REMOTE UNHEADING / DECOKING

PROJECT - PUGET SOUND REFINERY

A USER PERSPECTIVE
AND LESSONS LEARNED ON A
JOURNEY TO SAFER
OPERATION

Anthony Finfrock
Control Systems Engineer – PSR Projects
Automation Lead on Project

Copyright of SHELL OIL PRODUCTS US

PUGET SOUND’S JOURNEY

Background and the Case for Change

Project Scope
Today’s Safety Picture
The Coke Handling Experience
The Conversion Project Experienced
Outcome and Ongoing Journey
Key Learnings / Recommendations

Copyright of SHELL OIL PRODUCTS US September 2012 2

PUGET’S COKER PRE-2011

n 2-Drum,14-hr cycles, sponge coke,

small pit.
n Relocated to PSR and re-
instrumented
1984. “Manual” in most respects.
n Shell worldwide delayed coking safety
emphasis – historical perspective.
n Structure operations standardization.

n Some instrumented safety barriers

already in place for non-coke
operations - ie interlocking of valves
n Unheading and decoking – managed
by procedural controls
n Local decoking shelter provided
limited protection
Copyright of SHELL OIL PRODUCTS US September 2012 3
THE CASE FOR CHANGE AT PUGET SOUND
REFINERY

n “All life and health hazards mitigated to ALARP*”.

n Although each year brought risk reduction improvements, prior to

this project there was a very different paradigm. Proximity was
considered necessary and so we tolerated the risk which came
with it.
n Boilovers, mechanical failures, falling equipment, blowouts, toxic
hazards, fire, scalding, other thermal hazards, ergonomic
hazards, etc.
n “This person is likely to be very close by when the event occurs.”
n Removing the person from the structure was the best (and only?)
solution.
n The Puget Sound threat model is being used in development of
global hazard assessment models for coking operations.
Copyright of SHELL OIL PRODUCTS US September 2012 4
REMOTE DECOKING SCOPE

n Off-Unit BRM

n PLC with all decoking controls

integrated
n HMI – jet pumps, isolation, and

n Vibration monitoring for ‘clean

drum’ detection
n Integrated audio and video
monitoring
n New pneumatic winches and
rotary drives
n “E-to-A” package for remote
control
Decoking Control Panel

Copyright of SHELL OIL PRODUCTS US September 2012 5

OTHER SCOPE

n Remote unheading, top and

bottom, DeltaValve hydraulic slide
valves and supporting hydraulic
system
n Dual-side-entry feed charge,
extensive piping changes
n SIS System

n Integrate Decoking and Unheading

systems and SIS with existing
DCS structure interlock scheme

n Also – PSV relocations, vapor

pinch valve, deck modifications
Caption Futura Medium 8pt
Thermal Camera View of Bottom Unheading Valve

Copyright of SHELL OIL PRODUCTS US September 2012 6

TODAY'S SAFETY PICTURE

n It is not possible to decoke from n The DCU structure and coke

the cutting deck (would require handling operators jointly walk the
PLC code modification). structure and co-sign a permit to
n No one is on the structure at all open every drum.
while a drum is open, until after it n DCS console operator must
is empty and washed. manually advance interlock
n To be on cutting deck with jet system to allow unheading.
pump in operation (in bypass) n Excellent communications
requires permission from the plant between three parties who
manager. understand each others’ roles.
n Multiple systems provide
redundant interlocking:
Mechanical, hydraulic, and
electronic.
n Bypass process is well controlled
Copyright of SHELL OIL PRODUCTS US September 2012 7

and fully auditable.

