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Stress Engineering ServicesStress Engineering Services

forfor

Coke Drum Health MonitoringCoke Drum Health MonitoringAnd Reliability ImprovementAnd Reliability Improvement

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SES Engineering Services to Owners,SES Engineering Services to Owners,

Operators, and Designers of Delayed CokeOperators, and Designers of Delayed Coke

Drums..Drums..

4 Health Monitoring Systemsh Short and Long Term Strain

Monitoring of Coke DrumResponse to Daily Operation

h Cause and Effect ofOperation on Drum Damage

h Integration into local DCS

4 Defect Identification andAssessmenth Acoustic Emission Testing

h Inspection Planning &Coordination

4 Crack Growth Predictionh Fracture Mechanics and

Probabilistic Crack Growth

evaluations using actualoperating data

h Low Cycle Fatigue DamageAccumulation

4 Bulge Analysis

h Severity of bulges andgrowth rate

4 Drum Design and ModelingUsing Actual OperatingTransients

h Skirt

h Shell

h Piping and Nozzles

4 Life Assessment andExtension Recommendations

4 Metallurgical Consulting andTesting

h Weld Repair Procedures

h Creep Analysis and OmegaTesting

4 Heater Condition and LifeAssessment

4 Root Cause Failure Analysis

4 Forensic and LitigationSupport

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SES DrumBeatSES DrumBeatCoke DrumCoke Drum

Structural Health Monitoring ProgramStructural Health Monitoring Program

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Benefits of SES Program toBenefits of SES Program to

Coke Drum OperatorsCoke Drum Operatorsl Record and analyze actual measurements from

drum response to daily operation essential to

accurately assess, predict and extend drum Healthl Achieve a better understanding of cause and effect

of operation and processes on drum reliability

l Allow Operators to monitor, improve and

optimize daily operation versus drum damage tocreate Best Practices

l Make and Save Operators $$$$$$$$$$$$$$$$$$

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What SES does to improveWhat SES does to improve

Coke Drum Economics andCoke Drum Economics and

Reliability:Reliability:4 Install High Temperature Strain Gages,

Thermocouples and Intrinsically safe system tomonitor Shell and Skirt Regions

4

Hook Intrinsically Safe Logger into Local DCS orDirectly to SES

4 Retrieve Strain and Process Data routinely

4 Evaluate trends of recorded strain and damageversus daily operation:Cause and Effect

4 Provide Prompt Feedback and Analysis toOperators to allow for improvement

4 Provide Engineering Analysis and Support toExtend Life

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High Temperature Strain Gages,ocouples and Intrinsically safe system tr Shell and Skirt Regions

ntrinsically Safe Logger into Local DCSto SES

e Strain and Process Data routinely

te trends of recorded strain and damagdaily operation:Cause and Effect

Prompt Feedback and Analysis toors to allow for improvement

En ineerin Anal sis and Su ort to

What SES does to improveWhat SES does to improve

Coke Drum Economics andCoke Drum Economics and

Reliability:Reliability:4 Install High Temperature Strain Gages,

Thermocouples and Intrinsically safe system tomonitor Shell and Skirt Regions

4

Hook Intrinsically Safe Logger into Local DCS orDirectly to SES

4 Retrieve Strain and Process Data routinely

4 Evaluate trends of recorded strain and damageversus daily operation:Cause and Effect

4 Provide Prompt Feedback and Analysis toOperators to allow for improvement

4 Provide Engineering Analysis and Support toExtend Life

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Temperature distribution soon after Switching

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Skirt is forced outward during Fill transient

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High Temperature Strain GageHigh Temperature Strain Gage

with Intrinsically Safewith Intrinsically Safe

InstrumentationInstrumentation

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Structural Health MonitoringStructural Health Monitoring

Data Processing TasksData Processing Tasks

l Review Recorded Data for High Temperature Strain Gages

Thermocouples

l Correct Readings for Temperature Error

l Calculate each pair for Bi-Axial Principal Stressand Stress Intensity

l Determine Stress Range each Cycle

l Compile Histograms and Damage Accumulation

l Evaluate Process Cause and Structural Effect

l Compare Different Operating Procedures forresulting Structural Damage

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Measured Stress is caused byMeasured Stress is caused by

several conditionsseveral conditions

l Measured Stress isdue to

Pressure

Gravity and

Hydrostatic Thermal gradients

Flattening of Bulges

Solid CokeInterference

Solid Coke Friction Ring Bending from

Bulge Diameters

l Stress is composed of

Average stress in wall :Membrane

Bending Stressinside/outside wall

Secondary Stress forGeometric Equilibrium

Peak Stress at defects,undercuts, weld caps,radius transition

l Stress measurement onOD is independent ofsource of stress

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Typical Coking Cycle for Process and StressTypical Coking Cycle for Process and Stress

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Plot Stress Range for each CyclePlot Stress Range for each Cycle

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Histogram of Stress Ranges describes howHistogram of Stress Ranges describes how

often a stress happensoften a stress happens

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Calculate Fatigue Damage for each StressCalculate Fatigue Damage for each Stress

Component and Determine Cycle LifeComponent and Determine Cycle Life

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Histogram of Stress Ranges and DamageHistogram of Stress Ranges and Damage

for Low Cycle Fatiguefor Low Cycle Fatigue

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Operational Intelligence toreduce fatigue damage

Remaining Life Assessments

Integration With SES

DrumBeat Analysis

On-lineSensors Critical Control

Factors

OperatorLogs

Observations

SES

DCSInformation

Fatigue crack Growth PredictionLow Cycle Fatigue Damage

Accumulation

Outputs

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The Future DrumBeat.The Future DrumBeat.

An Automated and On SiteAn Automated and On Site

Structural HealthStructural Health

Monitoring SystemMonitoring Systemforfor

Improved Reliability ofImproved Reliability of

Delayed Coke DrumsDelayed Coke Drums

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SES DrumbeatSES DrumbeatInformation LinksInformation Links

l Remaining Life Evaluations of Coke Drums(pdf)

l Assessing Structural Integrity of Coke Drums(pdf)

l SES DrumBeat PowerPoint notes (pdf)

l Stress Engineering Services atwww.stress.com

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SES DrumBeatSES DrumBeatCoke DrumCoke Drum

Structural Health Monitoring SystemStructural Health Monitoring System

4 SES DrumBeat is a collection of procedures for processingstrain gage, thermocouple, and process data measured on acoke drum.

4 SES DrumBeat is becoming an automated software to routinelymanage large volumes of data in real time for cyclic damage

accumulation.4 SES DrumBeat will become an on-site system available to

provide clients with continuous update on coke drum operation.

4 SESDrumBeat.comis under development to provide clients asecure access to their results.

4

CokeDrum.comis under development to provide clients withinformation about SES and coke drum services.

4 Stress.comis the Stress Engineering Services web site forcomplete introduction to our upstream and downstreamengineering services.

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Stress Engineering Services, IncStress Engineering Services, Inc13800 Westfair East13800 Westfair East

Houston, TexasHouston, Texas7704177041

281-955-2900281-955-2900

www.stress.comwww.stress.com

This CD is the property of StressThis CD is the property of Stress

Engineering Services Inc. The informationEngineering Services Inc. The information

herein is confidential and is issued on theherein is confidential and is issued on the

understanding that no part thereof shall beunderstanding that no part thereof shall becopied or communicated to a third partycopied or communicated to a third party

without authorization in writing from Stresswithout authorization in writing from Stress

Engineering Services Inc.Engineering Services Inc.