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
previous location.
During pre-shutdown, thickness gauging was done using battery operated man lift trolley especially for the first
pipe rack in plant 16/17/18/19. Entire first pipe rack pipes in plant 16/17/18/19 were inspected using the man lift
& it had boosted the productivity during the gauging & inspection activities.
Insulated Hot Pipelines Thickness gauging
It was planned to assess for about 91 nos. insulated critical pipelines in plant 15 & 16 by thickness gauging
during the shutdown and 10 pipelines before the start of shutdown to facilitate start of thickness gauging from
the first day of Shutdown. Though it was insisted to remove insulation from few hot pipelines prior to shutdown,
job could not be taken up due to permit issue & scaffolding delay.
Decontamination activities further delayed the scaffolding provision (for insulation removal) due to permit issue,
which in turn delayed the inspection activities. Removal of insulation activity started on 10 th day of shutdown only
& till that time, only few pipelines at ground level was offered for inspection. Lack of coordination between
insulation removal team (Civil maint) & scaffolding removal team (Field maint.) hampered the jobs further. Lack
of clarity in scaffolding provision for pipeline thickness gauging activities was there due to involvement of
multiple scaffolding agencies (one for pipe replacement & other for insulation removal). Similarly a single
contractor was engaged for providing scaffolding in plant 14 & 16 (both are at far end) & the contractor was
unable to manage/coordinate material/man power.
Though during pre-shutdown, scaffolding arrangement was satisfactory, improper scaffoldings was being
provided during the shutdown period. Safe scaffolding was not provided during the shutdown outage due to
shortage of planks & ladders.
Scaffolding for Equipment
On the whole, Scaffolding work for equipment & heaters was at its best
when compared to any
CO boiler area
previous M & I shutdowns
executed in CPCL. One of the
reasons attributed for the
better quality of scaffolding
work is due to awarding
almost all major maintenance
contracts 2-1/2 months to 3
months prior to the start of
shutdown, which facilitated
enough time to mobilize
proper scaffolding materials &
work force to erect major external scaffolding as per standard procedure
as stipulated in the contract.
15-C-15 scaffolding
Winch at CO Stack
Scaffolding made by the major contractor (M/s.
L&T) at almost every location was done with
proper supporting, handrails, toe guards, etc.,
The circular scaffolding made externally over the
CO stack for 60 metres height was well made by
M/s. Sumith Engineering including a winch
mechanism to lift required materials to top
elevation to facilitate NDT inspection & painting.
Scaffolding work made for pipelines replacement
was also found to be intact in the pre-shutdown
Circular scaffolding
phase but, the standard of scaffolding was below
par during the shutdown outage due to shortage
of materials & manpower. Scaffolding work done
for most of the Columns & exchangers was not done to the safety requirements and the scaffolding work done to
renew external insulation of columns in CDU-II & FCC was totally unsafe.
More awareness in scaffolding safety with strict compliance to scaffolding procures is to be ensured in future.
1.6.2.4 EQUIPMENT MAINTENANCE
Super Critical Work scope - R-R Circuit, 15-F-01A, 02A, 16-F-01, 15-C-15 & 15-E-43
Maintenance work pertaining to major critical equipment involving huge machineries, considerable volume of prefabrication,
multi craft work force and larger scope of site work were all clubbed together as a single Super critical
work package and the job was awarded to Heavy Engineering Division of M/s. Larsen & Toubro, Powai for the
following equipment:-
R-R Circuit involving Riser, Reactor, Regenerator, Orifice Chamber, Stand pipes, ducts, Expansion
bellows, ZLGV’s, DFAH, CO Boiler
15-F-01A (Atmospheric Heater) having top 2.2 m height shell replacement & conversion of the removable
panels to permanent shell type (0.7 m height) along with internal refractory re-lining.
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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