MTC / REPORT / 01

REPORT NO. 27 / 2007

KALOL UNIT

PLANT TURNAROUND REPORT

(APRIL - MAY - 2007)

INDIAN FARMERS FERTILISER CO - OPERATIVE LIMITED

 INDEX

1 PREFACE

2 GENERAL DETAILS

SECTION PLANT PAGE NO.

3 MECHANICAL ł Ammonia 1 - 97
ł Urea 98 - 129
ł Offsites & Utility 130 - 143
ł B&MH 144 - 152

4 INSPECTION ł Ammonia 153 - 204

ł Urea 205 - 235
ł Offsites & Utility 236 - 248

5 INSTRUMENTATION ł Ammonia 249 - 259

ł Urea 260 - 263
ł Offsites & Utility 264 - 267
ł B&MH 268

6 ELECTRICAL ł Ammonia 269

ł Urea 270 - 271
ł Offsites & Utility 272 - 274
ł B&MH 275

7 CIVIL ł Ammonia 276

ł Urea 277
ł Offsites & Utility 278
ł B&MH 279

8 TECHNICAL ł Ammonia 280 - 282

ł Urea 283 - 285
ł Utility 286
 PREFACE

The Annual Plant Turnaround for the year 2007 was taken from 14th April 2007, for
carrying out Preventive maintenance of static & rotary equipments, Statutory IBR
inspection, Preventive maintenance of Electrical & Instrument systems, Civil related jobs
and for attending jobs which were pending for Shut down.

After ensuring availability of all the required material for shutdown and awarding
contracts for various shut down jobs, it was decided to stop Ammonia Plant and Urea
Plants on 14th April 2007. This shutdown report contains Plant wise and section wise
details of the jobs carried out. Ammonia plant was started on 3rd May 2007 and regular
production resumed on 7th May 2007. Similarly, Urea plant shutdown was completed
on 5th May 2007.

During start-up of Ammonia plant, coupling failure of Refrigeration Gas Compressor

(105-J) occurred on 9th May 2007 and hence, Ammonia Plant could be put back into
operation on 13th May’2007 and accordingly, Urea plant came into operation on 14th
May 2007.

The Turnaround was carried out smoothly due to meticulous planning of all activities like
planning of manpower, material and other resources. Due to exemplary efforts put in by
all Personnel at all levels, turnaround jobs could be completed in the scheduled period
of 29 days for Ammonia Plant and 21 days for Urea Plant.

Safety was one of the major aspects, which was given top most priority during the
execution of various jobs. All the jobs were carried out considering all safety aspects
and the use of safety equipments was ensured during execution of jobs. Necessary
training for safe working in the Plant was given to the Manpower employed by all
Contractors and strict vigilance was kept by Fire & Safety section during execution of
Critical jobs.

MECHANICAL
AMMONIA

x Synthesis Gas Compressor Drive Turbines 103-JAT & 103-JBT were taken for
retrofitting and major overhauling. In the post ESP scenario, with LNG as feed stock,
the power requirement of Syn. Gas Compressor reduced. To achieve this power, the
steam requirement was calculated at 182 Ton/hrs. for 103-JAT and 20 Ton/hrs. for
103-JBT. To achieve the required steam balance, the following modifications were
carried out in these Turbines.

¾ 103-JAT Turbine capacity was de-rated by installing old Nozzle Ring of 256
Tons/Hr in place of existing Nozzle Ring of 275 Ton/hrs.
¾ Higher capacity Nozzle Ring (28 Ton/day) was provided in 103-JBT Turbine to
replace the old Nozzle Ring (18 Ton/day).
¾ To take care of higher HP requirements in view of the above modification, a new
“Euroflex” make Shim Pack Coupling of 7500 HP was provided in place of Gear
Coupling (5200 HP).
¾ Over speed trip checking of 103-JBT was carried out at 12100 RPM.
x Routine preventive maintenance of Refrigeration Compressor train (105-J) was
carried out. However, during start-up, coupling hub of H.P.case rotor (coupling
between H.P. case & Gear box) got slipped from its position and there by causing
extensive damage to both coupling hub & Rotor shaft end. The machine was
assembled by replacing the spare rotor & gear coupling and put back in to operation
within 3 days.

x The existing TG 10 Governor of 101/105 -J Lube oil pump drive COPPUS Turbine
was replaced with electronic governing system consisting of TG 13E actuator having
PEAK 150 controller.

x Boiler Feed Water Pump 104-JA was overhauled.

x New Tushaco make screw pump was provided in place of existing imported gear
pump of motor driven 103-J seal oil pump.

x 115-JA pump rotor had seized during Shutdown & the same was overhauled by
replacing the pump rotor.

x Secondary Waste Heat Exchanger (102-C) was hydrotested at 40 kg/cm2g and 7

Nos. tubes (45 Nos. already plugged earlier) and 74 Nos. Tube to Tubesheet seal
welding leakages were attended after necessary de-hydrogenation and PWHT.

x New Synthesis Gas Converter (108-D) outlet to MP boiler inlet Elbow (14” x Sch 120)
had developed a crack in the parent metal and the same was attended during
running plant. In addition old Synthesis Converter (105-D) elbow (8” x Sch 120) was
having lamination defect. Both the elbows were replaced during shutdown by purging
the Synthesis loop, proper de-hydrogenation and PWHT.

x Routine preventive maintenance jobs of other rotary and static equipments were
carried out.

x Waste Heat Boilers 101-F, 112-C and 107-C were offered for IBR inspection.

UREA

x HP case compressor and Gear Box of Hitachi compressor Train were taken for
major overhauling. Drive Turbine and LP case was taken for preventive
maintenance. Lube oil console tank was thoroughly cleaned & fresh charge of
Servoprime 46-T Lube oil was loaded.

x M/s Stamicarbon carried out inspection of HP Vessel, viz. Autoclave, HP Stripper

and HP Condenser.

x 20” NB CS Vent Stack pipe was replaced with SS304 material, adopting special
ringing procedure.
x Chemical cleaning of Plate type heat exchanger, (H-1206) was carried out to verify
effectiveness of cleaning as per procedure given by M/s Alfa Laval.

x LP Vessels inspection was carried out and necessary repairs were undertaken as
per inspection findings.
x Prill Tower ID fans, Prill Cooling system (PCS) fans and Urea scraper were taken
for Preventive maintenance.

x Conveyor belts of Urea Product Conveyor (M-1403) & dust conveyor (M-1703)
were replaced.

OFFSITES

x All cooling water pumps, BFW pumps and turbines were taken for preventive
maintenance.

x Base plate of Cooling Water Pump P-4403 & Raw Water Pump P-4101-B were
replaced with new one fabricated departmentally.

x All 12 Nos. of Cold end baskets of Regenerative Air Preheater were replaced.

x IBR Inspection of BHEL Boiler, (GT-2068) was carried out.

x Re-Examination of Primary & Secondary Superheater coils along with associated

Header was carried out by M/s THARMEX LTD, Pune.

x The wooden structure of all cooling tower cells was inspected by M/s.Paharpur
Cooling Tower Pvt.Ltd, Vadodara, for Condition Assessment and also through a
committee of IFFCO Officials nominated by the competent authority. Necessary
corrective actions were taken.

x Rubber Expansion Bellows of Cooling Water Pump P-4401-C/D/E were replaced

with new bellows.

x Inside surface of 52” dia underground pipe line inter connecting old & new cooling
tower basin was painted with Epoxy paint after metal shot blasting & spray painting.

x All 28 Nos.of distributor valves of CW return headers were overhauled.

B & MH

x Existing worm Gear box of M-2112 & M-2117 conveyors were replaced with helical
Gear box.

x Overhauling of Reclaim machine was carried out.

x All Conveyors and drive Gearbox were taken for preventive maintenance.

x All packer scales and stitching machine were overhauled.

ELECTRICAL

x MCC-1 Section-A panel was replaced with new latest Siemens pannel.

x Preventive maintenance of all the transformers were carried out.

x Complete Overhauling of transformers having low IR values i.e. TR-2B & TR-7B was
carried out.

x Overhauling of all the MOCBs, Jyoti VCBs and TMG ACBs were carried out.
Retrofitting with Siemens 3WL breakers in feeders of K-1701 & K-1702 by removing
old 3WE outdated breakers.

x All critical motors installed at various locations in plants were overhauled.

x All the MOVs were thoroughly checked in various plants. Actuators of MOVs of SP-
152, SP-158, SP-159, SP-4, S-5, 4401/C, 4401/D were replaced with ROTORK
make actuators.

x Electrification of renovated Boiler control room was carried out.

x Preventive maintenance was carried out of all the rope switches installed in
conveyors.

INSTRUMENTATION
AMMONIA

x Related instrument jobs in control room and field was carried out for the New Peak-
150 woodward governor of 101J/105J lube oil console.

x Replacement old & obsolete pneumatic level transmitters with new SMART
electronic transmitters of M/s Masoneilan ,France make for better reliability &
performance. Tag no.LIC-1, LIC-13, LIC-3, LIC-101 in was done in phased manner.
This is phase III.

x AMC services of DCS/PLC systems/Analysers/UPSS,Belt weighers were carried out

with the help of supplier’s service engineers.

x Preventive maintenance of control valves was done .

UREA

x In Urea plant 2 nos. of old pneumatic transmitters of extended diaphragm type

(LICT-1353 & LICT-1282) were replaced with electronic transmitters for better
performance and reliability.

x Servicing of DCS/Omron PLC system for Hitachi compressor was carried out by
suppliers’ engineers.
x Servicing and overhauling of the control valves was done . Body of LRCV-1201
and HICV-1201 were replaced with repaired ones.

OFFSITE & UTILITY

x Installation & Commissioning of DCS in DM Plant was carried out. The connectivity
of DM Plant DCS and Boiler DCS through OFC cable was established. All these jobs
were carried out under supervision of supplier M/s Yokogawa India Limited
commissioning engineer.

x Maintenance of control valves was done.

x Three new control valves for LSHS temperature control were commissioned.

x Old pneumatic controllers were replaced with electronic controllers in ammonia

storage area.

x Removal and re–installation of various instruments to facilitate Mechanical

Maintenance /Production deptt./Technical deptt. activities were carried out in entire
plant areas as and when required during shutdown and start up.

B & MH

x Obsolete JSRL make bagging machine (10A & 10B) were replaced by new Power
build make machines.

x 40 MT Ashbee road weigh Bridge and weighing machines were overhauled and
calibrated.

CIVIL

x Damaged top cover plywood sheets of cooling towers were repaired.

x Repairs & Maintenance of Bitumastic lining, acid alkalis proof brick lining in strong /
weak effluent pit and HCl storage tank in water treatment plant and other plant area.

x Application of epoxy monolithic plaster on RCC Suspenders, walkways for

conveyors, beams, columns and staircase of transfer tower of silo building and other
areas in B & MH building.

x Application of IP Net protective coating on RCC wall of Conveyor gallery and other
structures (Silo, B & MH, Urea plant etc.)

x Application of Bitumastic lining for SB assembly unit & Anion Tanks in water
treatment plant.

x Application of epoxy painting in RCC Structure of bagging plant transfer tower, prill
cooling systems and hydrolyser urea plant area.

x Repairs of refractory lining work inside Primary, & Secondary Reformers and
Auxiliary & BHEL boilers.
x Repair of damaged flooring of Urea plant Prill cooling system.

x Repair of damaged AC sheet of cooling tower, reformer & other area in plant.

TECHNICAL
AMMONIA

x As a Energy Saving measure, LNG pre heater was installed for pre heating of LNG
to Aux. Boiler by using redundant Lube Oil Cooler of GHH Compressor.
x For improving the vacuum of 101JCA, a bigger size inter – after condenser was
installed by using a redundant inter-after condenser removed from NG Booster
Compressor.
x Carbon Steel Flanges (6 nos.) were replaced by SS Flanges in New Absorber piping
as a measure of reliability improvement.
x Isolation valves were provided in 9 nos. of critical relief valves to attend the relief
valves during running of the plant.
x Additional conventional relief valves (with isolation valves) were provided parallel to
the pilot operated relief valve in the discharge and recycle line of syn. gas
compressor (103-J). This will reduce the down time in case of mal functioning of
pilot operated valves which was being faced.
x For easy approach to the top of S-50 Converter, Old converter and 123-C, a massive
platform structure from ground floor was fabricated and erected .
x Modification in pre reformer piping area was carried out for heating of LNG feed to
reformer.
UREA
x As a pollution control measure to reduce ammonia vent to atmosphere a two bed
atmospheric scrubber (V-1206) was erected, commissioned and taken in line.
Associated heat exchangers and pumps were also installed, commissioned and
taken into operation.
x Desorber heat exchanger (H-1301) was replaced with a new plate type exchanger of
higher capacity.
x Redundant CO2 centrifugal compressor and PB CO2 reciprocating compressor were
disconnected from plant piping system.
x 11 nos. of control valves / FI / TI / PI were provided against different EWRs and
schemes.

OFFSITE
x A Control valve in the steam line to gas pre heater was provided.
 PLANT TURNAROUND APRIL - MAY - 2007
GENERAL - DETAILS

SR. NO. CATEGORY QUANTITY

(A) EQUIPMENT UTILIZED :

IFFCO :

135 T Kobelco 01 No
55 T HM Crane 01 No
55 T TIL RT-760 Tyre mounted mobile Crane 01 No
15 T COles Crane 01 No
18 T Tata Crane 01 No
10 T Escort Lift-N-Shift 01 No
14 T Escort Lift-N-Shift 01 No
03 T Forklift 03 Nos.
05 T Forklift 01 Nos.
10 T Truck 01 No
909 Tata ( Mini Truck) 01 No

(B) MANPOWER UTILIZED :

(I) IFFCO MANPOWER :

1 Mechanical }
2 Mechanical Services } Existing
3 Electrical } strength
4 Instrument }

(II) HIRED - CONTRACT MANPOWER :

Sr.
No. Category Man days
1 Mill Wright Fitter 83
2 General Fitter 777
3 Rigger 972
4 S.S. Rigger 2657
5 Fabricator 134
6 Grinder 148
7 Gas Cutter 71
8 IBR Welder 34
9 Non-IBR Welder 66
10 Carpenter 57
11 Mason 55
12 Machinist 00
13 Draftman 00
14 Master Rigger 00
 THE PLANT TURNAROUNDS AT A GLANCE

AMMONIA PLANT UREA PLANT

SR. PERIOD FROM PRODUCTION TO PRODUCTION
YEAR REASON IF ANY
NO.
FROM TO DOWN TIME FROM TO DOWN TIME
DAYS HRS DAYS HRS

01 1975 06-05-75 21-05-75 16.00 - 06-05-75 21-05-75 16.00 - Planned

02 1976 26-03-76 20-04-76 26.00 - 26-03-76 20-04-76 26.00 - Planned

03 76-77 05-12-76 22-01-77 49.00 - 05-12-76 24-02-77 51.00 - 101-JT B/D

04 1978 21-02-78 15-03-78 23.00 - 21-02-78 25-03-78 31.00 - 101-BJ B/D

K-1101/2, 3rd
05 1979 21-05-79 30-06-79 41.00 - 10-05-79 01-08-79 82.00 -
Stage Cylinder
101-B Headers
06 1981 12-04-81 10-05-81 29.00 - 08-04-81 12-05-81 35.00 -
Planned

07 1984 01-01-84 25-01-84 25.00 - 01-01-84 25-01-84 25.00 - Planned

Reformer
08 1986 19-03-86 03-05-86 45.00 - 04-03-86 01-05-86 59.00 - Revamping / HP
Scrubber B/D

09 1987 12-04-87 03-05-87 21.00 - 12-04-87 02-05-87 20.00 - Planned

10 1988 18-04-88 14-05-88 27.00 - 18-04-88 13-05-88 26.00 - Planned

11 1990 05-02-90 05-03-90 29.00 688.67 31-01-90 07-03-90 35.00 829.00 Planned

12 1991 24-02-91 13-03-91 18.00 429.08 23-02-91 14-03-91 20.00 459.25 Planned

13 1992 03-11-92 03-12-92 30.60 734.91 03-11-92 04-12-92 31.00 744.75 Planned

14 1993 12-09-93 23-10-93 42.00 986.50 12-09-93 29-10-93 47.00 1120.58 Revamp-II

Scrubber
15 1995 14-01-95 27-01-95 14.00 311.34 11-01-95 26-01-95 16.00 352.18
H-1203 -B/D
Autoclave V-1201
16 1996 14-06-96 13-07-96 30.00 712.00 13-06-96 13-07-96 30.00 694.25
Leakage

17 1997 12-05-97 17-06-97 35.60 875.00 12-05-97 17-06-97 36.20 870.50 Planned

18 1998 22-04-98 19-05-98 27.50 660.00 20-04-98 19-05-98 30.00 720.00 Planned

19 1999 12-04-99 30-04-99 18.00 434.50 11-04-99 28-04-99 17.00 409.75 Planned

20 2000 03-04-00 27-04-00 24.42 586.25 03-04-00 28-04-00 25.43 610.50 Planned

21 2001 25-03-01 14-04-01 20.90 501.50 25-03-01 15-04-01 21.26 510.25 Planned

22 2002 20-03-02 22-04-02 33.40 801.58 20-03-02 23-04-02 34.31 823.50 Planned

23 2003 28-05-03 25-06-03 28.04 673.00 28-05-03 25-06-03 28.33 679.83 Planned

24 2004 20-05-04 09-06-04 20.00 495.17 20-05-04 09-06-04 20.00 480.25 Planned

25 2005 22-05-05 29-06-05 38.75 930..50 22-05-05 24-06-05 33.85 812.50 Planned

26 2006 31-03-06 06-05-06 35.93 862.42 29-03-06 06-05-06 37.06 889.50 Planned

27 2007 14-04-07 08-05-07 23.72 569.25 14-04-07 05-05-07 21.38 513.0 Planned
 SHUT DOWN RELATED CONTRACT

Sr. Wo No. Description

Plant Vendor’s Name
No. & Date Of Job
1 Ammonia 9920043 Retrofit of TG-10 Wood word M/s Goodwill Governer
(Mech) 9920011 make Governor for 101J/ 105J service, Mumbai
19/01/2007 Lub oil drive turbine

2 Ammonia 9920125 Scaffolding, Blinding, M/s Anu Engineers, Baroda

(Mech) 14/02/2007 Deblinding.
3 Ammonia 9920350 Repair of 102-C & replacement M/s Skywin Erectors,
(Mech) 15/03/2007 of isolation gate valves for PIC- Ahmedabad
13A, PIC-13B, MIC-22
4 Ammonia 9920391 Overhauling & testing of various M/s Flotec Eng. Services,
(Mech) 23/03/2007 Relief valves in Ammonia, Urea Surat
& Offsites Plant
5 Ammonia 9920319 Overhauling & testing of RV & M/s Flotec Eng. Services ,
(Mech) 02/03/2007 Pilot operated valves in Surat
Ammonia plant
6 Ammonia 9920434 Replacement of elbows in 105- M/s Ganesh Engg,
(Mech 23/03/2007 D &108-D Ahmedabad
7 Ammonia 9920384 101 CA/ CB BFW Flange joint M/s Nicco Engg, Baroda
(Mech 24/03/2007 on line sealing
8 Ammonia 9920272 Insitu repair of critical valves M/s Efco, Hyderabad
(Mech) 03/03/2007 applied in process gas & steam
in Ammonia plant
9 Ammonia 9920147 Supply, Installation & M/s Rotork Controls india
(Mech) 20/01/2007 commissioning or gearbox for Pvt. Ltd
motor operated valve SP-1
10 Ammonia 9920453 Major overhauling & preventive M/s Spic SMO, Mumbai
(Mech) 02/04/2007 maint.of various Rotary
equipment of Ammonia, Urea &
Offsites plant
11 Ammonia 9920451 Major overhauling & preventive. M/s Rotodyne, Hyderabad
(Mech) 02/04/2007 Maint..of various Rotary
equipment of Ammonia, Urea &
Offsites plant
12 Urea (Mech) 9920122 Services of M/s Stami carbon M/s Stamicarbon
19/02/2007 Inspectors

13 Urea (Mech) 9920152 Supervisory services of M/s Alfa M/s Alfa laval (India) Ltd,
23/01/2007 laval Engineer for H-1206 Baroda

14 Urea (Mech) 9920369 Contract for : M/s Ganesh Engineers

30/03/2007 (1)Removal & Erection of CO2
spray cooler.
(2)20” size vent stack line
replacement from CS to SS
15 Urea (Mech) 9919807 Damper for K-1701/ k-1702 M/s C.Doctor & Company,
27/11/2006 Ahmedabad
16 Urea (Mech) 9920526 Expansion Bellow for K-1702 M/S Urja, Ahmedabad
10/04/2007
17 Mech 9920340 Re RLA study of pressure parts M/s TBW, Pune
(Offsites) 16/03/2007 of boiler

18 Mech 9920219 Tube sampling fabrication for M/s Shree Ganesh

(Offsites) 07/02/2007 Re-RLA study of boiler Engg.Co,Ahmedabaad
19 Mech 9920242 Insitu Machining, Overhauling & M/s Flotec Engg. Co, Surat
(Offsites) 09/02/2007 on line testing of safety valves
of Boiler
20 Mech 9920053 Insitu repairing of Gland packing M/s Amrutha Engg, New
(Offsites) 18/01/2007 of valves. Panvel
21 B&MH 15/00566/ Overhauling of Reclaim M/s EMTICI Engineering
(Mech) 9920259 Machine Ltd, V.V.Nagar
01/03/2007
22 B&MH 9920457 Overhauling of Tracking Rollers M/s Hosch Equipments,
(Mech) 9920458 Kolkata
04/04/2007
23 B&MH 9919119 Pennwalt Make Vibrating M/s Pennwalt, Mumbai
(Mech) 01/07/2007 Screen

24 Planning 9916832 Hydro jetting of Heat M/s Delux Hydro Services ,

06/01/2007 Exchangers tubes Mumbai
25 Planning 9920379 Opening & Boxed up of Heat M/s General Engineering
21/03/2007 Exchangers. works ,Bharuch
26 Planning 9920307 Assisting IFFCO during shut M/s General Engineering
13/03/2007 down /plant turnaround jobs works, Bharuch
27 Planning 9920313 Assisting IFFCO during shut M/s Saiyed & co, Saij
13/03/2007 down /plant turnaround jobs

28 Inspection 9920097 RFET of 102-C Tubes M/s Testex NDT, Mumbai

29/01/2007

29 Inspection 9919708 RFET of 142-C Tubes M/s Testex NDT, Mumbai

11/01/2007
30 Inspection 9919946 REFT & ECT of 108-C tubes M/s Testex NDT, Mumbai
11/01/2007
31 Inspection Radiography team, on round M/s NDT Services,
the clock basis Ahmedabad
32 Inspection 9920206 In-Situ metalography M/s.TCR Advance,Vadodara
12/02/2007
33 Inspection 9920128 Thickness Survey M/s NDT Services,
19/02/2007 Ahmedabad
34 Inspection 9920127 Dye Penetrant Teams M/s.NDT
09/02/2007 Services,Ahmedabad
35 Inspection 9920130 MPI Teams M/s.NDT
20/01/2007 Services,Ahmedabad
36 Inspection 9920131 UFD Teams M/s.NDT Services,
20/01/2007 Ahmedabad
37 Inspection 9920132 Automatic Ultrasonic Scanning M/s PDIL, Sindri
22/01/2007 of Reformer tubes.
38 Electrical 9920218 Servicing of TMG make LT Air M/s. Heatex Industries
20/02/2007 circuit breakers
39 Electrical 9920342 Maint.of transformers at plant M/s.VOLTAMP transformers
29/03/2007 site Ltd, Vadodara
40 Electrical 9919793 Replacement of MOVs in plant M/s Rorork controls India
21/11/2006 Ltd,Mumbai
9919795
21/11/2006
9920139
20/01/2007

41 Electrical 9920368 Overhauling of MOCB in 66KV M/s Sun Gentech Pvt. Ltd
26/03/2007 switch yard
42 Electrical 9920098 Replacement of MCC Panel. M/s Siemence Ltd,
23/01/2007 Vadodara
43 Electrical 9920326 Overhauling of CTR M/s CTR Manufacturing
02/04/2007 makeOLTC
44 Electrical 9920467 Servicing of Jyoti make HT M/s Gayatri sales& service
30/03/2007 Breakers
45 Instrument 9920145 Contract forMaint.of Control M/s.Hi-tech
05/03/2007 Valves Controls,Vadodara
46 Instrument 9919902 Preventive Maint. Of Ammonia, M/s Yokogawa India Ltd,
10/01/2007 Urea & Utility plants DCS Baroda
47 Instrument 9918774 Skilled Man power supply for M/s A-Z Instrument services,
22/02/2006 Shut down Baroda
48 Instrument 9918861 Preventive Maintenance of M/s L&T, Navi Mumbai
03/04/2006 Ammonia plant PLC
49 Instrument 9916234 Preventive Maintenance M/s Instrumentation Ltd,
27/11/2004 /Checking of Ammonia Plant Kota
UPSS
50 Instrument 9916725 AMC for UPS Batteries M/s AMCO Power Systems
18/02/2005 Ltd, Banglore
51 Instrument 9919529 AMC for servicing of Analyzers M/s ABB Analitical,
22/11/2006 Banglore
52 Instrument 9918899 Retrofitting job of Pneumatic M/s Dresser Valves,
24/03/2006 level trolls Mumbai
53 Instrument 9917069 Attending Level state level M/s Hi-Tech Systems &
23/03/2005 monitoring system of steam Services
drum 101-F

54 Instrument 9916240 Calibration & speed M/s Beacon Industrial

25/11/2004 measurement system of Electronics Pvt.Ltd,
compressors
55 Instrument 9920198 AMC for servicing of belt M/s EMTICI Engg Ltd, V.V,
05/02/2007 weigher system Nagaar

56 Instrument 9919984 Instrument erection contract for M/s A-Z Instrument services,
29/12/2006 D.M. Plant Baroda

57 Instrument 9919645 Erection & Commissioning of M/s Power Build Ltd, V.V
12/10/2006 Bagging Machine Nagar

58 Instrument 9915881 AMC for Allen Bradly PLC M/s Pima Controls Pvt. Ltd,
12/08/2006 Ahmedabad
59 Instrument 9920346 AMC for OMRON PLC of pf M/s Masibus Process Ists.,
16/03/2007 Hitachi compressor GandhiNagar

60 Instrument 9918045 Servicing & Maint. Of 40 T Ashbee Systems Pvt. Ltd

22/10/2005 Weigh bridge

61 Instrument 9918894 Erection & Commissioning of M/s Hi-Tech Systems &

22/03/2006 level state monitoring system of Services
steam drum level in boiler
62 Civil 9920085 Providing & applying epoxy M/s.Indochem Engineering
12/02/2007 monolithic plaster on RCC Comany
Suspenders,walkway for
conveyor,beams,columns and
staircase of transfer tower of silo
building & misc. work in B&MH
building and Urea plant.
63 Civil 9920444 Providing and applying IP net M/s.Krishna Chem, Mumbai
02/04/2007 protective coating on RCC wall
of conveyor gallery and other
structures (Silo, B&MH , Urea
plant etc.)
64 Civil 9920150 Repairs of Refractory lining M/s.Detrick
01/02/2007 work Inside Primary, Auxilary
Reformer and BHEL Boiler.

65 Civil 9920295 To carry out repair of damaged M/s Akruti, Ahmedabad

26/03/2007 Top cover Plywood sheets of
cooling Towers
66 Civil 9920056 Repair & Maintenance of M/s Indocom, Ahmedabad
17/01/07 Bitumastic lining, acid alkalis
proof brick lining in strong/ weak
effluent pit and HCL storage
tank in water treatment plant
and other plant areas

67 Civil 9919940 Shifting of debries /malvas etc. M/s Jalaram Construction

20/12/2006 From various location at plant
site.
68 Civil 9919924 Providing and applying epoxy M/s P. M.Patel
18/12/2007 painting in RCC structure of
bagging plant transfer tower,
prill cooling systems and
hydrolizer of urea plant
area,RCC coloumns, Pedestals
& other structures
69 Civil 9919939 Repair of damaged AC sheet of M/s Roshni Construction
18/12/2007 cooling tower, Reformer and
other area in plant.
 AMMONIA PLANT

AIR COMPRESSOR TRAIN (101-J)

101-JT Air Compressor Drive Turbine Preventive Maintenance.

Turbine was decoupled and both ends Journal bearings as well as Thrust bearings were
inspected and found in good condition and the same was fitted back. Gauss
measurement of shaft journal, thrust collar, journal and thrust bearing pads / base rings
bearings was carried out and found within limit. Bearing clearances were taken and
found within the design range. The governor drive GB at front end of the turbine was
also overhauled

101-JLP Air Compressor Preventive Maintenance.

101-JLP, gear box end was decoupled. Journal bearings and Thrust bearings were
inspected and found in good condition and the same was fitted back. Gauss reading of
thrust end journal bearing pads, thrust bearing pads, thrust bearing base ring and non
thrust end journal bearing pads were found to be high and hence were reduced to below
acceptable limit of 3 Gauss. Bearing clearances were taken and found within the design
range. The entire bag filters as well as Roll-O-Matic filters were replaced.

101-JR Gear Box Preventive Maintenance.

101-JR, HP end was decoupled. All the bearings were inspected and found in good
condition and the same was fitted back. Both the gear as well as Pinion were inspected
and found in good condition and fitted back the same. Gauss measurement of gear
shaft and bearings carried out and found within limit. Bearing clearances were taken and
found within the design range.

101-JHP Air Compressor Preventive Maintenance.

Drive end Journal bearing as well as thrust bearings were inspected and found good
condition and fitted back the same where as the non drive end journal bearing clearance
was measured and found above design range and hence the bearing pads were
replaced. Gauss readings of non thrust end journal bearing pads, thrust collar & non
thrust end journal shaft were found above limits and hence were reduced to below
acceptable limit of 3 Gauss.

Couplings Inspection

All the couplings were inspected and found to be O.K. All the DBSE and coupling
overhang/override were measured and found to be acceptable.

1
The readings taken during the preventive maintenance of 101J train are recorded as
under.

Design Clearances Before After

Description
(Inch) (Inch) (Inch)
101 JT

Thrust end bearing 0.007 - 0.009 0.011 0.011

Opp Thrust end
0.007 - 0.009 0.0082 0.0082
bearing
Axial Thrust 0.008 - 0.012 0.007 0.009

Thrust end Labyrinth N.A. 0.0078 0.0078

Opp. Thrust end
N.A. 0.0086 0.0086
Labyrinth
101 JLP

Thrust end bearing 0.006 - 0.008 0.009 0.009

Opp Thrust end
0.006 - 0.008 0.007 0.007
bearing
Axial Thrust 0.011 - 0.015 0.0078 0.007

101 JR
Drive gear North
0.010 - 0.011 0.0094 0.0094
bearing
Drive gear South
0.010 - 0.011 0.0094 0.0094
bearing
Axial Thrust 0.014 “ 0.0118 0.011

Pinion North bearing 0.010 - 0.012 0.011 0.011

Pinion South bearing 0.010 - 0.012 0.010 0.010

Free float N.A. 0.031 0.0385

Backlash N.A. 0.0157 0.0157

2
 Design Clearances Before After
Description
(Inch) (Inch) (Inch)
101 JHP

Thrust end bearing 0.004 - 0.007 0.0094 0.0051

Opp Thrust end
0.004 - 0.007 0.0067 0.0067
bearing
Axial Thrust 0.008 - 0.012 0.0094 0.0095
Thrust end
0.0067 0.0067
Labyrinth
Opp. Thrust end
0.0067 0.0067
Labyrinth
DBSE (With Rotor at extreme ends)

101 JT-JLP N.A. 10.511 10.511

101 JLP-JR N.A. 8.30 8.30

101 JR-JHP N.A. 8.294 8.294

Coupling Hub Overhang (+) / Override (-)

101 JAT N.A. -1.51 mm -1.51 mm

101 JLP ( JAT
N.A. 0.00 mm 0.00 mm
End)
101 JLP ( JR End) N.A. -0.10 mm -0.10 mm

101 JR ( LP End) N.A. +0.15 mm +0.15 mm

101 JR ( HP End) N.A. +0.60 mm +0.60 mm

101 JHP N.A. -0.13 mm -0.13 mm

3
Final alignment reading of the train is as under:

101-JT to 101-JLP (Before)

0.00 0.00
JLP JLP
E E
-0.30 R +0.12 0.00 A +0.01

-0.17 +0.01

101-JT to 101-JLP (After)

0.00 0.00
JLP JLP
E E
-0.27 R +0.10 +0.04 A +0.01

-0.19 +0.05

101-JLP to 101-JR (Before)

0.00 0.00
JR JR
E E
+0.41 R -0.06 +0.035 A +0.035

+0.33 +0.07

4
 101-JLP to 101-JR (After PM)

0.00 0.00
JR JR
E E
+0.21 R +0.02 +0.03 A +0.04

+0.23 +0.07

101-JR to 101-JHP (Before PM)

0.00 0.00
JR JR
E E
+0.04 R +0.69 -0.02 A +0.35

+0.72 +0.02

101-JR to 101-JHP (After PM)

0.00 0.00
JR JR
E E
+0.10 R +0.62 -0.03 A +0.04

+0.69 +0.005

SYNTHESIS GAS COMPRESSOR TRAIN (103-J)

103-JBT Retrofit & 103-JAT Revert back to original

After the execution of ESP-Phase – II the power requirement of synthesis gas

compressor reduced to 11601 KW at 9700 RPM for 1100 MTPD Ammonia plant (as
per LNG Case PFD) from 12396 KW for 987 MTPD Ammonia plant (Base case study by
HTAS). To achieve this power, the steam requirement was calculated at 182 ton / hr for
103-JAT and 20 ton / hr for 103-JBT.

5
Upon start up, to achieve the power, the steam consumption in 103-JBT was raised up
to rated capacity of about 20 ton / day, but still the power could not be achieved. Since
no scope was left with 103-JBT, the required power was achieved by increasing the
steam consumption in 103-JAT to 210 ton / day. This resulted in surplus MP steam
production of 18 ton per day in Ammonia plant.

For closing the steam balance of Ammonia Plant, it was proposed to retrofit 103-JBT
with a redesigned higher capacity Nozzle so as to increase the flexibility to consume 38
Kg steam. At the same time it was proposed to revert back the capacity of 103-JAT by
using the lower capacity (Original) Nozzle so as to increase the overall efficiency and
achieve the required operating parameters.

It was proposed to upgrade the 5200 HP coupling to 7500 HP coupling to accommodate

the increase in power of 103 JBT and torque transmitted between the two turbines.

Syn. Gas Compressor Drive Condensing Turbine 103-JBT Retrofitting:

Turbine was decoupled. Governor and connected oil pipe lines were removed. Exhaust
pipe line and elbow was removed. Top half of the casing was removed. Rotor assembly
was lifted after taking measurement of labyrinth clearances. The old nozzle ring was
removed without damaging the dowel pins. The new nozzle ring was checked for blue
match. Blue match in excess of 90 percent was obtained. Since the nozzle ring comes
in one half (Bottom half), it was made sure that the end faces of the same does not fouls
with the turbine’s top casing. The new cap screws for nozzle were slightly shorter in
length and hence it was not possible to lock the head by punching. So it was tightened
with the cap screws along with a washer of size 29 x 19.5 x 5 mm. The washer was
manufactured at our workshop and material used was, 22-Cr-Mo-V martensitic stainless
steel having ASTM Designation: A-565 Gr 616 & UNS Designation S42200 Condition T.

The parting plane of the top and bottom casing was inspected and scoring marks found
at four points. These were repaired by fusion welding & grinding followed by lapping.
The parting plane was repaired by metal spray technology. The build up surface ground
finish after the spray. Repair carried out as given below:

¾ Surface Preparation at worn out area with grinding

¾ Preheating of the parting plane.
¾ Spraying and fusing of EWAC 1005 EC, L&T powder
¾ Grinding and lapping to make the surface plane

6
Sketch of the New Nozzle Ring of 103-JBT:

7
Details of the Original Nozzle Ring and Modified Nozzle Ring

Sr. Original
Parameters Modified Nozzle Ring
No. 1974-2007

Normal 26000 kg/hr 10977 kg/hr

1 Capacity

Rated 28000 kg/hr 20866 kg/hr

Inlet : 545 psig at 610 F Inlet: 545 psig at 610 F

Normal
Exhaust : 4” Hga Exhaust: 4” Hga
Steam
2
Condition
Inlet: 545 psig at 610 F Inlet: 545 psig at 610 F
Rated
Exhaust: 4” Hga Exhaust: 4” Hga

5880 HP (4384 KW) at 2618 HP (1953 KW) at

Normal
10850 rpm 10348 rpm
3 Power
6385 HP (4760 KW) at 5200 HP (3879 KW) at
Rated
10850 rpm 10850 rpm

9.75 lb/hp-hr
Normal 5.62 kg/kw-hr
(5.88 kg/kw-hr)
Water
4
Rate
9.67 lb/hp-hr
Rated 5.38 kg/kw-hr
(5.88 kg/kw-hr)

111 psia (7.80 kg/cm2)

255.7 psia
Normal at 10977 Kg/Hr Throttle
(17.98 kg/cm2)
Ring Flow
5
pressure 218 psia (15.32 kg/cm2)
275.2 psia
Rated at 20866 Kg/Hr Throttle
(19.35 kg/cm2)
Flow

Total No. of nozzle

6 25 Nos. 20 Nos.
in the ring

8
103-JBT Rotor assembly was removed from bottom casing and was put on the stand.
The old gear coupling was removed from the Rotor. The new Euroflex coupling was
installed and the final overhang measured. As per the final overhang the coupling
locknut was designed and manufactured in our workshop. As there was an addition was
this new lock nut on rotor assembly, the Rotor was taken for balancing. The Euroflex
coupling hub was then removed and the coupling locknut installed for balancing the
same along with the rotor at 500 RPM at our workshop. After balancing the Euroflex
coupling hub was reinstalled and the locknut tightened.

Details of Euroflex Made Coupling Hub Installation On 103-JBT

Sr.
Description UOM Reading Remarks
No.

Coupling Make : EUROFLEX ( 103-JBT )

1.0 Coupling Hub Blue match % 85

Dry fit Stand off ‘A’

2.0 mm 13.7
( With ‘O’-Ring)
‘B’=’A’ made by
Wet fit Stand off ‘B’
3.0 mm 13.7 hand push of
( Without ‘O’-Ring)
hub.
4.0 Push Required ‘C’ mm 10.8 Design

Calculated hub over hang

5.0 mm 2.9
‘D’ = C - B

6.0 Actual Over Hang ‘E’ mm 2.85 Final

7.0 Hub Lock Nut step ‘F’ mm 3.15

Calculated Gap between Hub &
8.0 Locknut mm 0.25
F-D
Actual Gap between Hub face & Lock
9.0 mm 0.30 Final
nut face F - E

10.0 Maximum expander pressure PSI 23000

Kg
11.0 Maximum pusher pressure 106
/cm2
Pusher pressure hold up time at final
12.0 Min 30
pressure

9
Gauss measurements were done and the readings are as below:

Max. gauss reading

Sr. No. Component Description
Before After
1 Base Ring 1.3 1.3
2 Pads 2.4 2.4
3 Thrust Collar 3.2 3.2
4 Journal Bearing Shaft 1.4 1.4
5 Thrust Side Journal Area 3.0 3.0
6 Thrust Side Shaft End 2.5 2.5

The rotor was installed inside the casing. All the clearances were measured and found
within design range. Due to decrease in thickness of nozzle ring by 0.2 mm, nozzle
clearance increased to 0.065” which was on the higher side of the design range. Hence
it was decided to increase the thickness of the nozzle clearance adjusting shim (Inboard
shim) to reduce the clearance.

Details of 103-JBT nozzle clearance adjustment has been tabulated below

Sr.
Description Reading Remarks
No
1. Original Nozzle Ring Clearance 0.055”
Decrease in nozzle ring
2. Modified Nozzle ring thickness 1.683” thickness by 0.010”
3. New nozzle ring thickness 1.673” increases nozzle
clearance by 0.010”.
4. Changed nozzle clearance 0.065”
0.430”
5. Shim thickness Before retrofitting Increasing shim thickness
(10.90mm)
0.440” by 0.010” to result in
6. New Shim thickness decreasing nozzle
(11.20mm)
clearance by 0.010”
7. New nozzle clearance 0.055”
8. Final nozzle clearance obtained 0.059” Design : 0.055” – 0.065”

Since the thickness of nozzle clearance adjusting shim (Inboard shim) was increased by
0.010”, the axial float decreased by 0.010” to 0.002” which was well below the design
range of 0.008” - 0.012”. Hence the thickness of axial thrust adjusting shims (Outboard
shim) was reduced by 0.007” to get the desired thrust.

10
Details of axial thrust adjustment have been tabulated below.

Sr.
Description Readings Remarks
No
Increase in thickness of
1. Axial Float Before retrofitting 0.012” nozzle clearance adjusting
shim (Inboard) by 0.010”
Axial Float after increase in reduced axial float by 0.010” to
2. nozzle adjusting shim 0.002” 0.002”
thickness.
Thrust adjusting shim 0.187” Decrease in shim thickness by
3. 0.007” to result in increase in
thickness (4.75mm)
thrust by 0.007” to 0.009”
0.180”
4. New shim thickness
(4.55mm)
5. Axial float 0.009”
6. Final axial float obtained 0.008” Design : 0.008” – 0.012”

The oil deflector (governor side), part No 17, Delaval No HJ – 588 – AZ, was replaced
by new one and the turbine was boxed up. The final bearing clearances were noted and
found within design range. The governor was taken for preventive maintenance. The
servomotor assembly was dismantled, cleaned and reassembled.

Syn. Gas Compressor Drive Turbine 103-JAT

The turbine was taken for derating with original, lower capacity Nozzle ring. The existing
Nozzle ring was removed to install the original, lower capacity older ring. A detail
comparison of the Nozzle rings has been tabulated below:

Details of Original and Existing Nozzle Rings:

Existed Original
Sr. Higher Capacity Lower Capacity Nozzle.
Parameters
No. Nozzle. (1974-1997 )
(1997-2007) (2007 Onwards)
Capacity Normal 221019 221019
1
(kg/hr) Rated 275,000 256284
Inlet : 1450 PSIG at 824 Inlet : 1450 PSIG at 824
0 0
Steam Normal CF CF
2 Condition Exhaust : 5550F Exhaust : 5550F
(PSIG) Inlet : 1450 at 824 0F Inlet : 1450 at 824 0F
Rated
Exhaust : 555 F Exhaust : 555 F
Power Normal 14800 14800
3
(hp) Rated 18500 17900
Water Rate Normal 20.01 20.01
4
(Kg /kw-Hr) Rated 19.19

5 Total No. of nozzle in 48 48

the New nozzle block

11
The 8 Nos cap screws of the nozzle ring & gland ring were replaced by new one. The
rotor was installed in the casing and all clearances were noted. The turbine was boxed
up.

The original nozzle ring was lapped at our Mechanical Ammonia Workshop and was
taken to main work shop for blue match. Only 50 % blue match was found on table. The
nozzle ring was sent to M/S Mehul, Ahmedabad for surface finishing. After surface
grinding, blue match was checked on table and more than 90 % was observed. This
original nozzle ring was installed.
The gear coupling hub on 103-JAT rotor towards JBT side was removed and new
Euroflex make coupling hub was installed and the over hang was measured. As per the
overhang obtained, new coupling hub locknut was designed and made in workshop.

Both ends coupling hubs of 103-JAT rotor were removed and the rotor along with the
new coupling hub locknuts was balanced in workshop at 500 RPM. Euroflex make
coupling hub was installed on 103-JBT side of 103-JAT rotor and Johncrane make
coupling hub was installed on 103-JLP side of 103-JAT rotor.

Details of Euroflex Made Coupling Hub Installation on 103-JAT (103-JBT side)

Sr.
Description UOM Reading Remarks
No
Coupling Make : EUROFLEX ( On 103-JAT towards 103-JBT side) )
1.0 Coupling Hub Blue match % 85
Dry fit Stand off ‘A’
2.0 mm 12.27
( With ‘O’-Ring)
‘B’=’A’ made
Wet fit Stand off ‘B’
3.0 mm 12.27 by hand push
( Without ‘O’-Ring)
of hub.
4.0 Push Required ‘C’ mm 11.00 Design
Calculated hub over hang
5.0 mm 1.27
‘D’ = C - B
6.0 Actual Over Hang ‘E’ mm 1.23 Final

7.0 Hub Lock Nut step ‘F’ mm 1.45

Calculated Gap between Hub & Locknut
8.0 mm 0.18
F-D
Actual Gap between Hub face & Lock nut
9.0 mm 0.22 Final
face F - E
10.0 Maximum expander pressure PSI 23000

11.0 Maximum pusher pressure Kg /cm2 130

Pusher pressure hold up time at final
12.0 Min 30
pressure

12
Details of Johncrane Make Coupling Hub Installation On 103-JAT
(103-JLP side):

Sr.
Description UOM Reading Remarks
No

Coupling Make : EUROFLEX ( On 103-JAT towards 103-JLP side )

1.0 Coupling Hub Blue match % 85

Dry fit Stand off ‘A’
2.0 mm 11.66
( With ‘O’-Ring)
‘B’=’A’ made
Wet fit Stand off ‘B’
3.0 mm 11.66 by hand push
( Without ‘O’-Ring)
of hub.
4.0 Push Required ‘C’ mm 10.23 Design
Calculated hub over hang
5.0 mm 1.43
‘D’ = C - B
6.0 Actual Over Hang ‘E’ mm 1.40 Final
7.0 Hub Lock Nut step ‘F’ mm 1.68

8.0 Calculated Gap between Hub & Locknut mm 0.25

F-D
Actual Gap between Hub face & Lock nut
9.0 mm 0.28 Final
face F - E
10.0 Maximum expander pressure PSI 23000
Kg
11.0 Maximum pusher pressure 140
/cm2
Pusher pressure hold up time at final
12.0 Min 30
pressure

Axial Probe Installation on 103-JAT Rotor:

While installing axial probe on the 103-JAT rotor, it was found that, the space for axial
probe between the coupling hub rear end and a spacer provided for probe on the rotor,
had reduced. This happened because, the new Euroflex coupling hub had flanges at the
rear end. After studying it was decided to make a new spacer having OD of around 20-
30 mm larger than that of original spacer. Since the spacer is not subjected to steam
pressure and temperature material of grade F11 was found to be suitable.

New spacer was made from grade F-11, 6” x 600 # blind flange. The spacer was
balanced at 500 RPM. The original Spacer was removed and the new Spacer was
installed by heating to around 1000C using a gas cutter. Finally it was possible to install
axial probe at site.

13
Arrangement for installing Axial probe for 103-JAT:

14
The Details of the Existed and New Spacer for Axial Probe for 103-JAT:

15
Lock Nut for Euroflex Coupling Hub for 103- JBT:

16
The details of 103-JAT ( JBT Side) locking nuts:

17
The details of 103-JAT ( JLP Side) locking nuts:

18
103-JAT TTV Overhauling:

The TTV was taken for preventive maintenance. The complete assembly was
dismantled and cleaned. Ball bearing, oil seal and other locking pins were replaced.

Installation of New Euroflex Coupling between 103-JAT and 103-JBT

As part of revamping the 5200 HP Gear coupling was upgraded to 7500 HP Euroflex
Shim Packed Flexible coupling. The coupling hub with lock nut was already installed on
their respective shafts. For design DBSE and Coupling Hub travel, the design Nos of
Shims required was calculated at ‘9’ to get a design Pre-Stretch of 6 mm. But due to
variations in DBSE & coupling hub travel during installation, a practical method to
calculate the Nos of Shims was followed as follows:

Euroflex coupling between 103-JAT & 103-JBT, prestretch calculation:

Description Value Remarks

Step – I : Design calculation of No of shims required

DBSE Measured
333.43 mm
( With shafts at extreme ends ) for Record only
Hub Face to face Measured
329.53 mm
( With shafts at extreme ends ) for Record only
Hub Flange to Hub Flange
275.95 mm Measured
( With shafts at extreme ends )
Spacer flange to flange length 266.20 mm Design

Maximum Pre stretch possible 9.75 mm 275.95 – 266.20

Pre stretch required 6.00 mm Design

Total shim thickness required 3.75 mm 9.75 – 6.00

No of shims calculated 9 3.75 / 0.381

19
 Description Value Remarks

Step – II : Pre stretch obtained

Flexible element thickness 12.1 mm Design

Gap between Hub Rear end

14.6 Measured
flanges

Pre stretch obtained 5.0 mm 2 x ( 14.6 – 12.1)

Pre stretch required 6.00 mm Design

Difference 1.0 mm 6-5

0.5 mm Required Adjustment

Allowable difference
(Design) was done

Step – III : Adding shims to decrease pre stretch / Removing shims to increase pre
stretch

Pre stretch required 6.00 mm Design

Shims to be removed 2 Nos (6-5) / 0.381

Gap between Hub end flanges 14.9 mm Measured

Pre stretch obtained 5.6 mm 2 x (14.9 – 12.1)

Shims under compression 0.4 mm 6 – 5.6

Step – IV: Final pre stretch was measured at 5.6 mm with 7 Nos shims in place.
Three Shims on JBT side and four on JAT side.

20
Over Speed Trip adjustment of 103-JBT

Over Speed Trip of the condensing turbine 103-JBT was achieved as follows:

x Turbine was tripped after 5 Trials.

x The coupling was locked with a solo plate provided by Euroflex. In the 1st attempt,
speed as increased upto 12100 RPM but the turbine did not trip.
x The complete governor assembly was removed to check the clearance between
the trip lever and the OST pin. The gap between pin and lever was found 120 mills.
The lever was removed and on close inspection it was found that deep
depressions had developed due to hitting of the weight / pin. These depressions
were filled by weld deposits.
x 2nd trial was attempted and the turbine tripped at 11090 RPM. The 3rd trial was
attempted but the turbine did not trip. On dismantling the whole assembly was
again dismantled and inspected. It was observed that the weld deposit worn out
and new depressions had developed due to hitting of the weight (pin) on the lever.
The depressions were refilled using Incolloy electrode.
x 4th trial was made but the turbine did not trip.
x Finally part no 11, lever was replaced by new lever. The trip lever assembly was
installed and clearance measured. The gap was set to120 mills.
x As per the OEM’s instruction the clearance can be increased by increasing the
thickness of Part No 4, shim. Expecting the reverse to happen thickness was
reduced by 0.3 mm. But the clearance increased instead.
x Finally it was decided to reduce the clearance by reducing the length of lever, Part
No 2. by 1.0 mm. Final clearance was measured at 100 mills and the complete
assembly was assembled.
x The three way valve was overhauled. All its ‘O’- Rings were replaced.
x In the 5th attempt, the turbine tripped at 11800 RPM.

21
Emergency Trip Assembly of 103-JBT

22
23
24
103-JHP Synthesis Gas Compressor Preventive Maintenance.

The compressor was decoupled and thrust bearing and both end Journal bearing were
inspected and found O.K. Gauss readings of thrust end journal bearing’s base ring (8.8)
was found to be above limit and hence demagnetized to below 3 gauss. All pads were
Dye Penetration tested and no surface cracks were found. The final journal bearing
clearance was measured and found within limit. To get the required axial thrust 2 Nos,
0.07 mm gaskets were used

103-JLP Synthesis Gas Compressor Preventive Maintenance.

Journal bearings and thrust bearings were inspected and found O.K. Gauss readings of
thrust and both end journal bearing were measured and found within limit. Dye
penetration test was performed on all the pads and no surface cracks were found.

The bearing clearances measured before and after overhauling:

Design
Before After
Description Clearances
( Inch ) ( Inch )
( Inch )
103 -JBT
Thrust end bearing 0.010 - 0.012 0.010 0.010
Opp Thrust end bearing 0.010 - 0.012 0.010 0.010
Axial Thrust 0.008 - 0.012 0.012 0.008
103 - JAT
Thrust end bearing 0.010 - 0.012 0.009 0.010
Opp Thrust end bearing 0.006 - 0.008 0.008 0.008
Axial Thrust 0.011 - 0.015 0.015 0.010
103- JHP
Thrust end bearing 0.0023 – 0.0033 0.004 0.004
Opp Thrust end bearing 0.0023 – 0.0033 0.004 0.004
Axial Thrust 0.015” – 0.022” 0.0157 0.0157
Design
Before After
Description Clearances
( Inch ) ( Inch )
( Inch )
103-JLP
Thrust end bearing 0.002 – 0.004 0.007 0.007
Opp Thrust end bearing 0.002 – 0.004 0.004 0.004
Axial Thrust 0.015 – 0.022 0.015 0.0173
Coupling Hub Overhang ( +) / Override ( -)
103 JBT N.A. + 2.85 mm + 2.85 mm
103 JAT ( JBT End) N.A. + 1.23 mm + 1.23 mm
103 JAT ( LP End) N.A. + 1.40 mm + 1.40 mm

25
Performance Curve for New Nozzle Ring:

26
27
28
Final alignment reading of the train is as under:

103-JBT to 103-JAT (Before PM)

0.00 0.00
JAT JAT
W W
-0.13 R +0.17 -0.01 A -0.01

-0.03 -0.02

103-JBT to 103-JAT (After PM)

0.00 0.00
JAT JAT
W W
-0.27 R +0.01 +10.04 A +0.02

-2.9 -0.07

103-JAT to 103-JLP (Before PM)

0.00 0.00
LP LP
W W
-1.00 R -0.90 1.00 A 0.00

-1.92 -0.02

103-JAT to 103-JLP (After PM)

0.00 0.00
JLP JLP
E E
+0.25 R -0.44 -0.03 A +0.02

-0.20 -0.01

29
 103-JLP to 103-JHP (Before PM)

0.00 0.03
HP HP
W W
-0.69 R -0.58 -0.00 A -0.03

-1.25 -0.05

103-JLP to 103-JHP (After PM)

0.00 0.00
JR JHP
E E
+0.34 R +0.38 -0.01 A +0.06

+0.71 +0.05

REFRIGERATION COMPRESSOR TRAIN:

Refrigeration Compressor Drive Turbine, 105-JT Preventive Maintenance

Turbine was decoupled and both ends Journal bearings & Thrust bearings were
inspected and found O.K. Gauss measurement of thrust end journal bearing pads (6.0)
was found to be above limit and hence demagnetized to below 3.0 gauss. Gauss
reading of all other bearing and shaft journal was measured and found within limit.
Bearing clearances were taken and found within the design range. Greasing of governor
valve linkages was carried out. The governor drive GB at front end of the turbine was
also overhauled

Low Pressure Refrigeration Compressor, 105-JLP Preventive Maintenance.

