Work Procedure Rev, OSA PT. OSA INDUSTRIES INDONESIA No. : OSA-P-Sav-22 Date :30 March 2012 | Page Indonesia WORKSHOP REPAIR GENERAL PROCEDURE Checked & Approved by : Prepared by: (Harnf Hutajulu) operations Manager . | QC Engineer Controlled Co, ara| OSA PT. OSA INDUSTRIES INDONESIA _ No. Indonesia [Date :30 March 2012 | WORKSHOP REPAIR GENERAL PROCEDURE, Amendment Record Sheet Date of Revision Item No. Issue No. Description of Change T | Logo OSA From “OSA | 27March 2012 | Change Logo OSA ou Industries” to “OSA Industries indonesia” _| Taare py Hs Smoot Fae ae Controlled Cop,’ aintOSA Work Procedure | PT OSAINDUSTRIES INDONESIA [No. vosmP-sAva2 Rew 01 Industries } Indonesia ee Date _:30 March 2012 | Page: 3/8 WORKSHOP REPAIR GENERAL PROCEDURE Safety Procedures 1.0. Purpose ‘The purpose of this procedure is to establish guidelines and provide a Workshop Repair General Procedure system at PT. OSA Industries Indonesia and/or the contracts. The procedure shall meets to any requirement and binding to other procedure continuously. 2.0 Method 2.1 Competency and trained Man Power only authorized for repair and has been trained for safety training for any execution. 2.2. Safety action taken carefully to bleed off the remaining pressure at valve & actuator, also remaining energy from mechanism springs hold or stuck. 23. Take normally position between valve and actuator to be sure no more powerful action required for dissembling any loosen tightens bolt & nut. 24. Devices use by electrical power must be sure for any protection to drop off fuses at MCB, and ‘easy to manage release energy from main panel if emergency required. 2.5. Valve & actuator Stuck must be aware to keep the extra power mechanism action to avoid back power in order release devices or any tighten component/bolt/nut. Analysis the safety dissembling unit by prepare additional tools & equipment for safety dissembling unit accordingly 3.0 Valve & Actuator Receiving 40 Without “Controlled Copy” stomp, documents Uncontralled « 3.1 Identify the valves and actuator from size, ANSI, type, acting system, port size, 3.2 Record the manufacturer's name plate information on the side of the valve in the valve report. 3.3. Locate and identify the part & components on the valve & actuator a) Body valve and Actuator bb) all fittings and adjustable devices ) Flange type 4d) Bolt & nut type with Allen head screw. ji. Bolt head type. 3.4. Lifting for loading and unloading unit valve & actuator from truck, must be conducted by signal Man as receiving process. Lifting shall define rigging tools for robe tightens to the ‘goods, considering balance of weight to avold swing fall from lifting procedure. During Repair Service 4.1. Personnel must be wearing PPE during in repair service area. 4.2. Prepare proper tools & equipment as required and place in the boxes in free access area. Solvent chemical uses for easing and rust removal must be awared to point and not face to person or hot area. Controlled Coy teler OSA Saar Industries eee Indonesia Date :30March 2012 | Page: 4/8 | Work Procedure PT. OSAINDUSTRIES INDONESIA No. : OSA-P-SRV-22 | Rev. :01 WORKSHOP REPAIR GENERAL PROCEDURE | 43. Equipment force by pressure must be indicated the following connection tighted and safe socket to avoid release from pressure arising 44 Lifting equipment should be managed for loading & unloading dissembling parts/component ‘more than 15 kgsin the right position and free moving access area from person and stuffs. 4.5 Competency Man Power only authorized to conduct as supervisory technician the repair service, method execution as required due to detail SOP for EA valve & actuator type. 4.6. Sparkle from grinding or drilling devices shall be sure take action at the safe area from fire Inspection Purpose ‘The purpose of this procedure is to establish guidelines and provide an inspection procedures for VALVE WORKSHOP REPAIR system at PT. OSA Industries Indonesia and/or the contracts. The inspection shall be conducting by Engineering to find out instruction repair service respectively, and shall binding to Inventory Check List procedure. ut 12 13 14 1s 16 17 Check list to Inventory if the repair service unit must be replaced before dismantle from f/s, colleting from ex-stock Marunda warehouse both from new reconditioned or defective unit available to repair. Leak and function test valve to find out defective valve & actuator, record parameter issued and due to standard requirement test API, ANSL Dissembling valve and actuator to find defective and fallure damages parts/component, mounting and body condition. Take a notes and picture for EA damaged goods for any comparison before and after recondition. Clean up body & actuator, parts, component, devices to have the clear current