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HydrocarbonProcessing.com | MAY 2014

®

PROCESS DESIGN

Dynamic models improve safety for high-pressure vessels

ENVIRONMENT

Investigation reviews inert gas usage

SAFETY

Hazard analysis identifies alarm/control problems

SPECIAL REPORT:

Maintenance

and Reliability

Better performance, less downtime, better profitability – everyone approves of that.

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MAY 2014 | Volume 93 Number 5 HydrocarbonProcessing.com

SPECIAL REPORT: MAINTENANCE AND RELIABILITY

53 Reliability tips for centrifugal process pumps H. P. Bloch

61 Micro-alloyed steel: New standard for reformer tubes A. Steckmeyer, B. Fournier, H. Chasselin and C. Mougel

67 Evaluate piping for displacement-controlled loading J. Tharakan and M. Anisuzzaman

PROCESS DESIGN

71 Use dynamic models when designing high-pressure vessels J. Renfro, G. Stephenson, E. Marques-Riquelme and C. Vandu

REFINING DEVELOPMENTS

77 Innovative catalyst solution mitigates FCC operational issue J. Sexton, J. Highfield, N. Larsen, S. Ismail and D. Neuman

TERMINALS AND STORAGE—SUPPLEMENT

T-85 Use innovative solutions to return storage tanks back to service faster

J. Hair

SAFETY

95 Minimize false assurances in hazard analyses

M. Sawyer

ENVIRONMENT

99 What every refiner should know about nitrogen generation and delivery

D. Connaughton

Cover Image: In Rotterdam, an entire refinery was shut down, modernized and put back into operation. Bilfinger is the specialist for these extensive turnarounds. Photo courtesy of Bilfinger SE.

DEPARTMENTS 4 Industry Perspectives 10 News 21 Forum 23 Industry Metrics 101 Events 102 Marketplace 104 Advertiser Index 106 People COLUMNS 9 Editorial Comment

What separates the best-of-class companies from the rest? 25 Reliability

Make equipment decisions with up-to-date technical information 29 Automation Strategies

The automation challenge requires new approaches 31 Project Management Better strategies avoid project delays—Part 2

37 Global

Russian executives to build country’s first waste oil refinery 39 Petrochemicals

Ammonia production booms on cheap natural gas 43 Gas Processing

Asian gas market seeks lower pricing, infrastructure expansion: Part 1 45 Boxscore Construction

Analysis

Qatar’s petrochemical sector surges through new projects

49 Viewpoint

What characteristics define the world’s best refineries?

52

4MAY 2014 | HydrocarbonProcessing.com

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Reflections from a petrochemical giant

Frank Popoff, retired chairman and CEO of the Dow Chemi-cal Co., shared his insight on the petrochemiChemi-cal industry at the AFPM’s 2014 International Petrochemical Conference (IPC). With a career spanning over 41 years, Mr. Popoff has witnessed the evolution of the petrochemical industry between two Gulf coasts—the US and the Middle East.

As a former leader of an international petrochemical com-pany, Mr. Popoff shared some observations on the industry to IPC attendees. First, expect change in the business cycle; more importantly, embrace it. Since its inception, the petrochemical industry has always followed cycles. Unfortunately, companies still over-invest in new capacity at the top of the business cycle, thus creating an overcapacity situation. Second, change within the petrochemical industry is accelerating. Operating companies are enduring pressures internally and externally that are linked to underperformance, especially with respect to profits.

Reality vs.perception. Mr. Popoff also remarked that the public has a disconnected view of the downstream. In the 1950s, the pet-rochemical industry was viewed as an innovative and high-tech industry. Fast-forward to present day, the petrochemical industry is very disconnected from the public and the regulatory agencies. More importantly, younger people do not consider employment opportunities in the petrochemical industry. This perception of the industry must change.

Advice from a veteran. How can the downstream change its image? Mr. Popoff advised: First, companies will be judged by their deeds, and not by their media programs. Petrochemical com-panies must be active and visible in their communities. Corporate creditability is the key to success and the legacy of the industry.

FIG. 1. Former Dow Chemical Chairman Frank Popoff (left) is presented with the 18th Petrochemical Heritage Award by Jerry Law, president of the Founders Club.

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2014 Sessions will Focus on:

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• Catalysts • Modular construction

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Real-World Case Studies on:

• GTL technology development-The optimal path to Micro-GTL commercialization • Refi nery integration with gasifi cation

>> Plus, attendees will hear presentations on the economics of natural gas and ammonia production from off -gases. Don’t miss this opportunity to learn from industry experts and connect with top operators and technology leaders from across the global industry.

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• Professionals at Engineering & Construction

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V.K. Arora

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George Boyajian

Vice President, Business Development

Primus Green Energy

Jeff McDaniel

Commercial Director Velocys

Ebrahim Salehi

Process Engineer Hatch

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2014 Agenda at a Glance:

Wednesday, July 30, 2014

8:45 a.m. Keynote Presentation

9:15 a.m. The Economics of Monetizing North American Natural Gas

Tom Jones, Manager of Studies, Bechtel Hydrocarbon Technology Solutions, Inc.

