Confidential Client
Midwest USA
Refining
Innovative Design Enhances Reliability During FCC Furnace Replacement
Overview
A major Midwest refinery undertook a critical furnace replacement project as part of its ongoing commitment to safe, reliable, and environmentally responsible operations. Refineries play a vital role in producing transportation fuels and other essential products that support commercial, industrial, and consumer markets throughout North America. Maintaining the reliability and efficiency of key process units is essential to ensuring consistent production and long-term operational performance.
As part of a broader modernization effort, the client elected to replace an aging furnace serving a fluid catalytic cracking (FCC) unit. The existing furnace was approaching the end of its operational life and required replacement to improve long-term reliability while supporting environmental objectives, including reduced nitrogen oxide (NOx) emissions.
Nexus Engineering Group was engaged to provide multi-discipline engineering and design support for the project. The primary objective was to develop a replacement furnace design that would seamlessly integrate with existing operations while improving process reliability, maintaining safety system integrity, and supporting efficient plant performance. The project scope included process, mechanical, piping, instrumentation, electrical, and structural engineering services required to support successful implementation of the new furnace system.
Challenge
While developing the replacement design, the project team identified a significant operational challenge associated with the furnace's draft pressure measurement system.
Draft pressure instrumentation is a critical component of the facility's safety instrumented systems (SIS) and plays an important role in maintaining safe furnace operation. These instruments continuously monitor furnace pressure and support operational controls that help prevent unsafe operating conditions and unplanned unit trips.
Because the draft pressure instruments measure extremely small pressure differentials relative to atmospheric conditions, they are particularly susceptible to environmental influences. During engineering evaluations, the team determined that wind conditions could create fluctuations in the draft pressure readings, resulting in inaccurate measurements and reduced control stability.
These disturbances presented a unique challenge. Unreliable pressure data could negatively impact furnace performance, increase operating variability, and create unnecessary interactions with the SIS. Any solution needed to mitigate external influences without compromising instrument accuracy, system responsiveness, or compliance with refinery safety standards.
Compounding the challenge was the need to implement improvements within an active refinery environment where equipment reliability, operational continuity, and process safety remained top priorities throughout the project lifecycle.
Solution
Nexus developed an innovative engineering solution focused on improving the reliability and stability of the furnace draft pressure measurement system.
Through detailed analysis of instrument performance and environmental conditions, the team identified modifications that would reduce the impact of wind on pressure readings. The solution included strategic changes to the location and orientation of draft pressure transmitters, as well as the incorporation of shielding measures designed to minimize wind-induced pressure disturbances.
By addressing the root cause of measurement variability, the redesigned system significantly improved the consistency of draft pressure monitoring. The enhanced configuration provided more stable operating data to both the furnace control system and associated safety instrumented systems, reducing the potential for nuisance trips while improving overall furnace performance.
The successful implementation of these improvements helped ensure the new fluid catalytic cracking furnace could operate more efficiently and reliably under varying environmental conditions. The project demonstrated Nexus' ability to identify complex operational challenges, develop practical engineering solutions, and deliver value beyond traditional replacement scope. By combining process expertise, instrumentation knowledge, and a strong understanding of refinery operations, Nexus helped create a more robust and dependable furnace system that supports safe, long-term facility performance.
Services
- Process and Instrumentation Diagram (P&ID) Development
- Pressure Safety Valve (PSV) Documentation
- Mechanical and Instrument Installation Drawings
- Stress Analysis
- Instrument Data Sheet Development
- Power, Control, and Instrumentation Design
- Civil and Foundation Plans
- Multi-Discipline Engineering Coordination
- Safety Instrumentation Design Support
- Furnace Replacement Engineering
Project Director
