Manual Final

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Chapter

1 Online Box up

1.0 Introduction

1. Online Boxups are carried out to rectify leakages from weld joints, valve bodies / bonnets / glands, flanges or process lines by installing the box-up arrangement at the source of leakage to save production loss.

2. The box up is carried out by Equipment Maintenance however following sections have been assigned the functions as given below:

I. Project Engineering Section is responsible to carryout the engineering and provide design for boxup arrangement if required. This design is reviewed/approved in Sub SOC (M) meeting.

II. Fabrication Shop and Machine Shop provide assistance to fabricate the boxup arrangement.

III. Inspection Section is responsible of Inspection / test (s).

3. Area Engineer Equipment Maintenance is responsible for coordination and follow-up with different Sections.

4. Depending upon the requirement and nature of leakage, one of the under mentioned methods is used:-

Sealant Filled Boxup

Welding Boxup

Installation of box up arrangement at heat treated / stress relieved lines, valves or equipment (s) is limited and subject to the approval of Sub SOC(M).

Boxup of online leakages checklist CK-4.09-003-XX-306 (Latest revision) is filled before proceeding with online boxup.

Chapter 1–Online boxup

FAUJI FERTILIZER CO. LTD

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Sealant Filled Boxup 5. If the leakage from a flange is not removed by tightening or replacement

of bolts and isolation is not possible then a clamp is required to box up the leaking flange.

6. As mentioned earlier clamp design is provided by Project Engineering against a verbal request from Maintenance. Design / material of clamp is reviewed, discussed & approved by Sub SOC. (M).

7. Area Engineer sends MWRs to fabrication Shop / machine Shop for fabrication / machining of clamp as per drawing. Area Engineer coordinates and maintains follow up of the above activities. Final dimensions are confirmed in the field to avoid problems at the time of installation.

8. Before installing Box up arrangement, flange and clamp is cleaned properly. Gland packing is inserted in the groves (if applicable). Clamp is installed onto the leaking flange and clamp nuts are tightened evenly at both ends.

9. Sealant injection pump is hooked up at one of the Sealant injection hole of clamp (rest of the holes are provided with bolts). Suitable Sealant according to the process conditions is injected (as per check list CK-4.09-003-XX-306 latest revision for box up of online leakages). More than one injection points are used for larger clamps so that sealant is injected equally around the flanges.

10. Sealant injection is continued using different injection points until the inner space of clamp is completely filled and the leakage is removed.

11. Cap nuts with copper washers are provided on flange nuts, in case leakage establishes a path through them.

12. If cap nuts / copper washers of proper size are not readily available then nuts / bolts are seal welded.

Welding Box up 13. Box-up by welding pad / sleeve with nipple is employed to remove

leakages that can not be rectified by peening / welding.

14. Small pad, sleeve (in two halves) can be used to box-up, depending upon the situation. Valve and nipple assembly is also required to drain / vent the condensate / vapors. Material and thickness of pad / sleeve is always in accordance with line specification and rating.

15. Inspection section measures the thickness at the area to be welded and after comparing this with the actual thickness, size of the pad / sleeve is selected so that it covers the whole affected area.

16. Welding procedure is provided by PTE(GM) / Inspection Sections.



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17. After selecting the size, pad / sleeve is fabricated. Its contour is matched with the contour of line / valve as far as possible. In case of heavy / high pressure leakage, valve and nipple assembly is welded on the pad / sleeve. The pad / sleeve assembly is placed on the line / valve body and welded as per proper welding procedure.

18. In case of a valve, if the leakage through the body is not removed by above described means, then valve is boxed up completely

19. Box up arrangement is designed by Project Engineering against a verbal request from Maintenance.

20. Design is reviewed / discussed & approved by Sub SOC (M).

21. Fabrication and machine Shops fabricate the box up arrangement against MWR initiated by Area Engineer (E/M). Area Engineer is responsible to coordinate and follow up the job.

22. After fabrication, box up arrangement is installed in the area. Proper procedure is used for welding.



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CHECK LIST FOR BOX-UP OF ON LINE LEAKAGES

DATE:----------------------

TIME :--------------------

AREA:------------------

JOB DESCRIPTION:----------------------------------------------------

FOR INSPECTION & MECHANICAL : INSP. MECH.

1. Procedure for box-up.

By clamp & sealant injection ------- -------

By clamp and welding ------- ------

-

2. Clamp/Sleeve design OK ------- -------

3. Type of sealant ------- -------

o Form - 2 o Form - 3

o Form - 4 o Form - 5

4. Line material OK for welding. ------- -------

5. Line thickness OK for welding. ------- -------

FOR OPERATION OPERATION

6. Conditions OK for HOT work. ------- -------

7. Line contents OK for welding and ------- -------

purging carried out (if required).

8. Permission obtained from concerned ------- -------

Production Manager.

(INSPECTION) (MAINTENANCE) (SHIFT ENGR.) (UNIT MANAGER)


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Chapter

2 Hot Tapping

Introduction 1. This procedure is used to get an off - take or branch connection

from a process line or a vessel which is in service.

