Vendor Document Cover Sheet: Unit 10600 WBS

VENDOR DOCUMENT
COVER SHEET
DOCUMENT TITLE: TECHNICAL INSTALLATION, TOP No.: R1118111-S30015-VES-V00000-20033-N04
OPERATING AND MAINTENANCE MANUAL CONT. Doc. No.: 2044-00000-MS-225062
VENDOR. Doc. No.: PBE100041-52-MAINT-01
Project No: R1118111 UNIT 10600 WBS C03
Project Name: CLEAN FUEL PROJECT
PO Code: S30015
TOP PO No.: N/A
PO Description: CS & Cr-Mo Vessels Thick Upto 80mm
Material Type: VES
Requisition No.: R1118111-00000-MS-REQ-20008 Rev.0
Vendor Name: Godrej & Boyce Mfg. Co. Ltd.
Sub Vendor/ Sub Con. -

V-10614, V-10708, C-10801, C-10802, V-10633, V-10635 A/B/C/D , V-10716, V-
Equipment No.:
10721, V-14181
Doc Class / Category Z
Godrej & Boyce Revision A B C D E

Mfg. Co. Ltd.
Date 08-12-2020
Signature HBC
DOCUMENT STATUS SIGNED DATE

C1 - REVIEWED WITH NO COMMENTS
REVIEWED WITH COMMENTS AS NOTED. COMMENTS SHALL BE

C2 - CONSIDERED. REVISE AND RESUBMIT THE DELIVERABLE FOR
REVIEW. PROCEED WITH FABRICATION.
C3 - REJECTED DO NOT PROCEED WITH FABRICATION
C4 - RECEIVED FOR INFORMATION ONLY
SCF - SUPPLIER CERTIFIED FINAL

ISSUE OF CERTIFIED FINAL DOCUMENT DOES NOT RELIEVE SUPPLIER OF RESPONSIBILITY OR LIABILITY UNDER THE
CONTRACT/PURCHASE ORDER
1
TECHNICAL INSTALLATION,
OPERATING AND
MAINTENANCE MANUAL
1. RECORD OF REVISION
Revisio
Date Revision History Pages Issue
n
A 08-12-2020 - 1-33 Issue for Approval
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OPERATING AND
MAINTENANCE MANUAL
2. CONTENTS
Table of Contents
1. RECORD OF REVISION.....................................................................................................................................2
2. CONTENTS.......................................................................................................................................................3
3. INFORMATION ON DESIGN, PRINCIPLE OF OPERATION OF EQUIPMENT........................................................4
4. INSTRUCTIONS ON INSTALLATION EQUIPMENT...........................................................................................11
5. INSTRUCTIONS ON USE OF EQUIPMENTS AND SAFETY MEASURES TO FOLLOW AT OPERATIONAL STAGE
OFEQUIPMENT........................................................................................................................................................22
6. INTENDED RESOURCE CHARACTERISTICS DEPENDING ON DESIGN FEATURE...............................................27
7. CAUTION: LIST OF ERRONEOUS ACTIONS RESULTING IN BREAKDOWN OR INJURY......................................28
8. ACTION REQUIRED IN CASE OF ERRONEOUS ACTION...................................................................................29
9. CRITERIA OF LIMITING STATES......................................................................................................................30
10. INSTRUCTIONS ON WITHDRAWAL FROM OPERATION AND DISPOSAL.........................................................31
11. INFORMATION ON COMPETENCY OF SERVICE STAFF...................................................................................32
12. THE NAME, LOCATION AND CONTACT INFORMATION OF THE MANUFACTURER........................................33
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OPERATING AND
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3. INFORMATION ON DESIGN, PRINCIPLE OF OPERATION OF EQUIPMENT

3.1. Information on Design
Design Code : ASME Sec. VIII, Div. 1 [ Edition: 2017 ]

Wind Code : ASCE 7-05, Basic wind speed=144 kmph, Exposure Category = C , Topographic Factor-1,
Category-III
Seismic Code : N/A
Equipment No. Description Units Value

Internal Design Pressure bar (g) 37.2
External Design Pressure bar (g) 1.03 (F.V.)
Design Temperature for Internal Pressure & External Pressure °C 343
V-10614 Operating Pressure bar (g) 24.7
Operating Temperature °C 273
MAWP (Internal/External) @ Design Temperature bar (g) 37.991/1.03
MAP(New & Cold) bar (g) 38.739


Internal Design Pressure bar (g) 44

C-10801 Operating Pressure bar (g) 39.99
Operating Temperature °C 165.5/187.8
C-10802 Design Temperature for Internal Pressure & External Pressure °C 255
Operating Pressure bar (g) 36.2
Operating Temperature °C 224.2
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OPERATING AND
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V-10633 Operating Pressure bar (g) 20
MAP(New & Cold) bar (g) 39

V-10635 A/B/C/D Operating Pressure bar (g) 93.8

V-10721 Operating Pressure bar (g) 144
162.121/1.0
MAWP (Internal/External) @ Design Temperature bar (g) 3
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OPERATING AND
MAINTENANCE MANUAL

90 (Bott.),
Operating Temperature °C 101 (Top)

3.2. Applicable Documents
3.2.1. V-10614 :
Sr.
Title Client Doc. No. Godrej Drg. No. Sht.
No.
1 General Arrangement Drawing R1118111-S30015-VES-V10614-20005-B01 6VL-DA-067 1 of 7
Skirt & Lifting Attachment Detail

2 R1118111-S30015-VES-V10614-20006-B02 6VL-DA-067 2 of 7
Drawing
3 Nozzle Details Drawing R1118111-S30015-VES-V10614-20007-B02 6VL-DA-067 3 of 7
4 Details Of External Attachments 1 R1118111-S30015-VES-V10614-20008-B02 6VL-DA-067 4 of 7
5 Details Of Internal Attachments R1118111-S30015-VES-V10614-20009-B02 6VL-DA-067 5 of 7
6 General Notes R1118111-S30015-VES-V10614-20010-B02 6VL-DA-067 6 of 7
7 Details Of External Attachments 2 R1118111-S30015-VES-V10614-20008-B02 6VL-DA-067 7 of 7
3.2.2. V10708:
Sr.
Title Client Doc. No. Godrej Drg. No. Sht.
No.
1 General Arrangement Drawing R1118111-S30015-VES-V10708-20005-B01 6VL-DA-068 1 OF 6
Support Lugs & External

