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Furnace maintenance job card

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It is a Maintenance Job Card of a Cracking Furnace used for the production of VCM

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Furnace maintenance job card

  1. 1. HF-301A/B Maintenance Job Card Muhammad Rehan Maintenance Engineer
  2. 2. CRACKING FURNACE (HF-301A/B) Process: Thermal Decomposition Dry purified EDC is fed to Cracking Furnace where it decomposes into VCM and HCl. Cracking temperature is 5370C. Conversion efficiency is 56-60%. Reaction products and un-reacted EDC are cooled immediately in quench section to minimize coking and reaction reversal. HCl is separated from EDC and VCM, and sent to Oxy Chlorination Unit. Subsequently, EDC is separated from VCM and recycled. VCM is sent to Storage. C2H4Cl2  C2H3Cl + HCl ∆H= -30,500 Btu/lbmol H2, Natural Gas Fuel 350C, 1.5bar Furnace Feed 830C, 24bar Furnace Outlet 5000C, 20bar Convection Exit : 250 C Arch Flue Gas 2150C Temp : 685C (tube skin) Temp : 670 C Convection Zone Radiant Zone Total 32 tubes SS TP347H, SS321 & Incolloy 800H, 49’-6” length Stack Burner Total 72 burners CABIN, BOX-TYPE FURNACE Total 40 tubes, SS TP347H, 40’-3” Length MATERIAL OF FURNACE CARBON STEEL LINED WITH CASTABLE REFRACTORY
  3. 3. STACK The flue gas stack is a cylindrical structure at the top of all the heat transfer chambers. It collects the flue gas and exhaust it up high into the atmosphere. The stack damper works like a butterfly valve and regulates draft in the furnace. Stack anchors and refractory Damper
  4. 4. CONVECTION ZONE Part NPS Material Qty. Fin Tubes 4” 40 Sch SS TP347H & Incolloy 800H 24 Fin Tube 6” 40 Sch 12 Bare Tube 6” 80 Sch 4 Height: 25’2 1/8’’, Width: 8’ 6.5’’, Length:3 9’9’’ E A S T S I D E V I E W W E S T S I D E V I E W WEST SIDE VIEW FURNACE FEED FEED OUT 4” Fin tubes-Qty 24 6” Fin tubes-Qty 12 6” Bare tubes-Qty 4
  5. 5. RADIANT ZONE Type NPS Material Qty. Bare Tubes 6” 80 Sch SS TP347H 32 Height: 23’11’’, Width: 11’ 7.5’’, Length: 55’ WEST SIDE VIEW DOOR ENTRY Bare Tube 6” Qty 32 Tube Tree RADIANT IN FURNACE OUT Tube Tree
  6. 6. SIDE WALL BURNERS The burner tile is made of high temperature refractory. Primary & Secondary Air registers are located below the burner. The primary air register supplies primary air to be introduced first in the burner. Secondary air is added to supplement primary air. Burners include a pre-mixer to mix the air and fuel for better combustion. 9 X 2 sides X 4 rows SELAS Type K9306 Burners are capable to deliver 110,000,000 BTU/hr natural gas ITEM DESCRIPTION OF PART REQ FOR ONE FURNACE 1 CUP BLOCK 72 2 WELL BOARD 72 3 AIR SLEAVE 72 4 CERAMIC TUBE 72 5 AIR BODY ASSEMBLY 72 6 INSULATING RING 72 7 BAND 72 8 BOTTOM CASING ASSEM 72 9 TOP CASING ASSEMBLY 72 10 SHUTTER ASSEMBLY 72 11 TIP NOZZLE 72 12 EXTENTION NIPPLE 72 ITEM DESCRIPTION OF PART REQ FOR ONE FURNACE 13 TUBE GASKET 72 14 GASKET 72 15 MOUNTING PLATE 216 16 BURNER BLOCK ANCHOR 72 17 INSULATING WASHER 72 18 1/2 INCH FLAT WASHER 72 19 HEX NUT 1/2 X 13 72 20 HH CS 3/8-16 X 3/4" LG STL.ZINC 72 21 HEX NUT 3/8 X 13 72 22 SUPER 3000 CEMENT 72 23 SHUTTER PISTON MARKER 72 24 SELF TAPE SCREW 6-32 X 3/16 144
