L&T Heavy Engineering

© 2019 Larsen & Toubro Limited : All rights reserved 1Sensitivity : This Document is Classified as "LNT Internal Use".

Criticality in Coke Drum Repair

End to End solution…

By Nilesh Shah

L&T Heavy Engineering

© 2019 Larsen & Toubro Limited : All rights reserved 2Sensitivity : This Document is Classified as "LNT Internal Use".

Contents

Coke drum Repair

In-situ Dry Slot cutting

Site & Shop Fabrication

Modification & Upgradation of associated systems

12/4/2019

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© 2019 Larsen & Toubro Limited : All rights reserved 3Sensitivity : This Document is Classified as "LNT Internal Use".

Bulge Overlay,Base Metal Repair

&Clad Repair

Coke Drum Repair

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Methodology

▪ Resource arrangement for bulge overlay/crack repair at various elevation &orientation

▪ Temper bead technique for weld overlay & crack repair▪ Confined space working with climate control

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Bulge Overlay

Arrangement of Resources during shutdown…

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Bulge Overlay

Mockup

Clad Stripping

Surface finish after Gouging

Clad Stripping by Gouging

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Bulge Overlay

Inhouse developed Fully Automatic Weld overlay Systems

▪ Multiple systems for higher productivity▪ Temper bead technique for better mechanical properties & to avoid PWHT▪ Optimized weld parameters to minimize HAZ width▪ Inhouse pool of experienced welders▪ Prompt response for emergency shutdown

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Bulge Overlay

Surface finish after Weld Overlay

▪ Offer as weld bead finish

1:10 Taper

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Overlay patch after repair

Base Metal Repair

Connected patches by taper welding

▪ Precise gouging for avoiding damage to base metal▪ Temper bead technique for better mechanical properties & to avoid PWHT

Emergency RepairPlanned Repair

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Clad RepairAfter Gouging

After clad restoration

▪ Controlled depth gouging to avoid base metal damage▪ Clad restoration by fully automatic Welding

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InSitu Dry Slot Cutting

Coke Drum Skirt

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In-situ Dry Slot Cutting

▪ Space constraint: 200 mm between Skirt # Steam pipe▪ In-housed developed InSitu machine for safe working

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© 2019 Larsen & Toubro Limited : All rights reserved 13Sensitivity : This Document is Classified as "LNT Internal Use".

Site & Shop Fabrication

Coke Drum Manufacturing

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Field Fabrication @ IOCL-Gujarat & IOCL Panipat

▪ Site fabrication meeting all stringent quality norms▪ Stringent delivery & site installation in working refinery▪ Critical Heat treatment & Hydrotest at site

Total 08 nos Coke Drums anufactured

at site

Coke Drum Manufacturing

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Workshop Fabrication:

▪ State-of-the art manufacturing facility▪ Meeting all stringent customer / process licensor requirements▪ Largest Coke Drum manufactured; Dia. 10 m, Length 35 m▪ Timely delivery

Total 72 nos Coke Drums

manufactured

Coke Drum Manufacturing

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Coke Drum Manufacturing

Workshop Fabrication:

▪ Largest order executed : 8 nos. of Coke drum delivered in single dispatch

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Modification & Upgradationof

associated systems

Coke Drum

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CFD Nozzle Installation

▪ Critical set-up & fabrication at site▪ PWHT with +/- 5 deg. Temperature control Source: Delta Valve, USA

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Delta Valve Handling

▪ Critical Rigging of valves at larger radius distance & height▪ Design & fabrication of a dedicated fixture for safe handling

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Vapor Line Revamp

▪ Critical Rigging of spools at various elevations▪ Critical Heat Treatment & NDT▪ Working in congested area for modification / replacement

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Coke Drum: CapabilitiesField Repair

1. Bulge Overlay2. Clad Repair3. Base Metal/Seam Repair4. In-situ Dry Slot Cutting – Skirt5. Slot Crack Repair - Skirt

Manufacturing

1. Field Fabrication2. Workshop Fabrication

Other Services

1. Center Feed Nozzle2. Delta Valve Handling (BUD, TUD)3. Vapor Line Revamp4. FEA Services5. Bottom Flange Machining

Digital Solution

1. Life Cycle Assessment using IoT

Manufacturing

Other Services

Field Repair

Digital Solutions

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Thank You

L&T MRU Team:

Rajesh SinghSr. DGM – Marketing, MRUEmail: RAJESH.SINGH4@larsentoubro.comContact: +91 9920991424,

+91 022 6705 1676

Nilesh ShahHead – Execution, MRUEmail: NILESH.SHAH@larsentoubro.comContact: +91 9925232468,

+91 261 280 7424