Carmagen Newsletter

Our newsletter contains information and viewpoints on engineering topics relevant to the process and energy related industries.  The articles provide generalized information and should not be relied upon as advice for specific applications; nor should the statements or opinions contained therein be deemed to constitute engineering or consulting advice.  We note that advice can change depending on the factual circumstances unique to each project. 

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June 2018 

The article below is in the June Newsletter

• We started our engineering consulting company some 33 or so years ago (I was young then!) on the premise that companies and refineries would find it a useful asset to have access to very experienced engineers, scientists, and other professionals on an as needed basis.  On the oil company or the refinery's schedule - when they needed someone, for as long as they needed them, and what background that person should have.  Cost effective, efficient, and timely

January 2018 

The article below is in the January Newsletter

• Hydrogen induced cracking (HIC) may occur in pressure equipment that contain wet H₂S environments when hydrogen blisters form and are accompanied by cracks which link these blisters.  Since the blisters can form at various depths, the cracking will appear as a stair step appearance.  Hence, HIC may be referred to as "stepwise cracking."

November-December 2017 

The article below is in the November-December Newsletter

• Tank Overfill Protection "Better Practices"
  
  The Buncefield and CAPECO terminal explosions - what do these two tragic industry events have in common?  Besides costing tens of millions of dollars and injuring dozens of people, both of these storage tank incidents began when:
  • Storage tanks were being filled with flammable hydrocarbons,
  • The terminal crews involved in each of these incidents were operating without a functioning level instrument on the tank(s), and
  • The ensuing investigations determined that operations personnel had failed to recognize the associated risk and potential consequences of the scenario.

October 2017 

The article below is in the October Newsletter

• Systemic Design Failure of Reformer Heater Pigtails
  
  Catalyst-filled tubes in hydrogen, ammonia and methanol reformer heaters operate with metal temperatures in the range of 1,475°F to 1,750°F [800°C-950°C] with internal pressures between 250 to 500 psig [3.6-7.2 MPa].  They require high Ni-Cr alloyed and micro-alloyed metallurgies in cast and wrought form.  The industry practice standard to design tubes for a 100,000 hour [11.4 year] life based on creep rupture criteria is API 530, "Calculation of Heater Tube Thickness in Petroleum Refineries."

September 2017 

The article below is in the September Newsletter

• Top Ways a Refinery Can Use to Help Weather Current Market Conditions
  
  What are the top ways a refinery can use to help weather current market conditions is a question we posed to our 160+ engineers.  This is the next article in the series which includes responses from several different authors.

June-July 2017 

The article below is in the June-July Newsletter

• Assessment of Damage Mechanisms Affecting Pipeline Integrity
  
  The worst case scenarios for flaws and damage mechanisms affecting pipelines are ruptures.  This article will discuss the various types of flaws and damage mechanisms, the types of pipelines involved, and the regulations applicable to the mechanical integrity of both liquid and gas transmission pipelines.

May 2017 

The article below is in the May Newsletter

• Top Ways a Refinery Can Use to Help Weather Current Market Conditions
  
  What are the top ways a refinery can use to help weather current market conditions is a question we posed to our 160+ engineers.  This is the next article in the series which includes responses from several different authors.

April 2017 

The article below is in the April Newsletter

• Top Ways a Refinery Can Use to Help Weather Current Market Conditions
  
  What are the top ways a refinery can use to help weather current market conditions is a question we posed to our 160+ engineers.  This is the next article in the series which includes responses from several different authors.

March 2017 

The article below is in the March Newsletter

• Top Ways a Refinery Can Use to Help Weather Current Market Conditions
  
  What are the top ways a refinery can use to help weather current market conditions is a question we posed to our 160+ engineers.  This is the next article in the series which includes responses from several different authors.

February 2017 

The article below is in the February Newsletter

• Top Ways a Refinery Can Use to Help Weather Current Market Conditions
  
  As far as reliability and hence availability for production is concerned, this can be achieved by operating the plant within its design parameters and in part through the implementation of a well-managed inspection program.  There are many reference tools available to the refinery industry, which include several well written API standards and recommended practices.  The experience and professional knowledge of refinery inspection and engineering personnel is paramount to the successful and cost effective implementation of refinery programs.  Training of such personnel has to be structured and complete.

January 2017 

The article below is in the January Newsletter

• Top Ways a Refinery Can Use to Help Weather Current Market Conditions
  
  In general, a $1 improvement in the bottom line is equivalent to $10 - $25 needed on the top line.
  • Reduce labor costs by adjusting the organization to match current needs.
  • Reduce input costs (e.g., cost of fuel gas, electrical power).  Negotiate/renegotiate contracts.
  • Operate equipment to its available capacity (know your equipment).

November 2016 

The article below is in the November Newsletter

• The Top Ten Ways to Get the Best Pilot Plant for Your Buck
  
  Pilot plants are inherently expensive and time consuming; organizations are always looking for ways to reduce their costs and installation schedule.  Here are some of the best ways to make your next pilot plant project the most efficient, effective, fastest, and least costly.

October 2016 

The article below is in the October Newsletter

• Marine Terminal Safety Assessments
  
  Marine terminals that facilitate product imports and exports are a crucial and necessary part of the oil industry, and yet you rarely hear much in the media about the inherent risk that terminals may pose.  Every day in the US alone, there are thousands of product transfers involving millions of barrels of hydrocarbons and chemicals being moved via refinery and chemical plant docks as well as distribution terminals.  Each one of those transfers represents a risk of a safety or environmental event if minimum standards of care are not followed.

September 2016 

The article below is in the September Newsletter

• The Evolution and Need for Process Safety Management Regulations
  
  OSHA Process Safety Management regulations for the handling of a defined list of "Highly Hazardous Chemicals" became law in the United States in 1992.  These regulations were prompted by several major releases at facilities around the world that resulted in multiple fatalities both inside the respective plant and in their surrounding communities.  Since that time, the PSM regulations have been modified and adjusted periodically to best serve the interests of the refining and chemical industry and the general public.  Process Safety Management regulations consist of 14 Elements covering all aspects of Highly Hazardous Chemical management. 

