Delayed Coker Unit

DECEMBER 2019

Application Solutions Guide DELAYED COKER UNIT

Experience In Motion

1 Application Solutions Guide — Delayed Coker Unit (DCU) TABLE OF CONTENTS Crosshead With Free-fall Arrestors...... 38 THE GLOBAL COKING AND DECOKING Latching Mechanism...... 39 LANDSCAPE Winch...... 39 MARKET OVERVIEW...... 3 Pulley Blocks, Sheaves and Cable...... 39 A CLOSER LOOK AT DELAYED COKER AND Control Systems, Including Intelligent and HYDRAULIC DECOKING TECHNOLOGIES Automated Cutting...... 40 Delayed Coker Units...... 4 Drum Monitoring Systems...... 41 DCU System Overview...... 5 Remote Cutting and Automation...... 42 Process Description ...... 6 Tool Enclosures...... 42 Hydraulic Decoking Systems ...... 8 Hydraulic Decoking Explained ...... 9 COMMUNICATING OUR VALUE Value Proposition (Delayed Coker Systems, Pumps, Valves, Seals and Actuation Products). . . 43 FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS Product Positioning...... 44 Key Pump Products...... 12 Understanding a Customer’s Specific Business Drivers...... 44 Coker and Heater Charge Pumps...... 12 Guidelines on Decoking System Selection Criteria.45 Coke Handling and Dewatering ...... 13

General Service Pumps...... 13 APPENDIX DCU Process Pumps...... 14 Sourcing ...... 46 Valves and Actuation Equipment...... 22 Rotary/Cutting Tool View for DCU...... 47 Actuators for Refinery or Process Systems. . . . . 23 Actuator Products Overview...... 24 GLOSSARY OF KEY TERMS, ABBREVIATIONS AND ACRONYMS...... 48 Mechanical Seals and Systems...... 28

Piping Plans...... 32

FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS A Complete Range of Decoking System Equipment...... 34 Decoking Hoses...... 36 Rotary Joint...... 36 Drill Stems...... 37 Combination Cutting Tools ...... 37

2 Application Solutions Guide — Delayed Coker Unit (DCU) THE GLOBAL COKING AND DECOKING LANDSCAPE

MARKET OVERVIEW

With refinery feed slates becoming more viscous, Even with the natural gas production increase, the acidic or sulfur laden, global refiners are preparing world is still awash in heavy crude, and refiners are for heavier crudes and bitumen from the Middle East, increasingly utilizing delayed coking processes to Russia, Canada, Brazil and Venezuela. When selling produce clean transportation fuels from bottom-of- at sharp discounts to light or sweet intermediates, the-barrel residues. Since the first modern delayed heavier grades of oil now can account for about coking unit (DCU) was installed in 1928, Flowserve one-fourth of daily global supplies. Refiners must be has pioneered virtually every pumping technology able to convert this heavier crude into sellable gallons advancement in these essential residue conversion of gasoline, diesel and jet fuel. processes. Through its Worthington®, IDP®, Byron Jackson® and Pacific® heritage brands, Flowserve The Energy Information Administration’s (EIA) has become — and remains — the refining industry’s “International Energy Outlook — 2015” shows a preferred partner for delayed coking process pumps slowdown in refiners’ dependence upon heavy and hydraulic decoking systems, with more than oil feed slates. But there is still strong demand in 200 installations worldwide. certain markets due to national interests as well as a potential increase in demand with the reduction requirement of bunker fuels’ sulfur levels set to be implemented in 2025.

3 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

Delayed Coker Units

Delayed coker units are the primary selection Hot residual oil is fed to the bottom of a fractionator worldwide for the upgrading of heavy residues into where it mixes with condensed recycle . The usable liquid products due to their relatively low combined stream is heated in the furnace to initiate upfront capital investment . Despite the advent of coke formation in the coke drums . Coke drum fracking technologies and the production of lighter overhead vapor flows to the fractionator where it is crude, heavy crude still occupies a large portion separated into wet gas, unstabilized naphtha, light of the crude market today and will continue to in gas oils, heavy gas oils and recycle . During the coke the future . The market is strong for keeping current drum steam out and coking period, all steam and delayed cokers running . Despite the new lighter hydrocarbon vapors are directed to the blowdown crude slates available, new units are still being system where they are recovered . After the coke drum purchased worldwide due to new environmental cooling cycle is complete, the coke is hydraulically cut regulations and specific country national interests . from the drum and dropped into a pit or pads where water is separated from the coke and recycled . Flowserve can supply many of the pumps in the delayed coker unit, but we do have a specialty within the unit with the hydraulic decoking system . It is made up of 12–15 different pieces of equipment supplied by Flowserve, depending on the exact end user system . The heart of the system is the decoking jet pump . The remainder of the equipment is a mix of in-house designs and builds as well as buyouts specified by Flowserve engineering teams . Despite the multiple pieces of equipment mounted in the delayed coker unit separately, it should be treated by engineering and sales as a complete system .

In its simplest terms, delayed coking is a semi-batch thermal cracking process using alternating drums that are switched offline after filling . Support facilities include closed blowdown, coke cutting and handling, and a water recovery system .

4 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

DCU System Overview

Coking Section Coker Blowdown

Pumping heavy oil feeds such as vacuum-reduced The coke-drum blowdown system recovers crude (VRC) combined with heavy coker gas oils hydrocarbons and steam vapors generated during (HCGO) from the fractionator to the coker heaters is the quenching and steaming of filled coke drums . a difficult service . Low NPSHA and NPSHA drop at Pump applications commonly associated with the startup, due to furnace fouling, can lead to problem- coker blowdown drum and settling drum are tower causing, first-stage cavitation, reduced TDH and bottoms, sour water, slop oil, and quench and high axial thrust . Flowserve heater charge pumps recycle water services . are proven to overcome these conditions and provide reliable service in this critical application . Steam Generation

Steam is critical to successful DCU operation . Fractionation Section In the coker heater, steam helps maintain heater Coke drum effluent vapors are routed to a coil efficiency while suppressing coke formation fractionator where they are separated into light in heater tubes . Steam is used to purge full coke gases, unstabilized gasoline, distillate, HCGO and drums and heat empty ones . Flowserve is the a recycle stream . Flowserve pumps are required acknowledged leader in the design and application to handle a wide variety of services, including of boiler feed water pumps, offering a broad range fractionator bottoms, HCGO circulating reflux and of cost-effective solutions . product, light coker gas oils (LCGO), naphtha product, fractionator tower top reflux, lean sponge oil and sour water .

Vapor Recovery Unit

Vapor and liquid streams from the fractionator are further processed in the vapor recovery unit through absorber-stripped processes . Flowserve pumps perform a wide variety of services, including lean and rich amine transfer, stripper feed, lean oil, debutanizer reflux compressor suction drum, splitter overhead and bottoms, sour water, condensate and others .

