Classification: General Business Use

SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-304LW-001)

SEPARATOR
(EQUIPMENT #: P-304LW-001)

Prepared by: Reviewed by: Approved by:

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SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-304LW-001)

Guido F. Cozzi
Site Manager

Naoufal Akhrif
Operations Manager

Remington Tan
Senior Safety Officer

Elvin Tom
Operations Supervisor

Andrews Ackah
Operations Supervisor

Amro Burhan
Oliver Lazo Bibat Operations Supervisor
Operations Superintendent

Date: 28/04/2020 Date: 28/04/2020 Date: 28/04/2020

Contents
1. Purpose/Scope........................................................................................................................................4

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Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-304LW-001)

2. Terminology...........................................................................................................................................4
3. References:.............................................................................................................................................4
4. Frequency Of Maintenance Activity......................................................................................................4
5. Key Personnel Responsibilities..............................................................................................................5
6. HSE........................................................................................................................................................5
7. Requirements.........................................................................................................................................7
8. Other requirements.................................................................................................................................9
9. Spares, Tools & Special Consumables:.................................................................................................9
10. General Information.............................................................................................................................10
11. Before Execution.................................................................................................................................11
12. During Execution.................................................................................................................................11
13. After Execution....................................................................................................................................12
14. Process / Step- by- Step Methodology:................................................................................................13
15. Records Involved.................................................................................................................................17
16. Attachments.........................................................................................................................................18
17. Revision History..................................................................................................................................18

1. Purpose/Scope

To establish a procedure for Inspection, Cleaning, Testing and Maintenance repair / replacement
activities carried out for the Separator during turnaround, emergency shutdown or breakdown
maintenance meeting the Safety and Integrity objectives of the Plant.

The procedure provides generic guidelines for the inspection, cleaning, testing and Maintenance
repair / replacement of Separator.

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SEPARATOR (EQUIPMENT #: P-304LW-001)

All Involved personnel must fully understand the general and specific operating procedures. Any
issues arising during work periods must be brought to the immediate attention of the Team
Leader, Supervisor and Maintenance/Site Manager.

Procedure / guidelines outlined by this document are applicable to all who take part in the process
and must be fully adhered to.
Any deviation from the procedures / guidelines must necessarily have prior explicit approval of
the Maintenance/Site Manager.

2. Terminology
2.1. SMP :Standard Maintenance Procedure
2.2. PPE :Personal Protective Equipment
2.3. G-Urea :Granulated Urea
2.4. SF :SAFCO
2.5. OEM :Original Equipment Manufacturer’s
2.6. EDMS :Electronic Document Management System

3. References:
3.1. Relevant Equipment OEM Drawings in EDMS
3.2. Operation and Maintenance Manual in EDMS.
3.3. Equipment and Desiccant Specification Sheet in EDMS
3.4. Equipment Inspection Schedule

4. Frequency Of Maintenance Activity

S/N Maintenance Activity Frequency

Complete Inspection, cleaning, Desiccant

1. Every Turnaround (3 years)
replacement, Maintenance activities.

2. Breakdown & Corrective As required

5. Key Personnel Responsibilities

5.1. Maintenance Supervisor (MS)
5.1.1.Is responsible to carry out Mechanical/Electrical isolations as per JSA requirement.
5.2. Operation’s Supervisor (OS)
5.2.1.Is responsible to carry out Mechanical/Electrical isolations as per JSA requirement.
5.3. Electrical Supervisor (ES)
5.3.1.Is responsible to carry out Mechanical/Electrical isolations as per JSA requirement.
5.4. Maintenance Coordinator/Planner
5.4.1.Ensure spare parts and consumables required for the job are available.
5.4.2.Ensure all required resources are available (Manpower, Tools, etc.)
5.5. Helpers
5.5.1.Ensure that the area is clean before and after maintenance activity.
5.6. Techinician
5.6.1.Execute the job according to the job order.
5.6.2.Ensure all the required checklist are properly filled.

