Refinery - II M&I SD Oct-Nov 2018

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Chennai Petroleum Corporation Limited (A group company of Indian Oil)
Technical - Inspection
Chennai Petroleum Corporation Limited (A group company of Indian Oil)
Technical - Inspection
Soot blower target plate found dislodged & fallen in the gap
between lining & studded tube.
Radiant end tubesheet refractory was left as such. However damaged refractory at bottom section of ETS was
relined on all both sides.
Radiant return bend header box refractory lining was found in good condition.
Jobs Carried Out:
Radiant Section:
Without disturbing the radiant tubes, complete internal
refractory removal was carried out. 30% of west side casing
plate was also cut & removed during the decoking process.
Complete side wall casing plate & end plates were removed
completely.
Dislodged Target Plate & Refracory damages
Floor plate with refractory was retained since condition of refractory found satisfactory.
The prefabricated casing plates along with internal anchors & shelf plate setup was installed in 24 segments.
Subsequent to casing plate replacement, radiant section refractory relining was carried out under M/s. Phisem
consultant supervision as per Phisem drg. No: P430-1012 Rev.1.
Radiant tube creep measurement found to be satisfactory within 2% of OD enlargement. UT Gauging of
radiant coil was carried out and noticed with min. of 5.3 (B5)/ 6.7 (A14)/ 7.7 (B15)/ 9.0 (B16) mm thickness
(Size: 4”/6”/8”/10”) against 6.0/7.1/8.2/9.7 mm original thickness and found satisfactory.
In situ metallography (IMG) test was carried out on all 4 pass outlet tubes 10” tube number A16, B16,C16,D16
and found satisfactory.
Radiant tube hanger support conditions during initial inspection is given below.
Tube No.
1st support
from north
15-F-02A Tube support Condition
2nd support
from north
3rd support
from north
D13,14 Bolt & clamp missing Bent Bolt missing
D 11,12 Intact Normal Intact
C 7,8 Tube hanger missing Bolt missing Tube hanger missing
C 1,2 Tube in bend condition Bolt missing Normal
A 1,2 Normal Normal Not rested
A 5,6 Not rested Normal Normal
CRUDE DISTILLATION UNIT
(CDU/ VDU-II PLANT-15, 17, 18)
B 1,2 Bend condition Normal Bolt missing
15-F-02 A: View of Casing plate prefabrication, Painting & refractory jobs after erection
B 3
Normal
Support rested on bottom tube
support
B 5,6 Not rested Normal
Normal
Support rested on bottom tube
support
Hip section casing was patch repair done at few locations. Also ISMC200 was partially replaced for about 1m
length.
A 14,15 Normal Holding vertical clamp missing Normal
** Missing hanger supports were removed by contractor for enable the casing replacement.
Hip section castable refractory was completely renewed by shuttering after exposing all v anchors. Few
carburized anchors were replaced with new ones. The HIP section hanger support location was wrapped with
ceramic fibre blanket before lining the castable refractory.
All 12 nos. skin point thermocouples were renewed (B16, A16, B10, A10, D16, C16, C10 & D10 and shock
tubes - two nos) & provided at new locations. Skin point thermocouples were checked by Maint. – Instruments
and found satisfactory. Thermocouple welds were DP Tested and Ceramic blanket was wrapped at the
thermocouple coil before box-up.
The skin thermocouples were not provided as per the requirement. The radius of cover plate was not welded
properly as there was gap between tube and gap.
Damaged Burner no. 1, 4, 5, 8 & 12 muffle blocks were replaced. Refractory relining around the burner muffle
blocks were carried out.
Damaged burner tips were replaced with OEM tips.
Additional holes were provided on the HIP section casing plate for easy draining of water at external support
beam in order to drain the accumulated water.
15-F-02 A: Casing Replacement & Refractory renewal jobs
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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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