FAUJI FERTILIZER BIN QASIM LTD
BIN QASIM – KARACHI
INSPECTION DATE OF ISSUE:
UNIT INSPECTION JOB PACKAGE #: UR04 / TA-2023 JUNE 30, 2022
UNIT: UREA DESCRIPTION: PREPARED BY: ASD
TAG #: INTERNAL INSPECTION OF HP SCRUBBER REVIEWED BY: --
UH-221 (INSPECTOIN BY STAMICARBON VSM) PAGE 1 OF 5
TECHNICAL DATA:
Vessel description : High Pressure (HP) Scrubber
Service : CO2 + NH3 + Carbamate + Reaction gases + H2O
Design Pressure : Shell = 13 kg/cm2 Tube side = 164.8 kg/cm2
Design Temperature : Shell = 194 ºC Tube side = 190 ºC
Operating Pressure : Shell = 8 kg/cm2 Tube side = 144 kg/cm2
Operating Temperature : Shell = 110 ºC Tube side = 183 ºC
Hydrostatic Test Pressure : Shell = 19.5 kg/cm2.g Tube side = 248.33 kg/cm2
Corrosion Allowance : Shell = 3.2 mm Tube side = 2.0 mm
Radiography : Shell = Spot Tube side = 100%
Joint Efficiency : Shell = 0.85 Tube side = 1.0
Insulation : 100 mm
PWHT : Shell = No Tube side = Yes
Overall Length : 6803 mm
TOP BARREL END (SPHERE):
Materials: Sphere = A-516-70 (Overlayed with ER 309LMo first layer &
ER 25.22.2 second layer)
Upper pad, top cover,
side pad, blind flange = A-765 Gr. 2
Thickness: Sphere = 95 mm (lower portion)
120 mm (upper portion)
Weld Overlay = 8 mm (04mm + 04mm)
Top cover = 480 mm
Blind flange = 185 mm
ID of sphere = 2700 mm
TOP COVER (UPPER BLIND FLANGE):
Materials: Inlet tube, elbow &
TC Rod = BC 01
Sparger assembly, overflow
tube, lining tube = BC 05
Thickness: Plates = 05 mm
Inlet tube = 7.62 mm
Overflow tube, lining tube = 06 mm
TOP BARREL INTERNALS:
Material: Internals other
than Pall Rings = BC 05
Pall Rings = BC 03
Thicknesses: Top hold down
grid wire dia = 3.2 mm
All other internals = 06 mm
Pall Rings = 25 x 25 x 1.5 mm
Slot dimensions in
Grid Plate = 35 x 12 mm
Cc: Maintenance Planning Section Manager : ABDUL SAMAD
IMRAN-D:\Drive Wise\F Drive Data\Inspection Unit Data\Turnarounds\TA-2023\TA-2023 Job Package\Urea Plant (ASD)\IJP-UR04 TA-2023 (UH-221).doc
FAUJI FERTILIZER BIN QASIM LTD
BIN QASIM – KARACHI
INSPECTION DATE OF ISSUE:
UNIT INSPECTION JOB PACKAGE #: UR04 / TA-2023 JUNE 30, 2022
UNIT: UREA DESCRIPTION: PREPARED BY: ASD
TAG #: INTERNAL INSPECTION OF HP SCRUBBER REVIEWED BY: --
UH-221 (INSPECTOIN BY STAMICARBON VSM) PAGE 2 OF 5
EXCHANGER:
Materials: Tube sheet = A-266 Cl-2
Tubes = STAC 18005 BC 01
Upper tubesheet weld
overlay = ER 309 L Mo (1st layer) +
ER 310 Mo L (2nd & 3rd layer)
Lower tubesheet weld
Overlay = ER 309 L Mo (1st layer) + ER 25.22.2 (2nd layer)
Baffles = A 516 Gr. 60
Tie Rods = NFEN 10015 - Fe 360 BFN
Spacers = A 106 Gr. B
Thickness: Tubesheets = 366 mm
Tubesheets weld overlay = 12 mm
Tubes = Ø 25 mm x 2.5 mm thk.
