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Good Practices developed at Bottom of the Barrel's 2002 Coking.com Best Practices Seminar. Here's one group's discussion of Pigging, Steam Air Decoking and Spalling.

PIGGING

Pros Cons
  • Downtime to pig
  • Reduce production loss
  • Can do some inspection while pigging
  • Reduce environmental impact
  • Cleaner tubes
  • Doesn't require operator involvement
  • Time constraints after initial visits
  • Wear and tear on heater
  • Opportunity to work around heater
  • Entire tube cleaned
  • Downtime to pig
  • Reduce production loss
  • Increased environmental impact
  • Thermowells
  • Occasional problems with mule ears can increase time
  • Occasional problems with rolled tubes
  • Lack of final determination of clean
  • Mechanical damage to tube
  • Scheduling
  • Cost-price of spalling and fuel gas
  • Availability

STEAM AIR DECOKING vs PIGGING

STEAM AIR COKING PIGGING
Stainless tubes - 3 to 4 yr B/T steam air decoke
  • No spall
  • Velocity steam - adjust per feed rate
  • Safety
  • Water quench
  • Affluent pit
  • Fumes escaping
  • Increasing run links 150% to 300% w/pigging
  • Tough to monitor coke removal
  • Environmental concerns - SO2 emissions
  • Roof tubes TMTS drive SD's
Pros Cons
  • Reduced oil/oil downtime
  • Cost
  • Scheduling
  • Environmental impact
  • lack of info/cleanliness in convection section
  • Inorganics (won't remove as well or at all)
  • Mechanical damage to tubes - can depend on procedures
  • Manpower

SPALLING

1. Trigger - Tube skin temperature; pressure occasionally
2. Spall is limited to 1350 degrees
3. 9 to 12 hours

Steam VS BFW

  • Less success with each spall
  • Annual inspection on returns
  • Monitor NA in feed
Pros Cons
  • Longer run lengths
  • Inlet & outlet pressure, Delta across heater
  • 4 or more spallings before pigging or steam air decoking
  • Not usually done on two-pass heaters
  • Erosions
  • Can require reduced thru-put to spall - economics based
  • Carry over upsets heavy gas oil
  • Affects down steam equipment
  • Coke quality & cave ins

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