Prosedure HEX & HPWJ PDF

Document Number:
PT. BHUMI PHALA PERKASA

001/AFC/2018
PROCEDURE MECHANICAL CLEANING AIR FAN COOLER

DOCUMENT NUMBER : 001/AFC/2018
DOCUMENT TITLE : PROCEDURE AIR FAN COOLER
EQUIPMENT NAME : 011-E-1002, HC CONDENSATE COOLER
CLIENT : TANGGUH LNG
REVISION :A
APPROVAL SHEET
A – Approved
B - Approved with Comment
C – Resubmit for Approval
D – Retained for Information Only
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
Rev Issue Date Prepared Cheked Approved Issue Purpose Signature
by by by
A 08-08-2018 DYN ISSUED FOR REVIEW
REVISION SUMMARY
REV DATE DESCRIPTION OF CHANGE

A 08-08-2018 First Issued
Doc. No. 001/AFC/2018 Rev (A) Page 2 of 8

Table of Contents
Revision Summary
Table Contents
1 General
2 Applicable Specification, Code , Standard & Other References
3 Applicable Item
4 Procedure
4.1 Visual Inspection
4.2 Draining & free gas
4.3 Maintenance Task
4.3.1 Preparation
4.3.2 Install Blind
4.3.3 Open Hexagonal Plug and Nozzle
4.3.4 Mechanical Cleaning With High Pressure Pump
4.3.5 Tube Inspection
4.3.6 Re-install Hexagonal Plug and Nozzle
4.3.7 Bolt Tightening
4.3.8 Hydro test
4.3.9 Remove blind
4.4 Purging & Leak test
4.5 Waste Management & House keeping
5 Attachment
Doc. No. 001/AFC/2018 Rev (A) Pages 3 of 8

1. GENERAL
The objective of this procedure is covering for visual inspection of Fin Fan Cooler
Heat Exchanger and not limited to, open hexagonal plug, cleaning with high
pressure, Inspection with boroscope, install hexagonal plug, tube expansion and
thread repair.
2. APPLICABLE SPECIFICATION, CODE, STANDARD and OTHER REFERENCES

a) TEMA (Tubular Exchanger Manufacturers Association)
b) ASME code section VIII Division 1 2010 edition. Boiler & Pressure Vessel
c) API 661, 6th Ed Air Cooled Heat Exchanger For General Refinery
d) ASME B1.1 – 2003 screw thread
e) ASME B18.2.2 Square and Hex Nuts (Inch Series)
f) ASME B16.20 Metallic Gasket for Pipe Flanges Ring Joint, Spiral Wound,
and Jacketed
g) ASME B16.5 Pipe Flanges and Pipe Fitting
h) CONTRACTOR shall comply with the following company procedures
during Work performance as stated in the contract scope of work :
 900-PRC-EN-2321 “Non Hazardous Solid Waste Procedure”
 900-PRC-EN-2322 “Hazardous Waste Procedure”
 900-PRC-EN-2324 “Waste Water Management Procedure”
 900-PRC-HS-2222 “Confined Space Entry Procedure”
 900-PRC-HS-2238 “Working at Height Procedure”
 920-PRC-HS-2428 “Personal Protective Equipment Procedure”
 920-PRC-HS-2770 “HSSE Incident Reporting, Investigation and Lesson
Learned Procedure
 920-SSO-HS-2045 “Contractor Equipment Mobilization to Tangguh
LNG Site”
 APC-000-PRC-OP-200002 “Management of Lifting Operations and
Lifting Equipment”
3. APPLICABLE ITEM
- Fin Fan Cooler Heat Exchanger 11-E-1002 HC Condensate Cooler
4. Procedure
4.1 VISUAL INSPECTION
Prior start of the mechanical cleaning of Fin Fan Cooler heat exchanger, PT.
Bhumi Phala Perkasa will perform visual inspection to the hexagonal plugs
are free from leakage, fin tubes in good condition and not in bent condition,
Header & Nozzle still in good condition , coating material was not corrosion,
etc.

