HF-301A/B

Maintenance
Job Card

Muhammad Rehan
Maintenance Engineer
 CRACKING MATERIAL OF FURNACE
CARBON STEEL LINED WITH Flue Gas

FURNACE CASTABLE REFRACTORY 2150C

Stack

(HF-301A/B)
Process: Thermal Decomposition
Furnace Feed
Dry purified EDC is fed to Cracking Furnace
where it decomposes into VCM and HCl. 830C, 24bar Convection Zone
Total 40 tubes, SS
Convection Exit : 250 C
Cracking temperature is 5370C. TP347H, 40-3 Length
Arch
Conversion efficiency is 56-60%. Furnace Outlet Temp : 670 C

5000C, 20bar Radiant Zone

Reaction products and un-reacted EDC are
cooled immediately in quench section to Total 32 tubes
minimize coking and reaction reversal. SS TP347H, SS321 &
Incolloy 800H, 49-6
HCl is separated from EDC and VCM, and length
sent to Oxy Chlorination Unit.
Burner
Subsequently, EDC is separated from VCM Total 72 burners
and recycled. VCM is sent to Storage. Temp : 685C (tube skin)
H2, Natural Gas Fuel
C2H4Cl2 C2H3Cl + HCl
H= -30,500 Btu/lbmol CABIN, BOX-TYPE FURNACE 350C, 1.5bar
 STACK
The 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.

Damper

Stack anchors and refractory

 CONVECTION FURNACE FEED

ZONE
Part NPS Material Qty.
Fin Tubes 4 40 Sch SS TP347H 24
& Incolloy
Fin Tube 6 40 Sch 800H 12
Bare Tube 6 80 Sch 4
Height: 252 1/8, Width: 8 6.5, Length:3 99 E W
A E 4 Fin tubes-Qty 24
S S
T T

S S
I I
D D
E E

6 Fin tubes-Qty 12 V V
I I
E E
W W

6 Bare tubes-Qty 4

WEST SIDE VIEW FEED OUT

 WEST SIDE VIEW
RADIANT ZONE FURNACE OUT

Type NPS Material Qty.

Bare Tube 6 Qty 32
Bare Tubes 6 80 Sch SS TP347H 32 Tube Tree

Height: 2311, Width: 11 7.5, Length: 55

Tube Tree

RADIANT IN
DOOR ENTRY
 SIDE WALL
SELAS Type K9306 Burners are capable to deliver 110,000,000 BTU/hr natural gas

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 9 X 2 sides X 4 rows

and fuel for better combustion.
REQ FOR ONE REQ FOR ONE
ITEM DESCRIPTION OF PART ITEM DESCRIPTION OF PART
FURNACE FURNACE
1 CUP BLOCK 72 13 TUBE GASKET 72
2 WELL BOARD 72 14 GASKET 72
3 AIR SLEAVE 72 15 MOUNTING PLATE 216
4 CERAMIC TUBE 72 16 BURNER BLOCK ANCHOR 72
5 AIR BODY ASSEMBLY 72 17 INSULATING WASHER 72
6 INSULATING RING 72 18 1/2 INCH FLAT WASHER 72
7 BAND 72 19 HEX NUT 1/2 X 13 72
8 BOTTOM CASING ASSEM 72 20 HH CS 3/8-16 X 3/4" LG STL.ZINC 72
9 TOP CASING ASSEMBLY 72 21 HEX NUT 3/8 X 13 72
10 SHUTTER ASSEMBLY 72 22 SUPER 3000 CEMENT 72
11 TIP NOZZLE 72 23 SHUTTER PISTON MARKER 72
12 EXTENTION NIPPLE 72 24 SELF TAPE SCREW 6-32 X 3/16 144
 02 Well Board 04 Ceramic tube 08 Bottom casing assy.
01 Cup Block

03 Air Sleeve

11 Tip Nozzle
05 Air body assembly

14 Gasket

10 Shutter assembly

09 Top casing assy.

12 Extension nipple

16 Burner Anchor 06 Insulating ring

07 Aluminum Band
 Item # 16 Burner Anchor (Material SS)

Item # 02 Well Board (Material INS BOARD2300HD) Item # 11 Tip Nozzle (Material Alloy 800) Item # 12 Extension nipple (Material SS)
Item # 01 Cup Block (Material Formula 130)

