A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum,...
Transcript of A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum,...
![Page 1: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/1.jpg)
Floating Slide Plates for Coke ChutesA Case Study
![Page 2: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/2.jpg)
▪ Who is Structural Group?
▪ Case Study: 2017 Slide Plate Install
▪ Scope Development
▪ Engineered Solution
▪ Preplanning
▪ Implementation
▪ Closing remarks
▪ Open floor discussion/ Q&A period
![Page 3: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/3.jpg)
Materials & Engineering Support Services Specialty Contracting Services
WHO IS STRUCTURAL GROUP?
![Page 4: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/4.jpg)
▪ International Offices (3):
Abu Dhabi
Dubai
Qatar
▪ Corporate HQ:
Columbia, MD
▪ North America Offices (20):
Baltimore
Baton Rouge
Chicago
Dallas
Denver
Detroit
Ft. Lauderdale/Miami
Hartford
Houston
Kansas City
Lake Charles
Long Island
Los Angeles
New York
Philadelphia
Pittsburgh
San Francisco
Sarasota/West Florida
Springfield
Offices
![Page 5: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/5.jpg)
Case Study Background
▪ Background / Customer PROBLEMS
▪ 2- drum, delayed coking unit constructed in
1990.
▪ Evident concrete deterioration throughout
support structure and coke pit.
▪ Coke chutes lined with steel wear plates that
were a maintenance burden and required
replacement.
▪ Replacement planned for 2012 Turnaround
deferred due to cost and interference with
coke drum replacement.
▪ Engineered Solution OBJECTIVES
▪ Undertake structural concrete repairs.
▪ Remove and replace the steel wear plates.
ImplementationScope Development Engineered Solution Preplanning
![Page 6: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/6.jpg)
Condition Survey (2016)
▪ Primary Objectives:
▪ Identify, Quantify and Prioritize
Repairs.
▪ Using NDT, and Visual
Observation.
▪ Assessment Area Included:
▪ Coke Chutes (Hot Face)
▪ Coke Chutes (Underside)
▪ Coke Pit Walls
▪ Fines Settling Basin
ImplementationScope Development Engineered Solution Preplanning
![Page 7: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/7.jpg)
Condition Assessment: Deterioration Mapping
ImplementationScope Development Engineered Solution Preplanning
![Page 8: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/8.jpg)
Condition Assessment: Core Samples
▪ Four 3” diameter cores were
collected.
▪ Cores were extracted from the
South and East Pit Walls.
▪ Depths ranged from 2.5” to 8”
ImplementationScope Development Engineered Solution Preplanning
![Page 9: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/9.jpg)
Condition Assessment: Field Photographs
ImplementationScope Development Engineered Solution Preplanning
![Page 10: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/10.jpg)
▪ Floor Repair
▪ Top of Wall Repair
▪ Expansion Joints
▪ Weir Wall Modifications
▪ Coke Pit Wall Extension
▪ Outside Corner Repair
▪ Remove and Replace Slide Plates
ImplementationScope Development Engineered Solution Preplanning
Condition Assessment: Conclusions
![Page 11: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/11.jpg)
What is a Wear Plate?
ImplementationEngineered Solution PreplanningScope Development
![Page 12: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/12.jpg)
Typical Wear Plate Construction
Carbon Steel
Plate Welded to
Embedments
Mechanical
Anchorage
to Substrate
ImplementationEngineered Solution PreplanningScope Development
![Page 13: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/13.jpg)
Issues with Conventional Wear Plates
▪ Sections of wear-plate being
dislodged over time.
▪ On-going quarterly inspections
and emergency repairs.
▪ Operational downtime and on-
going maintenance costs.
▪ Inability to inspect concrete
structure below.
▪ Multi-million dollar, intrusive
replacement program.
▪ Cracked welds due to impact
from falling material and
thermal cycles.
Chute
Column
ImplementationEngineered Solution PreplanningScope Development
![Page 14: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/14.jpg)
INNOVATION: New “Floating” Slide Plate
Sacrificial
Stainless Steel
Floating Plate
ImplementationEngineered Solution PreplanningScope Development
![Page 15: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/15.jpg)
DESIGN HIGHLIGHT: Plate Mounting Bracket
▪ All components were fabricated from 304L Stainless Steel.
▪ Specialty components required 2+ month lead-time.
ImplementationEngineered Solution PreplanningScope Development
![Page 16: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/16.jpg)
DESIGN HIGHLIGHT: Front Nosing Plate
▪ Nosing plates were 304L SS and ½ thickness of the new wear plates.
▪ Plates were delivered to site in sections with the studs pre-welded.
ImplementationEngineered Solution PreplanningScope Development
![Page 17: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/17.jpg)
DESIGN HIGHLIGHT: New Slide Plate
▪ Slide plates (20’ x 40’) were made from 304L SS.
▪ Each plate was 4 separate sections welded on-site.
