HF-301A/B

Maintenance
Job Card

Muhammad Rehan
Maintenance Engineer

MATERIAL OF FURNACE

CRACKING
FURNACE

CARBON STEEL LINED

WITH CASTABLE
REFRACTORY

Flue
Gas
2150C

Stack

(HF-301A/B)
Process: Thermal Decomposition
Dry purified EDC is fed to Cracking
Furnace where it decomposes into
VCM and HCl.
Cracking temperature is 5370C.
Conversion efficiency is 56-60%.
Reaction products and un-reacted
EDC are cooled immediately in
quench section to minimize coking
and reaction reversal.
HCl is separated from EDC and
VCM, and sent to Oxy
Chlorination Unit.
Subsequently,
is separated
C2H4Cl2 EDC
C2H3Cl
+ HCl
from H=
VCM and
recycled.
VCM is sent
-30,500
Btu/lbmol
to Storage.

Furnace
Feed
830C,
24bar
Furnace
Outlet

Convection
Zone
Total 40
tubes, SS

Convection Exit :
250 C

TP347H, 40-3 Length

Temp : 670 C

Arch

Radiant Zone

5000C, 20bar

Total 32 tubes
SS TP347H, SS321 &
Incolloy 800H, 49-6
length

Burner
Total 72 burners
Temp : 685C (tube
skin)

H2, Natural Gas

Fuel

CABIN, BOX-TYPE FURNACE

STACK

The flue gas stack is a cylindrical

structure at the top of all the heat
transfer chambers.
It collects the flue gas and exhaust
it up high into the atmosphere.
The stack damper works like a
butterfly valve and regulates draft
in the furnace.
Damp
er

Stack anchors and

CONVECTIO
N ZONE
Part

NPS

Material

Qty
.

Fin Tubes

4 40
Sch

24

Fin Tube

6 40
Sch

SS
TP347H
& Incolloy
800H

Bare Tube

6 80
Sch

12
4

Height: 252 1/8, Width: 8 6.5,

Length:3 99

6 Fin tubesQty 12

WEST SIDE
VIEW

FURNACE
FEED

6 Bare tubesQty 4

E
A
S
T

W
E
S
T

S
I
D
E

S
I
D
E

V
I
E
W

V
I
E
W

4 Fin tubesQty 24

FEED OUT

RADIANT
ZONE

WEST SIDE
VIEW

Type

NPS

Material

Qty.

Bare
Tubes

6 80
Sch

SS TP347H

32

FURNACE
OUT

Bare Tube 6 Qty

32

Tube
Tree

Height: 2311, Width: 11 7.5, Length:

55

Tube
Tree

DOOR

RADIANT IN

SIDE WALL
BURNERS

SELAS Type K9306 Burners are capable to deliver 110,000,000 BTU/hr na

The burner tile is made of high

temperature refractory.
Primary & Secondary Air registers
are located below the burner. The
primary
air
register
supplies
primary air to be introduced first in
the burner. Secondary air is added
to supplement primary air.
Burners include a pre-mixer to mix
the air and fuel for better
combustion.

9 X 2 sides X 4 rows
ITEM

DESCRIPTION OF PART

1
2
3
4
5
6
7
8
9
10
11
12

CUP BLOCK
WELL BOARD
AIR SLEAVE
CERAMIC TUBE
AIR BODY ASSEMBLY
INSULATING RING
BAND
BOTTOM CASING ASSEM
TOP CASING ASSEMBLY
SHUTTER ASSEMBLY
TIP NOZZLE
EXTENTION NIPPLE

REQ FOR ONE

FURNACE
72
72
72
72
72
72
72
72
72
72
72
72

ITEM

DESCRIPTION OF PART

REQ FOR ONE

FURNACE

13

TUBE GASKET

72

14
15
16
17
18
19

GASKET
MOUNTING PLATE
BURNER BLOCK ANCHOR
INSULATING WASHER
1/2 INCH FLAT WASHER
HEX NUT 1/2 X 13
HH CS 3/8-16 X 3/4" LG
STL.ZINC
HEX NUT 3/8 X 13
SUPER 3000 CEMENT
SHUTTER PISTON MARKER
SELF TAPE SCREW 6-32 X 3/16

