VALERO, Houston FCCU Power Recovery Train Rerate and Upgrade

Title
VALERO, Houston
FCCU Power Recovery
Train Rerate and
Upgrade
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e
Existing
Line
GEPS Oil & Gas
FCC Unit Flow Diagram
Slide Valve Actuat
System
Isolation
Valve
Expansion Joint
Universal
Expansion
Joint
FD
Regenerator
Universal
Expansion
Joint
Orifice
Chamber
Bypass
Control
Valve
Universal
Expansion
Joint
Isolation
Valve
Existing Line
Inlet
Trip
Valve
rmal Operating Temp = 1330 deg F
3rd
Stage
Separator
FC
Inlet
Control
Vale
Critical
Flow Orifice
4th
Stage
Separator
Catalyst
Dump
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Flue Gas Steam
Generation
Expander
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Steam turbine –
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Typical Power Recovery Train
Axial compressor –
Motor/generator -
Expander
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GEPS Oil & Gas
Valero Houston PRT Rerate/upgrade
Key Job Considerations
¾ FCCU plant expansion requires more air flow and pressure.
¾ Train power increase can be accommodated by rerating
expander for increased flue gas.
¾ Steam turbine can be rerated to accommodate higher
starting power requirement while increasing reliability.
¾ Equipment foot prints and shaft end spacing must not
change.
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GEPS Oil & Gas
Valero Houston FCCU PRT Main A
Blower Rerat
¾ Reapplication of surplus
axial.
¾ Redesigned from 15 to 17
stages.
¾ Rerated for additional 30%
flow capability.
Unit during final
assembly
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ESTIMATED PERFORMANCE
GEPS Oil & GasAXIAL COMPRESSOR
ORIGINAL VS. RERATE
Valero Houston
PRT starter/makeup turbine
MAP CONDITIONS
P inlet 14.5 psia
T inlet 86F
60% Rel Humidity
3,600 RPM
65K BPD
DESIGN PT
– Expander/axial/motor/steam turbine
– Murray model R2JD7M2 turbine
– Originally 6,000 HP at 3,600 RPM
70K BPD
75K BPD
60K BPD
ORIGINAL
COMPRESSOR
RERATED COMPRESSOR
70
80
90
100
110
120
130
140
150
Volume Flow (Thousands of ICFM)
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160
170
180
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PRT Starter / Makeup Turbine
¾ Expander/axial/motor/steam turbine
¾ Originally 6,000 HP at 3,600 RPM
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¾ Rerated to 12,000 HP
¾ 100% increase in power
¾ Integral rotor in lieu of original
Built up rotor
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PRT Starter / Makeup Turbine
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Typical FCC Expande
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CONMEC FEX-125
INTAKE ASSEMBLY
¾ Reapplication of
surplus/unused unit
¾ Increased HP by over
50%
¾ Upgraded rotor design
for increased HP
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Valero Houston Hot Gas Expande
Rerate Detail
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GEPS Oil & Gas
FEX-125 Expander Re-rate/Upgrade
RED - Re-rated Unit
BLUE - Original Unit
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FCC Power Recovery:
Expander/generator Sets
GE CONMEC
Bethlehem, PA
USA
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GEPS Oil & Gas
¾ FCC expanders operating
conditions:
¾ Low pressures (< 30 psig)
¾ High temperatures (1100 to 1400
degrees F)
¾ High volume flow ( > 1,000,000 lbs/hr)
¾ High power density turbines (1,000
Hp per blade)
¾ Unique installation requirements
(such as large ducting)
¾ Must operate continually for long
periods of time > 32,0000 hours
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Unique Turbine Application
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¾ Expander Installation Options:
¾ Addition of an expander to the
current air blower train
– Expander
– Motor/generator
¾ Installation of a stand along
expander / generator set
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Installation Options
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¾ Plot Space
¾ Third stage
separator
¾ Piping
– Stainless steel
unlined piping
– Expander inlet
– Expander bypass
¾ Control system
–
–
–
–
Hot Valving
Isolation
Process controls
Generator controls
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Installation Requirement
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GEPS Oil & Gas
Information Require
¾ Tollgate 1: Feasibility Review
– (Customer to provide the following information)
– Regenerator temperature
– Regenerator pressure
– Regenerator flue gas flow rate
– Electricity costs
– Steam costs
¾ From this information GE CONMEC can estimate
– Power recovery
– Frame size of expander
– Reduction in annual energy costs
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GEPS Oil & Gas
Expander Paybac
Expander Payback
Average Size FCCU
$25,000,000
$/year
$20,000,000
$15,000,000
$10,000,000
$5,000,000
$0
$0.040
$0.050
$0.060
$0.070
$/kW-Hr
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$0.080
$0.090
$0.100
Valero/GE Conmec projects in production
¾Corpus Christi expander power upgrade
¾Wilmington expander reliability upgrade
¾Wilmington axial compressor reliability upgrade
¾Ardmore FCCU wet gas train upgrade
¾Paulsboro Hydrogen recycle compressor upgrade
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GEPS Oil & Gas
Upstream
Upstream
Oil & Gas Industry Value Chai
Midstream
Midstream
Industrial
Industrial Plants
Plants
Downstream
Downstream
Distribution
Distribution
Global
Global Services
Services
Drivers
• GT Efficiency & Fuel Flexibility
• Environmental Compliance
• Increasing Gas Production
• Service Response Time
• Reduced Life Cycle Cost
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Offerings:
• Fuel Conversions & Upgrades
• Emission Reduction Technology
• Turbo-Compressor Upgrade
• Local Presence … US Footprint
• CSAs & RM&D
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Nuovo Pignone
Services Leadershi
Thermodyn
Rotoflow
Center Of
Center Of
Excellence for:
Excellence for:
Compressors
• TurboExpanders
Gas & Steam Turbines
Reactors
AC / Gemini
Air-Coolers
Pumps - Valves
CONMEC
Rotoflow
Metering Systems
Odessa
Fuel Dispensers (L & G)
Center Of
Excellence for:
• Low to Medium
Pressure Compressors
• Low to Medium Power
Steam Turbines
Thermodyn
NP
AC Compressor
•
•
•
•
Center Of
Excellence for:
Screw Compressors
Single Stage Centrifugal
Custom Centrifugal
Rotary Vanes
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CONMEC
Center Of
Excellence for:
• Multi-vendor Services:
- Power Turbines
- Hot Gas Expanders
- Centrifugal & Axial Compressors
- Steam Turbines
Gemini
Center Of
Excellence for:
• High Speed Recips
Odessa
Center Of
Excellence for:
• 3rd Party GT Service