2 R1118111-S30015-VES-V10708-20006-B02 6VL-DA-068 2 OF 6
Attachments Detail Drawing
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OPERATING AND
MAINTENANCE MANUAL
3 Nozzle Details Drawing R1118111-S30015-VES-V10708-20007-B02 6VL-DA-068 3 OF 6
Internal Attachments & Nozzle

4 R1118111-S30015-VES-V10708-20008-B02 6VL-DA-068 4 OF 6
Detail Drawing
5 General Notes R1118111-S30015-VES-V10708-20005-B01 6VL-DA-068 5 OF 6
6 Details Of External Cleats R1118111-S30015-VES-V10708-20006-B02 6VL-DA-068 6 OF 6
3.2.3. C10801
Sr. Godrej Drg.
Title Client Doc. No. Sht.
No. No.
1 General Arrangement Drawing R1118111-S30015-COL-C10801-20006-B01 6VL-DA-069 1 OF 8
2 Detail Of Skirt & Lifting Attachment R1118111-S30015-COL-C10801-20007-B02 6VL-DA-069 2 OF 8
3 Detail Of Nozzles R1118111-S30015-COL-C10801-20008-B02 6VL-DA-069 3 OF 8
4 Details Of External Attachments 1 R1118111-S30015-COL-C10801-20009-B02 6VL-DA-069 4 OF 8
5 Details Of Internal Attachments R1118111-S30015-COL-C10801-20010-B02 6VL-DA-069 5 OF 8
Internal Packing & Distributor

6 R1118111-S30015-COL-C10801-20011-B02 6VL-DA-069 6 OF 8
Details Drawing
General Arrangement
8 R1118111-S30015-COL-C10801-20006-B01 6VL-DA-069 8 OF 8
Drawing(General Notes)
3.2.4. C10802
Sr. Godrej Drg.
No. No.
1 General Arrangement Drawing R1118111-S30015-COL-C10802-20006-B01 6VL-DA-070 1 OF 8
Detail Of Skirt & Lifting
2 R1118111-S30015-COL-C10802-20007-B02 6VL-DA-070 2 OF 8
Attachment
3 Detail Of Nozzles R1118111-S30015-COL-C10802-20008-B02 6VL-DA-070 3 OF 8

5 Details Of Internal Attachments R1118111-S30015-COL-C10802-20010-B02 6VL-DA-070 5 OF 8
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OPERATING AND
MAINTENANCE MANUAL
Internal Packing & Distributor

6 R1118111-S30015-COL-C10802-20011-B02 6VL-DA-070 6 OF 8
Details Drawing

General Arrangement
8 R1118111-S30015-COL-C10802-20006-B01 6VL-DA-070 8 OF 8
Drawing(General Notes)
3.2.5. V10633
Sr. Godrej Drg.
No. No.
Skirt & Lifting Attachments R1118111-S30015-VES-V10633-20006-B02

2 6VL-DA-078 2 OF 7
Drawing
3 Nozzles Details Drawing R1118111-S30015-VES-V10633-20007-B02 6VL-DA-078 3 OF 7
External Attachments Details R1118111-S30015-VES-V10633-20008-B02

4 6VL-DA-078 4 OF 7
Drawing
Internal Attachments Details R1118111-S30015-VES-V10633-20009-B02
5 6VL-DA-078 5 OF 7
Drawing
6 Demister Details Drawing R1118111-S30015-VES-V10633-20010-B02 6VL-DA-078 6 OF 7
7 General Notes Drawing R1118111-S30015-VES-V10633-20011-B02 6VL-DA-078 7 OF 7
3.2.6. V10635
Sr. Godrej Drg.
No. No.
Skirt & Lifting Attachments R1118111-S30015-VES-V10635-20006-B02

2 6VL-DA-079 2 OF 7
Drawing

4 6VL-DA-079 5 OF 7
Drawing
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OPERATING AND
MAINTENANCE MANUAL
3.2.7. V10716
Sr. Godrej Drg.
Sht.
No. Title Client Doc. No. No.
Skirt & Lifting Attachments

2 R1118111-S30015-VES-V10716-20006-B02 6VL-DA-080 2 OF 6
Drawing
External Attachments Details

4 R1118111-S30015-VES-V10716-20008-B02 6VL-DA-080 4 OF 6
Drawing
Internal Attachments Details
5 R1118111-S30015-VES-V10716-20009-B02 6VL-DA-080 5 OF 6
Drawing
3.2.8. V10721
Sr. Godrej Drg.
Sht.
Skirt & Lifting Attachments

2 R1118111-S30015-VES-V10721-20006-B02 6VL-DA-081 2 OF 7
Drawing
External Attachments Details

4 R1118111-S30015-VES-V10721-20008-B02 6VL-DA-081 4 OF 7
Drawing
Internal Attachments Details
5 R1118111-S30015-VES-V10721-20009-B02 6VL-DA-081 5 OF 7
Drawing
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OPERATING AND
MAINTENANCE MANUAL
3.2.9. V14181
Sr. Godrej Drg.
Sht.
Skirt & External Attachments R1118111-S30015-VES-V14181-20006-B02

2 6VL-DA-082 2 OF 5
Drawing

4 6VL-DA-082 4 OF 5
Drawing
3.3. SHIPPING DOCUMENTS
TITLE GODREJ DOC. NO. CLIENT DOC NO.

Transportation Arrangement PBE100041-TS R1118111-S30015-VES-V10614-20014-B12
Transportation Arrangement PBE100043-TS R1118111-S30015-COL-C10801-20015-B12
Transportation Arrangement PBE100044-TS R1118111-S30015-COL-C10802-20015-B12
Transportation Arrangement PBE100046-49-TS R1118111-S30015-VES-V10635-20015-B12
Packing And Shipping PCE100041-44/QA/Packing &
R1118111-S30015-VES-V00000-20032-N01
Procedure Shipping/001
3.4. SITE DOCUMENTS
TITLE GODREJ DOC. NO. CLIENT DOCUMENT NO.