2. Hot tapping is generally done on low and medium pressure lines. Before hot tapping on any line, service conditions are discussed between Process, Operation and Mechanical personnel, to ensure that operating pressure & temperature are within the allowable limits.

3. The location for Hot Tap is determined by suitability of space for installation and operation of hot tapping machine. Hot taps upstream of rotating machines / control valves are avoided.

4. Concerned Area Engineer of Equipment Maintenance is responsible for implementing the hot tapping procedure.

5. Inspection section is responsible for inspection / test (s).

6. Process and Production confirm suitability and location of hot tap.

7. Production provides permit for Hot Tap after necessary preparations.

8. As “Hot Tapping” is a critical activity carried out on a line or a vessel which is under pressure, therefore, proper precautions are taken and proper work procedure is followed to accomplish the work safely

Installation / Welding of Hot Tapping Nozzle 9. The “Hot Tap” location is selected, keeping in mind that the hot tap

machine can be installed and operated properly. Inspection section

Hot Tapping is not allowed on lines containing flammable liquids / gases, below

atmospheric pressure or on lines containing a combustible mixture at any pressure.

Hot tapping is also not allowed on stress relieved Lines / Equipment’s.

Chapter 2–Hot Tapping


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to check / scan the thickness of line where nozzle for hot tap is to be welded.

10. Welding of hot tapping nozzle on the line is the most critical step from safety point of view. In order to do this safely, ensure that :-

I. The line does not contain a combustible mixture.

II. The pipe wall is of adequate thickness to permit welding without burning through the pipe wall.

III. The flow is maintained in the line to dissipate heat from welding.

IV. The line does not contain a material that can decompose during hot tapping activity.

11. Ensure material, size and rating of nozzle is in accordance with line specifications (length of nozzle is kept at minimum possible). Weld the hot tapping nozzle on the line / vessel as per welding procedure.

12. The nozzle is accurately aligned with the flange face parallel to the pipe axis with a diametric tolerance of 1/32 of an inch (0.795mm). The center line of the nozzle accurately intersects the center - line of the pipe longitudinally. For angled branch connections nozzle size shall be at least one pipe size smaller than the main line size.

13. All the welds are full strength welds. If specified on the drawing, install reinforcing pad.

Installation of Tapping Valve 14. Ensure that size, rating and material of valve is in accordance with

the line specifications.

15. The tapping valve to be used must provide a clean full-round opening at least 3.20mm larger than the OD. of the specified cutter.

16. Install the valve using new gasket as per required specifications.

Tapping Operation 17. Install the tapping machine with proper adapter on the tapping

valve. The machine is adequately supported in order to prevent over-stressing the hot tapping nozzle. The bleeder of the machine

Before starting the actual hot tapping Operation, hot tapping check list (Production / Mechanical / Inspection) CK-4.09-002-XX-346) and Mechanical Check List For Hot Tap CK-4.09-001-XX-306 latest revision are filled and signed by relevant sections. Operation Dept. keeps the record of Check Lists in original and copy is retained by E/M Section.



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is positioned downward to drain the adapter & machine when the hot tap is completed.

18. Extend the boring bar until the pilot makes contact with the pipe wall then withdraw the bar completely and close the valve as a safety check on clearance.

19. If the fluid in the line is above 2600C or contains hydrogen or H2S, then purge the hot tapping machine with some inert gas like nitrogen through the bleeder connection. If purging is not required then proceed further.

20. Fully open the tapping valve and advance the boring bar until the pilot drill makes contact with the wall. Set the feed indicator scale at zero and start the cutting operation. The depth needed to make the cut depends on the main line size and thickness. (Calculate the amount of travel necessary to complete the cut before starting cutting operation).

21. When the pilot drill penetrates the pipe wall, close the tapping machine bleeder valve. Continue the drilling until the feed indicator shows the required depth has been reached.

22. Run the machine a few turns after the cut is complete to remove burs, but ensure not to exceed the allowable travel to avoid approaching the opposite wall of the pipe. In addition to monitoring the machine setting, completion of the cut can be determined by a reduction in resistance to hand cranking or a speeding up of the air motor. On power driven tapping machine, shut off the air and advance the cutter manually, if the cutter moves freely, the cut is complete.

23. Retract the cutter and close the tapping valve. Depressurize the adapter and tapping machine through the bleeder valve. Drain the machine carefully and safely, specially if it is a toxic gas. If the

trapped gas is H2S, purge the system carefully. Ensure proper personnel protective are used.

24. After depressurizing, remove the tapping machine. If the permanent tie-in is not immediately required, install a blind flange on the valve.



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CK-4.09-001-XX-306

MECHANICAL CHECK LIST FOR HOT TAP

Sr.

No.

