JULIO R.

ZEVALLOS GUERRA
Belongs to Petroperu Corporation
It is located in the north of Peru, in Piura
department.
It was created in 1917.
CCC was built in 1974, under UOP license.
Main plants are:
Distillation Unit (65000 B/D)
FCC Unit (19000 B/D)
Vacuum Unit (29000 B/D)
Gas Recovery Unit



XI Catalytic Cracking Complex
Turnaround
It is divided in 4 Units:
Engineering: Equipment Inspection
Coordination and Cost: Maintenance Planning
Plant Maintenance: Maintenance Execution
Shops: Welding, Tool machines, Pump repair



XI Catalytic Cracking Complex
Turnaround
It is turnaround of Catalytic Cracking Complex
Includes following plants: FCC, Vacuum, Merox, Gas
Recovery, Utilities, CO Boiler, Salt Water Facilities
Organization includes 20 zones, such as:
Repair of CO Boiler
Replacements on reactor
Repair of rotating equipment
Repair of fractionating column
Repair of vacuum furnace



XI Catalytic Cracking Complex
Turnaround
Replacement of FV4 reactor cyclone with two
cyclones

Replacement of the stripper, adding 1 more
plate.

XI Catalytic Cracking Complex
Turnaround
CYCLONE:
Bad mechanical condition: Heavy damage on
anti erosion protection of the cyclone
Efficiency lost
Accumulation of catalyzer on the bottom of
fraction column
Need of bigger cyclone for present operation
conditions
XI Catalytic Cracking Complex
Turnaround
STRIPPER:
Bad mechanical condition of Baffles and
stripper plates.
Damage of anti-erosion protection of
Baffles.
Mechanical failure of steam distributor.
Low efficiency on stripping of hydrocarbon
gases, due to higher load of FCC unit.
XI Catalytic Cracking Complex
Turnaround
To improve the catalyst separation of hydrocarbon
gases from the reactor, by saving catalyst, avoiding
contamination of the fraction system and to process
higher load of FCC unit.
Minimize dragging hydrocarbons to the regenerator.
To improve the thermal balance.
To reduce loss of hydrocarbons.
Overcome mechanical problems.
Increase operational reliability and flexibility

XI Catalytic Cracking Complex
Turnaround
REACTOR
REGENERATOR
RISER
STRIPPER
XI Catalytic Cracking Complex
Turnaround
REACTOR
REGENERATOR
RISER
STRIPPER
XI Catalytic Cracking Complex
Turnaround
There were programmed some previous works, mainly
fabrication of parts of riser and temporary structures.
In addition to Petroperus personnel, we contracted some
services:
ITEM SERVICE DESCRIPTION CONTRACTOR
1 Contracted personnel Minar
2 Rolled of plates Demem
3 Non Destructive Testing Qualitest
4 Installation of anti erosion protection Saterfi
5 Heat treating of Stripper and riser Inspectra
XI Catalytic Cracking Complex
Turnaround
Team 1 Team 2
PS01 External structure PC01 Bottom support for riser
PS02 External structure for head PC02 Structure for riser head
PS03 Internal structure bottom part PC03 Structure for riser
PS04 Internal structure medium part PC04 Balance Hoist riser segment
PS05 Internal structure top part PC05 Steam distributor superior # 1
PS06 Structure for gas line PC06 Steam distributor superior # 2
PS07 Top platform PC07 Steam distributor inferior
PS08 Hoisting rocker arm for head PC08 Baffles of Stripper
PS09 Bracket tools PC09 Baffles of Riser
PS10 Cyclone support PC10 Riser Segment
PC11 Scaffolding for Stripper
Following parts were manufactured in Petroperus
shops:
XI Catalytic Cracking Complex
Turnaround
PS01 External structure
XI Catalytic Cracking Complex
Turnaround
PS05 Internal structure top part
XI Catalytic Cracking Complex
Turnaround
PC10 Riser Segment
XI Catalytic Cracking Complex
Turnaround
PC05 Y PC06 Steam distributors
XI Catalytic Cracking Complex
Turnaround
Control of execution
XI Catalytic Cracking Complex
Turnaround
Replacement of internals were programmed to do during
the CCC turnaround.
In addition to Petroperus personnel, we contracted some
services:
XI Catalytic Cracking Complex
Turnaround
ITEM SERVICE DESCRIPTION CONTRACTOR
1 Welding service Minar
2 Heat treating Inspectra
3 Non Destructive Testing Qualitest
4 Installation of scaffolding R&H
5 Topography Vulcano
6 Installation of anti erosive protection Saterfi
XI Catalytic Cracking Complex
Turnaround
COLOR CODE
GREY : REMAINS
GREEN : REUSED
RED : REPLACED
BLUE : NEW
CYCLONE
REGENERATOR
FV3
HEATER FH1
REACTOR
FV4

RISER
VALV. FK2
VALV. FK1
ORIFICE
CHAMBER

FV16
VALV.
FK4
VALV.
FK3
GAS
LINE
GAS TO MAIN
COLUMN
GAS TO CO
BOILER
STRIPPER
XI Catalytic Cracking Complex
Turnaround
REGENERATOR
FV3
HEATER FH1
REACTOR
FV4

