Grant Harding, P.Eng. Technical Services Mgr. · Slide 32 © 2013, Chemetics Inc. ... Slide 35 ©...

© Copyright 2012, Chemetics Inc. All rights reserved.

Grant Harding, P.Eng.Technical Services Mgr.

“Operational Reliability When Designing for Maintenance ”

© Copyright 2012, Chemetics Inc. All rights reserved.Slide 2

Introduction – “Operational Reliability When Designing for Maintenance”


Owner wants – Minimum, Reliable + Easiest repairs Chemetics wants – Optimized, Rugged equip. designs

Best Achieved by working co-operatively at Shutdowns

Owner receives – Specific Info./Knowledge/Experiences Chemetics – Feedback

Mutually Beneficial Relationship

Case Histories – Strong Acid Brick Linings


Strong Acid Towers (6 global e.gs.)

Relevant Maint., Design, Construction Aspects Highlighted

#1 – Premature Abs. Shell Failure (+- 1yr.)


#1 – Large Area of Double Plating


#1 – Repair Pumping Nozzles


+-Quality - Nozzle Thimbles No Seals


#1 – Illustration of Nozzle Thimble Sealing


+-Quality – Cracking Around Nozzle Lining


+-Quality – Mortar Joints Very Thin


Contributing Factors to Premature Leaks


Lining Design - No membrane, Nozzle thimbles un-sealed

Steel Shell Shape/Roundness - Hollow areas under brick (acid can fill)

Lining Installation/QC/QA - Number of mortar joints very tight

Apparent Improvement Areas


Pecora Mastic + Teflon Sheet Membrane Nozzles Thimbles Centered, Sealed and

Bricked to Stronger Quality Presence during installation

Example #2 – Successful Pumping Repair


Ex. #2 – External Mastic Pumping


#2 – Steel Shell Roundness, Flat Spot


#2 – ID Brick Shape Undulation


#4 - Mastic Pumping in Progress


Ex. #2 – Comments


+-8 years for leak to develop. Pecora Mastic external pumping repair with good

results. No recurrence or spreading after +- 2 years. Shell roundness/voids under lining contributor to the

leak/thinned area. This operator has excellent reputation maintenance +

inspection in their acid plants. Good story not accident. Maintenance Tip – Thin Pecora with Xylene for pumping.

Ex. #3 - Old Tower in Bad Shape Major Repair


Ex. #3 – Steel Sulphate Bulges + Wrinkles


#3 – New Top Section and SS Skinning


#3 – Re-Skinning in Progress


#3 – Ready for External Mortar Pumping


Example #3 – Comments


Reasonably successful but best value ??? Complex, risky, but a possibility (awareness) Saved shutdown time, footprint, material

handling, $/resources and a big repair in shorter time. Extended useable life without demolition.

Ex. #4 – Dry Tower Gas Inlet Chronic Leaks


Ex. #4– View of Damage at Start of Repair


Ex. #4 – Final Repair, Not a Lasting One


© 2013, Chemetics Inc. All rights reserved.Slide 29

Example #4 - Tower Design Comparison

Existing Tower Design Chemetics Tower Design

Existing Tower Gas Inlet Nozzle Design Chemetics Tower Gas Inlet Nozzle Design


Brick Tower Design Comparison


Existing Tower Seal/Lining details

Polypropylene Sleeve

Pack Gap Solidly With

Ceramic Fiber Rope

and Mortar

Chemetics Tower Seal/Lining Details




Existing Tower Membrane details

6 mm Butyl or Chloro

Butyl Rubber

Chemetics Tower Membrane Details




Existing Tower Brick Thickness details

6 + 5 + 95 Brick +5+95 brick, Total

206 mm MINIMUM brick thickness

Chemetics Tower Brick Thickness Details

Total brick thickness 110 mm

Ex. #5 – Dry Twr. Outlet Area Replacement


Ex. #5 - Cut-out Based on U/T Testing


Ex. #5 – New Section Installed


Ex. #5 – Preparation + Cleaning (important)


Ex. #5 – Work Environment (+-best possible)


Ex. #5 – Finished Interior Quality


Ex. #6 – Finished Exterior


Ex. #5 – SARAMET® Shield Installed


Example #5 – Comments


Old Tower +- 23 yrs. at the time. Good Story – 2 yrs. no leaks or spread. Cleaning, Planning + Preparation – Most

important ! Maximize pre-fabrication (even for lining

repairs !) Improved reg. maintenance around acid outlet

may have extended time to leak.

Ex. #6 – Damage Below Tank Acid Inlet


Summary – “So Don’t Learn the Hard Way !”


Maintenance Side

Inspect linings internally each Outage Make mortar + packing repairs (retard progress) Preparation, pre-fabrication and cleaning paramount Critical Areas:

Acid Nozzles, Thimbles + Dip Pipes Gas Inlet Linings + Transitions Turbulent Areas Brick to SS “Drip Edge Transitions” Distributor Level Nozzle (circ. cracks) Steps in Lining Thickness Mortar loss/recession + brick movements in general



Design Side

Big investment, specialised layered construction Difficult to repair in a lasting way (contamination) Details very important (CS, membrane + lining)

Chemetics specify these Don’t leave to steel + brick suppliers

Try to remember “Value” not cost Follow “Cradle to Grave”



Installation Side

Use only reputable + experienced material suppliers + installers

Independent QC/QA recommended “Show you care !” “Trust but Check !”

Current Trend: For Large Dia. Towers steel roundness is an area to be aware of

Conclusion


“Hands-on” sharing of information + repair histories between Operators and Technology Suppliers is Key to ensuring “Consistent Operation” and good solutions.

“Operational Reliability When Designing for Maintenance”

THE END



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Copyright of all published material including photographs, drawings and images in this document remains vested in Jacobs and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.


Disclaimer

This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions of the regions and industries that are major markets for Jacobs Engineering Group Inc. (including subsidiaries and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements containing words such as “expects”, “believes”, “estimates” or similar expressions. Important factors that could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that are or will be major markets for Jacobs’ businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Jacobs Engineering Group Inc. believes that its expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation. Jacobs Engineering Group Inc. is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation, and neither Jacobs Engineering Inc. nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use.

Jacobs consists of many legally independent entities, constituting their own separate identities. Jacobs is used as the common brand or trade mark for most of these entities. In this presentation we may sometimes use “Jacobs”, “we” or “us” when we refer to Jacobs companies in general or where no useful purpose is served by identifying any particular Jacobs company.

Grant Harding, P.Eng. Technical Services Mgr. · Slide 32 © 2013, Chemetics Inc. ... Slide 35 ©...

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