CHECKPOINTS YES NO REMARKS

1 Tapping machine is in working condition and service conditions are not above the rating of the machine

-------

-------

2 Adapter is of proper rating & length so that hot tap can be done in the available boring bar travel

-------

-------

3 Drilling edge of cutter is sharp, properly angled & free of brazing welding defects

-------

-------

4 Availability of adequate space around the tapping machine to avoid any obstruction to hot tap operation or boring bar travel

-------

-------

5 Machine has been adequately supported to prevent overstressing of nozzle or equipment being tapped

-------

-------

6 Stub nozzle has been accurately aligned with flange face parallel to axis

-------

-------

Maximum diametric tolerance

7 Minimum clearance between cutter O.D. & entire path of travel of cutter is 1/8". Physically confirm this clearance by lowering the cutter upto the point where pilot drill touches the pipe surface. Ensure availability of adequate boring bar travel as given below: a) Add nozzle length to valve length required to clear pilot drill from valve seat. Further add tapping cut distance. Let this be equal to X.

-------

-------



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CK-4.09-001-01-306

Sr.

No.

CHECKPOINTS YES NO REMARKS

b) Physically crank pilot drill measure the available cutter travel from pipe surface to maximum pilot drill retrieval point so that valve can be closed. Let this be equal to 'Y'. C) Ensure that 'Y' is greater than 'X'

------- -------

------- -------

Do not exceed opposite travel to cut on wall of pipe

___________ __________________ __________________ Date: Name & Signature of

Technician

Signature of E/M Area Engineer



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CK-4.09-002-XX-306

HOT TOP CHECK LIST

(PRODUCTION / MECHANICAL / INSPECTION)

Checked by

Production

Yes / No

Checked by

Maintenance

Yes / No

Verified by

Inspection

Yes / No

1 Hot tap approval by Unit Manger

--------------

--------------

--------------

2 Line contents OK for hot tap

--------------

--------------

--------------

3 Line material & thickness OK

--------------

--------------

--------------

4 Operating conditions OK for hot tap

--------------

--------------

--------------

5 Location of hot tap OK

--------------

--------------

--------------

6 Conditions OK for hot work and permit issued

--------------

--------------

--------------

7 Welder qualified & understands proper welding procedure

--------------

--------------

--------------

8 Fire extinguisher & Scott air packs (when required) at job site prior to start of welding

--------------

--------------

--------------

9 Mechanical check list (CK-4.09-001-XX-306) is complete

--------------

--------------

--------------

10 If line temperature is above 500 0F or if line contains H2, with tapping connection is purged with inert gas

--------------

--------------

--------------



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CK-4.09-002-XX-306

Checked by

Production

Yes / No

Checked by

Maintenance

Yes / No

Verified by

Inspection

Yes / No

11 When cut is complete, toxic material

is vented through hose to safe location and tapping connection is purged with inert gas

--------------

--------------

--------------

PROD.____________ MECH.______________ INSP.___________


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Chapter

3 Exchanger Repair

1. Erect scaffolding at required places.

2. Remove end/head cover(s) by opening studs/bolts using appropriate tools and hoisting equipment.

3. Remove internals (if required).

4. Clean tube sheet.

5. Install blinds /test rings and hook up leak test assembly to carry out leak test.

6. Production unit will pressurizes the exchanger.

7. Inspection section will identify the problem area.

8. Repairs are carried according to one of the following procedures.

Tube Leakage 9. Arrange plugs in specific size and material.

10. Plug both ends of the leaking tube (s) using relevant procedure (s) - welding or any other.

Tube - Tube Sheet Joint Leakage 11. If leakage is through tube to tube sheet joint of one or more tubes, first

grind strength welding all around the tube end up to the sound surface of tube sheet with the help of pencil grinder and cutting burrs.

12. Inspection section identifies the leaking point.

13. Weld the ground portions according to the welding procedure provided.

Tube Sheet Ligament Crack Repair 14. If inspection / tests reveal that the crack (s) are in the tube sheet

ligament, first grind the tube sheet at crack location so that the crack is completely removed. Manufacturer is also consulted if required.

15. Inspection section will carry out liquid penetrant test to ensure that grinding to the sound metal has been achieved.


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16. Clean the ground surface (use acetone for urea grade and titanium material).

17. Weld the tube sheet ground portion according to welding procedure provided for the purpose.

18. After repairing leakage points using above mentioned repair procedure (s), Inspection section will again perform leak test to ensure that the leakage has been removed.

19. Before boxup ensure that all the seating and sealing surfaces are clean and free from scratches or other defects.

20. Clean studs/bolts and apply molykote or anti-seize on stud bolts.

21. Use new / reclaimed gaskets and place / fix them on their position.

22. Tighten stud / bolts according to standard tightening sequence and torque. Any overlap of head covers/flanges should be checked and corrected at this stage.

23. Remove isolation blinds and boxup nozzles using new/reclaimed gaskets.


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Chapter

4 Exchanger Cleaning

H.P. Jetting

1. Erect scaffolding at both ends of the exchanger.

2. Open studs/bolts of head covers and remove to ground.

3. Isolate / cordon off working area to restrict unauthorized persons entry.

4. Hang and firmly fasten canvas sheet or tarpaulin in front of tube sheet to restrict the water jet coming out from the other end of exchanger

5. Ensure process lines have been blinded or covered (if necessary).

6. Hook-up H.P. jetting machine and accessories (both electrical and fire/demin water connections).

7. Ensure High tension electric cables of machine are routed safely.

8. Apart from normal personal protectives use face shield, and protection suit while doing H.P. jetting.

9. Start and operate the H.P. jetting machine according to manufacturer’s instructions.

10. One operator or attendant should always be available at H.P. jetting machine and should follow manufacturers instruction to operate the machine.