105-JLP, gear box end was decoupled. Journal bearings and thrust bearings were
inspected and found O.K. Gauss reading of thrust bearing base ring (5.2) was found to
be high and hence were reduced below 3 Gauss. Gauss reading of all other bearings
and shaft journal was found to be within limit. All bearing clearances were taken and
found within the design range.

30
Gear Box Preventive Maintenance (105-JR).

101-JR, HP end was decoupled. All the bearings were inspected and found O.K. Both
the gear as well as Pinion were inspected and found to be O.K. Gauss readings of low
speed shaft south side bearing (3.7), High Speed south side bearing (12.0), High speed
shaft, North side bearing (4.2) were found to be above limit and hence were reduced
below acceptable limit of 3 gauss. Bearings clearance were measured and found within
limit.

The readings taken during the maintenance of 105-J train are recorded as under:

Design
Description Clearances Before After
( Inch )
105 JT
Thrust end bearing 0.007 - 0.009 0.010 0.010
Opp Thrust end
0.007 - 0.009 0.010 0.010
bearing
Axial Thrust 0.008 - 0.012 0.0138 0.0138
105 JLP
Thrust end bearing 0.006 - 0.008 0.0118 0.011
Opp Thrust end
0.006 - 0.008 0.011 0.011
bearing
Axial Thrust 0.011 - 0.015 0.014 0.013
105 JR
Drive gear North
0.010 - 0.011 0.016 0.016
bearing
Drive gear South
0.010 - 0.011 0.016 0.016
bearing
Axial Thrust 0.014 0.0196 0.0196
Pinion North bearing 0.010 - 0.012 0.0126 0.0.126
Pinion South bearing 0.010 - 0.012 0.0126 0.0.126
Free float N.A. 0.011 0.011

Refrigeration Compressor (105-JHP):

Rotor Replacement of 105-JHP Case:

After plant annual turnaround, the Ammonia plant was started on 03-05-2007 and
production resumed on 07-05-2007. The plant was running smoothly till 09-05-2007.
However, the machine tripped at around 23:50 Hrs on 09-05-2007. After restarting the
machine, abnormal vibrations were noticed in Gear Box and HP case of the machine, at
around 01:30 Hrs on 10-05-2007. The machine was immediately stopped for inspection.
On thorough inspection of the train, it was found that the HP case rotor coupling had
slipped from its position and thereby causing extensive damage to both coupling hub &
31
rotor shaft end. As an immediate measure, HP case rotor & coupling were replaced with
available spare ones and the machine train was put back into operation and regular
Production was lined up on 14-05-2007 onwards.

System was isolated, clearance for opening of the machine obtained. After removal of
top casing, general condition of internals was found good. No oil additives deposit was
found. Both the mechanical seals were in good condition. Labyrinth clearances were
found in limit. Lining marks were observed on the journal bearing pads; hence the pads
were replaced with new one.

Following jobs were carried out in HP Case during the Rotor replacement:

The activity list for the breakdown maintenance of 105-JHP Case in chronicle order is as
follows:

Date Sr Time Activity

No
05-05-2007 1 21:00 Hrs Machine put on slow run
07-05-2007 1 19:15 Hrs Speed up to minimum gov. speed
09-05-2007 1 23:50 Hrs Machine tripped due to.
10-05-2007 1 01:30 Hrs Machine restarted again. Heavy vibrations noticed and
machine was stopped for inspection.
2 09:30 Hrs Coupling between Gear Box and HP case was
opened. Noticed coupling hub of HP case had slipped.
3 Ammonia depressurization from HP case started.
4 Coupling between Turbine to LP case and LP case to
Gear Box opened.
5 Gear Box bearing probe wiring removed. Gear Box
cover, Gears and bearings removed. Inspection of
Gears and Bearings carried out.
6 Spare HP Compressor Rotor, Coupling, Bearings,
Labyrinths and other parts issued and cleaning
started.
7 Alternate bolts of the HP case opening started.
8 Gear Box assembled and boxed up.
11-05-2007 1 11:00 Hrs Clearance for opening the HP case received and
balance bolt opening started.
2 09:00 Hrs Gear Box opened again as vibration probes were
overlooked during box up.
3 14:00 Hrs Top casing removed.
4 15:30 Hrs Top half casing cleaning started.
5 17:00 Hrs Rotor removed from position after checking all bearing
and Labyrinth clearances.
6 18:00 Hrs Bottom half casing cleaning.
7 18:00 Hrs Assembly of Mechanical seals, new Gear Coupling
Hub and other parts on the spare Rotor started. This
activity was completed at 04:00Hrs on 12-05-2007.
8 16:30 Hrs Lock nut drawings made and given to Workshop.

32
 12-05-2007 1 07:00 Hrs Rotor placed in position. Clearances of Labyrinths
checked.
2 17:00 Hrs Top Casing put into position.
3 14:30 Hrs One ring was left out and could not be installed on the
HP case rotor due to lower Dia. than the coupling hub.
Therefore, Gear Box cover and output Gear pinion
removed again after probe removal.
4 17:00 Hrs HP case Coupling Hub removed in position for
installation of left out ring. Completed by 18:00 Hrs.
5 17:30 Hrs Lock Nut preparation for installation.
6 Both end bearings boxed up.
Casing bolt tightening.
Final tightening of casing bolts.
Alignment checking between HP case and Gear Box.
All three coupling box up.
Oil piping box up with new flexitallic gaskets.
Vibration probe fixing and wiring.

13-05-2007 1 07:00 Hrs Machine completed in all respect and handed over to
Production for operation.
2 09:00 Hrs Machine taken on slow roll. Minor oil leakage noticed
in one flange was tightened.

The following items were replaced issued from store:

Sr. Description Qty. Store Code

No.
1 Rotor 1 No 101050320000
(Detail embossed the Rotor
shaft End: I-171, ST18, 0355,
BFS – 20 52 Fx2)
2 Gear Coupling between G/B & 1 No 112050615000
HP Case , (Part No.: 1624 A)
3 Journal Bearings Pads 2 Sets 112050233500
(Symbol : BF395A) (1set=5 Nos.)

33
New Hydraulic gear coupling on 105-JHP was installed and the installation detail is as
follows:

Sr.
Description UOM Reading Remarks
No.
1.0 Coupling Hub Blue match % 100
Dry fit Stand off ‘A’
2.0 mm 9.15
( With ‘O’-Ring)
‘B’=’A’ made
Wet fit Stand off ‘B’
3.0 mm 9.15 by hand push
( Without ‘O’-Ring)
of hub.
4.0 Push Required ‘C’ mm 7.641 Design
Calculated hub over hang
5.0 mm 1.5
‘D’ = C - B
6.0 Actual Over Hang ‘E’ mm 1.8 Final
Maximum expander
7.0 PSI 20000
pressure
8.0 Maximum pusher pressure Kg /cm2 40
Pusher pressure hold up
9.0 Min 30
time at final pressure

105-JT – JLP – JHP COUPLING / SHAFT DBSE Detail was recoded and it is as
follows:

Sr. Descriptio 105-JT TO 105- 105-JLP TO Gear Gear Box TO

No. n JLP Box 105-JHP

1 DBSE 271.27mm. 265.68mm. 209.29mm.

2 Hub to Hub 271.27mm. 267.38mm. 207.05mm.

Hub Lock
3 Nut to Lock 236.96mm. 250.30mm. 197.29mm.
Nut
Shaft 2.0mm
4 -------- 1.5mm. -------- ------ --------
Overhang .

Hub
5 -------- 2.5mm. -------- -------- ------ 1.5mm.
Overhang

Lock Nut 0.008”

6 0.010” 0.009” 0.012” -------- ------
Gap (0.2mm.)

Spool Piece
7 231.65mm. 228.55mm. 176.10mm.
Length

34
 General view of Rotor Removal from bottom casing

Photograph showing Locknut installed on the 105-JHP Rotor Shaft

35
Locknuts on shaft for all the hydraulically fitted coupling hubs were installed. The locknut
sketch is given below:

LOCK NUT ON 105-JT:

36
LOCK NUT 105-JLP (TOWARD 105-JT):

37
LOCK NUT 105-JLP (TOWARD GB):

38
LOCKNUT 105-JHP:

39
Labyrinth Clearances recorded with old Rotor and with New Rotor. The readings are as
follows:

40
Free Axial Float and other readings are as follows:

105 JHP
Design Old Rotor New Rotor
Thrust end bearing 0.004 - 0.007 0.006” 0.006”
Opp Thrust end bearing 0.004 - 0.007 0.006” 0.006”
Axial Thrust 0.008 - 0.012 0.011”
Axial Float (Top casing removed, Thrust
0.65 mm 0.30 mm
Brg. Boxed up)
Axial Float (Top casing removed, Thrust
4.3 mm 4.5 mm
Brg. Removed)
Thrust Collar Run Out 0.0015”
GAUSS MEASUREMENT & DEMAGNETIZATION REPORT
Sr. No. Component Description Max. gauss reading
Before After
105-J, REF. GAS COMPRESSOR:
1 Turbine Free End Journal Bearing
1.1 Base Ring 1.1
1.2 Pads 1.3
1.3 Shaft Journal 2.6
2 Turbine Coupling End Journal Bearing
2.1 Shaft Journal Portion 2.6
2.2 Thrust Collar 2.8
2.3 Base Ring 4.0
2.4 Pads 6.0 0.2
2.5 Thrust Bearing 1.4
3 HP Case Coupling End Journal Bearing
3.1 Shaft Journal Portion 3.9 2.3
3.2 Pads 3
3.3 Bearing Base Ring 1.4
4 HP Case Free End Thrust Bearing
4.1 Thrust Bearing Shaft 12 3.1
4.2 Thrust Bearing Pads 2.0
4.3 Thrust Collar 5 0.9
5 LP Case Free End Thrust Bearing
5.1 Thrust Bearing Shaft 0.6
5.2 Thrust Bearing Pads 1.2
5.3 Thrust Bearing Base Ring 5.2 2.0
5.4 Thrust Collar 0.9
6 Gear Box
6.1 LS Shaft South side 1.4
6.2 LS Shaft South side Bearing 3.7 1.4
6.3 LS Shaft North side 2.0
6.4 LS Shaft North side Bearing 2.1
6.5 HS Shaft South side 0.9
6.6 HS Shaft South side Bearing 12.0 3.2
6.7 HS Shaft North side 1.3
6.8 HS Shaft North side Bearing 4.2 1.6

41
Locknuts were provided in all the hydraulic gear coupling of 105-J Train to avoid
slippage of the coupling hub. Rotor was not dynamically balanced after this modification.
However after this modification, the machine vibration reading noted from the Bentley
panel was normal and compared with the reading of the same before tripping of the
machine was also normal. Some sample vibration readings are as given below:

Comparative Statement of Bently Readings of 105-J Train:

BEFORE TURNAROUNE-2007 AFTER

TURNAROUNE-2007
Location Description Amplitud Amplitude in Mil
e in Mil
1H Turbine FJB (x) 0.60 0.59
1V Turbine FJB (y) 0.76 0.66
2H Turbine RJB (x) 0.65 0.41
2V Turbine RJB (x) 0.71 0.45
3H LP Compressor FJB (x) 0.40 0.86
3V LP Compressor FJB (y) 0.48 0.75
4H LP Compressor RJB (x) 0.25 0.37
4V LP Compressor RJB (y) 0.27 0.37
7H HP Compressor FJB (x) 0.77 0.63
7V HP Compressor FJB (y) 0.97 0.56
8H HP Compressor RJB (y) 0.96 1.09
8V HP Compressor RJB (y) 1.16 1.84
Operating Date :11-04-2007 Date :14-05-2007
Parameters Turbine Speed : 5850 Turbine Speed :6018
RPM RPM
Plant Load : 89 % Plant Load : 89 %
Time : 16:00 Hrs Time : 16:30 Hrs
Legend H-Horozontal, V-Vertical, FJB – Front journal Bearing,
RJB-Rear journal Bearing,
Remark Lock nut provided at coupling of Turbine shaft, LP compressor shaft
both end & HP compressor shaft

42
 Train Alignment Reading (All readings are in mm) are as below:

105-JT to 105-JLP (FINAL)

0.00 0.00
LP LP
E E
0.06 R -0.69 0.02 A 0.04

-0.63 0.07

105-JLP to 105-JR (FINAL)

0.00 0.00
JR JR
E E
0.00 R 0.35 -0.03 A 0.03

0.35 -0.005

105-JR to 105-JHP (FINAL)

0.00 0.00
JR JR
E W
+0.71 R +0.40 0.005 A -0.005

1.13 0.005

INDUCED DRAFT FAN 101-BJT TRAIN

ID Fan Drive Turbine, 101- BJT, Preventive Maintenance.

Turbine was decoupled and both ends bearings as well as thrust bearings were
inspected and found O.K. Gauss measurement of rotor both end shaft journal, journal
and thrust bearing pads / base rings and thrust collar, was measured and found within
limit. All the bearing pads were Dye Penetration tested and no surface cracks were
found. Bearing clearances were taken and found within the design range. The PGPL
governor was replaced. The governor oil cooler channel cover was replaced by new
channel cover fabricated at our workshop.

43
ID Fan, 101- BJ, Preventive Maintenance.

Journal bearings and thrust bearings were inspected and found O.K. Gauss reading was
taken and found below maximum allowable limit. All the bearing pads were Dye
Penetration tested and no surface cracks were found Bearing clearances were taken
and found within the design range. The bearing dust seals were replaced. Cooling water
was circulated in lines and no leaks were observed. The final bearing clearance was
measured and found within design range.

Gear Box, 101-BJR, Preventive Maintenance.

The gear and pinion were inspected and found O.K. All the bearings were inspected
and found O.K. Gauss measurement of gear shaft and bearings carried out and found
within limit. The oil was flushed with new oil. The final bearing clearance was
measured and found within design range.
Final clearances reading of the train is as under:

Design
Before After
Description Clearances
( Inch ) ( Inch )
( Inch )
101 BJT
0.005 - 0.005 –
Thrust end bearing 0.006 - 0.009
0.010 0.010
0.004 – 0.004 –
Opp Thrust end bearing 0.006 - 0.009
0.011 0.011
Axial Thrust 0.014 " 0.0157 0.0157
101 BJR
Pinion bearing (Turbine side ) 0.005 - 0.0108 0.009 0.009
Pinion bearing (Fan side ) 0.005 - 0.0108 0.0078 0.0078
pinion float N.A. 0.025 0.025
Gear bearing (Turbine side ) 0.005 - 0.0108 0.006 0.006
Gear bearing (Fan side ) 0.005 - 0.0108 0.0078 0.0078
Gear Thrust N.A. 0.027 0.027
Back lash N.A. 0.0149 0.0188
101 BJ
0.011 – 0.011 –
Thrust end bearing (coupling side) 0.008 - 0.012
0.014 0.014
0.011 – 0.011 –
Opp Thrust end bearing 0.008 - 0.012
0.013 0.013
Axial Thrust N.A. 0.054 0.054

44
Final alignment reading of the train is as under:

101 BJT to 101 BJR (Before PM)

0.00 0.00
GB GB
N N
-0.21 R -0.18 +0.10 A -0.18

-0.38 -0.06

101 BJT to 101 BJR (After PM)

0.00 0.00
GB GB
N N
-0.21 R -0.18 +0.10 A -0.18

-0.38 -0.06

101 BJR (G/B) to 101 BJ (Before PM)

0.00 14.80
FAN FAN
N N
-0.55 R -0.50 14.80 A 14.75

-1.06 14.75

101 BJR (G/B) to 101 BJ (After PM)

0.00 14.80
FAN FAN
N N
-0.55 R -0.50 14.80 A 14.75

-1.06 14.75

45
RETROFITTING OF 101/105-J LUBE OIL PUMP DRIVE COPPUS TURBINE:

The turbine speed was governed by TG10 type governor. In this retrofit the existing
governing system was replaced with electronic governor TG13E actuator having PEAK
150 controller.

To enhance the speed control of the turbine, the mechanical governor was replaced by
new Woodward electronic governor. The following were used for the retrofit:

x TG13E Actuator : 1 No.

x Magnetic Pick Up Unit (MPU) : 2 Nos.
x PEAK-150 Controller : 1 No.
x Tooth wheel : 1 No.
x MPU Cable : 200 Meters.

Turbine Detail is as follows:

x Make : COPPUS ENGINEERING, USA

x Sr. No : 71 T 9030
x Turbine type & size : TFV – 16L
x Rated Speed : 1750 RPM
x Normal Speed : 1450 RPM
x Power Rated : 50 HP
x Inlet steam Pressure : 525 PSIG
x Exhaust steam pressure : 50 PSIG
x Steam temperature : 610 F
x Trip Speed : 2200 RPM
x Rotation : Counter clockwise from coupling side
x Installation : Vertical

Peak 150 block diagram for the retrofitted TG 13 Governor is below:

46
 Peak 150 block diagram
Details of TG 13 mounting plate on turbine is as below:

47
 TG 13 mounting plate

MPU Gear for new Governor:

48
 MPU Gear

103-J SEAL OIL PUMP RELOCATION

The 103-J Seal oil pump was so positioned that, the after decoupling, the DBSE was not
sufficient for remove the mechnical seal of the pump at site. Hence whenever there was
a mechanical seal failure the pump had to be completely removed to attend the failure.
Hence both the seal oil pumps were shifted by about 4” away from their prime mover to
facilitate the removal of mechanical seal at site.

The Original & Final Position of 103-J Seal Oil Pump

New location of
Pump

Lube Oil Pump Prime Seal Oil Pump

Mover
Increased DBSE.

4”. The increased DBSE will

facilitate the removal of Mech.
Seal at site.
BOILER FEED WATER PUMP, 104-JA OVERHAULING AND DRIVE TURBINE 104-
JAT PREVENTIVE MAINTENANCE

BOILER FEED WATER PUMP, 104-JA OVERHAULING;

The Boiler Feed Water Pump 104-JA showed high vibrations. Before Shutdown, even
after realignment the vibrations did not stop. Further the shims of the coupling flexible
element were found broken. Hence it was decided to replace the complete rotor
assembly of pump. The turbine was taken for preventive maintenance.

104-J Rotor Assembly Replacement and Overhauling

The pump was decoupled and the alignment readings were noted. The flexible elements
and fasteners were inspected and found in good conditions. The coupling hub was
removed. Both end radial bearing sleeves was removed and inspected and found in
good condition. The bearing clearance was noted.

A systematic step by step procedure followed for complete dismantling, replacement of

rotor and reassembling, has been elaborated below:

x The NDE lube and cooling water lines were removed. The main oil reservoir and
the pumps were removed. Both end mechanical seals were locked and removed.
x The Discharge Diffuser – Head assembly constituting of Head, Discharge
Diffuser, Inner Head Gasket & Pressure Reducing Bushing, was removed with the
help of screw jack. A 1-1/4” x 12” long x UNF thread. stud was used as the jack.

x The Unitized internal assembly was pulled out with the help of a Hydra. Wooden
sleepers were kept below the assembly to guide the same. The assembly was
taken to main workshop and placed horizontally on floor for dismantling.
49
x The Shaft Sleeve Compression Nut, Shaft Sleeve, Seal Ring & Inlet Spacer
respectively came out with ease.

x The 1st Impeller Spacer Sleeve / Lock Nut got struck on the shaft and could not be
removed. The same was removed by cutting on lathe.

x The 1st stage Impeller also got struck on the shaft. The impeller was heated and
attempt was made to remove it by pulling with a special jack, but the same did not
come out. The rotor was cut and drilled on lathe to remove the impeller.

x Then the 1st set of Intermediate Cover with, Bushing, Wearing ring & Diffuser was
removed.

x Then the 2nd Impeller Spacer Sleeve / Lock Nut was removed & the 2nd stage
impeller was pulled out.

x Steps No 8.0 & 9.0 was repeated to dismantle the remaining stages i.e. from .3rd to
7th.

x Before removing each impeller, the following were measured and tabulated to
calculate the clearances :

x Impeller Wear Ring O.D.

x Impeller Spacer Sleeve O.D.
x Removed Suction Spacer /Intermediate Cover/ Discharge Spacer Wear Ring
I.D.
x Removed Suction Spacer / Intermediate Cover/ Discharge Spacer. Bushing
I.D.

x The run out of the new rotor assembly of Shaft, Impellers & Impeller Spacer
Sleeve was checked on ‘V’ Block and found within limit. The assembly was later
dismantled leaving behind the shaft assembled with Pressure Reducing Sleeve,
Pressure Reducing Sleeve Lock Nut, Shaft Sleeve & Shaft Sleeve Compression
Nut.

x The above assembly was placed vertically with the Pressure reducing Sleeve
seated in between two I-Beams and coupling end open towards top.

x Vertically installation was started with 7th Impeller with Wear Ring and the same
was locked with Spacer Sleeve.

x Then assembly of Discharge Spacer, Wearing ring, Bushing & Diffuser was
installed.

x Steps No 13 & 14 was repeated until the 1st Impeller and the 1st Impeller Lock Nut
was installed.

50
x After installing each impeller, the following were measured and tabulated to
calculate the clearances. :

x Impeller Wear Ring O.D & Spacer Sleeve O.D.

x Next Suction Spacer/Intermediate Cover/Discharge Spacer Wear Ring I.D.
x Next Suction Spacer / Intermediate Cover/ Discharge Spacer. Bushing I.D.

x Finally the Suction Spacer with Wear Ring was installed. This was followed by
installation of seal Ring, Shaft Sleeve & Shaft Sleeve Compression Nut. The
Unitized internal assembly was ready to be installed in the casing.

x The Unitized internal assembly was placed inside the casing and the Discharge
Diffuser – Head assembly bolted to the casing.

x Both ends mechanical seals were installed. The stationary and rotating rings of
both the mechanical seals were lapped and reassembled. All the ‘O’-Rings were
replaced by new ones.

x The centering of the complete rotor assembly was checked with a dial gauge. The
assembly was found to be having eccentricity of 0.2 mm towards the coupling end.
The coupling end bearing housing was lowered by 0.2 mm to nullify the eccentricity.

Preventive maintenance of Boiler Feed Water Pump Drive Turbine 104-JAT

The turbine float was measured and found to 0.0275” well above the design range of
0.011” – 0.016”. The coupling end journal bearings were dismantled and inspected and
found in good conditions. The bearing sleeve was cleaned and reassembled. The
diametrical clearance was measured and found within limit. The Non Drive End
Kingsbury thrust cum journal bearing was removed and dismantled. The seating area of
thrust pads were found damaged. The complete assembly was replaced by new one.
Gauss measurement of rotor as well as bearing was done and degaussing was done
wherever required. Both ends bearings were boxed up and final Axial Thrust was
measured at 0.010”.

The governing valve was dismantled for replacing the carbon rings and washers. 10 No
of carbon rings and washers were replaced by new ones. The rings and the washers
were placed alternatively.

The governing valve adjustment was done as follows:

x Total design valve opening / travel : 9/16”
x Half opening /travel : 9/32”
x Lever was set horizontal with valve 9/32” open.
x Servomotor piston was held at 7/32” from top stop and connecting rod was
adjusted so as to keep the valve just closed.

51
An overview of 104-JA, BFW PUMP during dismantling:

The readings of various clearances taken are as follows:

Design
Before PM After PM
Description Clearance
(Inch) (Inch)
(Inch)
104-JAT ( TERRY TURBINE)

Thrust end bearing 0.005-0.007 0.009 0.008

Opp thrust end bearing 0.005-0.007 0.006 0.006

Axial Thrust 0.011-0.0016 0.027 0.010

104 JA

Thrust end bearing 0.006 - 0.008 0.0068 0.006

Opp Thrust end bearing 0.006 - 0.008 0.008 0.006

Axial Thrust 0.014 0.010 0.012
DBSE 127 mm 129.5 129.5

52
53
 Clearance chart

The alignment readings are as follows.

104-JAT to 104-JA (Before PM)

0.00 0.00
JAT JAT
W W
-0.02 R -0.11 +0.06 A +0.07

-0.12 +0.13

104-JAT to 104-JA (After PM)

0.00 0.014
PUM P PUMP
W W
-0.26 R -0.27 0.08 A 0.05

-0.53 0.00

AMDEA PUMP DRIVE TURBINE (MURRY), 107-JT, PREVENTIVE MAINTENANCE

The turbine was decoupled and the coupling was inspected. The pump side flexible
elements we found broken. Bearings were inspected and found in good condition. The
final journal bearing clearances were measure and found within the design range. The
suction strainers were cleaned. Gauss measurements was taken and found below
maximum limit. Oil console was cleaned.

54
The alignment readings are as follows.

107-JT to 107-J (Before PM)

0.00 0.00
T JAT
W W
+0.20 R +0.40 -0.03 A +0.04

+0.50 +0.00

107-JT to 107-J (After PM)

0.00 0.00
T JAT
W W
+0.20 R +0.40 -0.03 A +0.04

+0.50 +0.00

The clearances readings are as follows:

Design
Before PM After PM
Description Clearance
(Inch) (Inch)
(Inch)

107-JT ( MURRY TURBINE)

Thrust end bearing 0.004 – 0.006 0.0058 – 0.0068 0.0059 – 0.0068

Opp thrust end bearing 0.004 – 0.006 0.0058 – 0.0062 0.0062 – 0.007

Axial Thrust 0.007 – 0.013 0.0101 0.010

55
LEAN aMDEA SOLUTION PUMP TRAIN

115-JA Pump Rotor Replacement Job:

During shut down, Preventive Maintenance was done and general condition of Bearings,
Couplings, and Gear Box was okay. After opening of bearing, clearance noted and
found to be within limit. Gauss measurement was also taken and found to be within the
limits.

After preventive maintenance of 115-JA Train, the equipment was taken in line in startup
of Ammonia Plant. 115-JA and Gear Box Coupling, Coupling bolts of the Gear Box
Coupling Hub was reported broken from production side. Upon inspection, coupling
bolts of the Gear Box Coupling Hub towards Gear Box Side was found sheared and
115-JA pump was found jam. There was no movement of Rotor in any direction.

Bearings were opened and found Okay. Casing bolts were opened. Top Casing was
found heavily jam and was not coming up with the help of jack bolts. There was
provision of only 2 jack bolts at 180 degree apart. After removal of Top casing with
difficulty, additional provision for 2 jack bolts at 180 degree apart was done in workshop.
Top casing weighing was done and it was 1370 Kgs.

After removal of Top casing, the following items were found seized with Rotor (Refer
KEPL Drawing No. KSO 010140 001 0100, Rev. 1):

x Stage Piece (Balancing Drum ring) - 2nd stage, Part No. 74-2.
x Impeller wear Ring – Ist stage, Part No. 25-1 (both sides).
x Impeller wear Ring – 2nd stage, Part No. 25-2.

Mechanical seals of both ends (Part No. 111-1 & 111-2) were found damaged.

Rotor assembly was removed from Bottom Casing. The Rotor was found heavily jam
and was not coming up with the help of 5 Ton EOT. The same was removed with the
help of RT Crane.

After thorough cleaning of casings and internals, the assembly was started with new
Dynamically Balanced Rotor assembly available at store. The Rotor assembly was
issued from store against Store code: 113150146300. Dimensions of Rotor were
recorded for making Drawing.

While assembly, stage Piece (Balancing Drum ring) - 2nd stage, Part No. 74-2 was not
properly fitted in the bottom casing groove. The OD of the ring was measured larger
than the corresponding ID.

ID of stage Piece (Balancing Drum ring) - 2nd stage, Part No. 74-2 in the bottom casing
was 389.62 mm & OD was 390.00 mm.

High spots were removed from casing grooves and a cut of 0.15 mm on the stage piece
ring OD was taken in the workshop. Match the ring with top and bottom casings.
Clearance with bottom casing was measured 0.02mm.
The rotor assembly was placed the in the bottom casing. Free float of the Rotor was
measure 15.8 mm against design of 6 mm minimum.
56
The rotor was fixed in position by tightening the journal bearing of both sides.
Clearances from Gear Box to Clutch side were measured and these are as follows:

Sr. Item Description Design Clearance Clearance

No. Clearance between Rotor between Rotor
Total shaft (Top shaft (Bottom
(mm) position) (mm) position) (mm)
1 Throat Bush, 00
Gear Box side
2 stage Piece (Balancing 0.510 – 0.569 0.30 0.30
Drum ring) - 2nd stage,
Part No. 74-2.
3 Impeller wear Ring – 0.580 – 0.656 0.30 0.25
2nd stage, Part No. 25-
2. Clutch end side
4 stage Piece (Center 0.510 – 0.569 0.35 0.30
ring) – Ist stage, Part
No. 74-1.
5 Impeller wear Ring – 0.580 – 0.656 0.40 0.25
Ist stage, Part No. 25-
1. Gear Box side
6 Impeller wear Ring – 0.580 – 0.656 0.30 0.25
Ist stage, Part No. 25-
1. Clutch end side
7 Throat Bush, 00
Clutch end

After taking all the measurement, the top casing half was boxed up. New mechanical
seals were installed ( Store code: 113155136900). All the gaskets were replaced with
new one. Bearings were assembled.

Bearing clearances are as follows:

Design Actual
Description
(mm) (mm)
Journal Brg. Cl. (Thrust end side) 0.217 to 0.249 0.20
Journal Brg. Cl. (Opp. Thrust end side) 0.217 to 0.249 0.24
Axial Thrust 0.35 to 0.40 0.35

115-JAT Turbine Preventive Maintenance:

Both ends bearings were opened and general condition of the bearings were found ok.
Clearances were measured and found within limit. Gauss readings were also taken and
found within limit.

57
115-JHT Hydraulic Turbine Preventive Maintenance:

Both ends bearings were opened and general condition of the bearings were found ok.
Clearances were measured and found within limit. Gauss reading was taken and found
within limit.

115-JA GEAR BOX:

Gear box top cover was opened. General condition of the gear teeth was found ok.
Gear box boxed up. Clearances of the bearing were measured.
x High speed pinion shaft Brg. (Turbine side): 0.15 – 0.20 mm
x High speed pinion shaft Brg. (Pump side): 0.18 – 0.22 mm
x Low speed Gear shaft Brg. (MOP side): 0.18 – 0.24 mm
x Low speed Gear shaft Brg. (Pump side): 0.18 – 0.24 mm

GAUSS MEASUREMENT & DEMAGNETIZATION REPORT:

Sr. No. Component Description Max. gauss reading

Before After
115-JAT
1 Turbine Thrust End
1.1 Thrust Pads 1.8
1.2 Thrust collar 1.2
1.3 Shaft Journal 0.8
1.4 Journal Bearing 2.2

2 Turbine coupling end

2.1 Shaft Journal 2.9
2.2 Journal Bearings 2.6
3 115-JA
3.1 Thrust Bearing Pads 7.0 1.6
3.2 Thrust Collar 2.9
3.3 Journal bearing 3.4
3.4 Shaft Journal 0.5

58
 Alignment readings of the train is as follows:

Turbine to Gear Box

Before:
0.00 +0.01
G /B G/B
S S
+0.45 R -0.15 0.00 A +0.01

+0.30 0.00

Final:
0.00 +0.01
G /B G/B
S S
+0.15 R +0.12 0.00 A +0.01

+0.27 0.00

Gear Box to Pump

Before:
0.00 +0.00
G /B G/B
S S
+0.18 R +0.02 +0.04 A +0.00

+0.20 +0.04

Final:
0.00 +0.00
G /B G/B
S S
+0.07 R +0.13 +0.04 A +0.00

+0.20 +0.04

59
 Pump to Clutch
Before:

0.00 +0.00
C lutch Clutch
S S
+0.55 R -0.75 +0.06 A -0.12

-0.20 -0.06

Final:

0.00 +0.00
C lutch Clutch
S S
-0.14 R -0.11 +0.00 A -0.06

-0.25 -0.06

115-JB Pump Preventive Maintenance

Pump bearings opened and checked the clearances and found to be within the limit.

SECONDARY WASTE HEAT EXCHANGER 102-C

This exchanger was repaired for leakages during anuual turn around of 2005 and 2006
by plugging and 45 tubes were plugged. It was decided to do hydrotest of Secondary
waste heat exchanger (102-C) immediately after taking shut down of Ammonia Plant.
Top & Bottom coves were opened. Hydrotest test was carried out at 40 Kg/cm2g by
motor driven BFW Pump 123-J. Seven (07) Nos. tubes and 74 Nos. tube to tube sheet
seal welding leak were noticed.

102-C was taken for Plugging of leaky tubes and welding of leaky tube to tube sheet
welding. Contract for the above job was awarded to M/S Skywin Erectors, Ahmedabad.
102-C is being used in Hydrogen service. Dehydrogenation of the tube sheet was
required for proper welding of plug and tube to tube sheet seal weld leak. Bottom
support fabrication for heating coils was done and installed in the bottom tube sheet with
the help of bottom channel cover flange. Schematic / Photograph arrangement of
heating coils and insulation showing the arrangement is as below:

60
Sketch for arrangement of heating coil and insulation

61
Following materials were used for Dehydrogenation and PWHT for each Tube Sheet:

x Thermocouples: 10 Meter long wire of 17 Gauge thickness – 1 No.

x Heating Coils: 25 Meter long wire of 10 Gauge thickness – 3 Nos.
x Heating Coils: 25 Meter long wire of 12 Gauge thickness – 10 Nos.
x Recorder: 3 Nos.
x Control Panel: 2 Nos.
x M10 X 1 ½ “ long CS Bolt with nut: 50 Nos.
x Ceramic Blanket (Cera Felt): 10 Bundles.

Photograph for arrangement of heating coil in bottom channel cover

62
Dehydrogenation of the Top & Bottom tube sheet was carried out as per the attached
procedure as given below:

63
 Time – Temperature curve for Dehydrogenation of 102-C

Dehydrogenation of the Top & Bottom tube sheet was carried out one by one to prevent
both the tube sheets reaching elevated temperature of more than 400 degree C at same
time. Total 15 Nos. thermocouples each were installed for recording temperature of Top
& Bottom tube sheets. Positions of these thermocouples and application of insulation
are shown as below:

64
 Position of Thermocouples arrangement in 102-C

Dehydrogenation process took around 40 Hrs. for both the tube sheets. After completion
of Dehydrogenation, ‘hydrojet cleaning’ of all the remaining 705 tubes (Upto 2006 shut
down, 45 tubes were already plugged from total of 750 tubes) were carried out to
facilitate RFET.

Then Remote Field Electromagnetic Test (RFET) of tubes was carried out by TesTex
NDT India Pvt. Ltd., Mumbai. During this test, Six (06) tubes were detected for wall loss
of 35% or more due to Baffle fretting. These 6 Nos. tubes were decided to be plugged.

Accordingly 13 Nos. tubes were plugged with T-Shaped plugs (see attached drg.) and
74 Nos. tube to tube sheet seal welding was done. To avoid dissimilar weld for tube and
tube sheet weld, plug was made from same material (F-11) as that of tube sheet. For
welding of plugs, filler wire ER 80SG, 2.4 MM was used. Sketch of ‘T-Shape’ plug is
shown below:

T-Shape’ plugs
65
After completion of above welding on both the tube sheets, the equipment was
rehydrotested at 125kg/cm2g. In this hydrotest, 18 Nos. old plug weld leak were noticed
in Top tube sheet and 22 Nos. tube to tube sheet seal weld & old plug weld leak were
noticed in Bottom tube sheet. The same was attended. DP Test was carried out in both
the tube sheets completely.

Dehydrogenation, Welding and PWHT for Repair of 102-C was done as per attached
procedure (Welding and PWHT was done as per QW -201.1 Section IX, ASME BPVC
which is attached below):

Welding Process : GTAW

Type : Manual

x BASE METALS (QW - 403):

P.No. 4 to P. No. 4
Specification : SA 182 Gr.- F11 to SA 213 Gr.-T11
Thickness Range: Tube Sheet 165mm (6½”), Tube :- 4.191 mm (8BWG)
Tube projection 4.76-6.35mm, Fillet of 4.76 mm.

x FILLER METALS (QW - 404):

Weld metal analysis : A No. 3

Filler Metal F No. :6
AWS No. (Class) : Filler: SFA 5.28 (ER 80SG)
Size of Filler wire : 2.4 mm

x POSITION (QW - 405):

Position of Groove Welding Progression : ALL

x PREHEAT (QW - 406):

Preheat Temperature min. : 125 to 150 degree C
Interpass Temperature max. : 300 degree C
Preheat Maintenance : 150 degree C

x DEHYDROGENATION:
Soaking Temperature: 350 degree C
Soaking time : 24 hours
Soaking Temperature: 620 degree C
Soaking time : 4 hours
Heating Rate : 50 degree C/hr
Cooling Rate : 50 degree C/hr
Loading/Unloading Temperature: 300 degree C

x GAS (QW - 408)

Shielding gas : Argon

Gas consumption : 99.995 %
Flow rate : 10 to 12 litters / min

66
x ELECTRICAL CHARACTERISTICS (QW - 409)

Current : DC
Polarity : EP for GTAW
Ampere (Range) : 80 to 130

x TECHNIQUE (QW - 410)

String or weave bead : String and weave

Initial & Interpass cleaning : Grinding & brushing
Single or multiple pass : Multiple
Travel Speed (Range) : 4 to 6 cm/min for GTAW

x WELD INSPECTION

Root weld : DP Test

Final weld : DP Test

x STRESS RELIEVING PROCEDURE

Soaking Temperature : 650 degree C

Soaking time : 1 hour
Heating Rate : 50 degree C/hr (Max.)
Cooling Rate : 50 degree C/hr (Max.)
Loading Temperature : 300 degree C
Unloading Temperature : 300 degree C

After completion of above welding, Post Weld Heat Treatment (PWHT) of the Top &
Bottom tube sheet was carried out one by one to prevent both the tube sheets at
elevated temperature of more than 400 degree C at same time.

PWHT of the Top & Bottom tube sheet was carried out as per the attached procedure
depicted as below:

Total 15 Nos. thermocouples each were installed for recording temperature of Top &
Bottom tube sheets. Positions of these thermocouples & application of insulation for the
purpose of PWHT was similar to the application in Dehydrogenation.

After completion of PWHT, the equipment was again hydrotested at 125kg/cm2g. In this
hydrotest, Two (02) Nos. plugs were noticed leaking. The same was attended.

67
 Time – Temperature curve for PWHT of 102-C

DP Test was carried out and found OK. The equipment was boxed up with new gaskets
and handed over to production.

68
At present a total of 60 Nos. tubes are plugged out of 750. The final layout of tube
plugged is as below:

69
 Layout of tube sheet

Annual Inspection of Boilers GT-1631(112-C), GT-1632(101-F), and

GT- 5217(107-C):

OPEN INSPECTION :

The IBR open inspection of all the above Boilers was carried out on 23/04/2007.

HYDROTEST:

Hydrotest of the following Boilers was carried out as under.

x GT-1631 at 15.0 Kg / cm 2 g Test Pressure on 27/04/2007.

x GT-5217 at 67.5 Kg / cm 2 g Test Pressure on 27/04/2007
x GT-1632 at 145.0 Kg / cm 2 g Test Pressure on 30/04/2007
The Boilers were inspected by IBR Inspector and found satisfactory.

Bench Test of RVs of Boiler No. GT- No.GT-5217 RVs:

Bench test of following Safety valves 1631 & Boiler was done on 23/04/2007 and the
readings are as under.

GT-1631, RV No.1 ( Front) RV No.2 ( Rear )

Pop. Pressure Reset Pressure Pop. Pressure Reset Pressure
2 2 2 2
10.5 Kg/cm g 9.5 Kg/cm g 10.0 Kg/cm g 9.5 Kg/cm g
GT-5217, RV No.1 RV No.2
Pop. Pressure Reset Pressure Pop. Pressure Reset Pressure
2 2 2 2
45.0 Kg/cm g 43.65 Kg/cm g 46.3 Kg/cm g 44.9 Kg/cm g

RV FLOATING:

Boiler No. GT-1632:

Steam test of Safety valves of GT-1632 was carried out on 04/05/2007 and the readings
are as under.

RV (Super
RV (North) RV (Middle) RV (South)
Heater)
Popping Press. 117.70 119.90 115.00 112.35
Kg/cm2g Kg/cm2g Kg/cm2g Kg/cm2g
Reset
112.20 112.70 108.00 105.15
Press.
Kg/cm2g Kg/cm2g Kg/cm2g Kg/cm2g

70
PLUGGING OF TUBES IN SECONDARY WASTE HEAT EXCHANGER (102- C) OF
BOILER REG. NO. GT-1632 :

During hydrotest, total 15 no. tubes were found leaking in Secondary waste heat
exchanger (102-C). These tubes were plugged through M/s sky win erectors
Ahmedabad.

ENGRAVING THE BOILER NO. 5217:

With reference to CIB letter No.SBSN / Tech / V-4/14415 Dated 27 July 2006 New
registration no.GT-5217 is engraved as per IBR Regulation 1950.

SPACER LOCK NUT FOR RV 107-C

14.3
28.2Ø

38Ø

ALL DIMENSIONS ARE IN MM.

SAFETY RELIEF VALVES OVERHAULING & SERVICING:

The following RVs were overhauled and serviced and tested on test bench

Reset
Sr. Valve Size Set Pressure
RV Tag NO. pressure
NO (inch) (kg/cm2g)
(kg/cm2g)
1 RV – MS 9 4” x 6” 42.2 38.0

2 RV – S 7 4” x 6” 14.8 13.3

3 RV – LS 1 4” x 6” 12.70 11.40

4 RV – 123 CA (2 Nos) 3” x 6” 122.0 110.0

5 RV – BFW 1 1.5” x 2.5” 92.0 82.8

6 RV – S 26 2.5” x 4” 14.10 12.6

7 RV – 103 JAT (2 Nos) 4” x 6” 46.4 42.0

8 RV – 103 JAT ¾” x 1” 46.4 41.7

9 RV – 104 JAT 6” x 8” 0.37 0.30

71
10 RV – 112 CA 1.5” x 3” 10.50 9.5

11 RV – 112 CB 1.5” x 3” 10.50 9.0

12 RV – 109 F 6” x 8” 19.0 17.0

13 RV – 110 F N & S (2 Nos) 3” x 4” 7.0 6.3

14 RV – 111 F 4” x 6” 6.3 5.6

15 RV – 112 F 4” x 6” 6.30 5.7

16 RV – 101 D 3” x 4” 43.9 39.6

17 RV – 102 D 3” x 4” 43.9 39.5

18 RV – 117 JLP 1.5” x 2” 15.8 14.2

19 RV – 115 JB AOP 1” x 2” 11.0 10.0

20 RV – 101 J 4” x 6” 36.90 33.20

21 RV – 129 C 1” x 2” 8.4 7.5

22 RV – 104 D1 6” x 8” 35.0 33.0

23 RV – 104 D 2 1.5” x 2” 34.10 30.6

24 RV – 101 E 1” x 2” 30.6 27.5

25 RV – PG 39 4” x 6” 5.3 4.7

27 RV- 123 CA 3” x 6” 122.0 110.0

28 PSV-986 4” x 6” 45.0 40.5

29 PSV-987 4” x 6” 46.3 41.7

30 PSV-117 0.5”x1” 57.08 ------

31 PSV- 111 0.5” x 1” 4.01 ----

32 103-JAT Sentinel RV 1” x 2” 46.40 -------

33 RV-104-F 1” x 2” 49.20 -----

72
The following Pilot Operated RVs were overhauled and serviced and tested on test
bench.

Set Reset
Sr. Valve Size
RV Tag NO Pressure pressure
NO (inch)
(kg/cm2g) (kg/cm2g)
1 RV – 102 F (Anderson Green ) 6” x 8” 29.5 26.5

2 RV-105-D (Anderson Green ) 3”x 4” 152.95 ----

3 RV-105-D (Tyco ) 3”x 4” 152.95 ----

4 RV – 103- J (Anderson Green ) 3” x 4” 158.93 ------

5 RV – 103- J (Tyco ) 3” x 4” 158.90 ------
6 RV – 106-F (Anderson Green ) 1.5’ x 2” 157.94 ------

HEAT EXCHANGERS & COOLERS CLEANING BY HYDROJETTING:

The Following Heat Exchangers were opened; tube bundle pulled out for hydro jetting of
shell, tube bundle & channel covers were boxed up.hydrotest was carried out as follows:

TUBE SIDE SHELL SIDE

Total PRESSURE PRESSURE
Qty.
SR EQUIP.
(No.)
NO. OF ( KG/CM2) (KG/CM2) REMARKS
NO. No. TUBES
DESIGN TEST DESI TEST
12 tubes are
plugged (See
1 108-C1A 1 1415 5.27 8.1 8.0 8.1 attached
sketch below)
2 108-C2A 1 1415 5.27 8.1 8.0 8.1
3 109-C1A 1 1150 30.58 46.0 5.29 8.1

4 109-C1B 1 1150 30.58 46.0 5.29 8.1

5 109-C2A 1 1150 30.58 46.0 5.29 8.1

6 109-C2B 1 1150 30.58 46.0 5.29 8.1

7 115-C 1 649U 29.9 10.6 15.8

8 116-C 1 300U 66.4 10.4 15.8

9 124-C 1 775 U 158 17.6 26.5

10 tubes are
plugged(See
10 130-JC 1 264 5.82 5.27 8.0
attached
sketch below)

73
74
Tube sheet layout of 130 JC

75
 Tube sheet layout of 108 C1A

THE FOLLOWING HEAT EXCHANGERS WERE OPENED FOR HYDROJETTING OF

SHELL/TUBES.HYDROTEST WAS CARRIED OUT AS FOLLOWS:

TUBE SIDE SHELL SIDE

SR Qty. Total No. PRESSURE PRESSURE REMARKS
EQP ( KG/CM2) (KG/CM2)
NO NO. of Tubes
Design Test Design Test
1 105-CA 1 2790 5.27 8.1 30.9 46.4
2 105-CB 1 2790 5.27 8.1 30.9 46.4
3 110-CA 1 763 5.60 8.1 5.27 8.1
4 110-CB 1 763 5.60 8.1 5.27 8.1
5 127-CA 1 3516 5.60 21.10 31.5
6 127-CB 1 3516 5.60 21.10 31.5
7 128-C 1 1200 5.60 8.09
8 129-JC 1 290 2.3 5.29
9 131-JC 1 348 11.90 5.27
10 173-C 1 294 10.60 5.27

THE FOLLOWING LUBE OIL COOLERS WERE HYDROJETTED:

SR. EQUIPMENT Qty.

DESCRIPTION REMARKS
NO. NO. NO.
1. 101-JLC 1,2 2 Lube Oil Cooler For 101-J

2 103-JLC 1,2 2 Lube Oil Cooler For 103-J

3 101-BJ LOC 3 Lube Oil Cooler For 101-BJ

4 107-J/JA LOC 2 Lube Oil Cooler For 107-J/JA

THE FOLLOWING GLAND CONDENSER AND SURFACE CONDENSER WERE

OPENED CLEANED BY HYDROJETTING AND BOXED UP :

SR.
EQUIPMENT NOS DESCRIPTION REMARKS
NO.
1. 101-JCA/JCB 2 Surface Condenser
2 101-JCA I/A 1 Condenser
3 101-JCB I/A 1 Condenser
4 101-JT GC 1 Gland Condenser
5 103-JBT GC 1 Gland Condenser
6 105-JT GC 1 Gland Condenser

76
MOTOR OPERATED VALVE SP – 1 GEAR BOX REPLACEMENT

The gear box of the motor operated valve SP – 1 had long cracks and hence new
gearbox was procured from M/S Rotorks Control Ltd. for replacement. During the Shut
down the gear box was replaced successfully.

77
 SKETCH FOR SP – 1 MOV GEAR BOX

PRIMARY REFORMER 101-B RADIANT ZONE:

The panel plate having bulging was replaced by new plate. All elbow and union leaks on
atomizing steam line were attended. The damaged burner blocks as per production list
were attended. The passing needle valves were replaced. Those air registers which
were hard to operate were attended.

Photograph of Primary Reformer after 1st Year of Revamp:

AUXILIARY BOILER, ITS BURNERS JOBS:

Preventive maintenance of all burners was carried out. External cleaning of tubes was
done with wire brush. The AG and Naphtha filter were cleaned. Arrangement for
installation of Oxygen Analyzers by the instrumentation was provided on the wall of the
Auxiliary Boiler.

VALVE GLAND REPLACEMENT:

The gland packing of the following valves were replaced by new packing.
x V-5 up stream block valve.
x PT-21 T X isolation valve.
x PIC 1A up stream block valve.
x 101 F Eye Hye top isolation valve.
x Start up heater plug valve.

78
x 103-J MOP steam isolation valve block valve.
x TRC -10.
x 101-J/105-J lube oil turbine steam outlet valve.
x 38 kg steam to NGBC isolation valve.
x PIC 1 A up stream.
x 105 kg to 103-JA near FIC 9, 10, 11, TX 1st vent valve.
x 38 kg steam to Pre Reformer vent valve above PICV 20 vent silencer rack area
x HCV 12
x 107-C high level switch top isolation valve.

FLANGE LEAK ATTENDED:

The following flange leak jobs were attended.

x 101 J discharge to mix feed coil line blind flange.
x LTS inlet line RV upstream flange.
x LTS Guard inlet line isolation valve upstream flange.
x BFW to 123 C (above 106 J) valve D/S flange.
x 142 CA/CB BFW outlet valve upstream flange.
x 101J/105J lube oil cooler bottom cooling tower side channel cover flange.
x 107 C south side top isolation valve flange.
x 107C vessel extra tapping flange.
x 107 C south side LG and its top flange.
x 107 C low level switch bottom tapping isolation valve upstream and downstream
flange.
x 107 C, LT 485 top tapping flange.
x 107 C RV upstream flange.
x 107C LAL-487 bottom flange.
x 107 C Blind flange.
x MICV-16 flange.
x 38 kg steam to NGBC block valve upstream flange.
x 112 C outlet to LTS guard 1st isolation valve U/S flange.
x 101-BJT exhaust line de-superheating station DM water collect line flange.
x PRC 25 U/S block valve U/S flange.
x 101-F south side LG lower nozzle (for LG) flange leak.
x 3.5kg steam to after condenser ejector d/s flange.
x HCV 12 flange.
x 181 C steam inlet main I/V flange.
x PIC 14U/S Flange.
x 101CA Chemical dozing flange.

VALVE BONNET LEAK JOBS ATTENDED:

The following valves were attended for bonnet leak.

x 101 F steam drum O/L valve bonnet.
x LT 13 top I/V bonnet.
x 106 F levels troll bottom I/V bonnet.
x 103 JAT MOV valve bonnet.
x R112 sample line valve bonnet and gland leak.
79
x 116 JT steam inlet flow TX HP tapping root I/V bonnet leak.
x MIC-61 B/V 2nd isolation valve bonnet.
x 116-JAT steam inlet flow T X HP tapping root isolation valve bonnet.
x 116 JAT PT – 924 HP tapping isolation valve bonnet.
x 105-kg steam drain 1st isolation valve behind PIC-15.
x P-110-B A.O.P outlet to small lube oil cooler outlet isolation valve.
x 121-C south side tube side drains isolation valve.

FABRICATION JOBS:

The major fabrication jobs carried out during this shut down is as below:

Replacement of Elbows of New Synthesis Gas Converter (108-D) & old Synthesis Gas
Converter (105-D) lines:

New Synthesis Gas Converter (108-D) Elbow

(14” NB x Sch120, P22 material Elbow)

80
During plant operation, New Synthesis Gas Converter (108-D) outlet to Synthesis gas
waste heat MP boiler inlet Elbow had developed a crack in the parent metal. The crack
was immediately attended by welding with a pad support after arresting gas leak by
peening in position. However the elbow itself was decided to replace in the shut down.

In the pre shut activity, thorough NDT of the spare elbow was carried out vide
radiography, 100% UT and DPT of edges, and it was found okay.

Purging and protection of the catalyst of converters was of great concern before
executing the above job. For purging, Nitrogen tankers were hired and a feed of 10 to 15
m3/hr was kept to make positive pressure in the catalyst bed of the converter. To do job
safely, blinds at the following points were provided:

x 105D Inlet –HCV-11 D/S & Bypass

x 122-C Inlet
x SP-1
x SP-70
x FIC-13 (Purge Gas)
x 105-E – NH3 Inlet and outlet
x 121-C Common flange blind
x 107-F NH3 Inlet from 106-F.

Following major activities were carried out:

x Cutting of existing Elbow.

x Weld edge preparation
x Dehydrogenation of old edges
x Set up & welding of new elbow
x Post weld heat treatment of joints

81
Position of the Elbow is as shown below in the Isometric:

82
 Sketch for Isometric of S-50 Elbow

As the elbow was in the Hydrogen service, Dehydrogenation of both the edges was
carried out. After welding, PWHT was also carried out. Curve attached below:

83
 Temperature - time curve for Dehydrogenation and PWHT

Dehydrogenation, Welding and PWHT for Repair of Elbow was done as per attached
procedure (Welding and PWHT was done as per QW -201.1 Section IX, ASME BPVC
which is attached below):

14” NB Schedule 120, ASTM A335 Gr-P22 Seamless Pipe to 14” NB Schedule 120,
ASTM A234 Gr-WP22 Seamless Elbow.
Welding Process :GTAW + SMAW
Type :Manual
x JOINT DESIGN (QW - 402)
Groove design: As per Drawing No: P1-ES-13068, Sheet 1 of 1,Rev 0.
x BASE METALS (QW - 403)
P-No. 5A Group No. 1 to P-No. 5A Group No.1
Specification : ASTM A 335 P22 to ASTM A234 Gr-WP22.
Thickness Range : 32 mm maximum
Pipe dia Range : 2-7/8” N.B. and above
x FILLER METALS (QW - 404)
Weld metal analysis : A No. 4
Filler Metal F No. : As per QW -432.1 (SFA 5.5)
AWS No. (Class) : Electrode SFA/AWS A 5.5-96 (E 9018 B3)
Filler SF A5.28 /AWS A 5.28-96 (ER 90SB3)
Size of electrode : 2.4 mm (Filler wire) for root & hot pass
2.5, 3.15, 4 mm (Electrode) for fill up and capping
x POSITION (QW - 405)
Position of Groove : 2G/5G
Welding Progression: Uphill
x DEHYDROGENATION
Loading Temp : 300 degree C/hr
Heating Rate : 60 degree C/hr
Ist Soaking Temperature : 400 degree C
Soaking time : 24 hours
Heating Rate : 60 degree C/hr
2nd Soaking Temperature : 620 degree C
Soaking time : 3 hours
Cooling Rate : 100 degree C/hr
Loading/Unloading Temperature: 300 degree C

x PREHEAT (QW - 406)

Preheat Temperature : 175 - 200 O C
Inter pass Temperature max.: 250 O C
x POST WELD HEAT TREATMENT (QW - 407)
Temperature : 704 to 760O C
Soaking time: 02 Hour minimum
Heating Rate : 200 O C / hr. max
Cooling Rate: 200 O C / hr. up to 300OC, then natural cooling under asbestos.
Loading : 200 degree C

84
x GAS (QW - 408)

Shielding gas : Argon

Gas purity : 99.995 %
Flow rate : 6 to 12 liters / min
Purging gas : Argon
Gas purity : 99.995 %
Flow rate : 10 to 15 liters / min

x ELECTRICAL CHARACTERISTICS (QW - 409)

Current : DC
Polarity : Straight for GTAW and Reverse for SMAW
Ampere (Range) : 90 to 120 for GTAW and 100 to 160 for SMAW

x TECHNIQUE (QW - 410)

String or weave bead : String and weave

Initial & Inter pass cleaning : Grinding & brushing

Single or multiple pass : Multiple

Travel Speed (Range):4 to 6 cm/min for GTAW, 8 - 16 cm/min for SMAW

x WELD INSPECTION

Bevel Edge : DP Test

Root weld : DP Test & 100 % radiography
Final weld : DP Test & 100 % radiography
x Hardness measurement after PWHT : 241 BHN Max.