72
216
72
72
72
72

20
21
22
23
24

72
72
72
72
144

02 Well
Board

01 Cup
Block

04 Ceramic
tube

08 Bottom casing
assy.

03 Air
Sleeve
11 Tip
Nozzle

05 Air body
assembly
14
Gasket

10 Shutter
assembly
09 Top casing
assy.

12 Extension
nipple
16 Burner
Anchor

06
Insulating
07 Aluminumring
Band

Item # 16 Burner Anchor

(Material SS)

Item # 01 Cup Block (Material

Formula 130)

Item # 05 Air body assembly

Item # 02 Well Board (Material INS

BOARD2300HD)

Item # 08 Bottom casing assy.

Item # 11 Tip Nozzle (Material Alloy

800)

Item # 09 Top casing assy.

Item # 12 Extension nipple

(Material SS)

Item # 07 Aluminum Band

Item # 03 Air
Sleeve(Material Alloy HT)

Item # 04 Ceramic tube

Item # 10 Shutter assembly

Item # 06 Insulating ring

Item # 14 Gasket

WALL
INSULATION
INSBOARD
2300 HD

Cup block
formula 130

KAST-O-LITE 20-45 G
ADTECH
KAST-O-LITE 22
PLUS
EMPIRE S
INSWOOL-HP
BLANKET
INSBOARD
2300HD
IFB 2300LI
INSBLOK-19

BURNER WALL REFRACTORY INSTALLATION

00:Burner side walls without

insulation

03: Alignment of
Anchors

01: Anchors
installation

04: IFB2300LI Bricks installation with layers of

INSWOOL Blanket

02: INSBLOK 19
installation

05: IFB2300LI Bricks installation with

SAIRSET Mortar

BURNER WALL REFRACTORY INSTALLATION

06: Filling gaps with

INSWOOL Blanket

09:IFB2300LI bricks installation

around burner

07:INSBOARD 2300HD installation as

burner well board

08: Cup block installation supported

with Anchor

10:Refractory
completion

ROOF & SIDE

WALL
INSULATION

INSWOOL-HP
BLANKET

EMPIRE S

KAST-O-LITE 22
PLUS

INSWOOL HP BLANKET
2300F Alumina-Silica Ceramic
Fiber Blanket
INSWOOL-HP BLANKET meets the
demand for a high temperature,
flexible blanket insulation with a
low iron content of less than 1%.
INSWOOL-HP BLANKET has
excellent strength, both hot and
cold.

KAST-O-LITE 20-45 G
ADTECH

Anchors

TUBE
TREE
Cast Axle

REFRACTORY
REQUIREMENT FOR
FURNACE

S#

MATERIAL DETAIL (DRW. LH 1044E7 )

UOM

REQUIRED FOR
ONE FURNACE

SIZE AND DETAIL

LOCATION OF APPLICATION

IFB 2300 LI 9X6X3

EA

740

STD 9"(229)X6"(152)X3"(76) STRAIGHT 23000

IFB

Brick lining use at burner

bottom side to hold.

IFB 2300 LI 9X4-1/2X3

EA

13460

STD 9"(229)X4-1/2"(114)X3"(76) STRAIGHT

23000 IFB

Brick lining use as second and

layer in furnace.

IFB 2300 LI 9X4-1/2X2-3/4

EA

60

9"(229)X4-1/2"(114)X2-3/4"(70) SPLIT 23000

IFB

Brick lining use at corner of

heat transfer duct.

IFB 2300 LI 9X4-1/2X2-1/4

EA

150

2-1/2 X 12X36

EA

785

PIECES BLOCK INSULATION (1900)

36(914)X12"(305)X2-1/2"(64)

Board use at back side wall

behind 2nd layer brick.

1 X 12X36

EA

850

PIECES BLOCK INSULATION (1900)

36(914)X12"(305)X1"(25)

board use with cs sheet 1st

layer at furnace wall.

5
6

INSBLOCK 19
INSBLOCK 19

9"(229)X4-1/2"(114)X2-1/4"(57) SPLIT 23000 Brick lining use under item 1 for

IFB
its support .

