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
16-F-03- CO Boiler:
Complete replacement of pre-fabricated & pre-dried out convection module in 3 segment along with tubes &
header boxes.
Combustion chamber partial casing plate replacement & complete relining of combustion dual refractory (5”
hot face + 5” back up) with new anchors.
Both burner housing replacement (One new assembly & other one fabricated)
RLA study of the CO boiler/connected piping & IBR license renewal
Internal painting in 16-C-16 / 51/ 52/ 53 were renewed with tank liner painting as per CPCL painting system
XI.
WFMPT was carried out for 08 nos. columns/ vessels viz. 16-C-59, 16-C-60, 16-C-259, 16-C-260, 16-C-271,
16-C-272, 16-C-273 & 16-C-275,
Optimix feed nozzle 8” ring CS material mix-up segments were replaced with A335 P5 pipe.
Reactor top outlet24” pipe line has wall thickness of 9.52 mm(Sch.:20) in vertical portion and 17.48
mm(Sch.:40)in horizontal portion.
Reactor top 24”outlet pipe line to 16-C-01 inlet U/S 1.5” TG point CS material was replaced with A335 P11.
HCO draw pipe line from 16-C-01 to 16-C-03 10”/6” and reflux 8” pipe line were replaced and hydrotested at
9.6KSC and 10.5KSC respectively.
Pipe support location in plant inside pipe rack were checked and corroded & pitted area in pipe lines were
replaced. Mild pitted area at support locations were provided with RF Pad.
Cooling water supply and return 24” pipe line at U/G to A/G interface portion below technological structure
replaced due to leak.
77 nos. Safety Valves were pre-pop tested, dismantled, serviced, reconditioned and bench tested.
16-F-03: Combustion Chamber Refractory
16-X-01- CO Stack:
Refractory re-lining of 0-10.0 m & 50-60.0 m elevation.
Stack health assessment by engaging M/s Varishitha Concrete Ltd.
Complete stack external painting.
3.1.3 Equipment & Piping
16-F-03: Convection Module Prefab & Erection
External patch for about 9.0 m 2 was provided on 16C01 shell (EL+
16-C-01: Patch Work
26400 mm to 29400 mm) due to bulging. All 5 nos. structured
packing beds were replaced. CRO spray nozzles of distributor above
Bed 5 ( EL+16435) was also replaced as per PE recommendations.
16-C-61: CBD vessel was replaced.
16-C-12: CO Boiler IBD- Internal Patch welding was carried out due to
severe erosion corrosion.
16-C-59: Debutaniser- External patch welding was done at four
locations due to severe CUI at insulation support ring & stiffener
rings.
16-C-274: Sand Filter Coalescer- Sacnd carryover with LPG was observed during start-up and observed with
poor fixing of sand retainer mesh. New mesh was properly fixed and boxed up.
Complete insulation removal of the columns (16C02, 16C03, 16C58 & 16C59) was carried out followed by
painting and insulation renewal.
External patch for about 12.0 m 2 was provided on 16-C-59 (at 4 elevations near insulation support ring).
3.1.4 Exchanger
One exchanger & 15 nos. of coolers were taken for maintenance as pre-shutdown activity.
Two fin fan coolers (16-E-108A1/D2) were anticipated for replacement & four fin fan coolers were anticipated
for retubing. However procurement of 6 nos. of fin fan coolers 16-E-108A1/A2/C1/C2/D1/D2 had been done
based on maintenance decision in order to save the time in case of retubing.
RLA study of the exchangers (16-E-04A/B, 16-E-07) were carried out & offered for IBR authorities for extension
of license.
NFT inspection was deployed for assessing the tube condition in the following Exchangers:-
Number of Exchangers retubed in this Shutdown:-
02nos. - 16-E-05 A & 16-E-05 B
Number of coolers / condensers tube bundles retubed in this Shutdown:-
S NO. EXCHANGER NO. EXCHANGER NAME
1 16-E-108 B1 Main Column OVHD Fin Cooler
28 nos. - 16-E-52, 16-E-52A, 16-E-53, 16-E-054, 16-E-56C, 16-E-57, 16-E-63A, 16-E-63B, 16-E-109A,
16-E-109B, 16-E-109C, 16-E-109D, 16-E-109E, 16-E-109F, 16-E-110A, 16-E-110B, 16-E-121A, 16-E-
121B, 16-E-159A, 16-E-159B, 16-E-251A, 16-E-251B, 16-E-253, 16-E-254, 16-E-259, 16-E-263A, 16-E-
263B, 16-E-264
Number of Exchanger/ Coolers tube bundles replaced in this Shutdown:-
Coolers
Air Fin Coolers
108D2
: 03 nos – 16-E-56 A, 16-E-56 B & 16-E-64
: 06nos. - 16-E- 108A1, 16-E- 108A2, 16-E-108 C1, 16-E-108-C2, 16-E- 108D1, 16-E-
FLUIDIZED CATALYTIC
CRACKING UNIT (FCCU – PLANT 16)
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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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