5 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

Process Description

Some derisively refer to the DCU as the “garbage The coking cycle can be as short as 10 hours can” of the refinery; in many cases, this is true . in a fuel-grade coker operation, which is built to Bottoms from atmospheric and vacuum distillation maximize throughput, or more than 24 hours for along with heavy cooler gas oils and recycle oils higher-value commercial coke products . are the feed slates for delayed coking . Once A lower coke drum operating pressure and less cracked, however, these residues are converted recycle will result in more liquid and less coke into valuable products . produced . A modern delayed coker that maximizes • Light gas to LPG and refinery fuel gas liquid yields typically has a coke drum top operating • Naphtha to gasoline pool pressure and a recycle to feed ration of 5% or • Gas oil to the refinery distillate blend pool for less . Needle coker production, however, usually heating oil demands a high pressure and a high recycle- to-feed ratio to achieve the desired needle • Coke, largely used as fuel for power plants coke properties . and steel mills and as anodes for the aluminum industry A vapor stream from the coke drum is routed to a fractionator (2), where it is separated into light Heavy oil feeds such as VRC or atmospheric- gases, unstabilized gasoline, distillate, heavy coker reduced crude are preheated in heat exchanges gas oil and a recycle stream . The coker fractionator (1) with coker gas oils and then fed to the bottom off gas is compressed in a wet-gas compressor, section of the coker fractionator (2) . Fresh feed which increases the pressure of the gas . This combines with recycle, which is net liquid from the stream then goes to a gas plant (5) along with the fractionator wash section above the feed inlet, and unstabilized gasoline, where it is further separated is routed to the coker heaters (3) with the coker into dry gas, LPG and stabilized gasoline . charge pumps . The coker gas plant is similar to a fluidized cat In the coker heater, the combined feed is heated to cracking (FCC) unit’s gas plant and usually consists 495°C (920°F) or more to allow the coking reaction of an absorber-stripper and debutanizer . Sour coker to occur in the coke drums . High-pressure steam, dry gas from the gas plant is scrubbed with amines steam condensate or boiler feed water is injected to remove hydrogen sulfide before it feeds the into heater coils at various locations to increase the refinery’s fuel gas system . The sour coker LPG is velocity through the tubes, therefore minimizing the treated with amine and caustic to remove hydrogen amount of coke deposited on the heater tubes . sulfide and mercaptan sulfur to make it suitable as Effluent from the coker heater accumulates in feedstock in other process units such as alkylation . insulated vessels called coke drums . The drums The gasoline, distillate and heavy gas oil from the allow sufficient time (i .e ., delayed) to thermally crack delayed coker are typically hydrotreated before the feed into lighter gases, naphtha, distillates, gas further processing in other refinery units . oil and coke .

6 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

Drum Cycle The dominant decoking process technologies are Coke drums are typically installed in pairs, with those licensed by AMEC Foster Wheeler, BHTS and one coker heater for every two coke drums . The CLG Technologies . The AMEC Foster Wheeler DCU feed stream switches between these two drums . process is summarized here . While one drum is filling with heater effluent, the Application: Upgrade residues to lighter other one is stripped with steam, quenched with hydrocarbon fractions using the selective yield water, drained, decoked and warmed up for the delayed coking (SYDEC) process . next cycle . Description: Charge is fed directly to the The full coke drum is first purged with steam, fractionator (1) where it combines with recycle and which initially flows to the fractionator and then the is pumped to the coke heater . The mixture is heated blowdown drum, to strip hydrocarbons from the to coking temperature, causing partial vaporization coke . After the coke drum is steamed out, water is and mild cracking . The vapor-liquid mix enters gradually introduced into the coke drum to cool the a coke drum (2 or 3) for further cracking . Drum drum and coke . overhead enters the fractionator (1), where it will Steam produced due to vaporizing the quench be separated into gas naphtha and light and heavy water is sent to the blowdown drum for gas oils . Gas and naphtha enter the vapor recovery condensation and recover water and heavy unit (VRU) (4) . There are at least two coking drums, hydrocarbons . The quench water flow rate then one coking while the other is decoked using high- increases until the coke drum is filled with water . pressure water jets . The coking unit also includes This water is subsequently drained from the coke a coke handling, coke cutting, water recovery and drum, and the top and bottom heads of the drum blowdown system . Vent gas from the blowdown are opened . system is recovered in the VRU .

The coke in the drum is cut and removed with high- Operating conditions: Typical ranges are: pressure water . The empty drum is then closed, • Heater outlet temperature purged and pressure-tested with steam . Vapors • Coke drum pressure from the coke drum in operation are used to heat • Recycle ratio, equiv . fresh feed the off-line, empty coke drum . • Increased coking temperature decreases coke Hydrocarbons condensed during the drum- production; increases liquid yield and gas oil end point heating step are drained to the blowdown drum or • Increasing pressure and/or recycle ratio increases fractionator . When the drum is heated sufficiently, gas and coke make, decreases liquid yield and it is ready to receive effluent from the coker heater gas oil end point and start the coking cycle .

7 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

Hydraulic Decoking Systems to 1935 . Decoking, however, was still a manual job accomplished by using cables, augers, beater balls About 150 years ago, pioneer oilmen in and hydraulically operated mechanical drills . northwestern Pennsylvania discovered that boiling In 1938, Flowserve Worthington designed and oil in small iron stills would yield kerosene, a very manufactured equipment for Shell Oil’s Wood River, valuable luminescent . Thus, the whaling industry Illinois, (USA) refinery — the world’s first hydraulic died and the refining industry was born . decoking installation . Flowserve supplied decoking In addition to kerosene, however, one of several tools, swivel joints, decoking control valves and by-products was also discovered: coke . And, of high-pressure water jet pumps for that system . In course, before the stills could be reused they had to 1940, Flowserve Pacific supplied the jet pumps for a be cleaned, i .e ., decoked . Thus, one of the grimiest, hydraulic decoking system at Standard Oil’s refinery nastiest refinery chores — which persist to this day in El Dorado, Indiana (USA) . — was born . Since then, Flowserve has pioneered many From the 1860s through World War I, crude oil significant advancements in hydraulic decoking . was processed in horizontal stills, singly and Integrated systems consisting of decoking later in series to increase output . Decoking was equipment, jet pump trains and control systems accomplished by laborers with picks and shovels . are matched to achieve guaranteed decoking The origin of the vertical coke drum coincided performance . Flowserve has transformed hydraulic with Standard Oil’s development of the Barton decoking into an increasingly safe, efficient and Process to convert gas oil to gasoline from 1912 automated process .

8 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

Hydraulic Decoking Explained The Decoking Process, Summarized High-pressure water cuts the coke out of the drum . Delayed coking is one of the most difficult refinery The cutting water pump, which is a multistage barrel units to operate and control . Page 8 depicts a very pump, takes suction from the decoking water tank simplified diagram of delayed decoking . The unit and delivers the high-pressure water through a hose takes vacuum residual (fresh feed) and heats and to the top of the drill stem . injects it into the main fractionator bottom . There it is mixed with an internal reflux recycle of heavy The discharge pressure of the cutting water pump cracked material . The total fresh and recycled varies according to the size of coke drum and type of feed is then heated in the coker furnace to a high coke produced . For large-diameter coke drums, the cracking temperature . Hot partially cracked feed discharge pressure can be more than 310 bar (4500 flows from the cooler furnace into coke drums, psi) . An air-, electric- or hydraulic motor-driven rotary where the reaction continues . Cracked distillate joint rotates the drill stem and cutting tool . vapor ascends in the coke drum and flows into the The cutting tool, equipped with downward-oriented, fractionator for separation . pilot hole and side-oriented cutting nozzles, is Coke remains in the drums and is periodically attached to the bottom of the drill stem . First, a pilot removed; that is the main reason for the coker hole is bored through the coke that has built up being a difficult unit to operate . Twice daily, filled in the drum with the downward-oriented nozzles . coke drums are switched off for coke removal, and The cutting tool is then pulled up to the top and empty drums are connected to the fill lines . The switched to side-oriented cutting nozzles . The drum that was just filled then goes through a cycle cutting tool then slowly moves through the length of of steaming out, cooling, opening, coke removal, the coke drum to loosen or cut out the coke . closing, steaming and pressure testing, heating and Coke handling. Coke and cutting water from the finally reconnecting to the furnace and fractionator . coke drums fall into an adjacent large concrete pit or pad . Water drained from the pit or pad Decoking System Components is collected in a nearby settling basin, which A decoking system typically consists of: separates small coke particles (i .e ., fines) from the water . • Jet pump — ISO 13709/API 610 (BB5) • Coke cutting equipment Water from the settling basin is pumped back to the decoking water tank for reuse . The decoking water − Decoking control valve tank also serves as storage for water that is used to − Rotary joint/drill stem/cutting tool assembly quench the hot coke drum . Coke in the pit or pad remains there long enough for the water to drain . • Decoking water tank A crane or front-end loader moves the dewatered • Main and local control panels and enclosed coke to a crusher . Then a conveyor belt typically operator cabin transfers the coke to storage, railcar, ship or some other transport method . In some units, the coke is cut directly into railcars or to a crusher and then sluiced as a water slurry to dewatering and storage facilities .

