Final Presentation

Presented by: Low Choon Ping

ID: HR/BFI/ST/049
Trait: Mech. Static
Contents
• Replacement of Resin Filter – F5105B
• Inspection of Steam Coil at Urea Solution Storage Tank – T3601
Replacement of Resin Filter – F5105B
Equipment no.: MSF-0210, Cation Exchanger
Physical Location: Utility Demin
Problem Description: ALS Finding
Job Description
• Scaffolding Required
• Crane Required (120 tonne)
• CFE Involved
• Removal of accessories by Electrical & Instrument Teams
• Rubber gasket for manhole & nozzle
Resin Filter/Cation Exchanger
• Vessel to contain resin.
• Consists of bottom plate, top basket and vortex breaker.
• Mushroom filters are installed on bottom plate and top basket.
• Shell are made of carbon steel.
• Basket and Plate are made of Stainless Steel.
• Rubber linings are installed on the inner surface of the vessel.
Drawing of Resin Filter
Findings in the Resin Filter
• Resins in the filter has reached its limit in its usefullness (Expired).
• The rubber lining in the filter starts to harden.
• There are cracks at several areas of the rubber lining, allowing resins
to settle in and corrode the shell of the filter (Acid corrosion).
Management of Change (MOC)
Ventillation Plan
Inspection of Steam Coil at US tank – T3601
Physical Location: Vacuum Unit.
Problem Description: Suspected steam coil leaked.
Job Information
• CFE involved
Drawing of US tank
Troubleshooting method & findings
• Operation team fully opened the supply steam, closed the turn valve
and opened the drain valve. However, there is no steam coming out
of the drain line.
• Maintenance team opened the manhole cover and found crystalized
urea deposits at the bottom of the tank.
• Steam is used to remove the crystalized urea accumulated at the
manhole and dilute the urea solution in the tank before it is safe for
entry.
Possible Effects to T3601 due to leaking Steam Coil
• Urea solution starts to solidify due to insufficient heating.
• Increased in the crystalized urea deposits leads to pressure drop in
the tank.
• The vacuum breaker on the tank might not be able to handle the
large pressure drop and hence, the tank collapse.
• The leaking steam mixes with the urea solution and dilutes it,
affecting the efficiency of the whole processes.
Failure history of T3601 and mitigation
May 2012
• Vacuum breaker’s internal chamber were clogged with urea solution
deposits and prevents it to function properly.
• Vacuum occurs inside the tank and causes it to collapse.

Mitigation method
• Developed 6 month PPM & checklist for all VB.
• Service all remaining VB & SV.
• Complete ERS (Equipment Reliability Service) & Maintenance Plan for
VB & SV.