INSBOARD 2300 HD 1 X 24X36

EA

25

PIECES CERAMIC FIBRE BOARD (2300)

36(914)X24"(610)X1"(25)

soft board use behind burner

block.

CERAMIC FIBRE BLANKET (2300) 6#

DENSITY 1(25)X24"(610)X25'(7620)

ROLL

PIECES CERAMIC FIBRE BLANKET (2300) 6#

DENSITY 1(25)X24"(610)X25'(7620)

ceramic blanket use behind

burner block.

INSBLOCK -19 3X12X36

EA

105

PIECES BLOCK INSULATION (1900)

36(914)X12"(305)X3"(76)

Use as first layer in duct.before

casting.

10

KS-4 PLUS CASTABLE

CUFT

80

Cu FT IN PLACE 2500 CASTABLE

For casting of Duct.UM in CUFT

as per density.

11

EMPIRES BRICKS 9X4-1/2X2-1/2

EA

1620

STD 9"(229)X4-1/2"(114)X2-1/2"(64) HIGH

DUTY FIRECLAY (FLOOR)

top bricks layer on furnace floor

12

KASTOLITE 22 PLUS

CUFT

165

Cu FT IN PLACE LUMNITE, HAYDITE,

VERMICULITE (1:2:4 Mix) (FLOOR)

castable refractroy use as 2nd

layer at furnace floor.

13

KASTOLITE 20-45 G

CUFT

110

Cu FT IN PLACE LUMNITE, HAYDITE,

VERMICULITE (1:6 Mix) (FLOOR)

castable refractroy use as 1st

layer at furnace floor.

UOM

REQUIRED
FOR ONE
FURNACE

SIZE AND DETAIL

LOCATION OF APPLICATION

INSWOOL HP BLANKET 1/2 X 24 X50

ROLL

21

PIECES CERAMICS FIBRE BLANKET (2300)-6#

DENSITY1/2"(13)X24"(610)X25'(7620)

use as exp.joint in floor and brick

lining.

15

SAIR SET MORTOR

LBS

6100

POUNDS SAIRSET MORTAR

mortor use to joint all bricks

16

ANCHOR LH 302 -3 SS310

EA

3250

17

ANCHOR LH 206 -9 SS310

EA

100

18

ANCHOR LH 206 -11 SS310

EA

40

19

ANCHOR LH 104 -6 SS310

EA

150

Y-CLIPS ANCHORS PER STD 2010, PART# 2010-07

use for castable refractory.

20

ANCHOR LH 104 -6 SS310 Y TYPE

EA

350

Y-CLIPS ANCHORS PER STD 2010, PART# 2010-08

use for castable refractory.

EA

ONE

PIECES CERAMIC FIBRE BLANKET (2600), 6

DENSITY 1/2(13)X24(610)X25'(7620)

FEET

40

LIN FT. LOCKING STAINLESS STEEL BAND

Cloth binding at tube tree top and

rad.in/out lines.

ROLL

ONE

PIECES CERAMIC FIBRE BLANKET (2300) 8#

DENSITY 2"(51)X24"(610)X25'(7620)

use for peep doors and other location.

FEET

20

LIN FT. 22 GAUGE 18 - 8 STAINLESS STEEL WIRE

use to bind thermal ceramic wool at all

location .

S#

MATERIAL DETAIL (DRW. LH

1044-E7 )

14

21
22
23
24

INSWOOL HTZ BLANKET # 6 Lbs

1/2X24X50
STAIN LESS STEEL STRIP FOR
BINDING OF CLOTH .
PIECES CERAMIC FIBRE BLANKET
2300
SS WIRE SOFT DIA 1 MM

3/16"(5) BENT BRICK ANCHORS PER STD 2101,

PART# 2101-11
V-CLIPS ANCHORS PER STD 2003, PART# 200304
V-CLIPS ANCHORS PER STD 2003, PART# 200306

use for castable refractory.

use for castable refractory.
use for castable refractory.

25

INSWOOL HP BLANKET # 6 SFT 300

SIZE 1X24"X25' # 8
SFT 250

ROLL

PIECES CERAMIC FIBRE BLANKET (2300) 8#

DENSITY 4"(102)X24"(610)X25'(7620)

used at tube tree top to protect as

cover with cloth.

