Larsen & Toubro

Heavy Engineering

Coke Drum - Engineering & Manufacturing Challenges

Hari Ravindran
At Galveston Tx

Its all about imagineering

L&T Heavy Engineering L&T Heavy Engineering

L&T at a Glance
Founded

Share Holders
Employees, 13% FIIs, 15% General Public, 24% Others, 15% Financial Institutions , 33%

1938
Number of Emp.

50,000+
Market Cap

USD 20+ Bn Sales ($ Bn)

11.7 8.5 9.8

Market Cap ($ Bn)

7.4 5.0

19.06 7.65

20.04

06-07
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07-08

08-09

09-10

10-11

2009

2010

2011
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L&T Heavy Engineering L&T Heavy Engineering

Our Experience Licenser wise

10 10 8 8 6 6 4 4 2 2 0 0
FW CB&I PB EM ***

Total Count 48 Nos

6 4

*** Under Secrecy agreement

- 32 Nos. Manufactured Under manufacturing - 16 Nos.

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L&T Heavy Engineering L&T Heavy Engineering

Coke Drum And L&T

Coke Drum Technical Challenges Design Creep Fatigue Analysis Skirt Optimization - Seismic and Fatigue Banana B M Movement t Top T Dished Di h d Nozzle N l Feed Spool Bolting - Gasket Relaxation Manufacturing Automatic Welding & Grinding Latest NDE Techniques TOFD Distortion Control at Weld Joints Skirt # Cone Junction Expertise in Heat Treatment Welding Capabilities
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L&T Heavy Engineering L&T Heavy Engineering

Design Capabilities
High cyclic loading at elevated temperature Design by Analysis Not empirical formulas C Creep Fatigue Buckling
Temperature 900 Pressure 500000.00

800

450000.00 400000.00

700

350000.00 600 T e m p e r a tu r e ( K ) P r e s s u r e (P a ) 300000.00 500 250000.00 400 200000.00 300 150000.00

L&Ts In-house capabilities for Finite Element Analysis.

200

100000.00 50000.00

100

0
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

0.00 Time (Hr)

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L&T Heavy Engineering L&T Heavy Engineering

Unique FEA capabilities Creep Fatigue

Hotbox

Feed Nozzle

Banana Analysis

Feed Bolting
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L&T Heavy Engineering L&T Heavy Engineering

Creep Fatigue Analysis of Skirt Joint (Hot Box)

Segmental 3-D model Axi-symmetric analysis In house FORTRAN program

: Determining effect of slots in skirt : Skirt without slots : Determining radiation effect in Hotbox

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L&T Heavy Engineering L&T Heavy Engineering

Temperature Plots

Warm Up (329.2K)

Oil in(533K)

Start Coking (727.4K)

Start Quenching (643.9K)

End Cutting (414.6K)

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L&T Heavy Engineering L&T Heavy Engineering

Stress Plots

Warm up (99.5 MPa)

Oil in (212 MPa)

Start Coking (236 MPa)

Start Quenching (103 MPa)

End Cutting (144 MPa)

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L&T Heavy Engineering L&T Heavy Engineering

Fatigue Life Study - Skirt Joint

Skirt MOC Skirt thk. (mm) 28.5 40.0 40.0 32.0 25.4 40 0 40.0 Inside radius of crotch h (mm) R12 R12 R25 R13 R25 R32 Hotbox Fatigue Fatigue g life* life# Height (mm) (Years) (Years) 638 665 665 582 925 857 19.2 22.2 45.9 6.5 17.3 44 2 44.2 4.75 4.55 2.52 Remarks Slotted Skirt Creep Range Slotted Skirt Slotted Skirt Without slot Without slot With t slot Without l t

SA 387 Gr 11 Cl 2 SA 387 Gr 11 Cl 1 SA 387 Gr 11 Cl 1 SA 387 Gr 11 Cl 2 SA 387 Gr 11 Cl 2 SA 387 Gr G 11 Cl 2

*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
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L&T Heavy Engineering L&T Heavy Engineering

Creep Buckling of Skirt

Allowable comp. stress for 1 Hr

Allowable comp. stress for 0.1mn Hr

FEA Model
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L&T Heavy Engineering L&T Heavy Engineering

