FIXED TUBE TYPE-EXCHANGER’S Doc.

No: OM-QA&QC/PL/MS-06
Rev.: 01
INSPECTION & CLEANING Page: 1 of 7

METHOD STATEMENT

FOR

INSPECTION & CLEANING OF FIXED TUBE TYPE-EXCHANGER

(FOR ST-A2001-E2, ST-A2001-E3, X-A2006-E01, X-A2101-E01, X-A2101-E03, X-A2101-E04, E-

A3115, ST-A3201-E2, ST-A4001-E2, E-A5004, E-A5007, E-A5011)

OQ AROMATIC PLANT TURNAROUND 2022

00 For the initial issue & approval Oct 07,2021 Israr Owais Ahmed

Rev. No. Details Of Revision Date Prepared by Checked by Approved by

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 FIXED TUBE TYPE-EXCHANGER’S Doc. No: OM-QA&QC/PL/MS-06
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INDEX

1. PURPOSE

2. PREPARATION

3. REFERENCES

4. RESPONSIBILITIES

5. TOOLS & EQUIPMENTS

6. PRESHUTDOWN ACTIVITIES

7. SHUTDOWN ACTIVITIES

8. SAFETY INSTRUCTIONS

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1. PURPOSE

The purpose of this method statement is to describe execution procedure for

inspection and cleaning of FIXED TUBE-TYPE EXCHANGER in a safe
manner.

2. SCOPE

The scope of this method statement covers following activities:

 Erection of external scaffolding
 Insulation removal.
 Blinding & Isolation
 Removal of channel head and back cover.
 Pre Inspection
 Cleaning of Channel head and back cover.
 100% visual inspection of tube sheets
 Hydro-jetting of tube bundle.
 Internal cleaning of shell.
 IRIS, ECT of tubes
 Hydro testing
 Repair if any (Welding/Machining)
 Reinstallation of channel head and back cover.
 Removal of external scaffolding
 NDT and QC inspections

3. REFERENCES
 Project Area Layout.
 Marked up P& ID
 General Arrangement & Detail Drawings
 Detailed scope of work

4. RESPONSIBILITIES
1. Descon Supervisor shall coordinate with OQ maintenance and operations
for obtaining work permits and acceptance / renewal of the permit.
2. The Descon Supervisor shall ensure blinding as per the approved blind list
and follow OQ blinding procedure before executing the job.
3. Descon Supervisor shall be responsible for safe execution of the activities
as per scope in accordance with OQ safety policy & procedures.

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4. Descon supervisor will deliver toolbox talk on the specific work to be carried
out as per OQ Permit to Work (PTW) and Job Safety Analysis (JSA) and
ensure that all necessary safety precautions are taken for the safe
execution.
5. Descon Planning Engineer will ensure that all necessary inputs such as
drawing’s material, consumables, tools and plant are arranged.
6. Descon supervisor shall be responsible for overall execution of job including
quality of the work within the specified schedule and observing OQ safe
work practices.
7. OQ inspection team will confirm the completion & quality of the job.

5. TOOLS & EQUIPMENTS:

1. All the required tools / materials like spanners, brass hammer, blinds,
gaskets, flange spreaders, belt slings /slings /shackles/eye bolts, shall be
made available on site. Descon will follow the flange management
procedure as per OQ recommendation.
2. Crane with appropriate capacity shall be available to site to be used for
blinding purposes.
3. Hydro jetting machine & adequate pneumatic equipment shall be made
available at site for cleaning & drying.

6. PRE SHUTDOWN ACTIVITES

1. Specific rigging plans to be identified, prepared and approved as per site
requirement.
2. Shifting of scaffolding material and erection of scaffolding as per
requirement after getting PTW.
3. Area for scaffolding erection will be identified & scaffolding will be erected
for installation of blinds as per requirement.
4. Shifting of all required tools, blinds, temporary gaskets, materials and
equipment near to the area prior to shut down.
5. Test rings & test blinds shall be available to site prior to hydro testing.
6. Obtain permit for removal of insulation from the flanges. Remove insulation
from tagged locations for blinding. Use dust masks while handling
insulation in addition to PPE used as per PTW & JSA.
7. Ensure that all blinding points are as per the blind lists marked on P&ID.
Correct size spanners, brass hammer, blinds and flange spreaders are
made available on site.
8. All lifting tools & equipment to have third party certificates.

