MAINTENANCE PROCEDURE
MUHAMMAD REHAN KHANMAINTENANCE ENGINEER
VCM Recovery Condenser Cleaning
CN-1F
VCM RECOVERY CONDENSER (CN-1F)Process Description
VCM recovery compressors (CM-3F/4F) recovers VCM continuously from Slurry stripping column (CL-1G), Waste Water stripper (CL-1D) & PSA unit
CM-1E discharge line up only during V/A activity
A line up is also available to recover VCM from Column feed tank (TK-2G)
CM-3F/4Fdischarge Compressed VCM to VCM recovery condensers (CN-1F/2F) in series.
VCM is condensed in CN-1F and then in CN-2F .
From CN-2F, Inert and uncondensed VCM is vented to PSA unit.
VCM RECOVERY CONDENSER (CN-1F)
Sh
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Gasket
Top cover
Bottom cover
Shell and tube type heat exchanger (BEM)
Single pass vertical heat exchanger
Shell: Cooling water, Tube: Recovered VCM
Shell: Material: Q-235B Nominal diameter: 900mm, thickness: 10mm
Tube: # of tubes: 1009 tubes (strength welded)OD: 19mm, Wall thickness: 2mmTotal length: 4500mmMaterial: 0Cr18Ni9
Other details can be found from the drawing T07B01-100FE20-0100 and T07B01-100FE20-0101
MAINTENANCE ACTIVITYHEALTH & SAFETY
Personal Protective Equipment
• Safety helmet, Safety shoes, Safety glass, Ear Plugs
• Face Shield during HP Water jetting• Safety Harness where required
Hazards
• Slip, Trip and Fall Hazard• Scaffolding work • VCM leakage during first flange break• Critical lifting and rigging• High Pressure Water Jetting• Crane tilting
Precautions
• Proper housekeeping
• Standard Scaffolding
• No modification of scaffolding without permit
• Ensure complete blinding
• Conduct Pre-rigging meeting
• Follow Rigging Plan
• Cordon-off work area
• Scaffolding & tarpaulin shield for jetting activity
MAINTENANCE ACTIVITYPREPARATIONS FOR SAFE RIGGING
Due to gravel area, Load distribution of crane is extremely critical
Foot pads and steel plates are used to distribute load over the ground
Steel plated should also be placed on drain channels for crane entry
MAINTENANCE ACTIVITYRIGGING PLAN
Weight of Condenser:
6.6 Tons
KATO NK-800 Crane
80 Tons capacity
Hook weight: 1 Ton
Allowable radius =13 m
Boom length = 36 m
Boom angle = 65-70 deg
CN-1F
Terminal Location
CN-1F
Ground Location
Approved rigging card is required along with lifting over permit
REQUIREMENTS
S # Consumables Qty. required Item Code1 Cotton Gloves 20 Pairs2 Cotton waste 2 Kg3 Teflon tape 2 EA4 WD-40 3 cans
S # Tools Qty. required Unit1 Striking spanner 36mm 2 EA2 Striking spanner 32mm 2 EA3 Combination spanner 32 mm 2 EA4 Combination spanner 27 mm 2 EA5 Combination spanner 24 mm 2 EA6 Combination spanner 22 mm 2 EA7 Combination spanner 19 mm 2 EA8 Brass Hammer 05 lbs. 3 EA9 PW hoses (Tested) 50’ long 3 EA10 Pipe wrench 14’’/18’’ 2 EA
S # Spares Qty. required Item Code1 SW Gasket without outer ring , D1:
908 MM, D2: 927 MM, D3, 947 MM2 2202.1007.0001
2 SW Gasket 6” 150# 2 0137.0134.00393 SW Gasket 4” 150# 2 2200.2408.10084 SW Gasket 3” 150# 10 2200.2408.00055 Non Asbestos 3” 150# 9 0137.0134.00176 SW Gasket 2” 150# 12 0137.0134.00887 SW Gasket 8’’ 150# 1 2200.2408.0025
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Construct Scaffolding on top and bottom head covers
Remove Insulation and Cladding and secure it
Perform blinding of VCM inlet, outlet and Cooling Water side
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Associated piping is removed from top and bottom head covers
Support is provided to the piping wherever is required.
All bolts of top head cover are removed
Head cover is removed and placed aside
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Remove all bolts except 08 bolts
Hold head cover with web belts & chain block
Remove head cover with remaining bolts
Modify Scaffolding planks
Place head cover on the floor
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Hold Pre-rigging meeting
Barricade area
Shift condenser slowly to the ground floor at designated location.
A guy wire is used to prevent the movement of the condenser due to wind.
Slings Capacity: 8 Ton each
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Condenser is then shifted to the location where HP water jetting arrangement is already done.
Jetting arrangement is done such that wooden planks are secured in wall arrangement and tarpaulin is used to prevent water showering.
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Construct Scaffolding walls to arrest water splash
Use tarpaulin to cover backside
Cordon-off complete area
All hoses connections are ensured
Perform inspection after cleaning
Perform hydro test from shell side with Polish Water at 450psi
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Transport condenser back to area
Lift and install shell back on top
Check and clean gasket surfaces
Install back both head covers
Construct Scaffolding platforms for head covers box up
Box up associated piping
Follow flange box up protocol
After complete box up, Operation performs Leak Test
THANK YOU
MUHAMMAD REHAN KHANMAINTENANCE ENGINEER
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