Oxy reactor maintenance job card

MR-203Maintenance

Job Card

Muhammad RehanMaintenance Engineer

OXY REACTOR (MR-203)

Cyclones

Dip Leg

Trickle Valves

Steam coils

Header and Sparger assembly

Air distributor grid

SkidC2H4 + 2HCl + ½ O2 C2H4Cl2 + H2O

Air Injection

Ethylene-HCl Injection

Fluidized Bed: Cupric Chloride (CuCl2) catalyst

Temperature: 232 oCPressure: 551.5 KPa

Process: Oxy Chlorination

Top Dish dome

M3, 48”

M4, 24”

M2, 24”

M1, 18”

78-ft

10-ft

It is a fluidized catalyst (CuCl2) bed reactor.

Air is supplied from the bottom of the reactor to keep the catalyst bed in a fluidized phase.

EDC-HCl Feeds are introduced through a Spargers into diffuser cups where all three reactants meet for the first time.

The reaction material is driven upwards with the flow of air where it comes in contact with catalyst.

The reactor is provided with a steam coil to absorb the heat generated due to the exothermic reaction.

AIR DISTRIBUTOR

GRIDPart Size Material Qty.

Diffuser Tube 2.5” C-276 137

Diffuser Cup 2.5” C-276 137 OD 25.4ID 10.3

DIP LEGS

FEED HEADER & SPARGERS

8”

3”

1”

Part Size Material Qty.

Header 8” A106 CS 1

Sparger 3” A160 CS 26

Nozzles 1” Alloy 20 137

Stud-Bolt 1 5/8” SS316 …

Stud-Bolt 2 3/4” SS316 …

Orifices 3/8" in diameter are drilled in the pipe to take a pressure drop 27.6- KPa at design flow rates.

FEED HEADER & SPARGERS

CYCLONES & TRICKLE VALVEPurpose: to remove entrained catalyst before leaving the reactor

Each cyclone imparts a swirling motion to the incoming gas stream, forcing the solid catalyst particles outward to the cyclone walls by centrifugal force. As the catalyst collects it falls into the bottom of the cyclone and from there to bed through fluidized bed due to its weight

Erosion resistant refractory cement

Total Flow Capacity: 40,324.4 Kg/ hour

Trickle Valve

REACTOR COOLING

COILSPurpose: The heat produced by the reaction is removed by direct generation of steam in vertical tubes immersed in the catalyst bed.

The tubes are arranged in several parallel passes, each containing eight, ten or twelve tubes in series.

About 6 percent of the water is vaporized to steam

The water and steam discharge into the steam drum where the steam disengages and leaves the system to a low pressure steam header

REACTOR COOLING

COILS

PURGE AIR HEADER

Purpose: It helps to avoid settling of the catalyst in dead areas of the reactor such as nozzles.

The fluidized catalyst in the reactor is composed of solid particles that will remain in motion

However, catalyst particles will settle out in "dead" areas of the reactor, particularly in the reactor nozzles, and pack into a relatively hard mass if allowed setting for extended periods.

To prevent settling of catalyst particles, a positive flow of dry purge air is provided continuously to each nozzle.

The purge air is preheated to minimize any condensation of water.

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To ensure Quality assurance in maintenance activities, HOLD POINTS are given for each activity and are highlighted as HOLD POINTS

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ACTIVITIES HAZARDS PRECAUTIONS

WORK AT HEIGHT

Person may fallAvoid over stepping the hand rails

Ensure worker is not ill or have height phobia

Material may fall

Use tool bags for shifting and keeping of tools

Use trays for keeping stud , bolts and other material

Ensure Scaffolding and Cladding material is secured with railings

HOT JOBS Fire in flammablesEnsure hot job protocol is followed

Assign fire watchers for each hot job

VESSEL ENTRY JOBS

Catalyst environment Use dust mask or other proper PPEs

Dehydration Water arrangements should be done in area

Asphyxiation(Low Oxygen) Ensure LEL and O2 monitoring is being done on defined intervals. Ensure adequate ventilation

