BASRAH GAS COMPANY –KHOR AL-ZUBAIR LPG UNITS Procedure Maintenance of Heat Exchangers to LPG Units [12.112.2-12.3] A 02 Validity Status Rev. number 12/01/2019 Issued for Review Date Prepared by Description Revision Index Company logo and business name Checked by Approved by Contrac tor Approv al Project name Company Identification Procedure for Field Cleaning of heat Exchangers to LPG Units [12.1-12.2-12.3] Job No. TBA Contractor logo and business name Company Approval Contractor Identification Contract No. . Vendor logo and business name Facility Name Order N. Scale Location BASRAH GAS COMPANY –KHOR AL-ZUBAIR ONSHORE Sheet of Sheets N.A 1 of 15 LPG UNITS Document Title Procedure for Field Cleaning of Heat Exchangers to LPG Units [12.1-12.2-12.3] Software: Microsoft Word 97-2003 Supersedes No. Superseded by No. Plant Area KAZ Plant Unit LPG unit File N° 40808597 Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA Validity Status Rev. . A 00 REVISION HISTORY Rev. Date Nr. of sheets A 11/01/2019 15 Description ISSUED FOR APPROVAL Sheet of Sheets 2 / 15 Owner Logo and business name of document Owner Company Identification Owner Identification NlA Revision Index Validity Status Rev. . A 00 Sheet of Sheets 3 / 15 INDEX 1- SCOPE AND FIELD OF APPLICATION ………………………………………………………………………...….. 4 2- DOCUMENTS REFERENCE …………………………………………………………………………….................. 4 2.1 CONTRACT DOCUMENTS …………………………………………………………………………………….…. . 4 2.2 INTERNATIONAL STANDARD & NORMS……………………………………………………………………. 4 3-ABBREVIATIONS AND DEFINITIONS………………………………………………………..……….............….. 4 3.1ABBREVATIONS ………………………………………………………………….............................…........… 4 3.2 DEFINITIONS …………………………………………………………………………………............................. 4 4- HSE …………………………………………………………………………………......................………………..……... 5 4.1 RISK ASSESSMENT FOR BUNDLE EXTRACTION & CLEANING ACTIVITIES…......….………… 5 4.2 SAFETY PRECAUTION ………………………………………………………………………………….…...…… 13 5- RESPONSIBILITY ………………….……………………………………………………………....................……… 13 6- RESOURCES ……………………………………………………………………………………….....................……..… 14 6.1-PERSONNEL ………………………………………………………………..................……………………………….. 14 6.2-EQUIPMENT……………………………………………………………..................………….………………………… 14 7- PROCEDURE ,……………………………………………………………....................……….……………………….. 15 8- ATTACHMENT ………………………………………………………………………….……………………...…………… 15 Owner Logo and business name of document Owner Company Identification Owner Identification NlA 1. Revision Index Validity Status Rev. . A 00 Sheet of Sheets 4 / 15 SCOPE AND FIELD OF APPLICATION The scope of this Procedure is to define the method adopted by BAFCO and describe the approach to perform for the Procedure for Extraction , Field Cleaning, Gaskets replacement, Hydro-test & reinstatement of tube Bundle for LPG Units [12.1-12.2-12.3] Accordingly to applicable Company (BGC) drawings and specifications. 2. DOCUMENTS REFERENCE : 2.1 CONTRACT DOCUMENTS: 2.2 To be provided by the client before starting the work. INTERNATIONAL STANDARD & NORMS - ISO 9001: 2008 Quality Management systems – Requirements - IS0 14001 : 2004 Environmental Management System . - OHSAS 18001: 2007 Occupational Health and Safety Management System . - TEMA-R Tubular Exchangers Manufacturing Association. - API-660 Shell & Tube Heat Exchangers for General Refinery Services . - ASME B31.3 process piping (latest edition) . 3. ABBREVIATIONS AND DEFINITIONS 3.1 ABBREVATIONS 3.2 4. Basrah Gas Company Bawabat Al-Fayhaa Co. Personal Protection Equipment Liquefied Petroleum Gasses : BGC : BAFCO : PPE : LPG DEFINITIONS - Site : Mean the location where the project is to be constructed and the vicinity thereof - Company : BGC - Contractor : BAFCO - Project Manager : PM - Site Manager : SM HSE Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA 4.1 Validity Status Rev. . A 00 Sheet of Sheets 5 / 15 RISK ASSESSMENT FOR BUNDLE EXTRACTION & CLEANING ACTIVITIES It is responsibility of the Construction Manager, HSE Project Supervisor to consider any concurrent risk or simultaneous operations when planning for execution of relevant activities, in order to identify the need for further Risk Assessment. It is responsibility of the Coating Supervisor to