PRC Unit P041 PCL DMs-Inspection Plan-IOLs-Rev 1

PETRORABIGH UNIT P041 (POLYPROPYLENE PP-1): PCLs SUMMARY WITH DMs-INSPECTION PLAN-IOLs
PCL Number
PCL Name
PCL Colour
PCL Description
Connected Equipment
Pressure
Range
Kg/Cm2
PFD Number
Temp
PCL Material
Range C
PWHT
Yes/No
Process Fluid Stream

Composition
Damage Mechanism
Integrity Operating Limits
Inspection Plan
Comments
Alert: Operation outside the IOLs given below can increase damage rate and may initiate a new Damage
Mechanism and hence can adversely affect insp. requirements and insp. interval. Also if there are other
additional IOLs specified by Process Licensor or Site Operating Practice, these shall be included. See Note 1.
P041-PCL-001
P041-PCL-002
Catalyst
C6H11 / C4H10
(100% HC)
Red Line
Dark Green Line
a) X-Cat from BL to Z-1100, D-1100 A, PCL-002, u/s of D-1552, u/s of R1102 L & UPD
b) From PCL-002/PCL-004 to R-1002A, D-1100 B, D-1101 B, PCL-002 (Z
CAT Drain), K-1102A, PCL-004 (u/s of R-1102A) & H-1121.
c) From F-1126/ D-1241 to K-1125, P1263, B-1262 & H-1262.
d) Additives from M-1651/H-1221/H-1222 to H-1203, F-1203, FD-1202, F1204, PCL-002 & SR-1263 A/B.
e) From and back to T-1261 Via E-1261 A/B (S/S).
f) From H-1201 B/ F-1205 to ATM.
a) from Unit - P010 (C6H11 & C4H10) to D-1100B, U/S of, D-1552, PCL001, R-1051, PCL-003.
b) From D-1101A/B / Z- 1052 to Z-1101/ Z-1053.
c) From PCL-001, NLD & ND to PCL-010, U/S of D-1552, D-1051 & PCL-010.
d)From Unit -P010 (C3H5, C4H6, C2H6) to R-1102 L, PCL-004,PCL-007,
PCL-010, EJ-1102A, PCL-009, PCL-011 & PCL-018.
e) Unit -P047 (PP2), PCL-004, PCL-009 & OPD to D-1153, D-1151 & PCL010.
f) From Additives, M-1651 to F-1282 Drain, PCL-004.
D-1511, D-1501, R-1051, D-1100 A/B, D-1101

A/B, R-1102 A, H-1121,F-1126, M-1651, D-1652
A/B, H-1251, H-1253, H-1254, F-1204, W-1251,
W-1253, W-1254, W-1255, CR-1203, F-1203,
FD-1202, H-1221, H-1222, W-1220, W-1221, W1222, Z-1203, Z-1209, SR-1262 A/B, SR-1263
A/B, SR-1267, DR-1261, SR-1261, H-1262, TK1261 & H-1201 B
2310-8110-20-P041-0001
2310-8110-20-P041-0003
2310-8110-20-P041-0004
2310-8110-20-P041-0011
D-1100 A/B, D-1101 A/B, Z-1101, R-1051, D1051, Z-1052, Z-1053, D-1511, D-1501, R1056, R-1057, E-1112, R-1102 L, E-1142 (S/S),
EJ-1102 A, D-1151, H-1121, H-1122, H-1123, Z1125, D-1162, Z-1162, D-1550, D-1551, D1552, H-1202, F-1203, F-1204, Additives, F1282, B-1282, P-1263 & M-1651
2310-8110-20-P041-0001 Rev-S1
2310-8110-20-P041-0002 Rev-S1
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0004 Rev-S2
2310-8110-20-P041-0005 Rev-S2
2310-8110-20-P041-0006 Rev-S3
2310-8110-20-P041-0011 Rev-S2
Rev-S1
Rev-S1
Rev-S2
Rev-S2
Atm to 70
Atm to 55
Amb to 100
Amb to 90
SS 304L
C/S & SS 304
No
No
H2O - Nil,
HC-10 to 100%,
Z17 - 100%,
CAT-90%
1)
2)
3)
4)
5)
Corrosion - General
Corrosion - Localized (No Flow)
Corrosion - Localized (Heat Traced)
Erosion Corrosion (2 Phase Flow & Solid Particles)
SCC-Chlorides(External)
1. Max. Operating Temperature: 105 C

