Costly Lessons Learned from Inspection Pitfalls of Coke Drums RefComm 2019 Galveston, TX Mahmod Samman, Ph.D., P.E. Houston Engineering Solutions, LLC (+1) 832-838-4894 [email protected]
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Costly Lessons Learned from
Inspection Pitfalls of Coke Drums
RefComm
2019
Galveston, TX
Mahmod Samman, Ph.D., P.E.Houston Engineering Solutions, LLC
(+1) 832-838-4894
www.hes.us.com
Company Background
2
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Overview
• Inspection of cone side of skirt attachment
• Smoothing of laser data
• Internal inspection of seam weld cracks
3
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Inspection of Cone Side of Skirt
Attachment
4
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In-Line Skirt
5
API 1996 Survey
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Shear Wave Ultrasonic Testing
6
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Case Study
7
Through-wall crack not detected
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Smoothing of Laser Scan Data
8
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Why?
• Drill-stem vibrations
• Digital noise
9
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Vibration Effect
10
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Signal Distortion
11
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Signal Filtering
12
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Signal Zoom
13
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Case StudyRadius map
Less smoothing More smoothing
14
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Case StudyBulging Severity (PSI)
Less smoothing More smoothing
15
Incorrect assessment of severe bulges
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Internal Inspection of Seam Weld
Cracks using Alternating Current Field
Measurement (ACFM)
16
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Classic Tri-Metal Joint Cracks
Base Metal
Circumferential Weld
Clad
Restoration Weld
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Common OD Cracks
Base Metal
Circumferential Weld
Clad
Restoration Weld
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Case Study
Base Metal
Circumferential Weld
Clad
Restoration Weld
Sensor Array
Almost through-wall crack not detectable using internal ACFM.
Need internal AND external ACFM, UT, or AET
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Recap
• Inspection of cone side of skirt attachment
• Smoothing of laser data
• Internal inspection of seam weld cracks
20
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