condition and always tag any releasing devices to re-install on the original position. Separate the good and damages parts, component to prepare the execution of recondition and repair service. Engineering Review a). Decide as the actual condition to repair for minor or major repair 'b) Action plan to execute repair service ) Failure analysis if any critical badly damaged caused of fluid process changing contained Data base recordable shall tag ID and all information for track and trace repair status monitoring, up-dating data base to manage F/s, service area, Tag no required for repair memo and remarks both for field and inventory. Woot "Coed Copy same, duane stneoncleds erated COL x araWork Procedure OSA PT.OSA INDUSTRIES INDONESIA | No. :O5A-SRV-22 [Rev :01 | _ Indonesia [Date :30March 2012 | Page: 5/8 | = 3 ; 1 WORKSHOP REPAIR GENERAL PROCEDURE Procurement Purpose The purpose of this procedure is to establish guidelines and provide Procurement procedures for VALVE WORKSHOP REPAIR system at PT. OSA Industries indonesia and/or the contracts. This procedure shall refer to any procurement pracess and binding to General Procurement Procedure as the master procedure therefore. 1.1 Record the requirement spare parts, components to procure and must be related standard from ‘original manufacture manual [API, ANSI, NACE, ASTM]. 1.2 Fabricate parts/component must be issued the laborary standard shall define and meet to the current requirement process, meet the temperature, pressure, flow capacity and typical of fluids characteristic. 4.3 Record all parts/component for actual dimensional parameter if no S/N, and must be adjusted to existing mounting and bracket as required 1.4 Differential material must be recognized and shall meet to the current requirement at safety factor standard, Soft goods must be stored for spare units net limited to requirement if any lack of reconcition need to secondary replacement or reworks 15 Action to Procure 4a) Uist of parts/component inquiry c/w spec, size, material comp b) Request for proposal to vendor or direct purchase )_ Prices must be leveling to normal price, and shall define the competitive price 4). Special price allowable accepted only for urgent/emergency requirement @) Propose for non-rate material contract for approval £). Delivery material shall meet to the repair service schedule due date completion 1.6 Up-date data to Inventory recordable for buffer stock and running stock always Fabrication Purpose ‘The purpose of this procedure is to establish guidelines and provide Fabrication procedures for VALVE WORKSHOP REPAIR, system at PT. OSA Industries Indonesia and/or the contracts. 1.1 Meterial/eomponent fabrication must be related to standard not limited the composition materia, original dimensional and meet to current process fluids media. 1.2 Fabrication by welding filler, must be meet to test to ensure from crack material and leaking following PWHT and WPS as required welding procedure standard. 1.3. Record all parts/component for actual dimensional parameter if no S/N, and must be adjusted to existing mounting and bracket as required. Differential material must be recognized and shall meet to the current requirement at minimum. Scrap material must be stored back to warehouse for junk material record. Without “Coniled Copy stomp, document is Uncontvaled Controlled Copy oe arte 2Os inl Work Procedure le | PT.OSA INDUSTRIES INDONESIA No -oSap-sav.22 | Rev. 01 Industries jie. seer seve eee Indonesia [Date :30March 2012 | Page: 6/8 r es / WORKSHOP REPAIR GENERAL PROCEDURE | 1.5. Action to Fabricate a) List of parts/component inquiry c/w spec, size, material comp, b) Request for proposal to vendor or direct fabrication ©) Prices must be leveling to normal price, and shall define the competitive price 4d). Special price allowable accepted only for urgent/emergency requirement €) Propose for non-rate material contract for approval f) Delivery material shall meet to the repair service schedule due date completion 1.6 Up-date dats to Inventory recordable for buffer stock and running stock always 1.7 Sub-contract to vendor for fabrication shall meet the standard and comply with requirements Recondition, repair sei Purpose The purpose of this procedure is to establish guidelines and provide Recondition, repair service procedures for VALVE WORKSHOP REPAIR system at PT. OSA Industries Indonesia and/or the contracts. 1.1 Parts/component/body must ensure could be reconditioned. Resize and over size dimensional is not allow to recondition if any devices not meet to mounting body. 1.2 Wall thickness reduce by process only allowable to recondition and shall meet the wall thickness requirement for re-metal, hard facing to the original dimens‘onal size. 1.3 Loosen and Tighten all Bolt & Nut shall allow to ANSI class requirement for torque moment, and shall re-check the final action before dispatch and packing, 1.4 Record all parts/component for actual dimensional parameter if no S/N, and must be adjusted to ‘existing mounting and bracket as required. 