2. DCCs Compositions: H2O-Nil.
3. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
4. Intermittent, By-Pass or Out-of-Service Periods (without adequate preservation): Max Period is limited to 10% higher than under Normal
Operating range. Additionally, should the normal operating practice require a minimum period for such conditions, these shall be observed.
5. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
procedures.
H2O - Nil,
HC- 100%
1)
2)
3)
4)
5)
6)
7)
8)
Corrosion - General
Corrosion - Localized (No Flow) (C/Steel)
Corrosion - Localized (No Flow) (SS 304)
Erosion Corrosion (Solid Particles)
Erosion Corrosion (Jacketed Piping)
Fatigue - Vibration

procedures.
1)
2)
3)
4)
Corrosion - General
Corrosion - General
Corrosion - Localized (No Flow) (C/Steel)
Corrosion - Localized (No Flow) (SS 304)
Corrosion - Localized (No Flow) (SS 304L)
Erosion Corrosion (Liquid Flashing)
PP SIMTECH COMMENTS:
1. SS 304L lines listed in "Walk the PCL" data for PCL-002 and PCL-014
moved to this PCL as the MOC and DCC are relevant to this PCL.
P041-PCL-001
P041-PCL-002
Repair of leaked two weld joint in 4"-VG-P041-32250-1SC0P010-NI

(2013)
1. Based on the upstream / downstream piping MoC given in the PFD,
certain sections marked as SS 304 in the PFD, has been considered as
CS during the PCL categorization process.
2. C/Steel & SS 304 lines listed in "Walk the PCL" data for PCL-001 and
PCL-003 moved to this PCL as the MOC and DCC are relevant to this
PCL.
g) From various PCL's and equipment to Atm and Flare
P041-PCL-003
C3H6
Dark Blue Line
Propane from P010 and Z-1051, Z-1052 to D-1550
R-1051, R-1056, R-1057, D-1550, Z-1052 & Z1053
2310-8110-20-P041-0001 Rev-S1
2310-8110-20-P041-0006 Rev-S3
0.02 to 71.5
Amb to 40
P041-PCL-004
CAT
Brown Line
a) From P-1041 A/B, PCL-002 to PCL-010 (U/S of R-1102L & D/S of Z-1102
L) & R-1102A.
b) From Unit -P-042, D-1652 A/B, S-1221 & Additives to D-1241, PCL-002,
H-1221, H-1222, PCL-019, Pellet, H-1301, H-1302 A/B/C/D/E.
c) From S-1371 to S-1372.
d) From various PCL's and equipment to Atm and Drain.
Z-1102 L, R-1102 L, H-1201 A/B, D-1240, D1241, F-1203, D-1652 A/B, S-1221, H-1221, H1222, SR-1262 A/B, H-1262, F-1286, H-1340,
H-1350 A/B/C, F-1351, H-1300, H-1331, H1301, Additives, H-1302 A/B/C/D/E & S-1312
2310-8110-20-P041-0001 Rev-S1
2310-8110-20-P041-0002 Rev-S1
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0011 Rev-S2
2310-8110-20-P041-0012 Rev-S2
2310-8110-20-P041-0013 Rev-S2
- 0.1 to 70.3
Amb to 70
P041-PCL-005
Hydrogen
Pink Line
Hydrogen from Unit - P010 to PCL - 010 ( U/S of R-1102 L & R-1102 A)
R-1102 L & R-1102 A
2310-8110-20-P041-0002 Rev-S1
2310-8110-20-P041-0003 Rev-S1
20.7 to 70
Amb to 40
P041-PCL-006
Orange Line
a) From H-1122 to Sampling, X-1201 and ATM.