assess, with the help of the HSE Officer in charge, to check the fully applicability of the above mentioned Risk Assessments. INCREASING LIKELIHOOD Reputation Environment Assets A People SEVERITY CONSEQUENCES No injury or health effect No damage No effect 0 No impact 1 Slight injury or health effect Slight damage Slight effect Slight impact 2 Minor injury or health effect Minor damage Minor effect Minor impact 3 Major injury or health effect Moderate damage Moderate effect PTD or up to 3 fatalities More than 3 fatalities Major damage Major effect 4 5 Massive damage Massive effect Never heard of in the Industry Moderate impact Major impact Massive impact The four steps of a RAM assessment: 1. Identify potential consequences (credible scenarios) 2, Estimate severity of each potential consequence 3. Estimate likelihood of potential consequence (past experience) 4. Estimate the risk rating B Heard of in the Industry C Has happened in the Organization or more than once per year in the Industry D Has happened at the Location or more than once per year in the Organization E Has happened more than once per year at the Location Owner Logo and business name of document Owner Company Identification Owner Identification NlA Revision Index Validity Status Rev. . A 00 Sheet of Sheets 6 / 15 Light Blue/Low: Manage for continuous improvement, although Businesses may set lower priority for Further Risk reduction. Blue/Medium: Manage for continuous improvement through the effective implementation of the HSSE Management System. Yellow/High: Identify and implement controls and recovery measures to reduce Risk to ALARP. Red/Serious: Identify and implement Controls and Recovery Measures to reduce the Risk to ALARP and provide a documented demonstration of ALARP by a Bow Tie or equivalent methodology. Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA Risk Ranking PRIOR to Controls HAZARD Persons Implemented Affected REQUIRED HAZARD CONTROL Validity Status Rev. . A 00 Risk Ranking AFTER Implemented control measures required to Consequence injury. Probability Consequence Probability Performing Authority, Supervisor and Operatives Blue Yellow Red Blue Blue Yello w Ensure that all essential materials/equipment’s (Multi Gas Detector, BA set, Full body Harness, Life line lighting etc) are available at the work location. C 4 HIGH Ensure necessary PTW/HITRA is obtained through CNOOC. By WHOM By When Nominate the person who L. Red Poor Task Planning 7 / 15 Controls For each hazard identified list the eliminate or minimize the risk of L. Blue Sheet of Sheets C 1 C 1 MED will be required to action the control measures. Probability JOB SUPERVSOR PRIOR TO START UP Conduct Tool Box Talk and use of all required PPE to be worn. Incompetent Personnel Performing Authority, Supervisor and Operatives C 3 HIGH MED JOB SUPERVSOR Incompete nt Personnel MED JOB SUPERVSIOR Oxygen Deficiency Ensure valid certification is checked prior to work commencing. Operatives Oxygen Deficiency Ensure all personnel are trained and competent for Confined Space Entry and works. C 3 HIGH Forced Air Supply, Ventilate if possible. Medical team to be informed of the location of the confined space work before work starts, and when the work is completed. Fixed and personal gas monitors to be used at all times C 1 Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA Risk Ranking PRIOR to Controls HAZARD Persons Implemented Affected REQUIRED HAZARD CONTROL Validity Status Rev. . A 00 Risk Ranking AFTER Implemented control measures required to Yellow Red Consequence Blue L. Blue Blue Yello w Red Existing Gases Present Performing Authority, Supervisor and Operatives E 2 MED Only qualified and authorized persons will be allowed in to a confined space. He will be trained in atmospheric testing, and CPR & First Aid qualified. The Recognition of the hazards of a confined space, fall protection, the use of the retrieval system, the duties and responsibilities of the attendant, the entrants and job supervisor. The person will also be trained in how to fill out a confined space permit listing all PPE requirement communication procedures and rescue plan. Test vessel atmosphere for flammable/toxic vapours, and oxygen deficiency Obtain CNNOC