Chapter

1
Online Box up

1.0
1.

Introduction
Online Boxups are carried out to rectify leakages from weld joints, valve
bodies / bonnets / glands, flanges or process lines by installing the boxup arrangement at the source of leakage to save production loss.
Installation of box up arrangement at heat treated / stress relieved
lines, valves or equipment (s) is limited and subject to the approval of
Sub SOC(M).

2.

The box up is carried out by Equipment Maintenance however following

sections have been assigned the functions as given below:

I.

Project Engineering Section is responsible to carryout the

engineering and provide design for boxup arrangement if required.
This design is reviewed/approved in Sub SOC (M) meeting.

II.

Fabrication Shop and Machine Shop provide assistance to fabricate

the boxup arrangement.

III.

Inspection Section is responsible of Inspection / test (s).

3.

Area Engineer Equipment Maintenance is responsible for coordination

and follow-up with different Sections.

4.

Depending upon the requirement and nature of leakage, one of the under
mentioned methods is used:-

Sealant Filled Boxup

Welding Boxup

Boxup of online leakages checklist CK-4.09-003-XX-306 (Latest

revision) is filled before proceeding with online boxup.

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Chapter 1Online boxup

Sealant Filled Boxup

5. If the leakage from a flange is not removed by tightening or replacement
of bolts and isolation is not possible then a clamp is required to box up
the leaking flange.
6.

As mentioned earlier clamp design is provided by Project Engineering

against a verbal request from Maintenance. Design / material of clamp is
reviewed, discussed & approved by Sub SOC. (M).

7.

Area Engineer sends MWRs to fabrication Shop / machine Shop for

fabrication / machining of clamp as per drawing. Area Engineer
coordinates and maintains follow up of the above activities. Final
dimensions are confirmed in the field to avoid problems at the time of
installation.

8.

Before installing Box up arrangement, flange and clamp is cleaned

properly. Gland packing is inserted in the groves (if applicable). Clamp is
installed onto the leaking flange and clamp nuts are tightened evenly at
both ends.

9.

Sealant injection pump is hooked up at one of the Sealant injection hole

of clamp (rest of the holes are provided with bolts). Suitable Sealant
according to the process conditions is injected (as per check list CK-4.09003-XX-306 latest revision for box up of online leakages). More than one
injection points are used for larger clamps so that sealant is injected
equally around the flanges.

10. Sealant injection is continued using different injection points until the
inner space of clamp is completely filled and the leakage is removed.
11. Cap nuts with copper washers are provided on flange nuts, in case
leakage establishes a path through them.
12. If cap nuts / copper washers of proper size are not readily available then
nuts / bolts are seal welded.
Welding Box up
13. Box-up by welding pad / sleeve with nipple is employed to remove
leakages that can not be rectified by peening / welding.
14. Small pad, sleeve (in two halves) can be used to box-up, depending upon
the situation. Valve and nipple assembly is also required to drain / vent
the condensate / vapors. Material and thickness of pad / sleeve is always
in accordance with line specification and rating.
15. Inspection section measures the thickness at the area to be welded and
after comparing this with the actual thickness, size of the pad / sleeve is
selected so that it covers the whole affected area.
16. Welding procedure is provided by PTE(GM) / Inspection Sections.

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Chapter 1Online boxup

17. After selecting the size, pad / sleeve is fabricated. Its contour is matched
with the contour of line / valve as far as possible. In case of heavy / high
pressure leakage, valve and nipple assembly is welded on the pad /
sleeve. The pad / sleeve assembly is placed on the line / valve body and
welded as per proper welding procedure.
18. In case of a valve, if the leakage through the body is not removed by
above described means, then valve is boxed up completely
19. Box up arrangement is designed by Project Engineering against a verbal
request from Maintenance.
20. Design is reviewed / discussed & approved by Sub SOC (M).
21. Fabrication and machine Shops fabricate the box up arrangement against
MWR initiated by Area Engineer (E/M). Area Engineer is responsible to
coordinate and follow up the job.
22. After fabrication, box up arrangement is installed in the area. Proper
procedure is used for welding.

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Chapter 1Online boxup

CHECK LIST FOR BOX-UP OF ON LINE LEAKAGES

DATE:----------------------

TIME :-------------------AREA:------------------

JOB DESCRIPTION:---------------------------------------------------FOR INSPECTION & MECHANICAL :

1.

INSP.

MECH.

-------

-------

Procedure for box-up.

By clamp & sealant injection

By clamp and welding

-------

------

2.

Clamp/Sleeve design OK

-------

-------

3.

Type of sealant

-------

-------

o
o

Form - 2
Form - 4

o
o

Form - 3
Form - 5

4.

Line material OK for welding.

-------

-------

5.

Line thickness OK for welding.

-------

-------

FOR OPERATION

OPERATION

6.

Conditions OK for HOT work.

-------

-------

7.

Line contents OK for welding and

purging carried out (if required).

-------

-------

8.

Permission obtained from concerned

Production Manager.

(INSPECTION) (MAINTENANCE)

-------

-------

(SHIFT ENGR.) (UNIT MANAGER)

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Chapter

2
Hot Tapping
Introduction
1. This procedure is used to get an off - take or branch connection
from a process line or a vessel which is in service.
2.

