“BSR BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doe No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —[Revision:2. Page: 1/38 ‘Tite: STIP for RFCC REACTOR AND REGENERATOR STANDARD INSPECTION PROCEDURE FOR RFCC REACTOR AND REGENERATOR | BI SON REFNG &PETROGHEWCAL Lc APPROVED FOR,USE Date: 7 b\eo1 By: BA. tthe Able. se [HEN IOIO [Far Approval —7- 6-H Atw PS 6 OWT A Ve [ST kim 00 at TIT [-16Mar-2010[— For Review | Bain] 8.6. Ob 1_| 28-Aug-2009 | For Approval | M. Endo Ha Dong HSuzuki | PL. Chat [18 Aug 2000"[— Tor Review ——]MEEnio | Ha Dong Rev [Dee Sus. —[ Prepared ty | Reviewed iy —|- Valid by-| Approve Document RevisionsBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doe No: BSR-MNT-INS-009 oe MAINTENANCE PROCEDURE SYSTEM —[Revision:2. Page: 2/38 ‘title: STIP for RFCC REACTOR AND REGENERATOR TABLE OF CONTENTS 1. PURPOSE 2. SCOPE........... zs 3. DEFINITION AND ABBREVIATION. 4, REFERENCE... 5, . REQUIRED EQUIPMENT AND TOOLS 5.1, Personal Protective Equipment (PPE).. 5.2. Inspection Tool. . 6. POSSIBLE FAILURES AND DETERIORATIONS n Point of Reactor and Regenerator 8. ACCEPTANCE CRITERIA .. 8.1. Acceptance Criteria of Refractory Lining. 8.2. Acceptance Criteria of Hexmesh Linin, 9, REPORTS AND RECORDS. 9A, 9.2. 10. INSPECTION DURING OPERATION . 11. ATTACHMENT De RAL Ue REOBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM frevision:2—_[Page: 3/38 ‘rite: STIP for RFCC REACTOR AND REGENERATOR 1. 5.1. PURPOSE This inspection procedure presents the areas to be inspected and the possible failures and/or deteriorations at the area for the appropriate maintenance of the vessels, Reactor and Regenerator. SCOPE This procedure is applied to the vessels, Reactor and Regenerator of RFCC unit for both off-stream and on-stream inspection. DEFINITION AND ABBREVIATION © Refractory Lining: Thick insulation lining, typically 100-150mm_ in thickness, is constructed on the ID of the vessels and/or parts. There are two types of Refractory Lining, one is applied for thermal insulation and another is applied for thermal insulation as well as for abrasion resistance. © Hexmesh Lining: Thin abrasion resistant lining, typically 19-25mm in thickness, is constructed mainly on the ID, sometimes on the OD, of the vessels and/or parts to protect it from abrasion. © RFCC:Residue Fluidized Catalytic Cracking © ID: Inside Surface © OD: Outside Surface © MT: Magnetic particle testing © PT: — Penetrant testing REFERENCE 8474L-0150-DW-0410-101/102: DISENGAGER/STRIPPER D1501 AND 1/2 STAGE REGENERATOR D1502/D1503 REQUIRED EQUIPMENT AND TOOLS Personal protective equipment and inspection tools, which are necessary for the inspection of Reactor and Regenerator of RFC unit, are stated as follows: Personal Protective Equipment (PPE) Inspectors are usually required to wear the following PPE: (1) dust-proof mask, earplug and goggles for catalyst dust protectionBSR BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doe No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —|Revision:2__|age: 4/38 |ritie: STIP for RECC REACTOR AND REGENERATOR 5.2. 6. (2) harness type safety belt for prevention of fall accident Inspection Tool (1) fiber scope or video camera: for checking the condition of the Refractory and/or Hexmesh Lining at the narrow space, where no one can access to for the inspection 2) hammer: for checking of an exfoliation and/or disbanding of the Refractory Lining and/or Hexmesh Lining (3) “dust-proof” digital camera: for making photographie records (4) soft ball: for checking no clogging with lining debris in the narrow spaces, such as Dipleg, where no one can access for the inspection (Soft ball should be used frequently for checking that no debris remains in the narrow spaces after the repair of the lining.) POSSIBLE FAILURES AND DETERIORATIONS The operating temperature of the Reactor in FCC unit reaches around 550 deg.C and the Regenerator around 750 deg.C. Catalyst moves with high velocity