Item # 05 Air body assembly Item # 08 Bottom casing assy. Item # 09 Top casing assy.
Item # 07 Aluminum Band

Item # 03 Air Sleeve(Material Alloy HT)

Item # 04 Ceramic tube Item # 10 Shutter assembly Item # 06 Insulating ring (Epitherm 1200) Item # 14 Gasket
BURNER WALL
INSULATION
INSBOARD 2300 HD

Cup block formula 130

KAST-O-LITE 20-45 G ADTECH

KAST-O-LITE 22 PLUS

EMPIRE S

INSWOOL-HP BLANKET

INSBOARD 2300HD

IFB 2300LI

INSBLOK-19
BURNER WALL REFRACTORY INSTALLATION

00:Burner side walls without insulation 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
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 EMPIRE S KAST-O-LITE 22 PLUS KAST-O-LITE 20-45 G ADTECH

INSWOOL HP BLANKET
2300F Alumina-Silica Ceramic Fiber
Blanket
INSWOOL-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.
Anchors
TUBE TREE

Cast Axle
 REFRACTORY
REQUIREMENT FOR
FURNACE
 REQUIRED FOR ONE
S# MATERIAL DETAIL (DRW. LH 1044-E7 ) UOM SIZE AND DETAIL LOCATION OF APPLICATION
FURNACE

Brick lining use at burner bottom side

1 IFB 2300 LI 9X6X3 EA 740 STD 9"(229)X6"(152)X3"(76) STRAIGHT 23000 IFB
to hold.
Brick lining use as second and layer in
2 IFB 2300 LI 9X4-1/2X3 EA 13460 STD 9"(229)X4-1/2"(114)X3"(76) STRAIGHT 23000 IFB
furnace.
Brick lining use at corner of heat
3 IFB 2300 LI 9X4-1/2X2-3/4 EA 60 9"(229)X4-1/2"(114)X2-3/4"(70) SPLIT 23000 IFB
transfer duct.
Brick lining use under item 1 for its
4 IFB 2300 LI 9X4-1/2X2-1/4 EA 150 9"(229)X4-1/2"(114)X2-1/4"(57) SPLIT 23000 IFB
support .
PIECES BLOCK INSULATION (1900) 36(914)X12"(305)X2- Board use at back side wall behind 2nd
5 INSBLOCK 19 2-1/2 X 12X36 EA 785
1/2"(64) layer brick.
PIECES BLOCK INSULATION (1900) board use with cs sheet 1st layer at
6 INSBLOCK 19 1 X 12X36 EA 850
36(914)X12"(305)X1"(25) furnace wall.
PIECES CERAMIC FIBRE BOARD (2300)
7 INSBOARD 2300 HD 1 X 24X36 EA 25 soft board use behind burner block.
36(914)X24"(610)X1"(25)
CERAMIC FIBRE BLANKET (2300) 6# DENSITY PIECES CERAMIC FIBRE BLANKET (2300) 6# DENSITY ceramic blanket use behind burner
8 ROLL 5
1(25)X24"(610)X25'(7620) 1(25)X24"(610)X25'(7620) block.
PIECES BLOCK INSULATION (1900)
9 INSBLOCK -19 3X12X36 EA 105 Use as first layer in duct.before casting.
36(914)X12"(305)X3"(76)
For casting of Duct.UM in CUFT as per
10 KS-4 PLUS CASTABLE CUFT 80 Cu FT IN PLACE 2500 CASTABLE
density.
STD 9"(229)X4-1/2"(114)X2-1/2"(64) HIGH DUTY FIRECLAY
11 EMPIRES BRICKS 9X4-1/2X2-1/2 EA 1620 top bricks layer on furnace floor
(FLOOR)
Cu FT IN PLACE LUMNITE, HAYDITE, VERMICULITE (1:2:4 castable refractroy use as 2nd layer at
12 KASTOLITE 22 PLUS CUFT 165
Mix) (FLOOR) furnace floor.
Cu FT IN PLACE LUMNITE, HAYDITE, VERMICULITE (1:6 Mix) castable refractroy use as 1st layer at
13 KASTOLITE 20-45 G CUFT 110
(FLOOR) furnace floor.
 REQUIRED FOR
S# MATERIAL DETAIL (DRW. LH 1044-E7 ) UOM SIZE AND DETAIL LOCATION OF APPLICATION
ONE FURNACE

