FLOATING HEAD TYPE- Doc.

No: OM-QA&QC/PL/MS-06
EXCHANGER’S INSPECTION & Rev.: 01
Page: 1 of 7
CLEANING

METHOD STATEMENT

FOR

INSPECTION & CLEANING OF FLOATING HEAD TYPE-EXCHANGER

(CLEANING WITH BOILER FEED WATER)

(FOR E-A1101A, E-A1101B, E-A1101C, E-A1101D, E-A1201A, E-A1201B, E-A1201C, E-A1201D)

OQ AROMATIC PLANT TURNAROUND 2022

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Descon Engineering
 FLOATING HEAD TYPE- Doc. No: OM-QA&QC/PL/MS-06
EXCHANGER’S INSPECTION & Rev.: 01
Page: 2 of 7
CLEANING

00 For the initial issue & approval Oct 07,2021 Israr Owais Ahmed

Rev. No. Details Of Revision Date Prepared by Checked by Approved by

INDEX

1. PURPOSE

2. PREPARATION

3. REFERENCES

4. RESPONSIBILITIES

5. TOOLS & EQUIPMENTS

6. PRESHUTDOWN ACTIVITIES

7. SHUTDOWN ACTIVITIES

8. SAFETY INSTRUCTIONS

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 FLOATING HEAD TYPE- Doc. No: OM-QA&QC/PL/MS-06
EXCHANGER’S INSPECTION & Rev.: 01
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CLEANING

1. PURPOSE

The purpose of this method statement is to describe execution procedure for

inspection and cleaning of FLOATING HEAD-TYPE EXCHANGER (Cleaning
with boiler feed water) in a safe manner.

2. SCOPE

The scope of this method statement covers following activities:

 Erection of External scaffolding
 Insulation removal.
 Blinding & isolation.
 Removal of channel cover, Floating head & Shell cover.
 Bundle pulling.
 Shifting of bundle to AP Jetting yard.
 Internal cleaning of shell & cover
 Hydro jetting of bundle.
 Shifting of Bundle to site.
 NDT and QC inspections
 Insertion of the bundle.
 Installation of floating head.
 Hydro testing
 Repair if any
 De blinding
 Reinstate insulation
 Removal of external scaffolding.

3. REFERENCES
 Project Area Layout.
 Marked up P& ID
 General Arrangement & Detail Drawings
 Detailed scope of work

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 FLOATING HEAD TYPE- Doc. No: OM-QA&QC/PL/MS-06
EXCHANGER’S INSPECTION & Rev.: 01
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CLEANING

4. RESPONSIBILITIES
1. Descon Supervisor shall coordinate with OQ maintenance and operations
for obtaining work permits and acceptance / renewal of the permit.
2. The Descon Supervisor shall ensure blinding as per the approved blind list
and follow OQ blinding procedure before executing the job.
3. Descon Supervisor shall be responsible for safe execution of the activities
as per scope in accordance with OQ safety policy & procedures.
4. Descon supervisor will deliver toolbox talk on the specific work to be carried
out as per OQ Permit to Work (PTW) and Job Safety Analysis (JSA) and
ensure that all necessary safety precautions are taken for the safe
execution.
5. Descon Planning Engineer will ensure that all necessary inputs such as
drawing’s material, consumables, tools and plant are arranged.
6. Descon supervisor shall be responsible for overall execution of job including
quality of the work within the specified schedule and observing OQ safe
work practices.
7. OQ inspection team will confirm the completion & quality of the job.

5. TOOLS & EQUIPMENTS:

1. All the required tools / materials like spanners, brass hammer, blinds,
gaskets, flange spreaders, belt slings /slings /shackles/eye bolts, shall be
made available on site. Descon will follow the flange management
procedure as per OQ recommendation
2. Crane with appropriate capacity (if required) shall be available to site to be
used for blinding & bundle lifting purposes.
3. Bundle puller & trailer shall be available to site
4. Hydro jetting machine and adequate pneumatic equipment shall be
available at jetting yard for bundle cleaning & drying.

6. PRE SHUTDOWN ACTIVITES

1. Specific rigging plans to be identified, prepared and approved as per site
requirement.
2. Shifting of scaffolding material and erection of scaffolding as per
requirement after getting PTW.
3. Area for scaffolding erection will be identified & scaffolding will be erected
for installation of blinds as per requirement.
4. Shifting of all required tools, blinds, temporary gaskets, materials and
equipment near to the area prior to shut down.

