Replacement of Lip Seal Gasket for Heat Exchanger

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WORK METHOD STATEMENT FOR TUBE BUNDLE REPLACEMENT WITH CUTTING & WELDING OF LIP SEAL GASKET ON HEAT EXCHANGER 

 

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2.0 PURP-/! 3.0 /&-P! 4.0 !5U)P'!"T 6.0 R!!R!"&!/ 7.0 /%!T8 PR!&%UT)-"/ 7.2 PR!P%R%T)-" 7.3 #UR)"+ /)T! !9!&UT)-" 7.4 /%!T8 )"/P!&T)-"/ :.0 R!/P-"/))$)T)!/ ;.0 5U%$)T8 )T)!/ 20.4 !9!&UT)-" - (-R  22.0 *-U/!!!P)"+

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PURPOSE

The purpose of this work method statement is to describe in detail all required measures taken in order to execute the job on TU! U"#$! R!P$%&!'!"T ()T* &UTT)"+ , (!$#)"+ - $)P /!%$ +%/!T. 2.0 SCOPE

This document is applicable to all emplo1ees and contractors working for TU! U"#$! R!P$%&!'!"T ()T* &UTT)"+ , (!$#)"+ - $)P /!%$ +%/!T under the control of.

3.0 EQUIPMENT Sl No

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EQUIMENT NAME

EQUIMENT TAG

PART NAME

LOCATION

TUBE SHEET

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.0 REFERENCES • • •

+eneral !ngineering Practices. !quipment #rawings %pplicable procedure? if an1.

.0 SAFET! PRECAUTIONS"

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@/% A@ob /afet1 %nal1sisB should be discussed with all concerned persons and to be

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followed strictl1. Rigging Plan to be approved from C&-'P%"%8 "%'! D before start an1 lifting activities and to be followed strictl1.

HEALTH# SAFET! AND EN$IRONMENT MEASURES %.1 PREPARATION

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!nsure all workers involved in the lifting operation put on PP! all times. rief individual worker the roles and responsibilities of each. (ork execution shall be monitored? witnessed and supervised in accordance to

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C&-'P%"%8 "%'! D specifications? requirements and */! rules.  emplo1ees shall be well informed especiall1 concerning inEplant working conditions.

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Recorded #ail1 Tool ox 'eeting is required. %ll activit1 shall be supervised b1 safet1 officer at site.

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%.2 LIFTING ATI$ITIES • •

!nsure safe work procedure for lifting operation is observed. !nsure proper lifting method E with the correct tools are used.

%.3 DURING SITE EXECUTION • • • • • • • • •

!nsure workers are distributed to each designated place. !nsure workers at all times to be in proper gear where required. !nsure all workers assigned are involved in its particular task. rief individual worker the roles and responsibilities before start work. !nsure support s1stems are installed accordingl1 as required. !nsure all tools to be used have been inspected and tag b1 /afet1 #ept. !nsure work areas are clearl1 marked to restrict access to authoriFed personnel onl1. !nsure that equipmentGs to be used are properl1 tagged and checked. !nsure that welders are qualified? with the correct PP!s? and well versed on the job at hand with the approved welding procedure

%. SAFET! INSPECTIONS Page 3 of 10

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)t shall be responsibilit1 of the /upervisor to routinel1 inspect the ph1sical areas under their control in an1 welding works. This inspection shall include determining !quipment? Rigging? supports? scaffolds and ladders are appropriatel1 installed or use? and if the job site is cleaned up after the da1Gs work.

.0 RESPONSIBILITIES"

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The Project 'anger , )n charge will be responsible to manage and direct project execution activities and ensure efficient implementation of works in accordance with the

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Project /pecification and standards. Project !ngineers , /upervisors will executed the job as instructed b1 Project )ncharge. The 5%H5& Representative of %l 'uFain , C&-'P%"%8 "%'! D shall witness all activities and tests performed and ensure that all works are carried out to C&-'P%"%8

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 "%'! D satisfaction. /upervisor shall monitor the execution of the works. oreman shall lead the work force during the execution of the works.

QUALIT!