Confined Space Entry Permit signed by Area Authority De-energize, lock-out and tag all energized equipment if applicable. Review hazardous properties of site contaminants with entrants and safety observer. Set up Ventilator, if necessary Review emergency procedures and perform a rescue drill for each Separator Provide safety observer outside vessel Wear proper level of PPE for the type of atmospheric contaminants Enter Work Area after Gas Monitoring is Performed and Entry Supervisor authorized work to commence By WHOM Nominate the person who Probability Consequence Probability eliminate or minimize the risk of L. Blue 8 / 15 Controls For each hazard identified list the injury. Sheet of Sheets E 1 LOW will be required to action the control measures. Probability JOB SUPERVSOR By When Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA Risk Ranking PRIOR to Controls HAZARD Persons Implemented Affected REQUIRED HAZARD CONTROL Validity Status Rev. . A 00 Risk Ranking AFTER Implemented control measures required to Yellow Red Consequence Blue L. Blue Blue Yello w Red Sharp Objects Performing Authority, Supervisor and Operatives By WHOM Nominate the will be required to action the control measures. Probability Wear cut resistant work gloves when the possibility of lacerations or other injury may be caused by sharp edges or objects C 3 HIGH Maintain all hand and power tools in a safe condition. Sharp Objects C 1 MED JOB SUPERVSOR C 1 MED JOB SUPERVSOR Keep guards in place during use Observe proper lifting techniques Handling Heavy Objects Performing Authority, Supervisor and Operatives Obey sensible lifting limits C 3 HIGH Use mechanical lifting equipment (hand carts, trucks) to move large, awkward loads Avoid handling debris that is awkward, over long, over weight limit Get assistance and dry glove surfaces to improve grip By When person who Probability Consequence Probability injury. 9 / 15 Controls For each hazard identified list the eliminate or minimize the risk of L. Blue Sheet of Sheets Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA Risk REQUIRED HAZARD CONTROL RankingPRIOR to HAZARD Persons Affected Controls Implemented Validity Status Rev. . A 00 Risk Ranking AFTER For each hazard identified list the Sheet of Sheets 10 / 15 By WHOM By When Controls control measures required to eliminate Implemented or minimize the risk of injury. Nominate the person who L. Blue Blue Yellow Red Consequence Probability Consequence Probability will be L. Blue Blue Yello w required to action the control measures. Probability Red Slips, Trips, Falls Performing Authority, Supervisor and Operatives C Inhalation and Contact with Hazardous Substances Performing Authority, Supervisor and Operatives Electrical Shock Performing Authority, Supervisor and Operatives C C 3 3 3 HIGH HIGH HIGH Clear walkways, work areas of equipment, tools, construction debris, and other materials Mark, identify, or barricade other obstructions Evaluate fall hazards above 4 ft.; use fall protection equipment (harness/lanyard), standard guardrails or other fall protection systems when working on elevated platforms above 6 ft. Anchorage points for fall arrest systems must be designed to support each worker Use heavy duty industrial ladders Provide workers proper skin, eye and respiratory protection based on the exposure hazards present Review hazardous properties of site contaminants with workers before operations begin De-energize or shut off utility lines at their source before work begins Use double insulated or properly grounded electric power-operated tools Ensure light sources are correctly rated Inspect all extension cords daily for structural integrity, ground continuity, and damage Cover or elevate electric wire or flexible cord passing through work areas to protect from damage Keep all plugs and receptacles out of water Use approved water-proof, weather-proof type if exposure to moisture is likely Follow Lockout-Tag out procedures in accordance with BGC C 1 MED JOB SUPERVSOR C 1 MED JOB SUPERVSOR Electrical Shock C 1 MED JOB SUPERVS OR Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA Risk REQUIRED HAZARD CONTROL RankingPRIOR to HAZARD Persons Affected Controls Implemented Validity Status Rev. . A 00 