  7. 7. 01 Cup Block 02 Well Board 11 Tip Nozzle 12 Extension nipple 05 Air body assembly 08 Bottom casing assy. 09 Top casing assy. 07 Aluminum Band 04 Ceramic tube 03 Air Sleeve 14 Gasket 10 Shutter assembly 06 Insulating ring16 Burner Anchor
  8. 8. Item # 01 Cup Block (Material Formula 130) Item # 02 Well Board (Material INS BOARD2300HD) Item # 11 Tip Nozzle (Material Alloy 800) Item # 12 Extension nipple (Material SS) Item # 05 Air body assembly Item # 08 Bottom casing assy. Item # 09 Top casing assy. Item # 07 Aluminum Band Item # 04 Ceramic tube Item # 03 Air Sleeve(Material Alloy HT) Item # 14 GasketItem # 10 Shutter assembly Item # 06 Insulating ring (Epitherm 1200) Item # 16 Burner Anchor (Material SS)
  9. 9. BURNER WALL INSULATION INSBLOK-19 EMPIRE S KAST-O-LITE 22 PLUS KAST-O-LITE 20-45 G ADTECH IFB 2300LI INSBOARD 2300HD INSWOOL-HP BLANKET Cup block formula 130 INSBOARD 2300 HD 8”
  10. 10. BURNER WALL REFRACTORY INSTALLATION 01: Anchors installation 02: INSBLOK 19 installation 03: Alignment of Anchors 04: IFB2300LI Bricks installation with layers of INSWOOL Blanket 05: IFB2300LI Bricks installation with SAIRSET Mortar 00:Burner side walls without insulation
  11. 11. BURNER WALL REFRACTORY INSTALLATION 06: Filling gaps with INSWOOL Blanket 07:INSBOARD 2300HD installation as burner well board 08: Cup block installation supported with Anchor 09:IFB2300LI bricks installation around burner 10:Refractory completion
  12. 12. ROOF & SIDE WALL INSULATION INSWOOL HP BLANKET 2300°F Alumina-Silica Ceramic Fiber Blanket INSWOOL-HP BLANKET meets the demand for a high temperature, flexible blanket insulation with a low iron content of less than 1%. INSWOOL-HP BLANKET has excellent strength, both hot and cold. INSWOOL-HP BLANKET EMPIRE S KAST-O-LITE 22 PLUS KAST-O-LITE 20-45 G ADTECH Anchors
  13. 13. TUBE TREE Cast Axle
  14. 14. REFRACTORY REQUIREMENT FOR FURNACE
  15. 15. S# MATERIAL DETAIL (DRW. LH 1044-E7 ) UOM REQUIRED FOR ONE FURNACE SIZE AND DETAIL LOCATION OF APPLICATION 1 IFB 2300 LI 9X6X3 EA 740 STD 9"(229)X6"(152)X3"(76) STRAIGHT 23000 IFB Brick lining use at burner bottom side to hold. 2 IFB 2300 LI 9X4-1/2X3 EA 13460 STD 9"(229)X4-1/2"(114)X3"(76) STRAIGHT 23000 IFB Brick lining use as second and layer in furnace. 3 IFB 2300 LI 9X4-1/2X2-3/4 EA 60 9"(229)X4-1/2"(114)X2-3/4"(70) SPLIT 23000 IFB Brick lining use at corner of heat transfer duct. 4 IFB 2300 LI 9X4-1/2X2-1/4 EA 150 9"(229)X4-1/2"(114)X2-1/4"(57) SPLIT 23000 IFB Brick lining use under item 1 for its support . 5 INSBLOCK 19 2-1/2 X 12X36 EA 785 PIECES BLOCK INSULATION (1900°) 36(914)X12"(305)X2- 1/2"(64) Board use at back side wall behind 2nd layer brick. 6 INSBLOCK 19 1 X 12X36 EA 850 PIECES BLOCK INSULATION (1900°) 36(914)X12"(305)X1"(25) board use with cs sheet 1st layer at furnace wall. 7 INSBOARD 2300 HD 1 X 24X36 EA 25 PIECES CERAMIC FIBRE BOARD (2300°) 36(914)X24"(610)X1"(25) soft board use behind burner block. 