(Pptsb-exe-tessb-000-Qac-prc-006) Cold Cutting and Surface Machining Procedure - Approved

Doc No:
PETRONAS TURCOMP ENGINEERING PPTSB-EXE-TESSB-000-QAC-PRC-

PENAPISAN SERVICES SDN BHD
006
(TERENGGANU) SDN
BHD Revision: 0
PROVISION FOR DISH HEAD INSTALLATION AND REPAIR WORK OF

Page 1 of 28
C-101 (CRUDE TOWER COLUMN) AND C-1104 (REFORMER STRIPPER
COLUMN) FOR PETRONAS PENAPISAN TERENGGANU SDN BHD
PROJECT : PROVISION FOR DISH HEAD

INSTALLATION AND REPAIR WORK OF
C-101 (CRUDE TOWER COLUMN) AND C-
1104 (REFORMER STRIPPER COLUMN)
FOR PETRONAS PENAPISAN
(TERENGGANU) SDN BHD SHUTDOWN
2023
CLIENT CONTRACT : PETRONAS PENAPISAN (TERENGGANU)

SDN BHD
NO. DOCUMENT : PPTSB-EXE-TESSB-000-QAC-PRC-006
TITLE DOCUMENT : COLD CUTTING AND SURFACE

MACHINING PROCEDURE
REVIEW : Z
CLASSIFICATION
Prepared by: Reviewed by: Reviewed by: Approved by:
………………...….. ………………...….. ………………...….. ………………...…..

Name :Mohd Akmal Name : M Azim Name : Name : Mohd Shukri Bin Mohd Nor
Date : 03/07/23 Date : 7/7/2023 Date : Date : 12 July 2023
Remarks :
1
PROVISION FOR DISH HEAD INSTALLATION AND REPAIR WORK OF C-101 (CRUDE TOWER COLUMN) AND
C-1104 (REFORMER STRIPPER COLUMN) FOR PETRONAS PENAPISAN TERENGGANU SDN BHD
COLD CUTTING AND SURFACE MACHINING PROCEDURE
Doc No: Revision:

0
PPTSB-EXE-TESSB-000-QAC-PRC-006
TABLE OF CONTENTS
NO CONTENTS PAGE
1 PURPOSE & SCOPE 3
2 DEFINITIONS 3
3 REFERENCES 3
4 SAFETY 3
5 RESPONSIBILITIES 3-5
6 FRONT END REQUIREMENT/PREPARATION 6-20
7 EXECUTION OF WORK 20-24
8 COMPLETION 25
9 PIPE COLD CUTTING AND RE-BEVELING FLOW CHART 26
10 INSPECTION AND TEST PLAN 27
11 PIPE CUTTING AND BEVEL/RE-BEVELING 28
2
Doc No: Revision:

0
1. PURPOSE & SCOPE

i) To set a safe and effective guideline to do the cold cutting and pipe re-beveling works follow
step by step machine operating procedures and safely.
ii) Applies to all on-site cold cutting and pipe beveling works.
iii) To ensure that cold cutting and pipe beveling work is conducted in an organized and proper
manner and ensure that the cutting and bevel is the best possible.
2. DEFINITIONS
i) Contractor : Tetradtech Sdn Bhd
ii) TSB : Tetradtech Sdn Bhd
iii) ITP : Inspection and Test Plan
iv) NDT : Non-Destructive Testing
v) WORK : Specified scope of work during cold cutting and re-beveling process
vi) LCSF : Low Clearance Split Frame
vii) LDSF : Large Diameter Split Frame
3. REFERENCES
i) Part No. 02-MAN-01. Trav-L-Cutter. Model E & HE, Standard & Atmospheric. WACHS. Rev.3
ii) Standard ASTM A106/A105A-ENGL 1999 - Seamless Carbon Steel Pipe
iii) Tubular Exchanger Manufactures Association (TEMA) – Eighth Edition
iv) Split Frame, Model LCSF/3 (1/2” – 36” O.D) Operation Instructions & Part Lists, Rev. 1
4. SAFETY
i) All work will be carried out according to the Job Safety Analysis (JSA).
ii) Standard PPE to be worn by all personnel.
iii) Work permits to be issued prior to the execution of work.
iv) If at any stage any personnel observes any potential hazards that may compromise the safety of the
personnel or the facility, the work must be immediately stopped, and the immediate superior is
informed.
v) Ensure hands and fingers are safe.
vi) Ensure no safety switch been bypassed.
vii) Proper housekeeping must always be maintained.
viii) If required, Tetradtech Sdn Bhd shall ensure to have or conduct e-vetting prior to mob.
ix) Ensure validity of green tag scaffolding inspection prior to use. If adjustment of the scaffolding is
needed, only competent person shall execute and validate by scaffolding inspector.
5. RESPONSIBILITIES
5.1 Portable Machining Coordinator
a) Overall responsibilities for production, quality, and safety issues
b) Shall ensure all works related to the pipe cold cutting and re- beveling are following the
approved procedure and act as the overall client interface throughout the duration of the
project.
3
Doc No: Revision:

0
c) To ensure that the work is performed in accordance with quality and HSE requirements.
d) To ensure that the production of the pipe cold cutting complies with the given time frame.
e) Shall be responsible for all workers, consumables, materials, and equipment necessary for the required
operation.
f) Overall responsibilities for production, quality, and safety issues.
g) Assist Service Development Engineer in commercial issues.
h) To ensure that the operations are performed in a safe manner and the product meets the
requirements specified herein.
i) Responsible for ensuring all the equipment, consumables, and materials utilized for the project are
following the stated requirements.
5.2 Service Development Engineer

a) To conduct a customer survey to get information on the degree of customer satisfaction covering
all aspects.
b) In conjunction with the operation team, solve site problems if they arise.
c) To be operationally and technically knowledgeable in concern.
d) Liaison with client’s representative during execution of the work for commercial and technical
issues.
e) In conjunction with operation team, plan for mobilization of equipment and manpower timely
manner.
f) Ensure all the promises/obligations to clients being delivered timely and in accordance to the
agreed quality and HSE standards.
g) To get feedback from client on the work done to ensure client’s satisfaction and meeting the
requirements.
5.3 Level III Machinist / Machinist Operator

a) To ensure the implementation of the procedure and ensure the workers are properly trained to
do the job.
b) Assist the Safety Supervisor to ensure that all operations are performed in a safe manner.
c) Assist the Safety Supervisor to ensure that all workers are well trained before starting to perform
their tasks to avoid accidents.
d) To ensure workers perform their work without neglecting quality aspects.
e) Ensure that all inspections and reports are performed correctly and submitted to the client on
time.
f) Responsible for ensuring the machines and other necessary accessories are in good condition
prior to use.
g) Ensure that the cutting/re-beveling process complies with the client’s specified requirements such
as the location of cut and beveling angle.
h) Ensure the right tools are selected based on the material of the pipe to be cut.
i) Ensure the pipe being properly supported prior to starting the cutting/re-beveling process.
5.4 Safety Supervisor

a) To ensure all the operations are performed in a safe manner.
b) To conduct Toolbox Talks.
c) To ensure all workers are well trained before starting to perform their task in order to avoid any
accident.
4
Doc No: Revision:

0
d) To ensure all workers comply with specific safety regulations at client’s premises.
e) To brief workers on stop, work policy, conduct safety pre-job briefing and JHA/JSA prior to start
work.
f) To brief workers regarding shortcut violation (ensure no safety switch been bypassed).
g) To perform accident / incident investigation (if any).
6. FRONT END REQUIREMENT/PREPARATION

