PACKAGE 4 (COKER UNIT) FOR

JUBAIL EXPORT REFINERY PROJECT

Document No. : SA-JER-DC021-CYSE-073201
Client : SATORP Document Title : Calculation of Coke Drum Horizontal
Movement due to BANANA EFFECT

List of Revision Description (Form-1)

Rev
Paragraph Revision Description Remarks
No.
01 Section 4.2 Added explanation on vertical and radial movement of
coke drum shell due to thermal expansion
01 Attachment 3 Added calculation sheet of vertical and radial movement
of coke drum due to thermal expansion
00 First issue to Company
 PACKAGE 4 (COKE UNIT) FOR
JUBAIL EXPORT REFINERY
PROJECT
Consortium of Chiyoda Corporation / Samsung Engineering

2-12-1, Tsurumichuo, Tsurumi-ku, Yokohama 230-8601, Japan

Contract No. : 3000235429 CONTRACTOR Job No. : 99010

Client : SATORP Document No. : SA-JER-DC021-CYSE-073201

Calculation of
Coke Drum Horizontal Movement
due to BANANA EFFECT

A. Fauzan/ S.Akabane/
01 28-May-2010 For Construction M. Arai K. Konno
F. Ando M.Kitamura
A. Fauzan/ S.Akabane/
00 15-Apr-2010 For Acceptance M. Arai K. Konno
F. Ando M.Kitamura
Project
REV. DATE STATUS Written by Checked by Approved by
Approver
 Doc. No.: SA-JER-DC021-
Calculation of CYSE-073201
Coke Drum Horizontal Movement
PACKAGE 4 (COKE UNIT) FOR Rev. No 01
JUBAIL EXPORT REFINERY due to BANANA EFFECT
PROJECT PAGE 2 of 9

TABLE OF CONTENTS

Page
1.0 SCOPE ---------------------------------------------------------------------------------------------- 3

2.0 REFERENCES ------------------------------------------------------------------------------------ 3

3.0 METHODOLOGY OF CALCULATION------------------------------------------------------- 3

4.0 CALCULATION CONDITIONS AND RESULT--------------------------------------------- 4

4.1 CALCULATION CONDITIONS ----------------------------------------------------------- 4

4.2 RESULT ---------------------------------------------------------------------------------------- 5

5.0 ATTACHMENTS ---------------------------------------------------------------------------------- 5

 Doc. No.: SA-JER-DC021-
Calculation of CYSE-073201
Coke Drum Horizontal Movement
PACKAGE 4 (COKE UNIT) FOR Rev. No 01
JUBAIL EXPORT REFINERY due to BANANA EFFECT
PROJECT PAGE 3 of 9

1.0 SCOPE

This report outlines calculation methodology and result of coke drum horizontal
movement due to BANANA EFFECT which is recommended by Licensor, Foster
Wheeler USA Corp. (hereinafter FW), to be considered in accordance to FW Dwg No.
119659-4-11-003 Rev J: Note No 13. The calculation result shall be applied such that
for detail design of piping, structural steel and instrument to allow coke drum horizontal
movement.

2.0 REFERENCES

Licensor (FW), document:

- FW Dwg No. 119659-4-11-001 Rev H: General Arrangement – Coker Unit 021
- FW Dwg No. 119659-4-11-003 Rev J: Design Data – Coker Unit 021

Methodology of calculation and thermal expansion data are based on the followings:
- “Bowing of Cryogenic Pipelines”, W.G. Flieder, Transactions od ASME, Sep 1961
- “Pipe Stress Engineering”, L.C.Peng, T.L.Peng, ASME Press, USA, 2009
- “ASME BPVC Sect II Part D, Table TE-1, 2007 with 2008 addenda”

3.0 METHODOLOGY OF CALCULATION

The horizontal deflection due to BANANA EFFECT in coke drum is estimated

using simplified bowing phenomena by the temperature difference between
diametrical shell sides.

