Join this session to hear the latest on API's 5th edition of Recommended Practice (RP) 751, Safe Operation of Hydrofluoric Acid Alkylation Unit. In this session, we're discussing maintenance from the operator perspective, integrity management and other safety programs for hydrofluoric (HF) acid alkylation units.
Reliability of critical FCC equipment often drives turnaround planning and cycle length. Cyclones, slide valves, refractory and major rotating equipment repair planning can make or break a FCC cycle. This session will review critical components of reliable FCC operation and what a turnaround inspection and repair plan should encompass to improve long term FCC reliability.
In this session we will show the results of a failure in a Mechanical Integrity Program. This track will also discuss event investigation results, along with, lessons learned and path forward, in hopes to enlighten all in the industry.
Facilitator: Dean Roberts, Ergon-West Virginia Refining Inc.
Reliability of critical FCC equipment often drives turnaround planning and cycle length. Cyclones, slide valves, refractory and major rotating equipment repair planning can make or break a FCC cycle. This session will review critical components of reliable FCC operation and what a turnaround inspection and repair plan should encompass to improve long term FCC reliability.
The FCCU continues to be challenged to process varying feeds in the refinery now and for the foreseeable future. This 101 series session will cover the FCC heat balance with an emphasis on feed properties and their effect on regenerator temperatures. Recommended optimization paths for regenerator temperature being too high or too low will be discussed.
Facilitator:
CJ Farley, Astron International, Inc.
Speakers:
Todd Miller, HF Sinclair Corporation
Kent Turner, W. R. Grace & Co.
FCC equipment advances will feature 2 presentations, one focused on the regenerator and one focused on the reactor. The first will discuss a next generation catalyst cooler technology used to debottleneck regenerator constraints and stabilize regenerator operation. The second will cover optimization of the FCC reactor riser hydrodynamic profile to minimize dry gas & coke, increase conversion, and improve reliability.
Facilitator: Todd Hochheiser, Johnson Matthey
1. Advanced Catalyst Cooler Features to Enhance FCC Operational Flexibility
Speakers:
Yongcan Gao, Technip
2. From Vision to Reality - FCC Reactor Riser Improvement
Speakers:
Javier Rios, Honeywell UOP
Nik Larsen, Marathon
Facilitator:
Andrew Mezera, Valero Energy Corporation
Panelists:
Ann Benoit, W. R. Grace & Co.
Richard Grove, Chevron U.S.A. Inc.
Nik Larsen, Marathon Petroleum Corporation
Steve Shimoda, Technip Energies
Bill Wilson, FCC Process Consultant
Reliability and Maintenance Bootcamp, Mechanical Integrity
This technical session is designed to give engineers and maintenance professionals a practical understanding of how API-579 Level 3 Fitness-for-Service (FFS) assessments—powered by Finite Element Analysis (FEA)—can solve complex reliability challenges in the oil and gas industry.
We will introduce advanced methods for evaluating equipment with damage mechanisms like corrosion, cracking, and dents. You’ll learn when Level 3 assessments are needed, how FEA is applied, and why these techniques offer better accuracy, safer outcomes, and longer equipment life.
Highlights include:
API-579 FFS framework and when to escalate to Level 3
Benefits of FEA: realistic modeling of stress, temperature, and pressure
Real-world case studies: pressure vessel corrosion, weld cracking, and pipe dents
Key takeaways for maintenance planning and repair decisions
Tailored for a broad operator-based audience, this session uses real examples—not just theory—to demonstrate how advanced analysis can enhance reliability, reduce costs, and support critical decisions.
Over the past 12 years, Ketjen FCC modeling engineers have simulated over 145 FCC units globally, identifying common challenges that prevent refiners from fully leveraging kinetic FCC models to maximize profitability. These challenges often stem from structural issues in model setup, poor-quality process measurements, or a lack of detailed knowledge about the models. This presentation will highlight 4 to 6 real-world examples, offering insights on how to: 1) avoid common modeling predicaments, 2) quickly identify if problems exist, and 3) implement actionable solutions.
Moderator:
Steve Shimoda, Technip Energies
Speaker:
Alan Kramer, Ketjen Corporation
Bridget Cadigan, Marathon Petroleum Corporation