deltavalve 2010 customer version
TRANSCRIPT
The contents of this presentation is PRIVILEGED and
CONFIDENTIAL material of Curtiss Wright Corporation and
should not be disclosed, used by or copied in any manner
by anyone. Any unauthorized use, dissemination of the
information or copying of this presentation is prohibited.
7200 Employees Worldwide
~2 Billion US Dollars in Sales
Offices in Singapore, Korea, UK, France, Germany,
Netherlands, Belgium, Italy, Sweden, Spain, Switzerland,
Canada, USA
Top Unheading
HPU &
Controls
Auto-Switch
Coke Cutting Tool
Bottom Unheading
Isolation Valve
Drill Stem
Enclosure
Why The Need For Change?
Traditional systems:
• Do not eliminate exposure
• Are expensive to operate & maintain
• Are complex to operate
Why The Need For Change?
Traditional systems:
• Do not safely allow processing of shot-coke
• Can not control a drum dump
Why The Need For Change?
Traditional systems:
• Simply are not safe
• 20 – 30 fatalities and numerous injuriesin past 10 years
Pre-Commercialization
• Prototype Fully Tested in Simulated Coker• Bond shear/thrust test
• Thermal test (200F – 1100F)
• Seat leakage test
• Finite Element Analysis• Thermal stress analysis of all critical components
• Thermal Cyclic fatigue study
• Thorough Analysis
• Metallurgy• Mating parts (wear surfaces)
• Switch-deck constraints
Totally Enclosed, Safe,
Simple to Operate, Reliable
COKE DRUM
DELTAGUARD
COKE DRUM
BOTTOM UNHEADING
DEVICE
TRANSITION SPOOL
WITH SIDE ENTRY
FEED
FIXED
CHUTESWITCH
DECK
DISCHARGE
CHUTE
DeltaGuard US Patents
6565714 6964727
6660131 6843889
6989081 7033460
7316762 5816787
7115190 7117959
International Patents
209822 255082
Other US and International
patents pending
Safe Unheading
• Totally enclosed system from top head to coke receiving area
• No exposure to personnel, unheading deck, or to plant equipment
• Isolation of a tary drum
• Isolation or controlof a drum dump
Safe Unheading
• Positive mechanical lockout• All required safety interlocks incorporated• Safe to operate using back-up methods• Remotely operable
Easy Operation
• Satisfy all safety interlocks
• Receive board permission
• Remove positive lockout pin
• Push open/close button
• Remotely operable from– Local control panel
– Control room
Increased Throughput
• Unheading time of 2-4 minutes
• For maximum increase in throughput, the DeltaGuardcan be configured to allow;– Drainage of coke & water through the port (Model GV815)
– Optional-throttling design control of coke and water through the port (Model GV820)
• Elimination of uncontrolled fallouts onto the switch deck eliminates down time for cleanup
Economic Benefits
• No head gasket to replace at each drum cycle
• No feed line coupling gaskets to replace at each drum cycle
• No feed line coupling, or alignment systems to maintain
• No time consuming water flushing required(can be done through the valve)
• No disassembly, cleaning and re-assembly required at each cycle
• No other replacement parts at each cycle
• No maintenance or replacement of tools
First Installation – September 2001
There have been:
• Over 500,000 combined cycles
• No recordable injuries
• No incidents
First Installation – September 2001
Have had:
• No effect on coker quality
• No effect on coker process,(in fact improved coker economics
significantly)
• No effect on coker operations
• No effect on coke drum
drilling operations
• No maintenance expense
• Significantly improved safety
• Eliminates exposures to personnel
• Significant reduction in maintenance
costs at turnarounds
DeltaGuard® Unheading Device
Only One Major Moving Part
• Ensures simplicity and reliability
• Significantly reduces need for spare parts
DeltaGuard® Unheading Device
Seating Technology
• All metal seating
– Nitrided gate and hard chromed seats
• Independent dual seats
– Floating top seat
– Static lower seat
– Double Block & purge/bleed
• Self cleaning
– Constant load keeps gate and seat surfaces together at all times
DeltaGuard® Unheading Device
Steam Purged Body
• Diagnostics Tool
• Regulates Body Temperature