9 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

Jet Pump Horizontal, Multistage, A Complete Range of Decoking System Double-casing Pumps (API-BB5) Equipment

Diffuser barrel pumps for high-pressure service . Whether for new equipment, system upgrades or First-stage, single- or double-suction, depending on replacement parts, Flowserve provides a complete available NPSH . Designed for both general purpose proven decoking system: (i .e ., spared) and special purpose (i .e ., unspared) • Jet pump train with lube oil skid listed herein applications such as decoking (i .e ., water cutting) . The API 610 material code normally specified . − There are options in markets in Europe and The API 610 seal code normally used is QBRW . Russia for historical reasons . Higher-pressure An auxiliary sealing device comprised of a close pumps have the option of being run at high clearance floating carbon throttle bushing is also speeds . used . API Plan 32 . − Typical MTBR on the pump with poor maintenance practices and high fines to 10 years or more at sites with exceptional maintenance practices . − Application typically has a low NPSHA . − For more information, see the high-energy barrel product positioning guide .

10 Application Solutions Guide — Delayed Coker Unit (DCU) A CLOSER LOOK AT DELAYED COKER AND HYDRAULIC DECOKING TECHNOLOGIES

Typical process flow diagram with critical pumps and valves

11 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Key Pump Products Coker and Heater Charge Pumps

The key pumps or “heart” in a DCU are the coker/ The Flowserve petroleum process pumps best heater charge pumps and the coke cutter jet pump . suited for these services are the between bearings A typical DCU uses BB-type pumps plus water and radially split designs . The API 610 material general service pumps . It should also be mentioned designation for the coker charge pump is normally that BB3 multistage pumps are found in boiler specified . feedwater and other heavy-duty applications . Mechanical seal selection is key to trouble-free Flowserve refinery pumps are fully compliant with operation of these critical pumps . However, new ISO 13709/API 610 current edition standards . and revamped units are typically supplied with pressurized dual seal and Plan 32/53 or Plan 32/54 . • Coking section These devices improve the efficiencies of these − Pump for heater charge piping plans .

• Fractionation section For HCGO, double-suction between bearings − Overhung process for general service radially split (BB2) design is recommended . Low-flow/high head pump is also used in HCGO • Vapor recovery unit and LCGO services . − Overhung process

• Coker blowdown − Overhung process

• Steam generation − Axially split, two-stage between bearings

12 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Coke Handling and Dewatering

Solids-handling Submersible Pumps

Choice of API materials in lineshaft (VS4) or cantilever (VS5) configurations . Non-ISO/ API designs

Slurry Sump Pumps

Hard metal type in either lineshaft

Sump Pumps

Choice of API materials in lineshaft (VS4) or cantilever (VS5) configurations

General Service Pumps

Process water sump; anti-foam; storm water sump; dirty oil sump

Vertical Turbine Pumps (API-VS6)

Multistage with above or below grade discharge, enclosed or semi-open impellers, open or enclosed lineshafts, single or double casing

Double-suction, Twin-volute Vertical Pumps

Wet-pit, double-suction impeller, between bearings, double-volute centrifugal pump

13 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

DCU Process Pumps

There are many applications within the DCU; these are listed below with comments relative to typical configurations .

RICH AMINE FRACTIONATOR COMPRESSOR QUENCH WATER TRANSFER RECIRC SUCTION DRUM

Splitter Bottoms LP Condensate Fractionator Reflux Stripper Feed

Splitter Overhead LPG Condenser Recycle LCGO Product Lean Oil

Blowdown Lower Bottoms Vacuum Resid HCGO Product Debutanizer Reflux

Blowdown Slop Oil

API Classification

Sending new table

14 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

OH2 OH2

Fully compliant with ISO 13709/API 610 (OH2) Fully compliant with ISO 13709/API 610 (OH2) design criteria, the pump is the workhorse of the oil • Broad application flexibility from innovative multi- and gas and hydrocarbon processing industries, channel diffuser technology, which supports more boasting unequaled versatility, reliability and safety . than 170 hydraulic configurations and easily • Lower operating costs due to comprehensive accommodates changing operating parameters hydraulic coverage and numerous specialty • Improved pump efficiency via diffuser tuning, configurations that permit precise selection for which widens operational flow window and best operating efficiency minimizes radial loads at any flow • Longer service life enabled by centerline- • Extremely low total cost of ownership thanks to supported casing that withstands nozzle loads long MTBF, low seal emission, long mechanical beyond ISO 13709/API 610 requirements and seal life, low energy consumption and low NPSH minimizes shaft misalignment, thereby extending • Improved plant and personnel safety enabled rotor, bearing and seal life by low vibration and noise levels • Stringent emissions containment with ISO 21049/ API 682 seal chamber Refer to literature PSS-10-5.2 at flowserve.com/library. • Easier maintenance thanks to back pullout design, enabling service without disturbing motor or casing connections

Refer to literature PS-10-5 at flowserve.com/library.

15 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

VS6 VS2

Diffuser-type, vertical turbine pump well-suited Double-suction vertical turbine pumps . ISO 13709/ for closed system and low NPSH applications . API 610 (VS2) compliant design available . Available in single or multistage units, as well as • Superior performance from innovative, double- standard and ISO 13709/API 610 (VS6) compliant suction impeller that produces more flow and designs . higher head at lower NPSHR • Broad application versatility due to extensive • High uptime with sealed-for-life bottom bearing hydraulic coverage plus wide variety of plus heavy-duty discharge head and integral line configurations, constructions and materials to suit shaft bracket, which ensure shaft concentricity application requirements and alignment • Lower installation costs with low NPSH first-stage • High operating efficiency promoted by renewable impeller that reduces suction can length impeller wear rings that restore original • Lower operating costs from available aftermarket clearances rebowl services that revitalize aged VPCs to • Reliable performance in applications containing reduce power consumption, downtime and silt or abrasive solids owing to optional enclosed maintenance costs lineshaft construction Refer to literature PS-40-2 at Refer to literature PS-40-4 at flowserve.com/library. flowserve.com/library.

16 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

BB3 OH2

With more than 10 000 units supplied, this highly Fully lined slurry pump built to ISO 13709/API 610 reliable pump is ideal for high-flow, high-pressure (OH2) and used in heavy oil processing . It reliably applications across the gamut of industries, and safely handles abrasive solids at elevated including oil and gas, chemical and desalination . temperatures without the danger of pump casing Designed to ISO 13709/API 610 (BB3) criteria . erosion . • Increased uptime enabled by opposed mounted • Low lifecycle cost provided by replaceable impellers operating in a double volute casing, mechanically fastened liners that protect the which provide inherent hydraulic balance over the pressure casing from erosion and abrasion full operating range • Process flexibility made possible by • Broad application versatility provided by interchangeable diffuser, casing liner and impeller, numerous options that permit the pump to be which allows operators to adapt performance to precisely configured for service requirements changing process conditions • Superior performance at elevated temperatures • Extended operating life ensured by a rigid, with near-centerline mounting oversized bearing frame that maintains shaft • Ease of maintenance facilitated by cap nuts on deflection below ISO/API requirements top half casing parting flange • Casing liners are available in multiple abrasion- • Emissions control with ISO 21049/API 682 seal resistant materials and surface treatments to meet chambers any process or operational requirement

Refer to literature PS-30-3 at flowserve.com/library. Refer to literature PS-30-3 at flowserve.com/library.