Hot tapping is generally done on low and medium pressure lines.

Before hot tapping on any line, service conditions are discussed
between Process, Operation and Mechanical personnel, to ensure
that operating pressure & temperature are within the allowable
limits.

Hot Tapping is not allowed on lines containing flammable liquids / gases, below
atmospheric pressure or on lines containing a combustible mixture at any pressure.

Hot tapping is also not allowed on stress relieved Lines / Equipments.

3.

The location for Hot Tap is determined by suitability of space for

installation and operation of hot tapping machine. Hot taps upstream of
rotating machines / control valves are avoided.

4.

Concerned Area Engineer of Equipment Maintenance is responsible

for implementing the hot tapping procedure.

5.

Inspection section is responsible for inspection / test (s).

6.

Process and Production confirm suitability and location of hot tap.

7.

Production provides permit for Hot Tap after necessary preparations.

8.

As Hot Tapping is a critical activity carried out on a line or a

vessel which is under pressure, therefore, proper precautions are
taken and proper work procedure is followed to accomplish the
work safely

Installation / Welding of Hot Tapping Nozzle

9. The Hot Tap location is selected, keeping in mind that the hot tap
machine can be installed and operated properly. Inspection section
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Chapter 2Hot Tapping

to check / scan the thickness of line where nozzle for hot tap is to
be welded.
10. Welding of hot tapping nozzle on the line is the most critical step
from safety point of view. In order to do this safely, ensure that :I.

The line does not contain a combustible mixture.

II.

The pipe wall is of adequate thickness to permit welding

without burning through the pipe wall.

III.

The flow is maintained in the line to dissipate heat from

welding.

IV.

The line does not contain a material that can decompose

during hot tapping activity.

11. Ensure material, size and rating of nozzle is in accordance with line
specifications (length of nozzle is kept at minimum possible). Weld
the hot tapping nozzle on the line / vessel as per welding procedure.
12. The nozzle is accurately aligned with the flange face parallel to the
pipe axis with a diametric tolerance of 1/32 of an inch (0.795mm).
The center line of the nozzle accurately intersects the center - line
of the pipe longitudinally. For angled branch connections nozzle size
shall be at least one pipe size smaller than the main line size.
13. All the welds are full strength welds. If specified on the drawing, install
reinforcing pad.
Installation of Tapping Valve
14. Ensure that size, rating and material of valve is in accordance with
the line specifications.
15. The tapping valve to be used must provide a clean full-round opening
at least 3.20mm larger than the OD. of the specified cutter.
16. Install the valve using new gasket as per required specifications.
Before starting the actual hot tapping Operation, hot tapping check
list (Production / Mechanical / Inspection) CK-4.09-002-XX-346) and
Mechanical Check List For Hot Tap CK-4.09-001-XX-306 latest
revision are filled and signed by relevant sections. Operation Dept.
keeps the record of Check Lists in original and copy is retained by E/M
Section.
Tapping Operation
17. Install the tapping machine with proper adapter on the tapping
valve. The machine is adequately supported in order to prevent
over-stressing the hot tapping nozzle. The bleeder of the machine

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Chapter 2Hot Tapping

is positioned downward to drain the adapter & machine when the

hot tap is completed.
18. Extend the boring bar until the pilot makes contact with the pipe
wall then withdraw the bar completely and close the valve as a
safety check on clearance.
19. If the fluid in the line is above 260 0C or contains hydrogen or H2S,
then purge the hot tapping machine with some inert gas like
nitrogen through the bleeder connection. If purging is not required
then proceed further.
20. Fully open the tapping valve and advance the boring bar until the
pilot drill makes contact with the wall. Set the feed indicator scale
at zero and start the cutting operation. The depth needed to make
the cut depends on the main line size and thickness. (Calculate the
amount of travel necessary to complete the cut before starting
cutting operation).
21. When the pilot drill penetrates the pipe wall, close the tapping
machine bleeder valve. Continue the drilling until the feed indicator
shows the required depth has been reached.
22. Run the machine a few turns after the cut is complete to remove
burs, but ensure not to exceed the allowable travel to avoid
approaching the opposite wall of the pipe. In addition to monitoring
the machine setting, completion of the cut can be determined by a
reduction in resistance to hand cranking or a speeding up of the
air motor. On power driven tapping machine, shut off the air and
advance the cutter manually, if the cutter moves freely, the cut is
complete.
23. Retract the cutter and close
adapter and tapping machine
machine carefully and safely,
trapped gas is H2S, purge
personnel protective are used.

the tapping valve. Depressurize the

through the bleeder valve. Drain the
specially if it is a toxic gas. If the
the system carefully. Ensure proper

24. After depressurizing, remove the tapping machine. If the permanent

tie-in is not immediately required, install a blind flange on the
valve.