• Creates a Barrier against
Coke migration
DeltaGuard® Unheading Device
Steam Purged Body
• Steam purged body
• Diagnostics Tool
• Regulates Body Temperature
• Creates a Barrier against
Coke Migration
• Supports Coke Containment
System
DeltaGuard® Unheading DeviceSeating Technology – Throttling Design
• Internal Coke Containment System
– Keeps coke fines from
entering the bonnet
– Reduces steam
consumption
DeltaGuard® Unheading Device
Maintenance
• Quick assembly and
disassembly with coke drum
• Minimal part requirements for
complete seat and seal
replacement
• Re-buildable on switch deck
during shutdowns
DeltaGlide™
Maintenance
• Smooth installation
• Balanced load
• Constant alignment
• On deck serviceable
DeltaGuard® Top Unheading Device
Based on DeltaGuard Bottom
Unheading Device Technology
• Double, live-loaded, dynamic,
metal seats
• Designed to keep coke out of
body cavity
• Steam purged body
• Low steam consumption
• Adaptable to all top head
diameters
• Hydraulically actuated
• On-site maintenance
DeltaGuard® Top Unheading Device
Based on DeltaGuard Bottom
Unheading Device Technology
• Double, live-loaded, dynamic,
metal seats
• Designed to keep coke out of
body cavity
• Steam purged body
• Low steam consumption
• Adaptable to all top head
diameters
• Hydraulically actuated
• On-site maintenance
HPU & Controls
Hydraulic Power Unit
• Simple, reliable and
redundant hydraulic system
• Minimal hydraulic system
requirements for valves,
fittings and piping
• One hydraulic cylinder
• One hydraulic line in and out
Drill Stem Guide / Blow-out Diverter
System Benefits:
• Totally contained cutting tool
• Protect against steam burns
• Protection from blow-outs/eruptions
• Interlocks incorporated
• Natural integration of Hydraulics/Controls with
bottom unheading system
• Proven technology
GV 850 Isolation Valve• Total Isolation Valve Solution
– Linear goggle Blind Principal
– Live Loaded, Self Cleaning Metal Seats
– Fully Bi-Directional Double Block and Purge Isolation
– Top Entry (field serviceable)
– Electro Hydraulic Actuator
– Manual De-Clutchable Override
GV 850 Isolation Valve
• Total Isolation Valve Solution
– Zero Non Turnaround Scheduled Maintenance
– Condition Diagnostics
– Optional Maintenance Jib
Live Loaded, Self Cleaning Metal Seats
• Double Live Loaded, Ultra Heavy Duty Metal Seals with Proven Reliability
• Seal Tightness Not Sensitive to Body Deflection
• Valve Torque / Thrust / Operation Not Sensitive to Body Deflection
• No Change In Seal Performance Over Time
Actuation• Electric Actuation
– Limitorque SMB CVA Series– Rotork– Customer Preference
• Electro Hydraulic / Continuous position indication / Manual De-clutchable Override
• Hydraulic Actuation• Manual Actuator if Requested
GV 850 Isolation Valve Models• VT (Sealed Body Cavity)
– For use in; • hydrocarbon liquids near
coking temperature
• solids laden hydrocarbon liquids
• dirty hydrocarbon vapor streams
• on/ off, throttling service
• VN (Open Body Cavity)
– For use in; • steam , water
• clean hydrocarbon liquids below coking temperature
• clean hydrocarbon vapor streams
• on /off, throttling service
GV 850 DCU Services by Model Number (DV Recommendation)
• GV850 VT– OH Vapor to Blow down
• XV 1023
– OH Vapor to Fractionator
• XV 1060
– Coke Condensate
• XV 1028
– Drain to Coke Pad
• XV 1029
– Manifold Isolation Valve
• XV 1038
– Wax Tailings/Steam
• XV 1050
– HC Liquids / Vapor Bypass to Fractionator
• XV 1065
• GV850 VN– Coke Drum Vapor discharge (PSV
Discharge)
• XV 1001, 1006
– Utility steam MOV
• XV 1039
– Quench Water MOV(purged)
• XV 1040
– Atmospheric Vent Valve
• XV 1041, 1042
– Quench Oil HCGO
• XV 1053, 1054
GV850 VT• VT
– Double, Metal, Self Cleaning Seats
– Live loaded
– Fully Sealed Body Cavity at all Times
• Seats extend into lower bonnet
• Seat extensions cover both surfaces of gate over full stroke
• Seat extensions are fully live loaded and purge pressure assisted
• Seat extensions are ground and polished to valve seat tightness
• Zero Cross Valve leakage with Purge
• Designed for continuous Static Purge.