8 CERAMIC FIBRE BLANKET (2300°) 6# DENSITY 1(25)X24"(610)X25'(7620) ROLL 5 PIECES CERAMIC FIBRE BLANKET (2300°) 6# DENSITY 1(25)X24"(610)X25'(7620) ceramic blanket use behind burner block. 9 INSBLOCK -19 3X12X36 EA 105 PIECES BLOCK INSULATION (1900°) 36(914)X12"(305)X3"(76) Use as first layer in duct.before casting. 10 KS-4 PLUS CASTABLE CUFT 80 Cu FT IN PLACE 2500° CASTABLE For casting of Duct.UM in CUFT as per density. 11 EMPIRES BRICKS 9X4-1/2X2-1/2 EA 1620 STD 9"(229)X4-1/2"(114)X2-1/2"(64) HIGH DUTY FIRECLAY (FLOOR) top bricks layer on furnace floor 12 KASTOLITE 22 PLUS CUFT 165 Cu FT IN PLACE LUMNITE, HAYDITE, VERMICULITE (1:2:4 Mix) (FLOOR) castable refractroy use as 2nd layer at furnace floor. 13 KASTOLITE 20-45 G CUFT 110 Cu FT IN PLACE LUMNITE, HAYDITE, VERMICULITE (1:6 Mix) (FLOOR) castable refractroy use as 1st layer at furnace floor.
  16. 16. S# MATERIAL DETAIL (DRW. LH 1044-E7 ) UOM REQUIRED FOR ONE FURNACE SIZE AND DETAIL LOCATION OF APPLICATION 14 INSWOOL HP BLANKET 1/2 X 24 X50 ROLL 21 PIECES CERAMICS FIBRE BLANKET (2300°)-6# DENSITY1/2"(13)X24"(610)X25'(7620) use as exp.joint in floor and brick lining. 15 SAIR SET MORTOR LBS 6100 POUNDS SAIRSET MORTAR mortor use to joint all bricks 16 ANCHOR LH 302 -3 SS310 EA 3250 3/16"(5) BENT BRICK ANCHORS PER STD 2101, PART# 2101- 11 use for castable refractory. 17 ANCHOR LH 206 -9 SS310 EA 100 V-CLIPS ANCHORS PER STD 2003, PART# 2003-04 use for castable refractory. 18 ANCHOR LH 206 -11 SS310 EA 40 V-CLIPS ANCHORS PER STD 2003, PART# 2003-06 use for castable refractory. 19 ANCHOR LH 104 -6 SS310 EA 150 Y-CLIPS ANCHORS PER STD 2010, PART# 2010-07 use for castable refractory. 20 ANCHOR LH 104 -6 SS310 Y TYPE EA 350 Y-CLIPS ANCHORS PER STD 2010, PART# 2010-08 use for castable refractory. 21 INSWOOL HTZ BLANKET # 6 Lbs 1/2X24X50 EA ONE PIECES CERAMIC FIBRE BLANKET (2600°), 6 DENSITY 1/2(13)X24(610)X25'(7620) 22 STAIN LESS STEEL STRIP FOR BINDING OF CLOTH . FEET 40 LIN FT. LOCKING STAINLESS STEEL BAND Cloth binding at tube tree top and rad.in/out lines. 23 PIECES CERAMIC FIBRE BLANKET 2300° ROLL ONE PIECES CERAMIC FIBRE BLANKET (2300°) 8# DENSITY 2"(51)X24"(610)X25'(7620) use for peep doors and other location. 24 SS WIRE SOFT DIA 1 MM FEET 20 LIN FT. 22 GAUGE 18 - 8 STAINLESS STEEL WIRE use to bind thermal ceramic wool at all location . 25 INSWOOL HP BLANKET # 6 SFT 300 SIZE 1X24"X25' # 8 SFT 250 ROLL 2 PIECES CERAMIC FIBRE BLANKET (2300°) 8# DENSITY 4"(102)X24"(610)X25'(7620) used at tube tree top to protect as cover with cloth. 26 FIRE PROOF CLOTHE ROLL 2 ALLUMINIZED FIBRE GLASS CLOTH 1/32"(1) THK this cloth used for tube tree and in/out lines of furnace. 27 RTV SILICONE TUBES. LBS 3 LBS SILICON RUBBER SEALANT GE RTV 116 (OR EQUAL) this RTV used for clothe pasting on tube tree and in/out lines of furnace. 28 INSWOOL HP BLANKET # 8 SIZE 2X24X12-1/2 ROLL 2 PIECES CERAMIC FIBRE BLANKET (2300°) 8# DENSITY 4"(102)X24"(610)X25'(7620) used at tube tree top to protect as cover with cloth. 29 INSWOOL HP BLANKET # 6 SIZE 2X 48 X12-1/2 ROLL 4 PIECES CERAMIC FIBRE BLANKET (2300°) 6# DENSITY 2"(51)X24"(610)X25'(7620) ceramic blanket use behind burner block.