Replacement old Synthesis Gas Converter (105-D) line Elbows (8” NB x Sch 120,
CS Elbow):

In the above Elbow, lamination was observed in UT in the last turn around inspection.
Hence the same was decided to replace in this shut down.

For isolation, the same blinds and method were used as explained for the 108D Elbow
replacement.

85
Position of the Elbow is as shown below in the attached Isometric:

Sketch for Isometric of 105-D Elbow

86
As the elbow was in the prolong service of Hydrogen, Dehydrogenation of both the
edges was carried out. as per Temperature - time curve below.

Temperature - time curve for Dehydrogenation and PWHT

87
Dehydrogenation, Welding and PWHT for Repair of Elbow was done as per attached
procedure (Welding and PWHT was done as per QW -201.1 Section IX, ASME BPVC
which is attached below):

8” NB X Schedule 120, ASTM A53 Gr. B Seamless Pipe to 8” NB X Sch. 120, ASTM
A234 WPB Seamless Elbow.

Welding Process : GTAW + SMAW

Type : Manual

x JOINT DESIGN (QW - 402)

Groove design : As per Drawing No: P1-ES-13068, Sheet 1 of 1,Rev 0.

x BASE METALS (QW - 403)

P-No. 1 Group No. 1 to P-No. 1 Group No.1

Specification : ASTM A53 Gr. B to ASTM A234 WPB
Thickness Range : 18 mm maximum
Pipe dia Range : 2-7/8” and above

x FILLER METALS (QW - 404)

Weld metal analysis : A No. 1

Filler Metal F No. : As per QW -432.1 (SFA 5.5)
AWS No. (Class) : Electrode SFA/AWS A 5.5-96 (E 7018 B2 L)
Filler SF A5.28 /AWS A 5.28-96 (ER 70SB2 / ER515)
Size of electrode : 2.4 mm (Filler wire) for root & hot pass
2.5, 3.15, 4 mm (Electrode) for fill up and capping
Type of electrode flux : Low hydrogen, heavy coated

x POSITION (QW - 405)

Position of Groove : 2G/5G

Welding Progression : Uphill

x DEHYDROGENATION
Soaking Temperature : 400 degree C
Soaking time : 24 hours
Heating Rate : 100 degree C/hr
Cooling Rate : 100 degree C/hr
Loading/Unloading Temperature: 200 degree C

x PREHEAT (QW - 406)

Preheat Temperature : 100 - 150 O C
Inter pass Temperature maxm. : 250 O C

88
x POST WELD HEAT TREATMENT (QW - 407)
Temperature : 625O C
Soaking time : 01 Hour minimum
Heating Rate : 200 O C / hr. max
Cooling Rate : 200 O C / hr. up to 300O C,
then natural cooling under asbestos.
Loading : 200 degree C

x GAS (QW - 408)

Shielding gas : Argon
Gas consumption : 99.995 %
Flow rate : 6 to 12 liters / min
Purging gas : NA

x ELECTRICAL CHARACTERISTICS (QW - 409)

Current : DC
Polarity : Straight for GTAW
Reverse for SMAW
Ampere (Range) : 90 to 120 for GTAW
70 to 190 for SMAW

x TECHNIQUE (QW - 410)

String or weave bead : String and weave
Initial & Inter pass cleaning : Grinding & brushing
Oscillation : N.A.
Method of back gouging : N.A.
Contact tube to work distance: N.A.
Single or multiple pass : Multiple
Travel Speed (Range) : 4 to 6 cm/min for GTAW
8 to 16 cm/min for SMAW
x WELD INSPECTION
Bevel Edge : DP Test
Root weld : DP Test & 100 % radiography
Final weld : DP Test & 100 % radiography
Hardness measurement after PWHT

REPLACEMENT OF LETDOWN STATION VALVES (PIC 13A, PIC 13B & MIC 22
ISOLATION GATE VALVES):
x Size : 150 NB x 1500 # ( IBR )
x End Connection : 150 NB , Sch.120 , Butt Weld
x MOC : ASTM A 217 Gr WC 6
x Service : Super Heated Steam

Entire HP Steam line was replaced with P11 material during KEP. However three CS
gate valves were remain to be replaced. There was failure of one valve body during
operation. Hence it was decided to replace the three valves with up graded material.

89
Hence following major replacement activities were carried out:

x Cutting of existing valves.

x Weld edge preparation
x Set up & welding of new valves
x Post weld heat treatment of joints

Photograph of Letdown station showing replaced valves:

Photograph of Letdown station

90
Position of the Valves is as shown below in the attached Isometric:

Sketch for Isometric of Letdown valves

91
After welding, PWHT was carried out as per attached time- temp. curve;

Temperature - time curve for PWHT

92
Welding and PWHT was done as per QW - 201.1 Section IX, ASME BPVC procedure
which is given below:

150 NB Schedule 120, ASTM A335 Gr. P11 Seamless Pipe to 150 NB, 1500#, Sch.
120, ASTM A217 Gr. WC6 Butt Welded Gate Valve.

Welding Process : GTAW + SMAW

Type : Manual

x JOINT DESIGN (QW - 402)

Sketch : IBR Fig. No. 28 (VIII)

Groove design :Single ‘V’ Butt Weld as per Drawing No P1-ES-

13067, Sheet 1 of 1, Rev 1 ( Enclosed)
x BASE METALS (QW - 403)

P-No. 4 Group No. 1 to P-No. 4 Group No.1

Specification : ASTM A 335 P 11 to ASTM A217 Gr. WC6
Thickness Range : 18 mm maximum
Pipe dia Range : 2-7/8” and above

x FILLER METALS (QW - 404)

Weld metal analysis : A No. 3

Filler Metal F No. : As per QW -432.1 (SFA 5.5)
AWS No. (Class): Electrode SFA/AWS A 5.5-96 (E 8018 B2 L)
Filler SF A5.28 /AWS A 5.28-96 (ER 80SB2 / ER515)
Size of electrode: 2.4 mm (Filler wire) for root & hot pass
2.5, 3.15, 4 mm (Electrode) for fill up and capping
Type of electrode flux : Low hydrogen, heavy coated
x POSITION (QW - 405)

Position of Groove : 6G
Welding Progression : Uphill
x PREHEAT (QW - 406)

Preheat Temperature min. : 150 O C

Inter pass Temperature min. : 300 O C

x POST WELD HEAT TREATMENT (QW - 407)

Temperature : 704 to 760O C

Soaking time : 01 Hour minimum
Heating Rate : 100 O C / hr. max
Cooling Rate : 100 O C / hr. up to 300O C,
then natural cooling under asbestos.

93
x GAS (QW - 408)

Shielding gas : Argon

Gas consumption : 99.995 %
Flow rate : 10 to 12 liters / min
Purging gas : Argon
Gas consumption : 99.995 %
Flow rate : 6 to 10 litres / min

x ELECTRICAL CHARACTERISTICS (QW - 409)

Current : DC
Polarity : Straight for GTAW
Reverse for SMAW
Ampere (Range) : 80 to 130 for GTAW
70 to 190 for SMAW
x TECHNIQUE (QW - 410)

String or weave bead : String and weave

Initial & Inter pass cleaning : Grinding & brushing
Oscillation : N.A.
Method of back gouging : N.A.
Contact tube to work distance: N.A.
Single or multiple pass : Multiple
Travel Speed (Range) : 4 to 6 cm/min for GTAW
8 to 12 cm/min for SMAW

x WELD INSPECTION

Bevel Edge : DP Test

Root weld : DP Test & 100 % radiography
Final weld : DP Test & 100 % radiography
Hardness measurement after PWHT

94
103-D – AIR NOZZLE

103-D Top cover (Air Nozzle) was removed for internal inspection. While taking out the
Air Nozzle, it was stucked and fouling with the liner. Air nozzle was removed with the
help of chain pulley blocks with care. After removal, it was found that the liner was
slightly bulged at certain locations. Grinding was done to remove the bulging. Air Nozzle
fins were also trimmed 5 to 6 mm by grinding.

95
Other Fabrication jobs are as tabulated below:

JOB
DESCRIPTION REMARKS
NO
Replaced 116-JA discharge line flange at down stream
1
of NRV by SORF flange of size 8’’ x 150 # , MOC SS
Replaced 107-JT & JAT steam inlet valve by Increased
2
new valve of higher rating i.e.6’’ x 900 # Rating valve
Replaced 101-JT steam inlet valve by new Increased
3
valve of higher rating i.e.6’’ x 900 # Rating valve
Flange was provided at 142 CA/CB gas inlet
4
line for blinding purpose during Hydro testing.
Provided isolation valve foe the two Nos RV of
5
123-C.
Removed 123-C RV outlet line which was
6
extended to drain near 101C
1-1/2’’ x
101-F north side level trolls top isolation valve
7 1500 # CS
replaced.
angle valve
FIC 470 transmitter HP&LP tapping thread leak
8
repaired and the box provided was removed
The Ball Trap
117-J HP case Inverted Bucket Moisture Trap was a spare of
9
was replaced by new Floating Ball type Trap. PB Compressor
of Urea Plant.
Hydrogen sample collecting valve of 108-D position to
10
be changed as it is fouling
107 JA discharge valve bypass line check and if required
11
replaced because of welding leaks two times
FICV 14 Down stream line pin hole leak. Box to be
12
removed and line support to be
Modified 101-L a MDEA filter shell to develop
14
interchangeability of filter with 103-L and 104-L
Provided Mono rail arrangement for easy
15
removal of 101-F steam drum R.V.
16 Step ladder was provided for 101-F RVs
Primary Reformer front side panel plate near The plate had
17
tunnel burner was replaced bulginess.
101 JT condensing RV replacing and its exhaust line
18 For safety
was extended for safety.
19 110 CA CO2 outlet line pin hole leak was attended.

20 116 JAT steam inlet line vent was extended For safety
103 J degassing tank was connected to oil console
21 directly. The existed connection ,to lube oil discharge
line of train, was removed

96
 109-C-2A tube side outlet flange was replaced by SORF
22
flange.
127-CA/CB cooling water outlet line repair /
23
Replacement.
Provided MS Chequered Platforms as per production
24
department’s requirement
Replaced the passing steam trap as per production
25
department’s requirement.
The valves of size less than 1”, having gland leak /
26 bonnet leak were replaced by new ones as per
production department’s list.

97
 UREA PLANT

ROTATING EQUIPMENT

CO2 COMPRESSOR- HITACHI MAKE (K-1801)

OVERHAULING OF CO2 COMPRESSOR HP CASE (K-1801-2)

x Decoupled the HP case from Gear box

x Alignment readings were taken and recorded. Details follow.

x Measured the rotor position.

x Installed the hydraulic jig to dismount the coupling hub, turned the Guide at the shaft
end, attached the oil system, installed the nipple joint, and connected the flexible
tube between oil system and bracket. Poured the oil (mixing ratio: castor oil 1:
Paraffin oil 1) in pump system, gradually increase the oil pressure, at 18000
psi, coupling hub removed.

x Journal bearing pads on Free end were opened for inspection. Clearances values
Found within acceptable limit. (Clearance values were measured are given in
Table-2).

x Journal bearing pads on Gear Box side were opened for inspection. Replaced by
new one, as the same were found to have higher clearances value. (Clearance
values measured are given in Table-2).

x Thrust bearing was opened for inspection. Thickness of the thrust pads was
measured and found clearances value within acceptable limits. (Clearance values
measured are given in Table-2).

x Disassembled the gas seal labyrinth and free end side head flange.

x Prepared the jig for removal of inner casing assembly. Installed the Guide rail, and
fixed to the casing with box nut, attached the four puller bolts to the inner casing
assembly with puller jig, turned the Traveling nuts equally to remove the inner casing
assembly and confirmed the inner casing assembly was properly guided till it was
removed.

x Disassembled inner case assembly. Removed the stage diaphragms (lower side &
upper side) one by one and rotor.

x Condition of labyrinths was good however increased clearances were found on some
labyrinths.. Measured the clearance values of all stage eye labyrinths, all inter stage
labyrinths, balance drum labyrinth. (Clearance values measured are given at
Table-1).

98
x Replaced complete set of labyrinths by new one. Measured the clearance values of
all new stage eye labyrinths, inter stage labyrinths and balance drum labyrinth.
(Clearance values measured are given in Table-4).

x Gauss measurement of pads , Thrust collar, journal shaft & bearing housing were
carried out by Inspection section and necessary demagnetization was carried out by
Inspection Section.

x DP testing of pads, thrust collar and shaft journal and the same were found
satisfactory.

x Reassembled the inner casing. Attached the jigs to the casing. Put the inner casing
assembly on the guide rail, attached the special tools to casing, tightened the
traveling nut uniformly and confirmed that the inner casing assembly was fully
assembled.

x Reassembled the free end side head flange, gas seal labyrinth & bearings. Mounted
the thrust collar and checked the rotor float. Rotor float was found to be 5.38 mm.

x Prepared the jig for mounting the coupling Hub. Jig was attached to the shaft.
Turned the guide on the shaft, attached the oil system, nipple joint & flexible pipe.
Attached the dial indicator on the end of sleeve. Measured and recorded the initial
position with dial gauge. Increased the thrust pressure to 1000 psi until the coupling
hub came in contact with shaft tightly. Increased the expansion pressure to 11000
psi. Again increased the thrust pressure to 4200 psi and held for 15 minutes. Finally
the coupling was installed with expansion pressure of 15000 psi and thrust pressure
of 16000 psi. Axial travel of coupling hub was ensured to be 2.15 mm.

Travel = 2.15 mm (Design limit: 1.95 mm to 2.15 mm)

Diametral Expansion = 0.068 mm (Design limit: 0.060 mm to 0.068 mm )

x Alignment between HP Case and Gear box was checked and corrected as per OEM
reference values. Details are given in this report.

x The Coupling spacer between HP Case & gearbox was assembled.

99
Table 1: Labyrinth Clearance (Diametrical) details for HP case

Design Max. Impeller Old New Before After

Allow- eye
value Laby. Laby. O/H O/H
Description able
OD
(mm) ID ID (mm)
(mm)
(mm) (mm)
(mm) (mm)

1st stage 0.72 –

A 1.16 A1 209.87 210.60 210.63 0.73 0.86
Impeller eye 0.96
labyrinth
A2 211.96 212.65 212.74 0.70 0.84
A3 213.92 214.62 214.75 0.70 0.83
A4 215.94 216.70 216.73 0.76 0.79
A5 217.91 218.72 218.72 0.75 0.75

2nd stage 0.72 –

B 1.1 B1 183.91 184.71 184.72 0.79 0.80
Impeller eye 0.94
labyrinth
B2 185.92 186.68 186.73 0.76 0.81
B3 187.96 188.70 188.72 0.74 0.76
B4 189.96 190.70 190.73 0.74 0.77
B5 191.94 192.69 192.74 0.75 0.80

C 3rd stage 0.72 – 1.1 C1 177.93 178.67 178.73 0.74 0.81

Impeller eye 0.94
labyrinth
C2 179.93 180.66 180.73 0.73 0.80
C3 181.95 182.66 182.74 0.73 0.79
C4 183.96 184.66 184.72 0.70 0.76
C5 185.94 186.70 186.74 0.76 0.80

D 4th stage 0.72 – 1.1 D1 177.40 178.65 178.73 0.70 0.83

Impeller eye 0.94
labyrinth
D2 179.92 180.68 180.73 0.76 0.81
D3 181.94 182.65 182.74 0.71 0.80
D4 183.96 184.66 184.73 0.70 0.76
D5 185.93 186.70 186.74 0.77 0.81

100
 th 1.02 –
E 5 stage 1.4 E1 151.94 153.14 153.04 1.20 1.10
Impeller eye 1.26
labyrinth
E2 153.46 155.12 155.03 1.16 1.07
E3 155.47 157.15 157.15 1.18 1.09
E4 158.00 159.12 159.14 1.12 1.14
E5 160.01 161.15 161.14 1.14 1.10
F 6th stage 1.02 – 1.4 F1 147.96 149.08 149.13 1.12 1.12
Impeller eye 1.26
labyrinth
F2 149.94 151.08 151.04 1.14 1.10
F3 151.96 153.11 153.13 1.14 1.15
F4 153.98 155.06 155.13 1.08 1.07
F5 156.01 157.01 157.14 1.00 1.07
Impeller Old New
eye Laby. Laby.
OD ID ID
(mm) (mm) (mm)
st
1 inter 0.20 – 0.56 - 195.38 195.77 195.65 0.40 0.27
G stage 0.44
labyrinth
2nd inter 0.20 – 0.56 - 184.32 184.79 183.65 0.47 0.30
H stage 0.44
labyrinth

3rd inter 0.20 – 0.56 - 174.25 175.68 175.56 0.48 0.31

I stage 0.44
labyrinth
4th inter 0.20 – 0.56 - 167.26 167.71 167.47 0.45 0.21
J stage 0.44
labyrinth

5th inter 0.20 – 0.54 - 152.18 152.72 152.40 0.56 0.22

K stage 0.42
labyrinth

Balance 0.20 – 0.56 L1 185.05 185.62 - 0.56 -

L Drum 0.44
labyrinth

L2 187.09 187.64 - 0.56 -

L3 189.00 189.65 - 0.54 -

101
Table 2: Bearing Clearance (Diametrical Clearance) Details for HP case

Description Before Design After

PM (mm) Value (mm) PM (mm)
Journal bearing clearance on Free 0.13 0.11 to 0.14 0.13
end
Journal bearing clearance on Gear 0.17 0.11 to 0.14 0.11( Bearing
Box side Replaced)
Thrust bearing clearance 0.27 0.25 to 0.35 0.29
Observations Oil/wax deposit was found on Bearing pads & thrust pads
Spares Journal bearing pads of gear box side, All labyrinths of Impeller eye
replaced and interstage labyrinths, balance drum labyrinth.
Inspection:
DP Test Found ok
Magnetism Check Performed by Inspection section
Demagnetization Performed as per the requirements by inspection Section

PREVENTIVE MAINTENANCE OF CO2 COMPRESSOR LP CASE (K-1801-1):

x Decoupled the LP case at both ends from Turbine & Gear box.

x Alignment readings were taken and recorded.

x Journal bearing pads on Turbine side were opened for inspection. Replaced by
new one as the same were found to have higher clearances value. (Clearance
values measured are given in Table-3).

x Journal bearing pads on Gear Box side were opened for inspection. Replaced by
new one, as the same were found to have increased clearances. (Clearance values
measured are given in Table-3).

x Thrust bearing was opened for inspection. Thickness of the thrust pads were
checked and found clearances value within acceptable limits. (Clearance values
measured are given in Table-3).

x Gauss measurement of pads, Thrust collar, journal shaft & bearing housing were
carried out by Inspection section and found within acceptable limit.

x DP testing of thrust pads, thrust collar and l shaft journal and the same found ok.

x Final alignment readings were taken and recorded. Alignment between LPS –
Turbine & LP-Gearbox was checked and corrected as per OEM reference values.

x The Coupling spacer between HP casing & gearbox was assembled.

102
Table 3: Bearing Clearance (Diametrical) Details for LP Case:

Description Before Design After

PM (mm) Value (mm) PM
(mm)
Journal bearing clearance on Turbine side 0.17 0.11 to 0.15 0.15
Journal bearing clearance on Gear Box side 0.15 0.11 to 0.15 0.13
Thrust bearing clearance 0.29 0.28 to 0.38 0.33
Observations Oil/wax deposit was found on Bearing pads & thrust pads.
Spares Journal bearing pads of gear box side and HP case side
replaced
Inspection:
DP Check Found ok
Magnetism Check Found high on Journal bearing pads (North and south bearings),
thrust collar
Demagnetization Done

PREVENTIVE MAINTENANCE OF CO2 COMPRESSOR DRIVE TURBINE (Q-1801):

x Decoupled the Turbine at LP case end.

x Alignment readings were taken and recorded. Details are given in this report.

x Journal bearing pads on free end were opened for inspection. Found clearance
values within acceptable limit. (Clearance values measured are given in Table-4).

x Journal bearing pads on LP case side were opened for inspection. Found clearances
values were within acceptable limit. (Clearance values measured are given in
Table-4).

x Thrust bearing was opened for inspection. Thickness of the thrust pads were
checked and found clearances value within acceptable limits. (Clearance values
measured are given in Table-4)

x Gauss measurement of pads, Thrust collar, journal shaft & bearing housing were
carried out by Inspection section and rectified (kept below 2 gauss).

x DP testing of pads, thrust collar and journal shaft and the same were found ok.

x Final alignment readings were taken and recorded. Alignment was corrected as per
OEM reference values.

x The Coupling spacer between LP casing & Turbine was assembled.

103
Table 4: Bearing clearance for Turbine

Description Before Design After

PM (mm) Value (mm) PM (mm)
Journal bearing clearance on free end 0.20 0.18 to 0.31 0.20
Journal bearing clearance on LP side 0.32 0.24 to 0.35 0.32
Thrust bearing clearance 0.23 0.25 to 0.35 0.23
Observations Oil/wax deposit was found on Bearing pads & thrust pads.
Spares replaced Nil
Inspection:
DP Test Found ok
Magnetism Check Max. Gauss value found on journal (LP side). After
demagnetization, gauss value came within acceptable limit.
Demagnetization Done

PREVENTIVE MAINTENANCE OF GEAR BOX M-1801:

High-speed Pinion Shaft and Bearings:

x Decoupled the High-speed pinion shaft at HP case end.

x Alignment readings were taken and recorded.

x Both Pinion shaft bearings (Offset Halves Type) were inspected and found to have
higher clearance values at minor dia. Wax deposit and scattered pitting was
observed on the white metal lining, which was more prominent on the bottom half of
both the bearings. Replaced both bearings by new one. Bearings manufactured and
supplied by M/S. Kanpur Metal Works were used. (Clearance values were measured
as given in Table.5).

x Gauss measurement of shaft journal & bearing housing was carried out by
Inspection section and found within acceptable limit.

x DP testing of shaft journal & bearing housing was done and the same was found ok.

Low-speed Gear Shaft and Bearings:

x Decoupled the Low-speed gear shaft.

x Alignment readings were taken and recorded.
x Both Low speed shaft bearings (Elliptical Type) were inspected and found
clearances values within acceptable limit. (Clearance values measured are given in
Table-5).

x Gauss measurement of pads, journal shaft, thrust collar & bearing housing were
carried out by Inspection section and found within acceptable limit.

x DP checking of pads, thrust collar, journal shaft & bearing housing and the same
found ok

104
Table 5: Bearing clearance for Gear Box

Description Before Design After

PM (mm) Value (mm) PM
(mm)
Journal bearing clearance 0.17 0.12 to 0.17 0.17
on LP side
Journal bearing clearance 0.18 0.12 to 0.17 0.18
Low speed shaft
on HP side
Thrust bearing clearance 0.43 0.38 to 0.61 0.41

Journal bearing clearance 0.27 0.14 to 0.18 0.14

on LP side
High speed shaft
Journal bearing clearance 0.30 0.14 to 0.18 0.14
on HP side
Gear backlash 0.54 0.383 to 0.54
0.608
Observations Oil/wax deposit was found on Bearing pads & thrust pads.
Spares replaced Both side Journal bearings of high speed pinion were replaced
by new one.
Inspection :
DP Check Found ok
Magnetism Check Found high on Low Speed and High Speed shaft bearings.
However, bearings were replaced with new ones.
Demagnetization Done.

LUBE OIL CONSOLE, T-1801:

In view of the wax deposits observed on all the bearings, it was decided to replace the
oil Servo Prime 46 T. In all, 43 drums, each of 210 Litre capacities were used at the time
of refilling.

After removal of oil, console walls and floor were cleaned thoroughly to remove the wax
adhered to the walls and floor. One no. gauge glass was replaced.

Lube oil pump drive turbine bearing cooling water supply lines were replaced with higher
size. Tapping of cooling water was also shifted from bottom to sidewise to avoid
clogging of the line because of accumulation of debris inside.

105
 ALIGNMENT READINGS: GEAR BOX TO LP COMPRESSOR:

Dial on LP Compressor Coupling

1 Div = 0.01mm
Before PM:

RADIAL AXIAL
0.00
0.00

+0.10 R -0.29 -0.01 A +0.01

-0.19 0.00

After PM

RADIAL AXIAL
0.00
0.00

-0.25 R -0.25 +0.01 A 0.00

-0.50 +0.01

Protocol Values

AXIAL
RADIAL
0.00
0

+0.01 A +0.00
-0.25 R -0.25

+0.01
-0.50

106
ALIGNMENT READINGS: GEAR BOX TO HP COMPRESSOR:

Dial on HP Compressor Coupling

1 Div = 0.01mm
Before PM

RADIAL AXIAL
0.00 0.00

+0.17 R -0.22 +0.08 A +0.04

-0.05
+0.12
After PM

RADIAL AXIAL
0.00 0.00

-0.13 R -0.13 +0.01 R -0.01

-0.26 -0.01

Protocol Values

RADIAL AXIAL
0.00 0.00

-0.12 R -0.12 -0.01 R 0.00

+0.24 +0.01

107
HP VESSELS:

M/S. Stamicarbon inspectors were called for inspection of HP Vessels vide Work Order
No. 9920122 Dated 19/02/2007 for inspection of HP Vessels (Reactor V-1201, Stripper
H-1201 and Condenser H-1202) for a total period of 9 days including travel (7 days stay
at site).

Scope of work of Stamicarbon (As per WO)

Visual inspection:

x Visual Inspection of all the three High Pressure Equipments H-1201, H-1202 &
V-1201 from Inside and outside (wherever feasible).

x Visual inspection of all the HP Nozzles / pipe lines wherever possible.

Thickness measurement:

x Liners of all the Three High Pressure Equipments.

x Weld overlays
x Tube sheet, Tube etc.
x Any other internals like Trays, Down comer etc.

Dimensional Measurement:

x Whole diameters of reactor trays, ferrules of HP Stripper etc.

x Gap between tray and liner etc.
x Any other items as per requirement.

Eddy Current testing:

HP Stripper (H-1201)

To undertake the Eddy Current Testing of tubes of newly installed HP Stripper H-1201
from inside, including the interpretation of test results for detection of tube thickness,
internal defects of the tubes etc. Top 3.0 to 4.0 meters of all the 2600 Nos. of tubes
shall be checked from the top tube sheet.

Replacement of the old stripper by a new stripper with 2600 tubes was carried out
during March - 2002. New Urea Stripper was designed by M/s. Stamicarbon and
manufactured by Larsen & Turbo Limited, Mumbai India.

HP Carbamate Condenser ( H-1202 )

To undertake the Eddy Current Testing of selected 220 nos. of tubes of HP Condenser
H-1202 for complete length, including the interpretation of test results for detection of
tube thickness, internal and external defects of the tubes along the complete length
including tube sheet thickness area etc.

108
REACTOR V-1201

Vessel manufacturer : Foster Wheeler John Brown Boilers LTD, USA

Year of fabrication : 1972
Liner : 5 mm X2CrNiMo17.13.2 Urea Grade
Trays : 11 HE-trays (8 mm BC.01) replaced in 1997

All the nozzles at the bottom and off gas line at the top were opened including all the
steam tracing lines. The top man way over was opened using hydraulic bolt tensioner at
500-kg/cm2 pressures. The cover was shifted by mono-rail and chain block towards
cooling tower side grating area and was put on wooden sleepers. Clearance was taken
from Production that the temperature inside is suitable for vessel entry. Compressed air
was provided from the bottom end and vacuum blower hose was arranged in the top
compartment. Aluminum ladders & hand lamps were provided in each compartment and
both the domes.

M/S. Stamicarbon inspectors carried out visual and NDT examination of liners and shell
areas. The bulged liners were inspected for any abnormal increase. All J-bolts were
checked for tightness and attended wherever required.

Conclusion of Stamicarbon report is reproduced below:

The top hemi-head was re-lined during TA-2002. In the gas phase the liner and welds
show a blue grey oxide layer. Small condensation spots have been observed. The liquid
level is about 5-10 cm above the tangent line. The top tangent weld has been checked for
SIIC. No indications have been observed.

In the liquid phase the BC.01 liner is brown to dark/brown. In the top area the liner is
slightly rough and changes to smooth in the bottom area. This indicates normal uniform
corrosion. The lowest wall thickness of the liner was found in compartment 2 (about 4.1
mm). Given the corrosion rate of about 0.05-0.10 mm/year, the remaining life will still be
considerable.

Next to the top tangent weld a new BC.05 segment was replaced in 2002. This segment
is slightly rough. In compartments 3, 4, 8, 9, 10 and 11 the circumferential welds are
patched (partly or completely). These patches or inserts liners (BC.05) are grey and
slightly etched. Bulging has not been observed anymore, except for some small portion
in compartment 5.

The trays are brown; rough in the top area and changes to smooth in the bottom area.
In the top and middle compartments the thickness of the trays has decreased some 2
mm in 6 years, which corresponds to a corrosion rate of 0.17 mm/year (per side). Also,
the tray holes show considerable corrosion in the top to middle compartments. The trays
in the top to middle compartments may need replacement after some 6-8 years from
now (but future measurements will give more accurate predictions).

GENERAL REMARKS
x Additionally measure the liner wall thickness in compartments 2, 3, 4 during next
inspections.
x Keep attention for bulging of the liner during next inspections.
x Improve the insulation of the top cover and the reactor top.
x Check all J-bolts of the trays and tighten them as necessary.
109
HP STRIPPER H-1201

Vessel manufacturer: Larsen & Toubro, India

Year of fabrication: 2001/2002

Tubes : 2600 tubes (Ö31 x 3.0 mm) BC.05
Overlay : 8 mm overlay welding BC.05
Liner : 8 mm BC.05

The top and bottom covers of the HP Stripper (H-1201) were opened using “Hydra Tight
Sweeny” make bolt tensioner at hydraulic pressure of 1000 kg /cm2. The top cover was
shifted below the platform using monorail hoist and chain blocks. The bottom cover was
lowered onto the wooden sleepers.

Conclusion of Stamicarbon report is reproduced below:

A thin blue grey oxide layer covers the overlay welding and liner in the gas phase
completely, except for the areas between the strip beads. The liner and liquid inlet box
in the liquid phase are grey and slightly etched. Corrosion has not been observed in top
and bottom compartments.

The wall thickness of the heat exchanger tubes has been measured by EC-technique.
The average thickness is 2.93 mm and the minimum is 2.70 mm. The corrosion rate
could not be determined since this is the first measurement by Stamicarbon.

The differences between the Stamicarbon and Testex measurements are caused by
differences in probes, calibration tubes and test frequencies.

Some 10% of the tubes have been measured over the full length. These measurements
showed that the wall thickness was between 3.2 mm and 3.3 mm in the non-corroded
parts. Between the tubes sometimes heavy oxide deposition is present on the top
tubesheet. It is advised to remove these thick deposits since they may interfere with the
liquid divider tubes.

The tubes are smooth inside. However, about 100-200 tubes show corrosion and slight
loss of wall thickness (< 0.5 mm) inside the tube at the location of the tube sheet welds.
This is due to excessive heat input and/or lack of backing gas during manufacturing. This
corrosion may limit the life of the stripper and should be kept under attention during next
inspections.

Tube #2531 shows an internal defect just below the tube sheet weld (see photo’s). This
tube needs to be plugged (for procedure see Appendix 2). The scaling thickness inside
the heat exchanger tubes is between 0.5 and 1.0 mm.

As per the recommendation of Stamicarbon, one no. tube #2531 was plugged. Due to
lack of access, tube was not machined out as per the STAC procedure; however,
plugging was done on the tube after puncturing the same using portable flexible grinder
FF-2. 30 nos. liquid divider tubes were replaced due to higher Delta P reported by
production Deptt.

110
After inspection by production department and getting clearance, the bottom manhole
was boxed up using new “Kempchen” gasket. After the bottom manhole was boxed up,
pressure drop measurement was carried out for each tube and the same was found
acceptable. After clearance from Production, the top man way cover was boxed up
using new “Kempchen” gasket (Size: 860 mm OD x 800 mm ID x 4 mm thick with 0.5
mm thick PTFE envelop)

Manhole tightening pressures for top and bottom covers

1st tightening round….. 400kg per /cm2

2nd tightening round….. 700kg per/cm2
rd
3 tightening round…... 1000kg per/cm2
Final tightening round/checking round 1000kg per/cm2

HP CARBAMATE CONDENSER H-1202

Tubes : 1970 tubes (Ö25 x 2.5 mm) X2CrNiMoN25.22.2 (BC.05)
Liner : 7 mm X2CrNiMoN25.22.2 (BC.05)
Vessel manufacturer : Larsen & Toubro, India
Year of fabrication : 1993

The top flange of H-1202 (off gas line) was opened. Then the top cover and Bottom
cover was opened with bolt tensioner at 500 kg/cm2 hydraulic pressure and shifted from
position. The partition plates, basket, segments and rasching rings were removed.

Conclusion of Stamicarbon report is reproduced below:

The corrosion resistant surfaces in the top and bottom compartments are in good
condition. The liners show some overall corrosion (about 0.05 mm/year in the top section
and nearly nil in the bottom section). About 10% of the heat exchanger tubes have been
measured over the entire length for minimum wall thickness by EC-technique. The
average wall thickness is 2.50 mm.

The corrosion rate is nearly nil. The tubes show burn-through defects at the top and
bottom tubesheets. Two tubes (#982 and 1214) need to be plugged this TA. These
defects need permanent attention during future inspections.
Small defects were observed and need to be repaired.

Two tubes (#982 and 1214) as recommended by stamicarbon were plugged. Tube
plugging was done after puncturing the tubes using FF-2 Flexible grinder.

After inspection & clearance from production the top and bottom covers were boxed up.
Both gasket seats of the vessel were thoroughly cleaned. The top and bottom cover
were lifted and put into position, provided new “Kempchen” gaskets (Size: 839 mm OD x
800 mm ID x 4 mm thick with 0.5 mm thick PTFE envelop) and hand tightened the nuts.
The gap between two flanges of the vessel was checked and tightening was done at
following hydraulic pressures.

1st tightening round……. 250 kg/cm2

2nd tightening round…... 350 kg/cm2
rd
3 tightening round……. 450 kg/cm2
4th/final checking round….. 450 kg/cm2
Connected liquid outlet line at Condenser bottom and tightened it.

111
General repair procedure ( recommended by Stamicarbon) for small repairs in
BC.01(SS-316 L Modified) and BC.05 (2RE69)

x Clean the area with a stainless steel brush

x Remove the defect with a pencil grinder
x Clean and degrease carefully
x Reweld by GTAW, using filler wire 18005 BC.05 (25/22/2 High Mn)
x Brand names : Sandvik 25.22.2.LMn or Thermanit 25/22H
x Use HF (high frequency) start-unit
x Use stringer bead technique
x Keep the heat input low
x Interpass temperature < 150°C
x Do not apply more weld deposit than needed
x Hold the torch for a few seconds at the stop position (to protect the end-crater
against oxidation)
x Check by dye penetrant testing for surface defects
x Check ferrite content : ferrite content < 0.6%
x Clean, if necessary, the repair by washing with 10% HNO3 and rinse with chloride
free condensate. Omitting of washing with 10% HNO3 can be considered if there is
no risk of embedding iron particles in the passive
x oxide layer of the stainless steel during the repair work.

Heat exchanger tube plugging procedure recommended by Stamicarbon:

The way of plugging differs from top and bottom tubesheet.

Stamicarbon suggested:

x To use cylindrical and flexible plugs.

x To plug always the top and bottom end of the referring tube.
x A positive leak should be made in the affected heat exchanger tube to allow leak
detection in case of a leaking plug.
x Leaking tube.
x Insufficient tube wall thickness.

When to plug a tube:

x Tube to tubesheet seal weld defect.

x Tube end selectively attacked.
x No tube protrusion.
x Serious burn through defect.

112
Plugging procedure
To plug in top tubesheet (Tubehole plugging in tubesheet )
x Always plug in tube hole.
x Machine the tube end down 5 mm deeper than the bottom of the plug to install. This
is required to create a positive leak in the affected tube.
x Clean the tube hole by reaming or by grinding over the length of the plug.
x Machine the plugs, material quality equal to material of heat exchanger tube
x Clean and degrease the plug and tube hole.
x Insert the plug.
x Protect the surrounding tube ends very careful with help of the old PTFE bushing.
This is extremely important at the top tube ends of a H.P. Stripper. ]
x Weld the plug in two layers, GTAW (material quality filler wire equal to aterial of heat
exchanger tube; rod diameter 1.2 mm to 2.0 mm); start / stop points staggered to
each other.
x After each layer of welding perform a penetrant test, an air soap test and a ferrite
check.

To plug in bottom tubesheet (IFFCO followed this procedure for plugging tube on
top and bottom tubesheet after discussions with )

x Always plug in tube end.

x Machine the tube end down until 50% of the tube to tubesheet weld metal is
removed.
x Clean the tube inside by reaming or by grinding at the location where the plug will be
positioned.
x Determine the inner tube diameter.
x Machine the plugs, material quality equal to material of heat exchanger tube
x Clean and degrease the plug and the inner tube hole.
x Insert the plug.
x Protect the surrounding tube ends very careful.
x Weld the plug in two layers, GTAW (material quality filler wire equal to material of
heat exchanger tube; rod diameter 1.2 mm to 2.0 mm); start / stop points staggered
to each other.
x After each layer of welding perform a penetrant test, an air soap test and a ferrite
check. General remarks regarding the execution of the plugging
x In order to be sure that the execution of the plugging is correctly welded we strongly
advice to perform a welding and welders qualification. For that reason we advise to
simulate in a workshop the conditions as present in the HP equipment.
x To simulate position, tube protrusion, including the limitations as a result of the
presence of the surrounding tube ends.

Examine this plug by macro examination of two cross sections, perpendicular.

113
 TUBE PLUGING SKETCH OF HP VESSELS SUGGESTED BY
M/S STAMICARBON

Dismantling of Existing CO2 Spray Cooler & Erection of New CO2 Spray Cooler
Dismantling:

This involved removal of existing Spray Cooler vessel including various piping and
structural platforms connected to CO2 Spray cooler as well as pipelines above
CO2Spray cooler for creating space to facilitate the removal of CO2Spray cooler in
assembled condition. Drawing No. P2-BS-04089 (For Existing H-1104) & Drawing No.
TF/IFFCO/32 (For New H-1104) were referred.

Following activities were involved for carrying out the dismantling:-

x Provided blinds in the existing pipe lines for hot work permit to carry out job i.e. C-1
(30”x150# ), C-2 (30”X150#), C-3 (8”x150#) C-4 (18”x150#) etc.

x Made temporary scaffolding around the vessel to facilitate removal and erection job.
The same was removed after completion of job.

x Disconnected all the piping connected to the vessel viz. C-1 (30”x150# ), C-2
(30”X150#), C-3(8”x150#), C4 (18”x150#) and bypass line (12”x150# )

x Hydronyl Hold down Plate (Part no.143) & Hydronyl Support ring (Part No. 144) were
removed from the old vessel for reuse. (These were re-fixed in new vessel after
erection.)

114
x Distributor Tray (Part No.200) was also removed from old vessel. The same was re-
fixed in new vessel.

x Demisters & Grids (Part No. 141) were removed. (These were re-fixed in new
vessel.)

x Structural members & platforms, and valves etc were removed. Ladders were
removed after shifting the vessel on ground.

x Exposed the vessel base plate from PCC/RCC cover, released the base pipes (8
nos. of SS-304 material) etc.

Vessel was cut from bottom of the shell.

x Old Vessel was lifted by Kobelco crane.

The details of lifting arrangement are as under:

Name of Crane : Kobelco
Boom Length : 42.7 Mtr.
Crane Radius : 25.7 Mtr.
Boom Angle : 56.7 Deg
lifting Weight : 7.67 Ton( as per the screen of Crane)

x The base plate was grouted and concrete was filled up to 2 feet height. This
foundation was required to be removed by Power Chisel i.e. pneumatic & electric
chisel Preparation of foundation to erect new vessel.

x All the pipelines connected to Co2 Spray Cooler removed after proper marking
before dismantling, so that identification of the same could be done easily at the time
of re-erection.

Erection of New CO2 Spray Cooler:

New Cooler skirt was placed on the same foundation bolts on which the old vessel was
kept. Modified plates were fabricated and placed on the foundation bolts to
accommodate the dimension of the base ring of the skirt of the new vessel. New vessel
skirt base ring was welded with the 8 nos. foundation plates. After installation of new
Spray cooler skirt shell, the Skirt Base Ring was covered under concrete. Dimensions &
elevations were checked to decide the actual length of the skirt so as to match the
nozzle elevations after placement of the new vessel on the skirt shell. The activities
involved in erection of new CO2 Spray cooler are given below.

Following activities were involved for carrying out the above job :-

x Leveling of floor by Power Chisel for removing concrete & and other fouling.
x Fixing and grouting of modified base plate.
x Welding of two lifting lugs.
x After erection, leveling of the equipment was maintained to achieve it within plumb, 1
mm per mtr.
x Installation of Skirt shell on foundation.

115
x Full circumferential cutting of skirt shell ( 2150 mm O.D. X 8 mm Thick) was done
after confirming the elevation requirements of the vessel. Skirt Shell was cut by
600mm to adjust vessel nozzle elevations.
x Installation of main vessel on foundation using Kobelco Crane.
x Welding of main shell dish end with skirt shell.
x Fixing up Hydronyl Hold Down Plate (Part no.29) & Hydronyl support ring (Part No.
30A) inside the vessel.
x Fixing up distributor Tray (Part No.30B) inside the vessel.
x Fixing up Demisters & Grids (Part No. 28) inside the vessel.
x Fabrication and Re-erection of removed pipelines and structures.

Dismantling of Existing 20” NB CS Vent Stack & Erection of New SS Vent Stack:

Dismantling of 20” NBx Sch STD. CS Pipe , Fabrication & Erection of 20” NB SS304L
Sch.10S Piping from elevation 129.23 mtr. to Elevation 175.50 mtr. was carried out.
This job was performed by M/S. ganesh Engineering, Ahmedabad against WO No.
9920369 Dtd. 30-03-2007 . Details of the complete job are given below: (Reference
Isometric Drg No. P2-DL-13168 sheet 1/1 Rev 0 ).

Activities involved:-

x Prefabrication of the 20” NB Sch 10 pipe line was done at site in three segments of
18 metre each. Root was TIG welded and final fill up with Arch welding. 10 %
radiography was carried out and repairs were attended prior to lifting the pipe
segments.
x Suitable lifting lugs were provided on new pipe segments for ease of rigging.
x Erected Scaffolding at site at two locations to facilitate cutting, removal and erection
of pipeline job as per site requirement.
x Cutting of existing 20” NB x Sch STD. CS Pipe line after elbow at 129.93 mtr
elevation & 8” NB tapping as shown in the isometric drawing Isometric Drg No. P2-
DL-13168 sheet 1/1 Rev 0 into three segments. Cs pipe was cut into three
segments. Each segment was removed separately using the two nos. winch in
tandem starting from the top segment.

x The lowering and lifting arrangement is shown in schematic view.

x Erection of prefabricated piping was done by Winch arrangement. Initially top pipe
segment was lifted and placed at site to meet the elevation requirement of the pipe
top end. Subsequently middle pipe segment was erected and placed in position.
Lastly, the bottom pipe segment was cut into the exact length requirement and
placed in position. The existing miter bend at the bottom was repaired from inside
due to poor penetration, prior to installing the pipe. Thickness of existing fabricated
bottom elbow was checked and found O.K.
x Field welds were DP tested after root run and 100 % radiographed after complete
welding. Repairing of weld joints was carried out based on NDT results.
x Fabrication of pipe supports and 8” branch pipes as per site requirement.
x One no. thermowell and one no. sample collection points were provided on 20 “ NB
pipe near 4 ata steam drum elevation.
x Construction of special components of piping like trunnion & guide supports were
made out of C.S. and S.S pipes/ plates.

116
117
LP VESSELS:

V-1101 (CO2 Knock out Drum):

Manhole was opened for internal inspection. Demister pads were found intact in
position. After getting clearance from production department the vessel manhole was
boxed up using new gaskets

V-1102 (NH3 Suction Filter):

Top cover was opened for internal inspection. Condition of Filter cloth was not
satisfactory hence changed the filter cloth (synthetic nylon, nyfil-80). After getting
clearance from production department the vessel top cover were boxed up using new
gaskets.

V-1103 (NH3 Suction Vessel):

Manhole was opened for internal inspection. The condition of longitudinal and
circumferential weld joints was found satisfactory. After getting clearance from
production department the vessel manhole and top cover were boxed up using new
gaskets

V-1202 (Rectifying Column):

Top cover and Manhole were opened for internal inspection. Condition of trays was
found satisfactory and intact in position. Welded the distributor plate support as it was
found damaged. After getting clearance from production department the vessel manhole
and all connected pipe lines were boxed up using new gaskets.

V-1203 (L. P. Absorber):

Perforated support grid just below top hand hole was displaced from its position and
was found distorted. The same was repaired and placed back in position after providing
additional support angle. Condition of weld joints of the vessel was found satisfactory.
After getting clearance from production department, the vessel manhole was boxed up
using new gaskets.

V-1207 (L. P. Scrubber):

Grating condition was satisfactory. Welded the distributor plate support. After getting
clearance from production department the vessel manhole and all connected pipe line
were boxed up using new gaskets.

V-1301 (2ND Disrober):

Nozzle condition was found satisfactory. One loose clamp of the tray was tightened.
After getting clearance from production department the vessel manhole was boxed up
using new gaskets.

118
V-1351 (Hydrolyser):

Fasteners of trays were found intact in position. Three nos. of bolt/nuts of steam inlet
flange were provided. One of Clamping loose bolt of steam inlet pipe to shell was
tightened. After getting clearance from production department the vessel manhole was
boxed up using new gaskets.

V-1352 (First Disrober):

Weld joint condition was found satisfactory. One missing clamp of the tray was provided.
All internals were found intact in position. After getting clearance from production
department the vessel manhole was boxed up using new gaskets.

V-1418 (Pre Evaporator Separator):

Tube to tube sheet weld condition was found satisfactory condition. Impingement cone
was found in intact condition. After getting clearance from production department, the
vessel manhole was boxed up using new gaskets.

V-1423 ( 1 ST Stage Evaporator Scrubber ):

one no of missing J Bolt provided After getting clearance from production department,
the vessel manhole was boxed up using new gaskets.

V-1424 and H-1424( 2nd Stage Evaporator Separator):

Flushing arrangement (Sparger) was provided on top dome. 1 ½ “ NB (SS 316) pipe
was bent into four pieces. The flange end connection of pipe pieces was made for ease
in removal and installation inside the vessel. 1.5 mm dia holes at 6” pitch on complete
circumference of pipe were provided. Orientation of hole was kept at 30q and 90q
alternatively towards inside wall of vessel. After getting clearance from production
department the vessel manhole was boxed up using new gaskets .

V-1501 (4 ATA STEAM DRUM): (Boiler No. GT-1664)

All the internals were found intact in position. Demister pads were found intact in
position. Condition of all weld joints was found satisfactory. Steam drum loop was
hydraulically tested at 11 kg/cm2 on 30.4.07, and the same was witnessed by IBR
Inspector. Also, IBR Inspector witnessed testing of Safety Relief Valves at test bench.
The set pressure was kept 7.12 kg/cm2 as per IBR guide line.

After getting clearance from production department, the vessel manhole was boxed up
using new gaskets.

V-1502 (23 ATA Steam Drum):

All the internal fittings were found in good condition. After getting clearance from
production department, the vessel manhole was boxed up using new gaskets.

V-1503 ( 9 ATA Steam Drum):

Nut of the south side U-clamp of inlet steam header was found loose, tightened it.
Welded the clit support of BFW line. After getting clearance from production department,
the vessel manhole was boxed up using new gaskets.
119
V-1811 (Ist Stage Separator):

Demister pads were found intact in position. Vortex breaker was found intact in position.
Overall condition of the vessel was found satisfactory. After getting clearance from
production department, the vessel manhole was boxed up using new gaskets.

V-1812 (IInd STAGE SEPARATOR):

Demister pads found intact in position. Vortex breaker found intact in position. Overall
condition of the vessel was found satisfactory. After getting clearance from production
department, the vessel manhole was boxed up using new gaskets.

V-1813 (IIIrd STAGE SEPARATOR);

Demister pads found intact in position. After getting clearance from production
department, the vessel manhole was boxed up using new gaskets.

TANKS:

T-1301 (Ammonia Water Tank):

Weld joints and nozzle condition was found to be satisfactory. Minor bulging was noticed
on the bottom plate of the tank, as has been found in the past. After getting clearance
from production department, the vessel manhole was boxed up using new gaskets.

T-1301-A (New Ammonia Water Tank):

All weld joints and nozzle condition was found satisfactory. After getting clearance from
production department, the vessel manhole was boxed up using new gaskets.

T-1401 (Urea Solution Tank):

Weld joints condition was found satisfactory. Stiffener provided on top roof plate was
found intact in position. Minor bulging was noticed on the bottom plate of the tank, as
has been found in the past. Minor bulging was noticed on the bottom plate of the tank,
as has been found in the past. After getting clearance from production department, the
tank manhole was boxed up using new gaskets.

T-1401-A (New Urea Solution Tank):

Nozzles and weld joint condition was satisfactory. After getting clearance from
production department, manhole was boxed up using new gaskets.

T-1501 (Condensate Tank):

Condition of Weld joint was found satisfactory. Condition of the patch plate and its weld
joints found satisfactory. After getting clearance from production department, manhole
was boxed up using new gaskets.

120
CLEANING AND HYDROJETTING OF HEAT EXCHANGERS:

The Hydrojetting job was awarded to M/s Delux Hydroblasting services, Mumbai vide
W.O. No. 16/00194/9916832 dated 16/03/2005. Following heat exchangers were
opened for cleaning by hydro jetting. After cleaning, exchangers were boxed up with
new gaskets.

x Surface condenser (H-1815)

x Main lube oil coolers (H-1814-A)
x Main lube oil coolers (H-1814-B)
x Flash tank condenser (H-1421)
x First Evaporator (H-1422) with DM water.
x First Evaporator condenser (H-1423)
x Second Evaporator (H1424) with D.M. water.
x Second Evaporator I condenser (H-1425)
x Second Evaporator II condenser (H-1426)
x First Evaporator Final condenser (H-1420)
x Recirculation heater (H-1204) with D.M. Water
x L.O.coolers of P-1102-A/B/C
x L.O. coolers of P-1201-A/B/C
x Reflux condenser (H-1352)
x Pre-evaporator condenser (H-1419)
x 3rd Inter Stage Cooler, H-1813 of Hitachi Train: Tube bundle pulled out after soaking
the same with special chemical solution arranged by laboratory Section , Despite of
soaking, heating and pulling was required to be done due to heavy fouling of the
bundle inside the shell.
x CCS - II Cooler (H-1207) : Tube bundle was pulled out as there was leakage noticed
from the shell side face of the tubesheet. New gasket was provided and the bunle
was inserted back after hydrojetting.

RELIEF VALVE OVERHAULING AND TESTING:

Following RV’s were removed, overhauled and tested on valve test bench by M/s Flotec
Engineering Services, Surat vide W.O.No. 9920319 .