26

FIRE PROOF CLOTHE

ROLL

ALLUMINIZED FIBRE GLASS CLOTH 1/32"(1) THK

this cloth used for tube tree and in/out

lines of furnace.

27

RTV SILICONE TUBES.

LBS

LBS SILICON RUBBER SEALANT GE RTV 116 (OR

EQUAL)

this RTV used for clothe pasting on

tube tree and in/out lines of furnace.

ROLL

ROLL

PIECES CERAMIC FIBRE BLANKET (2300) 8#

DENSITY 4"(102)X24"(610)X25'(7620)
PIECES CERAMIC FIBRE BLANKET (2300) 6#
DENSITY 2"(51)X24"(610)X25'(7620)

used at tube tree top to protect as

cover with cloth.
ceramic blanket use behind burner
block.

28
29

INSWOOL HP BLANKET # 8
SIZE 2X24X12-1/2
INSWOOL HP BLANKET # 6 SIZE 2X
48 X12-1/2

MAINTENANCE
ACTIVITIES

1. Decoking of Radiant & Convection

Zones tubes
2. Hydro testing of Convection zone tubes
3. Convection Zone tubes/ bends
replacement
4. Hydro testing of Radiant zone tubes
5. Radiant Zone tubes/ bends replacement
6. Burner inspection and repair
7. Tube Tree inspection and greasing
8. Refractory inspection & repair
To ensure Quality assurance in maintenance activities, HOLD POINTS are given for each activity and are

HSE HAZARDS

ACTIVITIE
S

HAZARDS
Person may fall

WORK AT
HEIGHT

PRECAUTIONS
Avoid over stepping the hand rails
Ensure worker is not ill or have height phobia
Use tool bags for shifting and keeping of tools

Material may fall

Use trays for keeping stud , bolts and other material

Ensure Scaffolding and Cladding material is secured with railings

HOT JOBS
VESSEL
ENTRY
JOBS

Fire in flammables

Ensure hot job protocol is followed

Assign fire watchers for each hot job

Chemical env.

Use dust mask or other proper PPEs

Dehydration/
Asphyxiation

Ensure 0% LEL, adequate Oxygen level and water arrangement. Ensure

adequate ventilation

Refractory material

Use chemical gloves and dust mask.

Material shifting with the help of crane should be done under the
supervision of qualified riggers

MATERIAL
SHIFTING

Material may fall

Use Cotton gloves while material handling

Ensure area is barricaded while shifting material
Person may slip or fall

RIGGING
ACTIVITIES

Use manila ropes for tools and material shifting

Material may fall

More than 10 kg weight should not be taken through step ladder

Material should not be transferred by hand through monkey ladders
All rigging activities should be done under the supervision of qualified
riggers
Area should be barricaded during lifting of material and Crane Operation

DECOKING ACTIVITY
Activity Description: Support for Decoking activity on radiant and
convection section
Consumables requirement
Molykote

01
can

Wire Brush

02

Cotton gloves

12

Cotton Cloth

02 kg

Tools requirement
Brass Hammer 5lbs

02

Combination Spanner
24, 36

02

Crow Bar

01

Manpower requirement
Supervisor

01

Fitter

02

Asst. fitter

01

Rigger

02

Other Requirements
Crane 80 Ton

01

DECOKING ACTIVITY
Activity Description: Support for Decoking activity on radiant and
convection section
S#

Job Method Statement

Scaffolding construction for spools removal

Removal of inlet and outlet spools

Installation of piping spool for decoking arrangement

Pig launching and pump operation

Changing orientation of piping spool

Breaking of coke inside radiant tubes

Flushing of tubes

Inspection of tubes by Process

Piping box up

INSPECTION OF FURNACE
Activity Description: Hydro testing of Convection zone tubes
Common Consumables

Molykote

01
can

Wire Brush

02

Cotton gloves

12

Cotton Cloth
Common
Tools

02 kg

Brass Hammer 5lbs

02

Combination Spanner

01

Crow Bar

01

01:Remove this spool and install

blind 4 150#

02: Remove this blind and install PG and

Vent assembly

Common Manpower
Supervisor

01

Fitter

02

Asst. fitter

01

Rigger

02

Other Requirements
Crane 80 Ton

01

Fork Lifter

01

Crow Bar

01

03: Remove this spool and install HT pump and

water filling assembly

INSPECTION OF FURNACE
Activity Description: Hydro testing of Convection zone tubes
S#

Job Method Statement

Remove covers from east and west side of the convection zone

Construct scaffolding inside and outside of the convection zone for inspection

Remove Furnace feed spool to convection zone and install blinds on both sides.