  17. 17. MAINTENANCE ACTIVITIES To ensure Quality assurance in maintenance activities, HOLD POINTS are given for each activity and are highlighted as HOLD POINTS 1. Decoking of Radiant & Convection Zones tubes 2. Hydro testing of Convection zone tubes 3. Convection Zone tubes/ bends replacement 4. Hydro testing of Radiant zone tubes 5. Radiant Zone tubes/ bends replacement 6. Burner inspection and repair 7. Tube Tree inspection and greasing 8. Refractory inspection & repair
  18. 18. HSEHAZARDS ACTIVITIES HAZARDS PRECAUTIONS WORK AT HEIGHT Person may fall Avoid 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 flammables Ensure hot job protocol is followed Assign fire watchers for each hot job VESSEL ENTRY JOBS Chemical env. Use dust mask or other proper PPEs Dehydration/ Asphyxiation Ensure 0% LEL, adequate Oxygen level and water arrangement. Ensure adequate ventilation Refractory material Use chemical gloves and dust mask. 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 fall More 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
  19. 19. DECOKING ACTIVITY Activity Description: Support for Decoking activity on radiant and convection section Consumables requirement Molykote 01 can Wire Brush 02 Cotton gloves 12 Cotton Cloth 02 kg Tools requirement Brass Hammer 5lbs 02 Combination Spanner 24, 36 02 Crow Bar 01 Other Requirements Crane 80 Ton 01 Manpower requirement Supervisor 01 Fitter 02 Asst. fitter 01 Rigger 02
  20. 20. S # Job Method Statement 0 Scaffolding construction for spools removal 1 Removal of inlet and outlet spools 2 Installation of piping spool for decoking arrangement 3 Pig launching and pump operation 4 Changing orientation of piping spool 5 Breaking of coke inside radiant tubes 6 Flushing of tubes 7 Inspection of tubes by Process 8 Piping box up DECOKING ACTIVITY Activity Description: Support for Decoking activity on radiant and convection section
  21. 21. INSPECTION OF FURNACE Activity Description: Hydro testing of Convection zone tubes Common Consumables Molykote 01 can Wire Brush 02 Cotton gloves 12 Cotton Cloth 02 kg Common Tools Brass Hammer 5lbs 02 Combination Spanner 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 01:Remove this spool and install blind 4” 150# 02: Remove this blind and install PG and Vent assembly 03: Remove this spool and install HT pump and water filling assembly
  22. 22. INSPECTION OF FURNACE Activity Description: Hydro testing of Convection zone tubes S # Job Method Statement 1 Remove covers from east and west side of the convection zone 2 Construct scaffolding inside and outside of the convection zone for inspection 3 Remove Furnace feed spool to convection zone and install blinds on both sides. 4 Remove vent line blind from the top bend and install air vent and pressure gauge assembly 5 Fill convection zone tubes with low temperature condensate 6 Ensure complete air removal from the tubes from the top blind and vent assembly 7 Connect hydro test pump at the bottom side assembly 8 Pressurize tubes step by step holding at 800psi for 30 minutes and then at 1200 psi for 30 minutes 9 Pressure will be hold and witness by Inspection section 10 On successful hydro test, release HT pressure in steps 11 Remove HT assembly and blinds and box up the flanges 12 Remove scaffoldings from inside and outside 13 Install both side covers. Ensure health of gasket 14 Install back the furnace feed spool and convection outlet spool Install PG and Vent assembly here 4” 150# blind to be installed on furnace feed line