TECHNICAL INSTALLATION, OPERATING AND PBE100041-44- R1118111-S30015-VES-V00000-
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OPERATING AND
MAINTENANCE MANUAL
MAINTENANCE MANUAL MAINT-01 20033-N04
3.5. DATASHEET REF. NO.
EQUIPMENT NO. CLIENT DOCUMENT NO.

V-10614 R1118111-10600-MS-DAS-20031
V-10708 R1118111-10700-MS-DAS-20015
C-10801 R1118111-10800-MS-DAS-20030
C-10802 R1118111-10800-MS-DAS-20001
V-10633 R1118111-10600-MS-DAS-20050
V-10635 A/B/C/D R1118111-10600-MS-DAS-20052
V-10716 R1118111-10700-MS-DAS-20018
V-10721 R1118111-10700-MS-DAS-20024
V-14181 R1118111-14180-MS-DAS-20001
3.6. RELEVANT PROCEDURES:
TITLE GODREJ DOC. NO. CLIENT DOCUMENT NO.

R1118111-S30015-VES-V00000-
Hydro test Procedure PCE100041-44/QA/HYDRO/001 20014-H07
R1118111-S30015-VES-V00000-
Bolt Tensioning Procedure PBE1000041-44/QA/BLT/001 20025-H99
Surface Preparation And Painting R1118111-S30015-VES-V00000-
Procedure PCE100041-44/QA/PAINTING/001 20013-H06
PCE100041-44/QA/Preservation & R1118111-S30015-VES-V00000-
Preservation & Storage Procedure storage/001 20034-N05
4. INSTRUCTIONS ON INSTALLATION EQUIPMENT.
4.1. INSTRUCTIONS ON INSTALLATION :
4.1.1. Preparations for Installation:
 Before installing the Vessels in to system, ensure that all the piping and safety gauges are in place.
 Allow enough space around the vessel to provide sufficient clearance for maintenance or
inspection purpose.
 Provide valves and bypasses in the piping system to permit isolation of the Vessel for inspection,
cleaning, and repairs.
 Provide thermometer wells and pressure gauge pipe taps in all piping to and from the Vessel, as
close as possible to the unit to detect operating performance of the unit.
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OPERATING AND
MAINTENANCE MANUAL
 Provide necessary air vent valves for the Vessel so that it can be plugged to prevent or relieve
vapour or gas.
 All loose pipings shall be installed on the Vessel as per the applicable P&IDs.
 The equipment is to be lifted into place.
 Lifting devices i.e. trunnion & tailing lug are designed for erection weight of the equipment. Proper
rigging must be used in lifting assembled Vessel.
4.1.2. General handling instructions:
 Prior to any planned lifting of a vessel, the site engineer should review the General Assembly
Drawing, Skirt & Lifting Attachments Drawing and Transportation Drawing. These drawing contains the
necessary data to plan normal lifting of the vessel.
 This information consists of the following items:
o Empty weight of the vessel in kilogram.
o Location of the longitudinal center of gravity.
o Lifting trunnion/cover location and tailing lug location on the Vessel.
o Details of Lifting trunnion/cover and tailing lug
4.1.3. Installation of the equipment:

PRELIMINARY CHECKS:
o Check the condition of the received equipment. It should be free from any damage and
rust.
o Ensure that the equipment and the components are in order according to the packing list.
(In case the components are damaged, the same shall be brought to the notice of Godrej &
Boyce Mfg. Co. Ltd., immediately.)
4.1.4. Handling:
Though the outer body of vessel is made of steel, due care shall be taken in handling it to avoid
damage. To ensure this the following guidelines should be followed:
o Use crane/ chain pulley block for unloading. Avoid any impact or shock to the equipment.
o Do not lift equipment using anchor holes. Strictly use the lifting points provided on the
equipment.
o Do not roll the equipment.
4.1.5. Erection:
 Study the layout drawing of the plant for equipment installation.

 Study the General Assembly drawing of the equipment.
 Erect the equipment as per the orientation plan / layout drawing taking following precaution:
1. Avoid any impact or shock to Vessel.
2. Use only recommended handling points to lift the equipment.
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OPERATING AND
MAINTENANCE MANUAL
 Level the equipment with plumb or spirit level.

 Tighten the Foundation Bolts.
 Connect all the pipelines to the equipment as per P&I Diagram.
 Site hydrotest may be performed if deemed necessary.
4.2. SET-UP/ADJUSTMENTS :
4.2.1. Erection equipment:

4.2.1.1. Hoisting equipment (Mobile Crane)
 All mobile crane operators shall be qualified by government or other equipment authorities. A set
of the manufacturer’s life tables shall be placed conspicuously in the mobile crane operator’s cab at
the jobsite. The capacities given shall be adhered to strictly. Additional boom sections installed on
the equipment shall be compensated by additional counter weights in accordance with the
instruction manual.
 Timber mat and / or steel mat shall be provided for treads or tires considering the soil bearings.
Basically, outriggers and jacks shall be provided on the mobile to guard it against tire failures and
overturning while lifting heavy equipment.
 When a risky condition is found, appropriate measures shall be taken immediately.
 Major items of inspection shall be as follows.
o All control mechanisms as to mal-adjustment.
o All control mechanisms as to excessive wear of components and contamination by lubricants or
other foreign matter.
o All control mechanisms as to malfunction.
o Deterioration or leakage in pneumatic or hydraulic systems.
o Electrical apparatus as to malfunctions and signal.
o Crane hooks with deformations or cracks.
o Deformed, cracked, or corroded members in the crane structure and boom.
o Ropes.
4.2.1.2. Wire Rope, Slings, Chains and Fittings
4.2.1.2.1. Wire Rope

Wire rope shall be of suitable size, grade & construction to withstand the maximum load imposed.
Wire rope in the main hoisting system shall be of ample length for the entire range of movement
specified with at least two full wraps of the rope on the hoist drum at all times. When any of the risky
conditions listed below is found, the wire rope shall be removed from the sling service and
appropriate measures shall be taken to improve the condition.
 In running ropes, six randomly distributed broken wires in one rope lay, or three broken wires in
one stand in one rope lay.
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OPERATING AND
MAINTENANCE MANUAL
 Wear of one-third of the original diameter of the outside individual wires.

