MESSRS :
Nghi Son Refinery and Petrochemical LLC.
Item No.: 042-H-101/102/103/104
Equipment Name: CCR : Continuous Catalyst
Regeneration Platforming Heater
Refractory Repair Procedure
FOR PROPOSAL
1
29/08/19
0
29/08/19
For Proposal
S.Sakurai
―
―
Prabakaran.B
REV.NO.
DATE
DESCRIPTION
APPROVED
CHECKED
CHECKED
MADE
TOTAL SHEETS
JOB NO.
DOCUMENT NO. OR SPECIFICATION NO.
(INCLUDING COVER)
------------
RP-19001-1
CONSTRUCTION DIVISION
REV.NO.
1
AGC Plibrico Co., Ltd.
CONTENTS
I.
GENERAL
II.
DRAWINGS
III.
INSPECTION REPORT OBSERVATIONS
IV.
PLANNED REPAIR PROCEDURE
AGC Plibrico Co., Ltd.
NO.1
1.0
GENERAL
This document covers the preliminary pre-shutdown inspection
observations, anticipated repairs, and the procedure to follow the repairs
for
Continuous
Catalyst
[042-H-101/102/103/104]
2.0
Regeneration
Platforming
Heater
APPLICABLE DRAWINGS
VM2156-001-A-001(B-7220:23-20)
VM2156-001-A-002(B-7220:23-21)
VM2156-001-A-004(B-7220:23-23)
VM2156-001-A-234(B-7220:23-750)
VM2156-001-A-235(B-7220:23-751)
3.0
INSPECTION REPORT OBSERVATIONS
a) Area around Observation Doors recorded higher skin temperatures.
b) Area around nozzles also recorded higher skin temperature
c) Layer of brick from the bottom two layers of partition wall as shown
has fallen down.
AGC Plibrico Co., Ltd.
NO.2
4.0
PLANNED REPAIR PROCEDURE
a) Area around Observation Doors recorded higher skin temperatures.
(a) Considering that it is a delicate area prone to higher temperatures
than regular lining area, it is proposed to apply a layer of 3mm
thick Ceramic Fiber Paper using Refractory Mortar or C/F Glue as
shown below.
(b) Area shall be dusted neatly, tamped and then glue applied
uniformly prior to application of C/F Paper.
(c) Installation to follow the method statement.
AGC Plibrico Co., Ltd.
NO.3
Above that observation door repair only temporary. Actual skin design
temperature is 87℃. Calculated temperature is approx. 176℃ after
repair, this will cause energy lost.
b) Area around nozzles also recorded higher skin temperature
(a) The C/F paper covering around nozzles may have been eroded.
(b) Kindly use a thin rod of say 2mm diameter to remove loose paper
particles from the annular gap between the nozzle and the lining
to possible depth.
(c) Blow air if possible to remove free debris.
(d) Fill it up with C/F Glue till surface. Apply coating cement 180 all
around for say 100mm width around the nozzle and including a
portion of the nozzle to protect the newly applied glue.
(e) Coating cement 180 may be applied at least after 24 hours, after
application of glue.
AGC Plibrico Co., Ltd.
NO.4
Clean debris
(f) Clean the debris around the Nozzle using tin care, taking care not
to enlarge the opening and then blow air to remove the debris and
dust.
Apply C/F Glue
(g) Apply C/F glue using mastic gun so that it penetrates the gap.
Leave 3-4mm gap on top so that subsequent later can penetrate
the gap for better hold / grip.
Apply Plistix
(h) Apply coating cement 180 all around for say 100mm and care
taken to cleanly fill the tip including overlap on the metallic nozzle
pipe.
(i) Detailed procedure as per the Method Statement
AGC Plibrico Co., Ltd.
NO.5
c) Layer of brick from the bottom two layers of partition wall as shown has
fallen down.
(a) The bricks need to be relined with maximum care taken to ensure
that the lining is bonded with the original lining.
(b) Full bonding can be done only by taking down the entire lining
and rebuilding it with proper engineering / design to take care of
the bonding between bricks so that it can withstand the forces /
stresses & strains it is exposed.
(c) But since the wall except the outer layer bricks is without much
damages ( as can be observed through the observation door ),
suggestion is to build the external layer of first two steps by tie
back system to the main wall using castable / mortise joint
( similar to tongue and groove joint).
AGC Plibrico Co., Ltd.
NO.6
(d) Proposed procedure is to remove inter locked existing wall as
shown in the sketch below from the existing main wall and then
cut grooves/mortise into the adjacent bricks using circular
diamond tipped cutting tool on a grinder.
(e) Similar grooves are cut into the new layer (replacement for fallen
off layer) and brick lining carried out.
(f) At each layer wherever mortise joints have been carried out,
castable lining is done by pouring with an external plywood
support.
(g) This monolithic lining will bond the outer layer of brick with inner
layer and the mortise joints will hold back the castable. For
existing lining which has not fallen, 2 bricks shall be removed as
shown and the same procedure carried out.
Casting of retaining blocks:
AGC Plibrico Co., Ltd.
NO.7
Grinding of bricks to create mortise joint
Retaining Blocks view from top
Retaining Blocks view from side
AGC Plibrico Co., Ltd.
NO.8
Retaining Block locations Image