

Concept of Reliability section introduced in Year 2014 as
a part of Central Engineering Services department.
Scope of work & Forward path was defined.
Reliability team established in Year 2015.
Services extended to complete plant including CPP.
Nominated cross functional Reliability co-ordinators.
Central Engineering Services
Inspection
Central Workshop
AM
Reliability
AM
TM - 2 Nos.
Tech – 1 No.
TM - 3 Nos.
ATM - 1 No.
Tech - 6 Nos.
Trainee- 2 Nos.
Sr. TM - 1 No.
GET – 1 No.
Tech - 1 No.
Replacement
of Retiring
Manpower
Tech - 1 Nos.
Reliability Section:
Statutory compliance related to IBR-1950, SMPV(U) Rules-2018, Gas Cylinder Rules2018, Petroleum Rules-2019, Factories Act and Rules.
Development of Mechanical integrity programs for static equipments and piping
Development of system for RCFA and CAPA
Residual life Analysis of critical equipments
Development of equipment specification, inspection procedures
Life cycle costing
Development of welding procedures, Qualifying WPS and Welders, In situ weld
inspection
Inspection Section:
Inspection & health monitoring of static equipments and piping
Condition monitoring of dynamic equipments
NDT services
Outside inspections
Corrosion monitoring
Safety valves calibration, preparing test schedules and maintaining status
Revenue budget
Sanctioned for 2019-20: Rs.75.3 Lakhs.
Sanctioned for 2020-21: Rs. 50.0 Lakhs.
Actual expenses till Dec-20: Rs.31.2 Lakhs.
Out of this, @ 40% budget is utilized for Inspection and Reliability.
Static & Rotary Equipments
MECHANICAL
INTEGRITY
Piping
Corrosion
RELIABILITY
Specification for New Equipments
MAINTENANCE
PREVENTION
Vendor Evaluation
Quality during Manufacturing
PROACTIVE
MAINTENANCE
FPA & RCFA
Welding Quality & NDT
Cap-Ex
INTEGRATED ASSET
MANAGEMENT
RLA & LCC
Insurance
Job Description
Action Plan
Preparing Master Equipment
List & Updating
Prepared Equipment Master Lists for static equipment,
piping, safety valves, rupture discs and rotary equipments
Defining criticality of Plant
Rating formats for criticality definition developed. Ratings
Equipments as per guidelines of obtained from Operation, Maintenance & TSD for all static,
API-580
rotary equipments and piping.
Preparing inspection plans
Inspection needs were identified and inspection frequencies
decided based on criticality defined.
Actual Inspection as per plan
Inspection plans released for implementation. Individual
maintenance sections to prepare yearly inspection schedules
based on equipment availability, etc. CES carries out /
follows-up for inspection & keeps records.
Job Description
Action Plan
Maintaining health history
Respective maintenance sections to update their monthly/
shutdown reports and other major maintenance reports on
KM server. CES to access that data from KM server – Activity
still wanting.
SAP PM module not maintained.
Recommending repair /
replacement plan
Improvements in design, MOC,
procedures
Separate inspection reports are generated in specific cases.
Recommendations, corrective actions, improvements are
discussed in monthly Reliability meeting
Job Description
Action Plan
Identifying corrosion issues - CUI,
SCC, Corrosion at supports
Corrosion issues shall be identified for complete
plant.
Inspection requirements, procedures shall be
prepared and used for complete plant.
Specific recommendations generated based on
detailed investigations.
Inspection and analysis
Providing solutions, suggesting
improvements
Job Description
Action Plan
Identifying exact service requirements
Past maintenance history
Future service needs, Operating margin
Optimization, Flexibility, Interchangeability
Reviewing and releasing specifications
Develop with TSD, Operation &
Maintenance team.
Job Description
Action Plan
Visiting vendor’s shops & evaluating capacity,
quality, reliability
Approving list of vendors for particular type of
equipment or service, or MOC e.g. vendors
approved for supply of shell and tube heat
exchangers
Vendor assessment form and rating system for
evaluation developed. Further inputs will be
taken from Purchase, Maintenance dept
Job Description
Reviewing scope before release of PO for critical static
and rotary equipments
Stage inspections at vendor's shop & ensuring quality
requirements
Witnessing performance test runs at vendor's shop
Release clearance for shipment
Action Plan
Job Description
FPA for breakdown incidents, chemical analysis, micrography, failure mode and pattern
Analyzing and suggesting improvements in MOC,
design, operating procedures
Competent team representing all concerned parties
Data collection, brain storming
Using problem solving techniques
Identifying root cause/es
Recommending CAPA
Learning & improvements
Sharing the evaluation with all concerned
Maintaining records
Action Plan
All major failures / breakdowns based on MAR
will be analyzed.
MAR line proposed (Rs.5.0 lacs/yr).
Format for failure analysis prepared.
Concerned HOD shall initiate the procedure.
A competent team comprising all concerned
sections will be formed in consultation with
Management. This investigating team will have
access to the failed parts and history of failed
eqpt / piping.
Outsourcing for chemical, mechanical and
microscopy. Root cause shall be analyzed, CAPA
recommended by the team. CES shall coordinate complete activity, keep record on KM
server and shall share with all concerned.
Job Description
Action Plan
Providing advanced services for analyzing
problems of rotary equipments – Vibration
Signature Analysis – Motor current signature
analysis, Orbit Analysis, Lube Oil Analysis.
Through external agencies.
ISO-18436-2 Level-II available.
Providing NDT services like LPT, MPT, UT,
Interpretation of RT, Endoscopy for all critical jobs
through available facility
ASNT Level-II available in MPT, LPT,
Welding Inspection, Radiography
Interpretation
Providing advanced NDT services like LFET, Eddy
Current, RFET, IRIS, In-situ metallography, Slow
motion Study, Helium Leak Detection, Surface
Roughness Measurement, RVI, PMI.
Through external agencies
Job Description
Action Plan
Preparing fresh WPS for important welding on piping
or static equipments planned in-house.
Training and ASNT certification of CES
staff needed.
Evaluating WPS prepared by contractors / vendors ASNT Level-II available in Welding
Inspection, Radiography Interpretation
Qualifying WPS and maintaining PQRs, Qualifying
welders
Ensuring quality and reliability of maintenance jobs
through NDT
CES shall act as TPI agency for all
important maintenance / replacement
jobs and shall witness and approve all
NDTs such as LPT, MPT, UT
Job Description
Action Plan
Identifying major equipments and piping for RLA
Based on criticality & failure
history
Residual life analysis utilizing advanced NDT techniques,
mechanical testing
External agencies can be
utilized.
De-rating of equipments based on present health condition
Life cycle costing for fresh procurements of capital
equipments,
Evaluating proposals, recommendation for procurement
Recommending action plan for procurement of capital
equipments
Job Description
Action Plan
Integrating Capex plan for complete plant
Budget monitoring for maintenance Capex
All Maintenance Capex plans will be
integrated. Status updating & Budget
monitoring.
Insurance claims for maintenance failures coordination
Coordination between Accts and Maintenance
for insurance claims


