INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY & Coke …€¦ · 1 Rio de Janeiro, August 2009....
Transcript of INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY & Coke …€¦ · 1 Rio de Janeiro, August 2009....
Coke Drum WorkshopCoke Drum Workshop
INTRODUCTION ofINTRODUCTION ofSAIJO FACTORY &SAIJO FACTORY &INTRODUCTION ofINTRODUCTION ofSAIJO FACTORY &SAIJO FACTORY &SAIJO FACTORY &SAIJO FACTORY &
Coke Drum TechnologyCoke Drum TechnologySAIJO FACTORY &SAIJO FACTORY &
Coke Drum TechnologyCoke Drum TechnologyCoke Drum TechnologyCoke Drum TechnologyCoke Drum TechnologyCoke Drum Technology
Rio de Janeiro, August 2009Rio de Janeiro, August 2009
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Rio de Janeiro, August 2009Rio de Janeiro, August 2009
CONTENTSCONTENTS
1. SAIJO Factory Profile
2 E i & C bili2. Experience & Capability
3 C tti Ed T h i3. Cutting Edge Techniques
4 Research & Development4. Research & Development
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1. SAIJO Factory Profile■L ti■Location
■History■History
■Brief Introduction
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SAIJO Factory ProfileSAIJO Factory Profile : Location: Location
Chiba Works
Nagoya Works
Okayama Works
TokyoTokyo
Tanashi Works
Oppama Works/Research & Development Center
Kobe Port
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Ehime Works-Niihama Factory
Ehime Works-Saijo FactorySaijo Factory
SAIJO Factory ProfileSAIJO Factory Profile : History: History
Established as a manufacturing base for large steel products
1974 Obtained U & U2 Stamps of ASME
19731973
1974 Obtained U & U2 Stamps of ASME
1984 Attained 100 unit ASME Stamped Products
1993 Obtained ISO 9001 certificate
1989 Concentrated on Reactors and Coke Drums
1993 Obtained ISO 9001 certificate
999
1996 Concentrated on Coke Drum Manufacturing
1999 Obtained ISO 14001 certificate
2006 Fabricated 100th Coke Drum
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2009 Total Coke Drums Awarded Since 1973 = 176!
SAIJO Factory ProfileSAIJO Factory Profile : Brief Introduction: Brief Introduction
To be played the embedded audio-video file of Saijo Factory’s Brief Introduction for about 6 minutes.
2.Experience & Capabilityp p y■World-wide Delivery■Coke Drum Weight & Size■Materials■Materials■Strict Quality Assurance■Site Assembly
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■Field Inspection Services
Experience & Capability : World-wide Delivery
176 Coke Drums Delivered Throughout the World
8(As of May 2009)
Experience & Capability : Coke Drum Weight & Size
One Drum Weight vs Built Year
600
One Drum Weight vs. Built Yearton(lbs) 176 Drums of Experience
Putting drum weight
Max. Weight : 560 ton( ID : 9.144 m )
(1,233 lb)
500
Putting drum weightin chronological order
Drums in North AmericaDrums in South America
(1,322)
(1,101)
(30 ft)
Max. ID : 9.8m
(32 ft)
400Others
Under fabrication> 20
(881)
200
300 > 20(665)
(441) very
er
ica
100
(441)
(220)
he fi
rst d
eliv
Sou
th A
me
9
0
1984
1988
1992
1996
2000
2004
2008
2012
1985
Th to
Experience & Capability : Coke Drum Weight & Size
One Drum Weight vs Built Year
600
One Drum Weight vs. Built Year
176 Drums of ExperiencePutting drum weight
The uniform thickness shell has prevailed since 2002
500
600 g gin chronological order
Step-up Shell Thk.
(1,322)
(1,101)
400Uniform Shell
Thk.
Thk.Uniform Shell
Thk.
