THERMO‐MECHANICAL MEASUREMENT OF U1 COKE DRUM …
Transcript of THERMO‐MECHANICAL MEASUREMENT OF U1 COKE DRUM …
A 02.27.19 Draft for Review CL/DP/LK HK
Rev. Date
(mm.dd.yy) Issue By Chk By.
Document No. 19Z05-SOW-A
Revision No. A
Page 1 of 15
FORT MCMURRAY, ALBERTA
THERMO‐MECHANICAL MEASUREMENT OF
U1 COKE DRUM 05C‐4
PROGRAM OVERVIEW
Project Document Number
Thermo‐Mechanical Measurement of U1 Coke Drum 05C‐4 19Z05‐SOW‐A Title Revision Number Page
Program Overview A 2 of 15
Contents
Section A: Summary ................................................................................................................................... 3
Section B: Design & Site Conditions ........................................................................................................... 4
1 ‐ Design Conditions .......................................................................................................................... 4
2 ‐ Site Conditions............................................................................................................................... 4
Section C: Scope of Work ........................................................................................................................... 4
1 ‐ General Overview ......................................................................................................................... 4
2 ‐ Pre‐Work ...................................................................................................................................... 7
3 ‐ Strain Gauge Spot Welding Guidelines ......................................................................................... 7
4 ‐ Thermocouple Tack Welding Guidelines ...................................................................................... 8
5 ‐ Field Wiring Guidelines ................................................................................................................. 9
6 ‐ Field Testing & Commissioning ..................................................................................................... 9
Section D: Attachments .............................................................................................................................. 9
Item 1 – Coke Drum 05C‐4 Datasheet ................................................................................................... 10
Item 2 – Instrument Installation View ................................................................................................... 11
Item 3 – Coke Drum Welding Location Diagram ................................................................................... 12
Item 4 – Strain Gauge Spot‐Welding Instruction ................................................................................... 13
Item 5 – Strain Gauge Product Sheet .................................................................................................... 14
Item 6 – Thermocouple Installation Detail ............................................................................................ 15
Project Document Number
Thermo‐Mechanical Measurement of U1 Coke Drum 05C‐4 19Z05‐SOW‐A Title Revision Number Page
Program Overview A 3 of 15
Thermo‐Mechanical Program Overview
Section A: Summary
This summary outlines the proposed Suncor field work to be performed on Coke Drum 05C‐4
during the plant turn‐around to install thermocouples and strain gauges on the surface of the
drum.
The objective of this program is to generate field measured temperature and strain data,
which will then be transformed into load history that would empower a realistic design of new
coke drums. The program will measure and quantify the degree of structural stress and strain
during the operation cycles. The scope of work will include installation of instruments, field
wiring, and a data logging panel during the April turn‐around shutdown period. During the
shutdown, the coke drum will not be in service and all insulation on the affected area will
have been removed.
A maximum of 90 thermocouples and 30 strain gauges will be welded on three windows of
the coke drum surface. Instrument locations shall be spaced approximately 0.5 to 1 foot apart
in both x‐and y‐axes. The instrument locations and spacing layout will follow a grid‐pattern,
which will be finalized after thermography of the coke drum is taken in March. Suncor field
support will install cabling from the instruments to junction boxes, and from the junction
boxes to the data logger panel. Zachry Canada and its Controls & Electrical subcontractor
(“Zachry”) will provide field support during the installation to commissioning completion
period.
The projected milestones associated with this program are:
Installation Start May 1, 2019
Commissioning completion May 8, 2019
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Program Overview A 4 of 15
Section B: Design & Site Conditions
1 ‐ Design Conditions
Equipment # 05C‐04
Applicable Code ASME Section VIII Div. 1
Process Fluid Solid Coke, Bitumen, Water, Steam, Hydrocarbons (Liquid & Gas)
Design Pressure As per attached Data Sheet (varies by shell course)
Design Temperature As per attached Data Sheet (varies by shell course)
Drum Material SA‐204 Gr C (base) C‐1/2 Mol with A‐240 Type 405 SS
(cladding)
2 ‐ Site Conditions
Ambient Temperature ‐20°C to 25°C
Electrical Area Classification
Zone 2 / Class 1 Division 2
Working Hazards Height, high temperature, electrical
Section C: Scope of Work
1 ‐ General Overview
The field scope of work consists of pre‐work, strain gauge & thermocouple welding, field
wiring from the instruments to associated junction boxes and data logger, and field testing &
commissioning. A general overview flow chart is shown on the following page.