Central Engineering Services
Reliability Section
Total Plant Static Equipments: 990 nos.
300
250
90
200
150
62
100
50
89
129
83
45
0
VCM
Critical
130
55
16
SPVC
Semicritical
EPVC
Noncritical
33
106
24
O&U
20
16
12
ETF
54
10
16
CPP
Reliability Section
500
450
400
350
300
250
200
150
100
50
0
Total Plant Dynamic Equipments: 1116 nos.
274
42
54
45
VCM
Critical
166
114
15
36
11
SPVC
Semicritical
EPVC
Noncritical
88
84
49
4
O&U
16
17
7
ETF
64
36
CPP
Reliability Section
Total Plant Piping: 5448 nos.
3000
2500
2000
1388
1500
1000
511
500
388
137
1170
Class-I
221
22
70
0
VCM
946
SPVC
Class-II
EPVC
Class-III
72
119
48
O&U
113
113
40
ETF
17
31
42
CPP
Reliability Section
80
500
450
70
400
60
350
50
300
250
40
200
30
150
20
100
10
50
0
0
PVC-E
VCM-E
Planned
O&U-E
ETF-E
Actual
CPP-E
Planned
Actual
Reliability Section
400
30
350
25
300
20
250
200
15
150
10
100
5
50
0
0
PVC-I
PVC-II
PVC-III
Thickness Survey Planned
VCM-I
VCM-II
VCM-III
O&U-I
Thickness Survey Actual
O&U-II
O&U-III
ETF-I
ETF-II
Visual Inspection Planned
ETF-III
CPP-I
CPP-II
CPP-III
Visual Inspection Actual