 Ringing, crushing, bird caging or any other damage resulting in distortion of the rope structure.
 Evidence of any heat damage from any cause.
 Reductions from nominal diameter of rope exceeding: 3/64 inch for diameters up to ¾ inch
inclusive,1/16 inch for diameters 7/8 inch to 1-1/8 inches inclusive,3/32 inch for diameters 1-1/4
inches to 1-1/2 inches inclusive.
 In standing ropes, more than two broken wires in one lay in sections beyond the end connection
or more than one broken wire at an end connection.
4.2.1.2.2. Wire Rope and Sling
 The safety factor for wire rope slings of all grades shall be not less than five.
4.2.1.2.3. Chain
 All chains shall be forged or electric welded steel link type of the proper size for the loads to be
lifted.
 Overloaded chains shall be discarded immediately.
4.2.1.2.4. Drum, Pulley and Sheave
 The diameter of the drum or pulley shall be not less than 20 times the rope diameter. The
diameter of sheaves shall be not less than 10 times the rope diameter.
4.2.1.2.5. Fitting
 All hooks, swivel hooks, anchor shackles, swivel sockets, safety hooks, cable clamps, turnbuckles,
and other attachment shall be made of drop forged steel.
4.2.1.3. Safety Factor

The minimum safety factors to be used for wire ropes & wire rope slings shall be of the values Table 1.
Item Minimum Safety Factor

Hoist Rope
3.5
Hoist Rope for Raising and Falling Boom
Wire rope for supporting boom
Wire rope for Turning 3
Wire rope for Guy rope of tension
Wire rope for Sling 5
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OPERATING AND
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4.2.1.4. Pre-commissioning instructions
4.2.1.4.1. Preparation of shims and Wedges:

Shims and Wedges shall be made of carbon steel. In general, shims and wedges shall be prepared by
machining or grinding as indicated in Table 2.
Table 2 (Unit mm)
Item Length Width Thk Angle

Shim 100-450 50-200 3.2,4.5,9,12,19,25 -
Wedg 6,9,12,16,19,25
100-450 50-200 4⁰-5⁰
e (Max. Thickness)
4.2.1.4.2. Preparations for Erection / Installation:

For smooth and safe lifting operation, following checks must be done prior to commencement of
theoperation and also ensure that all the piping and safety gauges are in place.
 Space around the equipment to provide sufficient clearance for installation and inspection
purpose.
 Install proper liquid level controls and relieve valves and liquid level and temperature alarms etc.
 Damages if any during transportation and storage to lifting lugs, anchor bolts etc.
 Centre lines marking for plumbing.
 Condition of lifting accessories such as slings, shackles, ropes etc.
 Level and coordinates marking on foundation.
 To prevent overloading, no temporary material and test water shall allowed.
 The bottom face of the supporting bracket plate shall be checked and cleaned if required.
 The steel structure where equipment is installed shall be thoroughly chipped and then be cleaned
completely with compressed air, etc.
 The required number of shims and wedges with the necessary tools shall be prepared and ready
for use.
Eyebolts, or other devices, if any, are installed only to lift the empty components to which they are
attached and not the complete assembled equipment, unless explicitly specified otherwise. Proper
lifting accessories must be used for lifting of equipment.
4.2.1.4.3. Precautions against storm
 When high wind velocity persists, all installation work shall be stopped.
 No equipment shall be installed under stormy winds, heavy rain or heavy snow.
4.2.1.4.4. Special Crew
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OPERATING AND
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 During Heavy Installation, a special crew shall be organized.

 The crew shall comprise general supervisor, signal/flag, crane operator, rigger, safety supervisor
etc. And the general supervisor will be responsible for delegating duties.
 The function of each individual of crew shall be clearly defined.
 Area involved should be cordoned off and entry of personal other than the special crew shall be
restricted. All installed equipment shall be aligned plumbness or level.
4.2.1.4.5. Plumbness
 Plumbness shall be checked by viewing from two directions 90⁰ apart with a transit. Check of
plumbness of very tall equipment shall be done early in the morning.
 Plumbness over the total height of the gasifier, the variation of the vessel center line from plumb
shall not exceed 3/4 inch (18 mm), both after fabrication & field installation.
 After alignment is finished and the lock nuts of the anchor bolts are tightened firmly, the shims
and wedges shall be tack-welded to each other and exceed in the shims and wedges shall be cut off
with a gas cutter.
4.2.1.4.6. Levelling
 The alignment lever shall be made using a spirit level instrument or a transit at four points on the
center line marked on the equipment in the shop.
 After levelling gas finished and the lock nuts of the anchor bolts are tightened trimly, the shims
and wedges shall be tack-welded to each other and any exceed in the shims and wedges shall be cut
off with a gas cutter.
4.2.1.4.7. General handling instructions:

Prior to any planned lifting of an equipment, the site engineer should review the general assembly
drawing and transportation drawing. This drawing contains the necessary data to plan normal lifting
of the equipment.
This information consists of the following items:
 Empty weight of the equipment in kilogram.
 Location of the longitudinal center of gravity.
 Lifting lug or trunnion location for equipment.
 Transportation Saddle location, for horizontal transportation.
4.2.1.4.8. Installation of the equipment (Preliminary Check):
 Check the condition of the received equipment and Ensure that the equipment and the
components are in order according to the enclosed packing list. (In case the components are
damaged, the same shall be brought to the notice of Godrej & Boyce Mfg. Co. Ltd., immediately.)
4.2.1.4.9. Erection:
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OPERATING AND
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 Study the layout drawing of the plant for equipment installation.

 Study the General Assembly drawing of the equipment.
 Erect the equipment as per the orientation plan / layout drawing taking following precaution:
 Avoid any impact or shock to equipment.
 Use only recommended handling points to lift the equipment.
 Tighten the Foundation Bolts.
 Connect the process & services pipelines to the equipment as per P&I Diagram.
4.2.1.4.10. Precaution:
 Use slings of suitable capacity for lifting the equipment.

