HF-301A/BMaintenance

Job Card

Muhammad RehanMaintenance Engineer

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 ZoneTotal 32 tubes

SS TP347H, SS321 & Incolloy 800H, 49’-6”

length

Stack

BurnerTotal 72 burners

CABIN, BOX-TYPE FURNACE

Total 40 tubes, SS TP347H, 40’-3” Length

MATERIAL OF FURNACE

CARBON STEEL LINED WITH CASTABLE REFRACTORY

STACKThe 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

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’’ EAST

SIDE

VIEW

WEST

SIDE

VIEW

WEST SIDE VIEW

FURNACE FEED

FEED OUT

4” Fin tubes-Qty 24

6” Fin tubes-Qty 12

6” Bare tubes-Qty 4

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 32Tube Tree

RADIANT IN

FURNACE OUT

Tube Tree

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 722 WELL BOARD 723 AIR SLEAVE 724 CERAMIC TUBE 725 AIR BODY ASSEMBLY 726 INSULATING RING 727 BAND 728 BOTTOM CASING ASSEM 729 TOP CASING ASSEMBLY 72

10 SHUTTER ASSEMBLY 7211 TIP NOZZLE 7212 EXTENTION NIPPLE 72

ITEM DESCRIPTION OF PART REQ FOR ONE FURNACE

13 TUBE GASKET 72

14 GASKET 7215 MOUNTING PLATE 21616 BURNER BLOCK ANCHOR 7217 INSULATING WASHER 7218 1/2 INCH FLAT WASHER 7219 HEX NUT 1/2 X 13 7220 HH CS 3/8-16 X 3/4" LG STL.ZINC 7221 HEX NUT 3/8 X 13 7222 SUPER 3000 CEMENT 7223 SHUTTER PISTON MARKER 7224 SELF TAPE SCREW 6-32 X 3/16 144

01 Cup Block02 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

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)

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”

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

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

ROOF & SIDE WALL

INSULATION

INSWOOL HP BLANKET 2300°F Alumina-Silica Ceramic Fiber BlanketINSWOOL-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

TUBE TREE

Cast Axle

REFRACTORY REQUIREMENT FOR

FURNACE

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.

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.

MA

INTEN

AN

CE

AC

TIV

ITIE

S

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

HS

E H

AZ

AR

DS

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

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 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

DECOKING ACTIVITYActivity 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

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 ACTIVITYActivity Description: Support for Decoking activity on radiant and convection section

INSPECTION OF FURNACEActivity 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

INSPECTION OF FURNACEActivity 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

CONVECTION ZONE TUBE/ BEND REPLACEMENTActivity 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.

CONVECTION ZONE TUBE/ BEND REPLACEMENTActivity 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

18Before 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.

PIC # 01

PIC # 02

PIC # 03 PIC # 04

PIC # 05 PIC # 06

PIC # 07 PIC # 08

PIC # 09 PIC # 10

INSPECTION OF FURNACEActivity 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 --

INSPECTION OF FURNACEActivity 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

RADIANT ZONE TUBE REPLACEMENTActivity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage, etc.

S # Job Method Statement

1Furnace 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.

RADIANT ZONE TUBE REPLACEMENTActivity 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.

S # Job Method Statement30 Install furnace outlet spool to quench with crane.31 Removal of all inserted blinds and box up the flanges

RADIANT ZONE TUBE REPLACEMENTActivity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage, etc.

Tube lifting beam

BURNER REPAIR WORKActivity 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

TUBE TREE PREVENTIVE MAINTENANCEActivity 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 021. 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.

TUBE TREE PREVENTIVE MAINTENANCEActivity 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.

TUBE TREE PREVENTIVE MAINTENANCEActivity Description: Cleaning and greasing of cast axle

REFRACTORY REPAIR WORKActivity Description: Repairing work of refractoryRefractory 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

REFRACTORY REPAIR WORKActivity Description: Repairing work of refractoryJOB 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

REFRACTORY REPAIR WORKActivity 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