in it. ‘These elevated operating temperatures and high velocity catalyst movement will cause failures and/or deteriorations of the component materials. Refractory Lining is applied on the component materials to insulate thermal heating, sometimes to protect abrasion as well as to insulate thermal heating. Hexmesh Lininig is applied on to protect the components from abrasion. Coking and/or carburization are likely to occur due to cracking reaction of the feed oil. Possible failures and/or deteriorations observed at Reactor and Regenerator are outlined in the following. (1) Exfoliation, Disbonding and Crack of Refractory High temperature processed gas enters into the underneath of the exfoliated and disbonded Refractory and into the cracks of it, which results in increasing the temperature of the component materials. (2) Exfoliation, Abrasion and Crack of Hexmesh Lining These failures cause abrasion of the component materials, which result in thinning of them.LBS. BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doe No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —|eevision:2.—_|page: $/38 Iritle: STIP for RFCC REACTOR AND REGENERATOR, 7.2. (3) Coking Coking is a deposit of carbon that is a by-product of the cracking reaction of feed oil. Spalling-off of deposited coke sometimes causes plugging of Dipleg. (4) Carburization Carbon, which is a by-product of the cracking reaction, enters into the component materials and results in hardening and embrittlement. (5) Creep Failure Local area, where overstressed due to different thermal expansion and/or above design temperature, suffers creep failure and results in cracking. (6) Sigma-phase Embrittlement Austenitic stainless steels, which are used at the temperature range between 550 and 800 deg.C, create sigma-phase precipitation resulting in hardening and embrittlement. (7) Gamma Prime Embrittlement Nickel based alloys, such as Inconel 625, which are used around 650 deg.C, create Gamma Prime precipitation resulting in hardening and embrittlement. (8) Sulfidation High temperature corrosion of the component metals due to sulfur or sulfur compounds contained in the feed oil. INSPECTION General (1) Refractory Lining (a) Visual inspection on the entire area and additional hammering test for suspicious area should be done. (b) When Refractory Lining has been used in operation for years, cracks may appear in the increased number and wider size in it. (©) Refractory Lining exfoliated due to cracks and separated from anchors should be repaired, Hammering test is effective for detecting them. (2) Hexmesh Lining (a) Visual inspection on the entire area and additional hammering test for suspicious area should be done. (b) When Hexmesh Lining has been used in operation for years, the surface is likely to be abraded by catalyst flow. Particular area may be abraded due to a high velocity flow of catalyst and/or the surface ofthe lining may be peeled off due to thermal expansion of the components. ‘The area of Reactor and Regenerator to be inspected is shown in “ATTACHMENT”. Inspection Point of Reactor and Regenerator The detailed inspection point is shown in from Fig 1 to Fig 18. tii Pred ons Ms 383088BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 (Been || MAINTENANCE PROCEDURE SYSTEM —_frevision:2 age: 6/38 lritie: STIP for RFCC REACTOR AND REGENERATOR 8. 