DCU Reliability Core team minutes of meetin

Members present : Satyan V/Theo Rajan/SanilKumar T/Raman R/Sanal S/Vijay S/Vasker De/Venketewara

Members absent: Nil

Next meeting on 19/02/2020 @ 15:00 hrs at MCR

Review of old points

Discussed Action /Follow
Sl NO Description on up by
Maint

1 CDSP structure vibration is high. 30/06/2017 RR/MS/SB

28/06/2017 ,
Elevator for CDSP area - Operations to the 8th 14/02/2019
2 floor to be ensured after fixing the CDSP structure & RR/MS/SB
vibration issues.
10/07/2019

Drum overhead 36" line vibration is more and is

3 leading to failure of spring supports 23/10/2019 RR/MS/SS/SB

The interconnection Platform /ladders work to be

4 expedited . 3/7/2017 RR/PKS/SB
 The cutting water high pressure hose to be hydro
tested as per OEM recommendations in every 6
5 months. Discussed in Operations meeting. As 13/02/2018 RR/SS/SKT/SB
priority inspection recommendations, it is to be
done at the earliest .

Change/reset the PSVs in chemical injection

6 system as per recommendation by process 16/01/2019 RR/SB
engineering

7 The drum bottom flange bolts replacement to be 15/5/2019 RR/SS/SB

done as per Inspection recommendations

APS transfer system – To be made as reference to

8 DHDT/CCR corrosive chemical handling system. 3/7/2019 RR/SS

Drum A key hole inspection window to be

9 1/1/2020 RR/SS/SB
widened at east side.

Bomb sampling connectors mismatch issues. The

requirement of Bomb samples at DCU to be
10 1/1/2020 RR/SB/VD
finalised and line pr rating to be provided for
procurement.

Maint Civil

Underground pits water seepage to be attened

-Cooling water pit jobs - Project pending jobs
11 shall be done by Civil group of Projects/ Civil. 24/11/2017 KR/RR/SB
Dewatering from these pits to be done on regular
basis.
12 CBD line leaks at DCU at different locations 12/6/2019 KR/RR/SS/SB

13 The DCU lift pit water ingress to be arrested 21/08/2019 KR/RR/SB

ID P 112 d/c line vibration,inspection

14 recommendation to be implemented
20/11/2019 KR/RR/SB

Maint Instr

Coke drum audio & video display to be

commissioned. These item were not supplied by
ESSAR. The compactable converter to be received
15 from Flowserve. The procurement action to be 19/9/2017 SKT/SB
done by instr- quote to be obtained and amount
to be deducted from ESSAR

Flare flow meter reading ID FI 9002 - Flow meter

16 range is 0-700 TPH and is showing intermittently 14/02/2019 SKT/SB
0.3 to 0.6 TPH
E&C

The blow down overhead HC shall be routed to

another location for the continuous disposal of
17 the stream. Scheme no:4189 . The scheme 4295 8/8/2018 MS/PKS/VD/ SB
for routing sour water to FCCU is to be looked
into along with scheme 4189
 1. The hanging spring support obstructing the
long travel of hoist shall be modified by E&C and
new spring support shall be procured by Maint.
18 ( Notification no:11027144) 2. The testing of 27/2/2019 MS/PKS/RR/ SB
the EOT/HOT shall be ensured by Maint-Equip as
per statutory requirement - test load facility and
approach shall be arranged .

The permanent provision for inspection shall be

19 provided injection area for Fractionator 30/10/2019 PKS/SS/SB/RR
overhead air fin fans

Explore the possibility of providing permanent

access to spring supports ( 8 numbers ) in coke
20 drum PSV outlet lines/ Overhead lines at BUD 15/01/2020 PKS/RR/SS/SB
platform for routine inspection/periodic
maintenance

21 The modification scheme for fractionator bottom 24/10/2017 Sam / SB

circulation line filter .

Elecrical

Permanent ignitor are to be made operable

22 19/9/2017 KGV/SB/RR
condition -3 nos transformer is damaged.

