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Process Optimization
Process optimization may offer some of the greatest benefits
to cost reduction in the future. The base premise should be
that there is a requirement to move fluid and that some device
is needed to provide this movement and some form of energy
must be applied to achieve the removal.
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Anything other than this basic requirement should be
considered surplus to requirements until a valid and
unshakable argument is put forward. Many pipeline stations
are equipped with emergency generators, building complexes,
water supply and treatment, back up fuel supplies and so on
that often require as much, if not more, maintenance than
the machinery trains. Buildings require heating and lighting,
and often air conditioning, which use energy and require
maintenance.
According to recent demographic data, while English remains
the world’s most popular language, it is the native language of
only around 35% of the global Internet population. In fact, it
is projected than in the near future, 60% of Internet users will
speak a language other than English. To ensure we continue
to provide valuable information about CB&I to our potential
customers – many of whom speak different languages – CB&I’s
Web site, www.CBI.com, is now available online in Russian and
Chinese. Arabic and Spanish versions are coming soon.
We will demonstrate our experience, technology and track
record at a number of forthcoming global trade shows in
2006:
• Global Petroleum Show 2006, 13-15 June 2006,
Calgary, Alberta, Canada
• Power-Gen International, 28-30 Nov 2006, Orlando,
Florida, USA
• GASTECH 2006, 4-6 Dec 2006, Abu Dhabi, UAE
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By using the capabilities of the machinery train such as would
be available from exhaust heat, secondary drivers or even the
incoming air supply, much of the extra energy required by the
machinery train can be provided without additional fuel use.
In addition, the availability of the train depends on its own
reliability and not that of an ancillary piece of equipment.
Removal of building and personnel support systems further
reduces complexity, as well as power and maintenance
requirements, leaving the machinery train as a self contained
and sustained entity.
ENVIRONMENTAL BENEFITS
While the initial focus had been on cost reductions, it became
quite apparent that the proposed techniques will also produce
considerable environmental benefits from the reduction in
energy consumption due to the following:
• Reduced manufacture of equipment for each
facility
• Reduced construction activities at site from the
reduction in buildings and equipment
• Reduced energy consumption at sites by adopting
remote operation
• Improved fuel utilization due to improved machinery
design
APPLICATION TO PROJECTS
These concepts were tested against various BP in-house
projects and confirmed that such savings can be achieved.
Areas for further design optimization were identified. The
confirmed concepts are being used on some BP projects
already. A similar analysis has been carried out for oil pipelines.
However, the effect of topography makes the analysis projectspecific
and general methodology difficult to apply.
CONCLUSIONS
This study work has demonstrated that an order of 20% cost
reductions can be achieved for gas pipeline facilities. The
other big bonus is the reduction in carbon footprint leading
to reduction in environmental impact from reduced facilities
and more efficient fuel usage. Many of these concepts can
also be used on oil pipelines as many of the principles for cost
savings relating to remote operation and modularization are
applicable to all pipelines.
Gurdial Singh
Hydrogen Plant Technology
Video
In April 2006, CB&I introduced a new video on hydrogen plant
technology. The video utilizes three-dimensional computer
animation to depict CB&I’s hydrogen plant capabilities and
EPC services. It integrates animated images, photos and
other graphics to describe the features and benefits of using
hydrogen plant technology, as well as CB&I’s experience in
designing and building these plants. The new video is available
on CD-ROM, runs six minutes and is playable on any computer
system.
Hot Off the Press ….
“Sulfur Review and Major Projects Review”, Hydrocarbon
Engineering, April 2006. CB&I recently contributed to
Hydrocarbon Engineering’s comprehensive overview of
the key sulfur technologies available to plant/refinery
operators. The section dedicated to CB&I spotlights our
proprietary sulfur recovery unit (SRU) technologies, our
oxygen enhancement technologies, our family of Resulf
tail gas treating unit (TGTU) technology, and the various
construction options we offer for SRU and TGTU projects.
“Coke Drum Design: Reliability Through Innovation”,
White Paper for the NPRA Annual Meeting, March 2006.
The paper examines the theories behind coke drum failure
and demonstrates ways of improving their reliability such as
installing CB&I’s vertical plate technology, which eliminates
the circumferential weld seams in the area prone to distortion
and cracking. In addition, the paper includes a description
of the new skirt attachments that have been developed for
coke drums, as well as an economic case for implementing the
vertical plate design. This paper also will be featured in the 3Q
2006 edition of Petroleum Technology Quarterly.
“Operation Hydrogen”, Hydrocarbon Engineering, February
2006. The article examines steam methane reforming (SMR)
based hydrogen plants and the design nuances that are
now typically a part of designing a modern hydrogen plant.
Factors to consider include the capability to handle multiple
feedstocks, setting an export steam amount that will fit within
a refinery’s steam balance, and controlling the export steam
purity.
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