Equipment: Hydrocracker Reactor 1st Catalyst Bed Support Structure. The maximum dP (pressure drop) was set as per original reactor design at 85 psid.

Problem: The operating pressure drop across the first catalyst bed of the reactor exceeded the designed set value of 85 psid well before the EOR schedule of 3 years before catalyst change-out. This caused multiple outtages in the hydrocraker operations resulting in loss of production $$$.

Results-Conclusion: FEA based solution established that the longest catalyst support beam limited the pressure drop across 1st Catalyst Support Bed Structure at a limiting load corresponding to maximum dP (pressure drop) = 150 psid. Hence the safe working limit of the pressure drop across the first catalyst bed was revised to 150 psid.

Analysis: Linear Static Structural-Thermal FEA Stress Analysis to establish actual strength by utilizing Limit Load Analysis to simulate Plastic collapse.

Benefits: The hydrocracker operations could safely and reliably continue to operate without any disruption throughout the SOR to EOR 3-year scheduled period, resulting in maximizing Hydrocracker plant throughput.