Session 1: Syngas

10:10 a.m. Co-processing of Waste CO₂ with Natural Gas to Produce High Value Transport Fuels

Paul E Koppel, Vice President, Process

Technology, Fluor Enterprises

10:35 a.m. Autothermal Reforming – a Preferred Technology for Conversion of Natural Gas to Synthesis Gas in Industrial GTL Applications

Neils Udengaard, Haldor Topsoe

11 a.m. Partial Oxidation Gas-Turbine Based Turbo-POx Syngas Generation

Technology for GTL Applications Kenneth Sprouse, Chief Technology Offi cer, Aerojet Rocketdyne Energy Systems 11:25 a.m. Lunch

Session 2: The Future of Non-FT

12:25 p.m. CO₂ and CO fermentation: A Route

from Waste to Fuels and Chemical Building Blocks at Scale

Dr. Michael Schultz, Vice President,

Engineering, LanzaTech, Inc 12:50 p.m. A New Era in GTL: Cost-Effective

Technology Enables Conversion of Natural Gas to Drop-In Liquid Fuels at Small Scale

Dr. George Boyajian, Primus Green Energy

Session 3: What’s New in Small-Scale GTL

2:10 p.m. Microchannel Fischer-Tropsch Reactors:

Enabling Smaller Scale GTL

Jeff McDaniel, Commercial Director, Velocys 2:35 p.m. Case Study: GTL Technology

Development – The Optimal Path to Micro-GTL Commercialization Ebrahim Salehi, Process Engineer, Hatch 3:05 p.m. Panel Discussion: Modular GTLs

Thursday, July 31, 2014

8:45 a.m. Keynote Presentation

9:15 a.m. Economics of Ammonia Production from Off-Gases

VK Arora, Director-Process & Operations,

Kinetics Process Improvements, Inc

Session 4: Emerging Technology

and Future Users

10:10 a.m. Mixed Alcohols as an Oxygenate and Fuel Extender

Peter Tijm, Chief Technology Offi cer, Standard Alcohol Company of America, Inc.

10:35 a.m. Case Study: Refi nery Integration with Gasifi cation

Dr. K.S. Balaraman, Chief Consultant, Wissenschaftler Consulting Engineers 11:05 a.m. Panel Discussion: Future Uses of GTL 12:30 p.m. Lunch

Session 5: Catalysts

1:30 p.m. Effect of Addition of Zeolite to Iron-Based Activated-Carbon-Supported Catalyst for Fischer–Tropsch Synthesis in Separate Beds and Mixed Beds

Avinash Karre, Jacobs Engineering 1:55 p.m. The New CatFTTM Process

Dr. Thomas Holcombe, President & CEO,

EnviRes LLC

Session 6: Modular Construction

Presentations TBD

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Editorial

Comment

STEPHANY ROMANOW, EDITOR

[email protected]

Hydrocarbon Processing | MAY 20149

INSIDE THIS ISSUE

49 

Viewpoint. What defines the world’s best refineries? New process equipment and a higher refinery complexity index do not guarantee a place on the world’s best refineries. Other metrics, such as return on investment, energy efficiency, net cash margins, maintenance practices and more, separate leading from laggard performance in the global refining industry.

52 

Maintenance and reliability. Operating companies use maintenance programs to protect their capital investments. Since equipment failures can result in expensive unit and plant shutdowns, or environmental or safety incidents, best-of-class companies maintain the mindset that spending to improve reliability and equipment conditioning is a great benefit to the organization.

71 

Process design.

In this article, rigorous models are used to simulate effective depressurization procedures for high-pressure vessels containing hazardous gases and liquids. Well-designed depressurized events review changes in the vessel’s contents (vapor and liquids) and the effects from changing pressure and temperature on these fluids. Extremes in temperature and pressure impact material choices to construct such vessels.

95 

Safety. Hazard analysis is a powerful and effective tool to evaluate potentially hazardous plant and process conditions. What are the best methods to use when identifying job hazards involving maintenance and operational tasks? This article reviews several proven methodologies to consider when performing

process safety reviews.

What separates the best-of-class companies

from the rest?

Many metrics can be used to define the top-performing downstream compa-nies. Often, it includes financial (profits) results, environmental and safety perfor-mance, equipment availability and more. However, organizational culture probably has the most impact in determining a com-pany’s performance. Also, it is the most difficult to change. Before a company can change its performance, it must amend or upgrade its organizational culture.

Managing people is the toughest task. A recent UK health, safety and en-vironment (HSE) research program iden-tified the top five human-factor errors. These factors, sourced from previous or-ganizational accidents listed in HSE data-bases, are:

1. Managing people 2. Procedures

3. Training and competence 4. Staffing

5. Organizational changes.

As the downstream workforce un-dergoes a significant shift change when experienced employees retire, the listed human factors will have an even higher impact on an organization’s performance. Staffing and training will carry heightened concerns as employers plan for a smaller workforce undertaking vital roles in the operation of process units and the main-tenance of equipment. More important, what resources will be used to train and certify plant operators and crafts? As fewer younger people enter apprentice and craft training programs, the pool of qualified and competent employees shrinks.

Maintenance is a key priority for

top-performing facilities. Achieving high

equipment availability is an organization’s ability to minimize the amount of annual-ized turnaround downtime. The less time that key equipment or process units are down for repair increases the uptime of

the facility. The world’s best downstream companies minimize both the duration and the cost during a turnaround by rig-orously challenging all of the work done and how that work is executed. By using state-of-the-art techniques for inspection and repair, they are able to achieve perfor-mance that significantly outpaces the rest of the world.

The organizational culture on mainte-nance is evolving. Predictive maintemainte-nance programs strive to monitor equipment and to do planned shutdowns, thus short-ening the total duration for repairs.

