Inlet Line Replacement Procedure

Repair Procedure For
Replacement of Inlet Line &

Bellow at NA Plant
Repair Procedure For Replacement of Inlet Line &

Bellow at Nitric Acid Plant
Prepar Checke Checke Check Review Review Approved

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Field Machinr Project Insp. S.H S.H Lead FM-
Maint. y Engg. Engg. Engg. FM-N Project North
Page 1 of 6
Inlet Line Replacement Procedure
Job Background:
Tail Gas Turbine (Y-102) Inlet line expansion joint was expanded and
spring support was impinged in the bulged line causing increase in
turbine radial vibrations resulting in plant shutdown. A temporary
repair was performed with pad welding at bulged pipe portion and
fixing the expansion joint its expanded form to start-up the plant.
The inlet line condition haven’t changed since the repair but
rehabilitation of line to its orignal condition is necessary for which
subject job is being carried out.
Job Scope:
Rehabilitate the inlet line to its original condition by replacement of
pipe bulged portion, inlet elbow, expansion joint and bottom spring
support (ST-052).
Piping Detail:
Line No.: TG053-DC4-1000/800-217H

Size: 32”, Sch 10S,
Material: SS-321
Service: Tail Gas at 430 C & 9.5 barg
Piping Spec: DC4
Expansion Joint: 32” Lateral Expansion Joint
Spring Support: Carpenter ST-052
Job Duration:
Ops handover time: 02 hr (Shutdown) + 15 hr (Compressor Cool

Down)
Maintenance Time (FM/MM/Insp): 64 hrs (to be confirmed by BAZ)
Ops Start-up time: 06 hrs (May change depending upon Ops. input)
Total P-P time: 87 hrs (~3.5 days)
Job Protocol:
Job will be started after the machine barring is stopped. During barring
activity, side activities such as S/F arrangements for canopy removal,
chain blocks tie-in etc. which shall not disturb the inlet line/nozzle
flange can be carried-out to minimize the shutdown time.
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Job Steps:
1. Pre-Arrangement (Outside the shutdown window):
1.1.Pre-fabrication activities of rigging structure at job location for

rigging activites afterwards.
1.2.Scaffolding arrangement outside burner hall for supports

inspection and readings.
1.3.Rigging Structure installation at job site for rigging activity

during outage.
1.4.Shop joint of Bellow with Elbow (01 No. of Bellow with Elbow 32”
Dia).
1.5.RT of shop joint of Bellow with Elbow performed in above step.
1.6.Machinery to install the dial indicators at machine to note down

the readings at hold points during shutdown.
2. Shutdown Activities:
During Machine Barring Activity:
As mentioned in job protocol above, to reduce the outage time side
activities will be
performed in this period (from plant shutdown till machine
complete stoppage). These side activities are as below:
Page 3 of 6
2.1.Scaffolding erection/adjustments which include S/F canopy

removal, S/F adjustment for machine flange opening, S/F for ST-
049 access.
2.2.First pad of insulation removal from the working locations of line

and bellow. (Depending upon line temperature, further insulation
can/can’t be removed).
2.3.Rigging arrangement installation and holding the line with chain

blocks.
3. Post-Handover Activities:
3.1.Lock the Spring Supports (ST-052) and (ST-049) in its cold
position and PTE to note down the readings before proceeding for
next steps i.e. machine flange de-bolting, line cutting (Hold Point:
PTE).
3.2.Machinery to note down the readings of dial indicator prior to

machine flange de-bolting. (Hold Point: Machinery)
3.3.TGT (Y-102) inlet nozzle piping 1st Flange de-bolting and holding
on its position. (Chain blocks would be holding the line before,
during and after this step is complete)
3.4.Control valve (BCV-6162) bolt loosening and holding on its
position with the help of rigging structure.
3.5.Line Cutting from Weld W3 (In 02 Spools, Spool S1 will be from
machine flange till elbow and Spool S2 will be from bulged pipe
till BCV-6162 D/S piping flange
3.6.Scaffolding adjustment for rigging of cut line spools.
3.7.Rigging activity of cut line spools S1 and S2 from their locations
to floor.
3.8.Shifting the spool S1 to its designated location (near P-103) for
its fabrication and welding work)
3.8.1. Cut the machine flange pipe spool and old bellow from
weld position W1.
3.8.2. Weld the machine flange pipe spool with new bellow
(already welded with elbow) at W1 position.
3.8.3. RT of above weld joint.
3.9.Shifting the spool S2 to floor for its fabrication.
3.9.1. Cut the pipe spool from marked location by QA/QC to cut-
off the healthy pipe portion from the bulged pipe portion.
3.9.2. Fabricate the spool for fit-up with new line. (Welding will be
performed as FJ instead of SJ for alignment purposes)
3.10. Shifting back the spool S1 at its location. (Don’t wait for RT Results)
3.11. S/F adjustment for rigging of spool S1 and bolting of
machine flange.
Page 4 of 6
3.12. Rigging the spool S1 for installation and hold it with chain
blocks.
3.13. Loose bolting of machine flange for alignment of the spool in
place.
3.14. Rigging the Spool S2 to its location for installation and
holding it with chain blocks.
3.15. Install back the new spring support (ST-052) in locked
condition with its bottom structure.
3.16. Loose bolting with control valve flange for alignment
purpose.
3.17. Field Joint weld to be done with back-pass of weld no. W3
and W4.
3.18. Dial reading by Machinery before start of machine flange
bolting. (Machinery)
3.19. Machine 1st flange bolting with new gasket. Maintain the
tolerances as per vendor manual. (Attached below)
3.20. Dial reading by Machinery after machine flange bolting.
(Hold Point: Machinery)
3.21. Burner Hall outside Line alignment. (Hold Point: PTE)
3.22. Internal inspection of line before final box-up. (Hold Point:
Inspection)
3.23. C.V flange bolting with new gaskets.
3.24. Unlock the spring supports at their cold positions. (Hold
Point: PTE)
3.25. Remove the chain blocks from location.
3.26. Insulation first pad redressing.
3.27. Necessary Housekeeping (Removal of combustible items,
consumables etc.) before start-up.
4. Post Shutdown Activities:

4.1.Final Insulation and cladding
4.2.*Scaffolding removal
4.3.Area Housekeeping
*- Platform around the bellow may be kept for post monitoring activity.
Appendix:
Below Machine Flange Alignment guideline/tolerance to be followed:
Page 5 of 6
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Inlet Line Replacement Procedure

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Repair Procedure For

Replacement of Inlet Line &

Repair Procedure For Replacement of Inlet Line &

Prepar Checke Checke Check Review Review Approved

Line No.: TG053-DC4-1000/800-217H

Ops handover time: 02 hr (Shutdown) + 15 hr (Compressor Cool

1. Pre-Arrangement (Outside the shutdown window):

1.1.Pre-fabrication activities of rigging structure at job location for

1.2.Scaffolding arrangement outside burner hall for supports

1.3.Rigging Structure installation at job site for rigging activity

1.5.RT of shop joint of Bellow with Elbow performed in above step.

1.6.Machinery to install the dial indicators at machine to note down

2.1.Scaffolding erection/adjustments which include S/F canopy

2.2.First pad of insulation removal from the working locations of line

2.3.Rigging arrangement installation and holding the line with chain

3.2.Machinery to note down the readings of dial indicator prior to

4. Post Shutdown Activities:

Below Machine Flange Alignment guideline/tolerance to be followed:

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