Rev.

WORK METHOD STATEMENT FOR TUBE

BUNDLE REPLACEMENT WITH CUTTING
& WELDING OF LIP SEAL GASKET ON
HEAT EXCHANGER

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SECTION TITLE

1.0 PURPOSE
2.0 SCOPE
3.0 EQUIPMENT
4.0 REFERENCES
5.0 SAFETY PRECAUTIONS
5.1 PREPARATION
5.2 DURING SITE EXECUTION
5.3 SAFETY INSPECTIONS
6.0 RESPONSIBILITIES
7.0 QUALITY
8.0 TOOLS AND EQUIPMENT TO BE USED
9.0 DOCUMENT SUBMISSION
10.0 SITE EXECUTION
10.1 PREPARATION
10.2 PRE SHUTDOWN ACTIVITIES
10.3 EXECUTION OF WORK
11.0 HOUSEKEEPING

1.0 PURPOSE
The purpose of this work method statement is to describe in detail all required measures taken
in order to execute the job on TUBE BUNDLE REPLACEMENT WITH CUTTING &
WELDING OF LIP SEAL GASKET.
2.0 SCOPE

This document is applicable to all employees and contractors working for TUBE BUNDLE
REPLACEMENT WITH CUTTING & WELDING OF LIP SEAL GASKET under the control
of.

3.0 EQUIPMENT

Sl No EQUIMENT NAME EQUIMENT TAG PART NAME LOCATION

NO
1 TUBE SHEET

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4.0 REFERENCES
General Engineering Practices.
Equipment Drawings
Applicable procedure, if any.

4.0 SAFETY PRECAUTIONS:

JSA (Job Safety Analysis) should be discussed with all concerned persons and to be
followed strictly.
Rigging Plan to be approved from <COMPANAY NAME > before start any lifting
activities and to be followed strictly.

HEALTH, SAFETY AND ENVIRONMENT MEASURES

5.1 PREPARATION
Ensure all workers involved in the lifting operation put on PPE all times.
Brief individual worker the roles and responsibilities of each.
Work execution shall be monitored, witnessed and supervised in accordance to
<COMPANAY NAME > specifications, requirements and HSE rules.
employees shall be well informed especially concerning in-plant working conditions.
Recorded Daily Tool Box Meeting is required.
All activity shall be supervised by safety officer at site.
5.2 LIFTING ATIVITIES
Ensure safe work procedure for lifting operation is observed.
Ensure proper lifting method - with the correct tools are used.
5.3 DURING SITE EXECUTION
Ensure workers are distributed to each designated place.
Ensure workers at all times to be in proper gear where required.
Ensure all workers assigned are involved in its particular task.
Brief individual worker the roles and responsibilities before start work.
Ensure support systems are installed accordingly as required.
Ensure all tools to be used have been inspected and tag by Safety Dept.
Ensure work areas are clearly marked to restrict access to authorized personnel only.
Ensure that equipments to be used are properly tagged and checked.
Ensure that welders are qualified, with the correct PPEs, and well versed on the job at
hand with the approved welding procedure

5.4 SAFETY INSPECTIONS

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It shall be responsibility of the Supervisor to routinely inspect the physical areas under
their control in any welding works. This inspection shall include determining Equipment,
Rigging, supports, scaffolds and ladders are appropriately installed or use, and if the job
site is cleaned up after the days work.

6.0 RESPONSIBILITIES:

The Project Manger & In charge will be responsible to manage and direct project
execution activities and ensure efficient implementation of works in accordance with the
Project Specification and standards.
Project Engineers & Supervisors will executed the job as instructed by Project Incharge.
The QA/QC Representative of Al Muzain & <COMPANAY NAME > shall witness all
activities and tests performed and ensure that all works are carried out to <COMPANAY
NAME > satisfaction.
Supervisor shall monitor the execution of the works.
Foreman shall lead the work force during the execution of the works.