Remove vent line blind from the top bend and install air vent and pressure gauge
assembly

Fill convection zone tubes with low temperature condensate

Ensure complete air removal from the tubes from the top blind and vent assembly

Connect hydro test pump at the bottom side assembly

Pressurize tubes step by step holding at 800psi for 30 minutes and then at 1200
psi for 30 minutes

Pressure will be hold and witness by Inspection section

10

On successful hydro test, release HT pressure in steps

11

Remove HT assembly and blinds and box up the flanges

12

Remove scaffoldings from inside and outside

13

Install both side covers. Ensure health of gasket

14

Install back the furnace feed spool and convection outlet spool

Install PG and Vent assembly

here

4 150# blind to be installed on

CONVECTION ZONE TUBE/ BEND REPLACEMENT

Activity Description: Replacement of tube or bend in convection zone due to low thickness, crack,
leakage, etc.
Common Consumables

INSPECTION OF TUBES

Spiral Wound gaskets

Cleaning of Weld joints, DPT and Hydro test is performed as preventive maintenance. Inspection will then recommend the
replacement of tube or bend

WD-40

03
can

S#

Job Method Statement

Scaffolding bed of 50ft X 40ft X 15ft is to be constructed on east side of furnace as Pic # 01

Tube pulling beam and arrangement is to be installed on the scaffolding as Pic # 02

Cutting of bend is to be done. Care should be taken that only marked bend by Inspection
should be cut

Tube will be hold from east side with sling. Additional sling is inserted from west side as well

Vessel entry is taken inside convection zone from top and bottom or radiant zone

Fabrication tools

Pulling of tube is done with the help of chain block.

Fitters tools

After the tube is completely pulled out. Use lifting arrangement to shift the tube from top to
bottom and vice versa with the help of crane

-01

PMI of all new tube material should be done for material verification

arrangement
Asst. fitter

04
-02

Prefabrication of tube is done in workshop. Put the tubes on stand and make alignment with
level , insert the shims for its straightening and make the parallel gape between two tubes.

Rigger

04

Welder

--

Fabricator

--

Wire Brush

04

Cotton gloves

24

Cotton Cloth
Common
Tools

05 kg

Rigging tools
Welding tools

Common Manpower
Tube pulling
Supervisor
arrangement
Fitter
Tube shifting

10

Make the bevel of the tubes in parallel shape and perform DPT of bevels

11

Start making Dam / purging / Root / hot pass / Filling and capping.

CONVECTION ZONE TUBE/ BEND REPLACEMENT

Activity Description: Replacement of tube or bend in convection zone due to low thickness, crack,
leakage, etc.
S#

Job Method Statement

12

Install the Attachment between two tubes for the alignment and for the proper fitness of
tubes to protect the weld joints.

13

These Attachment will be use in 4 locations after every 10 feet distances of both tubes. The
attachment will be tight by 2 U Clamps. The Lifting of both Tubes will be done by the Lifting
Eye which is weld between the attachments.

14

Shift the tubes on trailer to laydown area for performing radiography

15

After RT, shift tubes back to workshop and weld spear head cone and cleats for easy insertion
of the tubes

16

After clearing RT, shift tubes to area

17

Rigging of both tubes is done with the same beam and 04 chain block arrangements

18

Before the insertion of tubes first Attachment will be remove and then insert the tube . when
come up to 10 feet remove 2nd attachment , when insertion complete up to 20 feet remove
3rd attachment after all remove 4th attachment when insertion completed up to 30 feet

19

After insertion completion , cut down the spear head and do the bevel of both end together as
per field sizes , and tack the U bends , proceed the welding.