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6. HSE
6.1. Safety & Health

6.1.1.Approved JSA as applicable must be available and posted on site before the start of job.
6.1.2.Conduct safety talk with all working crew highlighting the JSA points and Hazardous
involved in the job task before starting the job.
6.1.3.Perform blinding before carrying out any activities.
6.1.4.Take a valid work permit before starting the job and display at job site.
6.1.5.Use only approved fresh air breathing apparatus.
6.1.6.Ensure the gas test reading normal.
6.1.7.The work area must be barricaded, warning sign to be posted and allow only concerned
people inside.
6.1.8.Proper Tightening Tools must be selected for Man ways opening / Box up, Internal trays,
support grids and structures removal / reinstallation, etc.
6.1.9.Use only Tested and certified Lifting /rigging tackles like chain block, slings, D-shackles
etc. as SHEM-08.06
6.1.10. Fork lifts / Crane and all other lifting equipment must be inspected prior to lifting and
certified.
6.1.11. Fork lifts / Crane operators and riggers must be qualified and certified.
6.1.12. No job to be performed if it’s windy.
6.1.13. Lifting plan should be prepared before lifting.
6.1.14. Do not allow more than four persons to ride in the crane basket. Use safety harness.
6.1.15. Use PPE’s stipulated in the work permit and compatible with the equipment service as
per SHEMS 08.08.
6.1.16. Use appropriate certified Scaffolding while working at height as per the SHEMS 08.09.
6.1.17. Personnel involve in all Maintenance activities must be well trained and ensure wearing
of proper PPE for the job.
6.1.18. Handle lubricants and aerosol sprays carefully as these are flammable materials.
6.1.19. Prohibit use of open flames while disassembling equipment at site.
6.1.20. Check condition of oil hoses if any hydraulic jacks are used to avoid injuries due to high
pressure oil spray.
6.1.21. The Hydro test pump must be certified and all the gauges should be calibrated.
6.1.22. Hydro jetting machine should have valid test certificate.
6.1.23. Experienced operator should be assigned for jetting.
6.1.24. All the flanges and end blinds shall be as per standard pressure rating related to
Pneumatic / Hydrostatic test shall be connected with respective gaskets and proper torque
tightened to avoid any jetting or leakages.
6.1.25. All High pressure Hoses shall meet the pressure rating and be connected with standard
clamps and threaded joints shall be tightened properly to avoid any type of pressure jetting
or leakages.
6.1.26. Minimum 2 calibrated pressure gauges shall be used for Pneumatic / Hydrostatic test.
Pressure gauges used for testing shall have dial graduated over range of double the intended
test pressure.
6.1.27. The dial of the gauges shall be positioned in such a way that they are clearly visible to the
operator controlling the pressure during the test. One of the pressure gauges shall be located
in the highest point.
6.1.28. Minimum of one PSV shall be installed in the test loop to avoid accidental over
pressurizing.
6.1.29. Pressure gauges & PSV’s should have valid test certificate.

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6.1.30. Before start of equipment dismantling, it is absolutely necessary to verify that:

6.1.30.1. The equipment is completely depressurized and purging has been done.
6.1.30.2. Blinding has been done as per the approved blind diagram.
6.1.30.3. The Vessel body has been cooled down nearly to ambient temperature.
6.1.31. Pre job task meeting should be conducted prior to start the job.

6.2. Environment

6.2.1.In case of any chemical/hazardous waste leakage to ground or atmosphere, inform the
Environment Engineer and dispose in accordance to the SAFCO Environment procedures.
6.2.2.Dispose of hazardous waste generated during the work as per SAFCO Environment
procedures.

7. Requirements
 LSR: Life Saving Rules – is a set of critical EHS Rules associated to high risk activities, if
violated may lead to serious consequence. These rules shall never be broken.

