Document pe8vkvVYwnKr7KvY9qj1nz9Za

STUDY GROUP MINUTES THREE-YEAR FCC RUMS EE FASO REFINERY R. L.'Flanders .and J. H. Morrison met with members of the El Paso Refinery (J. C. Keating, C. R. McGinnis, J. W, 3arcfoot, M.' E. Brown, N. L. Lewis. R. A. Norecn; P. J. O'Keefe, N. Payne, and J. R. Wheeler) November 7 to develop a list of design considerations and maintenance items required to permit operation of tee El Paso FCC Plant for three-year intervals between shut downs. The time interval of three years 'was. selected to correspond to the State of Texas requirement to inspect the CO Boiler and FCC Regan Gas cooler at three-year intervals. Maintenance and altera tion items contemplated for the next El Paso FCC Plant shutdown, April 1975, 'were also discussed and are included in the summary notes below. The personnel key to these minutes follows: REF/JKM--indicates a 'joint recommendation of persons listed. GROUP -vindicates' agreement between El Paso personnel, REF (Chevron Research representative) and JHM (Soeal Engineering Department representative). El Paso--indicates responsible group at 1 Paso Refinery made the decision or will handle the- work * --information developed in afternoon meeting with only M. L. Brown, RLF, and JHMin attendance. A. FCC Regenerator. Grid Support Posts and Peripheral Grid to Shell Seal 1. GROUP. These should be replaced by a single cylindrical support system as shown on Draviing GT-F-27348-0. This will require purchase of a 1-1/4 Cr grid knuckle section and a 1-1/4 Cr/carbor: steel cylinder support section. Soeal Engineering Department personnel have ordered needed material and will- arrange for fabrication of both knuckle section and support cylinder. 2. *JHM/MLBrown.. Details still under study by the Soeal . Engineering Department and not yet approved by El Paso are : a. Need for refractory lining on top side of knuckle section to lower temperature of weld and to mitigate hot 'spots. b. Desirability ,of packing void between cylindrical support and shell with KAOWOOL. c. Alteration to grid to grid knuckle section weld ' detail to permit easier fit up where grid is warped. Enel. - Figure 41 of 1974 Process Meeting Notes CHEV RR 010913 B. New Seals for FCC Rcgen 'Overflow Nell and/or Spent Catalyst Riser 1. El Faso Engineering group is aware of pros and cons of `"purchased*r.bellows seals versus "in-field" box-type seals. They plan to consolidate their thinking and position shortly. . Until then, Socal Engineering Department will obtain no bids and order no material. 2. *R1F/JHM will develop and transmit written recommendation to El Base on: a. Outer, shroud, over seal. b. Installation of Socal Engineering Department designed top well guide. (El Paso has details.) . c. Under grid secondary seal. (See Figure kl_. 1974- ' .Chevron Process Meeting "notes attached.)' C. FCC Regen Cyclone Shave Pockets 1. RLF. Decommission.shave-off pockets in all primary cyclones.. Use, Richmond Refinery procedure as a guide. (Both general data andcbtails left with Mel Brown.) 2 RDF.' Leave shave-off pockets of all secondary cyclones "as is" as erosion has not been a problem. 3.1 El Paso.agrees. D. Emergency. Water Spray. in Re gen1 Plenum , 1. RLF/JHN. Relocatenozzle to first elbow off regenerator. Tftli/JHM would appreciate opportunity, to review design.) 2. El Paso.tentatively agrees. , E. Catalyst Withdrawal System, ... FCC Regen1 ' 1. GROUP.' El Paso will design' and install a more' effective har"typc strainer, over grid drain hole. 2. RLF/JHM. Recommended'El Paso design a better under grid "slip joint or packing gland.in dump line. Socal Engineering Department will assist if so requested. El Paso will investigate. r.HFV ?. FCC Hegen Shell ... Rofracto-*y and Insulation CHOUF. El Paso will repair all bulged areas with "one-shot" refractory and alloy anchors. At least three (3) carbon steel anchor rods will be bent to Richmond Materials Lab for analysis:' 0. High Temperature Regeneration or Air Spargers ir. FCC- Regen JCK/RLF. Agreed neither of above process changes could bo justified in immediate future; no no special shudown work or studies are required. K. Replacement Air Cooler for FCC Regen Oases 1. CROUP.' Agreed bid for hi-temp regeneration operation, as. well as bid for replacement in kind should be obtained. 