GV 850 VN• VN
– Double, Metal, Self Cleaning Seats
– Live Loaded
– Fully sealed Body Cavity while in Open and Closed Positions Only
– Seat Seals are live loaded and Purge Assisted
– Zero Cross Valve Leakage with Purge
– Static purge while in fully open and closed positions.
– Flowing purge during stroke
Top Entry / In Line Serviceable
• All Internal parts accessible while installed
• Easy Disassembly and Re-assembly
• No Special Tools or Equipment
• Optional Maintenance Jib
Purge Steam Consumption Rates
Size Factory Test Results Steam Header
Sizing
Recommendations
10” .3 lb/hr 150 lb/hr
12” .36 lb/hr 180 lb/hr
18” .54 lb/hr 270 lb/hr
24” .72 lb/hr 360 lb/hr
30” .9 lb/hr 450 lb/hr
36” 1.1 lb/hr 540 lb/hr
Diagnostics
• Static Steam Pressurized Body and Bonnets– VN, Low Purge Steam in Open or Closed Positions
– VT, Low Purge Steam at all times
– Header sizing guideline;• 10 lbs/hr/inch of port Diameter/valve
• Steam Pressure and Flow Sensors– Real Time Verification of Positive Isolation
– Positive Confirmation of Seat / Gate Condition
Zero “Non Turnaround Scheduled” Maintenance
• No Maintenance of Packing
• No Maintenance of Seat Seals
• No Maintenance of Gate
Isolation ValvesValve Sizes and Connections
• Sizes From 3” to 48”
• 150#, 300# and 600#
• FF, RF, RTJ, Weld End
• No Maintenance
Certifications
• ASME Sec VIII Div 1 & 2
• U-Stamp Designation
• MAWP 1062 kPa (154 PSI) @ 504°C (940°F)
• FEA-Finite Element Analysis
• CRN# -ABSA
• PED certification including ATEX &
CE markings
• GOST-R certification
Field Services
Services Provided:
• Installation and commissioning supervision
• Warranty and repair
• Major rebuilds
• Site audits
• On-going maintenance
• Training
Field Services
DeltaValve Service Center:
– TapcoEnpro Facility – Barnsley, UK
– TapcoEnpro Facility – Houston, USA• Extensive history of valve repair
• Proven safety record
• Large scale operation
Units Sold (as of January 2010)
266 Bottom
Unheading Valves
131 Top
Unheading Valves
160 Isolation Valves
Customers
First Customer – Chevron Salt Lake City, Utah, USA
• Installation Sept 20, 2001
• No maintenance expense & no outages
• Eliminates personnel exposure and risks
• Fabricated design
• Transition spool bolted to drum
• 24 hr cycles
• ROI-Immediate maintenance & operational
savings-refinery specific
• Valve supported by structure,not by drum
• Continue to produce sponge coke
• 2 installed out of 2
Customers
Second Customer – Chevron Pascagoula, Mississippi, USA
• Installation February 2003
• No maintenance expense & no outages
• Eliminates personnel exposure and risks
• Fabricated design
• Transition spool connected to drum
• Reduced to 12 hr cycles
• ROI-Immediate maintenance & operational
savings-refinery specific
• ROI-Increase throughput
• Valve supported by structure, not by drum
• Produce shot coke
• 6 out of 6 bottoms & 6 tops installed
Customers
Fifth Customer – BP Texas City, Texas, USA
• Installation April 2004
• No maintenance expense & no outages
• Eliminates personnel exposure and risks
• Cast design
• Transition Spool integral to the drum
• 14 hr cycles
• ROI-Immediate maintenance &
operational savings-refinery specific
• ROI-Increase Throughput
• Valve supported by structure,
not by drum
• Produce of Shot Coke
• 6 installed
Customers
Sixth Customer – Citgo Lake Charles, Louisana, USA
• Installation July 2004
• No maintenance expense & no outages
• Eliminates personnel exposure and risks
• Cast design
• Transition Spool Integral to the drum
• 18 hr cycles
• ROI-Immediate maintenance &
operational savings-refinery specific
• ROI-Increase Throughput
• Valve supported by structure, not by drum