 Avoid any impact or shock to the equipment.
 Do not weld directly to the equipment pressure parts.
 Tighten the bolts for the piping connection using torque wrench / hydraulic bolt tensioner.
4.3. TECHNICAL MAINTENANCE
MAINTENANCE INSTRUCTIONS:
4.3.1. Maintenance:
 The maintenance and periodic inspection of the equipment must be carried out by qualified
personnel in accordance with the national regulations and the user’s safety and maintenance
standards and procedures.
 Under no circumstances should the equipment be opened while it still contains any hazardous
materials or when the internal pressure is above or below the local atmospheric pressure. The
equipment must be brought to atmospheric pressure by venting it to safe location, before opening.
4.3.2. Safety instructions:
 Do not remove covers, piping, or connections unless plant instructions for venting and draining
equipment have been followed. Removal of cover without first properly venting and draining
equipment may cause serious injury or death from rapid release of hot vapour /liquid
 Check equipment with internal corrosive environments for reduced wall thickness by visual
inspection and NDE techniques.
 Inspect equipment and systems to ensure that no unauthorized modifications have been made.
 Ensure that all safety relief devices for the equipment are in place and functioning properly
 Do not isolate the relieving device from the pressure system it is protecting.
 Do not repair an equipment when it is pressurized.
 Assure that oil and grease do not get into valves, fittings, and pipes of oxygen gas systems.
4.3.3. Bolted connections
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OPERATING AND
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4.3.3.1. Scope
This section provides recommendations for assembly and maintenance of external bolted joints
utilizing
gasketed sealing surfaces. Bolted joints considered are full access bolted covers, nozzles and
manways.
This section does not cover internal bolted joints if any. These recommendations are not intended to
supersede existing plant maintenance procedures where such procedures have been established and
used successfully for this type of equipment.
4.3.3.2. Preparation for assembly:
 All gasket joint surfaces shall be clean and free of all foreign materials.
 Inspect gasket surfaces for defects or damage that may hinder proper sealing of the gasket.
Suspect areas should be repaired prior to assembly of the joint.
 Nut faces and the flange or washer surfaces where the nut face bears should be clean and smooth.
If roughness, burrs, or surface irregularities are present, these irregularities should be dressed out
to provide as smooth a surface as possible.
 Threads on studs and nuts shall be cleaned. Thoroughly lubricate threads on studs and nuts as well
as contacting surfaces on which the nut face bears.
4.3.3.3. Assembly:
All bolted connections are to be tightened uniformly in a diametrically staggered pattern as shown on
the Bolt Tightening Pattern Sketch. Tightening to the listed torque values shall be achieved in multiple
steps as noted below, with each tightening increment performed in the same diametrically staggered
pattern.
This will ensure a uniform stress over the entire gasket surface. The procedure to use for tightening
bolted connections is as follows:
 The joint shall be snugged up squarely so that the entire flange face bears uniformly on the gasket.
 Tightening of the bolts shall be applied in at least three equal increments to achieve specified
torque values. It is suggested that 4 equal increments be used for bolt diameters above 2”.
 Alternatively, bolts can be tightened one flat at a time in a diametrically staggered pattern until
the specified torque is achieved.
If the bolted connection leaks, the nuts can be tightened in the pattern outlined on the Bolt
Tightening Pattern Sketch, one flat at a time. The spacing between the flanges must be equal
throughout the tightening process. This will ensure the gasket surface will not be distorted.
If a connection continues to leak, it must be disassembled and examined for the following:
 Indication of a leak path, such as a gouge across the gasket surface.
 Evidence of an interference between the mating connections.
 Evidence of distortion or out of roundness of either of the mating gasket surfaces. This is usually
best checked by measuring the gasket compression every 45 degrees around the gasket itself.
18
OPERATING AND
MAINTENANCE MANUAL
Thickness measurements should also be taken close to both the I.D. and the O.D. of the compressed
portion of the gasket to check against any possible rotation of the flange during bolt tightening.
 Evidence of bolt diameter reduction or "necking", which would indicate an overstressing of the
bolts.
In order to ensure that all bolted flanged joints remain tight, such joints should be tightened
uniformly
immediately after the equipment has been placed in service for the first time, and again after the
equipment has been operated at full load for the first time. It is recommended that periodic checks be
made during the first six months of operation to ensure proper tightness of all bolted joints.
Bolt Tightening Table:
Nozzl
Nozzl No. Of Load per bolt
Equipment e Rating Bolt Size
e Size Bolts kg(kN)
Mark
V-10635A/B/C/D A1 24” 900 20 2-1/2” 38846(380.95)
V-10721 A1 24” 1500 16 3-1/2” 82613 (810.16)
4.3.3.4. Bolt tightening pattern sketch
Bolt and nuts in a CRISS CROSS pattern using a minimum of four Torqueing passes.
a. Bring all nuts up snug-tight with a short wrench.
b. Torque to a maximum of 40% of the final torque value as shown in the drawingand in
accordance with a sequence of sketch 1 below.
c. Check the flange is bearing uniformly on the gasket.
d. Torque to a maximum of 70% of the final torque value given in the drawing.
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OPERATING AND
MAINTENANCE MANUAL
e. Complete the tightening to final torque value.

f. Tool Legacy Cross-Pattern Tightening Sequence and Bolt Numbering System
When Using a Single Tool.

Sequentially Clockwise Sequence for Ex.
For 16 No. of Bolts.
1-9-5-13 → 3-11-7-15 → 2-10-6-14 → 4-12-8-16
1-11-6-16 → 3-13-8-18 → 5-15-10-20 → 2-12-7-17 → 4-14-9-19
OR
Modified Sequence can may use, as below
1, 9, 5, 13, 3, 11, 7, 15, 2, 10, 6, 14, 4, 12, 8, 16
1, 17, 9, 5, 13, 3, 19, 11, 7, 15, 2, 18, 10, 6, 14, 4, 20, 12, 8, 16
4.3.3.5. Disassembly
Protection must be provided to assure that, on completion of bolt removal, parts will not fall free or
shift,
possibly leading to injury of personnel or damage to equipment. All mating flanges should be
adequately match-marked before disassembly is started. Bolts are to be loosened in the reverse of
the tightening process shown on the sketch.
4.3.3.6. Gaskets:
 Gasket selection should be in accordance with the original design.