b) From and back To H-1201 A/B via F-1201 A/B, H-1202, F-1202, E-1201
S/S, E-1202 S/S, E-1125 S/S, E-1126 S/S, F-1125 & F-1200.
H-1122, H-1123, H-1201 A/B, F-1201 A/B, F1202, H-1202, FD-1202, CR-1203, H-1203, X1201, E-1201 S/S, E-1202 S/S, E-1125 S/S, E1126 S/S, F-1125 & F-1200.
2310-8110-20-P041-0004 Rev-S2
2310-8110-20-P041-0011 Rev-S2
Atm to 2.2
P041-PCL-007
Purple Line
From CS1 Cylinders to R-1102 A & R-1102 L
R-1102 A & R-1102 L
2310-8110-20-P041-0002 Rev-S1
2310-8110-20-P041-0003 Rev-S1
1 to 100
1. SS 316L lines listed in "Walk the PCL" data for PCL-002 moved to
this PCL as the MOC and DCC are relevant to this PCL.

procedures.
P041-PCL-003

2. DCCs Compositions: H2O-Nil; H2 - 0.005%
procedures.
P041-PCL-004
No
H2O - Nil,
HC- 100%
No
H2O - Nil,
H2 - 0.005%,
HC-87.2 to 100%,
Z12- 8 to 19%,
CAT-Traces,
PP - 12%
1)
2)
3)
4)
5)
6)
7)
C/S
No
H2 - 100%,
H2O - Nil
1) Corrosion - General
2) Corrosion - Localized (No Flow)

procedures.
P041-PCL-005
40 to 100
SS 304L
No
H2O - 0.1 to 0.27%,

N2 - 42%,
PP - 57.7 to 99.99%
1)
2)
3)
4)

2. DCCs Compositions: H2O - 0.1 to 0.27%
procedures.
P041-PCL-006
Amb to 50
C/S
No
CO - 100%

procedures.
P041-PCL-007
Corrosion - General
Fatigue - Vibration.

2. DCCs Compositions: H2O - Nil; H2 - 0.2%
procedures.
P041-PCL-008
SS 316L
CS, SS 304 &

SS 304L
Corrosion - General
this PCL which is also mentioned in the given "Walk ther PCL" data for
PCL-008 and also the MOC and DCC are relevant to this PCL.
P041-PCL-008
Dark Green Dash and Dot Line
From H-1121 to PCL-10 (U/S of E-1161 S/S)
H-1121
2310-8110-20-P041-0004 Rev-S2
0.2
75
SS 316L
No
H2O - Nil,
H2 - 0.2%,
HC - Rem
1)
2)
3)
4)
5)
P041-PCL-009
Red Dash and Dot Line
From S-1102 A & PCL-002 to R-1102 A & H-1121
S-1102 A, R-1102 A & H-1121
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0004 Rev-S2
0.2 to 21
77 to 85
SS 316L
No
H2O - Nil,
HC- 100%
1)
2)
3)
4)
Corrosion - General

2. DCCs Compositions: H2O-Nil
procedures.
P041-PCL-009
P041-PCL-010
Dark Blue Dash and Dot Line
R-1102 A, R-1102 L, S-1102 A, E-1102A T/S, Da) From PCL-002/ PCL-005 to R-1102L
1103 A, E-1103A T/S, D-1151, D-1152, H-1121,
b) From PCL_008 (D/S of H-1121 to H-1121, PCL-002, OSBL-HOFCC & Unit- E-1161 S/S, Z-1161, D-1161, D-1162, F-1161
P-010 (TK-9550).
A/B, E-1166 S/S, F-1161 A/B, D-1166, F-1162
c) From various PCL's and equipment to Flare.
A/B, Z-1163, E-1167, D-1152, E-1152, F-1552
A/B.
2310-8110-20-P041-0002 Rev-S1
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0004 Rev-S2
2310-8110-20-P041-0005 Rev-S2
2310-8110-20-P041-0006 Rev-S3
0.2 to 55
30 to 120
C/S
No
H2O - Nil,
H2 - 0.03 to 0.16%,
HC - Rem to 100%
1)
2)
3)
4)
5)
6)
Corrosion - General
Erosion Corrosion (Liquid Flashing)
Fatigue - Vibration