PIECES CERAMICS FIBRE BLANKET (2300)-6#

14 INSWOOL HP BLANKET 1/2 X 24 X50 ROLL 21 use as exp.joint in floor and brick lining.
DENSITY1/2"(13)X24"(610)X25'(7620)

15 SAIR SET MORTOR LBS 6100 POUNDS SAIRSET MORTAR mortor use to joint all bricks
3/16"(5) BENT BRICK ANCHORS PER STD 2101, PART# 2101-
16 ANCHOR LH 302 -3 SS310 EA 3250 use for castable refractory.
11
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.
PIECES CERAMIC FIBRE BLANKET (2600), 6 DENSITY
21 INSWOOL HTZ BLANKET # 6 Lbs 1/2X24X50 EA ONE
1/2(13)X24(610)X25'(7620)
STAIN LESS STEEL STRIP FOR BINDING OF Cloth binding at tube tree top and rad.in/out
22 FEET 40 LIN FT. LOCKING STAINLESS STEEL BAND
CLOTH . lines.
PIECES CERAMIC FIBRE BLANKET (2300) 8# DENSITY
23 PIECES CERAMIC FIBRE BLANKET 2300 ROLL ONE use for peep doors and other location.
2"(51)X24"(610)X25'(7620)

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 .

INSWOOL HP BLANKET # 6 SFT 300 PIECES CERAMIC FIBRE BLANKET (2300) 8# DENSITY used at tube tree top to protect as cover with
25 ROLL 2
SIZE 1X24"X25' # 8 SFT 250 4"(102)X24"(610)X25'(7620) cloth.
this cloth used for tube tree and in/out lines of
26 FIRE PROOF CLOTHE ROLL 2 ALLUMINIZED FIBRE GLASS CLOTH 1/32"(1) THK
furnace.
this RTV used for clothe pasting on tube tree
27 RTV SILICONE TUBES. LBS 3 LBS SILICON RUBBER SEALANT GE RTV 116 (OR EQUAL)
and in/out lines of furnace.
INSWOOL HP BLANKET # 8 PIECES CERAMIC FIBRE BLANKET (2300) 8# DENSITY used at tube tree top to protect as cover with
28 ROLL 2
SIZE 2X24X12-1/2 4"(102)X24"(610)X25'(7620) cloth.
PIECES CERAMIC FIBRE BLANKET (2300) 6# DENSITY
29 INSWOOL HP BLANKET # 6 SIZE 2X 48 X12-1/2 ROLL 4 ceramic blanket use behind burner block.
2"(51)X24"(610)X25'(7620)
 1. Decoking of Radiant & Convection Zones tubes
MAINTENANCE 2. Hydro testing of Convection zone tubes
ACTIVITIES 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

To ensure Quality assurance in maintenance activities, HOLD POINTS are given for each activity and are highlighted as HOLD POINTS
 ACTIVITIES HAZARDS PRECAUTIONS
Avoid over stepping the hand rails
Person may fall
HSE HAZARDS Ensure worker is not ill or have height phobia
WORK AT
Use tool bags for shifting and keeping of tools
HEIGHT
Material may fall Use trays for keeping stud , bolts and other material
Ensure Scaffolding and Cladding material is secured with railings
Ensure hot job protocol is followed
HOT JOBS Fire in flammables
Assign fire watchers for each hot job
Chemical env. Use dust mask or other proper PPEs
VESSEL ENTRY Dehydration/ Asphyxiation Ensure 0% LEL, adequate Oxygen level and water arrangement. Ensure adequate ventilation
JOBS
Refractory material Use chemical gloves and dust mask.

Material shifting with the help of crane should be done under the supervision of qualified
riggers
Material may fall Use manila ropes for tools and material shifting
MATERIAL Use Cotton gloves while material handling
SHIFTING
Ensure area is barricaded while shifting material
More than 10 kg weight should not be taken through step ladder
Person may slip or fall
Material should not be transferred by hand through monkey ladders
RIGGING All rigging activities should be done under the supervision of qualified riggers
Material may fall
ACTIVITIES Area should be barricaded during lifting of material and Crane Operation
MULTIPLE JOBS
Slip and trip Proper housekeeping must be ensured throughout the shift
IN PARALLEL
DECOKING ACTIVITY
Activity 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