SR. SET RESET

RV NO. EQPT. NO. & NAME
NO. PRESSURE PRESSURE
Liquid Ammonia line from
1 RV-1101 A 31Kg/cm2 27.9 Kg/cm2
H-1102 to V-1102
Liquid Ammonia line from
2 RV-1101 B 31Kg/cm2 27.9 Kg/cm2
H-1102 to V-1102
Ammonia suction Vessel
3 RV-1102 A 31Kg/cm2 28 Kg/cm2
(V-1103 )
Ammonia suction Vessel
4 RV-1102 B 31Kg/cm2 28 Kg/cm2
(V-1103 )
5 RV-1103 A P-1102 A discharge 150 Kg/cm2 135 Kg/cm2
6 RV-1103 B P-1102 B discharge 150 Kg/cm2 135 Kg/cm2

121
7 RV-1103 C P-1102 C discharge 150 Kg/cm2 135 Kg/cm2
Liquid Ammonia line from
8 RV-1106 A Ammonia Plant to Ammonia 31Kg/cm2 27.9 Kg/cm2
filter.
Liquid Ammonia line from
9 RV-1106 B Ammonia Plant to Ammonia 31Kg/cm2 27.9 Kg/cm2
filter.
Liquid Ammonia line (hot)
10 RV-1107 A 31Kg/cm2 27.9 Kg/cm2
before Ammonia filter
Liquid Ammonia line (hot)
11 RV-1107 B 31Kg/cm2 27.9 Kg/cm2
before Ammonia filter
Cold Ammonia line from
12 RV-1108 A 31Kg/cm2 27.9 Kg/cm2
Ammonia storage tank to H1102
Cold ammonia line from
13 RV-1108 B 31Kg/cm2 27.9 Kg/cm2
Ammonia storage tank to H1102
Liquid ammonia line from Atm.
14 RV-1110 Ammonia .storage tank to H- 31Kg/cm2 27.9 Kg/cm2
1102
15 RV-1129 A 4 ata Steam Header 6 Kg/cm2 5.4 Kg/cm2
16 RV-1129 B 4 ata Steam Header 6 Kg/cm2 5.4 Kg/cm2
17 RV-1130 24 ata steam header 26 Kg/cm2 23.4 Kg/cm2
18 RV-1181 K-1801 final discharge 177 Kg/cm2 160 Kg/cm2
RV-1184
19 H-1102 outlet NH3 outlet 6 Kg/cm2 5.4 Kg/cm2
(CCS-I)
20 RV-1201 A V-1201 off gas line 165 Kg/cm2 150 Kg/cm2
21 RV-1201 B V-1201 off gas line 165 Kg/cm2 150 Kg/cm2
22 RV-1201 C V-1201 off gas line 165 Kg/cm2 150 kg/cm2
23 PSV-1201 A P-1201 A suction line 8.5 Kg/cm2 7.5 Kg/cm2
24 PSV-1201 B P-1201 B suction line 8.5 Kg/cm2 7.5 Kg/cm2
25 PSV-1201 C P-1201 C suction line 8.5Kg/cm2 7.5 Kg/cm2
26 RV-1202 A V-1202 off gas line LP System 6 Kg/cm2 5.4 Kg/cm2
27 RV-1202 B V-1202 off gas line LP System 5.7 Kg/cm2 5.13 Kg/cm2
28 RV-1202 C V-1202 off gas line LP System 6 Kg/cm2 5.4 Kg/cm2
29 RV-1203 P-1201 A suction line 8.5 Kg/cm2 7.5 Kg/cm2
30 RV-1205 P-1201 A discharge 165 Kg/cm2 148 Kg/cm2
31 RV-1206 P-1201 B discharge 165 Kg/cm2 149 Kg/cm2
32 RV-1206 P-1201 C discharge 170 Kg/cm2 154 Kg/cm2
33 RV-1209 V-1203 Vessel 10 Kg/cm2 9 Kg/cm2
RV-1221
34 P-1204 discharge to H-1203 16.5 Kg/cm2 15 Kg/cm2
(CCS-II)

122
35 RV-1224 C.W from utilities 6 Kg/cm2 5.4 Kg/cm2
36 RV-1301 RV of V-1301 6 Kg/cm2 5.4 Kg/cm2
37 RV-1351 RV of V-1351 24 Kg/cm2 22 Kg/cm2
38 RV-1351 A RV of P-1351 A 10 Kg/cm2 9 Kg/cm2
39 RV-1351 B RV of P-1351 B 10 Kg/cm2 9 Kg/cm2
40 RV-1352 RV of V-1352 6 Kg/cm2 5.4 Kg/cm2
41 RV-1501 A 4 ata Steam Drum 7.12 Kg/cm2 6.75 Kg/cm2
42 RV-1501 B 4 ata Steam Drum 7.12 Kg/cm2 6.6 Kg/cm2
43 RV-1503 23 ata Steam 25 Kg/cm2 23 Kg/cm2
44 RV-1504 9 ata Steam Drum 12 Kg/cm2 10.8 Kg/cm2
45 RV-1901 Ist stage discharge of K-1801. 7 Kg/cm2 6.3 Kg/cm2
46 RV-1902 II stage discharge (Hitachi) 28 Kg/cm2 26 Kg/cm2
47 RV-1903 K-1801 IIIrd stage discharge 111Kg/cm2 100 Kg/cm2
48 RV-1904 H-1811 First stage gas cooler 7 Kg/cm2 6.3 Kg/cm2
H-1812 Second stage gas
49 RV-1905 7 Kg/cm2 6.3 Kg/cm2
cooler
50 RV-1906 H-1813 Third stage gas cooler 7 Kg/cm2 6.3 Kg/cm2
51 RV-1913 Ejector system of Q-1801 0.20 kg/cm2 0.18 kg/cm2
52 RV-1914 Ejector system of Q-1801 0.20 kg/cm2 0.18 kg/cm2
53 RV-1916 23 ata Steam extraction 28 Kg/cm2 25 Kg/cm2
54 RV-1917 4 ata Steam exhaust 4 Kg/cm2 3.6 Kg/cm2
55 RV-NH3 RV to NH3 Plant Line 85 Kg/cm2 77 Kg/cm2

PRILL TOWER ID FAN K-1401/1:

During visual inspection, all the blades of this fan were found to be badly damaged.
Hammering marks were observed on the blades. It was decided to perform complete
overhauling of this fan and to replace the blades.

The scaffolding was provided in the fan cell. Replaced all the blades with new ones and
set the blade angle 100 with the help of protractor spirit level. All blade locking bolts of
K-1401/2, 3, 4 were loosened and blade angle was set at 100. The blades were
tightened.

The roller bearing (22220 EK , SKF make) were removed and replaced with Cooper
make Split type bearing (308 EX SI SRS and 308 EX GR SRS). V-belts (SPC 4000,
1set = 3 nos) were replaced.

Alignment of fan motor w.r.t. fan was carried out and the all V belts were fully tensioned.

Scaffolding was removed after completion of job. All internal and external surfaces were
cleaned by power tool and painting was carried out with 1 coat of epoxy primer and 2
coats of epoxy paint.

123
PRILL TOWER ID FAN K-1401/2,3 and 4:

Preventive maintenance of all these fans was carried out. Bearings were inspected.
Found OK. Fresh grease provided and boxed up. The blades were checked for
tightness.

V-belts (SPC 4000, 1set = 3 nos) were replaced. Alignment of fan motor w.r.t. fan was
carried out and the all V belts were fully tensioned.
All internal and external surfaces were cleaned by power tool and painting was carried
out with 1 coat of epoxy primer and 2 coats of epoxy paint.

INLET AIR FAN (K-1701) & EXHAUST AIR FAN (K-1702):

Bearings of both fans were opened, cleaned and checked. Found in good condition and
hence boxed up. Fresh lube oil charged. Rotor and casing of fans were cleaned. Bigger
size fan pulley of K-1701 was replaced by smaller size fan pulley. Fan pulley and motor
pulley of K-1702 were also replaced. Alignment of fan pulleys of K-1701 & K-1702 was
checked and corrected. Painting of internal surfaces of casing carried out.

Inlet air fan Discharge Damper and exhaust air fan Suction Damper were replaced with
new ones procured from M/S. C.Doctor India Pvt Ltd, Ahmedabad vide PO No. 9919807
Dtd. 27.11.2006.

The condition of the fabric of the expansion joints of K-1701 Discharge duct and K-1702
Suction duct was found to be deteriorated. The fabrics of these joints were replaced
which were procured from M/S. Urja Products Pvt Ltd vide Po No. 8820526 Dtd.
10.4.2007.

FLUIDIZED BED COOLER (H-1701) :

Fluidized bed cooler, dust Silos and cyclone separators were opened for inspection.
After inspection and cleaning, the same were boxed up.

CONVEYOR SYSTEM :

UREA PRODUCT CONVEYOR (M-1403) :

Preventive maintenance of Gear box was carried out. Oil seals were replaced. 12 nos of
plain return rollers were replaced with rubber lined return rollers. Skirt rubber pads were
replaced wherever found damaged. Alignment was checked and coupling bush were
replaced before boxing up the couplings.

LINK CONVEYOR (M-1419) :

The condition of the belt was deteriorated. Top rubber cover was found peeled off from
many locations. Belt was replaced by new one made of 4 ply Nylon, Grade HR-T1 &
width 800 MM.

All plain return rollers were replaced with rubber lined return rollers. Skirt rubber was
replaced wherever found damaged. Preventive maintenance of Gear box was carried
out. Alignment was checked and coupling bush were replaced before boxing up the
couplings.
124
PRILL COOLING SYSTEM LINK CONVEYOR (M-1421) :

Belt condition was found satisfactory. The joint of the belt was repaired by M/S. JK
Rubber. Preventive maintenance of Gear box was carried out. Alignment was checked
and coupling bush were replaced before boxing up the couplings.

DUST CONVEYOR SYSTEM (M-1703):

One rotary valve (M-1703/1) was replaced by new one. Bearing condition was found ok.

BUCKET CHANGE OVER MECHANISM (M-1401 A/B):

Bucket change over mechanism was cleaned. Pulley of the mechanism checked and
found OK. Replaced the Bearings (6314 & 6020) of mechanism.

SCRAPPER (M-1402 -1/2):

Scrapper arms were inspected for tightness. Checked scrapper floor slit plates. Cleaned
scrapper surface by power tool and applied one coat of epoxy Primer and two coats of
epoxy paint. Covered the scraper surface with aluminum sheets to prevent corrosion.
Fluid Couplings of scrapper arm was checked and found OK. Fluid coupling oil was
flushed. Checked condition of V belts (B 69, 1set = 4nos.) and tightened the belts. V-
belts of M-1402/2 replaced with new ones. Alignment checked and tightened belts.
Removed oil from scrapper main gear box, flushed the oil and opened the inspection
window of both the gear boxes and maintained the oil level. No abnormality was
observed during inspection of the gear box.

CHEMICAL CLEANING OF PLATE TYPE HEAT EXCHANGER (H-1206)

During shut down 2007, we had carried out chemical cleaning of plate type heat
exchanger in presence of M/s Alfa Laval (I) Ltd, engineer.

Prior to shutdown, one no. old SS vessel was modified to suit the site requirements. The
vessel was erected at site. Ne no. old pump ( P-1106, removed from service in the past)
was overhauled and installed at site. Suitable pipe line fabrication was carried out using
6 “ NB piping and fittings. Pipe layout was made in such a way that forward as well as
reverse flow conditions can be established as desired by Alpha Laval engineer for
effective chemical cleaning. Suitable NRVs, Strainers and isolation valves were
provided. Arrangements were also made for heating the vessel from outside using
Electric Heating Coils using SR Equipment. Since the circulation was continued for long
hours, the temperature of the solution reached 60 Deg C of its own and hence SR
Heating coiles were not required to be switched on.

The chemical cleaning procedure was given by M/s Alfa Laval. The details of Chemical
cleaning procedure is described below

x The indicative reading viz. Flow Rate, Temperature Program and Differential
Pressures shall be noted prior to taking the Plate Heat Exchanger for cleaning. Plate
Heat Exchanger to be taken out of duty, by closing all inlet and outlet valves and by
placing blind flanges wherever necessary.

125
x Plate Heat Exchanger to be drained completely. Arrangement and connection of
Pump, Hoses and interconnecting flanges etc. to be done and an open circuit from
Dosing Tank to Plate Heat Exchanger on one of the circuits (Primary or Secondary)
and back to be done. Arrangement done to have flow in counter current as well as
normal flow direction.

x Plate Heat Exchanger to be flushed with soft Water (at room temperature) on both
the sides in reverse condition i.e. flow from outlet to inlet. (DM Water was circulated
in Reverse Direction for one hour.)

x One of sides (Primary or Secondary) to be closed out while the second is taken in
circuit. (Only CW Circuit was taken up for Chemical cleaning)

x Hot Water / Condensate at around 70 Deg. Cent. to be circulated in the Plate Heat
Exchanger for 1 hour. (Due to hot ambient conditions, the Heating elements (SR
Equipment) were not switched on as temperature was achieved(60 Deg C, which
was considered sufficient as per Alpha Laval Engineer) due to continuous circulation.

x 6% - 8% Caustic solution to be circulated in the Plate Heat Exchanger for 3 hours.

The inlet should always be from bottom and outlet from the top.(46% Concentrated
NaOH was issued from Utility and was diluted to 6.57 % concentration DM Water
level was filled up in the tank equivalent to 3500 kg. 500 Kg Caustic Solution(46 %)
was added.

500 X 0.46 = 230 Kg NaOH

230 / 4000 X 100 = 5.8 % Concentration)

x Neutralization of Plate Heat Exchanger by draining (initially) and then flushing till pH
value of water coming out of Plate Heat Exchanger is around 7-8. (DM Water was
used for flushing the exchanger from both the directions i.e. Counter current as well
as regular flow direction, each for 15 minutes. pH value was ensured using pH
measuring strips)
x Chemical Cleaning of Plate Heat Exchanger using patented Alfa Laval Chemicals by
circulating the same for 3 hours (IFFCO may use sulphamic acid 8-10 %). The
solution should be prepared using 1:2 (Alfa Laval Cleaning Chemical: Water)
proportion of Chemicals provided by Alfa Laval at around 60 Deg. Cent. (IFFCO
used sulphamic acid procured vide PO No. 9920202 Dtd. 12.02.2007 from M/S.
Impex Corporation)
x The inlet should always be from bottom and outlet from top. (Sulphamic Acid was
used for circulation in Reverse direction initially. Flow was maintained for 1 hour. 300
Kg of Sulphamic acid was added in 3500 kg water. Concentration was maintained at
8.5 %.)
x Neutralization of Plate Heat Exchanger by draining (initially) and then flushing till pH
value of water coming out of Plate Heat Exchanger is around 7.
x The indicative reading viz. Flow Rate, Temperature Program and Differential
Pressures shall be noted to judge the cleaning of Plate Heat Exchanger. ( The
operating conditions were checked and found satisfactory after plant startup.)

126
STEAM /CONDENSATE JOBS:

Following Steam/Condensate jobs were carried out.

SR.
DESCRIPTION
NO.
PICV-1181 d/s drain I/V was passing and replaced by new one (Gate valve, ¾”
1
x 800# )
60 ata battery limit I/V ( main ) u/s drain I/V was passing and replaced by new
2
one (Gate valve, ¾” x 800# )
PICV-1128 u/s drain I/V was passing and replaced by new one (Gate valve, ¾”
3
x 800# )
P-1401A/B common condensate flushing I/V was passing and replaced by new
4
one (Gate valve, ¾” x 800#).
5 FI-1128 Sensing line to be shortened (relocated)
6 replaced P-1408 both condensate flushing valve ( ball valve, 1” x 800#)
7 Changed the gasket to attend the trap body leak (near P-1408 motor fan side )
Steam tracing ‘T’ joint was found leak, tightened with new taflon tape( Near
8
LRCV-1201 d/s condensate I/V)
P-1701-A Suction strainer condensate flushing I/V was passing and replaced
9
by new one (Gate valve, ¾” x 800#).
P-1401-B condensate flushing 1st I/V was passing and replaced by new one
10
(Gate valve, ¾” x 800#).
P-1401 A discharge condensate flushing I/V was passing and replaced by new
11
one (Ball valve, ¾” x 800#)
Leak was found inside the Insulation box near H-1201. Welded and after DP
12
check found Ok.
F-1206 – B drain I/V hard to operate and replaced by new one (Gate valve, ¾”
13
x 800#).
H-1206 C.W. common drain I/V hard to operate and replaced by new one
14
(Gate valve, ¾” x 800#).
P-1201 suction condensate flushing 1st I/V was passing and replaced by new
15
one (Gate valve, ¾” x 800#).
16 V-1418 condensate level pot level glass was found leaking, replaced the gasket
Flushing arrangement (Sparger) was provided for H-1424 ( Dome inside
17
flushing )
H-1502 channel cover leak , opened the channel cover and changed the
18
gasket by new one
H-1422 dome flushing I/V was passing and replaced by new one (Gate valve,
19
¾” x 800#).
20 HPF to NH3 to V-1201 first flange was found leak, changed the gasket.
Needle valve tapping, H-1208 downstream line was leaking and replaced by
21
new one (¾” x 800#).
22 To attend the vibration of LICV-1502A line, tighten the support fasteners.
Tracing o/l (3rd from V-1201) of H-1201 liquid out let line flange was found
23
leak, replaced the gasket.
Flash tank ejector 4 ata steam condensate outlet trap bottom cover was found
24
leak, replaced the gasket.
4 ata steam to H-1205 1st I/V was passing and replaced by new one (Gate
25
valve, ¾” x 800#).
Steam I/V valve near Autoclave was passing and replaced by new one (Gate
26
valve, ¾” x 800#).
127
 Autoclave weep holes steam I/V was passing and replaced by new one (Gate
27
valve, ¾” x 800#).
Melt return line HICV-1422 bypass I/V was passing and replaced by new one
28
(Gate valve, 2” x 800#).
29 Trap was provided u/s of HICV-1401 ( for M-1401 )
Condensate to melt return I/V u/s bottom flange was found leak, replaced the
30
gasket.
Pinhole leak was found near trap out let condensate line (HICV-1401), Welded
31
and after DP check found Ok.
32 RV-1201 A/B steam flushing inlet union leak. Rerouted the line

PROCESS JOBS :

Following Process jobs were carried out.

SR.
DESCRIPTION
NO.
1 H-1811 channel cover was leaking , replaced the gasket
C.W. In/Out to I/V/s Q-1814 bearing, to be shifted from bottom to top. Rerouted
2
the line
P-1102B dis. line I/V was passing and replaced by new one (Gate valve, 4” x
3
900#).
P-1201C I st Dis. I/V. was passing, lapped the body seat and replaced the
4
bonnet.
5 P-1201C Suction I/V bonnet was found leak and replaced the gasket
Needle valve tapping, H-1208 d/s. was leaking and replaced the valve (½” x
6
800# ).
P-1204A mech. Seal was attended and replaced the old pump with
7
reconditioned pump.
Hot NH3 supply RV u/s of MOV was passing and lapped the valve seat, tested
8
and fixed in the position.
3 way valve of N/C ratio u/s flange was found leaked and replaced the flange
9
gasket.
R.V. -1201 B was Passing badly. Overhauled the RV , tested and fixed the
10
position.
Pin hole leak was found in P-1352 A pump’s drain I/V ( at u/s of discharge I/V )
11
line. Welded it and after DP check found ok.
12 H-1201 sample 1st I/V is passing
13 P-1204 – B suction flange and pump casing leak
H-1207 channel cover flange was leaking, opened the channel cover, removed
14 the tube bundle, cleaned it from inside and outside, finally boxed up with new
gasket.
P-1102-A packing flushing sample I/V was passing , opened, lapped the body
15
seat and finally boxed up
P-1102-B packing flushing sample I/V was passing, opened , lapped the body
16
seat and finally boxed up.
17 HICV-1208 d/s sample I/V was broken, replaced it with new one (¾” x 2500#).
18 RV’s tail header drain line ( ½” ) replaced to ( 1” ) and provided I/V (¾” x 800# ).
H-1425 Condensate flushing line was loosed from thread ( C R Side ),
19
tightened with new taflon tape.
H-1425 Condensate flushing I/V not operatable and replaced by new one (Gate
20
valve, ¾” x 800#).
128
 P-1401 A/B suction drain I/V was passing and replaced by new one (Gate
21
valve, ¾” x 800# ).
P-1352A Dis. drain I/V (at u/s of dis. I/V) was passing and replaced by new one
22
(Gate valve, ¾” x 800# ).

GLAND REPAIR JOB :

Following Gland repair job were carried out by M/s Amrutha Engineering, New Panvel
vide W.O. No. 14/00750/9920053 dated 18/01/2007.

SR.
DESCRIPTION
NO.
1 Q-1801 60 ata chest valve g/l ( D M water plant side )
2 PICV-1129 u/s drain ( both line ) I/V is passing and its trap u/s I/v g/l.
3 PICV -1810 body steam coil I/V g/l
4 H-1205 drain steam injection I/V g/l
5 FIC-1302 ( 4 ata to V-1301 ) sensing line root I/V g/l
6 9 ata drum pressure tapping I/V g/l
7 4 ata steam to H-1205 1st I/V is passing ( 3rd floor ) & g/l
8 H-1202 top steam tracing I/V g/l. ( C. R. Side )
9 Steam tracing to PRCV-1201 I/V g/l near HICV-1202
10 Stem tracing I/V g/l at the bottom of H-1203 near CO2 inlet line
11 23 ata flushing to V-1351 level troll i/v g/l.
12 FIC-1352 by pass I/V flange leak and g/l.

129
 OFFSITES & UTILITY
PLANT

COOLING WATER PUMP ( P-4401/A):

Both the journal Bearings were checked and found okay.

The clearances were checked & following are the readings:

Sr. Design Actual

Description
No. Value Value (AM)
1 Total Float of the pump 10 mm 8.0 mm
2 Radial bearing Clearance coupling end 0.20 mm 0.16 - 0.18 mm
3 Radial bearing Clearance free end 0.20 mm 0.18– 0.20mm

Total Axial Float of the pump is 8.0 mm.

Both side glands of pump was repacked with 25 mm PTFE packing (454801214).
Coupling of pump with gear box was cleaned, checked and found O.K.

Alignment between pump and gear-box were checked, greasing is done & box-up the
coupling.

Elliott Turbine Q-4411:

Lufkin Gear-Box Maintenance:
Opened the GB Top cover by using RT-760 crane (from Admn. Side), checked the
gearwheel and pinion found O.K.
Removed the journal bearings and DP checked, found O.k.
The clearances were checked & following are the readings:

Gear wheel front brg. Clearance 0.26mm

Gear wheel rear brg. clearance 0.28mm
Pinion front brg. clearance 0.16mm
Pinion rear brg. clearance 0.19mm

130
Elliott Turbine Maintenance:

x Both the journal Bearings and thrust bearing were DP checked and found okay.
x Oil Cooler tubes were cleaned by Hydro jetting. Oil Cooler shell side was cleaned by
diesel.
x Fresh oil was charged in Governor (SERVO-PRIME 32).
x Oil console was drained; cleaned and fresh oil charged (SERVO-PRIME 32)
Approximately 620 ltrs of Oil was used.
x Main oil pump suction strainer was cleaned & boxed up.
x Auxiliary oil pump two nos suction strainers (336002060) were replaced & boxed up.
x The surface condenser was opened. Hydro jetting was carried out and boxed –up.
x The clearances were checked & following are the readings:

Sr.
Description Actual Value
No.
1 Axial Float on the turbine 0.25mm
2 Radial bearing Clearance coupling end 0.30mm
3 Radial bearing Clearance Governor end 0.23mm

Alignment readings between Gear Box & Cooling Water Pump

00 10.81

R A

+0.16 10.73 10.85

-022

10.81
-0.06

By Slip Gauge

131
Turbine to Gear box Alignment readings:

178.06
00
A
R
178.14 178.23
-0.33 -0.21

178.11
-0.52

COOLING WATER PUMP ( P-4402):

Preventive Maintenance of Urea Cooling Water Pump:

a) Coupling between the pump and motor was decoupled.

b) Both the journal bearings were checked & found okay.
c) The clearances were checked & following are the readings.
Free end side : 0.17 to 0.21 mm , Coupling side : 0.18 to 0.24 mm
d) Both the bearing housing was flushed with oil & fresh oil (SERVO-PRIME 68)
charged.
e) Radiator cooling water line opened and box-up after cleaning of radiator.
f) Coupling oil paper replaced and new grease filled.
g) The Discharged line NRV was opened for attending passing. The seal ring
(Neoprene rubber) was found damaged. This was local purchased from M/s
Bhavana Enterprises, A’bad and installed.
Checked the alignment between pump & motor and following are the readings:

0.0
0.00

R A

0.55 +0.40 -0.02 0.0

0.95 0.0

132
Triveni Turbine Q-4403:

The Preventive Maintenance was carried out on Triveni Turbine. The following are the
observations and action taken.

1. Speed governor, main steam valve, relay, over speed trip bolt, Main Oil Pump,
governor were overhauled and assembled back.
2. The hand oil pump was dismantled, cleaned and boxed up.
3. Journal bearings were checked, polished and assembled.
4. Exhaust Line Relief Valve was replaced with “cross-by” new RV.
5. The 10” gate type isolation valve installed on exhaust line was replaced with
“AUDCO’ make new gate valve.

BEARING CLEARENCES:

SR.NO POSITION CLERANCE

1. Front 0.18 / 0.19mm
2. Rear 0.21 / 0.23 mm

Rotor thrust float: 0.30 mm

Triveni Gear-box:

Pinion front bearing cl. 0.18 /0.19 mm

Pinion rear bearing cl. 0.18 / 0.19 mm
Gear wheel front end 0.21 mm
Gearwheel rear end 0.21 mm
Backlash 0.40 mm

COOLING WATER PUMP ( P-4403):

1. The foundation base frame of cooling water pump was planned for replacement
due to heavy corrosion on the frame.

2. Due to non-availability of dimensional drawing of base frame, only MS channels

were kept ready for fabrication of base frame.

3. The complete Pump Assembly (Weight: 6.6 Tons) was lifted with Kobelco crane
placed at other end of cooling water sump. The boom length was 110 feet and
radius was @ 27 mtrs during rigging of pump. The capacity of crane was 24 tons at
this radius & boom length.

4. After removal of pump, the base frame dimensions were picked-up & foundation
frame level was transferred by water column for final leveling.

5. New bolts were grouted for base frame.

133
6. Meanwhile, the pump was taken for preventive maintenance. The following
activities were carried out on pump.

¾ The journal bearings were opened, cleaned and checked for clearances.
¾ The coupling side journal was found damaged & the same was replaced. The
rear bearing was found ok.
¾ Journal bearing front cl. 0.15mm
¾ Journal bearing rear end cl. 0.16mm
¾ The rotor float was measured as 0.24 mm.
¾ Both side gland was repacked.

7. After readiness of RCC job for base frame, the frame was lowered on foundations
& level was maintained with previously transferred level by water column.

8. The pump was erected on foundation frame by Kobelco crane and alignment was
carried out. The alignment readings are as under ;-

13.40
0.00

R A

-0.32 +0.20 13.50 13.50

-0.12 13.55

COOLING WATER PUMP ( P-4401 / C):

(a) Checked the journal bearing Clearance at both ends

(b) Coupling end 0.17 to 0.20mm
(c) Free end 0.22mm. The bearing was replaced. The existing cl is 0.14 to 0.15 mm
(d) The rotor float was measured as 0.35 mm.
(e) Cleaned & greasing done after coupling.
(f) Checked the alignment.

0.00 5.0

R A

-0.30 +0.20 5.0 4.80

0.0 5.00

134
COOLING WATER PUMP ( P-4401 / D) :

(a) Checked the bearing Clearance at both end

(b) Coupling end 0.18 to 0.20 mm
(c) Free end 0.17 to 0.20 mm
(d) The rotor float was measured as 0.60 mm.
(e) Cleaned & greasing done after coupling.
(f) Checked the alignment:

0.00 5.75

R A

-0.42 0.38 5.70 5.75

0.0 5.70

COOLING WATER PUMP ( P-4404-E) :

(a) Coupling float was checked after de-coupling and observed as 0.14 mm
(b) The pump to motor alignment was checked and corrected.
(c) Both bearing top half opened. Both side bearing checked, found in healthy
condition.
(d) Bearing housing cleaned and fresh oil (SERVO PRIME 68 ) charged.
(e) The following are the alignment reading

0.00 0.00

R A

-0.11 -0.03 +0.08 +0.04

-0.14 +0.12

135
Raw water Pump P-4101 B:
The corroded base frame was replaced with MS base Frame. After removal of old base
frame, all foundation bolts were found in broken condition.

Preventive Maintenance of BFW Turbine Q - 5111:

a) Cleaned the Radial & Thrust bearings.

b) Checked the radial clearances of bearings using lead wire.
c) Alignment readings were checked.
d) The oil cooler covers were opened and hydro- jetting was carried out.
e) Cleaning / replacing oil filters and oil in the oil console.
f) Checked the oil lines, water line for leaks.
g) Suction filter of the MOP was cleaned.
h) The oil console was cleaned and fresh oil (servo-68) was charged.

Alignment Readings: Pump To Turbine

0.0 0.0
Error!
R A

-0.30 0.12 0.0 0.06

-0.21 0.06

Clearance Details :

Sr. Design Actual

Description
No. Value (mm) Value(mm)
1 Axial Thrust 0.28 - 0.33 0.21
2 Radial bearing Clearance coupling end 0.13 - 0.18 0.21
3 Radial bearing Clearance free end 0.13 - 0.18 0.29

136
BFW Pump P-5111:

a) Preventive maintenance was carried out on Pump.

b) Bearing top halves were removed.
c) Coupling end and free end bearing clearances were measured using lead wire.
d) Bearing pads were cleaned and polished using green rouge.
e) Bottom halves of the bearings were assembled, clearance checked & recorded.
f) Oil filter was removed, cleaned and re-installed.
g) Oil cooler was opened and cleaned by Hydro jetting.
h) Oil of the console was drained, cleaned and boxed up.
i) Very little chocking was observed in the BFW suction strainer with compared to
previous shut-downs. It was cleaned and assembled.

Sr.
Description Actual Value(mm)
No.
1 Axial Thrust 0.22
2 Coupling end Bearing Clearance 0.15
3 FE Bearing Clearance 0.16 to 0.17

BFW Pump ( MOTOR DRIVEN ) P-5112:

Preventive Maintenance:

a) Couplings between the Pump and Gear Box were decoupled after recording the
necessary match marks.
b) Initial alignment readings and axial float were measured and recorded.
c) Bearing top halves were removed.
d) Coupling end and free end bearing clearances were measured using lead wire and
recorded.
e) Bearing halves were cleaned and polished using green rouge.
f) DP check of all bearings and coupling hubs and found ok.
g) Thrust collar and the bearings assembled, clearance checked and recorded.
h) Oil tank & filter was cleaned.
i) Oil cooler was opened and cleaned.
j) Suction filter of the pump was cleaned.
k) Gear Box oil was replaced with new oil. (Servo -68)
l) Gearbox cooler cleaned.

137
Preventive Maintenance of Gear Box:

a) Coupling between the Gear Box and Motor was decoupled after recording the
necessary match marks.
b) Initial alignment readings and axial float were measured and recorded.
c) Bearing top halves were removed.
d) Coupling end and free end bearing clearances were measured using lead wire and
recorded.
e) Bearing halves were cleaned and polished using green rouge.
f) Gears were taken out, cleaned and inspected.
g) Gears were re installed. Backlash was checked and noted.
h) Bearings were assembled, clearance checked and recorded and boxed up.
i) Gear Box cover O rings were replaced.
j) Coupling is aligned with reference to match mark.

ALIGNMENT DATA :

Gear Box & Boiler Feed Pump

0.0 0.0

R A

0.24 -0.03 0.02 0.01

0.22 0.01

By inside micrometre

138
Alignment reading between Gear Box to Motor

By slip gauge

0.00 0.0

R A

0.12 0.10 0.01 0.01

0.22 0.02

Clearance Details of P-5112:

All the values are in mm

Sr. Actual value

Description
No. (mm)
1 Radial bearing clearance coupling end 0.15
2 Radial bearing clearance free end 0.14
3 Gear wheel front bearing clearance 0.18
4 Gear wheel rear bearing clearance 0.17
5 Pinion gear front bearing clearance 0.17
6 Pinion gear rear bearing clearance 0.17
7 Gear wheel thrust float 1.60
8 Pinion Gear thrust float 2.76
9 Gear backlash 0.50
10 Axial thrust of pump (after adjustment) 0.30

F. D. FAN TURBINE Q-5113 & F.D. FAN:

1. Between turbine and fan coupling rubber pads were checked and found OK.

2. Gearbox cover is opened and checked the gears and brings. The same was
cleaned; D.P. test was carried and assembled back.

3. Light dust was observed at main oil console. The same was cleaned and refilled with
new oil (SERVO PRIME 68).

4. The sentinel warning valve was checked and found OK.

5. The air dampners were attended for proper working. The Fan inlet air mesh screen
was changed.

6. The clutch oil (Servo Transfluid-A) was replaced.

139
 BEARING CLARENCES:

SR.
POSITION CLERANCE REMARKS
NO
1. Pinion thrust end journal bearing 0.13 Same bearing re-used
2. Pinion opp thrust end journal bearing 0.15 Same bearing re-used.
3. Gear wheel thrust end journal 0.15 Same bearing re-used.
bearing clearance
4. Gear wheel opp thrust end journal 0.16 Same bearing re-used.
bearing clearance
5. Fan turbine end roller bearing 0.13 Same bearing re-used.
clearance
6. Fan motor end roller bearing 0.12 Same bearing re-used.
clearance

Pinion thrust float: 0.23

Gear wheel thrust float: 0.21

ALIGNMMENT BETWEEN GEAR BOX AND FAN:

FD Fan to Gear box: Clamp on fan & Dial on Gear Box:

0.00
0.00

R A

+0.09 +0.18 +0.01 +0.02

+0.03
+0.22

STEAM LEAK & FABRICATION JOBS:

1. All Steam leak jobs attended as per the Shutdown job list. Seven nos ½” x 800 # &
two nos ¾” x 800# passing valves were replaced on Steam Traps lines on stem
header.
2. ¾” dia steam line was replaced at piller no 39.
3. One 3” x 150 # tapping was arranged for Chlorination system for Narmada water
project.
4. New cooling tower Water sample line root isolation valve( Size : ½” ) was replaced
with new 1” gate valve.
5. Fabrication jobs in Compressor house area was carried out as per job list.
6. Complete SS 304 patching was welded on Hogging ejector of Q-4411 to avoid
external corrosion on shell.
7. Weld joints of by-pass lines of discharge line of P-4401/C & D was reinforced with
SS 304 Pads.

140
RUBBER BELLOW REPLACEMENT
The following rubber bellows were replaced on suction & Discharge lines of Cooling
Water Pumps.
24” rubber bellows on discharge line of P-4404/E Pump.
32” rubber bellows on suction line of P-4401/C.
32” rubber bellows on suction line of P-4401/D.

BHEL BOILER JOBS (F-5111) :

BHEL BOILER INSPECTION:

Boiler was inspected by Boiler Inspector in open condition on 23.04.2007 & Hydrotest
was carried out at 89 Kg/cm2 pressure on 27.04.2007 and witnessed by Boiler
Inspector.
The nozzle seats of all three safety relief valves were in-situ machined by hand lapping,
overhauled & assembled. The RVs were floated on 30.04.2007 and their readings were
as follows.
Popping Pressure Reset Pressure
Description
Kg/cm2g Kg/cm2g
Drum Rear R.V. 72.0 69.80
Drum Front R.V. 69.0 66.70
Super Heater R.V. 64.60 61.80

The following safety valves were overhauled, tested with nitrogen medium at test bench.
The services of M/s Flotec Engg Services, Surat were taken for overhauling of Relief
valves. (Ref W.O. 9920391 dtd 23.03.2007)
F.D.Fan turbine Exhaust line 4 ata Header R.V.
14 ata Automisation line R.V.. This RV setting has been increased to 16.5 ata as per
modified burner requirements.
40 ata Soot Blower Header R.V.
40 ata steam line RV of Q-5114.
BFW turbine exhaust 4 ata R.V.
LSHS supply pump turbine exhaust R.V.
Steam drum connected all first and second isolation valves gland packing were
repacked. The services of M/s.Amrutha Engineering, New Panvel were taken for valve
gland repacking job. (Ref : WO No 9920053 dtd 18.01.2007)
As per Five Year action plan of RLA Study 2005 of BHEL Boiler, The replacement of
Primary & Secondary Super Heater Coils and Associated headers was due in Year
2007. Due to long delivery period of materials indented on M/s BHEL Triuchy, Re-
Examination study was carried out on Primary & Secondary Super Heater Coils and
Associated headers through M/s TBW ltd, Pune. (Ref WO No 9920340 dtd 16.03.2007).
for assessment of metal health. Preliminary report indicates no further deterioration in
the metallurgy of Coils.

141
 All inspection window glasses were cleaned and replaced where ever found broken.
All dampers of air duct were checked and made free by greasing for smooth
operation.
LRB-1 was taken for complete overhauling. The nozzle of lance tube of LRB was
found burn out. The feed pipe & lance tube (146012459210) were replaced and
assembled.
The seal air line NRVs were checked and found working normal.

RE - GENERATIVE AIR PRE-HEATER H-5111:

1) General condition of Cold End & Hot End baskets was found ok.
2) Hot End & Cold End side circumferential seals and radial seals were checked and
found healthy.
3) Both End Rotor Bearings (Spherical self aligning, withdrawal sleeve 22330 CCK
/C3 / W 33 ) housing were open for inspection. The condition of bearings were
found o.k. Boxed-up and fresh oil (C :100 , 5 ltrs) charged.
4) RAH Gear Box with sprocket with electric motor was replaced. Re conditioned
gearbox lying in stores was used. (Code : 335702001)
5) Bearings Clearances were checked by feeler gauge and this is the readings :
Clearance hot end bearing : 0.012”(0.30mm)
Clearance cold end bearing :0.008”(0.20mm)
6) Steam nozzle for swivel type soot blower of RAH unit was cleaned. The coupling
bolts of motor of this unit was replaced. Coupling pad (L-95) was also replaced.
7) The Cold end baskets were observed burn-out. The complete set (12 Nos) of cold
end baskets (141110503330) were replaced by opening the top cover of RAH unit.
Cooling Tower Jobs:

1) The wooden structure of all Cooling tower cells was inspected by M/s Paharpur
Cooling Tower Pvt Ltd, Vadodara and a committee of IFFCO Officials duly
nominated by GM. Scheduled preventive maintenance is planned over a period of
three years for revamping of cells as recommended by M/s PCTL.
2) The cooling tower distribution valves were attended for smooth operation and
isolation. One valve of Ammonia tower -1 (Lab side) was replaced.
3) The horizontal distribution header on Ammonia Cooling Tower was coated with
Corrosion Protection coating “ Regina-900” through M/s United Engineers,
Vadodara. (Ref : WO No : 9920545 dtd 17/04/2007)
4) The 52” dia under ground pipe interconnecting old & new cooling tower sumps was
epoxy painted from inside. Metal shot blasting & spray painting was used to carry
out this job. M/s Ashish Enterprises, Vadodara was engaged for execution of this
painting job (Ref : WO No 9920485 dtd 23.03.2007)

142
DM PLANT JOB:

(1) S-1 & S-2 tank outlet & Drain valve diaphragm were replaced.
(2) The diaphragms of all five SMB units inlet lines were replaced.
(3) The Degasser tower sump was opened and all first valves were attended.

PAINTING JOBS CARRIED OUT ON:

(1) Cooling water return header on the top of new cooling tower.
(2) All safety valves exhaust cylinders.

143
 B & MH PLANT

RECLAIM MACHINE ( M - 2116 )

Reclaim machine was taken for overhauling. Overhauling was carried out in the
supervision of M/s EMTICI, V.V. Nagar against PO No.: 9920259 dtd 01/03/2007. The
following major jobs were carried out:

Overhauling of Bucket Elevator Assembly

The following activities were carried out after thorough inspection of complete bucket
elevator assembly:

x Chain links were inspected by rotating the complete assembly. Damaged Circlips
were replaced at scattered locations based on their condition.
x Buckets were found in good condition.
x Bucket elevator drive shaft and top shaft bearings were inspected and were found in
good condition.
x Take-up unit was overhauled - complete set of Cone Washer replacement ( 28 nos.)
& checking of bearings, shaft & sprockets was carried out.
x Bucket elevator assembly was rotated and links & pins were lubricated.

Overhauling of scraper chain Assembly

The following activities were carried out after thorough inspection of complete scraper
chain assembly.

x The scrapper blades were removed during service on as and when required basis.
There were 43 blades installed on the scrapper chain. In order to rearrange the
scrapper blades, three nos. blades were installed on the chain so that distribution of
the blades on the chain could be uniformly maintained as four blades followed by
one blank. Total 46 nos. blades are installed on the chain.
x The scrapper blades were rearranged so that equal gaps are left out between the
blade missing areas.
x Complete chain was dismantled and taken out for the purpose of inspection and
cleaning. Chain was reassembled in position after thorough inspection. No
abnormalities were detected during examination of the chain and its components.
x Proper tightening and tack welding of nuts to avoid looseness during running.
x Replaced the Main Boom chain tightening device (take-up device) spring washers (
complete set consisting of 14nos. washers) and tightened the chain as per
requirement.
x Greasing of bearing of take-up unit of scraper chain was carried out.
x Tail end side sheave pulleys- two nos. with bearings were replaced .

King Post Assembly

Inspection and checking of King post Rollers at bottom end were found ok and filled its
housing by grease. Top end rollers were degreased.

144
Link conveyor

Pivot assembly of link conveyor was replaced with hardened pin and square block. Pin
and block were surface hardened by Nitriding.

Link conveyor tail end pulley bearings were greased.

Head end pulley was removed from position, its shaft was machined at the north side ,
remachined to required dimensions, replaced both the plummer blocks alongwith
bearings.

The gear box of link conveyor was taken up for complete overhauling.

Cleaning & over hauling of return rollers of Link conveyor carried out. All the carrying
rollers were replaced. 5 nos, return rollers were also replaced. Skirt sealing system
checked & adjusted.

Thorough cleaning of accumulated Urea inside the supporting structure of Link

conveyor belt carried out. Painting of the structure was also carried out. Grills of the
walk way towards South side were partly replaced as per the condition.

Traveling Gear box

Preventive maintenance of the gear box was carried out. Coupling bush were replaced
with new one. Oil was flushed. SS coupling guard was fabricated and installed. Gear
box coupled with motor after alignment.

Slewing Gear box

Slewing Gear box which was procured from M/S. Elecon against PO No.
9919535 was replaced. Also, the base plate for the gear box as well for the
drive motor were replaced in view of corrosion of motor base and also due
to the the distortion of the bolt holes/threads of gear box base plate. 12
teeth pinion, hub and pins were replaced.

Main Drive Gear box

Coupling bush of main drive gear box (FC 20) were replaced with new one. Plummer
block bearing was cleaned, checked and greasing was done. Main drive Gear box
coupled and alignment done. Fluid coupling oil- Servo Prime 32 Qty: 13.5 Litres ,
replaced

Duplex chain of main drive was replaced with Diamond Make BS Chain procured from
M/S. Industrial Chain Concern, Chennai against PO No. 9920129. Jockey pulley for
tension adjustment of duplex chain was replaced.

Main gear train

Replaced the main drive shaft and main drive gears (02nos.) Pinions could not be
installed due to non-availability of required backlash. Old pinions were placed back and
the new pinions were taken up for Profile cutting at M/S. Tech Drive, Ahmedabad so
that they can be replaced later on at the earliest. Replaced the pinions after profile
cutting appx. 10 days after shutdown.
145
Replaced Idlers Pin –02nos with extended length as compared to original length as
given below:

Original Length of the pin: 347 mm

Modified length of the new pin: 375 mm

Centre distance between the shafts was carried out. The following readings were
measured:

Centre Distance between Main Drive Shaft and first idler: 374.2 mm.
Centre Distance between first idler and second idler: 372.5 mm
Centre Distance between second idler and Bucket Elevator Shaft:375.3 mm.

All bearings were replaced with new one.

Scraper blades were synchronised with bucket elevator .

Other jobs

Thruster oil replaced and brake shoes checked.

Cardium compound provided on wire rope of hoisting mechanism.

Complete greasing carried out at all points of bearings of Reclaim machine.

Complete cleaning and painting of Reclaim machine carried out.

After completion of overhauling “no load” and “load” trial of Reclaim machine was
carried out in the presence of engineer of EMTICI and the machine was found working
satisfactorily. Machine was handed over after inspecting the limit switch.

Parts replaced in Reclaim machine

The following parts were replaced during overhauling:

A) MAINDRIVE

Main Drive Shaft & Housing 1 set

Main Drive Shaft Male Housing Needle Bearing NA 4824 4Nos
Boom Shaft Female Housing Needle Bearing NA 4824 4Nos
Main Drive Tension Jockey Pulley 1No
Main Drive Tension Jockey Pulley Needle Bearing NA 4908 2Nos
Duplex Chain for Main Drive 1No
Driving and driven sprockets for duplex chain of main drive 1 Set
Taper Roller Bearing for outer end of Scraper and Elevator
Shaft (One Each) SKF 33019 2Nos
Idler Shaft Pin 375 mm Long 2Nos
Spur Gear for Shaft of Scraper 1No
Spur Gear for Shaft of Bucket Elevator 1No

146
B) BOOM HOISTING AND ELEVATOR LIFTING DRIVE

Bottom Boom Hoisting Pulley 2Nos

Scrapper Blades 4Nos
Pin of Scrapper Blade’s Sprocket 10Nos
Boom Tail Pulley Spring washer 14Nos
Bucket Elevator Take-up Assy. Spring washer 2 sets 28Nos

C) SLEWING DRIVE

Slewing Gear Box Sr. No. WHG 31775 Model CVS 280 1No
Hub for Slewing 1No
Gear Pinion for Slewing 1No

D) LINK CONVEYOR DRIVE

Conveyor Pivot Link Bracket 1No

Head Pulley Plummer Block NTN 2Nos
Return Rollers 1No
Carrying Rollers 16Nos

PREVENTIVE MAINTENANCE OF PACKER SCALES

Replaced the Packer scale no. 10A & 10B with PBL make Machine. These packer
scales were procured against PO No. 9918971 Dtd. 19.4.2006 From M/S. PBL,
Vidhyanagar.

Following preventive maintenance jobs were carried out in the Packer Scales i.e.
Packer scales No. 1, 2,3,4,7 & 8.

Over hauling of coarse and fine feed gate assembly. Bearings were replaced.

Repairing of doors.

Over hauling of bottom flapper assembly. Bearings were replaced.

Servicing of all cylinders.

Overhauling of sack grip assembly. Bearings were replaced. Sack grip belts- 2no and
springs- 4 nos. were also replaced on each sackgrip assembly.

Alignment of stabilizer plate.

Overhauling of bucket assembly. Bearings and rubber packings were replaced.

2 nos.Toggle bearings of bucket assembly and 2 nos. toggle bearings of Load cell fork
were replaced.

Calibration of packer scales.

Cleaning and painting of all Packer Scales.

147
STITCHING MACHINES:

All the Stitching machines were completely overhauled.

Following spares were replaced in all the stitching machines:

Needle
Looper
Pressure Foot
Throat Plate
Feed Dog

Also needle bar, looper holder, pressure bar, pressure bar spring regulator knob, thread
Eyelet assembly, tension disk and thread cutter were also replaced in the stitching
machines as per the requirements.

PLANT TRANSFER CONVEYOR M-2110:

Inspection of Gear-box is done and checked the alignment between gearbox and
motor.
Oil flushing of gearbox is carriedout and new Oil is filled in the gearbox.
All the coupling rubber bushes replaced with new bushes.
All damaged Impact rollers, Carrying rollers, return rollers and self aligning rollers were
replaced.
All pedestal bearings of snub pulley, head pulley, tail pulley and gravity pulley checked
and greasing done.
Servicing of Head pulley Brush Roller was Carried out.
Repairing of Conveyor belt joint was carried out through M/S J. K. Rubber Industries.
Complete cleaning and painting of structure done.

FRESH UREA SHUTTLE CONVEYOR M – 2112:

Following jobs were carried out:

Replaced the existing worm drive gearbox with helical power saving Gear-box with new
coupling. This gear box was procured against PO No. 9918469 Dtd. 10.2.2006.
Complete Base frame was replaced after preparing foundation by civil section.

Coupling was done after proper alignment.

All noisy and damaged carrying , guide and return rollers replaced with new rollers.
Replaced 400 no. carrying rollers with new rollers .

Greasing done in all brgs. of head pulley, tail pulley, snub pulley and gravity pulley.

Complete cleaning of conveyor structure done.

M-2112 conveyor Tripper Gear box overhauled and realigned with motor. Checked it’s
drive chain.

Gravity take up weight box was badly corroded , so replaced with new SS Weight box.

148
RECLAIM CONVEYOR M-2117:

Following jobs were carried out:

Replaced the existing worm drive gearbox with new Helical power saving Gear-box.
This gear box was procured against PO No. 9918469 Dtd. 10.2.2006. Complete base
frame was replaced. Coupling was replaced with new and Coupling done after proper
alignment.

Replaced the Full length of belt of width 800mm in place of existing 750 mm.

All damaged and noisy return rollers, carrier rollers , guide rollers and impact rollers
replaced with new rollers.

Replaced the bed plate below the carrying rollers, where ever it was found damaged.

Gravity take up weight box was badly corroded , so replaced with new SS Weight box.

Complete greasing of all bearings of head pulley, tail pulley, snub pulley and gravity
pulley done.

BAGGING FEED CONVEYOR M-2121:

Following jobs were carried out:

Replaced the Gear box with repaired gearbox. Coupling and bushes were checked.
Gear box oil and coupling rubber bushes were replaced. Coupling was done after
proper alignment.

Nylon brush near head pulley was replaced.

Air cylinders overhauled.

Complete skirt board sealing system repaired and replaced damaged skirt blocks.

Replaced all damaged and noisy Return rollers, carrier rollers , guide rollers and belt
tracking rollers.

Complete greasing of all pedestal bearings done.

Complete cleaning and painting of structure done.

BAGGING HOPPER FEED CONVEYOR M – 2122:

Following jobs were carried out:

Replaced the complete gearbox with new Gear box .New foundation was made by Civil
section.

Coupling rubber bushes and gearbox oil was replaced.

Complete cleaning and painting of gear box done.

149
Coupling was done after proper alignment.

Arrangement for hoisting the gearbox was fabricated.

Diverter plate of hopper no. 3 and 4 overhauled.

In order to remove the Tripper of M-2122 , chutes were suitable modified and fixed at
one place.

Complete length of conveyor belt was replaced . For this purpose, used belt of M-2117
conveyor was used.

Skirt rubber with inner rubber sheet replaced.

.All return rollers, guide rollers and carrying rollers replaced by new rollers.

Complete greasing in all bearings done.

CONVEYOR M - 2122 A/B:

Following jobs were carried out:

Both gear boxes preventive maintenance done. Oil seals of gear box were replaced.
Checked the alignment and replaced the coupling rubber bushes.

Replaced the Gearbox oil with new .

Replaced the Skirt rubber.

Complete greasing in all pedestal bearings done.

DUST CONVEYOR:

Following jobs were carried out

Gear box overhauled, replaced the coupling rubber bushes and oil with new.
Coupling was done after proper alignment.

All damaged return rollers replaced.

All carrying rollers attended for free operation.

New skirt rubber with inner rubber sheet provided.

Complete greasing of all bearings done.

150
SLAT CONVEYOR M-2124 ( 1 to 8 & 9,10):

Following jobs were carried out :

Replaced the Slats and Slat conveyor chain of slat conveyor No. 10A with new one.

Gear Box of all the slat conveyors were undertaken for preventive maintenance.
Coupling bush were replaced. Gear Box oil was replaced. Gear Box painting was
carried out.

Gear Box Slat Conveyor No. 8 was replaced including motor.

Base structure of Gear Box of Slat Conveyor no. 4 was replaced due to high corrosion.

Coupling was done after checking alignment.

Complete greasing and servicing of all links and pedestal bearings.

Conveyor adjusting mechanism servicing was performed for all conveyors.

All Slats and chain of the damaged bag conveyor on platform were replaced. Its gear
box was undertaken for preventive maintenance and coupling bushes were replaced.

Cleaning and painting of all slat conveyors.

WAGON LOADER, TRUCK LOADER AND FLAT CONVEYOR M-2142:

Gear box of all the conveyors were subjected to preventive maintenance. Coupling bush
were replaced. Oil was replaced.

PAY LOADER CONVEYOR M-2113:

Following jobs were carried out.

All the carrying and return rollers were replaced with new ones.

Skirt frame was replaced with new skirt rubber and inner rubber sheet.

Overhauling of the gear box was carried out. Coupling bushes were replaced.

Replacement of gearbox oil and checking of alignment was done.

VIBRATING SCREEN:(A,B,C&D):

Following jobs were carried out on the Vibrating Screen,

Replacement of Mild steel spacing frame with Stainless Steel discharge domes with
cascade arrangement were replaced for Vibrating Screen no. A, C and D. This was
procured from Pennwalt against PO No. 9919119 dtd. 1.7.2006.

151
In order to suit the discharge spouts of new frames of the vibrating screens,
modifications were required to be carried out for proper discharge of urea on M-2121
Belt. Angles of all the spouts were required to be modified in the new assemblies as
they were not matching the site requirements.

All the screens were cleaned thoroughly. All the screen gaskets/ V seals were replaced.

Complete overhauling of Vibrating Screen no. B was also carried out.

Cleaning and painting of frame and structure for all the screens was carried out.

152
 AMMONIA PLANT

The following major inspection activities were performed in Ammonia Plant.

1. Inspection of primary reformer, catalyst tubes and risers with various NDT
Techniques. Details are given at Annexure-1 to 5

2. Automatic ultrasonic scanning of all the Catalyst and Riser tubes of primary
reformer after one year of operation, first time after revamp-III. Details are given at
Annexure-2

3. Visual inspection of equipments.

4. Inspection of steam drum (GT-1632) and its related pipelines and equipment based
on RLA study action plan.

5. Ultrasonic flaw detection on selected weld joints of critical pipelines and

equipments. Details are given at Annexure-6

6. Thickness measurement of various equipment was carried out .Details are attached
at Annexure-7

7. Thickness measurement of various pipelines was carried out .Details are attached
at Annexure-8

8. Measurement of residual magnetism at various parts of rotating equipments and

demagnetization of the same wherever required. Details are given at Annexure-9

9. Insitu metallography of selected equipment and pipelines were carried out. Line no.
HS-2H-12” (from steam drum to LT steam super heater coil) has shown presence
of micro cracks at the grain boundaries on parent metal just at the outlet of steam
drum and Line no. SG-1-12” (from Methanator to 114-C) has shown presence of
creep cavities & initial stage of cracking and approaching 3rd stage of creep
damage on the parent metal of one elbow. Both the lines will be inspected at more
locations to check its condition during next turnaround. Detailed summary of
observations and microstructure analysis is given at Annexure-10

10. Magnetic Particle Inspection of weld joints of LT shift converter (104-D), Refrigerant
Flash Drums 110-F, 111-F and 112-F from inside of the vessels.

11. Inspection of newly fabricated pipelines and fabrication jobs carried out
departmentally by Maintenance and Technical department.

12. Qualification tests of welders employed by contractors.

13. Low speed balancing of 103-JAT & 103-JBT rotor before & after installation of
coupling lock nut.

153
14. RFET of tubes of 102-C, 108C1A, 108 C2A and 142-CA.

15. Eddy current testing of SS tubes of 108 C1A and 108 C2A.

The detailed observations and recommendations for corrective actions required on

individual equipment are given below. All the observations were recorded during
inspection and were handed over to concerned Maintenance and Operation
group for necessary corrective action.

1.0 PRIMARY REFORMER 101-B:

1.1 RADIANT ZONE:

VISUAL INSPECTION:

Visual inspection of the entire furnace radiant zone, including harp assemblies,
refractory and insulation, burner-blocks, etc. was carried out. The detailed report
on observations made is enclosed herewith at Annexure-1.

OTHER NDT ACTIVITIES:

x Automatic ultrasonic scanning of all the 336 Catalyst tubes and 8 Risers tubes
was carried out during Shutdown by PDIL. Amongst all 336 tubes, 39 tubes are
placed in A grade,297 tubes are placed in B grade. Amongst 8 risers, 2 risers
are placed in A grade & 6 risers are placed in B grade. Details are attached at
Annexure-2.

x Radiography of 1st weld joint from top of all 8 risers was carried out to assess
the condition of the weld. No service defects were observed in any joint.

x DP test of 16 nos. of outlet manifold field weld joints, riser tube to weldolet weld-
joints was carried out for all the risers. NO service defect was revealed.

x DP test of 1st weld joint from top of selected catalyst tube in each row was
carried out randomly.

x The tubes numbers selected were,

x 121,122,220,222,321,322,421,422,519,522,619,622,723,821 & 822.

x NO service defect were revealed.

x Creep measurement of all the catalyst tubes was carried out using GO-NOGO
Gauge at tunnel slab level. Creep was found in the range of 0 - 0.17 % for 327
nos. of tubes and between 0.17 to 0.92 % in 09nos. of tubes. The detailed
report is enclosed at Annexure-3.

x Clearance measurement of outlet headers from the bottom floor was carried
out. The report is attached at Annexure-4.

x Spring hanger readings of catalyst tubes in cold condition were taken. The
report is attached at Annexure-5.