 The use of a non-hardening compound is recommended to aid in holding the gasket in place
during bolt up. The use of masking tape or a hardening compound is not recommended. Gasket
surfaces must be inspected for cleanliness and absence of scratches, erosion, etc., before gaskets
are installed.
4.4. REPAIR OF EQUIPMENT

Periodic inspection of the equipment shall be carried out with necessary visual checks, NDE etc. in
accordance with all Local regulations and owner’s policies. Any failures/damage observed shall be
reported to the concerned authority immediately before proceeding for any repair work.
4.4.1. Scope:
These instructions cover the repair procedure of Vessel.
4.4.2. General:
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OPERATING AND
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Regardless of the size, the care must be exercised to ensure that the equipment is always evenly
supported during repair. Uneven support may lead to damage of equipment. Care must be exercised at all
times to ensure that there is no sudden shift or jerk can result in damage to the equipment.
4.4.3. Repair of Pressure Components (Shell/Dished End/Forgings)

Any failure, if observed, shall be immediately reported to Manufacturer. No repair shall be performed on
the equipment without detailed repair procedure from manufacturer.
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OPERATING AND
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5. INSTRUCTIONS ON USE OF EQUIPMENTS AND SAFETY MEASURES TO

FOLLOW AT OPERATIONAL STAGE OF EQUIPMENT
5.1. INSTRUCTIONS ON USE OF EQUIPMENTS:
 This Equipments have parts designed for pressure as mention in the document (as per 3.1) which
must not be exceeded during Normal Operation.
 During operation protection measures are to be provided to control and safeguard the pressure
vessel against over pressure and overheating. These protective measures and devices must remain
operative and in good working order at all times when the pressure vessel is in operation.
 As the equipment will operate at elevated temperatures, measures must be taken to protect
personnel from injury due to contact with the hot equipment. The equipment must not be operated
without these measures in place, as they would also serve to protect the equipment from excessive
heat input from a local fire and without this protection, the design basis of the system safety
pressure relief devices provided would be compromised.
5.2. SAFETY MEASURES
5.2.1. SAFETY MEASURES DURING INSTALLATION & COMMISIONING
 Use slings of suitable capacity for lifting the equipment.

 Avoid any impact or shock to the equipment.
 Install the pipelines such that in the event of stoppage of fluid flow, the equipment remains full.
This is to smoothen out the hammering effect when the fluid supply is restarted.
 Do not weld directly to the equipment pressure parts.
 Tighten the bolts for the piping connection using torque wrench / hydraulic bolt tensioner.
5.2.2. SAFETY MEASURES DURING OPERATION
 In case of leakage, kindly shut off the equipment immediately to avoid any damage.
 The outside surfaces of equipment may get excessively hot during operation. Direct contact with
the equipment can cause severe injuries.
 Before starting the operation, a check shall be made on all Over-pressure protection devices.
Required pressure relief devices and/or overpressure protection are properly installed and in place
prior to initial operation.
 The overpressure protection shall be under such positive control that the pressure in the
equipment cannot exceed the Maximum allowable working pressure (MAWP) at operating
temperature.
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OPERATING AND
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 The selection and installation of the overpressure protection devices shall be done in the piping
system by the Contractor/ Process Licensor in accordance with Local regulations and owner’s
policies.
5.2.3. PROTECTIVE MEASURES OF PERSONNEL AND GENERAL PUBLIC IN CASE OF EMERGENCIES
 In case of probable emergencies, alert shall be issued to general public as well as the site staff.
 Proper refuge area shall be provided for the personnel to avoid any hazards.
 Operating personnel shall always use personal protection devices like helmets, industrial safety
shoes, eye-glasses, masks etc.
 In case of leakage of lethal fluids/gases, the area nearby the equipment shall be evacuated and the
operation must be immediately stopped.
 All the safety measures and necessary permits in accordance with Local regulations and owner’s
policies shall be taken care by Contractor/ Process Licensor.
5.2.4. MEASURES TO PROVIDE ASSISTANCE TO THE AFFECTED OF EMERGENCY CASES
 Immediate medical attention shall be given to the affected individuals.

 First aid facilities shall be readily available along with suitable first aid training to the Personnel.
 All the local regulations shall be followed for providing assistance to emergency cases.
5.2.5. PERIODIC DIAGNOSIS (INSPECTION)
5.2.5.1. NECESSITY OF INSPECTION

Inspection of the vessel should be carried out for the following:
 To inspect, measure and record the deterioration of material and to evaluate present health
condition of Vessel and its components for their soundness to continue in service.
 To ensure operational requirements is achieved.
 To determine cause of deterioration and to advise remedial measures.
 To recommend and forecast short term and long-term repairs and replacements to ensure further
run lengths on the basis of economics and safety.
 To initiate procurement action of material to meet recommended repair/replacement needs.
 To inspect while the repairs are in progress and to accept after completion of repairs.
 To maintain up to date maintenance and inspection records and history of equipment
performance.
 To keep the concerned operating and maintenance personnel informed about the condition of
equipment.
 To ensure that Vessel is inspected as per schedule of inspection and the statutory requirements as
applicable.
5.2.5.2. FREQUENCY OF INSPECTION

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OPERATING AND
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Following factors in general govern the frequency of inspection:

 Rate of deterioration and remaining corrosion allowance.
 Past experience in similar type of service.
 Shutdown of the unit.
 Operating requirements such as desired cleanliness, fouling, maintenance of required
performance etc. After going through the service history card, a regular inspection schedule can be
drawn. To determine the expected life of Vessel
 , following factors should be taken into consideration: -
 Corrosion rate.
 Pre-determined frequency of inspection.
 Any likely changes in process parameters.
 Frequency of shutdown of the unit.
All those equipment which can be spared during operation of the unit should be covered under
preventive maintenance schedule. In case where the equipment cannot be spared during operation,
its inspection frequency will coincide with the shutdown of the unit. After the initial commissioning
of the plant, first inspection of the equipment will be carried out as per designers recommendations
or after one year of service whichever is less. In general, following frequency shall be adopted for
inspection, which can however be improved upon or modified depending upon service conditions
and inspection requirements and findings.
5.2.5.3. INSPECTION SCHEDULE

Inspection schedule shall be made by Inspection in consultation with Process, Production and
maintenance departments. In the beginning of the year, this inspection schedule shall be circulated to
all concerned departments and the Vessel should be attended as per agreed schedule. Every effort shall
be made to schedule inspection evenly taking into consideration the monsoons and shutdown of
various units.
5.2.5.4. ON-STREAM/ IN-SERVICE INSPECTION
 Inspection is to be carried out for possible leaks from the flange.

