DRAFT

METHOD OF SATEMENT FOR TUBE

1.0 Intro
Introduc
ductio
tion
n
This method statement describes in detail the removal of existing tubes and installation of new
tubes for the Heat Exchanger.
2.0 Scope
Scope nd !urpo"e
!urpo"e o# Met$o
Met$od
d Stte%ent
Stte%ent
This document outlines the method for replacement of existing tubes for Heat Exchanger.
The procedure provides guidance for assessing the activities for replacement of tubes. This
guidance is based on the requirements set forth in the proect requirement! safet" requirement
and #ualit" assurance program.
2.1
2.1 O&
O&'e
'ect
cti(
i(e"
e"
This document provides guidance in implementing an effective program for replacement of 
Titanium tubes for the Heat Exchanger. This includes addressing programs for the following$
%&' (mplementin
(mplementing g commitments
commitments regarding the qualit"
qualit" of the wor).
%*' +anaging
+anaging and providing
providing oversight to ensure installation
installation and related qualit" control
control has
 been adequatel" addressed b" specifications! drawings! and procedures.
%,' +anaging
+anaging and providing
providing supervision
supervision and control
control to assure qualit" of wor) and closel"
implement-monitor schedule.
%' Recording
Recording installation
installation and test
test activities.
activities.
%/' H0E atat the time of
of wor).
wor).
This procedure is one component of a complete replacement of tube wor) program. This and
other procedures will be used! as needed! to provide assurance that replacement of tubes
activities are being conducted as required b" the specification and manufacturer procedures. (t
is not expected that completion of the entire procedure will be accomplished during an" one
inspection and -or ever" time the inspection procedure is used. (t is a continuing activit" until
all tubes are replaced.
2.2 In"pect
In"pection
ion nd Recordin)
Recordin) Re*uire%en
Re*uire%ent"
t"
The engineer should verif" that the supervisor-foreman with construction responsibilities for 
the replacement of tubes wor)s is familiar with the method statement and is issued with
copies of the inspection chec)lists and test plans. The engineer should satisf" procedures
 provided b" #A-#1 inspections to ensure the replacement of tubes wor)s meet specified
engine
engineerin
ering
g requir
requireme
ements
nts and drawin
drawings.
gs. As part
part of the assessm
assessment
ent!! the #1 inspect
inspection
ion
 procedures must ensure a quantitative or qualitative acceptance criteria for determining the
 prescribed activities have been accomplished satisfactoril".
The #1 inspection personnel! in coordination with site supervisor! should verif" that the
qualit"
qualit" of the wor)s and related testing activities
activities are within
within the proect
proect design specifications
specifications
requirements.
The
The supe
superv
rvis
isor
or shou
should
ld verif
verif"
" that
that the
the repla
replacem
cement
ent of tube
tubess wor)
wor)ss is acco
accomp
mplis
lishe
hed
d in
accordance with the specifications and the manufacturer2s procedures. The supervisor should
verif" an" testing and confirm that the information meets the proect requirements.
2.+ Tr
Trinin)
inin) nd
nd ,u-i#iction
,u-i#iction o# !er"onne-
!er"onne-
The supervisor should verif" that the personnel have sufficient )nowledge of the procedure
requirement. The supervisor should review an" training and qualification records for those

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DRAFT

individual
individualss who shall do the tas) to determine
determine whether the" are s)illed
s)illed enough to follow the
 procedure before the actual wor) is carried out.

+.0 Re"pon"i
Re"pon"i&i-it
&i-itie"
ie" nd re"ourc
re"ource"
e"