RISER
VALV. FK2
VALV. FK1 VALV.
FK4
VALV.
FK3
GAS
LINE
GAS TO MAIN
COLUMN
STRIPPER
GAST TO CO
BOILER
XI Catalytic Cracking Complex
Turnaround
COLOR CODE
GREY : REMAINS
GREEN : REUSED
RED : REPLACED
BLUE : NEW ORIFICE
CHAMBER

FV16
REGENERATOR
FV3
HEATER FH1
REACTOR
FV4

RISER
VALV. FK2
VALV. FK1 VALV.
FK4
VALV.
FK3
GAS
LINE
GAS TO MAIN
COLUMN
STRIPPER
GAS TO CO
BOILER
XI Catalytic Cracking Complex
Turnaround
COLOR CODE
GREY : REMAINS
GREEN : REUSED
RED : REPLACED
BLUE : NEW ORIFICE
CHAMBER

FV16
REGENERATOR
FV3
HEATER FH1
REACTOR
FV4

RISER
VALV. FK2
VALV. FK1 VALV.
FK4
VALV.
FK3
GAS
LINE
GAS TO MAIN
COLUMN
STRIPPER
GAS TO CO
BOILER
XI Catalytic Cracking Complex
Turnaround
COLOR CODE
GREY : REMAINS
GREEN : REUSED
RED : REPLACED
BLUE : NEW ORIFICE
CHAMBER

FV16
REGENERATOR
FV3
HEATER FH1
REACTOR
FV4

RISER
VALV. FK2
VALV. FK1 VALV.
FK4
VALV.
FK3
GAS
LINE
GAS TO MAINI
COLUMN
STRIPPER
GAS TO CO
BOILER
XI Catalytic Cracking Complex
Turnaround
COLOR CODE
GREY : REMAINS
GREEN : REUSED
RED : REPLACED
BLUE : NEW ORIFICE
CHAMBER

FV16
REGENERATOR
FV3
HEATER FH1
REACTOR
FV4

RISER
VALV. FK2
VALV. FK1 VALV.
FK4
VALV.
FK3
GAS
LINE
STRIPPER
GAS TO CO
BOILER
XI Catalytic Cracking Complex
Turnaround
COLOR CODE
GREY : REMAINS
GREEN : REUSED
RED : REPLACED
BLUE : NEW ORIFICE
CHAMBER

FV16
REGENERATOR
FV3
HEATER FH1
REACTOR
FV4

RISER
VALV. FK2
VALV. FK1 VALV.
FK4
VALV.
FK3
GAS
LINE
STRIPPER
GAS TO CO
BOILER
XI Catalytic Cracking Complex
Turnaround
COLOR CODE
GREY : REMAINS
GREEN : REUSED
RED : REPLACED
BLUE : NEW ORIFICE
CHAMBER

FV16
There are 92 joints to weld,
distributed as follows:
47 during previous works.
45 during replacement.
Welding type Electrode
Alloy steel
SMAW (Arc welding) E8018-B2
GTAW (TIG) ER80S-B2
Carbon steel SMAW (Arc welding) E7018
Clad (Inox) GMAW (MIG) OK.AUTROD-1679
Hex mesh and S-bar SMAW (Arc welding) E410 Ni-Mo
Electrodes required:
XI Catalytic Cracking Complex
Turnaround
Materials to weld are Chrome Molybdenum alloys (1 Cr, Mo).
ASTM-387 GR.11
ASTM-335 GR. P11
ASTM-234 GR. WP11
Welding these materials is rather difficult due to Chrome
content. Petroperus welders have to be trained in this welding
type in order to get required skill.
Replacement is done according to following technical standards:
API 31.3 for pipes in petroleum refineries
ASME Secc. VIII for pressure vessels
UOP Standards

XI Catalytic Cracking Complex
Turnaround
WPS - Welding procedures specifications
XI Catalytic Cracking Complex
Turnaround
Heat treating cycle
XI Catalytic Cracking Complex
Turnaround
Riser heat treating
XI Catalytic Cracking Complex
Turnaround
XI Catalytic Cracking Complex
Turnaround
XI Catalytic Cracking Complex
Turnaround
LIFTINGS
WEIGHT
(Tn)
1 Dismounting of gas pipeline 2.0
2 Dismounting of top platform 2.0
3 Dismounting of head with cyclone 9.5
4 Dismounting of top end of riser 9.5
5 Dismounting of riser segment 7.0
6 Dismounting of stripper baffles 0.4
7 Dismounting of steam distributor 0.4
8 Installation of Steam Distributor 0.2
9 Installation of new stripper baffles 0.4
10 Installation of riser segment 7.0
11 Installation of internal temporary structure 4.0
12 Installation of top end of riser 9.5
13 Installation of internal upper structure 4.0
14 Installation of new cyclones 7.7
15 Installation of Head with Plenum chamber 4.0
16 Installation of top platform 2.0
17 Installation of gas pipeline 2.0
XI Catalytic Cracking Complex
Turnaround
CRANE
It is a principal concern during a plant turnaround
Work is done according to safety procedures in
Petroperus safety handbook
Work permits are used for:
Works with heat or fire
Works in restricted areas
Works at height
Personal protective equipment is used for
different jobs


XI Catalytic Cracking Complex
Turnaround
XI Catalytic Cracking Complex
Turnaround
XI Catalytic Cracking Complex
Turnaround
RISER BAFFLES
STRIPPER
BAFFLES
XI Catalytic Cracking Complex
Turnaround