154
1.2 CONVECTION ZONE:

Visual inspection of HTand LT convection zone from bottom and top manhole was
carried out and observations made are as under:

H.T. CONVECTION SECTION:

From Bottom Manhole:

x Fiber Blanket protection sheet was found badly buckled and burnt off all
around the duct. Heavy lumps of burnt protection sheet was found sticked
near the tunnel burners

x All the tubes of mixed feed coil were found to have hard scaling on the entire
surface, and on some places the scale was loose also.

x All the Tunnel thermo wells were found in satisfactory condition.

x From Top Manhole:

x Incoloy protection sheet in the middle of south wall was found burnt off.

x One of the incoloy protection sheet in the bottom south-west side wall was
slipped from its position.

x HT and LT super heater coils were found in satisfactory condition.

x Supports of LT/HT steam super heater coils were found in satisfactory

condition.

x Extreme South side duct distribution plate was fall down while the other was
bent and hanged down.

x Insulation protection sheet inside the duct was badly distorted and burnt off.

x One of the insulation protection sheet just before the dampener was hanging
down.

x Dampener blades were found in satisfactory condition.

L.T.CONVECTION SECTION:

x Tube supports of BFW coil & NG feed preheater coil were found in
satisfactory condition as seen from the bottom.

x Few fins of tubes of NG feed preheater coil were found covered with
refractory debris at scattered locations.

x Loose refractory debris was found on the bottom floor of LT convection zone.

155
2.0 AUXILIARY BOILER:

Hot Well Area:

x Cladding sheet has got distorted at its East-South and West –South junction with
distributor plate.

x Distributor plate for the flue gas has got distorted at its bottom portion and at
West side.The stiffeners had badly damaged at scattered locations.

Furnace Area:

x Burner wall refractory was found to have cracks at scattered locations including
cones of the burners.

x Refractory bricks were found displaced inward at the North half of the wall
located at the bottom of the Coil –B.

x Blackish deposits were observed at the top half of North-West corner tubes. (15
tubes in each coil approx.)

x C-coil refractory was found to have cracks at scattered locations and at the
bottom of its both end refractory found damaged.

x In-situ metallography of selected tubes from replaced tubes in 2005 turnaround

and old tubes was also carried out and observations are mentioned at
Annexure-14

3.0 RLA STUDY RELATED EQUIPMENTS:

Visual inspection of the following equipment / pipelines / structures was carried out
as per the five year action plan recommended after RLA study carried out during
June 2003. Observations made are mentioned as below.

Steam Drum:

x Grayish black colouration was observed inside the drum.

x All cyclone separators were found intact in position.
x Demister pads were found intact in position.
x Minor pitting of approx. 0.5 to 0.75mm depth was observed at scattered locations.
x All the weld joints were found in satisfactory condition.

Steam Super Heater Coils:

x Supports were found in satisfactory condition.

x No surface defects or physical damage was observed.
x Overall condition of the coils was found satisfactory.

156
 High Temperature Headers:

x Both inlet and outlet headers of high temperature coils were found in
satisfactory condition.

x No surface defect observed.

Auxiliary Boiler Coils:

x Coil-C tubes were found in satisfactory condition.

x Tubes of Coil-A were found in satisfactory condition.

x Tubes of “Coil-B” were observed to have minor pitting on tubes at scattered

locations. In general condition of the tubes was found satisfactory.

Main steam Pipes:

No major abnormality was observed on pipe line. Minor scales & pitting were
observed. The overall condition of the pipeline found satisfactory.

Heat Exchangers (101 CA/CB, 102-C, 103-C):

Nozzles weld joint of BFW inlet and outlet line were checked visually, no
abnormality was observed. Condition of the weld joints were found satisfactory.

Structure and Supports:

x The structural support of steam drum, heat exchangers (viz., 101 CA/CB, 102-
C, 103-C) were found in satisfactory condition.

x The structural supports and hangers provided at the main steam pipe line were
found to be in satisfactory condition.

4.0 VESSELS AND OTHER EQUIPMENT:

Visual inspection/NDT of the following equipments was carried out. The detailed
observations/recommendations on individual equipments are given below:

103-D, SECONDARY REFORMER:

Bottom Dome:

x Erosion of refractory and scattered cracks was observed at few locations and
same were found more around both the gas inlet nozzles.
x Skirt liner was found slightly buckled inward (away from shell) at scattered
locations.
x Some of refractory brick slots were found chocked with alumina balls.
x Upper layer of refractory was found slightly damaged at scattered locations.
x Bottom floor refractory was found to have loosened.

157
Top Air and Gas Entry:

x Zig - Zag superficial scattered cracks were observed on the refractory lining all
over dome and shell.
x At few scattered locations cracks having approx. 3mm width were observed.
x Thermo well pipe was found bent/inclined upwards approx. 45 deg. from
horizontal axis.
x Shift liner observed slightly buckled particularly more on 3rd segment from top.
x Gap of approx.1” dia. was observed between shift liner of top shell to transfer
line liner location 5 deg. Clock to 9 deg. Clock position. Liner patch to transfer
line welding observed to have cracked (3” long appx.)
x Target hexagonal bricks and alumina balls were found in satisfactory condition.

101-CA/CB GAS INLET NOZZLE:

x Inward bulging of approx. 20 - 40mm was observed at the ID of liner segment in

scattered length but upto approx. 250mm length was maximum at the different
liner segments.

x Minor outward buckling was observed at the top half of both the inlet nozzle
end.

102 - C ,WASTE HEAT EXCHANGER:

Tube leakage was observed from 07 nos. of tubes and 74 nos. of seal welding at
bottom tube sheet during hydro test at 41 kg/cm2 after plant shutdown. For further
assessment of condition of tubes RFET was carried out. Inside of the tubes was
cleaned by hydro jetting to remove scaling. However 100 nos. of tubes could not be
tested as probe for the testing could not be passed through ID of the tubes due to
scaling. Total 605 nos. of tubes could be tested by RFET. Based upon the result of
RFET 06 nos. of tubes was plugged. Leakage was observed from 02 Nos. of tubes
and 18 nos. of seal weld at top tube sheet during hydro test at 125 kg/cm2 after
tube plugging and seal weld repair. The same were plugged. In all, total 92 Nos. of
seal welds were found leaky which were repaired. As on date total 60 nos. of tubes
are plugged as detailed given below. Tube /Plug seal welding was inspected by DP
test.

158
Tubes are counted from South to North and Row nos. counted from West to East

Tube nos. Seal welds

Tube nos. Seal welds
Row. plugged repaired (Bottom
plugged based repaired (Top
No. based on tube sheet)
on RFET result tube sheet)
hydro test
1
2
3 8,13
4
5
6
7 4,16
8 3,9,15,16,17,18
2,3,11,12,13,14,1
9 8
5,16,17
10 9 8 13,16,18
6,7,9,14,16,17,18,
11 13 7,8
19
5,6,15,16,17,18,1
12 15,22 7,11,21
9
5,6,7,8,10,11,16,1
13 9 8 19
7
14 10,15,16,18 6,10,11 23
7,8,10,11,12,13,1
15 20,22
4,15
16
17 11,12 16,23
18 4,10,11,16 14
19 25 4,5,10 20
20 3,4,9,10
21 17 17
22 3
23 6,13 3
24 3,5,6
25 7,12
26 4
27
28
29
30
31
32
Total
06 09 74 18
Tubes

Total tube plugged as on date =60

WPS for repairing of tube to tube sheet seal weld and plug weld is attached at
Annexure-11

159
104-D, LT SHIFT CONVERTER:

Catalyst of LT shift converter was replaced. The following inspection activities

were carried out.

x Magnetic particle examination of all the weld joints was carried out from the
inside of the vessel. Minor indications observed during testing were removed
by sandering and reexamined and were found satisfactory.

x Ultrasonic flaw detection of all the T-joints was carried out. No service defect
was observed.

x Hardness measurement was carried out at various locations and was found as
mention below.

a. On parent metal : 117 to 149 BHN

b. On HAZ : 117 to 167 BHN
c. On weld : 166 to 181 BHN

x Insitu metallographic was carried out and the observation is mentioned at

Annexure-10.

107 - D ,TRANSFER LINE:(From outside)

x Minor buckling of the liner was observed at scattered locations throughout the
length of the transfer line.

x Minor damage of the refractory was observed at flange ( entry) of the transfer
line.

101-F, STEAM DRUM:

x Grayish black colouration was observed inside the drum.

x All cyclone separators were found intact in position.
x Demister pads were found intact in position.

x Minor pitting of approx. 0.5 to 0.75mm depth was observed at scattered

locations.

x South side hole of phosphate dozing line (1” NB) found enlarged.
x BFW distribution pipe to pipe thread coupling fixing bolt was found loose and
its fastening nut was found missing from one end. Proper fastening was
recommended. Two nos. bolt of flange at the inlet of this pipe were also found
loose.

x One no. clamp of cover plate of riser located on East side was found loose.

x Hot vapour was found coming from the second down comer counting from
South side.

x Loose grayish black deposits were found all around the inside surface. Proper
cleaning was recommended.

160
102-F , RAW GAS SEPARATOR:

x Epoxy paint condition was found satisfactory, except at 2-3 locations where it was
found peeled off.

x Demister pads were found intact in position.

x Corrosion attack was observed on the repaired weld at the inside face of manhole
nozzle. Suitable protective coating may be applied at this location.

x Putty applied on the circumferential weld joint of manhole nozzle with shell was found
peeled off at some places where as in other places gap was observed at the edges of
the putty.

x Corrosion attack was observed on the weld joint at the face of liquid out nozzle weld
joint with shell. Suitable corrective action is recommended.

x Condition of Gas inlet nozzle located at East side was found satisfactory.

103-F, REFLUX DRUM:

x Demister pads were found intact in its position.

x Epoxy paint was found peeled off from the few small scattered locations at the
bottom half of the vessel. However epoxy primer was found intact at such location.

x Minor corrosion has started at the weld joint of Co2 inlet flange weld joint with vessel
stub end and on the face of Man way nozzle, suitable corrective action is
recommended.

104-F, SYN GAS COMPRESSOR SUCTION SEPARATOR:

x Demister pad condition was found satisfactory.

x Scattered thin scales were observed at bottom dish end.

x Weld joint condition was satisfactory.

x Grayish black coloration was observed on bottom area, whereas brownish coloration
was observed on remaining surface.

105-F, SYN. GAS COMPRESSOR 1ST STAGE SEPARATOR:

x The coloration of vessel was brownish black from inside.

x Demister pads were found intact in position.
x Scattered minor pittings were observed throughout the shell surface, the same was
observed in past also.
x Entire internal surface was found oily.
x The Overall condition of the vessel was found satisfactory.

161
107-F, PRIMARY AMMONIA SEPARATOR:

x Colouration of vessel internals was found blackish brown.

x Scattered thin scales were observed on the shell and dished end.

x Entire internal surface was found oily.

x The condition of all the weld joints of the shell, dished ends and nozzles was found to
be satisfactory.

109-F, REFRIGERANT RECEIVER:

x The shell had assumed Grayish black coloration.

x The condition of all the weld joints of the shell, dished ends and nozzles was found to
be satisfactory.

x Thin scales were observed on both the dished ends.

x Minor scattered pittings / scales were observed in a width of approx. 250mm

throughout the length of vessel at its bottom most portion. The same was observed in
past also.

x Entire internal surface was found oily.

x Overall condition of the vessel was found to be satisfactory.

110-F, FIRST STAGE REFRIGERANT FLASH DRUM:

x Brownish black colouration was observed inside the drum.

x Oil layer was found on the surface of shell.
x The Demister pad was found intact in position.
x Scattered mill scales were observed on the surface of the dish ends and shell.
x Overall condition of the vessel was found to be satisfactory.

x Magnetic particle examination of all the weld joint was carried out from inside. Minor
indications observed were removed by sandering and reexamined, No recordable
service defect was found.

111-F, SECOND STAGE REFRIGERANT FLASH DRUM:

x The shell inside surface had assumed blackish gray coloration.

x Entire internal surface was found oily.
x The demister pads were found intact in position.
x Scattered scales were observed on both the dished ends.
x Condition of all nozzle and shell weld joints was found satisfactory.
x Overall condition of the shell was satisfactory.
x Magnetic particle examination of all the weld joint was carried out from inside. Minor
indications observed were removed by sandering and reexamined, No recordable
service defect was found.

162
112 - F, THIRD STAGE REFRIGERANT FLASH DRUM:

x The demister pads were found intact in position.

x The coloration of the inside surface of shell was dark blackish.

x Surface of the vessel was found oily.

x Hard scales were observed in the shell which were more prominent on the dished
ends.

x Condition of all nozzles was found satisfactory.

x Condition of all weld joints was found satisfactory.

x Magnetic particle examination of all the weld joint was carried out from inside. Minor
indications observed were removed by sandering and reexamined, No recordable
service defect was found.

LP FLASH VESSEL (103-E2 LP):

TOP MANHOLE COMPARTEMENT:

x Demister pad was found intact in its position in satisfactory condition.

x Condition of weld joints was found satisfactory however these weld joints were
observed as if etching has occurred resulting in slightly differing colour in comparison
to adjacent shell surface.

x Bubble cap and its tray holding bolts were found loose at various locations.
x Grinding mark (2mm deep x 3 mm wide x 1.5 feet long appx) was observed on top
dished end on south side.

x 1 no bolt of 2”NB flange located on west side of shell was found loose(108J
discharge line to LP flash vessel)

x Overall condition of the compartment was found satisfactory.

SECOND (FROM TOP) MANHOLE COMPARTEMENT:

x Rectangular riser box and other fittings were found intact in position.

x Condition of weld joints was found satisfactory however these weld joints were
observed as if etching has occurred resulting in slightly differing colour in comparison
to adjacent shell surface.

x Holding bolts of tray fixing beam were found loose at scattered locations.

x External supports of surrounding pipelines of LP flash vessel were found to have

support bolt missing particularly on the bottom side of support. It was recommended
to check the same with support design.

163
B-201, FLARE STACK:

Bottom Compartment. (Knock Out Drum):

x Shell had assumed blackish Coloration.

x Epoxy coating observed to have peeled off all around the inside surface of knuckle
radius of bottom dished end and area surrounding the bottom drain nozzle.

x Loose metallic strips of gasket was observed hanging inside the I.D. of gas inlet
nozzle.

x Minor pitting was observed on circumferential weld joint between shell to bottom
dished end on south-east side and also surrounding 1.5”NB nozzle on south-east
side.

x Bottom dished end has not been painted from outside.

TOP COMPARTMENT(WATER SEAL DRUM)

x Bottom dished end could not be inspected as it was filled with water.

x Several scattered wide spread spots of brownish colour were observed on top half of
shell and top cone.

x The perforated conical round plate of seal pot was found to have buckled/distorted
throughout the circumference and seal pot duct pipe had considerable corrosion
attack on its OD.

x Considerable rust scales/corrosion scales was observed on the shell surface all
around, predominant around manhole located on south side. Ultrasonic Thickness
measurement was carried out to assess the corrosion attack on shell and seal pot.

x Suitable protective coating was recommended on internal surface of shell and dished
end to avoid further corrosion.

5.0 MISCELLANEOUS JOBS:

WELDER QUALIFICATION TESTS:

x Performance qualification test of 20 Nos. welders offered by M/s General

Engineering was carried out. 07 nos. of welders were qualified during the test.
These welders were allowed to perform various miscellaneous non-critical
departmental welding jobs in the plant.

x Performance qualification test of 11 Nos. welders offered by M/s Ganesh Engg.

was carried out. 08 nos. of welders were qualified during the test. These welders
were allowed to perform welding on various steam and process line modification
work.

164
x Welder qualification test of 05 Nos. welders of M/S. Sayyed & Co. was carried out. 02
welders were qualified. These welders were qualified for performing general purpose
welding jobs.

x Performance qualification test of 03 Nos. welders offered by M/s. Skywin Erectors

was carried out. 02 nos. of welders were qualified during the test. These welders
were allowed to perform welding HP steam line and 102-C tube/plug welding job.

D.P. TEST:

Dye penetrant examination of weld joints of all the pipelines fabricated by

contractors/departmentally, new pipeline fabrication / modifications job done by technical
and maintenance groups etc. was carried out after root run welding and after final
welding, as per requirement. Any defects observed during the tests were rectified in the
presence of inspector followed by DP test for acceptance.

RADIOGRAPHY:

In order to ensure immediate radiography work and urgent processing of films, teams
were hired on round the clock basis during entire shutdown period. Radiography was
performed on the weld joints of the pipe lines fabricated by all contractors as well as
departmentally as per the requirement.

INSITU METALLOGRAPHY EXAMINATION:

In order to evaluate the condition of certain critical plant equipment and pipelines
operating at more than 300 deg. C temperatures, parent metal, HAZ and welds , weld
joints of dissimilar material, Insitu metallographic examination was carried out. List of the
lines/equipment checked along with observations and remarks are mentioned at
Annexure-10

ULTRASONIC FLAW DETECTION OF WELDS:

Weld joints (selected only) of the critical pipe lines and equipment were ultrasonically
examined for assessing any development of service defects/growth of the acceptable
defects. No abnormalities were observed in any of the weld joints inspected. No
discontinuity was required to be repaired. The detailed list of pipeline inspected is
mentioned at Annexure-6

ULTRASONIC THICKNESS MEASUREMENT:

During the shutdown, ultrasonic thickness measurement was carried out on various
pipelines and equipment in the plant. The detailed results of inspection are attached
herewith at Annexure-7 (for equipment) and Annexure- 8(for pipelines).

GAUSS MEASUREMENT:

During this shutdown measurement of residual magnetism (gauss) on rotary and

stationary parts of various rotary equipment were carried out. Wherever residual
magnetism was higher than acceptable limits, same was demagnetized and brought
down within acceptable limits. The detailed results of inspection are attached herewith at
Annexure-9

165
INSTALLATION OF NEW PIPELINES:

During this shutdown, various pipelines in Ammonia Plant were installed for different
schemes and various tapping were taken by Technical Group. Inspection activities viz.
DP Test, Radiography review and repairs etc. were carried out on the weld joints as per
fabrication procedures.

OVER SPEED TRIP TEST:

Before startup, speed measurement and vibration measurement of 101-BJ Turbine,

104-JAT,104JT, 103-JAT were carried out.

BALANCING:

During this turnaround rotor of Syn. Gas compressor drive turbines 103-JBT and 103-
JAT were provided with lock nut at its coupling end. The same was checked for its
balancing condition before and after assembly of locknut and the balance condition
before assembly of locknut was restored on both the rotors.

HARDNESS MEASUREMENT:

During this shutdown one no. elbow of line SG-1303-10-14”(Syn. Loop boiler inlet line) &
SG-25-8”(Quench line to converter) was replaced by new one. Also distance piece &
block valve for HS-10,HS-11 & HS-12-6”(letdown station lines) was replaced. The post
weld heat treatment was carried out for the weld joints of above. The hardness observed
as mentioned below. WPS for the above are attached at Annexure-12 to 14.

HARDNESS IN BHN
LINE NO. PARENT WELD HEAT AFFECTED
MOC
METAL METAL ZONE
SG-1303-10-14,J-1 P-22 125 – 160 145 – 180 119 – 176
SG-1303-10-14,J-2 P-22 125 – 189 132 – 162 131 – 162
SG-25-8, J-1 CS 114 – 157 116 – 140 114 – 134
SG-25-8, J-2 CS 120 – 135 128 – 144 132 – 157
HS-10-6, J-1 P-11 128 – 142 158 – 199 131 – 171
HS-10-6, J-2 P-11 121 – 141 182 – 217 133 – 138
HS-10-6, J-3 P-11 124 – 142 202 – 225 135 – 149
HS-11-6, J-1 P-11 122 – 129 185 – 203 145 – 159
HS-11-6, J-2 P-11 126 - 133 174 – 205 132 – 145
HS-11-6, J-3 P-11 121 – 126 169 – 205 130 – 138
HS-12-6, J-1 P-11 120 – 140 180 – 195 132 – 172
HS-12-6, J-2 P-11 119 – 134 202 – 209 128 – 146
HS-12-6, J-3 P-11 134 – 141 181 – 224 145 – 163

166
 ANNEXURE-1

1.0 BURNER BLOCKS: No damage observed

2.0 BOTTOM HEADER INSULATION:

Outer insulation layer between tube no. 4 to 8 and 13 to 15 found fallen, rest of
the insulation was found intact in position.

3.0 ROOF INSULATION:

one no. block found fallen near the tube no. 133 and 134 in burner row no.1.In
general, the condition of the roof insulation is found to be satisfactory

4.0 All Canister base rings of risers found intact in position

5.0 REFRACTORY WALLS:

In general, Gap has increased between panel of bricks at many locations on all
wall.

x West Wall :

Inward bulging of 2nd brick panel counting from bottom was observed and few
bricks were found loose in this area.

x North Wall:

Vertical zig-zag cracks were observed at many locations and around the
cracks and at the junction of brick walls loose bricks were also observed.

x South Wall:

Insulation found fallen at tunnel slab level at scattered location and at same
location plate was found exposed.

Excessive gap observed at the vertical joint of brick panel at the location of
burner row no. 4.

Minor erosion of top panel of refratory brick was observed at the location of
burner row no. 4.

Peep hole bricks were found displaced inside for peep hole no. 3,4 and 5
counting from West side.

6.0 TUNNEL SLAB: All tunnel slabs were found intact in their position.

167
 Annexure - 2 (1/5)

GRADATION OF TUBES BY AUS CARRIED OUT BY PDIL

ROW NO.1 ROW NO.2

Tube Aus Tube Aus Tube Aus Grade Tube Aus

No. Grade No. Grade No. No. Grade

1 B 22 B 1 B 22 B

2 B 23 B 2 B 23 B

3 B 24 B 3 B 24 B

4 B 25 B 4 B 25 B

5 B 26 B 5 A 26 B

6 B 27 B 6 B 27 B

7 B 28 B 7 B 28 B

8 A 29 B 8 B 29 B

9 B 30 B 9 B 30 B

10 B 31 B 10 A 31 B

11 B 32 B 11 B 32 B

12 B 33 B 12 B 33 B

13 B 34 A 13 B 34 B

14 B 35 B 14 A 35 B

15 B 36 B 15 B 36 B

16 B 37 B 16 B 37 B

17 B 38 B 17 B 38 B

18 B 39 B 18 B 39 B

19 B 40 B 19 B 40 B

20 B 41 B 20 B 41 B

21 B 42 B 21 B 42 B

168
 Annexure – 2 (2/5)

GRADATION OF TUBES BY AUS CARRIED OUT BY PDIL

ROW NO. 3 ROW NO. 4

Tube Aus Tube Aus Tube Aus Tube Aus

No. Grade No. Grade No. Grade No. Grade

1 B 22 B 1 B 22 B

2 B 23 A 2 B 23 B

3 B 24 B 3 B 24 B

4 B 25 B 4 B 25 B

5 B 26 B 5 B 26 B

6 A 27 B 6 B 27 B

7 B 28 A 7 B 28 B

8 B 29 B 8 B 29 B

9 B 30 B 9 B 30 B

10 B 31 B 10 B 31 B

11 B 32 B 11 B 32 B

12 B 33 B 12 B 33 B

13 A 34 B 13 B 34 B

14 B 35 B 14 B 35 B

15 B 36 B 15 B 36 B

16 B 37 B 16 B 37 B

17 B 38 B 17 B 38 B

18 B 39 B 18 B 39 B

19 B 40 B 19 B 40 B

20 B 41 B 20 B 41 B

21 B 42 B 21 B 42 B

169
 Annexure – 2 (3/5)

GRADATION OF TUBES BY AUS CARRIED OUT BY PDIL

ROW NO. 5 ROW NO. 6

Tube Aus Tube Aus Tube Aus Tube Aus

No. Grade No. Grade No. Grade No. Grade

1 B 22 B 1 B 22 B

2 B 23 A 2 B 23 B

3 B 24 B 3 B 24 B

4 B 25 B 4 B 25 B

5 B 26 B 5 B 26 B

6 B 27 B 6 B 27 B

7 B 28 B 7 B 28 B

8 B 29 B 8 B 29 A

9 B 30 B 9 B 30 A

10 B 31 B 10 B 31 A

11 B 32 A 11 B 32 A

12 B 33 B 12 B 33 A

13 B 34 B 13 B 34 A

14 B 35 B 14 B 35 A

15 B 36 B 15 B 36 A

16 B 37 B 16 B 37 A

17 B 38 B 17 B 38 B

18 B 39 B 18 B 39 A

19 B 40 B 19 B 40 A

20 B 41 B 20 B 41 B

21 B 42 B 21 B 42 A

170
 Annexure – 2 (4/5)

GRADATION OF TUBES BY AUS CARRIED OUT BY PDIL

ROW NO. 7 ROW NO. 8

Tube Aus Tube Aus Tube Aus Tube Aus
No. Grade No. Grade No. Grade No. Grade
1 B 22 A 1 B 22 A
2 B 23 B 2 B 23 B
3 B 24 A 3 B 24 B
4 B 25 A 4 B 25 B
5 B 26 B 5 B 26 B
6 B 27 B 6 B 27 B
7 B 28 B 7 B 28 B
8 B 29 B 8 B 29 B
9 A 30 B 9 B 30 B
10 B 31 B 10 B 31 B
11 B 32 A 11 B 32 B
12 B 33 B 12 B 33 B
13 B 34 B 13 B 34 B
14 B 35 A 14 B 35 B
15 B 36 A 15 B 36 B
16 B 37 A 16 B 37 B
17 A 38 B 17 B 38 B
18 B 39 A 18 B 39 A
19 A 40 A 19 B 40 A
20 B 41 A 20 B 41 B
21 B 42 B 21 B 42 B

Annexure – 2 (5/5)

GRADATION OF RISER TUBES BY AUS CARRIED OUT BY PDIL

ROW NO. RISER NO. AUS GRADE

1 1 B
2 2 A
3 3 B
4 4 A
5 5 B
6 6 B
7 7 B
8 8 B

171
 Annexure – 3 (1/4)
CREEP MEASUREMENT OF PRIMARY REFORMER
CATALYST TUBES AT SLAB LEVEL

Tube Creep in Percentage Tube Creep in Percentage

No. No.
0.17 –
0 – 0.17 0.7 – 1.55 0 – 0.17 0.17 – 0.7 0.7 – 1.55
0.7
101 X 201 X
102 X 202 X
103 X 203 X
104 X 204 X
105 X 205 X
106 X 206 X
107 X 207 X
108 X 208 X
109 X 209 X
110 X 210 X
111 X 211 X
112 X 212 X
113 X 213 X
114 X 214 X
115 X 215 X
116 X 216 X
117 X 217 X
118 X 218 X
119 X 219 X
120 X 220 X
121 X 221 X
122 X 222 X
123 X 223 X
124 X 224 X
125 X 225 X
126 X 226 X
127 X 227 X
128 X 228 X
129 X 229 X
130 X 230 X
131 X 231 X
132 X 232 X
133 X 233 X
134 X 234 X
135 X 235 X
136 X 236 X
137 X 237 X
138 X 238 X
139 X 239 X
140 X 240 X
141 X 241 X
142 X 242 X
Total 42 Total 42

172
 Annexure – 3 (2/4)

CREEP MEASUREMENT OF PRIMARY REFORMER

CATALYST TUBES AT SLAB LEVEL

Tube Creep in Percentage Tube Creep in Percentage

No. No.
0 – 0.17 0.17 – 0.7 0.7 – 1.55 0 – 0.17 0.17 – 0.7 0.7 – 1.55
301 X 401 X
302 X 402 X
303 X 403 X
304 X 404 X
305 X 405 X
306 X 406 X
307 X 407 X
308 X 408 X
309 X 409 X
310 X 410 X
311 X 411 X
312 X 412 X
313 X 413 X
314 X 414 X
315 X 415 X
316 X 416 X
317 X 417 X
318 X 418 X
319 X 419 X
320 X 420 X
321 X 421 X
322 X 422 X
323 X 423 X
324 X 424 X
325 X 425 X
326 X 426 X
327 X 427 X
328 X 428 X
329 X 429 X
330 X 430 X
331 X 431 X
332 X 432 X
333 X 433 X
334 X 434 X
335 X 435 X
336 X 436 X
337 X 437 X
338 X 438 X
339 X 439 X
340 X 440 X
341 X 441 X
342 X 442 X
Total 42 Total 40 02

173
 Annexure – 3 (3/4)

CREEP MEASUREMENT OF PRIMARY REFORMER

CATALYST TUBES AT SLAB LEVEL

Tube Creep in Percentage Tube Creep in Percentage

No. No.
0 – 0.17 0.17 – 0.7 0.7 – 1.55 0 – 0.17 0.17 – 0.7 0.7 – 1.55
501 X 601 X
502 X 602 X
503 X 603 X
504 X 604 X
505 X 605 X
506 X 606 X
507 X 607 X
508 X 608 X
509 X 609 X
510 X 610 X
511 X 611 X
512 X 612 X
513 X 613 X
514 X 614 X
515 X 615 X
516 X 616 X
517 X 617 X
518 X 618 X
519 X 619 X
520 X 620 X
521 X 621 X
522 X 622 X
523 X 623 X
524 X 624 X
525 X 625 X
526 X 626 X
527 X 627 X
528 X 628 X
529 X 629 X
530 X 630 X
531 X 631 X
532 X 632 X
533 X 633 X
534 X 634 X
535 X 635 X
536 X 636 X
537 X 637 X
538 X 638 X
539 X 639 X
540 X 640 X
541 X 641 X
542 X 642 X
Total 41 01 Total 41 01

174
 Annexure – 3 (4/4)

CREEP MEASUREMENT OF PRIMARY REFORMER

CATALYST TUBES AT SLAB LEVEL

Tube Creep in Percentage Tube Creep in Percentage

No. No.
0 – 0.17 0.17 – 0.7 0.7 – 1.55 0 – 0.17 0.17 – 0.7 0.7 – 1.55
701 X 801 X
702 X 802 X
703 X 803 X
704 X 804 X
705 X 805 X
706 X 806 X
707 X 807 X
708 X 808 X
709 X 809 X
710 X 810 X
711 X 811 X
712 X 812 X
713 X 813 X
714 X 814 X
715 X 815 X
716 X 816 X
717 X 817 X
718 X 818 X
719 X 819 X
720 X 820 X
721 X 821 X
722 X 822 X
723 X 823 X
724 X 824 X
725 X 825 X
726 X 826 X
727 X 827 X
728 X 828 X
729 X 829 X
730 X 830 X
731 X 831 X
732 X 832 X
733 X 833 X
734 X 834 X
735 X 835 X
736 X 836 X
737 X 837 X
738 X 838 X
739 X 839 X
740 X 840 X
741 X 841 X
742 X 842 X
Total 42 Total 37 05

175
 ANNEXURE- 4

CLEARANCE OF OUTLET MANIFOLD FROM

GROUND FLOOR IN COLD CONDITION

HEADER LOCATION OF MEASUREMENT

NO. A B C D E F G H
1 160 175 175 170 185 190 180 190
2 190 165 185 200 200 165 170 190
3 175 185 180 185 190 170 185 180
4 190 200 195 190 200 170 170 200
5 185 200 200 180 180 170 175 180
6 190 170 165 190 180 170 185 200
7 170 190 180 200 190 170 180 180
8 160 190 200 200 200 200 200 170

NOTE : (1) All readings are in MM

(2) Readings are taken with insulation.

OUTLET MANIFOLD

A B C D E F G H

176
 Annexure - 5

TUBE SPRING HANGER LOAD READINGS OF

PRIMARY REFORMER HARP ASSEMBLY(101-B):

COLD LOAD READINGS IN MM:

ROW TUBE NOS. (SOUTH TO NORTH)

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
1 42
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41
1 20 22 25 26 23 22 17 20 22 25 26 27 25 23 18 23 22 20 20 24 25 12

2 15 22 22 17 15 19 22 20 24 20 20 22 22 24 20 18 16 20 20 20 17 12

3 13 25 21 24 22 22 23 21 22 25 23 27 22 25 20 21 22 24 22 22 25 17

4 20 25 22 22 22 23 23 20 27 23 22 24 25 24 22 22 22 24 22 24 22 15

5 14 23 22 22 22 20 18 20 19 20 22 21 22 22 20 22 22 21 24 22 24 17

6 12 24 22 21 18 20 17 17 19 21 18 22 17 22 20 22 21 21 23 24 24 16

7 17 26 22 23 23 22 22 22 23 25 23 21 22 17 20 20 18 18 22 22 22 14

8 14 22 21 23 18 21 20 22 23 22 24 24 23 20 21 22 22 22 22 24 23 18

TRANSFER LINE SPRING HANGER LOAD READINGS

ROW 1 2 3 4 5 6 7
READINGS 22 21 17 23 36 18 17

BOTTOM DRAIN READINGS

ROW 1 2 3 4 5 6 7 8
READINGS 97 97 97 98 97 97 95 95

AUXILIARY BOILER SPRING READINGS

SPRING S-E N-E S-W N-W

READINGS 60 60 62 60

177
 Annexure - 6

UFD OF WELD JOINTS OF FOLLOWING PIPELINES WAS CARRIED OUT:

NO. OF
SR.
LINE NO SIZE SCH FROM TO WELD REMARKS
NO
JOINTS
SG-1303-08- No
1 SG-1303-09-10” 10 120 108-D 11
14” (105-D) significant
SG-33-14 defect was
2 SG-1303-08-14” 14 120 108-D 10
(105-D) observed.
SG-1303-08-
3 SG-1303-08-10” 10 120 108-D 02
14” (105-D)
SG-1303-08-
4 SG-1303-12-10” 10 120 108-D 02
14” (105-D)
5 SG-1303-11-14” 14 140 107-C 123-C 12
6 SG-1303-10-14” 14 120 108-D 107-C 09
7 SG-1303-06-14” 14 100 121-C 124-C 15
8 A-21-10” 10 120 101B 103D 1
9 NG-9-12” 12 100 101B 103D 1
105-D,
10 SG-62A-4” 4 XXS 102-B 3
SG-32-6”
105-D,
11 SG-62B-4” 4 XXS 102-B 3
SG-32-6”

178
 Annexure - 7
THICKNESS MEASUREMENT SUMMARY OF EQUIPMENT: S/D-2007

Equipment
Shell Dish End Channel
Sr. Equipt . Description
No No. Nom./ Min. % Nom./ Min. % Nom./ Min.
% Red.
Design Measured Red. Design Measured Red Design Measured
Primary Shift
Effluent Waste
1 103 - C 55.56 58.80 - 20.63 29.90 -
Heat
Exchanger
104 - C Methanator
2 17.46 17.70 - 19.05 23.60 - 19.05 21.0 -
Feed Heater
Shift Effluent
3 106-C Feed Water 6.35 6.50 - 15.08 16.10 - 15.08 20.0 -
Heater
aMDEA
4 108-CA2 Solution 12.70 12.60 0.79 12.70 12.90 - 12.7 13.2 -
Cooler
aMDEA
5 108-CB2 Solution 12.70 12.60 0.79 12.70 12.80 - 12.7 13.1 -
Cooler
aMDEA
6 109-CA-1 Solution 12.70 12.20 3.94 12.70 14.30 - 25 25.3 -
Exchanger
aMDEA
7 109-CA-2 Solution 12.70 12.20 3.94 12.70 14.30 - 25 25.1 -
Exchanger
aMDEA
8 109-CB-1 Solution 12.70 13.00 0.79 12.70 22.70 - 25 24.2 -
Exchanger
aMDEA
9 109-CB-2 Solution 12.70 13.00 0.79 12.70 15.60 - 25 24.1 -
Exchanger
CO2 Stripper
10 110-CA 15.87 16.40 - 15.87 15.30 - 15.87
Condenser
CO2 Stripper
11 110-CB 15.87 15.87 11.70 - 15.87
Condenser
Methanator
12 114-C Effluent Feed 58.00 57.30 1.21 18 18.20 - 15.87 20.7 -
Water Heater
Methanator
13 115-C Effluent 12.50 12.40 0.80 12.50 14.40 - 17.46 20.2 -
Cooler
Synthesis Gas
Compressor
14 116-C 11.11 9.90 10.9 11.11 12.60 - 9.20
Interstage
Cooler
Synthesis Gas
15 124-C Compressor 20.00 20.00 0.00 16.00 19.30 - 88.9 93.6 -
After Cooler
Refrigent
16 127-CA 18.00 16.90 6.11 16.00 15.3 4.4
Condenser
Refrigent
17 127-CB 18.00 16.60 2.22 16.00 15.1 5.6
Condenser

179
 Refrigerant
18 128-C Compressor NA 11.30 11.4
Inter Cooler
Air
Compressor
19 129-JC 12.00 11.90 0.83
Inter Stage
Cooler No.1
Air
Compressor
20 131-JC 15.80 15.4 2.53
Inter Stage
Cooler No.2
Synthesis Gas
Methanator
21 136-C 15.80 15.40 2.53
Feed
Exchanger
Fuel Preheat
22 150-C 8.38 11.40 - 12.70 12.7 12.4 2.4
Exchanger
Fuel Preheat
23 151-C 8.38 10.70 - 9.52 8.38 10.6 -
Exchanger
Condensate
Stripper Feed
24 170-CA 9.50 9.20 3.2
Bottom
Exchanger
Condensate
Stripper Feed
25 170-CB 9.50 9.00 5.2
Bottom
Exchanger
Boiler
26 174-C Blowdown NA 10.10
Cooler
Stripped
27 173-C Condensate 9.50 8.40 11.6 NA 8.40 8.00
Cooler
28 106-D Methanator 44.50 45.00 - 43.70
Condensate
29 104-E 12.50 11.30 9.6 11.10 13.70 -
Stripper
1St Stage Ref.
30 110-F 9.52 9.00 5.4 9.52 11.00 -
Flash Drum
Second Stage
31 111-F Refrigent 9.52 10.10 19.05 22.60
Flash Drum
Third Stage
19.05(E) 22.6(E)
32 112-F Refrigent 9.52 10.20 9.52(W) 12.5(W)
Flash Drum
aMDEA
33 114-F 4.76 4.50 5.5 4.76 4.40 7.60
Storage Tank
Inhibitor Tank
34 118-F 6.00 10.20 - NA 10.10
118-F
New
35 142-F Instrument Air NA 13.90 NA 13.00
Receiver
Blow Down
36 156-F 11.11 10.70 3.7 NA 11.70
Drum
Process Gas
37 157-F 19.84 22.40 -
Separator

180
 Natural Gas
38 158-FA 24.00 23.20 3.3 24.00 23.30 2.9
Separator
Natural Gas
39 158-FB 24.00 23.80 0.8 24.00 23.10 3.7
Separator
Ammonia
40 172-F 12.00 11.40 5.0
Liquor Tank
New
41 2005-F Instrument Air 8.00 8.30 - 8.00 7.10 11.2
Receiver
New
2000-
42 Instrument Air NA 7.00 NA 8.10
SL,AD-A
Drier
New
2000-
43 Instrument Air NA 7.50 NA 8.00
SL,AD-B
Drier
Naptha
44 F-101 12.7 13.80 - 12.0
Deaerator
Process Feed
45 E-110A Stock NA 14.10
Preheater
Process Feed
46 E-110-B Stock NA 14.10
Preheater
Condensate
47 B-110 Drum for E- 8.00 8.00 - 8.00 11.20 -
110
Naptha
48 R-110 31.80 31.30 1.6
Hydrogenator
Knock Out
49 B-111 Drum For R- 6.00 6.30 - 6.0 9.10 -
110
Sulphur
50 R-111 35.00 35.70 -
Absorber
51 R-112 Pre Reformer 86.9 85.7 1.4 48.9
Knock Out
52 B-112 Drum For H- NA 6.50
111
Naptha
53 E-218 NA 6.40 NA 11.20
Condenser
Gas
54 E-3 5.00 4.60 8.0 5.00 5.00
Exchanger
Regeneration
55 E-4 5.00 5.90 -
Heater
Washing
56 K-1 18.00 18.00 -
Tower
57 R-1 Drying Vessel 36.00 35.90 0.3 36.00 36.20
58 R-2 Drying Vessel 36.00 35.90 0.3 36.00 35.90
59 B-201 K.O.Drum 10 9.7 3.0
Water Seal
60 B-201 Drum for B- 10 9.7 3.0
201

181
 CONVECTION SECTION COILS

SR COIL INLET HEADER OUTLET HEADER

DESCRIPTION
NO
DESIGN MEAS. %RED DESIGN MEAS. %RED DESIGN. MEAS %RED
BFW COIL
OFFSITES (LT
1 5.54 4.2 24.1 -- -- -- -- -- --
Convection, bottom
most)
BFW COIL
OFFSITES (LT
2 5.54 4.1 25.9 -- -- -- -- -- --
Convection, 2nd from
bottom)
NG FUEL FEED
3 3.9 3.4 12.8 7.0 7.0 -- 7.0 7.0 --
COIL
BFW COIL
4 5.5 4.9 10.9 27 25.2 6.66 -- -- --
AMMONIA
HT STEAM SUPER
5 8.0 7.7 3.77 -- -- -- -- -- --
HEATER COIL
LT STEAM SUPER
6 7.01 6.7 4.28 40.46 -- -- 40.46 -- --
HEATER COIL
AUXILLIARY
7 BOILER, 7.0 6.7 4.28 -- -- -- -- -- --
COIL-A
AUXILLIARY
8 BOILER, 7.0 6.8 2.85 -- -- -- -- -- --
COIL-B
AUXILLIARY
9 BOILER, 7.0 6.7 4.28 -- -- -- -- -- --
COIL-C
H-
10 7.11 7.30 - -- -- -- -- -- --
111(RADIANTCOIL)
H-111(CONVECTION
11 7.11 7.60 - -- -- -- -- -- --
COIL)
H-110
12 8.56 7.70 10.0 -- -- -- -- -- --
(RADIANTCOIL)
H-110
13 (CONVECTION 5.49 5.10 7.10 -- -- -- -- -- --
COIL)

182
 ANNEXURE- 8
AMMONIA PLANT PIPELINE THICKNESS MEASUREMENT SUMMARY

Nom Line Description

Sr. Nom thick Min Thk
Line No Bore % Red.
No. (mm) From To observed
(inch)
1 A-20 10 6.35 101-J 101B 5.2 18.11
2 A-21 10 21.41 101-B 103-D 21.6 -
3 BF-02 10 6.35 BF-1 104-J 7.6 -
4 BF-03 10 6.35 BF-1 104-JA 7.9 -
5 BF-35 4 8.56 SPEC.BREAK BF-22 8.7 -
6 BW-01H 14 23.8 101-CA 101F 23.5 1.26
7 BW-05H 14 23.8 101-CB BW-43HA,HB 24.4 -
8 BW-11H 8 15.06 BW-14H 103-C 14.4 4.38
9 BW-12H 8 15.06 BW-14H 103-C 14.3 5.05
10 BW-21H 18 29.36 101-F 101-CB 38.4 -
11 BW-35H 14 23.8 101-CA 101-F 22.3 -
12 BW-36H 14 23.8 101-CB 101-F 24.5 -
13 HS-10 6 14.27 HS-5 PIC-13A 13.2 7.49
14 HS-11 6 14.27 HS-5 PIC-13B 13.7 3.99
15 HS-12 6 14.27 HS-5 MIC-22 13.5 5.39
16 LS-10 8 6.35 PIC-17 D/S 8.5 -
17 LS-10 4 6.02 PIC-17 D/S 13.5 -
18 MS-1304.02 8 10.31 107-C 101-B 10.1 2.04
19 NG-01 6 7.11 BATT.LIMIT NG-2 7.1 0.14
20 NG-02 6 7.11 NG-1 101-D 7 1.55
21 NG-03 6 7.11 NG-1 102-D 6.3 11.39
22 NG-04 6 7.11 101-D NG-6A 6 15.61
23 NG-05 6 7.11 102-D NG-6A 6 15.61
24 NG-06 8 8.18 150-C 101-D 7.3 10.75
25 NG-09 12 21.4 101-B NG-11A TO H 21 1.87
26 NG-11A 6 14.3 NG-9 101-B 12.4 13.29
27 NG-11B 6 14.3 NG-9 101-B 12.3 13.99
28 NG-11C 6 14.3 NG-9 101-B 12.6 11.89
29 NG-11D 6 14.3 NG-9 101-B 13.3 6.99
30 NG-11E 6 14.3 NG-9 101-B 11.9 16.78
31 NG-11F 6 14.3 NG-9 101-B 12.1 15.38
32 NG-11G 6 14.3 NG-9 101-B 11.1 22.38
33 NG-11H 6 14.3 NG-9 101-B 13.5 5.59
34 NH-20 18 7.92 NH-21 128-C 6.7 15.4
35 NH-21 18 7.92 105-J 128-C 7.4 6.57
36 NH-23 12 6.35 105-J NH-33 6.0 5.51
37 NH-24A 12 6.35 NH-33 127-CA 6.3 -
38 NH-24B 12 6.35 NH-33 127-CB 6.4 -
39 NH-33 14 7.92 NH-23 NH-24 A/B 7.4 6.56
40 PW-01 6 10.97 102-F PW-4 10.5 4.28
41 PW-02 2 3.91 PW-3 PW-12 2.7 30.95
42 PW-03 2 3.91 PW-1 PW-12 5 -
43 PW-04 2.5 CS 5.16 PW-1 106-J 5.1 18.6
44 PW-04 2.5 SS 3.05 PW-1 106-J 2.4 21.31
45 PW-17 4 6.02 PW-1 171-C 4.5 25.24
46 PW-20 6 10.97 PW-20 170-J 10.4 5.20
47 PW-20A 6 10.97 PW-20 170-JA 7.7 29.81

183
48 PW-21 4 11.13 170-J 170-C 10.4 6.56
49 PW-21A 4 11.13 170-JA PW-21 12.1 -
50 PW-22 4 11.13 170-C 173-C 10.4 6.56
51 PW-28 4 11.13 PW-27 171-C 11.5 -
52 PW-28A 4 11.13 PW-27 171-C 11.3 -
53 PW-30 14 11.13 PW-29 PW-31 12.5 -
54 S-8 6 7.11 PIC-17 U/S 8.8 -
55 S-8 4 6.02 PIC-17 U/S 12.3 -
56 SG-09 10 9.27 116-C 129-C 9 2.91
57 SG-25 8 18.24 SG-23 SG-32(105D) 17.3 5.15
58 SG-29 4 11.13 SG-21-14’’ SG-76A/B-4’’ 10.4 6.56
59 SG-35 12 21.41 SG-1303.01.14 103-J 20 6.59
60 SG-42 4 8.56 FICV-8 VENT STACK 8.6 -
61 SG-42 3 7.62 FICV-8 VENT STACK 13.0
62 SG-44 4 6.02 SG-11 FICA-7 U/S (SG-45) 6.4 -
63 SG-44 3 5.49 SG-11 FICA-7 U/S (SG-45) 7.0 -
64 SG-45 6 7.11 FICA-7 D/S(SG-44) SG-6 7.2 -
65 SG-45 3 7.62 FICA-7 D/S (SG-44) SG-6 8.5 -
66 SG-51 8 15.06 SG-1303.04-8’’ SG-35-12’’ 14.1 6.37
67 SG-62A 4 17.12 102-B SG-32 16.8 1.86
68 SG-62A 4 17.12 102-B SG-32 16.4 4.20
69 SG-32 6 21.95 SG-62A/B SG-25 21.4 2.55
70 SG-76A 4 11.1 SG-25 102-B 10.6 4.50
71 SG-76B 4 11.1 SG-21 102-B 10.4 6.31
72 SG-1303.01.14 14 23.83 120-C SG-35 20 16.07
73 SG-1303.04.08 8 15.06 137-C SG-51 14.2 5.71
74 SG-1303.06.14 14 23.83 121-C 124-C 21 11.87
75 SG-1303.08.10 10 21.44 SG-1303.08.14 108-D 22.6 -
SG-33-14(105-
76 SG-1303.08.14 14 27.79 108-D 25.4 8.60
D)
77 SG-1303.09.10 10 21.44 SG-1303.08.14 108-D 21.0 2.05
78 SG-1303.10.14 14 27.79 108-D 107-C 25.2 9.31
79 SG-1303.11.14 14 31.75 107-C 123-C 27.8 12.44
80 SG-1303.12.10 10 21.44 SG-1303.08.14 108-D 21.8 -
81 FIC-14 10 9.53 U/S D/S 10 -
82 FIC-14 16 4.57 - - 5 -
83 PRC-1A 8 8.18 PRC-1A D/S 6.1 25.43
84 PRC-1A 6 7.11 U/S D/S 5.8 18.42
85 PRC-1A 3 7.62 - - 7.2 5.51
86 PRC-1 6 7.11 6’’U/S PRCV-1 5.8 18.42
87 PRC-1 3 5.5 - - 5.7 -
86 PRC-1 2 5.54 PRCV-1 FRCV-1 4.4 20.58
87 PIC-1A 4 6.02 - - 6 0.33
88 PIC-1A 6 7.11 - - 6 15.61
89 PIC-5 12 9.53 V-6 VENT(SP-73) 10.7 -
90 PIC-5 6 7.11 - - 6.8 4.36

184
 Annexure-9

GAUSS MEASUREMENT & DEMAGNETIZATION REPORT

Max. gauss reading

Sr. No. Component Description
Before After
101-J AIR COMPRESSOR
1 Turbine South Bearing
1.1 Journal bearing housing 2.0
1.2 Journal bearing shaft 0.6
1.3 Journal bearing pads 0.9
1.4 Journal bearing base ring T:4.0 B:3.8
1.5 Thrust collar 2.2
1.6 Thrust pads 0.6
2 Turbine North Bearing
2.1 Journal bearing shaft 2.3
2.2 Journal bearing pads 0.8
2.3 Journal bearing base ring 3.1
3 H P Case South Bearing
3.1 Journal Bearing Shaft 2.9
3.2 Journal bearing pads 4.7 1.2
3.3 Journal bearing base ring 5.0
4 H P Case North Bearing
4.1 Journal Bearing Shaft 8.8 1.5
4.2 Journal Thrust Collar 8.2 1.6
4.3 Journal Bearing Pads 2.1
4.4 Journal Bearing Base Ring 3.0
4.5 Thrust pads 2.0
5 L P Case Compressor
Thrust End
5.1 Journal Bearing Shaft 2.6
5.2 Journal Bearing Pads 4.8 1.3
5.3 Thrust Collar 3.6
5.4 Journal Bearing Base Ring 2.8
5.5 Thrust pads 15.9 1.3
5.6 Thrust Bearing Base Ring 20 1.4

6 L P Case Compressor
Turbine Side
6.1 Journal Bearing Shaft 3.5
6.2 Journal Bearing Pads 9.5 2.0
6.3 Journal Bearing Base Ring T:2.3, B- 3.5

185
 7 Gear Box
7.1 Shaft Journal (Low speed) 2.0
7.2 Journal Bearing (Low speed) 3.8
7.3 Shaft Journal (High speed) 1.3
7.4 Journal Bearing (High speed) 3.2
103-J SYN GAS COMPRESSOR
1 JAT Thrust End Bearing
1.1 Base Ring 2.0
1.2 Target plate 1.2
1.3 Thrust Pads 4.6 0.8
1.4 Shaft Journal 5.3 0.7
1.5 Thrust Collar 2.5
2 JAT Opposite Thrust End Radial Bearing
2.1 Journal Bearing Shaft 0.7
2.2 Journal Bearing Pads 0.8
2.3 Base Ring 2.0
3 JBT Non Drive (Thrust End) Radial Bearing
3.1 Base Ring 1.2
3.2 Pads 2.4
3.3 Bearing Housing 20 3.5
4 JBT Opposite Thrust End Radial Bearing
4.1 Base Ring 1.3
4.2 Pads 2.4
4.3 Thrust Collar 3.2
4.4 Journal Bearing Shaft 1.4
4.5 Thrust Side Journal Area 3.0
4.6 Thrust Side Shaft End 2.5
5 HP Case Thrust End
5.1 Pads 0.8
5.2 Thrust Shaft Area 1.0
6 HP Case Journal Bearing
6.1 Base Ring 8.8 1.9
6.2 Pads 2.0
6.3 Shaft Journal 2.7
7 LP Case Thrust End
71 Pads 0.8
7.2 Thrust Shaft Area 0.8
8 LP Case Journal Bearing
8.1 Base Ring 1.3
8.2 Pads 2.2
8.3 Shaft Journal 2.6

186
 Max. gauss reading
Sr. No. Component Description
Before After
105-J, REF. GAS COMPRESSOR:
1 Turbine Free End Journal Bearing
1.1 Base Ring 1.1
1.2 Pads 1.3
1.3 Shaft Journal 2.6
2 Turbine Coupling End Journal Bearing
2.1 Shaft Journal Portion 2.6
2.2 Thrust Collar 2.8
2.3 Base Ring 4.0
2.4 Pads 6.0 0.2
2.5 Thrust Bearing 1.4
3 HP Case Coupling End Journal Bearing
3.1 Shaft Journal Portion 3.9 2.3
3.2 Pads 3
3.3 Bearing Base Ring 1.4
4 HP Case Free End Thrust Bearing
4.1 Thrust Bearing Shaft 12 3.1
4.2 Thrust Bearing Pads 2.0
4.3 Thrust Collar 5 0.9
5 LP Case Free End Thrust Bearing
5.1 Thrust Bearing Shaft 0.6
5.2 Thrust Bearing Pads 1.2
5.3 Thrust Bearing Base Ring 5.2 2.0
5.4 Thrust Collar 0.9
6 Gear Box
6.1 LS Shaft South side 1.4
6.2 LS Shaft South side Bearing 3.7 1.4
6.3 LS Shaft North side 2.0
6.4 LS Shaft North side Bearing 2.1
6.5 HS Shaft South side 0.9
6.6 HS Shaft South side Bearing 12.0 3.2
6.7 HS Shaft North side 1.3
6.8 HS Shaft North side Bearing 4.2 1.6
115-JAT
1 Turbine Thrust End
1.1 Thrust Pads 1.8
1.2 Thrust collar 1.2
1.3 Shaft Journal 0.8
1.4 Journal Bearing 2.2
2 Turbine coupling end
2.1 Shaft Journal 2.9
2.2 Journal Bearings 2.6

187
 Max. gauss reading
Sr. No. Component Description
Before After
3 115 - JA
3.1 Thrust Bearing Pads 7.0 1.6
3.2 Thrust Collar 2.9
3.3 Journal bearing 3.4
3.4 Shaft Journal 0.5
104 - JA Thrust cum journal bearing
1 Thrust End
1.1 Journal bearing 2.2
1.2 Thrust Pads 5.8 1.7
1.3 Shaft Journal 2.7
1.4 Thrust collar 2.4
2 Coupling End
2.1 Shaft Journal 1.7