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Chapter 2Hot Tapping

CK-4.09-001-XX-306

MECHANICAL CHECK LIST FOR HOT TAP

Sr.
No.
1

CHECKPOINTS

YES

NO

REMARKS

Tapping machine is in working condition and

service conditions are not above the rating of
the machine

------- ------2

Adapter is of proper rating & length so that hot tap

can be done in the available boring bar travel

------- ------3
4

Drilling edge of cutter is sharp, properly angled

& free of brazing welding defects

------- -------

Availability of adequate space around the

tapping machine to avoid any obstruction to hot
tap operation or boring bar travel

------- ------5

Machine has been adequately supported to

prevent overstressing of nozzle or equipment
being tapped

------- ------6
7

Stub nozzle has been accurately aligned with

flange face parallel to axis

------- -------

Maximum
diametric
tolerance

Minimum clearance between cutter O.D. & entire

path of travel of cutter is 1/8". Physically confirm
this clearance by lowering the cutter upto the
point where pilot drill touches the pipe surface.
Ensure availability of adequate boring bar travel
as given below:

------- -------

a) Add nozzle length to valve length required to

clear pilot drill from valve seat. Further add
tapping cut distance. Let this be equal to X.

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Chapter 2Hot Tapping

CK-4.09-001-01-306
Sr.
No.

CHECKPOINTS

YES

NO

REMARKS

b) Physically crank pilot drill

Do not
measure the available cutter travel
exceed
from pipe surface to maximum ------- ------- opposite
pilot drill retrieval point so that
travel to cut
valve can be closed. Let this be
on wall of
equal to 'Y'.
pipe
C) Ensure that 'Y' is greater than
'X'
------- -------

___________
Date:

__________________
Name & Signature of
Technician

__________________
Signature of E/M Area
Engineer

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Chapter 2Hot Tapping

CK-4.09-002-XX-306

HOT TOP CHECK LIST

(PRODUCTION / MECHANICAL / INSPECTION)

Hot tap approval by Unit Manger

Line contents OK for hot tap

Line material & thickness OK

Operating conditions OK for hot tap

Location of hot tap OK

Conditions OK for hot work

permit issued

Welder qualified & understands

proper welding procedure

Fire extinguisher & Scott air packs

(when required) at job site prior to
start of welding

Mechanical check list (CK-4.09-001XX-306) is complete

10

If line temperature is above 500 0F or

if line contains H2, with tapping
connection is purged with inert gas

Checked by
Production

Checked by
Maintenance

Verified by
Inspection

Yes / No

Yes / No

Yes / No

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

-------------- --------------

--------------

and

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Chapter 2Hot Tapping

CK-4.09-002-XX-306

11

Checked by
Production

Checked by
Maintenance

Verified by
Inspection

Yes / No

Yes / No

Yes / No

When cut is complete, toxic material

is vented through hose to safe
location and tapping connection is
purged with inert gas

-------------- --------------

--------------

PROD.____________ MECH.______________ INSP.___________

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Chapter

3
Exchanger Repair
1.

Erect scaffolding at required places.

2.

Remove end/head cover(s) by opening studs/bolts using appropriate

tools and hoisting equipment.

3.

Remove internals (if required).

4.

Clean tube sheet.

5.

Install blinds /test rings and hook up leak test assembly to carry out leak
test.

6.

Production unit will pressurizes the exchanger.

7.

Inspection section will identify the problem area.

8.

Repairs are carried according to one of the following procedures.

Tube Leakage
9. Arrange plugs in specific size and material.
10. Plug both ends of the leaking tube (s) using relevant procedure (s) welding or any other.
Tube - Tube Sheet Joint Leakage
11. If leakage is through tube to tube sheet joint of one or more tubes, first
grind strength welding all around the tube end up to the sound surface of
tube sheet with the help of pencil grinder and cutting burrs.
12. Inspection section identifies the leaking point.
13. Weld the ground portions according to the welding procedure provided.
Tube Sheet Ligament Crack Repair
14. If inspection / tests reveal that the crack (s) are in the tube sheet
ligament, first grind the tube sheet at crack location so that the crack is
completely removed. Manufacturer is also consulted if required.
15. Inspection section will carry out liquid penetrant test to ensure that
grinding to the sound metal has been achieved.

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16. Clean the ground surface (use acetone for urea grade and titanium
material).
17. Weld the tube sheet ground portion according to welding procedure
provided for the purpose.
18. After repairing leakage points using above mentioned repair procedure
(s), Inspection section will again perform leak test to ensure that the
leakage has been removed.
19. Before boxup ensure that all the seating and sealing surfaces are clean
and free from scratches or other defects.
20. Clean studs/bolts and apply molykote or anti-seize on stud bolts.
21. Use new / reclaimed gaskets and place / fix them on their position.
22. Tighten stud / bolts according to standard tightening sequence and
torque. Any overlap of head covers/flanges should be checked and
corrected at this stage.
23. Remove isolation blinds and boxup nozzles using new/reclaimed gaskets.

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Chapter

4
Exchanger Cleaning
H.P. Jetting
1.

Erect scaffolding at both ends of the exchanger.

2.

Open studs/bolts of head covers and remove to ground.

3.

Isolate / cordon off working area to restrict unauthorized persons entry.

4.

Hang and firmly fasten canvas sheet or tarpaulin in front of tube sheet to
restrict the water jet coming out from the other end of exchanger

5.

Ensure process lines have been blinded or covered (if necessary).

6.

Hook-up H.P. jetting machine and accessories (both electrical and

fire/demin water connections).

7.

Ensure High tension electric cables of machine are routed safely.

8.

Apart from normal personal protectives use face shield, and protection
suit while doing H.P. jetting.

9.

Start and operate the H.P. jetting machine according to manufacturers

instructions.