 Conditions of ladders, platforms, foundation, pipe connections, fittings, paint, are to be inspected
during operation of equipment.
 Ultrasonic thickness measurement is to be carried out for operating temperature less than 70°C to
save time during shutdown.
 A record of condensate pH, Fe & Cu ppm is to be maintained as per on stream inspection manual.
5.2.5.5. INSPECTION OF GASKETS
 The new gasket should be thoroughly checked for scratches and damage surface.
 Gasket should be properly positioned before tightening of bolt.
 The use of particular type of gasket as specified by manufacturer is to be ensured.
24
OPERATING AND
MAINTENANCE MANUAL
5.2.5.6. INSPECTION OF VESSEL.

The gasket seating surfaces of Manways shall be cleaned thoroughly using chloride free solvents
and mechanical tools. After cleaning, these shall be checked by liquid dye penetrant/ magnetic particle
testing and offered to inspection for witnessing.
5.2.6. TRANSPORTATION
Prior to any planned lifting of Vessel, the site engineer should review the general assembly drawing and
transportation drawing. This drawing contains the necessary data to plan normal lifting of the Vessel.
This information consists of the following items:
 Empty weight of the Vessel in kilogram.
 Location of the longitudinal center of gravity.
 Lifting trunnions and tailing Lug on the equipment.
5.2.7. PACKING, CONSERVATION AND STORAGE CONDITIONS.
 Vessel shall be purged with Nitrogen, seal all the openings & maintain positive pressure of 0.5-0.7 bar
(g) if required to be stored after completion of site work.
 Equipment shall be stored in a dry area and shall not be exposed to direct sunlight.
 All the nitrogen shall be removed before opening any part of the Vessel.
 Before putting the Vessel for use again, it shall be thoroughly inspected for any defects/corrosion
during storage.
5.2.8. TECHNICAL EXAMINATION

During the vessels operation, they shall undergo a technical examination with the following periodicity:
By a specialist responsible for production control over the vessels operation together with a person
responsible for good condition and safe operation:
- external and internal examination - at least once every 5 years;
- hydraulic test with testing pressure - at least once every 10 years.
By a specialist of authorized company (if the vessel is subject to registration in Rostekhnadzor):
- external and internal examination - at least once every 5 years;
- hydraulic test with testing pressure - at least once every 10 years.
5.3. HYDROSTATIC TESTING

• The hydrostatic test pressure of the equipment is stated on equipment's nameplate and in the
General Arrangement drawing.
• Under no circumstance is the hydrostatic test pressure to be exceeded. Verify test pressure stamped
on the equipment nameplate prior to any field hydrotest. The recommended minimum metal
temperature during hydrotest is indicated in the General Arrangement drawing. Verify test temperature
prior to any field hydrotest.
• The chloride content of water shall be limited to 20 ppm.
25
OPERATING AND
MAINTENANCE MANUAL
• After filling the equipment with test water, hold for at least one hour, drain a sample and check the
temperature to ensure that it is higher than the minimum recommended hydrostatic test temperature.
5.3.1. SAFETY MEASURES DURING HYDROSTATIC TESTING
 The hydrostatic test shall be carried out with proper cordoning.

 Check properly all fitting and direction of valves before pressurizing the equipment.
 Pressure is to be applied at a steady rate. In no case should the vessel be subjected to a sudden
pressure surge. It is recommended that a relatively small capacity pump be used to apply hydrostatic
test pressure.
 During the test, area where test is performed shall be accessible by authorized personnel only.
5.3.2. DRAINAGE AFTER HYDROSTATIC TEST
 Following hydrostatic testing, the equipment shall be thoroughly drained and dried out. The
equipment shall be completely dried by passing dry air for sufficient time until no further increase in
relative humidity of outgoing air is observed.
26
OPERATING AND
MAINTENANCE MANUAL
6. INTENDED RESOURCE CHARACTERISTICS DEPENDING ON DESIGN FEATURE
 Intended service life for the equipment is 20 years. The service life can be extended subjective to
proper maintenance and periodic inspection.
 Periodic check on the thicknesses of main elements shall be made. The equipment can remain in
service until the specified corrosion allowance mentioned in GA drawing is not exceeded.
 Upon completion of service period, the equipment shall be immediately withdrawn from service.
 The withdrawn Vessel shall be completely inspected and decision shall be taken whether replacement
or repair is required.
 In case of replacement, old Vessel shall be suitably disposed off in accordance to local laws.
 The service life shall also be in accordance with local regulations and owner specifications.
27
OPERATING AND
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7. CAUTION: LIST OF ERRONEOUS ACTIONS RESULTING IN BREAKDOWN OR