PIC #

PIC #

PIC #

PIC #

PIC #

PIC #

PIC #

PIC #

PIC #

PIC #

INSPECTION OF FURNACE
Activity Description: Hydro testing of Radiant zone tubes
Common Consumables
Spiral Wound gaskets
WD-40

03
can

Wire Brush

04

Cotton gloves

24

Cotton Cloth
Common
Tools

05 kg

01:Remove this spool and

install bend elbow, PG and
vent assembly

Rigging tools
Welding tools
Fabrication tools
Fitters tools
Common Manpower
Tube pulling
Supervisor
arrangement
Fitter
Tube shifting

-01

arrangement
Asst. fitter

04
-02

Rigger

04

Welder

--

Fabricator

--

02: Remove this spool and install HT pump and

water filling assembly
03: Remove this blind and install HT
assembly

INSPECTION OF FURNACE
Activity Description: Hydro testing of Radiant zone tubes
S#

Job Method Statement

Remove Furnace outlet spool to quench column (Dia 6 x 10, 8 long spool). Crane is
required for this activity

Blinding to be done (03 blinds, 10 600# one end blind, 6 300# end blind and 3 150#
end blind)

Opening of six man ways (doors) of furnace, two each on east and west side and two at
the roof of radiant section

Construct scaffolding inside and outside the furnace for inspection

Fill tubes of radiant zone with low temperature condensate

Install hydro test assembly at the bottom drain spool and PG assembly on the top spool

Ensure complete air removal from the tubes

Pressurize tubes step by step holding at 800psi for 30 minutes and then at 1200 psi for 30
minutes

Hold time and witness by Inspection

10

Pressure release and draining of water

11

De-blinding and spools box up

RADIANT ZONE TUBE REPLACEMENT

Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage,
etc.
S#

Job Method Statement

Furnace radiant section tubes comes in shorter length and pre-fabrication in shops is required to make them as per
required length. To make one complete length tube of radiant section we need to join three pieces (two joints) for each
tube. It means for 32 tubes there will be 64 joints to be welded in shop.

Open six man ways (doors) of furnace, two each on east and west side and two at the roof of radiant section.

Construct scaffolding inside and outside the furnace for tubes cutting, removal and re-insertion.

Cut old tubes inside radiant zone of furnace (Material SS347, dia 6 sch 80, 50.3 ft long tubes).

Cut and remove skin TIs from old tubes of radiant section, There are nine (09) skin TIs installed in radiant section on
different tubes.

Cut and remove tube stoppers

Remove cut tubes and U bends from inside furnace and shift old tubes and U bends to designated location. Tubes will be
removed from furnace east side

Pre Fabrication of new tubes in workshop should be completed. All bevels should be checked by EPCL inspection section
before tack welding. Inspection provided WPS must be followed.

Perform DPT of root and final pass of all weld joints of new tubes.

10

Shift newly fabricated tubes to lay down area for Radiography Testing.

11

Repair any defect if found in RT. Again shift / return tubes to / from lay down area for re shoot.

12

Shift new tubes in furnace area for insertion in furnace radiant section after successful RT result.

13

Insert new tubes inside furnace and place them on tube tree supports.

RADIANT ZONE TUBE REPLACEMENT

Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage,
etc.
S#

Job Method Statement

14

Inspection section will inspect the tube tree and is any defect is found, repairing will be done accordingly

15

Shift U bends inside furnace radiant section (Material HK40 casted, dia 6 sch 80 long radius) U bends would be dye
checked before using them.

16

Weld U bends with tubes as per drawings and provided WPS (Tube material: SS347 and U bend material: HK40 casted).
This includes alignment of U bends and tubes, tack welding, root/hot pass, filling and capping. DPT will be performed on
root pass and complete joint of the weld.

17

Welding of thermo wells skin TIs nine (09) nos. on new tubes as per drawings; in presence of EPCL instrument engineer

18

Perform RT of all tube to U bends joints

19

Repair defect if found in any joint.

20

Perform DPT and Re shoot of defected area by RT.

21

Weld tube stoppers with tubes as per locations mentioned in drawing

22

After all joints RT successful, perform hydro test of complete radiant coil and hold the pressure for 30 minutes at 800psig
and then at 1200 psig.