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Program Overview A 5 of 15
1.1 All work is to be in accordance with Suncor safe work practices & procedures and shall
conform to Suncor Standards where applicable.
1.2 Suncor safe work permit system shall be complied with for all work.
1.3 Suncor is to provide welders and electricians to perform the work. Suncor is to provide
access to the designated coke drum. The expected working height can reach 100 ft from
ground level.
1.4 Attaching the thermocouples and strain gauges is done by surface welding. This is
achieved through resistance spot‐welding and tack welding on the drum’s exterior surface.
Since the welding process does not involve structural components of a pressure vessel and
due to the instruments being temporary in nature and not part of pressure containment,
Figure 1. Program Overview
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Program Overview A 6 of 15
Zachry’s opinion is that Pressure Equipment Safety Regulation (AR 49/2006) Sections
27(1)(b) and 27(2)(b) does not apply.
1.5 Suncor’s standards related to welding, namely, Corporate Technical Standards 0220, 0603,
and 0903 are deemed to be generally not applicable. Zachry will recommend to Suncor a
welding procedure for spot‐welding and tack‐welding.
1.6 Details of weld locations shall be specified in a Zachry drawing after thermography.
1.7 Welding will be performed at ambient temperatures when the drum is not in service.
1.8 Field wiring, installation of junction boxes, and data logger panel will occur after the QA
review of the welded instruments.
1.9 Electrical installation details shall be completed by Zachry in a CWP.
1.10 Zachry will oversee installation and perform the commissioning in conjunction with Suncor
plant personnel. Contact information for Zachry is:
a. Chris Semaka Phone: 403‐705‐6797 Email: [email protected] b. David Pennink Phone: 403‐705‐6797 Email: [email protected]
1.11 Zachry will provide field support to the Suncor field installation team, including:
Logistics & site mobilization
Excerpt from Pressure Equipment Safety Regulation (Alberta Regulation 49/2006): Welding, brazing and other joining procedures
27(1) A person who uses welding or brazing to construct or manufacture any pressure equipment
(b) shall not construct or manufacture pressure equipment by welding or brazing unless the welding or brazing procedure is registered in accordance with section 18.
27(2) If the code of construction for an item of pressure equipment requires qualification of a joining procedure other than welding or brazing, a person who uses that joining procedure to construct that pressure equipment
(b) shall not construct or manufacture that pressure equipment unless the joining procedure is registered in accordance with section 18.
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Program Overview A 7 of 15
Management of materials
Coordination with Suncor installation team
Installation procedures
Quality assurance and field testing of installed devices
Commissioning support
2 ‐ Pre‐Work
2.1. Suncor shall complete/provide necessary work permits and safety supervision.
2.2. Suncor and Zachry will conduct a pre‐job meeting to discuss safety procedures and to
review the work scope.
2.3. Suncor will provide scaffolding for access to the coke drum.
2.4. Zachry shall meet with Suncor at the site to plan logistics around the location of devices.
2.5. Access to the appropriate structural steel, supports, and cable trays will be made available
for field‐run wiring and installation of any cabling supports.
2.6. Suncor’s welders should be given the opportunity to hone their skills with the spot welding
and tack welding procedures (prov ided by Zachry in a CWP) prior to welding on
the coke drum. Current and other equipment settings can be checked and monitored at
this point to ensure that they are correct. This step shall be done in the field at a pre‐
determined safe location on a test plate prior to welding on the coke drum. Sample
instrument mounting material will be supplied to welders for testing by Zachry.