• Produce shot coke
• 4 installed
• remaining 4 currently being installed
Case Study 2
Shell Wilmington RefineryWilmington, California
Refinery Delayed Coker Unit Background
• 4 drum coker unit
• DeltaValve enclosed unheading system
• Foster Wheeler process licensed technology
Case Study 2
Shell Wilmington RefineryWilmington, California
Incident Background (May 2006)
• Main transformer failure and lost power to
some major equipment on the delayed coker
unit
• Not able to get heater trip system reset and get
heat back into the coke drums
Case Study 2
Shell Wilmington RefineryWilmington, California
Incident Background (May 2006)
• One coke drum has been charged for about 19
hours and the other drum had been charged for
about 7 hours
• Continued to put feed into the coke drums for 2
hours at about 230C (too cold for any coking
reactions to occur)
• Eventually operators stopped feed into the
coke drums, but the amount of cold feed was
too much
Case Study 2
Shell Wilmington RefineryWilmington, California
Event Procedure
• Successfully introduced steam and quench
water into both drums to cool the internal
materials
• Proceeded to unhead the first drum (19 hours
charging)
• Material in this drum was a slurry of coke
particles and cool tarry material, similar to the
consistency of road asphalt.
• Successfully emptied the first coke drum
Case Study 2
Shell Wilmington RefineryWilmington, California
Event Procedure
• Certain the second drum (7 hour feed) was
going to be mostly tar. Cause for significant
concern and extra precaution.
• Waited for second drum tar to cool sufficiently.
• Attempted to drain quench water through feed
line. Unsuccessful, tar plugged the line.
Case Study 2
Shell Wilmington RefineryWilmington, California
Event Procedure
• Added fire-water sprays into the coke pit as a
precautionary measure (concerns of a hot tar
flash fire.)
• Evacuated coke structure.
• Slowly opened the DeltaValve by remote
operation from an enclosed unheading shelter.
Case Study 2
Shell Wilmington RefineryWilmington, California
Outcome
• Hot water and liquid tar came from the bottom
of the coke drum through the valve.
• Dumped approximately 5000 barrels of tar into
the coke pit.
• Successfully unheaded the tarry drum without
incident.
Case Study 2
Shell Wilmington RefineryWilmington, California
Final Result
• No injuries
• No risk to personnel
• No damaged equipment
• No detrimental environmental impact
• No downtime
(estimated savings of up to $10 million)
Case Study 2
Shell Wilmington RefineryWilmington, California
“We are obviously thrilled with the performance of our DeltaValve unheading system, and we know the
cost of the system was justified economically just by this one event. The safety benefits of being able
to remotely un-head the drum and reclose it are, of course, priceless.
The industry has come a long way in terms of coker safety and DeltaValve has made an immense
contribution to that progress.”
Eric Brown
Crude, DCU Production Specialist
Tesoro (Shell ) Wilmington
Why Install the DeltaGuard®?
Safe Unheading• Totally enclosed system, eliminates exposure risks
Return on Investment• Immediate reduction of operating/maintenance expense
Refinery specific- ~ $200K+per drum per year
• Ability to process alternative crudes
• Increased production due to reduce cycle times
• Drum is drained directly through the device
Easy to Operate• Push button-open/close
Reliable Design• One major moving part
Experience (Proven Technology)
• 7 + years of maintenance free operation
• Over 500,000 combined cycles
• No safety incidents
Some of Our Customers