The long term recommendations of ATR 627 of

23 12/6/2019 KGV/SKT/VD/SB
BORL fire incident to be implemented :
 The solid state actuator is provided for CW MOVs
in CDSP. Its performance to be checked and
24 21/08/2019 KGV/SB
confirmed for further procurement for other
MOVs

For improving the visibility during cutting, the

lights to be changed to spot lights for chute area
25 21/08/2019 KGV/SB
for all drums and flood lights to be provided for
covering entire coke pit.
PE

ID P 139A/B both pumps are running due to

26 interlock of low header pressure. To be checked 21/08/2019 VD/RR/SB
for further modifications

Tha failure of BFW contraol valves ID LIC 1305

27 20/11/2019 VD/SKT/SB
/1301 for ID E 103/106

Discussed Action/Follow
Sl NO Shutdown job
on up
1 Heater APH SOB bottom flange is found leaking, 9/1/2018 PBG/RR/SB
to be taken up with vendor

The MP steam lines near heater burners, which

was envisaged for sootblower of burners are
2 having dead end and may cause corrosion in near 23/2/2018 PBG/RR/SB/SS
future. The dead ends to be avoided by extending
the line with steam trap.
 Failure of 32” R/V outlet line from Coke drum-A :
3 Cap welded to be changed - ESA item - to be 3/7/2017 PBG/SB
complied at the earliest.

Steam valve & check valve replacement on

4 heater coil inlet line. All the purge steam lines to 5/7/2017 PBG/SB
heater coil inlet is kept blinded now during
normal operation (16 nos)

Bowing noticed in cast support pipe and radiant 24/10/2017

5 coil tube s in IDH101A pass 3 and IDH101B pass PBG/RR/SB
3 and 4 to be corrected. 29/12/2017

Relocate the flexible hose on purge steam line

6 towards upstream of isolation valve as per the 13/6/2018 RR/PBG/SB/SS
recommendation in ATR 600 scheme

The feed pump suction MOV ID MOV 1202 was

7 stuck since commissioning and is to be changed 6/6/2019 PBG/KGV/SB
during shutdown (shutdown pending job)

The instrument air volume bottles fire insulations

8 to be removed for vessel thickness measurement. 24/10/2018 SKT/SS/SB
4 vessel to be replaced as per inspection
recommendation

Drum B BUD steam purge line leak to be

9 attended 7/8/2019 RR/SB/SS

10 Heater A SCAPH is leaking 1/1/2020 RR/SS/SB

11 FT 8201 HP, FT 8202 MP, FT 8203B LP B/L steam 15/01/2020 SKT/VD

flow to be checked.

Sl NO New points Discussed on Action/Follow up

Adequate measures for dust supression

shall be taken to control dust in coke
1 crusher area.as per per the
reccomendation of priority inspection
conducted by F&B

2 ABD underground 2" line leak

3
electrical cables associated with cutting hose to
be tied properly.
team minutes of meeting on 5th Feb 2020

Vijay S/Vasker De/Venketewaran K G/Ramesan P R/Suresh K S

Status Remarks Target Date

VC conducted on 6th Feb2020, in

which IIT-M Professors suggested
IIT M Prof. Meherprasad AK & Prof. the options of dampening the
Chandramouli's team visited DCU and their vibration on the source with
report received. The analysis by team from pendulum. Further
Cohin University students also in progress. recommendations based on this will
be given by IIT M ,revised date shall
be informed.

The structure supports to be provided at

4th floor - Connecting the lift to the already Meeting at IIT-M
vibrating structure might increase the The item shall be covered with IIT M before 15.02.2020
vibration of the lift, So other possibilities for study in point no 1,,revised date
shall be informed.
strengthening the same needs to be
explored.

Procurement of spring supports to

be done as per IIT study. Snubber
Cross guide provided for vapour line design recommendation with
specifications to be provided by E&C

The subject job involves the safety

The drawing for interconnection to columns of all the persons using the platform
and also has connections to a
by E&C - drawing shall be revised and column. Thus it can only be done
30.04.2020
released at the earliest
after receiving approved drawing
from E & C.
1) The high pressure pump made ready 2)
The separate testing arrangement location
identified in kone crane maint yard 3) The
pressure gauge procured (500 kg/cm2g) by
Instr 4) The safety procedures for testing
the hose to be obtained from Vendor and
the feedback to be obtained to test the
hose on its position also. 5) 1" NRV with
high pressure rating for testing procured.
Connection fabrication nearing
completion. HT of 2 hoses will be
completed as committed. The SMP
prepared for hose testing.The hose
28.02.2020
changing from the cutting tool
requires 3-4 days shutdown and it
can be done only during pigging
shutdowm in May 2020

Revised budgetory quote received.

