ZPEC DOCUMENT No.

PE-0414-RP-01
METHOD OF STATEMENT
Rev. No. 0
FOR
COLUMN SHELL REPLACEMENT
QA/QC DATE: 15th Oct 2019

1.0 PURPOSE:
This procedure describes the method of statement for rectification work with detailed activities to
be followed to shell replacement along with nozzle, tray support, internal & external attachments.

2.0 DETAIL OF ITEM UNDER REPAIR:

Owner: SAUDI ARABIAN OIL COMPANY
Name of Original Manufacturer: To be updated
Item Identification: 110-C-6; 110-C-9; 110-C-11
Original Code of Construction / Edition: As per Data Sheet
G.A.DRAWING NO./ REV NO. :

3.0 REFERNCE DOCUMENTS/CODES/STANDARDS

Construction Code: ASME SEC VIII Div. 1 Ed. 2017

Aramco Specification: 32-SAMSS-004; SAES-W-010; SAES-D-008
Process Industry Practice: VEFV 1100M
ZPEC Welding Procedure Specification (WPS): ZPEC-414-WB
ZPEC PT Procedure: ZPEC-0414-PT, Rev. 0
ZPEC MT Procedure: ZPEC-0414-MT, Rev. 0
ZPEC RT Procedure: PETROCHEM/RT/01, Rev. 11

4.0 DESCRIPTION OF WORK:

4.1 Removal of Damaged portion From Existing Column.
1. Identify the Equipment Tag No. (Column Tag No. 110-C—6; 110-C-9; 110-C-11)
2. Blast (Sweep blast) the equipment completely from both inside and outside so that no
traces of corrosion, paint or insulation left on column.
3. Carryout thickness mapping (Corrosion mapping) on complete equipment so the verification
method shall include both minimum and maximum thickness as per Saudi Aramco
specification SAEP – 1146 dated 9th July 2014
4. Perform Visual inspection on complete column and Magnetic particle inspection on
complete column pressure boundaries (Long weld joints, circumferential weld joints, nozzle
joints, etc.)
5. Mark Reference line (By punch) & Orientation mark and reference point before cutting the
damaged portion so that those references shall be used during fit-up of new replacement
shell segments.
6. Cut the shell segment along the punch marks

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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
Rev. No. 0
FOR
COLUMN SHELL REPLACEMENT
QA/QC DATE: 15th Oct 2019

7. After cutting the shell carryout bevel preparation as per the sketch shown in weld map, the
cut section shall be completely free from HAZ formed during oxy-acetylene cutting.
4.2 Fabrication of New Shell Segments (Column # 110-C-06; 110-C-09 & 110-C-11)
1. Identify the Equipment Tag No. (Column Tag No. 110-C—6; 110-C-9; 110-C-11) applicable for
each component
2. After clearance of receiving inspection, carryout material traceability and record the details in
traceability report for all pressure retaining components
3. Upon completion of material inspection, perform fitup as per drawing# and
welding of long seam, cir-seam and nozzle welds as per approved weld book no. PED-0414P
(Weld map shall be prepared and submitted as built after full column assessment)
4. Carry out Following NDE as minimum

S. No Joint Category NDE to be Carried out

1 Category A & B VT; MT; RT & UT
2 Category C VT; MT;RT& UT as accessible
3 Category D VT; MT & UT as accessible

5. Up on completion of All NDE and inspection from all parties, the shell segment shall be heat
treated as per approved heat treatment procedure# ZPEC-414-HT
6. After completion of PWHT repeat all NDE as same as before PWHT, additionally hardness shall
be ensured as per ZPEC-414-HM

4.3 Assembly of New Shell Segments with Column(Column # 110-C-06; 110-C-09 & 110-C-11)
1. After inspection completion by all party, the newly fabricated segment shall be fitup with old
column.
2. Care shall be take while performing fitup the heat treated area shall not be subject to any kind
of welding or heating.
3. Upon fitup completion (Closing joints # ), verify the column for water level, straightness
(verticality) and other dimension from previously marked reference line.
4. After successful inspection from all party, closing joint shall be welded as per approved WPS &
Weld map.
5. On completion, perform VT, MT, UT & RT of closing joints as applicable.
6. Where minor damage observed less than T/3 and not exceeding 100 Sq. mm in size shall be
welded/ repaired and MT/UT to be performed. Such spots shall be welded using WPS (without
PWHT) (Except newly fabricated shell segments)
7. Perform final visual and dimensional inspection of complete column for its suitability.

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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
Rev. No. 0
FOR
COLUMN SHELL REPLACEMENT
QA/QC DATE: 15th Oct 2019

4.3 Hydro Static Examination of Column(Column # 110-C-06; 110-C-09 & 110-C-11)

1. After Successful inspection completion, the complete column shall be subject to Hydrostatic
examination as per procedure no. ZPEC-414-HP
2. Holding time followed shall meet Saudi Aramco specification 32-SAMSS-004 and to the
satisfactory limit of all inspectors to complete pressure test inspection.
3. Hydro pressure shall be followed based on newly established MAWP after assessment and
design of complete column.

4.4 Painting and Insulation (Column # 110-C-06; 110-C-09 & 110-C-11)

1. Upon finish of Hydro pressure test, the column shall be thoroughly inspected for
complete draining of water
2. Further blasting and painting shall be carried out as per procedure # ZPEC-414-SP
3. Verify final DFT of equipment and release for insulation.

4.5 Painting and Insulation (Column # 110-C-06; 110-C-09 & 110-C-11)

1. After complete verification of documents and equipment’s, equipment shall be certified with R-
form as per the latest design condition for which hydrostatic examination carried out.

Records
1. Thickness mapping report
2. MPI report for all pressure retaining joints
3. RT report for newly welded category A, B & C joints
4. UT report for newly welded category A, B, C & D joints
5. Shop Hydrostatic report
6. Painting report
7. Traceability records for newly welded Pressure items
8. Alignment Verification & Dimensional report
9. Visual inspection report for complete column
10. Signed R2 Form for Alteration.

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