DOC NO.

: EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
SDN BHD REV. : 0
PAGE : 01 OF 07

COLUMN

MAINTENANCE PROCEDURE

REV. DATE DESCRIPTION PRE'D CHK'D APP'D

0 23/03/2018 ISSUED FOR REVIEW & APPROVAL FIRDAUS EZIL BAHARUN

CLIENT PETRONAS
TENDER TITLE MASTER SERVICE AGREEMENT (MSA) FOR TURNAROUND (TA) AND DAILY MAINTENANCE WORK FOR
MAIN MECHANICAL WORKS
TENDER NO. CTC/HC-GP/2017/131
 DOC NO. : EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
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TABLE OF CONTENTS

ITEM DESCRIPTION

1.0 OBJECTIVE

2.0 SCOPE

3.0 REFERENCE

4.0 ABBREVATION

5.0 RESPONSIBILITY

6.0 PROCEDURE

7.0 SAFETY

8.0 RECORD
 DOC NO. : EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
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1.0 OBJECTIVE

1.1 This procedure serves as a guideline for the preparation and execution of column
maintenance work to ensure the work performed in accordance to code and standard and
PETRONAS Technical Standard (PTS) requirement.

2.0 SCOPE

2.1 This procedure is intended to provide overview of the basic maintenance, inspection and
repair work on the column.

3.0 REFERENCE

PTS PETRONAS Technical Standard

ASME American Society of Mechanical Engineers

4.0 ABBREVATION

EMESB EPIC Mushtari Engineering Sdn Bhd

OPU PETRONAS Operating Unit
PTS PETRONAS Technical Standard
ITP Inspection & Test Plan
QA Quality Assurance
QC Quality Control
NDT Non-Destructive Test
PPE Personal Proctective Equipment
AFC Approved for Construction
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EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
SDN BHD REV. : 0
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5.0 RESPONSIBILITIES

5.1 Supervisor shall be responsible to the Project Engineer/Project Manager for the proper
preparation and supervising maintenance work.

5.2 QC Inspector shall ensure that all inspection to be carried out according to approved ITP. He
shall notify PETRONAS OPU Representative for witnessing and preparation of the relevant test
reports.

5.3 Site Safety Supervisor shall ensure the safety aspects in all stages of maintenance work in
accordance with authority and PETRONAS OPU requirements.

6.0 PROCEDURE

6.1 GENERAL

6.1.1 Site survey shall be carried prior work execution to gather and compile data to produce
proposal for maintenance work.

6.1.2 Proposal of maintenance work to be prepared shall contain at least:

i - Technical documentation such as construction drawing, P&ID drawing and previous

manufacturer final documentation.
ii - Data collection such as operating temperature and operating pressure.
iii - Current physical condition of the column.
iv - Record of previous maintenance works.
v - Accessibility to column for maintenance such as scaffolding and insulation requirement.

6.1.3 This proposal shall be presented to OPU and subsequently produce Technical Proposal. The
technical proposal shall contain at least:

i - Job method statement (JMS)

ii - Scheme of examination (SOE)
iii - Work and quality procedure
iv - Work schedule
vi - Equipment and manpower loading
vii - Job hazard analysis (JHA)

6.2 WORK EXECUTION

6.2.1 Prior work execution, ensure the unit has been isolated from the system, depressurize,
vented, drained and purge from hazardous material or gas.

6.2.2 All work to be executed shall be performed with valid permit to work (PTW).

6.2.3 Upon opening manhole , flange connection and related accessories, mark and place all item
on the wooden plate / plywood and secured properly to avoid missing.
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6.2.4 Request for inspection (RFI) shall be made to OPU inspection prior performing initial
inspection to determine type of maintenance work required to be carried out.

6.2.5 Upon completion of the initial inspection, maintenance work shall be carried out accordingly.

6.3 MAINTENANCE WORKS

6.3.1 Maintenance work of the column to be performed may consist of mechanical cleaning,
chemical cleaning and replacement of spare part and repair work.

6.3.2 Mechanical and chemical cleaning on the column shall be performed as per contract
requirement and approved cleaning procedure.