8.2. ACCEPTANCE CRITERIA When found any failures and/or deteriorations in the lining, itis very difficult to make a decision whether the lining should be used as it is or should be repaired. The judgment of repair or not repair should be decided by an inspector who has a lot of experience of the inspection of RFC unit. Acceptance criteria of Refractory Lining and Hexmesh Lining are described in the following. Acceptance Criteria of Refractory Lining (1) Crack: Basically, cracks less than 3mm in width and the lining adjacent cracks is firmly adhered to the component is acceptable. If the crack width is above 3mm and adjacent lining is confirmed tight adhering to the shell, the crack should be repaired with filling the refractory mortar into it, If the lining is seemed to lose the adhesion to the component or anchor, the lining should be repaired after removing it in whole thickness. (2) Exfoliation (Peel off) Surface exfoliation of thermal insulation lining less than one fourth of the lining thickness in depth, is acceptable. However, surface exfoliation of the thermal insulation lining with having the ability of the abrasion resistance less than one fourth of the whole lining thickness in depth, is not acceptable. Surface exfoliation above one fourth of the whole thickness of the lining is not acceptable. The lining where confirmed of being disbonded is not aeceptable and should be repaired. Acceptance Criteria of Hexmesh Lining, (1) Crack Basically, crack is not acceptable because that cracked mesh lining is likely to peel off in full thickness in future operation. The cracked mesh of lining should be repaired in full thickness. (2) Exfoliation Surface exfoliation less than 3mm in depth is acceptable. Surface exfoliation above 3mm and less than 6mm is not acceptable and should be repaired by surface coating of lining mortar. Exfoliation over 6mm should be repaired in full thickness. Loose mesh lining, that is called “biscuit”, should be removed in full thickness and should be filled with new lining mortar. Sato pies Paton Fla My 282010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT |_Doe No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM _revision:2. —_|Page: 7/38 : STIP for RECC REACTOR AND REGENERATOR OAL 9.2. (3) Abrasion Basically, an abraded lining should be repaired by coating or by full thickness filling with new mortar after removing remaining lining depends on the degree of the failure in thickness and extent. REPORTS AND RECORDS All information obtained from inspection should be carefully documented after each inspection because the proper inspection intervals and remaining life of the Refractory Lining and/or Hexmesh Lining can be determined based on such information. Reports The inspection report of Reactor and Regenerator of RFC unit should include the following information: (1) Date of an inspection (2) Date of the next scheduled inspection (3) Name of inspector (4) Descriptions of the conditions found (5) Photograph of the lining failure and condition (©). Photograph of the repair, before and after (7) NDT results including metallurgical investigation, if applied (8) Repairs performed. (9) Any recommendations Records Records are the backbone of the inspection control of Reactor and/or Regenerator of RFCC unit. The complete record file should consist of the following: (1) Construction and design information © Design specification * Design calculation © Manufacture’s drawing and data records * Results of lining material tests and analysis, (2) Operation and inspection history © Operating conditions * Inspection reports and data (photograph of lining condition, shell OD temperature measurement data, NDT etc) © Recommendations for repair or modification ABN oe pi. don Pr 38 2010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doe No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM _[Revision:2__|page: 8 /38 [ritle: STIP for RFCC REACTOR AND REGENERATOR 10. iL. (3) Repair and alteration information * Reason of repair/alteration © Repair procedure and results as for lining and vessel component material INSPECTION DURING OPERATION Inspection of the temperature measurement using “Infra-red Thermo-viewer camera” should be applied periodically during operation to reveal “HOT SPOT” area caused by the failure of Refractory Lining. When detected temperature rising, a continual measurement of the temperature of vessel OD should be recommended to obtain the history of temperature change and/or for estimating the Refractory Lining failure extent. Engineers in various categories, process, operation, mechanical design, maintenance and inspection, should discuss thoroughly and make a decision of further continuous operation with reviewing the inspection results. @ Inspection Interval of Temperature measurement during operation, 1) Before Tun-around, Inspector should measures surface temperature of Reactor & Regenerator with "Infrared Thermo-viewer Camara” to check the hot spot and refractory damages that may occur inside. 