Clamshell Minimizes Down Time on FCC Regenerator Overhead Line

Late one Friday a West Coast refiner contacted Senior Flexonics Pathway with an urgent request; “One bellows in the universal expansion joint of our FCC regenerator overhead line has failed, can you help us? ... The unit is down!”
Senior Flexonics Pathway On-Site Service unit recommended the “Clamshell” technique. It would solve the problem, in the shortest possible time. Although only one bellows had failed, the customer determined that both bellows needed to be replaced in the tandem assembly.
The following summary chronicles the sequence of events carried out by the Senior Flexonics Pathway On-Site Service unit from notification of the problem through completion of the “Clamshell” procedure.
FRIDAY/3:30 p.m. The Senior Flexonics Pathway On-Site Service unit received the verbal request from the West Coast refiner.
3:45 p.m. Engineering and estimating were notified, the OnSite group coordinated all details with the client over the next 11/2 hours, advising design and cost details.
5:00 p.m. The order was placed for two “clamshells” ... 52" diameter.
6:00 p.m. The Senior Flexonics Pathway Engineering Department had produced design drawings and the manufacturing instructions were started.
SATURDAY/5:00 a.m. Quality Assurance review of final engineering and planning was completed. The job was released for manufacturing.
8:30 a.m. Seam welding of both bellows tubes was completed.
9:00 a.m. Dye-penetrant check was completed on the bellows tube longitudinal welds. The bellows tubes were released for forming.
11:15 a.m. The bellows are formed, quality control and final inspection are completed. Fabrication on the remaining components continues.
6:00 p.m. Final inspection prior to shipping is finished.
7:30 p.m. Both clamshell bellows and related hardware are boxed and driven to the Knoxville airport, where the refinery’s corporate jet is waiting. The seats had already been removed to accommodate the hardware.
SUNDAY/7:30 a.m. Senior Flexonics Pathway On-Site Service group dispatches two teams of two men each to the job-site.
7:00 p.m. First two-man team begins the installation.
Both teams work around the clock in two 12-hour shifts over the next four and a half days to complete the “clamshell” on both expansion bellows.
The “Clamshell” procedure, including engineering design, manufacturing, transportation, and installation covered six and a half days ... a total of 1621/2 hours. The FCC was available for service again in record time.
To find out more about Senior Flexonics Pathway’s 24 hour a day, 7 days a week On-Site Services, contact Senior Flexonics Pathway or visit our website at www.myej.com