DELAYED COKING - COKE DRUMS – WORLD

WIDE TRENDS

Stress Engineering Services

Coke Drum User Group Seminar, Houston, Texas
November 19, 2008

Presented by Les Antalffy

© 2008 Fluor Corporation. All Rights Reserved.

Agenda
 Current Trends – Energy
Growth Outlook
 Surge in Delayed Coking Units
 Heavy/Light Crude Differentials
 Some Identified Delayed Coking
Projects Starting 2004-2009
 Coke Drum Delivery Importance
– Coke Drums Set Construction
 Global Coke Drum Fabricators
 Global Suppliers of Clad Plate
 Fluor’s Delayed Coking Initiative
 Clad Plate Layout in a Coke
Drum (Roll Bonded Clad vs
Explosion Bonded Clad)
 Some Recent Innovations In
Coke Drum Designs
 Panel Insulation Supported from
Hanging Straps
 Drum Transportation
 Drum Erection & Cranes
Required
 Be Prepared for the Unexpected
 Summary & Conclusions
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Current Energy Trends- Energy Growth Outlook

 World energy consumption will increase 71 % from 2003 to

2030
 Fossil fuels will remain the dominant energy source
 World
Oil use will grow from 80MM BPSD in 2003 to 98MM
BPSD in 2015 and to 118MM BPSD in 2030

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Current Trends – Energy Growth Outlook

Figure 1. World Marketed Energy Consumption by Region, 1980 - 2030

Quadrillion Btu
1,000
History Projections
800 722
Non-OECD 665
OECD 613
600 563
510
421
400
400 347 366
283 309

200

Sources:
History: Energy Information Administration (EIA),
International Energy Annual 2003 (May-July 2005). Web site www.eia.doe.gov/iea/.
Projections: EIA, Systems for the Analysis of global energy markets (2006).

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Recent Surge in Delayed Coking Units

 In recent years, starting from late 2004, there has been a

very significant upsurge in Delayed Coking resulting from
the increasing light/heavy crude price differentials.
 More than 20++ Delayed Coking projects were identified to
be started by 2008/2009.
 These projects result from:
– Economics of coker processing – heavy/light crude differentials
– To some extent, the outlook for future energy growth
– And to Delayed Coking being a good fit in a particular refinery
configuration
 Itis anticipated that there will also be a mini surge in
Europe in Delayed Coking activities in the future if margins
between heavy & light crudes are favorable.

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Current Trends –Heavy/Light Crude Differentials

 Recent trends in heavy/light crude oil price differentials

show that the wider the difference in crude quality, the
wider the price spread.
 Historicaltrends in crude and product differentials show that
product differential frequently moves ahead of the crude
price differential
 Therecan be significant economic benefits in processing
heavy crudes compared to light crudes, hence the recent
surge in Delayed Coking

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Heavy vs. Light Price Differentials Rise As Crude
Price Rises

Light Product Light Crude Oil

Prices Prices Increase
Increase Most

Crude Oil
Price
Increases
Residual Fuel Heavy Crude
Prices “Flat” Oil Prices
Increase Least

AV20080068-003.PPT 7
Heavy/Light Crude & Product Price Differentials

$36
Crude and Product Price Differentials $18

$32 $16
No.2 - 3%S Resid
Product Price Differential

$28 $14

Crude Price Differential

WTI-Maya
$24 $12

$20 $10

$16 $8

$12 $6

$8 $4

$4 $2

$0 $0
Jul-95

Jul-96

Jul-97

Jul-98

Jul-99

Jul-00

Jul-01

Jul-02

Jul-03

Jul-04
Jan-95

Jan-96

Jan-97

Jan-98

Jan-99

Jan-00

Jan-01

Jan-02

Jan-03

Jan-04

Jan-05
AV20080068-003.PPT 8
Current Trends –Heavy/Light Crude Differentials

 Both of the previous graphs show the economic benefits of

processing heavy crudes, hence there can be significant
benefits from Delayed Coking while heavy/light crude price
differentials are high.

