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

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




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




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.




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




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.




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




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.




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




Item 1 – Coke Drum 05C‐4 Datasheet




Item 2 – Instrument Installation View




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




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).




Item 5 – Strain Gauge Product Sheet

Optional bridge adaptor is not part of the purchased assembly.




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

thermo‐mechanical measurement of u1 coke drum …

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