+.1 Re"po
Re"pon"i
n"i&i-
&i-iti
itie"
e"
The
The pro
proect
ect mana
managegerr %145
%145TR TRA1
A1T4
T4R'
R'!! has
has over
overall
all respo
respons
nsib
ibil
ilit"
it" for
for the
the co6
co6
ordi
ordina
nati
tion
on and
and impl
implem
emenentat
tatio
ions
ns of the
the cutt
cuttin
ing
g and
and weld
weldin
ing
g activ
activit"
it"!! incl
includ
udin
ing
g
manpower
manpower and plant utili7ation!
utili7ation! engineering
engineering support! material scheduling
scheduling and cost
control.
3roect
3roect +anage
+anagerr %145TR
%145TRA1T A1T4R'
4R'!! 3roect
3roect Engine
Engineer
er %145TR
%145TRA1TA1T4R'4R' - will
will be
responsible for the replacement of tubes for the Heat Exchanger.
+.2 Re"ou
Re"ourc
rce"
e"
Mteri-
• Tubes$ Titanium
Titanium tubes %free
% free issued'.
!-nt nd E*uip%ent
• 1ompressor 
• Tube Expander
• Torque 1ontroller.
• Electrical Tools.
Tools.
• Hand Tools
• 8ifting and Rigging Equipment$ As per requirement %b" 18(E5T'.
• 0caffolding$ As per Requirement. %9" 18(E5T'.
• 4ther small hand tools and tac)les$ as per requirement.
E%p-o/ee" nd "u&contrctor"
"u&contrctor" it$ "peci-ied trinin) inc-ude t$e #o--oin)
• Engineers
• 0upervisor - Foreman
• Fabricators
• Fitters
• Helpers
• 4ther miscellaneous.
.0 Met$o
Met$odo-
do-o)
o)/
/
#uantit" of material
• Tube si7e$ Dia. &: mm 4D x ;.< mm thic).
•  5o. Tubes$
Tubes$ &/ 5os.
The following steps will be carried out for replacement of Tubes at 18(E5T
• After isolation of the plant! 18(E5T will remove end covers on either side of the Heat
Exchanger.
• 145TRA1T4R will remove the plugs b" drilling or tapping method to avoid damaging
the tubes.
• 1ut the tube from one end b tube cutter tools.
• 3ull the tube using h"draulic stub puller without damaging the tube sheet.
• 3lace the old tubes in a sage area on the wor) platform.
• 3ull all the balance tubes from the tube sheet using above method.

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• 1lean expansion grooves in the tube sheet using cleaning brush or b" air to remove debris
or deposit material.
• 1hec) the diameter of tube sheet bore b" using dial caliber.
• 1lan the baffle holes b" using power brush.
• (nspection of the tube sheet bore b" approved inspection method before inserting new
tubes.
•  3rior to inserting
inser ting the new tubes! inspection must be cleared b 18(E5T.
• (nsert new tubes and expand as per the specified values on both ends as per the calculation
method.
• The calculation method of values approved b" 18(E5T.
18(E5T.
• After the expansion tubes are measured and chec)ed using dial bore gauge and records the
value.
• Tubes ends shall be protrude from tubes plates of , mm.
• Tube ends shall be chec)ed after expanding to ma)e sure there is no damage.
• (nside surface of tubes ends in the expanded area shall be free of defects such as crac) or 
clear overlaps.
• 3repare the lea) test b" water for the Heat Exchanger %9" 18(E5T'.
• Attend the lea) tubes b" rolling or replacement after testing until exchanger is cleared b"
18(E5T.
3.0 He-t$4 S#et/ nd En(iron%ent Me"ure"
Me"ure"

3.1 !rep
!repr
rti
tion
on
•  5otif" all concerned in site for the date of material deliver".
• Ensure all wor)ers involved in the operation put on 33E all times.
• 9rief individual wor)er the roles and responsibilities of each.
• 1oordinate with concern department for tubes hoisting area.
• Ensure designated area is cleared of obstruction.
3.2 !ipe5T
!ipe5Tu&
u&ee -i#tin)
-i#tin)
• Ensure sage wor) procedure for replacement of tube operation is observed.
• Ensure proper method with the correct equipment are used.
• Ensure the pipes-tubes are firml" placed on the designated location before
releasing the hoisting hoo).
3.+ Durin)
Durin) Rep-ce%ent
Rep-ce%ent o# Tu
Tu&e"
• Ensure wor)ers are distributed to each designated place.
• Ensure wor)ers at all times to be in proper gear where required.
• Ensure all wor)ers assigned are involved in its particular tas).
• 9rief individual wor)er the roles and responsibilities before start wor).
• Ensure the pipe-tube lengths to suite site routes into designated wor) area.
• Ensu
Ensurere all
all tool
toolss to be used
used have
have been
been insp
inspec
ecte
ted
d and
and tagg
tagged
ed b" 0afe
0afet"
t"
Department. %9" 18(E5T'.
• Ensure wor) areas are clearl" mar)ed to restrict access to authori7ed personnel
onl".
• Ensure that equipment2s to be used are properl" tagged and chec)ed.

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DRAFT

3. Hou"e
Hou"e6ee
6eepin
pin)
)
• +aintain cleanliness and orderl" stoc)ing of material and tools.
• 3ic) up and dispose wastes and other debris prior to leaving site area.
• Remove
Remove safet" "ellow tape or other warning devices that were used to control
access to the wor) area.
• 0tore tools! equipment and unused materials properl" at the end
e nd of the wor)da".
3.3 S#et/
S#et/ In"pect
In"pection"
ion"
• (t shall be responsibilit" of the supervisor to routinel" inspect het ph"sical areas
under their control in pipe welding wor)s.

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