Diseño Tambor Coque
Diseño Tambor Coque
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Figure 5 Cylindrical shell sections of up to
46ft help eliminate several circumferential
weld seams, increasing endurance under
the most severe thermal cycles.
Base metal Type Tensile ksi Yield min. Typical weld Tensile ksi Yield min.
(typ) ksi metal selection (typ) ksi
A516-70 Carbon steel 7090 38 (46) EM12K 7095 58 (61 )
A204 C Carbon-1/2 Moly 7595 43 (52) EA2 7095 58 (61)
A387-11, CL2 11/4 Cr-1/2 Moly 75100 45 (58) EB2 80100 68 (75)
A387-12, CL2 1 Cr-1/2 Moly 6585 40 (50) EB2 80100 68 (75)
A387-22, CL2 21/4-1 Moly 75100 45 (58) EB3 90110 67 (80)
405 (clad) 13 Cr 6090 25 (36) ERNiCr-3 8095 40 (52)
410S (clad) 12 Cr 6090 30 (36) ERNiCr-3 8095 40 (52)
All weld metal and base metal in typical PWHT condition for material combinations. All weld metal data is from the SAW (submerged arc welding) process
Typical plate and weld metal properties
6
Table 2
cb&i 5/5/06 20:17 Page 3
stresses and leads to distortion and
cracking. The other, based on previous
research, was that the longitudinal
welds required to make the shell courses
were seemingly unaffected by the
thermal cycling, except in the areas
where those welds intersected the
circumferential ones.
After extensive research and analysis,
CB&I concluded that the best solution
to the problem of girth seam distortion
and cracking was to eliminate the
circumferential weld seams in the area
of concern. A method was developed for
successfully fabricating shell plates with
the long side oriented vertically. This
process allows fabrication of cylindrical
shell sections of up to 46ft without a
circumferential weld seam. The steel
mill manufacturing capability only
limits plate size. Currently, the largest
plates available are in the range of 46ft,
depending on the specified thickness
and alloy. Depending on plate size
limitations, up to five circumferential
weld seams can be eliminated, resulting
in a cylindrical shell section that can
endure the most severe thermal cycles
(Figure 5).
In late 1997, CB&I launched an
extensive investigation into the
feasibility of designing, fabricating and
erecting a vertical plate coke
drum. The resulting
conclusion was that such a
vessel could be economically
produced, providing a
uniform thickness through-
out the cylindrical portion of
the vessel. This method is
applicable to new construc-
tion (shop-built or field-
erected) projects, as well as
retrofit applications where
the lower cone and top head
sections of the vessels are
reused.
Vertical plate coke drums
Since 2000, CB&I has completed four
retrofit projects with the proprietary
vertical plate coke drum technology, all
of which were finished at an equal or
lower cost to the refiner than traditional
repair methods, and were much less
expensive than a full-vessel replacement.
The first successful installation of two
drums took place at a refinery on the US
West Coast in 2000. The refiner had
originally planned to replace two 20ft-
plus sections of distorted and cracked
shell on two of its coke drums, which
would still have left circumferential
seams in the section of the drum where
the bulging and cracking was most
pronounced. However, after reviewing
the vertical plate concept, the refiner
decided to modify its plan and replaced
all but the upper 9ft of shell with two
vertical plate courses reaching heights of
23.5ft and 40ft respectively.
For this project, CB&I performed all of
the turnaround activities itself, including
forming and welding the plates at one of
its fabrication shops, mobilising the
crane and all of the on-site materials, and
erecting the vessels. To execute the actual
shell replacement, CB&I cut the old
circumferential sections and then
removed them using a customised rail
system attached to the structure. From
there, the new vertical plate sections
were set in place. The project included
replacing a large nozzle in the top head
and sections of the skirt support, along
with post-weld heat treating and
hydrostatic testing, all within a span of
28 days. This vertical plate solution was
so successful that the refiner subse-
quently contracted to replace the shells
on an additional four coke drums.
In 2001, CB&I replaced the shell
courses on four coke drums for another
refiner that were originally fabricated
and installed by the company in
196869. These vessels had reached the
end of their useful life, and the coker
structure required major modifications
to meet current building codes. CB&I
recommended replacing the existing
can sections on the coke drums with
vertical plates. Total shell replacement
was approximately 65ft 8in in height.
