DOC NO.

: EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
SDN BHD REV. : 0
PAGE : 01 OF 06

HEAT EXCHANGER

MAINTENANCE PROCEDURE

REV. DATE DESCRIPTION PRE'D CHK'D APP'D

0 23/03/2018 ISSUED FOR REVIEW & APPROVAL FIRDAUS EZIL BAHARUN

CLIENT PETRONAS
TENDER TITLE MASTER SERVICE AGREEMENT (MSA) FOR TURNAROUND (TA) AND DAILY MAINTENANCE WORK FOR
MAIN MECHANICAL WORKS
TENDER NO. CTC/HC-GP/2017/131
 DOC NO. : EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
SDN BHD REV. : 0
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TABLE OF CONTENTS

ITEM DESCRIPTION

1.0 OBJECTIVE

2.0 SCOPE

3.0 REFERENCE

4.0 ABBREVATION

5.0 RESPONSIBILITIES

6.0 PROCEDURE

7.0 SAFETY

8.0 RECORD
 DOC NO. : EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
SDN BHD REV. : 0
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1.0 OBJECTIVE

1.1 This procedure serves as a guideline for the preparation and execution of heat exchanger
maintenance work to ensure the work performed in accordance to code and standard and
PETRONAS Technical Standard (PTS) requirement.

2.0 SCOPE

2.1 This procedure is intended to provide overview of the basic maintenance, inspection and
repair work on the heat exchanger.

2.2 The procedure is applicable to all type of TEMA heat exchanger.

3.0 REFERENCE

TEMA Standards of the Tubular Exchanger Manufacturers Association

PTS PETRONAS Technical Standard

4.0 ABBREVATION

EMESB EPIC Mushtari Engineering Sdn Bhd

OPU PETRONAS Operating Unit
PTS PETRONAS Technical Standard
ITP Inspection & Test Plan
QA Quality Assurance
QC Quality Control
NDT Non-Destructive Test
PPE Personal Proctective Equipment
AFC Approved for Construction
 DOC NO. : EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
SDN BHD REV. : 0
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5.0 RESPONSIBILITIES

5.1 Supervisor shall be responsible to the Project Engineer/Project Manager for the proper
preparation and supervising maintenance work.

5.2 QC Inspector shall ensure that all inspection to be carried out according to approved ITP. He
shall notify PETRONAS OPU Representative for witnessing and preparation of the relevant test
reports.

5.3 Site Safety Supervisor shall ensure the safety aspects in all stages of maintenance work in
accordance with authority and PETRONAS OPU requirements.

6.0 PROCEDURE

6.1 GENERAL

6.1.1 Site survey shall be carried prior work execution to gather and compile data to produce
proposal for maintenance work.

6.1.2 Proposal of maintenance work to be prepared shall contain at least:

i - Technical documentation such as construction drawing, P&ID drawing and previous

manufacturer final documentation.
ii - Data collection such as operating temperature and operating pressure.
iii - Current physical condition of the heat exchanger.
iv - Record of previous maintenance works.
v - Accessibility to heat exchanger for maintenance such as scaffolding and insulation
requirement.

6.1.3 This proposal shall be presented to OPU and subsequently produce Technical Proposal. The
technical proposal shall contain at least:

i - Job method statement (JMS)

ii - Scheme of examination (SOE)
iii - Work and quality procedure
iv - Work schedule
vi - Equipment and manpower loading
vii - Job hazard analysis (JHA)

6.2 WORK EXECUTION

6.2.1 Prior disassembling the heat exchanger, ensure the unit has been isolated from the system,
depressurize, vented, drained and purge from hazardous material or gas.

6.2.2 All work to be executed shall be performed with valid permit to work (PTW).

6.2.3 Upon disassembling, mark and place all dismantled item on the wooden plate / plywood and
secured properly to avoid missing.
secured properly to avoid missing.
DOC NO. : EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
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6.2.4 Request for inspection (RFI) shall be made to OPU inspection prior performing initial
inspection to determine type of maintenance work required to be carried out.

6.2.5 Upon completion of the initial inspection, maintenance work shall be carried out accordingly.

6.3 MAINTENANCE WORKS

6.3.1 Maintenance work of the heat exchanger to be performed may consist of mechanical
cleaning, replacement of spare part and repair work.

6.3.2 Mechanical cleaning on the heat exchanger tube is mainly used to rectify fouling heat
exchanger tube and divided into tube brushing, mechanical drill, water jet and high pressure water
jet. The mechanical cleaning to be performed may depend on the type of the heat exchanger to be
maintained.

6.3.3 Chemical cleaning is used to remove fouling deposits and scales during operation and clean
unit off-line with chemical solution.

6.3.4 The spare part to be replaced on the heat exchanger is mainly consist of gasket which shall
be replaced for re-assemble of the heat exchanger and other accessories such as valve and
instruments attached to flange connection.

6.3.5 Repair work to be carried out will be based on the inspection report recommendation and it
may depends on the type of the defects found on the heat exchanger such as leaking nozzle,
thinning on certain portion, flange surface defects and tube plugging. The repair work is mainly
involved with hot work activities.

6.3.6 All maintenance works shall be performed as per scope of work and approved procedure.

6.4 INSPECTION

6.4.1 Inspection of heat exchanger shall be carried out visually and using suitable non-destructive
test (NDT) in accordance with approved ITP.

6.4.2 The inspection on the shell can be carried out using radiographic testing (RT), ultrasonic
testing (UT), dye penetrant testing (DPT) and magnetic particle testing (MPT).

6.4.3 Advance NDT methods are required for inspection of the heat exchanger tube and it consists
of eddy current testing (ECT), remote field testing (RFT), near field testing (NFT) and magnetic flux
leakage (MFL).

6.4.4 Leak test and/or hydrotest shall be conducted to identify the location of leaking tube, verify
the results upon completion of rectification works and ensure no leaks upon boxing up the heat
exchanger. The test shall be performed in accordance with approved pressure test procedure.
 DOC NO. : EMESB-MSA-MTN-001
EPIC MUSHTARI ENGINEERING DATE : 23 MARCH 2018
SDN BHD REV. : 0
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6.5 RE-ASSEMBLING & BOX UP

6.5.1 Upon completion of maintenance work and inspection, all dismantled part shall be re-
assemble as per initial physical condition and construction drawing.

6.5.2 New gasket at all flange bolting connection shall be used during re-assembling work to
ensure the integrity of the connection. Prior bolt tightening, flange surface shall be cleaned
properly.

6.5.3 Bolt tightening procedure shall be submitted to OPU for approval to ensure the tightening
work in accordance with PTS requirements.

6.5.4 Upon completion of boxing up, final joint inpection with OPU inspection shall be performed
to verify the completion of the work.

6.5.5 Box up certificate shall be signed off by OPU inspection.

7.0 SAFETY

7.1 Signboard and warning signage shall be placed around the working area to ensure all personnel
aware of the work performed.

7.2 All personnel attending shall wear proper personal protective equipment (PPE).

7.3 Only authorized personnel shall be allowed to enter the work area.

8.0 RECORD

8.1 All observations, data and test results of production shall be documented in preapproved
agreed format and signed off by OPU inspection for final documentation.

8.2 This procedure shall be kept by EMESB QA/QC Department and made available to the
authorized personnel conducting the activity for reference.

8.3 All approved approved report shall be kept by EMESB QA/QC Department for final
documentation and made available once requested.