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-MS02 Cyclone Cones And Bracing Bar

Replacement Works

BSRTA4-MS02

REV NO DATE PREPARED BY: REVIEWED BY: APPROVED BY: REMARKS/ STATUS

01 25-Sep-2019 Joseph Khow Loke Weng Yau Loke Weng Yau

02

03

REV NUMBER:BSRTA4-MS02-
Technical Proposal
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BSRTA4-MS02 Cyclone cones and bracing bar replacement works
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TECHNICAL PROPOSAL
 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

Table of Contents

1. Purpose.......................................................................................................................... 3
2. Scope............................................................................................................................. 3
3. Location......................................................................................................................... 3
4. Competent Person.........................................................................................................3
5. Permit To Work.............................................................................................................3
6. Material, Machineries, Equipment...............................................................................3
7. WORK PROCEDURE........................................................................................................3
7.1. Pre-shutdown works.....................................................................................................3
7.2. Shutdown Works...........................................................................................................4
8. Final acceptance for the work.....................................................................................10
8.1. Final inspection............................................................................................................ 10
8.2. Completion:.................................................................................................................11
9. Emergency And Rescue Operation..............................................................................11

REV NUMBER:BSRTA4-MS02-
Technical Proposal
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BSRTA4-MS02 Cyclone cones and bracing bar replacement works
BSR 4TH PACKAGE 1
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TECHNICAL PROPOSAL
 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

1. Purpose
This method statement explains the safe work method of replacing the Cyclone dust cones and
bracing bars of 2nd Regenerator.

2. Scope
The scope of this method statement is applicable to 2nd Regenerator internal works.

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. Permit To Work
A written or printed document from the owner to allow the person to perform the mention
work.

6. 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

7. WORK PROCEDURE
7.1. Pre-shutdown works
 Prepare custom made size of scaffolding for Regenerator 2 internal scaffolding to replace
cyclone dust cone and bracing brackets.

REV NUMBER:BSRTA4-MS02-
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TECHNICAL PROPOSAL
 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

 Prepare air conditioning facilities for speed up cooling for Regenerator 2 for man entry
during shutdown.

7.2. Shutdown Works

7.2.1 General Works

 Equipment blinding work as per blind list.

 Open Regenerator 2 manholes and provide air conditioning ducting to expedite
cooling of Regenerator, and also better working environment for personnel working
on the scaffolding.
 Erect scaffolding for excess to the cyclone cones and the bracing brackets, as per
sketch below.

Plan View
Side View

Fig 1: Internal
scaffold
requirement in
Regenerator 2

 Remove the lining, and thereafter remove the diplegs brace around the lugs at
shell, as shown below.

REV NUMBER:BSRTA4-MS02-
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TECHNICAL PROPOSAL
 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 Plan View
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

Fig 3 : Diplegs
to be
remove
d in
Regene
rator 2

Fig 2: Internal
removal in
Regenerator 2

 Remove the 4 vertical diplegs, as shown below for one of the fours

Fig 3: Diplegs to
be removed in
Regenerator 2

REV NUMBER:BSRTA4-MS02-
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TECHNICAL PROPOSAL
 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

7.2.2 Cut and Remove Dust Cone

Method 1 – By Water Jet Cutting

 Cut the dust cones with water jet cutting.
 Care should be taken for the cut line to ensure the welding back of new cones will
not be shortened.

Details of cut line

Fig 4: Dust cone

cutting in
Regenerator 2

Method 2 – By Gouging
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TECHNICAL PROPOSAL
 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

 Cut the dust cones by gouging.

 After the weldment is gouged, to hack the refractory from outside inwards.

Fig 5: Refractory removal

details on cyclone

7.2.3 Install New Dust Cone

 Prior to welding back new cones, hack the refractory as per figure 5.
 Weld back the new cones as per figure 6.
 Erect internal scaffold inside cyclone.
 Weld hex mesh and reinstate refractory.
 Reinstate diplegs as per figure 7.

REV NUMBER:BSRTA4-MS02-
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TECHNICAL PROPOSAL
 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

Fig 6:
Fig 7:
Installing
Reinstate
new dust
diplegs
cones on the
cyclones

Install Dust Cone

7.2.4 Installing new bracing lugs and diplegs bracing

 Remove refractory as per figure 8 to facilitate the welding of new bracing lugs.

Plan View
Side View

Fig 8: Remove lining

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TECHNICAL PROPOSAL
 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

 Weld new bracing lugs as per figure 9.

Fig 9: Welding
bracing lugs details

 Install diplegs bracing as per figure 10.

Side View Plan View

Fig 10: Installing

dipleg bracing

 Install refractory on those welded lugs, and the cone area, as per figure 11.

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TECHNICAL PROPOSAL
 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

Side View Plan View

Fig 11: Welding hex mesh

and installing refractory

NOTE: Refractory lining repair shall be covered under refractory method statement.

8. Final acceptance for the work

8.1. Final inspection

When Cyclone dust cone and bracing bar installed, 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).

8.2. Completion:

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TECHNICAL PROPOSAL
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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

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.

9. 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.

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