Larsen & Toubro - Refining Community...Larsen & Toubro Heavy EngineeringHeavy Engineering Coke Drum...

Larsen & ToubroHeavy EngineeringHeavy Engineering

Coke Drum Coke Drum -- Engineering & Manufacturing ChallengesEngineering & Manufacturing Challenges

It’s all about imagineering ®

Hari RavindranAt Galveston Tx

L&T Heavy EngineeringL&T Heavy EngineeringL&T Heavy Engineering

L&T at a GlanceL&T at a GlanceFounded

1938Financial

Others, 15%

Share Holders

Number of Emp.

50,000+

Financial Institutions

, 33%

FIIs, 15%

Employees, 13%

15%

General Public, 24%

Market Cap

USD 20+ Bn

7.48.5

9.811.7Sales ($ Bn) Market Cap ($ Bn)

19.06 20.04 5.0

7.65

© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved15-May-12 / 282

06-07 07-08 08-09 09-10 10-112009 2010 2011


Our Experience – Licenser wise

10 Total Count

Our Experience Licenser wise

8

108 8

66

48 Nos

4

66

4

6

4

0

20

2

0

FW CB&I PB EM ***

Manufactured - 32 Nos.

© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved

Under manufacturing - 16 Nos.*** Under Secrecy agreement

/ 283


Coke Drum And L&T Coke Drum Technical Challenges

Design

Coke Drum And L&T

Design

• Creep – Fatigue Analysis

• Skirt Optimization - Seismic and Fatigue

B M t T Di h d N l• Banana Movement – Top Dished Nozzle

• Feed Spool Bolting - Gasket Relaxation

Manufacturing

• Automatic Welding & Grinding

• Latest NDE Techniques – TOFDLatest NDE Techniques TOFD

• Distortion Control at Weld Joints

• Skirt # Cone Junction

• Expertise in Heat Treatment


• Expertise in Heat Treatment

• Welding Capabilities

/ 284


Design Capabilities High cyclic loading at elevated

temperature

Design Capabilities

Design by Analysis – Not

empirical formulas

C800

900

450000.00

500000.00

Temperature Pressure

• Creep

• Fatigue600

700

K) 300000.00

350000.00

400000.00

a)

• Buckling300

400

500

Tem

per

atu

re (

150000.00

200000.00

250000.00

Pre

ssu

re (

Pa

L&T’s In-house capabilities forFinite Element Analysis.

0

100

200

0.00

50000.00

100000.00

© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved / 285

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Time (Hr)


Unique FEA capabilities – Creep FatigueUnique FEA capabilities Creep Fatigue

Hotbox Feed Nozzle


Banana Analysis Feed Bolting


Creep Fatigue Analysis of Skirt Joint (Hot Box)Creep Fatigue Analysis of Skirt Joint (Hot Box)

Segmental 3-D model : Determining effect of slots in skirt

Axi-symmetric analysis : Skirt without slots

In house FORTRAN program : Determining radiation effect in Hotbox



Temperature PlotsTemperature Plots

Warm Up (329.2K) Oil in(533K) Start Coking (727.4K)

Start Quenching (643.9K) End Cutting (414.6K)



Stress PlotsStress Plots

Warm up (99.5 MPa) Oil in (212 MPa) Start Coking (236 MPa)

Start Quenching (103 MPa) End Cutting (144 MPa)



Fatigue Life Study - Skirt JointFatigue Life Study Skirt Joint

Skirt MOCSkirt thk.

Inside radius of

h

Hotbox Height

Fatigue life*

Fatigue life# Remarks

(mm)crotch (mm)

g(mm) (Years) (Years)

SA 387 Gr 11 Cl 2 28.5 R12 638 19.2 4.75Slotted SkirtCreep RangeCreep Range

SA 387 Gr 11 Cl 1 40.0 R12 665 22.2 4.55 Slotted Skirt

SA 387 Gr 11 Cl 1 40.0 R25 665 45.9 2.52 Slotted Skirt

SA 387 Gr 11 Cl 2 32.0 R13 582 6.5 - Without slot

SA 387 Gr 11 Cl 2 25.4 R25 925 17.3 - Without slot

SA 387 G 11 Cl 2 40 0 R32 857 44 2 With t l tSA 387 Gr 11 Cl 2 40.0 R32 857 44.2 - Without slot

*Fatigue life at Skirt # Toricone joint ; # Fatigue life at slot tip

Conclusion :


• Increase in radius and hotbox height improve s fatigue life

• Lower skirt thickness gives flexibility & thus improving fatigue life


Creep Buckling of SkirtCreep Buckling of Skirt

Allowable comp. stress for 1 Hr Allowable comp. stress for 0.1mn Hr


FEA Model


Creep Fatigue Analysis - Nozzle AttachmentsCreep Fatigue Analysis Nozzle AttachmentsFE Model Temp-Coking Stress-Coking

