Stepwise Maintenance Activities for Major Static Equipment especially Pressure Vessels/ Distillation Columns:
Afsar Alam
KSE Approved | IELTS Qualified | Installation, Preservation, Pre-Commissioning & Maintenance | Mechanical Engineer at TR UAE
Hello Good Day Community, I will be sharing some training manuals rephrased by myself on the basis of my hands-on experience in maintenance field, it will be very easy to understand and stepwise for any fresh graduate to pass the maintenance interview and kick start their career as Mechanical foreman Mechanical supervisor for Static Equipment inside refinery or gathering centers or Gas Booster Stations:
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For Any Major Static Equipment:
Understanding the Physical Appearance of below equipment, The Parts of below equipment & Types of below equipment and at last Maintenance Procedure of these important equipment at any refinery:
1. Heat Exchangers
2. Pressure vessels
3. Distillation Columns
4. Fired Heaters
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Major Steps that must to do for shutdown and maintenance of any equipment:
1. Taking Work Permit
2. Preparing Materials and tools
3. Arranging Tool Box Talk on PPE & Hazards about ongoing work
4. Putting scaffolding to provide access to reach the valves, Blinds areas.
4. Isolation of all inlet Outlet, Drain Valves of that equipment.
5. Depressurization by venting and then Draining of equipment
6. Nitrogen Purging and Degassing (making it free from dangerous gases liquid or hazard from inside using its piping without opening equipment)
7. Opening Vent Valves to atmosphere and then opening Manways (Put exhaust fan on manways for 1-2 hours) to remove smell and left gases
8. Gas Testing by Safety Team and clearance for man entry inside vessel confined space
9. Preparation for confined space entry with attendant and rescue plan
10. Entering inside vessel maximum 2-4 people at once.
11. Water flushing and cleaning inside
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12. Removal of internals, distributions pipes, Baffles Plates and Anodes Bar etc.
13. Cleaning of Internals removed as well as proper cleaning of equipment from inside using detergents/Servo to make is it ready for Inspection.
14. Offer for Inspection.
15. Do repair work as per Inspection Action Task.
16. Offer for inspection after repair and get clearance to fix everything back inside.
17. Fixing back all external valves and doing final Box up.
18. Nitrogen Purging for making it oxygen free up to 5% oxygen
19. De-blinding and Handover to Operation.
20. After successful startup dismantle the scaffoldings.
21. Close the work permit
22. Move the crew and tools to next equipment or location
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Types of work permit and paper work required to start this work are:
1. Hot work or cold work permit
2. Vehicle entry permit for compressor, power generator, Trailers etc.
3. Confined Space Entry Permit with rescue plan.
4. Gas Testing and writing values on permits.
5. Tool Box Talk (TBT) Paper with signature of foreman and Safety
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Drafted by: Afsar Alam
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