6.1 SAFE OPERATION OF THE LDSF
a) The LDSF has dangerous pinch points between rotating and Stationary components do not stand
close to the machine while it is operating. serious injury could result.
b) Use of the counterbore slide requires the operator to feed the slide manually while the LSDF
rotates. This should be done only with the LDSF mounted on a horizontal pipe (with the machine in
vertical orientation)
6.2 RIGGING AND LIFTING THE LDSF
The LDSF frame can be lifted in any of the following configurations:

a) individual sections (each section 1/4 of the frame)
b) half-ring assemblies (each assembly consisting of 2 individual sections.
c) fully assembled frame, with hinge. Disassemble the frame into individual
sections only for storage, or for moving it if necessary.
When mounting the frame on the workpiece, you must have the LDSF fully assembled. Use the
hinge and jack to spread the ring open to install it on in-line pipe.
Lift Attachments
Two types of lift attachments are provided with the LDSF.
1) Use the lift eyes screwed into the top of the machine ONLY for lifting individual (1/4 ring) sections.
5
Doc No: Revision:

0
2) Use the lift brackets mounted on the outside of the frame to lift half-ring assemblies, or the fully
assembled frame.
3) The top eye of the bracket is for lifting the machine in a horizontal orientation.
4) The side eye of the bracket is for lifting the machine in a vertical orientation.
6
Doc No: Revision:

0
Assembling The LDSSF
Stand legs are supplied for assembling the LDSF frame on the floor to prepare it for mounting
on the pipe. Three legs are provided for each individual section of the frame. Insert the legs
into the holes in the bottom of the stationary ring when moving the sections to the assembly
location.
The latches at the end of each section are stamped with a letter identifying the joints—A, B,
C, and D. Assemble the sections so that the letters are matched up.
7
Doc No: Revision:

0
8
Doc No: Revision:

0
1) Lift each individual section of the frame out of the storage crate. Insert the stand legs and set the
sections down on the floor. Arrange the sections so that the joint letters are matched up.
2) Remove the wood end caps from the ends of the sections.
3) At each joint, press the sections together to engage the dowel pins.
9
Doc No: Revision:

0
4) On the stationary ring (underside of the machine), swing the latch bolts into place. Snug the nuts to
hold the bolts in place.
On the rotating ring, swing the latch bolts into place.
5) Snug the nuts to hold the bolts in place.
10
Doc No: Revision:

0
6) Tighten the nuts on the stationary ring latch bolts. The split line between the sections should close completely,
with no gap between the sections.
7) Tighten the nuts on the rotating ring latch bolts.
11
Doc No: Revision:

0
8) Attach the support block at each joint and insert and tighten the 4 screws.
Setting Up The LDSE
1) Attach the hinge to the LDSF stationary ring at the location with the holes provided.
12
Doc No: Revision:

0
2) Insert and tighten the two screws in each half of the hinge.
3) Remove the pins on the ends of the hinge and insert them through the eyes of the jack
screws. (You may need to turn the jack screws to set the jack to the appropriate length.)
13
Doc No: Revision:

0
Setting The Clamp Leg Positions
The LDSF clamps legs can be mounted in two positions:

• outer (standard) position for 82.5”-90” pipe diameter range
• inner position for 75”-82.5” pipe diameter range
Use the following procedure to change the legs from the outer to the inner position.
1) Turn the adjustment screw on the clamp leg counterclockwise until you can remove the leg.
2) Attach the cone spacer to the inner side of the stationary ring and tighten the screws.
14
Doc No: Revision:

0
3) Insert the leg through the cone spacer and press it all the way in. Turn the adjustment screw
clockwise to engage the threads on the leg and retract the leg for mounting the LDSF.
Make sure you set all 12 clamp legs to the same position. You will not be able to mount the LDSF on
the pipe correctly if the legs are not all the same.
Mounting The Machine
1) Make sure the frame locking pins are inserted through the rotating ring.
2) Loosen the nuts on the latch bolts at the joint opposite the hinge (both rotating and stationary rings).
Swing the latches out of the slots.
15
Doc No: Revision:

