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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
L&T Heavy Engineering
© 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
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 4Sensitivity : This Document is Classified as "LNT Internal Use".
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
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 5Sensitivity : This Document is Classified as "LNT Internal Use".
Bulge Overlay
Arrangement of Resources during shutdown…
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 6Sensitivity : This Document is Classified as "LNT Internal Use".
Bulge Overlay
Mockup
Clad Stripping
Surface finish after Gouging
Clad Stripping by Gouging
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 7Sensitivity : This Document is Classified as "LNT Internal Use".
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
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 8Sensitivity : This Document is Classified as "LNT Internal Use".
Bulge Overlay
Surface finish after Weld Overlay
▪ Offer as weld bead finish
1:10 Taper
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 9Sensitivity : This Document is Classified as "LNT Internal Use".12/4/2019
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
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 10Sensitivity : This Document is Classified as "LNT Internal Use".
Clad RepairAfter Gouging
After clad restoration
▪ Controlled depth gouging to avoid base metal damage▪ Clad restoration by fully automatic Welding
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 11Sensitivity : This Document is Classified as "LNT Internal Use".
InSitu Dry Slot Cutting
Coke Drum Skirt
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 12Sensitivity : This Document is Classified as "LNT Internal Use".
In-situ Dry Slot Cutting
▪ Space constraint: 200 mm between Skirt # Steam pipe▪ In-housed developed InSitu machine for safe working
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 13Sensitivity : This Document is Classified as "LNT Internal Use".
Site & Shop Fabrication
Coke Drum Manufacturing
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 14Sensitivity : This Document is Classified as "LNT Internal Use".
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
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 15Sensitivity : This Document is Classified as "LNT Internal Use".
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
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 16Sensitivity : This Document is Classified as "LNT Internal Use".
Coke Drum Manufacturing
Workshop Fabrication:
▪ Largest order executed : 8 nos. of Coke drum delivered in single dispatch
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 17Sensitivity : This Document is Classified as "LNT Internal Use".
Modification & Upgradationof
associated systems
Coke Drum
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 18Sensitivity : This Document is Classified as "LNT Internal Use".
CFD Nozzle Installation
▪ Critical set-up & fabrication at site▪ PWHT with +/- 5 deg. Temperature control Source: Delta Valve, USA
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 19Sensitivity : This Document is Classified as "LNT Internal Use".
Delta Valve Handling
▪ Critical Rigging of valves at larger radius distance & height▪ Design & fabrication of a dedicated fixture for safe handling
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 20Sensitivity : This Document is Classified as "LNT Internal Use".
Vapor Line Revamp
▪ Critical Rigging of spools at various elevations▪ Critical Heat Treatment & NDT▪ Working in congested area for modification / replacement
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 21Sensitivity : This Document is Classified as "LNT Internal Use".
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
L&T Heavy Engineering
© 2019 Larsen & Toubro Limited : All rights reserved 22Sensitivity : This Document is Classified as "LNT Internal Use".
Thank You
L&T MRU Team:
Rajesh SinghSr. DGM – Marketing, MRUEmail: [email protected]: +91 9920991424,
+91 022 6705 1676
Nilesh ShahHead – Execution, MRUEmail: [email protected]: +91 9925232468,
+91 261 280 7424