Central tube = Ø 219.1 mm x 20.62 mm thk.
Baffles = 13 mm
Tie Rods = Ø 14 mm
Spacers = Ø 21.3 mm x 2.9 mm thk.
Other details: Length of Tubes = 2770 mm
Tube pitch = 41 mm (Triangular)
Outer Tubes Tangent limit = Ø 1031.6 mm
No. of Tubes = 501 + one central tube
SHELL:
Material: Shell = A 516 Gr. 70
Thickness: Shell = 14 mm & 20 mm (at bellows)
ID: Shell = 1060 mm
BELLOWS:
Material: Bellows = A 240 SS 304
Backing Ring = A 240 SS 304
Thickness: Bellows = 2 mm
Backing Ring = 6 mm thk. x 20 mm wide
Axial movement of
the bellows = 5 mm
Other details: Predicted cycle life = 10,000
Inner dia. of Bellows = 1094.74 mm
Outer dia. of Bellows = 1178 mm
Pitch of Bellows = 12.19 mm (3 convex outwards)
Length of Bellows = 78 mm (Ref.)
CHANNEL HEAD (LOWER BARREL END):
Materials: Lower pad & Channel
Head = A 765 Gr. 2
All internals = STAC 18005 BC 05
Thickness: Lower pad = 451 mm
Channel Head = 352 mm
135 mm Long Shell = 82 mm
Weld Overlay = 8 mm
Cc: Maintenance Planning Section Manager : ABDUL SAMAD
IMRAN-D:\Drive Wise\F Drive Data\Inspection Unit Data\Turnarounds\TA-2023\TA-2023 Job Package\Urea Plant (ASD)\IJP-UR04 TA-2023 (UH-221).doc
FAUJI FERTILIZER BIN QASIM LTD
BIN QASIM – KARACHI
INSPECTION DATE OF ISSUE:
UNIT INSPECTION JOB PACKAGE #: UR04 / TA-2023 JUNE 30, 2022
UNIT: UREA DESCRIPTION: PREPARED BY: ASD
TAG #: INTERNAL INSPECTION OF HP SCRUBBER REVIEWED BY: --
UH-221 (INSPECTOIN BY STAMICARBON VSM) PAGE 3 OF 5
All plates, tubes, gussets = 6 mm
Orifice plate at the lower
End of central pipe = 20 mm
No. of holes in the
Bottom Head distributor = 642
Other details: Dia. of the holes = 7 mm
Pitch of the holes = 30 mm (square)
Two weep holes of Ø 6mm are inside the overflow tube above the distributor.
ID of channel head = 1060 mm
Date of Last Inspection: 2021 (Bottom Section)
A- PRE INSPECTION REQUIREMENTS:
1. Blinding of inlet and outlet lines with blind flanges.
2. Adequate ventilation shall be available for vessel entry.
3. Opening of top / bottom and side manway covers and placing it upside down for gasket faces and
overlay inspection.
4. Removal of pall rings, grid and funnels assembly.
5. Placement of internals / shower head assembly at suitable location (Note: removed internals should
be stored under cover to avoid exposure to chloride containing environment).
6. Arrangement of aluminum ladder for vessel entry, ladder bottom ends covered with rubber / cloth to
avoid any damage to tubesheet / tubes protruded ends.
7. Arrangement of rope ladder for vessel entry into sphere.
8. Arrangement of 02 nos. 48 volts light source with ELCB in top / channels heads and sphere,
separately.
9. Removal of external insulation and power brush cleaning of all inlet / outlet nozzle to barrel welds
and attachment i.e. lugs support welds for visual inspection and DPT.
B- REQUIREMENTS FOR EDDY CURRENT TESTING:
10. All tubes must be cleaned & dried with no obstacles inside the tubes for Eddy Current Testing.
11. Heat exchanger tubes must be cooled to ambient temperature (30C max).
12. Arrangement of 2000W, 220 Volts A/C, 50 Hz supply at working site for Eddy Current Inspection
equipment.