July 2016 

The article below is in the July Newsletter

• Compressed Air Systems
  
  Compressed air systems are required in almost all industries such as oil and gas, chemical and petrochemical plants, agro-chem plants, power plants, nuclear facilities, pulp and paper, food, pharmaceuticals, automotive, aerospace, IT/PC industry, industrial manufacturing, large commercial buildings, hospitals, R&D facilities, and so on.  The size and scope of the system depends on the type of facility.  Hydrocarbon processing facilities have very large air systems with complex configurations.

June 2016 

The article below is in the June Newsletter

• Unmanned Aerial Vehicle (UAV) Inspections Can Save Time and Money
  
  Equipment inspections within chemical plants and refineries are vital to ensure safe and efficient operations.  Maintenance inspections and turnarounds are costly and result in unavoidable downtime.
  
  Aetos, a member of MISTRAS Group, Inc., uses proven Unmanned Aerial Vehicle (UAV) technology that provides an alternative to current methods of turnaround planning, infrastructure inspections, environmental monitoring, and disaster relief.

May 2016 

The article below is in the May Newsletter

• Service Life Determination for Damaged Delayed Coker Drum
  
  Delayed cokers are an essential unit in oil sands plants and refineries since introduction of this technology to industry in the early 1930's.  The delayed coker drum operates under severe service conditions of not only high temperature to 900°F (482°C) but also quenching to near ambient temperatures.  The drums are also operated in a batch manner of approximately 24 hours which contribute to the severe, thermo-mechanical cyclic loading. 

April 2016 

The article below is in the April Newsletter

• Case Study - Energy Efficiency Improvement
  
  As follow-up to an earlier article on Profitability and Energy Efficiency Improvement, this is a case study of a job that we worked on.

March 2016 

The article below is in the March Newsletter

• Changes to ASME B31.3, "Process Piping"
  
  The 2014 edition of ASME B31.3 is a revision of the 2012 edition, was officially issued February 27, 2015, and became effective six months after that date.  As with previous editions, it includes several pages at the beginning that highlight where changes were made, and these are further identified by a margin note (14) in the body of the code placed next to the affected area.

February 2016 

The article below is in the February Newsletter

• Profitability / Energy Efficiency Improvement
  
  Every facility owner is very interested in  maximizing their profits.  With energy consuming a substantial portion of a petroleum refinery's or petrochemical plant's operating costs, the range of effort required to address this can vary significantly.  At Carmagen Engineering, Inc. (CEI), we're committed to the cause of improving energy profitability/efficiency in a cost effective manner.  We typically advise our clients not to jump into time and resource-intensive programs head first, but rather to take a phased approach.  We first focus on a few major opportunity areas based on our experience to reap the "low cost/no cost" opportunities first, and also identify/prioritize areas that are worthwhile for more detailed analysis.

January 2016 

The article below is in the January Newsletter

• Finding the Reliability - Maintenance Sweet Spot
  
  Benchmarking consultants provide information suggesting your maintenance costs and availability are not competitive.  Many tell you that you can reduce maintenance costs and increase availability.  This often seems counterintuitive particularly when they don't tell you how to make such improvements except in general terms.  Senior Management is eager to capitalize on cost reduction while reliability and operations personnel are concerned about operational shutdowns and surprises.

November 2015 

The article below is in the November Newsletter

• The Business of Engineering and Science Consulting - Part Three
  
  Since there has been a lot of interest in this series of articles, here are the last four rules that we thought were important to the building of our consulting business.

 

October 2015 

The article below is in the October Newsletter

• The Business of Engineering and Science Consulting - Part Two
  
  Since there has been a lot of interest in this series of articles, here are the next four rules that we thought were important to the building of our consulting business.

September 2015 

The article below is in the September Newsletter

• The Business of Engineering and Science Consulting
  
  I have threatened to write an article for this newsletter for years, thinking that our engineers and scientists would keep writing articles just to make sure I didn’t do it. Well – today is the big day, and I like the idea of writing an article.
  
  First off, please understand that I am NOT an engineer or scientist – my college major was psychology. That being said, since I have been with Carmagen since its inception some 28 years ago, I can actually talk some engineering and know who to go to when I need help. I know what corrosion holidays are (thanks, Jack), I know what some process solutions look like (dark beer, light beer or was it coffee, coffee with cream – thanks, Paul), and I can discuss tank bottom foundations, sand, gravel, concrete (thanks Roger and Vince). Second, this is not the typical technical article normally found in our newsletter and website.
  

June 2015 

The article below is in the June Newsletter

• Process Safety Management of Highly Hazardous Chemicals - Part 3
  
  This brief article is a continuation of prior articles on Process Safety Management (PSM) to provide information on requirements to minimize unexpected or accidental releases of toxic, reactive, and hazardous chemicals listed in the OSHA PSM Standard (1910.11), and to prevent potential disasters from occurring.  Information was largely obtained from the source documentation.  This brief article focuses on process hazard analysis (PHA) and operating procedures pertinent to PSM.

May 2015 

The article below is in the May Newsletter

• Process Safety Management of Highly Hazardous Chemicals - Part 2
  
  Further to Part 1, this brief article continues highlighting Process Safety Management (PSM) requirements to minimize the possibility of unexpected or accidental releases of toxic, reactive, or hazardous chemicals listed in the OSHA PSM standard 1910.119, and to prevent potential disasters from occurring.  It focuses on the elements of PSM, and information is largely obtained from the source documentation.