0
3) Loosen the nuts on the latch bolts at the hinge location (both rotating and stationary rings). Swing the
latches out of the slots.
4) Loosen, but do not remove, the two screws on the right side of the hinge assembly.
5) At the joint opposite the hinge, turn the jacking screw to separate the ring sections. Turn the screw
until the dowel pins are out of the holes. Retract the jacking screw completely.
6) At the hinge location, turn the jacking screw to separate the ring sections. Turn the screw until the
dowel pins are out of the holes. Retract the jacking screw completely.
16
Doc No: Revision:

0
7) Tighten the two screws on the right side of the hinge assembly.
8) Set the ratchet on the jack to retract the threaded rods (pulling the ends of the hinge together).
Operate the jack to open the LDSF. Make sure the dowel pins separate from the holes at both split
points.
9) Open the LDSF far enough to mount it over the pipe.

10) Rig the machine according to the instructions in “Rigging and Lifting the LDSF” earlier in this chapter.
11) Lift the machine and remove the stand legs.
12) Mount the machine over the pipe at the cutting location. Make sure the stationary ring and clamp legs
are on the fixed (supported) side of the cut line.
17
Doc No: Revision:

0
13) Reverse the ratchet on the jack. Operate the jack to close the machine on the pipe.
14) On the split line opposite the jack, swing the latch bolts on the stationary ring into the slots. (Loosen the
nuts if necessary.) Snug down the nuts to hold the latch bolts in place.
15) On the split line at the jack location, swing the latch bolts on the stationary ring into the slots. (Loosen the
nuts if necessary.) Snug down the nuts to hold the latch bolts in place.
16) Loosen, but do not remove, the two screws on the right side of the hinge assembly.
17) On the split line opposite the jack, the stationary ring latch bolts. The split line between the sections
should close completely, with no gap between the sections.
18) On the split line at the hinge, tighten the nuts on the stationary ring latch bolts. The split line between the
sections should close completely, with no gap between the sections.
18
Doc No: Revision:

0
19) Tighten the two screws on the right side of the hinge assembly.
20) Attach the support block to the stationary ring at each joint. Insert and tighten the 4 screws holding the
block.
21) Swing the latch bolts in the rotating ring into the slots at both split lines. Tighten the nuts to secure the
latch bolts.
22) Tighten all latch bolt nuts securely.

23) Turn the adjustment screws on the clamp legs in the centre of each section (4 legs at 90° angles) until the
clamp feet contact the pipe.
19
Doc No: Revision:

0
24) Measure the clearance between the stationary ring and the pipe at each clamp leg position and
adjust the legs as necessary so that the machine is centered on the pipe.
25) Tighten the 4 centre clamp legs to 30 lb-ft. Check the clearance at each location again and adjust if
necessary.
26) Tighten the other 8 clamp legs to 30 lb-ft.
27) Tighten the 4 center clamp legs to 60 lb-ft, then tighten the other 8 legs to 60 lb-ft.
28) Tighten the 4 center clamp legs to 90 lb-ft, then tighten the other 8 legs to 90 lb-ft.
29) Remove the rigging from the machine.
Mounting The Drive Motor Assembly
20
Doc No: Revision:

0
-
7) EXECUTION OF WORK
7.1 Setting up the Slides.
For parting and beveling, use a parting tool on one slide and a beveling tool in the other slide.
Either slide can be used for parting or beveling.
a) In the first slide, set the large spacer block into the tool holder in the low orientation
(with no gap at the side of the block). Tighten the mounting screw into the spacer
block.
b) Install a parting tool on top of the spacer block. Install the tool cover by sliding it over
the tool holder.
21
Doc No: Revision:

0
c) Set the tool back in the holder and tighten the screw in the tool cover. You will adjust
the tool position after mounting the slide to the machine.
d) In the second slide, set the small spacer block into the tool holder, and tighten the
mounting screw into the spacer block.
e) Install a beveling tool in the gap next to the spacer block.

