COKE HANDLING SYSTEM Rev.

: 1

COKE HOPPER 113-SHC-BN-001 Date: 21-01-13

OPERATION AND MAINTENANCE MANUAL
Document Nº OT.1080-11-A47 Pag.1/10

COKE HOPPER 113-SHC-BN-001

OPERATION AND MAINTENANCE MANUAL

COMECA LTDA.

CONTRACT Nº 42166001-PO-1131113001

Prepared by: ING M. Sc. HANS VAN HEYL COMECA LTDA.

Doc. Nº OT. 1080-11-A47

Rev. Revision Prep. Chk. App
Rev. Nº
Date Description By: By By
0 15-01-13 Issued for operation HVC HVC PJB
1 21-01-13 Issued for operation HVC HVC PJB

TABLE OF CONTENT
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1. INTRODUCTION.................................................................................................................... 4
2. DELIVERY OF COMPONENTS.................................................................................................5
3. EXCLUSIONS......................................................................................................................... 6
4. HOPPER OPERATION AND MAINTENANCE...........................................................................7
4.1 Operation and maintenance procedure.........................................................................7
4.1.1. Generalities..................................................................................................................7
4.1.2. Industrial Health and Safety.........................................................................................7
4.1.3. Equipment....................................................................................................................8
4.1.4. Materials......................................................................................................................9
4.1.5. Personnel......................................................................................................................9
4.2. Operation.......................................................................................................................9
4.3. Maintenance................................................................................................................10
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LIST OF TABLES

Pag.

TABLE 1. Minimum profile and personnel for inspection …………………………………………………….…………………….9

TABLE 2. Maintenance and inspection frequency……………………………………………………………..……………………..10
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1. INTRODUCTION
This is a general guidance for the hopper operation and maintenance for COMECA, specifically to
the DCU-SHC-STRUCTURAL EQUIPMENT project as a part of the expansion of the Refinery of
Cartagena – REFICAR.
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2. DELIVERY OF COMPONENTS
When the assembly of the metallic structure, the hopper and all its components is finished and has
been accepted by the client, the operation and maintenance process begins, this should guarantee
that the system´s performance will not be interrupted during the lifetime of the project.
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3. EXCLUSIONS
The following items are not within this manual scope:
 Concrete supports and foundation elements.
 Electronic and electric components, such as control switches, wires, trays, etc.
 Hydraulic and sanitary structures, drains and pipes.
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4. HOPPER OPERATION AND MAINTENANCE

4.1 Operation and maintenance procedure

4.1.1. Generalities
Before giving a start to the different tasks related to operation and maintenance, the contractor
must ensure he has studied the following numerals.

4.1.2. Industrial Health and Safety

 The contractor must develop and implement and Occupational Health and Industrial Safety
Program, according to the standards required by REFICAR, in such way that it allows an
effective analysis on health and safety threats and the jobsite, and that it makes easier control
measurements application to eliminate those threats.

 Additionally, the Occupational Health and Industrial Safety Program must consider: workers
training and competence program, Equipment and Safety elements inspection program,
Emergency plan in case of accidents at the jobsite, Incident and Accident Investigation, and
Management Program.

 The Contractor must attend an induction course required by REFICAR before entering the
jobsite. The same way he must give weekly talks about industrial safety to the workers.

 At the beginning of each task of the HSE supervisor the contractor must indicate the whole
working personnel which are the potential risks they will be put through and which are the
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general measurements that they can take to face them and must inspect all the personal
protection elements, equipment, and scaffolds.

 The contractor must count on the HSE supervisor presence for the operating and maintenance
tasks. His presence will be permanent while the activities are not finished. Between the
functions it is included, but not limited to, the realization of the ATS, permission request, good
condition verification and the usage of personal protection and industrial health equipment,
scaffolds, platforms and rails for installation.

 All the personnel at the jobsite must have at least the following personal protection items:
safety helmet, steel toed safety boots with insoles, reflective vest, gloves, clear and dark safety
glasses. For the tasks at heights, it is required that all the workers have safety harnesses in good
conditions attached to the lifeline. For personnel elevation mechanic elevators with handrails
will be used.

 Before entering the jobsite and every 30 days, the contractor must present the complete
social security documentation and parafiscals, attached to payment receipts.

4.1.3. Equipment
It is required that the equipment that the contractor utilizes for the development of the tasks is
found certified and in perfect condition. The basic equipment is the following:

 Scaffolds
 Personnel elevators
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 Tools

4.1.4. Materials
They are all the structural components that must be inspected, such as: support beams, stiffeners,
hopper body sheets, antiwear sheets, connection bolts and nuts.

4.1.5. Personnel
The personnel to execute the operation and maintenance tasks must be qualified to the
development of this type of job. On Table 1 the minimum recommended personnel is listed.

Table 1. Minimum profile and personnel for inspection

Personnel profile Profession or Title Years of experience Qty

Civil/Mechanical/Metallurgic/Material
Maintenance Engineer More than 10 years 1
s Engineer
Inspector Technician Mora than 10 years 1

All the personnel must be qualified and competent to develop the necessary tasks for the
inspection, operation and maintenance according to REFICAR regulations.

4.2. Operation

 During the operation of the hopper loading, no procedure is needed to be developed, unless
the system administrator requires some additional inspections in the operation area.
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4.3. Maintenance

Inspections of the hopper and its components must be done during the lifetime of the structure,
according to Table 2.

Table 2. Maintenance and inspection frequency

Element or Component Inspection Frequency Inspections to be done

Deformations, warps, bends, misalignments,
Grating, grating support,
Every 5 years mismatch, condition and thickness of the
bid support, stiffeners.
painting (corrosion)
Deformations, dents
Hopper body sheets Every 5 years Condition and thickness of the painting
(corrosion)
Adjustments or missing checking
Screws Every 5 years
Corrosion
Cracks
Welding Every 5 years
Corrosion
Wear level
Antiwear plate Every 2 years
Pieces lose

The contractor must deliver to REFICAR a detailed inspection report, where a complete
photographic and/or video record, plans and sketches with the findings and observations done are
included. In this report conclusions and recommendations must be enunciated, which must be
attended by REFICAR with the purpose of repairing any strangeness, avoiding major structure
damage and the possibility of accidents for the personnel responsible of the system operation.