April 2015 

The article below is in the April Newsletter

• Process Safety Management of Highly Hazardous Chemicals - Part 1
  
  A dreaded scenario for any company that works with highly hazardous substances is an incident that results in death, injury, and/or economic loss.  Several catastrophes have occurred in recent years, such as the accidents in Bhopal, India (1984), Norco, LA (1988), Pasadena, TX (1989), and Texas City, TX (2005) to mention a few.

March 2015 

The article below is in the March Newsletter

• Changes Contained in the 10th Edition of API 510, Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and Alteration
  
  The 10th Edition of API 510 was issued May 2014 and replaces the 9th Edition.  The following summarizes several of the key changes.  Please refer to the original document for details.

February 2015 

The article below is in the February Newsletter

• Top Ten Ways to Prepare for a Semi Regenerative Catalytic Reformer Regeneration
  
  Because semi regenerative catalytic reformers are regenerated so infrequently, it is critical to thoroughly prepare in advance and train personnel responsible for implementing the procedure.  Preparation and training increase the probability of optimized unit performance after oil in, and reduce the probability of delays, additional downtime, and incidents that can result in equipment reliability issues.

January 2015 

The article below is in the January Newsletter

• Top Ten Tips for Tower Troubleshooting
  
  Not all towers are the same, but they share some fundamentals.  The troubleshooting tips listed below can be used across a wide variety of towers to help bring about an efficient resolution to most problems. 

December 2014 

The article below is in the December Newsletter

• Ten Ways to Achieving Successful Turnarounds
  
  Turnarounds are the single biggest annual maintenance expenditure that a process plant can experience and have a major effect on future operations and safety.  Therefore, they need to be executed in an efficient and effective manner.  The following lists ten key areas that need to be addressed to achieve a "World Class" turnaround.

November 2014 

The article below is in the November Newsletter

• Top Ten Ways to Specify and Buy Reliable Centrifugal Pumps
  
  The following summarizes the top ten ways to specify and buy reliable centrifugal pumps. 

October 2014 

The article below is in the October Newsletter

• Top Ten Ways to Improve Catalyst Performance
  
  In-service catalyst deactivation is unavoidable, and poisoning incidents compound the problem.  The goal in catalytic processing is to minimize catalyst cost in ¢/bbl of feed while achieving process targets (conversion, selectivity, etc.) over the useful life of the catalyst.  Thus catalyst "management" is key to maximizing unit profitability.

September 2014 

The article below is in the September Newsletter

• Top Ten Ways to Control Corrosion in Process Plants
  
  Corrosion in industrial facilities in general, and process plants in particular, is a costly degradation mechanism.  It could also have safety, environmental, and equipment reliability consequences should it result in a loss in pressure containment.  Listed below are the top ten ways to control corrosion in process plants.

June 2014 

The article below is in the June Newsletter

• Top Ten Ways to Improve Fired Heater Efficiency
  
  Carmagen's April 2014 newsletter identified the Top Ten Ways to Increase Site Energy Efficiency.  This companion article focuses on improving fired heater efficiency.  Note that many of the items listed below can be done at no or minimal capital cost, and could yield significant fired heater efficiency improvement.

May 2014 

The article below is in the May Newsletter

• Top Ten Ways to Improve Mobile Crane Safety
  
  Mobile crane safety is an important aspect of overall construction safety as evidenced by the recently issued OSHA regulations in 29 CFR 1926.1400, Subpart CC - Cranes and Derricks in Construction.  Listed below are ten ways to improve crane safety on your site.

April 2014 

The article below is in the April Newsletter

• Top Ten Ways to Increase Site Energy Efficiency
  
  Assuming operational efficiency improvements have been realized to a large extent, further increases in site energy efficiency are accomplished via implementation of modest, incremental capital investment opportunities.  An energy loss analysis is conducted to quantify energy lost to air / water cooling followed by Process Flow Diagram brainstorming reviews to identify potential capital projects that will reduce fired heater and boiler fuel consumption.

March 2014 

The article below is in the March Newsletter

• Top Ten Ways to Improve Reliability and Control Maintenance Costs
  
  Decisions regarding reliability and maintenance can have a measurable impact on both maintenance costs and reliability in any plant.  The following lists ten key areas that can help you achieve positive results.

February 2014 

The article below is in the February Newsletter

• Plant Visitation to Assist Process Technology Selection
  
  Frequently when a refining company decides to pursue installation of a new or unfamiliar process technology in their facilities, they go through technology screening, bid solicitation, and rigorous technical and commercial evaluations to arrive at the best choice. Part of the evaluation may be to visit existing plants that are of similar design, style, and capacity to the target design of interest. Sometimes the visit may follow shortly after selection, if the client is more aware of the licensor design specialties, issues, etc. In other cases, the visit may occur before selection to assist in the decision process. The licensor or contractor usually arranges visitation meetings and a unit walk-thru at the sites.

January 2014 

The article below is in the January Newsletter

• Some Tips for Shell Thickness Evaluations of In-Service Aboveground Atmospheric Storage Tanks - Part 2
  
  An earlier article introduced the basic equations used in API-653 to determine whether the shell thickness of in-service aboveground atmospheric storage tanks is acceptable for continued operation.  It highlighted several items that inspectors and engineers should be aware of, and help avoid being overly conservative.  This article highlights several other items.

November 2013 

The article below is in the November Newsletter

• Galvanizing Isn't Always a Good Way to Stop Corrosion
  
  Galvanizing is widely used as a way to prevent corrosion of structural steel, and for piping used in water service.  A layer of zinc is applied to the surface of the steel, usually by dipping the component into a bath of molten zinc.  Zinc is anodic to steel, and, at any exposed areas of the steel, it provides sacrificial cathodic protection when the steel is exposed to aqueous corrosion.  It is this galvanic protection at breaks in the coating that makes galvanizing such a useful and widely-used corrosion control measure.