2. JHM. Replacement in kind bid should be available late Uovember/early December. Hi-temperature bid about 2-4 weeks later. X. FCC Regen Cyclone Hanger Rods GROUP. Carefully inspect and seal weld or otherwise repair as necessary. J. FCC Reactor Cyclone Hanger Rods GROUP. Carefully inspect and seal weld or otherwise- repair as necessary. K. Reactor Cyclones 1. GROUP. Obtain quote for set cf replacement carbon steel cyclones-. Existing units are oldest ones in Corporation. Metal deterioration makes weld repairs most difficult and not reliable. Will probably require replacement second scheduled shutdown from now. '2. RSF/JHM., Recommend at least three vendors be requested to bid. Also, suggest bid lists .outline general cyclone requirements rather than request exact duplicate units to obtain full benefit of latest cyclone technology and more competitive bids. L. - Reactor Lining 1. GROUP. Replace defective lining. S. t determine possibility of using "one-shot." CHEV BR ninois w m m z] K. Reactor 5. Bend 1. REF. No need to maintain straightening vane assembly "in S bend. 2. *Ifel Brown. El Paso will eliminate straightening vane or repair depending on which alternate is cheaper and easier. N. Reactor Grid Holes. 1. RI. Enlarged holes,not detrimental as long as integrity of deflector plate support bars and srid support pins are maintained. A new reactor grid is not (negative! needed. 2. CROUP. Viill re-establish original grid hole size in areas needed to assure above objective.. J. *RLP. Recommends four 4-inch holes be installed in . deflector'plate . -Will send El Paco Chevron Research sketch; El Paso tentatively plans to do work.. O. Reactor PrimaryDip Lems 1. RLF. Reactor _dip leg3 should be sealed and cELscharge into anulus area. 2. GROUP. 'Above will be done with either trickle valves or box seal'{whichever is cheaper). 3. JHM will send El Paso drawings of Pascagoula box seal installation. P. Reactor Secondary Dip Legs RLF is analyzing .possible benefits and will advise El Paso of~his recommendations. El Paso to generate rates of catalyst' in fractionator bottoms. a. R-205 Flare Inspection and Repair_______________ *S1 Paso is studying the scheduling and', other problems required to Inspect and repair R-205 flare during April 1975 shutdown. R. U-Bend Replacement and Repairs SI Paso has needed material on order for April 1975 shutdown. CHEV BB 010216 ESEWafrWI Pacific Slide Valve' in Regenerated. Catalyst U Bend . 1 1. . *E1 Paso expects major repairs. Anticipated life.' 'beyond one more run is uncertain. . 2. ''RL'F/JKM. Recommend bids' for a replacement chrome valve .be available from at least Chapman and TAFCO early May 1975 Delivery now of such valves is 8 months plus. {Pacific no longer sells slide valves..) 5. JHK will send_,El Paso drawings, of how Chapman plans to rebuild Pacific slide valves for Pascagoula eg' soon as details .are.finalized. Necking1Down of CO Boiler Stack 1. /RDF will send El Paso data on opacity of stack gr'ses versus velocity. Also recommends that increase in pressure of system be analysed as'to its effect on . possible overpressuring of PCC Precipitator, etc. 2- *JHM suggests El Paco 'design be reviewed by Socal Engineering Department as to possible adverse, noise' and/or vibration, problems (Pascagoula and Vancouver). Also, will design adversely affect PCC and/cr- CO Boiler 'blowers? . Regenerator Dense Bed Water Sprays RLF.recommends piping to these sprays be dismantled. El Paso is reviewing. Regen Torch Oil Installations 1. *RLF/JHM recommend the existing