If there have a broken coating and material structure found heavy corrossion
so need to replace the material based on visual inspection and NDT test (wall
thickness, DPT/MPT).
4.2 Draining & Free gas

When the plant stopped, the operation department continue to drain the
system and purging till the equipment in safe condition for maintenance
activities
4.3.1 PREPARATION
4.3.1.1 Tool,
PT Bhumi Phala Perkasa will check and prepare tools for
cleaning of heat exchanger as follows :
a. Tube Expander (if required)
b. Spreader Jack c/w hand pump
c. Hydraulic Torque Wrench
d. Manual Torque Wrench
e. Hammer Wrench (if required )
f. Podger Ring
g. Combination Wrench
h. High pressure water jet complete with accessories
i. Blind Flange based on ICC P&ID
j. Spade Blind based on ICC P&ID
k. Ring joint or SWG based on flange and standard or
client specification
l. Tarpaulin
m. Etc.
4.3.1.2 Permit To Work , Lifting Plan and ITP

PT Bhumi Phala Perkasa will ensure that the work permit,
lifting plan, ITP has been prepared and approved.
4.3.1.3 ICC
PT Bhumi Phala Perkasa will ensure ICCs are in place and the
heat exchanger is already in safe condition ( hydrocarbon
<4% LEL)
4.3.1.4 Scaffolding
PT Bhumi Phala Perkasa will ensure that the scaffolding
already installed (if required) on the unit for personnel
access,
4.3.1.5 Tarpaulin
Tarpaulin will installed to protect cleaning activities, water
waste will collect to the collector, then deliver to the waste
area as per waste management procedure , 900-PRC-EN-2321
“Non Hazardous Solid Waste Procedure” and 900-PRC-EN-
2322 “Hazardous Waste Procedure”.

4.3.2 Install Blind
Blinds will install to the inlet & outlet Nozzle 3” 150# (see attachment
for bolt dimensions)
Size Bolt Dia Wrench Size
3” 150# 5/8” 1 1/16”
4.3.3 OPEN HEXAGONAL PLUG

4.3.3.1 Marking
Before open hexagonal plug PIC PTBPP will give marking or
tagging to hexagonal plug and header box to perform
cleaning to header box and tube.
4.3.3.2 Inspect sheet plug
Perform visual inspection to the sheet plugs threaded and
plug hole threaded on header box.
4.3.3.3 Thread cleaning
Perform cleaning to female thread on header box and male
thread. Ensure the sheet plug and plug hole are clean from
rust and dirt with acceptance criteria screwed manually the
plug until contact with gasket seat surface without excessive
force.
4.3.4 MECHANICAL CLEANING WITH HIGH PRESSURE PUMP

Perform mechanical cleaning with high pressure pump to Air Fan
Cooler with pressure 3000 – 15000 Psi.
4.3.5 INSPECTION
After mechanical cleaning finish, inspection will performed to the
header box and finned tube.
4.3.6 RE-INSTALL HEXAGONAL PLUG

PT. Bhumi Phala Perkasa will perform visual inspection to hexagonal
plug and plug hole before re-install hexagonal plug to header box.
4.3.7 Bolt Tightening Plug Sheet and Nozzle

PT. Bhumi Phala Perkasa will perform bolt tightening to hexagonal
plug as data bellow :
Plug Sheet
Gasket Material Plug Diameter Torque N.M
Soft Iron 1” 250
Nozzle Size Bolt Dia Wrench Size Torque NM

3” 150# 5/8” 1 1/16” 149

4.3.8 Hydrotest
Hydrotest is required after the tubes cleaning are completed and
inspection has been done also the hexagonal plugs was installed, the
hydrotest will be done by other company
4.3.9 Remove Blind
The blinds will remove when the hydrotest is accepted and then
tightened the bolts as per bolting procedure,
Size Bolt Dia Wrench Size Torque NM

3” 150# 5/8” 1 1/16” 149
4.4 Purging & Test Leak

Leak Test will perform by The Company during nitrogen purge
4.5 Waste Management & House Keeping

Contractor shall be follow the company regulation related to the Waste
management no. 900-PRC-EN-2324 “Waste Water Management Procedure
Routine housekeeping are required to keep safe working & environmental
friendly , especially for the water waste must be collect to the waste collector
then send to the recommended area as per waste management procedure
5. Attachment & Table

5.1 Table of stud bolt

5.2 Bolt Torque

Document Number:

002/AFC/2018

EQUIPMENT NAME : 016-E-1001, VRA GAS COOLER
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.8 Hydro test
4.3.9 Remove blind
5 Attachment

1. GENERAL
thread repair.

and Jacketed
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
- Fin Fan Cooler Heat Exchanger 16-E-1001 VRA GAS COOLER
4. Procedure
etc.


activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin

4.3.2 Install Blind
Blinds will install to the inlet & outlet Nozzle (see attachment for bolt
dimensions)
6” 1500# 1 3/8” 2 3/16”

