HSE-SAF-PRO-00-0035

SAFETY
Rev. 0
04-Apr-2016
PLUG REAMER
Page 1 of 7

TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................. 2

2. SCOPE & PURPOSE ...................................................................................... 2

3. DEFINITIONS .................................................................................................. 2

4. PROCEDURE.................................................................................................. 3

5. RESPONSIBILITIES ....................................................................................... 4

6. REFERENCES ................................................................................................ 5

7. ATTACHMENTS ............................................................................................. 5

8. APPENDICES ................................................................................................. 5

9. REVISION HISTORY ...................................................................................... 7

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

0 04-Apr-16 First release Haresh Patel Refer sec. 9 Refer sec. 9

Next Scheduled Periodic Review: April/2019

HSE-SAF-PRO-00-0035 Page 1 of 7
 HSE-SAF-PRO-00-0035
SAFETY
Rev. 0
04-Apr-2016
PLUG REAMER
Page 2 of 7

1. INTRODUCTION

The plug reamer allows a plugged bleeder, drain, vent or instrument tap to be cleared safely
and efficiently, while minimizing the possibility of a spill, fire, or vapor release.
The plug reamer is engineered to meet the Plant needs within specifications outlined in this
procedure. This procedure provides the required information on the plug reamer tools and their
use. This device shall only be utilized by trained personnel for unplugging bleeder.
Cleaning of bleeder plug with “Plug Reamer” is high risk activity requiring careful consideration
before carrying out the task as there are many potential hazards such as:
i. Leak due to loose fitting/gland leak from tools
ii. Over pressurization of tool
iii. Toxic exposure due to leak from tool joint/gland/poor threading
iv. Tool accidentally detached from connection with process bleeder due to improper threading
v. Potential of chemical splash to eye/skin and PPE requirements
vi. Potential of tip of plug reamer breaking and sticking inside the process pipe and rendering
the process bleeder valve inoperable
vii. Exposure to chemical due to tool use by unauthorised or untrained personnel
viii. Potential for fatality or catastrophic PSE (Process Safety Event) if performed incorrectly
ix. Other hazards as applicable

2. SCOPE & PURPOSE

The purpose of this procedure is to provide a safe and reliable use of plug reamer tool for
clearing vents, bleeders, orifice taps, instrument taps, analyzer sample points, sight glass
drain valves on line, vessel, or other Plant equipment within the Q-Chem Facilities (Mesaieed
and Ras Laffan).
It shall be utilized with following conditions:
i. Valves having 1½” and smaller size only.
ii. System parameters do not exceed the plug reamer manufacturers recommendation (refer
to Appendix I).
iii. H2S service containing less than 50 PPM.

3. DEFINITIONS

 JSA – Job Safety Analysis

 Plug Reamer - A specialized engineered tool that allows clogged bleeder, vent, and
instrument tap valves to be cleaned safely and efficiently while containing process material
 PPE – Personal Protective Equipment
 PSE – Process Safety Event

HSE-SAF-PRO-00-0035 Page 2 of 7
 HSE-SAF-PRO-00-0035
SAFETY
Rev. 0
04-Apr-2016
PLUG REAMER
Page 3 of 7