2. DCCs Compositions: H2O - Nil; H2 - 0.03 to 0.16%
procedures.
P041-PCL-010
P041-PCL-011
Light Green Line
From R-1102 A to H-1121
R-1102 A & H-1121
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0004 Rev-S2
0.2
77 to 85
SS 316L
No
H2O - Nil,
H2 - 0.17 to 0.3%,
HC - Rem%,
Z17 - 0.003%,
Z18 - 0.0003%,
CAT - 0.02%,
PP - 86.7 to 89.3%
1)
2)
3)
4)
Corrosion - General
Fatigue - Vibration

2. DCCs Compositions: H2O - Nil; H2 - 0.17 to 0.3%
procedures.
P041-PCL-011
P041-PCL-012
Brown Dash and Dot Line
From D-1153 to Pelletizer
D-1153
2310-8110-20-P041-0003 Rev-S1
0.5
70
C/S
No
Solid PP (HC - 100%)
1. Max. Operating Temperature:75 C

procedures.
P041-PCL-012
P041-PCL-013
Dark Green Dot Line
From E-1124 S/S to H-1122, PCL-014, PCL-006 & ATM
E-1124 S/S, H-1123, H-1122, E-1121 S/S & E1122 S/S
2310-8110-20-P041-0004 Rev-S2
Atm to 3.5
Amb to 110
SS 304L
No
H2O - 0.62%,
N2 - 99.37%
1)
2)
3)
4)

2. DCCs Compositions: H2O - 0.62%.
procedures.
P041-PCL-013
P041-PCL-014
Purple Dot Line
N/A
F-1121, D-1550 & D-1151
Atm to 3
Amb to 50
C/S
No
H2O - Nil,
HC - 79.1%,
Z17 - 0.2%,
CAT - 5.2%,
PP - 16.5%
3) Erosion Corrosion (Solid Particles)

2. DCCs Compositions: H2O -Nil.
procedures.
P041-PCL-014
2310-8110-20-P041-0006 Rev-S3
Corrosion - General
P041-PCL-015
BaOH
Light Green Dot Line
BoDH from Z-1552
Z-1552
2310-8110-20-P041-0006 Rev-S3
0.5 to 3.5
Amb to 50
C/S
No
H2O - Nil,
HC- 100%

procedures.
P041-PCL-015
P041-PCL-016
BaOH + H2O
Orange Dot Line
From Z-1552 to D-1552
Z-1552 & D-1552
2310-8110-20-P041-0006 Rev-S3
0.5 to 3.5
Amb to 50
C/S
No
H2O
HC- 100%

2. DCCs Compositions: Establish Composition range for H2O.
3. Stream pH: Maintain within Normal Operating Range with Max and Min excursions limited to 5%.
procedures.
P041-PCL-016
P041-PCL-017
Moisture
Pink Dot Line
From F-1300 to Drain
F-1300
2310-8110-20-P041-0012 Rev-S2
0.02
46
SS
No
H2O

2. DCCs Compositions: Establish Composition range for H2O.
3. Stream pH: Maintain within Normal Operating Range with Max and Min excursions limited to 5%.
procedures.
P041-PCL-017
Prepared by PPSIMTECT Solutions Ltd. - UK
IDENTIFIED DAMAGE MECHANISMS, INSPECTION PLAN and IOLs REVIEWED and APPROVED by PRC
Page 1 of 2
PRC UNIT P041 PCL DMs-INSPECTION PLAN-IOLs Rev 1 - 30/03/2016
PETRORABIGH UNIT P041 (POLYPROPYLENE PP-1): PCLs SUMMARY WITH DMs-INSPECTION PLAN-IOLs
PCL Number
PCL Name
PCL Colour
PCL Description
Connected Equipment
PFD Number
Pressure
Range
Kg/Cm2
Temp
PCL Material
Range C
PWHT
Yes/No
Process Fluid Stream