2) Inspector should measures temperatures at least once per year during operation with “Infrared Thermo-viewer camera” to check the hot spot and Refractory damages that may occur inside. 3) Ifhot spot or damage is found during operation, more detail and frequent inspection should be considered. ATTACHMENT Inspection points are outlined the ATTACHMENT FIGURE and detailed inspection points are described in Fig | to Fig 18.BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 faa | | MAINTENANCE PROCEDURE SYSTEM [Revision 2 Page: 9/38 |ritte: STIP for RFCC REACTOR AND REGENERATOR FIGURE Inspection Points of Reactor and Regenerator of RFCC Unit Figl6 Figs Fig 15 Fig4Q) Fig Fig 14 Fig 4.(1) Fig 7 Fig6 Fig 14) Fig 12 Fig 13 Fig6-(1) Fig9 Fig8 Fig 10 Fig 1 Fig 144) Fig ls Fig 1-@) Fig 1 betes Fig 8-(1) Fig 1-2) Fig 4)BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT MAINTENANCE PROCEDURE SYSTEM Doc No: BSR-MNT-INS-009 RRevision:2 Page: 10/38 BACKFLUSH OIL INJECTOR -Erosion in Nozzle Slit -Abrasion of Hexmesh Lining. at Under-Half REFRACTORY at FIELD JOINTED PORTION -Bxfoliation and/or Spalling, TD REFRACTORY -Continuous Cracking (Blockwise) -Exfoliation and/or Spalling see Fig 1-(4) see Fig 1-3) see Fig 1-(2) SAMPLING NOZZLE Abrasion of Nozzle Tip (Top End) see Fig 1-(1) tad iy. ay 24,300BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 oR MAINTENANCE PROCEDURE SYSTEM —_|Revision:2_|Page: 11/38 |ritle: STIP for RFCC REACTOR AND REGENERATOR. 1.(1) RISER BOTTOM (incl. WYE SECTION) OD WELD -Crack due to Distortion | -to be Checked by MT \ f + CATALYST CONVEYING Abrasion at Nozzle Tip REFRACTORY -Exfoliation and/or Spalling at the Comer STEAM RING -Erosion of Nozzle Tip REFRACTORY and CERAMIC FIBER Exfoliation and/or Spalling of Refractory at the Comer Coming Off of Ceramie Fiber Blanket from the GapBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT ue! =~ MAINTENANCE PROCEDURE SYSTEM Doc No: BSR-MNT-INS-009 IRevision: 2 Page: 12/38 iritte: STIP for RFCC REACTOR AND REGENERATOR Fig 1-{2) I-1503 A-D (STABILIZATION INJECTORS) NOZZLE SLIT -Brosion due to Steam LOWER SURFACE -Abrasion Pinon i May 010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doe No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —|Revision:2.—_|Page: 13/38 rite: STIP for RECC REACTOR AND REGENERATOR Fig 13) 1-1501 A-F (FEED INE REFRACTORY, Exfoliation and/or Spalling around the Nozzle Tip NOZZLE TIP Erosion of Slit ‘NOZZLE SLEEVE Abrasion at Lower Side Surface tind tenga Pon ri My 24,2010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —|Revision:2. Page: 14/38 |ritte: STIP for RFCC REACTOR AND REGENERATOR Fig 1-{4) 1-1502.A-D (MTC INJECTORS) ‘CERAMIC FIBER -Coming Off around Nozzle Tip NOZZLE TIP -Erosion of Slit HEXMESH LINING Abrasion, Exfoliation and Spalting An ferrari mde iy May 8.2010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY Doc No: BSR-MNT-INS-009 MAINTENANCE DEPARTMENT DOCUMENT MAINTENANCE PROCEDURE SYSTEM —_|Revision:2__ Page: 15/38 iritte: STIP for RFCC REACTOR AND REGENERATOR Fig2_ STRIPPING COMPARTENT HEXMESH LINING a -Abrasion of ID RISER INLET -Abrasion of Edging Bar DOME, Distortion RISER OD Abrasion of HEXMESH Exfoliation, Spalling and LINING ‘Abrasion of HEXMESH LINING HEXMESH LINING Abrasion of Edging Bar RISER OD Abrasion of HEXMESH LININIGBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —Revision:2. Page: 16/38 ITitle: STIP for 1 RFCC REACTOR AND REGENERATOR Fig3 RISER SEPARATOR