Project Overview

The Client’s inspection group identified that the casing and refractory on the convection section were in poor condition. Several areas had been temporarily patched. As a result of the refractory failures, flue gasses had attacked the casing internally causing extensive metal loss and several locations had holes through along the entire length of the top portion of the north and south sections of the Convection Box. With the combined deterioration of the anchor system, casing and refractory, attempting a suitable permanent repair was not practical. The finned coil was constructed from A106 Grade B material and had been in service since 1971, approximately 370,000 hours. It was recommended that new tubes be used in the replacement and that the entire convection section be replaced as a whole to minimize on site work during the turnaround.

Convection Section Replacement (FEED and Detail) main Convection Section Replacement (FEED and Detail) first Convection Section Replacement (FEED and Detail) second

Performance Simulations

The Client requested that the convection section be brought up to current code, including construction and furnace damper.
During detailed engineering, the Client requested that Rally modernize the steam drum and platforms, which sit on top of the convection section, as part of this project’s scope. The steam drum and associated platforms were designed as a module to reduce the amount of work during the turnaround.

Additional Structural Reinforcement

  • Rally provided a Level 3 Construction Schedule, to capture construction activities during EDS. This schedule was used as a basis for the CAPEX estimate.
  • Rally managed the convection section vendor to ensure that the convection arrived on site in time for the planned turnaround.
  • All construction work packages were issued to construction planning 12 months prior to the planned turnaround, per the schedule.
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