Digital Exclusive: Safety, stability and standards in the oil and gas industry
R. DUNCAN, Pall Corporation, Deland, Florida (U.S.)
As escalating global trade tensions and market uncertainty continue to impact U.S. oil and gas prices, it is vital that refineries use all the tools at their disposal to maximize operational efficiency. Recently proposed changes to API 560, a refinery standard by the American Petroleum Institute (API), aim to improve the condition of fuel gas supplied to refinery and petrochemical fired heaters used in multiple refining processes.
Refineries should see this as an opportunity to enhance their operational reliability and create safer working environments–a critical factor in an industry where accidents can have catastrophic consequences. By using the advanced filtration technology necessary to meet the updated standards, refineries will also experience cost efficiencies. Failing to deploy such technologies could leave refineries facing further financial pressure–a consequence to be avoided at a time of geopolitical instability.
Maximizing operational efficiency. Fire heaters are essential industrial devices that play a crucial role in several production processes in oil and gas refineries. They are used to heat oil and gas to specific temperatures for processing and purification, and they help to produce steam, which is used in various refinery operations.
The API 560 standard is expected to take effect later this year and will, for the first time, require compliance with Annex Q, a standard mandating that all refinery and petrochemical plant fire heaters use fuel gas filtration and separation equipment that filters out 99.98% of all solid particulates and liquid aerosols greater than 0.3 micrometers. For context, the diameter of a typical human hair ranges from about 17 micrometers–181 micrometers, demonstrating the stringent nature of the specifications. Currently, these specifications are just recommended practice, but the proposed changes will shift this to a mandatory requirement, introducing a new layer of accountability to ensure fuel gas systems achieve enhanced performance levels.
Adhering to these requirements significantly diminishes the potential risks of clogging and damage to critical heater components, reducing operational disruptions and unexpected downtime. Oil and gas companies often allocate 30%–40% of their annual budget to equipment maintenance and reliability efforts1; an hour’s downtime in the oil and gas sector can cost a refinery up to $500,000.2
Using advanced filtration technology to meet the updated standards would therefore enable refining facilities to enhance their productivity and profitability by minimizing unplanned outages. This approach would not only enhance the operational reliability of critical refinery equipment but would also contribute to its longevity, increasing efficiency and reducing costs in the long-term.
Creating a safer workplace. Ensuring that fire heaters are supplied with fuel gas containing minimal contaminants has the added benefit of enhancing safety. The accumulation of solid particles and debris can clog heater tubes and coils and reduce heat transfer efficiency, which causes overheating and increases the risk of fires. Contaminants such as sulfur compounds can also corrode heater components, leading to structural failures and leaks. Ultimately a malfunctioning fire heater can lead to uncontrolled combustion, resulting in fires or explosions. Having stringent safety measures in place is therefore paramount, primarily for onsite staff. Unfortunately, there have been numerous fatalities and injuries at refineries due to these issues, but enhanced safety standards should reduce the risk of such catastrophic events.
Contaminants can also cause incomplete combustion, releasing harmful gases such as carbon monoxide that can adversely affect the air quality. Exposure to these gases can lead to health issues such as headaches, dizziness and more serious issues such as respiratory problems. By facilitating cleaner combustion processes, advanced filtration that aligns with the new standards will help to notably reduce harmful emissions and ensure that workers can operate in a safe environment.
A reduction in unexpected combustion also helps protect refinery equipment. Cleaner operations generally require less corrective action and fewer repairs over time, resulting in lower maintenance costs and increased efficiency.
Embracing the opportunity ahead. The proposed mandatory adoption of Annex Q represents a significant advancement in the methods used to enhance the performance of fire heaters-a critical piece of the puzzle in the oil and gas refining process.
It is pivotal that refineries get ahead of the expected changes by acting now and aligning their current operational practices with the new enhanced requirements. Pre-emptive action will prevent last minute scrambles to meet the new demands and protect refineries against non-compliance risks.
As the industry navigates a tumultuous economic and geopolitical landscape, optimizing output and continuing to enhance workers’ safety through the deployment of advanced filtration technology is crucial to maintaining reliable operations and achieving sustainable growth.
LITERATURE CITED
1 Innovapptive, "Challenges of oil and gas equipment maintenance," July 26, 2024, online: https://www.innovapptive.com/blog/challenges-of-oil-gas-equipment-maintenance
2 Clements, P., "Oil and gas operators encouraged to adopt AI in light of rising costs," Hydrocarbon Engineering, September 2024.
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