Central Engineering Services
Reliability Section
 CUI: Corrosion Under Insulation
CUI Programme for Finolex complex.
Classification of Equipment's & Piping's based on RBI programme:
Inspection Programme

Inspection Procedures & formats developed under Mechanical Integrity programme.

If any visible stain or rust mark observed, identified area need to be stripped off insulation.

Stripped off area need to be examined through ultrasonic thickness survey.
Prevention of CUI:

Low chloride content insulation material shall be used.

Aluminum foil of 0.1mm thickness with overlap of 50 mm to be used on Austenitic stainless
steel piping & equipment.

Protective paints & coating need to be apply based priority & opportunity.
Reliability Section
 CUI: O&U LSHS Line Report
Visual inspection & Thickness survey of LSHS 3” line at insulation removed
locations & near leaked elbow.
Minimum thickness measured on pipe is 3.6mm & on elbow: 2.6mm as
compared to specified thickness 5.5 mm.
Slight external corrosion observed on line.
To ensure the integrity of piping from P-8805 A/B to day tank T-9501 & identify
CUI, insulation pocketing required at few locations preferably near support area


Central Engineering Services
Reliability Section
 CPP Surface Condenser Retubing Job.
Tubes MOC change from CU-Ni 90/10 to CU-Ni 70/30.
Total Nos. of Tubes 6360 nos.
Tubes Manufactures through M/s Multimetal Ltd. Kota, Rajasthan.
QA Plan Prepared for tubes inspection.
After satisfactory inspection as per QA plan final approval given for tubes dispatch
as per PO.


Central Engineering Services
Reliability Section
 Surface Condenser Tubes Leakages:
70:30 Cu-Ni tubes leak after 82 days of service &
frequency of once in two weeks.
Failure investigation carried out through M/s TCR Advance
Engg. Services .
The initiation of puncture is observed from sea water
side. The puncture is associated with under deposit
corrosion by mode of pitting microbiological influenced
corrosion. leading to indication of inadequate sea water
treatment.
Recommendations- Consult the treatment experts for
optimizing the use of corrosion inhibitors ,micro biocides,
antiscalent & oxidizing biocide to prevent the nature of
damage.
Reliability Section
CPP: Steam Turbine Tripping at high vibration during startup
Fault tree analysis applied to RCFA.
Rubbing marks at front of oil scraper & increased clearance between shaft & oil
scraper indicates disturbance in shaft centring.
RecommendationsVibration signature & orbit Analysis need to be done prior to S/d & at time of
start up,
 Lube oil analysis need to be carried out at every 3 months frequency
SOP for various modes of STG operation -a) Start-up b) Normal operation
c)Temporary operation d)Emergency operation e) shutdown to be reviewed and
updated.
Alignment records with reference set-up and measurements need to be
maintained
Reliability Section
 R-1401 Coils Retainers Failure:
During 2019 shutdown it was observed coils
retainers (52 nos.) are fallen down.
FPA Carried out through M/s IRCLASS Mumbai
Failed bolt samples do not seem to be high
temperature resistance material SS310. It is more
likely to be a low carbon steel or Fe-based alloy
with total alloying element < 2%
Recommendations- Since the failed bolts were
completely oxidized, it is better to analyze other
adjacent bolts which are in comparatively good
condition in order to ascertain material selection
of design requirements based on application .
Reliability Section
 E-1410 & E-1411 Contamination of steam & condensate due to failure of E1410 Inner Tube.
OEM-Condensing Equipments. Replaced thrice since July-2010 to Feb-2019 through local contractors with SS-316L inner
pipe and outer pipe in CS construction.
Highly aggressive process stream in dual phase as well as carrying some coke – Highly corrosive-erosive.
As per latest P&ID, MOC for C-1401 bottom circuit up to D-1409 has to be SS-904L.
MOC for both exchangers have been corrected as per recommendations.
Reliability Section
 RCFA of N-4404-A Agitator Shaft Failure
M/s Shanti make GB (In place of Ekato) with new shaft from M/s Standard
Engineering was installed.
No indication of ductile fracture as there is not reduction of shaft diameter
or any cup & cone design.
Fracture is also not a brittle fracture as the crack progression is not in
exactly transverse direction. However final failure in overload zone can be
termed as brittle failure. Shiny surface is one of the indications of brittle
fracture.
Multiple cracks originated especially from peripheral area with progression
at 10-15° to shaft axis. Indicates Torsional Fatigue in rotational direction.
Micro-cracks developed under hard chrome plated surface might have
provided initiation points for the cracks. Micro-cracks on the surface were
visible.
Recommendations- Maintaining original MOC-904L instead of SS-316, NDT
before and after hard chrome plating, maintaining original dimensions to
avoid stress concentration, welding of cone on both side of shaft.
Reliability Section
 8” VCL header spool piece of VCM Filter F-4101 A/B/C/D Failure
Installed in project stage. Leakages are either on weld joints or ERW seam.
Thickness-satisfactory. Internal pitting indicating corrosion of SS-316L pipe material. Weld fit-up was inproper with incomplete penetration and lack of fusion.
Internal deposits were analysed -0.22% HCL acidity, pH can be below 2.0.
Crevice corrosion –Root cause. Recommended for complete replacement of headers with quality welding
and inspection.