10. One operator or attendant should always be available at H.P. jetting

machine and should follow manufacturers instruction to operate the
machine.
11. Carry out cleaning of all tubes with the help of high pressure water jetting.
The upstream pressure of jet should be in the range of 200-400 bar.
12. After satisfactory completion of cleaning, install blinds/test rings and hook
up leak test assembly to carry out leak test.
13. Production unit will pressurize the exchanger.
14. Inspection section will carry out the leak test.
15. If leak test is satisfactory, proceed further, other wise repair leakage point
as per Chapter 3.
16. After the leak test is clear obtain boxup permit.
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Chapter 4 - Exchanger Cleaning HP Jetting 15

17. Before boxup ensure that all the seating and sealing surfaces are clean
and free from scratches or other defects.
18. Install head covers using new gaskets, clean stud bolts and appropriate
hoisting arrangement.
19. Tighten fixed tube sheet side before floating side in exchangers of
floating tube sheet design.
20. Check and correct any overlap of head cover / flanges before final
tightening.
21. Tighten studs/bolts according to standard tightening sequence and
torque.
22. Remove isolation blinds.
23. Check nozzle flange gasket facings are clean and scratch free.
24. Boxup nozzles, using new gaskets.
25. Remove scaffolding.

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Chapter

5
Exchanger Cleaning - Mechanical
Mechanical Cleaning Of Heat Exchangers With Cooling Water On Shell
Side
1. Erect scaffolding at both sides of exchanger (if required).
2.

Remove stud bolts of cooling water side nozzles and tube side nozzles.

3.

Place studs / bolts and RJ gasket (if any) properly in a tray and arrange
their cleaning.

4.

Unbolt saddle supports of exchanger (if exchanger is to be lowered to

ground level) and remove to ground using proper hoisting tools.

5.

Place the exchanger between two dead ends and fix the rear side of
exchanger with one dead end.

6.

Match mark shell flange and channel.

7.

Remove end/ head cover (s) by opening studs / blots using appropriate
tools and hoisting equipment.

8.

Attach pulling slings with tubesheet with the help of eyebolts screwed into
tube sheet.

9.

If the tubesheet does not have the tapped holes or they have been worn
out, a sling is passed through tubes. A bearing plate or wooden log is
placed under the slings on the tube sheet face (to avoid damage to tube
end.).

10. The tube bundle is pulled with wire jack, come along or chain block using
sliding support trolleys and placed on the ground for cleaning.
11. Clean the tube bundle thoroughly using scrapers, water jet etc. SS
scrapers are used for SS tube exchangers.
12. After the tube bundle is satisfactorily cleaned, place it on the sliding
saddle and align it with the shell.
13. Before inserting tube bundle back in the exchanger , check and ensure
the following:I.

Orientation of the bundle.

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Chapter 5Exchanger Cleaning - Mechanical

II.

It is not being inserted topside bottom i.e. 180 deg. rolled.

III.

It is properly supported.

IV.

The correct gasket between shell and bundle has been installed
before insertion of bundle, and gasket surfaces are clean.

14. Insert the tube bundle gently and carefully into the shell. Use two come
alongs or chain blocks in parallel.
15. Ensure equal force is applied on both the sides so that insertion of tube
bundle is parallel and it does not stick into the shell.
16. When the tube bundle reaches its position, install head cover (s). For
floating tube heat exchangers, always install fixed head side before
installation of floating side.
17. Ensure that:I.

Channel head orientation is correct.

II.

Gasket seating surface are clean and scratch free.

III.

Correct gasket in a good condition is used.

IV.

The flange gap is equal all around.

18. Install studs / bolts. Ensure that proper tightening sequence and torque is
applied to the bolts using appropriate tools.
19. Prepare the exchanger for hydraulic test by installing pressure blinds on
tube side, hooking up hydraulic test assembly and hydraulic pump.
20. Production unit will pressurize the exchanger. Eqt. Maint. will assist by
operating the hydraulic pump.
21. Inspection section will carry out the hydraulic test.
22. If hydraulic test is satisfactory, proceed further , otherwise repair leakage
point as per Chapter 3
23. Remove pressure blinds.
24. Lift the exchanger from ground and place it on the saddle supports with
the help of appropriate hoisting tools.
25. Install and tighten saddle support nuts after aligning the exchangers with
inlet /outlet nozzle.
26. Boxup all nozzles using new gaskets (or reclaimed ones in case of good
RJ), clean stud bolts and after ensuring that all surfaces are clean and
free from damage.
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Chapter 5Exchanger Cleaning - Mechanical

MECHANICAL CLEANING OF EXCHANGERS WITH COOLING WATER ON

TUBE SIDE
27. Erect scaffolding at both sides of exchanger (if required).
28. Remove end / head cover (s) by opening studs / bolts using appropriate
tools and hoisting equipment.
29. Clean tubes one by one using brushes of compatible material and size.
Use SS brushes for SS tubes.
30. After satisfactory cleaning prepare exchanger for leak test or hydraulic
test as required by inspection section.
31. Production unit will pressurize the exchanger. Eqt. Maint will assist in
operation of hydraulic pump (if applicable).
32. Inspection section will carry out the leak or hydraulic test as applicable.
33. If the test is satisfactory , proceed further , otherwise repair leakage as
per Chapter 3
34. Obtain boxup work permit.
35. Before boxup ensure that all seating and sealing surfaces are clean and
free from scratches or other defects.
36. Install end covers with appropriate hoisting equipment and using correct
gaskets and clean stud bolts.
37. Tighten fixed tube sheet side before floating side in exchangers of
floating tube sheet design.
38. Check and correct any overlap of head cover/ flange before final
tightening.
39. Tighten studs / bolts according to standard tightening sequence and
proper torque.
40. Remove isolation / pressure blinds.
41. Check that nozzle flange sealing faces are clean and scratch free.
42. Box up nozzle, using new gasket.
43. Remove scaffolding after the exchanger has been taken in service and
no leakage is observed.

