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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

INSPECTION TEST REPORT ITEM TESTED INSPECTION DATE INSPECT BY DESIGN DATA YEAR MANUFACTURED CONSTRUCTION MATERIAL CORROSION ALLOWANCE 2002 CS / SS 304L 1.0 (S) / 0 (T) mm DESIGN PRESSURE TEST PRESSURE PRESSURE TEST DATE 15 (S) / 2,5 (T) kg/cm2 22 (S) / 4.8 (T) kg/cm2 2002 E-2570 30th January 2013 Khalid

FREQUENCY/ INTERVAL OF INSPECTION


MAX PERMITTED

INSPECTION INTERVAL (API) LAST INSPECTION DATE NEXT INSPECTION DATE REMAINING LIFE

120 Month(s) 30th September 2009 30th January 2023 <10 years

REASON FOR INSPECTION

Planned

Un-plan

Other (Process upset)

TYPE OF EXAMINATION/ TEST PERFORMED TYPE IF INSPECTION INSPECTION METHODS / TESTS USED HYDROSTATIC TEST OTHERS (PLEASE SPECIFY) Internal Visual Entire External UTG Coil

___________________ Signatory of Inspector Rev.5 / Sept 2011

__________________________ Signatory of R&I Supt/ Engineer Page 1 of 22

CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

INSPECTION SUMMARY E-2570 was shutdown for maintenance due to process upset. The exchanger was remove and inspected at Ad-meth workshop before cleaning condition. Inspection findings are as follows: Shell side appeared in good condition No plugging of tubes was observed except for fouling built up on tubesheets Expanded bellow also appeared in good condition Baffle tie rod noted slight bend. No issue Eddy current testing could not be performed due to heavy deposits on the internal side of tubes

RECOMMENDATION/ ACTION To perform hydrotest for the exchanger as per test pressure. Results passed

ACTION PARTY Mechanical

DATE CLOSED 3rd Feb 2013

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

THICKNESS DATA Location Channel plate Shell plate Shell cone 4 Glycol inlet nozzle(N5) 8 Glycol outlet nozzle(N6) 4 Hot oil inlet nozzle(HOS) 4 Hot oil outlet nozzle(HOR) 1 Drain nozzle(D) 1 Vent nozzle(V1) 1 Vent nozzle(V2) Current (t) mm 11.86 12.57 12.72 6.15 15.9 8.12 8.44 6.20 3.77 6.02 Previous (t) mm Design (t) mm 12.00 12.70 12.70 6.02 11.18 8.56 8.56 6.35 3.38 6.35 Corrosion Allowance (mm) 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 Condition Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance Thickness within tolerance

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

EQUIPMENT GA / LAYOUT

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

INSPECTION PHOTOGRAPHIC RECORD Photo Findings Overview of E-2570

Exchanger shell overview

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Internal shell appeared in good condition

Channel head overview

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Internal channel head condition

Shell cover(cone) overview

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Internal view condition

Internal view condition

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Floating tube sheet and tube bundle condition.

Tubesheet observed no plugging however fouling built up was observed

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Close view of fouling built up

Generally tube bundle appeared in good condition

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Floating head plate condition

Expansion bellow condition

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

After cleaning condition Shell internal

Close view

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Close view

Shell cover(cone)

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Internal view

Close view

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Expansion bellow condition

Channel head condition

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Channel head cover

Floating head plate condition

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Tubesheet condition

Close view of tubes

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Close view of tubes

Tube bundle. One tie rod noted slight bend. No issue

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

Close view.

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

INSPECTION CHECKLISTS RECORD

Pressure Vessel Inspection Checklist


Tick relevant boxes

Item
Heat Exchanger (Shell & Tube) 1) Check before and after cleaning 2) Visual check shell, cover, channel cover, floating head cover and nozzles condition 3) Visual check any erosion-corrosion attack on the tube ends 4) Visual check external tube any corrosion or damage condition 5) Perform NDT for tube

Completed [ ] NA

Comments

Could not be carried out due to heavy deposits on internal tubes

6) Visual check any disclose grooving of tubes and enlargement of baffle holes. 7) Check anodes condition (if any) 8) Inspect the impingement or wear plates for any sign of corrosion or erosion 9) Obtain thickness for shell/ nozzles and dead legs area 10) Check any insulation damage / CUI/ external corrosion 11) Check foundations bolting is double-nutted/ support condition 12) Check platform, ladders, handrails and davis condition 13) Check any painting damage 14) Gasket seating surface any damage 15) Hammer test on Lifting lugs 16) Hammer test on Shell small piping connection 17) Kettle-type exchanger check weir condition

NA NA NA Thickness within tolerance

Furnace (Fire Heater) 1) Check before and after cleaning NA

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

2) Check for porous refractory by hammer test and mark out for repair (if any) 3) Any damage of baffle brick 4) Check and damage or crack ferrules 5) Check any expose anchor 6) Replace feed tube (R1/R2) with correct material construction of Inconel with PMI (for F-8010 only) 7) Vacuum or remove dust on furnace bottom circumference of the refractory brick (for F-8010 only) 8) Fill up the bricks to bricks joints with Ceramic fibre if gap approximately >4mm (if any) 9) Check internal radiant coil thermo bond secured (for Hot Oil Heater only) 10) Check any sign of loose supports securing the radiant coils (for Hot Oil Heater only) 11) Check any ash formation built up / refractory drop out at the crossover fin coils from small doors area (for Hot Oil Heater only) 12) Obtain thickness for shell/ nozzles and dead legs area 13) Check any insulation damage / CUI/ external corrosion 14) Check foundations/ support condition 15) Check platform, ladders, handrails and davis condition 16) Check any painting damage 17) Check all internal apparatus like thermo well, etc condition Boiler 1) Check before and after cleaning 2) Check internal Steam drum and tubes condition 3) Check internal water drum condition 4) Check internal spacer tubes condition 5) Check for porous refractory by hammer test and mark out for repair (if any) 6) Perform require NDT 7) Obtain thickness for shell/ nozzles and dead legs area 8) Check any insulation damage / CUI/ external corrosion

NA NA NA NA NA NA

NA NA NA NA

NA NA NA NA NA NA

NA NA NA NA NA NA NA NA

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CHEVRON ORONITE PTE LTD INSPECTION TEST REPORT

9) Check foundations/ support condition 10) Check platform, ladders, handrails and davis condition 11) Check any painting damage 12) Check all internal apparatus like thermo well, etc condition

NA NA NA

Pressure Vessel (Column/ Vessel/ Reactor) 1) Check before and after cleaning 2) Visual check internal wall condition 3) Check chimney tray condition 4) Check bottom vortex strainer condition 5) Check demister pads condition 6) Check internal packing for any fouling or plugging in bed 7) Inspect the impingement or wear plates for any sign of corrosion or erosion 8) Perform require NDT 9) Inspect any loose of U-bolts & sign of cut or erosion between pipe 10) Check spray nozzle condition 11) Check any damage or weld shear off support 12) Check any bolt/ nuts loose for impeller blade 13) Check any sign of lining/ cladding failure 14) Obtain thickness for shell/ nozzles and dead legs area 15) Check any insulation damage / CUI/ external corrosion 16) Check foundations/ support condition 17) Check platform, ladders, handrails and davis condition 18) Check any painting damage 19) Perform hydro test for external/ internal coil 20) Check all internal apparatus like thermo well, etc condition NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA

Others Comment.

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