Training. Employees come to work with skills, knowledge and experience, and they are trained for plant tasks. However, there are huge performance differences among operators. Some are competent and some not so much. The goal is to en-sure that they all are truly competent, but that may not always be the case.

Organizations cannot just wave a magic wand and fix all problems. Without standards or discipline, it can take years to resolve the problem.

The fix. “Human error is a normal func-tion of humans; it is inevitable, but it may be preventable,” said Ian Nimmo, presi-dent & CEO, of the Center for Human Factors and Ergonomics, LLC. Everyone makes mistakes and has lapses in attention. Accordingly, management systems and tools should be used to reduce error rates.

Nimmo recommends that an organi-zation invest in a gap analysis and prepare strategic operational plans to identify a comprehensive investment plan. The plan will itemize a path to achieve total perfor-mance improvements in a prioritized way.

Human error introduces risk that must be addressed. Only when the holes in the protection system are sealed and perfor-mance is measured, then companies can find profits.

| News

EU-US Energy Council discusses

European energy security

The EU-US Energy Council met recently in Brussels, Belgium. Following the gathering, the council issued a statement indicating that developments in Ukraine prove the need for reinforced energy security in Europe.

“The Council underscored that energy relations with Russia must be based on reciprocity, transparency, fairness, non-discrimination, openness to competition and continued cooperation to ensure a level playing field for the safe and secure supply of energy,” the statement said.

Another result of the meeting was that the Council affirmed its support for Ukraine’s efforts to diversify its supplies of natural gas, including through the rapid enhancement of reverse flow capacities and increased gas storage capacity. The Council also issued remarks supporting the restructuring and reform of Naftogaz.

Hydrocarbon Processing | MAY 201411 BILLY THINNES, TECHNICAL EDITOR

[email protected]

News

US crude imports fall,

but share of top suppliers

highest in decades

While US total net crude oil imports fell during 2013, the share of imports last year from the US’ top three foreign oil suppliers—Canada, Saudi Arabia and Mexico—was the highest in at least four decades, according to preliminary annual trade data from the US Energy Information Administration’s (EIA’s)

Petroleum Supply Monthly report (FIG. 1).

These three countries provided almost three out of every five barrels of oil im-ported into the US market last year.

US net crude oil imports in 2013 de-clined 10.2% to 7.6 million barrels per day (MMbpd), the lowest level since 1996, as rising domestic crude oil pro-duction cut into the import volume needed to meet refinery demand.

The overall decline in US net imports has led to an increasing concentration of net imports from Canada, Saudi Arabia, and Mexico. Combined net oil imports from these countries decreased by 1.5% last year. As a result, the 4.6 MMbpd of oil supplied by these three countries ac-counted for 61% of total US net oil im-ports in 2013, up from 55% the year be-fore and their biggest share since at least 1973. These countries generally produce medium to heavy sour crude oil that is desirable to US refineries, while increas-ing US crude oil production from tight oil formations is typically of the light sweet quality. Also, with the exception of Saudi Arabia, these countries are near the US, with Mexico having a short ship-ping distance for its oil to the large num-ber of refineries along the US Gulf Coast. Canada, Saudi Arabia and Mexico have consistently been America’s three largest crude oil suppliers, although their rankings vary from year to year.

Canada. Crude oil imports averaged a record 2.5 MMbpd, up 3.9% from 2012. Canada has few other outlets for Alberta’s rising heavy crude oil produc-tion, so most of it is exported to the US.

Saudi Arabia. Crude oil imports averaged 1.3 MMbpd, down 2.6%, but still the second highest in five years. Through its Motiva Enterprises joint venture, the country’s state oil company is a partial owner of three large US Gulf Coast refineries that it partially supplies with Saudi crude.

Mexico. Crude oil imports of 850,000 bpd were down 13% and the lowest in more than 20 years, reflecting the contin-ued decline in Mexico’s crude oil produc-tion. Still, Mexico produces significant amounts of heavy crude that is well-suit-ed for US Gulf Coast oil refineries.

Oil spill contained

at S-Oil Korean refinery

S-Oil’s refinery in Ulsan, South Ko-rea, suffered an oil spill from a storage tank in early April. The spill was con-tained after three days, but not before 140,000 bbl of crude had leaked. To mitigate further problems with the dam-aged storage tank, refinery officials relo-cated an additional 380,000 bbl of crude. The spill started after a broken blending mixer created a hole in the storage tank. The refinery will conduct an investiga-tion into the exact cause of the accident

in cooperation with the police and the fire authorities of Ulsan.

Murphy Oil’s Wales

refinery facing closure

Murphy Oil has indicated it could be forced to close its Milford Haven refin-ery in Wales, UK, after talks with a pri-vate equity firm collapsed. Murphy’s UK subsidiary Murco said it had started 45 days of consultation with employees and their representatives on the future of the 135,000 bpd refinery.

UK refining remains a challenging market, caused in part by declining de-mand and increased international com-pletion, Murco said in a statement. The UK has seven oil refineries, down from a peak of 18 in the 1970s.

Murphy Oil has negotiated with nu-merous parties but has not yet been able to find a buyer for the refinery. Private equity company Greybull had been in ad-vanced stages of talks with Murco to buy the plant and associated assets for around $500 million, but exclusive talks between the two entities have expired.

“Our focus today is on helping our peo-ple understand what this means for them,” said Murco’s Director Tom McKinlay.