4. PROCEDURE

4.1. Requirements

i. Ensure plug reamer is designed to withstand the temperature and pressure of the system.
ii. Wear appropriate PPE as per the hazard identified for the task. (Minimum safety goggles
and face shield with chin guard along with other required PPE).
iii. Aim the bleeder plug cleaner in the safe direction and keep yourself away from line of fire.
iv. Follow the plug reamer procedures as specified in section 4.2..
v. All plug reamers shall have an inspection tag attached to the tool marked with:
a) Design pressure
b) Design temperature
vi. All plug reamers shall be as per the specification specified in the Appendix I or
specification approved by Technical Department.
vii. Do not repair or tamper with the tools, only workshop will carry out repair/replacement of
parts.
viii. Workshop shall perform inspection and hydro-test prior to use as per end user request.
ix. All plug reamer shall be visually inspected and hydro-tested prior to each use.
x. Only trained personnel shall use the plug reamer.
xi. Form a cross functional team to conduct the JSA for bleeder plug cleaning task prior to
using plug reamer.
xii. Consider the following potentials hazards during JSA:
a) Unauthorized use
b) Untrained personnel
c) Leak due to loose fitting
d) Leak due to gland leak from tools
e) Over pressurization of tool
f) Toxic exposure due to leak from tool joint/gland/poor threading
g) Fire due to presence of pyrophoric material
h) Tool accidentally detaches from connection with process bleeder due to improper
threading
i) Potential for fatality or catastrophic PSE (Process Safety Event) if performed incorrectly
j) Potential of chemical splash to eye/skin and PPE requirements
k) Potential of tip of plug reamer break and stick inside the process pipe and process
bleeder valve becoming inoperable
l) Use of non-inspected/damaged/non hydro-tested tools
m) Action to be taken in case of malfunctioning of tools, leaks etc.
n) Other hazards as applicable

HSE-SAF-PRO-00-0035 Page 3 of 7
 HSE-SAF-PRO-00-0035
SAFETY
Rev. 0
04-Apr-2016
PLUG REAMER
Page 4 of 7

xiii. Plug Reamer Approval Form (HSE-SAF-SFM-00-0154) is required to be completed for

following conditions:
a) System is not isolated or
b) System not depressurised or
c) Toxic chemical involved.

4.2. Operating Procedures

Follow the following steps for using the plug reamer safely:
i. Obtain and secure proper size of the plug reamer (Pipe size to valve size - correct length
of bleeder plug cleaner handles). Get hydro-test conducted.
ii. Inspect the plug reamer for physical condition. Check threads on the plug reamer and on
valve that is plugged. Check packing gland for good seal quality. Check bleeder valve on
plug reamer for open/close (Damaged thread on plug reamer or on bleeder valve can
cause detachment of plug reamer from bleeder leading to exposure of contents within the
bleeder valve while in use).
iii. Pull arrow head point back against end of the plug reamer.
iv. With plugged valve in closed position, screw plug reamer into valve and tighten securely.
v. Close bleeder valve on plug reamer.
vi. Open plugged process bleeder valve to the fully open position.
vii. Push plug reamer handle in until plug is reached.
viii. Turn handle of plug reamer to “grind” plug out of valve. DO NOT DRIVE ARROW POINT
INTO PLUG.
ix. When using on a pressurized system, monitor the pressure gauge on the plug reamer for
indications that the plug has been removed.
x. When arrow head point moves freely back and forth, pull handle back to original position.
xi. Close process bleeder valve that was plugged.
xii. Open plug reamer bleeder valve.
xiii. Close plug reamer valve and open the bleeder valve of the process line to ensure that the
bleeder is de-plugged.
xiv. If the bleeder is still plugged, repeat steps 4.2. (v) to 4.2.(xiii).
xv. When the bleeder is confirmed to be unplugged, close the bleeder valve of the process
line.
xvi. With bleeder valve on plug reamer open to assure plug reamer is de-pressured
completely, remove plug reamer from the bleeder valve.

5. RESPONSIBILITIES

5.1. Maintenance Workshop

i. Carry out the inspection and hydro-test using Plug Reamer Maintenance Inspection
Checklist (HSE-SAF-SFM-00-0153) prior to the use of plug reamer as per end user
request and provide inspection tag.

HSE-SAF-PRO-00-0035 Page 4 of 7
 HSE-SAF-PRO-00-0035
SAFETY
Rev. 0
04-Apr-2016
PLUG REAMER
Page 5 of 7

5.2. End user

i. Purchase plug reamer as per approved specification.

ii. Make sure that the purchased plug reamer has been inspected and provided with
inspection tag before putting it to use.
iii. Ensure that all plug reamers have valid inspection tags before use. The validity of the
inspection tag of plug reamer shall be one year.
iv. Ensure that the JSA for the bleeder plug removal is conducted and reviewed with all
concerned parties before starting the task.
v. Complete the Plug Reamer Approval Form if required as per Section 4.1.(xiii).
vi. Send the plug reamer to Workshop for inspection and hydro-test prior to use.
vii. Inspect the tools and fill the Plug Reamer End User Pre-Use Inspection Checklist (HSE-
SAF-SFM-00-0152) prior to the use and obtain consent from Supervisor for performing
bleeder de-plugging.
viii. Maintain the plug reamer in good condition and store at appropriate location so it will be
available when required.
ix. Plug reamer shall only be used by personnel who are trained on safe use of plug reamer.

