Jul 20
Welding Wonders
Welding Wonders
PLANNING, smart work and innovation are the secrets of success. Riding on the wings of these enablers, L&T’s Modification, Revamp and Upgrade (MRU) arm recently executed and won major orders.
MRU’s 6th coke drum project, for Mangalore Refinery & Petrochemicals Limited (MRPL), involved working simultaneously on three coke drums, with a challenging shutdown duration. A large weld overlay deposition had to be undertaken from within the drums. The shutdown period was largely dependent on the weld deposition rate, which necessitated round-the-clock arching.
Aided by L&T Heavy Engineering’s Technology Innovation Cell, maintenance and execution teams, the MRU arm developed an innovative welding technique, enhancing the automated GMAW welding by twin-torch welding. The welders were specifically trained to attain proficiency and handle multiple machines individually. The plan included preparations for simultaneous working at different elevations at peak time.

• India’s largest-ever weld deposition – 17 tonnes – in a coke drum repair project

• 28.64m x 2.1m area weld overlay completed by auto GMAW welding in one setting

• Working inside the drum with weld temperatures ranging from 150 degree Celsius - 180 degree Celsius, with round-the-clock arching

• Simultaneous inside overlay repair and outside circ-seam crack repair, reducing post-heating and equipment cooling time

• Adhered to 25-day timeline – despite client delays
The extensive experience and high skill level of the L&T team led to the safe completion of the project – with no quality giveaways, despite the immensely challenging target.
Metaphorically as a reward for the success in the MRPL project, a key hydrocarbon customer in the Middle East recently awarded an arterial contract to MRU.
The scope includes detailed engineering and supply of critical equipment and components, leading to multi-disciplinary site work. It will require staggered shutdowns during which the revamp has to be undertaken.
Next, as part of the Barauni Refinery expansion, MRU won a contract from the Indian Oil Corporation for revamping its Residue Fluid Catalytic Cracking unit. It involves capacity augmentation of the Unit and conversion into an INDMAX FCC unit. This will enhance the crude processing capacity of the refinery from 6 MMTPA to 9 MMTPA.


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