Expert Panel Discussion on Considerations for Heater Optimization and Future — Part 1
Gasoline Processes
Facilitator:
Matt Hutchinson, Axens North America
Moderator:
Joong Yang, Chevron U.S.A. Inc.
Panel:
Amit Gupta, Heurtey Petrochem Solutions
Bill McLaughlin, ExxonMobil Product Solutions Company
Ethan Spielvogel, Marathon Petroleum Corp.
Randy Stier, Valero Energy Corporation
Vivek Sundaram, LyondellBassel Industries
We are producing petroleum products in the current environment in which emissions reduction is demanded amidst rising consumer demand. The panel discussion will focus on safe operation and optimization of process fired heaters, including limitations with existing technologies to reduce emissions, and challenges with emerging technologies, e.g., hydrogen firing and electrification.
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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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Topic
Normalization of Deviance — The Pathway to Disaster
Reliability and Maintenance Bootcamp
In this session, we will discuss in detail the definition of Normalization of Deviance and how it has contributed to major accidents, including both Space Shuttle disasters. Examples will be provided of Normalization of Deviance in operating and maintaining process plants, as well as in our daily lives.
Participants will:
- Gain an understanding of how to stop Normalization of Deviance
- Learn how to identify and correct this behavior
- Take this concept home to apply with their families
Moderator:
Dean Roberts, Ergon Refining, Inc.
Speaker:
Rick Hoffman, Becht
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A First-Principles Approach to Root Cause Analysis and Human Error
Reliability and Maintenance Bootcamp
After more than 50 years of root cause analysis (RCA), you might expect problem solving to be a clear and straightforward process. It’s not. You can find yourself caught in unproductive debates. “Is that a contributing factor, or a causal factor?” “That’s a primary cause, but it’s not the main cause.” The result is frustration, inefficiency, and solutions that allow a repeat of the same problems.
A better approach to RCA is one built on evidence-based cause-and-effect relationships. The steps are simple: define the problem, explain why it happened, and identify solutions to reduce risk. Its focus is on having more reliable work processes, learning, and improving, which helps engage the frontline and minimize blame.
This session will explain the pitfalls of drifting from scientific problem solving and features a case study demonstrating how first-principles RCA leads to tangible improvements in reliability and human performance.
Participants will learn:
- Four common errors that arise when explaining why an incident occurred
- The biggest misconception about RCA
- Why effective RCA does not require any proprietary techniques, terminology, or software
- How RCA can be scaled for low-risk incidents and expanded as needed for higher-impact events.
- How to reduce “human error” by involving those who perform the work
Moderator:
Bill Clark, Phillips 66
Speakers:
Bill Clark, Phillips 66
Mark Galley, ThinkReliability
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SMR Heater Tube Inspection and Reliability
Lessons Learned, Fired Heater, Hydroprocessing
This session will cover the topic of using a SMR heater tube inspection technology and using the inspection results to increase hydrogen production.
Moderator:
Diane Dierking, Johnson Matthey
Speakers:
Scott McArthur, Phillips 66
Edgar Remedios, FOERSTER Instruments Inc.
Oliver Smith, Air Products and Chemicals
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Ensuring Safe and Efficient Transitions from Full Burn to Partial Burn
Lessons Learned, Fired Heater, FCC
This session will cover KPIs and operating scenarios for partial burn FCC units, including the challenges and consequences of maloperation. Additionally, this session will focus on considerations taken to ensure safe operation of the CO Boiler. Attendees will come away with a fundamental understanding of the key principles and potential hazards associated with partial-burn operation.
Moderator:
Joe Colmone, Honeywell UOP
Speakers:
Luis Bougrat, W.R. Grace & Co.
Zach Word, Phillips 66
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Topic
Capital Projects: Project Life Cycle Costs
Reliability and Maintenance Bootcamp
This session will introduce an integral part of maintenance and reliability engineers’ responsibilities to capital projects. How this relationship and communication is important to get safe, reliable, and maintainable equipment installed when working with a capital project team.
Participants will learn:
- What a project life cycle is
- What influences cost the most, and
- Industry standards for analysis
Moderator:
Bill Clark, Phillips 66
Speaker:
Dean Roberts, Ergon Refining, Inc.
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