MATERIAL SHIFTING

Material may fall

Material shifting with the help of crane should be done under the supervision of qualified riggers

Use manila ropes for tools and material shifting

Use Cotton gloves while material handling

Ensure area is barricaded while shifting material

Person may slip or fallMore than 10 kg weight should not be taken through step ladder

Material should not be transferred by hand through monkey ladders

RIGGING ACTIVITIES Material may fall

All rigging activities should be done under the supervision of qualified riggers

Area should be barricaded during lifting of material and Crane Operation

MULTIPLE JOBS IN PARALLEL Slip and trip Proper housekeeping must be ensured throughout the shift

VESSEL ENTRY ARRANGEMENTS

BLIND LIST (TOTAL: 08)

Size Line Number Location

14” 14-CS-HC-32-3205-GD-201 MR-203 Top flange on line to AS-201

4” 4-CS-IJ-32-3204-CAT-212 Cat- loading/un-loading line MR-203

1.5” 1 1/2-CS-1H-32-324-PA-004 Purge Air line to oxy Reactor

3” 3-CS-1H-32-3205-CAT-214 Oxy Bottom O/L

12” 12-CS-IJ-32-3203-BA-205(INS) PC-201 12" Line at FV-208 Down stream

2” 2-CS-IJ-32-3203-BA-208 Air to feed sparger line

1” 1-CS-IH-32-3535-N2-5224 N2 to feed sparger

6” 6-CS-IJ-32-3202-HVC-241 HCL/C2 feed to Oxy

VESSEL ENTRY REQUIREMENTS

S # Vessel Entry Requirement Responsibility

1 Marked P & ID of Blinds is available & Pasted at site signed by Area Assistant Engineer & SIC. Ops

2 Portable compressor air hoses should be removed Ops

3 Open Bottom Man way & top man way for ventilation Ops/ Maint.

4 Catalyst should be removed before Vessel Entry Ops

5 Adequate ventilation should be provided Ops

6 Ensure explosion proof lighting for the vessel entry Ops/ Maint.

7 Temperatures at all levels in reactor must be less than 40C Ops

8 Ensure ZERO LEL and O2 level equal to 21% Ops

9 A trained Stand By Man (SBM) should be deputed for vessel entry Ops/ Maint.

PPEs REQUIREMENT

S # PPE S # PPE

1 Mandatory PPEs 5 Full face Mask

2 Safety Harness 6 Chemical Gloves

3 Splash Goggle 7 Rubber shoes

4 Life line 8 Face ShieldVESSEL ENTRY HAZARDS

S # Chemical Hazard S # Chemical Hazard

1 EDC 3 Caustic

2 Ethylene 4 Copper Chloride Catalyst

Reference: Procedure for Vessel Entry Oxy Reactor (OPR-VCM-VE-01)

MANWAYS OPENING & BOX UPActivity Description: Manway opening and Box up

S # Hold Points

1 Check Flange Face Cleaning

2 Verify gasket size , material and quality

3 Ensure Lubrication of stud bolt

4 Ensure proper tightening sequence

5 Avoid Short bolting

6 Ensure Flange sign-off

Common Consumables

Gasket Sheet AFM 37 01

Molykote 01 can

Wire Brush 06

Cotton gloves 04

Cotton Cloth 02 kgManway 03 (48”)

Description Specification/ Qty.