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Some Of The Identified Delayed Coking Projects Starting
2004-9
(Excluding Coke Drum Replacement Projects)
 BP North America, Whiting, Indiana
 ConocoPhillips, Wood River, Illinois
 Ecopetrol, Barrcaberme, Colombia
 GGSR, Bathinda, India
 Indian Oil Company, Gujarat, India
 Indian Oil Company, Panipat, India
 Indian Oil Company, Paradip, India
 Imperial Oil, Kearl Lake, Alberta
 Irving Oil, New Brunswick, Canada
 KNPC, Kuwait
 Marathon Ashland Petroleum,
Garyville, Louisiana
 Marathon Ashland Petroleum, Detroit,
Michigan
 MOTIVA, Port Arthur, Texas
 PetroCanada, Alberta, Canada
 Petrobras,Comperj, Brazil
 Petrobras, Pernambuco, Brazil
 Petrobras, 3 Projects, Brazil
 Reliance, Jamnagar , India
 Repsol, Cartagena, Spain
 Tesoro, Anacortes, Washington
 Tesoro, Martinez, California
 Total, Port Arthur, Texas
 Total, Edmonton, Canada
 UTS Energy, Alberta, Canada
 Valero Energy Corporation, Port Arthur,
Texas
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Equipment Procurement and Delivery to Support
Construction Schedule

 One of the biggest challenges is to have materials at site as

required to support the project’s construction schedule.
 The
most important components in a Delayed Coking Unit
(DCU) are the coke drums
– Coke drum deliveries set the completion of the project
– In the recent past, coke drum deliveries have ranged up to as
much as 33+ months.
– One of the primary objective in Fluor’s Delayed Coking Initiative
was to supply coke drums with significantly shorter deliveries
– This enabled our Clients to start up their DCU’s in shorter time
spans
– Fractionators also have had extended deliveries because of clad
plate supply availability

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Coke Drum Delivery Importance

 Normal phased construction of a DCU requires the drums to

be at site before completion of the drum support tabletop
which occurs early during the construction phase.

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Setting The Coke Drums Sets Construction
Schedule

Coke drum being lifted

into a new Delayed
Coking Unit structure

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Coke Drum Supply

 Recently,
traditional coke drum fabricators have been over
extended or have had a large backlog
 Globally,
the clad plate mills have also been at peak
capacity and clad plate deliveries have been in the one year
plus range and in some instances even longer
 Cokedrum deliveries have recently been in the range of 28-
33 months and these longer deliveries extend construction
commensurately
 Today,
coke drum deliveries have improved to 18-24
months because of improved clad plate supply

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Coke Drum Fabricators

 Coke drums are relatively simple vessels with unique shapes,

tolerances and large sizes but can be difficult to fabricate to
the strict specifications and requirements dictated by the
severe thermal cycling of the drums
 Globally, the number of traditional experienced shop
fabricators of coke drums is limited:
– A.T.B. Riva Calzoni, Brescia, Italy (presently concentrating
on reactor fabrication)
– Felguera Caldereria Pesada, Gijon, Spain
– Japan Steel Works, Muroran, Japan (presently
concentrating on reactor fabrication)
– Sumitomo Heavy Industries, Saijo, Japan
 Some recent new comers to coke drum fabrication
– GGI, Willebroek, Belgium
– Idesa, Aviles, Spain
– Larsen and Tourbro, Hazira, India
– Mangiarotti, Sedegliano, Italy

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Present Back Log of Coke Drums by Fabricator

 GGI International (6)

 Idesa, Spain (8)
 Felguera, Spain (2)
 Larsen & Toubro, India (16)
 Mangiarotti, Italy (6)
 Sumitomo, Japan (38)

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Clad Plate Supply

 Traditionally, coke drums have been fabricated from roll bonded clad
mainly because of price and also because of the availability of larger size
plates
 In 2005 roll bonded clad plate deliveries were in range 12-14+ months.
 Globally, clad plate supply in 2007 was 245,000 metric tons and consisted
of
– 112,000 metric tons of roll bonded clad
– 133,000 metric tons of explosion bonded clad
 Today there are a very limited number of both roll bonded and explosion
bonded clad plate manufacturers in the world
 Explosion bonded clad deliveries however can be significantly shorter than
for roll bonded clad
 Recently Dynamic Materials Corporation (DMC) has been offering larger
clad plates competing with roll bonders. Explosion bonded clad plates have
been used for heads and cones in coke drums which require smaller plate
sizes.

