Case Studies

State-Based Alarming Solves Problems for Coker Unit

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About the Project A new, five-furnace Coker Unit at a major Middle East Refinery experienced high rates of non-relevant, inappropriate alarms during its normal cyclic operation. Since such an alarm system is ineffective, an alarm system design to eliminate those nuisances was desired. Coking in Brief A refinery coker unit processes residual refinery oil into more useful products, leaving behind solid carbon "coke." A coker consists of multiple drums, furnaces and additional equipment that process in a cyclic operation. State-Based Alarming Solves Problems for Coker Unit PAS PlantState Integrity ™ - Dynamic Alarming solution proves effective The coking process is as follows: • Startup heating of the hydrocarbon feed to a temperature high enough for cracking in a ready drum • Steady-state cracking operation, during which product is made and byproduct coke is formed and fills the drum • Diversion of feed flow to another ready drum • Decoke: Steaming of the coke-filled drum to remove residual product • Water quench of the coke-filled drum, then removal of the coke via automated high-pressure water wash • Repeat of the cycle Each coker sub-unit is heavily instrumented, with hundreds of sensors and potential alarms. Each state of the operating cycle has possible, but different, abnormal situations that can arise. Ancillary equipment for each coker drum also undergoes multi-state operation. Case Study

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