Post on 08-Apr-2018
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Stress Engineering ServicesStress Engineering Services
forfor
Coke Drum Health MonitoringCoke Drum Health MonitoringAnd Reliability ImprovementAnd Reliability Improvement
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SES Engineering Services to Owners,SES Engineering Services to Owners,
Operators, and Designers of Delayed CokeOperators, and Designers of Delayed Coke
Drums..Drums..
4 Health Monitoring Systemsh Short and Long Term Strain
Monitoring of Coke DrumResponse to Daily Operation
h Cause and Effect ofOperation on Drum Damage
h Integration into local DCS
4 Defect Identification andAssessmenth Acoustic Emission Testing
h Inspection Planning &Coordination
4 Crack Growth Predictionh Fracture Mechanics and
Probabilistic Crack Growth
evaluations using actualoperating data
h Low Cycle Fatigue DamageAccumulation
4 Bulge Analysis
h Severity of bulges andgrowth rate
4 Drum Design and ModelingUsing Actual OperatingTransients
h Skirt
h Shell
h Piping and Nozzles
4 Life Assessment andExtension Recommendations
4 Metallurgical Consulting andTesting
h Weld Repair Procedures
h Creep Analysis and OmegaTesting
4 Heater Condition and LifeAssessment
4 Root Cause Failure Analysis
4 Forensic and LitigationSupport
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SES DrumBeatSES DrumBeatCoke DrumCoke Drum
Structural Health Monitoring ProgramStructural Health Monitoring Program
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Benefits of SES Program toBenefits of SES Program to
Coke Drum OperatorsCoke Drum Operatorsl Record and analyze actual measurements from
drum response to daily operation essential to
accurately assess, predict and extend drum Healthl Achieve a better understanding of cause and effect
of operation and processes on drum reliability
l Allow Operators to monitor, improve and
optimize daily operation versus drum damage tocreate Best Practices
l Make and Save Operators $$$$$$$$$$$$$$$$$$
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What SES does to improveWhat SES does to improve
Coke Drum Economics andCoke Drum Economics and
Reliability:Reliability:4 Install High Temperature Strain Gages,
Thermocouples and Intrinsically safe system tomonitor Shell and Skirt Regions
4
Hook Intrinsically Safe Logger into Local DCS orDirectly to SES
4 Retrieve Strain and Process Data routinely
4 Evaluate trends of recorded strain and damageversus daily operation:Cause and Effect
4 Provide Prompt Feedback and Analysis toOperators to allow for improvement
4 Provide Engineering Analysis and Support toExtend Life
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High Temperature Strain Gages,ocouples and Intrinsically safe system tr Shell and Skirt Regions
ntrinsically Safe Logger into Local DCSto SES
e Strain and Process Data routinely
te trends of recorded strain and damagdaily operation:Cause and Effect
Prompt Feedback and Analysis toors to allow for improvement
En ineerin Anal sis and Su ort to
What SES does to improveWhat SES does to improve
Coke Drum Economics andCoke Drum Economics and
Reliability:Reliability:4 Install High Temperature Strain Gages,
Thermocouples and Intrinsically safe system tomonitor Shell and Skirt Regions
4
Hook Intrinsically Safe Logger into Local DCS orDirectly to SES
4 Retrieve Strain and Process Data routinely
4 Evaluate trends of recorded strain and damageversus daily operation:Cause and Effect
4 Provide Prompt Feedback and Analysis toOperators to allow for improvement
4 Provide Engineering Analysis and Support toExtend Life
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Temperature distribution soon after Switching
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Skirt is forced outward during Fill transient
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High Temperature Strain GageHigh Temperature Strain Gage
with Intrinsically Safewith Intrinsically Safe
InstrumentationInstrumentation
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Structural Health MonitoringStructural Health Monitoring
Data Processing TasksData Processing Tasks
l Review Recorded Data for High Temperature Strain Gages
Thermocouples
l Correct Readings for Temperature Error
l Calculate each pair for Bi-Axial Principal Stressand Stress Intensity
l Determine Stress Range each Cycle
l Compile Histograms and Damage Accumulation
l Evaluate Process Cause and Structural Effect
l Compare Different Operating Procedures forresulting Structural Damage
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Measured Stress is caused byMeasured Stress is caused by
several conditionsseveral conditions
l Measured Stress isdue to
Pressure
Gravity and
Hydrostatic Thermal gradients
Flattening of Bulges
Solid CokeInterference
Solid Coke Friction Ring Bending from
Bulge Diameters
l Stress is composed of
Average stress in wall :Membrane
Bending Stressinside/outside wall
Secondary Stress forGeometric Equilibrium
Peak Stress at defects,undercuts, weld caps,radius transition
l Stress measurement onOD is independent ofsource of stress
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Typical Coking Cycle for Process and StressTypical Coking Cycle for Process and Stress
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Plot Stress Range for each CyclePlot Stress Range for each Cycle
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Histogram of Stress Ranges describes howHistogram of Stress Ranges describes how
often a stress happensoften a stress happens
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Calculate Fatigue Damage for each StressCalculate Fatigue Damage for each Stress
Component and Determine Cycle LifeComponent and Determine Cycle Life
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Histogram of Stress Ranges and DamageHistogram of Stress Ranges and Damage
for Low Cycle Fatiguefor Low Cycle Fatigue
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Operational Intelligence toreduce fatigue damage
Remaining Life Assessments
Integration With SES
DrumBeat Analysis
On-lineSensors Critical Control
Factors
OperatorLogs
Observations
SES
DCSInformation
Fatigue crack Growth PredictionLow Cycle Fatigue Damage
Accumulation
Outputs
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The Future DrumBeat.The Future DrumBeat.
An Automated and On SiteAn Automated and On Site
Structural HealthStructural Health
Monitoring SystemMonitoring Systemforfor
Improved Reliability ofImproved Reliability of
Delayed Coke DrumsDelayed Coke Drums
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SES DrumbeatSES DrumbeatInformation LinksInformation Links
l Remaining Life Evaluations of Coke Drums(pdf)
l Assessing Structural Integrity of Coke Drums(pdf)
l SES DrumBeat PowerPoint notes (pdf)
l Stress Engineering Services atwww.stress.com
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SES DrumBeatSES DrumBeatCoke DrumCoke Drum
Structural Health Monitoring SystemStructural Health Monitoring System
4 SES DrumBeat is a collection of procedures for processingstrain gage, thermocouple, and process data measured on acoke drum.
4 SES DrumBeat is becoming an automated software to routinelymanage large volumes of data in real time for cyclic damage
accumulation.4 SES DrumBeat will become an on-site system available to
provide clients with continuous update on coke drum operation.
4 SESDrumBeat.comis under development to provide clients asecure access to their results.
4
CokeDrum.comis under development to provide clients withinformation about SES and coke drum services.
4 Stress.comis the Stress Engineering Services web site forcomplete introduction to our upstream and downstreamengineering services.
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Stress Engineering Services, IncStress Engineering Services, Inc13800 Westfair East13800 Westfair East
Houston, TexasHouston, Texas7704177041
281-955-2900281-955-2900
www.stress.comwww.stress.com
This CD is the property of StressThis CD is the property of Stress
Engineering Services Inc. The informationEngineering Services Inc. The information
herein is confidential and is issued on theherein is confidential and is issued on the
understanding that no part thereof shall beunderstanding that no part thereof shall becopied or communicated to a third partycopied or communicated to a third party
without authorization in writing from Stresswithout authorization in writing from Stress
Engineering Services Inc.Engineering Services Inc.