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
Nos. of exch./coolers. retubed
There were considerable reduction in the anticipated list of replacement of piping jobs and the actual
replacement was around 40% of the originally planned list.
There was a huge reduction in the planned replacement of CT-7
connected underground piping and finally executed after test
pit inspection for about 30 metres against 250 metres
scheduled originally.
Huge volume of work in critical piping replacement especially
in 1st piperack support location of Plants – 16, 17 & 18 (due to
severe corrosion at bottom section) was taken up well in
advance, pre-fabricated and executed for almost 90% of the
planned scope.
Partial replacement / internal de-choking of inlet headers of
16-E-108 D1-D2 was required as anticipated, but the pipeline
work was not taken up till the end of shutdown due to resource
constraints and partial dechoking alone was attempted by
window cutting at one or two locations.
TEST PIT for CT-7 piping inspection
The consolidated list of pipeline replacement, piping modification and thickness gauing executed unitwise –
Planned vs Actual is shown as tabulated below:-
INSPECTION EXECUTIVE SUMMARY
Unit
Retubing of Exchangers / Coolers (Planned VS Actual) – No. of tubes
Planned
Pre-Shutdown
During shutdown
Retubed Deferred Retubed Deferred Additional
Retubed
Actual Vs
Planned
14 3055 269 64 2482 240 133 2884 94 %
15 11970 1490 2799 5270 2275 1412 8172 68 %
Unit
Confirm repl.
Planned
Thickness Gauging, Pipeline Replacement & Modification status:
Actual
Replacement
Anticipate repl.
Planned
Actual
Actual Vs
Planned
Cold Lines
Planned
Thickness Gauging
Actual
Hot Lines
Planned
Actual
Actual
Vs Planned
Modification
Planned
Actual
Actual
Vs
Planned
16 12080 4720 276 5770 1200 0 10490 87 %
17 36 0 0 0 36 26 26 72 %
18 512 0 0 332 180 0 332 65 %
19 0 0 0 0 0 0 0 0
Total 27653 6479 3139 13854 3931 1571 21904 79 %
1.6.1.4 PIPING, STRUCTURAL WORK & PSV’s:
Meticulous planning done in Piping replacement work segregating list of pipelines in each plant for confirmed
replacement, anticipated replacement, thickness gauging of hot & cold pipelines. Extensive replacement of
piping was planned and execution of work was done to most of the extent but, there were shortage of
contractor resources for execution in the end resulted in forced waiving of recommended replacements, NDT
requirements, etc.,
14 79 71 66 24 66 % 62 9 238 48 19 % 7 6 86 %
15 58 45 10 4 72 % 69 66 267 80 43 % 40 32 80 %
16 102 83 88 38 64 % 182 124 123 69 63 % 24 19 79 %
17 40 20 28 12 47 % 67 67 13 13 100 % 4 3 75 %
18 29 25 16 7 71% 53 53 21 18 96 % 16 11 69 %
19 43 38 15 5 74 % 97 97 21 21 100 % 15 13 87 %
Total 351 282 223 90 65 % 530 416 683 249 55 % 106 84 79 %
In total, there was about 65% of the recommended replacement of piping jobs were completed.
Thickness gauging of cold pipelines was completed for about 71% of pipelines before the start of shutdown
and another 8% managed during the shutdown outage. In toto, 79% cold pipelines were only gauged
becaused of delay in scaffolding provision
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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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