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AGENDA
Various layered construction
Multiwall shells
Applications
Materials of construction
Connection of multiwall shell to head / flange
Design methodology
Proof testing by L&T
Manufacturing sequence
Advantages
g
In-service monitoring
Reference list
Conclusions
Larsen & Toubro Limited: April 2010. All rights reserved
MIPD
ECC
HED
EBG
E&C
AMMONIA CONVERTER
108 M Long
Worlds tallest
PRODUCT SPLITTER
1500 MT
Worlds largest
E.O. REACTOR
1200 MT
Worlds largest
FCC REGENERATOR
Larsen & Toubro Limited: April 2010. All rights reserved
DHDT REACTOR
HYDROCRACKER REACTOR
METHANOL CONVERTER
UREA REACTOR
Larsen & Toubro Limited: April 2010. All rights reserved
Coil Wound
Multiwall
Spiral Wrapped
Fig. ULW-2.1
Fig
ULW 2 1 of ASME
Sec.VIII,Div.1
&
Fig 4.13.1
Fig.
4 13 1 of ASME
Sec.VIII,Div.2
Notes:
(1) Inner shell
(2) Dummy layer, if used
(3) Layers
(4) Shell layer (tapered)
(5) Balance of layers
((6)) Gaps
p
CHEMICAL
INDUSTRIES
(H P Heat
Exchangers )
Exchangers..)
PETROLEUM
REFINERIES
(Hydrocracker
Reactors,
Separators)
OTHER
INDUSTRIES
((H P
Storage..)
Larsen & Toubro Limited: April 2010. All rights reserved
SHRINK STRESS
PRESSURE STRESS
RESULTANT STRESS
Larsen & Toubro Limited: April 2010. All rights reserved
Inside
radius
Inside
radius
Pa
Pa
MONOWALL VESSEL
MULTIWALL VESSEL
Circumferential stress
Load case: Design pressure + Shrink-fit stress +
Operating temperature
Larsen & Toubro Limited: April 2010. All rights reserved
Pa
MONOWALL VESSEL
MULTIWALL VESSEL
Circumferential stress
Load case: Design pressure + Shrink-fit stress +
Operating temperature
Larsen & Toubro Limited: April 2010. All rights reserved
3600
y
No. of layers
46
184
Start-up
cycle
Shut-down
cycle
22 065
22.065
22 065
22.065
21 to 440
440 to 21
50
50
8.38
8.38
Inside radius
OC
Inside
radius
di
Inside
radius
OC
OC
Monowall vessel
OC
Multiwall vessel
OC
Pa
P
Pa
Monowall vessel
Multiwall vessel
Pa
Inside radius
MPa
Inside radius
MPa
Inside radius
MPa
Inside radius
MPa
Inside radius
MPa
MANUFACTURING SEQUENCE
1st layer
2nd layer
y
Subsequent
layers
MANUFACTURING SEQUENCE
NDT of
circ
circ.
seams
before
PWHT
NDT after
PWHT
NDT after
Hydrotest
RT
Conventional UT
PT / MT
MANUFACTURING SEQUENCE
MANUFACTURING SEQUENCE
(1)
(2)
(3)
Larsen & Toubro Limited: April 2010. All rights reserved
welding
of
Circ.
seams
for
Multiwall,
inter-layer welding.
No special steps (such as sealing of gaps by
welding or buttering of the surface) are needed
before circ. seam welding.
No defects encountered in circumferential seams
at the plate interfaces.
Multiwall to Multiwall
Photograph of Circ Seam PTC.
Multiwall to
Monowall
Larsen & Toubro Limited: April 2010. All rights reserved
ADVANTAGES OF MULTIWALL
Theoretically no limitation for achieving any thickness of cross
section.
Plates in standard thickness range can be used. (Gives higher
flexibility
y in sourcing/
g/ availability
y of p
plates.))
homogeneity
during
manufacturing
at
mills.
