Prepared By

RM
F-101 Convection Coils Cleaning Job
Reviewed By
SA

DOCUMENT CODE TSD-CHEM-01-14 REV. # 00 DATE 17th Feb 2014 PAGE 1 of 5

F-101 Convection Section Coils Cleaning

Procedure

Prepared By Reviewed By Reviewed By Approved By

RM SA AGN RH
Sr. Process Engr. UM (Process-N) UM (Ammonia Ops.) Sr. DM T & P

PROCESS ENGINEERING SECTION

 Prepared By
RM
F-101 Convection Coils Cleaning Job
Reviewed By
SA

DOCUMENT CODE TSD-CHEM-01-14 REV. # 00 DATE 17th Feb 2014 PAGE 2 of 5

Background:
F-101 convection coil cleaning idea was perceived on the basis of physical inspection of coils in year-2015.
Convection coils inspection from the top revealed that there is a lot of contamination caused due to passing of
refractory dust, Mol. Sieve with waste gas during upsets. Based on physical observations and history of
convection coils, it is decided to clean top section coils E-175 (BFW pre-heat) & E-174B (Feed gas pre-heat).
Dry ice blasting method was selected after a lot of technical correspondence with multiple vendors and detailed
comparison of cleaning methods.
Benefits:
The prime benefits for clean finned are improved thermal performance and reduction of corrosion caused by
deposits. Based on this, we assure the following qualitative benefits, however it is difficult to make an exact
quantification due to unavailability of base line data.
1. Reduce risk of under deposit corrosion due to persistent presence of deposits.
2. Reduction in Stack Temperature due to better heat transfer in coils.
Criteria for success cleaning are physical observation post and after the cleaning.
We have selected a limited scope at top section with CO2 blasting and bottom will be covered in-house with
air lance. If panel removal activity remained safe and the results of cleaning prove to be successful, we will
expand the scope and take a view on it during TA to further enhance the benefits.

Dry Ice Blasting Equipment Details:

Diesel Air Compressor

01 Air Dryer of capacity 9 HP.
02 Two Ton capacity Chiller to maintain the temperature of Dry ice.
03 Two Dry ice pumps having 10 HP motor each

PROCESS ENGINEERING SECTION

 Prepared By
RM
F-101 Convection Coils Cleaning Job
Reviewed By
SA

DOCUMENT CODE TSD-CHEM-01-14 REV. # 00 DATE 17th Feb 2014 PAGE 3 of 5

Steps:

1. Removal of counter weights from both sides of F-101 (north & south).
2. Scaffolding provision around the F-101 panels at different levels. This is required to have proper access
and performing blasting activity. Platforms shall be moved based on requirement
3. Proper lighting arrangement will be done by electrical team in addition to existing lighting of F-101
4. F-101 panels need to be removed from north and south side starting from convection coil#18 to 26
5. Mobilization of equipment at site will be done by following all applicable safe work practices.
6. Certifications of all equipment shall be checked prior to installation and use at site
7. It will be ensured that highly skilled manpower is deputed by vendor for Dry ice blasting activity
8. Dry ice equipment shall be parked/installed as close as to F-101 so that hoses can be easily routed at
top of F-101
9. Blast cleaning equipment and cleaning agent should be shifted to the scaffold access platform at
different levels as required covering the full length and width of area to be cleaned
10. Provision of dry ice & compressed air (cleaning agent) is under scope of vendor G & ES
11. Hoses for CO2 blasting will be tied up properly to avoid any leakages.
12. GI sheets of 3 m width will be placed in between two tube supports below Row no 18 to ensure that
loose scale should not stick on the coils below. After complete cleaning of coil within two tube supports
GI sheet will be pull out and all loose material will be scrapped from sheet. After cleaning sheet will
be inserted into the next section between two tubes support.
13. CO2 testing in F-101 cross over section shall be performed periodically (after every 30mins.) during
the blasting activity and persons will be evacuated in case concentration exceeds 5000PPM
14. Irrelevant person entry will be prohibited within the area during this whole activity.
15. A stand by person is available for communication between skid operator and person performing CO2
blasting gun.
16. Air Blowing will be carried out to ensure dust free surface prior to CO2 blasting step.
17. CO2 blasting will be started from top row to bottom and we will first clean the area between two
adjacent tube support and then move towards next.