11. Carry out cleaning of all tubes with the help of high pressure water jetting. The upstream pressure of jet should be in the range of 200-400 bar.

12. After satisfactory completion of cleaning, install blinds/test rings and hook up leak test assembly to carry out leak test.

13. Production unit will pressurize the exchanger.

14. Inspection section will carry out the leak test.

15. If leak test is satisfactory, proceed further, other wise repair leakage point as per Chapter 3.

16. After the leak test is clear obtain boxup permit.

Chapter 4 - Exchanger Cleaning HP Jetting


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15

17. Before boxup ensure that all the seating and sealing surfaces are clean and free from scratches or other defects.

18. Install head covers using new gaskets, clean stud bolts and appropriate hoisting arrangement.

19. Tighten fixed tube sheet side before floating side in exchangers of floating tube sheet design.

20. Check and correct any overlap of head cover / flanges before final tightening.

21. Tighten studs/bolts according to standard tightening sequence and torque.

22. Remove isolation blinds.

23. Check nozzle flange gasket facings are clean and scratch free.

24. Boxup nozzles, using new gaskets.

25. Remove scaffolding.


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Chapter

5 Exchanger Cleaning - Mechanical

Mechanical Cleaning Of Heat Exchangers With Cooling Water On Shell

Side 1. Erect scaffolding at both sides of exchanger (if required).

2. Remove stud bolts of cooling water side nozzles and tube side nozzles.

3. Place studs / bolts and RJ gasket (if any) properly in a tray and arrange their cleaning.

4. Unbolt saddle supports of exchanger (if exchanger is to be lowered to ground level) and remove to ground using proper hoisting tools.

5. Place the exchanger between two dead ends and fix the rear side of exchanger with one dead end.

6. Match mark shell flange and channel.

7. Remove end/ head cover (s) by opening studs / blots using appropriate tools and hoisting equipment.

8. Attach pulling slings with tubesheet with the help of eyebolts screwed into tube sheet.

9. If the tubesheet does not have the tapped holes or they have been worn out, a sling is passed through tubes. A bearing plate or wooden log is placed under the slings on the tube sheet face (to avoid damage to tube end.).

10. The tube bundle is pulled with wire jack, come along or chain block using sliding support trolleys and placed on the ground for cleaning.

11. Clean the tube bundle thoroughly using scrapers, water jet etc. SS scrapers are used for SS tube exchangers.

12. After the tube bundle is satisfactorily cleaned, place it on the sliding saddle and align it with the shell.

13. Before inserting tube bundle back in the exchanger , check and ensure the following:-

I. Orientation of the bundle.

Chapter 5–Exchanger Cleaning - Mechanical


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II. It is not being inserted topside bottom i.e. 180 deg. rolled.

III. It is properly supported.

IV. The correct gasket between shell and bundle has been installed before insertion of bundle, and gasket surfaces are clean.

14. Insert the tube bundle gently and carefully into the shell. Use two come alongs or chain blocks in parallel.

15. Ensure equal force is applied on both the sides so that insertion of tube bundle is parallel and it does not stick into the shell.

16. When the tube bundle reaches its position, install head cover (s). For floating tube heat exchangers, always install fixed head side before installation of floating side.

17. Ensure that:-

I. Channel head orientation is correct.

II. Gasket seating surface are clean and scratch free.

III. Correct gasket in a good condition is used.

IV. The flange gap is equal all around.

18. Install studs / bolts. Ensure that proper tightening sequence and torque is applied to the bolts using appropriate tools.

19. Prepare the exchanger for hydraulic test by installing pressure blinds on tube side, hooking up hydraulic test assembly and hydraulic pump.

20. Production unit will pressurize the exchanger. Eqt. Maint. will assist by operating the hydraulic pump.

21. Inspection section will carry out the hydraulic test.

22. If hydraulic test is satisfactory, proceed further , otherwise repair leakage point as per Chapter 3

23. Remove pressure blinds.

24. Lift the exchanger from ground and place it on the saddle supports with the help of appropriate hoisting tools.

25. Install and tighten saddle support nuts after aligning the exchangers with inlet /outlet nozzle.

26. Boxup all nozzles using new gaskets (or reclaimed ones in case of good RJ), clean stud bolts and after ensuring that all surfaces are clean and free from damage.

Chapter 5–Exchanger Cleaning - Mechanical


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MECHANICAL CLEANING OF EXCHANGERS WITH COOLING WATER ON

TUBE SIDE 27. Erect scaffolding at both sides of exchanger (if required).

28. Remove end / head cover (s) by opening studs / bolts using appropriate tools and hoisting equipment.

29. Clean tubes one by one using brushes of compatible material and size. Use SS brushes for SS tubes.

30. After satisfactory cleaning prepare exchanger for leak test or hydraulic test as required by inspection section.

31. Production unit will pressurize the exchanger. Eqt. Maint will assist in operation of hydraulic pump (if applicable).

