F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D

T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

FA L KO R E N G I N E E R I N G S E R V I C E S P T E LT D
TA N A H T E M A S I K S D N B H D
GUSTEAM CORP SDN BHD
D M C M I D D L E C O . , LT D

TECHNICAL PROPOSAL

BSRTA4-MS05 MOV-001 Valve Body Remove /

Reinstate and Seat Machining Works

BSRTA4-MS05

REV NO DATE PREPARED BY: REVIEWED BY: APPROVED BY: REMARKS/ STATUS
01

02

03

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 1/ 10
 F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

Table of Contents

1. Purpose 3
2. Scope 3
3. Location 3
4. Competent Person 3
5. Permit To Work 3
6. Material, Machineries, Equipment 3
7. WORK PROCEDURE 3
7.1. Pre-shutdown works 3
7.2. Shutdown Work 5
7.3. Reinstating MOV-001 after Inspection / Lapping 8
8. Final acceptance for the work 9
8.1. Final inspection 9
8.2. Completion: 9
9. Emergency And Rescue Operation 9

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 2/ 10
 F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

1. Purpose
This method statement explains the safe work method of removing MOV-001 to ground level
open yard for valve seat lapping / machining works, and thereafter safely installing the MOV-
001 back into its original position.

2. Scope
The scope of this method statement is for MOV-001 removal / reinstatement to ground level
for valve seat lapping / machining works.

3. Location
Binh son Refinery - Vietnam

4. Competent Person
A person who has such practical and theoretical knowledge and actual experience of the
respective operation he is assigned to. If applicable he shall have obtained the approval from
the government bodies or certification as a certified and approved person.

5. Permit To Work
A written or printed document from the owner to allow the person to perform the mention
work.

6. Material, Machineries, Equipment

A. Air Compressor (390 cfm)
B. Generator (350 KVA)
C. 10 tons Chain Blocks
D. Lifting Belt & Sling
E. 300 T Mobile Crane
F. Fabricated rails and rigging columns assembly
G. Fabricated trolley structure with rollers
H. Special alloy valve seat lapping machine

7. WORK PROCEDURE
7.1. Pre-shutdown works
 Design and fabricate rigging columns and guided rails as per sketches below.
 Erect scaffold working platform for removal of existing gratings and support beams as per
figure 3.

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 3/ 10
 Rollers and
guide rails
F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

Lifting eye for

mounting chain
blocks and lifting
Fig 1: slings for MOV-
Rigging 001
Supports for
column and
mounting on
guided rail existing platform
for MOV- beams
001
Intermediate
and lower
hoist beam Note: To be fabricated in knock-
down parts to be assembled on
site during Turnaround, after a
section of platform is removed.

Locking bars to be
mounted in place once
MOV-001 is lifted onto
trolley

To be mounted
on ground floor
level

Fig 2:
Trolley
support for
MOV-001

 Erect the rigging column and guide rail in position for rigging MOV-001.
REV NUMBER:BSRTA4-MS04- Technical Proposal
01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 4/ 10
 F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
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G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

 Erect necessary scaffold hand railings to provide safe work environment while removing
MOV-001.

7.2. Shutdown Work

7.2.1 General Works

 Apply the Work Permit & get the Approval from BSR Operation.
 Blinding as per approved blind list. Inspect Blinding status by related department
(Hold Point).
 Remove small bore obstruction air purging piping and instruments.
 Disconnect instruments from MOV-001 to facilitate the removal works
requirement.

7.2.2 Removal of MOV-001

Method 1 - Lowering MOV-001 to ground level by rigging column and guide rails

 Equipment blinding work as per blind list. Gallotine blind may be installed first, and
once MOV-001 is removed it should be secured in position with an end plate flange.
 Hook up chain blocks on the rigging column and the lifting lugs of MOV-001.
 Unbolt the flanges of MOV-001, and rig up the valve using chain blocks.

Fig 3: Lifting of
MOV-001 via
chain blocks

 Once the valve is lifted off the piping, move the lifting beam along the guide rail to
the tail end, where the chain blocks are lowered.
 Once the valve is lifted off the piping, move the lifting beam along the guide rail to
the tail end, where the chain blocks are lowered.
 As the chain blocks are lowered to its limit, the chain blocks at the intermediate
lifting beam will now take over the lowering of valve.

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 5/ 10
 F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

 As the chain blocks on the intermediate lifting beam are lowered to its limit, the
chain blocks on the lower lifting beams will then take over the lowering of valve.
 MOV-001 will be lowered to ground level and directly onto a trolley support, where
the locking bars are then secured to ensure the stability of the valve during
movement to open yard area.

MOV-001 to be un-
flanged, rigged with chain
blocks on the jigs, see
details

Secured on existing
beam structure

Existing platforms and

Closed beams to secured
MOV-001 in place when
it is lifted and seated
onto the trolley
beams to be removed to
facilitate rigging and
dropping of MOV-001 to
ground level, to erect
scaffold staging for the
works.