Composition
Damage Mechanism
Integrity Operating Limits
Inspection Plan
Comments
Alert: Operation outside the IOLs given below can increase damage rate and may initiate a new Damage
Mechanism and hence can adversely affect insp. requirements and insp. interval. Also if there are other
additional IOLs specified by Process Licensor or Site Operating Practice, these shall be included. See Note 1.
P041-PCL-018
P041-PCL-019
Air
P041-PCL-020
P041-PCL-021
Cooling Water

2. DCCs Compositions: H2O-Nil; H2 - 0.2%
procedures.
P041-PCL-018
From H-1121/PCL-002 to H-1122
H-1121, D-1121 & H-1122
2310-8110-20-P041-0004 Rev-S2
0.2
80
SS 304L
No
Dark Blue and Yellow
From SK-1300 to U/S of H-1300, PCL-004 & PCL-020
F-1300, SK-1300, E-1301 S/S, S-1301, F-1301

D, E-1302 S/S, S-1302, F-1302 D, E-1303 S/S,
S-1303, F-1303 D, E-1304 S/S, S-1304, F-1304
D, E-1340 S/S, S-1340, F-1340 D, E-1350 S/S,
S-1350, F-1350 D
2310-8110-20-P041-0012 Rev-S2
0.05 to 2
Amb to 210
SS 304
No
Air
3) SCC-Chlorides (External)
None
P041-PCL-019
Red and Light Blue Dot Line
From H-1301, H-1302 A/B/C/D/E & PCL- 019 TO S-1312, S1371, U/S of S1372 & U/S of H-1222
H-1301, H-1302 A/B/C/D/E, S-1312 & S-1371
2310-8110-20-P041-0012 Rev-S2
2310-8110-20-P041-0013 Rev-S2
0.1 to 2.5
60
SS 304
No
H2O - Nil,
Air - TBS,
HC - Rem to 100%
2) Erosion Corrosion (2 Phase Flow & Solid Particles)

procedures.
P041-PCL-020
Brown and Light Blue Dot Line
Cooling water Supply to Generic Extruder Package and back
X-1201 & X-1202
2310-8110-20-P041-0011 Rev-S2
Atm to 4
36 to 46
SS 304
No
Cooling Water

3. Other Critical parameters such as Conductivity, pH, TDS (Total Disssolved Solids) and Treatment Chemicals are limited to 5% higher than
the known range under normal operation or adhere to the limts set by Site Operating Practice whichever is more stringent.
procedures.
P041-PCL-021
R-1102 L, E-1102A S/S, E-1103A S/S, E-1121

T/S, E-1122 T/S, E-1161 T/S, E-1162, E-1166
T/S, D-1550, D-1551, RU-1070, D-1552, E1552, E-1125 T/S, E-1126 T/S, E-1201 T/S, E1202 T/S, E-1261 A/B (T/S), E-1301 T/S, E-1302
T/S, E-1303 T/S, E-1304 T/S, E-1340 T/S & E1350 T/S
2310-8110-20-P041-0002 Rev-S1
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0004 Rev-S2
2310-8110-20-P041-0005 Rev-S2
2310-8110-20-P041-0006 Rev-S3
2310-8110-20-P041-0011 Rev-S2
2310-8110-20-P041-0012 Rev-S2
2.5 to 4
36 to 46
C/S
No
Cooling Water

procedures.
P041-PCL-022
TK-1071 to RU-1070, E-1051, R-1051, R-1056 &

E-1112
2310-8110-20-P041-0001 Rev-S1
2310-8110-20-P041-0002 Rev-S1
2310-8110-20-P041-0006 Rev-S3
0.1 to 5.4
2 to 60
C/S
No
Chilled water -100%
3) CUI

