DESCON ENGINEERING

PO BOX 46821, Abu Dhabi, UAE Tel. (971 2) 6440903 Fax.

(971 2) 6446786

METHOD STATEMENT FOR

CONTROL VALVES

SCOPE:

Identify, remove, servicing, calibration and re-installation of Control Valves.

RESPONSIBILITY:

1. The Area Supervisor / Engineer shall identify / tag the Control Valves for removal, reinstallation
and calibration.

2. All Control Valves in any area shall be removed and sent to the sub contractor on site workshop
for calibration by Descon area supervisors.

3. The area supervisor shall ensure that the requirement of proper scaffolding has been fulfilled prior
to start of job at site.

4. Two identification tags in BLUE color shall be installed on the line and control valve.

5. Rigging of Control Valves for removal and re-installation shall be done by the area supervisor
assigned for the job.

6. The supervisor will coordinate with BOROUGE Maintenance and Operations for obtaining work
permits and acceptance / renewal of the permit for blinding & de-blinding (where applicable) or
covering of lines with plastic.

7. The supervisor will deliver tool box talk on the specific work to be carried out highlighting the
hazardous chemicals / materials.

8. The supervisor shall ensure that all the gaskets for Control Valve removal & reinstallation are
available at site.

SAFETY:

1. The PPE requirements include hard hat with chin strap (if required), safety glasses, Coverall with
long sleeves, steel toed safety shoes, safety harness, working gloves and ear plugs when
working in operating plant.

2. A valid work permit for the job to be carried out.

3. Risk Assessment and tool box talk on the specific job.

4. Escape plan in case of emergency alarm at the plant including work location, wind direction,
escape route, assembly point etc.

5. All incidents & accidents will be reported to operations immediately.

6. Return permit at the end of shift / on completion of the work.

7. Follow BOROUGE safety guidelines.

 DESCON ENGINEERING
PO BOX 46821, Abu Dhabi, UAE Tel. (971 2) 6440903 Fax.
(971 2) 6446786

PROCEDURE FOR REMOVAL:

1. Obtain Work Permit from Operations for removal of Control valve

2. It shall be confirmed that the line is de-pressurized by Operations

3. Mark the direction and orientation of the control valve prior to dismantling by match marking or
punching on both the flanges.

4. Loosen bolts on both inlet and outlet sides of the Control Valve

5. While disengaging the bolts of Control Valve, ensure that it is held through crane, chain blocks or
a temporary support has been provided. Ensure safe removal by installing adequate rigging tools.

6. The area supervisor shall ensure that, if needed, a temporary support for inlet and outlet lines
connected with the Control Valve is provided.

7. Proper tagging and identification for re-installation must be ensured prior to removal of the Control
Valve from its location.

8. RTJ gaskets shall be hanged near to the Control Valve lines.

9. The removed Control valve shall be transported carefully to avoid any damage to instrumentation
connections.

10. Install end flange or cover the flanges of inlet / outlet line of the Control valve as required by
Operations.

WORKSHOP CALIBRATION:

1. Open the seat, plug & bottom flange of Control Valve.

2. Actuator of the Control Valve shall be opened only if instructed by Borouge. Otherwise offer
Borouge to inspect the seat plug and bottom flange.

3. Weld build up, machining, lapping shall be done as per the Inspection requirements and shall be
inspected by Borouge. Gland packing and gaskets shall be replaced accordingly.

4. In case the parts are beyond repair then replace all worn out parts as recommended by Borouge.

5. After final inspection of Borouge, re-assemble parts of the Control Valve

6. Calibration shall be conducted under the supervision of Borouge Instrument Technician /

Supervisor assigned to the job.

7. After successful calibration and witness, carry out hydrotest of Control Valve to check proper
sealing, packing tightness, body strength etc.

8. Conduct checks / repairs for positioner & air regulator for proper working

9. After final checks, mark & place the valve at assigned area for painting.

10. Painting of control valve to be carried out as per the procedure.

11. Transport the Control Valve back on site.
 DESCON ENGINEERING
PO BOX 46821, Abu Dhabi, UAE Tel. (971 2) 6440903 Fax.
(971 2) 6446786

PROCEDURE FOR RE-INSTALLATION:

1. After receiving the Control Valve on site, the area supervisor shall arrange for the work permit for
removing the end flanges & re-installation.

2. The supervisor shall also ensure that the gaskets and tools are available for re-installation. All
studs and bolts have been cleaned and anti-sieze applied to them. In addition, ensure that correct
location has been identified by cross checking the identification tag prior to installation.

3. While installing back the Control valve, it must be ensured that it is held properly through rigging
tools and sufficient support is available.

4. Engage the bottom studs initially at both inlet and outlet sides.

5. Ensure that temporary support is placed while engaging the studs and the flange facings are
clean

6. Slip the new gaskets at inlet outlet flanges and ensure proper placement. Engage further studs.

7. Tighten the flanges in criss-cross pattern and install masking tape on flange periphery.

8. After completion of works, return work permit.

HOUSEKEEPING:

1. Housekeeping of area shall be done and the area supervisor shall be responsible for
housekeeping of his area prior to work completion.

2. Remove all tools and equipment from the site.