New PSV procurement actions in progress PR to be created urgently to achieve 30.04.2020
the target on time

The bolt replacement on BUD- the practice Drum B - 1 bolt pending for
to be checked with BORL/MRPL. The stregth replacement. The bolt testing results 30.05.2020
of the replaced bolts to be checked by to be updated by Inspection,will be
Inspection. done during pigging s/d.

Work partialy completed. The calibration jar

facility provided. Existing line PMI done and PR:15531956 raised. RFQ floated. 30.04.2020
confirmed SS304

Shall be checked and provided completed

The list shall be updated by avoiding those
sample points which being taken very
rarely. The sampling connectors (sewage
lock type) are coded item. Sampling system
testing also to be done periodically as per
ATR.
The updated list provided -2 nos to
be fixed and the connectors to be
corrected for all . The Swagelok 5.03.2020
fittings being procured. PR:15552969
created for the 2 sampling points as
notified.

New JSP is prepared for work in CBD vessel Due to Non-availability of  water
pit for arresting water seepage to valve pit.
arresting civil items in Civil contract
The sand removal and shuttering in CBD pit awarded to M.N.B Nair, work cannot
to be completed for dewatering and work in
side valve pit. be started. New ARC to be arranged
The idntified leaking lines modified with
dummy flange / spool piece as per Work started with the Rs.20 lacs
discussion. As per operations meeting
minutes the CBD lines area in DCU to be ( 1/4th share Rs.80 lacs ) of M.N.B
Nair contract . We will continue the Work started on
excavated and changing of red soil to M work as long as the quantities are 4/2/2020
sand / baby metal to be done for entire
available.New contract being
unit. The line cut and end dummy provided arranged
at 12 locations for dead end of CBD sub
header.

Dewatering arranged and high pressure Due to Non-availability of water

arresting civil items in Civil contract No contractor
grouting with PU shall be attempted.Site awarded to M.N.B Nair, work cannot available
visited by the contractor Mr. Arunkumar
be started.

Support provided, concreate chipping to be Work done by DCU operational Completed

done assistance contractor - Madonna

As per the meeting with Vendor the The video system 10/12 made OK .
existing system shall be made operable and The remaining cameras being
the requirement and scope of work for the
Remote coke cutting finalised. The estimate checked, 10 nos ready balance 2 nos
20-Mar-20
will be ready after checking by
for remote coke cutting system (approx 25 vendor
Cr) forwarded for NPCB approval.

One pair instrument faulty leads to Once the parts ordered for CDU 3 is
inaccuracy of reading in lower range, Item received, it shall be used for 15-Mar-20
received and utilised for CDU 3. replacing at DCU

Hook up drawing provided, But hook up
was not done in Dec 18 shutdown. New
location near Pillar no L6 to L8 technically
cleared by E&C. Advance scheme forwarded
for engg drawing preparation.
NPCB proposal approved and the
engineering drawing preparation i/p
for Sch 4189 & 4295. The scheme to 15-May-20
be revised as per site modification
suggestion for pump location.
1. Structural drawing for spring support
Provided by E&C. Maint to initiate
procurement action
PO no and status to be provided by
Maint - CDD is in Feb 20
2. 29-Feb-20
The test load facility and approach -
Structural beam to be extended at west end Point 2- the drawing to be provided
by E&C
instead of east side. To be checked and
drawing to be provided by E&C- Site visit
conducted

Checked by E&C Drawing to be expedited by E&C 29-Feb-20

Checked by E&C . The additional load on the

E&C to provide drawing 15-Mar-20
structure to be checked and verified

2" P9 pipe have been delivered on

Grand Prix filter received , site jobs 30th Jan 2020 from M/s Mukesh 31-Mar 20
preparation in progress. metals and expected at site by 1st
week of Feb 20 .

Out of 5 , 2 Igniter made ready (one each New PR no: 15536663 raised for
from heater A&B). Others to be replaced - 3/31/2020
Spare procurement in progress. igniter parts. PO is ready.

1. Interlock modification and provision of

PSV - The CDSP HAZOP conducted and
suggested tha PSV is not feasible.
2. If the provision is given thro
interlock logic, there won't be any
difference between operation from LCP and
direct MOV. It won't be practical to operate
the unit in that condition as discussed by
operations & Maintenance. So the alternate
additional switch for bypass permission
shall be provided for double checking by
operator and panel engineer
For ensuring safety, the emergency
switch in LCP shall be used for feed
back for changing to local operation
and additional switches shall be
provided for individual MOVs at LCP. Work to start on
Work planned to start by P&U-
24.02.2020.
Electrical shortly thro' ARC. Work to
start on one pilot panel by
17.02.2020.
For checking the performance of the MOVs,
MOV 2509 & 2528 was kept ON for Drum
C/D and its performance is found OK. It is
recommended to change the actuator for
other MOVs also.
20 nos shall be changed as per list
provided by DCU operations with
current contigency fund allocation.
Fund allocation expected by
28.02.2020.PO will be ready by 31st
march.

