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  • Coker Vessel Life Extension Repair Implementation Amador AZZ DCU Bahrain 2015

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    Isaac
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    The document discusses a case study of repairs made to the coke drum of a delayed coker unit in Karlsruhe, Germany. Two bulging areas were identified and repaired through the application of a structural overlay using alloy 625 and three layers. The repair addressed cracking and bulging issues commonly seen in coke drums and was a successful alternative to more complex and time-consuming repair options. Over 40 similar projects have demonstrated long-term successful operation of this engineered repair approach.

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    Coker-Vessel-Life-Extension-Repair-Implementation-Amador-AZZ-DCU-Bahrain-2015

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    The document discusses a case study of repairs made to the coke drum of a delayed coker unit in Karlsruhe, Germany. Two bulging areas were identified and repaired through the application of a structural overlay using alloy 625 and three layers. The repair addressed cracking and bulging issues commonly seen in coke drums and was a successful alternative to more complex and time-consuming repair options. Over 40 similar projects have demonstrated long-term successful operation of this engineered repair approach.

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    © All Rights Reserved
    Скачайте в формате PDF, TXT или читайте онлайн в Scribd
    Отметить как неприемлемый контент
    54 просмотров15 страниц

    Coker Vessel Life Extension Repair Implementation Amador AZZ DCU Bahrain 2015

    Загружено:

    Isaac
    The document discusses a case study of repairs made to the coke drum of a delayed coker unit in Karlsruhe, Germany. Two bulging areas were identified and repaired through the application of a structural overlay using alloy 625 and three layers. The repair addressed cracking and bulging issues commonly seen in coke drums and was a successful alternative to more complex and time-consuming repair options. Over 40 similar projects have demonstrated long-term successful operation of this engineered repair approach.

    Авторское право:

    © All Rights Reserved
    Скачайте в формате PDF, TXT или читайте онлайн в Scribd
    Отметить как неприемлемый контент
    из 15

    Coker Vessel Life Extension

    Repair Implementation
    Pedro Amador, VP & Chief Technology Officer
    Bahrain, November 2015

    www.azz.com/wsi-europe 1
    General Coke Drum Statistics

    • API - 80% of all coke drums in operation are experiencing cracking


    • Cracking occurs within 5 to 7 years
    • Most are Cracking and Bulging

    www.azz.com/wsi-europe 2
    Typical Failures

    • Bulging
    – Circumferential Seams
    – Shell Course

    • Cracking (Partial and Through Wall)


    – Circumferential seam
    – Skirt to Shell welds
    – Shell plate cracks

    • ID Erosion/Corrosion
    – Delamination/wear of cladding

    www.azz.com/wsi-europe 3
    Case Study

    Delayed Coker Unit Karlsruhe Germany

    March 2012

    • The MiRO refinery, in Karlsruhe, has a


    capacity of 300,000 BBL/d
    • Drum Diameter - 7315 mm
    • Base Material 1,25Cr, ½Mo / 13CrMo44
    • Wall Thickness - 40.5mm + 2mm SS410

    Delayed Coking Unit

    www.azz.com/wsi-europe 4
    Case study MiRo

    • Planned T/A in 2012


    • Bulges in delayed coking unit increased
    rapidly,
    so emergent repair had to be executed
    • Analytical support and “Engineered Repair”
    developed
    • Machine welding used to implement
    structural
    improvement repair
    • Temperbead process eliminated requirement
    for PWHT

    Shell Bulging Damage

    www.azz.com/wsi-europe 5
    Case study MiRo

    Repair Options Evaluated

    Option Implementation Repair Repair


    Schedule Complexity Integrity
    Window Replacement Long High Low
    Section Replacement Long High Medium-
    Low
    Structural Overlay Short Low High

    www.azz.com/wsi-europe 6
    Case study MiRo

    Engineered repair solution


    • Plastic Strain Index Study performed
    • 2 bulge repair areas defined
    - #1 23m2
    - #2 27m2
    • Design required additional structural Area 1
    thickness:
    - 0.56” (14.3mm)

    Area 2

    Contour plot of the Plastic Strain Index (PSI)


    looking from the outside of the drum
    www.azz.com/wsi-europe 7
    Case study MiRo

    Final repair information

    Coke Drum D-001B Coke Drum D-001B


    Bulge repair Area 1 (includes taper zone) 27.7m² per layer
    Bulge repair Area 2 (includes taper zone) 30.6m² per layer
    Filler material Alloy 625
    Overlay thickness per layer 3/16˝ (5mm)
    Total Overlay one layer 58.3m²
    Overlay three layers 174.9m²

    www.azz.com/wsi-europe 8
    Temperbead Welding

    HAZ created by 1st weld layer

    HAZ is
    tempered by
    deposition of
    successive
    layers
    www.azz.com/wsi-europe 9
    Case study MiRo

    Site preparation

    Equipment Deck A lot of activity around the unit


    www.azz.com/wsi-europe 10
    Case study MiRo

    Mock-up: process evaluation & training

    Removal of bonded cladding Mock-up

    “Skim” gouging with Carbon Electrodes


    2-3mm thickness removed
    www.azz.com/wsi-europe 11
    Case study MiRo

    Surface preparation and gouging in the field

    Surface “prepped” Cladding removed Gouging in process 2 – 3 mm material removed


    410 cladding

    www.azz.com/wsi-europe 12
    Application of Strucrual Overlay on ID of The Vessel

    Fully Automated Weld Metal Overlay Welding Systems


    Application of NiCr625 Alloy on the ID of the vessel

    www.azz.com/wsi-europe 13
    Summary

    Results

    • Two bulged areas mitigated


    • Alloy 625 installed
    • Engineered Repair with 3 layers of overlay
    • Additional Cladding areas repaired: surface defects
    • Over 40 projects of this type have been performed
    and demonstrated years of successful operation

    www.azz.com/wsi-europe 14
    Contact

    Contact Information

    Pedro Amador
    VP & Chief Technology Officer –WSI
    PedroAmador@azz.com
    + 1 (678) 728-9100
    Norcross, GA, USA

    wsi-europe@azz.com

    www.azz.com/wsi-europe

    www.azz.com/wsi-europe 15

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