4.3.3.1 Marking
force.

4.3.5 INSPECTION


Plug Sheet
Soft Iron 1” 250

6” 1500# 1.3/8” 2 3/16” 1796

4.3.8 Hydrotest
4.3.9 Remove Blind

6” 1500# 1 3/8” 2 3/16” 1796




5.2 Bolt Torque

Document Number:

003/AFC/2018

EQUIPMENT NAME : 031-E-1002, REGENERATION GAS COOLER
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.8 Hydro test
4.3.9 Remove blind
5 Attachment

1. GENERAL
thread repair.

and Jacketed
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
- Fin Fan Cooler Heat Exchanger 31-E-1002 REGENERATION GAS COOLER
4. Procedure
etc.


activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin

4.3.2 Install Blind
Blinds will install to the inlet & outlet Nozzle 8” 300# (see attachment
for bolt dimensions)
8” 300# 7/8” 1 7/16”

4.3.3.1 Marking
force.

4.3.5 INSPECTION


Plug Sheet
Soft Iron 1” 250

8” 300# 7/8” 1 7/16” 420

4.3.8 Hydrotest
4.3.9 Remove Blind

8” 300# 7/8” 1 7/16” 420




5.2 Bolt Torque

Document Number:

004/AFC/2018

EQUIPMENT NAME : 051-E-1005, MP MR COMPRESSOR AFTER COOLER
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.8 Hydro test
4.3.9 Remove blind
5 Attachment

1. GENERAL
thread repair.

and Jacketed
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
- Fin Fan Cooler Heat Exchanger 51-E-1005 MP MR COMPRESSOR AFTER
COOLER
4. Procedure

etc.

activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin

4.3.2 Install Blind

Blinds will install to the inlet & outlet Nozzle 10” 600# (see
attachment for bolt dimensions)
10” 600# 1 1/4” 2”

4.3.3.1 Marking
force.

4.3.5 INSPECTION


Plug Sheet
Soft Iron 1” 250

10” 600# 1 1/4” 2” 1302
4.3.8 Hydrotest
4.3.9 Remove Blind

10” 600# 1 1/4” 2” 1302




5.2 Bolt Torque

Document Number:

005/AFC/2018

EQUIPMENT NAME : 051-E-1101, LP. STEAM CONTROL CONDENSOR
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.8 Hydro test
4.3.9 Remove blind
5 Attachment

1. GENERAL
pressure, Inspection, install hexagonal plug, tube expansion and thread repair.

and Jacketed
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
- Fin Fan Cooler Heat Exchanger , 51-E-1101 , LP STEAM CONTROL CONDENSOR
4. Procedure
etc.


activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin

4.3.2 Install Blind
Blinds will install to the inlet & outlet Nozzle 6” 150# & 10” 150# (see
6” 150# 3/4” 1 ¼”
10” 150# 7/8” 1 7/16”

4.3.3.1 Marking
force.

4.3.5 INSPECTION


Plug Sheet
Soft Iron 1” 250

6” 150# 3/4” 1 1/4” 264
10” 150# 7/8” 1 7/16” 420
4.3.8 Hydrotest
4.3.9 Remove Blind

6” 150# 3/4” 1 1/4” 264
10” 150# 7/8” 1 7/16” 420




Bolt Torque

Document Number:

006/AFC/2018

EQUIPMENT NAME : 051-E-1103, Condensate Flash Drum Condenser
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.8 Hydro test
4.3.9 Remove blind
5 Attachment

1. GENERAL
thread repair.

and Jacketed
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
Fin Fan Cooler Heat Exchanger , 051-E-1103, Condensate Flash Drum Condenser
4. Procedure
etc.


activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin

4.3.2 Install Blind
Blinds will install to the inlet & outlet Nozzle 6” 150# & 10” 150# (see
6” 150# 3/4” 1 ¼”
10” 150# 7/8” 1 7/16”

4.3.3.1 Marking
force.

4.3.5 INSPECTION


Plug Sheet
Soft Iron 1” 250

Nozzle size
6” 150# 3/4” 1 1/4” 264
10” 150# 7/8” 1 7/16” 420
4.3.8 Hydrotest
4.3.9 Remove Blind

6” 150# 3/4” 1 1/4” 264
10” 150# 7/8” 1 7/16” 420



Bolt Torque

Document Number:

007/AFC/2018

EQUIPMENT NAME : 051-E-1105 CONDENSATE FLUSH DRUM VENT
CONDENSOR
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.8 Hydro test
4.3.9 Remove blind
5 Attachment

1. GENERAL
pressure, Inspection, install hexagonal plug, tube expansion and thread repair.

and Jacketed
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
Fin Fan Cooler Heat Exchanger , 051-E-1105 CONDENSATE FLUSH DRUM VENT
CONDENSOR
4. Procedure
etc.


activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin

4.3.2 Install Blind
Blinds will install to the inlet & outlet Nozzle : (see attachment for bolt
dimensions)
4” 150# 5/8” 1 1/16”
8” 150# ¾” 1 ¼”
10” 150# 7/8” 1 7/16”

4.3.3.1 Marking
force.

4.3.5 INSPECTION



Plug Sheet
Soft Iron 1” 250
Nozzle size
4” 150# 5/8” 1 1/16” 149
8” 150# 3/4” 1 1/4” 264
10” 150# 7/8” 1 7/16” 420
4.3.8 Hydrotest
4.3.9 Remove Blind

4” 150# 5/8” 1 1/16” 149
8” 150# 3/4” 1 1/4” 264
10” 150# 7/8” 1 7/16” 420



5.2 Bolt Torque

Document Number:

008/AFC/2018

EQUIPMENT NAME : 71-E-1001B BOG COMPRESSOR AFTER COOLER
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.8 Hydro test
4.3.9 Remove blind
5 Attachment

1. GENERAL
thread repair.

and Jacketed
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
Fin Fan Cooler Heat Exchanger , 071-E-1001B BOG COMPRESSOR AFTER COOLER
4. Procedure
etc.


activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin

4.3.2 Install Blind
dimensions)
6” 150# ¾” 1 ¼”

4.3.3.1 Marking
force.

4.3.5 INSPECTION



Plug Sheet
Soft Iron 1” 250
Nozzle size
6” 150# 3/4” 1 1/4” 264
4.3.8 Hydrotest
4.3.9 Remove Blind

6” 150# 3/4” 1 1/4” 264



5.2 Bolt Torque

Document Number:

009/ST/2018

DOCUMENT NUMBER : 009/ST/2018
DOCUMENT TITLE : PROCEDURE SHELL AND TUBE
EQUIPMENT NAME : 031-E-1001 DEHYDRATION PRE-COOLER
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind shell & Tube
4.3.3 Open Cover inlet & outlet
4.3.4 Open Manhole
4.3.6 Air blowing
4.3.8 Re-install Cover inlet & outlet
4.3.9 Close manhole
4.3.11 Hydro test / Pneumatic
4.3.12 Remove blind
5 Attachment

1. GENERAL
The objective of this procedure is covering for inspection of Heat Exchanger and
not limited to, open covers, cleaning with high pressure, Inspection, repair as
finding.

c) ASME B16.20 Metallic Gasket for Pipe Flanges Ring Joint, Spiral Wound,
and Jacketed
d) ASME B16.5 Pipe Flanges and Pipe Fitting
e) CONTRACTOR shall comply with the following company procedures
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
Fin Fan Cooler Heat Exchanger , 31-E-1001 Dehydration Pre-Cooler
4. Procedure
Bhumi Phala Perkasa will perform visual inspection to the Coating Condition,
tube leakage, Nozzle condition , channel and covers condition, etc.
If there found a corrosion or deterioration from the visual inspect , then
further detail inspection are required.

activities
4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin
4.3.2 Install Blind

dimensions)

Location Size Bolt Dia Wrench Size
Shell inlet 14” 150# 1” 1 5/8”
Shell outlet 24” 150# 1 ¼” 2”
Tube inlet 30” 600 2” 3 1/8”
outlet
4.3.3 OPEN COVERS INLET & OUTLET TUBE

4.3.3.1 Open covers
When free gas & draining is complete and safe for
maintenance , PT.BPP will open the covers
4.3.3.2 Visual Inspection
When the covers are open , visual inspection will perform on
the covers , Channels, tube sheet
4.3.3.3 Repair (if required)
Due to optimization of the work schedule , Parallel work is
required if found any damage or deterioration during visual
inspection
4.3.4 Open Manhole (if Required)
If there is a program to inspect the shell side bundle, the manway
need to open

