Systems and methods for modifying an operating parameter of a coking system and adding a coke drum

• US 9,235,820 B2
• Filed: 11/01/2012
• Issued: 01/12/2016
• Est. Priority Date: 11/01/2012
• Status: Active Grant

• Current Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Original Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Inventors: Antalffy, Leslie P., Kirkpatrick, Kenneth D., Miller, George, Millet, Barry, Maitland, Charles
• Primary Examiner(s): Jarrett, Scott L
• Application Number:
  US13/666,834
• Publication Number:
  US 20140122141A1
• Time in Patent Office: 1,167 Days
• US Class Current: 1/1
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/06315 Needs-based resource requirements planning or analysis
• CPC Class Codes: G06Q 10/1097 Task assignment
• CPC Class Codes: G06Q 50/04 Manufacturing
• CPC Class Codes: Y02P 90/30 Computing systems specially adapted for manufacturing

Abstract

Systems for analyzing a benefit or detriment of (1) changing an operational condition or parameter, or (2) adding a coke drum to an existing coking system are disclosed. Contemplated systems can increase the cost effectiveness of coking systems by providing valuable analysis data.

Claims

1. A system of improving cost effectiveness of a coking system, comprising:

an operational first coke drum, and a second coke drum;

a database storing operating parameter data and corresponding life span data;

a first user device communicatively coupled to a hardware implemented analysis engine and a sensor, wherein the sensor obtains coke drum data associated with the first coke drum on an ongoing or periodic basis, and wherein the data comprises at least one of temperature data, damage data, pressure data and stress data; and

wherein the hardware implemented analysis engine is communicatively coupled to the database and configured to;

receive the coke drum data obtained via the sensor on the ongoing or periodic basis;

generate an estimation of a time to failure of the first coke drum based at least in part on querying the database and the coke drum data received;

analyze an effect of adding a third coke drum to the coking system on the first coke drum, wherein the effect is an increase in the estimated time to failure;

transmit to the first user device a recommendation (a) to modify an operating parameter of the first coke drum and (b) to fluidly couple the third coke drum to the first coke drum based on analyzing the effect of adding the third coke drum; and

modify the operating parameter of the first coke drum based at least in part on the recommendation.

2. The system of claim 1, wherein the first user device is configured to provide a user interface, and wherein the user input is received by the hardware implemented analysis engine via the user interface.

3. The system of claim 1, wherein the recommendation to modify the operating parameter of the first coke drum comprises a recommendation to expand a cycle time or a recommendation to utilize a more gradual quench rate.

4. The system of claim 3, wherein the step of generating the estimation of the time to failure of the first coke drum is made subsequent to detection of a damage in the first drum based at least in part on the coke drum data, and associating the damage with a cycle time.

5. The system of claim 4, wherein the damage comprises bulging.

6. The system of claim 4, wherein the damage comprises a crack.

7. The system of claim 4, wherein the damage comprises thinning in a wall.

8. The system of claim 1, wherein the step of generating the estimation of the time to failure of the first coke drum is made subsequent to detection of a problematic temperature gradient (PTG) of a portion of a wall in the first coke drum, and associating the temperature gradient with a shortened cycle time.

9. The system of claim 8, wherein the recommendation to modify the operating parameter is associated with a reduction to the problematic temperature gradient (PTG) during a heating step.

10. The system of claim 1, wherein the analysis engine is further configured to transmit a recommendation to modify a processing parameter to reduce a problematic temperature gradient (PTG) in at least one of a skirt attachment, a pressure boundary, and a supporting element of the first coke drum during a quenching step.

11. The system of claim 1, wherein the increase in the estimated time to failure results in a second estimated time to failure that is greater than a design life span of the first coke drum minus a number of years the first coke drum has been in operation, and wherein the recommendation comprises operating the first coke drum with a lengthened cycle time.

12. The system of claim 11, wherein the increase in the estimated time to failure results in a second estimated time to failure that is estimated to be at least twice the total of the design life span minus the number of years in operation.

13. The system of claim 11, wherein the increase in the estimated time to failure results in a second estimated time to failure that is at least three times the total of the design life span minus the number of years in operation.

14. The system of claim 1, wherein the second coke drum is operational.

15. The system of claim 1, wherein the coke drum data comprises damage data relating to at least one of a bulge, a crack and a thinning in a wall of the first coke drum.

16. The system of claim 1, wherein the analysis engine is further configured to generate the estimation of the time to failure of the first coke drum based at least in part on a bulge in a wall of the first coke drum.

17. The system of claim 1, wherein the analysis engine is further configured to generate the estimation of the time to failure of the first coke drum based at least in part on a crack in a wall of the first coke drum.

18. The system of claim 1, wherein the analysis engine is further configured to generate the estimation of the time to failure of the first coke drum based at least in part on a thinning in a wall of the first coke drum.

19. The system of claim 1, wherein the analysis engine is further configured to generate the estimation of the time to failure of the first coke drum based at least in part on a problematic temperature gradient in the first coke drum.

20. The system of claim 1, wherein the analysis engine is further configured to produce a physically perceivable rendering of the third coke drum fluidly coupled to the first coke drum.

21. The system of claim 1, further comprising a computer configured to produce a physically perceivable rendering of the third coke drum fluidly coupled to the first coke drum.

22. The system of claim 1, further comprising a computer configured to produce a schedule for procuring at least some components of the third coke drum.