JOB REPORT Pre T/A-2015Tag # SS-311-A Dated: 30-01-2015

Preventive Maintenance of Cat-Ion ExchangerSS-321-B

Contents Technical Data Job Scope Pre-Arrangements Pre-inspection Maintenance Work Final Inspection Box Up

TECHNICAL DATA: Equipment: Cat-ion ExchangerVendor : Ecodyne Dimension Outer Diameter = 2438 mm Overall Length = 3886 mm (tan-tan) Manway (Top) = 18 Media removal = 3 Filler Water Inlet / Outlet = 6 (Also Rinse inlet) CCR Blocking Air Inlet = 2 Regen. Backwash Inlet/Outlet = 4 Decationized water Outlet = 6 Design Condition : Service Flow per Unit = 91t/hr. (120t/hr.max) Design Pressure = 8.8 kg/cm2.gApprox. Difference Pressure =24-29 Kg/cm2.g Materials: Shell = Carbon Steel (Painted) Internals = SS-316 Internal Lining = Rubber Resin:Resin Type = PUROLITE Strong Acid CatIon C-100(H+ ) Resin Media Depth = 2.2m

Resin Media Volume = 10.2 m3 Regeneration Media = Dilute Acid (1.5% H2SO4)

Job Scope:To carry out complete internal inspection and preventive maintenance of Cat-Ion Exchanger against service notification #2000015109.Pre-Arrangements: Blinding of NozzlesInsert blinds to isolate vessel. Unloading mediaInstall unloading nozzles to discharge media. Complete media unloaded by process unit. Manway OpeningDismantle top manway for vessel entry. Removal of Distributer and HeaderRemoval of both Top and Bottom distributer for chemical cleaning. Scaffolding InstallationErrection of scaffolding inside the vessel for complete inspection.Pre-inspectionPre-inspection was carried by inspection unit and found following major observations:1. Blisters were found at various locations at top dish end random locations as well as on manway neck.

2. Fissure type cracks and water filled blisters were observed all over the rubber lining at shell, bottom plate, top dish end and header support.

3. Dis-bonding was found at few locations

4. Holiday testing was carried out inside the vessels and defects were observed at 45 different locations.

Maintenance Work:1. Removed distributer both Top (#14) and Bottom (#20) for chemical cleaning and replaced. Sleeves were also replaced.

2. Power brushing/ cleaning of Shell, top dish end, manway and bottom plate.

3. Dis-Bonding at various locations were rectified by rubber patching.

4. Application of Primer (PR-300) after proper cleanup.

5. Rubber (KeraButyl) Patching were done at all indicated point with the application of solution (Keracoll).

Final InspectionFinal Inspection done by the Inspection unit. DFT and Holiday Testing were performed. Box up Installation of header and distributor. Media Loading by Process unit. De blinding of Nozzles. Closing of Manway.Major Material UsedMaterial UnitQtyMaterial Number

Rubber KaraButylm241230000059

Keracoll SolutionKG51230000063

Primer(PR-300)TIN2

6 Equipment Utilities Prepared By :- Usama Bin Riaz