A lower shell course 46ft in height and
an upper shell course 18ft 8in in height
were fabricated. These courses comprised
eight shell plates, all of which were
formed in one of CB&Is fabrication
shops and then welded into two-plate
assemblies. The assemblies were then
shipped to the refinery, where the on-
site project team would first erect the
lower and upper shell courses and then
set one on top of the other to complete
the can section. In addition to replacing
the shell plates, braces were added to the
stairwell and the drum was insulated.
Working on a plant-wide, non-critical
turnaround basis, the can sections on all
four drums were replaced in 37 days.
The most recent vertical plate project,
which involved the replacement of a
35ft vertical section on a ten-year-old
coke drum, was completed on a
turnaround basis in 16 days. For this
project, CB&I utilised its can section
replacement method. This particular
vessel had experienced excessive
bulging and cracking in 60% of its
circumferential welds. Its shell courses
were replaced with new 35ft-long plates
arranged vertically in four sections.
Braces were also added to the vessel
stairwell and the drum was insulated.
Plate-by-plate replacement
In many refineries, the area surrounding
the coking unit does not permit the use
of a large-capacity crane to lift out the
entire can section. To replace the shells
on the four coke drums at the West
Coast refinery, for instance, the damaged
can sections had to be cut into smaller
vertical pieces, which were then
removed plate by plate. Likewise, the
new vertical plates had to be lifted into
place piece by piece, as shown in Figure
6. While not as fast as replacing the
entire can section, the plate-by-plate
replacement method is still a safe, low-
cost solution.
www. ept q. c om 00 PTQ Q3 2006
Figure 6 Plate-by-plate replacement method in progress
A
Upper skirt
10 thk
SA387-11 CL2
A
Elevation View AA
Tan line
Hot
box
See note #1
T
e
t
a
l
p
p
o
t
o
n
o
D
t
o
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s
d
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w
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a
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t
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s
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Lower skirt
1 thk
SA51670
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1 51/2
1 511/32
81/16
1
1/2
1/2
27.956
(Typ)
(Typ)
Stretchout of top plate
R=3
Figure 7 T-Rex skirt design
cb&i 5/5/06 20:17 Page 4
Innovations in skirt design
Another potential area of failure in coke
drums is the skirt-to-shell weld
attachment. Since most coke drums have
a knuckle transition from their cylinder
top to a conical bottom, a skirt assembly
is used to support the vessel at its lower
tangent line and provide uniformity of
support stresses in the structure. Since
thermal cycling is most severe near the
bottom of the coke drum, where
temperatures can reach up to 1000F, the
skirt and other attachment welds are just
as prone to cracking and premature
structural failure as the vessel wall.
Several alternative skirt designs have
been developed to counter these
failures. One such design is the T-Rex
skirt (Figure 7), which is a culmination
of best practices and lessons learned
from years of fabricating and repairing
coke drums. In service since the 1970s,
this design has proven to be one of the
most reliable skirts currently around.
Recently, a finite element analysis
(FEA) was performed on the T-Rex
design, the results of which were
compared to those for the conventional
design configuration. This is a transient
thermal analysis to establish the model
temperature profile over the load cycle
time history. The results of the thermal
load tests show that the T-Rex
configuration has lower stress levels at
all locations for the critical charge and
quench thermal cycles. This appears to
be due to the longer hot-box length,
which results in a more gradual thermal
gradient and also moves the gradient
lower on the skirt away from the welded
connection. As such, the FEA evaluation
shows that the T-Rex has substantially
reduced stresses as compared to other
skirts currently in operation. Some of
the features of the T-Rex design include
sloped attachment welds that help
reduce stress-related failures and an
attachment that covers the tangent weld
(unless an elongated straight flange is
utilised). The T-Rex design reduces
initial application costs and improves
long-term reliability over other designs
that have been evaluated.
Another design recently developed is
the Wrapper skirt (patent pending). This
employs a fabricated wrapper-type skirt
that conforms to the geometry of the
upper cone, knuckle transition and
lower cylinder to support the drum
primarily by bearing and frictional
forces rather than load bearing weld
attachments (Figure 8). This detail
provides a more flexible connection
between the skirt and vessel than
traditional methods, which improves
the fatigue resistance of the structure. In
addition, the extended contact between
the drum and skirt lessens thermally
induced stresses in both components
by ensuring a uniform temperature
gradient between the two. Finally, the
elimination of the weld attachment
substantially reduces large pre-stresses
from weld shrinkage, weld-induced
heat-affected zones and high local
stresses in the structure, which likewise
improves the overall fatigue resistance
of the structure and supporting skirt.
