introduction of saijo factory &saijo factory...

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Coke Drum Workshop Coke Drum Workshop INTRODUCTION of INTRODUCTION of SAIJO FACTORY & SAIJO FACTORY & INTRODUCTION of INTRODUCTION of SAIJO FACTORY & SAIJO FACTORY & SAIJO FACTORY & SAIJO FACTORY & Coke Drum Technology Coke Drum Technology SAIJO FACTORY & SAIJO FACTORY & Coke Drum Technology Coke Drum Technology Coke Drum Technology Coke Drum Technology Coke Drum Technology Coke Drum Technology Rio de Janeiro, August 2009 Rio de Janeiro, August 2009 1 Rio de Janeiro, August 2009 Rio de Janeiro, August 2009

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Page 1: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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

1

Rio de Janeiro, August 2009Rio de Janeiro, August 2009

Page 2: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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

2

Page 3: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

1. SAIJO Factory Profile■L ti■Location

■History■History

■Brief Introduction

3

Page 4: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

SAIJO Factory ProfileSAIJO Factory Profile : Location: Location

Chiba Works

Nagoya Works

Okayama Works

TokyoTokyo

Tanashi Works

Oppama Works/Research & Development Center

Kobe Port

4

Ehime Works-Niihama Factory

Ehime Works-Saijo FactorySaijo Factory

Page 5: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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

5

2009 Total Coke Drums Awarded Since 1973 = 176!

Page 6: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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.

Page 7: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

2.Experience & Capabilityp p y■World-wide Delivery■Coke Drum Weight & Size■Materials■Materials■Strict Quality Assurance■Site Assembly

7

■Field Inspection Services

Page 8: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

Experience & Capability : World-wide Delivery

176 Coke Drums Delivered Throughout the World

8(As of May 2009)

Page 9: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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

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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

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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%)

11

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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

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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

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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”

15

y

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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.

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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.

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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

19

SkirtInside Radius

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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.

20

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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”)

21

(2010) 2 6,096 (20 ) 35 (1-3/8 )

Original Rectangular MaterialΣ19

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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

22

requirements for the surface finish of welds. Grinding Indication

Page 23: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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

Page 24: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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

24

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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

25

Thermocouple & high temperature strain gauge

(Static, Thermal and Fatigue)More Accurate FEA Study verified by the

experimental dataSpecimen

Page 26: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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

Page 27: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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】

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

Waveform Strain control;under zero mean strain

Test Condition

27

-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

Page 28: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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)

28

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)

28

Page 29: INTRODUCTION of SAIJO FACTORY &SAIJO FACTORY …refiningcommunity.com/wp-content/pdf/rio09/RIO09-Sumitomo-Saijo... · SAIJO FACTORY &SAIJO FACTORY & Coke Drum TechnologyCoke Drum

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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