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Rules Reference SHEM’s

Safe Systems of Work SHEM 08.00

Confined Space Entry SHEM 08.10

Safety at Height SHEM 08.09

Lifting Operations SHEM 08.06

Energy Isolations SHEM 08.05 & SHEM 08.10

Disabling Safety System SHEM 07.08

Created Openings SHEM 08.09

Vehicle Safety SHEM 08.01

Line Breaks SHEM 08.10

Management of Change SHEM 09.00 – SHEM 06.00

6.1 Safety Concerns

6.1.1 Many vehicles and equipment working in same area.
6.1.2 Pedestrians working nearby vehicles.
6.1.3 Working with Riggers
6.1.4 Working at height
6.1.5 Working with rotating equipment
6.1.6 Electrical hazards (Line breaks)
6.1.7 Lifting operation
6.1.8 Disabling safety system
6.1.9 Ammonia/Dust inhalation
6.1.10 Eye and Skin Irritation
6.1.11 Heat stress
6.1.12 Slips, Trips & Fall

6.2 Safety Requirements

6.2.1 Company uniform (Fire resistant)
6.2.2 High visibility Workwear

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6.2.3 Hard Hat

6.2.4 Safety Glass (indoor/outdoor)
6.2.5 Steel toed Safety Shoes
6.2.6 Dust Mask (Full face mask when needed)
6.2.7 Hand gloves (as per HSE standards)
6.2.8 Safety harness for working at heights.

8. Other requirements
8.1.1.All maintenance activities will be under strict supervision of SAFCO Supervisor.
8.1.2.There must be clear and complete communication between the maintenance & operation
supervisors to ensure safety and integrity.
8.1.3.Proper Area shall be designated to keep piping’s and Desiccant, etc.
8.1.4.Inspection tools calibration certificates to be reviewed by SAFCO Inspection.
8.1.5.All related Inspection reports shall be immediately submitted to SAFCO inspection for
review & approval.
8.1.6.All repairs will be done as per SAFCO inspection & process recommendations.
8.1.7.Final box up will be done after clearance and box up certificate duly signed by from
Operation, Inspection, Maintenance & Process.
8.1.8.Studs and nuts removed from different sections should be free of nicks, burrs, chips, dirt
and corrosion. Nuts should turn freely on studs.
8.1.9.Erect proper scaffolding for work as required, and use it only after it is tagged fit for use.

9. Spares, Tools & Special Consumables:

9.1.1.SPARES
9.1.1.1. Refer to SAP and Micro Data Reference Manual.

9.1.2.TOOLS

9.1.2.1. Use only calibrated measuring tools for taking critical equipment dimensions.
9.1.2.2. Use only tested and certified lifting/rigging tackles like chain block, slings,
shackles etc.
9.1.2.3. Use any special tools supplied by OEM.
9.1.2.4. Use calibrated torque wrenches.
9.1.2.5. Refer attached OEM / Manufacturer Equipment Drawings.

SL # Tools Description Remarks

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1. Forklift
2. Crane
3. Impact Wrench
4. 24V lighting, GFCI protected & explosion proof.
5. Air movers
6. Material Basket
7. Spanners
8. Chain pulley blocks / Crane
9. Hydro Jetting Machine
10. Hydro Test Pump
11. High Pressure Water hoses
12. Tested and calibrated Pressure gauges & PSVs
13. Welding Machine
14. Torqueing Machine

10. General Information

10.1 Before proceeding with overhaul check for below preparations:

10.1.1 Valid Work Permit shall be made available before the start of any activity
10.1.2 Ensure to use calibrated precision pressure gauges for hydro testing
10.1.3 Vessel internals and all related Gaskets should be handled with utmost care
10.1.4 Clean area around the equipment.
10.1.5 Arrange bins and polythene bags to preserve equipment parts and avoid contamination
by dust or other foreign matter.
10.1.6 Mobilize all tools and materials near the equipment.