Other nations Mexico Saudi Arabia Canada

2003

Source: US EIA, February 2014 Petroleum Supply Monthy

US annual net crude imports 200

3– 20 13, MMbpd 0 2 4 6 8 10 12 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

News

12

“For over three years, we have left no stone unturned in trying to find a buyer for the plant. Our efforts highlight the challenges and ongoing changes confronting the Eu-ropean refining industry and are in no way a reflection on the attitude and work ethic of the Murco team. We will continue to do all we can to ensure our employees are supported during this time.”

The plant employs 370 staff and be-tween 100 and 150 contractors.

BP to close Bulwer Island

refinery in Australia

BP intends to halt refining operations at its 102,000-bpd Bulwer Island refin-ery in Brisbane, Queensland, Australia, by mid-2015. Andy Holmes, president of BP Australasia, said that the growth of very large refineries in the Asia-Pacific region was driving structural change within the fuels supply chain in Australia

and putting huge commercial pressure on smaller-scale plants.

“It’s against this background that we have concluded that the best option for strengthening BP’s long-term supply po-sition in the East Coast retail and com-mercial fuels markets is to purchase prod-uct from other refineries,” he said. “And while more of our transport fuel demand will be met by imports in the future, ample supplies are available to maintain Australia’s energy security.”

To ensure no disruption to customers, alternate supply arrangements have been made. This includes imports of jet fuel and a long-term agreement with Caltex to supply motor spirit and diesel from the nearby Lytton refinery.

It is expected that it will take some 12 months to implement the changes re-quired to maintain supply and safely shut down the process units.

Once processing has been halted, the import jetty, aviation fuel tanks and asso-ciated pipelines will remain operational while other storage tanks and pipelines will be placed on a care and maintenance basis pending a decision to convert the site to a multi-product import terminal.

The processing units will be isolated and made safe while plans for their even-tual removal and any environmental re-mediation are developed.

BP currently employs some 380 staff at the refinery. Between now and mid-2015, this is expected to fall to around 25. The Bulwer Island refinery was built on reclaimed land by Amoco between 1964 and 1965 and was bought by BP in 1984. Over the years, it has been subject to a number of modifications and im-provements. In 2000, it was significantly upgraded to produce low-sulfur fuels.

IChemE unveils

new process safety

alliance with Texas A&M

The Institution of Chemical Engineers (IChemE) and Texas A&M Engineering have signed an agreement paving the way for a suite of new process safety products and services. The memorandum of under-standing (MOU) will see both organiza-tions commit to collaboration in process safety education and strategic leadership.

The Texas A&M Engineering Experi-ment Station is home to the Mary Kay O’Connor Process Safety Center, which Select 151 at www.HydrocarbonProcessing.com/RS

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Australia - Asia Pacific Phone +61 7 3867 5555 Fax +61 7 3265 2768 [email protected] France Phone +33 5 4902 1600 Fax +33 5 49021616 [email protected]

North & South America Phone +1 651 636 3900 Fax +1 651 638 3171 [email protected]

News

14

houses one of the world’s biggest process safety libraries and is regarded as a leader in process safety education.

The MOU was signed at the Ameri-can Institute of Chemical Engineers 2014 Spring Meeting in New Orleans, Louisiana, by IChemE chief executive David Brown and Sam Mannan, director of the Mary Kay O’Connor Process Safety Center.

“This is good news for IChemE and good news for Texas A&M, but,

impor-tantly, this is good news for chemical and process engineers with an interest in pro-cess safety,” Dr. Mannan said.

The collaboration’s projects and pri-orities will be announced at IChemE’s Hazards 24 process safety conference next month in Scotland.

“Texas A&M and IChemE are both recognized as international leaders in the provision of process safety products and services,” Mr. Brown said. “This new

agreement will help us to share infor-mation more freely and cooperate on a range of new projects.”

Siemens and McAfee

team up to offer industrial

security services

Siemens and McAfee, a division of Intel Security, are extending their part-nership to enhance the security offer-ings for industrial customers to protect against rapidly evolving global cyber threats. This partnership utilizes the depth of both companies’ security port-folios and further enhances the joint ef-fort started in 2011.

Industrial customers face unique new challenges including a wider range of cy-ber threats than ever before. They often lack the resources necessary to respond efficiently to security incidents, and they do not have access to the global threat intelligence that would allow proactive defensive measures. This critical informa-tion is needed in order to keep up with evolving government regulations, indus-try standards, sector-specific best practic-es, and other risk information necessary for making informed business decisions.

The cooperation with McAfee will complement Siemens’ service offerings by leveraging security solutions such as next-generation firewall, security infor-mation and event management, endpoint security, and global threat intelligence as part of its managed security service along with offering professional services. These offerings provide greater visibility and control at the factory level while reducing the risk of intellectual property theft.

In addition, the companies will con-tinue to cooperate on the development of security products and solutions, specifi-cally based on industrial protocols, that will enhance managed security service offerings for the process and factory auto-mation industry.

Air Products to supply

nitrogen for Singapore hub

to store petrochemicals

Air Products was awarded a contract to supply liquid nitrogen to Singapore’s Jurong Rock Caverns ( JRC) project, an underground storage facility for petro-chemical products. It is the first of its kind in the country and across Southeast Asia.

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News

17 JRC is being developed by the JTC

Corp., a government agency responsible for industrial infrastructure development in Singapore. Located on Jurong Island, the JRC project will complement and enhance the existing infrastructure and support the growth of the chemicals and energy clusters.