October 2013 

The article below is in the October Newsletter

• Integrity Operating Windows
  
  Integrity Operating Windows establish a safe operating regime for equipment and can be used to trigger a Management of Change review of any changes that might reduce equipment integrity.  They can also define limits beyond which short term operation is possible, and to set a safe operating period beyond which corrective action is required.

September 2013 

The article below is in the September Newsletter

• Changes to API 650, Twelfth Edition - Welded Tanks for Oil Storage
  
  Three addenda were issued for the Eleventh Edition of API 650 in 2008, 2009, and 2011 since it was first published in June 2007.  The Twelfth Edition of API 650 was published in March 2013.  The following highlights several of the changes that were made and is not all inclusive.  Refer to API 650 for complete information.  One general comment is that sections that were previously called "Appendix" are now called "Annex."

August 2013 

The article below is in the August Newsletter

• Pipeline Reliability Risk Assessment
  
  Carmagen Engineering, Inc. recently conducted a study for an overseas client to identify the risk associated with a change in quality of gas fed to a natural gas pipeline.  The corrosion impact of the change in gas composition was evaluated using published data and gas compositions and operating data supplied by the client.  The resultant change in risk was assessed considering a range of damage scenarios according to the methodology defined in ASME B31.8S.  This standard covers managing integrity of onshore pipelines that handle nominally dry gas. 

June 2013 

The article below is in the June Newsletter

• Unsaturated Gas Plant Retrofit Concepts
  
  Refinery processes, such as coking and catalytic cracking, produce substantial quantities of sour gases.  Unsaturated gas plant feeds are largely comprised of paraffinic and olefinic light hydrocarbon components, such as C₂'s and lighter, C₃ - C₄, plus some C₅ and naphtha, H₂S, and other light material.  C₃'s and C₄'s can be recovered as separate streams, or as LPG, since these streams represent saleable hydrocarbon products of considerable value.

May 2013 

The article below is in the May Newsletter

• Some Tips for Shell Thickness Evaluations of In-Service Aboveground Atmospheric Storage Tanks - Part 1
  
  The original required design thickness of an aboveground atmospheric storage tank shell is determined based on the hydrostatic head of liquid in the tank.  The hydrostatic head produces circumferential and longitudinal stresses in the shell, and the shell thickness is selected to keep these stresses within safe, allowable limits.  This approach is analogous to determining the minimum required thickness of a pipe or pressure vessel due to internal pressure.

April 2013 

The article below is in the April Newsletter

• Underground Obstructions
  
  Underground obstructions are any buried object or obstacle that interferes with our completing planned work.  Some common underground obstructions are production lines, fire water lines, cooling tower water lines, electrical feeders, communication cables (fiber optic cables, phone lines, instrumentation lines), bell pile bases, and foundation footings.
  
  In a "Greenfield" project, coming into contact with most of these objects, provided the unit hasn't been commissioned, generates impacts that are primarily limited to cost and schedule. 

March 2013 

The article below is in the March Newsletter

• Crude Oil Entrainment of Settled Water in Arabian Light/Medium/Heavy Pipelines
  
  The existence of free water, i.e., liquid, as a separate phase in the bottom section of flowing or stagnant crude oil lines is of prime concern.  This free water phase provides the electrolyte necessary for the progression of various forms of corrosion, utilizing the corrosive agents most typically found in the crude oil, such as hydrogen sulfide (H₂S).  Besides the more benign or tolerable "general corrosion" caused by H₂S, both sulfide stress corrosion cracking (SSCC) and hydrogen induced cracking (HIC) may also occur, with their potential for leading to unexpected, catastrophic failure of the crude oil line pipe. 

February 2013 

The article below is in the February Newsletter

• Shell Repairs to Aboveground Atmospheric Storage Tanks Using Lap-Welded Patch Plates
  
  API-653, Tank Repair and Alteration, intends that repairs and alterations made on Aboveground Atmospheric Storage Tank (AST) result in general equivalence to API-650 requirements.  Section 9 of API-653, contains specific requirements that are intended to meet this objective.  After the AST has been in service for some time, thinning due to corrosion may require that sections of the shell be repaired in order for the tank to have adequate strength for its next period of operation.  Such repairs are generally done by installing insert plates into the shell using full-thickness butt welds. 

January 2013 

The article below is in the January Newsletter

• Revamp Screening Studies
  
  In the early phases of revamp project conceptual engineering, it is usually beneficial to perform screening-type studies to explore  various approaches or potential options in order to achieve the desired objectives.  It is also advantageous to understand the salient factors/drivers that may validate facilities upgrade strategy.  Further, such activities can quickly reveal the complexity, potential ramifications, and preliminary economic differentials for implementing a specific option or change relative to other paths. 

November/December 2012 

The article below is in the November/December Newsletter

• How Safe Are Your Docks?
  
  Every year incidents at Marine Terminals cost operating companies hundreds of thousands of dollars in downtime, equipment replacement, and environmental clean-up costs.  Outdated marine terminal facilities may also result in longer tanker loading or unloading times which translate to increased costs and potential increased rates.  More importantly, many personal injuries and fatalities have occurred which may have been avoided with the right equipment and operatng procedures in place. 

October 2012 

The article below is in the October Newsletter

• Aboveground Atmospheric Storage Tank Bottom Plate Corrosion
  
  The required internal inspection interval of an Aboveground Atmospheric Storage Tank (AST) must be determined based on corrosion rates measured during previous inspections or anticipated based on experience with similar tanks in similar service.  Bottom plate corrosion normally controls the required internal inspection interval, and this corrosion may occur both from the top side and the underside. 

September 2012 

The article below is in the September Newsletter

• Using Single Blend Optimizer to Quickly Maximize Bunker Profits
  
  In the current global economic downturn, we can increase profit margins in the face of constantly increasing fuel and operating costs by using a bunker blend optimization tool.  By optimization, we mean maximizing profit, and as such, money has to be explicitly included in blend optimization calculations. 