32. Inspection section will carry out the leak or hydraulic test as applicable.

33. If the test is satisfactory , proceed further , otherwise repair leakage as per Chapter 3

34. Obtain boxup work permit.

35. Before boxup ensure that all seating and sealing surfaces are clean and free from scratches or other defects.

36. Install end covers with appropriate hoisting equipment and using correct gaskets and clean stud bolts.

37. Tighten fixed tube sheet side before floating side in exchangers of floating tube sheet design.

38. Check and correct any overlap of head cover/ flange before final tightening.

39. Tighten studs / bolts according to standard tightening sequence and proper torque.

40. Remove isolation / pressure blinds.

41. Check that nozzle flange sealing faces are clean and scratch free.

42. Box up nozzle, using new gasket.

43. Remove scaffolding after the exchanger has been taken in service and no leakage is observed.


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Chapter

6 Guide lines for working in

Confined Spaces

1. Make all necessary arrangements as per relevant work instructions.

2. Arrange ladders (Rope, wooden or steel), cradles and other items for entry/access to repair location if applicable.

3. Erect scaffolding inside the vessel, if required.

4. Arrange two way communication between personnel inside and outside, if required.

5. Use special safety harness & ensure 2nd life line for working in vertical vessels having single entry on top, if required.

6. Prior to entry, ensure following as double check.

I. Isolation of equipment/vessel as determined by Production Unit.

II. Inside Skin temperatures at different locations/elevations is bearable to human body.

III. Purging/draining of vessel.

IV. Fresh air circulation.

V. Oxygen content is adequate.

VI. Lighting (48 Volts or 220 Volts with ELCB) is adequate.

7. Obtain vessel entry and work permits as per work permit procedure depending upon nature of job (i.e., Cold & Hot).

8. Light oxy-acetylene torch outside the vessel and then send inside. Bring torch outside after heating/Cutting. Do not leave extinguished oxy-acetylene torch/Hose inside.

9. Ensure that welding lead and holder insulation is in perfect condition.

10. Keep one person as watchman out side the manhole while work is in Progress. (The numbers may be increased depending on nature and type of job).

Chapter 6–Guide Lines For Working In Confined Spaces


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11. Carry out repair/Maintenance as per applicable procedure.

12. Confined space entry is a restricted and controlled entry. Do not allow unconcerned persons to enter.

13. Obtain special permission for using 220 V tools, involving Safety and Production Unit.

14. Count Persons/tools before entry and after exist.

15. Clear out the vessel of all tools, consumable, foreign objects and personnel prior to commencing the boxup

During Break hours, keep one person stationed on manway entry to minimize chances of accidental entry.


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Chapter

7 Removal and Reinstallation of

Control Valves and PSVs

1. Erect scaffolding platform (if required).

2. Before removing PSV ensure that its vent line is properly supported.

3. Ensure that instrument connections have been removed in case of control valves.

4. Remove actuator before removing the valve if required.

5. Open studs/ bolts and remove control valve / PSV using appropriate tools and hoisting arrangement.

6. While handling PSVs ensure that it is always vertical.

7. Shift* Control Valve / PSV to instrument shop.

8. Check and repair sealing surface (s) of line flanges if required.

9. Shift Control Valve / PSV to field after repair / calibration.

10. Install control Valve / PSV using new gaskets, clean stud bolts and appropriate hoisting arrangement.

11. Check flange misalignment and overlap and correct if necessary.

12. Tighten studs/ Bolts using proper tightening sequence and torque.

Shifting of Control Valves / PSVs from field to instrument shop is the responsibility of instrument engineer during normal plant operations. During T/A’s and shutdown’s of duration six days (prod. to prod.) or more it is the responsibility of concerned Equipment Maintenance Engineer.


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Chapter

8 Scaffold Erection

1. Determine the size and strength of the scaffold to conform with the required working space and expected working load.

2. Ensure that scaffold material is in healthy condition and free of defects that can pose a safety hazard. Pipes used are free of cracks, bends and their ends are in original shape. Hinges and threads are not damaged/ slipping. Planks are free of cracks, knots and binding strips are intact.

3. Check ground condition for erection of the scaffold. If ground is soft, provide base plates/ sole boards underneath the posts (i.e. vertical pipes).

4. All the posts are in upright condition and all members (i.e. ties, bearers, runners and bracing) are erected and fixed firmly.

5. Where required the 1st bottom member (runner) is placed close to the ground level and 2nd runner clears the man height.

6. Tie up the scaffold with hand railings / permanent structure of the plant (to enhance stability) where necessary.

7. Provide planks on the working platform and tie up with binding wire or with runners (i.e. horizontal pipes) and enclose the platform with safety railings.

