maintenance procedure vcm recovery condenser cleaning

16
MAINTENANCE PROCEDURE MUHAMMAD REHAN KHAN MAINTENANCE ENGINEER VCM Recovery Condenser Cleaning CN-1F

Upload: muhammad-rehan-pmp

Post on 02-Jun-2015

299 views

Category:

Engineering


6 download

DESCRIPTION

This is the fourth presentation in series of "Training on maintenance Procedures"

TRANSCRIPT

Page 1: Maintenance procedure vcm recovery condenser cleaning

   

 

MAINTENANCE PROCEDURE

MUHAMMAD REHAN KHANMAINTENANCE ENGINEER

VCM Recovery Condenser Cleaning

CN-1F

Page 2: Maintenance procedure vcm recovery condenser cleaning

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.

Page 3: Maintenance procedure vcm recovery condenser cleaning

VCM RECOVERY CONDENSER (CN-1F)

Sh

ell-T

ub

e sh

ee

t-T

ub

es

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

Page 4: Maintenance procedure vcm recovery condenser cleaning

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

Page 5: Maintenance procedure vcm recovery condenser cleaning

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

Page 6: Maintenance procedure vcm recovery condenser cleaning

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

Page 7: Maintenance procedure vcm recovery condenser cleaning

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

Page 8: Maintenance procedure vcm recovery condenser cleaning

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

Page 9: Maintenance procedure vcm recovery condenser cleaning

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

Page 10: Maintenance procedure vcm recovery condenser cleaning

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 

Page 11: Maintenance procedure vcm recovery condenser cleaning

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

Page 12: Maintenance procedure vcm recovery condenser cleaning

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

Page 13: Maintenance procedure vcm recovery condenser cleaning

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. 

Page 14: Maintenance procedure vcm recovery condenser cleaning

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

Page 15: Maintenance procedure vcm recovery condenser cleaning

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

Page 16: Maintenance procedure vcm recovery condenser cleaning

THANK YOU

MUHAMMAD REHAN KHANMAINTENANCE ENGINEER