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SAT-TEC-P-065 Separator P-306LW-001 SMP
SAT-TEC-P-065 Separator P-306LW-001 SMP
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
SEPARATOR
(EQUIPMENT #: P-306LW-001)
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
Guido F. Cozzi
Site Manager
Naoufal Akhrif
Operations Manager
Remington Tan
Senior Safety Officer
Elvin Tom
Operations Supervisor
Andrews Ackah
Operations Supervisor
Amro Burhan
Oliver Lazo Bibat Operations Supervisor
Operations Superintendent
Contents
1. Purpose/Scope........................................................................................................................................4
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
2. Terminology...........................................................................................................................................4
3. References:.............................................................................................................................................4
4. Frequency Of Maintenance Activity......................................................................................................4
5. Key Personnel Responsibilities..............................................................................................................5
6. HSE........................................................................................................................................................5
7. Requirements.........................................................................................................................................7
8. Other requirements.................................................................................................................................9
9. Spares, Tools & Special Consumables:.................................................................................................9
10. General Information.............................................................................................................................10
11. Before Execution.................................................................................................................................11
12. During Execution.................................................................................................................................11
13. After Execution....................................................................................................................................12
14. Process / Step- by- Step Methodology:................................................................................................13
15. Records Involved.................................................................................................................................17
16. Attachments.........................................................................................................................................18
17. Revision History..................................................................................................................................18
1. Purpose/Scope
To establish a procedure for Inspection, Cleaning, Testing and Maintenance repair / replacement
activities carried out for the Separator during turnaround, emergency shutdown or breakdown
maintenance meeting the Safety and Integrity objectives of the Plant.
The procedure provides generic guidelines for the inspection, cleaning, testing and Maintenance
repair / replacement of Separator.
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
All Involved personnel must fully understand the general and specific operating procedures. Any
issues arising during work periods must be brought to the immediate attention of the Team
Leader, Supervisor and Maintenance/Site Manager.
Procedure / guidelines outlined by this document are applicable to all who take part in the process
and must be fully adhered to.
Any deviation from the procedures / guidelines must necessarily have prior explicit approval of
the Maintenance/Site Manager.
2. Terminology
2.1. SMP :Standard Maintenance Procedure
2.2. PPE :Personal Protective Equipment
2.3. G-Urea :Granulated Urea
2.4. SF :SAFCO
2.5. OEM :Original Equipment Manufacturer’s
2.6. EDMS :Electronic Document Management System
3. References:
3.1. Relevant Equipment OEM Drawings in EDMS
3.2. Operation and Maintenance Manual in EDMS.
3.3. Equipment and Desiccant Specification Sheet in EDMS
3.4. Equipment Inspection Schedule
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
6. HSE
6.1. Safety & Health
6.1.1.Approved JSA as applicable must be available and posted on site before the start of job.
6.1.2.Conduct safety talk with all working crew highlighting the JSA points and Hazardous
involved in the job task before starting the job.
6.1.3.Perform blinding before carrying out any activities.
6.1.4.Take a valid work permit before starting the job and display at job site.
6.1.5.Use only approved fresh air breathing apparatus.
6.1.6.Ensure the gas test reading normal.
6.1.7.The work area must be barricaded, warning sign to be posted and allow only concerned
people inside.
6.1.8.Proper Tightening Tools must be selected for Man ways opening / Box up, Internal trays,
support grids and structures removal / reinstallation, etc.
6.1.9.Use only Tested and certified Lifting /rigging tackles like chain block, slings, D-shackles
etc. as SHEM-08.06
6.1.10. Fork lifts / Crane and all other lifting equipment must be inspected prior to lifting and
certified.
6.1.11. Fork lifts / Crane operators and riggers must be qualified and certified.
6.1.12. No job to be performed if it’s windy.
6.1.13. Lifting plan should be prepared before lifting.
6.1.14. Do not allow more than four persons to ride in the crane basket. Use safety harness.
6.1.15. Use PPE’s stipulated in the work permit and compatible with the equipment service as
per SHEMS 08.08.
6.1.16. Use appropriate certified Scaffolding while working at height as per the SHEMS 08.09.
6.1.17. Personnel involve in all Maintenance activities must be well trained and ensure wearing
of proper PPE for the job.