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 2007 Total World Wide Production of Roll Bonded Clad
Plate by Manufacturer

NSSC, 9% (Japan) Mittal Steel USA

(Lukens), 4% JSW, 40%
(Japan)

Mittal
(Industeel), 10%
(France)

Voest-Alpine,
18% (Austria)

JFE, 19%
(Japan)

Courtesy J.S.W .

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 2007 Global Production and Usage of Roll
Bonded Clad Plate
2007 Total World Production of Roll Bonded Clad
Plate 111,700 MT
Gas Treatment,
Refinery & 14%
Petrochemical, 36%
Coke Drums,
18%

Dam/Dam
Gates, 3%
Food, 2%

Pulp, 2% Other, 3%
Desalination, 10%
Chemical Tanker
Pollution Control, 2%
10%
Courtesy
J.S.W.

AV20080068-003.PPT 19
Major Suppliers of Explosion Bonded Clad Plate

 Dynamic Materials Corporation

– USA
– France
– Sweden
– Germany
 Asahi – Japan
 Han Wha – Korea
 SMT – The Netherlands
 Otherincluding Chinese and Indian manufacturers mainly
supplying to domestic customers

AV20080068-003.PPT 20
 2007 World Wide Production of Explosion
Bonded Clad Plate 133,000 MT

China, 60.4%
Europe (SMT), 1.6% (Domestic Consumption)
Europe (DMC), 11.2%

U.S., 13.6%
(DMC)
Other, 0.4% India, 1.3%
Japan, 6.4%
Korea, 5.1%
(Asahi)
(Han Wha)
Courtesy DMC AV20080068-003.PPT 21
Roll Bonded Clad Plate
ADVANTAGES
 Cost advantage for plate
thickness <2½ (65mm)
 Usually larger plates sizes
available than explosion bonded
plate
 Clad materials are usually
stainless steels, nickel alloys,
copper alloys and some
specialized alloys including
titanium
DISADVANTAGES
 Requires steel mill rolls
 Requires heat treatment
furnaces
 Cladding thickness limitation
usually 1.5mm to 8mm
 Small plates/quantities can be
expensive to produce
 Some materials such as
titanium, zirconium & tantalum
are difficult to bond
 Thickness of backer material
usually <3” (75mm)
 Some alloys may be susceptible
to sensitization
AV20080068-003.PPT 22
Explosion Bonded Clad Plate Advantages &
Disadvantages
ADVANTAGES DISADVANTAGES
 Ability to bond alloys not readily  Cannot bond as large plates as can
bonded by hot rolling be produced by roll bonding
 Alloy cladding can be thicker, up to  Cost disadvantage <2½” (65mm)
25mm & even thicker where thickness
required – e.g. tubesheets
 Alloy sensitization not an issue
 Generally faster delivery
 Cost advantage over 2½” (65mm)
thickness
 Bonding sizes can be relatively
small for special applications – e.g.
tubesheets
 Explosion bonded cladding can be
applicable to plates up to and
including 175mm thickness

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Hot Roll Bonding Clad Plate Manufacture

Assembling the Welding the Evacuation

package package

Courtesy of VoestAlpine

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Hot Roll Bonding Clad Plate Manufacture cont.

Furnace Rolling the Plasma Cutting

package followed
by heat treatment

Courtesy of VoestAlpine

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Hot Roll Bonding Clade Plate Manufacture cont.

Leveling Grinding Final Check

Courtesy of VoestAlpine

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Explosion Bonded Clad Plate Manufacturing

Illustration courtesy of DMC

AV20080068-003.PPT 27
Explosion Bonded Cladding

 The explosion bonded detonation energy creates a regular,

well shaped, sinusoidal type wave form along the bond line
indicative of high mechanical bond properties & that the
manufacturing operation is in the optimal of range of the
essential variable parameters.
 Nochange in metallurgical characteristics or specification
compliance of either of the bonded materials occurs.