DOME ID Abrasion (detailed Figure shown below) of HEXMESH LINING CEILING and COVER PLATE ID. Abrasion of HEXMESH LINING HEXMESH LINING ‘Abrasion9)| BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT ARES | MAINTENANCE PROCEDURE SYSTEM Doc No: BSR-MNT-INS-009 lRevision:2 Page: 17/38 ‘Title: STIP for RFCC REACTOR AND REGENERATOR, Fig 4 D-1501 (REACTOR : DISENGAGER) CEILING and COVER PLATE HEXMESH LININIG -Abrasion of Edging Bar GAS TUBE ID -Deposition of Carbon CYCLONE OUTLET Failure of HEXMESH LINING due to Distortion of the Cyclone see Fig 4-(1) Crack at Welds see Fig 4-(2) smterm our see Fig 4-(2) REFRACTORY, -Crack, Exfoliation, Spalling and Deterioration ton ei M8 2010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —|Revision:2.__[Page: 18/38 iTitte: STIP for RFCC REACTOR AND REGENERATOR Fig 4.(1) CYCLONE COLLECTOR, CEILING COVER PLATE “Hard to Open due to Heavy Carbon Deposition CYCLONE INLET -Abrasion of HEXMESH LINING Abrasion of Edging Bar of HEXMESH LINING Check Deposition of Carbon, which becomes an obstruction for movement of Riser HEXMESH LINING Failure due to Contact of Extended Riser during Oneration | fs sso sere t 5 aa ‘Check Deformation due to the Eccentric Movement of Riser: (appox. 10mm clearance gap BRAIDED METAL HOSE Ee all around at designing)BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM _Revision:2__[Page: 19/38 iritle: STIP for RECC REACTOR AND REGENERATOR Fig 4-(2) CY-1501 A-F (REACTOR CYCLONES) SUPPORT ROD -Deterioration of Metal (Elongation due to Creep) CYCLONE ID and CEILING CORNER -Abrasion of HEXMESH LINING HEXMESH LINING ID Abrasion at Comer and. Conical Area Crack at Weld PIPE OD. Deposition of Carbon CYCLONE ID 7 HEXMESH LINING ID Abrasion of HEXMESH -Abrasion, LINING HEXMESH LINING -Abrasion of Retainer Bar (Edging Bar) HEXMESH LINING Abrasion at the [D Comer (This area is hard to check, but must ‘be checked) DISK PIN “Thinning due to Wear DIP LEG ID Abrasion of HEXMESH LINING SEAT of DISK/PIPE Increase of Clearance due to Wear of Pipe SeatBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —fRevision:2. Page: 20/38, (rite: STIP for RFCC REACTOR AND REGENERATOR Fig REACTOR TOP REFRACTORY -Failure of Flange Comer (Exfoliation, Spalling and Crackine) REFRACTORY Failure at Comer (Exfoliation, Spalling and Cracking) HEXMESH LINING Failure at the End of Lining REFRACTORY -Deposition of Carbon ANITICOKING STEAM RING CYCLONE OD le Deposition of Carbor -Erosion of Nozzle ‘Deposition of n ac iy. May 38,2019BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doe No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM _fRevision:2._|Page: 21/38 {ritte: STIP for REKCC REACTOR AND REGENERATOR Fig6 STRIPPER STEAM RING REFRACTORY, -Thinning due to Abrasion -Abrasion at upper Portion -Expanding of Nozzle Bore due to Erosion GRID PLATE -Thinning due to Abrasion { : -Deformation PACKING -Thinning due to Abrasion yaa we Patene Root ate ‘SUPPORT BEAM Thinning due to Erosion andlor Abrasion non iy My 82080BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —Revision:2 Page: 22/38 BSR. iritte: STIP for RFCC REACTOR AND REGENERATOR Fig 6(1) STRIPPER BOTTOM STEAM RING Thinning due to Abrasion at upper Portion -Expanding of Nozzle Bore due to Erosion RISER PIPE -Failure of HEXMESH LINING due to Buckling and/or Deformation REFRACTORY Continuous Cracking (Blockwise Cracking), Exfoliation and Spalling at the Comer AMNinbt rs pains ton ei Mey 24210BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 on MAINTENANCE PROCEDURE SYSTEM revision? —_[Page: 23/38 (rite: STIP for RFCC REACTOR AND REGENERATOR Fig 7 SPENT CATALYST STANDPIPE REFRACTORY ~Failure at Field Welding Portion 2 eevee REFRACTORY | -Continuous Cracking Fat eaperet oe (Blockwise Cracking) Disbonding see Fig 7-(2) REFRACTORY -Abrasion ides ietibies iden Ma 36,2010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY oe MAINTENANCE PROCEDURE SYSTEM MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 