ADVANTAGES OF MULTIWALL
Shrink fitting of multiwall induces compression in the inner
layers, which counters the pressure stresses and thus creating
additional reserve strength.
ADVANTAGES OF MULTIWALL
V ti
t
id
l warning
i
f
bl
Venting
system
provides
early
for
any problem
initiated from the inside surface of the vessel.
REFERENCE LIST
L & T has manufactured and supplied 50 + Multiwall
vessels for Ammonia, Urea & other Petrochemical
services operating for periods up to 20+ years.
Customer / Location
Kribhco - Hazira
Haldor
Topsoe
245
360
ADM
1971 x
16995
Haldor
Topsoe
165
260
ADM
1964 x
20000
Chambal Fertliser,
Gadepan
Process
Licensor
Design
Press.
Kg/Cm2
Sr.
No
Haldor
Topsoe
245
370
ADM
3005 x
21455
Thk
mm
H2
Material Of Construction Year Of Partial
(Multi-Wall)
Supply Press.K
2
g/cm
1988-89
179
1989-90
1989
90
100
SA 387 GR.11 CL 2 +
SA 533 GR. B CL.2
1992
158
98
SA 387 GR.11 CL 2 +
1993
102
(30+34x2)
145
1993
155
SA 387 GR.11 CL 2 +
1996
157
(32+41x3)
155
SA 387 GR.11 CL 2 +
1996
157
(32+41x3)
110
(40+35x2)
SA 204 GR. B +
SA 533 GR. B CL 2
72
SA 204 GR
GR. B +
(20+25x2)
SA 533 GR. B CL 2
155
(35+40x3)
Tata Chemicals
Babrala
Haldor
Topsoe
155
Tata Chemicals
Babrala
Haldor
Topsoe
155
IFFCO Aonla
Haldor
Topsoe
245
NFL Vijaipur
Haldor
Topsoe
245
370
450
370
370
ADM
DIV.2
ADM
ADM
2805 x
23436
2705 x
21274
3000 x
22425
3000 x
22425
(48.5x3)
10
11
12
13
14
Process
Customer / Location
Licensor
FACT Udyogmandal
IFFCO - Phulpur
RCF, Trombay -I
Indo Gulf
Chambal Fertiliser
Gadepan
Haldor
Topsoe
Haldor
T
Topsoe
Haldor
Topsoe
Haldor
Topsoe
MW
Kellogg
MHI/P.T Kaltim
Pasifik Amoniak,
Indonesia
Haldor
Topsoe
Petronas Ammonia
Syngas Project
Haldor
Topsoe
Design Design
Design
Press. Temp.
Code
Kg/Cm2
C
158
245
120
245
188
155
155
370
370
370
370
290
370
370
ADM
ADM
ADM
ADM
ADM
ADM
ADM
Dimension
s
(ID X L)
mm
2700 x
20940
3000 x
22425
2000 x
16300
3000 X
22425
2800 x
29650
3300 x
22980
2700 x
20600
Thk
mm
Material Of Construction
(Multi-Wall)
94
SA 387 GR.11 CL 2 +
(30+32x2)
155
SA 387 GR.11 CL 2 +
(32+41x3)
56
SA 387 GR.11 CL 2 +
(24+32)
148
SA 387 GR.11 CL 2 +
(25+41x3)
107+ 6
SA 302 GR. A +
(27+40x2)
110
SA 387 GR.11 CL 2 +
(32+39x2)
111
SA 387 GR.11 CL 2 +
(25+43x2)
H2
Year Of Partial
Supply Press.
2
Kg/cm
1996
105
1997
157
1998
82
1998
157
1998
116.2
1998
103
1999
111
16
Customer / Location
Process
Licensor
Uhde
Design Design
Dimensions
Design
Press. Temp.