1.5. Modification shall allow not to change any function, specification and system to operate the unit for reason of re-positioning or swapping parts/component from other scrap unit if any, Action to recondition Dissembling Recondition, repair service Parts/ component replacement Re-assembling Coating & Painting Testing Packing 1.6 Up-date data recordable to Master Data Base. 1.7. Sub-contract to. vendor for recondition repair service shall meet the standard and comply with requirements and acknowledge by the Company. ‘Without *Conroled Copy” stomp, docoment i Uncontroed , Controlled Co; RLWork Procedure PT. OSA INDUSTRIES INDONESIA | No. : OSA-P-SRV-22 | Rev. :01 [ate :30March 2012 | Page: 7/8 | WORKSHOP REPAIR GENERAL PROCEDURE Pressure & Function Testing 1.0 Purpose ‘The purpose of this procedure is to maintain a system which identifies the leak and function test for valve & operated device due to standard EA type of API, ANSI, NACE, ASTM, ISO. 2.0 Scope Every valve is to be hydrostatically tested to ensure the pressure integrity of valve body. The valve seat is also checked to verify that leakage past the relevant standard and customer requirement Function test is required for complete operating valve & operated devices ensure to operable & reliable. 3.0 Definitions 2. Product Result of a set interrelated or interacting activities which transforms inputs into outputs. b. Record Document —_: Stating results achieved or providing evidence of activities performed. Inspection Conformity evaluation by observation and judgment accompanied as appropriate by measurement, testing or gauging. 4, Bidirectional Valve: Avalve designed for sealing in either direction. e. Plug Prevents flow or leakage into the down stream conduit when in the closed position. Valves shall be single or double seated, bidirectional ‘or unidirectional, Unidirectional valves shall be marked with a flow irection arrow. f. Closure Member: That part of a valve which is positioned in the flow stream to.permit, obstruct or regulate flow. 4.0 References Material 4.1 AVIW-TBM-001 ‘Work Instruction of Test Bench Machine AYFC-1 4.2. APIStandard 598: Valve Inspection and Test 4.3, APISpecification Specification for Pipeline Valves (Gate, Plug, Ball and Check Valves) 6D 4.4 APIStandard 608: Metal Ball Valves-Flanged, Threaded and Welding Ends 4.5 ASMEB1.20.1 Pipe Threads, General Purpose (inch) 46 ASMEBI6.11 Forged Steel Fitting, Socket-Welding and Threaded 4.7 ASMEBI6.34 Valves - Flanged, Threaded, and Welding Ends 48 MSSSP-55 Quality Standard for Steel Castings for Valves, Flanges and Fittings and other Piping Components - Visual Method 4.9 MS55P-91 : Guidelines for Manual Operation of Valves With “Controle Copy” stomp, documents Uncontrolled Controlled Copy eaeOSA Work Procedure PT. OSA INDUSTRIES INDONESIA No. :OSA-P-SRV-22 | Rev. :01 Industries LI Indonesia Date :30 March 2012 | Page: 8/8 WORKSHOP REPAIR GENERAL PROCEDURE Packaging 1.0, Purpose 20 3.0 40 ‘The purpose for Packaging is to find the best and safe for material transportation both for on and off shore delivery. The procedure is not limited to recondition valve & operated devices, but for sure as a guide line to various materials required for packaging. ‘Scope Every valve and actuator must be bended at packaging for delivery requirement, safe for loading and unloading, safe while boat transportation fram shaking and hook to avoid damages goods. Packaging Method 3.1. Sizing and weight material to prepare wooden raw material 3.2. Material take in place on top available Pallet, and shall fit at surface to ensure proper position at bottom site in balance and fully bended by stect plating 3.3. Wrap all face Pallet with wooden and nailed strongly to form container frame and cover all Material 3.4. Direction informative to hook up and loading-unloading Description 4.1 Construction Pallet & Wooden Box with equal dimensional to material size nailed for any connection and shall pallet at bottom side. 4.2 Locking All boxes must be bended between Materials to the wooden box by steel plate and have no shaking for load & unload action. 4.3 Packing Uist Destination, Material spec Info and Quantity. 4.4 Delivery Must be safe from hook and maneuver during loading-unloading, easy for rigging wrap and robe tighten for lifting. 4.5. Final Check : Final Check list before delivery must be approved by authorized personnel or Supervisor Without “Contreled Cony” stomp, document is Uncortaled Controlled Co) Dewrere