4.3.6 Air blowing

Air blowing is required before inspection , to clean the water in the
internal tubes , cause of water blast
4.3.7 INSPECTION
After mechanical cleaning is done , inspection will performed as per
inspection procedure
4.3.8 RE-INSTALL COVERS

PT. Bhumi Phala Perkasa will perform visual inspection to the covers
before installing them especially on the gasket face .
4.3.9 Close Manhole & Joint Inspection

Close man way and tighten the bolt as per procedure ,
Joint inspection, Do the joint inspection before close the manhole
and covers between Maintenance – Operator & Inspector

Below is the table of the bolt tightening Torque:

Location Size Bolt Dia Wrench Size Torque
Shell inlet 14” 150# 1” 1 5/8” 630
Shell outlet 24” 150# 1 ¼” 2” 1302
Manhole 24” 150# 1 ¼” 2” 1302
Tube inlet 30” 600 2” 3 1/8” 5783
outlet
4.3.11 Hydrotest / Pneumatic

If the Hydrotest is required after the tubes cleaning and inspection are
completed and covers are installed, the hydrotest will be done by
other company
4.3.12 Remove Blind



4.5.1 Waste management
Contractor shall be follow the company regulation related to the
Waste management no. 900-PRC-EN-2324 “Waste Water
Management Procedure
4.5.2 House keeping
Routine housekeeping are required to keep safe working &
environmental friendly , especially for the water waste must be
collect to the waste collector then send to the recommended area as
per waste management procedure


5.2 Bolt Torque

Document Number:

010/ST/2018

DOCUMENT NUMBER : 010/ST/2018
DOCUMENT TITLE : PROCEDURE SHELL AND TUBE
EQUIPMENT NAME : 041-E-1012, LPG REINJECTION COOLER
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY


Table of Contents
Revision Summary
Table Contents
1 General
3 Applicable Item
4 Procedure
4.3.1 Preparation
4.3.2 Install Blind
4.3.3 Open Channel Head
4.3.4 Pull out tube bundle
4.3.5 Deliver bundle to cleaning area
4.3.7 Air blowing
4.3.9 Insert tube bundle
4.3.10 Hydrotest / Pneumatic Test
4.3.11 Re-install Channel Head Cover
4.3.13 Remove blind
5 Attachment

1. GENERAL
The objective of this procedure is covering for inspection Tube Bundle and not
limited to, open Covers, cleaning with high pressure water, Inspection Tube
sheet, Covers , shell side, tube side, etc .

c) ASME B16.20 Metallic Gasket for Pipe Flanges Ring Joint, Spiral Wound,
and Jacketed
d) ASME B16.5 Pipe Flanges and Pipe Fitting
e) CONTRACTOR shall comply with the following company procedures
Learned Procedure
LNG Site”
3. APPLICABLE ITEM
Heat Exchanger , 041-E-1012 LPG Reinjection Cooler
4. Procedure
Prior start of the mechanical cleaning of the heat exchanger, PT. Bhumi Phala
Perkasa will perform visual inspection to the covers, channel box, tube sheet
& tube leakage, tube bundle in good condition and coating material was not
corrosion, etc.
If there found any damage from the visual inspection so need to repair or
replace with further detail inspection

When the plant stopped, the operation department will continue to drain
the system and purging till the equipment in safe condition for maintenance
activities

4.3.1 PREPARATION
4.3.1.1 Tool,
f. Podger Ring
l. Tarpaulin
m. Etc.

4.3.1.3 ICC
<4% LEL)
4.3.1.4 Scaffolding
access,
4.3.1.5 Tarpaulin
4.3.2 Install Blind

dimensions)
Location Size Bolt Dia Wrench Size
Shell inlet 4” 150# 5/8” 1 1/16”
Shell outlet 8” 150# ¾” 1 ¼”

Tube inlet 4” 300# ¾” 1 ¼”
outlet
4.3.3 OPEN Channel Head Cover

4.3.3.1 Open covers
When free gas & draining is complete and safe for
maintenance , PT.BPP will open the channel head cover
4.3.3.2 Blind Flange
Install blind flange to the inlet & outlet tube side
4.3.3.3 Visual Inspection
When the cover is opened, visual inspection will perform on
the cover, Channel, tube sheet, nozzles
4.3.3.4 Repair (if required)
Due to optimization of the work schedule , Parallel work is
required if found any damage or deterioration during visual
inspection
4.3.4 Pull out Bundle
4.3.4.1 Ensure the scaffolding are installed and safe condition
4.3.4.2 Ensure thread (Lug) on the tube sheet in good condition
4.3.4.3 Ensure the bundle puller in good condition and tested
4.3.4.4 Ensure lifting gear are prepared properly and meet with the
capacity of lifting
4.3.4.5 Ensure lifting plan is approved
4.3.4.6 Conduct Pre Use Inspection
If all above items are ready then pull out the bundle as per Bundle
puller Operating procedure
4.3.5 DELIVER BUNDLE TO THE CLEANING AREA