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Chapter

6
Guide lines for working in
Confined Spaces
1.

Make all necessary arrangements as per relevant work instructions.

2.

Arrange ladders (Rope, wooden or steel), cradles and other items for
entry/access to repair location if applicable.

3.

Erect scaffolding inside the vessel, if required.

4.

Arrange two way communication between personnel inside and outside, if

required.

5.

Use special safety harness & ensure 2nd life line for working in vertical
vessels having single entry on top, if required.

6.

Prior to entry, ensure following as double check.

I.

II.

Isolation of equipment/vessel as determined by Production Unit.

Inside Skin temperatures at different locations/elevations is

bearable to human body.
III.

Purging/draining of vessel.

IV.

Fresh air circulation.

V.

Oxygen content is adequate.

VI.

Lighting (48 Volts or 220 Volts with ELCB) is adequate.

7.

Obtain vessel entry and work permits as per work permit procedure
depending upon nature of job (i.e., Cold & Hot).

8.

Light oxy-acetylene torch outside the vessel and then send inside. Bring
torch outside after heating/Cutting. Do not leave extinguished oxyacetylene torch/Hose inside.

9.

Ensure that welding lead and holder insulation is in perfect condition.

10. Keep one person as watchman out side the manhole while work is in
Progress. (The numbers may be increased depending on nature and type
of job).
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Chapter 6Guide Lines For Working In Confined Spaces

11. Carry out repair/Maintenance as per applicable procedure.

During Break hours, keep one person stationed on manway entry to
minimize chances of accidental entry.
12. Confined space entry is a restricted and controlled entry. Do not allow
unconcerned persons to enter.
13. Obtain special permission for using 220 V tools, involving Safety and
Production Unit.
14. Count Persons/tools before entry and after exist.
15. Clear out the vessel of all tools, consumable, foreign objects and
personnel prior to commencing the boxup

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Chapter

7
Removal and Reinstallation of
Control Valves and PSVs
1.

Erect scaffolding platform (if required).

2.

Before removing PSV ensure that its vent line is properly supported.

3.

Ensure that instrument connections have been removed in case of

control valves.

4.

Remove actuator before removing the valve if required.

5.

Open studs/ bolts and remove control valve / PSV using appropriate tools
and hoisting arrangement.

6.

While handling PSVs ensure that it is always vertical.

7.

Shift* Control Valve / PSV to instrument shop.

8.

Check and repair sealing surface (s) of line flanges if required.

9.

Shift Control Valve / PSV to field after repair / calibration.

10. Install control Valve / PSV using new gaskets, clean stud bolts and
appropriate hoisting arrangement.
11. Check flange misalignment and overlap and correct if necessary.
12. Tighten studs/ Bolts using proper tightening sequence and torque.
Shifting of Control Valves / PSVs from field to instrument shop is the
responsibility of instrument engineer during normal plant operations. During
T/As and shutdowns of duration six days (prod. to prod.) or more it is the
responsibility of concerned Equipment Maintenance Engineer.

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Chapter

8
Scaffold Erection
1.

Determine the size and strength of the scaffold to conform with the
required working space and expected working load.

2.

Ensure that scaffold material is in healthy condition and free of defects

that can pose a safety hazard. Pipes used are free of cracks, bends and
their ends are in original shape. Hinges and threads are not damaged/
slipping. Planks are free of cracks, knots and binding strips are intact.

3.

Check ground condition for erection of the scaffold. If ground is soft,

provide base plates/ sole boards underneath the posts (i.e. vertical
pipes).

4.

All the posts are in upright condition and all members (i.e. ties, bearers,
runners and bracing) are erected and fixed firmly.

5.

Where required the 1st bottom member (runner) is placed close to the
ground level and 2nd runner clears the man height.

6.

Tie up the scaffold with hand railings / permanent structure of the plant
(to enhance stability) where necessary.

7.

Provide planks on the working platform and tie up with binding wire or
with runners (i.e. horizontal pipes) and enclose the platform with safety
railings.

8.

Provide rungs/steps to access working platform of the scaffold.

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Chapter

9
Maintenance of Level glasses
1.

Mark the leaking points.

2.

Ensure the isolating points.

3.

Tighten the bolts at vendor specified tightening torque.

4.

If leakage persist replace the glass(s) as per vendor procedure.

5.

In case of straight type glasses, loosen and remove cover.

6.

Check the condition of gasket, glass (s), mica sheet (if any) and seat of
body for erosion / corrosion.

7.

Is mica sheet, glass or gasket are damaged then replace with new one.

8.

Thoroughly clean all the parts of GLG.

