ELEFSIS REFINERY UPGRADE PROJECT

TÜV RHEINLAND HELLAS ACTIVITIESINSPECTOR / AUDITOR: SIDIROPOULOS ELEFTHERIOS

OWNER • HELPE

EPCM CONTRACTOR• TECNICAS REUNIDAS

WORKS CONTRACTOR • J/V EAMT (EKME-ATERMON-METKA-TMUCB)• METRON • GENKAT • MAZO

THIRD PARTY INSPECTION & NOTIFIED BODY• TÜV RHEINLAND HELLAS

Distillation of 2.200.000 tn fuel oil high concentrate

sulfur (>3%) to:

1. Production of Diesel 1.320.000 tn with low sulfur (automotive)

2. Production of naphtha 450.000 tn

appropriate for petrochemicals and

gasoline

3. Thermal energy of 250 MW clean gas form low caloric for

heaters instead of fuel oil

U-36

AMINE RECOVERY UNIT

U-37

SOUR WATER UNIT

U-38

SULPHUR UNIT

U-72

BOILER FEED WATER / STEAM

SYSTEM

U-33

HYDROGEN UNIT

U-73 CONDENSATE RECOVERY SYSTEM

U-74 DEMINERALISED WATER SYSTEM

U-70 INTERCONNECTING

U-75

COOLING WATER SYSTEM

U-78 PLANT & INSTRUMENT AIR

SYSTEM

U-80

REFINERY FUEL OIL SYSTEM

U-81

FUEL GAS SYSTEM

U-82

FLARE SYSTEM

U-85

SULPHUR STORAGE & HANDLING FACILITIES

UTILITIES – AREA 2 TÜV RHEINLAND

HELLAS DUTIES

TÜV RHEINLAND SHOP INSPECTION

Inspector Sidiropoulos Eleftherios for ERUP

From August 2009 until July 2011 several inspections completed successfully in European countries manufacturers to bring and delivered equipments and vessels in compliance with PED97/23 , European and other international standards.

Pressure vessels in Italy, Switzerland & Poland

Heat exchangers in Greece and Sweden

Valves in Finland

Sulphur handling package in Finland and Estonia

Radar level transmitters in Sweden

ERUP locate in Elefsina Attica Greece. It is an extension/upgrading of HELPE premises. Our duties listed as follows but not limited to:

PIPING according to ASME B31.3

Radiography interpretation.

Ultrasonic thickness & weld check.

Liquid Penetrates of Socket welds & when needed.

Magnetic Particles of bevel ends & when needed.

PWHT of CS and Low Alloy steels, Preheating and Post heating check.

PMI of Stainless steel & Duplex.

Hardness & Ferrite tests.

Hydro tests & Pneumatic tests

Visual check of welds before & during final acceptance tests.

Mechanical tests witnessing and acceptance of PQR and issuing of WPQs.

Witnessing of bolt tightening procedures for critical flanges.

ATMOSPHERIC TANKS according to API 650

Traceability and material check

NDTs as per applicable code.

Vacuum test of bottom plates.

Diesel test of shell and base plates connection.

Plumpness & Roundness check.

Local deviations (peaking & banding) check.

Witnessing of welding procedures, welders and w.operators qualification.

Any grinding cause local low thickness was UT measured and filled (built up) with the approved welding repair method. UT & PT witnessed.

Nameplates checked.

Pneumatic tests on reinforcing pads and Hydrostatic tests (Atmospheric) .

FLANGE ALIGNMENT & PIPING SUPPORT

POSITIVE MATERIAL ID. (PMI) & PRESSURE TEST

OTHER ACTIVITIES FLARE ERECTION SULPHUR HANDLING PACKAGE CONSTRUCTION PLUMB & LEVELLING OF VESSELS & HEAT EXCHANGERS FLANGE AND SHAFT ALIGNMENTS OF PUMBS & AIR

COOLERS COOLING TOWER CONSTRUCTION STEAM BOILERS CONTSTRUCTION REFRACTORY APPLIANCE, HAMMER & LAB TEST

WITNESSING INTERNALS DIMENSIONAL CONTROL AND LEAK TEST. TRANSFER LINE GOLDEN JOINTS (FIT UP/WELDING/NDTs) INSULATION CHECK PAINTING CHECK

Refractories /Hammer test

Transfer line (Reactor) / PSA

PUMPS & AIR COOLERSDuring prealignment flanges were checked for parallelism. Shaft alignment

performed as per manufacturers manual and the applicable codes. After hydrostatic test final flange and shaft alignment performed.

Alignment activities were done according to API code & HELPE specifications

Notified Body services NOTIFIED BODY ACTIONS NDT review NDT operators qualification

review Welding procedures, welders

and welding operators review Welding consumables review Hydrostatic test witnessed Drawings and engineering

calculations check Stress analysis reports

witnessing Particular material appraisal

(PMA) review Nameplate check

CE marking of Area 2

units are going to be

stamped from NoBo 2221

TÜV RHEINLAND HELLAS.

ERUP TEAM

FIELD INSPECTION GIAMAS DIMITRIOS

SIDIROPOULOS ELEFTHERIOS

CHATZIFOTIADIS PANTELIS

LAMBIRIS LAMBROS

DOVAS CHRISTOS

GKOSDIS GEORGIOS

KYAMIDIS CHRISTOS

DOCUMENT CONTROL & ADMINISTRATION

MIKELIS EMMANUEL

TSANTYLA ANASTASIA

SHOP INSPECTION SIDIROPOULOS ELEFTHERIOS

CHATZIFOTIADIS PANTELIS

KARATHODOROS ELIAS

LAMBIRIS LAMBROS

MIKELIS EMMANUEL

WORKSHOP MANTAS FOTIS

LAMBIRIS LAMBROS

DOVAS CHRISTOS

CHATZIFOTIADIS PANTELIS

DOCUMENT REVIEW

MENTZOS MICHAEL

MOURKOS THEOFANIS

Technical Director: Paparidis Georgios

TO BE CONTINUED