Central Engineering Services
Reliability Section
Sr. Equipment
No. No.
Equip. Description
Tube MOC
Technique
Job Completion Remark
Action
1
E-1207
RECYCLE GAS HEATER
SA-179
MagWave
17/11/18
All Tubes < 20%
2
E-1418
EDC PRE HEATER
SA-179
RFET
17/11/18
62 nos. Tubes > 30%, Total 8 nos. Tubes plugged
3
E-1420
EC QUENCH CONDENSER-IV
SA-179
RFET
18/11/18
5 nos. Tubes 21-31%
4
E-1303 A
HEADS COLUMN REBOILER
SA-179
RFET
24/10/18
4 nos. Tubes wall loss> 30% plugged.
5
E-1309 A
VACUUM COLUMN REBOILER SA-179
RFET
6
E-1502 B
HCL COLUMN REBOILER
SA-179
RFET
22/10/18
19 nos. Tubes 21-30%
7
8
E-1201
SA-179
SA-179
RFET
18/05/19
E-1202
ETHYLENE FEED HEATER
HCL FEED HEATER
RFET
18/05/19
22 tubes 0-20%
104 tubes 0-20%
9
E-1203
OXY PURGE AIR PREHEATER
SA-179
Saturated EC 20/05/19
20 tubes 0-20%
10 E-1205
RECYCLE GAS CHILLER
SA-179
Saturated EC 20/05/19
200 tubes 0-20%
11 E-1323 A/B
EDC PREHEATER
SA-179
RFET
20/05/19
8 tubes 31-40% plugged
Exch. Replaced
12 E-1403
HCL INTERCHANGER
SA-334 Gr-1
RFET
23/05/19
12 tubes 20-30% plugged
Exch. Replaced
13 E-1502 A
HCL COLUMN REBOILER
SA-179
RFET
22/05/19
241 tubes 0-20%
14 E-1504 A
VCM COLUMN REBOILER
SA-179
RFET
21/05/19
713 tubes 0-20% & 6 tubes blocked
15 E-1504 B
VCM COLUMN REBOILER
SA-179
RFET
23/05/19
659 tubes 0-20% 58 tubes blocked
16 E-1309 B
VACUUM COLUMN REBOILER SA-179
RFET
24/12/2020
7 nos. tubes wall loss 31-40%,plugged
24/10/18
Exch. Replaced
57 nos. Tubes 21-30%
Reliability Section
 CPP Turbine Vibration signature & Orbit Analysis
43MW BHEL make Steam Turbine generator installed in CPP in 2009.
Turbine minor shutdown planned in 2018.
Vibration analysis conducted through M/s GE oil & Gas India Pvt. Ltd.
Vibration signatures captured in transient & steady state .
Various diagnostics plots were analyzed.
Second balance resonance sync. amplification factor observed to be around
4.5 at turbine front bearing indicating insufficient damping on rotor.
Turbine front bearing clearances may be checked for conformity to OEM protocol.
Bearing fitment should be checked and corrected if required to ensure proper
interference fit in bearing housing.
Reliability Section
 Motor Current Signature Analysis
EDC Feed pump PM 1401 A/B repetitive
failure of motor.
Detailed Vibration & MCSA conducted
through M/s SPM .
Rotor bar health falls in level 4 severity
hence trending required on half yearly
basis.
Motor Soft foot needs to be eliminate.
Motor proper earthing required & earthing
continuity needs to be ensured.
Reliability Section
 Rotary equipment Lube Oil & Wear
Particle Analysis.
For ETF Ethylene Compressor Lube oil &
WPA conducted through M/s Predict
technologies.
For CPP Turbine Lube oil & WPA conducted
through M/s Chemtech Laboratories.
Few fresh oil sample also analyzed.
Advantage:
Determine in wear & tear in component.
Lubrication suitability for continued use.
Reliability Section
 CPP:PRDS Line Stress Analysis
For Trouble shooting for support dislocation in
bypass line supports and failure at TEE detailed
stress analysis conducted.
Job
has
been
completed
as
per
recommendation after stress analysis.: Till date
no failure noticed up to the Tee section.
Off late failures being noticed in downstream
section and complete job is planned.
Reliability Section
 Main steam Line from CPP to O&U Stress Analysis.
12” process steam line delivers steam from Captive power plant to O&U plant.
During start up many thermal expansion & thermal movement related problem observed.
CPP area pipe line drop from pipe rack & at O&U few location experience large movement.
Few supports are broken.
Stress analysis carried out through M/s ND Engg. Services pvt. ltd.
Analyze complete line in CAESAR & suggest various modification in line & support.
Partial job completed remaining job completed in suitable opportunity.
Reliability Section
 R-1401 & R-1402 O/L Piping & Radiation coils.
Being high temperature service piping need to evaluate for microstructure
degradation.
MOC: SA 312 TP 347
Insitu Metallography conducted through M/s TCR Engineering Services pvt. ltd.
Locations identified for metallography
Microstructure free from any micro cracks.
Maintain trending record for analysis
Reliability Section
 R-1402 Convection/Radiation Inlet Outlet piping.
Videoscopy is a technique on NDT used for visual inspection where
the area inaccessible for human eye.
After decoking process the internal surface of piping need to inspect.
For internal piping inspection Remote visual inspection carried out
through M/s NDTS.
Inspected length de-cocked only minor scale of 0.3mm to 0.5mm
observed.
Reliability Section
 R-4301E/F
Surface
roughness
Assessment
mechanical & electrochemical polishing.
after
After mechanical & electrochemical polishing of PVC reactors no
tools available for quality assessment for surface roughness.
New Roughness tester procured & conducted surface roughness
measurement after mechanical polishing.
Desired level of surface roughness achieved & electro polishing
job avoided.
Reliability Section
 Positive material Identification:
Positive Material Identification is a rapid non-destructive method & is performed
on a wide range of components and assets and provides a semi-quantitative
chemical analysis.
Conducted for CPP Boiler #1 & Boiler #2 pressure parts like Radiant & Convection
section, Desuper heater -I , Desuper heater-II , main steam line nozzles etc.
Conducted for CPP Boiler new received spares bed super heater coils.
Engineering advice in up gradation of MOC if any deviation noted.
Reliability Section
 Ultrasonic Flaw Detection:
Ultrasonic testing is a Non-destructive technique based on propagation of
ultrasonic wave in object or tested material.
UFD conducted for R-1201 Oxy-chlorination reactor boiler feed water coil weld
joint health assessment .
No abnormality observed.