Fig 4: Lifting of
MOV-001 via chain
blocks in stages to
ground level

MOV-001 to be lifted to
ground level onto trolley
structure, secured in place
with 2 closed beams, and
pushed to open area for
lapping works.

 The trolley structure is moved according to the path as shown in figure 5.

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 6/ 10
 F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
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D M C M I D D L E C O . , L T D
W
Ar
ea
 At the open yard area, professional lapping / machining equipment is set up and
ready to service the valve.
 The trolley structure is moved according to the path as shown in figure 5.

Path of trolley structure

after the MOV-001 is
lowered and secured

Fig 5: Path of
movement for MOV-
001 to open yard

Method 2 - Lowering MOV-001 to ground level by direct crane lifting

 Equipment blinding work as per blind list. Gullotine blind may be installed first, and
once MOV-001 is removed it should be secured in position with an end plate flange.
 Position and set up the 300 ton crane.
 Hook up the lifting sling from the crane to the lifting lugs of MOV-001.
 Unbolt the flanges of MOV-001, and lift up the valve.
 Tag line must be used to control the lifting operations.
 Qualified crane operator, rigger, signal man, and lifting supervisor must be used for
the job.
 The valve will be lifted directly onto a valve stand in the open yard area for
inspection and lapping / machining if necessary, as shown in figure 6.
 At the open yard area, professional lapping / machining equipment is set up and
ready to service the valve.

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 7/ 10
 F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

W
or
k Ar
ea

300-ton crane parked

Valve trolley location
supp
ort
locati
on
locati
on

Fig 6: Crane
location for
direct lifting

7.2.3 Valve lapping / machining

 MOV-001 valve is left on the trolley structure which also acts as a valve stand for
inspection, or lapping / machining.
 Request BSR for inspection of the valve internal surface for scratches and marks.
 Take instruction from BSR if in-situ lapping / machining is required.
 Lapping / machining equipment will be standby on site, and if BSR gave instruction
to lap and repair, machine will be mobilise and mounted on the valve.

NOTE: Valve seat lapping is not a confirmed job but an anticipated works, method statement
will be prepared upon award of job.

7.3. Reinstating MOV-001 after Inspection / Lapping

Method 1 - by lifting column and Guide rail method

 Push the trolley structure holding the valve back to the bottom of the lifting column.

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 8/ 10
 F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

 Hook up chain blocks on the rigging column’s lower lifting beam and the lifting lugs
of MOV-001.
 Start to hoist up MOV-001 until such time when the intermediate lifting beam of the
rigging column is able to take over the lift.
 Proceed to hoist up MOV-001 until such time when the top lifting beam of the
rigging column is able to take over the lift.
 Proceed with the lift by the top lifting beam of the rigging column until MOV-001
lowest point had cleared the platform baseline.
 Move the lifting beam along the guide rail to the tail end, where the temporary end
plate flange of the Gullotine blind is removed and the valve is lowered into position.
 De-blind in accordance to the blind list and spade out the Gullotine blind prior to
start-up.

Method 2 - by direct lifting method

 Hook up the lifting sling from the crane to the lifting lugs of MOV-001.
 Tag line must be used to control the lifting operations.
 Qualified crane operator, rigger, signal man, and lifting supervisor must be used for
the job.
 The valve will be lifted into position, remove the end plate flange of the Gullotine
blind, and reinstate MOV-001 into position.
 De-blind in accordance to the blind list and spade out the Gullotine blind prior to
start-up.

8. Final acceptance for the work

8.1. Final inspection

When MOV-001 re-installed, properly completed in full compliance with all applicable
procedures, Site Supervisor shall arrange for final inspection with present of all related
BSR disciplines and third parties (where applicable).

8.2. Completion:

The work completion including housekeeping, handing over equipment to Operation,

returning material/spare parts to Warehouse.
The full set of Maintenance and Inspection Reports (Test Package) dossiers shall be
submitted to BSR Package-l Manager as attachment of FINAL ACCEPTANCE PROTOCOL.

9. Emergency And Rescue Operation

The following are the practices and emergency plans to be executed during Emergency.
 Immediately inform supervisor in charge and company’s safety supervisor.
 Immediately inform safety supervisor and client’s representative for emergency
assistance.

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 9/ 10
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G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D

 Depending on nature of emergency;
 Immediately retrieve the person using safe method.
 If personnel are unconscious, try to revive personnel using CPR.

 Fire and Toxic substance.

 Evacuate immediately.
 If fire is small, use fire extinguisher and try to extinguish the fire.
 For toxic substance, evacuate and inform supervisor immediately.

Upon arrival of emergency assistance, explain the current emergency situation and cause of
emergency.

REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 10/ 10