Project Overview

The Client’s inspection group identified that the convection section of their naphtha platformer charge heater was in poor condition. Sulphurous flue gases had attacked the casing where the refractory had separated from its anchors, leading to several holes in the roof. The combined deterioration of the refractory, anchor system, and casing meant further repairs were impractical. The convection section tubes were also nearing the end of their service life, and the vent stack had damper reliability issues and insufficient draft. The Client engaged Rally to replace the entire convection section of the heater, including the stack.

Convection Section Replacement (FEED and Detail) main Convection Section Replacement (FEED and Detail) first Convection Section Replacement (FEED and Detail) second

Scope Definition

Rally worked with the Client’s preferred heater vendor to optimize the design of a new convection section and stack. The goal was to improve duty and draft whilst still integrating seamlessly with the radiant sections below.
At Rally’s recommendation, the steam drum on top of the convection section was replaced at the same time. Rally modularized the steam drum piping and access platform so that they could be trial fit on top of the new convection section prior to lifting. This took fit-up risk out of the turnaround.
All new equipment was designed to meet modern codes and standards, including the multi-blade damper and steam drum.

Detailed Deliverables

Material requisitions (MRs) were issued for the new convection section and stack, the steam drum and module, pressure relief valves, modern oxygen analyzers, and other instruments. Rally closely managed the convection section and steam drum vendors to ensure on-time arrival of new equipment.
Construction work packages (CWPs) were produced to reinforce the existing radiant sections, lift and remove the old convection section, execute the lifts of the new convection section, stack, and steam drum module, tie into adjacent piping and wiring, and upgrade instruments. All CWPs were issued to the Client’s planning group 12 months prior to the scheduled turnaround.

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