VISAKH REFINERY

FORMAT OF INSPECTION WORK LIST

TECHNICAL DEPARTMENT Doc. No. OCP/TSD/FR/305/Rev.2
Rev. Date : 16-Jan-02
(Ref. Pro.:OCP/TSD/PR/204)
Page 1 of 8

WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping Date: 23/04/2019 09:28
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK INSP. BY: B M JEELANI
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

10 74K-801A 1. 1” dia LO lines 2 No’s South side bolts were observed corroded. 1. Carry out replacement of corroded
bolts in kind.
2. Carry out welding of the U-Clamp
2.Pipe line U Clamp support weld was observed detached.
support.

20 74G-801A 1. 3” dia Lube oil line Pedestal support was observed corroded. 1. Carry out painting of the corroded
pedestal support.

2. ½” dia line connected to 3” dia lube oil line was observed corroded.
2. Carry out replacement of the ½¿ dia
line for approx...3mtrs.
3. ½” dia line from 3rd b/v of 3”-LO-3907-B1M observed with paint
failure.
3. Carry out removal of paint blisters and
carry out painting.
4. ¾” dia line from I/L of duplex oil filter valve wheel missing.

4. Carry out servicing of the valve and

5. Duplex oil filter was observed with paint failure. provide wheel.

6. Bolts connected to suction and discharge line of Duplex oil filter 5. Carry out painting on the Duplex oil
were observed corroded. filter.

7. Bolts connected to flange joints of TI 3939, TE 3906 were observed 6.Carry out replacement of corroded
corroded. bolts in kind.

7. Carry out replacement of corroded

bolts in kind.

Page 1 of 8 Tuesday, April 23, 2019

 WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

30 74E-801A 1. 2” dia Flare line (2”-FL-74-3903-A11A) was observed severely 1. Carry out replacement of the 2” dia
corroded at ground level. line up to first floor.

2. 2” dia line support angles were observed corroded at 4 No’s 2. Carry out replacement of the support
locations. angles.

3. 3” dia lube oil line (3”-LO-74-3901,2,3,4,5, - B1M) were observed 3. Carry out replacement of damaged
insulation damage. insulation.

40 74V-801A 1. 2” dia drain line severe corrosion scales were observed at the 1. Carry out replacement of the corroded
bottom. section.

2. 6” dia line (6”-RP-74-3901-IS) was observed insulation damaged. 2. Carry out removal of insulation and
offer for further inspection.

3. 2” dia lube oil line b/v bolts were observed corroded.

3. Carry out replacement of corroded
4. ¾” dia flare line from LT 3901 / LG 3901 to flare header at first
bolts in kind.
floor bottom embedded in concrete.

4. Carry out chipping and offer the line

5. Insulation damage was observed on 6” dia line (6”-RP-74-3902-
for further inspection.
B4A).

5.Carry out replacement of insulation.

6. ¾” dia connected to 6” dia line (6”-RP-74-3902/3-B4A) flange joint
bolts were observed severely corroded. U Clamp was observed
missing
6. Carry out replacement of the corroded
bolts in kind.
7. 3/4” dia line Severe corrosion was observed at Ground floor
location.
7. Carry out replacement of ¾¿ dia line
for approx.¿5mtrs.
8. ¾” dia line from bottom of 74V-802A drain take off line flange
observed embedded in soil. U Clamp was observed missing.
8. Carry out chipping of the line and
offer for further inspection.
9. 6” dia line (6”-RP-74-3903-B4A) was observed paint failure.
9. Carry out removal of paint blisters and
carry out painting.
Page 2 of 8 Tuesday, April 23, 2019
 WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

50 74V-803 1. ¾” dia take off connected to 14”-RP-74-3906-B4A was observed 1. Carry out replacement of the ¾¿ dia
corroded. take off lines 5 No.s

2. ½” dia line flanges downstream of the take-off were observed 2. Carry out replacement of the ½¿ dia
corroded. line flanges.

3. Block valves were observed corroded under insulation. 3. Open cold insulation and offer for
further inspection. Be prepared to carry
out replacement of 9 No¿s valves
4. Vessel connected TE3901 observed severely corroded.

4. Carry out replacement of the corroded

5. Channel support of the lines observed corroded at 3 No’s location. section.

6. 14”-RP-74-3941-B4A-IC connected TI 3955 ¾” dia flange bolts 5. Carry out repairs to the structural
were observed corroded. supports.

7. 14” dia line PT-3909 connected ½” flange joints were observed 6. Carry out replacement of corroded
corroded along with ½” dia valve. bolts in kind.

8.PT-3909 connected supports was observed corroded. 7. Carry out replacement of corroded
bolts in kind along with valve.

9. 4”-RP-74-3942-B4A connected ¾” dia drain line observed

corroded. 8. Carry out replacement of the structural
support in kind.

10. 14”-RP-74-3938-B4A connected ¾” dia valve to PT-3911

observed corroded along with ½” dia line 9. Carry out replacement of the ¾¿ dia
drain line.

10. Carry out replacement of the ½¿ dia

and ¾¿ dia line.

