Completed projects – فن فولاد سابین

1. Fajr Jam Gas Refining 2. ITS Tekno Sains Co 3. Z-Subsea Co 4. Oil and gas refining 5. Biston power plant

Analysis of stresses on the absorption tower during welding and PWHD and its effects on the device

Post-weld heat treatment (PWHT) is often applied to pressure vessels and welded pipes to enhance mechanical and metallurgical properties. During PWHT, a pressurized component made of carbon steel on which PWHT is applied is heated to a temperature of about 620 °C and the high temperature is maintained for 1-2 hours. Local PWHT of a vertical pressure vessel is sometimes planned on a construction site with a vertical position, because there are some constraints related to the construction, such as limited access path to the vessel location, and large capacity cranes. In this project, the importance of considering creep deformation in structural integrity assessment of PWHT operations was revealed.

Analysis of steel water tank by FEA method

The current project was performed on a water storage tank based on the procedures of API 579 – Fitness for Service, ed. 2021 to assess whether the storage tank constructed based on API 650 is fit for the upcoming service or not. The investigations were carried out in this report in two separate sections. The first one is a checklist to compare the customer calculations of the storage tank designed in compliance with API 650 and the second part is finite element analysis (FEA) of the storage tank whether to approve design requirements or not. In the second section, a quantity known as the equivalent stress is computed at critical regions of the storage tank and compared to the allowable value of equivalent stress of the material of the storage tank to determine if the storage tank is suitable for the intended design conditions or not. Fatigue evaluation was made based on the number of applied cycles of a stress or strain range at different critical points in the storage tank. Based on formulas stated in Annex 3-F (Design Fatigue Curves) of ASME Section VIII Division 2, 2017, allowable number of cycles for startup and shutdown as well as wind load cycles were calculated.

Leak rate calculation for leak-before-break (LBB) analysis of a subsea pipeline by Finite Element Analysis

This project was performed to evaluate the crack opening displacement (COD) which is a key parameter in leak-before-break (LBB) assessment of the piping systems by direct weight function-based method. The focus of this project was a circumferential-cracked pipe with non-linearly through-wall distributed stress loaded on the crack face. Finite element analyses (FEA) were performed to calculate COD associated with different crack face pressure (CFP) loadings. The approach of J-integral and J-resistance curve for ductile crack extension was adopted in carrying ductile fracture analyses to define the critical crack length. Finally, a flow model is used to perform the calculation of detectable leakage.

Fitnss For Service assesment (FFS) for gas treatment tank

This project aimed to perform a fitness-for-service assessment of Hydrogen-induced cracking (HIC) damaged vessel. Our FFS assessment project was a pressure vessel in gas treating unit. Level 3 of API 579-1/ASME fitness-for-service-1accepted the vessel to return to normal operation rejected before in level 1&2 due to MSD and more importantly weld position.

Creep-fatigue damage evaluation of a process reactor using ASME-NH code methodology

Critical equipment of power plants and petrochemical industries is sometimes subjected to both creep and fatigue loading simultaneously. Under combined creep–fatigue loading, the creep deformation affects the fatigue behavior of the material depending on the relative duration of stress relaxation due to creep within service life. In this project, evaluation of creep and fatigue damage was carried out for a reheater tube using elastic analysis method of ASME-NH code. The reheater material was 304 stainless steel.