FCC Hot Gas Expander Reliability Upgrade Evaluation.

Abstract

The hot gas expander (PRT) is an integral part of the refinery’s fluid cat cracker unit’s PRT train. Since 1995, the PRT has experienced four unplanned outages due to blade and steam baffle bolting failures. These failures were extensive and very expensive. The cost (mechanical repair and lost opportunity) added up to tens of millions of dollars along with tremendous stress and strain on the organization, to which no cost can be attributed. A PRT reliability upgrade project was initiated to improve the reliability of the PRT train with the objective of achieving back-to-back four-year reliable runs. The project was also to evaluate potential opportunities for debottlenecking without compromising reliability. The purpose of this paper is to share the methodology and various tools used to carry out a vigorous technical and economic assessment and to share results for a PRT upgrade project. As a result, key indicators and activities have been established to keep this machine available.