Decoking facility image
Decoker with equipment callouts

Industry-Leading Decoking Systems

The world’s most advanced hydraulic decoking systems from Flowserve provide more than 200 refineries with optimized output, increased reliability and unparalleled personnel safety. Whether your decoking unit (DCU) requires new equipment, system upgrades or replacement parts, we can provide a complete and proven solution globally along with superior aftermarket support to keep your operation safe, efficient and profitable.

Our engineers design and build each decoking system to optimally match the unique characteristics of your site’s DCU configuration and feed slates.

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Pioneer of decoking systems

We leverage more than 80 years of decoking experience from our Worthington®, Pacific® and IDP® heritage brands; Flowserve Worthington designed and manufactured equipment for the world’s first hydraulic decoking installation. Since then, we have pioneered significant advancements in integrated systems consisting of decoking equipment, jet pump trains and controls that maximize reliability, minimize maintenance costs, and can help you realize fail-proof DCU safety. Watch our Decoking System Overview Video.

 

Discover more about how Flowserve can help you enhance refinery performance with proven expertise in decoking equipment and systems.

Jet Pump

Jet Pump

The largest pump in your refinery should be the most reliable. The Flowserve WIK pump is the industry leader with documented run time of greater that 10 years before service.

The jet pump is well-suited for special purpose, unspared and high-power density applications. It’s built to meet or exceed ISO 13709/API 610 (BB5) standards.

 

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Decoking Control Valve

Decoking Control Valve

 

The Decoking Control Valve (DCV) from Flowserve features a proven, simple design with minimal moving parts to provide cost-effective, trouble-free operation. This single valve controls the flow from the high-energy jet pump and provides three distinct functions: 

  1. Recirculation (bypass) flow control for pump protection
  2. Pre-fill of decoking lines and hoses at a predetermined flow rate to prevent water hammer
  3. Full flow to the decoking tool nozzles; very low pressure drop (high Kv [Cv]) in full flow for reduced energy consumption

When maintenance is required, the cartridge design minimizes downtime; quick change-out can be done on-site in less than a day without the need to disconnect any flow path flanges.

 

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Rotary Joint

Rotary Joint

The Flowserve Rotary Joint transfers water from the decoking hose to the drill stem and spins the complete drill stem and cutting tool assembly. It is mechanically attached to the crosshead in order to be lowered and raised during operation.

A sealing system enables high-pressure water from the jet pump to pass into the rotating drill stem without leakage. A high-pressure decoking hose connects the static cutting-water riser line on the hose deck to a goose-neck elbow inlet on the Rotary Joint. This flexible connection makes it possible to lower and raise the complete decoking assembly.

 

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Cutting Tool

Cutting Tool

The AutoShift Slim combination cutting tool from Flowserve and simplifies processes, reduces cycle times, and — most importantly — improves safety. Additional benefits include:

  • Robust construction to prevent tool damage
  • Slim profile to reduce stuck tools
  • Shifting flexibility to free stuck tools
  • Ease of maintenance with field-replaceable nozzles

Older model combination cutting tools from Flowserve, such as the Rotaryshift and Flowserve standard diameter Pacific tools, can be upgraded to AutoShift Slim technology with a retrofit kit that includes redesigned nozzles and a mounting plate that fits existing Flowserve combination tool bodies.

 

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Supplemental Equipment

Supplemental Equipment

In addition to being the world leader in barrel pump technology, Flowserve continues to advance the performance and reliability of supplemental equipment to provide a complete decoking system.

  • Isolation and bleed valves
  • High-pressure decoking hoses
  • Drill stem guides
  • Winch systems, including console
  • Pulley blocks, sheaves and wire ropes
  • Cutting tool enclosures
  • Latching mechanisms
  • Lube oil skids
  • Operator consoles
  • Operator shelters
  • Proximity limit switches
  • Tensiometers and instrumentation
  • Threaded tubular steel drill stems
  • Maintenance Tools

 

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Crosshead

Crosshead — Free Fall Arrestor

The Crosshead and Free Fall Arrestor unit from Flowserve guides and centers the Rotary Joint, drill stem, and cutting tool in the coke drum.

The Free Fall Arrestor ensures safe operation by preventing cutting equipment from free falling in the event of suspension failure. Built into the crosshead, no electric or pneumatic connections are required for activation. The crosshead is designed to safely absorb all torque loads normally sustained from cutting operations.

Flowserve latching mechanisms enable stowing of the crosshead (cable-gripping or rail-gripping) when not in use, providing a safe and practical way to remove tension on the cable and winch (air and electric actuation are available).

 

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Control System

Controls (Automation)

Automated coke cutting can be achieved thanks to advancements in remotely operated cutting tool design developed by Flowserve — coupled with smart monitoring and control technology. Options range from pre-programmed cutting to full automation.

Fully automated systems feature cutting control with continuous feedback signals about equipment and drum status. These systems include embedded intelligence to process signals for monitoring and control, so operator interface is required only for sequence exceptions.

Operator and plant safety are enhanced by integrating an automated cutting system with PLC interlocks for fail-safe control of crucial equipment and operating parameters.

 

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