June 2012 

The article below is in the June Newsletter

• What Makes Outstanding Negotiators Outstanding?
  
  Negotiating is persuading the other party to accept your way ... and for them to feel satisfied with the outcome.  Negotiating is a critical business (and personal) skill ... which can be learned and improved.  Why are some people consistently very successful in their negotiations, while other people achieve only average results?  Outstanding negotiators have certain characteristics that differ from those of other negotiators. 

May 2012 

The article below is in the May Newsletter

• Changes in API 653, Tank Repair, Alteration, and Reconstruction
  
  Two addenda have been issued for the Fourth Edition of API 653 since it was published in April 2009.  Addendum 1 was issued August 2010, and Addendum 2 was issued January 2012.  The following highlights several of the changes that were made and is not all inclusive.

April 2012 

The article below is in the April Newsletter

• Petroleum Coke Formation
  
  Unwanted coke formation in high temperature petroleum processing can result in significant effects on unit performance such as:
  • Flow constriction in pipes and vessels
  • Blockages on grids, sheds, and trays
  • Increased back pressure on fixed catalyst beds
  • Decrease in heat transfer efficiency (especially for fired heaters and heat exchangers)

These problems will not only reduce unit productivity but may also increase the frequency and duration of unit turnarounds.

March 2012 

The article below is in the March Newsletter

• Licensor Technology Selection
  
  Proper refinery or process facility planning often necessitates the use of third-party licensed technology to enhance the client's project objectives, which typically target optimized performance, safe and reliable operation, and maximized profitability.  Most selections are typically handled as separate technical and commercial evaluations by experienced staff proficient in that area.

February 2012 

The article below is in the February Newsletter

• Canadian Oil Sands - Challenges and Opportunities
  Mining, Separation, Upgrading
  
  "Alberta's oil-sands region is awash with companies from Japan, South Korea, China and Norway, as well as big international players like Royal Dutch Shell PLC and BP PLC – all competing for access to an estimated 170 billion barrels of oil recoverable using current technology.  Alberta is now second only to Saudi Arabia in recoverable oil reserves, thanks to improvements in technology and higher oil prices that have made the labor-intensive oil-sands projects more economical.  The oil sands represent a unique opportunity for investors.  Of all the oil currently produced in the world, five out of six barrels are state-owned or state-controlled.  Of the portion that remains – oil available for public investment – half is in Canada’s oil sands.”  (Edward Welsh in the Wall Street Journal, November 29, 2010).  The American Petroleum Institute has broadcast a series of radio advertisements supporting the growth of the oil sands industry suggesting that 300,000 American jobs will be created in support of this growth.  Construction of the Keystone Pipeline, a $7 Billion investment, if built, will bring Athabasca oil to the Gulf Coast.

January 2012 

The article below is in the January Newsletter

• Nano Refining
  
  The popular perception of a petroleum refinery generally conjures up images of large-scale towers, vessels, reactors, pumps, and compressors facilitating processes measured in thousands of barrels or tonnes of crude oil, steam, and derived products.  What is less appreciated is how much of modern refining is pinioned on the use of materials whose functions can only be properly understood and controlled by delving into the world of the very small.  That refineries operate today at a high efficiency, can largely be attributed in good part to a shift from property-based processing, reliant on bulk measures such as viscosity, boiling point, pour point and color, into refining strategies tuned to transformations at the molecular level enabled by new materials.  Modern refining is the confluence of macro-scale engineering with nano-scale catalytic chemistry.

November 2011 

The article below is in the November Newsletter

• Product Quality and Energy Use Improvements Through Better Process Control
  
  After a plant has been built, it has a control system that reflects the "state of the art" at the time of construction and commissioning.  It then typically operates with the "as built" controls for many years.  In a complex refinery or chemical plant, many process units are typically added or modified over a number of years.  So, we end up with field instrumentation, controls, and control rooms that are probably very dissimilar.  This leads to the usual maintenance challenges because we must deal with many different product vendors, spare parts that are becoming harder to get, and often find ourselves in a situation where modern network technologies cannot be used to extract and store process data for archiving and analysis.  In addition, there may be too many control rooms that require significant upkeep, and that do not meet current "best practices" standards.

October 2011 

The article below is in the October Newsletter

• Proprietary CTI
  
  In the July 2011 issue of the Carmagen eNews, George Swan introduced the use of Competitive Technology Intelligence (CTI) as an important element in developing a good business plan.  That article focused on patent searching and systematic (computerized) evaluation of technical threats to a commercial position.  Consideration of patent timing, intensity, and focus can lead to a "map" of competitor Intellectual Property (IP) strategies.  This article continues to examine CTI tools focusing on the use of non-patent sources to determine how IP fits into competitor strategies.

September 2011 

The article below is in the September Newsletter

• Designing Delayed Coker Drums to ASME VIII Division 2
  
  Coke drums in delayed coker units are pressure vessels that are used in the oil sands and conventional petroleum refinery processing industries for the thermal cracking of reduced bitumen to recover additional saleable gas and liquid product streams.  The drums are typically constructed to the requirements of ASME VIII Division 1, although they are in a low cycle, thermal-mechanical service environment.  Recent practice has been to introduce design by analysis considerations from ASME VIII Division 2, even though service temperatures of the actual equipment exceed the design limits of the Division 2 Code [1, 2].

August 2011 

The article below is in the August Newsletter

• Calculating Safety Valve Fire Relief Loads for Multicomponent Systems
  
  According to the ASME Code, pressure vessels must be protected against overpressure caused by exposure to external fires.  When a vessel containing liquid is exposed to an external fire, the contained liquid will vaporize and, potentially, cause the vessel pressure to exceed its maximum allowable working pressure unless the resulting vapor is relieved at a flow rate equal to the vapor generation rate.