When the bundle was pull out, then the bundle send to the cleaning
area directly

Perform mechanical cleaning with high pressure pump to the tube
bundle internal and external with pressure 3000 – 15000 Psi.
4.3.7 AIR BLOWING

Air blowing is required before inspection , to clean the water in the
internal tubes , cause of water blast

4.3.8 INSPECTION
After mechanical cleaning is done , inspection will performed as per
inspection procedure
4.3.9 DELIVERY BUNDLE TO PLANT SITE

When the bundle are inspected and accepted, then deliver to plant
site for installation
4.3.10 INSERT TUBE BUNDLE

4.3.10.1 Ensure the scaffolding are installed and safe condition
4.3.10.2 Ensure thread (Lug) on the tube sheet in good condition
4.3.10.3 Ensure the bundle puller in good condition and tested
4.3.10.4 Ensure lifting gear are prepared properly and meet with
the capacity of lifting
4.3.10.5 Lifting plan is approved
4.3.10.6 Conduct Pre Use Inspection
If all above items are ready, then insert the bundle as per Bundle
puller Operating procedure ,
Reminder to install gasket of bundle to tUbe sheet must be installed
before bundle insert to the shell side
4.3.11 Hydrotest / Pneumatic

If the Hydrotest is required after the tubes cleaning and inspection are
completed and covers are installed, the hydrotest will be done by
other company
4.3.12 RINSTALL-CHANNEL HEAD COVER

PT. Bhumi Phala Perkasa will perform visual inspection to the covers
before installing them especially on the gasket face .
4.3.13 BOLT TIGHTENING

Below is the table of the bolt tightening Torque:
Location Size Bolt Dia Wrench Size Torque
Shell inlet 4” 150# 5/8” 1 1/16” 149
Shell outlet 8” 150# ¾” 1 ¼” 264
Tube inlet 4” 300# ¾” 1 ¼” 264
outlet

4.3.14 Remove Blind


4.5.1 Waste management
Contractor shall be follow the company regulation related to the
Waste management no. 900-PRC-EN-2324 “Waste Water
Management Procedure
4.5.2 House keeping
Routine housekeeping are required to keep safe working &
environmental friendly , especially for the water waste must be
collect to the waste collector then send to the recommended area as
per waste management procedure


5.2 Bolt Torque

Document Number:

011/HPWJ/2018
PROCEDURE OPERATING HPWJ PUMP

DOCUMENT NUMBER : 011/HPWJ/2018
DOCUMENT TITLE : PROCEDURE OPERATING HPWJ PUMP
EQUIPMENT NAME : WOMA
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
PT. BPP
by by by
REVISION SUMMARY

Page 2 of 8
1. Latar Belakang
Prosedur kerja ini berisikan langkah/panduan dalam melaksanakan pekerjaan
pengoperasian ultra high pressure kapasitas 20k Psi dan 40k Psi. Penggunaan ultra high
pressure ini bertujuan untuk memudahkan pada saat proses pembersihan sisi tube pada
heat exchanger model Shell & Tube, Air Fan Cooler, Plate Heat Exchanger maupun
Printed Heat Exchanger.
2. Lingkup
Pekerjaan ini akan diaplikasikan pada setiap unit HEX yang ada di area BP BERAU Ltd.
3. Standard Yang Digunakan

a) ASME code section V
b) ASME code section VIII Division 1 2010 edition.
c) ASME code section II Part A, B, C 2010 edition.
d) ASME code section VIII Division 1, NONMANDATORY APPENDIX HH
e) API 510 Pressure Vessel Inspection Code : Maintenance Inspection, Rating,
Repair and Alteration
f) API 660 Shell and Tube Heat Exchanger for General Refinery Services
g) API 661 Air Fan Cooler
h) Manufacture Standard NLB and WOMA
4. Informasi Penting Kesehatan, Keselamatan dan Lingkungan

