JUSTIFICATION FOR APPLICATION OF FLAME SPRAY ZINC ONTO WELDS OF

ANHYDROUS AMMONIA SERVICE VESSELS

BACKGROUND:
Since 2012, a large number of leakages have been found in tubes and tube to
tubesheet (TTS) joints of Methanator Feed/Effluent Exchangers (E-209A) due to which
large nos. of tubes have been plugged.
In order to identify root cause of problem, M/s Haldor Topsoe was consulted who
performed detailed engineering study of exchanger and declared existing design and
tube material satisfactory for the service. However, M/s Topsoe recommended
changing process configuration i.e. cold gas on tube side and hot gas on shell side to
keep tubes colder in order to avoid their buckling.
M/s Holder Topsoe recommendation has been further discussed in Plant Progress
Review Committee dated Feb 13, 2015 and the house has jointly agreed to implement
this modification in turnaround (TA-2016). Accordingly, mechanical package for
modification of piping scheme has been prepared and approved.
PRESENT SITUATION:
In order to change process configuration i.e. cold gas on tube side and hot gas on
shell side, piping modification will have to be carried out as per PTE mechanical
package and total 18 nos. of new weld joints will be included in 18"-P236-63D & 18"P238-63D lines out of which 14 nos. of joints will be Shop welded which will have to be
post weld heat treated as per piping specifications and ASME Codes.
RECOMMENDATION:
Inspection Unit has only one PWHT machine which fulfills PWHT requirements during
routine plant operation. Therefore, in order to performed PWHT of 14 nos. of 18"
weld joints it is imperative to take additional external PWHT services due to extensive
scope of PWHT. A formal purchase requisition is initiated to avail subject services.
Management approval is request for the same, please.
JOB SCOPE:
Post Weld Heat treatment of full circumferential welds of 18 Schedule XS pipes, as
per following procedure:
Heating Rate: 200 deg. C per hour
Soaking Temperature: 700~730 deg. C
Soaking time: 2 hours
Cooling Rate: 200 deg. C per hour up to 450C, then further cool under insulation up
to ambient temperature
RECOMMENDED VENDOR:
1. M/s Inspectest
2. M/s OAG Services
Email:oagsat@gmail.com
Cell# 03017614607
NOTES FOR THE VENDOR:
1. Vendor to clearly confirm the adequacy and compatibility of his heat treatment
machine at 03 phase 480V/60 Hz and also specify the input current of each
machine.
2. Atleast 02 numbers of PWHT Machines with crew, heating pads and other
accessories to be provided by the vendor each of which should have atleast 06
numbers of channels.

ASSISTANCE BY FFBL:
1. Power Supply
2. Scaffolding arrangement
SPECIAL CONDITIONS:
1. PWHT shall be performed in accordance with approved procedure of FFBL
2. PWHT shall be performed as per safe work practices / FFBL safety rules.