Packaging these skirt designs with the
previously discussed vertical plate
proprietary technology provides a
comprehensive vessel solution that not
only improves the lifespan of a refinerys
delayed coking vessels, but also saves the
owner significant repair and replacement
costs. These designs can be used during
retrofit projects such as coke drum repair
or replacement, as well as for
incorporation into new unit designs.
Economics of vertical plate
coke drums
While the installation of vertical plate
technology will reduce the capital
refinery owners will need for repairing
and replacing their vessels, it is too early
to quantify the actual observed benefit,
since the existing vertical plate coke
drums in service have not seen enough
coke production cycles. However, the
cost and benefits associated with the
technology can be demonstrated using a
lifecycle value assessment (LCVA)
methodology, which establishes a true
cost of ownership. This tool, which was
developed by the Pembina Institute, is a
value assessment model that allows
owners to combine initial Capex and 20
years Opex for both conventional
drums and the vertical plate coke
drums. The methodology also considers
the direct financial losses arising from
unplanned outages of the drums, and
also applies net present value (NPV)
principles to further assess the expected
cost savings. A rigorous NPV calculation
can demonstrate the excellent value of
these innovations. However, for the
purposes of this discussion, a simplified
LCVA model is utilised as follows:
Conventionally designed drums
Capex The initial Capex outlays for four
vertical plate coke drums are assumed to
be $26.1 million. In this example, the
drums come at an initial Capex
premium of $2.175 million compared to
conventional drum designs. Thus,
Capex for conventional drums is
assumed to be $23.9 million.
Opex At an average of 14 hours per unit
cycles, each conventional drum in
operation will go through 313 cycles per
year, which translates into 6260 cycles
over a 20-year period. As previously
mentioned, Livingston and Saunders
reported that the coke drums in their
survey began to through-wall crack at
roughly 2400 cycles, while an
independent 1996 API Survey confirmed
that the first through-wall cracks on
conventional drums typically occur in
the 30005000 cycle range (Figure 3).
Based on these findings, no fewer than
11 cracks per drum may reasonably be
predicted during the 20-year period.
For simplicity, it is assumed that
planned outages deal with 30% of the
cracks that will appear (three cracks), so
the remaining eight cracks will
significantly dictate more expensive
unplanned refinery stoppages of the
coke drums, which is where the Opex
cost is greatest. In this example, costs are
determined for a planned turnaround,
and then a 30% uplift is applied for
unplanned events. It is assumed that
each stream-to-stream unplanned
outage will last an average of six days.
Thus, to remedy a through-wall crack, it
will cost (in 2005 dollars):
Costs of a single crack repair (20
workers * six days * two 10-hour shifts *
$85 per hour) + (materials, scaffolding/
equipment, insulation, repairs and so
on) = minimum $225 000
Costs of crack repairs over a 20-year
period Three planned events * ($225 000)
+ eight unplanned events * ($225 000 *
1.3) = $3 million in repair costs for each
drum, or $12.1 million for all four drums.
Direct financial losses The greatest
impact occurs when one considers the
lost revenues caused by the afore-
mentioned cracking events. In addition,
there are hazardous plant risks that can
accompany the cracking. For the eight
unplanned refinery stoppages that will
occur over the 20-year period, if the
example drum pair has a capacity of
25 000bbl/day and the product is valued
at 85% of the WTI value (an average of
$50 per bbl):
Direct financial losses over a 20-year
period Eight unplanned events/drum
pair * six days for each event * 25 000
bbl/day * (0.85 * $50) = $51 million in
lost revenues for each drum pair, or
$102 million for all four drums.
www. ept q. c om 00 PTQ Q3 2006
Support
Coke drum
shell
Coke drum
shell
R3
H2
H1
R2
R1
Figure 8 Wrapper design
cb&i 5/5/06 20:17 Page 5
Vertical plate coke drums
Capex As previously mentioned, the
initial Capex outlays for four vertical
plate coke drums is assumed to be $26.1
million.
Opex The vertical plate technology is
expected to defer cracking substantially.
Since 75% of the critical circumferential
weld seam footage has been eliminated,
we can assume there will be 75% fewer
cracks. Thus, the Opex for shell cracking
on a vertical plate coke drum may be 11
* 0.25 = three events over the 20-year
period, of which 30%, or one, of the
events will be planned and the
remaining two events will be
unplanned. Using the same analysis as
with the conventionally designed coke
drums over the same 20-year period:
Costs of crack repairs over a 20-year
period One planned event * ($225 000) +
two unplanned events * ($225 000 * 1.3)
= $810 000 in repair costs for each drum,
or $3.2 million for all four drums.
