BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and 1504)

F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D
T A N A H T E M A S I K S D N B H D
G U S T E A M C O R P S D N B H D
D M C M I D D L E C O . , L T D
FA L KO R E N G I N E E R I N G S E R V I C E S P T E LT D
TA N A H T E M A S I K S D N B H D
GUSTEAM CORP SDN BHD
D M C M I D D L E C O . , LT D
TECHNICAL PROPOSAL
BSRTA4-MS01 RFCC Slide Valve Works Proposal

(SV-1501, 1502, 1503 and 1504)
BSRTA4-MS01
REV NO DATE PREPARED BY: REVIEWED BY: APPROVED BY: REMARKS/ STATUS
01
02
03
REV NUMBER:BSRTA4-MS04- Technical Proposal

01 BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and
BSR 4TH PACKAGE 1 1504)
TECHNICAL PROPOSAL Page 1/ 10
Table of Contents
1. Purpose 3
2. Scope 3
3. Location 3
4. Competent Person 3
5. Material, Machineries, Equipment 3
6. Work Procedure 3
6.1. Pre Shutdown Work 3
6.2. Shutdown Work 5
6.3. Removal of Actuator and orifice plate from Slide Valve 5
6.4. Cutting the SV-1503 / SV-1504 valve body 6
6.5. Flue gas line internal scaffold and preparation of new SV-1503 / SV-1504 valve
body 8
6.6. Install new SV-1503 (SV-1504) valve body and reinstate actuators 9
7. Final acceptance for the work 10
7.1. Final inspection 10
7.2. Completion: 10
8. Emergency And Rescue Operation 10

1. Purpose
This method statement explains the safe work method of supporting the slide valve (SV),
supporting the top and bottom flue gas line section of the valve body, as well as securing the valve
body before cutting and removing it and replacing it with a new valve body.
2. Scope
The scope of this method statement is applicable to SV-1503 and SV-1504 valve body replacement
and SV-1501, SV-1502 internal parts replace.
.
3. Location
Binh Son Refinery, Vietnam.
4. Competent Person
A person who has such practical and theoretical knowledge and actual experience of the
respective operation he is assigned to. If applicable he shall have obtained the approval from the
government bodies or certification as a certified and approved person.
5. Material, Machineries, Equipment

A. Air Compressor (390 cfm)
B. Generator (350 KVA)
C. Gouging Machine (600 Amp)
D. Hydro jet cutting machine
E. Diamond wire cutting machine
F. Welding Machine (400 Amp)
G. Chain Blocks
H. Lifting Belt & Sling
I. 90 T Mobile Crane
J. 40ft Trailer
K. Air blowers and air ducts
6. Work Procedure
6.1. Pre Shutdown Work
 Design and fabricate 2 sets of SV actuator support skids for SV-1503A & B (and SV-1504A &
B), load tested to hold 1 ton load. Design and fabricate SV valve body lifting jigs, load tested
to carry 2 tons of load as per sketches below.
Fig 1:
Actuator
Support skids
x 2 sets
Heavy duty
castor wheels
with lock, 4 nos
Lifting eye for

mounting chain
blocks
Knock-down
structure to be
assembled on
SV platform
Height of
bracing at
middle of Fig 2: SV
SV valve body lifting
body from Jigs
platform
Heavy duty
castor wheels
Removable with lock, 4 nos
pieces
 Erect scaffold platforms at external under the Slide Valve platform for bracing installation.
 Weld surface preparation of new SV-1503 and SV-1504 valve body.
 Install temporary steel structure bracing to platform supports above SV-1503 / SV-1504.
 Install SV actuator support skids and assemble SV body lifting jigs at SV-1501, SV-1502, SV-
1503, SV-1504 platform. Lock all castor wheels.
 Mobilize construction tools, equipment and set-up the 90 T Mobile Crane as layout plan
below.

