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98581 RESTORATION OF A PETROLEUM REFINERY VESSEL USING WELD METAL OVERLAY

Picture for 98581 RESTORATION OF A PETROLEUM REFINERY
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Product Number: 51300-98581-SG
ISBN: 98581 1998 CP
Author: Ernie Benn, Simon Yuen, Andrea Weston, Michael J. Jirinec, George Y. Lai, Mark Stoutamire
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An atmospheric crude tower was subjected to accelerated corrosion over a short period of time. The corrosion mechanism was due primarily to changes in the feed, with higher quantities of sulfur compounds being processed at higher operating temperatures. The corrosion damage extended over a height of 14ft (4.3m) between the medium gas oil and diesel zones in the carbon steel section of the tower. In view of the criticality of the vessel to the refinery’s operations, a decision was made to restore the vessel integrity using weld metal overlay. After a complete structural design review, it was determined that temporary supports would be needed to withstand the wind shear and dead weight loads during the welding. This paper describes: the measures taken to minimize shell distortion and buckling of the shell during welding; the weld deposition sequence of the ER70S-7 carbon steel build-up and the corrosion protection barrier of ER317L; the corrosion monitoring systems in place before and after the repair; and the crude testing program including a Reactive Sulphur species test. Keywords: high temperature sulphidation, weld overlay, structural tuning, preheat, buckling, corrosion monitoring
An atmospheric crude tower was subjected to accelerated corrosion over a short period of time. The corrosion mechanism was due primarily to changes in the feed, with higher quantities of sulfur compounds being processed at higher operating temperatures. The corrosion damage extended over a height of 14ft (4.3m) between the medium gas oil and diesel zones in the carbon steel section of the tower. In view of the criticality of the vessel to the refinery’s operations, a decision was made to restore the vessel integrity using weld metal overlay. After a complete structural design review, it was determined that temporary supports would be needed to withstand the wind shear and dead weight loads during the welding. This paper describes: the measures taken to minimize shell distortion and buckling of the shell during welding; the weld deposition sequence of the ER70S-7 carbon steel build-up and the corrosion protection barrier of ER317L; the corrosion monitoring systems in place before and after the repair; and the crude testing program including a Reactive Sulphur species test. Keywords: high temperature sulphidation, weld overlay, structural tuning, preheat, buckling, corrosion monitoring
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