17 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

End Suction Horizontal Single Stage BB2

Heavy-duty paper stock pump designed primarily In full compliance with ISO 13709/API 610 (BB2) for pulp and paper applications, but also has standards, centerline mounted pump with single- considerable use in the chemical processing, stage, double-suction impeller and double volute mining, water resources, and oil and gas industries . casing with top nozzles is engineered for heavy • High uptime and efficiency ensured by process services . unobstructed suction, large streamlined flow • Increased uptime enabled by double-suction channel, and semi-open impeller with back impeller that minimizes thrust problems, reduces pump-out vanes, which prevent air binding and NPSHR, and allows mechanical seals to operate clogging, even in thick, pulpy mixtures at equal and low pressure • Reduced maintenance provided by rigid one- • Excellent high-temperature performance provided piece bearing frame; ensures positive alignment by centerline mounting plus gasketing with metal- and offers ample access to gland and seal to-metal fit to ensure proper sealing and alignment chamber • Installation ease with top-top, side-top and side- • Reliable, efficient performance with a steep head- side nozzle configurations available to meet any capacity curve, which prevents driver overload customer piping layout and minimizes changes in flow, despite changes • Safety and environmental compliance with ISO in system head 21049/API 682 seal chambers • Low total cost of ownership resulting from high- • Power recovery turbine configuration available efficiency, low-maintenance design Refer to literature PS-20-4 at flowserve.com/library. Refer to literature PS-10-16 at flowserve.com/library.

18 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

BB5 BB2

Extra heavy-duty barrel pump intended for Two-stage, centerline mounted pump engineered special purpose, unspared, high-power density for safe, reliable operation in heavy-duty process applications . Pumps are custom engineered to services and elevated temperatures . Fully compliant customer requirements, often exceeding with ISO 13709/API 610 (BB2) . ISO 13709/API 610 (BB5) . • Extended reliability and life made possible by • Outstanding reliability assured by low static heavy-duty, single- or dual-volute casings with deflection, the result of a large diameter shaft a staggered arrangement, which ensures radial and short bearing spans balance • Optimized efficiency due to precision-cast, low • Application versatility provided by numerous specific speed impellers, multi-vane diffuser and options — including 50- or 60-cycle operation and milled channel collectors to ensure repeatable top-top, side-top and side-side nozzle orientations performance — that permit the pump to be precisely • Smooth, stable performance with multi-vane, split configured for service and site requirements diffuser and channel ring collectors that eliminate • Increased reliability provided by stiff shaft design, radial imbalance which ensures trouble-free operation below the • Performance tested in accordance with API and first critical speed Hydraulic Institute standards • Environmental regulatory compliance with ISO • Ease of maintenance with back pullout, cartridge- 21049/API 682 seal chambers style construction Refer to literature PS-30-4 at flowserve.com/library. Refer to literature PS-30-9 at flowserve.com/library.

19 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Condensate Transfer Gas Oil Sidestream

• Operating conditions: 150°C (300°F), • Operating conditions: 345°C (650°F), 7 bar (100 psi) 14 bar (200 psi) • API material code — C-6 • Recommended pump: • Mechanical seal: pusher type API material code — S-5 • Auxiliary seal system: Plan 23 • Mechanical seal: metal bellows • Auxiliary seal system: Plan 02/53 Fractionator Overhead Reflux

• Operating conditions: 107°C (225°F), Fractionator Overhead Product 7 bar (100 psi) • Operating conditions: 107°C (225°F), • Recommended pump: 17 bar (250 psi) API material code — S-5 • Recommended pump: • Mechanical seal: metal bellows API material code — S-5 • Auxiliary seal system: Plan 11/52 • Mechanical seal: metal bellows • Auxiliary seal system: Plan 11/52 Fractionator Overhead Sour Water

• Operating conditions: 107°C (225°F), Dilute Tower Feed 5 bar (75 psi) • Operating conditions: 150°C (300°F), • Recommended pump: 12 bar (175 psi) API material code — A-8 • Recommended pump: • Mechanical seal: metal bellows, Plan 11/53 API material code — S-6 • Mechanical seal: metal bellows Light Distillate Sidestream • Auxiliary seal system: Plan 02/53 • Operating conditions: 260°C (500°F), 14 bar (200 psi) Preheat Condensate Steam Removal

• Recommended pump: • Operating conditions: 121°C (250°F), API material code — S-5 7 bar (100 psi) • Mechanical seal: metal bellows • Recommended pump: • Auxiliary seal system: Plan 02/53 API material code — C-6 • Mechanical seal: pusher type • Auxiliary seal system: Plan 23

20 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Diluent Pump Coker Recovery Oil

• Operating conditions: 107°C (225°F), • Operating conditions: 65°C (150°F), 14 bar (200 psi) 14 bar (200 psi) • Recommended pump: • Recommended pump: API material code — S-6 API material code — S-6 • Mechanical seal: pusher type • Mechanical seal: pusher type • Auxiliary seal system: Plan 11/52 • Auxiliary seal system: Plan 11/52

Diluent Surge Drum Sour Water Removal Steamout Sour Water

• Operating conditions: 107°C (225°F), • Operating conditions: 65°C (150°F), 7 bar (100 psi) 5 bar (75 psi) • Recommended pump: HPX, • Recommended pump: API material code — A-8 API material code — A-8 • Mechanical seal: metal bellows • Mechanical seal: pusher type • Auxiliary seal system: Plan 11/52 • Auxiliary seal system: Plan 11/53

Quench Water Hydraulic Decoking Pump, Cutting Equipment and Water Service Pumps • Operating conditions: 93°C (200°F), 7 bar (100 psi) • These pumps will be discussed in the following section, Hydraulic Decoking . • Recommended pump: API material code — S-6 • Mechanical seal: metal bellows • Auxiliary seal system: Plan 13

Wash Oil

• Operating conditions: 204°C (400°F), 10 bar (150 psi) • Recommended pump: API material code — S-5 • Mechanical seal: metal bellows • Auxiliary seal system: Plan 02/53

21 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Valves and Actuation Equipment Operating Conditions: • High Temperatures The key valves in a DCU are the coker and heater • Coking Service charge valves, coke bottoms and frac charge . A typical DCU uses specialty control and ball valves . • HP Steam Blowdown It should also be noted there are several other • High-pressure Water Service general service valves in the power house portion • High Cycles of applications . • Temperature Cycling When converting heavy hydrocarbon streams to • Erosive Conditions lighter industrial products, the thermal cracking process calls for the frequent operation of the isolation valve system during the coke drum Valve Types: switching operation . • Axial flow for anti-cavitation trim Flowserve designs provide trouble-free operation • Globe control valve, with pilot-operated trim: in heavy coking applications . In addition, our tight shutoff with anti-cavitation trim unique engineering requires significantly less • High-performance butterfly valve maintenance during purging operations, which • Eccentric rotary plug valve saves energy costs . • Segmented ball control valve Flowserve’s experience includes a broad range of • Metal-seated trunnion ball valve AOV (air) and MOV (motor) actuators and systems . • RSBV, rising stem ball valve We draw on years of Flowserve experience and • Anti-erosive angle control valve field data from working on DCUs to determine the • Noise abatement trim precise amount of service duty that can be applied • Variety of isolation valves — type gate, plug and ball to actuator and valve stem sizing, preventing failures caused by increased torque as coke builds up .