Crane area
Work Area
Fig 3 : Crane Layout plan
6.2. Shutdown Work

6.2.1 General Works
 Apply the Work Permit & get the Approval from BSR Operation.
 Blinding as per approved blind list. Inspect Blinding status by related department
(Hold Point).
 Remove small bore obstruction air purging piping and instruments.
 Disconnect instruments from SV-1501, SV-1502, SV-1503, and SV-1504 to facilitate
the removal works requirement.
6.2.2 Lock all spring supports
 Record and mark the all spring supports in hot condition as per list of support.
 Lock the all spring supports after cool down the pipe and record.
6.2.3 Add support bracings

 Add bracings and supports on the flue gas line section on top of SV-1503 / SV-1504
valve body, and also the flue gas line section below the SV-1503 / SV-1504 valve
body.
 Align Slide Valve actuator support skids to ensure SV are securely seated and
balance on the skid.
6.3. Removal of Actuator and orifice plate from Slide Valve
 Disconnect the all instrument cables for actuator.
 Unbolts the actuator from SV body.
 Remove SV actuator.
 Remove internal parts such as stem, disc and orifice plate from valve body.
 Place the internal parts properly on tray containers and safe keep.
 Unlock the castor wheels and move the SV actuator support skids to aside and lock
the wheels
SV-1503A
SV-1504A
SV
SV-1503B
actuator
SV-1504B
support
(seated on
platform)
1st/2nd Regen Flue Gas Line
Fig 4: Schematic representation of SV actuator support setup
6.4. Cutting the SV-1503 / SV-1504 valve body

Method 1: by Gouging
 This method is only applicable if hot work is allowed for the cut
 Set up lifting belts and chain blocks on the lifting eye of the SV valve body lifting jig to
ensure SV valve body is properly secured.
 Remove the bottom welds of the SV-1503 (SV-1504) valve body by gouging.
 Remove the top welds of the SV-1503 (SV-1504) valve body by gouging.
 Hack off / chip off the refractory of the top and bottom weldment of the SV valve body
from external inwards.
 Once the SV valve body is free off from the flue gas line, unlock the castor wheels and
push the lifting jigs out to the platform area accessible by crane.
 The SV valve body will be lifted to ground level with a 90 ton crane onto lorry.

Fig 5: Roll out

of SV valve
body
Removable
pieces
SV valve body
lifting jigs on castor
wheels with locks
Fig 5: Roll out of SV valve body
Method 2: by Hydro jetting

 Ensure the work area is cordoned off to prevent unauthorized entry of personnel.
 Remove the bottom welds of the SV-1503 (SV-1504) valve body by hydrojet cutting.
 Remove the top welds of the SV-1503 (SV-1504) valve body by hydrojet cutting.
 Note that this is the method used in previous Turnaround but it is not a preferred
method by FES as this will cause wetting of all the internal refractory, thereby creating
difficulties and delays in start-up drying out, as new and existing refractory dry out are
not the same.

Method 3: by diamond wire cut (Best method)

 Set up diamond wire cutting machine on bottom welds of the SV-1503 (SV-1504) valve
body with more offsets towards the valve body (unwanted portion).
 Once the cut is completed, transfer the diamond wire cutting machine onto the top
welds of the SV-1503 (SV-1504) valve body with more offsets towards the valve body
(unwanted portion).
 Once the cut is completed, remove the diamond wire cutting machine.
 Prior to the shutdown a mock up cut can be done to demonstrate to BSR for approval
of this method.
Sample picture of
cutting through
concrete with rebar
Sample picture of
cutting through
dissimilar material
and note the surface
flatness after the cut
Diamond wire cutting machine
6.5. Flue gas line internal scaffold and preparation of new SV-1503 / SV-1504 valve body
 Open-up the manholes below the SV valve body that was cut.
 Set-up the ventilation as per approved ventilation plan.

 Set up the internal lighting.

