HYBRID PETROLEUM INSTITUTE. Furnaces and Heaters Reliability and Asset Integrity Solutions

Transcription

1 HYBRID PETROLEUM INSTITUTE We provide technology solutions for inspections and assessments of high accuracy, which support to process companies, transport and power generation to increase its usefulness, reduce operational and safety risks and improve its operational planning. Hybrid Petroleum Institute is built over a foundation of scientific and technological edge that has innovated and has shaped the process industries, transportation and power generation over the past forty years. A privately held company with global presence, respond to their needs and we focus on tools to deliver operational and maintenance decisions. Pipe cleaning for furnaces and heaters by PIG technology CALLE AJUSCO. 15, COLONIA PORTALES, C.P , DEL. BENITO JUÁREZ, MEXICO D.F. TEL , , , Furnaces and Heaters Reliability and Asset Integrity Solutions

2 WHAT IS PIG TECHNOLOGY? The method of "pigging" refers to the application in the maintenance of pipelines, this means, the practice of using indicators of inspection / cleaning with "PIG" (pigs) devices to perform various operations on a pipeline without stop product flow. This is accomplished by inserting the "pigs" in a launch station, a funnel-shaped section "Y" in the pipe. The launcher/launching station is closed and the pressure of the product in the pipeline is used to push along this until it reaches the receiving station. Its main feature two major objectives: Internal cleaning of pipes. Integral inspection in the pipeline (pipeline integrity). Without interrupting the flow the pig is forced through the pipe by the flow of the product, or can be towed by other devices or cables.

3 The pigs may be cylindrical or spherical, as it passes through the line makes a clean sweep, scraping the sides of the pipe and pushing debris ahead. If along the pipe system has butterfly valves, the procedure cannot be performed. Otherwise with ball valves, not causing any problems because the inner diameter of the ball can be specified with the same diameter of the pipe (assuming they are full bore valves). View cut the pipe as the PIG system interacts. Cleaning Pig typical

4 The "Pigging" method has been used for many years to clean larger diameter pipelines in the oil industry. But nevertheless, it is nowadays, the use of smaller diameter systems "pigging" is increasing in many continuous process plants and plant where furnaces operate this in order to seek greater efficiency and lower costs in their processes. APPLICATIONS: Storage and filling systems. In oil and gas pipeline systems. Furnaces and heaters direct fire. Transfer processes.

5 PIG s types and its uses Although for the first time, the use of the pigs were just to clean lines, pigging method has evolved with the development of new technologies. The first basic utility of this method is to insert the pig in the pipe and remove unwanted materials (sediments, rust, sludge, coke, etc.). Another utility are the inspection pigs, which are used for comprehensive inspection of the line inside. Special Pigs that are used to connect a line or isolate certain line. The Gel Pigs, is used to increase performance by eliminating solid or semi-solid waste on pipe, or to reduce corrosion or cleaning the line before an inspection with a smart pig In addition, the Sealing pigs are used to remove fluid from the pipe as well as serve as an interface between two different products within a pipe. The types of pigs used include mandrel type pigs, the foam pigs, molten solid pigs and spherical pigs.

6 PIG s types

7 PIG SYSTEM FOR CLEANING FURNACES AND HEATER The pipe cleansing technology consists of propelling with "water or gas" generally a polymer pig (for reasons of flexibility) bullet shaped, circumferentially covered of steel, chromium, and tungsten that are screwed into the body of the pig which navigates through the inner section of the serpentine tubing, including bends of 180 (U BENDS) and 90 (heads). Flexible Pig INTERNAL CLEANING IN FURNACES Internal deposits in pipes (coke) The process is bidirectional, allowing to the cleaning system (PIG) navigate the furnace tubes in both directions. It is the only process that can lead the Pig to travel only in the most polluted sections with repeated movement from front to back and vice versa.