procedures.
P041-PCL-023
E-1051, E-1142 T/S, D-1103 A, E-1167, E-1124

T/S, D-1240 (Jacketing) & D-1241 (Jacketing)
2310-8110-20-P041-0001 Rev-S1
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0004 Rev-S2
2310-8110-20-P041-0005 Rev-S2
2310-8110-20-P041-0006 Rev-S3
2310-8110-20-P041-0011 Rev-S2
3) CUI

procedures.
P041-PCL-025
P041-PCL-026
P041-PCL-022
Cooling Water
Yellow Line
P041-PCL-023
Chilled water
Light Blue Line
Chilled water supply from TK-1071 to RU-1070, E-1051, R-1051

(Jacketing), R-1056 (Jacketing) & E-1112
Steam
Corrosion - General
Fatigue - Vibration
SCC-Chlorides (External)
Red Dot Line
Cooling water Supply to R-1102 L, E-1102A S/S, E-1103A S/S, E-1121 T/S,
E-1122 T/S, PCL-006 Jacketing line, E-1161 T/S, E-1162, E-1166 T/S, D1550 (Jacketing), D-1551 (Jacketing), RU-1070, D-1552 (Jacketing), E1552, E-1125 T/S, E-1126 T/S, E-1201 T/S, E-1202 T/S, E-1261 A/B (T/S), E1301 T/S, E-1302 T/S, E-1303 T/S, E-1304 T/S, E-1340 T/S & E-1350 T/S
and back
P041-PCL-024
1)
2)
3)
4)
H2O - Nil,
H2 - 0.2%,
HC - Rem
Dark Blue and Orange Dot Line
Steam line to E-1051, E-1142 T/S, D-1103 A, E-1167, E-1124 T/S, D-1240
(Jacketing), D-1241 (Jacketing), PCL-022 U/S of E-1102 A & D-1551
4.5 to 7
160 to 200
C/S
No
Steam
1. Revised Walk the PCL Data vide Mail dated 15/03/2016 and TRANSINX_INSP-148 is considered.
1. Revised Walk the PCL Data vide Mail dated 15/03/2016 and
TRANS-INX_INSP-148 is used.
P041-PCL-024
P041-PCL-025
Steam Condensate
Purple and Yellow Dot Line
Steam Condensate from E-1142 T/S, X-1201 & X-1202
E-1142 T/S, X-1201 & X-1202
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0011 Rev-S2
0.1
103
SS 304L
No
Steam Condensate -100%

3. Other Critical parameters such as Conductivity, pH and TDS (Total Disssolved Solids) are limited to 5% higher than the known range
under normal operation or adhere to the limts set by Site Operating Practice whichever is more stringent.
procedures.
P041-PCL-026
Nitrogen
Dark Blue and Purple Dot Line
Nitrogen line to PCL-002, TK-1071, E-1124 S/S & F-1203
TK-1071, E-1124 S/S & F-1203
2310-8110-20-P041-0001 Rev-S1
2310-8110-20-P041-0004 Rev-S2
2310-8110-20-P041-0006 Rev-S3
2310-8110-20-P041-0011 Rev-S2
0.1 to 3.5
Amb
C/S
No
Nitrogen -100%
None
E-1051,D-1103 A, E-1167, E-1124 T/S, D-1240

(Jacketing) & D-1241 (Jacketing)
2310-8110-20-P041-0001 Rev-S1
2310-8110-20-P041-0003 Rev-S1
2310-8110-20-P041-0004 Rev-S2
2310-8110-20-P041-0005 Rev-S2
2310-8110-20-P041-0011 Rev-S2
1 to 2
114 to 133
C/S
No
Steam Condensate -100%

procedures.
P041-PCL-027
2310-8110-20-P041-0011 Rev-S2
200
SS 304
No
Steam

procedures.
P041-PCL-028
2310-8110-20-P041-0011 Rev-S2
2 to 5.5
Amb
SS 304L
No
DM Water -100 %
1. Max. Operating Temperature: 45 C (Amp temperature assumed as 40 deg C)