( )
(881)
ton
(lb)
200
300(665)
(441)
100
(441)
(220)
10
0
1984
1988
1992
1996
2000
2004
2008
2012
Fabrication Experiences of Coke Drums
Experience & Capability : Materials
Fabrication Experiences of Coke Drums for Individual Base Materials
Total Number 1763Cr 1Mo ¼V
C-½Mo2¼Cr-1Mo
Total Number 1763Cr-1Mo-¼V2, (1%)
1Cr-½Mo
12, (7%)2¼Cr-1Mo12, (7%)
1¼C ½M
1Cr ½Mo29, (16%)
1¼Cr-½Mo121, (69%)
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Chronological Fabrication Experiences of
Experience & Capability : Materials
Chronological Fabrication Experiences of Coke Drums for Individual Base Materials
Total Number 176
6
7
3Cr-1Mo- ¼V 2
4
5
1Cr-½Mo
2¼Cr-1Mo 12
29
2
31¼Cr-½Mo
C-½Mo
121
12
1
C-½Mo
CS
12
12
0
1984
1988
1992
1996
2000
2004
2008
2012
Experience & Capability : Strict Quality AssuranceSkilled Welders S fSkilled Welders Solid Performance Anywhere
ASME Qualified Welders: Over 120
Honing their skills through the training program
ASME Qualified Welders: Over 120
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Experience & Capability : Site AssemblyAssembling Experience in South America Shipping Fit-up
Assembling Experience in South America
*Surface Transportation
*Both processes are out of
14Field Welding*Erection
are out of Sumitomo’s scope
Experience & Capability : Site AssemblyAssembling Experience in South America Assembling Experience in South America
The great extent of our capabilities for a site
Ex.-1)Buckling analysis verification
passembly
g ytaking the reduction in the material properties due to PWHT on site and the field weld groove fit up conditionweld groove fit-up condition into consideration
Ex 2)Ex.-2)Applied organization to meet “ASME Field Assembly”
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y
In Service AUT Inspection for Coke Drum
Experience & CapabilityExperience & Capability : Field Inspection Services: Field Inspection Services
In-Service AUT Inspection for Coke Drum Dual PA Sector Scan (by using 2 PA Probes) and Dual TOFD Simultaneous
Inspection SystemS f C Detection and Accurate Height Sizing by Phased Array for Fatigue Cracks in
the Clad Restoration Weld and its Heat Affected Zone
Dual PA Sector Scan Probes
PA Linear Scan Probes
16A Subsidiary of Sumitomo Heavy Industries, LTD.
S.H.I. EXAMINATION & INSPECTION, LTD.
Experience & CapabilityExperience & Capability : Field Inspection Services: Field Inspection Services
In Service AUT Inspection for Coke DrumIn-Service AUT Inspection for Coke Drum
Contribution to ASME PVP 2003by PDVSA & S H I EIby PDVSA & S.H.I.EI
17A Subsidiary of Sumitomo Heavy Industries, LTD.
S.H.I. EXAMINATION & INSPECTION, LTD.
3 C tti Ed T h i3. Cutting Edge Techniques
■Integral Skirt Fabrication■Integral Skirt FabricationTo bring longer fatigue life by utilizing Sumitomo’s large scale facilities
■Automatic Devices■Automatic DevicesTo achieve high-level productivities and quality
■Production Process Control■Production Process ControlTo meet short delivery times and customer requests
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Integral Skirt Attachment Design
Cutting Edge TechniquesCutting Edge Techniques : Integral Skirt Fabrication : Integral Skirt Fabrication Integral Skirt Attachment Design
Shell Plate Section before M achining
Machining by the large scale vertical lathe enable us to manufacture the skirt attachment portion up to the coke drum
Ad
diameter 12m(39ft).