The lights of bridge crane was supplied by

foreign vendor and is very expensive. Enquiry floated to flameproof light
fitting suppliers. Awaiting reply. PR
Equivalent indegenous light fittings is being raised.
explored

1. Interlock modification shall be

8 nos orifice plate changed to smaller size of
1.6 mm. As both heater are online, both done with pressure, flow and pump
running indication-HAZOP to be
pumps came online, discharge pr. 54
kg/cm2g and flow is 9.8 TPH. As per pump done. Or
 28th Feb 2020.
2. Data for Flow and pressure
performance curve, if flow is more than 8 requirement shared with Vendor. Impeller modelling
tph, the pressure shall drop drastically as  and Feasibility
observed. ID P 139B serviced and taken The modification of pump to achieve check by vendor.
back on line- no improvement observed- required flow and pressure has been
checked with using existing motor.
still both pumps running while both heaters The final recommendation is
online.
awaited

BFW header pressure reduced at utility and

is being checked for further reduction. The
pr reduction is possible only if the turbine is RFC Number:“KR/2020/MFG -  28th Feb 2020.
on line with running on reduced rpm. PO HAZOP to be
4507588280 placed for replacing valve body DCU/10524- RFC” created Completed.
CDD to be provided by Instr. RO/ Control
valve shall be looked in.

Status Remarks Target Date

Action plan to be given by vendor. Date to be provided by Maint / DC 2021 S/D

Spool pieces removed which do not

required shutdown. Remaining jobs to be Date to be provided by Maint / DC 2021 S/D
done during shutdown.
Material was not available during shutdown PO 4507603835 placed for P9 20MM 2021 S/D
- to be procured by DC. plates. Delivery by February 2020

Material was not available during shutdown

in Dec 2018.To be procured by DC. The
quality of NRV (P9 material and welded
NRV) to be ensured.
PO 4507616997 Placed for 16 Nos of
check valves and gate valves(CDD 2021 S/D
07.04.2020)

Heater was not opened during shutdown, Pipe support / beams received at 2021 S/D
shall be done in next availability W/H (PO 4506736269)

6 Hoses and 12 flanges delivered. PO 4507610412 / 50 placed for

flanges( 80 Nos) (CDD 05.03.2020)
Additional flexible hose & flanges to be PR 15470677 raised for Hoses
2021 S/D
procured
(40Nos)

Procurement to be done by DC. Details of

PR15474615, Bid due date
electrical components are provided by 31.01.2020
2021 S/D
electrical

DCU items received. Shall be replaced in shutdown 2021 S/D

Procedure for repair to be obtained from

vendor as the crack is on BUD steam purge
nozzle and it is integral part of the BUD PO given for material, Material to be Pigging S/D
system.Taken up with the vendor and it received.
shall take few months for receiving the
material

Internal Inspection to be done 2021 S/D

North side coil leak confirmed and isolated. during shutdown
Checked by Instr FI 8201B and 8203B lead lines are 2021 S/D
plugged and S/D job

Status Remarks Target Date

To be provided as per JHSSEC

recommendation.
ABD line to be excavated in phased
manner.
 Heater outlet spare spool pieces to be made ready for changing
26 during pigging shutdown. There is another suggestion in RPIP to 6/4/2018 &
remove the MOV's with spool pieces at the coil outlet lines for 20/6/2018
reduction of steam and increase of drum inlet temp.

PMI mismatch on NITON valves, Heater B o/l MOVs PMI

4 3/7/2017
mismatch to be attended

MTO given by E&C as per
VD/MS/ advance scheme and Maint
RR
initiated procurement actions
Niton to supply the items and
RR/SB
taken up through EIL
HAZOP completed. The engineering drawing also shall
be prepared by BCG. MTO for procurement fone for the
scheme by BPCL is forwarded to BCG for further follow
up.
The item shall be removed as the valve removal
proposal is on under RPIP by BCG
S/D