DOLPHIN OIL FIELD EQUIPMENT SERVICESLLC. P.O.BOX:8402, ABU-DHABI B Teaser seane % DOCUMENT NO.: DOES /SD/EX-01/10, ae eet y pith * REV [BATE] PREPARED BY REVIEWED BY DESCRIPTION 0 | 20.05.2019 | VINOD NAIR ‘DEREK COLLINS ORIGINAL ISSUE ee ornBs 01 i " rT DOLPHIN OIL FIELD EQUIPMENT SERVICESL.L.C, X:8402, ABU-DHABI —U.AE. in me 02-8543 700; FAX.02-8842232, Contents: ‘the item 1, Purpose 03 2. Scope 03 3. Equipments 03 4, Responsibilities 03 5. Procedure -Preparations 04 6. Procedure-General os 7. Procedure-Tube Removal 06 ts 8. Procedure-Retubing Expansion 7 < 9. Safety 8 10.Quality 08 11. Reference 08 12, Reports 0 Tae efDOLPHIN | OTL FIELD EQUIPMENT SERVICESL.L.C. P.0.BON:8402, ABU-DHABI — Pa TEL. M2 SeGTNFARZESAET 1, Purpose: ‘The purpose of this document is to establish @ safe procedure for partial retubing of ive fixed type heat ‘exchanger tubes in ADGAS LNG Plant 7 & 26, Train:2 at Das Island. 2. Scope ‘The provision of tools, equipment, labour, QA/QE Staff and supervision including detalled method statements and risk assessments in order to carry out partial retubing of following heat exchangers. 1, 7-£-201—Waste Heat Boiler (R&R 10/P/002) 7-£-202— Sulphur condenser No.1 ( R&R 9/P/051) 7-£-204— Sulphur Condenser No.3 (RR 9/?/050 Rev.t 17-£-207 ~ Sulphur Condenser No.a (RBR 09//049) 26£-102~ Surface Condenser (R&R 10/P/123) 3. Equipments 3.1 Weld Removal tool for tubes up to 3” OD 3.2 Chamfering tools. 3.3 Welding machine 3.4 Tube pulling tools and equipments. 3.5 Tube expanding machines. 3.6 Angle grinding machines. 3.7 Tube expanders. 3.8 Monde SS 3 enters . 3.11 Tube internal cutters with spare tips. 3.12 Spears. AB Cranes iffequired to the required capacity 4.4 Project Manager Co-ordinates with the client and site engineer for effectively carrying out the scope of work within the prescribed period and the cost. Responsible for submission of daily reports tothe client. Reports to the ‘general manager. Location of work: Abudhabi- Mussaffeh: Office ese} sett© DOLPHIN OIL FIELD EQUIPMENT SERVICESL.L.C. P.O.BOX:#402, ABU-DHABI — TE en se TOOFAROD SSa202 42 mangers anaes tote ot mane ss rorotnar Astetre. all activities at site along with client's planning team, co-coordinating with cient’s Quality control team, ‘stores for issue and return of materials, preparation of daily reports, time sheets etc. Reports to the Location- ADGAS-Das Island - 45 toenn ssa tent ness Reese ore eunon thi type procedure within the schedule, Co-coardinating with cient’s ware house for shifting of materials to and from site etc.. Reports to the site engineer. Location-ADGAS Das Island 46 St. Technician Carrying out retubing activities as per the instructions from the site foreman. Location-ADGAS-Das Island. 4.7 Assistant Technicians: {Assist Sr.Technician in carrying out the retubing activities. Location — ADGAS Das Island 4.8 Welder: Qualified as per weld procedure specification pertaining to the Job. Reports to the foreman. Location- ADGAS Das Island 5. SAFETY 5.1 Allthe HSE procedures in line with job specific requirements to be followed 5.2 Ensure HSE induction to all employees and special trainings as required forthe job. 5.3 Job specific risk assessments to be carried out before start of any work reel aP.0.BOX:8402, ABU-DHABI —' DOLPHIN OIL FIELD Ei DUIPMENT SERVICESLLC. ‘TEL, 02-8543700; FAN.02-6542252 Baie 5.4 Tool box talks to be conducted at the start of every shift and if required before specific works. 15.5 Ensure availabilty of all required PPE in good condition 5.6 Check for proper barricading atthe area of work. 5.7 Cover the entire open drain hole around the area of work. 5.8 Ensure availablity ofall fire fighting equipments at site in coordination with clients HSE department and fire brigade. 