22 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

DCU Valve Applications Include: Actuators for Refinery or • High-pressure Pump Inlet Isolation Process Systems • Cutting Water Pump Isolation Many refineries will vary their use of actuators from • Quench Extraction AOV or MOV . Flowserve offers an extensive range • Overhead Vapor Isolation of electrical, fluid power and gear box actuators . • Coke Drum Bypass Isolation For example, the Flowserve Limitorque MX non- intrusive, multi-turn actuator . These actuators • Coke Drum Switching provide a comprehensive network for users . • Coke Drum Feed Isolation The QX quarter-turn actuator would be used for • Quench Extraction Isolation any quarter-turn application (e .g ., ball valves) . • Light Coker Gas Oil Pump EBV On new projects, the actuators are normally • Heavy Coker Gas Oil Pump EBV purchased with the valves and not directly by the EPC or OEM . • Frac Bottoms EBV • Frac Bottoms Pump Recirculation Key Certifications and Standards • Coke Filter Isolation Compliance • Furnace Charge Pump Inlet Isolation • Available according to ATEX 94/9/EC Ex II 2GD c IIC T6 • Furnace Charge Pump Discharge Isolation • NEMA4 and NEMA4X per NEMA 250 • Furnace Feed Isolation • IP66/IP66M and IP67/IP67M configurations • Charge Pump Recirc • Manufactured and tested in compliance with • Main Feed Heater Flow ISO 9001 and EN 15714 Part 3 for pneumatic • Bottoms/Product Streams actuators and Part 4 for hydraulic actuators • Sour Water • Actuator spring design in compliance with EN 13906 • Overhead Gas • Available valve interface in compliance with • BFW Steam ISO 5211 • Water/Coke Fines • Corrosion protection in compliance with ISO • Wet Gas Compressor Anti-surge 12944-2 and EN 15714; optionally available up to and including C5-M • Available in compliance with NACE specification MR0175 for sour gas applications • Available for use in safety integrated systems up to and including SIL Level 3 in accordance with IEC 61508 • Available in compliance with PED 97/23/EC, ASME BPVC Sec . VIII Div . 1, EN 13445-3 Part 2 for Unfired Pressure Vessels • Available according to CU TR and GOST-R

23 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Actuator Products Overview DCU and Refining (Downstream O&G) Actuators Overview: • Limitorque actuator products Rotork is the leading supplier of electric actuators • They are defined into three primary categories: in the oil & gas industries, especially refining . They − Electric Actuators — heavy-duty electric space developed the first non-intrusive electronic actuator in the early 1990s primarily for the refining industry − Fluid Power Actuators — LFPS and continue to enjoy success, although mitigated − Gearboxes (manual and motorized) by the market reset, in global regions .

• Electric actuators are segmented into two Flowserve Limitorque followed with the first categories: generation MX in the late 1990s and is believed − Intrusive: the controls cover must be removed, to be second in the refining market . Limitorque’s exposing the controls to the environment, in strategy is to attempt to isolate specifications to the order to configure position and torque limits — higher non-intrusive technology against Rotork . We types are SMB and L120 . have been successful if the specification can be limited to the Rotork IQ products and Limitorque’s − Non-intrusive: the control covers are not MX and QX . It should be noted that the downstream removed in order to configure position and markets are very competitive . torque limits — types are MX and QX . − Both intrusive and non-intrusive types are • When Auma is included, both Rotork and available in multi-turn for rising stem valves — Limitorque non-intrusive technology advantages SMB, L120 and MX . are mitigated and the projects are won on pricing only . This is particularly true in the current reset in − For quarter-turn valves (BFV, BV and plug), the oil & gas environments . only the non-intrusive QX is available . − Limitorque supplies mechanical gearboxes for either manual or automated service . For multi-turn applications, “V” bevel gearboxes and the “SR” spur gearboxes can be supplied . − Limitorque supplies WG and HBC worm gearboxes for quarter-turn applications .

• Limitorque also offers optional network protocols which can be fitted to non-intrusive electric actuators .

24 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

• The upstream and downstream oil & gas markets QX Quarter-turn Actuator and QXM Limited sometimes require isolation valves that must move Multi-turn, Non-intrusive Actuators to a pre-determined position (open, closed, mid- stroke position) when mains power is removed . QX This is referred to as a “fail-safe” actuator and The Flowserve Limitorque QX quarter-turn smart typically “just in time” power must be supplied . electronic valve actuator mimics the state-of-the- Rotork offers their CVA actuator with super- art, multi-turn MX actuator by including a unique cap technology to power an actuator to a pre- absolute encoder for tracking position without the determined position . Auma uses a mechanical use of batteries . The QX design provides enhanced device similar to a coil spring to move the actuator safety and reduced downtime through improved to a pre-determined position . Limitorque continues diagnostics, built-in selftest (BIST) features and to develop technology on our QX actuator . LimiGard fault protection .

MX Multi-turn, Non-intrusive Actuator Brushless DC Motors Flowserve Limitorque introduced the MX electric actuator in 1997 as the first smart actuator providing The QX family of actuators was the first non-intrusive uncompromised reliability and performance in an actuator to employ advanced brushless DC motors . easy to use design . BLDC motors eliminate sparks, reduce mechanical and electrical noise, and dissipate heat better than Limitorque MX Single-phase ACV motors with brushes . The brushless actuator design Flowserve Limitorque introduced the innovative lasts longer than conventional motors and allows MX electronic actuator with technical features that for more accurate positioning while permitting a were market firsts: a patented absolute encoder, global range of voltages (single-phase and three- patented Limigard technology, and easy-to-use phase ACV and DCV) to be connected without menus in multiple languages . These features and modification . the implementation of a BLDC (brushless DCV) motor were included in the feature-rich QX quarter- turn electronic actuator . All of the innovative features devised for the MX and QX are now combined in the single-phase ACV MX, including a BLDC motor .

25 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Limitorque Intrusive Electric Actuators

L120 Multi-turn Actuator

The Flowserve Limitorque L120 Series, with more than 25 years of field-proven reliability, is a long- standing product of choice for any valve requiring either rotary or linear actuation . Regardless of the valve design, the L120 performs consistently and predictably in any situation demanding positive, dependable control .

SMB Multi-turn Actuator

With more than 50 years of proven performance and reliability, the eight models in the Flowserve Limitorque SMB Series offer rugged dependability from the smaller SMB-000 through the industry’s largest electric valve actuator, the SMB-5XT . An extensive gearing selection for each actuator size delivers unmatched versatility for meeting exacting operating speed requirements . Three-phase, single-phase, pneumatic and DC motors are available to meet wide ranges of power and speed . Optional controls include an integral reversing starter and control voltage transformer package, an actuator-mounted control station, and position indication feedback .

LPS Pneumatic Quarter-turn Limitorque Fluid Power Systems Scotch Yoke Actuators

Limitorque is dedicated to providing heavy-duty, Equipment performance and safety standards fluid-powered valve actuators and control systems continue to evolve and increase across the for the oil and gas industry . Every product accounts infrastructure industries . To more aggressively meet for the most recent and stringent industry standards these demands, Flowserve Limitorque is offering the for safety and service life, providing users with LPS pneumatic Scotch yoke actuator — specifically unprecedented operating life and maintenance designed to meet or exceed the latest and most intervals . rigorous of these requirements .