10.2 Refer attached Vessel Data / Specification Sheet.

10.3 Refer attached Manufacturer Drawings.
10.4 Refer OEM General Operation and Maintenance Manual

11. Before Execution

S/N ACTIVITY RESPONSIBILITY
Carry out mechanical isolations as per JSA Operation’s Supervisor (OS)
1.
requirement. Concerned Supervisor (MS)
Fulfill the requirement of specialized skilled TA & CM Planner / Maintenance Planner
2.
manpower / Service provider to execute activities. (MP)
3. Erect the scaffolding at required areas. Services Supervisor (SS)

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Concerned Supervisor (MS)

Service provider supervisor (SPS)
Services Supervisor (SS)
4. Remove the insulation from required areas. Concerned Supervisor (MS)
Service provider supervisor (SPS)
TA & CM Planner / Maintenance Planner
Issue and collect all required spares, special tools, (MP)
5.
blinds, etc. for the Maintenance activities. Concerned Supervisor (MS)
Service provider supervisor (SPS)
TA & CM Planner / Maintenance Planner
Inspect the materials, blind, gasket, Vessel internal
(MP)
6. materials, gaskets etc. for being in line with
Concerned Supervisor (MS)
specification.
Service provider supervisor (SPS)

12. During Execution

S/N ACTIVITY RESPONSIBILITY
Approved JSA, Rigging Plan, Work Permit and Concerned Supervisor (MS)
1.
Blind Diagram are displayed at job location. Service provider supervisor (SPS)

2. Blinds installation as per approved Blinding Concerned Supervisor (MS)

Diagram displayed at job location. Service provider supervisor (SPS)
Lifting / Hydrostatic Testing / Hydro Jetting
3. Concerned Supervisor (MS)
Equipment are certified and verified for good
Service provider supervisor (SPS)
working condition.

4. Safe Scaffoldings are installed with valid Certified Concerned Supervisor (MS)
Tags. Service provider supervisor (SPS)

5. Ensure all the Mechanical works are done as per

Concerned Supervisor (MS)
SMP procedure.

6. Torqueing done to the recommended value and Concerned Supervisor (MS)

torqueing tags fixed / installed. Service provider supervisor (SPS)

7. Concerned Supervisor (MS) / Mechanical

Fill all the checklists related to the SMP.
Technicians (MT)

13. After Execution

S/N ACTIVITY RESPONSIBILITY
Operation’s Supervisor (OS)
1. Ensure that all de-blinding done with new gaskets.
Concerned Supervisor (MS)
2. Torqueing done at de-blinded locations to the Concerned Supervisor (MS)
recommended value and torqueing tags fixed / Service provider supervisor (SPS)

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installed.
Flange joint tightening checklist prepared and Concerned Supervisor (MS) / Mechanical
3.
attached. Technicians (MT)
Operation’s Supervisor (OS)
4. Fix back all removed insulations Concerned Supervisor (MS)
Service provider supervisor (SPS)
Operation’s Supervisor (OS)
5. Remove all scaffoldings. Concerned Supervisor (MS)
Service provider supervisor (SPS)
Housekeeping done at site and Work Permit
Concerned Supervisor (MS)
6. returned to the Operations after completion of the
Service provider supervisor (SPS)
work.
Surplus / Unused Material / Spares return to Stores/ Concerned Supervisor (MS)
7.
Warehouse through proper procedure. Service provider supervisor (SPS)
Dispose the scrap materials at designated area as Concerned Supervisor (MS)
8.
per SAFCO procedure. Service provider supervisor (SPS)
Scan and attach filled and signed checklists to
9. Concerned Supervisor (MS)
related SAP Work order.
Ensure that all mechanical isolations are
10. Operation’s Supervisor (OS)
normalized.

14. Process / Step- by- Step Methodology:

STEP S/N ACTIVITY DESCRIPTION RESPONSIBLE REMARKS
Activity
13.1 PREPARATION FOR BLINDING AND SEPARATOR MAN WAYS OPENING
1
Prepare containers or drums to preserve all removed bolts of MS/SPS
13.1.1
Separator.
13.1.2 Designate the area to keep Separator Internal and all related Gaskets.
13.1.3 Erect the Scaffolding at required areas if any.
13.1.4 Remove all claddings and Insulation if any from required areas.
Collect and shift all required spares, special tools, related blinds, etc.
13.1.5
to site.
Shift all required tools and tackles, Air movers, 24-volt lightings, etc.
13.1.6
to site prior to starting the job
Inspect the materials, blind, Separator internal materials, related
13.1.7
gaskets etc. for being in line with specification.
13.1.8 Arrange approved fresh air breathing apparatus if applicable.