IRevision:2 _[Page: 24/38 lnitle: STIP for RECC REACTOR AND REGENERATOR Fig 7) E? 501 (SPENT CATALYST LINE EXPANSION JOIN’ REFRACTORY -Failure at Field Welding Portion CERAMIC FIBER BLANKET (KAOWOOL) Disappearance 2 REFRACTORY {| -Failure (Exfoliation and/or Spalling) SEALING BRAID Deterioration, Deformation, Disappearance BELLOWS -Deformation -Deterioration due to Gamma Prime Precipitation CLIP ANCHOR Deterioration (CERAMIC FIBER BLANKET (KAOWOOL) Disappearance REFRACTORY Failure (Exfoliation and/or Spalling) SEALING BRAID Deterioration, Deformation, Disappearance CLIP ANCHOR “Deterioration REFRACTORY -Failure at Field Welding Portion tone My 2010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —|Revision:2._[Page: 25/38 [ritte: STIP for RFCC REACTOR AND REGENERATOR Fig 7-(2) SV-1502 (SPENT CATALYST SLIDE VALVE) REFRACTORY ORIFICE DISK -Abrasion -Abrasion of Edge | | Abrasion of HEXMESH LINING LIP SEAL -Check Remaining of Lip -Abrasion (No Deposition of -Check Smooth Movement Foreign Materials) ORIFICE/DISK -Check Clearance between Orifice and Disk DISK and GUIDE -Abrasion of Hard SurfacingBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS.009 Seen || MAINTENANCE PROCEDURE SYSTEM —[pevision’2__ [Page: 26/38 iritle: STIP for RFCC REACTOR AND REGENERATOR Fig8 02 (FIRST REGENERATOR) REFRACTORY } — ~ Continuous Cracking BLAST PIPE (Blockwise Cracking) Cracking at Attached Welds Disbonding -to be Checked by PT =f an Ur, LIFT PIPE 4 Abrasion of PipeOD [~Y SPENT CAT STANDPIPE “Exfoliation and Spalling of REFRACTORY at the End HEXMESH LINING | “Abrasion AIR RING CATALYST DEFRECTOR Erosion of Nozzle Bore Abrasion of HEXMESH -Exfoliation and/or Spalling LINING of Abrasion Resistant Lining (Ete eeeeeeee eee Deformation of Plate REFRACTORY + Continuous Cracking (Blockwise Cracking) Disbonding, see Fig 8-(1)BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —_Revision:2-—_|Page: 27/38 |rite: STIP for RECC REACTOR AND REGENERATOR Fig 8-(1) PV-1501 (PLUG VALVE) STEM TUBE OD -Abrasion, HEXMESH LINING -Abrasion PLUG. -Abrasion of HEXMESH LINING -Spalling, SHEET RING - Abrasion of HEXMESH LINING Spalling HEXMESH LINING -Abrasion and/or Spalling NOTE: Blectrohydraulic actuator, Position indicator, Valve seat and other parts should be disassembled and maintained by Manufacture.BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT Doc No: BSR-MNT-INS-009 eSer MAINTENANCE PROCEDURE SYSTEM —_|revision:2.—_|Page: 28/38 {ritle: STIP for RFCC REACTOR AND REGENERATOR Fig 9 CY-1502 (FIRST REGENERATOR CYCLONES FIRST STAGE) SUPPORT ROD -Deterioration of Metal (Elongation due to Creep) ID HEXMESH LINING Abrasion especially at Comer and Ceiling DUCT ID Abrasion of HEXMESH LINING PIPE ID Abrasion of HEXMESH LINING BELL MOUTH (GAS INLET) -Abrasion of HEXMESH LINING at Comer HEXMESH LINING Abrasion at Conical Area HEXMESH LINING Abrasion at the ID Comer (This area is hard to check, but must be checked) HEXMESH LINING Abrasion of Retainer Bar (Edging Bar) DIP LEG ID. -Abrasion of HEXMESH LININGBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT Doc No: BSR-MNT-INS-009 oe MAINTENANCE PROCEDURE SYSTEM lRevision: 2 Page: 29/38 ‘Title: STIP for RFCC REACTOR AND REGENERATOR Fig 10 CY-1503 HEXMESH LININIG Abrasion of Retainer Bar FIRST REGENERATOR CYCLONE SECOND STAGE) PIPEID -Abrasion of HEXMESH LINIG HEXMESH LINING Abrasion at Conical Area (Edging Bar) CYCLONEID =" Abrasion of HEXMESH LININIG CYCLONE ID Abrasion of HEXMESH LINING at Comer and HEXMESH LINING Abrasion at Conical Area HEXNESH LINING r Abrasion at ID Comer Th (This area is hard to check, ~~ but must be checked) ao Ceiling.BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —[Revision:2.