How to Make the Optimal Use of Scheduled Plant Downtime

Related Vendors

DÜPERTHAL Sicherheitstechnik GmbH & Co. KG

Glatt Ingenieurtechnik GmbH

EDL Anlagenbau Gesellschaft mbH

Rösberg Engineering Ingenieurgesellschaft mbH für Automation

As-built documentation and mobile access

During the shutdown time all work and inspection steps were logged, thanks to the documentation software LiveDOK (see Technology 2). LiveDOK makes it possible to administer, search and correct all the documents, plans and records of industrial plants, digitally and in real time. Changes, additions and new documents are imported immediately, and are visible to all project participants at all times.

Fig. 3: With LiveDOK plants can be electronically documented, avoiding the time-consuming processes of multiple alterations and searching for paper documents.
(Source: Rösberg)

During the I&C safety inspections, employees also especially came to appreciate the mobile access possibilities (Fig. 3). For instance, during the shutdown time work could be carried out in the control rooms without paper documentation. Points on the daily schedule which would otherwise have had to be located and marked in hard-copy files could be processed and administered comfortably on a tablet PC. At the end of the shift, the necessary protocols were available in digital form.

At the same time, the documentation was always up-to-date, because ProDOK, together with LiveDok, ensures ‘living’ as-built documentation which always reflects the current status, and provides mobile access options – even when, as in this case, comprehensive checklists for a wide range of inspections had to be worked through.

Waste heat boiler for the energetic use of heat from flue gas flows

In parallel to the inspection procedures, new projects were also realized in the refinery. One of these concerned the FCC (fluid catalytic cracking) plant, where the heavier crude oil fractions are split into valuable olefins, gasoline, gasoil and heavy oil components.

This plant was to be enlarged by the addition of heat recovery steam generators, which enable the heat content of the flue gases from the FCC plant to be used to generate mediumpressure steam. In this way the waste heat from the process, which would otherwise be lost in the atmosphere, is recuperated and energy efficiency of the plant is improved.

Fig. 4: The flue gas initially deposits dust on the heat exchanger assemblies in AHK 1, which therefore have to be cleaned using a shotcleaning system during normal operation of the plant. In this way the fly ash collects in the funnels below the heat recovery steam generators, and is removed.
(Source: MiRO/Rösberg)

The heat recovery plant (AHK) is integrated into MiRO’s FCC plant (Fig. 4).

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How to Make the Optimal Use of Scheduled Plant Downtime

As-built documentation and mobile access

Waste heat boiler for the energetic use of heat from flue gas flows