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FCC Special Valves Best Practices To Increase Performance Reliability Service Life Natalini Remosa FCCU Galveston 2014
FCC Special Valves Best Practices To Increase Performance Reliability Service Life Natalini Remosa FCCU Galveston 2014
Mauro Natalini
Deputy Manager - Valve Engineering Dept.
REMOSA
Cagliari, Italy
Tel +39.070.2020237 / Mob +39.366.6891228
m.natalini@remosa-valves.com
www.remosa-valves.com
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OVERVIEW
2
REMOSA History
3
IMI Severe Service
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FCCU - Fluidized Catalytic Cracking Unit
Valve Installations
Fractionator
1A - Regenerated Catalyst Slide Valve (Single Disc) Wet Gas / LPG
1B - Spent Catalyst Slide Valve (Single Disc) Reactor
1C - Recirculated / Cooled Catalyst Slide Valve (Single Disc)
1D - Flue Gas Slide Valve (Double Disc) Separator Naphtha / Gasoline
2 - Double Disc Through Conduit (Double Disc) - Isolation
9 1D LCO / Middle Distillate
4 or 10
Regenerator HCO / Fuel Oil
Orifice 1B
Chamber Expander 5 2
Pump
3 Around
1C 5 5
Pumps
3, 9 6
7 Bottom
5 5
8 1A
4 or 10 Residual
Stack 2
Catalyst 5 5
Withdrawal
Air
CO Boiler or 3 - Butterfly Valve Pumps
3A - Diverter Valve
Waste Heat Boiler 4 - Goggle Valve / Automatic Blind - Isolation 5 5
5 - High Perform. Gate Vlv. (Double Disc) - Isolation
3A 6 - Catalyst Withdrawal Plug Valve - Control
3 4 4 3 4 4 7 - Catalyst Withdrawal Valve - Isolation Bottom
Electrostatic 8 - Special Check Valve - Air Blower Discharge
Precipitator 9 - Variable Orifice Valve – Control
Flue Gas Cooler 10 - Double Clapet Isolation Valve - Isolation
3 4 4 3 4
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FCCU - Fluidized Catalytic Cracking Unit
REMOSA / Z&J Products
Slide Valve Diverter Valve
(Single Disc) (Pendulum Type)
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CASE HISTORY #1
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CASE HISTORY #1
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CASE HISTORY #1
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CASE HISTORY #2
Original Valve
Original Cold vertical clearances
between internal sliding parts
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CASE HISTORY #2
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CASE HISTORY #2
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CASE HISTORY #3
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CASE HISTORY #3
Orifice Plate
Guides
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CASE HISTORY #3
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CASE HISTORY #3
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CASE HISTORY #4
3D of VO Valve
VO Valve Installed
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CASE HISTORY #4
Such analysis is carried out to maximize valve performance and to ensure a long-lasting service
of the plant, in terms of flow-dynamic behavior and erosion resistance of the valve, for both
single-phase and two-phases flows.
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CASE HISTORY #4
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CASE HISTORY #5
FLUE GAS DIVERTER VALVE: “… to reduce the emissions for the plant”
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CASE HISTORY #5
FLUE GAS DIVERTER VALVE: “… to reduce the emissions for the plant”
- The leakage test, witnessed by German TUV Inspector, showed a performance much
better than the (strict) limit imposed by Customer (below 0,05% of Total Flow).
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Engineering Advantage and Technical Services
REMOSA Expertise
• Tailor‐made solutions according to customer’s needs /
standards and to local regulations
• Overall production capabilities (100% in-house
manufacturing)
• High‐End Engineering capabilities (FEM, CFD, 3D CAD)
performed in‐house by experienced designers with practical
on‐field background
• Wide R&D and Testing Capabilities (Hot Stroke, Leakage
Test, FAT)
• Field Service activities performed by skilled, trained and
experienced personnel
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Turnaround Strategies & Best Practice
FIELD SERVICE
Since 1955, REMOSA has been operating in the field
of industrial maintenance and specifically within
refineries and petrochemical plants.
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Turnaround Strategies & Best Practice
FCC Network: Group of Companies Dating Back 138 Years
FCC Worldwide Network:
Cagliari, ITALY (REMOSA - Headquartier)
Duren, GERMANY (Z & J – Headquartier)
Houston, USA (Z & J / REMOSA – Facilities)
Vanderbijlpark, SOUTH AFRICA (Z & J – Facilities)
Shanghai, PR CHINA (Z & J– Facilities)
IMPROVEMENTS:
- More Local Support: Customer Care, Consultant and Training;
- More Prompt Action: Engineers and Specialists ready to go around the world in less then 24hrs;
- More Expertise & Service: Reliable Repairs, Refurbishments and Revamping Projects;
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Turnaround Strategies & Best Practice
FIELD SERVICE
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Turnaround Strategies & Best Practice
FIELD SERVICE
MINIMIZING TOTAL DOWNTIME
Plan the turnaround, with a qualified valve/control system manufacturer, no later than 6
months prior to the scheduled shutdown
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Turnaround Strategies & Best Practice
FIELD SERVICE
MINIMIZING TOTAL DOWNTIME
• Recommendation for the necessary level of spare parts must have “on hand” for the Turnaround
• Proposed Turnaround procedure
• Definition of Valve Contractor work
• Definition of Valve Contractor responsibility
• Planning and Scheduling of Turnaround activities
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Turnaround Strategies & Best Practice
FIELD SERVICE
MAXIMIZING ELAPSED TIME BETWEEN TURNAROUNDS
Failure of parts
Catalyst build up on the guides and disc running surfaces
Excessive wear on internals
Internal bolts failure
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Turnaround Strategies & Best Practice
FIELD SERVICE
MAINTAINING RELIABLE PERFORMANCE
Selection of a qualified valve contractor PLANNING
&
PRIMARY QUALITY OF VALVE CONTRACTOR MANAGEMENT
Valve manufacturing expertise
In-house valve engineering expertise
Complete shop capability for field support
Valve modification experience MAINTENANCE
Excellent safety record REFERENCE LIST
Quick response terms
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CONCLUSIONS
www.remosa-valves.com
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