ImplementationEngineered Solution PreplanningScope Development
![Page 18: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/18.jpg)
DESIGN HIGHLIGHT: Material Selection
▪ Continuous issues with CS wear plate corrosion/erosion on slide
plates and in coke handling system
ImplementationEngineered Solution PreplanningScope Development
![Page 19: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/19.jpg)
DESIGN HIGHLIGHT: Material Selection
▪ The plant installed a “test plate” in 2011
▪ ¼” 304 SS plate welded on top of CS in slide zone
ImplementationEngineered Solution PreplanningScope Development
![Page 20: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/20.jpg)
DESIGN HIGHLIGHT: Material Selection
▪ 2013: Installed CS plate with 0.109” thick 317L SS cladding after
major plate failure.
▪ Final Decision: Solid 304 SS material chosen for long term benefits.
ImplementationEngineered Solution PreplanningScope Development
![Page 21: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/21.jpg)
Slide Plate Construction: Off-Site Welding
10’ x 20’ 10’ x 20’
ImplementationPreplanningScope Development Engineered Solution
![Page 22: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/22.jpg)
Slide Plate Construction: Off-Site Welding
ImplementationPreplanningScope Development Engineered Solution
![Page 23: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/23.jpg)
Slide Plate Construction: Off-Site Welding
ImplementationPreplanningScope Development Engineered Solution
![Page 24: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/24.jpg)
Slide Plate Construction: Shipping Plates To Site
ImplementationPreplanningScope Development Engineered Solution
![Page 25: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/25.jpg)
Slide Plate Construction: On-Site Welding
Preplanning ImplementationScope Development Engineered Solution
![Page 26: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/26.jpg)
Slide Plate Construction: On-Site Welding
Preplanning ImplementationScope Development Engineered Solution
![Page 27: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/27.jpg)
Slide Plate Construction: On-Site Welding
Preplanning ImplementationScope Development Engineered Solution
10’ x 40’
10’ x 40’
![Page 28: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/28.jpg)
▪ We developed a comprehensive Weld Distortion Control Guide to
compliment the WPS to control warping, twisting, and or curling.
Slide Plate Construction: Distortion Control
Preplanning ImplementationScope Development Engineered Solution
![Page 29: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/29.jpg)
Step #1: Layout Slide Plate Mounting Brackets
Preplanning ImplementationScope Development Engineered Solution
![Page 30: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/30.jpg)
Drill Bracket Holes On-Site to AVOID Rebar
Preplanning ImplementationScope Development Engineered Solution
![Page 31: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/31.jpg)
Step #2: Existing Slide Plate Demolition
Preplanning ImplementationScope Development Engineered Solution
![Page 32: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/32.jpg)
Oxygen (Oxy) Lance Cutting
Preplanning ImplementationScope Development Engineered Solution
![Page 33: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/33.jpg)
Oxy Lance Cutting Continued…
Preplanning ImplementationScope Development Engineered Solution
![Page 34: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/34.jpg)
Step #3: Install Stainless Steel Brackets
Preplanning ImplementationScope Development Engineered Solution
![Page 35: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/35.jpg)
Drill, Epoxy, and Set Brackets
Preplanning ImplementationScope Development Engineered Solution
![Page 36: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/36.jpg)
Step #4: Install Chute Nosing Plates
Preplanning ImplementationScope Development Engineered Solution
![Page 37: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/37.jpg)
Nose Plate Installation- Concrete Removal
Preplanning ImplementationScope Development Engineered Solution
![Page 38: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/38.jpg)
Nose Plate Installation- Concrete Placement
Preplanning ImplementationScope Development Engineered Solution
![Page 39: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/39.jpg)
Step #5: Installation of New Slide Plates
PLATE
FAB
AREA
LIFT
LOCATION
Preplanning ImplementationScope Development Engineered Solution
![Page 40: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/40.jpg)
Actual Plate Installation (May 2017)
Preplanning ImplementationScope Development Engineered Solution
![Page 41: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/41.jpg)
▪ Structural was able to value engineer
a solution from the original design that
saved Phillips 66 millions.
▪ Total on-site duration (28 days).
▪ Project completed on-time and on-
budget.
▪ ZERO safety incidents or first-aids.
▪ NDT inspection in Q4 2017 (6 months
after install) revealed NO issues with
system performance.
![Page 42: A Case Study - Refining Community...Case Study Background Background / Customer PROBLEMS 2- drum, delayed coking unit constructed in 1990. Evident concrete deterioration throughout](https://reader033.fdocuments.in/reader033/viewer/2022053016/5f17ecab5cf9e017311dda81/html5/thumbnails/42.jpg)
Questions?
Thank You!
Matthew Hickey, P.Eng., PMP
Project Manager
Stephanie Keeth
Area Mechanical Engineer
COME VISIT US AT BOOTH No.72 FOR MORE INFORMATION!