API RP 751 Section 6
HF Alkylation, Mechanical Integrity
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.
Facilitator: Herb Haught, CVR Energy
Speaker: Monica Plowman, Ethos Mechanical Integrity
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HF Alky Isobutane Exchanger Bypass Leak
Learnings from Incidents, HF Alkylation
In 2021, hydrofluoric acid vapors were detected by the safety instrumented subsystem (SIS) line of sight laser detection system, which activated both the rapid acid dump system and the fire suppression/unit deluge system. The source of the leak was determined to be the bypass line around the isobutane recycle cooler. Topics discussed: Residual Elements, CMLs for high RE, PMI for high RE, low flow and process deadleg identification.
Speaker:
Mark Geisenhoff, Flint Hills Resource
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Casting Quality Issues in HF Alky Valves
HF Alkylation
Over the last few years, there has been an increase in through body leaks on cast HF Alkylation valves. This presentation will review several real life examples of casting failures on valves in HF Alkylation service including cross sections of the failure location. These failures have occurred on both low RE carbon steel and Alloy 400 (M35-1) castings. Some common causes of casting failures will be reviewed including sand inclusions, porosity and varying levels of shrinkage. Common locations of casting quality issues with HF Alkylation valves will be discussed including the bottom bowl area and the body to end flange transition on Alloy 400 plug valves. The presentation will also cover some of the methods that are being implemented in the industry to improve the casting quality of HF Alkylation valves along with efforts to standardize and consolidate requirements for these valves.
Speaker: Michael Alford, Marathon Petroleum
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Learnings from the Philadelphia Energy Solutions Incident
HF Alkylation, Learning From Incidents
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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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