Air Products’ liquid nitrogen will be used as a blanketing gas for the oil storage caverns for safety purposes.

“We are honored to have been select-ed by JTC to take part in and supply this groundbreaking solution to oil storage needs,” said Leong Wah Fong, managing director of Air Products Southeast Asia.

“Singapore’s energy and chemical in-dustry is a strategic market for us and we have built a foundation to serve its needs through diverse supply modes.”

Air Products began serving petrochemi-cal customers on Jurong Island in 1997 through an air separation plant located at Sakra. To meet the increasing gas demand in Singapore’s major chemical hub, the company has recently announced a pipeline extension from the area to the newly devel-oped areas in Tembusu to expand coverage. In addition to the air separation plant on Jurong Island, the company also has a fleet of road tankers delivering liquid prod-ucts, a helium and specialty gas plant in Senoko and an epoxy additives and a poly-amide plant in Gul Crescent.

US demand for filters

to reach $14.8 billion

in 2018

US demand for filters will advance 3.6% annually to $14.8 billion in 2018, with re-placement demand accounting for the vast majority of filter sales. This is according to a report from The Freedonia Group.

“The filter aftermarket will be aided by the increasing penetration of newer products,” said report contributor David Petina, “particularly motor vehicle cabin air filters, diesel emissions filters, and many varieties of home air and water fil-ters, as well as rising end-user awareness of their recommended service lives.”

The development of filters featuring technologies that extend their service life will have a mixed impact on demand, boosting sales since they are priced at a premium, but also restraining demand in volume terms. Both the original equip-ment and replaceequip-ment filter markets will

be aided by regulatory changes—particu-larly regarding potable water quality, diesel engine emissions and pollution from elec-tric utilities—supporting sales of existing filters and the development of new prod-ucts. The improved outlook for manufac-turing and capital investment will also sup-port filter demand stemming from greater purchases of equipment that require filters.

The motor vehicle market will contin-ue to account for the largest portion of

to-tal demand, with a 27% share in 2018, ow-ing to the high volume of filters sold both as original equipment and in the aftermar-ket. Motor vehicle filter demand will be supported by a rising number of vehicles in use and increasingly strict standards for vehicle emissions. Value growth will also be supported by the introduction and increasing adoption of newer products, such as cabin air filters and other specialty and high-value vehicle filters. Demand for

To learn more about Ariel Compressors, please visit www.arielcorp.com

With more than 19,000 possible frame and cylinder configurations for API 618 process service, Ariel compressors can be designed and built to maximize your unique process operation. Ariel has been producing durable, low-maintenance reciprocating compressors since 1966 and API 618 compressors since 1999. Ariel offers high quality compressors that ensure long continuous run-times. Visit www.arielcorp.com to find an Ariel Process distributor in your region.

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News

19 filters in the industrial and

manufactur-ing, consumer, and utilities markets will all witness above-average growth.

In 2013, fluid filters and internal com-bustion engine and related filters account-ed for 37% and 35% of total filter sales, respectively. However, air filters, which represented the remaining 28% of sales in 2013, will achieve the fastest gains through 2018, benefiting from changes in pollution regulations, improvements in manufactur-ing activity, rismanufactur-ing consumer interest and rebounding construction spending.

US approves Jordan Cove

LNG exports in Oregon

The US Energy Department has con-ditionally authorized the Jordan Cove Energy Project to export domestically pro-duced LNG to countries that do not have a free-trade agreement (FTA) with the US. The exports will originate from the Jordan Cove LNG terminal in Coos Bay, Oregon.

The Jordan Cove application was next in the order of precedence after the Ener-gy Department conditionally authorized the proposed Cameron LNG facility, ac-cording to department officials. Subject to environmental review and final regula-tory approval, the facility is conditionally authorized to export at a rate of up to the equivalent of 0.8 Bcfd of natural gas, for a period of 20 years.

US federal law generally requires ap-proval of natural gas exports to countries that have an FTA with the US. For coun-tries that do not have an FTA with the US, the Natural Gas Act directs the US Department of Energy (DOE) to grant export authorizations unless the DOE finds that the proposed exports “will not be consistent with the public interest.”

“Given the situation in Ukraine, this license sends a positive signal to our al-lies and to energy markets that the United States is ready to join the growing global gas trade,” US Senator Lisa Murkowski (R-Alaska) said. “While this license moves us in the right direction, I would be strongly opposed to any ‘pause for further study,’ as some have proposed.”

Dresser-Rand wins US

Gulf supplier safety award

Dresser-Rand, a global supplier of rotating equipment solutions, recently won a Gulf Coast Oil & Gas Award for its

health, safety and environmental (HSE) programs and initiatives.

“Our employees are our most valued asset and we are committed to their well-being,” said Vincent Volpe, Dresser-Rand’s CEO. “Safety is a core, critical company value. Our total recordable injury rate for 2013 was 0.38—a great result and one of which we are extremely proud.”

The judges of the Gulf Coast Oil & Gas Awards reviewed more than 400 entries

and selected 75 finalists. Dresser-Rand was one of four finalists in the health and safety category.

“This recognition elevates our com-mitment to becoming an operationally excellent company without injuries,” said Peter Salvatore, Dresser-Rand’s chief safe-ty officer. “Our ultimate goal is to elimi-nate workplace injuries through disci-plined processes, execution and employee empowerment and engagement.”