IMPACT ON THE COKE HANDLER
REPLACING PROXIMITY WITH TECHNOLOGY

AUDIBLE
EXPANDED n Coke qualities
n Bed condition
VISUAL
VISUAL n Drum cleanliness
TACTILE
n Fall-out
INFO
n Stem position, rotation,
n Winch drive
n Supplemental
& movement n Coke, bed, and
n Winch / Cable drum condition
n Chute n Certain events
AWARENESS

Copyright of SHELL OIL PRODUCTS US September 2012 8

NEW EYES AND EARS

DRUM,
STEM, DERRICK, PUMPS,
COKE BED,
WINCH & CABLE WATER SYS
CHUTE & PIT

Falling coke and water

Top head environment
Stem rotation, movement Coke quality
Pit/chute clear

Stem position, movement,

Valve pos feedback
and rotation Vibration / APEX
Pressures, levels, temps
Cable tension (automatic) (Inferred cleanliness)
Logic states
Derrick ZS’s

Fall-out
Winch air pressure and
Coke condition/quality
movement
Veins, cleanliness

Copyright of SHELL OIL PRODUCTS US September 2012 9

THE PROJECT EXPERIENCE
“LOTS OF LEARNINGS ON ALL SIDES”
n Lots of players with differing expectations n Project schedule slip required plant to
of timing and mutual interactions. We accommodate a more intensive
failed to resolve during front end construction period than planned.
engineering / pre-PO. n Commissioning was highly coordinated,
n Automation intensive - detailed especially the last few days and hours.
coordination was required during design. n Some site resources were scheduled
Resources were blocked in advance, solid for a full year in advance of the
which limited our flexibility. turnaround. Implementation required “full
n DCU-experienced lead constructor commitment” for 10-12 weeks.
working with local project management.
n Electrical/automation contractors very n DCU outage was 42 days, as planned –
experienced at site. Specialty contractors PSR’s longest ever. However this was
chosen for pertinent experience. the shortest Shell remote
unheading/remote decoking outage thus
far.
n All systems were functional from start-up
(note challenges below).
Copyright of SHELL OIL PRODUCTS US September 2012 10
WHAT WORKS WELL

n Pump and valve integration, logic, and controls in the Flowserve PLC.

n Integration with other systems – DCS, SIS, Unheading and Decoking

all play nice together.
n Derrick/stem instrumentation and components – reliable. Especially
the running-line tensiometer position/payout/tension instrument and
automation of the tension logic.
n Clean Drum indication on HMI is reasonably accurate– usually within
several feet. Cone section is the most challenging.
n Coke handler has adequate tools to cut drums in similar time to pre-
project – and their environment is much safer (and more pleasant as
well).
n Communication between coke handler, structure operator, and console
/ DCS operator is more complete.

Copyright of SHELL OIL PRODUCTS US September 2012 11

VIDEO CAMERA VIEWS

4-Square View Chutes

Top Head View IR / Thermal Camera – Pit and Maze

Copyright of SHELL OIL PRODUCTS US September 2012 12

CHALLENGES WE’VE OVERCOME

n Stability problems between the remote decoking PLC and the APEX
vibration processing unit.
n Audio system requires complex to maintain. (Flowserve has changed
design to simplify.)
n Audio failures were difficult to diagnose without experience.

n Audio quality was initially poor. Noise-cancelling mics made significant

difference.
n Video system (non-Flowserve, legacy) needed considerable work to
make it useable.
n Puget initially required a ‘training system’ – not a good use of
resources.
n Graphics were a challenge.

n Hoist control logic in the PLC initially contained errors which passed
FAT undetected.
Copyright of SHELL OIL PRODUCTS US September 2012 13
ONGOING CHALLENGES

Pneumatic hoist controls –

n “E-to-A” controls work, but are limited by the limitations of pneumatic hoists. Lots
of play, difficult to control precisely. Documentation was adequate to operate and
maintain, but too limited to allow advanced troubleshooting.
n Stock components are delicate. Flowserve has since revised design to address
this.
Audio monitoring –
n The system requires some nursing, such as an occasional power cycle.

n Parts development continues, and parts are slow in coming.

Vibration monitoring / Clean Drum indication –

n Vibration probes are subject to mechanical damage from insulation (and
Insulators). Has been difficult for us to keep functional.
n Adjustments require an on-site visit – the APEX is a specialized part, and model
adjustment is a function Flowserve performs.

