Enhance Coker Profitability by Conducting Periodic Audits

Historically, Pace Setter Petroleum Refineries conduct reviews/audits of their delayed coker units plus other major processing units every 3-5 years. These important surveys primarily address changes in processing feed stocks and production requirements as well as assessing application of new technologies to improve unit profitability.

• Site-specific coker unit evaluation (Cold Eye Review)
• A system called Photo-Logics to record and review the collected data.
• A written report with a firm direction towards Operator Driven Reliability (ODR)

Facilitate advancement to “Pacesetter Performance.”

The important qualifications are:

• Analysis from an owner’s perspective, as the site evaluator formerly was with major refining companies.
• Where possible, enhance plant identified potential improvements.
• Conduct an unbiased “cold eyes” evaluation, to generate new ideas.
• This site audit requires minimal but effective effort from plant technical and operations personnel.
• Obtain agreement/commitment from key plant personnel on worthwhile improvements identified by the audit.

Technical Issues Addressed in Audits

Important areas include:

• Current and future processing objectives and potential improvement opportunities.
• Review of key operating practices and procedures.
• Reliability assessment of key equipment performance and online maintenance.
• Incidents/near misses, their causes and corrective action taken.
• Capability of safety facilities and important reminder activities.

Evaluate

• Operator surveillance rounds by walking the rounds with operators and witnessing shift turnover.
• Operator depth of knowledge for equipment and up-keep.
• Depth of knowledge of the Delayed Coker process.

Inspect

• Safety equipment
• Auto start equipment
• Safety interlocks system (heaters, coke drum valves, un-heading)
• Fire protection
• Egress
• Housekeeping

Review

• Procedures and on-deck witness of these tasks: top and bottom drum un-heading, coke drum, switching, and coke drum drilling
• Operations routine duties (minor preventive maintenance)
• List of bad actors (reoccurring problems)
• Preventive maintenance program with schedule, task list, and history.
• Equipment status including age and up-keep.

Audit Incentives/Expectations

Overall incentives for conducting audits are increased profitability by:

• Higher on-stream production
• Improved yields
• Enhance plant personnel knowledge and performance
• Meaningful profitability results and other benefits
• Substantial no and low cost changes
• Reasonable potential investments are identified and priorities noted
• The cost of an Audit is normally recovered in 2-3 months

Our in-depth analysis evaluates potential improvements and establishes incentives for changes. Potential improvement opportunities can then be prioritized.
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