5.3. Technical

i. Approve the specification for plug reamer.

5.4. Safety

i. Owner of the procedure and review/update the procedure as per the ‘Key Business
Document Revision, Update and Tracking procedure (QC-IMT-PRO-00-0001).

5.5. Training

i. Provide training on how to use “Plug Reamer” safely to end users as per the Global
Training Matrix (AD-TRN-MTX-00-0001).

6. REFERENCES

6.1. HSE-SAF-CBT-00-0002 - Use of Plug Reamer Training Presentation

7. ATTACHMENTS

7.1. HSE-SAF-SFM-00-0152 Plug Reamer End User Pre-Use inspection Checklist

7.2. HSE-SAF-SFM-00-0153 Plug Reamer Maintenance Inspection Checklist
7.3. HSE-SAF-SFM-00-0154 Plug Reamer Approval Form

8. APPENDICES

8.1. Appendix I: Plug Reamer Specification

HSE-SAF-PRO-00-0035 Page 5 of 7
 HSE-SAF-PRO-00-0035
SAFETY
Rev. 0
04-Apr-2016
PLUG REAMER
Page 6 of 7

Appendix I: Plug Reamer Specification

Tool specification will be only type 3, Flow Boss Cleaner. (Tools can be ordered in 1/4",
1/2", 3/4", and 1" MNPT's)
Specification of components pressure gauge, glycerin filled, dual span 1000 psig (~ 68
Bars), constructed of 316 stainless steel, for restriction refer to ASME B40.1. Fittings and
connectors, constructed of 316 Stainless Steel conforms to ANSI, B36.10, ANSI B1-20.1,
MIL-P, 7150B, bar stock material ASME tool not to exceed 1000 0 F(~5370 C) . All
component supplied conform to ANSI, ASME, ASTM and ISO-9000

Packing type will be grafoil – all graphite. Packing rated for up to 1000 0 F. PH for packing
will be 0-14 ph. Pressure for packing will be 1000 psig maximum. Construction will be lattice
braid. Minimum operating temperature will be -150 0 F at packing gland.
Gauge to
measure
pressure

Plug Reamer
Arrow Head Point
(Drill bit welded to
T-Handle flexible cable)
(welded to
flexible cable)

Ball valve
Adjustable
bleeder with
packing gland
position
for seal around
locking
T-Handle stem
attachment

MM# 300036147 CLNR,BLED,ANGL,90°,1/2",3400L-12,T3

MM# 300036148 CLNR,BLED,ANGL,90°,1",3400L-12,T3

MM# 300036149 CLNR,BLED,ANGL,90°,3/4",3400L-12,T3

HSE-SAF-PRO-00-0035 Page 6 of 7
 HSE-SAF-PRO-00-0035
SAFETY
Rev. 0
04-Apr-2016
PLUG REAMER
Page 7 of 7

Types 3 Plug Reamer

(A) Straight Plug Reamer

(B) 90 0 Angle Plug Reamer

(C) 60 0 Angle Plug Reamer

9. REVISION HISTORY

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

Carl Poldrack
Narayanan
Roehl Bartolome
Sankarakrishnan
Ali Al-Marri
Arantelo Abreu
Dirk Perrin
Ashok D Kher
Saleh Abdulla
Victor S Calma
0 30-Sep-15 First release Haresh Patel Anuraag B
Niranjan R
Malve
Kamble
Abdulla S Al-
Suhael Qureshi
Khulaifi
Abdul W Sheikh
Anthony D
Mohamed A Patel
Dugat

HSE-SAF-PRO-00-0035 Page 7 of 7