Method Statement for retubing of Heat Exchanger.Full description
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METHOD OF SATEMENT FOR TUBE EXTRACTION FROM TUBESHEET
1.0 Intro Introduc ductio tion n
This method statement describes in detail the removal of existing tubes and installation of new tubes for the Heat Exchanger. 2.0 Scope Scope nd !urpo"e !urpo"e o# Met$o Met$od d Stte%ent Stte%ent
This document outlines the method for replacement of existing tubes for Heat Exchanger. The procedure provides guidance for assessing the activities for replacement of tubes. This guidance is based on the requirements set forth in the proect requirement! safet" requirement and #ualit" assurance program. 2.1 2.1 O& O&'e 'ect cti( i(e" e"
This document provides guidance in implementing an effective program for replacement of Titanium tubes for the Heat Exchanger. This includes addressing programs for the following$ %&' (mplementin (mplementing g commitments commitments regarding the qualit" qualit" of the wor). %*' +anaging +anaging and providing providing oversight to ensure installation installation and related qualit" control control has been adequatel" addressed b" specifications! drawings! and procedures. %,' +anaging +anaging and providing providing supervision supervision and control control to assure qualit" of wor) and closel" implement-monitor schedule. %' Recording Recording installation installation and test test activities. activities. %/' H0E at at the time of of wor). wor). This procedure is one component of a complete replacement of tube wor) program. This and other procedures will be used! as needed! to provide assurance that replacement of tubes activities are being conducted as required b" the specification and manufacturer procedures. (t is not expected that completion of the entire procedure will be accomplished during an" one inspection and -or ever" time the inspection procedure is used. (t is a continuing activit" until all tubes are replaced. 2.2 In"pect In"pection ion nd Recordin) Recordin) Re*uire%en Re*uire%ent" t"
The engineer should verif" that the supervisor-foreman with construction responsibilities for the replacement of tubes wor)s is familiar with the method statement and is issued with copies of the inspection chec)lists and test plans. The engineer should satisf" procedures provided b" #A-#1 inspections to ensure the replacement of tubes wor)s meet specified engine engineerin ering g requir requireme ements nts and drawin drawings. gs. As part part of the assessm assessment ent!! the #1 inspect inspection ion procedures must ensure a quantitative or qualitative acceptance criteria for determining the prescribed activities have been accomplished satisfactoril". The #1 inspection personnel! in coordination with site supervisor! should verif" that the qualit" qualit" of the wor)s and related testing activities activities are within within the proect proect design specifications specifications requirements. The The supe superv rvis isor or shou should ld verif verif" " that that the the repla replacem cement ent of tube tubess wor) wor)ss is acco accomp mplis lishe hed d in accordance with the specifications and the manufacturer2s procedures. The supervisor should verif" an" testing and confirm that the information meets the proect requirements. 2.+ Tr Trinin) inin) nd nd ,u-i#iction ,u-i#iction o# !er"onne!er"onne-
The supervisor should verif" that the personnel have sufficient )nowledge of the procedure requirement. The supervisor should review an" training and qualification records for those
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individual individualss who shall do the tas) to determine determine whether the" are s)illed s)illed enough to follow the procedure before the actual wor) is carried out. +.0 Re"pon"i Re"pon"i&i-it &i-itie" ie" nd re"ourc re"ource" e" +.1 Re"po Re"pon"i n"i&i&i-iti itie" e"