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 FLOATING HEAD TYPE- Doc. No: OM-QA&QC/PL/MS-06
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CLEANING

5. Test rings & test blinds shall be available to site prior to hydro testing.
6. Obtain permit for removal of insulation from the flanges. Remove insulation
from tagged locations for blinding. Use dust masks while handling
insulation in addition to PPE used as per PTW & JSA.
7. Ensure that all blinding points are as per the blind lists marked on P&ID.
Correct size spanners, brass hammer, blinds and flange spreaders are
made available on site.
8. All lifting tools & equipment to have third party certificates.
9. Test ring thread holes to be cleaned and greasing if required.

7. SHUTDOWN ACTIVITES
A. BLINDING ACTIVITIES

1. OQ operation to carry out draining, purging and isolation of equipment for

handing over to Descon.
2. Installation of required blinds as per signed marked Up P&ID.
3. Blind tracking list (BTL) must be attached all the time along with the permit.

B. OPENING, INSPECTION, MAINTENANCE & CLEANING FOR FLOATING

HEAD TUBE TYPE.

1. Obtain permit prior to start the job. All works shall be carried out only after
PTW’s are issued.
2. Removal of associated Piping
3. Removal of Channel/Floating Heads & drop down through crane.
4. Gas test will be carried out by AGT
5. Offer for as found inspection to OQ.
6. Bundle Pulling through bundle puller.
7. Shifting of Bundle to Hydrojetting Yard.
8. Necessary arrangement shall be carried out for hydro jetting of tubes. Make
sure areas are barricaded with tarpaulin.
9. Hydro jet cleaning (using boiler feed water) of tubes as per scope and
inspection requirement.
10. Air blowing if required.
11. Plug the Defective Tubes (if required).
12. Tube repair (Re Tubing-Rolling) by OQ if required.
13. Channel cover & channel head cleaning/power brushing & offer for
inspection.

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CLEANING

14. If any repair is found in shell and weld joints, then repair will be carried out
as per OQ instructions with OQ approved WPS.
15. Offer the shell to OQ for Inspection after repair.
16. Shifting of Bundle to site & insertion of the bundle.
17. Reinstall back channel head & channel cover
18. Carry out shell side test and identify any leakage of tubes and then plug if
required.
19. Carry out tube test to check gaskets of channel head covers
20. Draining of water & perform housekeeping.
21. Offer for final inspection to OQ.

C. BOX UP / DEBLINGING

1. Obtain box-up certificate from OQ Inspection/Operation.

2. Upon receiving box up certificate from OQ inspection, process and
maintenance, channel head covers shall be boxed up using new gasket.
3. Remove blinds and box-up flanges with new gaskets. Restoration of
insulation as per requirement.
4. Mechanical isolation sheet (blind list) will be signed by DESCON/ OQ
operation as per de-blinding.
5. Descon will assist OQ.to carry out leak testing /Inerting of the exchanger
with nitrogen by operation
6. Test ring thread holes to be cleaned and greasing if required

8. SAFETY INDUCTION

During execution of the job all safety measure shall be adopted to ensure safe
work.
1. The workers will be made aware of OQ safety requirements related to this
activity through daily toolbox and safety talks in line with OQ Permit to Work
(PTW) and Job Safety Analysis (JSA) for the daily tasks to be performed.
2. Adequate PPE includes:
a. Helmet
b. Safety glasses
c. Coverall with long sleeves
d. Steel toed safety shoes
e. Appropriate gloves
f. Dust mask (if required)
g. Ear plugs as per job requirement.
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 FLOATING HEAD TYPE- Doc. No: OM-QA&QC/PL/MS-06
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CLEANING

h. Individual toxic clip (if required)

i. Other PPE may be worn as per job requirement(s)
3. The workers will be made aware of safety requirements related to this
activity through daily toolbox and safety talks. The work crew who is involve
in confined space and blinding/de-blinding should be fit tested.
4. Tool Box Talk (TBT) shall be performed in each shift and JSA along with
Permit to Work (PTW) requirements will be communicated by area lead to
work crew and shall be understood before starting any work.
5. Escape plan must be available at the work location, indicating:
a. The escape route
b. Emergency assembly point
c. Emergency call out numbers
6. Access and good housekeeping must be maintained at site.
7. All waste material must be segregated to ensure proper housekeeping at all
times during the activities to avoid any tripping hazards or blocking of
emergency access points.
8. All equipment will be inspected by OQ & HSE (Descon) prior to use and
inspection record will be maintained.

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