Coke Tower Design

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
15-May-12
07-08
08-09
09-10
10-11
2009
2010
2011
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2011 2011 Larsen Larsen & & Toubro Toubro Limited Limited : : All All rights rights reserved reserved
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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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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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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Unique FEA capabilities Creep Fatigue
Hotbox
Feed Nozzle
Banana Analysis
Feed Bolting
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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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Temperature Plots
Warm Up (329.2K)
Oil in(533K)
Start Coking (727.4K)
Start Quenching (643.9K)
End Cutting (414.6K)
15-May-12
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Stress Plots
Warm up (99.5 MPa)
Oil in (212 MPa)
Start Coking (236 MPa)
Start Quenching (103 MPa)
End Cutting (144 MPa)
15-May-12
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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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Creep Buckling of Skirt
Allowable comp. stress for 1 Hr
Allowable comp. stress for 0.1mn Hr
FEA Model
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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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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
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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
15-May-12
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Hazira Manufacturing Complex

Jetties Shipbuilding MHI Turbine & Boiler HE Shops HE Shops Forging MFF Shops 2011
15-May-12
15 / 28
Automatic Welding
15-May-12
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Automatic Grinding
Chipback Grinding
Clad stripping
Cone C-Seam Grinding

15-May-12
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Distortion Control
Welding Fixture
Set up Fixture
Cone Rolling
15-May-12
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Latest NDE Techniques - TOFD
8 CHANNEL TD POCKET SCAN
8 CHANNEL TD POCKET SCAN
On Job TOFD
15-May-12
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Skit # Cone Junction
Weld build up
In house machining 10m
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Expertise in Heat Treatment
Temperature Profile
Local PWHT
Vertical Deformation
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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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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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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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Worlds World s Largest Coke Drum

Aug-2011
630 MT 9.8 m ID
15-May-12
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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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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
Hari.ravindran@larsentoubro.com
15-May-12
28

Coke Tower Design

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Larsen & Toubro

Coke Drum - Engineering & Manufacturing Challenges

Its all about imagineering

L&T Heavy Engineering L&T Heavy Engineering

USD 20+ Bn Sales ($ Bn)

11.7 8.5 9.8

Market Cap ($ Bn)

L&T Heavy Engineering L&T Heavy Engineering

Our Experience Licenser wise

Total Count 48 Nos

*** Under Secrecy agreement

- 32 Nos. Manufactured Under manufacturing - 16 Nos.

L&T Heavy Engineering L&T Heavy Engineering

Coke Drum And L&T

L&T Heavy Engineering L&T Heavy Engineering

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.

0.00 Time (Hr)

L&T Heavy Engineering L&T Heavy Engineering

Unique FEA capabilities Creep Fatigue

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

L&T Heavy Engineering L&T Heavy Engineering

Start Coking (727.4K)

Start Quenching (643.9K)

End Cutting (414.6K)

L&T Heavy Engineering L&T Heavy Engineering

Warm up (99.5 MPa)

Oil in (212 MPa)

Start Coking (236 MPa)

Start Quenching (103 MPa)

End Cutting (144 MPa)

L&T Heavy Engineering L&T Heavy Engineering

Fatigue Life Study - Skirt Joint

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

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

L&T Heavy Engineering L&T Heavy Engineering

Creep Fatigue Analysis - Nozzle Attachments

L&T Heavy Engineering L&T Heavy Engineering

Creep Fatigue Analysis - Feed Spool Bolts

L&T Heavy Engineering L&T Heavy Engineering

Capabilities-Enhancing Manufacturing Capabilities Enhancing Coke Drum Life

L&T Heavy Engineering L&T Heavy Engineering

Hazira Manufacturing Complex

L&T Heavy Engineering L&T Heavy Engineering

L&T Heavy Engineering L&T Heavy Engineering

Cone C-Seam Grinding

L&T Heavy Engineering L&T Heavy Engineering

L&T Heavy Engineering L&T Heavy Engineering

Latest NDE Techniques - TOFD

8 CHANNEL TD POCKET SCAN

8 CHANNEL TD POCKET SCAN

L&T Heavy Engineering L&T Heavy Engineering

Skit # Cone Junction

In house machining 10m

L&T Heavy Engineering L&T Heavy Engineering

Expertise in Heat Treatment

L&T Heavy Engineering L&T Heavy Engineering

L&T Heavy Engineering L&T Heavy Engineering