9.

Assemble the level glass parts as per sequence given in the relevant
instruction manual.

10. Tighten the bolts in four steps at 20%, 40%, 75% and 100% of the given
torque value.
11. Use criss-cross tightening sequences starting from center to upper / lower
ends.
12. If after step # 4 there are pitting or erosion / corrosion marks on the
gasket facing remove flange bolts and shift the GLG to shop.
13. Remove the all glasses and send the body to Machine Shop for removal
of irregularities.
14. Repeat step # 7 to 10.
15. After assembling shift the level glass to site and install it at its location
with new gaskets.
16. Carryout hydraulic test of GLG if required.
17. Pre-heat the level gauge to eliminate the thermal stresses (if applicable).

FAUJI FERTILIZER CO. LTD

- 23 -

Chapter

10
Hot insulation
1.

Following instructions are followed for hot insulation work to be

carried out on equipment, piping and tanks, etc :-

2.

Use the correct thickness of Rockwell for hot insulation depending upon
the size of piping and temperature of fluid being handled. For selecting
the Rockwell thickness Insulation Thickness table-I is used.

3.

Apply the specified thickness of Rockwell around the pipe or equipment

firmly. Use annealed galvanized iron wire ( 1mm) for binding of
Rockwell.

4.

Cover the full length of pipe required to be insulated with Rockwell.

5.

Prepare/fabricate metal jacketing from aluminum sheet. Roll the metal

jacketing as per dia of piping or equipment. Fabricate boxes for valves,
flow transmitters, line flanges, etc. For piping upto dia 24 inch, 0.6mm
thick aluminum sheet is used. For piping dia greater than 24 inches and
for all equipments 1mm thickness aluminum sheet is used.

6.

Install prefabricated aluminum pieces onto the Rockwell. Use stainless

steel self-tapping screws for fastening of jacketing sheets.

7.

Joints of aluminum jacketing are placed in such as manner that liquid

ingress is not possible.

8.

For stream traced SS lines pieces of asbestos sheet (3mm thk) are
placed between pipe and stream tracing line. For such lines 0.1mm
thickness aluminum foil is wrapped around the steam traced line before
applying the hot insulation.

FAUJI FERTILIZER CO. LTD

- 24 -

TABLE-I

INSULATION THICKNESS
PERSONNEL
PROTECTION

HOT INSULATION
OPERATING TEMPERATURE
0

UPTO 151
150 200

201
250

251
300

301
350

351
400

401
450

451
500

501
550

651 UPTO 301

700 300 400

401
500

UPTO
302

393
482

483
572

573
662

663
752

753
842

843
932

933 1023 1113 1203 UPTO 573

1022 1112 1202 1292 572
752

753
932

303
392

551
600

601
650

SIZE
INCH
1

30

30

30

30

40

40

50

50

60

60

60

70

30

30

30

30

30

30

40

40

50

50

60

60

70

70

70

30

30

30

30

30

40

40

50

50

60

60

70

80

80

90

30

30

30

30

40

40

50

50

60

60

70

80

80

90

90

30

30

40

30

40

50

50

60

70

70

80

90

90

100

110

30

30

40

40

40

50

60

70

70

80

90

90

100

110

120

30

30

50

10

40

50

60

60

70

80

90

90

100

110

120

130

30

40

50

12

40

50

60

70

70

80

90

100

110

120

120

130

30

40

50

14

40

50

60

70

80

90

90

100

110

120

130

140

40

40

50

16

40

50

60

70

80

90

100

110

110

120

130

140

40

40

50

18

50

60

60

70

80

90

100

110

120

130

140

150

40

40

50

20

50

60

70

80

80

90

100

110

120

130

140

150

40

50

50

22

50

60

70

80

90

100

110

120

130

140

150

160

40

50

50

24

50

60

70

80

90

100

110

120

130

140

150

160

40

50

50

26

50

60

70

80

90

100

110

120

130

140

150

160

40

50

50

28

50

60

70

80

90

100

110

120

130

140

160

170

40

50

50

30

50

60

70

80

90

110

120

130

140

150

160

170

40

50

50

32

50

60

70

90

100

110

120

130

140

150

160

170

40

50

50

34

50

60

70

90

100

110

120

130

140

150

160

170

40

50

50

36

50

60

70

90

100

110

120

130

140

150

170

180

40

50

50

EQUIP

50

60

80

90

100

110

120

130

140

150

170

180

40

50

50

INSULATION THICKNESS mm

FAUJI FERTILIZER CO. LTD

- 25 -

FAUJI FERTILIZER CO. LTD

- 26 -

Chapter

11
Cold Insulation

1.

Following instructions are followed for carrying out cold insulation on

piping and equipment :-

2.

Thickness of cold insulation for piping or any equipment is

determined on the basis of temperature and dia of pipe. For
selecting the thickness Insulation thickness Table-I is used .

3.

Polyurethane half sections are applied in single or multiple layers

(Multiple layer sections are used when thickness is greater than
60mm).

4.

Apply two layers of vapor barrier mastic with fiber glass fabric
(glass gauge) in between the layers.

5.

Apply 15-20mm thickness fiber glass blanket and compress it to

10mm. Finally the aluminum sheet is applied and fastened by
stainless steel self tapping screws or rivets. Thickness of aluminum
sheet used is 0.6mm for pipe dias over 24 inch and all other
equipments.

