WELDING THE DAMAGED JACKET OF REACTOR

1.0 PURPOSE:
    
    To  describe a  standard operating procedure for  welding   the damaged jacket of reactor.
    
2.0    SCOPE:
    
    The standard operating procedure describes in detail the method of welding the damaged jacket of reactor.
    
    This SOP is applicable for welding of damaged jacket of reactor where the production clearance is not available for position welding/hot job and also for position welding where the production clearance available by obtaining welding work permit.
    
3.0    RESPONSIBILITY:
    
    The responsibility of welding the damaged jacket  of  reactor lies with the staff of rank not lower than supervisor of  maintenance department.
    
    The  responsibility of preparing, reviewing  and approving  the standard  operating  procedure lies with the  Manager  -  Maintenance,  Head of Production and Head of QAD respectively.
    
4.0    METHOD:
    
4.1    Welding the damaged jacket of reactor where production clearance is not available for position welding/hot job.
    
4.1.1    Isolate the equipment electrically.
    
4.1.2    Dismantle the Motor, gear box from the reactor.
    
4.1.3    Remove insulation of the reactor. 
    
4.1.4    Dismantle all the connected lines from the reactor shell as well as jacket.
    
4.1.5    Remove bolts of the  four cleats. 
    
4.1.6    Take out the reactor using chain pulley block from the position and keep it on reactor trolley.
    
4.1.7    Take it to the mechanical work shop.
    
4.1.8    Clean  the portion  that is to be welded  using wire brush  and then with emery paper.
    
4.1.9    Weld the reactor jacket at the damaged portion or replace  part of the jacket with new plate as required.
    
4.1.10    Test the reactor jacket hydraulically upto 1.5 times the  working pressure in the jacket.
    
4.1.11    Check for any leakage of the reactor jacket. 
    
4.1.12    If  the jacket leaks drain water from the jacket and  weld  the  portion where it is leaking.
    
    
4.1.13    Repeat the steps  4.1.10 to 4.1.12 till the leak is rectified.
    
4.1.14    Shift   the  reactor  to the production block, erect the  reactor  in  its  position and assemble the gear box, motor and all lines connected lines.
    
4.1.15    Insulate the jacket.
    
4.1.16    Restore the power supply to the equipment.
    
4.1.17    Record the data in history card of the equipment.
    
4.2    Welding the damaged jacket of reactor where the production clearance is available by obtaining welding work permit.
    
4.2.1    When the reactor jacket welding is to be done in position, obtain welding work permit from the concerned departments.
    
4.2.2    Remove  the  insulation  of the jacket.
    
4.2.3    Isolate the equipment electrically.
    
4.2.4    Dismantle the Motor, gear box from the reactor.
    
4.2.5    Dismantle all the connected lines from the reactor shell as well as jacket.
    
4.2.6    Clean  the portion  that is to be welded  using wire brush  and then with emery paper.
    
    
4.2.7    Weld the reactor jacket at the damaged portion or replace  part of the jacket with new plate as required.
    
4.2.8    Test the reactor jacket hydraulically upto 1.5 times the  working pressure in the jacket.
    
4.2.9    Check for any leakage of the reactor jacket. 
    
4.2.10    If  the jacket leaks drain water from the jacket and  weld  the  portion where it is leaking.
    
4.2.11    Repeat the steps  4.1.8 to 4.1.10 till the leak is rectified.
    
4.2.12    Insulate the jacket .
     
4.2.13    Restore the power supply.
    
4.2.14    Record the welding data in the history card of the equipment.
    
5.0    RECORDING:
    
    The  responsibility of recording the welding of jacket  in  the equipment history  card  as per the SOP lies with the staff of  rank  not lower than maintenance supervisor.
    

Reactor, damaged jacket, engineering