Gasket Size: ..….. / 01

Stud Bolt Size: 1-1/4” L8” / 16

Ring Spanner 46mm Striking

Common Tools

Brass Hammer 5lbs 02

Brass Hammer 10lbs 01

Crow Bar 01

Other Requirements

Crane 80 Ton 01

Fork Lifter 01

Crow Bar 01

Common Manpower

Supervisor 01

Fitter 02

Asst. fitter 01

Rigger 02

Manway 04 (24”)


Gasket Size: ….. / 01

Stud Bolt Size: 7/8” L8” / 36

Ring Spanner 36 Striking

Manway 02 (24”)



Stud Bolt Size: 1.5” L6” / 20

Ring Spanner 50 Striking

Manway 01 (18”)



Stud Bolt Size: 1” L7.5” / 44

Ring Spanner 41mm Striking

M3, 48”

M4, 24”

M2, 24”

M1, 18”

TOP DOME INSPECTIONActivity Description: Inspection of Weld Joints and thickness monitoring of top dome

S # Job Method Statement Time (hrs)

0 Shift scaffolding material from ground to the top platform using crane

1 Install scaffoldings: 1) from top platform till top head and 2) inside vessel from top manway till dome top

18

2 Remove insulation and cladding from outside side and keep at safe place 12

3 Hot job arrangement (Canopy) to be done outside for the power brushing 02

4 Do power brushing of the top dome from inside and outside on circumferential weld joint and dome

13

5 Inspection to perform visual inspection and UFD/ UT of weld joint and dome 16

6 Rectification in case of low thickness or weld leech out (as per inspection recommendation)

7 Inspection after rectification

8 Install back the Insulation 16

9 Remove scaffolding from inside and outside 08

10 Housekeeping to be done on the platform and remove all insulation and scaffolding material

02

Top Dish dome

Requirements

Welding machines 03

Baby grinder 02

Power Brush 12

Grinding stones and burrs 12

Electrode & Filler Wire 10 kg

Wire Brush 06

CYCLONESActivity Description: De-choking of cyclones and inspection of Trickle Valve

S # Manpower Qty

1 Supervisor 01

2 Fitter 02

3 Asst. Fitter 02

4 SBM 01

5 Rigger 01

6 Scaffolding team 01

S # Tools Qty

1 Drill Machine 01

2 Drill Bit 1” Length 1 feet 01

3 Drill bit extension 01

1st Stage

3rd Stage

2nd Stage

S # Special PPEs Qty

1 Safety harness 02

2 Lifeline 01

3 Full face mask 02

4 Chemical Suit 02

5 Dust Mask 100

6 Cotton Gloves 100

S # Job Method Statement Time

1 Construct scaffolding platform at top manway (M03) 1

2 Open the top manway (M03) 2

3 Construct the scaffolding inside reactor from top manway up till 11” height to reach Cyclones

5

4 Engage chain blocks at cyclone grids to remove spacer spools 2

5 Remove three spacer spools 6” (02) and 8” (01) 3

6 Adjust Scaffolding for initial inspection 1

7 Inspection of Cyclones and trickle is done by Process and Inspection 1

8 Cleaning and De-choking of Cyclones is done along with the greasing of trickle valve

6

9 Installation of internal scaffolding up to top weld joint for inspection 8

10 Power brushing of weld joint of top dome 10

11 Inspection (UT / UFD / DPT) 10

12 S/F removal until spacers 8

13 Adjustment and box up of three spacers 3

14 Removal of scaffolding from middle MW 4

15 Removal of planks from top MW 2

16 Final inspection by process / inspection + box up form sign off 2

FEED HEADER AND SPARGERSS # Material Qty Item Code

1 8” 150 #SW gasket 01 0137.0134.0027

2 3” 150# SW gasket 26 0137.0134.0039

Activity Description: To remove, inspect and re-installation of Feed header and spargers

S # Manpower Qty.

1 Supervisor 01

2 Fitter 04

3 Rigger 02

4 Asst. Fitter 02

S # Tools Qty.

1 Combination Spanner 32, 41mm 02

2 Ring Spanner 32, 41mm 02

3 Brass Hammer 10lbs 01

4 Pipe Wrench 24”, 36” 02

5 Brass Hammer 5lbs 02

6 Crow Bar 02

S # Others Qty.