Direct financial losses In terms of lost
revenues caused by cracking, the same
assumptions apply from above, but for
only two unplanned events. Thus:
Direct financial losses over a 20-year
period Two unplanned events/drum pair
* six days for each event * 25 000bbl/day
* (0.85 * $50) = $12.7 million in lost
revenues for each drum pair, or $25.5
million for all four drums.
Based on the LCVA, it can be seen that
the lifecycle Opex and lost revenue costs
over a 20-year period for four
conventionally designed coke drums
total about $114 million, compared with
about $29 million for coke drums using
vertical plate technology. Thus, vertical
plate coke drums can save refinery
owners approximately $85 million over
the 20-year period, not to mention the
added advantages of greater plant safety.
Note that these calculations are
conservative, as downtime in a delayed
coker unit, as in any key processing unit,
affects the overall throughput of the
refinery. Also, without a rigorous
inspection and maintenance schedule,
failures can occur at inopportune times
such as the summer driving season when
product values are at their peak. Hence,
the direct financial losses due to outages
are likely to be greater than described in
this discussion, and the corresponding
benefits of vertical plate technology are
likely to be that much higher.
Future outlook
Since 2000, CB&I has completed four
vertical plate projects, bringing its total
number of vertical plate coke drums in
service to 11. These projects have
included the full circumferential can
section replacement of shells ranging
from 3573ft, as well as new lower
knuckle and skirt assemblies. As far as
improving the reliability and lifespan of
coke drums go, as previously mentioned
none of the vessels have been in service
long enough to allow quantification of
the actual improvement. However, the
vertical plate coke drums installed at
the West Coast refinery in 2000 have
seen about six years of service and are
approaching 2000-plus cycles with no
evidence of any unusual distortion.
Currently, four more drums are under
contract. The first project is for a
Canadian refiner and includes two new
drums of slightly larger dimensions to be
installed during a turnaround later this
year. This project is unique in that the
drums are being fabricated in three
segments. The segments are then to be
transported to the site and installed
through the side of the structure during
the outage while seams are being welded
in place. The second project is for two
drums being erected on site and installed
on the table top for final assembly.
As feedstocks become heavier and the
need for coking capacity continues to
rise, refiners will need more than ever to
have coke drums that provide greater
reliability than traditionally possible.
Whether it is a retrofit application, a full
vessel replacement or part of a new
process unit, vertical plate coke drums
will be able to endure the most severe
thermal cycles and outlast any conven-
tionally designed vessel. Implementing
a T-Rex or wrapper design for the
support is expected to further improve
the life of these vessels.
This article is based on a paper (AM-06-48)
presented at the NPRA Annual Meeting, Salt
Lake City, Utah, 20 March 2006.
References
1 Weil N A, Rapasky F S, Experience with
vessels of delayed coking units, API 23rd
Midyear Meeting, 1958.
2 Boswell R S, Ferraro T, Remaining life
evaluation of coke drums, Plant Engineering,
Design and Responsibility Symposium,
Energy Engineering Conference, 1997.
3 Antalffy L P, Malek D W, Pfeifer J A, Stewart
C W, Grimsley B, Shockley R, Innovations
in delayed coking coke drum design, ASME,
1999.
4 Livingston B, Saunders K L, Coke drums
failure prediction evaluation using
probabilistic techniques, ASME, 1998.
5 Penso J A, Lattarulo Y M, Seijas A J, Torres J,
Howden D, Tsai C L, Understanding failure
mechanisms to improve reliability of coke
drums, ASME, 1999.
6 ASME Section II parts A & C, plus Plate and
Electrode Manufacturers brochures and
CB&I data.
Coby W Stewart is business development
manager, Chicago Bridge & Iron, The
Woodlands, Texas, USA.
Email: [email protected]
Aaron M Stryk is global marketing
manager, Chicago Bridge & Iron, The
Woodlands, Texas, USA.
Email: [email protected]
Lee Presley is product and engineering
manager, pressure vessels and special
structures, Chicago Bridge & Iron, The
Woodlands, Texas, USA.
Email: [email protected]
www. ept q. c om 00 PTQ Q3 2006
acs
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