13. Two hand held Motorola radio-sets should be available as required by “M/s Stamicarbon”.
14. Protection to be provided for equipment against rain, sunshine, etc.
15. A small table with 02 chairs shall be available at site for EC Equipment and Stamicarbon Inspector at
site.
C- VISUAL INSPECTION:
16. Corrosion resistant surfaces of top cover for corrosion and fillet welds of showerhead assembly
connection strips for cracking.
17. Condition of overflow / explosion chamber and weld joints
18. Internal condition of sphere and strip overlay welding for any etching, scaling, condensation
corrosion etc.
19. Condition of pall rings and grid / funnel assembly.
20. Top / bottom tubesheets and tube to tubesheet weld joints for any etching, corrosion etc.
21. Nozzles to overlay weld joints and all welds of the carbamate overflow line.
22. Bottom head surfaces and health of gas/liquid divider and central pipe and orifice plate.
23. Expansion bellows / shroud from outside of the vessel.
24. Gasket faces for any cuts marks / dents / recess.
Cc: Maintenance Planning Section Manager : ABDUL SAMAD
IMRAN-D:\Drive Wise\F Drive Data\Inspection Unit Data\Turnarounds\TA-2023\TA-2023 Job Package\Urea Plant (ASD)\IJP-UR04 TA-2023 (UH-221).doc
FAUJI FERTILIZER BIN QASIM LTD
BIN QASIM – KARACHI
INSPECTION DATE OF ISSUE:
UNIT INSPECTION JOB PACKAGE #: UR04 / TA-2023 JUNE 30, 2022
UNIT: UREA DESCRIPTION: PREPARED BY: ASD
TAG #: INTERNAL INSPECTION OF HP SCRUBBER REVIEWED BY: --
UH-221 (INSPECTOIN BY STAMICARBON VSM) PAGE 4 OF 5
25. Nozzle to barrel welds and attachment welds.
26. Lower portion of sphere and gas outlet nozzle (B1) for condensation corrosion.
27. Inspection of top funnel support plates over the support ring which were observed grooved in TA-
2018 inspection.
D- DYE-PENETRANT TESTING:
28. All longitudinal and circumferential welds of carbamate overflow line.
29. 100% DPT of top and bottom tube to tubesheet (TTS) weld joints.
30. Fillet welds of showerhead gussets/strips in top cover.
31. Nozzle to weld overlay joints of 02 nozzles (inlet react. gases & carbamate outlet nozzles) in sphere.
32. Two circumferential welds of expansion bellow in explosion chamber.
33. Fillet welds of 06 strips connecting gas/liquid divider to bottom cover overlay.
34. Inlet / outlet nozzles to barrel weld joints and lugs / support welds externally.
35. DPT of all support welds of top funnel.
36. DPT of sealing faces of Manway nozzle, bottom channel / cover and top channel / cover.
37. 100% DPT of top channel welds below the overflow chamber.
E- ULTRASONIC THICKNESS MEASUREMENTS:
38. UT thickness measurements of explosion / overflow chamber.
F- WELD OVERLAY THICKNESS & GROOVE DEPTH MEASUREMENT:
39. Thickness measurement of top, bottom and sphere manway cover overlay.
40. Thickness measurement of pall rings chamber, overflow chamber, overflow weir and area above top
tubesheet.
41. Thickness measurement of top and bottom tubesheet overlay.
42. Thickness measurement of ESW strip overlay weld at selected locations inside the sphere and bottom
barrel end using cladding thickness gauge.
43. Explosion groove depth measurement in explosion chamber.
G- FERRITE MEASURMENT:
44. Measurement of ferrite contents after all welding repairs locations and should be < 0.6 in base metal
and < 1 in welds.
45. 100% ferrite content check on all the weld joints at root and final pass required for shower head
assembly modification as per issued IFC package.