8 PIG SYSTEM FOR CLEANING FURNACES HEATERS INTERNAL CLEANING IN FURNACES The Pig travels through the serpentines and is available in diameters from 101 mm (4 ") to 914 mm (36") and can pass short radius elbows and U-bends easily. Typical installation of launcher / receiver Each Pig has a series of interchangeable cleaning studs, each of which is placed in the body of the pig. These studs are scattered radially along the body to provide a total cleaning at 360 of the pipe. BEFORE AFTER

9 PIG SYSTEM FOR CLEANING FURNACES HEATERS The pig size, the number of nails, stud material, geometry and height are matched to each stage of a cleaning cycle. An advantage of this device is that by changing the height of the studs you can control the speed at which deposits are removed and the amount of water to be used to push the device. TYPES OF STUDS AND APPLICATIONS TBC type HMT type SH type HW6 type TWB type Function: To remove particles of coke left in the pipes and at the same time exert a polishing action on the inner section thereof, being allowed to exceed 10% or 12% of the internal diameter of the pipe. INTERNAL CLEANING IN FURNACES Function: Cutting coke with more surface contact. Function: Cut thicker coke on the surface of the tube. Function: Chopping coke surface thereby releasing the pressure inside through its embrittlement to be removed with the following asparagus. Function: To remove coke on tube wall not exceeding 8% to 10% of the internal diameter of the pipe, combining form of attack with use of washers.

10 ADVANTAGES VERSUS SOME PIPE FURNACES CLEANING SYSTEMS COMPARISON OF VARIABLES STEAM DECOKING HIDROJET CHEMICAL CLEANING MECHANICS DRILL SANDJET S. PIGGING Erosión en tubería By default wear. Abrasive wear effect. Wear by chemical corrosion. Abrasion wear. Abrasion wear. Recalentamiento a la estructura (elongación) Impacto ambiental Tiempo de ejecución Taponamiento de la tubería Riesgo laboral Efectividad Global Change in the molecular structure. Fumes, solid and liquid contaminants. Solid and liquid contaminants. Damage by chemical reaction. Fumes, Chemical Substances and solid contaminants. Physical action by friction. Solid contaminants. Physical action by friction. Solid contaminants. Midst High Midst High High Low Moderate risk during hath scraped. High temperature 75 % physical guarantee of total detachment of coke. High risk for pipe clogging. High pressures. 50 % Process limited by returns. Exposure to chemicals. 70 % uniformly clear adhering coke. Operation at high risk (knocking). 75 % Limited to cleaning furnaces with heads. High risk for pipe clogging. High risk impact of bullets. 60 % Limited by returns. 100 % Guarantees complete coils cleaning.

11 GENERAL BENEFITS OF THIS TECHNOLOGY A) Fully guaranteed 100% detachment any adhesions (coke - ferric sulfate -. Silica, etc.), that are attached along the internal section of the pipe, heads and 180 and 90 curvatures. B) Reduction in "Cost" by 40% compared to cleaning with traditional methods such as: Chemicals, Water Jet, Sand Blasting, etc. C) Decreased downtime (lost profits) by 65% by way of internal cleansing and stop the system in general and at the same time the DECOKING of pipes is done, can be performed in the home and around Furnace, collateral maintenance services such as: Refractory Repair, Plumbing and Welding changes thereof with a through said furnace, welding pipe anchoring, welding External Drywall, Painting Furnace shell.

12 D) Lengthening in the "times of operation of the equipment. E) Ratio fluency increase and decrease in rates pressure, turbulence and temperatures. F) Totally friendly to the environment because the system is "mechanical" type and does not use any type of chemical or high temperatures and pressures, so the serpentine tubing is not subject to sudden temperature changes and corrosive actions (acid). G) HERMETICITY tests certification along the entire pipe system. H) Increase the life of the pipeline, as the studs used for decoking and hath scraped thereof are selected with a "Rockwell" hardness less than that of the pipe, so never exerts an abrasive action in the inner surface, which added to the two-way technology allows pigs locate only in areas of the pipe submit adhesions (coke).

13 I) Once have detached all contaminated attached elements located in the inner section of the pipeline, with the pigs using studs "metal", which exert an action of "polishing" along the inside of the pipe, giving a finish as if new, thus slowing the processes of pollution along the pipe, U-bend and heads. In conclusion the pig technology method has proved to be one of the best options for internal furnaces pipe cleaning, maximizing equipment efficiency at lower cost and reducing downtime for maintenance.