JOB REPORT Pre T/A-2015

Tag # SS-311-A
Dated: 30-01-2015

Preventive Maintenance of Cat-Ion Exchanger

SS-321-B

Contents

Technical Data
Job Scope
Pre-Arrangements
Pre-inspection
Maintenance Work
Final Inspection
Box Up
1

Equipment Utilities
Riaz

Prepared By :- Usama Bin

JOB REPORT Pre T/A-2015

Tag # SS-311-A
Dated: 30-01-2015

TECHNICAL DATA:
Equipment:

Cat-ion Exchanger

Vendor :

Ecodyne

Dimension
Outer Diameter =

2438 mm

Overall Length =

3886 mm (tan-tan)

Manway (Top) =

18

Media removal =

Filler Water Inlet / Outlet =

6 (Also Rinse inlet)

CCR Blocking Air Inlet =

Regen. Backwash Inlet/Outlet =

Decationized water Outlet =

Design Condition :

Service Flow per Unit = 91t/hr. (120t/hr.max)

Design Pressure =

8.8 kg/cm2.g

Approx. Difference Pressure =

24-29 Kg/cm2.g

Materials:
Shell =

Carbon Steel (Painted)

Internals =

SS-316

Internal Lining =

Rubber

Resin Type =

PUROLITE Strong Acid CatIon C-100(H+ )

Resin Media Depth =

2.2m

Resin:

Equipment Utilities
Riaz

Prepared By :- Usama Bin

JOB REPORT Pre T/A-2015

Resin Media Volume =

10.2 m3

Regeneration Media =

Dilute Acid (1.5% H2SO4)

Tag # SS-311-A
Dated: 30-01-2015

Job Scope:
To carry out complete internal inspection and preventive maintenance of Cat-Ion Exchanger
against service notification #2000015109.

Pre-Arrangements:
Blinding of Nozzles
Insert blinds to isolate vessel.
Unloading media
Install unloading nozzles to discharge media. Complete media unloaded by process unit.
Manway Opening
Dismantle top manway for vessel entry.
Removal of Distributer and Header
Removal of both Top and Bottom distributer for chemical cleaning.
Scaffolding Installation
Errection of scaffolding inside the vessel for complete inspection.

Pre-inspection
Pre-inspection was carried by inspection unit and found following major observations:
1. Blisters were found at various locations at top dish end random locations as well as on
manway neck.
3

Equipment Utilities
Riaz

Prepared By :- Usama Bin

JOB REPORT Pre T/A-2015

Tag # SS-311-A
Dated: 30-01-2015

2. Fissure type cracks and water filled blisters were observed all over the rubber lining at
shell, bottom plate, top dish end and header support.

3.

3. Dis-bonding was found at few locations

Equipment Utilities
Riaz

Prepared By :- Usama Bin

JOB REPORT Pre T/A-2015

Tag # SS-311-A
Dated: 30-01-2015

4. Holiday testing was carried out inside the vessels and defects were observed at 45
different locations.

Maintenance Work:
5

Equipment Utilities
Riaz

Prepared By :- Usama Bin

JOB REPORT Pre T/A-2015

Tag # SS-311-A
Dated: 30-01-2015

1. Removed distributer both Top (#14) and Bottom (#20) for chemical cleaning and replaced.
Sleeves were also replaced.
2. Power brushing/ cleaning of Shell, top dish end, manway and bottom plate.
3. Dis-Bonding at various locations were rectified by rubber patching.
4. Application of Primer (PR-300) after proper cleanup.
5.

Rubber (KeraButyl) Patching were done at all indicated point with the application of
solution (Keracoll).

Equipment Utilities
Riaz

Prepared By :- Usama Bin

JOB REPORT Pre T/A-2015

Tag # SS-311-A
Dated: 30-01-2015

Final Inspection
Final Inspection done by the Inspection unit. DFT and Holiday Testing were performed.

Box up

Installation of header and distributor.

Media Loading by Process unit.
De blinding of Nozzles.
Closing of Manway.

Major Material Used

Material

Unit

Qty

Material Number

Rubber KaraButyl

m2

1230000059

Keracoll Solution

KG

1230000063

Primer(PR-300)

TIN

Equipment Utilities
Riaz

Prepared By :- Usama Bin