuming; otherwise, the results
may not be useful.
Restriction orifices set the instrument
purge and aeration or steam flow rates
and should be well labelled. Piping
restriction orifices usually have tabs, as
shown in Figure 7. Without a tab or
other marking, the orifices cannot be
easily distinguished from gaskets or
spacers. Usually coupling restriction
orifices do not have tabs and special care
must be taken to identify them properly.
As mentioned above, have a checklist
prepared in advance so nothing is
overlooked.
It is common for internal standpipes,
risers and other equipment to have
impulse and aeration lines located inside
the reactor or regenerator. This is an
extremely harsh service and these lines
commonly fail due to thermal expansion
or impingement. Sometimes they can be
damaged during turnaround when used
as a stepping stool, foothold or when
they collide with other equipment.
Figure 8 shows two examples where
thermocouples were damaged during
turnaround. The photograph on the left
shows the thermocouple bent out of the
way for access to the cyclone; the
photograph on the right shows damage
that occurred during scaffold installation.
If you notice any damage, alert the

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Figure 6 A local pressure gauge should be on the same leg as the impulse line, with a
separate block valve for the local gauge

Figure 7 Piping restriction orifices usually have tabs

Figure 8 Two examples of thermocouples damaged during turnaround

PTQ Q2 2009 23

you can keep up with the wash cycle)

and order a new pair of boots. Use the
old pair for the turnaround, but most
likely you will dispose of them afterwards
and switch to the new pair. A locker
located at the unit is a good idea, if
possible, to store your harness, coveralls
and miscellaneous supplies. Another
suggestion is to have an assigned office
in a nearby turnaround trailer.
Purchase metal markers in advance,
such as Nissen solid paint markers, and
use a different colour to your inspection
group. Also required are a personal
flashlight and a heavy-duty light for
your group. Select the higher wattage
versions the Pelican Sabre and
Streamlights Vulcan are good examples
commonly used in industry.
Another important accessory is a
digital camera. Make sure you follow the
proper procedures for its use within the
unit. Find an inexpensive model, but
keep in mind that FCC catalysts can be
tough on delicate equipment. A spare
camera is a good idea. A good inexpensive
model is the Nikon Coolpix.

Figure 9 Poorly installed pressure tap

Conclusion

Figure 10 Strips of duct tape and a roll of dental floss can make it easier for one
person to perform an accurate elevation survey
turnaround foreman of the importance
of these lines remaining intact or being
replaced. Failed or improper purge and
aeration flow rates can cause major
circulation and attrition problems
during operation.

Internal elevation surveys

The shutdown is the only time that the

elevation of internal equipment and
instrumentation taps can be measured
accurately. It is important to measure
pressure tap elevations and penetrations,
as well as noting their position in the
vessel. For example, consider the pressure
tap shown in Figure 9. This tap does not
extend far enough into the bed and is
located in the crotch of a plate air grid
distributor. Installations such as this one
are poorly aerated and will result in a
faulty bed level or density readings.
A laser level system may provide a
more accurate elevation survey, but an
effective alternative is a simple string
level. Strips of duct tape attached to
coveralls for convenience and a roll of
dental floss make the task easier for one
person to perform, as tangles can be
discarded. Mark the elevations in a
common area, as shown in Figure 10,
and then measure all of the marks
relative to one point such as the bottom

24 PTQ Q2 2009

tangent line. Stripper internals, catalyst

distributors, steam and air rings, pressure
and temperature taps, cyclone dipleg
outlets, and standpipe entrances are a
few examples of important elevations to
include. Becoming familiar with these
elevations will help you to understand
dense bed catalyst levels and equipment
submergence levels, especially during
shutdown and startup operations.

Safety and inspection supplies

One frequently overlooked item when

preparing for a turnaround is the need
to gather safety and inspection supplies
in advance. Scrambling around at the
last minute or borrowing equipment
can be time-consuming or even unsafe.
The refinerys material store or
warehouse should have most of the
required safety supplies, including work
gloves and DuPont Tyvek suits. Be sure
to order several pairs in the correct size.
Obtain a safety harness and respirator
for the duration of the turnaround, as
having your own will prevent you
having to constantly readjust it. Get
into the habit of always having these
items with you and be prepared at a
moments notice to do a quick inspection.
This saves a lot of time.
Have at least three sets of coveralls (so

An FCC turnaround is a large

undertaking, requiring several years of
preparation. Its execution involves a
large portion of the plant. A successful
turnaround benefits a units operability,
safety, reliability and profitability for the
life of the unit. Remember to always
think before you act and, above all, be
safe. The author would like express
gratitude to the various operating
companies for the opportunity to
support their technical service needs.
Pocket Sabre is a mark of Pelican Products.
Vulcan is a mark of Streamlight-Flashlights.
com
References
1 Jawad Z S, FCC fundamentals: coke yield/
delta coke, PTQ, Q2 2007.
2 Jawad Z S, FCC fundamentals: cyclones
and vendor datasheets, PTQ, Q4 2007.
3 http://en.wikipedia.org/w/index.php?title
=Turnaround&diff=268066545&oldid=245
081232

Ziad S Jawad is a Refining and FCC

Technical Manager for Shaws Energy &
Chemicals Group in Houston, Texas. He is
responsible for technology and design in
the reliability and optimisation of FCC and
refining revamp projects.
Email: zee.jawad@shawgrp.com

Links
More articles from the following
categories:
Fluid Catalytic Cracking
Revamps, Shutdowns and Turnarounds

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