INSPECTION SECTION MONTHLY REPORT 2007

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September, 2007

TO: PTM & MI

FROM: Inspection Engineers

SUB: Activities Carried Out During (3rd -30th Sept)

TECHNICAL EVALUATION

S.NO FILE STATUS

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1 Hardness tester Comments prepared
2 Orifice Flange Comments prepared
3 De-aerator vessel Comments prepared
4 Spiral weld pipes Comments prepared
5 MS fittings Comments prepared
6 Radiography Viewer Comments prepared
7 Holiday detector Comments prepared

TECHNICAL REQUIREMENTS/ORDERING INFORMATION

S.NO EQUIPMENT STATUS

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1 Base Unit vessel To be issued to Stationary Section
2 De-Gasifier Vessel To be issued to Stationary Section

PLANT PIPING

S.NO SPOOL STATUS

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1 3” Ø kerosene R/D line to 601-J completed
2 6” Ø kerosene R/D line In-progress
3 12” Ø splitter feed line from 110-C to In-progress
102-E
4 8” Ø line from 101-F TO 203-J completed
5 3” Ø Naphtha R/D line In-progress
6 4” Ø line from 107-J/JA to 105-E In-progress

PLANT EQUIPMENT (INSPECTION)

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301-CN (TEXAS TOWER)

Following activities carried out on Texas tower 301-CN and witness by
Inspection Section, UOP & Luigi Resta personals.
 DPT of 4 nos. trunnions carried out found ok
 Channel Cover, shell cover, floating head & Expansion bellow
dismantled for replacement of Gaskets & cleaning of Texas tower.
 Tube Bundle completely pulled out & external cleaning by air
blowing carried out.
 Internal cleaning of tubes carried out by air blowing & rodding (of
some tubes). 2 nos. tubes found chocked.
 DPT of both tube sheets carried out found ok.
 DPT of Expansion Bellow carried out, found ok.
 Girth flanges gaskets replaced after cleaning of gasket seating
surface by manually & power brushing.
 Hydro test of tube side carried out at 54kg/cm2, found ok.
 Hydro test of shell side carried out at 42 kg/cm2, found ok.
 Differential hydro test (final test) at both sides carried out at 44
kg/cm2, found ok.
 In the end purging by nitrogen gas of both shell & tube side carried
out in order to dry the equipment completely. Equipment is
pressurized by nitrogen gas.

BOILER #2
 Government Boiler Inspector visited boiler # 2 on 17th of Sep 2007,
found OK.
 Internal cleaning of steam drum, mud drum & external
cleaning all the accessible tubes inside the combustion, super
heater chamber & from inspection windows carried out.
 DPT of man ways covers of steam drum, mud drum & hand hole
covers of super heater header carried out. Found ok.
 Radiography of boiler tubes from inspection windows & bends of
superheated tubes carried out. Found ok.
 UT Monitoring of steam & mud drum carried out from inside.
 Gauging of boiler tubes for any bulging carried out. Found ok.
 3 no. cyclone separators open for internal inspection. Condition
of all cyclone separators found satisfactory.
 Radiography/thickness shots of boiler feed water line carried out,
found ok.
 Fabrication & welding of new SS plate of super heater chamber
carried out as per inspection requirement.
 Skin plate towards combustion chamber side replaced by Stationary
Section.
 Steam & mud drum internally paint with 1 coat of Apexier.

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 Hydro test of boiler at 26.5 kg/cm 2 (hold up to 30minutes) carried

out, a drop of 0.5 kg/cm2 observed. Test found ok.

BOILER 3
 Note issued to Stationary Section regarding welding of tube
supports in the next annual shut down of boiler.

TANKS
TANK 4 (Decommissioned For Major Repair)
 Preparation of work scope for major repair is in progress.

TANK 18 (Decommissioned For Major Repair)

 Installation of foam/sprinkler lines is in progress.
 Welding of curb angle completed from inside & outside.
 Welding of doubler at 3rd course from top is in progress.
 Radiography of 5 nos. T-joints, 2 nos. vertical & 1 no. horizontal
of 2nd last course & 3 nos. top courses carried out, found ok.
Intimates to Construction Section accordingly.
 Lying & tacking of roof plates is in progress.

