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    MJR For 30M Maintenance Check of Check Valves

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    xtremewhiz
    1) The document provides maintenance procedures for 30-monthly checks of Class 1 check valves. 2) The work requires a 12-hour shutdown and involves mechanical and visual inspections of the check valves and associated piping for leaks, damage or corrosion. 3) Detailed maintenance procedures include leak testing the valves, replacing any worn parts, and documenting inspection results in the maintenance records.

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    © All Rights Reserved
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    MJR For 30M Maintenance Check of Check Valves

    Uploaded by

    xtremewhiz
    150 views9 pages
    1) The document provides maintenance procedures for 30-monthly checks of Class 1 check valves. 2) The work requires a 12-hour shutdown and involves mechanical and visual inspections of the check valves and associated piping for leaks, damage or corrosion. 3) Detailed maintenance procedures include leak testing the valves, replacing any worn parts, and documenting inspection results in the maintenance records.

    Original Description:

    Maintenance routine for check valves

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    MJR for 30M Maintenance Check of Check Valves

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    1) The document provides maintenance procedures for 30-monthly checks of Class 1 check valves. 2) The work requires a 12-hour shutdown and involves mechanical and visual inspections of the check valves and associated piping for leaks, damage or corrosion. 3) Detailed maintenance procedures include leak testing the valves, replacing any worn parts, and documenting inspection results in the maintenance records.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    150 views9 pages

    MJR For 30M Maintenance Check of Check Valves

    Uploaded by

    xtremewhiz
    1) The document provides maintenance procedures for 30-monthly checks of Class 1 check valves. 2) The work requires a 12-hour shutdown and involves mechanical and visual inspections of the check valves and associated piping for leaks, damage or corrosion. 3) Detailed maintenance procedures include leak testing the valves, replacing any worn parts, and documenting inspection results in the maintenance records.

    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    of 9

    - 1 -

    30M-CHECK FOR CLASS 1 CHECK VALVES


    MJR REF No.: MJR-M-30M-0023.BOGT
    TITLE: 30-Monthly Check for Class 1 Check Valves
    SAP MTCE STRATEGY CODE: NG02 30-Monthly
    EQUIPMENT: Class 1 Check Valves (Critical check valves)
    MANUFACTURER: N/A
    TYPE/MODEL: N/A
    WORK SPECIFICATION: 72FP PM # Preventive Maintenance
    SHUTDOWN REQUIRED: Yes
    SHUTDOWN HOURS: 4
    ASSOCIATED MJRs: N/A
    MANHOURS REQUIRED: 12
    DISCIPLINE SKILL NO. OF PERSONS MANHOURS
    SN EXPERT
    Mechanical 2 2 X 4
    Electrical

    Instrument
    Operator 1 1 X 4
    Others Inspector
    Specialist / Contractor
    TOTAL 3 12
    1.0 SAFETY & ENVIRONMENTAL REQUIREMENTS
    1) Carry out JHA
    2) Raise PTW
    3) Carry out Tool box talk
    4) Mechanical Isolation required

    5) Keep the work site and environment clean and avoid slippery surfaces

    2.0 SPECIAL TOOLS


    1) Mechanical Tool Box
    - 2 -

    2) Lapping blocks
    3) Spectacle blinds
    3.0 SPARE PARTS AND CONSUMABLES
    S/N DESCRIPTION QTY UNIT SAP NO
    1 Kimtech Towel 1 Box 1000383227
    2 Alvania Grease 1 Can 1000388068
    3 Lapping compounds (#600,
    #1200, #3000) 1 Set -
    4 Tags 1000972086
    4.0 PROCEDURE
    4.1 General
    1) Inform the operations supervisor and the local operator of the work
    to be carried out.
    2) Obtain all required authorization before carrying out any
    overrides/isolation of safety critical equipment.
    3) Ensure LOTO procedures are kept when isolating process to remove the
    check valves.

    4) Ensure that Class 1 check valves should be labelled or tagged in the


    field with this identifying number.
    5) Ensure that Inspection records for each Class 1 check valve shall be
    maintained.
    6) Follow the maintenance instruction of the valve manufacturer as
    required.

    4.2 Detailed Maintenance Procedures


    1) Make a walk around visual inspection the check valve and piping
    around.
    2) Look at the operator’s log and check passing valve register for any
    information on any of the class 1 check valves
    3) Check for any obvious signs of external leakage.
    4) Check for any obvious damage to rigid /flexible pipework, valves,
    hangers and fittings or signs of advanced corrosion.
    5) The leakage test of the class 1 check valve should be carried out
    with the operator just before commencement of depressurization of
    the facility for shutdown as follows:
    a. Stop operation of the process containing the check valve to be
    - 3 -

    tested
    b. Depressurize the upstream of the check valve.
    c. Apply the downstream pressure to the check valve
    d. Observe the pressure increase of the upstream section to detect
    any internal leakage of the check valve.

    Note: Performance standard - No visible internal leakage in the


    backward pressure. Leak test should be conducted prior to
    depressurization of the facility for Shutdown

    6) If the check valve leakage has been identified, the piping should be
    isolated / blinded and the check valve should be removed for
    internal check/repair at the workshop.