1. Bahaya-bahaya umum
Potensi bahaya dari pekerjaan ini terhadap pekerja dan fasilitas:
- Area kerja mengandung H2S – Pekerja bisa terhirup H2S.
- Peralatan ultra high pressure yang menggunakan engine driven – Pekerja
dapat terkena pressure tinggi pada saat proses pembersihan.
- Area kerja terdapat binatang berbisa – Pekerja bisa tergigit.
- Area licin apabila terjadi hujan – pekerja terpeleset
2. Langkah Pencegahan
Lakukan langkah-langkah berikut ini agar pekerjaan dapat dilakukan dengan
selamat.
- Job Site inspection
- Pastikan anda dan kru dalam keadaan sehat dan fit dalam melakukan
pekerjaan ini.
- Selalu pastikan izin keselamatan kerja yang diperlukan (GPTW) telah disetujui
sebelum pekerjaan dimulai.
- Pastikan kru menggunakan PPE sesuai dengan scope pekerjaan.
- Segera lakukan SWA apabila pekerjaan yang dilakukan berbahaya untuk
diteruskan.
Pages 3 of 8
5. Peralatan Yang Digunakan
1. Ultra High Pressure WOMA
2. Flexible Lance
3. Barracuda Nozzle, Straight, Rotating
4. Foot Valve
6. Personel yang Terlibat

- 1 orang operator ultra high pressure
- Supervisor
- Helper
- Safety standby
7. Peralatan Keselamatan
Gunakan Alat Pelindung Diri (APD) yang tertera dibawah ini untuk mengurangi paparan
terhadap potensi bahaya yang mungkin timbul selama melakukan pekerjaan.
No Deskripsi Alat Pelindung Diri/Peralatan Keterangan
Keselamatan Lainnya
1 Standar Safety Hat
Safety Shoes
Safety Glasses
Pakaian Kerja & Rain coat Digunakan Selama Bekerja
Face Shield
Hand Gloves Light Duty &
Rubber
2 Khusus Digunakan pada saat menginstall
Insulating Gloves
peralatan electrical
Hepa Mask (OV/AG Gunakan pada saat tercium bau
Organic/Vapor/Acid) gas
8. Parameter & KOndisi Operasi Normal

Batasan yang
Peralatan/Proses Parameter Normal
diizinkan
Lower Explosion Limit (LEL) 0% 10%
CO 0 ppm 10 ppm
Multi Gas Detector
H2S 0 ppm 5 ppm
Oxygen 19.5%-23.5% 19.5%-23.5%
Pages 4 of 8
9. Objek Yang Di Periksa
Object pemeriksaan adalah sebagai berikut:
Pages 5 of 8
10. Pelaksanaan
No. Urutan Tugas Pekerjaan
1 Persiapan
Semua crew mempersiapkan segala hal yang berhubungan dengan pekerjaan ini
yakni toolbox meeting dan mempersiapkan tools.
Potensi Bahaya
Bahaya tersandung, terpeleset, area kerja licin/berlumpur, terdapat pipa panas
diarea kerja, terpapar H2s & CO, adanya sarang tawon, lipan, ular dan binatang
buas lainnya.
Tindakan Pencegahan & Pengendalian
Posisikan tubuh anda pada posisi aman, gunakan PPE standar,safety helmet,
safety shoes, hand gloves, safety glass, periksa kadar gas H2S dengan gas
detector, pastikan area kerja terbebas dari binatang berbisa & buas.
2 Pemeriksaan Mesin Ultra High Pressure
Sebelum melakukan pekerjaan pembersihan pastikan fuel di dalam tanki ultra high
pressure sudah cukup, aksesoris ultra high pressure seperti flexible lance, hose
Pages 6 of 8
water, foot valve dan nozzle sudah tersedia.
Potensi Bahaya
buas lainnya.
3 Menyalakan Peralatan Ultra High Pressure
Setelah semua sudah di pastikan untuk peralatan dan fuel di unit ultra high
pressure maka mesin siap di nyalakan dengan putar kunci ke arah kanan dari main
panel atau tekan tombol ON.
Pasang flexible lance lengkap dengan nozzle pada sambungan yang terdapat di
pompa plunger.
Isi tanki denga air bersih dan pasang selang air, sambungkan ke dalam tanki air
untuk proses pembersihan HEX.
Potensi Bahaya
Peralatan menggunakan installasi listrik, Bahaya tersandung, terpeleset, area kerja
licin/berlumpur, terdapat pipa panas diarea kerja, terpapar H2s & CO, adanya
sarang tawon, lipan, ular dan binatang buas lainnya.
Pastikan operator peralatan ECT Qualified Person, Posisikan tubuh anda pada
posisi aman, gunakan PPE standar,safety helmet, safety shoes, hand gloves,
safety glass, periksa kadar gas H2S dengan gas detector, pastikan area kerja
terbebas dari binatang berbisa & buas.
4 Melakukan Pekerjaan Pembersihan Secara Mekanikal
Pages 7 of 8
- Operator ultra high pressure di nyatakan siap setelah pemasangan
scaffolding, buka cover channel pada unit HEX yang akan di lakukan
pembersihan sudah selesai.
- Posisikan penempatan nozzle, flexible lance pada are tube yang akan
di lakukan pembersihan
- Pekerjaan pembersihan tube secara mekanikal dengan menggunakan

