View
215
Download
0
Category
Preview:
Citation preview
“Operational Reliability When Designing for Maintenance ”
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 2
Introduction – “Operational Reliability When Designing for Maintenance”
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 3
Owner wants – Minimum, Reliable + Easiest repairs Chemetics wants – Optimized, Rugged equip. designs
Best Achieved by working co-operatively at Shutdowns
Owner receives – Specific Info./Knowledge/Experiences Chemetics – Feedback
Mutually Beneficial Relationship
Case Histories – Strong Acid Brick Linings
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 4
Strong Acid Towers (6 global e.gs.)
Relevant Maint., Design, Construction Aspects Highlighted
#1 – Premature Abs. Shell Failure (+- 1yr.)
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 5
#1 – Illustration of Nozzle Thimble Sealing
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 9
+-Quality – Cracking Around Nozzle Lining
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 10
Contributing Factors to Premature Leaks
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 12
Lining Design - No membrane, Nozzle thimbles un-sealed
Steel Shell Shape/Roundness - Hollow areas under brick (acid can fill)
Lining Installation/QC/QA - Number of mortar joints very tight
Apparent Improvement Areas
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 13
Pecora Mastic + Teflon Sheet Membrane Nozzles Thimbles Centered, Sealed and
Bricked to Stronger Quality Presence during installation
Example #2 – Successful Pumping Repair
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 14
Ex. #2 – Comments
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 19
+-8 years for leak to develop. Pecora Mastic external pumping repair with good
results. No recurrence or spreading after +- 2 years. Shell roundness/voids under lining contributor to the
leak/thinned area. This operator has excellent reputation maintenance +
inspection in their acid plants. Good story not accident. Maintenance Tip – Thin Pecora with Xylene for pumping.
Ex. #3 - Old Tower in Bad Shape Major Repair
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 20
Ex. #3 – Steel Sulphate Bulges + Wrinkles
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 21
#3 – Ready for External Mortar Pumping
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 24
Example #3 – Comments
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 25
Reasonably successful but best value ??? Complex, risky, but a possibility (awareness) Saved shutdown time, footprint, material
handling, $/resources and a big repair in shorter time. Extended useable life without demolition.
Ex. #4 – Dry Tower Gas Inlet Chronic Leaks
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 26
Ex. #4– View of Damage at Start of Repair
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 27
Ex. #4 – Final Repair, Not a Lasting One
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 28
© 2013, Chemetics Inc. All rights reserved.Slide 29
Example #4 - Tower Design Comparison
Existing Tower Design Chemetics Tower Design
Existing Tower Gas Inlet Nozzle Design Chemetics Tower Gas Inlet Nozzle Design
© 2013, Chemetics Inc. All rights reserved.Slide 30
Brick Tower Design Comparison
Existing Tower Design Chemetics Tower Design
Existing Tower Seal/Lining details
Polypropylene Sleeve
Pack Gap Solidly With
Ceramic Fiber Rope
and Mortar
Chemetics Tower Seal/Lining Details
© 2013, Chemetics Inc. All rights reserved.Slide 31
Brick Tower Design Comparison
Existing Tower Design Chemetics Tower Design
Existing Tower Membrane details
6 mm Butyl or Chloro
Butyl Rubber
Chemetics Tower Membrane Details
© 2013, Chemetics Inc. All rights reserved.Slide 32
Brick Tower Design Comparison
Existing Tower Design Chemetics Tower Design
Existing Tower Brick Thickness details
6 + 5 + 95 Brick +5+95 brick, Total
206 mm MINIMUM brick thickness
Chemetics Tower Brick Thickness Details
Total brick thickness 110 mm
Ex. #5 – Dry Twr. Outlet Area Replacement
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 33
Ex. #5 – Preparation + Cleaning (important)
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 36
Ex. #5 – Work Environment (+-best possible)
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 37
Example #5 – Comments
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 41
Old Tower +- 23 yrs. at the time. Good Story – 2 yrs. no leaks or spread. Cleaning, Planning + Preparation – Most
important ! Maximize pre-fabrication (even for lining
repairs !) Improved reg. maintenance around acid outlet
may have extended time to leak.
Summary – “So Don’t Learn the Hard Way !”
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 43
Maintenance Side
Inspect linings internally each Outage Make mortar + packing repairs (retard progress) Preparation, pre-fabrication and cleaning paramount Critical Areas:
Acid Nozzles, Thimbles + Dip Pipes Gas Inlet Linings + Transitions Turbulent Areas Brick to SS “Drip Edge Transitions” Distributor Level Nozzle (circ. cracks) Steps in Lining Thickness Mortar loss/recession + brick movements in general
Summary – “So Don’t Learn the Hard Way !”
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 44
Design Side
Big investment, specialised layered construction Difficult to repair in a lasting way (contamination) Details very important (CS, membrane + lining)
Chemetics specify these Don’t leave to steel + brick suppliers
Try to remember “Value” not cost Follow “Cradle to Grave”
Summary – “So Don’t Learn the Hard Way !”
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 45
Installation Side
Use only reputable + experienced material suppliers + installers
Independent QC/QA recommended “Show you care !” “Trust but Check !”
Current Trend: For Large Dia. Towers steel roundness is an area to be aware of
Conclusion
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 46
“Hands-on” sharing of information + repair histories between Operators and Technology Suppliers is Key to ensuring “Consistent Operation” and good solutions.
“Operational Reliability When Designing for Maintenance”
THE END
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 47
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 48
Copyright
Copyright of all published material including photographs, drawings and images in this document remains vested in Jacobs and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.
© Copyright 2012, Chemetics Inc. All rights reserved.Slide 49
Disclaimer
This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions of the regions and industries that are major markets for Jacobs Engineering Group Inc. (including subsidiaries and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements containing words such as “expects”, “believes”, “estimates” or similar expressions. Important factors that could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that are or will be major markets for Jacobs’ businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Jacobs Engineering Group Inc. believes that its expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation. Jacobs Engineering Group Inc. is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation, and neither Jacobs Engineering Inc. nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use.
Jacobs consists of many legally independent entities, constituting their own separate identities. Jacobs is used as the common brand or trade mark for most of these entities. In this presentation we may sometimes use “Jacobs”, “we” or “us” when we refer to Jacobs companies in general or where no useful purpose is served by identifying any particular Jacobs company.
Recommended