188
 ANNEXURE-10
DETAILS OF INSITU-METALLOGRAPHIC INSPECTION

SR. MICROSTRUCTURE
LOCATION MOC REMARK
NO. OBSERVATION
Location: 1
(Parent Metal) Microstructure shows ferrite and IInd stage of
On face of 1st spheroidial carbide structure. creep
Bend of NG-9- Degradation of pearlite observed in degradations.
1. P 11
12” (101B- terms of spheroidzation. Possibilities Monitor after 1
mixed feed coil of isolated creep cavities are year of
outlet to NG- observed. (Plate: 1 & 2) service.
11)
Microstructure at weld shows ferrite IInd stage of
Location: 2 and bainite in dendritic form where creep
(Weld/Haz) as at HAZ shows fine-grained degradations.
On weld betn. bainite and ferrite structure. Monitor after 1
Pipe & Bend of Microstructure at parent metal year of
2. P 11
NG-9-12” shows ferrite and spheroid carbide service.
(101B-mixed structure. Degradation of bainite is SEM analysis
feed coil outlet observed. Possibilities of isolated showed few
to NG-11) creep cavities are observed. (Plate: isolated creep
3 & 4) cavities.
Microstructure at weld shows ferrite IInd stage of
and bainite in dendritic form where creep
Location: 3
as at HAZ shows fine-grained degradations.
(Weld/Haz)
bainite and ferrite structure. Monitor after 1
Between Pipe
Microstructure at parent metal year of
& bend
3. P 11 shows ferrite and spheroid carbide service.
NG-9-12”
structure. Degradation of pearlite SEM analysis
(101B-mixed
observed in terms of spheroidzation. confirms the
feed coil outlet
Possibilities of isolated creep presence of
to NG-11)
cavities are observed. oriented creep
(Plate: 7 & 8) cavities.
Location: 4 Fusion is
Microstructure at parent metal (P11)
(Weld / HAZ normal, no
shows essentially ferrite structure with
of P-11) cracking
carbides. Where as at HAZ
On dissimilar observed at
microstructure shows fine and coarse-
Weld between interface/alloyed
grained ferrite and carbide structure.
pipe & Nozzle of P 11 to region.
4. Possibility of creep damage is observed
header 304H AT P11 side
at P11 side. Weld metal shows dendritic
NG-9-12” approaching 3rd
structure of solid solution of nickel.
stage of creep
(101B-mixed (Plate: 11 & 12)
damage.
feed coil outlet SEM examination –evaluation is kept on
Monitor after 1
to NG-11) next page
year of service.
Location: 5
(Weld/Haz) Microstructure at parent metal (SS The oxalic acid
On dissimilar 304H) shows austenite grains with etching
Weld Between twins. Carbide precipitation observed at confirmed the
pipe & Nozzle of 304H the grain boundaries. At HAZ presence of
5. Header to microstructure shows coarse-grained carbide at the
NG-9-12” 304H austenitic structure, carbide grain
precipitations. boundaries.
(101B-mixed
Weld metal shows dendritic structure of Monitor after 2
feed coil outlet solid solution of nickel. (Plate: 15 & 16) years of service.
to NG-11)

189
SR.
LOCATION MOC MICROSTRUCTURE OBSERVATION REMARK
NO.
Location: 6
Microstructure at weld metal shows ferrite
(Weld/Haz)
and carbides in dendritic form. Where as
On Weld IInd stage of
at HAZ microstructure shows fine and
Between BFW creep
Carbon coarse-grained ferrite/pearlite structure.
6. outlet Nozzle degradations.
Steel Parent metal shows fine-grained
BW-9H-8’’ & Monitor after 1
ferrite/pearlite structure. Initial stage of in-
103-C Shell at year of service.
situ spheroidzation of pearlite is observed.
top towards East
(Plate: 17 & 18)
side
Location: 7 Microstructure at weld metal shows
(Weld/Haz) ferrite and carbides in dendritic form.
2nd stage of
On weld betn. Where as at HAZ microstructure
creep
flange & Bend shows fine and coarse-grained
damage.
7. of gas inlet P 11 ferrite/pearlite structure.
Monitor after
nozzle.PG-6 – Parent metal shows fine grained
1 year of
18 towards essentially ferrite structure. Indications
service.
east side of of creep cavities are observed at grain
103-C boundaries. (Plate: 19 & 20)
Microstructure at weld metal shows
Location: 8
ferrite and carbides in dendritic form.
(Weld/Haz)
Where as at HAZ microstructure
PG 7-10 (103C Monitor after
shows fine and coarse-grained
8. Gas outlet line P 11 2 years of
ferrite/pearlite structure.
1st bend weld & service.
Parent metal shows fine grained
Haz with pipe
essentially ferrite structure. (Plate: 23
towards 106D)
& 24)
Location: 9 Microstructure sows ferrite and Needs
(Parent Metal) spheroidized pearlite structure. replacement.
HS-2H-12 (Plate: 25 & 26) Presences of
Carbon
9. (Parent metal) , micro cracks
Steel
120 mm below are observed
the bottom butt at the grain
weld of valve boundaries.
Location: 10
Microstructure sows fine-grained
(Parent Metal) Monitor after
ferrite and pearlite structure. In situ
10. SG-34-14 On P 11 2 years of
spheroidzation of pearlite observed.
face of gas service.
(Plate: 29 & 30)
outlet bend
Microstructure at weld metal shows
ferrite and bainite in dendritic form.
No significant
Location: 11 Where as at HAZ microstructure
degradation
(Weld/Haz) shows fine and coarse-grained ferrite/
observed.
11. SG-34-14 On P 11 bainite structure.
Monitor after
weld & Haz of Parent metal shows fine-grained
2 year of
gas outlet bend ferrite/pearlite structure. Initial stage of
service.
in-situ spheroidzation of pearlite is
observed. (Plate: 31 & 32)

190
 MICROSTRUCTURE
SR. NO. LOCATION MOC REMARK
OBSERVATION
Microstructure at weld metal shows
ferrite and bainite in dendritic form.
Where as at HAZ microstructure
Location: 12 IInd stage of
shows fine and coarse-grained
(Weld/Haz) creep
ferrite/ bainite structure.
SG-34-14 On degradations.
12. P 11 Parent metal shows fine-grained
weld & Haz of Monitor after
ferrite/pearlite structure. Of in-situ
pipe of gas 1 year of
Spherodization of pearlite is
outlet bend service.
observed.
Indications of creep cavities are
observed. (Plate: 33 & 34)
Microstructure shows fine-grained
ferrite and pearlite structure at HAZ.
Location: 13 IInd stage of
In-situ spheroidzation of pearlite is
(Weld/Haz) creep
observed.
A-21-10 On 1st degradations.
13. P 11 Parent metal microstructure shows
weld/Haz of Monitor after
ferrite and spheroidized pearlite.
coil outlet 2 years of
Possibilities of creep degradations in
header service.
form of creep cavities are observed
at grain boundaries.(Plate: 37& 38)
Microstructure shows fine-grained
ferrite and pearlite structure at HAZ.
IInd stage of
Location: 14 In-situ spheroidzation of pearlite is
creep
(Weld/Haz) observed.
degradations.
14. A-21-10 On 1st P 11 Parent metal microstructure shows
Monitor after
pipe of coil ferrite and spheroidized pearlite.
2 years of
outlet header Possibilities of creep degradations in
service.
form of creep cavities are observed
at grain boundaries.(Plate: 39 & 40)
Location: 15
Microstructure at weld shows ferrite
(Parent Metal) No significant
pools in austenite matrix with
101B Harp On degradation
carbides.
field weld of G- is observed.
15. Microstructure at parent metal shows
outlet manifold 4859 Monitor after
primary and secondary carbides in
between tube 2 year of
austenitic matrix in cast form. (Plate:
no.27-28, service.
41 & 42)
Raw No.8
Location: 16 Microstructure at weld shows ferrite
No significant
(Weld/Haz) pools in austenite matrix with
degradation
101B Harp On carbides.
G- observed.
16. weld of Microstructure at parent metal shows
4859 Monitor after
weldolet tube primary and secondary carbides in
2 year of
no.28, Raw austenitic matrix in cast form. (Plate:
service.
No.8 43 & 44)
Location: 17
Microstructure at weld shows ferrite
(Weld/Haz) No significant
pools in austenite matrix with
101B Harp On degradation
carbides.
weld of G- is observed.
17. Microstructure at parent metal shows
weldolet to 4859 Monitor after
primary and secondary carbides in
riser between 2 year of
austenitic matrix in cast form. (Plate:
tube no.21-22, service.
45 & 46)
Raw No.8

191
 MICROSTRUCTURE
SR. NO. LOCATION MOC REMARK
OBSERVATION
Location: 18 Microstructure at weld shows ferrite
No significant
(Weld/Haz) pools in austenite matrix with
degradation
101B Harp On carbides.
G- is observed.
18. weld of riser Microstructure at parent metal
4859 Monitor after
weldolet to shows primary and secondary
2 year of
outlet manifold carbides in austenitic matrix in cast
service.
Raw No.8 form. (Plate: 47 & 48)
IInd stage of
Location: 19 Microstructure shows fine gained creep
(Parent Metal) Carbon ferrite and pearlite structure. In situ degradations.
19.
PIC 13B inlet Steel spheroidzation of pearlite is Monitor after
spool piece observed. (Plate: 49 & 50) 1 year of
service.
Location: 20 IInd stage of
Microstructure shows fine gained creep
(Parent
SA516 ferrite and pearlite structure. In situ degradations.
20. Metal)
Gr.70 spheroidzation of pearlite is Monitor after
104D LTS On observed. (Plate: 51 & 52) 1 year of
shell service.
IInd stage of
Location: 21
Microstructure shows fine gained creep
(Weld/Haz)
SA516 ferrite and pearlite structure. In situ degradations.
21. 104D LTS On
Gr.70 spheroidzation of pearlite is Monitor after
bottom DE
observed. (Plate: 53 & 54) 1 year of
Weld
service.
Microstructure at weld shows fine IInd stage of
Location: 22
dendritic structure of ferrite and creep
(Weld/Haz)
SA516 carbides. Where as HAZ degradations.
22. 104D LTS On
Gr.70 microstructure shows fine-grained Monitor after
Longitudinal
ferrite and pearlite structure. (Plate: 1 year of
Weld & shell
55 & 56) service.
Location: 23
Microstructure at HAZ shows fine-
(Weld/Haz)
grained ferrite/bainite/pearlite
SG-1303, 09- Monitor after
structure. Where as parent metal
23. 10 (H-36) On P-22 one year of
microstructure shows ferrite and
108D service.
bainite/pearlite structure. (Plate: 57
converter inlet
& 58)
nozzle
Location: 24
Microstructure at HAZ shows fine-
(Weld/Haz) IInd stage of
grained ferrite and bainite structure.
SG-1303, 09- creep
Where as parent metal
10 (H-36) On degradations.
24. P-22 microstructure sows ferrite and
108D Monitor after
bainite structure. Bainite is observed
converter inlet 1 year of
degrading in to carbides and ferrite.
nozzle of bend service.
(Plate: 59 & 60)
at bottom

192
SR. MICROSTRUCTURE
LOCATION MOC REMARK
NO. OBSERVATION
Microstructure shows fine grained With SEM
essentially ferrite structure. analysis it
Presence of coarse and fine aligned indicates
cracks in the longitudinal direction degraded
observed. These cracks are having microstructure
Location: 25 typically characteristics thermal under Creep
(Parent Metal) degradations. mechanism.
25. Carbon
MIC-22 Up stream (Plate: 63,64 & 65) However exact
Steel
piece cause is not
(At Crack) clear.
Recommended
to evaluate for
defect root
cause
investigation.
Location: 26 Microstructure at HAZ shows fine-
(Weld/Haz) grained bainite and ferrite structure.
SG-1303 08-14 Parent metal microstructure shows IInd stage of
(H-36) On 108D in situ spheroidzation of creep
26. converter inlet line P-22 pearlite/bainite structure. Indications degradations
bend at up stream of isolated creep cavities are monitor after 1
of HV-487 HAZ of observed. (Plate: 68 & 69) year of service.
bend (North side
of control valve)
Microstructure at HAZ shows fine-
Location: 27
grained bainite and ferrite structure. IInd stage of
(Weld/Haz)
Parent metal microstructure shows creep
SG-1303 08-14
27. P-22 in situ spheroidzation of degradations.
(H-36) On 108D
pearlite/bainite structure. Indications Monitor after 1
converter outlet
of isolated creep cavities are year of service.
nozzle
observed. (Plate: 70 & 71)
Location: 28 Microstructure at HAZ shows fine-
No significant
(Weld/Haz) grained bainite and ferrite structure.
degradations.
SG-1303 08-14 Parent metal microstructure shows
28. P-22 Monitor after 2
(H-36) On 108D tempered bainite structure. (Plate:
years of
converter outlet 72 & 73)
service.
nozzle Haz of pipe
Microstructure at HAZ shows fine-
Location: 29
grained bainite and ferrite structure. IInd stage of
(Weld/Haz)
Parent metal microstructure shows creep
SG-1303 10-14
29. P-22 in situ spheroidzation of degradations.
(H-36) On 107C
pearlite/bainite structure. Indications Monitor after 1
Gas inlet nozzle of
of isolated creep cavities are year of service.
pipe
observed. (Plate: 74 & 75)
Microstructure at HAZ shows fine-
Location: 30 grained bainite and ferrite structure. IInd stage of
(Weld/Haz) Parent metal microstructure shows creep
30. SG-1303 11-14 P-11 in situ spheroidzation of degradations.
(H-34) On 107C pearlite/bainite structure. Indications Monitor after 1
Gas outlet nozzle of isolated creep cavities are year of service.
observed. (Plate: 76 & 77)

193
SR. MICROSTRUCTURE
LOCATION MOC REMARK
NO. OBSERVATION
Location: 31 Microstructure at HAZ shows fine-
(Weld/Haz) grained bainite and ferrite structure. IInd stage of
SG-1303 11- Parent metal microstructure shows creep
31. 14 (H-34) On P-11 in situ spheroidzation of pearlite/ degradations.
107C Gas bainite structure. Indications of Monitor after 1
outlet nozzle & isolated creep cavities are observed. year of service.
Haz of pipe (Plate: 78 & 79)
Location: 32
(Weld/Haz) IInd stage of
SG-1303 11- Microstructure at HAZ shows fine creep
32. 14 (H-34) On P-11 grained bainite/ferrite structure, degradations.
123C Gas (Plate: 80 & 81) Monitor after 1
outlet inlet year of service.
nozzle
Microstructure at weld shows
Location: 33
dendritic structure ferrite/carbides
(Weld/Haz) IInd stage of
and bainite structure. Where as
SG-1303 11- creep
parent metal microstructure shows
33. 14 (H-34) On P-11 degradations.
ferrite and spheroidized pearlite
123C Gas Monitor after 1
structure. Indications of isolated
intlet nozzle year of service.
creep cavities are observed at grain
Haz of bend
boundaries. (Plate: 82 & 83)
Presence of
creep cavities
and initial stage
Location: 34
Microstructure shows essentially of cracking is
(Parent Metal)
ferrite structure with few grain confirmed by
SG-1-12 On
boundary carbides. Indication of SEM analysis.
34. face of 3rd P-11
creep damage in form of cavitation Approaching
bend of gas
and cracks are suspected. 3rd stage of
intlet line to
(Plate: 84 & 85) creep damage.
114-C
Monitor after
six month of
service
Location: 35
(Weld/Haz) Microstructure shows proper fusion
NG-11 /H-6 between parent metal and weld. No IInd stage of
On P11 to P-11 significant defect observed. HAZ creep damage
35. ss304H to microstructure shows fine-grained monitor after
Dissimilar joint 304H ferritic structure. Indication of creep one year of
of inlet cavities at suspected at P11 service.
manifold Raw side.(Plate: 88 & 89)
No.8
Location: 36
(Parent Metal)
Aux. Boiler No significant
Coil- B side degradation
Microstructure shows fin grained
south to north 106 observed.
36. ferrite and pearlite structure. (Plate:
(west side) old Gr.B Monitor after 2
90 & 91)
tube no.5 years of
Counting from service.
south to north

194
 MICROSTRUCTURE
SR.NO. LOCATION MOC REMARK
OBSERVATION
Location: 37
(Parent Metal) No significant
Aux. Boiler A degradation
Microstructure shows fine-grained
side (west 106 observed.
37. ferrite and pearlite structure. (Plate:
side) New Gr.B Monitor after
92 & 93)
tube no.7 2 years of
Counting from service.
south to north
Location: 38
(Parent Metal) No significant
Aux. Boiler B degradation
Microstructure shows fine-grained
side (east 106 observed.
38. ferrite and pearlite structure.
side) old Tube Gr.B Monitor after
(Plate: 94 & 95)
no.15 2 years of
Counting from service.
south to north
Location: 39
(Parent Metal) No significant
Aux. Boiler A degradation
Microstructure shows fine-grained
side (east 106 observed.
39. ferrite and pearlite structure. (Plate:
side) New Gr.B Monitor after
96 & 97)
tube no.7 2 years of
Counting from service.
south to north
Microstructure at HAZ shows
IInd stage of
coarse-grained ferrite and pearlite
Location: 40 creep
structure with initial stage of
(Weld/Haz) Carbon degradations.
40. spherodization Where as parent
102B SG-62 Steel Monitor after
metal microstructure shows ferrite
B-4 line 1 year of
and in-situ spherodized pearlite.
service.
(Plate: 98 & 99)
IInd stage of
Microstructure shows fine-grained
Location: 41 creep
ferrite and pearlite structure. In situ
(Weld/Haz) Carbon degradations.
41. spheroidzation observed both at
102B SG-62 Steel Monitor after
HAZ and parent metal.
A-4 line 1 year of
(Plate: 102 & 103)
service.
Carbide
precipitations
are expected
during
Location: 42 service.
(Weld/Haz) However
NG-11 A/H-6 Microstructure shows fine-grained during shut
On SS304H to 304H worked austenitic structure with down due
42. ss304H to twins. Carbide precipitations are care may be
Dissimilar joint 304H observed at the grain boundaries. taken by
of inlet (Plate: 106 & 107) avoiding
manifold Raw sulfur related
No.8 impurities
from external
source to
avoid IGSCC
attack.

195
 Annexure-11

WELDING PROCEDURE SPECIFICATIONS

(SEE QW -201.1 SECTION IX, ASME BPVC)

WPS NO.: 102-C T/TS

Welding Process : GTAW

Type : Manual

1. JOINT DESIGN (QW - 402)

Groove design : As per Tube bundle drawing

Backing : N.A.
Others : N.A.

2. BASE METALS (QW - 403)

P.No. 4 to P. No. 4
Specification : SA 182 Gr. - F11 to SA 213 Gr.-T11
Thickness Range : Tube Sheet 165mm (6 ½”), Tube: - 4.191 mm
(8BWG)
Tube projection 4.76 - 6.35 mm
Fillet of 4.76 mm

3. FILLER METALS (QW - 404)

Weld metal analysis : A No. 3

AWS No. (Class) : Filler: SFA 5.28 (ER 80SG)
Size of Filler wire : 2.4 mm

4. POSITION (QW - 405)

Position of Groove : ALL

Welding Progression :
Other :

5. PREHEAT (QW - 406)

Preheat Temperature min. : 125 to 150 degree C

Interpass Temperature max. : 300 degree C
Preheat Maintenance : 150 degree C

6. DEHYDROGENATION

6.1 Soaking Temperature : 350 degree C

Soaking time : 24 hours
6.2 Soaking Temperature : 620 degree C
Soaking time : 04 hours
Heating Rate : 50 degree C/hr
Cooling Rate : 50 degree C/hr
Loading/Unloading Temperature : 300 degree C

196
7. GAS (QW - 408)

Shielding gas : Argon

Gas consumption : 99.995 %
Flow rate : 10 to 12 litters / min
Purging gas : NA
Gas consumption : NA
Flow rate : NA

8. ELECTRICAL CHARACTERISTICS (QW - 409)

Current : DC
Polarity : EP for GTAW
Ampere (Range) : 80 to 130
Other :

9. TECHNIQUE (QW - 410)

String or weave bead : String and weave

Initial & Interpass cleaning : Grinding & brushing
Oscillation : N.A.
Method of back gouging : N.A.
Contact tube to work distance : N.A.
Single or multiple pass : Multiple
Travel Speed (Range) : 4 to 6 cm/min for GTAW

10. WELD INSPECTION

Root weld : DP Test

Final weld : DP Test

11. STRESS RELIEVING PROCEEDURE

Soaking Temperature : 650 degree C

Soaking time : 1 hour
Heating Rate : 50 degree C/hr (Max.)
Cooling Rate : 50 degree C/hr (Max.)
Loading Temperature : 300 degree C
Unloading Temperature : 300 degree C

197
 Annexure-12

WELDING PROCEDURE SPECIFICATIONS

(SEE QW -201.1 SECTION IX, ASME BPVC)

FOR REPLACEMENT OF 14” NB x Sch 120 Elbow:

14” NB Schedule 120, ASTM A335 Gr-P22 Seamless Pipe to 14” NB Schedule 120,
ASTM A234 Gr-WP22 Seamless Elbow.
Welding Process : GTAW + SMAW
Type : Manual
1. JOINT DESIGN (QW - 402)
Groove design : As per Drawing No: P1-ES-13068, Sheet 1 of 1,Rev 0.
2. BASE METALS (QW - 403)
P-No. 5A Group No. 1 to P-No. 5A Group No.1
Specification : ASTM A 335 P22 to ASTM A234 Gr-WP22.
Thickness Range : 32 mm maximum
Pipe dia Range : 2-7/8” N.B. and above
3. FILLER METALS (QW - 404)
Weld metal analysis : A No. 4
Filler Metal F No. : As per QW -432.1 (SFA 5.5)
AWS No. (Class) : Electrode SFA/AWS A 5.5-96 (E 9018 B3)
Filler SF A5.28 /AWS A 5.28-96 (ER 90SB3)
Size of electrode : 2.4 mm (Filler wire) for root & hot pass
2.5, 3.15, 4 mm (Electrode) for fill up and capping
4. POSITION (QW - 405)
Position of Groove : 2G/5G
Welding Progression: Uphill
5. DEHYDROGENATION
Loading Temp : 300 degree C/hr
Heating Rate : 60 degree C/hr
Ist Soaking Temperature : 400 degree C
Soaking time : 24 hours
Heating Rate : 60 degree C/hr
2nd Soaking Temperature : 620 degree C
Soaking time : 3 hours
Cooling Rate : 100 degree C/hr
Loading/Unloading Temperature: 300 degree C

198
6. PREHEAT (QW - 406)
Preheat Temperature : 175 - 200 O C
Inter pass Temperature max.: 250 O C
7. POST WELD HEAT TREATMENT (QW - 407)
Temperature : 704 to 760O C
Soaking time : 02 Hour minimum
Heating Rate : 200 O C / hr. max
Cooling Rate : 200 O C / hr. up to 300OC, then natural cooling
under asbestos.
Loading : 200 degree C
8. GAS (QW - 408)
Shielding gas: Argon
Gas purity : 99.995 %
Flow rate : 6 to 12 liters / min
Purging gas : Argon
Gas purity : 99.995 %
Flow rate : 10 to 15 liters / min
9. ELECTRICAL CHARACTERISTICS (QW - 409)
Current : DC
Polarity : Straight for GTAW and Reverse for SMAW
Ampere (Range) : 90 to 120 for GTAW and 100 to 160 for SMAW
10 TECHNIQUE (QW - 410)
String or weave bead : String and weave
Initial & Inter pass cleaning : Grinding & brushing
Oscillation : N.A.
Method of back gouging : N.A.
Contact tube to work distance: N.A.
Single or multiple pass : Multiple
Travel Speed (Range) :4 to 6 cm/min for GTAW, 8 - 16 cm/min for SMAW
11. WELD INSPECTION
Bevel Edge : DP Test
Root weld : DP Test & 100 % radiography
Final weld : DP Test & 100 % radiography

12 Hardness measurement after PWHT : 241 BHN Max

199
 Annexure-13

WELDING PROCEDURE SPECIFICATIONS

(SEE QW -201.1 SECTION IX, ASME BPVC)

FOR REPLACEMENT OF 8” NB x Sch 120 Elbow:

8” NB X Schedule 120, ASTM A53 Gr. B Seamless Pipe to 8” NB X Sch. 120, ASTM
A234 WPB Seamless Elbow.

Welding Process : GTAW + SMAW

Type : Manual

1. JOINT DESIGN (QW - 402)

Groove design : As per Drawing No: P1-ES-13068, Sheet 1 of 1,Rev 0.

2. BASE METALS (QW - 403)

P-No. 1 Group No. 1 to P-No. 1 Group No.1

Specification : ASTM A53 Gr. B to ASTM A234 WPB
Thickness Range : 18 mm maximum
Pipe dia Range : 2-7/8” and above

3. FILLER METALS (QW - 404)

Weld metal analysis : A No. 1

Filler Metal F No. : As per QW -432.1 (SFA 5.5)
AWS No. (Class) : Electrode SFA/AWS A 5.5-96 (E 7018 B2 L)
Filler SF A5.28 /AWS A 5.28-96 (ER 70SB2 / ER515)
Size of electrode : 2.4 mm (Filler wire) for root & hot pass
2.5, 3.15, 4 mm (Electrode) for fill up and capping
Type of electrode flux : Low hydrogen, heavy coated

4. POSITION (QW - 405)

Position of Groove : 2G/5G

Welding Progression : Uphill

5. DEHYDROGENATION
Soaking Temperature : 400 degree C
Soaking time : 24 hours
Heating Rate : 100 degree C/hr
Cooling Rate : 100 degree C/hr
Loading/Unloading Temperature: 200 degree C

200
6. PREHEAT (QW - 406)

Preheat Temperature : 100 - 150 O C

Inter pass Temperature maxm. : 250 O C

7. POST WELD HEAT TREATMENT (QW - 407)

Temperature : 625O C
Soaking time : 01 Hour minimum
Heating Rate : 200 O C / hr. max
Cooling Rate : 200 O C / hr. up to 300O C,
then natural cooling under asbestos.
Loading : 200 degree C

8. GAS (QW - 408)

Shielding gas : Argon

Gas consumption : 99.995 %
Flow rate : 6 to 12 liters / min
Purging gas : NA

9. ELECTRICAL CHARACTERISTICS (QW - 409)

Current : DC
Polarity : Straight for GTAW
Reverse for SMAW
Ampere (Range) : 90 to 120 for GTAW
70 to 190 for SMAW

10. TECHNIQUE (QW - 410)

String or weave bead : String and weave

Initial & Inter pass cleaning : Grinding & brushing
Oscillation : N.A.
Method of back gouging : N.A.
Contact tube to work distance: N.A.
Single or multiple pass : Multiple
Travel Speed (Range) : 4 to 6 cm/min for GTAW
8 to 16 cm/min for SMAW
11. WELD INSPECTION

Bevel Edge : DP Test

Root weld : DP Test & 100 % radiography
Final weld : DP Test & 100 % radiography
Hardness measurement after PWHT

201
 Annexure-14

WELDING PROCEDURE SPECIFICATIONS

(SEE QW -201.1 SECTION IX, ASME BPVC)

FOR REPLACEMENT OF GATE VALVES:

150 NB Schedule 120, ASTM A335 Gr. P11 Seamless Pipe to 150 NB, 1500# , Sch.
120, ASTM A217 Gr. WC6 Butt Welded Gate Valve.

Welding Process : GTAW + SMAW

Type : Manual

1. JOINT DESIGN (QW - 402)

Sketch : IBR Fig. No. 28 (VIII)

Groove design : Single ‘V’ Butt Weld as per Drawing No P1-ES-

13067, Sheet 1 of 1, Rev 1 ( Enclosed)
2. BASE METALS (QW - 403)

P-No. 4 Group No. 1 to P-No. 4 Group No.1

Specification : ASTM A 335 P 11 to ASTM A217 Gr. WC6
Thickness Range : 18 mm maximum
Pipe dia Range : 2-7/8” and above

3. FILLER METALS (QW - 404)

Weld metal analysis : A No. 3

Filler Metal F No. : As per QW -432.1 (SFA 5.5)
AWS No. (Class) : Electrode SFA/AWS A 5.5-96 (E 8018 B2 L)
Filler SF A5.28 /AWS A 5.28-96 (ER 80SB2 /
ER515)
Size of electrode : 2.4 mm (Filler wire) for root & hot pass
2.5, 3.15, 4 mm (Electrode) for fill up and capping
Type of electrode flux : Low hydrogen, heavy coated
4. POSITION (QW - 405)

Position of Groove : 6G
Welding Progression : Uphill

202
5. PREHEAT (QW - 406)

Preheat Temperature min. : 150 O C

Inter pass Temperature min. : 300 O C
6. POST WELD HEAT TREATMENT (QW - 407)

Temperature : 704 to 760O C

Soaking time : 01 Hour minimum
Heating Rate : 100 O C / hr. max
Cooling Rate : 100 O C / hr. up to 300O C,
then natural cooling under asbestos.
7. GAS (QW - 408)

Shielding gas : Argon

Gas consumption : 99.995 %
Flow rate : 10 to 12 liters / min
Purging gas : Argon
Gas consumption : 99.995 %
Flow rate : 6 to 10 litres / min

8. ELECTRICAL CHARACTERISTICS (QW - 409)

Current : DC
Polarity : Straight for GTAW
Reverse for SMAW
Ampere (Range) : 80 to 130 for GTAW
70 to 190 for SMAW
9. TECHNIQUE (QW - 410)

String or weave bead : String and weave

Initial & Inter pass cleaning : Grinding & brushing
Oscillation : N.A.
Method of back gouging : N.A.
Contact tube to work distance: N.A.
Single or multiple pass : Multiple
Travel Speed (Range) : 4 to 6 cm/min for GTAW
8 to 12 cm/min for SMAW

203
10. WELD INSPECTION

Bevel Edge : DP Test

Root weld : DP Test & 100 % radiography
Final weld : DP Test & 100 % radiography
Hardness measurement after PWHT

204
 UREA PLANT

During Shutdown 2007, the following major inspection activities were performed in the
Urea plant.

1 Internal inspection of High-pressure vessels by M/S Stamicarbon Viz Autoclave

(V-1201), H. P. Stripper (H-1201) and H.P. Condenser (H- 1202).

2 Eddy Current testing of H. P Condenser and H.P Stripper tubes was carried out
by M/S Stamicarbon.

3 Internal inspection of other vessels in the Plant.

4 Ultrasonic thickness measurement of HP lines in the Plant. Detailed report is

attached at Annexure-1.

5 Ultrasonic thickness measurement of lines other than H.P lines in the plant.
Detailed report is attached at Annexure-2.

6 Ultrasonic thickness measurement of various equipment in the Plant. Detailed

report is attached at Annexure-3.

7 Dye Penetrant examination and radiography of weld joints of lines fabricated,

erected and offered by Mech. Maint. / Technical Department as per the
requirement.

8 Qualification tests of welders employed by contractors.

9 Residual magnetism measurement and demagnetization, wherever required of

Hitachi compressor (K-1801) Train. Detail report is attached at Annexure-4.

10 Degaussing of 60 ata steam line joint from 200 gauss to 60 gauss. and then root
weld carried out by E 6013 electrode and fill up by E-7018 using welding
transformer unit. Detail report is attached at Annexure-5.

10. Insitu-Metallography of selected equipment and pipelines was carried out.

Summary of observations and microstructure analysis is given in Annexure-6.

11. The detailed observations and recommendations for corrective actions required
on individual equipments are given below. All the observations were recorded
during inspection and were handed over to concerned maintenance and
operation group for necessary corrective action.

205
1.0 HIGH PRESSURE VESSELS:

High-pressure equipment of the Urea Plant was inspected by Stamicarbon from April
20. to April 25. 2007. Main observations are listed here :

AUTOCLAVE (V-1201):

VISUAL INSPECTION:

Thorough visual inspection of the liner, its welds, trays and internals was carried out
by M/S Stamicarbon. The observations made by them are reproduced below.

Top cover

x The sealing face has a circumferential groove. Further the condition is

satisfactory.

x The overlay welding is covered with a thick blue grey oxide layer and shows open
craters up to 2-3 mm depth.

x The sleeve of nozzle R3 (renewed in 2002) show some condensation corrosion

inside and around the weld to the cover.

x The gas outlet nozzle C2 shows inside scaling and some minor corrosion.

Gas Phase:

x The sealing face has a circumferential groove.

x The manway shows a blue grey oxide.

x No corrosion observed at the knuckle radius.

x The liner in the hemi-head shows a thin blue grey oxide layer & Small
condensation spots are observed.

x The top tangent weld has been checked for SIIC (stress induced intergranular
cracking) by a specialized EC-gap technique. No indications have been
observed.

Liquid Phase:

x Liquid level is about 5-10 cm above the tangent line.

x Top shell liner of BC.05 material is grey and slightly rough.

x Next to BC.05 liner is old liner of BC.01 material and is brown to dark brown.

x In the top area the liner is slightly rough and changes to smooth in the bottom
area. This indicates normal uniform corrosion slightly higher in top than in bottom.

206
x In compartment no-2 at a spot opposite to the downcomer shows a thickness of 3.8
mm just below the circumferential weld.(Exact location between 5th and 6th clit
counting from west to southside looking from manyway).

x Patches or inserts liners in compartments 3, 4, 8, 9, 10 and 11 are grey and slightly

etched.

x Bulging has not been observed anymore, except for some small portion in
compartment 5 which is very small and it is advised to keep it under attention.

x The longitudinal and circumferential welds are grey and rough in the top
compartments and changes to smooth in the bottom compartments.

x The downcomer is brown (BC.01); slightly rough in the top going to smooth in
bottom.

x The funnel is grey (BC.05) and slightly rough.

x In compartments 3 and 5 some parts of the downcomer have been made of BC.05
material, which is grey and etched. The welds of the downcomer show hardly any
corrosion.

x A gas cushion (blue/reddish oxides) has been observed around the liquid boxes in
compartments 2 to 6.

x The I-clips (BC.05) are bright grey and show some cross-cut end attack, specially in
the top area.

x The J-bolts and nuts are slightly etched. Some J-bolts are loose and should be
tightened.

x The HE-trays are brown; rough in the top area and changing to smooth in the
bottom area.

x The tray holes show considerable corrosion in the top to middle compartments.

x Wall thickness of the trays has decreased in top to middle compartments.

Liner thickness and other measurements:

The weld overlay thickness is measured with a Fischer DualScope MP4 (accuracy ~0.5
mm). The wall thickness of the liner was measured using a Panametrics Epoch LT with
a 5 MHz DA-301 probe (accuracy 0.1 mm). The measurements have been taken at the
same location as during previous inspections. Also, some measurement were taken in
compartment 2 and 3.

207
 Main Liner Thickness
Location Min. Max. Remarks Design/
(mm) (mm) Installed
Thk.(mm)
Compartment 1 4.64 Corrosion Rate as 6.50
Liner observed by (new)
Stamicarbon is 0.08 5.00 (old)
(mm/Year)
Compartment 2 3.8 4.7 Installed thickness 5 5.00
Liner mm.
Compartment 3 4.2 4.4 Installed thickness 5 5.00
Liner mm.
Compartment 5 4.82 Corrosion Rate as 5.00
Liner observed by
Stamicarbon is 0.09
(mm/Year)
Compartment 9 4.67 Corrosion Rate as 5.00
Liner observed by
Stamicarbon is 0.06
(mm/Year)
Downcomer Thickness
Downcomer in 8.1 8.4 The replaced
Compartment 5 downcomer part in 9.50
compartment 5 has a
wall thickness of 9.8-
10.0 mm.
Downcomer in 8.9 9.3 9.50
Compartment 9
Tray Thickness
Tray Thickness in 5.8 6.0 8.00
Compartment 1
Tray Thickness in 6.0 6.3 8.00
Compartment 5
Tray Thickness in 7.3 7.7 8.00
Compartment 9
Hole Diameter of Trays
Compartment 1 10.0 11.0 8.00
Compartment 5 10.0 11.0 8.00
Compartment 9 9.0 9.5 8.00

Top Cover 7.5 8.5 Overlay welding

Man way 6.8 6.9 Replaced 2002 6.5
Top dome 6.5 6.7 Replaced 2002 6.5
Liner below dome 6.5 6.7 750 mm section BC.05 – 6.5
replaced 2002
Bottom Dome 6.1 6.5 Replaced 1993 7.00

Other Areas

Note: These corrosion rates of the liner are normal for Stamicarbon reactors.

208
INSERT LINER:

Compartment Thickness Installed Year of

Nos. observed(MM) Thickness (MM) Replacement
3 6.5-6.8 - 1997
4 6.2-6.3 - 1999
8 6.4-7.0 - 2000
9 - - 2001
10 6.3-6.5 - 2002
11 6.5-6.8 - 2002

HP STRIPPER (H-1201):

VISUAL INSPECTION:

Top cover :

x The sealing face has some minor mechanical damage but condition is
satisfactory.

x The overlay welding is grey and smooth (machined) but no defects have been
observed.

x The center plate is covered with oxides but no corrosion has been observed.

Top channel :

x The sealing face is satisfactory.

x A thin blue grey oxide layer covers the overlay welding and liner in the gas phase
(man way, dome and part of cylinder) completely, except for the areas between the
strip beads. The liner and liquid inlet box in the liquid phase are grey and slightly
etched. Corrosion has not been observed.
x The overlay welding on the tube sheet is grey and slightly etched.
x The tube welds are bright and smooth. Between the tubes sometimes heavy oxide
deposition is present. It was advised to remove these deposits at the locations where
they may interfere with the liquid divider tubes.

x The tubes are smooth inside.

x However, about 100-200 tubes show corrosion and slight loss of wall thickness (<
0.5 mm) inside the tube at the location of the tube sheet welds.

x Tube #2531 shows an internal defect just below the tubesheet weld (see photo’s).
This to be plugged (top in tubesheet; bottom in tube ).

x The liquid divider tubes are grey and etched. Some urea deposits and oxide flakes
obstruct some of the liquid holes.

209
Bottom channel :

x The sealing face is satisfactory.

x The overlay welds in the manway are grey and slightly etched.

x There are gaps of 1-2 mm depth present between the strip beads.

x The overlay welds in the hemi-head are grey and etched; at the start/stop locations
slightly rough.

x The liner in the cylindrical section is grey and slightly etched.

x The tubesheet is covered with a thin blue grey oxide layer, which indicates the
presence of a gas cushion up to some 50 mm below the tubesheet.

x Some black coloration at the gas/liquid interface indicates some oil fouling.

x The tubes inside are smooth.

x Some etching is present at the cross section.

x The liquid outlet pipe and the gas inlet pipe are bright shiny and showed no defects.
Their nozzles and welds are in satisfactory condition.

BOTTOM COVER:

x The sealing face is in good condition.

x The overlay welding is very smooth and shows no defects.

x The vortex strips are in good condition.

SCALING MEASUREMENT:

x The scaling measurement was done in 30 nos tubes.

x The scaling thickness inside the heat exchanger tubes is between 0.5 and 1.0 mm.

Thickness Measurement:

Wall thickness of tubes:

All stripper tubes were measured for minimum wall thickness by Eddy Current technique
in the top 3-4 m. The accuracy of the measurement is 0.05 mm. The main results are :

x Lowest minimum wall thickness : 2.70 mm

x Highest minimum wall thickness : 3.05 mm
x Average minimum wall thickness : 2.93 mm

210
Also, some 234 tubes (~10%; rows 1,11,23,32,41,53,63) have been measured over the
full length. These measurements showed that the wall thickness was about 3.27 mm in
the non-corroded parts (bottom).
Minimum Maximum Design
Thickness Thickness Thickness mm
mm mm (Minimum)
Man way (Overlay) 13.00 15.00 8.00
Dome area (Overlay)- 8.00 10.00 8.00
minimum 7.5 mm
betn.the strip beads
Cylindrical area 8.10 8.80 8.00
(Liner)-Gas phase
Cylindrical area 8.10 8.20 8.00
(Liner)-Liquid phase
Tube sheet-Overlay 9.50 10.00 8.00
weld (Machined) (Machined)
Top Cover (Overlay) 9.00 10.00 8.00

Wall thickness of overlay welding and liner :

The weld overlay thickness is measured with a Fischer DualScope MP4 (accuracy 0.5
mm).The wall thickness of the liner was measured using a Panametrics Epoch LT with a
5 MHz DA-301 probe (accuracy 0.1 mm).

BOTTOM DOME:

Minimum Maximum Design

Thickness Thickness Thickness mm
mm mm (Minimum)
Man way (Overlay) 13.00 15.00 8.0
Dome area (Overlay) 9.00 12.00 8.0
Cylindrical area (Liner) 8.20 8.60 8.0
Tube sheet-Overlay 9.00 10.00 8.0
weld (Machined) (Machined)
Bottom Cover (Overlay) 11.50 13.50 8.0

TOP DOME:

* One no tube(# 2531) which was plugged on top & bottom tubesheet was DP tested
after Seal run & final welding.Ferrite measurement was carried out.Nil ferrite was
observed on welds.

H.P. CONDENSER H-1202:

VISUAL INSPECTION:

Top cover:

x The sealing face is satisfactory.

x The liner is grey and show some etching.
x The liquid inlet line and welds are bright grey and smooth.

211
Top channel :

x The internals (liquid inlet box with pall rings and liquid/gas divider plate) are grey and
slightly etched.

x The tray holes are 7.5 to 8.0 mm.

x The gasket sealing face is satisfactory.

x The liner and welds in the man way are grey and smooth.

x The liner and welds in the channel are grey and slightly rough.

x The liner around the gas inlet is partly covered with a blue grey oxide scale.

x The tray support clips are grey and slightly etched.

x The weld of one patch plate is penetrated and needs to be repaired. Because a clip
is partly located on top of the patch plate, it is necessary to remove the clip, repair
the weld and re-install the clip. In order to avoid future problems, please cut in the
weld metal (and not in the liner). Same was removed by grinding and no corrosion
was observed. Clit was again welded.

x The tube-to-tube sheet welds are bright grey and smooth.

x The tubes in the outer circumference are grey and etched; in the inner circumference
they are blue/brown and smooth. This indicates slightly more corrosion at the outer
circumference.

x A lot of tubes show burn-through defects. Some burn-through defects were repaired
during manufacturing.

x Also some tubes show inside some grinding spot around the burn through defects.
Keep attention to these spots during next general shutdowns.

Bottom Channel :

x The sealing face is satisfactory, but it has 3 grooves in circumferential direction.

x The manway liner is grey and smooth.

x In the hemi-head and cylindrical area the liner is grey and etched.

x All liner welds and repairs are bright and smooth (end craters slightly etched).

x The tubesheet welds are bright shiny and smooth; the tube sheet overlay is slightly
etched.

x Also at the bottom section many tubes show burn-through defects (some already
repaired during manufacturing).

x Two tubes (# 982 and 1214) show heavy burn through spots and wall thickness loss
at the burn through spot. These two tubes were plugged.
212
Bottom cover :

x The sealing face is satisfactory, but there are 3 circumferential grooves present at
the sealing face.

x The liner is grey metallic and hardly etched.

x The vortex breaker and welds are smooth.

x However, the welds vortex breaker of the supports to the liner were not fully seal
welded.Same were seal welded and DP tested

* Two nos tubes (# 982 & 1214) which was plugged on top & bottom tubesheet was DP
tested after Seal run & final welding.Ferrite measurement was carried out.Nil ferrite was
observed on welds.

THICKNESS MEASUREMENT

Wall thickness of tubes

About 11% of the tubes (219 tubes) of the condenser have been measured over the
entire length for minimum wall thickness by Eddy Current technique (accuracy 0.05
mm). The main results are:

x Lowest minimum wall thickness : 2.45 mm

x Highest minimum wall thickness : 2.55 mm
x Average minimum wall thickness : 2.50 mm
x Average minimum wall thickness in April 2001 : 2.52 mm

Average corrosion rate since April 2001 : 0.00 mm/year

Weld Overlay and Liner thickness measurement:

The wall thickness of the liner was measured using a Panametrics Epoch LT with a 5
MHz DA-301 probe (accuracy 0.1 mm).
The weld overlay thickness has been measured using a DualScope MP4 (accuracy 0.5
mm).

BOTTOM DOME:

Minimum Maximum Design

Thickness Thickness Thickness
(mm) (mm) (mm)
Man way (Liner) 5.60* 7.10 6.0
Dome area (Liner) 6.70 7.10 6.0
Cylindrical area (Liner) 6.50 7.10 6.0
Tube sheet-Overlay 8.00 9.00 8.0 (Min)
weld
Bottom Cover (Liner) 19.0 20.0 18.0

x One spot near vertical seam is 4.6 mm

213
 TOP DOME:

Minimum Maximum Design

Thickness Thickness Thickness mm
mm mm (Minimum)

Man way (Liner) 6.10 7.40 6.0

Dome area (Liner) 6.40 6.80 6.0
Cylindrical area (Liner) 6.30 6.80 6.0
Tube sheet-Overlay weld 7.00 10.00 8.0 (min)
Top Cover( Liner) 19.0 20.0 18.0

2.0 INSPECTION OF OTHER VESSELS:

H-1131 A ( L.O COOLER FOR P-1102 A )

x Rusting and pittings were observed on the tube sheet.

x 2-3 mm deep pittings were observed on the channel divider plate.
x Minor scaling was observed inside the tubes.

H-1131 B ( L.O COOLER FOR P-1102 B/C )

x Tube to tube sheet joints were found satisfactory.

x Minor scaling was observed inside the tubes.

H-1204 ( Recirculation Heater):

x Cleaning of bottom tube sheet was not proper as hard scaling was observed
on entire surface of tube sheer and orifice plugs.

x Orifice plugs at bottom of tube sheet was found intact in position.

x Brownish coloration was observed on top tube sheet.

x Tube to tube sheet joint at top tube sheet was observed satisfactory.

x Thin brownish scale was observed on the inside of all tubes.

H-1207 (Circulation System-II Cooler ):

x Heavy corrosion/ pitting and scaling were observed on the tube sheet area.

x Corrosion & pittings were observed on the inside of end covers.

x Scaling was observed on the inside of all tubes.

x Outside surface of the tubes was found satisfactory. Tube bundle was pulled
out from the shell.

x Inside surface of shell was grayish in colour and all weld joints were found in
satisfactory condition.

214
H-1231 A/B ( L.O COOLER FOR P-1201 A/B)

x Tube to tube sheet joints were found satisfactory.

x Minor scaling was observed inside the tubes.

H-1352 (Reflux Condenser):

TOP TUBE SHEET:

x Scaling was observed on the tube sheet and the cleaning was not proper.After
hydrojetting tube to tubesheet welding was inspected and found satisfactory

x Hard scaling were observed on the inside surface of all the tubes looking from the
top end.

BOTTOM TUBE SHEET:

x Tube to tube sheet welding was found satisfactory on CW inlet side.

x Thick scaling was found on the CW outlet side tube sheet which was recommended
to clean properly.

x (c) On cooling water outlet side, grey scaling & dust was observed inside almost all
the tubes. Proper cleaning was recommended.

x Entire inside surface of cooling water outlet line was found covered with thick gray
color scales.

x Brownish rusting scales were observed on entire surface of Inlet & Outlet channel
and also on the inner surface of CW inlet line.

H-1419 (Pre-evaporator Condenser) :

BOTTOM TUBESHEET:

x Tube to tube sheet weld wasfound satisfactory.

x Scaling was observed on the inside surface of tubes on CW outlet side.

x 1 ½ “ nozzle pipe was observed partially choked.

TOP TUBESHEET:

x Tube to tube sheet weld was found satisfactory.

x Minor scaling was observed inside the tubes.

x Brownish coloration was observed on the tube sheet.

x Overall condition of heat exchanger found satisfactory.

215
H-1420 ( FINAL CONDENSER ) :

x Bottom tube to tube sheet welding was found satisfactory.

x Rusting/ brownish scaling was observed on inside surface of channel covers.

H-1421 (Flash Tank Condenser):

x Tube to tube sheet welding was found satisfactory.

x Minor scales were observed inside the some tubes.
x All tubes were found filled with water.

H-1422 ( 1st Stage Evaporator ) :

x The shell and Dish ends have assumed grayish black in coloration with scattered
brownish and whitish patches.

x Grayish hard scales were observed at scattered locations.

x Colouration of the tube sheet was grayish.
x (d)) Tube to tube sheet weld joints were found satisfactory.

x Grayish scales were observed on the inside surface of tubes.

x Condition of impingement cone was found satisfactory.

x Impingement cone to support welding was found satisfactory.

x Condensate distributor was found satisfactory.

x Water was found accumulated at the bottom of the dish end.

H-1423 (First Stage Evaporator Condenser):

x Tube to tube sheet welding was found satisfactory.

x Minor scales were observed inside few tubes.
x Tube sheet was found brownish in coloration.
x All tubes were found filled with water.

H-1424 ( 2 nd Stage Evaporator ) :

x Colouration of vessel was found black in coloration just above the dish end welding.
Rest of the surface was found bright.

x Tube to tube sheet weld joints were found satisfactory.

x Impingement cone was found bent in downward direction at two locations, one is in
north-west direction and the other is in south-east direction

x Thin whitish scaling was observed inside of all tubes.

x Water and debris was found on the bottom of the dish end.

216
H-1425 (Second Evaporator First Condenser):

x Tube to tube sheet welding was found satisfactory.

x Whitish scale was observed inside the tubes.
x Overall condition of vessel was found satisfactory.

H-1426 (Second Evaporator Second Condenser):

x Tube to tube sheet welding was found satisfactory.

x Tube sheet was found brownish in coloration.

x All tubes were found filled with water.

H-1814-A and H-1814 B ( L.O. Cooler of Hitachi Compressor ):

x Tubes and tube sheet were found satisfactory.

x Epoxy coating was found damaged in the dome cover of H-1814A.

H-1815 ( Surface Condenser for Hitachi Compressor ):

SOUTH SIDE HALF (West side channel)

Bottom half:

x Tube sheet found in satisfactory condition.

x Minor scaling was observed inside the tubes.

Top half:

x Tube sheet was found in satisfactory condition.

x Minor scaling was observed inside the tubes.

x Epoxy coating was found damaged at some localized spots.

SOUTH SIDE HALF (East side channel)

Top half:

x Tube sheet was found in satisfactory condition.

x Minor scaling was observed inside some of the tubes.
x Epoxy coating was found damaged at the edge of the tube sheet.

Bottom half:

x Tube sheet was found in satisfactory condition.

x Minor scaling was observed inside some of the tubes.
x Water was found coming out from some of the tubes

217
North side Half (East side cover)

x Tubes and tube sheet surface condition was found satisfactory.

x Epoxy coating was found peeled off at several locations from seating surface, edge
of partition plate and adjacent area near tube sheet, channel cover. .

North side Half (West side cover)

x Tubes and tube sheet surface condition found satisfactory.

x Epoxy coating was found damaged at many locations resulting in minor corrosion of
shell material underneath.

T-1301 ( Ammonia Water Tank ):

x Brownish coloration on bottom plate and bottom half of shell and silver bright
coloration on top half of shell was observed.

x Bottom plate was found bulged up side at different locations. Same was observed in
past also.

x Weld joints and nozzle condition was found to be satisfactory.

T-1301-A ( New Ammonia Water Tank) :

x Brown coloration on bottom plate and bottom half of shell and silver bright coloration
on top half of the shell was observed.

x All weld joints and nozzle condition was found satisfactory.

T-1401 ( Urea Solution Tank ):

x Bottom plate is having bulging upward as has been observed in the past.

x Weld joints condition was found satisfactory.

x Dark brown coloration was observed inside the tank.

x Stiffener provided on top roof plate was found intact in position.

T-1401-A ( New Urea Solution Tank ):

x Brownish gray coloration was observed on the inside of the shell.

x Nozzles and weld joint condition was satisfactory.

218
T-1501 (Condensate Tank):

x Brownish black coloration was observed inside the tank.

x Condition of Weld joint was found satisfactory.

x Condition of the patch plate and its weld joints was found satisfactory.

x North side support to clit welding of west side return condensate line was found
cracked.

x In general, condition of the tank was found satisfactory.

V-1101 ( CO2 Knock Out Drum ):

x Epoxy paint was found peeled off from few locations, however primer at these
locations was found intact and no sign of corrosion was observed.

x Demister pads were found intact in position. At few locations it was found chocked
(covered) with yellow color debris.

x Grey debris was found at the bottom dished end, proper cleaning was
recommended.

V-1102 ( NH3 Suction Filter ) :

x Oily surface was observed inside the vessel.

x Overall condition of the equipment was found satisfactory.
x Colouration of vessel was found brownish from inside.

V-1103 ( NH3 Suction Vessel ):

x Coloration of vessel inside was blackish.

x The condition of longitudinal and circumferential weld joints was satisfactory.

x Oil layer and debris were found on the bottom-dished end.

x Proper cleaning was recommended.

V-1202 ( Rectifying Column ):

From Top Manhole:

x Coloration of vessel was grayish at man hole position and blackish at dome and
shell portion.

x Black hard scales were observed at the top dish end and also at the shell portion.

x Brownish grey hard scales were observed on the surface of trays.

x Condition of trays was found satisfactory and intact in position.

219
From Bottom manhole:

x Colouration of top cone was silver with black patches where as brownish coloration
was found on bottom-dished end.

x Condition of the weld joints was found satisfactory.

x Overall condition of the vessel was found satisfactory.

V-1203 ( L. P. ABSORBER ):

From Top End:

x Colouration of shell was observed grayish black.

x Perforated support grid just below top hand hole was found intact in position.

From Bottom End:

x Colouration of shell was observed brownish black whereas in some areas it was
grayish.

x Condition of weld joints was found satisfactory.

V-1207 ( L. P. Scrubber ):

From Top Manhole :

x Colouration of shell portion was observed grayish black.

x Grating condition was satisfactory.

V-1301 ( 2ND Desorber ):

Bottom Compartment:

x Brownish coloration was observed inside the vessel.

x One clamp of the tray was found loose.

x Nozzle condition was found satisfactory.

Top Compartment:

x Brownish coloration was observed inside the vessel.

x All fasteners and its clamp of the tray were found in good condition.

x Top nozzle was found satisfactory.

x Scaling inside the 4” nozzle at south end was observed.

220
V-1351 ( HYDROLYSER ) :

Visual inspection of only top and bottom compartment was carried out.

Top Compartment:

x Top dish end and shell has assumed brownish black coloration and brownish sludge
was found sticking on the edge of trays.

x Trays had brownish coloration.

x Fasteners were found intact in position.

x Condition of top tray was found satisfactory.

Bottom Compartment:

x Brownish coloration was observed from inside.

x Fasteners of trays were found intact in position

x Oil layer was observed all around the bottom compartment.

x Three nos. of bolt/nuts of steam inlet flange were found missing/loose.

x Clamping bolt of steam inlet pipe to shell was found loose.

V-1352 ( First Desorber ):

From Bottom Manhole:

x Brownish coloration was observed inside the vessel.

x One clamp of the tray was found missing.

x Weld joint condition was found satisfactory.