  23. 23. CONVECTION ZONE TUBE/ BEND REPLACEMENT Activity Description: Replacement of tube or bend in convection zone due to low thickness, crack, leakage, etc. INSPECTION OF TUBES Cleaning of Weld joints, DPT and Hydro test is performed as preventive maintenance. Inspection will then recommend the replacement of tube or bend Common Consumables Spiral Wound gaskets WD-40 03 can Wire Brush 04 Cotton gloves 24 Cotton Cloth 05 kg Common Tools Rigging tools Welding tools Fabrication tools Fitter’s tools Tube pulling arrangement -- Tube shifting arrangement -- Common Manpower Supervisor 01 Fitter 04 Asst. fitter 02 Rigger 04 Welder -- Fabricator -- S # Job Method Statement 1 Scaffolding bed of 50ft X 40ft X 15ft is to be constructed on east side of furnace as Pic # 01 2 Tube pulling beam and arrangement is to be installed on the scaffolding as Pic # 02 3 Cutting of bend is to be done. Care should be taken that only marked bend by Inspection should be cut 4 Tube will be hold from east side with sling. Additional sling is inserted from west side as well 5 Vessel entry is taken inside convection zone from top and bottom or radiant zone 6 Pulling of tube is done with the help of chain block. 7 After the tube is completely pulled out. Use lifting arrangement to shift the tube from top to bottom and vice versa with the help of crane 8 PMI of all new tube material should be done for material verification 9 Prefabrication of tube is done in workshop. Put the tubes on stand and make alignment with level , insert the shims for its straightening and make the parallel gape between two tubes. 10 Make the bevel of the tubes in parallel shape and perform DPT of bevels 11 Start making Dam / purging / Root / hot pass / Filling and capping.
  24. 24. CONVECTION ZONE TUBE/ BEND REPLACEMENT Activity Description: Replacement of tube or bend in convection zone due to low thickness, crack, leakage, etc. S # Job Method Statement 12 Install the Attachment between two tubes for the alignment and for the proper fitness of tubes to protect the weld joints. 13 These Attachment will be use in 4 locations after every 10 feet distances of both tubes. The attachment will be tight by 2 U Clamps. The Lifting of both Tubes will be done by the Lifting Eye which is weld between the attachments. 14 Shift the tubes on trailer to laydown area for performing radiography 15 After RT, shift tubes back to workshop and weld spear head cone and cleats for easy insertion of the tubes 16 After clearing RT, shift tubes to area 17 Rigging of both tubes is done with the same beam and 04 chain block arrangements 18 Before the insertion of tubes first Attachment will be remove and then insert the tube . when come up to 10 feet remove 2nd attachment , when insertion complete up to 20 feet remove 3rd attachment after all remove 4th attachment when insertion completed up to 30 feet 19 After insertion completion , cut down the spear head and do the bevel of both end together as per field sizes , and tack the U bends , proceed the welding.
