Stress Engineering Services

for
Coke Drum Health Monitoring
And Reliability Improvement

April 12, 2001 Stress Engineering Services, Inc 1

 SES Engineering Services to Owners,
Operators, and Designers of Delayed Coke
Drums…..
4 Health Monitoring Systems
h Short and Long Term Strain
Monitoring of Coke Drum
Response to Daily Operation
h Cause and Effect of
Operation on Drum Damage
h Integration into local DCS
4 Defect Identification and
Assessment
h Acoustic Emission Testing
h Inspection Planning &
Coordination
4 Crack Growth Prediction
h Fracture Mechanics and
Probabilistic Crack Growth
evaluations using actual
operating data
h Low Cycle Fatigue Damage
Accumulation
4 Bulge Analysis
h Severity of bulges and
growth rate
April 12, 2001 Stress Engineering Services, Inc
4 Drum Design and Modeling
Using Actual Operating
Transients
h Skirt
h Shell
h Piping and Nozzles
4 Life Assessment and
Extension Recommendations
4 Metallurgical Consulting and
Testing
h Weld Repair Procedures
h Creep Analysis and Omega
Testing
4 Heater Condition and Life
Assessment
4 Root Cause Failure Analysis
4 Forensic and Litigation
Support
2
 SES DrumBeat Coke Drum
Structural Health Monitoring Program

April 12, 2001 Stress Engineering Services, Inc 3

 Benefits of SES Program to
Coke Drum Operators
l Record and analyze actual measurements from
drum response to daily operation essential to
accurately assess, predict and extend drum Health
l 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 to
create “Best Practices”
l Make and Save Operators $$$$$$$$$$$$$$$$$$

April 12, 2001 Stress Engineering Services, Inc 4

 What SES does to improve
Coke Drum Economics and
Reliability:
4 Install High Temperature Strain Gages,
Thermocouples and Intrinsically safe system to
monitor Shell and Skirt Regions
4 Hook Intrinsically Safe Logger into Local DCS or
Directly to SES
4 Retrieve Strain and Process Data routinely
4 Evaluate trends of recorded strain and damage
versus daily operation: Cause and Effect
4 Provide Prompt Feedback and Analysis to
Operators to allow for improvement
4 Provide Engineering Analysis and Support to
Extend Life
April 12, 2001 Stress Engineering Services, Inc 5
 What SES does to improve
Coke Drum Economics and
Reliability:
4 Install High Temperature Strain Gages,
Thermocouples and Intrinsically safe system to
monitor Shell and Skirt Regions
4 Hook Intrinsically Safe Logger into Local DCS or
Directly to SES
4 Retrieve Strain and Process Data routinely
4 Evaluate trends of recorded strain and damage
versus daily operation: Cause and Effect
4 Provide Prompt Feedback and Analysis to
Operators to allow for improvement
4 Provide Engineering Analysis and Support to
Extend Life
April 12, 2001 Stress Engineering Services, Inc 5
 Temperature distribution soon after Switching

April 12, 2001 Stress Engineering Services, Inc 6

 Skirt is forced outward during Fill transient

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 High Temperature Strain Gage
with Intrinsically Safe
Instrumentation

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 Structural Health Monitoring
Data 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 Stress
and 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 for
resulting Structural Damage

April 12, 2001 Stress Engineering Services, Inc 9

 Measured Stress is caused by
several conditions

l Measured Stress is l Stress is composed of

due to – Average stress in wall :
– Pressure Membrane
– Gravity and – Bending Stress
Hydrostatic inside/outside wall
– Thermal gradients – Secondary Stress for
– Flattening of Bulges Geometric Equilibrium
– Solid Coke – Peak Stress at defects,
Interference undercuts, weld caps,
radius transition
– Solid Coke Friction
– Ring Bending from l Stress measurement on
Bulge Diameters OD is independent of
source of stress

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 Typical Coking Cycle for Process and Stress

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 Plot Stress Range for each Cycle

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 Histogram of Stress Ranges describes how
often a stress happens

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 Calculate Fatigue Damage for each Stress
Component and Determine Cycle Life

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 Histogram of Stress Ranges and Damage
for Low Cycle Fatigue

April 12, 2001 Stress Engineering Services, Inc 15

 Integration With SES
“DrumBeat” Analysis
On-line
DCS Sensors Critical Control
Information Factors

SES
Operator Observations
Logs Outputs

Operational Intelligence to Fatigue crack Growth Prediction

reduce fatigue damage Low Cycle Fatigue Damage
Remaining Life Assessments Accumulation

April 12, 2001 Stress Engineering Services, Inc 16

 The Future DrumBeat….

An Automated and On Site

Structural Health
Monitoring System
for
Improved Reliability of
Delayed Coke Drums

April 12, 2001 Stress Engineering Services, Inc 17

 SES Drumbeat Information 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 at

www.stress.com

April 12, 2001 Stress Engineering Services, Inc 18

 SES DrumBeat Coke Drum
Structural Health Monitoring System
4 SES DrumBeat is a collection of procedures for processing
strain gage, thermocouple, and process data measured on a
coke drum.
4 SES DrumBeat is becoming an automated software to routinely
manage 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.com is under development to provide clients a
secure access to their results.
4 CokeDrum.com is under development to provide clients with
information about SES and coke drum services.
4 Stress.com is the Stress Engineering Services web site for
complete introduction to our upstream and downstream
engineering services.
April 12, 2001 Stress Engineering Services, Inc 19
April 12, 2001 Stress Engineering Services, Inc 20
 Stress Engineering Services, Inc
13800 Westfair East
Houston, Texas
77041
281-955-2900
www.stress.com

This CD is the property of Stress

Engineering Services Inc. The information
herein is confidential and is issued on the
understanding that no part thereof shall be
copied or communicated to a third party
without authorization in writing from Stress
Engineering Services Inc.
April 12, 2001 Stress Engineering Services, Inc 20