Risk Ranking AFTER For each hazard identified list the Sheet of Sheets 11 / 15 By WHOM Controls control measures required to eliminate Implemented or minimize the risk of injury. Nominate the person L. Blue Blue Yellow Red Consequence Probability Consequence Probability who will L. Blue Blue Yello w Red Caught In/Between Moving Parts Performing Authority, Supervisor and Operatives C 4 High Identify and understand parts of equipment which may cause crushing, pinching, rotating or similar motions Assure guards are in place to protect from these parts of equipment during operation Provide and use proper work gloves when the possibility of pinching, or other injury may be caused by moving/ handling large or heavy objects Maintain all equipment in a safe condition Keep all guards in place during use De-energize and lock-out machinery before maintenance or service. C 1 MED be required to action the control measures. Probability JOB SUPERV SOR By When Owner Logo and business name of document Owner Company Identification Owner Identification Revision Index NlA Risk REQUIRED HAZARD CONTROL RankingPRIOR to HAZARD Persons Affected Controls Implemented Validity Status Rev. . A 00 Risk Ranking AFTER For each hazard identified list the Sheet of Sheets 12 / 15 By WHOM Controls control measures required to eliminate Implemented or minimize the risk of injury. Nominate the person L. Blue Blue Yellow Red Consequence Probability Consequence Probability who will L. Blue Blue Yello w Red Breakdown of Communica tions Performing Authority, Supervisor and Operatives be required to action the control measures. Probability Standby man has to be in contact with workers inside the confined space at all times. Radios will have to be used for communications between the work party and the standby man if he cannot communicate with them by talking from outside. C 4 High Radios have to be checked before the operation commences. If the radios break down the personnel must leave the confined space. Standby man to log personnel in & out C 1 MED JOB SUPERV ISOR By When Owner Logo and business name of document Owner Company Identification Owner Identification NlA 4.2 Revision Index Validity Status Rev. . A 00 Sheet of Sheets 13 / 15 SAFETY PRECAUTION Using certified lifting equipment only The work area kept free of debris underfoot. No loose clothing worn. Using anti-spark manual hammer only Never use self-made tools. Sharp edges of tools protected when stored or carried, and cutting edges kept sharp Tools kept clean and clear of grease The correct type of tool selected for the job Tools returned to the toolbox when not in use . Advanced warning signs should be placed at working area. All equipment should be bonded and earthed. All operatives to be provided with fire resistant ( FR) clothing. Only trained operatives to use the machineries . Always check machineries before commencing activities. Use high visibility vests to perform the job. All disposals should be removed from the site . Electric connections and cables should be kept to minimum length and re-routed away from wet areas. Operations area fitted with enough and promptly reachable fire Fighting equipment . 5. RESPONSIBILITY Project Field Engineer, in cooperation with Site Manager (and related staff) is responsible to supervise that the activities performed by BAFCO are carried out according to approved procedure and according to the instructions of BGC supervision . Project inspector will require, check and manage, for properly checking visually the bundle after extraction process . HSE supervisor will be responsible for all safety requirements and related rules to avoid harms and incidents for involved working staff and nearby facilities . All activities will be hold until get the confirmation of issuance of PTW which will be maintained by Permit Holder Person . Owner Logo and business name of document Owner Company Identification Owner Identification NlA 6. RESOURCES 6.1 PERSONNEL 6.2 - Site Manager - HSE Focal Point - Qualified Inspector; - Piping-Heat Exchanger Foreman/ - Electric Technician . - Scaffolder. - Cleaning Crew. - Hydro-test operator - Qualified Crane Operator. - Vacuum Truck Operator.. - .Permit Holder - Jet Cleaner Operator . - Forklift Operator. Revision Index Validity Status Rev. . A 00 Sheet of Sheets 14 / 15 EQUIPMENT - Crane (50T) - Tube Bundle Puller set for Heat Exchanger - Forklift. - Jet Cleaner. - Steam Jet Equipment (if required) - Generator set.