PROCESS ENGINEERING SECTION

 Prepared By
RM
F-101 Convection Coils Cleaning Job
Reviewed By
SA

DOCUMENT CODE TSD-CHEM-01-14 REV. # 00 DATE 17th Feb 2014 PAGE 4 of 5

18. After completion of CO2 blasting air blowing will be carried out once again to remove residual scale
and dust particles.
19. Dust will be collection and dispose off properly.

Dry Ice Blasting Methodology

1. Air Blowing: To get maximum results of Dry Ice blasting surface should be dust free. For this
purpose, we blow high pressure air at 10 to 12 bar to remove the dust particles from the surface
area.
2. Energy Transfer: With dry ice blasting, dry ice pellets are propelled out of the blasting gun at
supersonic speed and impact the surface. The energy transfer knocks off the contaminant without
abrasion. The force of this impact is the primary means of cleaning
3. Micro-Thermal Shock: The cold temperature during dry ice blasting of the dry ice pellets hitting
the contaminant creates a micro- thermal shock (caused by the dry ice temperature of -79 C)
between the surface contaminant and the substrate. Cracking and delamination of the contaminant
occurs furthering the elimination process.
4. Gas Pressure: The final phase of dry ice blasting has the dry ice pellet explode on impact,
and as the pellet warms it converts to a harmless CO2 gas which expands rapidly underneath
the contaminant surface. These forces off the contaminant from behind. The contaminant is
then relocated, typically falling to the ground. Since the dry ice evaporates, only the contaminant
is left for disposal.

SAFETY PRECAUTIONS:
1. Use tested and tagged rigging equipment (belts, shackles and crane) for heavy rigging at height
(opening of panels)
2. Dust masks to be used throughout the activity by the persons carrying out blasting activity
3. Use proper protective clothing and leather gloves for handling of dry ice equipment and also
during the blasting activity so as to avoid exposure to extremely cold temperature (-79 oC)
4. Hoses of CO2 & air mixture to be routed in such a way that they do not entangle into walkways.
5. Perform periodic monitoring of LEL in the vicinity of blasting job & in cross-over section of
furnace. If CO2 observed above 5000 ppm; work should be stopped in cross-over section.

PROCESS ENGINEERING SECTION

 Prepared By
RM
F-101 Convection Coils Cleaning Job
Reviewed By
SA

DOCUMENT CODE TSD-CHEM-01-14 REV. # 00 DATE 17th Feb 2014 PAGE 5 of 5

RESPONSIBILITIES:
1. Scaffolding & Platform Installation as per requirement. (Responsibility: Maintenance)
2. Mobility and availability of all required equipment. (Responsibility: Maintenance)
3. Dry Ice Cleaning of Convection Coils (Responsibility: Gulf Engineering & Contracting Services
Pvt. Ltd., 3rd Party Contractor)
4. Wooden plank/Cladding Sheet/GI Sheet to be provided (Responsibility: Maintenance)
5. Job Supervision/Reporting (Responsibility: Process)
6. Provision of proper lighting (Responsibility: Electrical)
7. GI sheet availability (Responsibility: Maintenance)
8. LEL meter provision and CO2 measurement in nearby area. (Responsibility: Operations)
9. Right after arrival dry ice system provide 35 Amps electrical connection, tagging of all vendor
electrical equipment. (Responsibility: Electrical)
10. Issuance of permit to work for CO2 blasting activity and equipment entrance to area.

ATTACHMENTS:
1. MSDS Dry Ice/Solid CO2
2. F-101 Coils Layout
3. F-101 Panels Model

PROCESS ENGINEERING SECTION