AV20080068-003.PPT 28
Explosion Bonded Austenitic Clad to Ferritic
Material Interface

Detonation Front

Cladding Material

Base Material

Photo courtesy of DMC

AV20080068-003.PPT 29
Fluor’s Delayed Coking Initiative Supply Chain Solution –
Clad Plate Supply & Quicker Drum Deliveries

 In 2005 Fluor qualified 2 additional coke drum fabricators

 Fluor also purchased quicker delivery explosion bonded
clad plates from DMC which were used by Fluor’s coke
drum manufacturers for the labor intensive coke drum
heads and cones
 Fluor also entered into a continuing supply agreement with
the 2 European roll bonded clad plate manufacturers for a
continuing month to month supply of clad plate from
– Mittal (Industeel) – France
– VoestAlpine – Austria

AV20080068-003.PPT 30
Typical Clad Plate Layout in a Coke Drum

AV20080068-003.PPT 31
Typical Clad Plate Layout in a Coke Drum

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Some Recent Innovations in Delayed Coking
Coke Drum Design/Fabrication

 Constant wall thickness drums-heavier drums but reduced

weld stress concentrations
 Consideration
of coke restraining cool down shrinkage of
drum-(CITGO Patent) heavier drums-claimed service life
improvement
 Modified skirt to cone joints-improve fatigue life
– Internally radiused attachment at weld
– External wrap around skirt attachment
– Skirt to cone attachment forging
– Stress Engineering Services’ “egg in cup” design
 Vertical shell strake design (CB&I patent)-to counter drum
bulging

AV20080068-003.PPT 33
Some Recent Innovations in Delayed Coking
Coke Drum Design/Fabrication Continued

 Grinding of internal & external of welds smooth & flush

 Elevated clad plate yield strengths (60Ksi, 1¼Cr-1/2Mo)
 Layout of adjacent plates with comparable yield strengths
 Alignment tolerances between adjacent plates and
tolerances on allowable drum local flatness
 Use of comparable strength welding consumables
 AUT (TOFD) of weld seams in lieu of radiography
 Insulation
– Hanging strap insulation supports
– Removable insulation panels which can permit weld
inspection

AV20080068-003.PPT 34
Typical Coke Drum Skirt Attachment Details

AV20080068-003.PPT 35
Coke Drum Hot Box Example

Thermal Animation (°F)

AV20080068-003.PPT 36
Coke Drum Hot Box Example cont.

Maximum Stress Intensity for Heat Up

AV20080068-003.PPT 37
Coke Drum Hot Box Example cont.

Maximum Stress Intensity for Cool Down

AV20080068-003.PPT 38
Coke Drum Hot Box Example cont.

Maximum Stress Range (Heat Up – Cool Down)

AV20080068-003.PPT 39
Coke Drum Hot Box Example cont.

Maximum Stress Range (Heat Up – Cool Down)

AV20080068-003.PPT 40
Fabrication of Integral Skirt Attachment From
Plate

AV20080068-003.PPT 41
Rough Machining of Integral Skirt Attachment

AV20080068-003.PPT 42
Internal Machining of Integral Skirt Attachment

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External Machining of Integral Skirt Attachment

AV20080068-003.PPT 44
Weld Overlaying of Integral Skirt Attachment

AV20080068-003.PPT 45
Stress Engineering Services – “Egg in Cup”
Design

Design permits radial thermal

expansion/contraction between skirt and
support flange welded to cone
AV20080068-003.PPT 46
Assembly of Verticle Strake Design Coke Drum

Photo Courtesy of CB&I

AV20080068-003.PPT 47
Vertical Strake Plate for Drum Assembly

Photo Courtesy of CB&I

AV20080068-003.PPT 48
Coke Drum Shell Bulging

Photo Courtesy of CB&I

AV20080068-003.PPT 49
 New Technology Insulation Support
Hanging Insulation Support Strap
Carbon steel floating
support rings Support brackets
for support rings Drum sidewall