Central Engineering Services
Reliability Section
 RLA 1402 Radiation Coil RLA: Year 2016
EDC Cracker commissioned in May 2000.
Exceeded Design life.
 Completed Approximate 130,000 hrs. till May-2016.
 General Design life for heater is 100,000 hrs.
Decided for FFS & RLA study for better Cap-Ex planning.
Coil operate below creep limit hence indefinite creep life available.
To ensure no further metallurgical deterioration microstructure need to asses at
regular interval.
Reliability Section
 RLA 1401 Radiation Coil RLA: Year 2019
EDC Cracker commissioned in 1993 & Radiation coils revamped in 2009.
 Completed Approximate 84,000 hrs. till Apr-2019.
 General Design life for heater is 100,000 hrs.
Decided for FFS & RLA study for better Cap-Ex planning.
Tube passes level-3 assessment & fit for continues operation in present operating
conditions.
Metallographic degradation observed in the form of Creep voids, hence to ensure
no further metallographic degradation taking place, need to inspect
microstructure & hardness at periodic interval of 2 yrs.
Reliability Section
 E-2201 Outlet Tube sheet FFS Assessment:
Tube Leakage was noticed from Waste heat recovery boiler after 1-1/2 year service.
 Tubes Insitu ECT conducted through M/s NDTS sever wall thinning>80% observed &
hence necessary to replace tubes.
 Before restoring tube replacement it was necessary to conduct detailed assessment
of fitness of Outlet tube sheet for continual service as per API 579 ASME FFS1
 FFS carried out by M/s TCR Advanced in 2017.
 Based on the assessment it is judged that tube sheet is fit for service and may be
returned to operation ensuring its machined surface, free from any indication by
NDT.
 The future operation would continue strictly as per the parameters specified by the
OEM / process licensor.
Reliability Section
 E-8110(inter stage cooler & E-8112(Start up gas cooler): FFS
Assessment
Equipment are erected & commissioned in 2000 & are critical in nature for
ethylene reliquefication.
 Tubes Insitu ECT conducted through M/s NDTS in June-2018.
 Fitness for service Level-1 assessment as API-579 carried out.
Tube passes level-1 assessment & fit for continues operation in present operating
conditions.
ECT report also indicate no any major flaw.
Remaining life calculation indicate indefinite life but for monitoring tubes health
condition ECT may be carried out at every 5yrs of frequency.
Both exchangers are running trouble free service till now.