2. Other Critical parameters such as Conductivity and pH are limited to 5% higher than the known range under normal operation or adhere
to the limits set by Process Licensor whichever is more stringent.
procedures.
P041-PCL-029
1. Revised Walk the PCL Data vide Mail dated 15/03/2016 and TRANSINX_INSP-148 is used.
2. C/Steel lines listed in "Walk the PCL" data for PCL-025 moved to this
PCL as the MOC and DCC are relevant to this PCL.
P041-PCL-027
Condensate
Dark Blue and Dark Green Dot Line
Steam Condensate from E-1051,D-1103 A, E-1167, E-1124 T/S, D-1240

(Jacketing) & D-1241 (Jacketing)
P041-PCL-028
Steam
Purple and Pink Dot Line
Steam (HS/ MS/ LS) to Generic Extruder Package
P041-PCL-029
Demineralized Water
Light Green and Purple Dot Line
DM water supply to S-1371, U/S of D-1552, TK-1071 & Generic Extruder

Package
P041-PCL-030
Instrument Air
Dark Blue and Light Green Dot Line
Instrument air to Generic Extruder Package
X-1201 & X-1202
2310-8110-20-P041-0011 Rev-S2
Amb
SS 304
No
Air (Utility)
None
P041-PCL-030
P041-PCL-031
Nitrogen
Purple and Grey Dot Line
Nitrogen line to Generic Extruder Package, H-1201A/B, PCL-006 & D-1652

A/B
X-1201 & X-1202,H-1201A/B & D-1652 A/B
2310-8110-20-P041-0011 Rev-S2
0.7 to 3.5
Amb
SS 304L
No
Nitrogen
None
P041-PCL-031
Light Green and Light Blue Dot Line
Utility water to Generic Extruder Package
X-1201 & X-1202
2310-8110-20-P041-0011 Rev-S2
Amb
SS 304
No
Utility Water
1. Max. Operating Temperature: 45 C (Amp temperature assumed as 40 deg C)

procedures.
P041-PCL-032
P041-PCL-032
P041-PCLUnidentified
Dark Green and Light Blue Dot Line
Nitrogen + H20 + H2 to ATM/ Flare
X-1201 & X-1202
S-1371, U/S of D-1552, TK-1071, X-1201 & X1202
None
2310-8110-20-P041-0004 Rev-S2
1) Fatigue - Vibation
2) Corrosion Shielding / Under Deposit (External)
1. Revised Walk the PCL Data vide Mail dated 15/03/2016 and TRANSINX_INSP-148 is used.
2. C/Steel lines listed in "Walk the PCL" data for PCL-031 moved to this
PCL as the MOC and DCC are relevant to this PCL.
P041-PCL-Unidentified
PP SIMTECH COMMENTS :
PRC has provided Walk the PCL data for the lines which are unidentified
in the marked P & IDs. PP SIMTECH has reviewed the line numbers
listed in this Walk the PCL data and shifted to the respective PCLs.
However there are few more lines which could not be identified with
the existing PCLs. For such lines, the additional inspection plan
(except general corrosion) is given in this PCL which is numbered as
F041-PCL- Unidentified. PRC/Inovx to review the lines listed in this PCL
inspection Plan and shift the same to relevant PCLs based on the MoC
and DCCs present.
IOLs: Note 1
PRC Actions for Setting IOLs By Process/Operation Engineers
1. Measure and Establish Operating Temperatures.
2. If the presence of listed Damage Causing Chemicals (DCCs) or their composition is uncertain or presence of certain other DCC is suspected, instigate chemical sampling to confirm actual DCCs present and their composition.
3. Measure and establish actual Min. and Max. pH to set IOL
4. Establish Conductivity, pH to set IOL.(Specific PCL-029)
5. Establish Conductivity, pH and TDS (Total Dissolved Solids) to set IOL.(Specific PCL-025, PCL-027 and PCL-032)
6. Establish Conductivity, pH, TDS (Total Dissolved Solids) and Treatment Chemicals concentration to set IOL. (Specific PCL-021, PCL-022 and PCL-023)
7. Analyse and confirm moisture is 'Nil', unless moisture/H2O is poison to the process.(Specific to PCL- 001 to PCL-005, PCL-007 to PCL-011, PCL-014 to PCL-015, PCL-018, PCL-020)
8. If there are other additional IOLs specified by Process Licensor or Site Operating Practice, these shall be included.
IOLs: Note 2
a) It should be noted that Pressure, Temperature & Process Fluid Stream Compositions provided by PRC (as shown above for each PCL) is the known Range under Normal Operation
b) Agreed IOLs shall be set and monitored by Operations / Process Department and the impact of any excursions shall be jointly reviewed by Process/Operations/Inspection Dept, ideally on a quarterly basis.
Prepared by PPSIMTECT Solutions Ltd. - UK
IDENTIFIED DAMAGE MECHANISMS, INSPECTION PLAN and IOLs REVIEWED and APPROVED by PRC
Page 2 of 2
PRC UNIT P041 PCL DMs-INSPECTION PLAN-IOLs Rev 1 - 30/03/2016