INJURY
 Resting the complete equipment on transportation skid in vertical erected condition will cause the
equipment to topple. The skid is meant for rotation of equipment only. The equipment shall rest
on saddles only. (See transportation drawing for instructions).
 Touching the surface of equipment during operation may cause severe burn injuries to operator
as the operating temperature is very high.
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OPERATING AND
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8. ACTION REQUIRED IN CASE OF ERRONEOUS ACTION
 In case of leakage due to pressurizing of the equipment, the equipment shall be stopped
immediately. The components in question shall be thoroughly inspected and suitable
replacements shall be done in case of failure in consultation with Original Equipment
manufacturer (OEM).
 In case of accident during transportation, the equipment shall be thoroughly inspected for
damage and suitable repair work shall be carried out in consultation with OEM.
 In case of burn injuries due to hot surfaces, immediate medical help shall be given to the
personnel depending on the severity of the burn.
 All the necessary actions taken shall be in accordance with local regulations and owner’s
specification.
29
OPERATING AND
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9. CRITERIA OF LIMITING STATES
 Following are the limiting states of the equipment beyond which the equipment may not operate
safely:
 The equipment is designed to operate at the pressure not more than the MAWP stated on the
drawing/Nameplate. Also, the operating temperature shall in no case exceed the design
temperature stated on the drawing/ Nameplate.
 The mechanical wear (corrosion) is the major part limiting the operation of the equipment. When
the actual corrosion exceeds the specified corrosion allowance on the drawing, the limiting state
of equipment is reached. Further usage of the equipment shall be stopped.
 The equipment shall not be continued in operation if any visual deformation, crack, bend etc. is
observed.
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OPERATING AND
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10.INSTRUCTIONS ON WITHDRAWAL FROM OPERATION AND DISPOSAL
 In case of withdrawal from operation, it shall be made sure that the equipment is depressurized and
free from hazardous fluids.
 After the withdrawal of pressure, the equipment shall be suitably disposed off i.e. recycle the metal
in accordance with local regulatory authority guidelines or owner’s specification.
 The disposal of the equipment is sole responsibility of owner/contractor.
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OPERATING AND
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11.INFORMATION ON COMPETENCY OF SERVICE STAFF
 The Equipment must be operated by sufficiently experienced and qualified personnel, in accordance
with national regulations, the safety standards of the user.
 The filling, connection and disconnection of the vessel must be carried out by qualified personnel in
accordance with national regulations and in compliance with the user’s safety and maintenance
standards and procedures.
 The equipment operator must be well conversant with the local safety regulations.
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OPERATING AND
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12.THE NAME, LOCATION AND CONTACT INFORMATION OF THE

MANUFACTURER
o MANUFACTURER:
o Authorized Person: Paresh Nerurkar
o Location: Plant 15, Godrej and Boyce Mfg. Co. Ltd,
Pirojshanager, Vikhroli (East)
Mumbai – 400079
o IMPORTER:
PSS Netherlands
BV Sharjah Branch, JI-2044
o FOR:
Thai Oil Public Company Limited
Clean Fuels Project-Thailand
33

Vendor Document Cover Sheet: Unit 10600 WBS

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VENDOR DOCUMENT

Project No: R1118111 UNIT 10600 WBS C03

Project Name: CLEAN FUEL PROJECT

TOP PO No.: N/A

PO Description: CS & Cr-Mo Vessels Thick Upto 80mm

Material Type: VES

Requisition No.: R1118111-00000-MS-REQ-20008 Rev.0

Vendor Name: Godrej & Boyce Mfg. Co. Ltd.

Sub Vendor/ Sub Con. -

Godrej & Boyce Revision A B C D E

DOCUMENT STATUS SIGNED DATE

REVIEWED WITH COMMENTS AS NOTED. COMMENTS SHALL BE

C3 - REJECTED DO NOT PROCEED WITH FABRICATION

C4 - RECEIVED FOR INFORMATION ONLY

SCF - SUPPLIER CERTIFIED FINAL

3. INFORMATION ON DESIGN, PRINCIPLE OF OPERATION OF EQUIPMENT

Design Code : ASME Sec. VIII, Div. 1 [ Edition: 2017 ]

Equipment No. Description Units Value

External Design Pressure bar (g) 1.03 (F.V.)

Design Temperature for Internal Pressure & External Pressure °C 343

V-10614 Operating Pressure bar (g) 24.7

Operating Temperature °C 273

MAWP (Internal/External) @ Design Temperature bar (g) 37.991/1.03

MAP(New & Cold) bar (g) 38.739

Internal Design Pressure bar (g) 39.4

Design Temperature for Internal Pressure & External Pressure °C 468

Design Temperature for Internal Pressure & External Pressure °C 255

MAWP (Internal/External) @ Design Temperature bar (g) 44.78/1.03

Internal Design Pressure bar (g) 35

External Design Pressure bar (g) 1.03 (F.V.)

Design Temperature for Internal Pressure & External Pressure °C 150

MAWP (Internal/External) @ Design Temperature bar (g) 35.917/1.03

MAP(New & Cold) bar (g) 39

Internal Design Pressure bar (g) 105

External Design Pressure bar (g) 1.03 (F.V.)

Design Temperature for Internal Pressure & External Pressure °C 155

MAWP (Internal/External) @ Design Temperature bar (g) 107.1/1.03

MAP(New & Cold) bar (g) 114.938

Internal Design Pressure bar (g) 37.2

External Design Pressure bar (g) 1.03 (F.V.)

Design Temperature for Internal Pressure & External Pressure °C 370

Operating Temperature °C 234

MAWP (Internal/External) @ Design Temperature bar (g) 38.175/1.03

MAP(New & Cold) bar (g) 50.423

Internal Design Pressure bar (g) 158.6

External Design Pressure bar (g) 1.03 (F.V.)

Design Temperature for Internal Pressure & External Pressure °C 150

V-10721 Operating Pressure bar (g) 144

Internal Design Pressure bar (g) 3.5

External Design Pressure bar (g) 1.03 (F.V.)

Design Temperature for Internal Pressure & External Pressure °C 500

V-14181 Operating Pressure bar (g) 0.05

MAP(New & Cold) bar (g) 11.2

Skirt & Lifting Attachment Detail

3 Nozzle Details Drawing R1118111-S30015-VES-V10614-20007-B02 6VL-DA-067 3 of 7

4 Details Of External Attachments 1 R1118111-S30015-VES-V10614-20008-B02 6VL-DA-067 4 of 7

5 Details Of Internal Attachments R1118111-S30015-VES-V10614-20009-B02 6VL-DA-067 5 of 7

6 General Notes R1118111-S30015-VES-V10614-20010-B02 6VL-DA-067 6 of 7

7 Details Of External Attachments 2 R1118111-S30015-VES-V10614-20008-B02 6VL-DA-067 7 of 7

1 General Arrangement Drawing R1118111-S30015-VES-V10708-20005-B01 6VL-DA-068 1 OF 6

Support Lugs & External

3 Nozzle Details Drawing R1118111-S30015-VES-V10708-20007-B02 6VL-DA-068 3 OF 6

Internal Attachments & Nozzle