fixed torch oil nozzles be converted to retractable-type nozzles to ensure three years of operation. Existing small nozzles could be blinded off and abandoned .and 5-inch water spray nozzles, used for this service. (See. U-. above.') Oil should be atomised to minimise .hot spots and cat' attrition. ' 2. *RLF will supply nozzle details. El Paso has details on retractable nozzles. Regen Secondary Dip Peg3 RDF.. Recommends these be extended to within 4 feet .of grid to out down on fines recycling. CHEV -G- XSecond-Stage G.as' Compressor 1. GROUP , Pant history or failures of this equipment 'indicates corrective action must be taken to permit three-year FCC Plant runs. 2. 1JCK.requested .local. Engineering Department and CRevron Research in-depth study of this problem as soon as possible to pinpoint problem and recommend corrective action. JHC'V'ftDF.will set up. This study is related to Item AA. Y. Doughnut Rings in Reactor Stripper JKi'i recommended either replacement of existing damaged , doughnut rings per Detail D of PA-l8-22'+22-0 or installation of horizontal restricting, plates. Mel Brown .will accept one of these alternates, after .Socal Engineering Department pro vides'additional details. JHtt will'handle. 1Z. Precipitator El Paso group, did not feel reliability of, precipitator was a problem as far as three-year runs. They do feel that detailed inspection and thorough workmanship is important during shutdown periods. . They agree operator startup procedures are important. RDF transmitted a copy of Richmond Refinery precipitator operating-, startup procedures to Dick Noreen for reference. AA. Recovery Area Column Exchanger. and Reboller Reliability El Paso is analyzing replacement bundle needs, bypass require ments if any, etc., to determine what is needed. 3B. How Rotor forK-l301 Air Blower and Other Spare Parts_. El Paso is studying. Some common rotating elements for Hawaii/21 Faso now .exist. CC. Regen Primary Dip Legs and Trickle Valves GROUP. These should be retained to save catalyst on' startup. Thinned sections of pipe will be replaced. Consideration will be given to extending hexmesh lining to the outlet of the pipe top to bottom. DD. Reactor to Fractionator Line Mitres and Fractionator Bottoms Nipples 1. El Faso plans to thoroughly inspect all mitres for possible cracking-as occurred recently at El Scgunno, (This, was last done in. 1570.) 2. El Faso also plans to' inspect all nipples and attachments in fractionator bottoms systems for fatigue cracks.. EE. Re gen Grid Manway El Faso does not require design check out of this installation by Socal Engineering Department. CHEV BR fHno OUTGOING TELEGRAM 16RR 1-13-75. 4: 10 PM J.C KEATING ATTN C MCGINNIS/M L BROWN EL FASO REFINERY' EL PASO TEXAS IN ANSWER TO JCK PHONE INQUIRY TO R L FLANDERS WE SUGGEST FOLLOWINGFCC SHUTDOWN ITEMS SHOULD BE GIVEN SPECIAL ATTENTION IN YOUR DECISION TO POSSIBLY DELAY SCHEDULED SHUTDOWN TILL 1976. LETTER DESIGNATIONS ARE PER OUR NOVEMBER IZf 1974 LETTER: C. , REGEN CYCLONE SHAVE POCKETS CATALYST'LOSS WILL INCREASE AND. REPAIRS WILL BE MORE EXPENSIVE' AS TIME GOES ON. UNLIKELY THAT THIS.WILL FORCE A SHUTDOWN. F. REGEN'SHELL REFRACTORY/INSULATION ' ', RECOMMEND YOU,MONITOR THIS WITH INFRARED AND/OR HAND PYROMETER' ONCE EVERY SIX WEEKS TO ASSURE INTEGRITY. H. REPLACEMENT AIR COOLER I. AWAIT RESULTS OF RADIOACTIVE-WATER LEAKAGE TEST NOW UNDER WAY. 2. VERIFY PRESSURE DROP FROM PLUGGED TU3ES DOES NOT LIMIT ' PRESSURE RELIEFING CAPACITY OF GAS SYSTEM' FROM REGENERATOR. H. REACTSR -CYCLONES MONITOR QUANTITY AND SIEVE ANALYSIS OF CATALYST IN FRAC BOTTOMS WEEKLY TO VERIFY INTEGRITY OF SYSTEM. R. U-BEND. REPLACEMENT MOST CRITICAL ITEM ON SHUTDOWN LIST AS FAR AS DEFERRAL IS CONCERNED. MEANINGFUL ON STREAM MONITORING UNLIKELY BUT INVESTIGATING . POSSIBILITY WILL CALL MEL BROUN 1-15. X.- SECOND-STAGE GAS COMPRESSOR - SPECIAL. REPORT IN PREPARATION. 'ttwimit |j~"7 CRR-1806 (500-2-62)