Manpower requirement
Supervisor 01
Fitter 02
Asst. fitter 01
Rigger 02

Other Requirements
Crane 80 Ton 01
DECOKING ACTIVITY
Activity Description: Support for Decoking activity on radiant and convection section

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
INSPECTION OF FURNACE
Activity Description: Hydro testing of Convection zone tubes
Common Consumables

Molykote 01 can
Wire Brush 02
Cotton gloves 12 01:Remove this spool and install blind 4 150# 02: Remove this blind and install PG and Vent assembly
Cotton Cloth 02 kg

Common Tools
Brass Hammer 5lbs 02
Combination Spanner 01
Crow Bar 01

Common Manpower
Supervisor 01
Fitter 02
Asst. fitter 01
Rigger 02

Other Requirements
Crane 80 Ton 01
Fork Lifter 01
03: Remove this spool and install HT pump and water filling assembly
Crow Bar 01
INSPECTION OF FURNACE
Activity Description: Hydro testing of Convection zone tubes
S# Job Method Statement Install PG and Vent assembly here
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 4 150# blind to be installed on furnace feed line
CONVECTION ZONE TUBE/ BEND REPLACEMENT
Activity Description: Replacement of tube or bend in convection zone due to low thickness, crack, leakage, etc.

Common Consumables INSPECTION OF TUBES

Spiral Wound gaskets Cleaning of Weld joints, DPT and Hydro test is performed as preventive maintenance. Inspection will then recommend the replacement of tube or bend
WD-40 03 can
S# Job Method Statement
Wire Brush 04
Cotton gloves 24 1 Scaffolding bed of 50ft X 40ft X 15ft is to be constructed on east side of furnace as Pic # 01
Cotton Cloth 05 kg 2 Tube pulling beam and arrangement is to be installed on the scaffolding as Pic # 02
Common Tools 3 Cutting of bend is to be done. Care should be taken that only marked bend by Inspection should be cut
Rigging tools
4 Tube will be hold from east side with sling. Additional sling is inserted from west side as well
Welding tools
Fabrication tools 5 Vessel entry is taken inside convection zone from top and bottom or radiant zone
Fitters tools 6 Pulling of tube is done with the help of chain block.
Tube pulling arrangement --
After the tube is completely pulled out. Use lifting arrangement to shift the tube from top to bottom and vice versa
Tube shifting arrangement -- 7
with the help of crane
Common Manpower
Supervisor 01 8 PMI of all new tube material should be done for material verification
Fitter 04 Prefabrication of tube is done in workshop. Put the tubes on stand and make alignment with level , insert the shims
9
Asst. fitter 02 for its straightening and make the parallel gape between two tubes.
Rigger 04
10 Make the bevel of the tubes in parallel shape and perform DPT of bevels
Welder --
Fabricator -- 11 Start making Dam / purging / Root / hot pass / Filling and capping.
CONVECTION ZONE TUBE/ BEND REPLACEMENT
Activity Description: Replacement of tube or bend in convection zone due to low thickness, crack, leakage, etc.
S# Job Method Statement
Install the Attachment between two tubes for the alignment and for the proper fitness of tubes to protect the weld
12
joints.
These Attachment will be use in 4 locations after every 10 feet distances of both tubes. The attachment will be tight
13
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
Before the insertion of tubes first Attachment will be remove and then insert the tube . when come up to 10 feet
18 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
After insertion completion , cut down the spear head and do the bevel of both end together as per field sizes , and
19
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 FURNACE
Activity Description: Hydro testing of Radiant zone tubes
Common Consumables
Spiral Wound gaskets
WD-40 03 can
Wire Brush 04
Cotton gloves 24
Cotton Cloth 05 kg

Common Tools
Rigging tools 01:Remove this spool and install bend
Welding tools elbow, PG and vent assembly
Fabrication tools
Fitters tools
Tube pulling arrangement --
Tube shifting arrangement --
Common Manpower
Supervisor 01
Fitter 04
Asst. fitter 02 02: Remove this spool and install HT pump and water filling assembly
Rigger 04
03: Remove this blind and install HT assembly
Welder --
Fabricator --
INSPECTION OF FURNACE
Activity 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)

Opening of six man ways (doors) of furnace, two each on east and west side and two at the roof of radiant
3
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 REPLACEMENT
Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage, etc.
S# Job Method Statement
Furnace radiant section tubes comes in shorter length and pre-fabrication in shops is required to make them as per required length. To make one
1 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 TIs from old tubes of radiant section, There are nine (09) skin TIs 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

Pre Fabrication of new tubes in workshop should be completed. All bevels should be checked by EPCL inspection section before tack welding. Inspection
8
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 REPLACEMENT
Activity 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.

