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Coke drum applications Claudio Allevato
- 1. Coke Drum Strain Gage Installation and Data Processing Stress Engineering Services Examples Over View of System Data Processing Procedures Stress Results Richard Boswell Stress Engineering Services - CONFIDENTIAL 1
- 2. SES Engineering Services to Owners, Operators, and 4 Health Monitoring Systems h Short and Long Term Strain Monitoring of Coke Drum Response to Daily Operation h Cause and Effect of Operation on Drum Damage h Integration into local DCS 4 Defect Identification and Assessment h Acoustic Emission Testing h Inspection Planning & Stress Engineering Services - CONFIDENTIAL 2 Coordination 4 Crack Growth Prediction h Fracture Mechanics and Probabilistic Crack Growth evaluations using actual operating data h Low Cycle Fatigue Damage Accumulation 4 Bulge Analysis h Severity of bulges and growth rate Designers of Delayed Coke Drums….. 4 Drum Design and Modeling Using Actual Operating Transients h Skirt h Shell h Piping and Nozzles 4 Life Assessment and Extension Recommendations 4 Metallurgical Consulting and Testing h Weld Repair Procedures h Creep Analysis and Omega Testing 4 Heater Condition and Life Assessment 4 Root Cause Failure Analysis 4 Forensic and Litigation Support
- 3. Stress Engineering Services Coke Drum Applications • Low Cycle Fatigue : What to expect • EHMS: Equipment Health Monitoring System • SES DrumBeat Analysis Examples • Other Design Analysis and Measurement Application Examples Stress Engineering Services - CONFIDENTIAL 3
- 4. Analysis of Data Stress Engineering Services - CONFIDENTIAL 4
- 5. A NOTABLE QUENCH STRESS Stress Engineering Services - CONFIDENTIAL 5
- 6. Coke Drums Fail by Low Cycle Fatigue and not by Age Alone Stress Engineering Services - CONFIDENTIAL 6
- 7. Coke Drum Failed During Quench : Crack from Inside Stress Engineering Services - CONFIDENTIAL 7
- 8. Coke Drum Failed During Quench After Repair Stress Engineering Services - CONFIDENTIAL 8
- 9. Typical Girth Cracking Inside Coke Drum Stress Engineering Services - CONFIDENTIAL 9
- 10. Crack Growth Scenario Stress Engineering Services - CONFIDENTIAL 10
- 11. Example of Coke Drum Cracking Stress Engineering Services - CONFIDENTIAL 11
- 12. Example of Probabilistic Crack Growth Calculation Stress Engineering Services - CONFIDENTIAL 12
- 13. Radial stress, crack length=1.0 in.,1 hour into fill Stress Engineering Services - CONFIDENTIAL 13
- 14. Example of Bulged Plates from a Coker Stress Engineering Services - CONFIDENTIAL 14
- 15. Coke Drum Remaining Life • Sections of two drums were replaced and operated safely until replacement in 1 year • Two drums were routinely inspected and repaired on two week schedule in final 3 months Stress Engineering Services, Inc. 15
- 16. Finite Element Model of Bulged Drum Stress Engineering Services - CONFIDENTIAL 16
- 17. Axial Stress Contours Suggest Inspection Points Stress Engineering Services - CONFIDENTIAL 17
- 18. Stress Engineering Services - CONFIDENTIAL 18
- 19. Stress Engineering Services - CONFIDENTIAL 19
- 20. Stress Engineering Services - CONFIDENTIAL 20
- 21. Stress Engineering Services - CONFIDENTIAL 21
- 22. Stress Engineering Services - CONFIDENTIAL 22
- 23. OPERATING AXIAL STRESS Stress Engineering Services - CONFIDENTIAL 23
- 24. Cracked Skirt to Shell Attachment Stress Engineering Services - CONFIDENTIAL 24
- 25. High Temperature Strain Gage is a Platinum Tungsten Sensor rated for 1100 F Stress Engineering Services - CONFIDENTIAL 25
- 26. High Temperature Strain Gage: Hoop & Axial w/ TC Stress Engineering Services - CONFIDENTIAL 26
- 27. Typical High Temperature Strain Gages with TC Stress Engineering Services - CONFIDENTIAL 27
- 28. High Temperature Strain Gage: Hoop & Axial w/ TC Stress Engineering Services - CONFIDENTIAL 28
- 29. SES DrumBeat Strain and Stress Calculations Hoop HTSG ΔR ΔV Recorded Microstrain TC Apparent Microstrain Corrected Hoop Microstrain Axial HTSG ΔR ΔV Recorded Microstrain Corrected Axial Microstrain Hoop Stress Axial Stress Delta Stress Histogram Stress Engineering Services - CONFIDENTIAL 29 Fatigue Damage Crack Propagation Analysis Stress Range per Cycle
- 30. Measured Stress • Measured Stress is due to – Pressure – Gravity and Hydrostatic – Thermal gradients – Global and Local – Flattening of Bulges – Solid Coke Interference – Solid Coke Friction Stress Engineering Services - CONFIDENTIAL 30