SCHEDULE SCOPE

14/10/2016 10:27:34AM
UNIT: A102-SOUTH-U6600 UNIT NAME: MOGAS ALKYLATION
FLOC: A102-C6604 FLOC NAME: HF STRIPPER COLUMN
EQUIP ID: C6604 EQUIP NAME: HF STRIPPER COLUMN
LEGAL REG: REG AGENCY:
INSP SCHD ID: CAIR00007892 SHELL REG NO: 20020631

CAIR7892: Weld Repair to C6604 E4 Nozzle [TA]

DETAILS OFFLINE? YES
LAST INSP DATE: SCHD CAT: CATEGORY 1 INTRUSIVE? NO
NEXT INSP DATE: 31/10/2016 RESP DISC: ME AND EI RECURRING? NO
USR NEXT INSP DT: 31/10/2016 SCHD DRV: RECOMMENDATION STATUS: FINAL APPROVAL
TM INTRVL INSP DT: TIME INTRVL: SAP RELEASE DATE: 13/10/2016

COMP ID: GENERAL MECH: MECH TYPE:

ACTIONS

DETAIL CTGRY DETAIL NAME QUALIFIER DETAIL VALUE UOM

NARRATIVE
Condition as Found:
2 x transverse linear indication found at 6 o'clock position on WNF to nozzle neck weld on DN350 E4 nozzle on C6604, 20mm and 12mm length respectively. 2 x
transverse linear crack found on internal side of nozzle with MPI. Linear indication extends on internal side through weld metal into parent metal.
Nominal thickness of nozzle neck is 12.7mm. Linear indication was ground to a depth of 5.4mm internally and still existed in both weld metal and parent metal.
The region where linear indication existed had a very fine brown scale on external side of nozzle. Paint was removed at location and area was MPI on external side
of nozzle weld and linear indication was found, approximately 10mm long in weld only. This indication has propagated through the full thickness of the weld from ID
to OD. No leak was detected OTR.

Recommendation:
CAIR7892: Weld Repair to C6604 E4 Nozzle [T/A]
RAM:3/E People
Target End Date: 31/10/2016

Specifications:
A job-specific Inspection and Test Plan (ITP) including all weld procedures and supporting qualification records shall be submitted to Viva Inspection and approved
prior to the commencement of any fabrication works.
A Manufacturers Data Report shall be submitted upon completion .
Reference Viva drawing T995901 for materials of construction and other fabrication details pertaining to C6604.
1. As of 13/10/2016, E4 nozzle has been ground with J-groove configuration internally to a depth of 5.4mm at location of transverse linear indication at 6 o'clock.
Continue grinding to a depth of 6.0mm with a 10.0mm flat landing centred over original weld (figure 2 in attachment). Edges of weld preparation shall be bevelled at
70deg.
2. MPI. Contact inspection. Intent is to see if ground area has removed linear indication in parent metal, and confirm linear indication only exists in original weld
metal and to define length. This must be noted prior to welding.
3. At acceptance of MPI, hydrogen evacuation, 150degC minimum for 30minutes.
4. Weld out internal in accordance with WPS . Low hydrogen electrode shall be used.
5. Grind out on external side of weld. Grind to width of existing external weld cap, minimum depth 6.0mm. Bevel angle shall be dictated by the known width of linear
indication which was welded over from the inside. It may be necessary to increase ground out width/open up bevel angle.
6. MPI area externally ground. If indication exists, contact inspection.
7. Upon acceptance of MPI, hydrogen evacuation, 150degC minimum for 30minutes.
8. Weld out external in accordance with WPS . Low hydrogen electrode shall be only used.
9. MPI internal/external side cap. RT region where new weld metal has been deposited .
10. Upon acceptance of NDT, carry out local PWHT 650 DegC minimum for 1 hour hold time. Temperature shall be controlled from 300degC. Maximum
heating/cooling rate 200degC/hr.
11. Carry out hardness test, the hardness shall not exceed 248Hv10 in any area of weld.
12. MPI pad welded area after completion of PWHT and acceptance of hardness test .
13. PMI pad welded area and surrounding HAZ, minimum 4 areas.
14. Restore shell outside coating to GRAP 3.12.30 System M8.
15. Clock gasket face at completion of work to check for deformation.

Attachments:
L:\Engineering\Inspection\IDMS Documents\6600-C6604-CAIR7892-Oct2016.pdf

Signed Action Completed: Date:

REPORT ID:R407-2.4.2-31JAN2013 PAGE 1 OF 1