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%ll the 5ualit1 related documents H Procedures shall be submitted and get it approved

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from C&-'P%"%8 "%'! D )nspection before proceed to work? /ubmission of weld map H location map identif1ing the welding work shall be prepared

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 b1 the 5%H5& !ngineer if required. /ubmission of )TP A)nspection Test PlanB shall be prepared b1 the 5%H5& !ngineer  efore )nstallation of the new equipment 5& )nspector should verif1 the new equipment

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, !xisting equipment mating flange gasket face. The 5ualit1 department A5%5& representativeB shall ensure that the alignment is done to

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C&-'P%"%8 "%'! D satisfaction The required materials shall be checked for conformance before use. %ll the calibrated inspection tools to be used.  5& inspector coEordinate with C&-'P%"%8 "%'! D inspector for all inspection and

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 "#T activates.   The1 shall be responsible to assure? monitor , control qualit1 activities for the tube

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 bundle replacement work. -bserve the stage wise inspection as per the approved inspection and test plan A)TPB for 

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the job. Page  of 10

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+et clearance from C&-'P%"%8 "%'! D representativeAsB at site before proceeding

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for the subsequent stages. )nspection report shall be prepared and get it signed from C&-'P%"%8 "%'! D

TOOLS AND EQUIPMENT TO BE USED" • • • • • • • • •

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(elding +enerator Portable (elding machine 'obile crane. orklift Rigging tools /tandard tools %ir compressor  olt torqueingH Tensioning &old &utting machine. Tower light

DOCUMENT SUBMISSION FOR APPRO$AL • • •

@/% A@- /%!T8 %"%$8/)/B (ork 'ethod statement. 5%H5& documents.

10.0 SITE EXECUTION

10.1 PREPARATIONS •

/ubmitted documents to be followed up and get approval. Revision will be done? if

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required. /ite facilit1 to be mobiliFed to the site allocated area. &heck and receive free issue materials as per requirement. )n case materials have an1

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discrepanc1 refer materials list? same shall be informed to C&-'P%"%8 "%'! D. 10.2 PRE SHUTDOWN ACTI$ITIES • • • • • •

%ppl1 the work permit as per the @ob to be executed. !rection of scaffolding b1 C&-'P%"%8 "%'! D as per %$ 'UI%)" Requirement. /upport the &hannel )nlet b1 scaffolding and chain block. Removal of )nsulation b1 C&-'P%"%8 "%'! D as per %$ 'UI%)" Requirement. %ll required tools and equipment to be made available near to the working area. Ph1sical verification and dimension inspection to be done and tie the metal tag as per the drawing.

10.3 EXECUTION OF WORK  *EQUIPMENT NAME + A" , TUBE SHEET INSPECTION AND CLEANING  

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+et the applicable work permit from the operation. linding , #eE blinding b1 team. Removal of &hannel inlet and channel outlet b1 team. Remove the stud bolts in the 2J3sequence A36 noGs of stud bolts to be removedB b1 torqueing. Remove the jack bolts b1 hand tools. &ut , remove the 03 nos. of centering pin b1 grinding and new centering pin provided  b1 C&-'P%"%8 "%'! D during installation of tube bundle. Perform cutting b1 2 mm grinding in the @oint noJ E +/ E03 A Reference drawing no:  D0553-E6301A/B-D -002, Rev. 03)

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Rearrange , )nstall alternate stud bolts sequentiall1 at the uncut lip seal locations. %fter finishing the cutting? *old the channel head lifting lug A03 nos.B using chain block , crane and remove the balance stud bolts. Remove the channel head cover for inspection and cleaning. &leaning b1 team. Tube /heet inspection and cleaning followed b1 inspection. %fter inspection and cleaning? centering pin shall be inserted to the shell flange. &hannel cover shall be installed using &rane b1 team. Page  of 10

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@ack bolts shall be installed. %ll /tud bolts shall be reinstalled with :0K of torqueing value. %fter torqueing of all the bolts? 2J3 alternative stud bolt shall be unbolted and removed. (elding shall be performed at @oint noJ E +/ E03 A Reference drawing no: - D0553 E6301A/B-D -002, Rev. 03) on the unbolted locations b1 two welders located at

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opposite side in clock wise direction as per approved (P/. /tud bolts shall be installed sequentiall1 and alternativel1 in the welded locations. %fter completing all welding at both side of tube sheet flange? #PT and inspection shall  be carried out. 200K of torqueing value shall be applied to the stud bolt. Reinstall the @ack bolts. Pneumatic test shall be done for the final lip seal weld joint b1 appl1ing soap solution to identif1 integrit1 of joint A Pneumatic test pressure value provided b1 C&-'P%"%8

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 "%'! DB. Reinstall the disconnected channel inlet and outlet line with new gasket followed b1 inspection. #eEblinding shall be done followed b1 inspection and torqueing.