26 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

LPC Compact Pneumatic LHS and LHH Limitorque Hydraulic Scotch Yoke Actuator Scotch Yoke Actuators

The Limitorque Pneumatic Compact (LPC) Scotch The Limitorque Fluid Power family of heavy-duty yoke is a robust yet lightweight, modular, pneumatic, actuators includes the Limitorque Hydraulic Scotch piston-type actuator design, with nodular ductile yoke actuators (LHS and LHH) . cast iron or carbon steel housing and carbon steel Often lighter and more compact than its LPS ENP cylinders . The LPC actuator is available in both counterpart, the LHS/LHH offers a choice for those spring-return and double-acting configurations, preferring hydraulic motive power . For some, such with an easy field conversion feature from Fail Close as those working in an offshore environment, it Clockwise to Fail Open Counter-Clockwise . It is may be the only practical option in terms of fluid- ideally suited for smaller size valves . The LPC is power availability and performance requirements . fully complementary to the LPS, employing a similar The LHS/LHH Limitorque hydraulic actuators have design philosophy and meeting the same industry a robust, modular Scotch yoke design, and are specifications, but in a more, lower cost package . available in both spring-return and double-acting configurations . They are suitable for actuating ball, butterfly and plug valves or any other quarter- turn applications . LHS hydraulic actuators deliver precisely controlled torque (contact factory for larger sizes) .

27 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Mechanical Seals and Systems Delayed Coker Unit Applications

Safe and reliable handling of fluid is vital in today’s Typical Services hydrocarbon processing plants . Complex refining • Acids techniques generate a broad range of shaft sealing − Engineered Bellows challenges . • Amine A growing focus on environmental stewardship − Engineered Pusher demands continuous innovation in process − Engineered Bellows containment . • Caustic The Flowserve commitment to technology − Standard Cartridge Bellows development has produced sealing solutions for: − Engineered Bellows • Zero emissions on services containing volatile • Flashing Hydrocarbons hazardous air pollutants − Engineered Pusher • Specialized applications, including viscous • Non-flashing Hydrocarbons refinery bottoms, polymerizing fluids and − Engineered Pusher flammable gases • Hot Hydrocarbons • Corrosive, caustic, acidic, sour and abrasive − Engineered Bellows products • High-pressure; High-viscosity Hydrocarbons • A wide range of temperatures − Engineered Pusher • High speeds and pressures • Water − Standard Cartridge Pusher • Tolerance to process upsets − Engineered Pusher API 682 • Water — Sour

Flowserve seals and support systems for the • Standard Cartridge Pusher refinery industry satisfy all requirements of the latest − Engineered Pusher edition of API 682 . • Water — Hot − Engineered Pusher

Specialty Applications • Low-temperature Containment Seal • High-temperature Containment Seal • Pressurized Pump Gas Seal • Integrally Geared Equipment • Turbomachinery; Compressors

28 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Decoking Jet Water Pump Seals Flowserve has established a very successful formula for designing and applying decoking jet water seals . In 2016, Flowserve released a new seal design with additional pressure-handling capability . Both seal types are available for use in decoking jet water applications, depending on conditions of service and customer preferences .

Seals up to 750 psi (51.7 bar)

29 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Seals up to 1500 psi (103.4 bar) Flexible stator cartridge seals are built for extended This compact, medium- to high-pressure seal reliability in high-pressure and high-speed pumps . features a high balance face that meets the lowest Fully compliant with API 682 Type A requirements . hydrocarbon emissions level — less than 500 ppm . Designed to suppress flashing and minimize heat generation .

For more information, refer to FSD152 and FSD216.

Descriptions of Engineered Seals Applied in Delayed Coker Units

The family of balanced pusher and metal bellows seals designed to fully comply with the design and qualification requirements of API 682 . Pusher Seals

Dual pressurized pusher seals are capable of zero emissions . Provide reverse pressure capability for API 682 Arrangement 3 requirements .

For more information, refer to FSD152.

30 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Balanced rotating metal bellows seals provide Balanced rotating metal bellows seals are designed exceptional reliability in corrosive and non-corrosive for refinery and petrochemical services at high fluids, especially those that crystallize . Fully and low temperature extremes, beyond the reliable compliant with API 682 Type B design requirements . usefulness of elastomers . Meet API 682 Type C requirements . For more information, refer to FSD109. For more information, refer to FSD111.

When extreme temperatures push the limits of elastomers, stationary metal bellows seal offers reliable sealing at high speeds . Meets all API 682 Type C requirements .

For more information, refer to FSD111.

31 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

Piping Plans

Flowserve recognizes that one of the most effective ways to achieve long, uninterrupted mechanical seal life is to create a healthy environment around the seal faces . Piping plans help keep mechanical seals run cool and clean, promote safe handling of dangerous fluids, and extend the operational availability of rotating equipment . The following pages provide a concise summary of the most essential piping plans used successfully in today’s process plants . Each plan shows all the standard and optional components referenced successfully in today’s process plants . Each plan also shows all the standard and optional components referenced in API 682 and recommended by Flowserve . Consult your local Flowserve sales engineer to identify the right solution that satisfies your application requirements .

32 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN DELAYED COKER UNIT PRODUCTS

33 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

A Complete Range of Decoking Decoking Control Valve System Equipment The decoking control valve is placed just downstream of the pump and is often mounted Whether for new equipment, system upgrades or on the pump . It serves to isolate the drums from replacement parts, Flowserve provides a complete the pump and allows it to continue running during proven decoking system: normal cutting operations . Three-position valve with no true shutoff Jet Pump Train • Bypass • Current standard is a 6WIK15 . − Provides minimum flow bypass for the jet pump − Always open to prevent deadheading pump • Typical MTBR on the pump can be anywhere from one to two years at sites with poor maintenance • Pre-fill practices and high fines to 10 years or more at − Provides low-pressure, pre-fill sequence until sites with exceptional maintenance practices . system filled, then provides full flow to the combination tool for cutting • S6 modified material is most common . • Application typically has a low NPSHA . • Full flow − Provides full cutting pressure to cutting assembly

− Low-pressure drop Cv of more than 200

34 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Bypass (left), prefill (center) and cut (right) modes. The actuator (not shown) would be mounted on top of the valve.

The current main offering is the advanced other during normal operation . Bleed valves function decoking valve to bleed the pressure between the DCV and the drum isolation valves at all sites where they are • Primary actuation is MOV with option for AOV installed . At cold weather sites, they are used to • Hard seats drain the system of water when a drum is not being • Pressure breakdown via internal orifice plates cut during the winter to prevent freezing . − Bypass orifice plates can be accessed with Most of the installed base has air actuators on the the valve body installed in the field bleed and isolation valve, but most new installations • Field-maintainable cartridge construction use MOVs .

Isolation and Bleed Valve These are buyout items available from the Flowserve Valve division . The isolation valves are typically ball valves . They function to isolate the drums or pumps from each

Bypass (left), prefill (center) and cut (right) modes. The actuator (not shown) would be mounted on right side of valve as shown.

35 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Decoking Hoses • Manufactured per API-7K unless metal jacketed • Swivel flange to avoid twisting The hose‘s purpose is to allow the high-pressure water to be transported from a fixed point to the • Arranged to be non-draining to reduce tower moving rotary joint . dimensions or self-draining to aid maintenance • Design follows oil field practice and is a buyout item • Metal jacketing available

Rotary Joint

The rotary joint provides rotational motion to the cutting tool and has a sealing system to allow the high-pressure water from the jet pump to pass into the rotating drill stem without leakage .