(ID X L)
Code
Kg/Cm2
C
mm
155
370
ADM
230
300
DIV.2
2700 x
30400
3010 X
11550
17
Uhde
230
300
DIV.2
2855 X
10200
18
Snamprogetti, Italy /
OMIFCO,Oman-2 nos.
Haldor
Topsoe
230
370
ADM
2800 x
21540
Thk
mm
H2
Material Of Construction Year Of Partial
(Multi-Wall)
Supply Press.
2
Kg/cm
2001
102
94
(30+32x2)
192
SA 387 GR
GR.11
11 CL 2 +
SA 533 GR. B CL.2
SA 387 GR.11 CL 2 +
2003
129.5
(48x4)
182
2003
105
(44+46x3)
142
2004
158.02
(25+39x3)
16 65
16.65
(MPA)
270
DIV 2
DIV.2
3250 x
31000
174
(4x43.5)
SA 387 GR
GR.11
11 CL
CL.2
2
2004
111 5
111.5
Haldor
Topsoe
155
380
ADM
2800 X
20,000
96
(24+36x2)
SA 387 GR 11 Cl 2 +SA
533 Gr B Cl 2
2005
87
H ld
Haldor
Topsoe
225
430
ADM
3000 X
20,300
2006
117
225
430
ADM
2006
117
103
413
135
13 Cr Mo V910 as per
EN 10028-2
SA 387 G
Gr. 11 CL2
2007
55 53
55.53
225
398
184 (47x4)
13CrMov9-10
2008
93.9
19
B
Burrup
F tili
Fertilizers
Pt
Pty Ltd
Ltd, KBR,
KBR USA
Australia
20
21
IFFCO A l I & II
IFFCO-Aonla
169 (42
(42x3+43)
3+43) 13 Cr
C Mo
M V910 as per
EN 10028-2
Phulpur-II: 3 Nos.
22
RCF-Trombay
23
KBR EBIC E
KBR-EBIC-Egypt
t
Haldor
Topsoe
KBR
24
KBR
2400 x
16,210
DIV 2 / 3810/3313 x
DIV.2
U2
23470
ADM
3600 x
17540
120 (40x3)
Sr.
No
Customer / Location
Process
Licensor
Design
Press.
Kg/Cm2
Design
Temp.
C
Design
Code
25
KBR
188
398
ADM
26
Haldor
Topsoe
218
325
DIV.2
2600 x 22545
Uhde
234.5
Uhde
KBR
PIDEC, Iran
Ammonia
Casale
27
29
30
31
Dimensions
(ID X L)
mm
Thk
mm
188
Material Of Construction
(Multi-Wall)
Year Of
Supply
H2 Partial
Press.
2
Kg/cm
13CrMov9-10
13CrMov9
10
2008
93.9
2008
144.8
2009
132.5
2009
106.5
2009
110.2
Under
Exec
108.1
(47 x 4)
300
DIV.2
3010 x 16730
247.5
(49.5 x 5)
234.5
300
DIV.2
2855 x 14725
235
(47 x 5)
166.29
285
DIV.2
3000 x 26700
158
(40x3+38)
183.54
300
DIV.2
3100 x 29300
184
(46 x 4)
Customer / Location
4
5
Process
Licensor
Design Design
Dimensions
Design
Press. Temp.
(ID X L)
Code
C
mm
Kg/Cm2
Haldor
Topsoe
270
IFFCO Aonla
Expansion
Haldor
Topsoe
245
Haldor
Topsoe
245
IFFCO Phulpur
Expansion
Haldor
Topsoe
245
QAFCO 4, Qatar
Uhde
225
-20
50
50
50
50
ADM
ADM
2260 x 5460
2260 x 5460
2260 x 5460
Thk
mm
130
40 + 2 x 45
SA 516 Gr 70
100
SA 537 Cl 1 +
30 + 2 x 35
SA 533 GR. B CL 2
100
SA 537 Cl 1 +
30 + 2 x 35
SA 533 GR. B CL 2
100
SA 537 Cl 1 +
30 + 2 x 35
SA 533 GR. B CL 2
172
43 x 4
345
Snam-Technip JV /
Oman India Fertilizer
Co., Oman (2 nos.)