Creep Fatigue Analysis - Nozzle Attachments

FE Model Temp-Coking Stress-Coking

Analysis Fluctuating piping loads pressure and temperature Banana Effect - Horizontal moment of drum

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L&T Heavy Engineering L&T Heavy Engineering

Creep Fatigue Analysis - Feed Spool Bolts

FE Model Temp-Coking Stress-Coking

Analysis Fluctuating pressure and temperature Model includes Effect of bolt pre-load Creep relaxation and gasket relaxation
2011 2011 Larsen Larsen & & Toubro Toubro Limited Limited : : All All rights rights reserved reserved

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L&T Heavy Engineering L&T Heavy Engineering

Capabilities-Enhancing Manufacturing Capabilities Enhancing Coke Drum Life

SAW welding Automatic grinding Distortion control at weld joints Latest NDE Techniques
TOFD on Less Thickness

Skirt # Cone Junction Expertise in Heat Treatment Welding W ldi C Capabilities biliti
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L&T Heavy Engineering L&T Heavy Engineering

Hazira Manufacturing Complex

Jetties Shipbuilding MHI Turbine & Boiler HE Shops HE Shops Forging MFF Shops 2011

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L&T Heavy Engineering L&T Heavy Engineering

Automatic Welding

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L&T Heavy Engineering L&T Heavy Engineering

Automatic Grinding

Chipback Grinding

Clad stripping

Cone C-Seam Grinding

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Distortion Control

Welding Fixture

Set up Fixture

Cone Rolling
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L&T Heavy Engineering L&T Heavy Engineering

Latest NDE Techniques - TOFD

8 CHANNEL TD POCKET SCAN

8 CHANNEL TD POCKET SCAN

On Job TOFD
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L&T Heavy Engineering L&T Heavy Engineering

Skit # Cone Junction

Weld build up

In house machining 10m

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L&T Heavy Engineering L&T Heavy Engineering

Expertise in Heat Treatment

Temperature Profile

Local PWHT

Vertical Deformation
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L&T Heavy Engineering L&T Heavy Engineering

Welding Capabilities
More than 6000 qualified welding procedure Team of T f 500 + qualified lifi d welders ld

Narrow Groove Submerged Arc Welding Gas Tungsten Arc Welding Shielded Metal Arc Welding Submerged arc Strip/ Electro Slag Strip cladding Flux Cored Arc welding Gas Metal Arc Welding Automatic inside overlay

Carbon-Steels Low Alloys Steels (Cr-Mo / CrMo-V) Quenched & Tempered Steel Low temp Nickel steel Inconel Chemistry

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L&T Heavy Engineering L&T Heavy Engineering

Conclusion
L&T has developed all technical capabilities under one roof to meet technical challenges in Coke Drum manufacturing and increase life span of Coke Drum. Drum Some of which mentioned below: Skirt optimization considering fatigue and buckling at elevated temperature Shape control of coke drum during manufacturing including Outof-Roundness and peaking g and automated clad stripping pp g operation p to increase SAW welding fatigue life at weld seam Alternative weld build up design to increase fatigue life

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L&T Heavy Engineering L&T Heavy Engineering

Contribution 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, ASME PVP 2009. Simulation of Temperature Field of TIG Welding Using FDM , ASME PVP 2009. Non-Linear Creep-Buckling Analysis: An Approach Based On WRC-443 For Development Of Allowable Compressive Stresses In Coke Drums, ASME PVP 2010. An Approach Based On Code Case 2605 For Fatigue Evaluation Of Vanadium Modified Materials Reactor, ASME PVP 2010. Design Of Skirt To Cone Joint In Coke Drum: A Parametric Approach Based On Fatigue Analysis ASME PVP 2011

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L&T Heavy Engineering L&T Heavy Engineering

Worlds World s Largest Coke Drum

Aug-2011

630 MT 9.8 m ID
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L&T Heavy Engineering L&T Heavy Engineering

Track Record

Year: 2009 Year: 2004

Coke Drum: ABB Process 8.5 85m ID, 310 MT Each, 04 Nos

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

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L&T Heavy Engineering L&T Heavy Engineering

Track Record

Y Year: 2010

Year: 2012

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

Coke Drum: Petrobras Process 8.9 m ID, 245 MT Each, 16 Nos,

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Thank a you You Imagine.We Create

[email protected]
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