There are two legacy designs in service:

• Worthington-style RJ • Pacific-style RJ Pacific pneumatic • The current main offering is dependent on location and previous customer installations • Many installations worldwide are air powered, but this legacy item has air-powered winches; new installations are using electric or hydraulic power .

Worthington electric

36 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Drill Stems

There are two types of drill stems: the FLS standard • Certified API thread gauge and hydrostatic tests threaded drill stems, and an optional welded stem . • Supplied in standard 20-foot segments, stocked The welded stems are only provided upon specific in Vernon request, typically in the aftermarket . • Drill stems serve to connect the rotary joint to the cutting tool and transfer the water and torque from the rotary joint to the cutting tool . • High flexural strength, heat-treated material • Sections joined with NC lathe cut API extreme line threads

Combination Cutting Tools The primary offering currently is the AutoShift with slim nozzle design . The cutting tool is the equipment in the drum • Shifts modes automatically and remotely by water actually removing the coke . It has a bore mode, pressurization and depressurization WITHOUT which has four nozzles pointing down that creates lifting the tool out of the drum . This is an important ~6’ (2 m) hole . After the hole is drilled, it can be selling feature . Switching of the tool is achieved automatically switched using the water pressure when the decoking control valve changes from full to cut mode, which has two nozzles pointed flow to bypass . horizontally to remove the remainder of the coke . • Override manual shifting feature is inherently There is a long legacy of prior cutting tools that designed into the tool and used to either set the Flowserve supplies, but many of the tools currently tool position at startup or manually shift as the installed are listed below: need arises . • The slim nozzle setup allows • Rotary Shift Cutting Tool the cutting tool to be more − Original nozzle design streamlined, which requires − Slim nozzle design less force to remove it • AutoShift Cutting Tool if the coke collapses − Original nozzle design during cutting . − Slim nozzle design

37 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Crosshead With Free-fall Wheeled Type Arrestors • Typically seen with rail gripping fall arrestor • Available with cable gripping fall arrestor The crosshead with freefall arrestor has two functions . The primary function during normal operation is to counteract the torque created by the rotary joint and ensure all of the rotational motion is driven into the cutting tool instead of the suspension system . The secondary function is to prevent a catastrophic collapse of the cutting assembly if the wire rope breaks . This is the free-fall arrestor system . It is not used on a normal basis, but is necessary to be maintained regularly to ensure it is in working order .

Flowserve has sold two types of crossheads and free fall arrestors:

Shoe Type

• The Flowserve current standard offering is the shoe type with cable gripping fall arrestor − Not available with rail gripping fall arrestor Wheeled type crosshead with rail gripping freefall arrestor

Shoe type crosshead with cable gripping free fall arrestor

38 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Latching Mechanism Pulley Blocks, Sheaves and Cable

The latch is located at the top of the tower and can The pulley blocks guide the wire rope from the lock the crosshead in the parked position . It should winch to the cutting assembly, where there is a be used to take the load off of the winch and wire traveling block mounted to the crosshead . rope system during normal operation .

Winch

• The winch lifts and controls the cutting assembly . • The majority of installations worldwide has air- powered winches, but this is a legacy item and new installations are using electric or hydraulic power . • The typical winch in North and South America is purchased from Ingersoll Rand . • There are several legacy vendors for the Hamburg systems, but most recently the vendor is Zollern .

39 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Control Systems, Including Intelligent and Automated Cutting

The control system is a PLC-based system that allows the operator to control the cutting equipment safely by being removed from the proximity of the cutting tools, winches, etc . Each control system is different for every end user and depends on the equipment supplied, refinery standards and licensor requirements . They are typically made up of the following sections:

Field Instruments Operator Panels

• Pressure Transmitters • These can be located at the pump, on the cutting deck and/or remotely, depending on the system . • Flow Transmitters • New units have HMI screens that provide the operator all the • Proximity Switches information in the entire system to help with both operation and • Tensiometer troubleshooting .

Safety and Operational Interlocks

The interlocks surround the pump, high-pressure High-pressure water has caused fatalities in water and cutting assembly location to ensure that delayed coker units in the past, but not with an the proper process is followed so that no high- operational Flowserve control system . pressure water is released outside the drum .

40 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Drum Monitoring Systems • There is a proprietary filtering program that eliminates some background noise and can also Drum monitoring systems are the key to both remote determine drum cleanliness . and automated cutting . These technologies are • This system requires a site survey to confirm driving the new units and upgrades . feasibility and microphone placement .

Video Drum Monitoring Vibration Drum Monitoring

This offering is a buyout of cameras and a camera This system provides information that was not previously server . Flowserve puts in the camera requirements available to the operators on local cutting systems . It and location specifications to make the system directly measures the vibration on the drum wall and work . It is not typically tied into the control system . provides a strip chart of the vibration to the operator to show the cleanliness of any given section of drum . Audio Drum Monitoring • The system uses the frequency and amplitude of • This allows the operator (who normally is the vibration signal from the cutting tool water jet to on top of the cutting deck listening to the determine drum cleanliness prior to refilling the drum . water jets in the drum) to hear the same • This is the system that is the heart of the automation information in a remote location . algorithm . • The system consists of two to three microphones • All the information is displayed on the HMI screen per drum located along the length of the drum . for the operator to cut the drum .

41 Application Solutions Guide — Delayed Coker Unit (DCU) FLOWSERVE OPPORTUNITIES IN HYDRAULIC DECOKING SYSTEMS

Remote Cutting and Automation Tool Enclosures

• These systems are the heart of the new control Tool enclosures sit on top of the drum unheading system upgrades for aftermarket as well as most device and enclose the cutting tool, preventing it new original equipment units . from spraying high-pressure water on the cutting • The driver for remote cutting is safety . This is the deck in case of control system malfunction . They strongest trend currently in North America and are a passive safety device . Often, they also Europe, but is being pushed elsewhere including incorporate a drill stem guide . Flowserve also has a China, the Middle East and Latin America . sealed version that can divert any off gasses from the drum to a safe location . This is a buyout item in • The driver for automation can also be safety, North America due to patent issues . but refinery management concern about inexperienced operators can also drive them toward automation . This is a risky conversation with operations, as some are dead set against it . • Automation is not a panacea for the refinery that will remove operators . There are still cases due to the nature of coke cutting and the coker in general being unpredictable, that operators may still need to be involved at times .

42 Application Solutions Guide — Delayed Coker Unit (DCU) COMMUNICATING OUR VALUE

COMMUNICATING OUR VALUE

Value Proposition (Delayed Decoking Systems, Pumps, Valves, Seals and Actuation Products)

FLOWSERVE PROPOSITION CUSTOMER BENEFIT

Flowserve sets the highest standards in Ethical business business integrity in its dealings with suppliers A trustworthy partner to work toward their project success practices and customers .

The Flowserve number one goal is to remove Increased safety engineered into the system to take the Safety the operator from the deck . operator out of harm’s way

To provide operator safety from harm’s way Reduced downtime due to mechanical failure increases Reliability requires that Flowserve engineer the operation throughput and reduces the need for operators to be of the unit and the equipment for reliability . placed in harm’s way .

Engineering The Flowserve depth of engineering experience Optimized product and material selection for each excellence is unparalleled in hydraulic decoking . application ensures reliable operation .

Flowserve has been the leader through its Lessons learned have been built into today’s products Experience various heritages since the process was with constant development to improve, increasing commercialized in 1938 . reliability, maintainability and product life .