Advantage
highest stress pointsf kit t h d
・To make a larger inside radius 【R = 38mm(1.5”) - 50mm(2”)】
R
Offse
t
of skirt to head・No circumferential welds joint
at highest stress point of skirt to head
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SkirtInside Radius
Cutting Edge TechniquesCutting Edge Techniques : Integral Skirt Fabrication : Integral Skirt Fabrication Effect on Stress Intensity Range & Fatigue Life (Comparison Example)
80
100
)
700
800
Effect on Stress Intensity Range & Fatigue Life (Comparison Example)
σ1-σ
2
Viewpoint Viewpoint m)
0
20
40
60
nten
sity
(ksi
)
400
500
600
mp(
F゚)
inside inside
112.2
ksi
(R=1
3mm
87.9
ksi
(R=3
8mm
)
-60
-40
-20
00 20000 40000 60000 80000 100000 120000
Stre
ss In
100
200
300 Tem
S1-S2(Case1)
z
Integral Type,R=38mm
Conventional Type, R=13mm
-80time(sec)
0S1 S2(Case1)S1-S2(Case2) R1.0S1-S2(Case3) R1.5Temp
Principal Stress difference Vs. Time 5000
6000
7000
Cyc
les)
100
110
120
e k
si
(758.4) (Mpa
)
(689.5)
(827.4)
N : 2.1 times
1000
2000
3000
4000Fa
tigue
Life
(C
60
70
80
90
Stre
ss R
ang
Stress Range
(620.5)
(551.6)
Conventional Type“Stress Intensity Range” can be reduced to about 80% level by enlarging the inside radius from 13mm to 38mm
・
20
0
1000
0.25 0.5 0.75 1 1.25 1.5 1.75
Inside Radius inch (mm)
50
60Fatigue Life
(12.7) (25.4) (38.1)
R=13mm, 3060 cyclesradius from 13mm to 38mm.
The fatigue life can be extended to about 2 times by enlarging the inside radius.
・
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Cutting Edge TechniquesCutting Edge Techniques : Integral Skirt Fabrication : Integral Skirt Fabrication
Fabrication Experience of the Integral SkirtFabrication Experience of the Integral SkirtDrum ID
Applicable Max ID = 12 000mm (39’)
Built Year Drums Drum ID Inside Radius of
the Skirt Attachment
Applicable Max. ID 12,000 (39 )
1992 2 7,620 mm (25’) 20 mm (0.8”)
2002 6 8,484 mm (27.8’) 35 mm (1-3/8”)
2006 2 6,400 mm (21’) 30 mm (1-1/8”)
2007 3 6,100 mm (20’) 25 mm (1”)
2009 2 7 620 (25’) 30 (1 1/8”)2009 2 7,620 mm (25’) 30 mm (1-1/8”)
2009 2 6,400 mm (21’) 30 mm (1-1/8”)
(2010) 2 6 096 mm (20’) 35 mm (1-3/8”)
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(2010) 2 6,096 (20 ) 35 (1-3/8 )
Original Rectangular MaterialΣ19
Cutting Edge TechniquesCutting Edge Techniques : Automatic Devices : Automatic Devices Surface Finish of Welds with Special MachineSurface Finish of Welds with Special Machine
Typical Requirements for Surface Finish of Weld
Longitudinal seam
Surface Finish of Weld■Ground smooth & flush both outside
and inside the shell
■Grinding indication direction below
Grinding IndicationAx
is of
Vess
el
Grinding indication direction below top T.L. to be arranged parallel with the vertical axis of the Vessel
■Roughness of weld surface to meets
AE sensorVertic
al Asome specific value (Ex.