    7) Carry out visual checks for wear & corrosion should be carried out
    on all parts, and any affected parts should be replaced immediately.
    Note: See the manufacturer manual for dismantling/reassembly/repair
    of the check valves

    8) Place the valve on a level surface; with the discharge side facing
    upwards, slowly pour water into the valve. Check for water leaking
    through the seat seal to the intake side. If water leaks through
    then the valve will have to be either renewed or have the seats
    reground and retested.

    9) Ensure that the valve reinstatement is carried out with correct


    assembly of bolts, nuts and gasket.

    10) Attach an inspection sticker on the check valve, where the


    inspection date is indicated.

    5.0 WORK CLOSE-OUT AND HANDOVER

    1) Remove all unused parts and scraps, and clean up the site.

    2) Remove #DO NOT OPERATE” sign as displayed.


    - 4 -

    3) Inform Plant Operator of job completion.

    4) Walk around system/equipment with Operator to check instrument is


    indicating correctly

    5) Close out permit to work and handover unit for operation.

    6.0 FEEDBACK OF CHANGES


    1) Generate a request for any identified modifications to work
    procedures arising from HSE requirements or changes of the
    circumstances of the work specified, such request for changes shall
    be addressed to the Discipline Lead in Corporate Maintenance
    accompanied by a request for changes in SAP using a Z6 Notification.
    2) Document additional corrective actions required to be carried out in
    the course of this planned maintenance activity by raising a Z1
    Notification in SAP specifying additional work and any other
    additional material requirements. For corrective work carried out
    during this procedure, without recourse to extra materials, this
    shall be documented as part of the equipment history by using a M3
    Notification in SAP.
    7.0 DOCUMENTATION
    1) Complete and submit the completed check list and observation sheet.

    2) Input report to SAP-PM for update and spares used.

    8.0 REFERENCES
    1) DEP 80.45.10.11-Gen. Overpressure and under pressure # prevention
    and protection
    2) DEP 01.00.02.12-Gen. Preparation of safeguarding memoranda and
    process safeguarding flow scheme
    3) PML203.04 - Valve Maintenance Strategy

    4) Manufacturer IOM manual

    9.0 APPENDICES
    1) Checklist for Class 1 Check Valve
    - 5 -

    2) Disassembly/Reassembly/Repair of Check Valves


    3) List of Class 1 check valves

    Responsibility Name Signature Date


    Checked by
    Supervisor

    APPENDIX 1

    30-MONTHLY CHECKLIST
    CLASS 1 CHECK VALVE

    Location/Unit/Area: Date:
    Maker: Work Order No:
    Equipment No:

    Item Description Y/N Remark


    1 Make a walk around visual inspection of the check valve and piping
    around.
    2 Check for any obvious signs of external leakage.
    3 Check for any obvious damage to rigid /flexible pipework, valves,
    hangers and fittings or signs of advanced corrosion.
    4 The leakage test of the class 1 check valve should be carried out
    before depressurization of the facility with the operator as
    follows:
    a. Stop operation of the process containing the check valve to be
    tested
    - 6 -

    b. depressurize the upstream of the check valve.


    c. Apply the downstream pressure to the check valve
    d. Observe the pressure increase of the upstream section to detect
    any internal leakage of the check valve.
    Note: Performance standard - No visible internal leakage in the
    backward pressure
    5 If the check valve leakage has been identified, the piping should be
    isolated / blinded and the check valve should be removed for
    internal check/repair at the workshop.
    6 Carry out visual checks for wear & corrosion should be carried out
    on all parts, and any affected parts should be replaced immediately.
    Note: See the manufacturer manual for dismantling/reassembly of the
    check valves
    Observations:

    Work Executor Work Executor Approved by


    Name
    Signature/Date

    APPENDIX 2: Disassembly/Reassembly/Repair for Check Valves


    1. Dual Plate Check Valves
    Note: Check valve types without external hinge and stop pin retailers
    is illustrated as an example below.

    CAUTION! THE SPRING IS UNDER TENSION.


    Lay the valve flat with spring uppermost. Record and mark each valve
    disc to enable them to be reassembled in their original location
    Remove the 4 grub screws in the front face (BR10)
    Knock out the keeper plates (BR08)
    Lift the whole internals out of the valve after lifting the stop pin
    vertically.

    Place the disc assembly flat at the side of the body and remove the
    carriers (BR06) from the ends of the hinge pin & stop pin (BR03)
    Apply a vertical force downwards on the tensioned spring to hold it in
    position. Slide the hinge pin & stop pin (BRO3) out of the spring coils.
    - 7 -

    Gently release the force on the spring (BO4) until free and then remove.
    Ensure all components are clean and are without unusable wear marks.
    Lay the valve body flat with the carrier slots uppermost
    Position the two valve discs (BO2) correctly as marked at the side of
    the body and insert the hinge pin (BR03) through the ears to align them.

    Lay the spring in the ‘Vee’ between the plates # See Figure 1.