(if required) - Tools for the application of Dismantling. - Scaffolding. Hydro-test Set ( HP pump, Hyro-test header , pressure/ temperature digital Recorder, Gauges, safety/ block valve ,water tank and accessories ) - Chemical cleaning skid . Other required fittings for bundle extraction, cleaning ,hydo-test, and reinstatement of unit. Tree light kit. Owner Logo and business name of document Owner Company Identification Owner Identification NlA 7. Revision Index Validity Status Rev. . A 00 Sheet of Sheets 15 / 15 PROCEDURE 1- The Intended unit s to be subjected for maintenance operation should be shut-down by BGC responsibility . 2- Isolating all the existing inlet and outlet block valves and emergency shut down valves by BGC responsibility 3- Each unit should be drained and purged by Nitrogen gas from liquids and de-pressurized from process gasses by making vents and drains for the liquids by BGC responsibility. 4- Dismantling for the line flanges and cover for each heat exchanger by using proper tools and equipment and gently remove the gaskets elements and checking the gaskets position status (This should be verify by BGC inspector ) . 5- Install standards spades and blinds for all nozzles and block valves to prevent any passage of gasses from the lines that connected with the exchanger and to avoid leak through from the valves to be prepared for Hydro-test process. This activity within BGC responsibility . 6- Start cleaning step by using proper equipment and tools by using chemical cleaning skid with effective solvent . 7- After completion of cleaning activity the shell will be drained and the sour material of cleaning to be disposal . The tube bundle will subject to visual inspection under BGC supervision and get the approval of bundle cleanness. 8- Provide all necessary equipment, scaffolding and manpower for bundle extraction process . 9- Install the bundle tube puller equipment to start the extraction task of the bundle . 10- After completion of tube bundle extraction stage ; the tube bundle will be laid down on platform or on the adjacent ground . Only qualified, knowledgeable employees are to be allowed to perform rigging tasks rigging capacity charts shall conform to the appropriate standard capacity ratings. Ensure that the crane and other lifting equipment have a minimum Safety Working Load (SWL) in excess of the equipment weight. All handling activities must be performed with extreme care and by qualified personnel. Basically, cranes and, in general, each lifting equipment, shall be selected according to the above lifting load data and to the distance of the areas (i.e. ; distance from receiving area to the final assembly area) As crane capacity (SWL) is depending on the crane outreach, a detailed study shall be done to determine the site lifting plan . 11- Carry out the visual inspection for the tube bundle under BGC supervision for fouling evaluation of bundle status . 12- If the bundle still contain sludge fouling , it will be subject to mechanical cleaning by using steam and warm water jet . 13- Replacement of tube sheet gaskets for both sides (new gaskets to be supplied by BGC) 14- The bundle will be inserted inside the shell by means of the same equipment and tools. 15- Carry out the Hydro-test activity as per the required pressure ( design pressure x1.5 times) and approved hydro-test procedure. 16- Reinstatement for all dismantled parts of the exchanger. 17- Hand over for the exchanger to BGC . 8. ATTACHMENT - Puller Equipment technical data sheet - ISO 9001: 2008 Quality Management systems IS0 14001 : 2004 Environmental Management System . OHSAS 18001: 2007 Occupational Health and Safety Management System Owner Logo and business name of document Owner Company Identification Owner Identification NlA Revision Index Validity Status Rev. . A 00 Sheet of Sheets 16 / 15 IMPORTANT: All Required documents i.e. certificates, data sheets, plans which relevant to this procedure will be submitted after awarding the contract.