3 ‐ Strain Gauge Spot Welding Guidelines
3.1. The strain gauge is a highly specialized instrument with specific welding requirements. The
Kyowa GW‐3C spot welder (need to confirm whether Suncor can supply an equivalent) is
recommended to complete the spot welding for the KHCM strain gauge. The strain gauge
is mounted on a thin plate made of Inconel 600 (P43 material). It is recommended the
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Program Overview A 8 of 15
welding contractor should weld with P3 (coke drum surface) to P43 (strain gauge mounting
material).
Detailed spot‐welding procedures from the manufacturer are listed in Attachment 4.
Zachry highly suggests the welding contractor follow the manufacturer’s suggested
installation procedure to ensure correct installation of the strain gauges.
3.2. Strain gauges installed per location follow either a 3‐gauge (rosette) pattern or a 1‐gauge
(axial) pattern. The installation sketch example as seen in Attachment 3 is preliminary.
Final placement of strain gauges will depend on thermography. Suncor will receive
finalized drawings on instrument locations in a separate CWP.
3.3. After welding all strain gauge locations, Zachry will perform a QA inspection.
3.4. Contractor to submit ITP to Suncor QA for approval.
4 ‐ Thermocouple Tack Welding Guidelines
4.1. The Type K skin thermocouples are attached to stainless steel washers. A low‐alloy mild
steel threaded stud (P1 material) will be welded on to the drum surface. It is
recommended the welding contractor should weld with P3 (coke drum surface) to P1
(thermocouple stud). Tack welding will be used to attach the threaded stud to each
location as specified on a Zachry drawing. A sketch of the washer‐type skin thermocouple
and stud/nut assembly is shown in Attachment 6. The recommended tack‐welding
procedure will be submitted by Zachry.
4.2. After the studs are welded, Zachry will perform a QA inspection of the entire welded area.
4.3. Suncor field support will then insert the thermocouple washers and thread the nut onto the
stud.
4.4. Contractor to submit ITP to Suncor QA for approval.
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Program Overview A 9 of 15
5 ‐ Field Wiring Guidelines
5.1. Field wiring associated with the instruments, junction boxes and data logger panel will be
installed by Suncor’s electricians with oversight by Zachry.
5.2. All documentation to attach instrument cables, junction boxes, and control panel will be
issued in a CWP. This will include all necessary wiring diagrams, guidelines, and procedures.
6 ‐ Field Testing & Commissioning
6.1 The data logger will have been calibrated and shop‐tested with strain gauges and
thermocouples prior to shipping to Site. Zachry will oversee the field‐testing to ensure the
field‐installed cables and devices function as designed.
6.2 Commissioning will be overseen by Zachry and Suncor engineering personnel.
Section D: Attachments
Item No. Type Description
1 Datasheet Coke Drum 05C‐4 Datasheet
2 Drawing Markup Instrument Installation View
3 Sketch Coke Drum Welding Location Diagram
4 Instruction Strain Gauge Spot‐Welding Instruction
5 Product Sheet Strain Gauge Model
6 Sketch Thermocouple Installation Detail
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Program Overview A 10 of 15
Item 1 – Coke Drum 05C‐4 Datasheet
Project Document Number
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Program Overview A 11 of 15
Item 2 – Instrument Installation View
Project Document Number
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Program Overview A 12 of 15
Item 3 – Coke Drum Welding Location Diagram
The proposed grid layout will be finalized pending thermography results. A separate CWP will be issued
detailing the exact locations.
3‐gauge rosette
pattern
1‐gauge axial
pattern
X‐AXIS
Y‐AXIS
Elevation View
Project Document Number
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Program Overview A 13 of 15
Item 4 – Strain Gauge Spot‐Welding Instruction
The strain gauge
mounting surface is
Inconel 600 (P43
material). The strain
gauge (P43) will be
welded to the coke
drum surface (P1).
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Program Overview A 14 of 15
Item 5 – Strain Gauge Product Sheet
Optional bridge adaptor is not part of the purchased assembly.
Project Document Number
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Program Overview A 15 of 15
Item 6 – Thermocouple Installation Detail
The threaded thermocouple is attached to two (2) 303 SS washers. The threaded stud (P1 material)
will be welded to the surface of the drum (P3 material).
Drum Surface, P3
Threaded stud
(low alloy, mild
steel, P1)
Tack weld