larsen & toubro - refining...
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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
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06-07 07-08 08-09 09-10 10-112009 2010 2011
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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.
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Under manufacturing - 16 Nos.*** Under Secrecy agreement
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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
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• Expertise in Heat Treatment
• Welding Capabilities
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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
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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)
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Unique FEA capabilities – Creep FatigueUnique FEA capabilities Creep Fatigue
Hotbox Feed Nozzle
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Banana Analysis Feed Bolting
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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
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Temperature PlotsTemperature Plots
Warm Up (329.2K) Oil in(533K) Start Coking (727.4K)
Start Quenching (643.9K) End Cutting (414.6K)
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Stress PlotsStress 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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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 :
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• 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 SkirtCreep Buckling of Skirt
Allowable comp. stress for 1 Hr Allowable comp. stress for 0.1mn Hr
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FEA Model
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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
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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
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Creep relaxation and gasket relaxation
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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
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Welding Capabilities
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Hazira Manufacturing ComplexHazira Manufacturing Complex
2011
HE ShopsHE Shops ForgingShipbuilding MHI Turbine & Boiler MFF ShopsJetties
2011
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Automatic WeldingAutomatic Welding
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Automatic GrindingAutomatic Grinding
Chipback Grinding Clad stripping
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Cone C-Seam Grinding
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Distortion ControlDistortion Control
Welding Fixture Set up Fixture
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Cone Rolling
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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
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On Job TOFD On Job TOFD
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Skit # Cone JunctionSkit # Cone Junction
Weld build up In house machining ≤ 10m Ø
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Expertise in Heat TreatmentExpertise in Heat Treatment
Temperature Profile Local PWHT
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Vertical Deformation
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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
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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
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Alternative weld build up design to increase fatigue life
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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
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World’s Largest Coke DrumWorld s Largest Coke DrumAug-2011
630 MT
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630 MT9.8 m ID
2515-May-12
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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
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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,
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Thank youa youYou Imagine…….We Create
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