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Hydrocarbon Processing | MAY 201421

Forum

GULF PUBLISHING EVENTS

[email protected]

IRPC 2014: Defining the

course of the global HPI

Leading hydrocarbon processing in-dustry (HPI) executives and technical ex-perts will come together June 24–26 in Ve-rona, Italy, to share ideas, innovation and vision for the global downstream industry at Hydrocarbon Processing’s fifth annual International Refining and Petrochemical Conference (IRPC).

As major forces reshape the HPI, man-agers and engineers are actively seeking information and solutions to make their companies more efficient, to increase equipment reliability and to meet safety and environmental regulations. Many downstream products are commodity products and traded worldwide. To par-ticipate in the international downstream markets, HPI companies will put into ac-tion innovative technologies and ideas to improve the profitability and performance of existing plants. Such developments will be used to build grassroots plants.

Where innovation happens. IRPC 2014 will feature more than 70 technical presentations by company leaders, man-agers, engineers and other profession-als. In addition, the 2014 forum will use three technical tracks to cover the broad spectrum of HPI topics and disciplines. The tracks are refining, petrochemicals and biofuels.

The refining track will address the pro-cessing of heavy oil into clean transporta-tion and marine fuels. Presentatransporta-tions will address new processing technologies to handle present-day crudes, and heavy and extra-heavy feedstocks. The petrochemi-cals track will focus on olefins and aro-matic operations and demand trends. The biofuels track will feature next-generation biofuels and the methods to integrate them into transportation fuel systems.

Other technical sessions are dedicated to energy efficiency, process optimization, corrosion mitigation/prevention meth-ods, petrochemical-refinery integration, clean fuel technologies, advanced catalytic

technologies, licensed technologies for re-fining and petrochemicals, water manage-ment, process control, process modeling / simulation, maintenance techniques and planning and plant management.

The conference will feature several keynote presentations. Giacomo Respoli, Vice President of Research and Develop-ment Projects of Eni SpA, will discuss the design of Eni’s biorefinery and the future of the downstream. On Day 2, Bakheet Al-Rashid, CEO and president of Kuwait National Petroleum, will share his view on the European refining industry and the factors reshaping the region.

Forefront of the industry. The HPI is a global industry; success hinges on com-panies and their staff finding accurate and vital information in real time to make in-formed and profitable decisions. At IRPC 2014, HPI professionals will have the op-portunity to network and brainstorm with executive and leaders that are charting the course of the global HPI.

Meeting place for the global HPI. Companies involved in the following areas will benefit from attending IRPC: refin-ing, natural gas processrefin-ing, technology and equipment manufacturing,

consult-ing, construction and engineerconsult-ing, chemi-cals and petrochemichemi-cals, and oil and gas services and supplies.

Eni’s Venice biorefinery tour. IRPC 2014 will begin with an exclusive tour of Eni’s Venice biorefinery, the first refinery in the world to convert from a conven-tional refining complex into a biofuel-pro-duction operation based on Eni’s patented Ecofining technology.

Following the conversion, the Venice biorefinery will be able to produce high-grade biofuels, including green diesel, green naphtha, LPG and, potentially, jet fuel, from biological raw materials to meet the EU directive on renewable energy and derive 10% of energy in conventional fu-els from renewables by 2020. With the startup of the green refinery, Eni will be able to produce around 300,000 tpy of green diesel in 2014. The feedstock will initially be palm oil; in the second phase, the green refinery will process animal fats, used oil, oils from algae and other types of biological waste.

For more information about the 2014 International Refining and Petrochemical Conference, hosted by Gulf Publishing Company and Hydrocarbon Processing, please visit HPIRPC.com.

FIG. 1. A tour of Eni’s Venice biorefinery is a preconference event. This refinery is converting from a conventional refining complex to biofuel production.

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Hydrocarbon Processing | MAY 201423

The OPEC Reference Basket for crudes fell $1.23 in March. Changes in the crude oil markets are attributed to a slowdown in China’s economy and reduced crude oil demand by refineries. Non-OPEC supply growth is expected to outpace global consumption growth and stabilize oil prices. North America leads in new production stemming from shale oil in the US and growth in the Canadian oil sands. Global product markets are expected to receive support from increased diesel and gasoline demand by OECD nations. 0 10 20 30 40 50 6070 80 0 1 2 3 4 5 6 7 F J D N O S A J J M A M F J D N O S A J J M A M F 2012

Production, Bcfd Gas pric

es, $/Mcf

2013 2014

Production equals US marketed production, wet gas. Source: EIA.

Monthly price (Henry Hub) 12-month price avg. Production

US gas production (Bcfd) and prices ($/Mcf)

45 60 75 Oil pric es, $/bbl 90 105 120 135 Dubai Fateh W. Texas Inter. Brent Blend F J D N O S A J J M A M F J D N O S A J J M A M F 2013 2014 2012 Source: DOE

Selected world oil prices, $/bbl

Global refining margins, 2013–2014*

WTI, US Gulf Arab Heavy, US Gulf Brent, Rotterdam Dubai, Singapore LLS, US Gulf -50 5 1015 20 25 30 35 40

Mar 13 Apr 13 May 13 Jun 13 Jul 13 _{Aug 13 Sep 13} Oct 13 _{Nov 13} Dec 13 Jan 14 Feb 14 Mar 14