5.9 Depute one dedicated safety watcher at the area of work, 5.10 Identify and explain the emergency escape routes and muster points to all employees. 5.11 Investigate and report all incidents and near misses at site. 5.12 Check the proper issuance and closing ofall the work permit. 5.13 Coordinate with the plant operation team to ensure that the equipment fr retubing is properly drained, fushed and doesnot contain any hazardous substances which can bi potential to any kindof sk 5.14 Ensure avalabilty of all fire fighting equipments as demanded by thetype of ob being handled. 5.15 Cary out proper housekeeping ofthe are Allthe surrounding shall be cleaned continuously and must be {eee from any debris Zé 6. Procedure Preparations 6.1 Selection of equipments and associated tools “The right equipment alongwith all the acessories required is tobe selected forre-tbing of condensers Thisshal be ened by thes eningrncongitation with he Manage Pan and machineries ne refering to ADGAS requirements. Refer fOlstoF equipments attached- Attachment-A Joa ta for aa 2 : 6.1.4 Classification of the area where the equipment sto be used. Zone requiements considered for AADGAS Das island facies. 6.1.2 Type of tube bundle straight Fixed Tube bundle. 6,1 Thickness ofthe tube sheet Maximum 50 mm 4.4 Material of construction of tube Carbon Ste! 6.15 Diameterand length ofthe tube: 19.1 mm, 381mm, 50.8 mm, 76.2 mm 6.16 Tube to Tube sheet Joint - Welded) 6.1.7 Any other job speife requirements — Packed to sea worthy conditions 62 Avaiabltyof power and compressed air tthe ste- Avaliable 63 Ensure that the equipments and the tools meet the following requirements before transportation to the sie 6.3.1 All checks are carried out as per the area requirements Pa softtEs DOLTEIN OIL FIELD EQUIPMENT SERVICESL.L.C, 8402, ABU-DHABI - UAE. x Theos Ta SEAS TOO FAR GD SeA2252 6.3.2 No hydraulic hoses are leaking. 6.3.3 _Allsafety guards are in position. 6.3.4 An operation manual is available for easy reference. 635 There areno open electrical circuits. 6.3.6 All the fuses, cut offs etc are in position. 6.3.7 _Catry out trial run of the machines, 6.3.8 The machinery and all other accessories are properly packed as per the transport requirements. 1644 Once the machines and accessories are identified the same shall be shifted to theswork site, 655 All the materials shall be packed to sea worthy conditions with a proper packing list 66.46 The machines along with ll the accessories shall be safely unloaded at aidantiied location at the area % of work, 7. Preparation of Site é 17.1 Barricade the area of work with proper “DO NOT ENTER! sfgnboa 7.2 If the work is at an elevated area, ensure that there is proper certified séaffOlding and it has a valid “Safe for use certificate” in place. 7.3 Ensure that there isa hot work permit for catrying out the retubing. 7.4 Check ifthe heat exchanger or tube bundle is isolated, drained and cleaned from all hazardous substances and is safe for work 7.8 Cover all the open drainage facilities around the area of work and make fire resistant habitats prior to commencement of work. 7.6 Ensure the availabilty of all the PPE in place. 7.7 Identify i the source of power, compressed air based on mobilized equipments. ‘7.8 Check availabilty of space for easy removal of tube. if sufficient space Is not available for pulling the tubes in{whole length, make necessary arrangements to cut the tube into pleces to remove them. 7.9 Ensure that the technicians are fully equipped with all his PPE including but not limited to safety fhelmets, goggles, safety shoes, hand gloves and any other job specific PPE requirements. 