Featured Project: Record-Setting Flareless Hydrocracker Turnaround – Deer Park, Texas
A major Deer Park refinery needed a complete, single-vendor turnaround solution for its 55,000 bpd hydrocracker:
- Depressurization of a >95% hydrogen system
- Multiple nitrogen purges
- Vapor control on temporary frac tanks holding chemical wash water
- Final treatment of contaminated wash water
They chose Envent because only one company can deliver all four phases safely, on-budget, and faster than anyone else.
The Challenge
- High-purity hydrogen depressuring (explosion risk)
- TCEQ HRVOC & Refinery MACT 2 flare minimization requirements
- Simultaneous vapor control on frac tanks
- Treatment of caustic/chemical wash water before disposal
- Zero safety incidents, zero delays
Envent’s Total Turnaround Solution – Three Integrated Systems
| Phase | Equipment & Link | Purpose |
|---|---|---|
| 1 – Hydrogen Depressuring | Turnaround Safety Skid + EMECS-70 + 2× EMECS-42 | >99.9% destruction of hydrogen & residual HCs |
| 2 – Frac Tank Vapor Control | Heat exchanger + knockout + EVAC-1000 scrubber | 100% capture of chemical wash vapors |
| 3 – Wash Water Decontamination | Liquid-phase carbon vessels | Final polishing before discharge/disposal |
Key Safety Features
- Turnaround Safety Skid with redundant high-pressure regulators, dual fuel shutdowns, and remote emergency stop
- Continuous LEL, H₂S, pressure, and temperature monitoring
- Full PHA/HAZOP/MOC participation with refinery team
Result: Zero flare usage, zero incidents, and the fastest hydrocracker decommissioning in plant history — one full day ahead of schedule.
Proven Benefits – Fastest Ever
| Benefit | Delivered Outcome |
|---|---|
| Turnaround Speed | One day early – new plant record |
| Safety | Zero incidents during 95%+ hydrogen handling |
| Regulatory Compliance | Full TCEQ & Refinery MACT 2 flare minimization |
| Single-Vendor Simplicity | One contract, one point of contact, one perfect execution |
| Client Workload | Envent handled all engineering, permitting, and execution |
This project remains the gold standard for Gulf Coast hydrocracker turnarounds.
Planning Your Next Hydrocracker, FCCU, or Coker Turnaround? Get your Free Total Turnaround Scope & Quote today. Call Envent’s Turnaround Division at 888-997-9465 or email [email protected] — one team, one solution, zero worries.
