Trouble Shooting in Delayed Coker Unit Inspection Experience Gupta Sujith MRPL DCU Mumbai 2016 PDF

TROUBLE SHOOTING IN DELAYED COKER UNIT-
INSPECTION EXPERIENCE
Vipul Gupta P Sujith

Senior Engineer-Inspection, TS DGM (TS-Inspection)
vipulgupta@mrpl.co.in sujithp@mrpl.co.in
TROUBLE SHOOTING IN
DELAYED COKER UNIT
CONTENTS
• Introduction
Learning from :
• Coker Heater
• Coker Fractionator
• Coke drum Chute area
• Cutting deck piping & Small bore tapping’s
• Summary and Discussion

MRPL’s DCU DETAILS
• Licenser - M/s Lummus Technology
• PMC- M/s EIL
• Contractor (CDSP) – M/s Punj Lloyd
• Contractor (BOP) – M/s TEIL
• Capacity - 3.0 MMTPA
• Feed - VR formed from distillation of Arab heavy Crude
• On-Stream Factor - 8000 Hrs/yr (333.33 days)
• Turn Down – 50 %
• Through put ratio: 1.10 (This is defined as the ratio of combined
heater feed flow rate (including the internal recycle stream from
the bottom of wash section) to the DCU fresh feed rate.
• Design feed TAN < 0.5
Learning from Coker Heater
Observations /analysis Corrective measures Feedback
• 02 instances of Bulging and • Replacement of tube • Online inspection is
sagging of radiation section tubes sections beyond 5% limited to Visual
enlargement in OD. inspection
• Size: 114.3mm OD X 11.13mm
Thk , MOC: 9Cr-1Mo (SA 335 Gr • RT carried out to check • Off line inspection
P9) the extent of coke includes visual and
• Dimensional measurement deposition at random dimensional check,
revealed bulging Photo locations thickness & hardness
measurements and RT for
• Bulging and sagging due to coking • Thickness measurement, checking coke deposition.
and localised heating. Hardness check, visual
and dimensional • Additional no. of skin
• Metallurgical analysis of Samples inspection thermocouples.
of failed tubes
• Results indicate comparable

metallurgical damage in bulged
tubes with 5% and more.
Learning from Coker Fractionator
Observations Corrective measures Analysis/Feedback
• Column opened for internal • Coke deposits were • Damage to Coke strainer
inspection subsequent to heater removed and Strainer caused by damage to
charge pump flow issue. assembly was repaired overflow down pipes
Blockage suspected. Sketch which aggravated the coke
• Overflow down pipes were deposition.
• Coke deposits on bottom dish fixed back as per the
end. Coke strainer observed modified supporting • Also, over flow down pipe
damaged and partially blocked arrangement recommended damaged due to self
by tray vendor. weight and insufficient
• Overflow down pipes supporting.
connected to chimney tray #1 • Refractory repair work was
sheared and were lying on the carried out along with dry • Efficient dry out
bottom dish end. out procedures and special
Photos castable if any for use
• Refractory damage approx during shutdown ?
50% of the area on top of
chimney tray#1. KAST-O-
LITE 20 Photos
Learning from Coke drum Chute area
Observations Corrective measures Analysis/Feedback
• Coke drum chute is provided • Restoration of damaged • Failure due to Improper

