Refinery - II M&I SD Oct-Nov 2018

Chennai Petroleum Corporation Limited (A group company of Indian Oil)
Technical - Inspection
Chennai Petroleum Corporation Limited (A group company of Indian Oil)
Technical - Inspection
Replacement of 03 nos. of coolers & 06 nos. of Air Fin Coolers.
RLA study of the exchangers (16-E-04A/B, 16-E-07) & offered for IBR authorities for extension of license.
1.4.5 Plant 19 : Propylene - Major Jobs:
Equipment & Piping-
External patch plating was carried out in 03 nos. of vessels
Replacement of 2 nos. of vessels & complete insulation renewal for 06 nos. of Columns
WFMPT for 08 nos. columns/ vessels
23 nos. Safety Valves were pre-pop tested, dismantled, serviced, reconditioned and bench tested.
Partial replacement of 43 nos. of pipelines & 13 nos. of modification jobs.
UT gauging of 118 nos. of uninsulated/safety insulated pipelines in plant 19 as a pre-shutdown activity using
manlift & scaffolding.
Exchanger-
Replacement of 02 nos. of coolers.
1.4.6 Plant 86 : DCU - Major jobs:
Heaters-
Mechanical decoking of 86-F-01A/B furnace radiant & convection coils combining two passes in each
heaters.
1.4.7 Flare & Offsite Major jobs:
Replacement of flare tip (29-X-02) & molecular seal drum (29-X-
04) with a new one supplied by the OEM (M/S John Zink Co. Ltd.,
UK).
Replacement of water seal drum assembly (29-C-06) with a new
one supplied by M/S Indcon Projects & Equipment Limited., New
Delhi.
Water Seal drum repl.
Replacement of 24” Flare stack
(29-X-01) from water seal drum
outlet up to 30” molecular seal
inlet flange.
Ref-2 Flare tip repl.
Replacement of Acid gas KOD
(29-C-11B) with a new one supplied by M/s Unique Chemplant Equipments.
Partial replacement of the leaky/clamped 24” DHDS flare header for about
6.0 m length (approx.) near road 6 & B junction.
De- mountable flare hook up to 36” Ref-II flare header near Ref-2 flame
generator shed by projects.
1.5. INSPECTION ACTIVITIES
1.5.1. Major Inspection & Advanced NDT Techniques:
The following NDT activities were carried out during the shutdown:
Remote Field Eddy Current Testing (RFET) of AFCs (15-E-24A/45/16E & 16-E-108B1)
Eddy Current Testing (ECT) of 15-E-21B, 15-E-25B, 15-E-44B
Ultrasonic Flaw Detection in FCC Reactor stripper section, 16-E-152A, 16-E-152B, 15-E-44A, 15-E-44B
In-situ Metallography of Heater tubes, heater supports, Reactor internal surface.
Positive Material Identification (PMI) of piping in CDU-2 & FCCU
Ultrasonic Thickness Gauging of pipelines, heater tubes & equipments.
Dye Penetrant Examination of root welds of alloy steel heater tubes and piping under replacement, skin
point thermocouple welds.
Wet Fluorescent Magnetic Particle Testing (WFMPT) for 16-C-59/60/259/260/271/ 272/273/275, 17-C-
04/41, 19-C-03 & 19-D-02/03
Radiographic Examination of replacement welds & piping modification weld joints
Hydrostatic Testing of heat exchangers, pressure vessels after hot work jobs and piping after modifications
and replacements.
1.5.2. Statutory Inspection:
RLA study of 3 nos. of waste heat boilers (16-E-04A/B & 16-
E-07) along with CO boiler was carried out by engaging M/s
APT Inspection technologies & same were offered to IBR
authorities for extension of license.
An extensive Non Destructive testing Examination (Visual
inspection, Dye penetrant test, UT, dimensional
measurement, UT gauging, Deposit analysis, IMG test,
Hardness measurement, Fluorescent magnetic particle test,
Oxide scale thickness measurement) of all CO Boiler
components was made at all vulnerable locations such as
butt welds, fillet welds, stub welds, ligaments etc. Wire
brush cleaning or grinding was done for adequate width
near butt welds to permit ultrasonic flaw detection and dye
penetrant testing. Destructive testing of sample pieces was
also carried out after selecting few samples.
RLA Study
INSPECTION EXECUTIVE SUMMARY
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Refinery - II M&I S/D Oct-Nov 2018 - Inspection Report
Refinery - II M&I S/D Oct-Nov 2018 - Inspection Report
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