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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)
Corrosion - Localized (Heat Traced)
Erosion Corrosion (Solid Particles)
Erosion Corrosion (Jacketed Piping)
Fatigue - Vibration
SCC-Chlorides(External)

1. Max. Operating Temperature: 95 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.

1)
2)
3)
4)

Corrosion - General
Corrosion - Localized (No Flow)
Corrosion - Localized (Heat Traced)
Erosion Corrosion (Solid Particles)

Corrosion - General
Corrosion - Localized (No Flow) (C/Steel)
Corrosion - Localized (No Flow) (SS 304)
Corrosion - Localized (No Flow) (SS 304L)
Erosion Corrosion (2 Phase Flow & Solid Particles)
Erosion Corrosion (Liquid Flashing)
SCC-Chlorides(External)

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)

PP SIMTECH COMMENTS:
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

PP SIMTECH COMMENTS:
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.

1. Max. Operating Temperature: 45 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.

P041-PCL-003

1. Max. Operating Temperature: 75 C


2. DCCs Compositions: H2O-Nil; H2 - 0.005%
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.

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)

1. Max. Operating Temperature: 45 C


2. DCCs Compositions: H2O-Nil.
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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)

1. Max. Operating Temperature: 105 C


2. DCCs Compositions: H2O - 0.1 to 0.27%
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.

P041-PCL-006

Amb to 50

C/S

No

CO - 100%

1) Corrosion - General
2) Corrosion - Localized (No Flow)

1. Max. Operating Temperature: 55 C


2. 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.
3. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
procedures.

P041-PCL-007

Corrosion - General
Corrosion - Localized (No Flow)
Corrosion - Localized (Heat Traced)
Fatigue - Vibration.
SCC-Chlorides(External)

1. Max. Operating Temperature: 80 C


2. DCCs Compositions: H2O - Nil; H2 - 0.2%
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
procedures.

P041-PCL-008

SS 316L

CS, SS 304 &


SS 304L

Corrosion - General
Corrosion - Localized (No Flow)
Erosion Corrosion (2 Phase Flow & Solid Particles)
SCC-Chlorides(External)

PP SIMTECH COMMENTS:
1. SS 316L lines listed in "Walk the PCL" data for PCL-010 moved to
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
Corrosion - Localized (No Flow)
Erosion Corrosion (Solid Particles)
SCC-Chlorides(External)

1. Max. Operating Temperature: 90 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.

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
Corrosion - Localized (No Flow)
Corrosion - Localized (Heat Traced)
Erosion Corrosion (2 Phase Flow & Solid Particles)
Erosion Corrosion (Liquid Flashing)
Fatigue - Vibration

1. Max. Operating Temperature: 125 C


2. DCCs Compositions: H2O - Nil; H2 - 0.03 to 0.16%
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.

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
Corrosion - Localized (No Flow)
Fatigue - Vibration
SCC-Chlorides(External)

1. Max. Operating Temperature: 90 C


2. DCCs Compositions: H2O - Nil; H2 - 0.17 to 0.3%
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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


2. 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.
3. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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)

1. Max. Operating Temperature: 115 C


2. DCCs Compositions: H2O - 0.62%.
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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%

1) Corrosion - General
2) Corrosion - Localized (No Flow)
3) Erosion Corrosion (Solid Particles)

1. Max. Operating Temperature: 55 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.

P041-PCL-014

2310-8110-20-P041-0006 Rev-S3

1) Corrosion - General
2) Corrosion - Localized (No Flow)

Corrosion - General
Corrosion - Localized (No Flow)
Corrosion - Localized (Heat Traced)
SCC-Chlorides(External)

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%

1) Corrosion - General
2) Corrosion - Localized (No Flow)

1. Max. Operating Temperature: 55 C


2. DCCs Compositions: H2O-Nil.
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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%

1) Corrosion - General
2) Corrosion - Localized (No Flow)

1. Max. Operating Temperature: 55 C


2. DCCs Compositions: Establish Composition range for H2O.
3. Stream pH: Maintain within Normal Operating Range with Max and Min excursions limited to 5%.
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.