Implanted within the aftermarket group with the sole objective to resolve operational issues quickly and Aftermarket support Dedicated decoking specialist in the region provide expert recommendations on upgrades and safety outlook

Skilled team to handle upgrades and repairs . Localized Local Quick Fully equipped Quick Response Centers are to reduce downtime, full access to Flowserve component Response Centers located in many regions around the globe . drawings, procedures and standards .

Specialist group capable of maintaining, servicing and Aftermarket solutions Long-term maintenance upgrading equipment to meet operating goals throughput

Constant discussions with all process licensors End users and licensors have direct access to engineers and a triennial decoking symposium dedicated Industry partnerships to influence design needs and ensure concerns are to the communications of concerns and properly communicated . developments

43 Application Solutions Guide — Delayed Coker Unit (DCU) COMMUNICATING OUR VALUE

Product Positioning Understanding a Customer’s Specific Business Drivers Flowserve has more than 90% of the market . We are often perceived as the technology leader, but this Each individual refinery site requires deep perception is challenged by Ruhrpumpen and at the understanding of the customers and external end user level is driven primarily by relationship . organizations that support a decoking system . This The products listed herein are sold as a system in often will be different from the rotating equipment the OE market and must be supported as a system maintenance and reliability specialists with whom for aftermarket . The aftermarket for the decoking we interact for pumps and seals . Each can have a system is split into parts, repairs, replacement units significant role as influencer or decision maker . and major upgrades . Flowserve must maintain a strong sales and technical relationship over the life Operations management is heavily involved of the delayed coker unit to ensure we keep the with equipment decisions: large aftermarket potential in our hands . • I&E group is involved with control systems, valve actuation and sometimes valve maintenance . The coker operators are often very hard on the decoking equipment regardless of affiliation, but at • Fixed equipment reliability and maintenance sites cut by third parties the equipment can have groups often support equipment above grade at lower mean time between repair (MTBR), depending the cutting deck and in the structure . on the company and training level . Technical and • Third party coke handling companies are timely parts support for the site is important in expanding their roles . maintaining the relationship . • Enterprise SME influence customers with multiple refineries .

Process licensor or engineering contractors develop the specifications that apply to the specific process license . They are often involved in major upgrades or drum replacement . Drum replacements are significant opportunities for decoking system upgrades such as remote/automated cutting, drum monitoring, etc .

44 Application Solutions Guide — Delayed Coker Unit (DCU) COMMUNICATING OUR VALUE

Flowserve must understand the customer’s specific Guidelines on Decoking System business drivers and risk profile . This will impact Selection Criteria spares and maintenance strategies . Flowserve must also understand the customer’s planned There are several areas of the hydraulic decoking maintenance cycles and restrictions . system that have to be selected in order to specify • Maintenance between coke cuts an entire system . • Do they allow access to structure during the • Pump Hydraulics: The pump hydraulics are cutting process? selected based on the customer drum size . For sizing of the system, contact the product team . • Do they require cranes to position equipment or The primary pump product is the WIK and is spares? usually in a high-pressure classification . • Maintenance performed during short planned • Winch and Rotary Joint Drive: electric, air or outages such as furnace decoking (different from hydraulic drum decoking) . This is an offline process to clean furnace tubing and nozzles with a duration of one • Cutting Equipment Scope to three days several times per year . • Control System • Unit outages are typically every four to five years . • Ancillary Options: There may be other options − This is the preferred window for major structure that are requested by the customer, including equipment and jet pumps . but not limited to: operator shelters, soft starters, pump VFDs and tool enclosures . For the common Flowserve must identify opportunities for use of requests, a Flowserve specification is available, support resources to facilitate meeting account but all special requests will be reviewed by the support requirements . CommOPS team . • Decoking Specialist • Sales/Product Management Decoking • Technical Services and CommOPS • Repair Services — QRC and FS • Regional Parts Specialist and RPSO

45 Application Solutions Guide — Delayed Coker Unit (DCU) APPENDIX

APPENDIX

Sourcing

Currently Flowserve has two business unit locations building and servicing hydraulic decoking systems: Vernon (LPO) Design, Build and Service and Hamburg Service . Both factories have historical ties to hydraulic decoking and have been manufacturing these systems for well more than 50 years . The selection of the BU is decided by the product director based on the EPO sourcing guide in Vernon, and considers project location, plant loading, plant commercial competitiveness and project preference .

46 Application Solutions Guide — Delayed Coker Unit (DCU) APPENDIX

Rotary/Cutting Tool View for DCU

47 Application Solutions Guide — Delayed Coker Unit (DCU) SECTION BREADCRUMB HERE

GLOSSARYOVERVIEW OF KEY TERMS, ABBREVIATIONS AND ACRONYMS The global demand for fresh water is continuously While there is plenty of optimism for growth in growing, but fresh water sources are limited and desalination, it does not come without a few, not always available where population and industry significant cautions. needs it. Only 2.5 percent of the world’s water is • Political unrest in the Middle East and North Africa fresh water and 70 percent of this remains frozen is always a risk. in polar ice caps and snow. The remaining 97.5 API: American Petroleum Institute MTBR:• Anticipated mean time restructuring between repair and/or privatization of percent of the world’s water is in the oceans and BIC: best in class NC: state-ownedpneumatic control concerns in Saudi Arabia and other seas. Desalination allows this large water resource CommOps/CSOA: Commercial OPS has NPSHA:Gulf netStates positive in response suction head to low available oil prices and to be tapped for human use. Desalinated water replaced customer service and order acquisition OE: revenuesoriginal equipment has the potential to slow the pace of is needed for human consumption and for many DCU: delayed coking unit investment. manufacturing processes. PLC: process logic control EBV: emergency block valve QRC:• Environmental Quick Response approvals Centers and activism in the US Desalination plants operate in more than 120 EIA: Energy Information Administration and Europe can delay investments. Projects are countries, but they only provide 1.5 percent of the RP: Ruhrpumpen EPO: Engineered Products operation generally subject to intensive scrutiny, especially world’s water supply. Some countries, such as RPSO: regional procurement service officer where seawater intake and brine disposal may FCC: fluidized cat cracking Saudi Arabia and the United Arab Emirates count on RSBV: rising stem ball valve harm the environment. HCGO: heavy coker gas oils desalination plants for over 70 percent of their water. SME: subject matter experts HMI: human machine interface But the need for new desalination capacity is real The climate for capital expenditures (CAPEX) SPO: secondary product operation and will likely remain a priority in many areas of the I&E: instrument and electrical in desalination is a good one. GWI forecasts SYDEC: selective yield delayed coking world, even with many state budgets under strain. CAPEXISO: International to grow from Standards 2016 levels Organization of US$3.3 billion VRC:Advances vacuum-reduced in membrane crude technology and energy to LCGO:US$5.8 light billion coker in 2020,gas oils a 14.8 percent CAGR. VRU:recovery vapor arerecovery making unit desalination more economical. Sixty-fiveLPO: lead percent product of operation this growth will take place in VTP:Ground vertical water turbine conservation, pumps a major driver for future the Middle East and North Africa, where investment MOV: motor-operated valve WC,demand, WCC or will WIK: likely multistage remain process a priority barrel in growth pump areas. has not kept pace with demand and ground water MRO: maintenance, repair & operations Finally, CAPEX forecasts for the Asia-Pacific and conservation is a priority. More than 70 percent Americas are strong, even though these regions of these investments will be on large Seawater represent a small percentage of the total sum. Reverse Osmosis (SWRO) plants with a capacity greater than 50,000 m3/d.

48 Application Solutions Guide — Delayed Coker Unit (DCU) North America

Latin America

Europe

Middle East

Africa

Asia-Pacific

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