60 74KM-801B 1. 6”-RP-74-3909-B4A line observed corrosion under insulation. 1. Carry out removal of insulation and
offer for further inspection.

2. 1.5” dia take off line observed severely corroded.

2.Carry out replacement of the 1.5” dia
Page 3 of 8 Tuesday, April 23, 2019
take off at 4 No’s locations.
 WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

3. ¾” & ½” dia line connected to 6” line bolts were observed

moderately corroded.
3. Carry out replacement of the bolts in
kind.
4. 2” dia flare line observed severely corroded. (2”-FL-3906-A1A)

4. Carry out replacement of the 2” dia

line for approx.5mtrs from flange to top
horizontal section along with 2” dia
valve.

70 74E-801B 1. 3” dia Lube oil lines (3”-LO-74-3914/3917/39173/3911/3910/3912- 1. Remove insulation of the 3” dia lines
B1M) and offer for further inspection.

2. 3” dia line & 2” dia flange joint bolts were observed corroded. 2. Carry out replacement of 3” dia flange
bolts at 17 No.s locations and 2” dia
flange bolts at 5 No.s locations.

80 74V-801B 1. 2” dia LG 3902 connected flange bolts were observed corroded. 1. Carry out replacement of 2” dia flange
bolts in kind.

2. 6”-RP-74-3915-B1A line flange joint bolts were observed corroded.

2. Carry out replacement of 6” dia flange
bolts in kind.
3. 2” dia drain line bolts were observed corroded and connecting valve
was observed corroded.
3. Carry out replacement of 2” dia flange
bolts along with valve.
4. 1.5” dia N10 nozzle connected valve and piping observed corroded.

5.6”-RP-74-3913-B1A connected b/v bolts were observed corroded

4.Carry out replacement of valve along
and pipe line connected supports were observed corroded.
with piping.

5. Carry out replacement of corroded

bolts along with the channel supports.

90 74V-804 1. ¾” dia LT-3906A drain line to CBD observed severely corroded. 1. Carry out removal of insulation and
offer for further inspection.

2. ¾” dia connected to 3906A/B observed CUI.

2. Carry out removal of insulation and
offer for further inspection.
Page 4 of 8 Tuesday, April 23, 2019
 WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

3.3/4” dia LT-3906A/B/C, LT-3905 flange joint bolts were observed

corroded.
3. Carry out replacement of the ¾¿ dia
flange bolts in kind.
4. 6” dia line connected valves observed corroded at the exposed
section.
4. Carry out replacement of the corroded
valves in kind.
5. ¾” dia drain line connected pipe angle supports were observed
corroded.
5. Carry out structural support repairs
jobs.
6. 4” dia line (4”-RP-74-3939-IC) connected ½” dia PT-3910 was
observed severely corroded.
6.Carry out replacement of the ½¿ dia
line.
7. 4” dia line (4”-RP-74-3939-IC) connected PI-3930, PT 3953 flange
bolts were observed severely corroded.
7. Carry out replacement of corroded
bolts in kind.
8. 4” dia line (4”-RP-74-3939-IC) orifice flange connected lead lines
(FE-3901) were observed severely corroded along with valves.
8. Carry out replacement of the line for
approx.¿6mtrs along with the valves and
9. 2” dia CBD line connected ¾” dia valve severely corroded. carry out replacement of the corroded
bolts.

10. ¾” dia take off line was observed severely corroded.

9. Carry out replacement of the ¾¿ dia
valve in kind.

10. Carry out replacement of the ¾¿ dia

line for approc..1mtrs .

100 74V-807 1. 3”-RP-74-3932-B4A line was observed not resting on support. 1. Carry out structural support repairs
jobs.

110 74V-806 1.5” dia line ( 1.5”-LO-74-3925-B4A) angle support was observed Carry out structural support repairs jobs.
corroded.

Page 5 of 8 Tuesday, April 23, 2019

 WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

120 Sea Water lines 1. 4” dia Sea water supply line (4”-SW-74-3901-A5Y) connected to 1. Carry out cleaning and painting as per
74E-801A was observed with paint blisters and paint failure. advisory.

2. 4” dia line Sea water return line (4” –SW-74-3901-A5Y) was 2. Carry out replacement of the 4¿ dia
observed severely corroded and paint blisters were observed on the line for approx.4mtrs.
line.

3. Carry out cleaning and offer for further

3. 4” dia Sea water supply line (4”-SW-74-3903-A5Y) connected to inspection.
74E-801B was observed with paint blisters, deep pitting and paint
failure.
4. Carry out replacement of the 4¿ dia
line for approx.4mtrs.
4. 4” dia line Sea water return line (4” –SW-74-3904-A5Y) was
observed severely corroded and paint blisters and deep pitting were
observed on the line. 5. Carry out replacement of the 4¿ dia
line for approx.2mtrs.

5.4” dia Sea water supply line connected to 12” dia header line was
observed oozing.
6.12” dia Sea water supply header line (12-SWS-74-3911-A5Y) was
observed oozing and line observed corroded along with end flange and
flange bolts.
7. 12” dia sea water return header line (12-SWR-74-3912-A5Y) was
observed pain blisters and support location corroded.
6. Carry out replacement of the 12¿ dia
line below grating location along with
end flange and bolts.
7. Carry out cleaning and painting as per
advisory and carry out replacement at the
corroded location.
8. Carry out replacement of the 8¿ dia
line for approx..4mtrs.