8. Provide rungs/steps to access working platform of the scaffold.


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Chapter

9 Maintenance of Level glasses

1. Mark the leaking points.

2. Ensure the isolating points.

3. Tighten the bolts at vendor specified tightening torque.

4. If leakage persist replace the glass(s) as per vendor procedure.

5. In case of straight type glasses, loosen and remove cover.

6. Check the condition of gasket, glass (s), mica sheet (if any) and seat of body for erosion / corrosion.

7. Is mica sheet, glass or gasket are damaged then replace with new one.

8. Thoroughly clean all the parts of GLG.

9. Assemble the level glass parts as per sequence given in the relevant instruction manual.

10. Tighten the bolts in four steps at 20%, 40%, 75% and 100% of the given torque value.

11. Use criss-cross tightening sequences starting from center to upper / lower ends.

12. If after step # 4 there are pitting or erosion / corrosion marks on the gasket facing remove flange bolts and shift the GLG to shop.

13. Remove the all glasses and send the body to Machine Shop for removal of irregularities.

14. Repeat step # 7 to 10.

15. After assembling shift the level glass to site and install it at its location with new gaskets.

16. Carryout hydraulic test of GLG if required.

17. Pre-heat the level gauge to eliminate the thermal stresses (if applicable).


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Chapter

10 Hot insulation

1. Following instructions are followed for hot insulation work to be carried out on equipment, piping and tanks, etc :-

2. Use the correct thickness of Rockwell for hot insulation depending upon the size of piping and temperature of fluid being handled. For selecting the Rockwell thickness Insulation Thickness table-I is used.

3. Apply the specified thickness of Rockwell around the pipe or equipment

firmly. Use annealed galvanized iron wire ( 1mm) for binding of Rockwell.

4. Cover the full length of pipe required to be insulated with Rockwell.

5. Prepare/fabricate metal jacketing from aluminum sheet. Roll the metal jacketing as per dia of piping or equipment. Fabricate boxes for valves, flow transmitters, line flanges, etc. For piping upto dia 24 inch, 0.6mm thick aluminum sheet is used. For piping dia greater than 24 inches and for all equipments 1mm thickness aluminum sheet is used.

6. Install prefabricated aluminum pieces onto the Rockwell. Use stainless steel self-tapping screws for fastening of jacketing sheets.

7. Joints of aluminum jacketing are placed in such as manner that liquid ingress is not possible.

8. For stream traced SS lines pieces of asbestos sheet (3mm thk) are placed between pipe and stream tracing line. For such lines 0.1mm thickness aluminum foil is wrapped around the steam traced line before applying the hot insulation.


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TABLE-I

INSULATION THICKNESS

HOT INSULATION PERSONNEL

PROTECTION

OPERATING TEMPERATURE

0 C UPTO

150 151 200

201 250

251 300

301 350

351 400

401 450

451 500

501 550

551 600

601 650

651 700

UPTO 300

301 400

401 500

0 F UPTO

302 303 392

393 482

483 572

573 662

663 752

753 842

843 932

933 1022

1023 1112

1113 1202

1203 1292

UPTO 572

573 752

753 932

SIZE INCH

INSULATION THICKNESS mm

1 ½” 30 30 30 30 40 40 50 50 60 60 60 70 30 30 30

2” 30 30 30 40 40 50 50 60 60 70 70 70 30 30 30

3” 30 30 40 40 50 50 60 60 70 80 80 90 30 30 30

4” 30 40 40 50 50 60 60 70 80 80 90 90 30 30 40

6” 30 40 50 50 60 70 70 80 90 90 100 110 30 30 40

8” 40 40 50 60 70 70 80 90 90 100 110 120 30 30 50

10” 40 50 60 60 70 80 90 90 100 110 120 130 30 40 50

12” 40 50 60 70 70 80 90 100 110 120 120 130 30 40 50

14” 40 50 60 70 80 90 90 100 110 120 130 140 40 40 50

16” 40 50 60 70 80 90 100 110 110 120 130 140 40 40 50

18” 50 60 60 70 80 90 100 110 120 130 140 150 40 40 50

20” 50 60 70 80 80 90 100 110 120 130 140 150 40 50 50

22” 50 60 70 80 90 100 110 120 130 140 150 160 40 50 50

24” 50 60 70 80 90 100 110 120 130 140 150 160 40 50 50

26” 50 60 70 80 90 100 110 120 130 140 150 160 40 50 50

28” 50 60 70 80 90 100 110 120 130 140 160 170 40 50 50

30” 50 60 70 80 90 110 120 130 140 150 160 170 40 50 50

32” 50 60 70 90 100 110 120 130 140 150 160 170 40 50 50

34” 50 60 70 90 100 110 120 130 140 150 160 170 40 50 50

36” 50 60 70 90 100 110 120 130 140 150 170 180 40 50 50

EQUIP 50 60 80 90 100 110 120 130 140 150 170 180 40 50 50


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Chapter

11 Cold Insulation

1. Following instructions are followed for carrying out cold insulation on piping and equipment :-

2. Thickness of cold insulation for piping or any equipment is determined on the basis of temperature and dia of pipe. For selecting the thickness Insulation thickness Table-I is used .

3. Polyurethane half sections are applied in single or multiple layers (Multiple layer sections are used when thickness is greater than 60mm).