The The pro proect ect mana manage gerr %145 %145TR TRA1 A1T4 T4R' R'!! has has over overall all respo respons nsib ibil ilit" it" for for the the co6 co6 ordi ordina nati tion on and and impl implem emen entat tatio ions ns of the the cutt cuttin ing g and and weld weldin ing g activ activit" it"!! incl includ udin ing g manpower manpower and plant utili7ation! utili7ation! engineering engineering support! material scheduling scheduling and cost control. 3roect 3roect +anage +anagerr %145TR %145TRA1T A1T4R' 4R'!! 3roect 3roect Engine Engineer er %145TR %145TRA1T A1T4R' 4R' - will will be responsible for the replacement of tubes for the Heat Exchanger. +.2 Re"ou Re"ourc rce" e" MteriTubes$ Titanium Titanium tubes %free % free issued'. • !-nt nd E*uip%ent 1ompressor • Tube Expander • Torque 1ontroller. • Electrical Tools. Tools. • Hand Tools • 8ifting and Rigging Equipment$ As per requirement %b" 18(E5T'. • 0caffolding$ As per Requirement. %9" 18(E5T'. • 4ther small hand tools and tac)les$ as per requirement. • E%p-o/ee" nd "u&contrctor" "u&contrctor" it$ "peci-ied trinin) inc-ude t$e #o--oin) Engineers • 0upervisor - Foreman • Fabricators • Fitters • Helpers • 4ther miscellaneous. • .0 Met$o Met$ododo-o) o)/ /
#uantit" of material Tube si7e$ Dia. &: mm 4D x ;.< mm thic). • 5o. Tubes$ Tubes$ &/ 5os. • The following steps will be carried out for replacement of Tubes at 18(E5T After isolation of the plant! 18(E5T will remove end covers on either side of the Heat • Exchanger. 145TRA1T4R will remove the plugs b" drilling or tapping method to avoid damaging • the tubes. 1ut the tube from one end b tube cutter tools. • 3ull the tube using h"draulic stub puller without damaging the tube sheet. • 3lace the old tubes in a sage area on the wor) platform. • 3ull all the balance tubes from the tube sheet using above method. •
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1lean expansion grooves in the tube sheet using cleaning brush or b" air to remove debris or deposit material. 1hec) the diameter of tube sheet bore b" using dial caliber. 1lan the baffle holes b" using power brush. (nspection of the tube sheet bore b" approved inspection method before inserting new tubes. 3rior to inserting inser ting the new tubes! inspection must be cleared b 18(E5T. (nsert new tubes and expand as per the specified values on both ends as per the calculation method. The calculation method of values approved b" 18(E5T. 18(E5T. After the expansion tubes are measured and chec)ed using dial bore gauge and records the value. Tubes ends shall be protrude from tubes plates of , mm. Tube ends shall be chec)ed after expanding to ma)e sure there is no damage. (nside surface of tubes ends in the expanded area shall be free of defects such as crac) or clear overlaps. 3repare the lea) test b" water for the Heat Exchanger %9" 18(E5T'. Attend the lea) tubes b" rolling or replacement after testing until exchanger is cleared b" 18(E5T.
5otif" all concerned in site for the date of material deliver". Ensure all wor)ers involved in the operation put on 33E all times. 9rief individual wor)er the roles and responsibilities of each. 1oordinate with concern department for tubes hoisting area. Ensure designated area is cleared of obstruction.
3.2 !ipe5T !ipe5Tu& u&ee -i#tin) -i#tin) • • •
Ensure sage wor) procedure for replacement of tube operation is observed. Ensure proper method with the correct equipment are used. Ensure the pipes-tubes are firml" placed on the designated location before releasing the hoisting hoo).
Ensure wor)ers are distributed to each designated place. Ensure wor)ers at all times to be in proper gear where required. Ensure all wor)ers assigned are involved in its particular tas). 9rief individual wor)er the roles and responsibilities before start wor). Ensure the pipe-tube lengths to suite site routes into designated wor) area. Ensu Ensure re all all tool toolss to be used used have have been been insp inspec ecte ted d and and tagg tagged ed b" 0afe 0afet" t" Department. %9" 18(E5T'. Ensure wor) areas are clearl" mar)ed to restrict access to authori7ed personnel onl". Ensure that equipment2s to be used are properl" tagged and chec)ed.
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3. Hou"e Hou"e6ee 6eepin pin) ) • • •
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+aintain cleanliness and orderl" stoc)ing of material and tools. 3ic) up and dispose wastes and other debris prior to leaving site area. Remove Remove safet" "ellow tape or other warning devices that were used to control access to the wor) area. 0tore tools! equipment and unused materials properl" at the end e nd of the wor)da".
3.3 S#et/ S#et/ In"pect In"pection" ion" •
(t shall be responsibilit" of the supervisor to routinel" inspect het ph"sical areas under their control in pipe welding wor)s.