July 2011 

The article below is in the July Newsletter

• Competitive Technology Intelligence (CTI):  Surveying the Competitor Landscape
  
  An important element of good business plans is knowledge of the competition, not only their current operations but also probable future trends.  This is particularly relevant for the refining and chemical process industry where technology evolution is critical to improving profitability.  Benchmarking against the competition provides a basis for key investment decisions, but benchmarking is often a formidable task since the required information is not easily accessible.  However, over 90% of valuable competitor technology insights may be found in the public domain; the challenge is to collect "intelligence" from multiple sources and then fit the pieces of the puzzle together to create a unified picture of the competitor landscape.

June 2011 

The article below is in the June Newsletter

• About Compressor Drivers in Gas Production and Transmission Applications
  
  Gas compressors that are used in natural gas production and transmission applications are fundamentally of two types:  positive displacement and centrifugal or turbo-compressors.  Displacement compressors are reciprocating or rotary screw machines.  Displacement compressors are designed to move relatively small quantities of gas at high pressure differentials.  Smaller and medium sized reciprocating compressors, and for smaller gas flows lately, rotary screw compressors are applied in gas production and gathering where high pressure differentials are required.  Turbo-compressors convey gas in large quantities with a relatively low pressure rise.  Larger size turbo-compressors have been mostly utilized in long distance transmission services.

May 2011 

The article below is in the May Newsletter

• Logistical Forensics
  
  Logistics, the flow of petroleum crude movements and product distribution, plays a major role in refinery operations.  Logistical problems cause refiners' nightmares.  If precipitates overwhelm desalters, then flows may need to be reduced in the entire refinery.  If a process stream is contaminated, then blended products may be off spec.  If a delivered product is unacceptable to customers, then entire distribution systems may get backed up.  Because any of these problems may be related to contamination or process failures, they may be subject to litigation.  In such cases, determination of responsibility falls to "logistical forensics."

April 2011 

The article below is in the April Newsletter

• Biodiesels - What are They?
  
  Three distinct types of biodiesels form the bulk of what is available today:
  
  • Fatty Acid Methyl Esters (FAME) or Fatty Acid Ethyl Esters (FAEE)
  • Hydrogenated Biomass (Vegetable or Animal Fat) Oils Biodiesel
  • Gasified Biomass Fischer-Tropsch Synthesized Biodiesel
  
  Biodiesels are also categorized by "generations," where FAME-type biodiesels are the 1st generation, while the hydrogenated biomass oil and Fischer-Tropsch diesels are part of the 2nd generation.

March 2011 

The article below is in the March Newsletter

• Increasing Fired Heater Thermal Efficiency
  
  Increasing the thermal efficiency of a Fired Heater reduces the heater's carbon footprint and operating costs.  For example, assuming a Fired Heater with a heat release of 100 MBTU/hr, an increase in efficiency of 1% will result in a savings of $38K/yr at a fuel cost of $4 per MBTU. 

February 2011 

The article below is in the February Newsletter

• Lowering Your Facility's Carbon Footprint
  
  A facility's carbon footprint is related to the CARBON emitted to the atmosphere.  There has been pressure in recent years to lower the amount of carbon emitted from industrial facilities.  Expectations are that this pressure will continue via increasingly stringent legislative mandates that facilities must meet. 

January 2011 

The article below is in the January Newsletter

• Evaluate New Machinery Purchases Using Life Cycle Costing Tools
  
  Capital costs of new projects attract the most attention of both management and vendors.  However, it must be recognized that operating and maintenance (O&M) expenses are also as significant.  Unfortunately, evaluating the total cost of ownership of a plant asset on a common basis with the capital cost is difficult:  so managers tend to give priority to initial cost.  In extreme cases, the potential O&M costs might not be considered at all when specification and purchasing decisions are being made and are driven only by initial capital cost and schedule considerations.  Consequently, poor reliability and performance of our machinery equipment do not show up until the plant is actually up and running.

October 2010 

The article below is in the October Newsletter

• Process Operating Stress Test (POST) = Pathway to Improved Unit Profitability
  
  The first step toward maximizing process performance is to assess the overall “health” of the existing operation.  Analogous to cardiac stress testing, methodology is available for systematically testing refinery or chemical process units, and extending their normal operating envelope.  The Process Operating Stress Test (POST) protocol comprises a series of incremental changes in process variables (typically targeting higher severity operation) which results in corresponding responses of key process parameters, e.g., conversion, yields, etc.  Statistical analysis of these responses facilitates diagnosis of probable process limitations and sets the stage for developing both optimization and unit debottlenecking strategies.  An important outcome is also a blueprint for addressing identified process constraints.

September 2010 

The article below is in the September Newsletter

• Are Large Amendments Needed for Our Rotating Equipment Specifications?
  
  I heard the complaints of several technical managers of an EPC (Engineering, Procurement, Construction) company.  There were complaining about the proliferation of voluminous technical specifications for rotating equipment:  reams and reams of paper in addition to commonly used industry standards.  They felt that there were frequent duplications and contradictions in such specifications, frustrating them or the vendors, and causing costly delays.  While these specific complaints were directed towards rotating equipment specifications, especially for compressors, the same can often be said for other equipment specifications (e.g., pressure vessels, heat exchangers, storage tanks, etc.).

August 2010

The article below is in the August Newsletter

• Preservation of Process Machinery
  
  In the early nineties, a decommissioned and subsequently mothballed fertilizer plant located in the United States was purchased, dismantled, and reconstructed at a location half way around the world.  When I visited this plant about 10 years after it was restarted at its new location, it was producing fertilizer at a fraction of the investment cost of a brand new plant.  This attested to good storage protection because the plant had sat idle for a considerable time before it was relocated.  This is just one example demonstrating that long-term storage protection of sensitive machinery such as compressors, pumps, and associated drivers saves money.