Haldor
Topsoe
234.5
KBR
169
70
75
60
ADM
DIV.2
2350 x 3640
2400 x
10740
Material Of
Construction
(Multi-Wall)
1983
1995
1995
1996
2003
1999
2004
2004
SA 516 Gr. 70
136
36 + 2x32 + 36
SA 516 Gr
Gr. 70
104
SA537 Cl1 +
30 + 2 x37
SA 533 GR. B CL 2
136
4 x 34
H2
Year Of Partial
Supply Press.
2
Kg/cm
SA 516 Gr. 70
Customer / Location
Process
Licensor
Design
Press
Press.
Kg/Cm2
NFL Bhatinda
Mitsui
260
Chambal Fertlisers,
Gadepan (2 nos.)
TEC
184
Design
Temp
Temp.
C
210
220
Design
Code
Dimensions
(ID X L)
mm
ADM
Thk
mm
Material Of
Construction
(Multi-Wall)
148
SA 533 Gr. B Cl 2
37 x 4
+ Ti Liner
2450 x 27300
SA 533 GR. B CL 2
84 + 7
NFL Nangal
Expansion
Urea Casale
240
220
ADM
1200 x 29000
1996
1998
2000
57 + 8
H2
Year Of Partial
P
Supply Press.
2
Kg/cm
SS 25 - 22 - 2 Liner
Customer / Location
Process
Licensor
RPL, Hazira
Nova
Nova
Design Design
Press Temp.
Press.
Temp
Kg/Cm2
C
195
190
195
315
340
340
Design
Code
Dimensions
(ID X L)
mm
Thk
mm
Material Of
Construction
(Multi-Wall)
Year Of
Supply
H2
Partial
Press.
2
Kg/cm
Div 2
2743 x 6463
225
SA 516 Gr. 70
1989
23+3, 50 x 4
Monel Clad
259
SA 516 Gr. 70
1996
32+3,, 56 x 4
Monel Clad
237
SA 516 Gr. 70
1996
22+3, 53 x 4
Monel Clad
305
SA 516 Gr. 70
2009
45+3, 52 x 5
Monel Clad
Div 1
2900 x 1610
GAIL, Auriya
RPL, Hazira
Nova
Nova
195
190
340
340
Div 2
Div 1
2900 x 1610
3800 x 2900
IOCL, Panipat
REFERENCE LIST.Summary
Ammonia Converters: 35 nos.
Ammonia Separators: 10 nos.
Urea Reactors: 4 nos.
Solution Adsorbers: 4 nos.
Hydrogenation Reactors: 2 nos.; Towers: 2 nos.
Hydrocracker Reactors: 3 nos.; Secondary Reactor: 1
no. (supplied by Struthers Wells)
TO CONCLUDE ...
Multiwall construction is proven design and fabrication
technology for high pressure vessels in varied process
services including Ammonia Converters, Hydrocracker
R
Reactors,
t
S
Separators
t
etc.
t
Design & manufacture of Multiwall equipment fully conforms
to ASME Code.
Multiwall construction provides higher operational safety
due efficient to venting
g of diffused g
gases, such as Hydrogen
y
g
and inherent ability to provide an early warning in case of
any failure originating from inside of vessel.
Multiwall
M
lti ll construction
t
ti
f ilit t
facilitates
use off thinner
thi
plate
l t sections
ti
which have inherent ability to achieve better/superior
metallurgical control /structure and thus, it is not only cost
effective,
ff ti
b t may be
but
b a better
b tt
alternative
lt
ti
f
for
Hi h Pressure
High
P
Vessels / Reactors.
Larsen & Toubro Limited: April 2010. All rights reserved
THANK YOU