Margins, US$/bbl

Global refining utilization rates, 2013–2014*

60 70 80 90 100 Mar 14

Mar 13 Apr 13 May 13 Jun 13 Jul 13 Aug 13 Sep 13 Oct 13 Nov 13 Dec 13 Jan 14 Feb 14

Utilization rates, %

US EU 16 Japan Singapore

US Gulf cracking spread vs. WTI, 2013–2014*

-100 10 20 30 40 50 60 Feb 14 Mar 14 Mar 13 Apr 13 May 13 Jun 13 Jul 13 Aug 13 Sep 13 Oct 13 Nov 13 Dec 13 Jan 14

Cracking spread, US$/bbl

Prem. gasoline unl. 93 Jet/kero Gasoil/diesel, 0.05% S Fuel oil, 1% S

Apr 14

Rotterdam cracking spread vs. Dubai, 2013–2014*

Prem. gasoline unl., 50 ppm S

Jet/kero Fuel oil, 1% SGasoil, 10 ppm S

-30 -20 -10 10 20 30

Cracking spread, US$/bbl

0

Feb 14

Mar 13 Apr 13 May 13 Jun 13 Jul 13 _{Aug 13} Sep 13 Oct 13 _{Nov 13} Dec 13 Jan 14 Mar 14 Apr 14

Singapore cracking spread vs. Brent, 2013–2014*

-20 -10 0 10 20 30 Feb 14

Mar 13 Apr 13 May 13 Jun 13 Jul 13 Aug 13 Sep 13 Oct 13 Nov 13 Dec 13 Jan 14 Mar 14

Cracking spread, US$/bbl

Prem. gasoline unl. 92

Jet/kero Gasoil, 50 ppm SFuel oil, 180 CST, 2% S

Apr 14 78 8082 84 86 88 9092 94 96 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5 Stock change and balance

World consumption World production 2015-Q1 2014-Q1 2013-Q1 2012-Q1 2011-Q1 2010-Q1 2009-Q1

Supply and demand, MMbpd

Stock change and balanc

e, MMbpd

Source: EIA Short-Term Energy Outlook, April 2014.

Forecast

World liquids fuels supply and demand, MMbpd

* Material published permission of the OPEC Secretariat; copyright 2014; all rights reserved; OPEC Monthly Oil Market Report, April 2014.

Brent dated vs. sour crudes (Urals and Dubai) spread, 2013–2014*

Light sweet/medium sour crude spread, US$/bbl

Dubai Urals -2 0 2 4 6 8

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Hydrocarbon Processing | MAY 201425

Reliability

HEINZ P. BLOCH, RELIABILITY/EQUIPMENT EDITOR

[email protected]

Make equipment decisions with up-to-date

technical information

Answering lube practice-related questions is important. These questions provide insight on the status of education and technology, along with trends in understanding equipment reli-ability, safety and more. Hopefully, these trends are moving for-ward; however, they sometimes stagnate or even regress.

Several professionals dealing with machinery in petrochemi-cal plants and oil refineries have mentioned that their mean-time-between-failures (MTBF) on process pumps are no longer as favorable as they were two decades ago. Interestingly, such negative trends can be attributed to “tightening” specifications without reviewing the end effects.

Oil-mist and high-pumping temperatures. Recently, the man-ager from a prominent oil-mist-system supplier made this point:

“I have had numerous questions lately about hot services and how we (the company) size oil-mist nozzles (or reclassifiers, as shown in FIG. 1) for temperatures of the pumpage. We never

re-ally considered temperature before, and the limits imposed seem to be getting lower. Two refineries, among the world’s six larg-est, set specifications limiting oil-mist temperatures to 450°F. At present, I even have one specification that indicates a 300°F limit. Many specifications call for “heavy-service-factor reclas-sifiers” on pumps in hot service. But what is the basis for such restrictions? Was the pumping temperature ever a concern with the highly successful oil-mist systems at your best-of-class (BOC) employer 20 or 30 years ago?”

Answer. The answers can be found in many texts; they are not secrets. Since the 1960s and on numerous occasions, pure oil mist has been applied with great success to all types of API pumps, as shown in FIG. 2. _{These applications include dozens of}

pipe-still-bottoms pumps with fluid temperatures of 740°F (393°C) in some of the world’s largest oil refineries.

As in a number of other services, oil-mist lubrication has been outstandingly successful, and BOC oil refineries are pleased with pure oil mist. Regrettably, below-average performers seem to be held back by personnel with little ability to analyze why they have problems and their competitors do not. For example, they have no knowledge of optimum reclassifier location, effects of in-advertently bypassing the oil mist around certain bearings, lubri-cant type best suited for critically important hot-service pumps, etc. Some would rather voice opinions than search for facts.

To assist people with older (outdated) information on pumps and lubrication systems, a field trip to review later-model API-610 style pumps is a viable solution. They could visit the pumps either in the field or on one of the numerous pump manufactur-ers’ websites. With a first-hand view, the person with the ques-tion may realize that a high-temperature mechanical seal and

some ambient air space are located between the pumpage and the bearings, as illustrated in FIG. 3. _{Therefore, most of the heat is}

radiated to the surrounding air. Also, barrier seals often assist in further heat removal.

Differences in heat removal. There is obviously a signifi-cant heat loss along the shaft between the pumpage in the pump casing and the lightly loaded and thinly oil-coated radial bear-ing in the bearbear-ing housbear-ings of API process pumps. Additional heat will be lost while moving from the radial bearing to the more highly loaded thrust bearing set. Long-term bearing hous-ing temperatures on liquid oil-lubricated pump bearhous-ings have

FIG. 1. Cut-away of an oil-mist reclassifier. Oil mist enters from the left; as the bore diameter becomes smaller, its velocity increases. The small oil-mist globules combine into heavier globules, which then coat the bearing’s rolling elements.