July 2010

The article below is in the July Newsletter

• Agitated Vessel Heat Transfer Design
  
  There has been continued growth of refinery-based downstream processing involving petrochemicals, polymers and specialty chemicals such as lube oil additives, high impact, crystal and expandable polystyrenes, certain synthetic fibers, vat dyes, wire enamels, automotive/airplane plastics, etc.  Therefore, the ability to design for types of equipment not typically associated with refinery units is now considered to be a useful tool for the hydrocarbon processing engineer.  Such a design area involves heat transfer in agitated vessels such as Continuous Stirred Tank Reactors (CSTRs) or in Batch Operations.

June 2010

The article below is in the June Newsletter

• Engineering Coordination Tips During Front-End Engineering Design
  
  This might be a statement of the obvious to many, but it's surprising how often some fundamental coordination tips for successful front-end engineering design and execution are forgotten under pressure.  There can be exceptions and additions to any project; so, these tips are not all inclusive.  This article hopes to provide a checklist for such work and why we need to remember.

May 2010

The article below is in the May Newsletter

• Opportunities for Refinery and Petrochemical Plant Integration
  
  Changes in the transportation fuels industry, dictated by environmental and political pressures, will significantly impact the demand for conventional refinery fuel products and put increased pressure on refining margins.  However, refinery facilities are valuable assets that can be used for the co-production of products other than conventional transportation fuels.  As capacity is freed-up by reduced demand for conventional refinery fuels, more opportunities become available for production of such alternate co-products.

April 2010

The article below is in the April Newsletter

• Calculating Blending Profitability
  
  In the current uncertain economic environment, it is extremely important to determine how much money, if any, you make on every barrel of blended product.  The basic principle is simple.

March 2010

The article below is in the March Newsletter

• Changes to API 650, Eleventh Edition – Welded Steel Tanks for Oil Storage
  
  Two addenda have been issued for the Eleventh Edition of API 650 since it was published in June 2007.  Addendum 1 was issued November 2008, and Addendum 2 was issued November 2009.  The current article highlights several of the changes that were made and is not all inclusive.  Refer to API 650 for complete information.

February 2010

The article below is in the February Newsletter

• Fluid Cat Cracking – Still a Profitable Refining Process
  
  In the current climate of significantly reduced refining margins, it is critically important to maintain perspective and emphasis on the areas that still produce a good financial return. Fluid Catalytic Cracking (FCC) has been, and remains, one of the most important and most profitable processes in a refinery operation.

January 2010

The article below is in the January Newsletter

• Are you Ready for the Future?
  
  In today's environment of excess capacity, poor profit margin, and capital restraint, should operating plants consider directing their efforts at optimizing process operations and improving reliability? Despite the current downturn and restrictions on expenditures, this is the best time to consider investing in the future. This can be achieved by identifying and resolving persistent reliability problems before utilization increases and profit margins improve.

October 2009

The article below is in the October Newsletter

• Methods to Determine Diesel Cetane Number
  
  ASTM recently published an updated ASTM D7170 test method for Derived Cetane Number (DCN) measurement using the ignition delay principle, which provides for an economical and reliable way to determine the diesel fuel cetane number.
  
  The cetane number is a very important property of diesel oils indicating the quality of the ignition of the diesel fuel (the higher, the better), somewhat analogous to octanes for gasoline.

 

September 2009

The article below is in the September Newsletter

• Effective Lump Sum Contracting
  
  Many project management professionals believe that properly administered engineering, procurement and construction contracts awarded as the result of competitive lump sum bidding can save an owner up to 10 percent vs. reimbursable cost contracts when market conditions are favorable for lump sum.  This has been proven in an examination of contract performance over the last century.  But... and there are a few significant "buts"... the market conditions must enable the assembly of a competitive slate of qualified bidders committed to the lump sum, and the bidding development, commercial and technical bid conditioning review, contract award, and the administration of the contract must be done in a professional manner.

August 2009

The article below is in the August Newsletter

• Making or Saving Money in Non-Process Engineering Areas for Petroleum Refineries
  
  This is part two of our series on making and/or saving money in refineries.  What is your best cost-effective tip for refineries is a question we posed to our 180+ engineers.  The majority of our engineers have 35+ years of experience, so they know what they are talking about.  This article contains their answers for the non-process engineering side of the refining industry.  There are several "repeat tips" from our first article, since they also apply to the non-process engineering area.

July 2009

The article below is in the July Newsletter

• Independent Project Reviews
  
  For major capital projects, structured reviews of progress and planning are often done at significant milestones/transition points to validate activities as being consistent with project objectives.  This article provides a summary of the Independent Project Review Process, which is a key element to successful capital project execution. 

June 2009

The article below is in the June Newsletter

• Making or Saving Money in Process Engineering Areas for Petroleum Refineries
  
  What is your best cost-effective tip for refineries is a question we posed to our 180+ engineers.  The majority of our engineers have 35+ years of experience, so they know what they are talking about.  The following are their answers for the process engineering side of the refining industry.  There will be another article that will cover this topic for the non-process side of the industry as well.

May 2009

The article below is in the May Newsletter

• Research Reality (Part 2): Limitations of Model Compound Research
  
  In Part I of this series on "research reality", we summarized the factors that limited the application of laboratory research to engineering models (the Chemical Research Space - Figure 1).  To probe process phenomena, research experiments are based on model compounds in a constant matrix.  In this part of the series, we elaborate on the factors that affect the choice of model compounds for both upstream and downstream petroleum research.

April 2009

The article below is in the April Newsletter

• Article 4 - API 579-1 Fitness-For-Service (FFS) - Pitting Assessment
  
  Pitting corrosion is evaluated differently than general corrosion. This article discusses the evaluation of widely scattered pitting using API 579-1/ASME FFS-1 2007 Fitness-For-Service Level 1 assessment procedures.