H- EDDY CURRENT TESTING (BY M/S STAMICARBON):
46. Eddy Current Examination of 100% tubes over the full length as per M/s Stamicarbon
recommendations for measurement of thickness loss (higher corrosion rate was found in TA-2019
inspection)
I- MODIFICATION IN THE SHOWER HEAD ASSEMBLY OF HP SCRUBBER:
47. Modification in the shower head assembly to be carried out as per attached Mechanical Package
PTE/P/0818/1152.
48. M/s Stamicarbon has provided special repair procedure for Shower Head assembly which outline step
by step procedure to assure proper modification in shower head assembly (procedure attached),
execution of the same needs to be ensured by maintenance team.
49. All fit-up checks and NDTs i.e. DPT and Ferrite Check to be carried out mentioned in attached
procedure by “M/s Stamicarbon”.
Cc: Maintenance Planning Section Manager : ABDUL SAMAD
IMRAN-D:\Drive Wise\F Drive Data\Inspection Unit Data\Turnarounds\TA-2023\TA-2023 Job Package\Urea Plant (ASD)\IJP-UR04 TA-2023 (UH-221).doc
FAUJI FERTILIZER BIN QASIM LTD
BIN QASIM – KARACHI
INSPECTION DATE OF ISSUE:
UNIT INSPECTION JOB PACKAGE #: UR04 / TA-2023 JUNE 30, 2022
UNIT: UREA DESCRIPTION: PREPARED BY: ASD
TAG #: INTERNAL INSPECTION OF HP SCRUBBER REVIEWED BY: --
UH-221 (INSPECTOIN BY STAMICARBON VSM) PAGE 5 OF 5
J- MAPPING OF BOTTON GAS DISTRIBUTION PLATE HOLES:
50. Mapping of all holes sizes of bottom gas distribution plate after modification of holes diameter
carried out in TA-2021 by PE to ensure any further enlargement holes.
K- FINAL INSPECTION & BOX-UP:
51. Final inspection after fulfilling the recommendations, if any, of activities 'B' thru G'.
52. Issue box-up certificate & report.
L- TIME ALLOCATION:
Visual Inspection = 12 hrs.
Dye Penetrant Testing = 12 hrs.
UT Thickness Measurement = 02 hrs.
Weld Overlay Thick. Measurement = 02 hrs.
Ferrite Content Measurement = 02 hrs.
Eddy Current Examination = 24 hrs.
Final Inspection = 02 hrs
External inspection & DPT = 04 hrs.
Total Time Required for Inspection = 60 hrs.
M- INSPECTION EQUIPMENT:
Chalk, Metal Marker (Chloride free), Torch, Magnifying glass, Vernier Calipers, Pit Gauge, PT Kit, UT
Thickness Gauge, Cladding Thickness Gauge, Ferrite scope, Eddy current instrument and recorder.
N- SAFETY REQUIREMENTS:
Vessel entry permits.
Watchman at manway.
All electrical power supply system such as transformer, generators etc should be placed outside the
vessel.
Cotton gloves, overall, cover cloth for safety boots.
O- REFERENCE DRAWINGS:
BSL Industries Drawing # 610008-121-A (As built General Layout)
BSL Industries Drawing # 610008-22-E (Tubesheets & Baffles)
BSL Industries Drawing # 610008-23-F (Top barrel Sphere)
BSL Industries Drawing # 610008-24-B (Bottom Channel Head & Internals)
BSL Industries Drawing # 610008-25-B (Miscellaneous Details)
BSL Industries Drawing # 610008-26-G (Top Sphere Internals)
BSL Industries Drawing # 610008-27-A (Bellows Details)
BSL Industries Drawing # 610008-28-E (Top Cover & Sparger)
BSL Industries Drawing # 610008-29-B (Steam Tracing Coil)
Cc: Maintenance Planning Section Manager : ABDUL SAMAD
IMRAN-D:\Drive Wise\F Drive Data\Inspection Unit Data\Turnarounds\TA-2023\TA-2023 Job Package\Urea Plant (ASD)\IJP-UR04 TA-2023 (UH-221).doc