FIG. 2. Oil-mist lubrication applied to a pump bearing housing in accordance with API-610, 12th Ed. Note: Dual mist-injection points and use of face-type bearing protector seals prevent the mist from escaping to the atmosphere.2

26MAY 2014 | HydrocarbonProcessing.com

Reliability

never exceeded 240°F (116°C) in pumps at major oil refiner-ies. Operation at these temperatures would require installing a

personnel protection shield on bearing housings. In the 1970s, ISO VG100 mineral oil-based lubricants were used in many of the open-oil-mist systems. Pure oil-mist-lubricated pumps use neither oil rings (slinger rings) nor constant level lubricators.

Today, one either uses a specially formulated, moderately priced mineral oil/synthetic oil mixture or a more expensive, pure synthetic ISO VG68 in pure oil-mist systems. These serve pumps with fluid temperatures from 600°F to 740°F. With ISO VG 68 diester-based synthetic lubes, bearing housing tempera-tures have yet to exceed 190°F (88°C), and, with pure oil-mist bearing, cooling is no longer needed.1, 2

For the past 40 years, the reclassifier selection has never been influenced by pumping temperatures in API-style pumps. This temperature rating does not enter the picture, especially when applying oil mist per modern API-610 standards. The oil mist must flow from the space nearest the bearing housing protec-tor seal to the center of the bearing housing, as shown in FIG. 2.

Through-flow mode, incidentally, was routinely done at BOC plants after 1977.

As an aside, if occasional risk takers were to use a close-coupled non-API pump for a 740°F hydrocarbon service, they would be making a totally unacceptable choice. In that instance, changing the system would become a priority task.

Consider changing the system. It has been said that one

cannot change the safety and reliability culture without first changing the system. Of course, the system is the organization.

FIG. 3. API-style pump with Flush Plan 53C—pressurized and cooled barrier fluid circulation in the outboard seal of a dual-seal configuration. A tapered pumping ring maintains circulation while running. The pressure is maintained and fluctuations are compensated in the seal circuit by a piston-type accumulator, upper right. Note the distance from pumpage to bearing housing and the advanced-style bearing housing protector seal. Source: AESSEAL Inc., Rotherham, UK, and Rockford, Tennessee.

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28

Reliability

If we allow specifications to be written or amended by people who are not informed on new developments and standards, then the company or employer will soon lag behind others. Without detailed lubrication knowledge, an employer will lose more ground to the competition. Of course, a specification up-date will sometimes make sense and provide benefits for safety and reliability. Yet, when an unduly tight specification is issued, then the exact opposite may result.

Vision. When working or purchasing rotating equipment, con-sider the whole picture and always make informed choices. Not allowing oil mist to be applied in pumping services over 300°F raises the question: What lube application method will these user-specifiers choose for the 600°F and 740°F pumps? Other than well-proven oil mist, only liquid oil sprayed directly into a rolling element bearing’s cages is a suitable option for the reli-ability-focused engineer. Returning to wet sumps with tricky oil rings and constant-level lubricators is very maintenance-inten-sive. An even worse choice is reverting to grease-filled single-point automatic lubricators for motors.1 _{Premium-grade motor} greases separate into soap and oil when pressurized. Lesser-quality greases, while not separating as readily under pressure, will not provide superior protection. Only plantwide oil mist answers all of these concerns.

As of 2013, well over 130,000 process pumps are success-fully lubricated by plantwide oil-mist systems. Also, 26,000 electric motors use oil mist on their bearings, and some of these have been using oil mist for 35 years without ever replacing or changing a bearing. Based on decades of successful installations, applying pure oil-mist systems on electric motor drivers makes sense and can yield rapid payback.

Nudging some user-specifiers to reliability-focused choices should be a priority. Perhaps some could be persuaded to attend a simple vendor-arranged update on plantwide oil-mist sys-tems. Oil mist is highly successful for lubricating electric motors in the 15 hp–500 hp range. Of course, there is no diplomatic way to remind an indifferent purchaser that making informed choices is better than selecting equipment based on old anec-dotes. By not including electric motor lubrication and standby/ storage protection in cost-justification studies, the uninformed have locked entire plants into a cycle of avoidable expenditures. Their BOC competitors have captured the lead by making wise choices decades ago.

LITERATURE CITED

1 _{Bloch, H. P. and A. R. Budris,} Pump User’s Handbook: Life Extension, 4th Ed., 2013, The Fairmont Press, Inc., Lilburn, Georgia, p. 296.

2 _{Bloch, H. P.,} Pump Wisdom: Problem Solving for Operators and Specialists, John Wiley & Sons, Hoboken, New Jersey.

HEINZ P. BLOCH resides in Westminster, Colorado. His professional career commenced in 1962 and included long-term assignments as Exxon Chemical’s regional machinery specialist for the US. He has authored over 580 publications, among them 18 comprehensive books on practical machinery management, failure analysis, failure avoidance, compressors, steam turbines, pumps, oil-mist lubrication and practical lubrication for industry. Mr. Bloch holds BS and MS degrees in mechanical engineering. He is an ASME Life Fellow and maintains registration as a Professional Engineer in New Jersey and Texas.