The simplified model assumes that the temperature difference ΔT between one
side and the other of shell is linear.
ΔT ε=1/2α ΔT

y
D

Neutral axis
ε=-1/2α ΔT
Temp Strain
Fig.1 Strain at location y

The thermal stress at location “y” and assumes the temperature profile under the
boundary conditions being both ends fixed is expressed in the following:

1 r 2
σ r = Eε r = E αΔT =σ r
2 D/2 max D

where D is diameter shell, E is elastic modulus, α is thermal expansion

coefficient.
 Doc. No.: SA-JER-DC021-
Calculation of CYSE-073201
Coke Drum Horizontal Movement
PACKAGE 4 (COKE UNIT) FOR Rev. No 01
JUBAIL EXPORT REFINERY due to BANANA EFFECT
PROJECT PAGE 4 of 9

The fictitious moment is calculated in the following equation:

2 2
M = ∫ σ r rdA = σ max ∫ r 2 dA = σ max I
D D

where I is inertia moment.

The bowing displacement is calculated in the following using beam theory.

d2y M 2 1 1 2 1 αΔT
2
=− = −σ max I = EαΔT I =−
d x EI D EI 2 D EI D
dy αΔT
=− x + C1
dx D
αΔT x 2
y=− + C1 x + C 2
D 2

For a cantilever model, the boundary conditions are dy/dx=0, y=0 at x=0. Then we
get C1=C2=0, the above equation is obtained in the following:

αΔT x 2
y=−
D 2
αΔT L2
y=− at x=L
D 2

x y

L
Fig.2 Cantilever Model

4.0 CALCULATION CONDITIONS AND RESULT

4.1 CALCULATION CONDITIONS

BANANA EFFECT of coke drum is anticipated during quenching of decoking cycle.

Calculation conditions are based on presuming the most severe and possible
temperature distribution when water being introduced to coke drum for cooling.
Water is channeling to one side of the coke drum and bringing quench design
temperature of 150oC, while on the other side of the drum, heated coke is still
maintaining its coking design temperature of 480oC.
 Doc. No.: SA-JER-DC021-
Calculation of CYSE-073201
Coke Drum Horizontal Movement
PACKAGE 4 (COKE UNIT) FOR Rev. No 01
JUBAIL EXPORT REFINERY due to BANANA EFFECT
PROJECT PAGE 5 of 9

In calculating horizontal movement, coke drum height is divided into two stages, i.e.
1st and 2nd stage. 1st stage is subject to temperature difference between diametrical
shell sides (BANANA EFFECT) which is taken from bottom fixation point to normal
coke fill level. 2nd stage having diametrical constant temperature (mean
temperature), where height is defined from normal coke fill level to top of nozzle. At
last, both of horizontal movements calculated from both stages are combined to
obtain total horizontal movement at top of coke drum due to BANANA EFFECT.

For detail input and coke drum sketch, refer to Attachment-1 “Calculation Sheet of
Coke Drum Top of Nozzle Horizontal Movement due to BANANA EFFECT”.

4.2 RESULT

Calculation result shows horizontal movement at top of coke drum nozzle due to
BANANA EFFECT is 208.4 mm.

In addition, in term of top nozzles vertical movement, FW specified on FW Dwg No.

119659-4-11-003 Rev J note 13 (b) that 200 mm vertical movement (upward) for
01
coke drum top nozzles should be considered (refer to Attachment-2-2). This data is
in line with the value shows by calculation result performed by vendor (see
Attachment-3). Moreover, as shown by Attachment-3, theoretical radial movement
of coke drum shell at coking condition is 32.2 mm.

In conclusion, the below data shall be applied for further related design purposes.
01 1. Top nozzles horizontal movement due to banana effect = 208.4 mm
2. Top nozzles vertical movement due to thermal expansion = 200 mm
3. Coke drum shell radial movement due to thermal expansion = 32.2 mm

5.0 ATTACHMENTS

Attachment-1 Calculation Sheet of Coke Drum Top of Nozzle Horizontal Movement

due to BANANA EFFECT
Attachment-2 FW Dwg No. 119659-4-11-001 Rev H: General Arrangement –
Coker Unit 021
FW Dwg No. 119659-4-11-003 Rev J: Design Data Coke Unit 021
01 Attachment-3 Calculation Sheet of Theoretical Vertical (upward) and Radial
Movement of Coke Drum Shell Due to Thermal Expansion.
PROJECT: PACKAGE 4 (COKER UNIT) FOR JUBAIL EXPORT REFINERY PROJECT Date: 2010/2/3 Rev.0