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

1) Corrosion - General

1. Max. Operating Temperature: 51 C


2. DCCs Compositions: Establish Composition range for H2O.
3. Stream pH: Maintain within Normal Operating Range with Max and Min excursions limited to 5%.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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

PP SIMTECH COMMENTS:
1. SS 304L lines listed in "Walk the PCL" data for PCL-010 moved to
this PCL as the MOC and DCC are relevant to this PCL.

1. Max. Operating Temperature: 85 C


2. DCCs Compositions: H2O-Nil; H2 - 0.2%
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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

1) Corrosion - General
2) Corrosion - Localized (No Flow)
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%

1) Corrosion - General
2) Erosion Corrosion (2 Phase Flow & Solid Particles)
3) SCC-Chlorides (External)

1. Max. Operating Temperature: 65 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. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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

1) Corrosion - General

1. Max. Operating Temperature: 51 C


2. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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

1) Corrosion - General
2) Corrosion - Localized (No Flow)

1. Max. Operating Temperature: 51 C


2. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
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.
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.

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%

1) Corrosion - General
2) Corrosion - Localized (No Flow)
3) CUI

1. Max. Operating Temperature: 65 C


2. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
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.
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.

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

1) Corrosion - General
2) Corrosion - Localized (No Flow)
3) CUI

1. Max. Operating Temperature: 205 C


2. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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
Corrosion - Localized (No Flow)
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

PP SIMTECH COMMENTS:
1. Revised Walk the PCL Data vide Mail dated 15/03/2016 and TRANSINX_INSP-148 is considered.

PP SIMTECH COMMENTS:
1. Revised Walk the PCL Data vide Mail dated 15/03/2016 and
TRANS-INX_INSP-148 is used.

P041-PCL-024

PP SIMTECH COMMENTS:
1. SS 304L lines listed in "Walk the PCL" data for PCL-027 moved to
this PCL as the MOC and DCC are relevant to this PCL.

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%

1) Corrosion - General
2) Corrosion - Localized (No Flow)
3) SCC-Chlorides (External)

1. Max. Operating Temperature: 108 C


2. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
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.
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.

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%

1) Corrosion - General
2) Corrosion - Localized (No Flow)

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%

1) Corrosion - General
2) Corrosion - Localized (No Flow)

1. Max. Operating Temperature: 138 C


2. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
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.
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.

P041-PCL-027

2310-8110-20-P041-0011 Rev-S2

200

SS 304

No

Steam

1) Corrosion - General
2) SCC-Chlorides (External)

1. Max. Operating Temperature: 205 C


2. Flow Rate/Velocity of Process Fluid Stream: Limit High and Low Flow Rate/Velocity excursions to 10% of the Normal Operating Range.
3. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
procedures.

P041-PCL-028

2310-8110-20-P041-0011 Rev-S2

2 to 5.5

Amb

SS 304L

No

DM Water -100 %

1) Corrosion - General
2) Corrosion - Localized (No Flow)

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.
3. 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.
4. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
procedures.

P041-PCL-029

PP SIMTECH COMMENTS:
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)

1) Corrosion - General
2) Corrosion - Localized (No Flow)

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

1) Corrosion - General
2) Corrosion - Localized (No Flow)

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) Corrosion - General

1. Max. Operating Temperature: 45 C (Amp temperature assumed as 40 deg C)


2. 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.
3. Start-up, Shutdown, Chemical and Steam Cleaning Operation Parameters: These shall be as per process Licensor and/or Site approved
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)

PP SIMTECH COMMENTS:
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:
1. SS 304L lines listed in "Walk the PCL" data for PCL-026 moved to
this PCL as the MOC and DCC are relevant to this PCL.

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