 Erect internal scaffold access from bottom manhole to SV-1503 (SV-1504) valve body
area, as per sketch below.
 Grind off damaged V anchors from existing pipe internal.
 Weld new V anchors if required.
 Edge preparation of top and bottom flue gas line of the SV valve body as per approved
WPS, in preparation for welding new SV valve body.
Fig 6: Internal scaffold schematic
6.6. Install new SV-1503 (SV-1504) valve body and reinstate actuators
 The new SV-1503 (SV-1504) valve body will be lifted by the 90 ton crane onto the
platform.
 Use chain block and lifting slings to rig up the new SV valve body from the platform by
the same lifting jig.
 Push the lifting jig to the flue gas line area and align the new SV valve body onto the
top and bottom section of the flue gas line.
 Fit up the valve body to the flue gas line and tag weld as per WPS.
 Valve material SA516, Gr 70 Thickness 30 mm and edge preparation shall be visually
inspected before welding.
 Follow up with necessary NDT as per ITP.

 Weld Hex mesh or V anchors and repair refractory from internal.

 Install internal parts such as stem, disc and orifice plate on new valve body.
 Push the SV actuator support to facilitate installation of the actuators A & B.
 Connect back the instruments for SV- 1503 A & B (SV-1504 A & B).
 Slide Valve testing.
NOTE: Actuator Re-installation of SV-1502 and SV-1502 is the same as SV-1503 and SV-1504
Refractory lining repair shall be covered under refractory method statement.
7. Final acceptance for the work

7.1. Final inspection
When SV-1503, SV-1504 body valve replaced and re-installed internal part, properly
completed in full compliance with all applicable procedures, Site Supervisor shall arrange for
final inspection with present of all related BSR disciplines and third parties (where
applicable).
7.2. Completion:
The work completion including housekeeping, handing over equipment to Operation,

returning material/spare parts to Warehouse.
The full set of Maintenance and Inspection Reports (Test Package) dossiers shall be
submitted to BSR Package-l Manager as attachment of FINAL ACCEPTANCE PROTOCOL.
8. Emergency And Rescue Operation

The following are the practices and emergency plans to be executed during Emergency.
 Immediately inform supervisor in charge and company’s safety supervisor.
 Immediately inform safety supervisor and client’s representative for emergency assistance.
 Depending on nature of emergency;
 Immediately retrieve the person using safe method.
 If personnel are unconscious, try to revive personnel using CPR.
 Fire and Toxic substance.
 Evacuate immediately.
 If fire is small, use fire extinguisher and try to extinguish the fire.
 For toxic substance, evacuate and inform supervisor immediately.
Upon arrival of emergency assistance, explain the current emergency situation and cause of
emergency.


BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and 1504)

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

BSRTA4-MS01 RFCC Slide Valve Works Proposal (SV-1501,1502,1503 and 1504)

Încărcat de

Drepturi de autor:

Formate disponibile

F A L K O R E N G I N E E R I N G S E R V I C E S P T E L T D

BSRTA4-MS01 RFCC Slide Valve Works Proposal

REV NUMBER:BSRTA4-MS04- Technical Proposal

REV NUMBER:BSRTA4-MS04- Technical Proposal

5. Material, Machineries, Equipment

Lifting eye for

REV NUMBER:BSRTA4-MS04- Technical Proposal

Fig 3 : Crane Layout plan

6.2. Shutdown Work

6.2.2 Lock all spring supports

6.2.3 Add support bracings

1st/2nd Regen Flue Gas Line

Fig 4: Schematic representation of SV actuator support setup

6.4. Cutting the SV-1503 / SV-1504 valve body

REV NUMBER:BSRTA4-MS04- Technical Proposal

Fig 5: Roll out

Fig 5: Roll out of SV valve body

Method 2: by Hydro jetting

REV NUMBER:BSRTA4-MS04- Technical Proposal

Method 3: by diamond wire cut (Best method)

Diamond wire cutting machine

REV NUMBER:BSRTA4-MS04- Technical Proposal

 Set up the internal lighting.

Fig 6: Internal scaffold schematic

REV NUMBER:BSRTA4-MS04- Technical Proposal

 Weld Hex mesh or V anchors and repair refractory from internal.

7. Final acceptance for the work

The work completion including housekeeping, handing over equipment to Operation,

8. Emergency And Rescue Operation

REV NUMBER:BSRTA4-MS04- Technical Proposal

S-ar putea să vă placă și