1 Chain Block 3 Ton 02

2 Web Belt 3 Ton 02

3 Crane for shifting header 01

4 Lifter 01

BOM 8” 80Sch A106 Pipe

8” 150# CS Flange

3” 80Sch A106 Pipe

3” 150# CS Flange

6mm CS plate

5/8” Stud Bolt 100mm

3/4“ Stud Bolt 120mm

Weld O-let

1-1/2” Pipe Alloy 20 cb

Qty. 01 01 01 26 6’ X 6’ 208 08 137 20 m

S # Job Method Statement

1 Open manway # 02 and shift the manway cover to ground with the help of crane

2 Remove all 137 nozzles and shift them to workshop

3 Remove all 26 Spargers and shift them to workshop

4 Remove main 8” header and shift it to ground and then workshop using Crane and Lifter

5 Inspection will perform visual inspection of header, Spargers and all nozzles and suggest repair or replacement if required

6 Shift header, Spargers and nozzles to area

7 Install header with the help of chain blocks , Ensure box up quality assurance

8 Install all 26 Spargers, Ensure box up quality assurance

9 Install all 137 nozzles, Ensure box up quality assurance

10 Align all 137 nozzles as per Process recommendation with the help of alignment assembly

11 Final inspection will be done by Process and inspection

12 Box up Manway # 02, Ensure box up quality assurance

DIFFUSER CUPSS # Material Qty Item Code

1 2-1/2” Diffuser Cup 137 0137.0048.0021

2 2-1/2” 80S Pipe C-276 1m DC

3 Er-NiCr3 (Filler Wire) 5kg

4 Washers 137 In-house Fab.

Activity Description: To replace the diffuser cups (Material Hastelloy C-276)

S # Manpower requirement Qty.

1 Supervisor 01

2 Fabricator 02

3 Welder 02

4 Asst. Fitter 02

S # Tools Qty.

1 SS Filler wires for de-choking 10

2 Alignment Jig 01

3 Welding Machine + leads 01

4 Argon Cylinders 02

5 Baby grinder 01

6 Angle grinder 01

S # Other requirements Qty.

1 Inside Scaffolding 01

2 Fire Blankets 05

BOM 8” 80Sch A106 Pipe

8” 150# CS Flange

3” 80Sch A106 Pipe

3” 150# CS Flange

6mm CS plate

5/8” Stud Bolt 100mm

3/4“ Stud Bolt 120mm

Weld O-let

1-1/2” Pipe Alloy 20 cb

Qty. 01 01 01 26 6’ X 6’ 208 08 137 20 m

S # Job Method Statement

1 Open manway # 01 and shift the manway cover to ground with the help of crane

2 Construct scaffolding platform inside the reactor to access the diffuser tubes

3 Inspection of cups will be done by Inspection. Recommendations will be generated accordingly . Inspection will mark the diffuser cups and provide recommendation accordingly

4 Hot job arrangements will be done

5 As per inspection recommendation, diffuser cups will be cut and grinding will done

6 Welding will done as per WPS provided by Inspection

7 DPT will be performed to ensure weld quality

8 Washers will be welded if found dislodged

9 DPT of washers will also be done

10 Remove scaffolding and then remove material from the reactor

11 Housekeeping inside the vessel will be performed

12 Manway # 01 will be boxed up after ensuring quality

S # Material Qty Item Code

1 4” U-Bend CS 05

2 Argon gas 1

3 Er-70S3 5kg

4 Clamps 4” 05


1 Supervisor 01

2 Fabricator 02

3 Welder 02

4 Asst. Fitter 02

S # Tools Qty.