    Apply the force to the spring (BO4) to keep it in position and rotate
    the top leg through 180 degrees such that the #heel” of the leg remains
    nearest the discs (B02) through its movement # See figure 1.
    Still holding the spring (BO4) in place, insert the hinge pin (BR03)
    through the discs and spring until the spindle is fully secured in both
    sides of the discs (B02).

    Insert the stop pin (BR03) into position through the upper coils of the
    spring (BO4).
    Position the carriers (BR06) onto the ends of the pins making sure that
    the chamfered end of the carrier is at the hinge pin end.
    Lift the assembly and lower it into the valve body. Insert the keeper
    plates (BR08) into the slots above each carrier and align the grub screw
    holes. Screw in the grub screws (BR10) until they are below the face of
    the valve.

    2. Swing Check Valves


    If the Body-Bonnet is leaking, tighten the bolts (Pos. 31). If the
    gasket is damaged, replace the gasket (Pos. 30)
    If the valve not fully closed and passing internally, flush the valve in
    order to remove debris trapped inside the check valve.
    All the other repairs should be performed by the valve manufacturer

    APPENDIX 3: List of Class 1 Check Valves


    - 8 -

    No Tag No. Functional Location Size


    1 V-01-09 NG.BNYNA.SIL4PKG-V-01-09 2" Dual Plate Check Valve, TEG
    injection line to in let to
    main pre-separator
    2 V-02-09 NG.BNYNA.SIL4PKG-V-02-09 2" Duel Plate Check Valve, TEG
    injection line to in let to
    main pre-separator
    3 V-23-10 NG.BNYNA.V-8131-V-23-10 2" Duel Plate Check Valve
    4 V-511 NG.BNYNA.P-8160A-V-511 2" Duel Plate Check Valve
    5 V-518 NG.BNYNA.P-8160B-V-518 2" Duel Plate Check Valve
    6 V-525 NG.BNYNA.P-8161A-V-525 2" Duel Plate Check Valve
    7 V-532 NG.BNYNA.P-8161B-V-532 2" Duel Plate Check Valve
    8 V-507 NG.BNYNA.P-8160A-V-507 2" Swing Check Valve. Full
    bore
    9 V-12-14 NG.BNYNA.P-8168-V-13-14 2" Duel Plate Check
    Valve
    10 V-606 NG.BNYNA.P-8162A-V-606 2" Swing Check Valve, Full
    bore
    11 V-610 NG.BNYNA.P-8162B-V-610 2" Swing Check Valve, Full
    bore

    12 V-603 NG.BNYNA.P-8168-V-603 2" Swing Check Valve, Full


    bore
    13 V-812 NG.BNYNA.P-8165B-V-812 2" Swing Check Valve,
    Reduced Bore
    14 V-816 NG.BNYNA.P-8165A-V-816 2" Swing Check Valve,
    Reduced Bore
    15 V-839 NG.BNYNA.P-8163-V-839 2" Duel Plate Check Valve
    16 V-01-16 NG.BNYNA.M-8180-V-01-16 2" Swing Check Valve, Gas
    export line to NLNG
    17 V-02-16 NG.BNYNA.M-8180-V-02-16 2" Swing Check Valve, Gas
    line to BCOT fuel gas
    distribution manifold
    18 V-12-21 NG.BNYNA.P-8170-V-12-21 2" Duel Plate Check valve
    19 V-21-22 NG.BNYNA.V-8180-V-21-22 2" Duel Plate Check
    Valve
    20 V-319 NG.BNYNA.V-8140-V-319 2" Duel Plate Check Valve
    - 9 -

    21 V-19-23 NG.BNYNA.V-8140-V-19-23 2" Duel Plate Check Valve


    22 V-320 NG.BNYNA.V-8140-V-320 2" Duel Plate Check Valve,
    Fuel gas line from BCOT
    to slug flash vessel
    23 V-322 NG.BNYNA.V-8140-V-322 2" Swing Check Valve, Full
    bore
    24 V-701 NG.BNYNA.V-8161-V-701 2" Swing Check Valve, Full
    bore
    25 V-16-27 NG.BNYNA.P-8190A-V-16-27 2" Duel Plate Check Valve
    26 V-19-27 NG.BNYNA.P-8190B-V-19-27 2" Duel Plate Check Valve
    27 V-26-27 NG.BNYNA.P-8191A-V-26-27 2" Duel Plate Check Valve
    28 V-29-27 NG.BNYNA.P-8191B-V-29-27 2" Duel Plate Check Valve
    29 V-49-27 NG.BNYNA.S-8190A-V-49-27 2" Duel Plate Check Valve
    30 V-71-27 NG.BNYNA.S-8190B-V-71-27 2" Duel Plate Check Valve
    31 V-46-27 NG.BNYNA.S-8190A-V-46-27 2" Duel Plate Check Valve
    32 V-67-27 NG.BNYNA.S-8190B-V-67-27 2" Duel Plate Check Valve
    33 V-01-29 NG.BNYNA.F-8170-V-01-29 2" Swing Check Valve
    Instrument air header to
    flare

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