—_| Page: 30/38 + DIPLEG ID | | -Abrasion of HEXMESH LINING DISK PIN ] | if DIPLEG ID Abrasion of HEXMESH LINING SEAT of DISK/PIPE -Increase of Clearance due to ‘Wear of PIPE SeatBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT MAINTENANCE PROCEDURE SYSTEM Doc No: BSR-MNT-INS-009 IRevision: 2 (Page: 31 /38 [ritle: STIP for RECC REACTOR AND REGENERATOR Fig 12_D-1502/D-1503 (OUTLET: REFRACTORY 8 S -Failure at Field Joint Welding REFRACTORY “Failure at the Comer Atbiteoeop iin REFRACTORY Failure at the Comer OUTLET PIPE ID -Failure of REFRACTORY Petes i May 282010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —_[Revision:2 Page: 32/38 frite: STIP for RFCC REACTOR AND REGENERATOR Fig 13 EX-1502 (EXPANSION JOINT BETW} IERATORS) REFRACTORY. Failure at Field Welding Portion BELLOWS, -Deformation -Deterioration due to Gamma Prime Precipitation REFRACTORY -Failure (Extoliation, Spalling) SEALING BRAID Deterioration, Deformation, Disappearance SEAL ROD Deterioration, Fall awayBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | Dec No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —|evision.2. [Page 33/38 1B {ritle: STIP for RECC REACTOR AND REGENERATOR Fig 14_D-1503 (SECOND REGENERATOR) REFRACTORY Continuous Cracking (Blockwise Cracking) -Disbonding HOT SPOT at OD (Failure of REFRACTORY) Check HOT SPOT at OD with Infra-red Thermo-viewer camera During Operation REFRACTORY Failure at Conical Area AIR RING -Erosion of Nozzle Bore -Exfoliation and/or Spalling of Abrasion vee Fig 141) Resistant Lining i i i AIR LIFT PIPE OUTLET | Erosion | XN AIR LIFT PIPE CAT LOADING/UNLOADING NZL REFRACTORY | | “Buckling Failure of REFRACTORY around Failure Nozale End SLEEVE PLATE Deterioration Plt Pn 28,218BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT |_Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —Revision:2 —_[Page: 34/38 BSR ‘title: STIP for RFCC REACTOR AND REGENERATOR, Fig 14-(1) CYCLONE DIPLEG RETURN HINGE RING “Thinning due to Wear DISK “Deformation SEAT of DISK/PIPE -Inctease of Clearance due -Wear of Seat rai, to Wear of Pipe Seat « \ GUIDE ROD -Pailure (Break)BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT Doc No; BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM — [Revision:2.—_ Page: 35/38 RATOR EXTERNAL CYCLON) REFRACTORY, DUCT ID “Abrasion “Failure of REFRACTORY DUST POT. -Abrasion of REFRACTORY CYCLONE INLET DUCT Failure of REFRACTORY REFRACTORY Abrasion of Edging Bar REFRACTORY -Abrasion DIP PIPE ID, -Abrasjon of = i + T SEAT of DISK/PIPE -lncrease of Clearance due to Wear of Pipe Seat REFRACTORY “Failure at Conical Area NOTE: Inside of Dip Pipe should be inspected using small ITV or Bore Camera, Because no one can access into the Dip Pipe. After maintenance work, should be confirm that no debris of lining and/or foreign materials are remained in it using a soft-ball, dropping through it. Fig 16 FLUE GAS OUTLETBINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 uaa) MAINTENANCE PROCEDURE SYSTEM _fRevision:2._|Page: 36/38 |title: STIP for RFCC REACTOR AND REGENERATOR REFRACTORY Failure at Comer REFRACTORY -Failure at Field Welding Portion See Fig 15 L + REFRACTORY : Continuous Cracking Lo (Blockwise Cracking) i Disbonding, i [ |} I 7 a I zt i : a | [| a | | inde so bite intdon ri My 38 2010BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM Revision; 2 |Page: 37 / 38 [ritte: STIP for RECC REACTOR AND REGENERATOR Fig 17 WITHDRAWAL WELL. REFRACTORY -Continuous Cracking (Blockwise Cracking) -Exfoliation and/or Spalling REFRACTORY Failure at Field Welding Portion, AIR RING OD -Abrasion AERATION INLET NOZZLE | Abrasion at Nozzle End see Fig 18BINH SON REFINING & PETROCHEMICAL LIMITED COMPANY MAINTENANCE DEPARTMENT DOCUMENT | _ Doc No: BSR-MNT-INS-009 MAINTENANCE PROCEDURE SYSTEM —Revision:2. Page: 38/38 TIP for RFCC REACTOR AND REGENERATOR 18 SV-1501 (REGENERATOR CATALYST SLIDE VALVE} DISK ORIFICE -Abrasion of -Abrasion of Edge HEXMESH LINING REFRACTORY. ‘brasion LIP SEAL, -Check Remaining of Lip -Abrasion -Check Smooth Movement (No Deposition of Foreign Materials) ORIFICE/DISK Check Clearance between Orifice and Disk DISK and GUIDE Abrasion of Hard Surfacing aed on ay May 262018