f) Set the tool back in the holder and tighten the set screw in the side of the tool holder.
You will adjust the tool position after mounting the slide to the machine.
g) Turn the star wheel on both slides clockwise to fully retract the slide.
7.2 Mounting the Slides on the LDSF

a) On both slides, turn the jacking screw so that the end plate is all the way forward.
Snug the screw, but do not over-tighten it.
22
Doc No: Revision:

0
b) Install the mounting blocks for both slides on the rotating ring. Leave the
screws loose so you can mount the slide.
c) Slide the base plate of the slide beneath the mounting blocks.
d) Push the slide forward until the tracking wheel is against the pipe. Snug down
the screws in the mounting block just tight enough to hold the slide. It will need
to move when you run the machine to set the slide positions.
e) Remove the frame locking pins from the rotating ring and put them in their
storage locations on the side of the machine.
f) When you have both slides mounted, connect the hydraulic lines to the machine
and turn on the HPU.
g) Operate the LDSF slowly through one complete rotation. As the tracking wheel on
each slide travels over the surface of the pipe, it will push the slide back so that it
is in position to contact the pipe at the high point (the location where the
clearance is least).
h) Securely tighten the screws in the slide mounting blocks to hold the slides
in position.
i) Turn the jacking nuts on both slides back all the way to release the springs for
operation.
j) Loosen the tool set screws in both slides and move the tools forward until they are
about 1/16” from the pipe. Tighten the set screws.
k) Ensure whole cutting equipment set is on water level and blades meet the marked cutting location for vertical
vessel/pipe cutting. Obtain permission from client prior proceeding cutting.
23
Doc No: Revision:

0
7.3 Performing the Cut

a) Turn on the power at the HPU. Set the operating pressure to 2000 psi.
b) Remove both frame locking pins from the rotating ring and put them in their “parking” holes in
the stationary ring.
c) Make sure that the trip is disengaged.

d) Turn on the hydraulic power and slowly operate the machine through one rotation to
check clearances and make sure the slide tracking wheels are following the pipe surface.
Stop the machine.
e) Loosen the trip lock lever and push the trip in to engage it.
f) Start the machine and set the flow to 14 gpm at the HPU. Make sure the star wheels are
striking the trip. Ensure coolant does not
g) Operate the machine until the tools begin cutting the pipe. Use of coolant is ingress
below.
insulation of equipment
recommended for better cutting performance and to increase tool life.

h) Adjust the speed as necessary for optimum cutting performance. Make sure both slides
are advancing and both tools are cutting.
i) Operate the machine until the cutting operation is complete. Turn off power at the HPU.
j) Turn the star wheels on both slides to retract them.
7.4 Performing the Counterbore

a) Turn the knob on the counterbore slide to advance the tool close to the pipe surface.
b) Make sure that the trip is disengaged. It is recommended to remove the trip when counterboring.
c) Turn on the power at the HPU.
d) Start the machine. Turn the counterbore knob each rotation of the LDSF to feed the slide.
e) Continue feeding the counterbore slide as the machine operates. Use of coolant is recommended
for better cutting performance and longer tool life.
f) Stop the machine periodically to check and measure the counterbore.
24
Doc No: Revision:

0
g) When the counterbore is complete, turn off hydraulic power.