6.1.18. Handle lubricants and aerosol sprays carefully as these are flammable materials.
6.1.19. Prohibit use of open flames while disassembling equipment at site.
6.1.20. Check condition of oil hoses if any hydraulic jacks are used to avoid injuries due to high
pressure oil spray.
6.1.21. The Hydro test pump must be certified and all the gauges should be calibrated.
6.1.22. Hydro jetting machine should have valid test certificate.
6.1.23. Experienced operator should be assigned for jetting.
6.1.24. All the flanges and end blinds shall be as per standard pressure rating related to
Pneumatic / Hydrostatic test shall be connected with respective gaskets and proper torque
tightened to avoid any jetting or leakages.
6.1.25. All High pressure Hoses shall meet the pressure rating and be connected with standard
clamps and threaded joints shall be tightened properly to avoid any type of pressure jetting
or leakages.
6.1.26. Minimum 2 calibrated pressure gauges shall be used for Pneumatic / Hydrostatic test.
Pressure gauges used for testing shall have dial graduated over range of double the intended
test pressure.
6.1.27. The dial of the gauges shall be positioned in such a way that they are clearly visible to the
operator controlling the pressure during the test. One of the pressure gauges shall be located
in the highest point.
6.1.28. Minimum of one PSV shall be installed in the test loop to avoid accidental over
pressurizing.
6.1.29. Pressure gauges & PSV’s should have valid test certificate.
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
6.2. Environment
6.2.1.In case of any chemical/hazardous waste leakage to ground or atmosphere, inform the
Environment Engineer and dispose in accordance to the SAFCO Environment procedures.
6.2.2.Dispose of hazardous waste generated during the work as per SAFCO Environment
procedures.
7. Requirements
LSR: Life Saving Rules – is a set of critical EHS Rules associated to high risk activities, if
violated may lead to serious consequence. These rules shall never be broken.
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
8. Other requirements
8.1.1.All maintenance activities will be under strict supervision of SAFCO Supervisor.
8.1.2.There must be clear and complete communication between the maintenance & operation
supervisors to ensure safety and integrity.
8.1.3.Proper Area shall be designated to keep piping’s and Desiccant, etc.
8.1.4.Inspection tools calibration certificates to be reviewed by SAFCO Inspection.
8.1.5.All related Inspection reports shall be immediately submitted to SAFCO inspection for
review & approval.
8.1.6.All repairs will be done as per SAFCO inspection & process recommendations.
8.1.7.Final box up will be done after clearance and box up certificate duly signed by from
Operation, Inspection, Maintenance & Process.
8.1.8.Studs and nuts removed from different sections should be free of nicks, burrs, chips, dirt
and corrosion. Nuts should turn freely on studs.
8.1.9.Erect proper scaffolding for work as required, and use it only after it is tagged fit for use.
9.1.1.SPARES
9.1.1.1. Refer to SAP and Micro Data Reference Manual.
9.1.2.TOOLS
9.1.2.1. Use only calibrated measuring tools for taking critical equipment dimensions.
9.1.2.2. Use only tested and certified lifting/rigging tackles like chain block, slings,
shackles etc.
9.1.2.3. Use any special tools supplied by OEM.
9.1.2.4. Use calibrated torque wrenches.
9.1.2.5. Refer attached OEM / Manufacturer Equipment Drawings.
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
1. Forklift
2. Crane
3. Impact Wrench
4. 24V lighting, GFCI protected & explosion proof.
5. Air movers
6. Material Basket
7. Spanners
8. Chain pulley blocks / Crane
9. Hydro Jetting Machine
10. Hydro Test Pump
11. High Pressure Water hoses
12. Tested and calibrated Pressure gauges & PSVs
13. Welding Machine
14. Torqueing Machine
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
4. Safe Scaffoldings are installed with valid Certified Concerned Supervisor (MS)
Tags. Service provider supervisor (SPS)
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
installed.
Flange joint tightening checklist prepared and Concerned Supervisor (MS) / Mechanical
3.
attached. Technicians (MT)
Operation’s Supervisor (OS)
4. Fix back all removed insulations Concerned Supervisor (MS)
Service provider supervisor (SPS)
Operation’s Supervisor (OS)
5. Remove all scaffoldings. Concerned Supervisor (MS)
Service provider supervisor (SPS)
Housekeeping done at site and Work Permit
Concerned Supervisor (MS)
6. returned to the Operations after completion of the
Service provider supervisor (SPS)
work.