  25. 25. PIC # 01
  26. 26. PIC # 02
  27. 27. PIC # 03 PIC # 04
  28. 28. PIC # 05 PIC # 06
  29. 29. PIC # 07 PIC # 08
  30. 30. PIC # 09 PIC # 10
  31. 31. INSPECTION OF FURNACE Activity Description: Hydro testing of Radiant zone tubes 01:Remove this spool and install bend elbow, PG and vent assembly 03: Remove this blind and install HT assembly 02: Remove this spool and install HT pump and water filling assembly Common Consumables Spiral Wound gaskets WD-40 03 can Wire Brush 04 Cotton gloves 24 Cotton Cloth 05 kg Common Tools Rigging tools Welding tools Fabrication tools Fitter’s tools Tube pulling arrangement -- Tube shifting arrangement -- Common Manpower Supervisor 01 Fitter 04 Asst. fitter 02 Rigger 04 Welder -- Fabricator --
  32. 32. INSPECTION OF FURNACE Activity Description: Hydro testing of Radiant zone tubes S # Job Method Statement 1 Remove Furnace outlet spool to quench column (Dia 6” x 10”, 8’ long spool). Crane is required for this activity 2 Blinding to be done (03 blinds, 10” 600# one end blind, 6” 300# end blind and 3” 150# end blind) 3 Opening of six man ways (doors) of furnace, two each on east and west side and two at the roof of radiant section 4 Construct scaffolding inside and outside the furnace for inspection 5 Fill tubes of radiant zone with low temperature condensate 6 Install hydro test assembly at the bottom drain spool and PG assembly on the top spool 7 Ensure complete air removal from the tubes 8 Pressurize tubes step by step holding at 800psi for 30 minutes and then at 1200 psi for 30 minutes 9 Hold time and witness by Inspection 10 Pressure release and draining of water 11 De-blinding and spools box up
  33. 33. RADIANT ZONE TUBE REPLACEMENT Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage, etc. S # Job Method Statement 1 Furnace radiant section tubes comes in shorter length and pre-fabrication in shops is required to make them as per required length. To make one complete length tube of radiant section we need to join three pieces (two joints) for each tube. It means for 32 tubes there will be 64 joints to be welded in shop. 2 Open six man ways (doors) of furnace, two each on east and west side and two at the roof of radiant section. 3 Construct scaffolding inside and outside the furnace for tubes cutting, removal and re-insertion. 4 Cut old tubes inside radiant zone of furnace (Material SS347, dia 6” sch 80, 50.3 ft long tubes). 5 Cut and remove skin TI’s from old tubes of radiant section, There are nine (09) skin TI’s installed in radiant section on different tubes. 6 Cut and remove tube stoppers 7 Remove cut tubes and U bends from inside furnace and shift old tubes and U bends to designated location. Tubes will be removed from furnace east side 8 Pre Fabrication of new tubes in workshop should be completed. All bevels should be checked by EPCL inspection section before tack welding. Inspection provided WPS must be followed. 9 Perform DPT of root and final pass of all weld joints of new tubes. 10 Shift newly fabricated tubes to lay down area for Radiography Testing. 11 Repair any defect if found in RT. Again shift / return tubes to / from lay down area for re shoot. 12 Shift new tubes in furnace area for insertion in furnace radiant section after successful RT result. 13 Insert new tubes inside furnace and place them on tube tree supports.
  34. 34. RADIANT ZONE TUBE REPLACEMENT Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage, etc. S # Job Method Statement 14 Inspection section will inspect the tube tree and is any defect is found, repairing will be done accordingly 15 Shift U bends inside furnace radiant section (Material HK40 casted, dia 6” sch 80 long radius) U bends would be dye checked before using them. 16 Weld U bends with tubes as per drawings and provided WPS (Tube material: SS347 and U bend material: HK40 casted). This includes alignment of U bends and tubes, tack welding, root/hot pass, filling and capping. DPT will be performed on root pass and complete joint of the weld. 17 Welding of thermo wells skin TI’s nine (09) nos. on new tubes as per drawings; in presence of EPCL instrument engineer 18 Perform RT of all tube to U bends joints 19 Repair defect if found in any joint. 20 Perform DPT and Re shoot of defected area by RT. 21 Weld tube stoppers with tubes as per locations mentioned in drawing 22 After all joints RT successful, perform hydro test of complete radiant coil and hold the pressure for 30 minutes at 800psig and then at 1200 psig. 23 Hydro test will be witnessed by EPCL inspection engineers. 24 All scaffolding inside and outside will be removed after hydro test. Care should be taken while removing scaffolding pipes 25 Perform housekeeping from inside and outside of the furnace 26 Box up of all six man ways of radiant section after signing of box up certificate from all interfaces.