Copyright of SHELL OIL PRODUCTS US September 2012 14

RECOMMENDATIONS

Video is essential ‘kit’ for a coke handler. Install a system which

is reliable and will provide at least four views simultaneously.
(Open head, winch drum, chute, and crane location.)
The coke handling experience becomes increasingly visual because of the
loss of proximity. Instrumentation provides valuable feedback but is too
indirect to portray some of the nuanced events that require near-
instantaneous response.
Audio is near-essential. Provide a system which is
reliable and low-noise. Multiple locations is helpful,
particularly near the cone and mid-to-upper drum.
Audio provides information which is not offered by any other instrument, including
certainty of clean drum, proximity to drum wall during cut, coke bed condition,
etc.

Panel ergonomics should be a key deliverable because of the

attention and static body posture required. Work with a coke
cutting operator to design the panel.
Avoid replacing physical controls with HMI touch screen controls.
Prevent requiring continuous pressure on a joystick, as this becomes an ergonomic
nightmare which leads to ‘creative solutions’ by the user.

Copyright of SHELL OIL PRODUCTS US September 2012 15

RECOMMENDATIONS - 2

Make human presence on the cutting deck an absolute no-no

during decoking; otherwise the entire premise is compromised.
There are multiple examples of sites which have spent big money to install remote
decoking only to use it with people on the deck and/or not to use it at all. Its clear
that making this transition requires resolve; use it.

HMI graphics need to be simple to use, consistent, and

well understood by the coke handler.
Agree on design and dynamic behaviour well ahead of the FAT, so that FAT
testing can include complete graphics.

Consider hydraulic or electric winches.

Puget retained pneumatic winches because we had been successful with them and
were already undertaking a substantial change. They are the root cause of several
of our ongoing challenges. Flowserve advised us to avoid pneumatic.

Copyright of SHELL OIL PRODUCTS US September 2012 16

RECOMMENDATIONS - 3

Assure that your FAT accurately and completely represents the

finished system. FAT thoroughly to not only prove correct
operation but assure no undesired operation can occur.
FAT with a complete and final version of both PLC code and HMI graphics. This
probably requires an early review cycle with live graphics.
Use an actual hoist, or a realistic model, and monitor it during all operations.

Be generous with spare parts, both for commissioning

and ongoing. Many of the parts are relatively delicate
considering the coking process, and many are long-lead.
Cameras, microphones, audio server parts, running-line tensiometer (line rider),
E-to-A system, PLC and HMI, joystick, etc. Note: Flowserve is revising parts
spec to improve robustness.

Take care in arranging commissioning activities and resources,

especially if remote decoking is being commissioned in
conjunction with other complex changes. Missing a step or
double-booking a resource can easily cost you hours or days.

Copyright of SHELL OIL PRODUCTS US September 2012 17

AND FINALLY…

Assure that you have full and complete knowledge of the decoking process at your
facility on the project team. At PSR, decoking was not as well understood or
documented as most other processes, and the operator on special assignment
provided an extremely valuable resource.

Copyright of SHELL OIL PRODUCTS US September 2012 18

 Q&A

Copyright of SHELL OIL PRODUCTS US September 2012 19

 ADDITIONAL SLIDES

Copyright of SHELL OIL PRODUCTS US Footer Month 2010 21

LEGAL DISCLAIMER

Disclaimer: This document is made available for information only and on the condition that (i) it may not be
relied upon by anyone, in the conduct of their own operations or otherwise; (ii) neither the [Shell] company issuing
this document nor any other person or company concerned with furnishing information or data used herein (A) is
liable for its accuracy or completeness, or for any advice given in or any omission from this document, or for any
consequences whatsoever resulting directly or indirectly from any use made of this document by any person,
even if there was a failure to exercise reasonable care on the part of the issuing company or any other person or
company as aforesaid; or (B) make any claim, representation or warranty, express or implied, that acting in
accordance with this document will produce any particular results with regard to the subject matter contained
herein or satisfy the requirements of any applicable federal, state or local laws and regulations; and (iii) nothing
in this document constitutes technical advice, if such advice is required it should be sought from a qualified
professional adviser.

Copyright of SHELL OIL PRODUCTS US September 2012 22