Surplus / Unused Material / Spares return to Stores/ Concerned Supervisor (MS)
7.
Warehouse through proper procedure. Service provider supervisor (SPS)
Dispose the scrap materials at designated area as Concerned Supervisor (MS)
8.
per SAFCO procedure. Service provider supervisor (SPS)
Scan and attach filled and signed checklists to
9. Concerned Supervisor (MS)
related SAP Work order.
Ensure that all mechanical isolations are
10. Operation’s Supervisor (OS)
normalized.
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
REMARK
STEP S/N ACTIVITY DESCRIPTION RESP.
S
Activity SEPARATOR MAN WAYS OPENING, SEPARATOR ENTRY PREPARATION
13.2
2 AND PRELIMINARY INSPECTION.
This SMP is provided as a general guideline for the
Note: maintenance of the Air Dryer.
Refer to OEM drawings & manuals for any specific details.
Assist operation to connect utility hoses for decontamination if
13.2.1
required.
Start opening and removal of all Man ways nuts and bolts / studs one
13.2.2
by one.
13.2.3 Open all man ways.
All removed bolts & nuts clean, inspect and preserve them properly
13.2.4
in storage containers.
Inspect the gasket seating area of man ways and mating flanges by
13.2.5 visually for any damages / defects and protect all the gasket seating
areas properly.
13.2.6 Install Air movers to all man ways. MS/SPS
13.2.7 Provide sufficient explosion proof low voltage lighting.
13.2.8 Arrange drinking water, tools & materials at job site.
Arrange certified / trained stand by man with all necessary
13.2.9
safety equipment.
Take Vessel Entry Permit (Hot Work Permit) and conduct gas
test.
13.2.10
Mention tested gas values in corresponding Vessel Entry
Permit
Fulfill all permit requirements and follow SAFCO Vessel Entry
13.2.11
safety procedures.
Conduct preliminary inspection by Inspections & Process prior
13.2.12
to any internal cleaning / repair / replacement activities.
ACTIVIT SEPARATOR INTERNALS REMOVAL FOR CLEANING OR REPLACEMENT
Y3
13.3
SEPARATOR SHELL INTERNAL INSPECTION AND CLEANING
Carryout detailed inspection of Separator and other sections by
13.3.1
inspections & process prior to any cleaning / repair activities
13.3.2 Open and remove all internal man ways if any. MS/SPS
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
Activity
13.4 INSPECTION & REPAIRS
4
Offer the Separator and all the internals for detailed
13.4.1 Inspection to both Inspection and Process.
Carry out Separator shell and recommended internals buffing
13.4.2 and cleaning prior to DPT and TML to the satisfaction of MS/SPS
Inspections.
Carry out Weld areas DPT and TML according inspection
13.4.3 program.
Carry out all recommended repairs / replacement / correction
13.4.4 works as per issued Inspection and Process reports.
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
Activity
13.6 FINAL INSPECTION, SEPARATOR BOX-UP & DE-BLINDING
6
After the final acceptance from Inspection & Process remove
13.6.1
all tools, lightings & air movers from the Separator.
Prepare the box-up certificate duly signed by Inspection,
13.6.2 Process, Operation and Maintenance for Separator man ways
boxed-up.
Before fixing the Gasket, make sure that gasket seating areas
13.6.3
properly cleaned and free from any damages.
Take proper care for fixing the man ways cover flanges, extra
13.6.4
precautions need to be taken to ensure the integrity of gasket. MS/SPS
All the bolts to be greased / lubricated properly and Torqueing
13.6.5
done to the recommended value.
Confirm torqueing tags fixed / installed.
13.6.6
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
16. Attachments
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Doc. No.: SAT-TEC/P-065
Classification: General Business Use
SAFCO-IBB
Maintenance Department - (Elect / Mech / Inst)
SEPARATOR (EQUIPMENT #: P-306LW-001)
UNDER DEVELOPMENT BY
3. Blind list NA
IBB OPERATION
UNDER DEVELOPMENT BY
4. Blind Diagram NA
IBB OPERATION
General Arrangement
5. EDMS
Drawing
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Doc. No.: SAT-TEC/P-065