  35. 35. S # Job Method Statement 30 Install furnace outlet spool to quench with crane. 31 Removal of all inserted blinds and box up the flanges RADIANT ZONE TUBE REPLACEMENT Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage, etc. Tube lifting beam
  36. 36. BURNER REPAIR WORK Activity Description: Burner inspection and repair (if required) S # Job Method Statement 0 Ensure gas valve is isolated 1 Carefully remove the SS Bend hose pipe dia ½ inch, this may be damaged if mishandle or rotate. 2 Remove the Top & Bottom casings. 3 Remove the tip nozzle with SS pipe dia ½ inches very carefully to protect the ceramic sleeve. 4 Remove the Air body assembly from the Furnace wall; it is installed with 04 bolts and klinger gasket. 5 Remove the ceramic tube, this part is very brittle and may be damaged during mishandling. Be care full and do not remove if there is no need. 6 Need to clean out all parts from dust and rust, do the power brush cleaning of all parts and them perform the DPT of extension pipe nipple and Tip nozzle.. 7 Insulation should be replaced from Air body and top bottom casings. 8 Do the painting works on all stationary parts. Should be high temperature aluminum silver color. 9 Assembly of new and refurbished parts of Burners required as per Drawing. 10 Final box up with new gaskets , Ceramic and Klinger Common Consumables Klinger sil 4401 300mm OD & 220 mm ID 3 mm T 01 Thermal ceramic 2300 01 Wire Brush 06 Cotton gloves 04 Cotton Cloth 02 kg Tools Ring Spanner 18mm 02 Open Spanner 18mm 02 Pipe Wrench 12 inch 01 Brass hammer 2lbs 01 Allen key 5.5mm 01
  37. 37. TUBE TREE PREVENTIVE MAINTENANCE Activity Description: Cleaning and greasing of cast axle Common Consumables ROCOL Anti Seize compound 01 can Kerosene 01 can Wire Brush 04 Cotton gloves 12 Cotton Cloth 02 kg Common Tools Brass Hammer 5lbs 02 Combination spanner 22 02 Crow Bar 01 Other Requirements Lifting beam 01 Rigging equipment 01 Crow Bar 01 Common Manpower Supervisor 01 Fitter 02 Asst. fitter 01 Rigger 02 1. Remove canopy from the top roof of furnace. It is fasten with nut bolts. 2. Carefully remove the fire clothe which protect heat from the opening between roof and Tube Tree carefully. It is binded with SS wire and strip. 3. Install a U-type support H-Beam eye hooks to hang chain block of 10 ton capacity on it.
  38. 38. TUBE TREE PREVENTIVE MAINTENANCE Activity Description: Cleaning and greasing of cast axle 3. The chain block will lift the tube tree up to 1/4 inch to free the Cast Axle. After removing, a spare cast axle is inserted in place. Clean all parts with kerosene. 4. Grease all parts of cast axle and rollers with high temperature ROCOL Anti Seize compound. 5. Now do the same lifting procedure and installed back all parts after greasing. 6. Remove U support beam and chain block and reinstall the fire cloth and then canopy.