8. 8” dia sea water supply line 8”-SWS-74-3907-A5Y was observed

9. Carry out replacement of the 8¿ dia
with cement box and observed corroded at elbow location.
line for approx..4mtrs

9. 8” dia sea water return line 8”-SWS-74-3908-A5Y was observed

10. Carry out replacement of the 8¿ dia
with cement box and observed pin hole leak at PG & LG stub
line for approx..4mtrs.
locations.

11. Carry out replacement of the 8¿ dia

line for approx..6mtrs.
Page 6 of 8 Tuesday, April 23, 2019
 WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

10. 8” dia sea water supply line 8”-SWS-74-3909-A5Y was observed

with cement box, flange and flange connected bolts were observed
corroded.

11. 8” dia sea water return line 8”-SWS-74-3910-A5Y was observed

pin hole leak at 3 No’s locations and channel section connected nozzle
was observed corroded.

130 CBD Lines 1. 2” dia CBD line (2”-CBD-74-3906) was observed severely corroded 1. Carry out replacement of the 2¿ dia for
approx..10mtrs

2. 2” dia CBD line (2”-CBD-74-3902) connected to 74V-805 was

observed severely corroded. 2. Carry out replacement of the 2¿ dia
line for approx.10mtrs.

3. 2” dia CBD line (2’-CBD-74-3903) connected to 74E-803 was

observed corroded at Clamp support location. 3. Carry out replacement of the 2¿ dia
line for approx..2mtrs.

4. 2” dia CBD line (2”-CBD-74-3901 ) connected to 74E-802A flange

observed corroded. 4. Carry out replacement of the 2¿ dia
flanges.

140 Flare Line 2” dia line (2”-FL-74-3911) PSV 3909A/B O/L were observed Carry out replacement of the 1.5” dia and
corroded 2nd floor below grating location. (2” dia line 2 No’s , 1.5” 2” dia line 3mtrs each.
dia line 1 No’s).

150 74E-802A 1.Channel section O/L nozzle was observed severely corroded. 1.Carry out replacement of the channel
section nozzle.

2. ¾” dia (3/4”- LO-74-3923 ) was observed corroded .

2.Carry out replacement of the ¾” dia
line for approx.4mtrs

160 OWS line 1. 6” dia OWS line (6”-OWS-74-3907-A5Y) was observed paint 1. Carry out cleaning and offer for further
blister at bottom of the pipe. inspection.

2. 6” dia OWS line (6”-OWS-74-3909-A5Y) was observed corroded at 2. Carry out replacement of the 6¿ dia
U Clamp location at 2 No.s locations. line for approx.4mtrs.

170 2"¿ Spill back line of Chiller Insulation on the line was removed & severe CUI was observed on the In view of the leak observed on 74-K-
compressor ¿ 74K-801B line. Line was observed with perforation at 6’o clock position on the2” 801B spill back line, prefabricate the
elbow. Leak was observed upstream of the control valve74UV3910. spill back spool (Approx. 1.5 mts
CUI is suspected on the line d/s of the control valve74UV3910. long)for 74-K-801A compressor also.
Page 7 of 8 Tuesday, April 23, 2019
 WORK LIST No. : 18-688922 IWL.DESC.: CCR: IAT for CCR chiller section connected piping
LOCATION : CCR LOC.DESC.: Continuous Catalyst Regeneration - MS BLOCK
Equipment : REF:
Inspection of chiller connected lines is carried out in CCR unit. Following are the
observations & recommendations.

Sl No. LOCATION/ITEM OBSERVATION RECOMMENDATION

Follow Piping spec B4A spec of VRCFP.

Use ASTM A 333 Gr.6 pipe for
replacement.
For 2-inch size Sch XS
For 3-inch size ¿ Sch STD
Use filler wire ER70-S2 for welding
Offer fit up, weld visual Radiography -
20%
Offer hydro test of the spool piece at
30Kg/cm2.
Strip off the 3" line d/s of the control
valve & offer for inspection.

180 2¿" Spill back line of Chiller
compressor ¿ 74-K-801A
CUI observed on the 2” spill back line at the exposed location. Severe Carry out 100% replacement of spool
CUI is suspected on the 2” spool d/s of isolation valve up to control piece (2" x 3") from the block valve up to
valve. control valve(approx.1.5 mtrs long).
Follow Piping spec B4A spec of VRCFP.
Use ASTM A 333 Gr.6 pipe for
replacement.
For 2-inch size Sch XS
For 3-inch size ¿ Sch STD
Use filler wire ER70-S2 for welding
Offer fit up, weld visual Radiography -
20%
Offer hydro test of the spool piece at
30Kg/cm2.
Strip off the 3" line d/s of the control
valve & offer for inspection.

____________________________
HEAD-INSPECTION

Page 8 of 8 Tuesday, April 23, 2019