From Top Manhole:

x Brownish coloration was observed inside the vessel.

x All fasteners were found intact

x Weld joint condition was found satisfactory.

x All internals were found intact in position.

x Water was found leaking from the inlet flange of reflux line.

221
V-1418 (Pre Evaporator Separator):

x Colouration of the vessel was found grayish at the top and brownish at the bottom
dish end.

x Condition of the cone and weld joints were found satisfactory.

x Grayish hard scales were found on the entire surface of tube sheet.

x Grayish hard scaling was observed on inside surface of all the tubes.

x Tube to tube sheet weld appeared to be in satisfactory condition.

x Impingement cone was found in intact condition.

x Water was found on the bottom of the dish end.

V-1423 ( 1 ST Stage Evaporator Scrubber ):

x Brownish coloration was observed inside the vessel.

x Minor damage of the demister pads was observed, also its supporting ring was
slightly lifted upward at few locations

x Solidified urea solution particles were found adhered at demister pads at few
locations.

x Nut of one no. J Bolt was found missing.

V-1501 (4 ATA STEAM DRUM):

x Coloration of shell and Dish ends was found brownish black.

x Distribution sparger was found intact in position.

x Demister pads were found intact in position and condition of the same was found
satisfactory.

x Water was found at bottom of the vessel.

x Condition of all weld joints were found satisfactory.

x Hard scaling was observed at both dished ends.

222
V-1502 ( 23 ATA Steam Drum ):

x Brownish black coloration was observed inside the vessel.

x All the internal fittings were found in good condition.

x Overall condition was found satisfactory.

V-1503 ( 9 ATA Steam Drum):

x Coloration of Shell and dished end was observed grayish black for the bottom half
where as brownish gray for top half.

x Scattered scales were observed on both the dished ends.

x Undercuts of approx. 0.5 mm depth were observed on the Manhole flange to dished
end welding at scattered locations.

x Nut of the south side U-clamp of inlet steam header was found loose.

x Welding of the clit support of BFW line was found cracked and the same was
marked for repair.

V-1811 (Ist Stage Separator):

x Demister pads were found intact in position.

x Vortex breaker was found intact in position.
x Overall condition of the vessel was found satisfactory.

V-1812 (IInd STAGE SEPARATOR):

x Demister pads were found intact in position.

x Vortex breaker was found intact in position.
x Overall condition of the vessel was found satisfactory.

V-1813 (IIIrd STAGE SEPARATOR);

As seen from the manhole no abnormality was observed.

Miscellaneous jobs:

x Inspection of damaged prill tower fan.Report and photographs.Detailed report is

attached at Annexure-7.

x Ultrasonic flaw detection of journal bearing of pinion shaft of K-1801 gearbox to

check its bonding.

223
 ANNEXURE-1
UREA PLANT PIPELINE THICKNESS MEASUREMENT SUMMARY OF HP LINES

Line Description
Nom Nom Min Thik.
Sr. %
Line No Bore Thick Observed
No. Red
(inch) (mm) (mm)
From To
8
23.01 K-1801-4TH 22.80 0.91
1 CO-2124-8”F10 STAGE GA-1602-8”-F2
4 13.49 13.0 3.63
DISCHARGE
3 11.13 11.7
2 CO-2122-6”E10 6 10.97 H-1813 V-1813 10.10 7.93
K-1801,HP
CASE-3 RD
3 CO-2129-8”F10 8 23.01 H-1813 22.40 2.65
STAGE
DISCHARGE
CO-F10-2199-
4 13.49 CO-E10-2139-PP25 12.80 5.11
CO-2140- PP25
4
PP25F-10 CO-F10-2140-
0.75 5.56 DRAIN 6.10
PP25
6 14.27 K-1101-2 GA-1201 16.00
BYEPASS
5 GA-1112-F2 1.5 7.14 6.60 7.56
LINE
0.75 5.54 6.90
GA-1112-6”-
6 GA-1201X4-6” 6” 13.33 H-1201 14.80 NIL
F2
7 GA-1202-1”-F2 1” 6.35 GA-1112-6”F2 GA-1203-1”-X1 5.70 10.24
GA-1202-1”-
8 GA-1203-1”-X1 1” 4.55 HP SCRUBBER 4.00 3.94
F2
GA-1202-1”-
9 GA-1204-1”F2 1” 4.55 PR-1231 3.70 18.68
F2
K-1801,CO- H-1201,GA-112-6”-
10 GA-1602-F2 8 23.01 21.70 5.69
2124-8”-F10 F2
GA-1602-8”-
11 GA-1603-4”-F2 4” 11.13 PIC-1810 11.60 NIL
F2
MA-1106/A-4”- 4” 8.56 P- 8.50 0.70
12 MA-1123-4”-E2
E2 1” 4.55 1102ADISCH. 4.70
MA-1106-B-4”- P-1102-A,MA- MA-1123-4”-E2,MA-
13 4” 8.56 7.20 15.89
E2 1605-6” 1203-4”
15 MA-1123-4”-E2 4” 8.56 P-1102B MA-1605-6”-E2 8.1 5.37
16 MA-1201 3 8.56 P-1102/B MA-1605-6” 6.200 18.64
2 5.54 4.80 13.36
3” 7.62 MA1201/MA- 7.30 4.20
17 MA-1202-3”-X4 V-1201
1605-6”-E2
MA-1106/B-4”-
18 MA-1203-4”-X4 4” 11.13 PR-1230-6”-X1 9.00 19.14
E2
6 7.11 MA-1122-6” MA-1603-4” 6.40 9.99
19 MA-1603-C2
4 6.02 MA-1603-4” P-1102/CSUCT. 4.90 18.60
P-
3 7.62 MA-1604 -4” 6.20 18.64
1102/CDISH.
20 MA-1604
4 8.56 MA-1604-3” MA-1605-6” 7.00 18.22
1.5 5.08 MA-1604-3” MA-1605-6” 3.80 25.20
MA-1123-4”-
21 MA-1605-6”-E2 6” 14.27 MA-1106/B-4”-E2 13.30 6.80
E2
4” 6.02 MA-1604-4”- 5.60 6.98
22 MA-1607-4”-C2 MA-1116-4”-E2
0.75 3.91 E2 3.00 23.27
RV OF P-
4” 6.02 MA-1503-6”-C2 5.10 15.28
1102C
23 MA-1609-4”-C2
RV OF P-
1.5” 5.08 REDUCER(1.5”X 1”) 4.60 9.45
1102C

224
24 PR-1201-8”-X1 8” 19.58 V-1201 H-1201 12.80 34.62
HP-CONDENSER
HP-
PR-1202-10”- H-1202
25 10” 24.33 STRIPPER 21.10 13.28
X1
H-1201
HP-
CONDENSER V-1201(VAPOR
26 PR-1203-8”-X1 8” 19.58 19.0 2.96
H-1202 LINE)

HP-
V-1201(LIQUID
27 PR-1204-8”-X1 8” 19.58 CONDENSER 19.40 0.92
LINE)
H-1202
STRIPPER
28 PR-1205-8”-X1 8” 19.58 BOTTOM H- V-1202 13.00 33.61
1201
29 PR-1205-6”-X1 6” 15.24 PR-1205-8” V-1202 12.20 19.95
AUTO CLAVE
30 PR-1208-4”-X1 4” 10.40 PR-1206-4-X1 8.0 23.08
TOP
SCRUBBER- AUTO CLAVE
31 PR-1212-4”X1 4” 10.40 8.70 16.35
H1203 BOTTOM
PR-1201-8”-
32 PR-1213-2”-X4 2” 5.54 PR-1205-6”-X1 6.60
X1
P-1201-B-
33 PR-1224-3”-X4 3” 7.62 PR-1638-4” 5.40 29.13
(DISCH.)
P-
34 PR-1225-3”-X4 3” 7.62 1201A/B,PR- H-1203 6.90 9.45
1638-4”
PR-1224-3”-
35 PR-1226-2”-X4 2” 5.54 PR-1666-2”-X4A 6.10
X3
MA-1203-4”- H-1202 HP
36 PR-1230-6”,X1 6” 15.24 15.0 1.7
X1 CONDENSER
H-1203 HP
37 PR-1231-3”-X1 3” 8.12 PRCV-1201,V-1203 7.90 2.71
SCRUBBER
P-1201-A-
38 PR-1234-3”-X4 3” 7.62 PR-1638-4” 6.20 18.64
(DISCH.)

225
 ANNEXURE-2
UREA PLANT PIPELINE THICKNESS MEASUREMENT SUMMARY(OTHER
PIPELINES)

Line Description
Nom Min
Sr. Nom
Line No Thk. Observed % Red
No Bore
(mm) thk.(mm)
From To
1 PR-1354-4”-X7 4 3.05 P-1351A/B H-1351A/B/C 3.10
2 PR-1357-6”-X3 6 3.40 V-1352 P-1351A/B 3.80
3 PR-1404-4”-X3 4 3.05 P-1401 V-1409 2.50 18.03
4 PR-1637-3”-X4A 3 9.14 P-1201/C PR-1638-4” 9.00 1.53
13.4 P-1201A/B/C,
5 PR-1638-4”-X4A 4” PR-1230-6” 12.20 9.561
9 PR-1637-3”-X4A
6 PR-1666-2”-X4A 2” 5.54 PR-1367-3”-X4A PR-1226-2”-X4 6.50
7 PW-1601-4”-B1 4” 6.02 PW-1352 H-1303 5.70 5.32
8 PW-1602-4”-B1 4 6.02 H-1303 PW-1354 5.30 11.96
9 PW-1603-4”-B1 4 6.02 PW-1352 T-1301/A 5.20 13.62
2”- WN1(HITACHI
10 PW-1604-2”-B6 2 2.77 DW-4302 SCOPE)
3.00
11 SC-1102-14”-B1 14 9.53 SC-1228 SC-1101 9.10 4.46
12 SC-1210-8”-C2 8 8.18 P-1204 SC-1210-10”-C2 9.00
13 SC-1210-10”-C2 10 9.27 SC-1210-8”-C2 H-1207 8.80 5.07
14 SC-1216-4”-B4 4 6.02 LICV-1204 SC-1407 4.80 20.27
15 SC-1216-2”-B4 2 3.91 V-1204 LICV-1204 4.40
P-1501 & P-
16 SC-1501-4”-B4 4 6.02 T-1501 4.70 21.93
1506
17 SC-1505-6”-B4 6 7.11 V-1503 T-1501 7.00 1.55
18 SC-1512-4”C1 4 6.02 SC-1213 LCV-1501 5.20 13.62
19 SC-1523-3”B4 3 5.49 HEADER SC-1409-4”-B4 4.00 27.14
20 SC-1601-10”-C2 10 9.27 SC-1211 H-1418 8.20 11.54
21 SC-1602-2”-B4 2 3.91 SC-1603 PR-1616 2.90 25.83
22 SC-1604-1”-B4 1 4.55 SC-1411 PR-1663 4.20 7.69
23 SC-1605-1.5”-B4 1.5 5.08 H-1418/A SC-1407 4.70 7.48
24 SC-1606-10”-C2 10 9.27 H-1418 SC-1211 9.20 0.76
25 SC-1607-1”-B4 1 4.55 SC-1226 PR-1636 3.10 31.87
ST- HITACHI
26 SC-1610-4”-B4 4 6.02 5.50 8.64
5152(EXISTING) BATT.LMT
DISCH.DAMPN
27 SC-1617-0.5-B4 0.5 3.73 SC-1609 3.70 0.80
ER
28 ST-1123-14” 14 9.53 PICV-1129 ST-1106 10.20
29 ST-1205-6”-C1 6 7.11 V-1502 H-1201 6.50 8.58
30 ST-1206-8”-B4 8 8.20 ST-1506-16”-B4 H-1204 7.80 4.88
31 ST-1502-2”-B4 2 5.54 ST-1502-8” PICV-1502A 4.60 16.97
8.50
32 ST-1502-8”-C1 8 8.18 ST-1116 ST-1503-12”
33 ST-1502-3”-B4 3 7.62 PICV-1502A ST-1502-12” 5.90 22.57
34 ST-1603-8”-B4 8 8.18 ST-1506-18”-B4 H-1418/A 8.10 0.98
17.4 60 ATA HITACHI
35 ST-1606-12”-E3 12 17.30 1.08
8 HEADER BATTERY LMT
HITACHI 23 ATA
36 ST-1607-12”-C1 12 9.52 9.00 5.46
BATTERY LMT HEADER
ST- HITACHI
37 ST-1608-16”-B4 16 9.53 9.60
1128(EXISTING) BATTERY LMT
6.61
38 ST-1612-12”-C1 12 9.53 ST-1607 ST-1181 8.90
VOL-BOT,P-
39 ST-1618-0.5-B4 0.5 3.73 ST-1611
1201/C
FS-1101,VAPOR
40 MA-1119-1”-B2 1 4.55 MA-1110-1”-B2 3.90 14.29
ELIMINATOR

226
 Annexure - 3
THICKNESS MEASUREMENT OF EQUIPMENT DURING S/D-2007

Shell Dish End Channel

Sr. Equip. Equip. Nom
Min./
No. No. Description ./ Min./ % Nom./ Min./ Nom./ Re
Red Meas
Desi Measured Red. Design Measured Design d.
ured
gn
STEAM COND.
1 T-1501 10.0 9.8 10.00 10.0
TANK
2 T-1418 MAIN LO TANK 06.0 5.8
3RD STAGE
3 V-1813 30.0 29.3 30.00 28.4
EVAPORATOR
2ND STAGE
4 V-1812 10.0 9.8 12.0 11.4
EVAPORATOR
1ST STAGE
5 V-1811 6.0 6.0 6.0 5.9
EVAPORATOR
PRE-
6 V-1418 12.0 12.0 12.0 10.2
EVAPORATOR
UREA
7 V-1409/A SOLUTION 6.0 6.5
FILTER
UREA
8 V-1409/B SOLUTION 6.0 6.4
FILTER
9 V-1406 FLASH DRUM 8.0 8.4
LEVEL TANK
10 V-1353 FOR REFLUX 6.0 5.8 6.0 6.0
CONDENSER
RECTIFYING
11 V-1202 9.0 9.7 11.0 11.5
COLUMN
NH3 SUCTION
12 V-1103 21.0 20.4
VESSEL
AMMONIA
13 V-1102 11.0 10.8
FOLTER
14 V-1101 CO2 K.O DRUM 10.0 8.8

SURFACE
15 H-1815 14.4
CONDENSER

ND
2 STAGE GAS
16 H-1812 10.0 9.8 12.0 11.1
COOLER

1ST STAGE GAS

17 H-1811 12.0 11.9 12.0 10.7
COOLER

2ND STAGE
EVAPORATOR
18 H-1426 7.0 7.7 9.0 8.9
2ND
CONDENSER

227
 2ND STAGE
EVAPORATOR
19 H-1425 12.0 13.4 18.3
1ST
CONDENSER

2ND STAGE
20 H-1424 10.0 11.6 12.0 10.8
EVAPORATOR

1ST STAGE
21 H-1423 8.0 10.8 10.0 13.0
EVAPORATOR

FLASH TANK
22 H-1421 8.0 7.6 11.0 11.6
CONDENSER

23 H-1207 CCS-II COOLER 10.0 9.9 10 7.8

RECIRCULATIO
24 H-1204 11.0 11.0 9.0 9.2
N HEATER

LP NH3
25 H-1102 9.4
PREHEATER
RD
3 STAGE GAS
26 H-1813 10.0 9.6 10.0 9.2
COOLER

228
 Annexure- 4
GAUSS MEASUREMENT & DEMAGNETIZATION REPORT

Sr. No. Component Description Max. gauss reading

Before After
K-1801,CO2 COMPRESSOR
1 Turbine South Bearing
1.1 Journal bearing shaft 1.5
1.2 Journal bearing pads 0.7
1.3 Journal bearing base ring 1.3
1.4 Thrust bearing base ring 1.6
1.5 Thrust collar 1.2
1.6 Thrust pads 1.4
2 Turbine North Bearing
2.1 Journal bearing shaft 20 0.9
2.2 Journal bearing pads 4.5 0.9
2.3 Journal bearing base ring 5.2 1.8
3 H P Case South Bearing
3.1 Journal Bearing Shaft 2.2
3.2 Bearing Pads 2.2
3.3 Bearing base ring 12 2.1
4 H P Case North Bearing
4.1 Journal Bearing Shaft 1.8
4.2 Journal Thrust Collar 1.8
4.3 Thrust Pads 3.8 0.6
4.4 Journal Bearing Pads 5.2 1.2
4.5 Journal Bearing Base Ring 15 3.0
5 L P Case South Bearing
5.1 Journal Shaft Portion 2.0
5.2 Journal Bearing Pads 6.3 0.6
5.3 Journal Bearing Base Ring 2.3
6 LP Case North Bearing
6.1 Journal shaft Portion 2.0
6.2 Journal Bearing Pads 6.3 1.0
6.3 Journal Bearing Base Ring 1.0
6.4 Thrust Collar 5.2 3.0
6.5 Thrust Pads 16 2.0
7 Gear Box
7.1 High Speed Pinion Shaft 2.9
7.2 Pinion Shaft Bearing 4.6 2.3
7.3 Low Speed Pinion Shaft 0.9
7.4 Gear Bearing 10.2 2.8
7.5 Sleeve bearing 7.9 2.0

229
 ANNEXURE-5

Report of Magnetization of 60 ata steam pipeline ( From BHEL Boiler to P.B.

Compressor Turbine ) weld joints and its repair work

(1) Bevel edges of weld joints W2 and W3 were found to be heavily magnetized
leading to difficulty in welding.

(2) Gauss measurement was carried out on the bevel edges of W1 and W3 and was
found to be around 200 gauss.

(3) Degaussing was carried out with coil method & electromagnet Yoke method and
was reduced to 28 - 30 gauss.

(4) As further degaussing could not be achieved, root and hot pass welding was done
with E-6013 electrode. DPT and root radiography was carried out.

(5) Final fillup was carried out with E-7018. DPT and radiography of final weld was
carried out.

(6) Welding was carried out using AC transformer.

LEGEND: W1,W2,W3,W4 –BUTT WELD JOINTS

NOTE: Modification of pipeline from Weld joint W1 to W4 Carried out for isolation of
PB compressor Steam Turbine

230
 ANNEXURE-6

DETAILS OF INSITU-METALLOGRAPHIC INSPECTION

MICROSTRUCTURE
SR.NO. LOCATION MOC REMARK
OBSERVATION
Location: 1 Carbon Microstructure shows fine gained IInd stage of
(Parent Metal) Steel ferrite and pearlite structure. In situ creep
HP STRIPPER spheroidzation of pearlite is degradations.
1.
H-1201 observed. (Plate: 108 & 109) Monitor after 1
Stub end gas year of service.
outlet top side
Location: 2 2RE69 Microstructure at weld shows fine No significant
(Weld/Haz) dendritic structure of austenite solid degradations.
HP STRIPPER solution with carbide precipitations During next
H-1201 at inter dendritic regions, where as available
2.
Stub end gas at parent metal microstructure opportunity
outlet top side shows coarse austenite grains internal inspection
without any carbide precipitants. of welding is
(Plate: 110 & 111) recommended.
Location: 3 Carbon Microstructure shows ferrite and Monitor after one
(Parent Metal) Steel pearlite structure, in situ year of service.
HP STRIPPER spheroidzation of pearlite is
3. H-1201 observed. Indications of creep
Stub end cavities are observed.
Liquid inlet top (Plate: 112 & 113)
side
Location: 4 2RE69 Microstructure at weld shows fine No significant
(Weld/Haz) dendritic structure of austenite solid degradations.
HP STRIPPER solution with carbide precipitations During next
H-1201 at inter dendritic regions, where as available
4.
Stub end at parent metal microstructure opportunity
Liquid inlet top shows coarse austenite grains internal inspection
side without any carbide precipitants of welding is
(Plate: 116 & 117) recommended.
Location: 5 Carbon Microstructure shows fine gained IInd stage of
(Parent Metal) Steel ferrite and pearlite structure. In situ creep
HP STRIPPER spheroidzation of pearlite is degradations.
5. H-1201 observed. (Plate: 118 & 119) Monitor after 1
Stub end gas year of service.
Inlet bottom
side
6. Location: 6 2RE69 Microstructure at weld shows fine No significant
(Weld/Haz) dendritic structure of austenite solid degradations.
HP STRIPPER solution with carbide precipitations During next
H-1201 at inter dendritic regions, where as available
Stub end gas at parent metal microstructure opportunity
Inlet bottom shows coarse austenite grains with internal inspection
side few carbide precipitants (Plate: 120 of welding is
& 121) recommended.
7. Location: 7 Carbon Microstructure shows fine gained IInd stage of
(Parent Metal) Steel ferrite and pearlite structure. In situ creep
HP STRIPPER spheroidzation of pearlite is degradations.
H-1201 observed. (Plate: 122 & 123) Monitor after 1
Stub end Liquid year of service.
outlet bottom
side

231
SR.NO. LOCATION MOC MICROSTRUCTURE OBSERVATION REMARK
Microstructure at weld shows fine No significant
Location: 8 dendritic structure of austenite solid degradations.
(Weld/Haz) solution with carbide precipitations at During next
HP STRIPPER inter dendritic regions, where as at available
8. H-1201 2RE69 parent metal microstructure shows opportunity
Stub end Liquid coarse austenite grains with few internal
outlet bottom carbide precipitants (Plate: 126 & 127) inspection of
side welding is
recommended.
Location: 9 Microstructure fine grained relativity
(Parent Metal) uniform ferrite and pearlite structure
HP with few widmanstaten ferrite
CONDENSER Carbon structures. In situ spheroidzation of Monitor after 2
9.
H-1202 Steel pearlite is observed. years of service
Stub end Liquid (Plate: 128 & 129)
outlet bottom
side
Microstructure at weld shows fine No significant
Location: 10
dendritic structure of ferrite pools in degradations.
(Weld/Haz)
austenite solid solution with carbide During next
HP
precipitations at inter dendritic regions, available
CONDENSER
10. SS 316 where as at parent metal opportunity
H-1202
microstructure shows coarse austenite internal
Stub end Liquid
grains without any carbide precipitants inspection of
outlet bottom
(Plate: 130 & 131) welding is
side
recommended.
Location: 11 Microstructure shows fine gained ferrite
(Parent Metal) and pearlite structure. In situ
IInd stage of
HP spheroidzation of pearlite is observed.
creep
CONDENSER Carbon (Plate: 132 & 133)
11. degradations.
H-1202 Steel
Monitor after 1
Stub end Gas
year of service.
outlet bottom
side
Location: 12 SS 316 Microstructure at weld shows fine No significant
(Weld/Haz) dendritic structure of ferrite pools in degradations.
HP austenite solid solution with carbide During next
CONDENSER precipitations at inter dendritic regions, available
12. H-1202 where as at parent metal microstructure opportunity
Stub end Gas shows coarse austenite grains without internal
outlet bottom any carbide precipitants.(Plate: 134 & inspection of
side 135) welding is
recommended.

232
 MICROSTRUCTURE REMARK
SR.NO. LOCATION MOC
OBSERVATION
Location: 13 Carbon Microstructure fine grained relativity Monitor after 2
(Parent Metal) Steel uniform ferrite and pearlite structure years of
HP with few widmanstaten ferrite service.
CONDENSER structures. In situ spheroidzation of
13.
H-1202 pearlite is observed.
Stub end (Plate: 136 & 137)
Liquid Inlet top
side
Location: 14 SS Microstructure at weld shows fine No significant
(Weld/Haz) 316 dendritic structure of austenite solid degradations.
HP solution without carbide precipitations,
CONDENSER where as at parent metal
14.
H-1202 microstructure shows coarse
Stub end austenite grains without any carbide
Liquid Inlet top precipitants (Plate: 138 & 139)
side
Location: 15 Carbon Microstructure fine grained relativity IInd stage of
(Parent Metal) Steel uniform ferrite and pearlite structure. creep
HP In situ spheroidzation of pearlite is degradations.
15. CONDENSER observed. (Plate: 140 & 141) Monitor after 2
H-1202 year of service.
Stub end Gas
Inlet top side
Location: 16 SS Microstructure at weld shows fine No significant
(Weld/Haz) 316 dendritic structure of ferrite pools in degradations.
HP austenite solid solution with carbide During next
CONDENSER precipitations at inter dendritic available
16. H-1202 regions, where as at parent metal opportunity
Stub end Gas microstructure shows coarse internal
Inlet top side austenite grains without any carbide inspection of
precipitants.(Plate: 142 & 143) welding is
recommended.
Location: 17 Microstructure shows fine gained IInd stage of
(Parent Metal) ferrite and pearlite structure. In situ creep
H-1203 Carbon spheroidzation of pearlite is observed. degradations.
17.
Stub end Steel (Plate: 144 & 145) Monitor after 2
Liquid outlet year of service.
top side
Microstructure at weld shows fine No significant
Location: 18
dendritic structure of ferrite pools in degradation
(Weld/Haz)
austenite solid solution without observed.
H-1203 SS
18. carbide precipitations, where as at Monitor after 2
Stub end 316
parent metal microstructure shows years of
Liquid outlet
coarse austenite grains without any service.
top side
carbide precipitants (Plate: 146 & 147)
Location: 19 Microstructure shows fine gained IInd stage of
(Parent Metal) ferrite and pearlite structure. In situ creep
H-1203 Carbon spheroidzation of pearlite is observed. degradations.
19.
Stub end Steel (Plate: 148 & 149) Monitor after 2
Liquid Inlet top year of service.
side

233
 MICROSTRUCTURE
SR.NO. LOCATION MOC REMARK
OBSERVATION
Location: 21 Carbon Microstructure shows fine gained IInd stage of
(Parent Metal) Steel banded ferrite and pearlite structure. In creep
H-1203 situ spheroidzation of pearlite is degradations.
21.
Stub end Gas observed.(Plate: 152 & 153) Monitor after 2
Inlet bottom year of service.
side
Location: 22 SS 316 Microstructure at weld shows fine No significant
(Weld/Haz) dendritic structure of ferrite pools in degradations.
H-1203 austenite solid solution with carbide During next
Stub end Gas precipitations at inter dendritic regions, available
22. Inlet bottom where as at parent metal opportunity
side microstructure shows coarse austenite internal
grains without any carbide precipitants. inspection of
(Plate: 154 & 155) welding is
recommended.
Location: 23 Carbon Microstructure shows fine gained ferrite IInd stage of
(Parent Metal) Steel and pearlite structure. In situ creep
H-1203 spheroidzation of pearlite is observed. degradations.
23.
Stub end Gas (Plate: 156 & 157) Monitor after 2
outlet bottom year of service.
side
Location: 24 Carbon Microstructure shows fine gained ferrite IInd stage of
(Weld/Haz) Steel and pearlite structure. In situ creep
H-1203 spheroidzation of pearlite is observed. degradations.
24.
Stub end Gas (Plate: 158 & 159) Monitor after 2
outlet bottom year of service.
side

234
 ANNEXURE-7

Inspection Report of damaged Prill tower fan(K-1401/1)

(a) All the 9 nos blades of fan observed to have been severely damaged/blades
broken on the non-cutting side edges. Photograph of damaged fan attached below.

(b) 3 nos Nut/bolts fastened on the drilled holes for balancing purpose found bent and
2 nos were intact in position.

Prill Tower fans 2,3 and 4 found in satisfactory condition.

235
 OFFSITES & UTILITY
PLANT

During Shutdown 2007, the following major inspection activities were performed in Utility
Plant.

x Inspection of BHEL boiler drums and furnace tubes.

x Re-examination of Primary & Secondary Super heater tubes by M/S Thermax, Pune.
x Inspection of deaerator.
x Inspection of RAH
x Inspection of Cooling Towers structures.

The detailed observations on individual equipment are given below. All the
observations were recorded during inspection and were handed over to
concerned Maintenance and Operation group for necessary corrective action.

1.0 BHEL BOILER ( GT-2068 ):

Visual inspection of Steam Drum, Mud Drum, Furnace tubes and Super heater
tubes was carried out during this shutdown. Also, ultrasonic thickness
measurement of all accessible tubes, steam drum, mud drum and super heater
tubes was carried out. The following observations were made during visual
examination.

STEAM DRUM:

x The internal surface of the drum had assumed blackish brown coloration.
x All the weld joints were found in good condition and free from any corrosion
attack.
x One no. angle support nut of distribution pipe (3rd counting from West side)
found loose.
x One no fastener of bottom plate just opposite 4th C clamp was found missing.
Overall condition of the steam drum was found to be satisfactory.

x Ultrasonic thickness measurement was carried out. Min. thickness was

observed to be 102.9 mm against nominal specified thickness of 97 mm in
cylindrical shell area and 83.2 mm on dished end against nominal specified
thickness of 77 mm.

Detailed report is attached at Annexure- 1

MUD DRUM:

ƒ The shell had assumed blackish brown coloration.

ƒ The condition of the weld joints was found satisfactory.

236
The tube stub ends were free from any defect.

In general, the overall condition of the mud drum was found satisfactory.

Ultrasonic thickness measurement was carried out. Min. thickness was observed
to be 82.2 mm in cylindrical shell area against nominal specified thickness of 78
mm and 58.4 mm on dished end against nominal specified thickness of 57 mm.
Detailed report is attached at Annexure - 2

DEAERATOR:

Inspection of the deaerator head and the storage shell was carried out.
Observations are as under.

Deaerator Head :

x Two nos. spring loaded safety valve located on the top observed to have
leakage from “O” ring.

x 5th sieve trays(counting from bottom ) was found lifted dislocated from its
position and crack was also observed at the north corner of its East side
segment.

Deaerator Storage Shell :

x Brownish coloration was observed inside the shell.

x Condition of the weld joint was found satisfactory.
x One no. nipple was found fallen inside the shell.

Regenerative Air heater (RAH):

x Cold End : All the buckets were found to have many loose/displaced fins.
x Hot End : All the buckets were found intact in position.

FURNACE TUBES:

In general, the condition of the furnace tubes and super heater tubes exposed to
flue gases was satisfactory. The thickness measurement of Stage-I & Stage-II
Primary and Secondary Super heater tubes, Bank tubes, Sidewall tubes, Baffle
wall tubes, D-Panel tubes, Cut corner tubes, Rear wall tubes and Front wall tubes
was carried out. Two nos. tubes sample from primary & secondary super heater
tubes was taken for lab analysis purpose for re-examination by M/S Thermax,
Pune and new piece of tube welded at these locations, weldjoints of the same
were inspected by DP test and radiography and were found satisfactory.
Thickness measurement of 1”NB vent line at Primary super heater outlet header
was carried out & the same was found to be 2.43 mm against the nominal
thickness of 4.55 mm, replacement of the same was suggested. The Summary
indicating the thickness of individual type of the tubes is given below:

237
 MIN.
SR, DESIGN REFER
DESCRIPTION THK. %RED
NO. THK.(MM) ANNEXURE
(MM)
1 SOUTH MANHOLE:
(A) BAFFLE WALL TUBES 4.4 4.5 2.22 Annexure - 3,7
(B) D-PANEL TUBES 4.8 4.5 - Annexure - 3,7
(C) CUT CORNER TUBES 5.0 4.5 - Annexure - 3,7
(D) REAR WALL TUBES 5.0 4.5 - Annexure - 3,7
(E) FRONT WALL TUBES 4.2 4.5 6.66 Annexure - 3,7
2 NORTH MANHOLE:
(A) BANK TUBES 3.5 3.6 2.78 Annexure - 4,7
(B) BAFFLE TUBES 4.4 4.5 2.22 Annexure - 4,7
(C) NORTH SIDE WALL TUBES 5.0 4.5 Annexure - 4,7
3 PRIMARY SUPERHEATER 6.1 7.1 14.08 Annexure - 5,7
TUBES INSIDE
FURNACE(STAGE-I)
4 SECONDARY SUPERHEATER 5.2 5.6 7.14 Annexure - 6,7
TUBES INSIDE FURNACE
(STAGE-II)

2.0 General Manager IFFCO Kalol unit had constituted a committee for detailed
health study of cooling towers at IFFCO Kalol Unit. The detailed observations of
the same are summarized below.

Committee has inspected the following cooling towers

x H-4401 (6 cells for Ammonia plant, i.e. A-1 to A-06)

x H-4402 (3 cells for Urea plant, i.e. U-1 to U-3)
x H-4403 (2 cells for Ammonia plant, i.e. A-7,A-8)
x H-4404 (3 cells for Ammonia/Urea plant, i.e. New Cooling Tower, NT-1 to
NT-3)

Major thrust of inspection was given on the following areas.

x Exterior wooden structures.

x Interior wooden structures.

x Exterior steel structures.

x CT Return risers and distributor headers.

x Concrete structure

238
Exterior wooden structures:

Sr.No. Item Satisfactory Repair/ Replace

H-4401 (6 cells for Ammonia plant)
1 Endwell casing & ¥
access doors
2 Stairway ¥
3 Fan Deck ¥
4 Fan Deck ¥
railing/supports
5 Ladders ¥
6 Distribution deck ¥
7 Distribution deck ¥
covers
8 Louvers x
Louvers are cracked / damaged at several
locations. It is recommended to replace the
louvers by FRP material.

H-4402 (3 cells for Urea plant)

1 End wall casing & ¥
access doors
2 Stairway ¥
3 Fan Deck ¥
4 Fan Deck ¥
railing/support
s
5 Ladders ¥
6 Distribution deck ¥
7 Distribution deck ¥
covers
8 Louvers x Louvers are cracked/ damaged at several
locations. It is recommended to replace the
louvers by FRP material.

H-4403(2 cells for Ammonia plant, i.e. A-7,8)

1 End wall casing & x Cracked at many places. Both the end walls
access doors need replacement by FRP material.

2 Stairway ¥
3 Fan Deck ¥
4 Fan Deck ¥
railing/supports
5 Ladders ¥
6 Distribution deck ¥
7 Distribution deck ¥
covers
8 Louvers x Louvers are cracked/damaged at several
locations. It is recommended to replace the
louvers by FRP material.

239
 H-4404 (3 cells for Urea Plant, i.e. New Cooling Tower)
1 End wall casing & ¥
access doors
2 Stairway ¥
3 Fan Deck x Deck wooden flooring TG planks has started
deterioration & needs replacement within 1-2
years.
4 Fan Deck ¥
railing/supports
5 Ladders ¥
6 Distribution deck ¥
7 Distribution deck ¥
covers
8 Louvers x Louvers are cracked/damaged at several
locations. It is recommended to replace the
louvers by FRP material.

Interior wooden structures ( Plenum area and distribution area)

Sr.No. Item Satisfactory Repair/ Replace
H-4401 (6 cells for Ammonia plant)
1 Load bearing Columns ¥
2 Diagonals ¥
3 Partition and doors ¥
4 Drift eliminators ¥
5 Walkway ¥
6 Long rails x CS fastening bolts/nuts of lap joints of
joining members has got corroded at
several places.
H-4402 (3 cells for Urea plant)
1 Load bearing Columns ¥
2 Diagonals ¥
3 Partitions and doors x Partition wall wooden planks are
dislocated at several places.
4 Drift eliminators ¥
5 Walkway ¥
6 Long rails ¥
H-4403 (2 cells for Ammonia plant, i.e. A-7,A-8)
1 Load bearing Columns ¥
2 Diagonals ¥
3 Partitions and doors ¥
4 Drift eliminators ¥
5 Walkway ¥
6 Long rails x CS fastening bolts/nuts of lap joints of
joining members has got corroded at
several places.
H-4404 (3 cells for Urea plant, i.e. New Cooling Tower)
1 Load bearing Columns X One column of cell no.1 and one column
in cell no. 2 has got bent.
2 Diagonals ¥
3 Partitions and doors ¥
4 Drift eliminators x At few locations drift eliminators has got
dislocated/removed from its place.
5 Walkway ¥
6 Long rails ¥
240
Exterior steel structures:

Sr.
Item Satisfactory Repair/ Replace
No.
H-4401 (6 cells for Ammonia plant)
Steel structures X At few places corrosion
1 a) Pipes supports is observed and repair /
b) Cable trays replacement / painting
c) Ladders and hand railings is required.
d) Connecting platform for H-4403
H-4402 (3 cells for Urea plant)
1 Steel structures X At few places corrosion
a) Pipes supports is observed and repair/
b) Cable trays replacement /painting
c) Ladders and hand railings is required.

H-4403 (2 cells for Ammonia plant, i.e. A-7,A-8)

1 Steel structures X At few places corrosion
a) Pipes supports is observed and repair/
b) Cable trays replacement/painting is
c) Ladders and hand railings required
Connecting platform for H-4403
H-4404 (3 cells for Urea plant, i.e. New Cooling Tower)
1 Steel structures X At few places corrosion
a) Pipes supports is observed and repair/
b) Cable trays replacement/painting is
c) Ladders and hand railings required

CW Return risers and distribution headers:

Sr.
Item Satisfactory Repair/ Replace
No.
H-4401 (6 cells for Ammonia plant)
1 Return Risers ¥
2 Horizontal distribution headers ¥
H-4402 (3 cells for Urea plant)
1 Return Risers ¥
2 Horizontal distribution headers ¥
H-4403 (2 cells for Ammonia plant, i.e. A-7,A-8)
1 Return Risers ¥
2 Horizontal distribution headers ¥
H-4404 (3 cells for Urea plant, i.e. New Cooling Tower)
1 Return Risers ¥
2 Horizontal distribution headers ¥

241
 Concrete structure:

Sr.
Item Satisfactory Repair/ Replace
No.
H-4401 (6 cells for Ammonia plant)
1 Inside basin ¥
2 Outside basin ¥
H-4402 (3 cells for Urea plant)
1 Inside basin ¥
2 Outside basin ¥
H-4403 (2 cells for Ammonia plant, i.e. A-7,A-8)
1 Inside basin ¥
2 Outside basin ¥
H-4404 (3 cells for Urea plant, i.e. New Cooling Tower)
1 Inside basin ¥
2 Outside basin ¥

3.0 MISCELLANEOUS JOBS:

D.P. TEST:

Dye penetrant examination of weld joints of all the pipelines fabricated by

contractors/departmentally, new pipeline fabrication / modifications job done by
technical and maintenance groups etc. was carried out after root run welding and
after final welding, as per requirement. Any defects observed during the tests were
rectified in the presence of inspector followed by DP test for acceptance.

RADIOGRAPHY:

In order to ensure immediate radiography work and urgent processing of films, teams
were hired on round the clock basis during entire shutdown period. Radiography was
performed on the weld joints of the pipe lines fabricated by all contractors as well as
departmentally wherever required.

HARDNESS MEASUREMENT:

Measured the core hardness of pinion shaft for gear box of C.W. Pump, P-4403
and found to be 286 to 320 BHN.

242
 ANNEXURE -1

THICKNESS MEASUREMENT REPORT OF STEAM DRUM

SHELL Design Thickness : 97 mm

POINT NO. TOP BOTTOM NORTH SOUTH
(W to E)
1 103.6 104.5 104.4 104.8
2 - - 104.7 105.3
3 - - 104.5 104.3
4 - 104.2 104.3
5 - - 104 104.4
6 102.9 105.3 103.6 104.7
DISH END: Design Thickness : 77 mm

POINT NO. TOP BOTTOM NORTH SOUTH

East 83.2 83.5 83.3 83.2
West 83.3 83.2 83.7 83.3

ANNEXURE -2

THICKNESS MEASUREMENT REPORT OF MUD DRUM

SHELL: Design Thickness : 78 mm

POINT NO. TOP BOTTOM NORTH SOUTH

(W to E)
1 82.7 82.8 82.8 82.2
2 82.5 82.8 82.9 82.7
3 83.1 83.1 83.0 82.9
4 83.0 83.6 82.9 83.2
5 83.1 83.2 83.0 83.2
6 82.7 83.3 82.9 83.3
DISH END Design Thickness : 57 mm

POINT NO. TOP BOTTOM NORTH SOUTH

East 58.4 58.9 59.1 59.1
West 59.3 58.6 59.3 59.2

243
 ANNEXURE -3

THICKNESS MEASUREMENT REPORT OF D-PANELTUBES ,CUT CORNER

TUBES, REAR WALL TUBES, FRONT WALL TUBES AND BAFFLE WALL TUBES:

D-PANEL TUBES FRONT WALL TUBES:

TUBE NO. TOP BOTTOM SL. NO. TOP BOTTOM
1 5.2 5.3 1 5.0 5.1
8 5.2 5.2 7 5.0 5.1
14 5.0 5.0 13 5.0 4.9
20 5.1 5.2 21 5.0 5.1
26 4.9 5.0 29 4.2 4.5
32 5.0 5.1 35 5.1 5.1
48 5.1 5.1 41 5.2 5.0
44 5.0 5.1 44 5.2 5.4
50 5.1 5.0 BAFFLE WALL TUBES:
56 5.0 4.9 SR. NO. TOP BOTTOM
62 5.1 5.3 1 5.2 5.2
68 4.9 5.1 8 5.1 5.2
72 5.3 5.4 14 4.8 4.8
21 4.5 4.5
27 4.8 4.8
CUT CORNER TUBES: 35 4.6 4.6
TUBE NO. TOP BOTTOM 43 4.5 4.4
73 5.1 5.1 50 4.8 4.8
80 5.1 5.3 55 4.9 4.9
86 5.2 5.3 62 4.7 4.8
92 5.1 5.1
98 5.0 5.0
105 5.3 5.2
REAR WALL TUBES:
TUBE NO. TOP BOTTOM
106 5.0 5.0
113 5.3 5.5
116 5.2 5.4

Note : 1. All readings are in MM

2. Refer annexure-7 showing tube layout & numbers identifying the individual
tubes.
3. Design thickness of tubes : 4.5 mm

244
 ANNEXURE -4

THICKNESS MEASUREMENT REPORT OF BANK TUBES,

BAFFLE WALL TUBES AND SIDE WALL TUBES:

BANK TUBES “A” WALL(Design Thickness : 3.6 mm)

TUBE NO. TOP BOTTOM

2 3.5 3.9
7 3.8 3.7
12 3.6 3.7
BANK TUBES “B” WALL(Design Thickness : 3.6 mm)
TUBE NO. TOP BOTTOM
17 3.5 3.6
BANK TUBES “C” WALL(Design Thickness : 3.6 mm)
TUBE NO. TOP BOTTOM
22 3.9 3.5
23 3.6 3.5
BAFFLE (“D”) WALL TUBES (Design Thickness : 4.5 mm)
TUBE NO. TOP BOTTOM
32 5.2 5.1
37 5.1 5.2
42 5.2 5.1
NORTH SIDE WALL TUBES: (Design Thickness : 4.5 mm)
TUBE NO. TOP BOTTOM
2 5.0 5.2
7 5.2 5.5
12 5.5 5.0
17 5.1 5.0

Note : 1. All readings are in MM

2. Refer annexure-7 showing tube layout & numbers identifying the individual
tubes.

245
 ANNEXURE -5

THICKNESS MEASUREMENT REPORT OF PRIMARY SUPERHEATER

TUBES (STAGE-1):

BEND-A
TUBE NO. Minimum Measured Thickness
3 6.1
9 6.7
13 7.0
16 6.8
19 6.9
22 6.5
29 7.0
33 6.9
36 7.1
BEND-B
TUBE NO. Minimum Measured Thickness
3 7.1
9 7.2
15 7.3
21 7.3
27 7.0
33 7.3
39 7.3
BEND-C
TUBE NO. Minimum Measured Thickness
3 6.3
9 6.3
15 6.5
21 6.6
27 6.6
33 6.8
39 6.7
BEND-D
TUBE NO. Minimum Measured Thickness
3 7.2
9 6.2
15 6.7
21 6.8
27 6.8
33 6.5
39 6.2

Note : 1. All readings are in MM

2. Refer annexure-7 showing tube layout & numbers identifying the individual
tubes.
3. Design thickness of tubes : 7.1 mm

246
 ANNEXURE -6

THICKNESS MEASUREMENT REPORT OF SECONDARY SUPERHEATER

TUBES (STAGE-2):

WEST WALL BEND

TUBE NO. Minimum Measured Thickness
1 5.6
7 5.6
13 5.6
19 5.5
23 5.6
29 5.7
SOUTH WALL BEND
TUBE NO. Minimum Measured Thickness
1 5.3
7 5.4
13 5.5
19 5.4
25 5.5
31 5.7
37 5.5
EAST WALL BEND
TUBE NO. Minimum Measured Thickness
1 5.9
7 5.2
13 5.4
19 5.4
25 5.2
31 5.4
1 5.9

Note : 1. All readings are in MM.

2. Refer annexure-7 showing tube layout & numbers identifying the individual
tubes.

3. Design thickness of tubes : 5.6 mm

247
 ANNEXURE-7

NORTH SIDE WALL TUBES N

SOUTH WALL BEND

WEST WALL BEND
W
1 17 NORTH MANHOLE

SECONDARY 1
D A R Y SUPERHEATER
COIL(STAGE-2) EAST BANK TUBES (A,B,C)
WALL

A
BEND
PRIMARY 14
SUPERHEATER 18

B
COIL(STAGE-1) 27 1
C
A
B C D
117 13 44
1 D
BAFFLE WALL TUBE
REAR WAL TUBES

BAFFLE WALL TUBES(D)

63

FRONT WALL
CU
T
CO
10 R
NE
2 R
TU
BE
S
D- PANEL TUBES 2

72
2
SOUTH MANHOLE

BHEL BOILER FURNACE LAYOUT

(GT-2068)

248
 AMMONIA PLANT

Control valve : Maintenance jobs

FRCV- 1 : C/V diaphragm was opened and checked, C/V bottom flange was opened
and cleaned. General cleaning was done in positioner. C/V stroke was checked.

FRCV-2 : Replaced all gland packing. Actuator diaphragm was opened and checked,
found ok. Finally checked stroke.

FRCV-3 : C/V bottom flange was opened and cleaned trim part & refixed. Actuator
diaphragm was opened and checked found ok, same was refixed. All parts were
cleaned and overhauled. General cleaning of valve positioner was done. Replaced
gland packing. C/V stroke was checked.

ARCV-3 : C/V was opened from bonnet. Plug and seat taken out for inspection did
machining on plug. All parts were cleaned and overhauled & checked it for tight shut
off on test bench. Provided new gland packing and stroke was checked.

PICV-14 : C/V was opened from bonnet. Inspected Plug and seat. All parts were
cleaned, overhauled and assembled checked it for tight shut off on test bench. Serration
work on flange was carried out. Provided new gland packing & gaskets, finally C/V
stroke was checked.

FiCV-485: C/V was opened from bonnet. Inspected Plug and seat & machining were
done on plug/seat & Cage.Lapping was carried out & checked it for tight shutoff on test
bench. Finally reinstalled & checked stroke.

LCV-490: C/V was opened from bonnet. Inspected Plug and seat & machining were
done on plug/seat & checked it for tight shutoff on test bench. Finally reinstalled &
checked stroke.

PICV-181: Control valve was opened from line. Replaced bonnet & Line gaskets to
attend leakage. General cleaning was carried out & finally checked stroke online.

LCV-21: Control valve was opened from line. Inspected plug/seat ,machining carried out
& tight shutoff was checked on test bench. General cleaning was carried out & finally
checked stroke online.

MICV 1A TO 9A : General cleaning & checking was carried out & finally checked the
stroke.

MICV 1 TO 9 : General cleaning & checking was carried out & finally checked the
stroke. Replaced the diaphragm of MICV-1.

MICV 24 TO 32 : General cleaning & checking was carried out & finally checked the
stroke.

249
MICV- 32 : C/V was opened from line flanges. Diaphragm was opened and checked
and replaced and refixed. Plug and seat were machined and lapped . All parts were
cleaned, overhauled & assembled and stroke was checked.

LCV-105 : Control valve was opened from line, all parts were cleaned and overhauled.
C/V assembled & reinstalled and finally stroke was checked.

LCV-103 : Control valve was opened from line. All parts were cleaned and overhauled.
C/V assembled & reinstalled and finally stroke was checked.

FRCV-5 - Actuator diaphragm was opened and checked. Provided new gland packing.
& stroke was checked. Modified the feedback lever & provided new positioner of
Masoneilan make.

LCV-16 : General cleaning was carried out & provided new gland packing & checked
stroke.

LCV-18 : General cleaning was carried out & provided new gland packing & checked
stroke.

LCV-19 : General cleaning was carried out & provided new gland packing. & checked
stroke.

TRCV-142 : General cleaning was carried out & provided new gland packing & checked
stroke.

TRCV- 10 : C/V diaphragm was opened and replaced by new one. General cleaning
was done in positioner. C/V stroke was checked.

PICV-13A,13B & MICV-22 : C/V preventive Maintenance was done. Finally C/V stroke
was checked. Opened all tubing & CVs were dropped from line for flushing & reinstalled
& reconnected the tubing. Removed the grease nipple & plugged it.

FICV-9,10,11 : Preventive maintenance was carried out of all three valves. Checked
the stroke found ok.

FICV-7, 8, 15 : Preventive maintenance was carried out of all three valves. Checked
the stroke found ok.

PICV-3 & PICV-3a (old PICV-1027) : Opened the positioner & linkage of the PICV-3
valve & realigned the positioner & linkage system & finally checked stroke of both the
control valves.

PICV-1027: New control valve was installed by tech. dept. Cabling & tubing was done &
finally checked the stroke.

PICV-6 ; (V-27) : General cleaning was carried out & provided new gland packing &
checked stroke.

PRCV-4 : General cleaning was carried out & provided new gland packing & checked
stroke.

250
FICV-14 : C/V was opened from line. Plug, seat, cage were taken out, All parts were
cleaned, overhauled, finally assembled & reinstalled and checked stroke.

MICV-61 : CV was opened from bonnet & replaced the gasket. Provided new gland
packing and checked stroke.

MICV-56,57: Both the valves were removed from line overhauled all the parts &
Positioner then reinstalled with new gaskets & checked the stroke.

PCV-103J(Lube oil console): Opened the CV from line overhauled all the parts, found
actuator spring damaged ,replaced it with new one also replaced the diaphragm,
assembled & installed & adjusted it for 1.5 Kg/cm2 pressure in start up.

Sour oil Valve (103J HP) : Removed the valve from line overhauled the parts &
reinstalled & finally stroke was checked. Shaft of the valve replaced.

MICV-13 : Butterfly C/V was opened from line. Inspected internals(baffle) & cleaned, &
removed welding burs from line finally reinstalled and checked stroke.

USY-400 : Removed the valve from line overhauled the parts, checked it for passing on
test bench & reinstalled. Finally stroke was checked.

General Maintenance & stroke checking :

For total 88 nos. control valves general /cleaning, greasing & preventive maintenance
were carried out . Provided new gland packings wherever required. Also valve
positioner was cleaned and air header & regulator also flushed finally stroke was
checked.Tag no. of important control valves are as below :

1. TRCV-142,142A 11. LICV -416 21. LCV-134

2. V-7 12. FICV-470 22. LIC-185
3. V-5 13. PRCV-25 23. MICV-13,14,15,16
4. PRC-23 14. PRCV-24 24. PICV-20
5. V-18 15. PRCV-18 25. PICV-1016A & B
6. FCV-1017 16. LCV-1007: 26. PICV-7
7. V-4 17. PICV-002 27. TRC-12
8. V-1 18. PICV-006 28. TRCV-11
9. V-16 19. LCV-5 29. LCV-2
10. PIC-28 20. PIC-17 30. V-102

251
COMPRESSOR HOUSE JOBS :
Air Compressor (101J) :-
1. Removed all Radial , Axial and key-phasor probes along with relevant junction boxes,
speed pick-ups, T/C, pressure gauges and THI’s to facilitate mechanical jobs. After
completion of jobs the same were fixed back after cleaning/functional checking and
gap voltage adjustments for radial and axial probes were carried out.
x Replaced the probe of Probe Pt. No. EA
x Replaced the probe conduits of Probe Pt. No. 3V ,3H & AV,AK
2. HIC-101J : General cleaning and overhauling of governor positioner carried out ,
replaced its gauges, and air regulator, and checked lock out relay, cylinder leakage .
Positioner was fixed and stroke checking was performed.
3. ZSH-101J : Limit switch cable was replaced from LS to JB & wiring work & LS
installation work done.

4. PT-79 (Vacuum Tx.): Relocated the transmitter, for that related cabling, wiring &
impulse tubing work carried out.

5. Trip system of all compressors were checked with production people as per
design trip value.

6. All the Compressor Trip Sol. Valves coils were checked. Also all the JBs were
opened and termination were checked. Finally provided new sealing.

7. Beacon makes speed indicators of 101J,105J,103J were removed & shifted to

electronic workshop & modification & repairing work was carried out by company
service engineer to match the speed of local indication and control room display(4 to
20 mA. Output)

Ammonia Refrigeration Compressor (105J):-

1. Removed all Radial , Axial and Key-Phasor probes along with relevant junction
boxes, speed pick-ups,T/C, pressure gauges and THI’s to facilitate mechanical jobs.
After completion of jobs the same were fixed back after cleaning/functional checking
and gap voltage adjustments for radial and axial probes were carried out.
x Replaced the probe of Probe Pt. No. 8V

2. PRC-9 – 105J Governor’s pneumatic actuator assembly was checked . Replaced

complete actuator assembly. Checked Its stroke and lockout relay function.

Synthesis Gas Compressor (103J) :-

1. Removed all radial , axial and key-phasor probes along with relevant junction boxes,
proximeters , speed pick-ups,T/C, pressure gauges to facilitate mechanical jobs.
After completion of jobs the same were fixed back after cleaning/functional checking
and gap voltage adjustments for radial and axial probes.
x Replaced the probe of Probe Pt. No. 1H, 9B
x Replaced the probe conduits of Probe Pt. No. 3V ,3H .
x Removed & refixed 103JBT probes & governor positioner to facilitate mech. for
turbine OST work.

252
2. PRCV-12: Replaced the Piston/Cylinder & Positioner assembly with spare one. Its air
regulator, gauges was replaced. Checked air failure function. Stroke-checking from
control room was performed.

3. MIC-23: Replaced the Governor Positioner with calibrated one. stroke was checked
from control room . Controller action was reversed from DCS.

4. Probe Pt. No.BA.BB (103JAT Axial) : Prepared probe brackets as per new mech.
Coupling design & internal available space & provided new probes & checked the
float with mech. and adjusted the gap voltage.

5. Removed unused gauges/switches/cables/JB. From local panel of lube oil console.

6. Referruling & Cable glands sealing were provided for all T/C head of LP & HP case.

7. Calibration of all I/P convertor of Governor Positioners were carried out.

(HIC-101J,PRC-9,MIC-23,PRC-12)

8. Repaired the sol. Valve cable of FICV-7 control valve.

FIELD INSTRUMENTS JOBS :

1. TI-147: Replaced the heater outlet RTD with the new RTD.
2. LIC-105 and LIC-103 controller’s general maintenance were carried out.
3. Replaced TI-0046 and TI-0047 with new T/W and T/C of 102-C.