23

Hydro test will be witnessed by EPCL inspection engineers.

24

All scaffolding inside and outside will be removed after hydro test. Care should be taken while removing scaffolding pipes

25

Perform housekeeping from inside and outside of the furnace

26

Box up of all six man ways of radiant section after signing of box up certificate from all interfaces.

RADIANT ZONE TUBE REPLACEMENT

Activity Description: Replacement of tube in radiant zone due to low thickness, crack, leakage,
etc.
S#

Job Method Statement

30

Install furnace outlet spool to quench with crane.

31

Removal of all inserted blinds and box up the flanges

Tube lifting
beam

BURNER REPAIR WORK

Activity Description: Burner inspection and repair (if required)
S#

Job Method Statement

Ensure gas valve is isolated

Carefully remove the SS Bend hose pipe dia inch, this may be damaged if
mishandle or rotate.

Remove the Top & Bottom casings.

Remove the tip nozzle with SS pipe dia inches very carefully to protect the ceramic
sleeve.

Remove the Air body assembly from the Furnace wall; it is installed with 04 bolts and
klinger gasket.

5
6

Common Consumables
Klinger sil 4401 300mm OD &
220 mm ID 3 mm T

01

Thermal ceramic 2300

01

Remove the ceramic tube, this part is very brittle and may be damaged during
mishandling. Be care full and do not remove if there is no need.

Wire Brush

06

Cotton gloves

04

Need to clean out all parts from dust and rust, do the power brush cleaning of all parts
and them perform the DPT of extension pipe nipple and Tip nozzle..

Cotton Cloth

02 kg

Insulation should be replaced from Air body and top bottom casings.

Ring Spanner 18mm

02

Open Spanner 18mm

02

Do the painting works on all stationary parts. Should be high temperature aluminum
silver color.

Pipe Wrench 12 inch

01

Assembly of new and refurbished parts of Burners required as per Drawing.

Brass hammer 2lbs

01

Allen key 5.5mm

01

10

Final box up with new gaskets , Ceramic and Klinger

Tools

TUBE TREE PREVENTIVE MAINTENANCE

Activity Description: Cleaning and greasing of cast axle
Common Consumables
ROCOL Anti Seize
compound

01
can

Kerosene

01
can

Wire Brush

04

Cotton gloves

12

Cotton Cloth
Common
Tools

02 kg

Brass Hammer 5lbs

02

Combination spanner 22

02

Crow Bar

01

Common Manpower
Supervisor

01

Fitter

02

Asst. fitter

01

Rigger

02

Other Requirements
Lifting beam

01

Rigging equipment

01

Crow Bar

01

1. Remove canopy from the top roof of

furnace. It is fasten with nut bolts.
2. Carefully remove the fire clothe which
protect heat from the opening between
roof and Tube Tree carefully. It is binded
with SS wire and strip.

3. Install a U-type support H-Beam eye

hooks to hang chain block of 10 ton
capacity on it.

TUBE TREE PREVENTIVE MAINTENANCE

Activity Description: Cleaning and greasing of cast axle

3. The chain block will lift the tube tree up

to 1/4 inch to free the Cast Axle. After
removing, a spare cast axle is inserted in
place. Clean all parts with kerosene.
4. Grease all parts of cast axle and rollers
with high temperature ROCOL Anti Seize
compound.

5. Now do the same lifting procedure and installed back all parts
after greasing.
6. Remove U support beam and chain block and reinstall the fire

TUBE TREE PREVENTIVE MAINTENANCE

Activity Description: Cleaning and greasing of cast axle

REFRACTORY REPAIR WORK

Activity Description: Repairing work of refractory
Refractory materials in furnace

ANCHORS INSTALLATION

CERAMIC FIBRE BLANKET (2300) 6#

DENSITY

Old anchors would be grind off and surface preparation would be made for the installation of new anchors.

INSULATED FIRE BRICKS 2300 LI.

The first layer of the dual lining would be formed with the J type stud in place and tape or rubber tubing covering
the exposed threads.

