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
machineries & a meticulous plan. The anticipated job scope in R-R circuit was found to be almost in line with
requirement after equipment opening and considerable replacement of heater tubes were reduced from the
planned scope of work. It appears that the scheduled no. of engg. days (28 days) as per standard guidelines were
are not reviewed further in line with the extensive scope of work planned this time, especially when multiple
agencies had to perform with heavy machineries around R-R circuit & CO Boiler. It was felt that the no. of days
scheduled is not practical enough to complete the scope of work in critical equipments.
Though FCCU work was scheduled for a total of 33 days, actual completion of work witness with respect to type of
equipments is tabulated as below:-
Type of Eqpt.
Handing over of last Equipment
S/D day of
Completion
R-R Circuit Riser Bottom manway box up 38 th day
CO Boiler Comb. chamber manway box up 38 th day
FCCU Charge Heater Box up of floor manway 38 th day
Though CDU-2 work was scheduled for a total of 30 days, actual completion of work witnessed with respect to
type of equipments is tabulated as below:-
Type of Eqpt.
Handing over of last equipment
S/D day of
Completion
15-F-01A Manway boxup 35 th day
15-F-01B Manway boxup 36 th day
15-F-02A Manway boxup 36 th day
15-F-02B Manway boxup 36 th day
Columns / Vessels 15-C-05 (Kero Stripper) boxup 37 th day
Heat Exchangers 15-E-111A/B 38 th day
Piping Modification 2” velocity line provision in 15-F-02B 39 th day
Piping Replacement
2” stabiliser naphtha from 15-E-18A/B shell O/l to FCC riser
(2”-P-15-4215-A1A)
41 st day
INSPECTION EXECUTIVE SUMMARY
CO Stack Bottom door box up 37 th day
Columns / Vessels 16-C-01 Main column / 16-C-59 (Debutaliser) 38 th day
Heat Exchangers 16-E-251A/B 33 rd day
Piping Modification
Piping Replacement
Routing of Raw Oil for 16-G-102A/B Seal flushing
(16-C-25187 R.0)
2” Net liquid pipeline from WGC-I to WGC-II
(9910-016-005-2018)
32 nd day
37 th day
In line with handing over of major equipment, piping modification & replacement work had to be trimmed in the
fag end of shutdown including waiving of few NDT requirements and deferring a few due to paucity of time.
1.6.3.2 CDU-2 :
During the planning stage, it was well thought that the major Atmospheric & Vacuum heaters 15-F-01A & 02A
under critical path along with 15-C-15 Vacuum column top dished end replacement. Out of the above, it was very
clear that the total outage had to be decided based on 15-F-02A heater due to complete radiant refractory
replacement along with casing and a activity based time schedule should have been made to arrive the no. of
engg. days. But, it appears that the scheduled no. of engg. days (25 days) as per standard guidelines was not
reviewed further in line with the extensive refractory & other scope of work including additional days for
decontamination & dry out. It was felt that the no. of days scheduled is not practical enough to complete the
extensive scope of work in critical equipment (vis.) 15-F-02A heater with complete radiant refractory replacement
including casing along with changing of convection intermediate tubesheets involving considerable Alloy steel
welding / NDT requirements.
In line with handing over of major equipment, piping modification & replacement work had to be trimmed in the
fag end of shutdown including waiving of few NDT requirements and deferring a few due to paucity of time.
1.6.3.3 Wax & Propylene :
There was no major critical works planned in Wax & Propylene units other than routine maintenance work and
anticipated repairs / replacement. Both the units were scheduled for a total of 30 days, but the actual completion
of work witnessed with respect to type of equipments is tabulated as below:-
Type of Eqpt.
Handing over of last Equipment
S/D day of
Completion
14-F-01 Manway boxup 35 th day
14-F-101 Manway boxup 20 th day
Columns / Vessels
Heat Exchangers
Piping Modification
Piping Replacement
14-C-15 (Inert gas holder)
19-C-01
14-E-65A/B/C (R22 Condenser)
19-E-02A /04
Mass flow meter for FO Supply & Return line in 14-F-01(14-D-25317
R.1)
19-E-05 tube side I/L & O/L-BV Provision for isolation purpose & PT
provision for monitoring (19-C-25457)
14-T-1hot solvent gut wash 2” (9910-014-008-2016)
17 th day
40 th day
35 th day
36 th day
32 nd day
36 th day
33 rd day
2” FG header take off to 19-C-5 (9910-019-004-2018) 35 th day
In line with handing over of major equipment, piping modification & replacement work had to be trimmed in the
fag end of shutdown including waiving of few NDT requirements and deferring a few due to paucity of time.
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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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