FCC Expansion Joints for Refinery complex in Africa
MACOGA has completed the detailed engineering, manufacturing and testing of a complete set of FCC Expansion Joints for an African Refinery Project. The refinery is expected to be the world’s biggest single-train facility, upon completion in 2019.
The processing facilities at the refinery include a crude distillation unit (CDU) and associated facilities, a mild hydrocracking (MHC) unit, residual fluid catalytic cracking (RFCC), naphtha hydrotreater and RFCC gasoline hydrodesulfurisation (HDS) unit, as well as alkylation units.
The high-tech Expansion Joints provided by MACOGA have been designed as per UOP specifications and comprises the following units:
REGENERATED CATALYST STAND PIPE UNIVERSAL EXPANSION JOINT
COLD WALL DESIGN Type 1
I.D. 2000 mm - Length: 5000 mm
Inconel 625 LCF bellows – 2 ply testable – sealed design
Refractory lining Resco RS17 EC
Abrasion lining Rescobond AA22S
Hexagonal Mesh 304H
Design Pressure: 6.41 Kg/cm²
Bellows Design Temperature: 538 °C
SPENT CATALYST STAND PIPE UNIVERSAL EXPANSION JOINT
COLD WALL DESIGN Type 2
I.D. 1950 mm - Length: 5000 mm
Inconel 625 LCF bellows – 2 ply testable – sealed design
Refractory lining Resco RS17 EC
Abrasion lining Rescobond AA22S
Hexagonal Mesh 304H
Design Pressure: 6.41 Kg/cm²
Bellows Design Temperature: 538 °C
RECIRCULATION CATALYST STAND PIPE No. 1 UNTIED UNIVERSAL EXPANSION JOINT
COLD WALL DESIGN Type 1
I.D. 1830 mm - Length: 5000 mm
Inconel 625 LCF bellows – 2 ply testable – sealed design
Refractory lining Resco RS17 EC
Abrasion lining Rescobond AA22S
Hexagonal Mesh 304H
Design Pressure: 6.10 Kg/cm²
Bellows Design Temperature: 538 °C
Medium: 775 °C
RECIRCULATION CATALYST STAND PIPE No. 2 UNTIED UNIVERSAL EXPANSION JOINT
COLD WALL DESIGN Type 1
I.D. 1830 mm - Length: 5000 mm
Inconel 625 LCF bellows – 2 ply testable – sealed design
Refractory lining Resco RS17 EC
Abrasion lining Rescobond AA22S
Hexagonal Mesh 304H
Design Pressure: 6.10 Kg/cm²
Bellows Design Temperature: 538 °C
Medium: 775 °C
COOLED CATALYST UNTIED UNIVERSAL EXPANSION JOINT
COLD WALL DESIGN Type 1
I.D. 1080 mm - Length: 2500 mm
Inconel 625 LCF bellows – 2 ply testable – sealed design
Refractory lining Resco RS17 EC
Abrasion lining Rescobond AA22S
Hexagonal Mesh 304H
Design Pressure: 4.85 Kg/cm²
Bellows Design Temperature: 538 °C
Medium: 775 °C
REACTOR INTERNAL UNTIED UNIVERSAL EXPANSION JOINT
COLD WALL DESIGN Type 1
I.D. 900 mm - Length: 900 mm
ASTM B 424 (UNS 8825) bellows – single ply
Design Pressure: 0.35 Kg/cm²
Bellows Design Temperature: 538 °C
These FCCU expansion joints incorporate 2-ply testable bellows where each ply is designed for the full operating conditions. If a hole or stress crack develops in the inner ply during service, the outer ply takes over without exposing operators to increased risk or creating the need for an unscheduled shutdown. 2 ply testable bellows system improves reliability and makes the expansion joint more maintenance friendly. The annular space between plies can be monitored for leakage to detect a ply failure. This will serve as a warning of an imminent problem. A pressure device in the outer ply alerts about the inner ply failure. The 2-ply testable bellows also allows inspectors to pressure test the inner and outer ply during shutdowns.
These FCC Expansion Joints undergo a comprehensive quality control and testing program including:
— Review Drawings
— Advanced Review of Calculations
— Check Material and welding consumables certificates
— Review and update WPS, PQR and WQR
— Review NDE Procedures & Operator Qualification
— 100% RT- Radiographic Examination
— 100% PT - Liquid Penetrant Examination
— MT - Magnetic Particle Examination
— Hardness Testing of Welds
— Pressure & Leak Detection Test
— 100% PMI - Positive Material Identification
— 100% Inspection of Refractory Lining by API Inspector
— Surface Preparation & Paint System
