Refinery - II M&I SD Oct-Nov 2018

Chennai Petroleum Corporation Limited (A group company of Indian Oil)
Technical - Inspection
3.0 FLUIDIZED CATALYTIC CRACKING UNIT- FCCU
3.1 MAJOR OBSERVATIONS & JOBS EXECUTED:
Chennai Petroleum Corporation Limited (A group company of Indian Oil)
Technical - Inspection
Stripper section weld defect at joint no. CS-2 weld joint was repaired (1 spot). Bulged portion IMG & UT was
carried out and found satisfactory.
Following are the highlights of jobs executed during the shutdown.
Decontamination of column, connected piping and process circuits was carried out with oxidizer chemical (0.3-
0.4% oxidizer with DM water) by M/S Spanchem technology, to neutralize pyrophoric iron Sulfide and to remove oil
traces from the surface. After decontamination, columns were handed over to maintenance.
3.1.1 16-F-01
Replacement of pre-fabricated & pre-dried out convection module set along with tubes & header boxes.
Radiant shell replacement for about 32.0 m2 at bottom two shell course & bottom half radiant refractory
renewal for about 158.0 m2.
Additional strengthening of radiant shell was carried out by providing external support beams & external
circumferential patch at the middle shelf location.
RISER:
“Wye” section replacement with a prefabricated “Wye”
Section (from bottom flange @ EL +2100 to EL +5000)
with vibracast lining.
Riser top lid cover replacement with ARL lining on both
sides.
Optimix nozzles (3 Nos.) with barrel were replaced.
Disengaging arm - Eroded portion weld repair & ARL lining
with hexmesh replacement. Disengaging arm guide plates
eroded portion replacement and stopper plate
strengthening.
Cold wall refractory lining repair.
Refractory Lining Repair
REGENERATOR:
Regenerator cyclone (2 pairs – 4 nos.) complete
replacement as 2 segments each
(Main Barrel & Dip leg with middle section)
16-F-01 Convection Module Prefab.& Erection
3.1.2 SPECIAL EQUIPMENTS
REACTOR:
VSS Chamber replaced with prefabricated VSS chamber with
dish end & both elbows along with all 4 nos. equalizer pipes
were replaced.
Crossover duct eroded portions replacement.
Hard coke deposition removal & ARL repair/ replacement at
eroded portions.
Reactor cyclone parent metal partial replacement & ARL repair.
Reactor cyclone dip leg replacement with modified long cone
16-F-01 Radiant Shell Replacement
Replaced VSS Chamber
Air grid complete replacement (3 Segments).
Ski Jump location cover plate replacement.
Big manway cover & flange in-situ machining
Internal castable refractory relining for about 20.0
m 2 .
STANDPIPE & SLIDE VALVES:
RCSP internal refractory repair using Sure flow 17E.
Slide valve servicing & spare part replacement in all slide valves
CO Main duct replacement with internal ARL.
Replaced Regen. Cyclones
CO By-pass duct bulged portion replacement & crack location weld repair and DP test.
COB inlet & outlet Zero Leak Guillotine Valves (ZLGV) seal & retainer ring replacement and refractory lining
repair.
16-EB-03: Flue Gas Line Expansion Bellow replacement.
MAB suction filter house complete replacement with in-house fabrication. MAB suction hood silencer
repaired.
FLUIDIZED CATALYTIC
CRACKING UNIT (FCCU – PLANT 16)
design as per UOP.
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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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