6.3.3 The spare part to be replaced shall be inspected and determined accordingly.

6.3.4 Repair work to be carried out shall be based on the inspection report recommendation .

6.3.5 All maintenance works shall be performed as per scope of work and approved procedure.

6.4 INTERNAL CLEANING , INSPECTION & REPAIR WORK

6.4.1 Confine space entry (CSE) permit shall be obtained prior intenal cleaning work.

6.4.2 Proper intenal scaffolding, ventilation and lighting shall be proviede for entry and work
execution.

6.4.3 Initial inspection shall be perfomed prior cleaning work.

6.4.4 Using access from manway door, open all tray manway from middle down tra to bottom tray.
Ensure tray manways and bolts are store d properly. Ensure tray valves are not damaged.

6.4.5 Tray sections can have sharp edges . Extra care shall be taken when crawling through column
to prevent personal injury.

6.4.6 Water washes each tray ensuring all trays are clean. Inspect all tray and downcomers for
damage, missing bolts, etc. check all tray for level and possible distortion. Record all findings.

6.4.7 Inspect all tray support rings for damage or weld failure. Inspect and clean distributor pipe.

6.4.8 Internal shell cleaning by using compressed air.

6.4.9 Flush/clean on bottom of column. Remove sludge/hard deposits by scrapper or others tools
(if any).

6.4.10 Proceed Power tool s or Hand tools cleaning (SSPC-SP2/SP3) on top & bottom of ellipse
head/dish weldment, nozzles, vent & drains point as per SOE.

6.4.11 Inspect and clean distributor pipe above top tray.

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6.4.12 When all tray manways are open, replace all missing or damaged tray sections, bolts and
valves. Inspect and clean downcomer section on all even numbered trays.

6.4.13 Upon completion of internal cleaning and inspection, inspection on the intenal vessel such
as shell, vortex breaker, weldments, nozzles, internal pipes, stiffener, down comer, tray,
supporting, bubble cap, drains etc. shall be performed as per SOE.

6.4.14 Damaged and/or defects section shall be repaired as per approved work procedure
accordingly.

6.5 TRAY CLOSURE

6.5.1 When all tray inspection and repair work is finished, box-up tray manway sections, working
in reverse order and ensuring bolts are torques to the correct value.

6.5.2 Thoroughly inspect to ensure no foreign bodies are left behind at each level are in bottom of
column.

6.5.3 Final clean of bottom of column.

6.5.4 Dismantle and remove scaffolding from bottom of column.

6.6 EXTERNAL INSPECTION

6.6.1 Inspection on the external to be performed on the vessel shell to check for corrosion
esspecially corrosion under insutlation, paint condition and integrity of the weld joint.

6.6.2 All defects identified shall be rectified in accordance with approved procedure, code &
standard and PTS requirements.

6.7 DE-ISOLATION & BOX UP

6.7.1 Upon completion of maintenance work and inspection, all dismantled part shall be re-
assemble as per initial physical condition and construction drawing.

6.7.2 New gasket at all flange bolting connection shall be used during re-assembling work to
ensure the integrity of the connection. Prior bolt tightening, flange surface shall be cleaned
properly.

6.7.3 Bolt tightening procedure shall be submitted to OPU for approval to ensure the tightening
work in accordance with PTS requirements.

6.7.4 De-isolate all flange connection.

6.7.5 Upon completion of boxing up, final joint inpection with OPU inspection shall be performed
to verify the completion of the work.

6.7.6 Box up certificate shall be signed off by OPU inspection.

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7.0 SAFETY

7.1 Signboard and warning signage shall be placed around the working area to ensure all personnel
aware of the work performed.

7.2 Confines space entry work shall be performed in accordance with law and regulation for
confine space entry. Confine space entrance personnel shall have valid CSE certificate.

7.3 All personnel attending shall wear proper personal protective equipment (PPE).

7.4 Only authorized personnel shall be allowed to enter the work area.

8.0 RECORD

8.1 All observations, data and test results of production shall be documented in preapproved
agreed format and signed off by OPU inspection for final documentation.

8.2 This procedure shall be kept by EMESB QA/QC Department and made available to the
authorized personnel conducting the activity for reference.

8.3 All approved approved report shall be kept by EMESB QA/QC Department for final
documentation and made available once requested.