7.0 QUALITY

All the Quality related documents / Procedures shall be submitted and get it approved
from <COMPANAY NAME > Inspection before proceed to work,
Submission of weld map / location map identifying the welding work shall be prepared
by the QA/QC Engineer if required.
Submission of ITP (Inspection Test Plan) shall be prepared by the QA/QC Engineer
Before Installation of the new equipment QC Inspector should verify the new equipment
& Existing equipment mating flange gasket face.
The Quality department (QAQC representative) shall ensure that the alignment is done to
<COMPANAY NAME > satisfaction
The required materials shall be checked for conformance before use.
All the calibrated inspection tools to be used.
QC inspector co-ordinate with <COMPANAY NAME > inspector for all inspection and
NDT activates.
They shall be responsible to assure, monitor & control quality activities for the tube
bundle replacement work.
Observe the stage wise inspection as per the approved inspection and test plan (ITP) for
the job.

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Get clearance from <COMPANAY NAME > representative(s) at site before proceeding
for the subsequent stages.
Inspection report shall be prepared and get it signed from <COMPANAY NAME >

8.0 TOOLS AND EQUIPMENT TO BE USED:

Welding Generator
Portable Welding machine
Mobile crane.
Forklift
Rigging tools
Standard tools
Air compressor
Bolt torqueing/ Tensioning Cold Cutting machine.
Tower light

9.0 DOCUMENT SUBMISSION FOR APPROVAL

JSA (JOB SAFETY ANALYSIS)
Work Method statement.
QA/QC documents.

10.0 SITE EXECUTION

10.1 PREPARATIONS
Submitted documents to be followed up and get approval. Revision will be done, if
required.
Site facility to be mobilized to the site allocated area.
Check and receive free issue materials as per requirement. In case materials have any
discrepancy refer materials list, same shall be informed to <COMPANAY NAME >.

10.2 PRE SHUTDOWN ACTIVITIES

Apply the work permit as per the Job to be executed.
Erection of scaffolding by <COMPANAY NAME > as per AL MUZAIN Requirement.
Support the Channel Inlet by scaffolding and chain block.
Removal of Insulation by <COMPANAY NAME > as per AL MUZAIN Requirement.
All required tools and equipment to be made available near to the working area.
Physical verification and dimension inspection to be done and tie the metal tag as per
the drawing.
10.3 EXECUTION OF WORK
<EQUIPMENT NAME > A: - TUBE SHEET INSPECTION AND CLEANING

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Get the applicable work permit from the operation.

Blinding & De- blinding by team.
Removal of Channel inlet and channel outlet by team.
Remove the stud bolts in the 1:2sequence (24 nos of stud bolts to be removed) by
torqueing.
Remove the jack bolts by hand tools.
Cut & remove the 02 nos. of centering pin by grinding and new centering pin provided
by <COMPANAY NAME > during installation of tube bundle.
Perform cutting by 1 mm grinding in the Joint no: - GS -02 (Reference drawing no: -
D0553-E6301A/B-D -002, Rev. 03)

Rearrange & Install alternate stud bolts sequentially at the uncut lip seal locations.
After finishing the cutting, Hold the channel head lifting lug (02 nos.) using chain block
& crane and remove the balance stud bolts.
Remove the channel head cover for inspection and cleaning. Cleaning by team.
Tube Sheet inspection and cleaning followed by inspection.
After inspection and cleaning, centering pin shall be inserted to the shell flange.
Channel cover shall be installed using Crane by team.

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Jack bolts shall be installed.

All Stud bolts shall be reinstalled with 60% of torqueing value.
After torqueing of all the bolts, 1:2 alternative stud bolt shall be unbolted and removed.
Welding shall be performed at Joint no: - GS -02 (Reference drawing no: - D0553-
E6301A/B-D -002, Rev. 03) on the unbolted locations by two welders located at
opposite side in clock wise direction as per approved WPS.
Stud bolts shall be installed sequentially and alternatively in the welded locations.
After completing all welding at both side of tube sheet flange, DPT and inspection shall
be carried out.
100% of torqueing value shall be applied to the stud bolt.
Reinstall the Jack bolts.
Pneumatic test shall be done for the final lip seal weld joint by applying soap solution to
identify integrity of joint ( Pneumatic test pressure value provided by <COMPANAY
NAME >).
Reinstall the disconnected channel inlet and outlet line with new gasket followed by
inspection.
De-blinding shall be done followed by inspection and torqueing.

