CSB Lessons Learned: Fired Heater Tubing Failure
Fired Heater, Lessons Learned
The CSB will discuss its investigation of the November 19, 2023, fired heater tube rupture at a refinery in Martinez, California. The incident occurred during the initial startup of a renewable diesel hydroprocessing unit, resulting in a fire that seriously injured one employee. Topics will include fired heater safe operating limits, worker proximity to fired heaters, safety instrumented systems that detect low process flow into fired heaters, burner operation, valve misalignments, and corporate oversight.
Participants will: Gain an understanding of both the process-side and combustion-side causes that contributed to the tube rupture; Identify potential deficiencies that may exist at their own units; and Review the CSB’s industry recommendation to API for suggested revisions to API RP 556 (Instrumentation, Control, and Protective Systems for Gas Fired Heaters).
Moderator:
Willis Jernigan, AFPM
Speaker:
Melike Yersiz, U.S. Chemical Safety Board
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Lessons Learned: De-propanizer Corrosion
Lessons Learned, Alkylation
Moderator:
Liana Siegel, Marathon Petroleum Corporation
Speakers:
Jhouly Osorio, Marathon Petroleum Corporation
Ezequiel Vicent, OLI Systems Inc.
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Chemical Injection Sound Principles
Lessons Learned, Crude
Topic 1. Proper Configuration for Chemical Addition Applications
This segment focuses on common best practices and pitfalls for chemical injections.
Learning Objectives:
- Types of injectors
- Use of diluent
- Injection placement / ideal locations
Topic 2. Special Case Study for Caustic Injection
This segment focuses in on injecting caustic in the crude unit to further reduce chlorides in the crude tower overhead system, reducing corrosion potential.
Learning Objectives:
- When to use caustic & when NOT to use caustic
- Proper injection practices
- Potential pitfalls, including an example
Moderator:
Tim Oubre, Halliburton Multi-Chem
Speakers:
Tim Oubre, Halliburton Multi-Chem
Jeff Zurlo, TotalChem, LLC
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Lessons for Success: Mastering Project and Turnaround Integration
Turnaround Roundtable, Lessons Learned
This session will share lessons learned from a high complexity turnaround that had a large scale debottleneck project integrated into the turnaround scope. We will review key successes and opportunities to understand what this team would repeat or change for future events.
Moderators:
Andrew Jakubowski, Flint Hills Resources, LLC
Jimmy Mendler, Chevron Phillips Chemical Company LP
Speaker:
Sarah Earl, Chevron Phillips Chemical Company LP
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The Journey: Transforming Reliability Outcomes Through Technology and Maintenance Practices
Lessons Learned, Maintenance
In an era of rapid technological advancement, achieving positive reliability outcomes requires a strategic blend of innovation and foundational maintenance practices. This presentation explores how organizations can harness emerging technologies to enhance awareness and enable early anomaly detection. By integrating data-driven insights with proven maintenance strategies, companies can improve operational reliability and efficiency. Through an open discussion, we will explore the real-world challenges and opportunities that arise when merging traditional maintenance with cutting-edge technology.
The session is designed as an introductory-level discussion that highlights the value of combining traditional hands-on maintenance practices with modern monitoring tools to support a more comprehensive and reliable approach to decision-making. Together we aim to uncover practical strategies for building a resilient, future-ready maintenance culture. Participants will be encouraged to share experiences and insights on navigating common pitfalls—such as over-reliance on digital tools, integration complexities, and maintaining a balance between automation and human expertise.
Moderator:
Dean Roberts, Ergon Refining, Inc.
Speakers:
Jaxson O'Brien, CHS Inc.
Mark Sannes, Flint Hills Resources, LLC
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HF Alkylation: Incident Sharing and Lessons Learned
HF Alkylation, Lessons Learned
Speaker:
Gary Kemeny, PBF Energy Inc.
Liana Siegel, Marathon Petroleum Company
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Fired Heater Flooding
Lessons Learned
Fired Heater Flooding incidents continue to occur. Flooding is a term used to indicate operation of a fuel rich condition, resulting in unburned fuel or combustibles in the firebox and/or flue gas. This presentation will touch on causes, indications and provide response examples and possible prevention of fired heater flooding operation.
Moderator:
Sam Lordo, Becht
Speakers:
Jose Corcega, John Zink
Bill Weimer, John Zink
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