Calculation Sheet of Coke Drum Top of Nozzle Horizontal Movement due to BANANA EFFECT
B-01 ATTACHMENT-1
Simplified Modeling by Bowing Fictitious Moment And Displacement

ε=1/2α ΔT
Sketch of Coke Drum (typ.) Total horizontal thermal movement (banana effect):
y 208.4 mm
D
Top of Nozzle, L'
Neutral axis 2nd Stage
(Constant Temp.)
ε=-1/2α ΔT
Temp. Strain Mean Temp
Equations (480oC+150oC)/2= 315oC 107.7 mm
Fig.1 Strain at location y

Normal Coke Fill Level, L

x y

Fig.2 Cantilever Model

1st Stage
(Bowing)
1 Shell Material SA-387 Gr.11 Cl.2
2 Shell Higher Half-Side Temperature (Coking) T2 ℃ 480
Higher half-side Temp:
3 Shell Lower Half-Side Temperature (Quenching) T1 ℃ 150 o
480 C
4 Height, from bottom fixation to Top of Nozzles H mm 32,298 (Coking Design Temp.)
5 Shell Outside Diameter D mm 9,883 Lower half-side Temp:
6 Level of Temperature Profile Normal Coke Fill Level 150oC
(Quenching Design
7 Height for Constant Temperature (Top to Fill Level) L' mm 10,290 Temp.)

Design Conditions
8 Height for Temperature Difference (Bowing) L mm 22,008
9
10
11 Temperature Difference ΔT ℃ 330.0
12 Mean Temperature Tmean ℃ 315.0
13 Thermal Expansion Coefficient at T2 α2 mm/mm/℃ 14.220E-6
Bottom Fixation
14 Thermal Expansion Coefficient at T1 α1 mm/mm/℃ 12.427E-6
15 Mean Thermal Expansion Coefficient at (T2+T1)/2 α mm/mm/℃ 13.316E-6
16 Constant αΔΤ /D 1/mm 4.4464E-07
17 Horizontal Deflection Angle at L y' deg. 0.56

Calculations
18 Horizontal Deflection at L y mm 107.7
19 Top Horizontal Deflection Angle at L' y' deg. 0.56
20 Top Horizontal Deflection at L' y mm 208.4
21
Reference
(1) "Bowing of Cryogenic Pipelines", W.G.FLIEDER, Transactions od ASME, Sep, 1961.
(2) ASME Boiler & Pressure Vessel Code Sect II Part D, Table TE-1, 2007 with 2008 addenda
(3) "Pipe Stress Engineering", L.C.PENG, T.L. PENG, ASME Press, USA, 2009
PROJECT: PACKAGE 4 (COKER UNIT) FOR JUBAIL EXPORT REFINERY PROJECT Date: 2010/5/25 Rev.0

Calculation Sheet of Theoretical Vertical (upward) and Radial Movement

of Coke Drum Shell Due to Thermal Expansion (1)
ATTACHMENT-3

1 Shell Material SA-387 Gr.11 Cl.2

2 Shell Temperature (Coking) T1 ℃ 480
3 Skirt Temperature (Coking) T2
Design Conditions

℃ 399
4 Ambient Temperature T amb ℃ 21
5 Height of skirt (bottom fixation to bottom T.L.) H1 mm 26,350
6 Height of shell (bottom T.L. to top T.L) H2 mm 2,438
7 Shell Inside Diameter D mm 9,800
8 Coke Drum Shell Thickness T mm 41.5

1 Thermal Expansion Coefficient at T1 α2 mm/mm/℃ 1.422E-05

Calculations

2 Thermal Expansion Coefficient at T2 α1 mm/mm/℃ 1.386E-05

3 Coke drum shell vertical movement (upward) mm 184.7 (2)
4 Coke drum shell radial movement (upward) mm 32.2

Note (1) Calculation based on information received from vendor (Sumitomo Heavy Industries, Ltd.)
(2) As design basis, 200 mm shall be used in accordance to Foster Wheeler USA Corp Dwg No. 119659-4-11-003 Rev J note 13 (b)

(Drawing obtained from Sumitomo Heavy Industries, Ltd.)

Reference
(1) ASME Boiler & Pressure Vessel Code Sect II Part D, Table TE-1, Thermal Expansion Coefficent B, 2008