Transcript ELEFSIS REFINERY UPGRADE PROJECT

TÜV RHEINLAND HELLAS ACTIVITIES
INSPECTOR / AUDITOR: SIDIROPOULOS ELEFTHERIOS
OWNER
• HELPE
EPCM CONTRACTOR
• TECNICAS REUNIDAS
WORKS CONTRACTOR
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J/V EAMT (EKME-ATERMON-METKA-TMUCB)
METRON
GENKAT
MAZO
THIRD PARTY INSPECTION & NOTIFIED BODY
• TÜV RHEINLAND HELLAS
Distillation of 2.200.000 tn
fuel oil high concentrate
sulfur (>3%) to:
1. Production of Diesel
1.320.000 tn with low
sulfur (automotive)
2. Production of
naphtha 450.000 tn
appropriate for
petrochemicals and
gasoline
3. Thermal energy of
250 MW clean gas
form low caloric for
heaters instead of fuel
oil
U-85
U-36
AMINE RECOVERY
UNIT
SULPHUR STORAGE
& HANDLING
FACILITIES
U-37
SOUR WATER UNIT
U-38
SULPHUR UNIT
U-82
FLARE SYSTEM
U-72
BOILER FEED
WATER / STEAM
SYSTEM
U-81
FUEL GAS SYSTEM
UTILITIES – AREA 2
TÜV RHEINLAND HELLAS
DUTIES
U-80
REFINERY FUEL OIL
SYSTEM
U-33
HYDROGEN UNIT
U-78 PLANT &
INSTRUMENT AIR
SYSTEM
U-73 CONDENSATE
RECOVERY SYSTEM
U-75
COOLING WATER
SYSTEM
U-74
DEMINERALISED
WATER SYSTEM
U-70
INTERCONNECTING
TÜV RHEINLAND
SHOP INSPECTION
Inspector Sidiropoulos Eleftherios for ERUP
From August 2009 until July 2011 several
inspections completed successfully in
European countries manufacturers to bring
and delivered equipments and vessels in
compliance with PED97/23 , European and
other international standards.
Pressure vessels in Italy, Switzerland &
Poland
 Heat exchangers in Greece and Sweden
 Valves in Finland
 Sulphur handling package in Finland and
Estonia
 Radar level transmitters in Sweden
ERUP locate in Elefsina Attica Greece. It is an extension/upgrading of
HELPE premises. Our duties listed as follows but not limited to:
PIPING according to ASME B31.3
 Radiography interpretation.
 Ultrasonic thickness & weld check.
 Liquid Penetrates of Socket welds & when
needed.
 Magnetic Particles of bevel ends & when
needed.
 PWHT of CS and Low Alloy steels,
Preheating and Post heating check.
 PMI of Stainless steel & Duplex.
 Hardness & Ferrite tests.
 Hydro tests & Pneumatic tests
 Visual check of welds before & during final
acceptance tests.
 Mechanical tests witnessing and
acceptance of PQR and issuing of
WPQs.
 Witnessing of bolt tightening procedures
for critical flanges.
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ATMOSPHERIC TANKS according to
API 650
 Traceability and material check
 NDTs as per applicable code.
 Vacuum test of bottom plates.
 Diesel test of shell and base plates
connection.
 Plumpness & Roundness check.
 Local deviations (peaking & banding)
check.
 Witnessing of welding procedures,
welders and w.operators qualification.
 Any grinding cause local low thickness
was UT measured and filled (built up)
with the approved welding repair
method. UT & PT witnessed.
 Nameplates checked.
 Pneumatic tests on reinforcing pads and
Hydrostatic tests (Atmospheric) .
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FLANGE ALIGNMENT & PIPING SUPPORT
POSITIVE MATERIAL ID. (PMI) & PRESSURE TEST
OTHER ACTIVITIES
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FLARE ERECTION
SULPHUR HANDLING PACKAGE CONSTRUCTION
PLUMB & LEVELLING OF VESSELS & HEAT EXCHANGERS
FLANGE AND SHAFT ALIGNMENTS OF PUMBS & AIR
COOLERS
COOLING TOWER CONSTRUCTION
STEAM BOILERS CONTSTRUCTION
REFRACTORY APPLIANCE, HAMMER & LAB TEST
WITNESSING
INTERNALS DIMENSIONAL CONTROL AND LEAK TEST.
TRANSFER LINE GOLDEN JOINTS (FIT UP/WELDING/NDTs)
INSULATION CHECK
PAINTING CHECK
Refractories /Hammer test
Transfer line (Reactor) / PSA
During prealignment flanges were checked for parallelism. Shaft alignment
performed as per manufacturers manual and the applicable codes. After
hydrostatic test final flange and shaft alignment performed.
Alignment activities were done according to API code & HELPE
specifications
Notified Body services
CE marking of Area 2
units are going to be
stamped from NoBo 2221
TÜV RHEINLAND HELLAS.
NOTIFIED BODY ACTIONS
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NDT review
NDT operators qualification
review
Welding procedures, welders
and welding operators review
Welding consumables review
Hydrostatic test witnessed
Drawings and engineering
calculations check
Stress analysis reports
witnessing
Particular material appraisal
(PMA) review
Nameplate check
ERUP TEAM
Technical Director: Paparidis Georgios
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FIELD INSPECTION
 GIAMAS DIMITRIOS
 SIDIROPOULOS ELEFTHERIOS
 CHATZIFOTIADIS PANTELIS
 LAMBIRIS LAMBROS
 DOVAS CHRISTOS
 GKOSDIS GEORGIOS
 KYAMIDIS CHRISTOS
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DOCUMENT CONTROL &
ADMINISTRATION
 MIKELIS EMMANUEL
 TSANTYLA ANASTASIA
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SHOP INSPECTION
 SIDIROPOULOS ELEFTHERIOS
 CHATZIFOTIADIS PANTELIS
 KARATHODOROS ELIAS
 LAMBIRIS LAMBROS
 MIKELIS EMMANUEL
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WORKSHOP
 MANTAS FOTIS
 LAMBIRIS LAMBROS
 DOVAS CHRISTOS
 CHATZIFOTIADIS PANTELIS
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DOCUMENT REVIEW
 MENTZOS MICHAEL
 MOURKOS THEOFANIS
TO BE CONTINUED