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1.0 Introduction
This method statement describes in detail the removal of existing tubes and installation of new
tubes for the Heat Exchanger.
2.0 Scope and Purpose of Method Statement
This document outlines the method for replacement of existing tubes for Heat Exchanger.
The procedure provides guidance for assessing the activities for replacement of tubes. This
guidance is based on the requirements set forth in the project requirement, safety requirement
and Quality assurance program.
2.1 Objectives
This document provides guidance in implementing an effective program for replacement of
Titanium tubes for the Heat Exchanger. This includes addressing programs for the following:
(1) Implementing commitments regarding the quality of the work.
(2) Managing and providing oversight to ensure installation and related quality control has
been adequately addressed by specifications, drawings, and procedures.
(3) Managing and providing supervision and control to assure quality of work and closely
implement/monitor schedule.
(4) Recording installation and test activities.
(5) HSE at the time of work.
This procedure is one component of a complete replacement of tube work program. This and
other procedures will be used, as needed, to provide assurance that replacement of tubes
activities are being conducted as required by the specification and manufacturer procedures. It
is not expected that completion of the entire procedure will be accomplished during any one
inspection and /or every time the inspection procedure is used. It is a continuing activity until
all tubes are replaced.
2.2 Inspection and Recording Requirements
The engineer should verify that the supervisor/foreman with construction responsibilities for
the replacement of tubes works is familiar with the method statement and is issued with
copies of the inspection checklists and test plans. The engineer should satisfy procedures
provided by QA/QC inspections to ensure the replacement of tubes works meet specified
engineering requirements and drawings. As part of the assessment, the QC inspection
procedures must ensure a quantitative or qualitative acceptance criteria for determining the
prescribed activities have been accomplished satisfactorily.
The QC inspection personnel, in coordination with site supervisor, should verify that the
quality of the works and related testing activities are within the project design specifications
The supervisor should verify that the replacement of tubes works is accomplished in
accordance with the specifications and the manufacturers procedures. The supervisor should
verify any testing and confirm that the information meets the project requirements.
2.3 Training and Qualification of Personnel
The supervisor should verify that the personnel have sufficient knowledge of the procedure
requirement. The supervisor should review any training and qualification records for those

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individuals who shall do the task to determine whether they are skilled enough to follow the
procedure before the actual work is carried out.
3.0 Responsibilities and resources
3.1 Responsibilities:
The project manager (CONTRACTOR), has overall responsibility for the coordination and implementations of the cutting and welding activity, including
manpower and plant utilization, engineering support, material scheduling and cost
Project Manager (CONTRACTOR), Project Engineer (CONTRACTOR) / will be
responsible for the replacement of tubes for the Heat Exchanger.
3.2 Resources:
Tubes: Titanium tubes (free issued).
Plant and Equipment
Tube Expander
Torque Controller.
Electrical Tools.
Hand Tools
Lifting and Rigging Equipment: As per requirement (by CLIENT).
Scaffolding: As per Requirement. (By CLIENT).
Other small hand tools and tackles: as per requirement.
Employees and subcontractors with specialized training include the following
Supervisor / Foreman
Other miscellaneous.
4.0 Methodology
Quantity of material
Tube size: Dia. 19 mm OD x 0.64 mm thick.
No. Tubes: 15 Nos.
The following steps will be carried out for replacement of Tubes at CLIENT
After isolation of the plant, CLIENT will remove end covers on either side of the Heat
CONTRACTOR will remove the plugs by drilling or tapping method to avoid damaging
the tubes.
Cut the tube from one end b tube cutter tools.
Pull the tube using hydraulic stub puller without damaging the tube sheet.
Place the old tubes in a sage area on the work platform.
Pull all the balance tubes from the tube sheet using above method.
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Clean expansion grooves in the tube sheet using cleaning brush or by air to remove debris
or deposit material.
Check the diameter of tube sheet bore by using dial caliber.
Clan the baffle holes by using power brush.
Inspection of the tube sheet bore by approved inspection method before inserting new
Prior to inserting the new tubes, inspection must be cleared b CLIENT.
Insert new tubes and expand as per the specified values on both ends as per the calculation
The calculation method of values approved by CLIENT.
After the expansion tubes are measured and checked using dial bore gauge and records the
Tubes ends shall be protrude from tubes plates of 3 mm.
Tube ends shall be checked after expanding to make sure there is no damage.
Inside surface of tubes ends in the expanded area shall be free of defects such as crack or
clear overlaps.
Prepare the leak test by water for the Heat Exchanger (By CLIENT).
Attend the leak tubes by rolling or replacement after testing until exchanger is cleared by

5.0 Health, Safety and Environment Measures

5.1 Preparation

Notify all concerned in site for the date of material delivery.

Ensure all workers involved in the operation put on PPE all times.
Brief individual worker the roles and responsibilities of each.
Coordinate with concern department for tubes hoisting area.
Ensure designated area is cleared of obstruction.

5.2 Pipe/Tube lifting

Ensure sage work procedure for replacement of tube operation is observed.

Ensure proper method with the correct equipment are used.
Ensure the pipes/tubes are firmly placed on the designated location before
releasing the hoisting hook.

5.3 During Replacement of Tubes:

Ensure workers are distributed to each designated place.

Ensure workers at all times to be in proper gear where required.
Ensure all workers assigned are involved in its particular task.
Brief individual worker the roles and responsibilities before start work.
Ensure the pipe/tube lengths to suite site routes into designated work area.
Ensure all tools to be used have been inspected and tagged by Safety
Department. (By CLIENT).
Ensure work areas are clearly marked to restrict access to authorized personnel
Ensure that equipments to be used are properly tagged and checked.

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5.4 Housekeeping

Maintain cleanliness and orderly stocking of material and tools.

Pick up and dispose wastes and other debris prior to leaving site area.
Remove safety yellow tape or other warning devices that were used to control
access to the work area.
Store tools, equipment and unused materials properly at the end of the workday.

5.5 Safety Inspections

It shall be responsibility of the supervisor to routinely inspect het physical areas

under their control in pipe welding works.

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