4. Apply two layers of vapor barrier mastic with fiber glass fabric (glass gauge) in between the layers.

5. Apply 15-20mm thickness fiber glass blanket and compress it to 10mm. Finally the aluminum sheet is applied and fastened by stainless steel self tapping screws or rivets. Thickness of aluminum sheet used is 0.6mm for pipe dias over 24 inch and all other equipments.


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TABLE-I

INSULATION THICKNESS

COLD INSULATION

OPERATING TEMPERATURE

0 C +20

0 -1 20

-21 -40

-41 -60

-61 -80

-81 -100

-101 -120

-121 -140

-141 -160

-161 -180

0 F +68 +32

+31 -4

-5 -40

-41 -76

-77 -112

-113 -148

-149 -184

-185 -220

-221 -256

-257 -292

SIZE INCH

INSULATION THICKNESS mm

1 ½” 25 30 40 40 50 60 70 70 80 80

2” 25 30 40 50 50 60 70 80 80 90

3” 25 30 40 50 60 70 80 90 90 100

4” 25 30 40 50 60 80 90 90 100 110

6” 25 40 50 60 70 80 100 100 110 120

8” 25 40 50 60 80 90 100 110 120 130

10” 25 40 50 70 80 90 110 120 130 130

12” 25 40 50 70 80 100 110 120 130 140

14” 25 40 60 70 80 100 110 130 130 140

16” 25 40 60 70 90 100 120 130 140 150

18” 25 40 60 70 90 110 120 130 140 150

20” 25 40 60 80 90 110 120 140 150 160

22” 25 40 60 80 90 110 130 140 150 160

24” 25 50 60 80 100 110 130 140 150 160

26” 30 50 60 80 100 120 130 150 160 170

28” 30 50 60 80 100 120 130 150 160 170

30” 30 50 60 80 100 120 140 150 160 170

32” 30 50 60 80 100 120 140 150 160 170

34” 30 50 70 80 100 120 140 150 160 170

36” 30 50 70 80 100 120 140 160 170 170

EQUIP 40 60 80 90 110 130 150 170 180 190


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Chapter

12 Coating And Wrapping

1. Following instructions are followed for the coating and wrapping of under ground lines using polyethylene coated tapes :-

Surface Preparations 2. Remove welding slag, sludge, rust and hard scale from pipe surface

using grinder, power brush, scraper, emery, etc. Use detergent or kerosene to remove oil and grease.

Primer Application 3. Immediately after surface cleaning apply a uniform coat of primer

(bitumen + thinner) which is free of drippings and holidays. Always apply primer on dry and clean surface.

Tape Application 4. When the primer is dried-out, apply the wrapping tapes in the following

sequence :

i. Use the correct tape size selected from the following table.

Nominal Pipe Size 12” 14-20” >20”

Tape Size 4-6” 8” 12”

Tape Overlap 1/2” 3/4” 1 1/2”

ii. Apply first layer of polyethylene anti rock tape (black).

iii. Apply second layer of polyethylene anti rock tape (white).

5. Ensure recommended overlap of tape. Extra care is required when coating the bends to avoid wrinkles.

6. Be careful to avoid tape disbonding due to entrapped air.

7. Visual check and holiday test to be carried out to ensure the coating continuity by Inspection Section.


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Chapter

13 Refractory Repair & Insulation

1. Following instructions are followed for the repair and installation of refractory :-

2. Inspect the refractory, to identify and mark the areas to be repaired or reinstalled. In the reinforced casting, the presence of regular cracks (even if deep) 1 - 1.5mm wide is normal, crack depth upto the metallic shell is not acceptable. If the width is larger, break the castable up to shell for a width including at least three anchors. Similarly areas which are found defective or damaged greater than 150 x 150mm are demolished / saw cut upto the shell for an area including at least 3 anchors. Lining edge are cut slightly dovetail.

3. Castable bags are stored in a shaded dry place. Castable is inspected for any sign of hydration before using. Castable bags with expired shelf life are not used. The entire bag is rejected if there is evidence of partial set.

4. A test panel is prepared for each type of castable material to be applied. Test panel preparation and the required examinations are:-

i. Size of test panel required is 900 x 900mm, with a lining thickness and anchoring system equal to that specified for the installation. The anchors are bolted to the form to permit removal of the panel after the castable has been cured.

ii. The panels are cured for 24 hours and hammer tested as per the procedures given herein :-

a. The forms are disassembled and the panels used are cross-sectioned (2-directions). There shall be no indications of voids, laminations and honeycombs.

b. A section about 150mm square is cut from any one of the four cut sections from each panel. These 150mm sections are then dried for 18 hours at 1050C and weighed and measured to determine density.

c. Three compressive strength and one linear change specimens are cut from any one of the four cut sections of the panel. The specimens are tested for compliance with the specified linear change, and compressive strength.

Chapter 13 – Refractory Repair and Insulation

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5. Clean the shell surface before the castable installation. Install the new anchors and coat them with bitumen mastic. Use clean tools for casting.

6. Ensure that forms / shuttering is rigid and well braced. Non-absorbent materials such as ply-wool, steel, plastics, etc are used for shuttering. Forms are made sufficiently tight and water proof to prevent leakage. The surfaces in contact with concrete are uniform, smooth and well oiled. Forms are constructed / assembled so as to facilitate their removal without damage to the concrete.