Max.125μinRa) Circumferential seam
Sumitomo has been developing grinding machines to satisfy the customer
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requirements for the surface finish of welds. Grinding Indication
Cutting Edge TechniquesCutting Edge Techniques : Production Process Control: Production Process Control
P d ti
Fabrication ScheduleProject
ScheduleDrawing
Comprehensive Project Planning & Scheduling
i
ProductionInnovation
Sequence
Weekly Schedule
Director 6System
Time & Resource Scheduling lti l j t
Progress D t
Insure conformance to delivery
Scheduleacross multiple projectsData
Feed back & Rescheduling
ReduceLead time
More
Major Machine & Critical Path
ReschedulingProduct
Work Processes
23Progress Daily Check Board at each area in the shop
4 R h & D l t4. Research & Development■Skirt Attachment Examination■Skirt Attachment Examination
To establish innovative skirt structures by the experiment
■I t i W ldi M t i l■Improvement in Welding Material(Strength Matching of Welding Metal)
To help shell to less bulge by controlling the weld metal strength
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R&D R&D : : Skirt Attachment ExaminationSkirt Attachment ExaminationStatic Loading Test and Thermal Test
FEA Modeling
Static loading test Thermal testFull Size
Static Loading Test and Thermal Test
Full SizeSpecimen
Actual strength measurement based upon various experiments
(Static Thermal and Fatigue) Full Size
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Thermocouple & high temperature strain gauge
(Static, Thermal and Fatigue)More Accurate FEA Study verified by the
experimental dataSpecimen
R&D R&D : : Skirt Attachment ExaminationSkirt Attachment ExaminationFatigue Test
Displacement
High-Frequency Heating System 1¼Cr-½Mo
Materials
Fatigue Test
Displacement Meter
Waveform Strain control;under zero mean strainWaveform; triangular
Test Condition
Thermocouple
Waveform; triangular
Temperature RT,500℃ (932˚F)Strain rate (S-1) 10-3 High-Frequency
Work CoilWork Coil
Test
26500 (932˚F) TestR.T. Test
Specimen Displacement Meter Chip
R&D R&D : : Skirt Attachment ExaminationSkirt Attachment ExaminationSetting for fatigue curveStatic loading test verification of FEA
Tested at room tem perature
0.1Total strain range ⊿εt
Strain Rate ; 10 -̂3
Tested at room tem perature
0.1Total strain range ⊿εt
Strain Rate ; 10 -̂3
①③③
g gStatic loading test verification of FEA
0.01
range
P lastic strain range ⊿εp
Elastic strain range ⊿εe
0.01
range
P lastic strain range ⊿εp
Elastic strain range ⊿εe②
④⑥
0.001
Strain r
【Manson Coffin Equation】
0.001
Strain r
【Manson Coffin Equation】
⑤
0.0001
1.E+02 1.E+03 1.E+04 1.E+05N um ber of cycles to failure
【Manson-Coffin Equation】⊿εt = ⊿εp + ⊿εe = Cp・Nf-Kp + Ce・Nf-Ke
0.0001
1.E+02 1.E+03 1.E+04 1.E+05N um ber of cycles to failure
【Manson-Coffin Equation】⊿εt = ⊿εp + ⊿εe = Cp・Nf-Kp + Ce・Nf-Ke
C om pression Load 16 kN
-400
-200
0
④⑥
-1 200
-1,000
-800
-600
Strain (μ
)
FEA Test
①
②
⑤
Waveform Strain control;under zero mean strain
Test Condition
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-1,600
-1,400
1,200
0 100 200 300 400 500 600
Distance from the edge of test piece (m m )
③-1~5Waveform; triangular
Strain rate (S-1) 10-3
R&D R&D : Improvement in Welding Material: Improvement in Welding MaterialDeveloped welding materials for 1¼Cr-½Mo
℃ ℃ ℃
:Ts of Weld Metal after Improvement:Ys of Weld Metal after Improvement
p gto lower the yield strength of the weld metal
750
800
690℃×4Hrs(LM P19.83)
690℃×8Hrs(LM P20.13)
690℃×20Hrs(LM P20.51)
Ts of C onventionalW eld M etal
:Ys of Weld Metal after Improvement
Decrease the weld metal yield strength to be within a close percentage of the base metal yield strength
650
700
750
Ts of Base M etal(101.5ksi
)
p g y g
15%
550
600
650
Stress(M
Pa)
Ys of C onventionalW eld M etal
(87.0ksi)
Gap
450
500
550
(72.5ksi)
Target Zone460±40Mpa(66.7±5.8ksi)
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400
450
17.50 18.00 18.50 19.00 19.50 20.00 20.50 21.00
LM P(x10 3̂)
Ys of Base M etal
(66.7±5.8ksi)
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Q ti W l dQ ti W l dQuestions WelcomedTEL: 81-3-6737-2671FAX: 81 3 6866 5123
Questions WelcomedTEL: 81-3-6737-2671FAX: 81 3 6866 5123FAX: 81-3-6866-5123
http://cokedrum.shi.co.jp:8080/index.phpFAX: 81-3-6866-5123
http://cokedrum.shi.co.jp:8080/index.php
Thank You !Thank You !
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