7.40 The work shall commence after final checks and clearance to pull the tube bundle. 7.11 Prepare a job specific risk assessment and review the same along with the execution team. 6.12 Conduct 2 tool box talk and explain the risks involved to all engaged in the work. 8, Procedure- Tube Removal This procedure covers the methodology & documentation requirements for removal of tubes from Equipments 7-£-201/202/204/207 & 26-£-102. ee} sortP.O.BOX:8402, ABU-DHABI - UAE. ‘TEL, 02-8843700; FAN.02-§542232, Ere) ze DOLPHIN OIL FIELD EQUIPMENT SERVICESL.L.C, 8.1 Inspect the tube sheet fo ts cleanliness and presence of any hazardous substances. Carryout thorough cleaning ofthe tube sheet and the tubes to remove any such contamination and make it safe for hot work 8.2 Identiy the defective tube to be removed in partial re tubing, mark the same using wood plugs 8.3 Remove tube to tube sheet weld metal wth the help of pneumatic weld removal tool 84 Carry out cutting of tube on one Tube Sheet using Push Type Internal Tube Cutter sultable for the size of tube being cut. The Push Type Internal Tube Cutter is used with a portable electric or pneumatic dill Motor. 85 The cutter quickly cuts through the walls of the ferrous / non ferrous tubes as a step in their removal from the tube sheet, 8.6 The Internal Tube Cutter is inserted into the tube , power is applied pressing the cutter inward and the ‘cutting bit cuts the tube The tool bit contacts the tube inner wall and pierces it as turning is continued shearing the tube in one revolution. 8.7 The Cutter is centered in the tube using plots depending on the tube sizes. Hand operated One Revolution Cutter can be used for Non Ferrous Tubes and thin walled ferrols tubes. These are operated on the eccentric principle and are rotated inthe clockwise cirectich using a ratchet. £88 The tube is plled out ofthe bundle or Heat exchanger fromm {the end opposite tothe one ut by internal tube cutter. The equipment used for tube puling® Continuous Hydrate Tube Puller comprising of & pulling gun with a power pack controlled by rémte, 8.9 Operation - + insert thred mandr él Shgpeeio tube using and impact wrench, + Mount Pling Gin onta mare, start pulling operation using auto slow start feature to break expansion joint. This minimizes rik of breaking tubes. «+ swit tomate puling tbe is completely removed. When the tube free a tol canbe insérted into the jaws to enable to pull the tube by hand. + unscrew mandrel rom the free tube and proceed tothe next tube 8.30 | Thenext operation to pull ut the stubs remainingin the tube shee after internalcuting using an Electric / Hydraulic Stub Puller. 8.11 Operation ‘+ Insert self tapping spear in the tube stub. ‘* Mount stub pulling double acting cylinder over the spear locking it with a horse shoe lock. ‘+ Apply hydraulic pressure to the eylinder and slowly pull the stub out of the tube sheet, ‘+ Repeat above sequence til ll stubs are removed from the tube sheet. Pas] refitP.O.BOX:8402, ABU-DHABI - U.AE. Doran TEL. 02-$$43700; FAX.02-5842232, DOLPHIN OIL FIELD EQUIPMENT SERVICESL.L.C, 8.12 Split ew of the removed tubes axially and hand over to the client for further grit blasting and inspection requirements, 8.13 Shiftall other scrap tubes to the scrap yard or as instructed by the engineer in charge. 9. Procedure ~ Retubing & expansion {9.1 Collect new tubes from the stores and shift them near the heat exchanger 9.2 Clean the tubes from dirt or any other contamination 9.3 Clean & repair tube sheets & tube holes if required, Carry out repairs (weld build up / epoxy compound application / machining) to tube sheets as instructed by engineer in charge. This will ‘be in the scope of the main contractor. %, 9.4 Inspect tube sheet after machining & dling for conformance with the dimensions specified inthe ‘drawings. All tube holes should be inspected with Go / No Go Gauge. %, 9.5 Tube whole finish should be smooth and free from any burs & longitudinal seratches. 