7. Demin or drinkable water is used for mixing. The quantity of water is maintained according to the supplier’s instructions. Mixing of the charge is done by hand or using paddle mixture. Add 80% of recommended water and mix for one minute. Stop mixer and check consistency of the wet mix by means of the “ball in hand test”. For this test make a ball of mixture in your hand and through it upto a height of 300mm. If the shape of ball remains almost unchanged ratio is correct. If the ball is deshaped it shows excess of water in mixture. If the ball is cracked, it means mixture is dry. Add remaining 20% water and continue mixing for 1-2 minutes.

8. Refractory is not applied or poured when the metal surface temperature exceeds 300C or below 50C. ICE is used to keep the temperature of demin water below 250C. In cold weather warmed demin water is used.

9. Casting is executed with continuity. Edges of adjacent castable are well wetted before repair. Castable is used within 20 minutes of mixing. Material showing sign of setting is rejected. On vertical walls casting is carried out from bottom to top. In multi-layers lining the surfaces of restart casting, are not in the same plane.

10. Curing of casting is done for 24 hours with atomized water or using wet jute-bags. It keeps casting moist during setting period. Curing is started as soon as the exposed surface is hard enough to permit spraying, without washing out the cement. Forms are removed at least 12 hrs. after pouring. Afterwards 24 hrs. of air drying Dryout and heating of casting is done as per recommended procedure.

11. After dryout out and heating, repairs are checked through “Hammer test”. In this test a 500 gms ball point hammer is struck over the entire surface. The center spacing is kept approximately 500mm. If problems are detected by hammer impact sound, closer spacing is used to delineate the size of defect. Voids, hollow sounding areas and any soft or dry fill areas that reduce the effective thickness is repaired.

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Chapter

14 Painting

PAINT: This may be defined as any liquid material containing drying oils alone or in combination with natural resins and pigments which when applied to a suitable substrate, will combine with oxygen from the air to form a solid, continuous film over a substrate. This provides a weather resistant decorative surface. This also prevents corrosion or disintegration of the structure by the environment.

Following general instructions are followed for various painting jobs.

Surface preparation: All foreign matter having potential of negatively effecting paint adhesion and painting result like grease, oil, petroleum, mill scale, old loose paint and other substances are removed by using coarse cloth, emery paper, power brush or sandblasting.

Primer application: Application of specified thickness of primer on various steel surface (structure, vessels, pipe etc.) is carried out according to manufacturer’s specification. Dry film thickness should be checked. Primer may be applied by brush and spray gun. Number of coats to be applied is determined by total dry film thickness required as per recommendation of the manufacturer.

Paint application: Application of specified thickness of paint on various steel surface (structure, vessels, pipe etc.) is carried out according to manufacturer’s specification. Dry film thickness should be checked. Paint may be applied by brush and spray gun. Number of coats to be applied is determined by total dry film thickness required as per recommendation the of manufacturer.

INSPECTION AND TESTING The following inspection and testing shall be performed during and after completion of application of paint system. a) Visual examination of surface preparation in accordance with Svensk

standard SIS 05.059.00 – 1967.

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b) Check drying time of primer, intermediate and topcoats in accordance

with the directions of the paint manufacturer.

c) Check dry film thickness by suitable non-destructive method. d) Visual examination of appearance and uniformity of the surface

painted.

DEFECTS If, during above inspections, painting or surface preparation defects are

observed, the job shall be redone to meet acceptable standards.

COLOUR

Colours for structure, Equipment, lines etc. of various services are selected

according to the Annex.I.

SURFACES NOT TO BE PAINTED

The following surfaces shall not be painted, except if specifically asked.

a) Concrete surfaces b) Masonary surfaces c) Aluminum surfaces d) Galvanized steel surfaces e) Stainless steel surfaces f) Monel surfaces g) Copper surfaces h) Brass surfaces i) Glasses of level gauges j) Equipment nameplates k) Piping and equipment to be insulated l) Surfaces with concrete fireproofing

NOTE:Painting of prill tower, furnaces, tanks is carried out according

to Snam’s specifications GA-E-60718, GA-E-60701 & GA-E-60719 respectively.

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Annex.I

S.NO. EQUIPMENT/LINE COLOUR CODE

01 Surface of uninsulated piping and equipment with an operating

temperature upto 70 oC. (Fire fighting excluded)

GRAY RAL-7035

02 Surface of uninsulated piping and equipment with an operating

temperature over 70 oC.

ALUMINUM RAL-9006

03 Piping and equipment for fire fighting

RED RAL-3002

04 Natural Gas Line YELLOW RAL-1016

05 Uninsulated machinery with an

operating temperature upto 70 oC.

GRAY RAL – 7035

06 Uninsulated machinery with an

operating temperature upto 70 oC

ALUMINUM RAL-9006

07 Structural steel, pipe supports GRAY RAL-7010

08 Ladders, stairways, walkways, handrails

YELLOW RAL-1016

09 Furnaces GREEN RAL-6021

10 Tanks GRAY RAL-7035

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Documents

Manual Final