March 2009 

The article below is in the March Newsletter

• Fuel Reduction Projects for Steam Systems
  
  With today's high cost of fuel, an audit of your steam facilities offers an opportunity for significant dollar savings by recovering heat now discharged as waste. Six areas which offer significant energy and fuel savings are discussed.

September 2008 

Below is a list of articles in the September newsletter

• 2008 - A Great Year for Holidays
• Lightning Protection for Instrumentation
• 2008 Survey of Blending On-Line NIR Analyzers

May 2008 

Below is a list of articles in the May newsletter

• Changes in API 650, Welded Steel Tanks for Oil Storage
• Article 3, API 579-1 Fitness for-Service (FFS) - Nozzle Assessment
• Changes in API 653, Tank Inspection, Repair, Alteration, and Reconstruction

February 2008 

Below is a list of articles in the February newsletter

• Research Reality
• Article 2 - API RP 579 Fitness-for-Service
• Process Plant Bad Actor Program

December 2007 

Below is a list of articles in the December newsletter

• The Ten (Actually Twelve) Commandments for Achieving Successful Turnarounds
• Fluid Catalytic Cracking Unit Flue Gas and Transfer Line Refractory Lining System Development
• Those Stinkin' Mercaptans … They're Back

September 2007 

Below is a list of articles in the September newsletter

• It's in Refiners' Interest to Train New Blending Engineers Fast
• OSHA Announces Increased Emphasis on Petroleum Refineries
• Article 1: Reduce Your Maintenance Costs With Fitness-For-Service (FFS) Assessments

June 2007 

Below is a list of articles in the June newsletter

• Changes Contained in Addendum 4 of API 570:Piping Inspection Code
• Changes Contained in the 9th Edition of API 510: Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair and Alteration
• Achieving Full Reliability of Typical Bad Actor Heat Exchangers in Crude Units, Catalytic Reformers, and FCCUs

March 2007 

Below is a list of articles in the March newsletter

• A Realistic Approach to Weldor Training and Testing
• Does Your Plant Have A Turnaround Manual?
• Experience With 100% Mechanical Reliability of Refineries' Bad Actor Heat Exchangers
• Calculating the Potential Surge Pressure in Liquid Filled Piping Systems

December 2006 

Below is a list of articles in the December newsletter

• Computerized Inspection Management Systems
• Changes Contained in Addendum 2 of API 653, Tank Inspection, Repair, Alteration and Reconstruction
• Changes in API 650, Welded Steel Tanks for Oil Storage
• Cost Management - Part 3 Data Collection and Analysis

September 2006 

Below is a list of articles in the September newsletter

• Cost Management - Part 2, Cost Control
• Risk Based Inspection
• How FCCU Trickle Valves Affect Catalyst Losses - Part 2

June 2006 

Below is a list of articles in the June newsletter

• Cost Management - Part 1
• NIR Analyzer Precision Targets for Gasoline Blending Applications
• How FCCU Trickle Valves Affect Catalyst Losses - Part 1

April 2006 

Below is a list of articles in the April newsletter

• Transition in the Chemical Industry
• Significant Energy Savings Achievable Even At "Smaller" Refineries
• Invention Disclosures and Documentation
• Training the Current and Next Generation of Refinery Engineers

February 2006 

Below is a list of articles in the February newsletter

• Guidelines Will Enable Determination of Unknown Loss in Refineries and Terminals Promoting Closure of Mass/Volume Balances
• Managing Boiler Water Treatment Steps is Critical
• The Choice is Yours … Protecting Proprietary Technology

November 2005 

Below is a list of articles in the November newsletter

• Application of Temperature Activated Relief Devices
• Part 2 - How to Develop NIR Property Models That Work
• Special Safety Considerations for Hot Tapping

August 2005 

Below is a list of articles in the August newsletter

• Application of Temperature Activated Relief Devices - Part 1
• Comparing Knock Engines With NIR Analyzers for In-Line Blending
• Hot Tap Inspection Considerations
• Hot Tap Installation Considerations

May 2005 

Below is a list of articles in the May newsletter

• Applied Chemistry Puts Specialty Process Back On Track
• How Thick Does A Nozzle Neck Have To Be On An Existing API-650 Storage Tank?
• Hot Tap Location and Design Considerations
• Resonance and Magnification in Piping System Vibration

February 2005 

Below is a list of articles in the February newsletter

• Applied Chemistry Spans Molecules, Models, and Refinery Reality
• Controlling Piping System Vibration
• Hot Tap Guidelines

December 2004 

Below is a list of articles in the December newsletter

• Unit Integrity Audit - the "Carmagen Engineering" Way
• Screening Piping Vibration Problems
• More Energy Efficiency Improvement Tips
• Can You Afford Not to Apply R&M Principles On Your Next Capital Project?
• Hot Bolting for Flange Leakage Control

October 2004 

Below is a list of articles in the October newsletter

• How Much Cash Is Going Up In Smoke?
• Common Causes of Flange Leakage
• Common Causes of Piping Vibration

July 2004 

Below is a list of articles in the July newsletter

• Fouling and Plugging Cause High Reactor Pressure Drop and Premature Shutdown in Hydroprocessing Units
• Flange Joint Assembly and Bolt-up Procedures
• Flange Bolt Tightening Methods
• All About Nickel Alloy Welding Electrodes

March 2004 

Below is a list of articles in the March newsletter

• Thoughts On Crane Safety & Prequalification of Suppliers
• Assessing the Creep Life of FCCU Internals
• New Appendix G of API-653 Provides for Tank Bottom Inspection Qualification Guidelines
• New Requirements for Welded-on Plates to Storage Tank Bottoms

September 2003 

Below is a list of articles in the September newsletter

• Processing High TAN or Corrosive Crudes
• Let Weld Metal Match Base Metal
• Contemporary Problems in Blending Automation
• Vaccinate Against the Tube-to-Tubesheet Plague

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