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Naseer Ahmed
Dawood Hercules Chemicals, Pakistan
D
awood Hercules Chemicals Ltd. is a MH-4 (Manhole no. 4) were opened. Internal
1350 MT/day Urea fertilizer producing inspection revealed that welding joint nos. 22,
plant. The Plant is located near Lahore, 23 and 24 were badly corroded. Most of the
Pakistan and is in operation since 1971. Our shell plate area between UC-4 and MH-4 was
Ammonia unit is a M.W. Kellogg (now KBR) also found corroded up to 25 mm (1) max
design with 815 MT/day of ammonia. It has deep, having an original thickness of 45 mm.
CATACARB CO2 stripping system.
Temporary Repairs
The corroded weld joint nos. 22, 23, 24 and
weld around UC-4 were ground off, re-welded
and radio graphed (see Fig. no. 6).
For this purpose, it was decided to install a dimensions 10x 6x , 10x 2x and 10
lining of thick SS 304 sheet on the corroded x 7x were used. Two weep holes were also
area which was approximately 52m2 (560 sq. ft). provided in these plates to detect leakage if any.
But the corroded irregular internal surface of
shell was a problem. Cielcote Epoxy Grout
648CP was tested for its suitability and used as
filler between the liner and the shell. PASSIVATION
Passivation requirement
Due to limitation of the manhole size, standard After maintenance work on carbon steel
size sheets were cut into 203 x 559mm (8 x equipment or prolonged period of shutdown of
22) size, overlapped and welded. To ensure catacarb system passivation is necessary.
proper filling, after welding each sheet segment Following passivation procedure was used in
Cielcote was filled in the cavity between sheet consultation with M/S Eickmeyer & Associates.
and shell and then welding of next sheet
segment was started. In this way all the affected Passivation activity summary
area was lined. Passivation of the system was done with
solution of catacarb corrosion inhibitor 922-A
The affected portion of the shell also needed and Hydrogen Peroxide in de-mineralized water.
strengthening for pressure containment.
Reinforcement of most affected portion of shell The system was filled with de-mineralized water
from the outside was carried out by welding and circulation was established at design rates
rolled C.S. plates of thickness on the outer using de-sulphurised Natural Gas. Corrosion
periphery. Three segment plates of C.S.
The joint was radio graphed and the results Electric heater coils were installed and inside
showed a 100% homogeneous weld with only root, hot pass and filling / capping were
one minor un-sharp porosity pore on the outer completed after achieving the pre-heat
cap bead which was accepted. temperatures.
Vessel verticality after stress relieving was The root was gouged and grinded from the
registered as E/W 0 inch and N/S 1/8 inch outside. Dye-Penetrant examination of the root
which was very good. showed many small defects which were ground
Problems were experienced during pre-heating out and the final D/P test indicated a perfectly
and stress relieving by the sub-contractor which clean weld.
resulted in a waste of time but this time loss was
regained by planning in forward direction. After installation of heater coils, outside weld
was completed. Radiographic testing (RT) of
Insulation of the new segment was started in the joint was done before stress relieving. The
parallel to avoid heat loss during pre-heat and results indicated a good weld joint except one
stress relieving. The missing part of the gas inlet single slag entrapment just below the outside
nozzle was also installed. cap at an angle of 20 towards East measured
from North of vessel ( 0o ). The defect was
6. Installation of top segment accepted as the nature of inclusion and size was
Bench marks were fixed to the top section of acceptable within the relative ASME Code.
101-E which was then lifted and positioned Heating coils were installed and the joint was
vertical with the help of the trailing crane. The stress relieved as per procedure. Then the joint
section was then shifted on to the new segment. was again radio graphed. No defect was found
The load cell registered 72.2 tons. The problem except the same fault as previous.
of uneven landing level was again experienced
which was resolved in the similar way as at After completion of stress relieving, the crane
lower joint A. was released. Verticality of the vessel was
As anticipated from the measurements already continuously monitored during welding and
taken, ovality at east side was 12 mm and that at stress relieving.
west side was 22 mm. The vessel was aligned
and jack bolts were used to reduce wall steps
Conclusion
1. The hot potassium carbonate CO2 removal
system, inhibited by metavanadate can operate
very successfully without corrosion. Properly
passivated, the inhibitor layer is tight and
impervious but the system is sensitive to
destabilizing upsets.
Figure 3 Closer
Figure view
9 Closer ofof
view lining weld
Lining of completion
new segment Figure 10 Welding of lining in new segment in
progress