  39. 39. TUBE TREE PREVENTIVE MAINTENANCE Activity Description: Cleaning and greasing of cast axle
  40. 40. REFRACTORY REPAIR WORK Activity Description: Repairing work of refractory Refractory materials in furnace CERAMIC FIBRE BLANKET (2300°) 6# DENSITY INSULATED FIRE BRICKS 2300 LI. KS-4 PLUS CASTABLE KASTOLITE 22 PLUS KASTOLITE 20-45 G SAIR SET MORTOR ANCHOR LH 206 -9 SS310 INSBOARD 2300 HD 1 X 24X36 INSWOOL HP BLANKET # 6 & # 8 SIZE 1X24"X25' CERAMIC TUBE Common Tools Brass Hammer 5lbs 02 Brass Hammer 10lbs 01 Crow Bar 01 Common Manpower Supervisor 01 Fitter 02 Asst. fitter 01 Rigger 02 A Dog leg type joint would be formed between the old and the new refractory The old refractory would be sprayed with water before new refractory is poured in place ANCHORS INSTALLATION Old anchors would be grind off and surface preparation would be made for the installation of new anchors. The first layer of the dual lining would be formed with the J type stud in place and tape or rubber tubing covering the exposed threads. The “V” portion wing nut shall then be attached after the first and before the second layer is formed All anchor weld attachments shall be bend tested. Bend testing shall be performed by bending the anchor in the vicinity of the weld 15- degree and back in the direction of greatest resistance without evidence of failure
  41. 41. REFRACTORY REPAIR WORK Activity Description: Repairing work of refractory JOB PREPARATIONS & METHOD STATEMENT A shuttering used for casting refractories would be thoroughly painted with PVC solution, oiled or greased Material for shuttering would be steel sheet or wood. Castables refractory is to be mixed in a paddle mixer of 4-12 cubic foot capacity. Mixers should assure rapid & uniformly mixing. pouring the full batch and clean the mixture from batch to batch Mixer must be clean. (Some substances found in dirty mixers combine with the cement in Castables can lower the ultimate strength of the Castables) Potable water fit for drinking should be used in mixing Castables refractories Temperature of water is maintained between 50°F to 70°F. However, it should never exceed 100°F (38°C). PH value of water should be between 6.0 and 7.5. For Kastolite-22 for 100 lbs., 6 US gallon of water would be added. In order to ensure homogenized mixing, first pour about 1/3 of refractory material and 1/3 of water while mixer paddles are in operation. Pour remaining refractory material and water in same sequence ( that is 1/3 in every step) while ensuring homogenized mixing. The surface of the vessel and adjoining refractory would be sprayed with water before cast able pouring to ensure premature loss of moisture from the mix. Castables would be poured into forms immediately after they are mixed. In any case should the time between mixing and casting not to be exceed up to 20 minutes The cast able would not be allowed to dry till 24 hours in order to allow proper curing & to avoid dusting during operation. All Castables would be vibrated during pouring to avoid air pockets in refractory. Shuttering would be removed from the refractory surface only after 24 hours of refractory application. The refractory would be air dried indefinitely after curing and finally dry out would be carried out. Refractory Mixer machine
  42. 42. REFRACTORY REPAIR WORK Activity Description: Repairing work of refractory JOB PREPARATIONS & METHOD STATEMENT Curing would be carried out at a temperature of about 1000°F during operation (in case of major refractory replacement. Remove old anchor and weld new anchor when you do full rehabilitation of refractory Don't patch the cracks that normally occur in the Castables after dry out. These are natural cracks. These cracks should not exceed 1/16” and are needed for expansion. Large cracks in any moldable lining should be repaired by cutting out the material around the crack to a minimum width of 3” and depth of two inches. Sides to be cut should be tapered to assure a V type anchor for the patching material. If anchors are exposed, these should be adequately cleaned to effectively retain the patch S # Job Method Statement for installing Ceramic Wool insulation 1 Arrange required material as per drawing BOM 2 weld anchor on metal surface of wall as per drawing (LH-1044-E-7) 3 Install SS-310 I type anchors with proper WPS CS to SS-310. 4 Install refractory anchor at specified location , Pitch distance as per Drawing 5 Install INSWOOL blanket over I type anchor as per thickness. 6 Place the tope lock over I type anchors 7 Apply the high temperature mortar paste over the anchor lock to protect from heating and burning. Quality Testing of refractory Hammer test would be carried out on the newly installed refractory. The lining shall be struck with a 1lbs ball point machinist hammer over the entire surface after 24 hrs. Approximate spacing for striking shall be 12” for AP-Green 94 Plus and 20” for other low density materials. If problems are detected visually or by hammer impact sound, closer spacing shall be used to delineate the size of the defect. Voids large than 6”x6” and any sort of dry fill areas that reduce the effective lining thickness by more than ¼ of the original thickness shall be considered defective and shall be repaired. If refractory is inspected after complete dry out, areas containing cracks greater the 1/16in (1.5mm) are considered defective and shall be repaired

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