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
16
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 TIs 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.
RADIANT ZONE TUBE REPLACEMENT
Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage, etc.
S# Job Method Statement
30 Install furnace outlet spool to quench with crane.
31 Removal of all inserted blinds and box up the flanges

Tube lifting beam

BURNER REPAIR WORK
Activity 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 inch, this may be damaged if mishandle or rotate.

2 Remove the Top & Bottom casings.

Common Consumables
3 Remove the tip nozzle with SS pipe dia inches very carefully to protect the ceramic sleeve.
Klinger sil 4401 300mm OD & 220 mm 01
ID 3 mm T
4 Remove the Air body assembly from the Furnace wall; it is installed with 04 bolts and klinger gasket.
Thermal ceramic 2300 01
Remove the ceramic tube, this part is very brittle and may be damaged during mishandling. Be care full and Wire Brush 06
5
do not remove if there is no need. Cotton gloves 04
Need to clean out all parts from dust and rust, do the power brush cleaning of all parts and them perform Cotton Cloth 02 kg
6
the DPT of extension pipe nipple and Tip nozzle..
Tools
7 Insulation should be replaced from Air body and top bottom casings. Ring Spanner 18mm 02
Open Spanner 18mm 02
8 Do the painting works on all stationary parts. Should be high temperature aluminum silver color.
Pipe Wrench 12 inch 01
Brass hammer 2lbs 01
9 Assembly of new and refurbished parts of Burners required as per Drawing.
Allen key 5.5mm 01
10 Final box up with new gaskets , Ceramic and Klinger
TUBE TREE PREVENTIVE MAINTENANCE
Activity 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

Common Manpower
Supervisor 01
Fitter 02
Asst. fitter 01
Rigger 02
1. Remove canopy from the top roof of furnace. It is
Other Requirements fasten with nut bolts.
Lifting beam 01
3. Install a U-type support H-Beam eye hooks to hang
2. Carefully remove the fire clothe which protect chain block of 10 ton capacity on it.
Rigging equipment 01 heat from the opening between roof and Tube Tree
Crow Bar 01 carefully. It is binded with SS wire and strip.
TUBE TREE PREVENTIVE MAINTENANCE
Activity 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.
5. Now do the same lifting procedure and installed back all parts after greasing.
4. Grease all parts of cast axle and rollers with high
6. Remove U support beam and chain block and reinstall the fire cloth and then
temperature ROCOL Anti Seize compound.
canopy.
TUBE TREE PREVENTIVE MAINTENANCE
Activity Description: Cleaning and greasing of cast axle
REFRACTORY REPAIR WORK
Activity Description: Repairing work of refractory
Refractory materials in furnace ANCHORS INSTALLATION
CERAMIC FIBRE BLANKET (2300) 6# DENSITY Old anchors would be grind off and surface preparation would be made for the installation of new anchors.
INSULATED FIRE BRICKS 2300 LI.
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.
KS-4 PLUS CASTABLE
The V portion wing nut shall then be attached after the first and before the second layer is formed
KASTOLITE 22 PLUS
KASTOLITE 20-45 G 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
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
A Dog leg type joint would be formed between the old and the new refractory
Asst. fitter 01
Rigger 02 The old refractory would be sprayed with water before new refractory is poured in place
REFRACTORY REPAIR WORK
Activity Description: Repairing work of refractory
JOB 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. Refractory Mixer machine

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 50F to 70F. However, it should never exceed 100F (38C). 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 REPAIR WORK
Activity Description: Repairing work of refractory
JOB PREPARATIONS & METHOD STATEMENT
Curing would be carried out at a temperature of about 1000F 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

Quality Testing of refractory

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)
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.

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
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
6x6 and any sort of dry fill areas that reduce the effective lining thickness
by more than of the original thickness shall be considered defective and
shall be repaired.

Apply the high temperature mortar paste over the anchor lock to protect from If refractory is inspected after complete dry out, areas containing cracks
7
heating and burning. greater the 1/16in (1.5mm) are considered defective and shall be repaired