with a 19 mm thk abrasion chute plates and welding welding consumable /
resistant plate on top of concrete. capping with hard facing procedure
Photo electrodes.
• No hard facing was
• Failure of Chute plates of 2 nos. • Inspection and repair of performed on site
drums balance drums Chute fabrication welds.
plates.
• Plate material ABRAZO 400 by
TATA Steel UK (Carbon steel
with hard facing).
Learning from Small bore tapping’s
Observations Corrective measures Analysis/Feedback Sort
(1) Failure in Wet gas compressor • Replacement of the failed • Cause of failure is
2nd Stage discharge 0.75” PG assemblies and mechanical fatigue due
tapping Photo modification of the existing vibration
supporting arrangement.
• Crack observed near the stiffener
support to 0.75” pipe weld • Hardness values of failed
upstream of isolation valve. sections were checked and
MOC Carbon steel with PWHT found within acceptable
limits.
(2) Stripper overhead line connected
0.75” PT tapping shear. MOC • No sign of internal or
Carbon steel with PWHT. Photo external corrosion in visual
inspection and thickness
• Circumferential through survey
thickness crack all around the
periphery resulting in shearing. • Inspection of balance
tappings and corrective
action
Learning from Antifoam lines
• Repeated failures observed in • Replacement of the failed • Analysis of failed pieces
Antifoam line connected to portions of the line. indicate that failures were
Coke drum. Line size 3” and Minor pitting noticed due to combined effect of
MOC 9Cr-1Mo (SA335 Gr P9) corrosion and vibration.
• Hardness check carried
• Failures were limited to out for site welds. • Corrosion part is being
common portion of the line studied further.
used for supply of Antifoam • Radiography & re-PWHT
and top cooling water. • Few cases of improper
• Re-examination of the PWHT also contributed to
• During hydrotest after repair, joints was carried out failures in presence of
leaks detected at multiple after PWHT. vibration.
locations. All leaks were from
cracks in the weld HAZ. • Modification for providing
isolation valves on the drum
• Higher hardness values were nozzles for ease of
recorded at certain locations maintenance in case of
failure.
• Normal values also observed
for few failed portions. Photo
Learning from coke drum PSV line
• Coke drum connected 24” PSV • Replacement of the failed • Probable cause of
header has 2 nos. PSV’s mounted section of the piping. failure:-
for individual drums. higher hardness of the
• Identification of reducers fitting
• Crack observed on weld HAZ of having similar heat nos. Higher hardness of weld
Eccentric reducer (10”X12” SA Vibration related.
234 Gr WP9) connected to PSV
outlet line. • Feedback required on
similar issues
• Circumferential through
thickness crack from
12 O’clock to 1 O’clock position
on the 10” side of the reducer in
HAZ of the reducer to flange
weld.
• No sign of external or internal

corrosion. Higher hardness
recorded on the reducer and both
welds of the reducer-Photo
Summary & Discussion
• Coker Heater online monitoring techniques and acceptable limits of tube bulging ?
• Fractionator refractory repair frequency and dry out procedures ?
• Small bore tapping’s Inspection techniques ?
• Coke drum connected lines support modification to contain vibration?
• Coke drum Laser Mapping and RVI frequency and any additional techniques used for
inspection? Link
THANK YOU
vipulgupta@mrpl.co.in
sujithp@mrpl.co.in
Learning from Coker Heater
Back
Back
Back
Back
Learning from drum Chute area
Back
Learning from Antifoam lines
Back
Back
Back
Learning from coke drum PSV line
Back
Coke drum Inspection
Observations/Future Inspection plans Feedback Required
• Coke Drum 9 Mtr ID and 41 Mtr Height • LASER mapping and RVI frequency for 24
MOC 1.25Cr-0.5Mo Base with SS410 Clad hour cycle time ?
• LASER Mapping and RVI carried out in • Finite element analysis to study thermal
September 2014 as a base line measurement stresses using the temperature data of the
for all 4 drums. No major abnormalities drums along with other operational history?
notices.
• Any other type of online/shutdown inspection
• Second round of inspection in 2017. to be performed for checking the integrity of
the drums on regular basis?
• Inspection of the Key Holes provided in the
coke drum skirt to identify cracks is planned
during upcoming shutdown.
Back

Trouble Shooting in Delayed Coker Unit Inspection Experience Gupta Sujith MRPL DCU Mumbai 2016 PDF

Uploaded by

Copyright:

Available Formats

Trouble Shooting in Delayed Coker Unit Inspection Experience Gupta Sujith MRPL DCU Mumbai 2016 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Trouble Shooting in Delayed Coker Unit Inspection Experience Gupta Sujith MRPL DCU Mumbai 2016 PDF

Uploaded by

Copyright:

Available Formats

TROUBLE SHOOTING IN DELAYED COKER UNIT-

Vipul Gupta P Sujith

• Summary and Discussion

• Results indicate comparable

• Coke drum chute is provided • Restoration of damaged • Failure due to Improper

• No sign of external or internal

• Fractionator refractory repair frequency and dry out procedures ?

• Small bore tapping’s Inspection techniques ?

• Coke drum connected lines support modification to contain vibration?

You might also like