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Coke Drum Weld Design for Better Fatigue Performance

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Delayed coking process is one of the major process technologies used for breaking down the heavy, long chain hydrocarbon molecules of the residual oil into shorter coker gas oil (and petroleum coke as by-product). Severe cyclic operating conditions are involved in these units. The main vessels, coke drums, are exposed to multiple damage mechanisms, as summarized in API 934G and J.

Product Number: 51323-19182-SG
Author: Haixia Guo, Frank Vacha, Sunil Nayar, Mark Odegard, Enzo Falo, Simon Yuen
Publication Date: 2023
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Low cycle fatigue is a dominating damage mechanism for coke drums due to the batch cyclic operation and water quenching process. Resistance to low cycle fatigue is one of the major considerations when designing new drums. In a major coke drum replacement project, lab testing was employed to assist selection of weld profile, welding processes for clad restoration, and to generate the fatigue curves for the specific weld design. This paper summarizes part of the main testing results and findings from the lab testing program, using samples made with C-0.5Mo steel with Alloy 625 cladding. These testing results supported design selection for better fatigue resistance and are anticipated to increase service life of the new coke drums.

Low cycle fatigue is a dominating damage mechanism for coke drums due to the batch cyclic operation and water quenching process. Resistance to low cycle fatigue is one of the major considerations when designing new drums. In a major coke drum replacement project, lab testing was employed to assist selection of weld profile, welding processes for clad restoration, and to generate the fatigue curves for the specific weld design. This paper summarizes part of the main testing results and findings from the lab testing program, using samples made with C-0.5Mo steel with Alloy 625 cladding. These testing results supported design selection for better fatigue resistance and are anticipated to increase service life of the new coke drums.

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