SHUTDOWN / MAINTENANCE ENGINEERING (Course Duration 2 Moths)
- Codes, standards & specifications: ASME, ANSI, ASTM, API, NACE, MSS, AISI, AWS, AWWA & PFI
- Material science of various piping materials, including carbon steel (CS), alloy steel (AS), stainless steel (SS), Hastelloy, Inconel, copper nickel, etc.
- Welding procedure specifications (WPS), WPQR, and WPQT
- Permit to work system: confined space entry, work at height, excavation, lockout & tagout, positive mechanical isolations, electrical safety, heat stress, and fire prevention methods
- Preparation & identification of blind lists as per P&ID, and fabrication of blinds as per ASME B16.5 flange specifications
- Pre-shutdown activities: hot bolting as per the shutdown work list, location identification of rotating equipment, static equipment, and piping systems as per scope of work
- Installation of blinds at battery limits during shutdown as per operation department instructions; support to operation department for process lines and systems, including chemical cleaning (ZYME-FLOW), de-carbonization, steam-out, and water flushing
- Heat exchangers (fixed tube type, floating head type, kettle type): tube bundle hydro jetting, tube bundle replacement, tube rolling, tube seal welding with tube sheet, channel section repair as per inspection work list, shell hydrotest, tubes hydro test, and reverse hydro test
- Fractionators, reactors, absorber columns, knock-out drums, and vessels: internal cleaning by chemical, mechanical, and manual methods
- Replacement and repair of internal fittings: demister pads, bubble cap trays, ballast trays, chimney trays, sieve deck trays, downcomers, overflow weirs; hydro testing of trays, final inspection, and box-up of equipment
- Heaters, furnaces, and boilers maintenance and repairs: as per inspection work list, tube replacement of various alloy steel grades (P1, P4, P5, P9, P11); hanger support and bracket support replacements, thermowells & thermocouples replacements, damper plates renewals, refractory repairs, convection and radiant section tube decarbonization, chemical cleaning, pigging, hydrotesting, air blowing; burner cleaning and servicing, burner tip replacements
- Fuel gas system air blowing, final inspection, and box-up
- Piping systems renewals and modifications: as per QC & Engineering department work list; tie-ins and hot tapping as per requirements
- Shutdown documentation: updating and submission of records; start-up activities, de-blinding at battery limits