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Optimization & Troubleshooting Process Optimization Distillation Columns Fired Heaters Vacuum Systems Pumps & Compressors Reboilers & Condensers Crude Preheat FCC Gas Plant
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PROCESS OPTIMIZATION AND TROUBLESHOOTING

Due to our unique work process and focus on revamps, Process Consulting Services has the experience to serve as an exceptional process optimization and troubleshooting partner.

We understand equipment performance and the fundamentals of equipment design. From distillation column internals to fired heaters, our experience and our understanding of the fundamentals allow us to efficiently identify problem areas and potential solutions. Our expertise with design tools supports confident decision-making through quantitative analysis of problem severity and solution effectiveness.

Process Consulting Services engineers understand connected process systems. We have extensive experience with large capital revamp projects of entire units, which requires careful consideration of the whole unit impact of individual modifications. In units like CDU/VDUs or FCCUs with complex heat and pressure balances, solutions must be approached holistically to avoid disappointing or unexpected outcomes.

Contact us today to discuss your specific process optimization or troubleshooting needs. Follow the links below for more information.

 PROCESS OPTIMIZATION

Process Consulting Services can help optimize unit operation to maximize profitability today. Online process optimization is a low-to-no cost activity that can bring unit operation in line with refinery goals such as:

  • Minimizing jet fuel production

  • Maximizing diesel production

  • Maximizing energy efficiency

  • Maximizing vacuum resid cutpoint

  • Etc.

Working alongside our customers’ engineers and operators, Process Consulting Services analyzes overall unit heat and mass balance and equipment capabilities to identify the most profitable operating strategies. Process optimization often includes a troubleshooting component to identify small limits and flag them for remediation at the next opportunity.

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Distillation Column Troubleshooting

We have experience designing and troubleshooting a wide range of distillation internals, including conventional trays, high efficiency trays, structured packing, random packing, vapor horns and Schoepentoeters, trough distributors, spray headers, and more. Our column troubleshooting approach relies on collection of accurate field data for comparison against simulations and other calculations. Our methods include:

  • Participation in development and execution of test plans to pinpoint root cause(s)

  • Field survey with high accuracy digital pressure gauges and thermocouples

  • Process simulation to understand heat balance and fractionation performance

  • CFD of flash zone internals

  • Identification of unit operating changes to unload specific column sections and move column to more reliable operating window

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Fired Heater Troubleshooting

Understanding the cause of coking, high tube metal temperatures (TMTs), high pressure drop, low draft, high firebox pressure, or a combination of several of these problems requires accurate field data and rigorous analytical models. Process Consulting Services can help troubleshoot fired refinery process heaters by employing the following tools:

Field survey

  • Process and flue gas pressure and temperature profiles

  • Oxygen profile to identify air preheater leaks

  • Forced draft and/or induced draft fan performance

  • Burner pressures

Engineering calculations

  • Well-stirred firebox models (FRNC-5, HTRI)

  • Tube-by tube hydraulic analysis including film and metal temperatures

  • Geometry-specific analytical methods for hot spots and peak heat fluxes

  • Design rules for firebox size and burner spacing

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Vacuum System Troubleshooting

 
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Vacuum systems including steam jet ejectors, liquid ring vacuum pumps, and associated intercondensers are common causes of frustration due to poor or inconsistent performance. In addition to understanding the performance of each individual piece of equipment, vacuum systems must be considered as a whole, because the performance of each item can have significant upstream and downstream impacts. Identifying the root cause of poor vacuum system performance requires careful field data gathering, field tests, and a large experience base.

Our detailed troubleshooting approach includes:

  • Participation in development and execution of test plan

  • Detailed field survey of entire vacuum system pressure and temperature profile

  • Pinpointing of root cause(s) of poor vacuum performance

  • Identification of process changes to minimize tower operating pressure (if any)

  • Identification changes to stabilize vacuum system performance and avoid instability/breaking

Pump and Compressor Troubleshooting

Troubleshooting pump and compressor performance or control issues requires accurate field data collection and careful analysis. When troubleshooting pumps and compressors, Process Consulting Services begins by conducting a detailed pressure survey with high accuracy digital gauges. After the initial survey, specific tests can be developed to validate or rule out potential causes of the performance or control issue. Detailed field measurements are compared against rigorous hydraulic and mass balance calculations to guide the troubleshooting process.

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Reboiler and Condenser Troubleshooting

Reboiler and condenser problems are the cause of many distillation issues. Careful troubleshooting can determine the root cause(s) of heat input or heat removal problems. The troubleshooting process is guided by comparison of detailed field data against PRO/II, HTRI, and rigorous hydraulics calculations. Depending on the situation, CFD may also provide useful insights.

Common Reboiler and Condenser Problems:

  • Exchanger sizing

  • Fouling, coking, and polymerization

  • Column draw/return arrangement

  • Draw/return piping

  • Heat flux limits

  • Low LMTD

  • Low cooling water or heating medium flow

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Crude Unit Preheat Train Troubleshooting

Poor crude preheat train performance is common and leads to a number of serious issues affecting unit throughput and reliability. Working with DCS data and field survey information, Process Consulting Services can identify problem areas and make recommendations to optimize crude unit performance. PCS engineers have completed field evaluations of the preheat trains in nearly 100 different crude units. Field measurements and plant DCS data are compared against process simulations and equipment rating software to identify opportunities for improvement.

Common Crude Preheat Train Problems:

  • Crude hydraulic bottlenecks

  • Product and pumparound hydraulic bottlenecks

  • Desalter too hot or too cold

  • Products leaving crude preheat train too hot for storage

  • Rapid exchanger fouling

  • Control problems resulting in instability, such as in heater pass flows

  • Inability to remove enough heat in crude and vacuum column pumparound and overhead

 FCC Gas Plant Troubleshooting

In the FCC Unit, Process Consulting Services can help with troubleshooting activities such as:

  • Detailed hydraulic survey of FCCU fractionation section from reactor outlet nozzle, through main fractionator, wet gas compressor, absorber/stripper, debutanizer, etc.

  • Identify operating changes to increase wet gas compressor discharge pressure or capacity

  • Locate gas plant bottlenecks in piping, valves, distillation columns, reboilers, and condensers

  • Identify operational changes to unload gas plant equipment and/or maximize C3 recovery

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For more information or to discuss your specific needs, please Get in touch.