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9. Test ring thread holes to be cleaned and greasing if required.

7. SHUTDOWN ACTIVITES
A. BLINDING ACTIVITIES

1. OQ operation to carry out draining, purging and isolation of equipment for

handing over to Descon.
2. Installation of required blinds as per marked P&ID.
3. Blind tracking list (BTL) must be attached all the time along with the permit.

B. OPENING, INSPECTION, MAINTENANCE & CLEANING FOR FIXED TUBE

1. Obtain permit prior to start the job. All works shall be carried out only after
PTW’s are issued.
2. Blinding as per signed blind list.
3. Remove end covers & drop down using crane
4. Gas test will be carried out by AGT
5. Offer for as found inspection to OQ.
6. Necessary arrangement to be done for hydrojetting of tubes. Make sure
areas are barricaded with tarpaulin.
7. Hydro jet cleaning of tubes as per scope and inspection requirement.
8. Air blowing if required.
9. Tube inspection internally ECT/IRIS test to be done by OQ inspection.
10. Plug the Defective Tubes (if required).
11. Tube repair (Re Tubing-Rolling) by OQ if required.
12. Channel cover & channel head cleaning/power brushing & offer for
inspection.
13. If any repair is found in shell and weld joints, then repair will be carried out
as per OQ instructions with OQ approved WPS.
14. Offer the shell to OQ for Inspection after repair
15. Carry out shell side test and identify any leakage of tubes and then plug if
required.
16. Reinstall back channel head & channel cover
17. Carry out tube test to check gaskets of channel head covers
18. Draining of water & perform housekeeping.
19. Offer for final inspection to OQ.

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C. BOX UP / DEBLINGING

1. Obtain box-up certificate from OQ Inspection/Operation.

2. Upon receiving box up certificate from OQ inspection, process and
maintenance, channel head covers shall be boxed up using new gasket.
3. Remove blinds and box-up flanges with new gaskets. Restoration of
insulation as per requirement.
4. Mechanical isolation sheet (blind list) will be signed by DESCON/ OQ
operation as per de-blinding.
5. Descon will assist OQ.to carry out leak testing /Inerting of the exchanger
with nitrogen by operation
6. Test ring thread holes to be cleaned and greasing if required

8. SAFETY INDUCTION

During execution of the job all safety measure shall be adopted to ensure safe
work.
1. The workers will be made aware of OQ safety requirements related to this
activity through daily toolbox and safety talks in line with OQ Permit to Work
(PTW) and Job Safety Analysis (JSA) for the daily tasks to be performed.
2. Adequate PPE includes:
a. Helmet
b. Safety glasses
c. Coverall with long sleeves
d. Steel toed safety shoes
e. Appropriate gloves
f. Dust mask (if required)
g. Ear plugs as per job requirement.
h. Individual toxic clip (if required)
i. Other PPE may be worn as per job requirement(s)
3. The workers will be made aware of safety requirements related to this
activity through daily toolbox and safety talks. The work crew who is involve
in confined space and blinding/de-blinding should be fit tested.
4. Tool Box Talk (TBT) shall be performed in each shift and JSA along with
Permit to Work (PTW) requirements will be communicated by area lead to
work crew and shall be understood before starting any work.
5. Escape plan must be available at the work location, indicating:
a. The escape route
b. Emergency assembly point

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c. Emergency call out numbers

6. Access and good housekeeping must be maintained at site.
7. All waste material must be segregated to ensure proper housekeeping at all
times during the activities to avoid any tripping hazards or blocking of
emergency access points.
8. All equipment will be inspected by OQ & HSE (Descon) prior to use and
inspection record will be maintained.

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