Analysis

• Fluctuating piping loads

• pressure and temperature

• Banana Effect - Horizontal moment of drum



Creep Fatigue Analysis - Feed Spool BoltsCreep Fatigue Analysis Feed Spool BoltsFE Model Temp-Coking Stress-Coking

Analysis

• Fluctuating pressure and temperature

• Model includes Effect of bolt pre-load

• Creep relaxation and gasket relaxation


Creep relaxation and gasket relaxation

/ 2813


Manufacturing Capabilities-Enhancing Coke Drum LifeManufacturing Capabilities Enhancing Coke Drum Life

SAW welding

Automatic grinding

Distortion control at weld joints Distortion control at weld joints

Latest NDE Techniques

TOFD on Less Thickness

Skirt # Cone Junction

Expertise in Heat Treatment

W ldi C biliti


Welding Capabilities


Hazira Manufacturing ComplexHazira Manufacturing Complex

2011

HE ShopsHE Shops ForgingShipbuilding MHI Turbine & Boiler MFF ShopsJetties

2011



Automatic WeldingAutomatic Welding



Automatic GrindingAutomatic Grinding

Chipback Grinding Clad stripping


Cone C-Seam Grinding


Distortion ControlDistortion Control

Welding Fixture Set up Fixture


Cone Rolling


Latest NDE Techniques - TOFDLatest NDE Techniques TOFD

8 CHANNEL TD POCKET SCAN8 CHANNEL TD POCKET SCAN 8 CHANNEL TD POCKET SCAN8 CHANNEL TD POCKET SCAN


On Job TOFD On Job TOFD


Skit # Cone JunctionSkit # Cone Junction

Weld build up In house machining ≤ 10m Ø



Expertise in Heat TreatmentExpertise in Heat Treatment

Temperature Profile Local PWHT


Vertical Deformation


Welding CapabilitiesWelding Capabilities

• More than 6000 qualified welding procedureT f 500 + lifi d ld• Team of 500 + qualified welders

Narrow Groove Submerged Arc Carbon-SteelsWelding

Gas Tungsten Arc Welding

Shielded Metal Arc Welding

Low Alloys Steels (Cr-Mo / Cr-Mo-V)

Quenched & Tempered SteelShielded Metal Arc Welding

Submerged arc Strip/ Electro Slag Strip cladding

Flux Cored Arc welding

Low temp Nickel steel Inconel Chemistry

Flux Cored Arc welding

Gas Metal Arc Welding

Automatic inside overlay



ConclusionConclusionL&T has developed all technical capabilities under one roof to meettechnical challenges in Coke Drum manufacturing and increase lifespan of Coke Drum Some of which mentioned below:span of Coke Drum. Some of which mentioned below:

Skirt optimization considering fatigue and buckling at elevatedtemperature

Shape control of coke drum during manufacturing including Out-of-Roundness and peaking

SAW welding and automated clad stripping operation to increaseg pp g pfatigue life at weld seam

Alternative weld build up design to increase fatigue life


Alternative weld build up design to increase fatigue life

/ 2823


Contribution to International SocietyContribution to International Society “Creep-Fatigue Interaction in Coke Drums: An Approach Based on API

579-1/ ASME FFS-2007”, ASME PVP 2009.

“Numerical Simulation of Transient Temperature in SMAW”, ASMEPVP 2009.

“Simulation of Temperature Field of TIG Welding Using FDM ”, ASMEPVP 2009.

“Non-Linear Creep-Buckling Analysis: An Approach Based On WRC-443For Development Of Allowable Compressive Stresses In Coke Drums”,ASME PVP 2010.

“An Approach Based On Code Case 2605 For Fatigue Evaluation OfVanadium Modified Materials Reactor”, ASME PVP 2010.

“Design Of Skirt To Cone Joint In Coke Drum: A Parametric ApproachBased On Fatigue Analysis” ASME PVP 2011



World’s Largest Coke DrumWorld s Largest Coke DrumAug-2011

630 MT


630 MT9.8 m ID

2515-May-12


Track RecordTrack Record

Coke Drum: ABB Process – 8 5 m

Year: 2004Year: 2009

Coke Drum: FW Process – 9.8 mCoke Drum: ABB Process 8.5 m ID, 310 MT Each, 04 Nos

Coke Drum: FW Process 9.8 m ID, 520 MT Each, 04 Nos



Track RecordTrack Record

Y 2010

Coke Drum: CB&I Process – 8.0 m ID 240 MT Each 04 Nos

Year: 2010

Coke Drum: PetrobrasProcess – 8.9 m ID, 245 MT

Year: 2012

ID, 240 MT Each, 04 Nos Process 8.9 m ID, 245 MT Each, 16 Nos,



Thank youa youYou Imagine…….We Create

© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved© 2011 Larsen & Toubro Limited : All rights reserved15-May-12 28

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