1 Power Brush 02

2 Wire Brush 02

3 Welding Machine + leads 01


5 Baby grinder 01

6 Angle grinder 01


S # Job Method Statement for U-bend replacement

1 From manway # 02, this activity is done when Spargers are removed and sent for inspection

2 Cleaning of U-Bends with Wire brush or Power brush is done

3 Visual inspection and Ultrasonic Testing of U-bends is performed

4Due to low thickness, inspection will recommend to replace the U-Bend a(if required) and mark the U-bend to be replaced

5 Cutting, grinding and welding is done to replace the recommended U-Bend

6 Hydro test of coil is performed at 1200psi

7 Radiographic testing is performed for ensuring the quality of weld joints

STEAM COILSActivity Description: Inspection of U-bends and replacement (if required)

S # Job Method Statement for Clamp installation

1 From manway # 04, inspection of steam coil is performed

2 Inspection recommend the U clamps to be replaced if required

3 U-clamps are already available and replace accordingly

SPARES TO BE MADE AVAILABLE IN STOCK


1 4” 150# gate valve with instrument 01

2 Ball Valve 3/4” 150# 20

3 Ball Valve 1” 150# 01

4 Ball Valve 1.5” 150# 01

5 Ball Valve 2” 150# 01

6 Ball Valve 3” 150# 04

7 Ball Valve 4” 150# 02


1 Supervisor 01

2 Fitter 04

4 Asst. Fitter 02

PURGE AIR HEADERActivity Description: Replacement and rectification of valves and check valves on this circuit

SPARES TO BE MADE AVAILABLE IN STOCK


9 NRV 1.5” 150# 02

10 NRV 2” 150# 02

11 SW Gasket 3/4” 150# 40

12 SW Gasket 1” 150# 06

13 SW Gasket 1.5” 150# 06

14 SW Gasket 2” 150# 06

15 SW Gasket 3” 150# 08

16 SW Gasket 4” 150# 04


1 3” 150# SO flange 05

2 3” XXS CS Pipe 1

3 Er-70S3 5kg


1 Supervisor 01

2 Fabricator 02

3 Welder 02

4 Asst. Fitter 02

S # Tools Qty.

1 Welding Machine 01


3 Baby grinder 01

4 Angle grinder 01


1 Fire Blankets 10

NOZZLES REPLACEMENTActivity Description: Cutting, grinding and welding of the nozzles on the shell of the reactor

TI-1-7

TI-1-14

SHUTDOWN JOB SCOPE (JUNE-2014)PREVENTIVE MAINTENANCEACTIVITY DESCRIPTION WHAT TO CHECK HOW TO CHECK RESPONSIBILITY SUPPORT REQUIRED FROM MAINTENANCE

Inspection of Top DomeThickness on top Dome plate Ultrasonic testing

InspectionScaffolding Construction (inside and outside)Insulation/ Cladding removalPower BrushingWeld joints Visual inspection and DPT

Inspection of Cyclones and trickle valveCatalyst Choking

Visual Inspection ProcessScaffolding Construction Spacers removalDe-choking (if required)Working of Trickle Valve

Inspection of Feed header, Spargers and nozzles

Corrosion/ ErosionVisual Inspection Inspection

Process Removal, installation and alignmentAlignment of nozzles

Inspection of U-bends of Steam coilsThickness monitoring of U-bends Ultrasonic testing

Visual Inspection Inspection Replacement of U-bends (if required) Visual inspection of any damage

Purge Air header piping inspection Inspection and cleaning of circuit including valves and check valves Visual inspection Operations Removal, cleaning and replacement (if

required)

TEMPORARY REPAIRACTIVITY DESCRIPTION TR # HOT/ COLD JOB RESPONSIBILITY

Replacement of Diffuser cups and tubes EDC/VCM/606 HOT Maintenance

Lining installation in top Manway # 03 EDC/VCM/614 HOT Maintenance

Welding of U-bend support plate EDC/VCM/677 HOT Maintenance

LT-201 spool piece replacement at Platform 2 EDC/VCM/614 HOT Maintenance

INSPECTION RECOMMENDATIONACTIVITY DESCRIPTION HOT/ COLD JOB RESPONSIBILITY

Replacement of nozzles # LT-201, TI1-14 and TI1-15 HOT Maintenance

Inspection of Oxy Feed inlet spool and replacement (if required) COLD Maintenance

Oxy reactor maintenance job card

Engineering

Transcript of Oxy reactor maintenance job card