REGENERATOR & VESSEL HEAD REMOVAL

In 1998, Destec Engineering performed a world first when it commenced preliminary cutting to remove the Regenerator Head at the Coryton Refinery, UK – 25 days in advance of day 1 of the planned turnaround start date, allowing the head to be lifted on mechanical day 2.

Cutting of both the vessel shell and internal refractory was carried out dry, from the outside. and included all necessary weld preparation ready for reinstatement of the head.

The dry cutting operation is carried out using portable milling or grinding equipment running on two circumferential, parallel rails, fixed either side of the cut line. The method is relatively quick, with very little post operative cleaning – unlike water jet cutting, which can take as long as 10 days to 'mop-up'. Thus, the method effectively reduces overall plant down time and is very environmentally friendly.

Destec, has continued with development of the technique and equipment, and in 2006, with the number of projects carried out well into double figures. the company carried out a Regenerator Head removal at Fawley Refinery, UK. At 17m diameter, 22mm wall thickness and 125mm refractory lining thickness, this is the largest Destec has undertaken so far, and one of the largest undertaken anywhere in the world.

The dry cutting method developed by Destec is now readily available to use anywhere in the world and the growing number of satisfied customers who have benefited from this unique system extends from the UK and Europe through the Middle East.

SIZE RANGES FROM 2 METRE DIAMETER THROUGH TO 20 METRES
Which can be further extended with custom built rails.

A Fluid Catalytic Cracking Unit has been an integral part of oil refineries since 1942, when it was introduced in the USA. An FCCU accepts chains of hydrocarbons and breaks them into smaller ones in a chemical process call cracking. This allows refineries to utilize their crude oil resources more efficiently, making more products such as Petrol for which there is a high demand.

A continuous FCCU has a primary reactor, a distillation column for separating out the crack hydrocarbons, and regeneration unit for cleaning the catalysts and preparing them for reuse.

Regenerator & Vessel Head turnarounds are the most critical operations in the refinery life cycle and numerous factors need to be carefully considered during project planning, such as:

  • Site safety
  • Scope of the work
  • Cutting methods to be employed and machine tools required
  • Establishing capabilities of contracting team
  • Mobility of contracting team
  • Quality assurance provided by contractor
  • Estimated turn around time
  • Predicted weather conditions
  • Possible disruption to other processes
  • Logistics
  •  Costs

Bringing all these factors satisfactorily together for a smooth, speedy and ‘event-free’ turn around, particularly in remote or inhospitable areas of the world, can be a major concern for refinery operators.

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Download the Destec Regenerator & Vessel Head Removal PDF

    Dry Cuttings Operations by Oil & Gas solutions provider, Destec Engineering, offer a range of advantages for the turnaround of the even the largest FCCU Regenerator & Reactor Vessel Head:

    • Fast, efficient dry cutting process
    • Cutting can start even before plant is shut down
    • The actual cutting operation take 24 – 36 hours
    • Weld preps can be machines on one or both sides of the cut line (depending on whether the same head is to be reused)
    • Cutting of Overhead lines also available by Destec
    • In House designed machines attached externally to the vessel via purpose make tracks
    • Steel is cut using milling heads followed by a diamond cutting of the refractory
    • Clean – little or no post operative cleaning (unlike waterjet cutting that can take up to 10 days to ‘mop-up’)
    • Non-polluting and environmentally friendly
    • Over 10 years experience in Regenerator Head & Vessel removal. Largest project to date: 17m Diameter with 125mm refractory wall thickness
    • Highly skilled team
    • Portable equipment – team has ability to work worldwide
    • Total Project planning and execution.

    For more information about our products and services call us on 01522 791721 or email us at service@destec.co.uk