Project Overview
- Code of Construction: ASME Section VIII, Division I
- Drums 3100 & 3200: WSI conducted engineering analysis for all six drums, working two drums in parallel, head-to-head against a competitor.
- Base Material: SA387 Grade 11 Class 2
- Thickness: 1.88” + 1/16” cladding
- Dimensions: 29’ ID x 112’ H
- Seam Repair Requirements:
- Gouge cladding
- Preheat – 350° F
- Temper Bead Filler – ER70S-B2L
- Structural Weld Overlay (Temperbead Process) – ERNiCrMo-3 / Alloy 625
- Bulge Repair Requirements:
- Preheat – 350° F
- Temper Bead – ERNiCrMo-3 / Alloy 625
- 8:1 taper
Challenges
- Limited Real Estate: Congested work area with multiple contractors required WSI to coordinate with the customer to optimize their existing plan for a shorter schedule.
- Peak Season Craft Shortage: WSI’s unique ability to mobilize our world-class skilled craftsmen and industry-leading equipment provided confidence in execution coverage and offered risk mitigation for potential found work opportunities.
- Largest Turnaround Activity in Site History: This was the most extensive and complex scheduled plant shutdown ever undertaken at this facility.
- Engineering-Based Maintenance Approach: WSI’s Engineering Group utilized our proprietary analysis to optimize repair strategies tailored to the use of our machine-welding systems.
- Complex Contracting Strategy: WSI worked closely with our Client Partner and various sub-trades to ensure schedule adherence and seamless execution of a challenging work scope.
- Adverse Weather Conditions: During this outage, the Gulf Coast experienced the coldest January since 2007. Below-normal temperatures, heavy rainfall, and flooding hit the area hard, creating very challenging conditions for all crews onsite.
The WSI Difference – Engineering and Equipment
- BSF Analysis (Bulge Severity Factor): WSI analyzed all six drums with repair & mitigation plans. WSI classifies bulges based on severity and risk, according to API TR 934J, a technical report from the American Petroleum Institute (API) that provides guidance and best practices for the inspection, assessment, and repair of coke drums and their peripheral components withing delayed coking units.
- WSI Owned/Built/Maintained All Equipment Deployed:
- DragonX AutoGouge to remove cladding
- BPV HotPulse Orbital GTAW™ used on all seam repairs
- NG4 GMAW Automated Weld Machines for SWOL
- Equipment mobilized to work both drums simultaneously
Results
WSI outperformed the competition and showcased why we are the Leaders in Coke Drum repair and maintenance.
- Drum 3100: Work completed in 23 days (46 shifts)
- Seam repair – 90 feet in 5 sections
- Bulge repair – 936 square feet
- Drum 3200: Work completed in 18 days (36 shifts)
- Seam repair – 60 feet in 4 sections
- Bulge repair – 216 square feet
- Showcased proprietary DragonX AutoGouge: WSI’s Automated Gouging System increases productivity, minimizes prep time, and delivers a smoother finish with precise depth control.
- Minimized Craft Exposure: Just six (6) WSI personnel did the work of 20+ craftsmen via automation. The automated process reduced contact with hazardous elements by removing the individual from the workfront.
- Proprietary Machine HotPulse GTAW™ Application: WSI’s system of wire preheating, precise dabbing mechanics, and controlled waveforms decreases porosity, improves grain refinement, and is significantly less susceptible to fit up imperfections in field joints. This provides superior weld quality with increased production rates with reduced risk of failure.
- Optimized Schedule to Reduce Onsite Critical Path: WSI’s extensive experience and use of industry leading automated equipment strategically shortened the project’s overall timeline by decreasing the duration of the critical tasks that directly impacted the project end date.
- In-house Engineering Support: WSI’s internal team of engineers and technicians provided expert solutions and 24-hour technical support, eliminating the need rely of external vendors or contractors.
- Goal Zero: WSI’s safe work practices resulted in ZERO injuries, lost time, and downtime.
“WSI provided expertise in planning, which condensed our schedule. Along with that, quality, reporting, housekeeping, and safety were exceptional.” – Turnaround Manager