13.1.9 Conduct pre job task meeting.

13.1.10 Ensure system is properly isolated, flushed, drained, purged, tag out

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& ready for blinding.

13.1.11 Lose all flanges bolts.
Inspect the gasket seating area of mating flanges by visually for any
13.1.12
damages / defects.
13.1.13 Blind the Separator as per operation approved blind list.

REMARK
STEP S/N ACTIVITY DESCRIPTION RESP.
S
Activity SEPARATOR MAN WAYS OPENING, SEPARATOR ENTRY PREPARATION
13.2
2 AND PRELIMINARY INSPECTION.
This SMP is provided as a general guideline for the
Note: maintenance of the Air Dryer.
Refer to OEM drawings & manuals for any specific details.
Assist operation to connect utility hoses for decontamination if
13.2.1
required.
Start opening and removal of all Man ways nuts and bolts / studs one
13.2.2
by one.
13.2.3 Open all man ways.
All removed bolts & nuts clean, inspect and preserve them properly
13.2.4
in storage containers.
Inspect the gasket seating area of man ways and mating flanges by
13.2.5 visually for any damages / defects and protect all the gasket seating
areas properly.
13.2.6 Install Air movers to all man ways. MS/SPS
13.2.7 Provide sufficient explosion proof low voltage lighting.
13.2.8 Arrange drinking water, tools & materials at job site.
Arrange certified / trained stand by man with all necessary
13.2.9
safety equipment.
Take Vessel Entry Permit (Hot Work Permit) and conduct gas
test.
13.2.10
Mention tested gas values in corresponding Vessel Entry
Permit
Fulfill all permit requirements and follow SAFCO Vessel Entry
13.2.11
safety procedures.
Conduct preliminary inspection by Inspections & Process prior
13.2.12
to any internal cleaning / repair / replacement activities.
ACTIVIT SEPARATOR INTERNALS REMOVAL FOR CLEANING OR REPLACEMENT
Y3
13.3
SEPARATOR SHELL INTERNAL INSPECTION AND CLEANING
Carryout detailed inspection of Separator and other sections by
13.3.1
inspections & process prior to any cleaning / repair activities
13.3.2 Open and remove all internal man ways if any. MS/SPS

13.3.3 Open and remove all internals as per process / inspection

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recommendations for further inspection /cleaning / repair

/replacement.
Carryout Separator internal cleaning from top to bottom by
mechanically or hydro jetting as recommended and according to
13.3.4
hydro jetting procedure and to the satisfaction of Process /
Inspection.
Offer the equipment for top to bottom inspection to Process &
13.3.5 Inspection after cleaning. Ensure all connecting pipelines are clean &
free of any debris.
13.3.6 All removed internals shift and kept at designated area.

Clean all internals by low pressure hydro jetting according to hydro

13.3.7
jetting procedure and to the satisfaction of process.
All the removed bolts & nuts clean, inspect and preserve them
13.3.8
properly in storage containers.

Activity
13.4 INSPECTION & REPAIRS
4
Offer the Separator and all the internals for detailed
13.4.1 Inspection to both Inspection and Process.
Carry out Separator shell and recommended internals buffing
13.4.2 and cleaning prior to DPT and TML to the satisfaction of MS/SPS
Inspections.
Carry out Weld areas DPT and TML according inspection
13.4.3 program.
Carry out all recommended repairs / replacement / correction
13.4.4 works as per issued Inspection and Process reports.

Activity SEPARATOR INTERNALS REINSTALLATION, INTERNAL MAN WAYS

13.5
5 BOX-UP AND FINAL INSPECTION.
After getting the final acceptance from Inspection & Process
13.5.1 reinstall all removed and cleaned or new Separator internals
in appropriate positions.
Prepare the box-up certificate duly signed by Inspection,
13.5.2 Process, Operation and Maintenance for Separator internal
man ways if any boxed-up.
Box-up all internal man ways after the final acceptance from MS/SPS
13.5.3
Inspection & Process.
13.5.4 Offer the Separator for the Inspection to Process.

