vibration testing and troubleshooting of coke drums...• the two drums vibrated in a comparable...
TRANSCRIPT
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Vibration Testing and
Troubleshooting of Coke Drums
Mahmod Samman, Ph.D., P.E.Senior Associate
Stress Engineering Services, Inc.
Coking.com Calgary Conference
September 2009
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OVERVIEW
• Vibrations Basics
• Drum Dynamics
• What is Affected
• Potential Consequences
• Case study
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VIBRATIONS BASICS
� Response of a flexible structure to excitation
(fluid flow, pressure pulsations, sloshing, etc..)
� Components
• Mass (inertia)
• Spring stiffness (Force–Displacement)
• Dashpot viscous damping (Force–Velocity)
� Basic characteristics:
• Natural frequency (or frequencies)
• Mode shapes
� Input – output
• Force
• Displacement
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DRUM DYNAMICS
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WHAT IS AFFECTED
� Pipes and pipe supports
� Base-plate bolts and grout
� Non-structural (stairs, lights, guardrails,..)
� Machinery (elevator, pumps, ..)
� Superstructure (concrete and steel)
� Foundation system (substructure and soil)
� Humans!
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POTENTIAL CONSEQUENCES
• Operator discomfort or fatigue
• Poor performance
• Acceleration of corrosion damage
• Interruption of operations during repairs
• Fatigue cracks (leaks/ fires)
• Bodily injuries
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WHAT TO DO?
• Measure• Vibrations
• Strain
• Process variables
• Analyze• Stress / fatigue
• Human tolerance
• Mitigate• Process
• Structure
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CASE STUDY - 1
• Two-drum unit
• “Significant” vibrations in structure
• Conflicting views on � When they vibrate the most
� Which one vibrates more
• Failures� Piping supports
� Anchor bolts
� Base plate grout
• Is the unit safe?
• Can the process be optimized to
minimize vibrations?
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DRUM DESIGN AND OPERATION1996 API Coke Drum Survey, 2003
• 16 feet in diameter - relatively small for the mid
80’s
• 76 feet in height - average to tall
• Slender drums
• Very common 1 ¼ Cr -1/2Mo material
• 17 hour fill cycle - average to relatively slow
operation
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OBJECTIVES
• Monitor vibrations in the drums, piping, and
structure.
• Obtain synchronized temperature and strain
measurements.
• Determine the timing and characteristics of
maximum vibrations.
• Determine severity of dynamic stresses and
potential for fatigue damage in the structure.
• Conduct sensitivity analysis of vibrations versus
process variables.
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PROCEDURE
• Installed 33 sensors and two data acquisition
systems on the drums, piping, and structure.
• Monitored the unit for a period of 20 days (14
cycles)
• Processed and analyzed the data in time and
frequency domain.
• Analyzed the correlation between key process
variables with vibration, strain, and temperature
measurements.
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INSTRUMENTATION
Vibration data acquisition system
16 channel unit
16 seismic accelerometers @ 102 samples per second
2 strain gages (low-speed DC channels)
Temperature data acquisition system
StrainDAQ unit
16 thermocouples
1 sample per two seconds
Data collection was continuous without interruption
during the entire monitoring period.
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Sensor Layout
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Example Quench Transient
Quench
TEMPERATURE
ACCELERATION
TIME
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CYCLE 9 - DRUM B QUENCH
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
11035 11037 11039 11041 11043 11045 11047 11049 11051 11053 11055
TIME FROM START OF CYCLE 9 (SEC)
DIS
PL
AC
EM
EN
T (
IN)
Drum B - West Dir. (in)
Drum B - North Dir. (in)
Drum B - Down Dir. (in)
Integrated Displacement Data
Large Transient Displacement
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ONLINE DRUM B
0
0.02
0.04
0.06
0.08
0.1
0.12
1 3 5 7 9 11 13Cycle
Vib
rati
on
in
In
ch
es R
MS
0
50
100
150
200
250
Maxim
um
Va
lues (
GP
M)
DRUM B PIPE
DRUM A PIPE
DRUM A
DRUM B
STRUCTURE
DRUM B ONLINE
Vibration Versus Flow Rate
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Strain Gauge Data
Low dynamic strains
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CASE-1 SUMMARY
• Drum vibration magnitude was maximum during the quench part of the cycle in the East-West direction.
• The two drums vibrated in a comparable manner both from magnitude and frequency standpoints.
• The maximum recorded peak displacements were 0.58, 0.35, and 0.23 inches for the drums, the piping, and the structure, respectively.
• Measured dynamic strains in the structure were below the fatigue-inducing levels
• The correlation between vibration levels and recorded process parameters was established
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CASE STUDY -2
• Four-drum unit.
• Blow-down line.
• Cracks and leaks.
• Angled-tee joint.
• Thermal cycles.
• 3D loads.
• Vibrations.
• Why?
• How to fix it?
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1. Instrumentation � Strain gages
� Thermocouples
2. Extraction of loading conditions
3. Finite element analysis
4. Fatigue Assessment
ACTION PLAN
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Intrinsically Safe Instrumentation System
INSTRUMENTATION
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FIELD MONITORING
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TEMPERATURE MEASUREMENTS
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THERMAL GRADIENTS
Every forth cycle
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CLOSEUP
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PAD THERMAL GRADIENTS
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Extracted load casesFive thermal profiles during the coking cycle
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Thermal Load Case
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Von Mises Stress in the pipe
outside inside
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Von Mises Stress inside the pad
outside inside
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Fatigue Assessment
• Maximum thermal stress range is 92 ksi.
• Alternate stress is 49.8 ksi.
• Correction for E at 4000F
• Fatigue life is 4,441 cycles.
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CASE-2 SUMMARY
• Vibrations and pressure are not the main problem.
• The failure is caused by severe thermal transients that
generate 92 ksi stress range in the pipe at the location
of cracks.
• Recommendations to minimize stresses and increase
fatigue life:
• Redesigned integral fitting.
• Fatigue-resistant welds.
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Questions?
Mahmod Samman, Ph.D., P.E.
Stress Engineering Services, Inc.
281-955-2900