TANK 33 (New Construction)

 9th course horizontal welding from inside and outside is progress.
 Welding of curb angle is in progress.
 Spiral Stairway and landing platform tack welded on new location,
work is in progress.
 Pontoon overhead welding is in progress.
 Welding of vertical joints of foam dam is in progress, also repairs
marked & repair work is in progress.
 Shifting of top platform is in progress.
 Fabrication & welding of 2nd D-door is in progress.
 1 no. Welder Qualification for overhead position carried out, found
ok.
 Installation of 3 nos. auto bleeder vent on deck completed.
 Installation of 4 nos. 6”Ø roof and pontoon man way rim vent
completed. Welding is in progress.
 Fabrication of 4”Ø movable drain line section completed.
 Welding of doublers of various mixer holes, man holes completed.

TANK 36 (Decommissioned For Major Repair)

Vacuum Testing of shell to annular joint completed.
 DPT of seal passes of 2 nos. sumps 24” Ø carried out, repairs
marked. Later on rectified by Construction Section.

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 DPT of annular to shell welding carried out at few locations, found

ok.
 Photography of roof structure carried out.
 Welding of doublers from inside of bottom course is in progress.
 Installation and Welding of 2nd bottom sump is in progress.
 Sandblasting & painting of new curb angle completed.

TANK 51 (In-Service Tank)

 Hydro testing of 2 nos. foam lines and 1 nos. sprinkler line
carried out each at 16.5kg/cms2. Found OK.

TANK 56 (De-commissioned for major repair)

 Pit/buildup work of top course and shell top course completed..
 Removal of old bitumen pad completed. To be checked.
 Note issued to Construction Section regarding bottom survey of
tank.

TANK 58 (De-commissioned for major repair)

 No activity started yet by Construction Section after issuing of
work scope.
 Inspection of roof structure carried out through inspection
windows. Roof structure section under crown plate to be inspected
after its removal. Reminder sends to Construction Section regarding
its removal.
 Visual inspection of top course & curb angle carried out. Work
scope to be issued.

OMC LINES

JOINTS REPAIRS
WELDED RADIOGRAPHY (RT & REMARKS
THIS
MONTH TOTAL VISUAL
LINE #1
Line handed over to oil
6ӯ 13 90 45 Nil
movement
(HSD)
LINE #2
Line handed over to oil
6ӯ 10 89 44 Nil
movement
(KERO)
Line tied-in temporarily.
LINE #3
Permanent hook-up will be
6ӯ Nil 62 9 Nil
carried out after removal of
(F/W)
old line.
LINE #4 Line handed over to oil
3 40 20 Nil
6ӯ (MS) movement.

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LINE #5
Only RT of tie-in joints is
8ӯ 2 82 39 Nil.
pending.
(F.OIL)

 Total 281 nos. joints of 6”Ø have been welded.

 Total 82 nos. joints of 8”Ø have been welded.

MATERIAL INSPECTION
FITTINGS, M.S PIPES & VALVES
 Inspection of different dia and sizes of fitting, M.S. pipes & Valves at
warehouse carried out. Note issued to material section.

BRASS HX TUBES
 Inspection of 100 nos. brass tubes carried out near stationary w/s,
found OK. Note issued to material section.

101-CN GASKETS
 Inspection of gaskets of 101-CN carried out at warehouse, 2 nos.
gaskets rejected. Note issued to material section.

VISIT TO M/s SADIQ STEELS

 Visited M/s Sadiq Steel for the inspection of 7 nos. MS coils at Sher Shah.
Inspection & ultrasonic thickness monitoring of all the MS coils carried out, found
ok. 4 nos. coils found acceptable where as 3 found rejected on the basis of
material specification. Note issued to Material Section

JP-1 LINE
 Visited 6”Ø JP-1 line near Chamra Chorangi, 4-ft exposed section of
line coated by civil section.
 Excavation of 6”Ø JP-1 line in front of PSO gas terminal completed
by civil section to remove the concrete footing, work is in progress.
 Visited 6”Ø JP-1 line at Chamra Choragi, line found exposed in
trench being excavated by KW&SB for the installation of concrete
sewerage line.

XCL LINE
 Inspection carried out of 10”Ø F.Oil line 130’, 12”Ø line 80’ & 8”Ø
line 110’ at Khy-e-Nishat located in between khy-e-Ittehad and
Hafiz. Workscope issued to stationary section.

ANTENNA MAST BEHIND TANK FARM OFFICE

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 Visual inspection carried out. Scrap & paint required. Intimated to

Civil Section. Work completed by Civil Section.

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