Central Engineering Services
Reliability Section
Year
Dept.
Project
Base Metal
Welding Process
WPS
WPS
Prepared Qualified
Welder
Qualified
2016
ETF
Ethylene hot gas line repl.
SA 106 Gr.B to SA 106 Gr. B
GTAW
Yes
Yes
Yes
2017
ETF
Ethylene Line replacement
SA 106 Gr.B to SA 106 Gr. B
GTAW+SMAW
Yes
Yes
Yes
2019
ETF
Ethylene Line replacement
SA 106 Gr. B to SA 106 Gr. B
GTAW+SMAW
Available Available
Yes
2019
O&U
RO Water Piping replacement Duplex & Super duplex
GTAW
Yes
Yes
Yes
2020
ETF
VCM Line replacement
SA 106 Gr.B to SA 106 Gr. B
GTAW+SMAW
Yes
Yes
Yes
2020
PVC
VCL Header Replacement
SS 316L to SS 316L
GTAW
Yes
In progress In Progress
2020
CPP
PRDS Modification
SA 335 P22 to SA 335 P22
GTAW+SMAW
Yes
In progress In Progress
 CPP Turbine Signature & Orbit Analysis
Scope of work has been prepared to conduct the signature & orbit Analysis.
Tentative Planning in Sep-2021.
 Fire Water Pump In-situ Performance (CPP)
Procedure for Pump Insitu performance test has been prepared.
Activity already completed for ETF and Main plant Fire water pumps.
 Eddy Current Testing of CPP Surface Condenser
Planning for conducting ECT in Sep-2021.
Previous data available for comparison.
 8” VCL Header Replacement
WPS prepared. Procedure qualification and welder qualification balance.
Complete inspection during fabrication in lieu of TPI.
 R-1401 Radiation Coil RLA
Temperature excursions beyond design temperature during Dec-20 decoking
shutdown.
 DG Set Performance Test
Identification of engine for in-situ top overhauling.


Central Engineering Services