How did Becht help prevent an FCC shutdown after amine system leaks?

Becht rapidly deployed experts who recommended and validated a clamp-and-wrap repair, allowing safe operation until the next turnaround without unplanned downtime.

Why are amine system leaks in FCC units a concern?

Amine stress corrosion cracking can compromise mechanical integrity, risking further leaks, safety issues, and costly unscheduled shutdowns.

What value did Becht’s temporary repair solution provide?

The solution avoided a costly FCC shutdown, maintained safe weekend operations, and provided a clear plan for permanent repair during the next turnaround.

Preventing FCC Shutdown After Amine System Leaks

A refinery experienced multiple leaks in the amine system of its FCC unit’s LPG treatment section, with amine stress corrosion cracking suspected as the root cause. The client urgently needed guidance on whether a temporary repair could be safely implemented or if a full unit shutdown was required. Concerns extended beyond the leaks themselves to the mechanical integrity of the system in the event of further cracking. With production at risk, the client sought immediate expert support.

Objective

The refinery required:

A feasibility assessment of temporary repair options (e.g., clamp, wrap)
A clear understanding of the leak mechanism and potential for further failures
Confidence in the mechanical integrity of the system to allow safe continued operation until a permanent repair could be scheduled

The goal was to avoid an unscheduled FCC shutdown and defer permanent repair to the next planned turnaround.

Approach

Becht deployed a multi-disciplinary expert team within two hours, convening a virtual meeting with the client to gather information, review available data, and provide immediate feedback.

During this first session, Becht offered preliminary confirmation that a mechanical clamp with a tie-bar/strongback could be a safe temporary solution. The client engaged a local contractor to begin clamp design immediately, with Becht reviewing and approving the proposed clamp-and-wrap design.

When a second leak appeared late on a Friday, Becht reassembled the expert team to advise on safe weekend operations, ensuring the refinery could continue production without interruption.

Solution

Becht recommended the installation of a temporary clamp-and-wrap solution that would restore containment, reinforce system integrity, and allow continued operation until the next scheduled turnaround. This solution was implemented successfully, avoiding the need for a quick and unplanned shutdown.

Value

By leveraging Becht’s rapid mobilization and cross-disciplinary expertise, the refinery:

Continued safe operations through the weekend and beyond
Avoided an unplanned FCC shutdown, saving significant downtime and lost revenue
Gained a clear, structured path to permanent repair during the next turnaround, rather than reacting to an emergency situation

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