4. TI-61, 63, 64: Provided new junction box to remove pipe conduit & K type TC
cable laid from T/C head to new installed JB & wiring & checking was carried out.

5. 16 nos. Primary reformer bottom header thermocouple taken out and replaced all
by new T/Cs with new thermo wells.

6. Removed the entire tunnel T/Cs for inspection and refixed and replaced TI-69,
71, 74, 76, 77 T/Cs with new T/Cs.

7. Removed & reinstalled the instruments of ID fan and 104J to facilitate mech. Job.

8. Removed the 115JA and B instruments (Speed pickup, probes, T/Cs) to facilitate
mech. Work for the inspection of bearings.

9. TICV-406: Repaired the Hand jack assembly & checked operation of control
valve.

10. 11. USY-930: Removed the Sol. valve & Pneumatic connection & reconnected to
facilitate mech. Work.

11. Mechanical DP measurement / Hydro testing machine tubing done. Provided high
range pressure gauges for hydro test of vessels and lines.

12. Removed & refixed the Thermocouples & instrument of 103D, 112C, 108C2A &
109C2A to facilitate mech. Work.

13. Instrument air headers flushing were carried out in different areas.
253
14. LTS/HTS 3/8” SS. sample tubing from sample point to Lab. was done & provided
needle valves for isolation as per requirement of Lab.

15. Boiler Inspection: Provided Pressure gauges on HP pump and steam drum,
102C, pressure transmitter flushing and zero checking and other related work
with Boiler Inspection were carried out.

16. Provided new 4” flange connection for the installation of new coming O2
analyser, at Auxiliary Boiler. Tapping was closed with blind flange.

17. Provided Rota meters and help to facilitate mech. for welding work at elbow
leakage of S-50 (Syn. Converter)

18. 105D Metal temp. : All 12 Metal temperatures points (tag nos. MTI-105-1 to MTI-
105-12) from local panel to control room DCS were shifted as per requirement of
production people , for that provided all new thermocouples, Junction box and
related cabling and wiring work was carried out at T/C head, JB. And control
room. New configuration at DCS was done.

19. Annunciator -D : New Minillec make annunciator was commissioned and for that
necessary fabrication and wiring work carried out. Its functional testing for
individual group alarm was performed and found satisfactory.

20. 101F: Steam drum level monitoring system- “LEVELSTATE”.: Repairing work at
card level was carried out by Hitech service engineer. Finally performance was
checked. Found satisfactory.

21. ARC-3, LICV-12 control valve copper tubing was replaced with new SS. Tubing.

22. FT-934, FT-470, FT-471: Transmitter orifice tapping leakage was attended by
welding job and FT-935, FT-936 leakage was attended by providing new fittings.

23. 22. H-110-C: Faulty Cable of Flame scanner from local panel to Scanner was
replaced & necessary cable glanding /wiring done.

24. H-111: Ignitors were removed from furnace & cleaned & checked. Provided 2
nos. new spark plug.

25. 24. MIC-7 New cable laid from J.B to I/P converter as old one was faulty.

26. Two Junction Boxes near 107C were removed and shifted to new pole to
facilitate technical people to restructure the ladder fabrication job.

27. Removing and refixing of instruments at different location to facilitate mech. job
and as per requirement of production people were carried out.

28. C.G.Circulator : Rota meters removed from line then overhauled & fixed back.
General cleaning of other instruments were carried out & checked performance.

29. Provided new sample tubing in LP flash vessel.

254
Following ISO related quality/Safety affecting instruments were calibrated:-

1. PT-7 9. PT-8 17. PT-10 25. PT-80

2. PT-150 10. PT-5 18. PT-4 26. FT-1
3. PT-62 11. PT-9 19. PT-36 27. TI-104E
4. FT-2 12. FT-3 20. FT-100 28. FT-1005
5. AR-1 13. PT-1027 21. FT-1006 29. TI-0011
6. PIC-1A 14. TI -0117 22. TI-0007 (TRC-10) 30. TIC-1025
7. TI-0026 15. TI-0039 23. TI-0036
8. PT-501 16. PT-503 24. PT-28

Following CDM related instruments were calibrated:-

1. FR-33 3. FR-6 5. FQI-181

2. PI-82 4. FI-65 6. PI-676

CONTROL ROOM JOBS :

1. Bently Vibration monitoring Panel to DCS(ALR-121 card) communication cable was

repaired by resold ring the wires on new D connector.

2. SP-4 : New MOV : Removed the interface Relay for indication in PLC and provided
direct wiring for MOV closing/Opening indication.

Technical Dept. Jobs :

1. PICV-1027 : Installed new control valve at pre-reformer and necessary cabling,

wiring & tubing job carried out. Finally checked the stroke.

2. FI-104E (Vortex) : New installation work for flow meter & related cabling, wiring work
and Configuration in DCS work carried out.

3. Provided 02 nos. new THIs for newly installed CNG preheater

Annual Maintenance of UPSS, DCS and PLC .

FUJI make UPSS

1. The preventive maintenance of UPSS was carried by M/s IL, Jaipur against the
AMC. General cleaning, servicing and configuration of parameter checking were
done.

2. UPSS to AVR Auto changeover was checked and found OK.

AMCO Battery

1. 7 nos. of Battery cells were replaced with the new cells in battery bank.
(cell no. 167,168,169,170,171,172,173,).

255
2. Cleaned all battery cells , terminals , inter cell connections. Did Topping of distilled
water in cells and tightened all inter cell connections and cables and measured the
Sp.gr and Voltage of each cell . Found total Voltage 246.8 V .

3. Battery bank was charged. After charging , Measured the Voltage of each cell . Total
Voltage reading was found to be 288 V .

4. 2 cycles of charging and 2 cycle of discharging were carried out . Reading of each
battery cell was taken.

5. Checking of UPSS & Battery operation was carried out and found ok. Details are
as under :

x Duration of discharging 20 minutes*

x AC load current 105 A
x AC output voltage 115 V ac
x Battery discharge up to 192 V dc
x Alarm settings for UPS-1 201 VDC
x Trip setting for UPS-1 192 VDC
x Alarm settings for UPS-2 202 VDC
x Trip setting for UPS-2 195 VDC

* Battery bank Performance is not satisfactory as per service engineer & recommended
to replace batteries Bank

YIL DCS:

DCS shutdown maintenance activities were carried out as per the AMC procedure.
The following activities were carried out in Ammonia plant.

1. Before starting preventive maintenance activities / AMC, Images of all control

stations were saved by on-line option on EOPS. Updated all EOPS parameters on
ENGS station. Saved tuning parameters of all control stations on ENGS. Taken total
HDD back up through boot loader & builder tools back up of both ENGS.Save tuning
parameters of BCV and FCS0101 on CS3K ENGS. Taken project back up and kept
on other HIS HDD.

2. The system was dismantled as per plant clearance and operating conditions like dust,
moisture and temperature were checked. All parameter were checked and found
within limits. Interior of system cabinets (SCN and I/O cards), FCS, CTBC, ENGS and
OPS were cleaned thoroughly. PCBs were inspected and inspection of data bus and
connectors were done. No abnormality was observed.

3. Printers and ECHU were cleaned / overhauled, wherever applicable.

EFCD/ENGS/EOPS/EFMS system and CPU back-up battery voltages and grounding
was checked and the same were found within specified limits in all stations.

4. Function of each component of the DCS was checked. YOKOGAWA diagnostic

software was run on FCS and BCV, the results of the test Program indicated the
healthiness of the system.

256
5. Calibration of I/O cards of selected 2 cards in each nest was checked and found OK.

6. Redundancy checks were performed on HF-BUS, Vnet, CPU, PS, AAB841 and MAC-
2 cards wherever applicable. As per redundancy feature, control transfer is taking
place to the standby properly. Presently left CPU and MAC-2 cards are in control in
all stations While checking I/O card redundancy in FCS0101, It was noticed that all
AAB841 loop card was not defined as duplex card in IO builder. Defined all redundant
card as a duplex in builder and check the redundancy feature, same was found
satisfactory except one AAB841 of location F4-3, which is presently showing fail due
to ELCO board problem.

7. The following components were replaced which were identified faulty during
Preventive maintenance. HKU of EFMS#03 of Centum-XL not working properly.
Replaced the HKU with the spare HKU brought by YIL . One MAC2 card was found
faulty, same was collected by YIL for repair/replacement on returnable basis.
Replaced faulty 24DC nest cooling fan of EFCD-2 and faulty Roof fan of ETBC
panels of Centum-XL and system cabinet of FCS0101 (provided connector TB for
roof fan connection). Presently all fans are functioning ok. Faulty HDD of HIS161
was replaced with spare HDD brought by YIL

8. Replaced 06 Nos. Battery of EFCD/EFMS with new battery . All HIS was upgraded
with R3.07 revision.

9. One Spare PC was loaded with HIS0164(Engs Station CS3000) key code and kept
ready for standby use. Other spare PC was checked for OS and found working
satisfactory. These PCs can be used as a spare for any running HIS by loading with
respective key codes.

10. Latest backup both total HDD and builder tools were taken for Centum XL and
CS3000 Latest project back up was taken on HDD and CD .

11. 105D metal temperature(12Nos) configured /defined in DCS .

12. LIC-480 ( Dehydrator level) scheme was modified and implemented as per IOC of
production people and taken trial for the same. Found ok.

HIMA PLC

HIMA PLC shutdown/ preventive maintenance activities were carried out as per the
AMC procedure.

1. Cleaning of filters, fans, cabinets etc. was carried out for all the four PLC stations.

2. Checked the redundancy of all the four PLC at card ,CPU and power supply level.

3. Modification was done in logics I-302, I-307 as per the MWO.

4. Faulty F-3237 card at locations 1314 in PLC-2 was replaced by new card.

5. Back up copy of all the programs (ELOP and Wizcon) were taken.

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ABB CO2 and CH4 Analyser(AR-1 & AR-2)

1. Preventive maintenance of ABB make CO2 and CH4 analyser was carried out.

CO2 and CH4 Analyzer were checked. Condition of sample cell was very good.
Optical alignment and phase alignment performed and sensor CPU board, detector
and cell were checked.

2. Manual Calibration of CO2 and CH4 analyser was performed & found ok.

CAPITAL JOBS CARRIED OUT IN ANNUAL TURNAROUND:

1. LIC-1, LIC-13, LIC-3, LI-101 : Replaced pneumatic head assembly by electronic

head assembly. Laid single pair cables of level troll and I/P for the respective valve to
JB’s.Configured the level trolls in DCS. Performed calibration and checked stroke
through DCS.

- Laid new cable from J.B to LRC-1 transmitter & termination done.

2. PEAK-150 FOR 101J/105J LUBE OIL CONSOLE: Installed new Peak-150

Woodward governor in control room and Pick up probes on pump and necessary
cabling, JB. mounting, wiring work was carried out. Finally checked the operation of
pump from Peak-150 found satisfactory. All the work was carried out in presence of
supplier service engineer and mech. Staff.

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 ISO 9001:2000

PREVENTIVE MAINTENANCE JOBS WERE CARRIED OUT As per the ISO

9001:2000

1. FUJI UPSS : The preventive maintenance of UPSS was carried by M/s I/L, Jaipur.
The general cleaning, servicing and configuration and parameter checking were
done as per AMC. The trip setting noted down using the hand held configurator.
Battery back up test carried out. Redundancy test and smooth change over function
for the UPS1 and 2 were checked.

2. YIL DCS :The preventive maintenance of DCS was carried by M/s YBL as per the
AMC. All EFCD, EOPS, EFMS and Engineering station cards were removed from
cabinet / panel and cleaned. Replaced the fans, cleaned the filter, panels and
cabinets. Checked the redundancy for CPUs, MAC2 cards, power supply and HF
buses. Engineering station and EOPS healthiness checked through software.

3. HIMA PLC :The preventive maintenance of HIMA PLC was carried out by M/s L & T
Ltd.as per the AMC. Cleaned filters, fans, cabinet and physical inspection were
carried out. Checked the redundancy for CPU, input and output cards, power supply
cards and HIMA buses.

4. AMCO BATTERIES BANK: The preventive maintenance of batteries was carried

out by M/s AMCO Ltd. as per the AMC.

5. CONTROL VALVES : Preventive maintenance of control valves were carried out by

general cleaning, greasing, positioner & I/P checking, gland replacement / tightening,
stroke checking.

6. TURBINE GOVERNOR CONTROLLERS:

x HIC-101J for 101JT: Carried out general cleaning and overhauling. Changed air
regulator of Governor positioner, stroke checked and overhauled.

x PRC-12 & MIC-23 for 103JAT & JBT : Carried out general cleaning and
overhauling of Governor positioner, stroke checked and completely overhauled.

x PRC-9 for 105JT : General cleaning, overhauling of governor positioner was

carried out and checked stroke.

7. CONTINUOUS IMPROVEMENT:

x Replaced old pneumatic level transmitters with new SMART electronic

transmitters for better reliability & performance. (LIC-1,13,3,101)

x Replaced old mechanical governor of 101J/105J lube oil console pump with new
Woodward make Peak-150 for better performance of compressors.

x CALIBRATION OF INSTRUMENTS : Safety & Quality affecting instruments were

checked and calibrated.

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 UREA PLANT

HITACHI (CO2) COMPRESSOR:

1. All RTDs and Thermocouples removed to facilitate Mech. Maintenance jobs.

Checked and installed back after mech. Maintenance job was over/ completed.

2. All vibration probes extension cables, Proximeter were removed, checked, and
installed back to facilitate Mech. Maintenance jobs. Probe for XE-1808 B was
replaced by new one.

3. Followings transmitters were calibrated:-

LICT-1821, LICT-1803, LICT-1805, LICT-1807, PI-1809, LT-1809, PT-1836, FT-

1801 (Antis urge), PT-1802A & B

4. Local Control Panel and Turbine ` Control Panel was cleaned. All wiring connection
were tightened.

5. TI – 1803 (Local indicator) was replaced by new one.

6. Followings Trip and Alarm Switches were cleaned, and checked for setting :-

PSLL-1838A,B,&C, PSL-1812, PSL-1813, PSLL-1844, PSHH- 1839A,B,&C, PSHH-

1843A,B,&C, PSLL-1801A,B,&C,PSL-1816, LSHH-1804, LSHH-1808, LSHH-1806,
PSL-1843, PSLL-1818A, B&C, LSHH-1822.

7. All junction boxes were cleaned, terminal tightened.

CONTROL/ MARSHALLING ROOM:

1. Annual preventive maintenance of DCS, under A.M.C. with Yokogawa India,was

carried out by Yokogawa Engineers. Batteries for FCS were replaced by new ones.
Battery Voltage of all ICS and FCS were taken and found O.K. Functionality
checking of FCS and all ICS by diagnostic soft - ware was carried out, by Yokogawa
representatives and found to be O.K.

2. DCS Scan time was more as compared to recommended scan time. Control loops’
assigned priority / scan time were properly changed, considering plant requirement,
and recommended idle time was achieved.

3. Annual preventive maintenance of OMRON PLC, under A.M.C. with “Masibus”

Gandhinagar was carried out. PLC CPU Battery of both CPU was replaced by new
ones.

4. Cleaning “Woodward” Governor console, for Siemens turbine in the control room,
was carried out.

5. Autoclave level measuring System’s Radiac Relay unit for LR- 1201 was calibrated.
The spare radiac relay also was calibrated.

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OTHER PLANT JOBS:

1. LRC-1201 and LH-1201 detectors were removed and installed back to facilitate
Mech. Maintenance jobs.

2. Stripper source of LRCV-1201 was removed and was shifted to the storage pit and
source was refixed after Mech. Maint. Work was over and put in line.

3. Radio active source of LR-1201 (Auto clave) was removed and source was shifted to
the storage pit. Source was refixed after Mech. Maint. Work was over, & put in line.

4. 8 nos. HP Thermowell removed and hydro tested. And all thermo well were refixed.
Following Thermo well were replaced by new one. TR-1205 Auto clave bottom and
TR-1206 Auto clave top.

5. Preventive maintenance of turbine flow meter for cooling water to Urea Plant was
carried out.

6. Following ISO Quality affecting instruments were calibrated:-

PT-5303, PT-4405, PT-1121, PT-1145, PT-1201, PT-1202, PT-1422, PT-1421, PT-

1105, PT-1802, SI-1401A, SI-1401B, FT-1201.

7. O2 Analyzer Panel was shifted to the new location near sample point at Hitachi
Comp. on ground floor, and put in line.

8. P-1102C: - Cables with J/B, for lubes oil pressure switches & Speed Indicator and
process high pressure discharge switches, were relocated at suitable place by
replacing them with new ones as the old cables were not in good condition.

9. LICT-1353 Transmitter ( Pneumatic ) was replaced by new Electronic Transmitter.

10. Following Transmitters were calibrated :

LT-1481, LT-1421, LICT-1207, LICT-1203, LICT-1202, LT-1481, PT-1282,

PT-1481, LT- 1701 A & 1701 B. LRCV-1201. PT- 1202. PT -1201C.

11. Following alarm and trip switches were calibrated :

PAHH-1194, PAH-1193, PHCO-1363A&B, PLCO-1102A, PLCO-1201A,

PALL-1195, PLCO-1102B, PSLL-1101, LSL-1357.

12. Coordinated with Production / Maintenance people for miscellaneous plant Jobs
related Production requirement, Mechanical maintenance’s requirements and
instruments maintenance jobs.

13. I/P Converters of following control valves were replaced by new. PRCV-1504, HICV-
1581, TICV-1701A.

14. PT-1130 and PT-1131 Both Transmitter were shifted in new location as line is re-
routed.

15. Instrument air header was flushed at various point.

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TECHNICAL AND GENERAL ENGINEERING RELATED JOBS:

Coordinated and worked for the jobs, pertaining to instrumentation area, with General
Engineering, mechanical maintenance, and production staff for installation and
commissioning of the Approved Schemes for 2006-07 and executed by

x General Engineering section, and,

x Mechanical Maintenance section.

Following was done for the above jobs:

1. Engineering work in DCS for new instrument loops was completed.

2. Input and output cards, required for these new control loops, were provided and
related signal cables were connected and all these new loop were checked for
proper functioning.

3 Existing instruments and control valves were removed and re fixed at new location
as per new P & I diagram or as required in the plant, and necessary cabling, tubing
were rerouted / relayed. Hard wiring, cabling, and engineering modification / changes
required at the DCS end for these job were completed and the loops were re
commissioned.

WEEP WHOLE CHECKING OF HP VESSELS:

1. Coordinated with production persons for weep holes tubings.

CONTROL VALVES:

1. Following control valves’ complete overhauling was carried out by dropping them
from line. Necessary parts were replaced. Trim parts were repaired by metal filling
and machining, surface finishing with turning and lapping. Hydraulic pressure testing
was carried out after complete assembly of the valves.

HICV-1202, LRCV-1201, HICV-1201, PRCV-1201, TICV-242, PICV-1353,PCV-1221,

PCV-1501, HICV-1422, FICV-1102, LCV-1501, LICV-1101,PCV-1979A, LICV-1501,
TICV-1701B, HICV-1101, FICV-1282, LICV-1401.

2. Following control valves’ partial overhauling and necessary parts replacement was
carried out by opening from the bonnet without dropping them from line. Necessary
parts were replaced. Trim parts were repaired by metal filling and machining,
surface finishing with turning and lapping :

LICV-1201, PICV-1201, FRCV-1201, FICV-1281, LICV-1204, LRCV-1421,TRCV-

1101, HICV-1421, HICV-1801, PICV-1810.

262
3. 30 nos. of the control valves’ preventive maintenance and oil painting was carried
out & valve stroke were checked including some of these important control valves:

LICV-1420, FRCV-1421, TICV-1201, TRCV-1201, HICV-1221A&B, LICV-1203,

PICV-1481, LICV-1430, PICV-1301, LICV-1425, LICV-1281,FICV-1385, PRCV-
1421, PICV-1421, PICV-1422, HICV-1425, PICV-1129,LICV-1504, PICV-1128,
LICV-1204, HICV-1101, LICV-1201, PICV-1131,PICV-1502A&B, TRCV-1422, LICV-
1502B, HICV-1422, PICV-1424

4. Monoblock valve of N/C Ratio meter was replaced by a new one, and put in line.

263
 OFFSITES & UTILITY
PLANT

BOILER PLANT:

CONROL ROOM JOBS:

1. Cleaning of DCS & PLC panels & hardweres were done under the CAMC Contract.
Following jobs are carried out.

x Replaced the 3 nos. of FANS making abnormal sounds.

x Upgraded the HIS software version from R 3.05 to R3.07. This is required for
Boiler and DM DCS Connectivity.

x Shifted the DCS and PLC engineering station at new location (Engireering room
is made under the control room renovation. )

x Redundency check of DCS and PLC were done. Found o.k.

x OPC connectivity between PLC to DCS HIS was found lost.

x Recovered the OPC connectivity after re-installing the Windos operating System
Windos XP SP -1 and configurating the OPC servers in HIS0161.

2. Operation of 2 nos. of MOVs were checked from DCS operator panel and after that
taken in line

3. Eye-Hye Drum Level indicator Relay Board was relocated.

FIELD JOBS:

1. Following field switch set value were checked.

x LSLL-1, LSL-2, LSL-3 of steam drum level .

x LLCO-5111, LAL-5111 and LAH-5111 of Deareator.
x PSL-1 F.D. Fan lube oil pressure low AOP START.
x PSL-11,PSH-12 of Furnace pressure.
x PSL-24, PSL-25, PSN-26 & PSL-27 of Ignition and fuel gas line.
x PSL-21 ,PSL-22 & PSL-23 fuel oil header

2. Checked set value of following lube oil system switches of motor and
turbine driven BFW pump.

x PAL-5114, PLCI-5113, PLCO-5112 for P-5111

x PAL-5113, PLCI-5112, PLCO-5111 for Q-5111
x PAL-5115, PLCI-5114, PLCO-5113 for P-5112
x PLCI-5115 M-5112 AOP

3. Sample Filter of O2 Analyser was replaced with new one.

264
4. TR-13 Furnace Temp. T/C was replaced with a new one.

5. Following Damper’s limit switches, solenoids valves, air regulators etc. were
overhauled and checked its operation.

6. F.D. fan inlet damper and F.D. fan outlet damper.

7. Air heater inlet damper and Air heater outlet damper.
8. EYE-HYE Electrodes were checked and tighten all the terminal.

9. Press.gauges PI-2, PI-3, PI-4 & PI-5 were calibrated w.r.t. Boiler Inspection.

10. Installed F/I conv. & proxi switch for speed measurement of BFW pump P-5111 &
taken it in DCS.

11. Installed F/I conv. & proxi switch for speed measurement of LSHS Oil charge pump
P-5114 & taken it in DCS.

12. LNG heating temp. c/v TCV-25 was installed by Tech. deptt.Carried out necessary
cable connections in field JB & DCS marshalling cabinet. Temp. control loop was
taken in DCS.

13. Carried out all instrument jobs as per mech. requirement. BFW pump ( Motor/
Turbine driven) pressure switches, tacho generator, TI & PI were removed and
installed back.

14. Checked instruments as per ISO calibration schedule.

CONTROL VALVES:

1. Following control valves were removed from line for complete overhauling.
(Inspection/maint. of Seat/Plug, valve positioner, I/P Convertor, Actuator
diaphragm,Gland packing, cleaning of Air supply regulator,replacement of gasket
as required, c/v stroke checking etc. )

2. TCV-1(increased cv of valve), PCV-3065B, PCV-3(light machining of seat/plug

was carriedout), MICV-4401, FCV-1, PRCV-50, FRCV-22, PCV-3008, PCV-25,
PICV-5153, PICV-5151, GHTV, BTV-4A, BTV-4B, pHCV-4401

3. Following control valves were opened from Bonnet for partial

maintenance.(Inspection of Seat/Plug, valve positioner, Actuator diaphragm,Gland
packing, c/v stroke checking etc. )

4. TCV-3201A, TCV-3201B, TCV-3201C, PCV-1, LCV-5111, LCV-3064A, B/F Fire &

Safety, HOHTV, HORV, LRCV-4, PICV-1, LCV-3051B, LCV-3058B, LCV-
3056B, LCV-3053B, LCV-3064B

5. Following control valve’s preventive maintenance was carriedout.(General cleaning

& c/v stroke checking.)

265
6. PCV-3009, LCV-3051A, LCV-3058A, LCV-3065A, LCV-3053A, LCV-01, LCV-02,
Fire Hydrant, MICV-4401, PCV-50, PCV-2, TCV-2, FCV-2, BTV1-1,BTV1-2, BTV1-3,
, BTV-2-1.

IGNITORS:

Both Burner’s ignitor gun, spark plug, and gas & Oil flame scanners were
cleaned and checked. All furnace draft PI impulse lines were flushed with 7.0 kg/cm2
air.

D.M. WATER TREATMENT PLANT:

1. DCS RELATED JOB:

x Laid Cable trays & Instrument cables for field Instruments(I/P Convertors,
Transmitters) from local Junction Box to control room, Operator Consoles to
Marshalling and system cabinet. Laid the power cables from MCC indications &
controls from DM Marshalling room to MCC-2A/2E. Terminated the all cables
with lugs, ferrules .as per termination details & drawings.

x Laid the system cables between Operator consoles and system cabinet. Laid V-
net & OFC cables from Boiler Control Room to D.M. Control Room inside the
HDPE Conduit. Connected Vnet & OFC at both ends.

x Installed DCS Operator Consoles, Marshling and system cabinets , Other system
accessories (like Ethernet switches , LIU, Print server etc. ).

x Laid & Terminated UPS Power supply cable ( 110 VAC ) from Urea PDB to D.M.
PDB through Isolator switch & MCB.

x 3 Nos. of Earth pits ( System Earth, Panel Earth & Shield Earth) were made.
Earthing cables from Marshalling, system cabinet are connected to Earthing
strips located at marshalling room.

x 19 Nos.of new Electronic transmitters and 4 Nos. of I/P converters were

calibrated and installed.

x Erected and commissioned the DCS system for the D.M. Plant . All the
Sequence logic , Motor controls, Open loops and close loops are taken in line
through DCS. Performance of DCS system was observed found satisfactory.

Note : All the above mentioned activities were carriedout under guidence
and supervision of installation and commissioning engr. from
M/S YIL, Bangalore.

266
NH3 STORAGE:

x Replaced Amm. Vapour press. Controller(440R) of new Amm. Storage tank.

x Installed 3 nos. of UT-350 Electronic Temp. Controller for LSHS tank-A/B/C

COOLING TOWER:

x Q- 4411 (Eliot Turb.) All radial vibration probes , speed pick-up unit were removed
& reinstalled to facilitate mech. maint.
x Q-4411 Gear box pump side radial vibration probe no:3 was replaced with new one.
x 2 nos. of new thermowell were fixed on disch. line of P-4401B and P-4403
x FI-96 (C.W. to Amm. plant) flow transmitter was replaced with new one.
x Q-4401B turbine steam flow transmitter was relocated.
x R.W. inlet flow element (ANNUBAR) was removed from line. Same was cleaned
& fixed back.

I.G. PLANT:

Attended all running jobs.

Servicing and calibration of ABB make H2 analyzer of new I. G.
Plant. ( Service engineer From M/s ABB has completed this work.)

WEIGH BRIDGE:

x Calibrated the Ashbee make weigh bridge with standard weights

x upto 30 tones (near main gate)
x Calibrated the Mettler -Toledo make weigh Bridge with standard
x weights upto 25 tones (near pilot lab.)

EFFLUENT TREATMENT PLANT:

x Overhauling of SBA control valve and its valve positioner.

x Cleaning of sampling system and calibration of Ammonia analyzer.

267
 B&MH PLANT

BAGGING & MH PLANT:

1. POWER BUILD MAKE AUTOMATIC BAGGING M/C. (P/S No. 1,2,3,4,7 & 8)

x Checked wiring terminals in the main panel, local panel, Solenoid boxes, and
loadcell boxes.
x Cleaned and checked CIC-25, relays board, fuses, and all sensors.
x Checked function and calibration of all Packer Scales.

2. J.R.S.L MAKE AUTOMATIC BAGGING M/C (Computpak) Packer Scale No: 10A
& 10B)

x Installation & commissioning of new PBL make automatic bag filling machine in
place of JRSL make bag filling m/c No.10A
x and 10B panels are taken in line and checked performance of
x both m/c’s was observed, found satisfactory.
x All PCB's of computpak panels 9A/9B were removed and cleaned.
x Calibrated Computapak(UBM) 9A/9B
x Cleaned/checked all sensors of both auto bag placers.
x Cleaned the local panels and PLC Panels.and tightened all wiring
x terminals of local / PLC Panels.
x All oil lubricator was overhauled.

3. WEIGH SCALES: (Mettler-Toledo/Libra make)

x Cleaned the weighing scales , Digital Indicators.

x Cleaned the PCB of digital indicator.
x Calibrated all weighing scales.

4. BELT WEIGHER SYSTEM:

x Cleaned/Overhauled the tacho-meter assembly.

x Checked the healthiness of loadcells, tacho-meter, digital indicator.
x Checked the load cell performance by actually putting weights and checking milli
volts, the performance was found satisfactory.

5. DUST EXTRACTION SYSTEM:

x Cleaned the Dust Extraction Panel.

x Cleaned all field instruments (C/V,FlowTx,LevelTx etc.)related to
x DES.

268
 AMMONIA PLANT

1. Preventive maintenance carried out on transformers: TR-6, TR-21 & TR-22 and the
job details are as under:

x Inspection of primary and secondary cable boxes, end termination, checking

and tightening of connections.

x Measurement for Insulation resistance, BDV of transformer oil.

x Alarm & tripping contacts of Buchholz relay and MOG were checked.

x Condition of silica gel was checked. Discharged silica gel was recharged.

x Oil leakages from the transformers were attended and damaged gaskets were
replaced.

2. Preventive maintenance carried out on all the feeder compartments in MCC-5,

MCC-5 A/B, MCC-13 & MCC-16 and the job details are as under:

x Checked the tightness of outgoing terminals.

x Cleaned the feeder compartments.
x Replaced damaged/ worn out contacts, etc.

3. Overhauled the following motors:

101J, 104J, 104 JA, 104 JT, 104JTA, 106J, 107 JT, 118J, 118JA and 118 JB

4. Following existing Limitorque MOVs are replaced with new ROTORK actuator and
commissioning, testing and modification in wiring is done accordingly.

SP-152, SP-158,SP-159 and SP-4

5. Replacement of heating elements of PGR heater and carried out preventive

maintenance of local panels..

6. Preventive maintenance of TMG Breakers installed in MCCs was carried out.

269
 UREA PLANT

1. Preventive maintenance carried out on transformers: TR-7A, TR-17, TR-18, TR-

20 and the job details are as under:

x Inspection of primary and secondary cable boxes, end termination, checking

and tightening of connection.

x Measurement for Insulation resistance, BDV of transformer oil.

x Alarm & tripping contacts of Buchholz relay and MOG were checked.

x Condition of silica gel was checked. Discharged silica gel was recharged.

x Oil leakages from the transformers were attended and damaged gaskets were
replaced.

2. Preventive maintenance of all the feeder compartment in MCC 6 and MCC 14,
MCC 15 were carried out.

x Checked the tightness of cable & wiring terminals in the

feeders.

x Cleaned the feeder compartments.

x Replaced damaged/ worn out contacts, etc.

x Preventive maintenance of following MOVs were carried out:

MOV1101, MOV 1102, MOV 1201, MOV 1202, MOV 1203, MOV 1501 & MOV
1801.

3. Overhauled the following motors.

P1814 B, P1501, P1408, M1402 /1, M1402/2, P1131A, P1131 B, P1231 A, P1231
B, M1403/1,P1817, M1419, M1421, M1403/2, P1401 A, P1401 B, P-1231 C,
K1401/1, K1401/2, K1401/3 and K1401/4

4. Preventive maintenance carried out on all rope switches installed on conveyors:

M1402, M1403, M1419 & M1421 and replaced defective one with new.

5. Laying of power & control cables, Commissioning and testing of new chemical
cleaning pump, motor P-1206 and circulation pump motors P-1210 A & B.

270
6. Shifting, Commissioning and testing of P-1304 C & D motors at new location.

7. Retrofitting with Siemens 3WL breakers in feeders of K-1701 & K-1702 of PCS MCC
No-14 by removing 3WE old outdated breakers.

8. Overhauled the transformer TR-7B to improve the IR values of windings by lifting the
entire core. Inspection and cleaning of winding and replaced transformer oil. Painted
the transformer to arrest leakages with special anti-corrosive paint.

9. Preventive maintenance of TMG Breakers installed in MCCs was carried out.

271
 OFFSITES & UTILITY
PLANT

OFFSITES :
1. Preventive maintenance carried out on transformers: TR-1A, TR-1B, TR-1C, TR-
4A, TR-4B, TR-15, and job details are as under:

x Inspection of primary and secondary cable boxes, end termination, checking

and tightening of connection.
x Measurement for Insulation resistance, BDV of transformer oil were carried
out on each transformer.
x Alarm & tripping contacts of Buchholz relay and MOG were checked.
x Condition of silica gel was checked. Discharged silica gel was recharged
.
x Oil leakages from on the transformers were attended and damaged gaskets
were replaced.

2. Preventive maintenance of all the feeder compartments in MCC-3, DG MCC were

carried out:

x Checking the tightness of cable & wiring terminals in the feeders.

x Cleaned the feeder compartments.

x Replaced damaged / worn out contacts, etc.

x Tightness of the bolts of bus bars in DG Panel was checked.

3. Preventive maintenance jobs were carried out in 66 KV switchyard:

x Cleaning of insulators of all the CT & PT units, bus bar support, lightning
arrester, breakers, etc.

x Insulation Resistance was measured of all the CTs & PTs.

x All the moving parts of isolators were cleaned and lubricated.

x 11 KV VCB panels were cleaned and outgoing cable terminals were checked
for its tightness or hot spot.

4. Preventive maintenance jobs were carried out in 11 KV MPSS:

x Checked the tightness of outgoing terminals.

x Cleaned the feeder compartment of both Jyoti & siemens panel.

x Replaced damaged /worn out contacts, etc.

272
UTILITY :

1. Preventive maintenance carried out on transformers: TR-2A, TR-3A, TR-3B, TR-8,

TR-11, TR-12, TR-13 & TR-14 and the job details are as under:

x Inspection of primary and secondary cable boxes, end termination, checking

and tightening of connection.

x Measurement for Insulation resistance, BDV of transformer oil were carried out
on each transformer.

x Alarm & tripping contacts of Buchholz relay and MOG were checked.

x Condition of silica gel was checked. Discharged silica gel was recharged.

x Oil leakages from the transformers were attended and damaged gaskets were
replaced.

2. Overhauled the transformer TR-2B to improve the IR values of windings by lifting

the entire core. Inspection and cleaning of winding and replaced transformer oil.

3. Preventive maintenance of all the feeder compartment in MCC 1, 2, 2B/2E, 2A, 2F,
were carried out.

x Checked the tightness of cable & wiring terminals in the feeders.

x Cleaned the feeder compartments.
x Replaced damaged / worn out contacts, etc.

4. Overhauled the following motors.

P4401/B, P5111/A, 5111/B, P5112/A, P5112/B, P-5113, P-5118/A, P-5118/B,
P-5117, P-5119, P4411B, P4403, P4412, P-4215/A, & P-4215/B.

5. Checking of terminal box of all HT Motors i.e. P4402B, P4401C, P4401D, P4404 and
E5112.

6. Following existing defective / worn-out MOVs are replaced with new ROTORK
actuator and commissioning, testing and modification in wiring is done accordingly.

S-5, 4401/C & 4401/D

7. Electrification of renovated Boiler control room.

8. Replacement of old MCC-1, SECTION-A panel with new SIEMENS panel and
commissioning & testing of the same.

273
5. Preventive maintenance of HT JYOTI Breakers installed in 11KV MPSS & 66KV
Switchyard were carried out.

6. Preventive maintenance of Minimum Oil circuit Breakers (MOCB) installed in 66KV

Switchyard was carried out.

7. Complete servicing of CTR make OLTC of TR-1C was carried out.

274
 B & MH PLANT

1. Preventive maintenance carried out on transformer: TR-5A, TR-5B, and the job
details are as under:

x Inspection of primary and secondary cable boxes, end termination, checking and
tightening of connection.

x Measurement for Insulation resistance, BDV of transformer oil were carried out on
each transformer.

x Alarm & tripping contacts of Buchholz relay and MOG were checked. Servicing of
Buchholz Relay of Tr-5B was carried out.

x Condition of silica gel was checked. Discharged silica gel was recharged.

x Oil leakages from on the transformers were attended and damaged gaskets were
replaced.

2. Preventive maintenance of all the feeder compartments in MCC 4, & 9 were carried
out:

x Checked the tightness of outgoing terminals.

x Cleaned the feeder compartment.
x Replaced damaged /worn out contacts, etc.

3. Overhauled the following motors.

Dust Conveyor motor, M2110, M2112, M2116/1,M2116/2, M2116/3, M2116/5,

M2114, M2117 ,M2122, M2122/A1, M2122/A2, M2123, P2704A, P2704B, P2163A,
P2162A, P2162B and P2142.

4. Preventive maintenance carried out on all rope switches installed on

conveyors: M2110, M2112, M2117, M2121, M2122 & M2123 and replaced defective
one with new.

275
 AMMONIA PLANT

1. AUXILIARY BOILER:

x Repairing of burner blocks for burner no. 3, 4 and 5.

x Repairing of Header and other refractory work inside the auxiliary boiler.

x Repairing existing hot point panels on north side of auxiliary boiler by insulating
castable materials.

2. PRIMARY REFORMER:

x Repair of insulation bricks along with back up insulation after the removal of old
damaged refractory.

x Removing / reconstruction of tunnel walls in primary reformer including bottom

floor, tunnel slabs.

x Repair of nozzle refractory repair for secondary reformer 104-J.

x Replacement of AC sheets roofing for pent house area of primary reformer.

276
 UREA PLANT

1 Repairing of scrapper floor of Prill tower by filling the joints of existing tiles
and replacement of damaged acid proof brick lining, repair of vatas by epoxy
system.

2 Providing and laying IP Net painting on outside surface of bucket room, lift
cabin, RCC structure for top area of Prill Tower, IP Net coating for first floor
and second floor area of Urea plant including column, slab, beam etc.

3 Epoxy painting of RCC structure of Prill bucket room, lift cabin room,
stair case at Prill Tower top level .

4 Painting of conveyor gantry from Prill tower to Silo.

5 Bitumastic flooring of stair case and first floor and second floor area of Prill
cooling system area.

6 Repairing of floor by filling epoxy joints for Mandana stone for ground floor
area of urea plant.

7 Replacement of damaged AC sheets for prill cooling system, Hitachi

compressor shed and control room shed area.

8 Bitumastic lining for top floor of prill tower.

9 Making RCC pedestal for modification of conveyor at prill tower.

10 Repair of damaged precast slab near Urea plant.

11 Breaking of RCC for dismantling of old foundation of Make up sump and

grouting / concreting for new foundation of Make up sump assembly.

277
 OFFSITES & UTILITY
PLANT

1 WATER TREATMENT PLANT:

x Repairing of supports for pipeline in Water treatment plant & floor of H2SO4
tank near cooling tower sump side.

x Repairing of floor by bitumastic lining for SB assembly unit and around Anion
tank in water treatment plant.

x Epoxy grouting of nozzle in new cooling tower sump.

x Outside/Inside RCC repairing work in new cooling tower sump.

x Replacement of water proof ply wood on cooling water spreading area of

Ammonia side cooling tower.

x Breaking of concrete for the and grouting of

2 BOILER HOUSE:

x Repairing of castable refractory for burner’s side, floor and superheated zone
inside BHEL boiler.

x Replacement of AC sheets in BHEL Boiler roof.

x Interior and exterior renovation of Control room by civil work.

3 COOLING TOWER:

x Repairing of damaged top cover plywood sheets of cooling tower

x Filling of coal tar for leakage water planks of cooling towers.

x Strengthening of wooden structure for new cooling tower.

x Making line open by carryout excavation for the repair of leakge cooling tower
line near sand filter,

x Repair and grouting of pump foundation for raw water pump near raw water
storage tank and cooling tower sump area.

x Dismantling of HCl tank foundation.

278
 B & MH PLANT

1 Repairing of Walk way for conveyor belt No. 2117 inside the Silo by
Bitumastic work.

2. Epoxy painting of Transfer tower and conveyor gantry from Silo to B & MH.

3 Repairing of Hopper floor / Packer scale floor with epoxy monolithic plaster.

4 IP Net coating of RCC columns, ceiling, slab, beams and other RCC structure
in Bagging plant (Hopper floor) at first floor and ground floor area.

7 Replacement of AC sheets roofing for waste bags storage area and truck
loading area and roof replacement of contractor cabin in B & MH.

8 Replacement of AC sheet for Loco shed.

9 Making new Gear Box foundation for M-2110, M-2112, and M-2117

10 Epoxy painting to RCC column, beam, slab at GF,FF SF and track loading
area.

279
 AMMONIA PLANT

INSTALLATION OF LNG PREHEATER FOR PREHEATING OF LNG TO AUX.

BOILER:

As per approved scheme (Ref. Suggestion No. SS/Amm/05/05) , redundant lube

oil cooler of GHH compressor in Urea plant was modified in work shop as per
drawing no. 03-EL-13576-SG1 OF 1-REV1 to make it fixed tube sheet design from
floating head design.

After hydro testing , It is installed on reverse saddle welded at the shell of 173-C
and tapping of gas inlet to tube side has been taken from down stream of PRCV-
18 with bypass arrangement.

The tapping of steam inlet to shell side has been taken from LP stem header to
104-E and condensate outline has been connected to condensate out let line of
150-C/151-C with steam trap.

Size of gas inlet /outlet line: 150mm NB XSch40, CS

Size of steam inlet line: 1-1/2’’ NB x Sch 80, CS
Size of condensate outlet line: 1’’NB, CS/SS

INSTALLATION OF BIGGER SIZE INTER/ AFTER CONDENSER FOR 101-JCA:

It was observed that some uncondensed steam was coming out from after
condenser of 101-JCA even after adjusting the LP steam header pressure.

To overcome above problem bigger size inter-after condensers(852-C) of NG

booster compressor was removed and installed in place of existing inter-after
condensers of 101-JCA.

The details of inter-after condensers are as follows:

1 101-JCA inter/after condenser(Existing):

Inter condenser 42no. , 19 mm OD tubes of 2438mm length, Area=6.13m2
After condenser 32no. , 19 mm OD tubes of 1219mm length, Area=2.33m2

2 Installed NGBC Inter/After condenser:

Inter condenser 120no. , 19 mm OD tubes of 2500mm length, Area=17m2
After condenser 120no. , 19 mm OD tubes of 1500mm length, Area=10m2
The existing ejectors of 101-JCA are used with this bigger size inter-after
condenser.

With higher area, the problem of uncondensed steam in existing after

condenser of 101JCA will be removed.

280
REPLACEMENT OF 6 NOS. CS FLANGES BY SS FLANGES:

With reference to Drawing No. 4132-1013-6318, During ESP-Phase-I, CS flanges was

installed in control valve FV-470 and its isolation valves in discharge line of 115JA/JB.
The same was replaced by SS flanges . The size and rating of replaced flanges are as
follows:

x Size of control valve mating flanges: 16’’NB X600#,Sch XS, Material: SS304
x Size of isolation valve mating flanges: 16’’x300# , Sch XS, Material : SS304

INSTALLATION OF ISOLATION VALVES IN U/S & D/S OF SAFETY RELIEF

VALVES : (Ref : EWR NO.A240 , A251 /A252)

Full bore isolation valve with locking arrangement has been provided in following RVs
for ease of maintenance even in normal running plant.

x RV-104-D1: Inlet to HTS converter

x RV-106F: Outlet from secondary ammonia separator 106-F
x RV-110-F, 111-F & 112-F: 1st, 2nd and 3rd stage refrigerant flash drum.
x RV-MS-9: In MS -2-12’’ line from MS steam header
x RV-101-D &RV-102-D : Inlet to Desulphuriser
x RV-103-J: Outlet from Syn gas compressor after cooler 124-C
x RV-105-D: Recycles gas from ammonia converter feed/effluent exchanger(121C)
x RV-104D2: Inlet to LTS Converter
x RV-102-F: Raw gas separator outlet

Total 25 nos. valves of different sizes has been installed to complete the above referred
EWR.

INSTALLATION OF ADDITIONAL CONVENTIONAL RVs(EWR- A241) :

Additional conventional RVs (with isolation valves) in parallel to existing Pilot operated
relief valves in 103 discharge and recycle lines has been installed to improve the
reliability of the system.

Normally pilot operated valves shall remain in line and newly installed conventional
safety relief valves will be taken in line in case of malfunctioning of pilot operated relief
valves.

Inlet size: 3’’NB X1500#, RTJ, Outlet size: 4’’x300#, RF

Existing platform has been extended to operate the newly installed isolation valves and
for ease of maintenance.

ERECTION OF STAIR CASE STRUCTURE FOR CONVERTER(S-50)&

BOILER(107-C) :

Staircase structure of approx. 26 meter height has been fabricated and erected to
reach converter and waste heat boiler top.

Also, total five connecting pathways have been provide to reach other vessels in
nearby vicinity. The above job was carried out M/s J & J.

281
ERECTION OF VENT CONTROL VALVE AND SILENCER(SM-387) ON START
UP VENT LINE OF WASTE HEAT BOILER (107-C): EWR-A-248Dated
22/05/2006.

In existing system manual isolation valves are used for controlling the steam
venting during start up of waste heat boiler and vent line is connected to exhaust of
RV on waste heat boiler top.

Vent control valve of size 80mm NB has been installed on 50mm NB vent line of
waste heat boiler (107-C). Connection of vent line has been providing to silencer
installed at new stair case structure. The silencer installed was redundant final
stage silencer of NP/PB CO2 compressor having following details:-

Type: Straight through type flanged both end, Flow Rate: 38772Kg/Hr.
Inlet : 16’’NB X150# , Outlet : 16’’ NBX150#
Body Dia: 30-3/8’’ , Overall length: 112’’
Total Weight : 590 Kgs.

By implementing the above modification will avoid noise pollution and unsafe
condition by spillage from vent line, if any.

OTHER MODIFICATION JOBS IN AMMONIA PLANT:

1. New control valve PICV-1027 of size 6’’NBX1500# has been installed in

place of spool piece in vent line of Pre-Reformer.during Shutdown 2006 ,
the existing control valve PICV-1027 was installed in parallel to PICV-3 at
HTS inlet and spool piece was provided.

2. Tapping of 3’’ NB from desul-phuriser exit line of 6’’NB , has been provided
for sending R-LNG to prereformer unit for pre-reformer unit operation with
R-LNG.

3. Erection of 3’’ NB by pass line of E-110 with connection to u/s of flow

orifice in pre-reformer unit. This will help in measuring flow of R-LNG going
to Pre-reformer unit.

4. Modification in 6’’ inlet line (6’’-NV-1102.01-F34) to R-111 for taking sulphur

bed absorber in line with R-LNG operation of pre-reformer unit.

5. For carried out this job total 9 joints of 6’’NB has been fabricated.

6. The outlet system of the LT shift converter has been modified to decrease
the pressure drop across the reactor. The originally designed “elephant
stole “outlet system has been modified as suggested by M/s Haldor Topsoe.

7. The lower pressure drop across reactor will result in a higher suction
pressure for the synthesis gas compressor and thereby reduce the power
consumption of the compressor.

282
 UREA PLANT

ISOLATION OF NP/PB CO2 COMPRESSOR:

Following modification job was carried out for the isolation of NP/PB compressor:-

1. 60 ATA steam supply line to NP CO2 compressor turbine(Q-1101-1) has been

cut off by removing connection of line ST-1105-100-E3 from line ST-1104-200-
E3 and spool piece with vent has been provided.

2. 60 ATA steam supply to PB CO2 compressor turbine (Q-1101-2) has been cot
off by removing tee connection and providing reducer and elbow.

3. 23 ATA steam exhaust line from PB CO2 compressor turbine9Q-1101-2) has

been cut off by providing elbow at the tapping point in line no. ST-1116-300-C1.

4. 4 ATA steam inlet to NP CO2 compressor turbine(Q-1101-1) has been

removed by providing elbow and reducer at tapping point in line no. ST-1106-
350-B4.

5. Main lube oil pump turbine (Q-1113) exhaust line (ST-1120-150-B4) has been
cut off by removing tapping point and spool piece of size 20 inch has been
provided in line no. ST-1128-5000-B4.

6. P-114A-B condensate discharge to H-1115/6 has been cut off by providing

elbow at tapping point in line no. SC-1106-100-B4.

7. 40ata steam line from Urea plant to inlet of fuel oil pump turbine (Q-5114) in
utility has been cut off by providing elbow at tapping point.

8. 40ATA steam header to Urea plant (ST-5155-150-D1) has been cut off at
tapping point and elbow has been provided in line no ST-5153-150-D1.

9. PB CO2 compressor(K-1101-2) final discharge to HP stripper (H-1201) has

been cut off by providing cap at tapping point.

10. NP PB CO2 compressor cooling water supply line has been cut off by cutting
and blinding tapping point from supply header(CWS-4410-30’’-B13) and return
header(CWR-4410-30’’-B13)

Following isometric drawings has been approved by IBR Inspector for carrying
out above modification job:-

¾ Drg. No. 02-DL-13456-SH 1 Of 1- Rev.1

¾ Drg. No. 02-DL-13457-SH 1 Of 1- Rev.1
¾ Drg. No. 02-DL-13458-SH 1 of 1- Rev.1
¾ Drg. No. 02-DL-13459-SH 1 of 1- Rev.1 :
¾ Drg. No. 02-DL-13460-SH 1 Of 1- Rev.1
¾ Drg. No. 02-DL-13461-SH 1 Of 1- Rev.1
¾ Drg. No. 03-DL-13579-SH 1 Of 1- Rev.0
¾ Drg. No. 03-DL-13581-SH 1 Of 1- Rev.1

283
 By above modification , steam losses will be saved by total isolation of steam
lines and steam traps. Cooling water circulation to inter/after coolers of
NP/PB CO2 compressor and surface condenser(H-1114) will stop. Power will
be saved by stopping lube oil pumps and oil centrifuge for main L.O. console.

INSTALLATION OF TWO BED ATMOSPHERIC SCRUBBER (V-1206):

Existing atmospheric vent scrubber(V-1206) has been removed and new two bed
atmospheric scrubber with internals and associated piping modification has been
installed by foundation support modification on 3-1/2 floor of Urea plant.

Details of new V-1206 are as follows:-

O.D. =1510mm, Overall Length: 6925mm, Weight: 2080 Kgs.(Empty)
Design Pressure: 1.2Kg/Cm2g, Design temp. : 200 Deg C
Hydro test pressure: 1.8 Kg/Cm2g
Design Code: ASME SEC. VIII. Div. 1 Edition 2004
Main shell: SA240 TP 304L, 5thk
Internals: By M/s Kevin enterprises.

As build drawings no. : AEV-06042 SH 1OF 1& SH 2 OF 2 of M/s Aero Engineers.

The piping modification was done as per isometric drawings nos. 02-DL-13452
Sheet 1 of 13 to Sheet 13 of 13. By installation of new vent scrubber, ammonia
venting to atmosphere will reduce.

INSTALLATION OF PLATE TYPE HEAT EXCHANGER H-1301:

Existing Desorber heat exchanger (3nos.) of shell & tube type has been removed
and new plate type procured from M/s GEA, Germany has been installed in
hydrolyser section.

Details of removed desorber heat exchanger are as follows:

1. H1301-A(Overall length : 7069mm , O.D. =655mm , Weight =4175Kgs)

2. H1301B (Overall length : 10180mm , O.D. =356mm , Weight =1800Kgs)
3. H1301C (Overall length : 10180mm , O.D. =356mm , Weight =1800Kgs)

Details of new Plate type heat exchanger are as follows:

Overall dimensions: 1423mmx1190mm, Weight: 1250Kgs

Installation of PHE will improve the flexibility in Hydrolyser system’s operation and
improve effluent quality on consistent basis from hydrolyser system.

INSTALLATION OF CIRCULATION COOLER(H1210):

Removed desorber heat exchanger (H1301A) has been installed as circulation

cooler (H-1210) at 1st floor after modification of shell inlet/ outlet nozzles. The size
of inlet and outlet nozzle has been increased from 100mm NB to 200 mm NB. The
associated cooling water piping has been completed with inch dia welding as
follows:-

CW outlet line: Approx. 295 inch-Dia welding

CW Inlet line: Approx. 312Inch –Dia welding

284
The above tapping of cooling water has been taken from cooling water header
near pre-evaporator condenser (CW-1607-18’’-B13 and CW-1608-18’’-B13)

SHIFTING OF PROCESS WATER PUMP (P-1304C/D) AND INSTALLATION OF

NEW CIRCULATION PUMP(P-1210 A/B):

Existing process water pump (P-1304C/D) has been removed from its location and
shifted to location of removed lean Carbamate pump(P-1200A/B) after necessary
foundation modification and associated piping modification.

New circulation pumps (P-1210A/B) , procured from M/s Jyoti has been installed at
the location of process water pump (P1304C/D) along with associated piping
modification.

TAPPING FOR NEW PLATE TYPE EXCHANGER (H-1206) IN PARALLEL TO

CCS-I COOLER: (EWR: U233 Dated 14/03/2006):

Tapping has been taken from lines of existing CCS-I cooler for the piping of new
H-1206 along and foundation for additional CCS –I cooler has also been prepared.

The sizes of tapping are as follows:

1. CW inlet of 16’’ĭ size with butterfly valve.

2. CW outlet of 14’’ ĭ size with butterfly valve
3. Condensate inlet of 16’’ĭ with butterfly valve
4. Condensate outlet of 14’’ĭ with butterfly valve

Isolation valves in CW inlet and outlet line of existing cooler has also been
provided.

Availability of spare CCS-1 cooler will facilitate total removal of heat from CCS-1
maintaining CCS-1 inlet temperature to LPCC throughout the year and this will
improve the performance of LP system on consistent basis for the whole year.

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 OFFSITES PLANT

All the tapping has been taken form the existing system for the hook up of new system
of Narmada water supply scheme. The material for the above taping has been arranged
from the in house stock and the job has been completed by SOR contractor.

INSTRUMENT JOBS:

1. Installation of LICV-1206 control valve along with its air line.

2. Installation of HICV-1210 control valve along with its air line
3. Installation of FI-1208 vortex flow meter.
4. Installation of FICV-1284 control valve along with its air line.
5. Installation of HICV-1418 control valve along with its air line.
6. Installation of pressure gauges, temperature gauges & thermocouple and its wiring
up to existing junction boxes on different floors in Urea plant.

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