FAUJI FERTILIZER CO. LTD

- 27 -

TABLE-I

INSULATION THICKNESS
COLD INSULATION
OPERATING TEMPERATURE
0

+20
0

-1
20

-21
-40

-41
-60

-61
-80

-81
-100

-101
-120

-121
-140

-141
-160

-161
-180

+68
+32

+31
-4

-5
-40

-41
-76

-77
-112

-113
-148

-149
-184

-185
-220

-221 -257
-256 -292

SIZE
INCH
1

25

30

40

40

50

60

70

70

80

80

25

30

40

50

50

60

70

80

80

90

25

30

40

50

60

70

80

90

90

100

25

30

40

50

60

80

90

90

100

110

25

40

50

60

70

80

100

100

110

120

25

40

50

60

80

90

100

110

120

130

10

25

40

50

70

80

90

110

120

130

130

12

25

40

50

70

80

100

110

120

130

140

14

25

40

60

70

80

100

110

130

130

140

16

25

40

60

70

90

100

120

130

140

150

18

25

40

60

70

90

110

120

130

140

150

20

25

40

60

80

90

110

120

140

150

160

22

25

40

60

80

90

110

130

140

150

160

24

25

50

60

80

100

110

130

140

150

160

26

30

50

60

80

100

120

130

150

160

170

28

30

50

60

80

100

120

130

150

160

170

30

30

50

60

80

100

120

140

150

160

170

32

30

50

60

80

100

120

140

150

160

170

34

30

50

70

80

100

120

140

150

160

170

36

30

50

70

80

100

120

140

160

170

170

EQUIP

40

60

80

90

110

130

150

170

180

190

INSULATION THICKNESS mm

FAUJI FERTILIZER CO. LTD

- 28 -

Chapter

12
Coating And Wrapping
1.

Following instructions are followed for the coating and wrapping of under
ground lines using polyethylene coated tapes :-

Surface Preparations
2. Remove welding slag, sludge, rust and hard scale from pipe surface
using grinder, power brush, scraper, emery, etc. Use detergent or
kerosene to remove oil and grease.
Primer Application
3. Immediately after surface cleaning apply a uniform coat of primer
(bitumen + thinner) which is free of drippings and holidays. Always apply
primer on dry and clean surface.
Tape Application
4. When the primer is dried-out, apply the wrapping tapes in the following
sequence :
i.

ii.

Use the correct tape size selected from the following table.
Nominal Pipe Size

12

14-20

>20

Tape Size

4-6

12

Tape Overlap

1/2

3/4

1 1/2

Apply first layer of polyethylene anti rock tape (black).

iii. Apply second layer of polyethylene anti rock tape (white).

5.

Ensure recommended overlap of tape. Extra care is required when

coating the bends to avoid wrinkles.

6.

Be careful to avoid tape disbonding due to entrapped air.

7.

Visual check and holiday test to be carried out to ensure the coating
continuity by Inspection Section.

FAUJI FERTILIZER CO. LTD

- 29 -

Chapter

13
Refractory Repair & Insulation
1.

Following instructions are followed for the repair and installation of

refractory :-

2.

Inspect the refractory, to identify and mark the areas to be

repaired or reinstalled. In the reinforced casting, the presence of regular
cracks (even if deep) 1 - 1.5mm wide is normal, crack depth upto the
metallic shell is not acceptable. If the width is larger, break the castable
up to shell for a width including at least three anchors. Similarly areas
which are found defective or damaged greater than 150 x 150mm
are demolished / saw cut upto the shell for an area including at
least 3 anchors. Lining edge are cut slightly dovetail.

3.

Castable bags are stored in a shaded dry place. Castable is

inspected for any sign of hydration before using. Castable bags with
expired shelf life are not used. The entire bag is rejected if there
is evidence of partial set.

4.

A test panel is prepared for each type of castable material to be applied.

Test panel preparation and the required examinations are:i.

Size of test panel required is 900 x 900mm, with a lining thickness

and anchoring system equal to that specified for the installation.
The anchors are bolted to the form to permit removal of the panel
after the castable has been cured.

ii.

The panels are cured for 24 hours and hammer tested as per the
procedures given herein :-

a. The forms are disassembled and the panels used are crosssectioned (2-directions). There shall be no indications of voids,
laminations and honeycombs.
b. A section about 150mm square is cut from any one of the four cut
sections from each panel. These 150mm sections are then dried
for 18 hours at 1050C and weighed and measured to determine
density.
c. Three compressive strength and one linear change specimens are
cut from any one of the four cut sections of the panel. The
specimens are tested for compliance with the specified linear
change, and compressive strength.
FAUJI FERTILIZER CO. LTD
- 30 -

Chapter 13 Refractory Repair and Insulation

5.

Clean the shell surface before the castable installation. Install the
new anchors and coat them with bitumen mastic. Use clean tools
for casting.

6.

Ensure that forms / shuttering is rigid and well braced. Nonabsorbent materials such as ply-wool, steel, plastics, etc are used
for shuttering. Forms are made sufficiently tight and water proof to
prevent leakage. The surfaces in contact with concrete are uniform,
smooth and well oiled. Forms are constructed / assembled so as to
facilitate their removal without damage to the concrete.