h) Retract the counterbore slide and remove it from the tool holder of the LDSF slide.
8. COMPLETION
8.1 Removing the LDSF from the pipe
a) Operate the machine to align the split lines of the rotating ring with the matching split lines of the
stationary ring (A to A, B to B, etc.). Stop the machine with the split lines on both rings lined up.
b) Insert the 2 frame locking pins through the rotating ring.
c) Turn the starwheels on both slides to retract them.
d) Loosen the screws in the slide mounting brackets and remove the slides from the LDSF.
e) Remove the drive assembly from the LDSF.
f) Rig the LDSF and make sure the lifting device is holding it securely before you loosen
the clamp legs.
g) Turn the adjustment screws on the clamp legs to loosen the legs. Retract the legs all
the way.
h) Remove the support blocks from the stationary ring at the hinge location and the
opposite location where the machine will be split.
i) Loosen the nuts on the latch bolts at the joint opposite the hinge (both rotating and
stationary rings). Swing the latches out of the slots.
j) Loosen the nuts on the latch bolts at the hinge location (both rotating and stationary
rings). Swing the latches out of the slots.
k) Loosen, but do not remove, the two screws on the right side of the hinge assembly.
l) At the joint opposite the hinge, turn the jacking screw to separate the ring sections.
Turn the screw until the dowel pins are out of the holes. Retract the jacking screw
completely.
m) At the hinge location, turn the jacking screw to separate the ring sections. Turn the
screw until the dowel pins are out of the holes. Retract the jacking screw completely.
n) Tighten the two screws on the right side of the hinge assembly.
o) Set the ratchet on the jack to retract the threaded rods (pulling the ends of the hinge
together). Operate the jack to open the LDSF. Make sure the dowel pins separate from
the holes at both split points.
p) Replace the wood end caps on each of the sections.
q) Open the LDSF far enough to remove it from the pipe.
r) Lift the LDSF from the pipe and move it to a location where you can set it down.
Install the stand legs and set the LDSF on the floor.
s) If you are finished with the machine, disassemble it for storage.
25
Doc No: Revision:

0
9. PIPE COLD CUTTING AND RE-BEVELING FLOW CHART
Figure 9: Pipe cold cutting and re-beveling flow chart
26
Doc No: Revision:

0
10. INSPECTION AND TEST PLAN
Figure 10: Inspection and Test Plan Form
27
Doc No: Revision:

0
11. PIPE CUTTING AND BEVEL/RE-BEVELING REPORT
28

(Pptsb-exe-tessb-000-Qac-prc-006) Cold Cutting and Surface Machining Procedure - Approved

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

(Pptsb-exe-tessb-000-Qac-prc-006) Cold Cutting and Surface Machining Procedure - Approved

Uploaded by

Copyright:

Available Formats

Doc No:

PETRONAS TURCOMP ENGINEERING PPTSB-EXE-TESSB-000-QAC-PRC-

PROVISION FOR DISH HEAD INSTALLATION AND REPAIR WORK OF

PROJECT : PROVISION FOR DISH HEAD

CLIENT CONTRACT : PETRONAS PENAPISAN (TERENGGANU)

TITLE DOCUMENT : COLD CUTTING AND SURFACE

Prepared by: Reviewed by: Reviewed by: Approved by:

………………...….. ………………...….. ………………...….. ………………...…..

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

1 PURPOSE & SCOPE 3

6 FRONT END REQUIREMENT/PREPARATION 6-20

7 EXECUTION OF WORK 20-24

9 PIPE COLD CUTTING AND RE-BEVELING FLOW CHART 26

10 INSPECTION AND TEST PLAN 27

11 PIPE CUTTING AND BEVEL/RE-BEVELING 28

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

1. PURPOSE & SCOPE

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

5.2 Service Development Engineer

5.3 Level III Machinist / Machinist Operator

5.4 Safety Supervisor

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

6. FRONT END REQUIREMENT/PREPARATION

6.2 RIGGING AND LIFTING THE LDSF

The LDSF frame can be lifted in any of the following configurations:

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

Assembling The LDSSF

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

On the rotating ring, swing the latch bolts into place.

5) Snug the nuts to hold the bolts in place.

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

7) Tighten the nuts on the rotating ring latch bolts.

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

Setting Up The LDSE

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

Setting The Clamp Leg Positions

The LDSF clamps legs can be mounted in two positions:

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

Mounting The Machine

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

COLD CUTTING AND SURFACE MACHINING PROCEDURE

Doc No: Revision:

9) Open the LDSF far enough to mount it over the pipe.

COLD CUTTING AND SURFACE MACHINING PROCEDURE