Technological improvements are rapidly changing the methods and equipment used to clean and decoke furnace coils in refining and chemical process operations. Along the way, the nature and scope of work offered by pigging service providers is evolving.
As plant maintenance professionals look to gain maximum value from their service company partners, it is important to recognize how these new developments can provide substantive increases in safety, speed, and effectiveness. The following are four key technological and procedural trends in furnace pigging and decoking:
- Pumping capabilities. Pumps, engines, controls and other equipment for a pigging operation are contained on a specially designed, trailer-mounted unit. Recently developed units are marvels of engineering that offer increased pumping capacities and efficiencies while complying with the size and weight limitations of transportation regulations.
Until recently, the most advanced units contained two pumps. The latest units now offer triple pumping capabilities, allowing pigging to be performed from three furnace inlets simultaneously, generating a 33-percent increase in productivity. Even when high capacity pumping is not needed, the availability of three separate pump/ drive combinations provides ready-to-go redundancy in the event of equipment problems.
Other configurations, known as "quad" pumping units, are also available. However, it is important to note that, while these units are equipped with four pumps, they have only two drive engines. An engine problem on a quad unit decreases cleaning power by half. The distinction between quad and triple pumping is important in considering the pumping capacity and true redundancy requirements for a project. Also significant are the considerable demands placed on flow enhancement technicians to maintain safety and productivity. Triple pumping units are operated by three dedicated technicians, while quad units have two technicians responsible for four pumps.
- Control automation. Control rooms in modern pumping units have automated virtually every function, improving both safety and efficiency. For example, fluid tanks contain guided radar level sensors with automatic shutdown pre-sets and digital readouts for operators.
Extensive automation, combined with higher pumping capacities, means faster project completion and a quicker turnaround for the plant. With furnace downtime costing plants up to $50,000 per hour, automation provides quantifiable value.
- Safety and environmental. Significant advances have been made to keep personnel safer and mitigate risk. Current pumping units are designed with dual egress routes out of the cab, high-visibility LED lighting, non-slip stair and handrail configurations, and other safety features.
From an environmental view, conventional pumping units with older engines and high-soot exhaust are a liability. Conversely, state-of-the-art pumping units are fitted with Tier 4F turbodiesel engines that meet strict California emissions requirements. Modern units are also self-contained with spill pans to protect against leaks or overflows.
- Service expansion. Plant personnel is now calling on their pigging service company partners for a broader range of associated services. Instead of only cleaning the furnace, plants are taking proactive measures, such as soda ash pacification to resist corrosion, or intelligent pigging to confirm cleanliness and assess the integrity of the furnace. They want the same service company to help with dirty effluent filtration, safety planning, cost savings analyses and turnaround schedules. In these scenarios, the pigging service company must not only be able to perform additional services but also have the experience and expertise to work with plant personnel in a more consultative role.
Plants are also increasingly preferring a single source for services indirectly related to pigging operations -- such as vacuum services or hydro blasting -- to reduce procurement costs and improve project coordination.
Pigging and decoking technology are changing rapidly, resulting in greater productivity, profitability, and safety for plants willing to take advantage of recent advances.
For more information, call (844) 243-5557, email sales@usadebusk. com, or visit www.USADeBusk.com.