7.

Demin or drinkable water is used for mixing. The quantity of water is

maintained according to the suppliers instructions. Mixing of the
charge is done by hand or using paddle mixture. Add 80% of
recommended water and mix for one minute. Stop mixer and check
consistency of the wet mix by means of the ball in hand test.
For this test make a ball of mixture in your hand and through it
upto a height of 300mm. If the shape of ball remains almost
unchanged ratio is correct. If the ball is deshaped it shows excess
of water in mixture. If the ball is cracked, it means mixture is dry.
Add remaining 20% water and continue mixing for 1-2 minutes.

8.

Refractory is not applied or poured when the metal surface

temperature exceeds 300C or below 50C. ICE is used to keep the
temperature of demin water below 25 0C. In cold weather warmed
demin water is used.

9.

Casting is executed with continuity. Edges of adjacent castable are

well wetted before repair. Castable is used within 20 minutes of
mixing. Material showing sign of setting is rejected. On vertical walls
casting is carried out from bottom to top. In multi-layers lining the
surfaces of restart casting, are not in the same plane.

10. Curing of casting is done for 24 hours with atomized water or

using wet jute-bags. It keeps casting moist during setting period.
Curing is started as soon as the exposed surface is hard enough
to permit spraying, without washing out the cement. Forms are
removed at least 12 hrs. after pouring. Afterwards 24 hrs. of air
drying Dryout and heating of casting is done as per recommended
procedure.
11. After dryout out and heating, repairs are checked through Hammer
test. In this test a 500 gms ball point hammer is struck over the
entire surface. The center spacing is kept approximately 500mm. If
problems are detected by hammer impact sound, closer spacing is
used to delineate the size of defect. Voids, hollow sounding areas
and any soft or dry fill areas that reduce the effective thickness is
repaired.

- 31 -

Chapter

14
Painting
PAINT:
This may be defined as any liquid material containing drying oils alone or in
combination with natural resins and pigments which when applied to a
suitable substrate, will combine with oxygen from the air to form a solid,
continuous film over a substrate. This provides a weather resistant decorative
surface. This also prevents corrosion or disintegration of the structure by the
environment.
Following general instructions are followed for various painting jobs.
Surface preparation:
All foreign matter having potential of negatively effecting paint adhesion and
painting result like grease, oil, petroleum, mill scale, old loose paint and other
substances are removed by using coarse cloth, emery paper, power brush or
sandblasting.
Primer application:
Application of specified thickness of primer on various steel surface
(structure, vessels, pipe etc.) is carried out according to manufacturers
specification. Dry film thickness should be checked. Primer may be applied
by brush and spray gun. Number of coats to be applied is determined by total
dry film thickness required as per recommendation of the manufacturer.
Paint application:
Application of specified thickness of paint on various steel surface (structure,
vessels, pipe etc.) is carried out according to manufacturers specification. Dry
film thickness should be checked. Paint may be applied by brush and spray
gun. Number of coats to be applied is determined by total dry film thickness
required as per recommendation the of manufacturer.
INSPECTION AND TESTING
The following inspection and testing shall be performed during and after
completion of application of paint system.
a)

Visual examination of surface preparation in accordance with Svensk

standard SIS 05.059.00 1967.

- 32 -

b)

Check drying time of primer, intermediate and topcoats in accordance

with the directions of the paint manufacturer.

c)

Check dry film thickness by suitable non-destructive method.

d)

Visual examination of appearance and uniformity of the surface

painted.

DEFECTS
If, during above inspections, painting or surface preparation defects are
observed, the job shall be redone to meet acceptable standards.
COLOUR

Colours for structure, Equipment, lines etc. of various services are selected
according to the Annex.I.
SURFACES NOT TO BE PAINTED
The following surfaces shall not be painted, except if specifically asked.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)

Concrete surfaces
Masonary surfaces
Aluminum surfaces
Galvanized steel surfaces
Stainless steel surfaces
Monel surfaces
Copper surfaces
Brass surfaces
Glasses of level gauges
Equipment nameplates
Piping and equipment to be insulated
Surfaces with concrete fireproofing

NOTE:Painting of prill tower, furnaces, tanks is carried out according

to Snams specifications GA-E-60718, GA-E-60701 & GA-E60719 respectively.

- 33 -

Annex.I
S.NO.
01

02

03
04
05
06
07
08
09
10

EQUIPMENT/LINE
Surface of uninsulated piping and
equipment
with
an
operating
temperature upto 70 oC.
(Fire fighting excluded)
Surface of uninsulated piping and
equipment
with
an
operating
temperature over 70 oC.
Piping and equipment for fire
fighting
Natural Gas Line
Uninsulated machinery with an
operating temperature upto 70 oC.
Uninsulated machinery with an
operating temperature upto 70 oC
Structural steel, pipe supports
Ladders,
stairways,
walkways,
handrails
Furnaces
Tanks

- 34 -

COLOUR
GRAY

CODE
RAL-7035

ALUMINUM

RAL-9006

RED

RAL-3002

YELLOW
GRAY

RAL-1016
RAL 7035

ALUMINUM

RAL-9006

GRAY
YELLOW

RAL-7010
RAL-1016

GREEN
GRAY

RAL-6021
RAL-7035

- 35 -