13.5.5 Remove all internal scaffoldings from Separator.

Carry out Process & Inspection side final internal visual

13.5.6
inspection of Separator from top to bottom before closing off.

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Activity
13.6 FINAL INSPECTION, SEPARATOR BOX-UP & DE-BLINDING
6
After the final acceptance from Inspection & Process remove
13.6.1
all tools, lightings & air movers from the Separator.
Prepare the box-up certificate duly signed by Inspection,
13.6.2 Process, Operation and Maintenance for Separator man ways
boxed-up.
Before fixing the Gasket, make sure that gasket seating areas
13.6.3
properly cleaned and free from any damages.
Take proper care for fixing the man ways cover flanges, extra
13.6.4
precautions need to be taken to ensure the integrity of gasket. MS/SPS
All the bolts to be greased / lubricated properly and Torqueing
13.6.5
done to the recommended value.
Confirm torqueing tags fixed / installed.
13.6.6

13.6.7 Carry out de-blinding with new gaskets.

All the bolts to be greased / lubricated properly and Torqueing
13.6.8
done to the recommended value.

Activity SEPARATOR EXTERNAL INSPECTION, REPAIRS, GRIT BLASTING AND

13.7
7 PAINTING
Erect Scaffolding at required external / full areas of the
13.7.1
Separator.
Remove all claddings and Insulation from required / full
13.7.2
areas according to the requirement.
Offer the equipment for top to bottom external inspection to
13.7.3
Process & Inspection.
MS/SPS
External Steam tracing coil / tubs inspection by process /
13.7.4 inspection, recommended testing, repair / replacement done,
if applicable.
Carry out Separator shell external recommended areas
13.7.5 buffing and cleaning prior to DPT and TML to the
satisfaction of Inspections.
Carry out Weld areas DPT and TML according inspection
13.7.6
program.
Carry out all recommended repairs / replacement / correction
13.7.7
works as per issued inspection and process reports.
Carry out grit blasting and painting activities for
13.7.8 recommended / full areas of the Separator shell external
surfaces as per Inspections recommendation.
13.7.9 Offer the equipment for top to bottom final inspection to

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Inspection & Process after all recommended repairs and

painting activities.
After getting the final acceptance from Inspection & Process
13.7.10 fix back or replace all removed / damaged Insulation and
claddings.
Remove all external scaffoldings from outside of the
13.7.11
Separator.
Activity
13.8 HOUSEKEEPING
8
Remove all tools & lifting equipment, do the Housekeeping at
13.8.1 site and return the Work Permit to the Operations after the job
completion.
Return all Surplus / Unused Material / Spares to Stores/
13.8.2
Warehouse through proper procedure.
Dispose all the scrap materials at designated area as per MS/SPS
13.8.3
SAFCO procedure.
Fix back or replace all removed / damaged Insulation and
13.8.4
claddings.
Remove the erected Scaffolding and shift all scaffolding
13.8.5
materials to designated area.

15. Records Involved

 Check list
 JSA
 Blind list
 Blind Diagram
 General Arrangement Drawing
 Assembly Drawing for Erection
 Dedusting System Flow Diagram
 Specification Sheet

16. Attachments

S/N Document Ref. # Attachment

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1. Check list SMCL-P-304LW-001

2. JSA IBB- MAINTAINENCE

UNDER DEVELOPMENT BY
3. Blind list NA
IBB OPERATION
UNDER DEVELOPMENT BY
4. Blind Diagram NA
IBB OPERATION

General Arrangement
5. EDMS
Drawing

Assembly Drawing for

6. EDMS
Erection

Dedusting System Flow

7. EDMS
Diagram

8. Specification Sheet EDMS

17. Revision History

Revision History
Rev. No. Date Description of Changes

Printed copies of this document are not controlled unless stamped “CONTROLLED” in red ink herePage 16 of 16
Doc. No.: SAT-TEC/P-066