9.6 Measure the actual tube hole diameter for 10% of tubes and calculate the average tube hole diameter. 9.7 inspect the tubes & measure the tube outer diameter & wall thickness for 10966 tubes. Calculate average “Tube outer diameter & Wall thickness. 19.8 Caleulate the required Tube inner Diameter after 6 % expansion follows; + Required inner Diameter + After6% Expansion = Tube ID + Clearance + 2X 0.06 X Wall thickness. + Where, Clearance jube Hole diameter - Tube Outer diameter 9.9 Similarly, Calculate the Tube Inner diameter after 8 % expansion. 9.10 Using Micro Processor based Tube Expansion System expands one tube slowly increasing the torque setting, After the required tube Inner diameter after expansion (within 6 to 8 ) as calculated in step 4 is reached, note down the torque value. Set this Torque value inthe machine. 9.11 Using the torque value obtained in step 6 above expand the remaining tubes. Measure the tube Inner diameter after each expansion using a calibrated inside Dial Caliper. 9.12 Carry out tube to tube sheet welding with a qualified welder a per clients approved WPS. 9.13 After welding of all tubes in both tube Sheets, trim the tubes to the required projection from the tube sheet face using Tube End Facer. 9.14 Carry out hydro testing of the heat exchanger (shell & tube side} to required pressure and detect for any leaks. {9.15 Prepare a Tube Exoansion Report as per enclosed Document DOES/TEXP/002 _—_—Rev. 0. 10.Quality: 10.1 ll the company quality procedures tobe followed and the execution team tobe trained to follow company quality policy. vase| eetDOLTEIN IN OF. FIELD RQUIPMENT SERVICES LLC: LPH a Tongs MRO FAR RSA 110.2 Allthe QC Records shall be in place and is fulfilled stage wise specific to each job requirements. 10.3 Ensure that the job is being caried out to the entire satisfaction ofthe client. 10.4 Correlate allthe material test certificates with material heat numbers and report deviations if any. 410.5 Prepare stage wise inspection reports as per ITP and submit to the client for approval 110.6 Prepare a final quality dossier and submit the same in triplicate to the client for final review and approval 11,References: 111. Client's Tender drawings. 11.2 Equipment Drawing a 11.3 Operating Manuals of tube pullers, expanders. 7 11.4 HSE Manuals. 111.5 ADGAS HSE Manuals and method statements, 12.6 Risk assessments, , 111.7 Lessons Learned from similar projects in the past. 12.8 Any other job specific requirements. Pare eetDOLFEIN IN OX FIELD EQUIPMENT SERVICESLL.C. 34402, ABU-DHABI ~ Toes Ta seSTN TROD ESS 12.Re EXPANSION REPORT FOR TUBE SHEET Document No.: DOES/TEXP/002 Rev. 0 1. Tube Hole OD : 2. Tube OD 3. Tube ID hp. 4, Tube ID after 6 % Expansion: 5, Tube ID after 8 % Expansion: Sr.No. Row No. Tube No. | Tube ID after Expansion 1 SS 2 Ps \ 3 ‘ 4 5 dé 6 7 8 9 10 uu Remarks: ~*~ ¥ For DOLPH eo mueenFex Name : Ramel: Sina tue yy Signature: Date: Peel rooritDOLPHIN OIL FIELD EQUIPMENT SERVICES L.L.C. 8402, ABU-DHABI - UAE. =o Tisai FAX,02-$542232 CALCULATION OF TUBE EXPANSION Document No.: DOES/TEXP/002 Rev. 0 Tube Hole OD : 19.30 mm TubeOD — : 18.05 mm Tube ID 1 14.83mm Tube Thickness: 2.11 mm Clearance: 19.30 - 19.05 = 0.25 mm Formula ae Tube ID after Expansion: Tube OD + Clearance + (2 x Wall Thickness x %) Tube ID after 6 % Expansion: 15.33 mm 8, Tube ID after 8 % Expansion: 15.42 mm oe een ~ Remarks: f For DOLPHIN OILFIELD EQUIPMENT SERVICES For CLIENT / TPL ‘Name e ‘ Signatur ~~ Date: = re nent