*EQUIPMENT NAME + B" , TUBE BUNDLE REPALCEMENT • • • •

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+et the applicable work permit from the operation. linding , #eE blinding b1 team. Removal of &hannel inlet and channel out let b1 team. Remove the stud bolts in the 2J3 sequence A36 noGs of stud bolts to be removedB b1 torqueing. Remove the jack bolts b1 hand tools. &ut , remove the 03 nos. of centering pin b1 grinding and new centering pin provided

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 b1 C&-'P%"%8 "%'! D during installation of tube bundle. Perform cutting b1 2 mm grinding in the @oint noJ E +/ E03 A Reference drawing no: -

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 D0553-E6301A/B-D -002, Rev. 03) Rearrange , )nstall alternate stud bolts sequentiall1 at the uncut lip seal locations.

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%fter finishing the cutting? *old the channel head lifting lug A03 nos.B using chain block , crane and remove the balance stud bolts. Remove the channel head cover for inspection and cleaning. &leaning b1 team. Remove the Tube sheet bundle using bundle puller b1 team. Perform grinding to cut the gasket from @oint noJ E +/ E02 A Reference drawing no:  D0553-E6301A/B-D -002, Rev. 03) . &arefull1 remove the gasket from both side of the tube sheet. +asket faces of new tube sheet shall be cleaned and #PT to be done. >isual inspection to be done for the removed gasket b1 inspection team.

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eveling of +asket at @oint noJ E +/ E03 A Reference drawing no: - D0553-E6301A/B-D

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-002, Rev. 03) as per the drawing. Prior to fit up of gaskets to the new tube sheet gasket faces? the base metal of the gasket

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shall be prepared to required profileHweld geometr1 in accordance with the drawings. Preheating at L=7M &N shall be done as per the approved (P/ and documents b1 gas

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torch. it up of lip seal at new tube sheet flange shall be performed at @oint noJ E +/ E02 A Reference drawing no: - D0553-E6301A/B-D -002, Rev. 03)  b1 using & clamps fixing

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to tighten lip seal with flange in equal distance as required followed b1 inspection. Preheating at L=7M &N shall be done as per the approved (P/ b1 gas torch. (elding shall be performed as per approved (P/? followed b1 #PT and inspection. Prior to install tube sheet? centering pin shall be inserted to the shell flange.  "ew tube sheet shall be installed using bundle puller b1 team. &hannel cover shall be installed using &rane b1 team. @ack bolts shall be installed. %ll /tud bolts shall be reinstalled with :0K of torqueing value. %fter torqueing of all the bolts? 2J3 alternative stud bolt shall be unbolted and removed. (elding shall be performed at @oint noJ E +/ E03 A Reference drawing no: - D0553 E6301A/B-D -002, Rev. 03) on the unbolted locations b1 two welders located at

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opposite side in clock wise direction as per approved (P/. /tud bolts shall be installed sequentiall1 and alternativel1 in the welded locations.

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%fter completing all welding at both side of tube sheet flange? #PT and inspection shall  be carried out. 200K of torqueing value shall be applied to the stud bolt. Reinstall the @ack bolts. Pneumatic test shall be done for the final lip seal weld joint b1 appl1ing soap solution to identif1 integrit1 of joint A Pneumatic test pressure value provided b1 C&-'P%"%8

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 "%'! DB. Reinstall the disconnected channel inlet and outlet line with new gasket followed b1

inspection. #eEblinding shall be done followed b1 inspection and torqueing. • 11.0 HOUSEKEEPING %l 'uFain shall perform the house keeping activities on dail1 basis as per plant safet1 standard requirement.

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'aintain cleanliness and orderl1 stocking of material , tools. Pick up and dispose wastes , other debris to C&-'P%"%8 "%'! D 1ard or ware

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house prior to leaving site area. /tore tools? equipment and unused materials properl1 store at the end of the workda1.

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