KS-4 PLUS CASTABLE

The V portion wing nut shall then be attached after the first and before the second layer is formed

KASTOLITE 22 PLUS

All anchor weld attachments shall be bend tested. Bend testing shall be performed by bending the anchor in the
vicinity of the weld 15-degree and back in the direction of greatest resistance without evidence of failure

KASTOLITE 20-45 G
SAIR SET MORTOR
ANCHOR LH 206 -9 SS310
INSBOARD 2300 HD 1 X 24X36
INSWOOL HP BLANKET # 6 & # 8 SIZE
1X24"X25'
CERAMIC TUBE
Common
Tools
Brass Hammer 5lbs

02

Brass Hammer 10lbs

01

Crow Bar

01

Common Manpower
Supervisor

01

Fitter

02

Asst. fitter

01

Rigger

02

A Dog leg type joint would be formed between the old and the new refractory
The old refractory would be sprayed with water before new refractory is poured in place

REFRACTORY REPAIR WORK

Activity Description: Repairing work of refractory
JOB PREPARATIONS & METHOD STATEMENT
A shuttering used for casting refractories would be thoroughly painted with PVC solution, oiled or greased
Material for shuttering would be steel sheet or wood.
Castables refractory is to be mixed in a paddle mixer of 4-12 cubic foot capacity.

Refractory Mixer machin

Mixers should assure rapid & uniformly mixing. pouring the full batch and clean the mixture from batch to batch
Mixer must be clean. (Some substances found in dirty mixers combine with the cement in Castables can lower the ultimate strength
of the Castables)
Potable water fit for drinking should be used in mixing Castables refractories
Temperature of water is maintained between 50F to 70F. However, it should never exceed 100F (38C). PH value of water should
be between 6.0 and 7.5.
For Kastolite-22 for 100 lbs., 6 US gallon of water would be added.
In order to ensure homogenized mixing, first pour about 1/3 of refractory material and 1/3 of water while mixer paddles are in
operation. Pour remaining refractory material and water in same sequence ( that is 1/3 in every step) while ensuring homogenized
mixing.
The surface of the vessel and adjoining refractory would be sprayed with water before cast able pouring to ensure premature loss of
moisture from the mix.
Castables would be poured into forms immediately after they are mixed. In any case should the time between mixing and casting
not to be exceed up to 20 minutes
The cast able would not be allowed to dry till 24 hours in order to allow proper curing & to avoid dusting during operation.
All Castables would be vibrated during pouring to avoid air pockets in refractory.

REFRACTORY REPAIR WORK

Activity Description: Repairing work of refractory
JOB PREPARATIONS & METHOD STATEMENT
Curing would be carried out at a temperature of about 1000F during operation (in case of major refractory replacement.
Remove old anchor and weld new anchor when you do full rehabilitation of refractory
Don't patch the cracks that normally occur in the Castables after dry out. These are natural cracks. These cracks should not exceed
1/16 and are needed for expansion.
Large cracks in any moldable lining should be repaired by cutting out the material around the crack to a minimum width of 3 and
depth of two inches. Sides to be cut should be tapered to assure a V type anchor for the patching material.
If anchors are exposed, these should be adequately cleaned to effectively retain the patch
Quality Testing of refractory

S
#

Job Method Statement for installing Ceramic Wool

insulation

Arrange required material as per drawing BOM

weld anchor on metal surface of wall as per drawing (LH-1044-E7)

Install SS-310 I type anchors with proper WPS CS to SS-310.

Install refractory anchor at specified location , Pitch distance as

per Drawing

Install INSWOOL blanket over I type anchor as per thickness.

Place the tope lock over I type anchors

If problems are detected visually or by hammer impact

sound, closer spacing shall be used to delineate the size of
the defect. Voids large than 6x6 and any sort of dry fill
areas that reduce the effective lining thickness by more
than of the original thickness shall be considered
defective and shall be repaired.

Apply the high temperature mortar paste over the anchor lock to
protect from heating and burning.

If refractory is inspected after complete dry out, areas

containing cracks greater the 1/16in (1.5mm) are

Hammer test would be carried out on the newly installed

refractory.
The lining shall be struck with a 1lbs ball point machinist
hammer over the entire surface after 24 hrs.
Approximate spacing for striking shall be 12 for AP-Green
94 Plus and 20 for other low density materials.