<EQUIPMENT NAME > B: - TUBE BUNDLE REPALCEMENT

Get the applicable work permit from the operation.
Blinding & De- blinding by team.
Removal of Channel inlet and channel out let by team.
Remove the stud bolts in the 1:2 sequence (24 nos of stud bolts to be removed) by
torqueing.
Remove the jack bolts by hand tools.
Cut & remove the 02 nos. of centering pin by grinding and new centering pin provided
by <COMPANAY NAME > during installation of tube bundle.
Perform cutting by 1 mm grinding in the Joint no: - GS -02 (Reference drawing no: -
D0553-E6301A/B-D -002, Rev. 03)
Rearrange & Install alternate stud bolts sequentially at the uncut lip seal locations.

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After finishing the cutting, Hold the channel head lifting lug (02 nos.) using chain block
& crane and remove the balance stud bolts.
Remove the channel head cover for inspection and cleaning. Cleaning by team.
Remove the Tube sheet bundle using bundle puller by team.
Perform grinding to cut the gasket from Joint no: - GS -01 (Reference drawing no: -
D0553-E6301A/B-D -002, Rev. 03).
Carefully remove the gasket from both side of the tube sheet.
Gasket faces of new tube sheet shall be cleaned and DPT to be done.
Visual inspection to be done for the removed gasket by inspection team.

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Beveling of Gasket at Joint no: - GS -02 (Reference drawing no: - D0553-E6301A/B-D

-002, Rev. 03) as per the drawing.
Prior to fit up of gaskets to the new tube sheet gasket faces, the base metal of the gasket
shall be prepared to required profile/weld geometry in accordance with the drawings.
Preheating at 95 C shall be done as per the approved WPS and documents by gas
torch.
Fit up of lip seal at new tube sheet flange shall be performed at Joint no: - GS -01
(Reference drawing no: - D0553-E6301A/B-D -002, Rev. 03) by using C clamps fixing
to tighten lip seal with flange in equal distance as required followed by inspection.
Preheating at 95 C shall be done as per the approved WPS by gas torch.
Welding shall be performed as per approved WPS, followed by DPT and inspection.
Prior to install tube sheet, centering pin shall be inserted to the shell flange.
New tube sheet shall be installed using bundle puller by team.
Channel cover shall be installed using Crane by team.
Jack bolts shall be installed.
All Stud bolts shall be reinstalled with 60% of torqueing value.
After torqueing of all the bolts, 1:2 alternative stud bolt shall be unbolted and removed.
Welding shall be performed at Joint no: - GS -02 (Reference drawing no: - D0553-
E6301A/B-D -002, Rev. 03) on the unbolted locations by two welders located at
opposite side in clock wise direction as per approved WPS.
Stud bolts shall be installed sequentially and alternatively in the welded locations.

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After completing all welding at both side of tube sheet flange, DPT and inspection shall
be carried out.
100% of torqueing value shall be applied to the stud bolt.
Reinstall the Jack bolts.
Pneumatic test shall be done for the final lip seal weld joint by applying soap solution to
identify integrity of joint ( Pneumatic test pressure value provided by <COMPANAY
NAME >).
Reinstall the disconnected channel inlet and outlet line with new gasket followed by
inspection.
De-blinding shall be done followed by inspection and torqueing.
11.0 HOUSEKEEPING
Al Muzain shall perform the house keeping activities on daily basis as per plant safety standard
requirement.
Maintain cleanliness and orderly stocking of material & tools.
Pick up and dispose wastes & other debris to <COMPANAY NAME > yard or ware
house prior to leaving site area.
Store tools, equipment and unused materials properly store at the end of the workday.

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