Layers of insulation

Stainless steel self

tapping screws
Outer layer of
insulation is offset
from inner layer

Stainless steel Standing seam

T-316 jacketing with single fold
Picture Courtesy of TufSeam
Inner layer of insulation protected from
heat by 0.006” stainless steel foil &
poultry netting between vessel wall and
inner layer

AV20080068-003.PPT 50
 Birdcage Insulation Supports

Insulating hanger Strap

“Birdcage” Insulation
Supports, no clips need to
be welded to the shell

Picture Courtesy of TufSeam

AV20080068-003.PPT 51
Installation of Insulation Panels

Insulation can be installed in

the horizontal or vertical
position and panels can be
removed for weld seam
inspection

Picture Courtesy of TufSeam

AV20080068-003.PPT 52
Coke Drum Transportation

 Fabrication shop to ship

– Barge
– Multi Wheeled Transporters
 Ocean Transportation
– Self lift ships
– Ocean going barge
– Roll on – roll off
 Transportation from port to jobsite
– Multi Wheeled Transporters
 Transportation arrangements for coke drums need to be
finalized well ahead of required transportation date.

AV20080068-003.PPT 53
Typical Inland Barge Shipment to Ocean
Transport Ship

AV20080068-003.PPT 54
Typical Inland Barge Shipment to Ocean
Transport Ship Cont.

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Typical Multi Wheeled Transporter

AV20080068-003.PPT 56
A Typical Self Lift Ship

AV20080068-003.PPT 57
Ocean Transportation-Offloading From Barge
Onto Transport Ship.

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Ocean Transportation – Offloading At Delivery
Port.

AV20080068-003.PPT 59
Ocean Transportation – Offloading Cont.

AV20080068-003.PPT 60
Transportation From Port to Jobsite

AV20080068-003.PPT 61
Transportation From Port to Jobsite Cont.

AV20080068-003.PPT 62
Coke Drum Erection

 Modern day large drums with single thickness shells weigh

around 500 tons
 Because of space availability and the requirement for a long
reach, replacement coke drums usually require 2,500 ton
cranes
 2,500 ton cranes are very limited in the U.S. as well as
globally
 New drums in new units usually require smaller capacity
cranes

AV20080068-003.PPT 63
Coke Drum Erection cont.

2,500 Ton Cranes in the U.S.

 Abnormal Load Engineering ALE - 1 (Available Jan. 2009)

 Deep South - 2 (1 out of service)
 Lampson -2
 Mammoet -2

These cranes require at least 1 year booking time.

AV20080068-003.PPT 64
Drum Replacement in Louisiana

AV20080068-003.PPT 65
Drum Replacement In Mississippi

AV20080068-003.PPT 66
Drum Replacement in Mississippi

AV20080068-003.PPT 67
Drum Replacement in Minnesota

Replacement of
2 drums in a four
drum Coker unit
in Minnesota

AV20080068-003.PPT 68
Drum Replacement in Minnesota

AV20080068-003.PPT 69
Drum Replacement in Ohio

AV20080068-003.PPT 70
Typical 2,500 Ton Cranes

AV20080068-003.PPT 71
Typical 2,500 Ton Cranes Cont.

AV20080068-003.PPT 72
Small Diameter Lighter Weight Coke Drum
Erection

AV20080068-003.PPT 73
The Unexpected Sometimes Happens –
Be Prepared

AV20080068-003.PPT 74
The Unexpected Sometimes Happens –
Be Prepared Cont.

AV20080068-003.PPT 75
The Unexpected Sometimes Happens –
Be Prepared Cont.

AV20080068-003.PPT 76
Summary & Conclusions

 The recent surge in Delayed Coking activities has strained clad plate
manufacturers & coke drum fabricators
 The limited number of drum fabricators have a good backlog
 Clad supply situation has improved and explosion bonded cladding is
being used for coke drums
 Operating life expectancy of coke drums can be improved through
– Single thickness wall design
– Good attention to skirt to cone attachment
 Integral forging
 SES “egg in cup” design
 Other special designs
– Attention to other fabrication details
 Drum panel insulation and hanging strap “birdcage” support concept is
gaining popularity
 Transportation and erection of coke drums can be major operations
 Be prepared for the unexpected

AV20080068-003.PPT 77