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PETRORABIGH UNIT P041 (POLYPROPYLENE PP-1): PCLs SUMMARY WITH DMs-INSPECTION PLAN-IOLs

Process Fluid Stream

Integrity Operating Limits

Dark Green Line

D-1511, D-1501, R-1051, D-1100 A/B, D-1101

C/S & SS 304

1. Max. Operating Temperature: 105 C

1. Max. Operating Temperature: 95 C

Repair of leaked two weld joint in 4"-VG-P041-32250-1SC0P010-NI

g) From various PCL's and equipment to Atm and Flare

Dark Blue Line

Propane from P010 and Z-1051, Z-1052 to D-1550

R-1051, R-1056, R-1057, D-1550, Z-1052 & Z1053

R-1102 L & R-1102 A

a) From H-1122 to Sampling, X-1201 and ATM.

From CS1 Cylinders to R-1102 A & R-1102 L

R-1102 A & R-1102 L

1. Max. Operating Temperature: 45 C

1. Max. Operating Temperature: 75 C

1. Max. Operating Temperature: 45 C

H2O - 0.1 to 0.27%,

1. Max. Operating Temperature: 105 C

1. Max. Operating Temperature: 55 C

1. Max. Operating Temperature: 80 C

CS, SS 304 &

Dark Green Dash and Dot Line

From H-1121 to PCL-10 (U/S of E-1161 S/S)

Red Dash and Dot Line

From S-1102 A & PCL-002 to R-1102 A & H-1121

S-1102 A, R-1102 A & H-1121

1. Max. Operating Temperature: 90 C

Dark Blue Dash and Dot Line

1. Max. Operating Temperature: 125 C

Light Green Line

From R-1102 A to H-1121

R-1102 A & H-1121

1. Max. Operating Temperature: 90 C

Brown Dash and Dot Line

From D-1153 to Pelletizer

Solid PP (HC - 100%)

1. Max. Operating Temperature:75 C

Dark Green Dot Line

From E-1124 S/S to H-1122, PCL-014, PCL-006 & ATM

E-1124 S/S, H-1123, H-1122, E-1121 S/S & E1122 S/S

1. Max. Operating Temperature: 115 C

Purple Dot Line

F-1121, D-1550 & D-1151

1. Max. Operating Temperature: 55 C

Light Green Dot Line

BoDH from Z-1552

1. Max. Operating Temperature: 55 C

Orange Dot Line

From Z-1552 to D-1552

Z-1552 & D-1552

1. Max. Operating Temperature: 55 C

Pink Dot Line

From F-1300 to Drain

1. Max. Operating Temperature: 51 C

Prepared by PPSIMTECT Solutions Ltd. - UK

PRC UNIT P041 PCL DMs-INSPECTION PLAN-IOLs Rev 1 - 30/03/2016

Process Fluid Stream

Integrity Operating Limits

1. Max. Operating Temperature: 85 C

From H-1121/PCL-002 to H-1122