ultra high pressure di nyatakan selesai setelah di lakukan inspeksi
bersama dengan pihak Field Representative CPI dan SMBR.
Potensi Bahaya
Peralatan menggunakan tekanan tinggi, Bahaya tersandung, terpeleset, area kerja
Pages 8 of 8
Pastikan operator peralatan ultra high pressure Qualified Person, Posisikan tubuh
anda pada posisi aman, gunakan PPE standar,safety helmet, safety shoes, hand
gloves, safety glass, periksa kadar gas H2S dengan gas detector, pastikan area
kerja terbebas dari binatang berbisa & buas.
5 Mematikan Mesin Ultra High Pressure
Mesin di matikan setelah pekerjaan dinyatakan selesai dengan memutar kunci ke
arah kiri atau tombol OFF.
Lepas flexible lance beserta nozzle dari pompa plunger dan gulung dengan benar
flexible lance dan di tempatkan ke dalam tool box.
Potensi Bahaya
Peralatan menggunakan installasi listrik, Bahaya tersandung, terpeleset, area kerja
Pastikan operator peralatan Ultra High Pressure Qualified Person, Posisikan tubuh
anda pada posisi aman, gunakan PPE standar,safety helmet, safety shoes, hand
gloves, safety glass, periksa kadar gas H2S dengan gas detector, pastikan area
kerja terbebas dari binatang berbisa & buas.
11. Informasi Pengendalian Dokumen
Description Date
Approval Date
Revision No. Date Notes

1.0 20-11-2017 Newly Issued
Pages 9 of 8
Document Number:
PT. BHUMI PHALA SOP-BPP-TRP-12-

AFCST-2018
PERKASA
THREAD REPAIR PROCEDURE

DOCUMENT NUMBER : SOP-BPP-TRP-12-AFCST
DOCUMENT TITLE : THREAD REPAIR PROCEDURE
EQUIPMENT NAME : AFC & Shell and Tube
CLIENT : N/A
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
Fabricator
Rev Issue Date Prepared Checked Approved Issue Purpose Owner Signature
by by by
REVISION SUMMARY

Page 2 of 7
Table of Contents
Revision Summary ........................................................................................................................... 2
Table of Contents ............................................................................................................................. 3
1. General......................................................................................................................................... 4
2. Applicable Specification, Code & Standard ................................................................................. 4
3. Applicable Item............................................................................................................................. 4
4. Thread Repair Procedure............................................................................................................. 4
6. Acceptance Criteria ...................................................................................................................... 4
7. Documentation ............................................................................................................................. 4
Pages 3 of 4
1. GENERAL
This procedure covers minimum requirements for thread repair of sheet plugs for Air Cooled
Heat Exchanger 042-E-1010
2. APPLICABLE SPECIFICATION, CODE AND STANDARD

- ASME B1.1 – 2003.
3. APPLICABLE ITEM
- Air Cooled Heat Exchanger and Shell ana Tube
4. THREAD REPAIR PROCEDURE

4.1. Oversize Thread Repair Method
Oversize thread repair method is used when the condition of the thread is not feasible or
damaged.
4.1.1. Application
4.1.1.1. Drill out the old threads using drill machine. Using recommended drill bit (1
1/8”-12UNF to 1 1/4”-12UNF) on the broken plug sheet. The shank of the
tap also lists the recommended drill size.
4.1.1.2. Tap the hole using the Screw Thread Insert (STI) tap (hand tap).
4.2. Cleaning Thread Method/ Minor Repair
Cleaning thread method is used when there is dirt on the thread and thread still in good
condition.
4.2.1. Application
4.2.1.1. Make sure the thread is in good condition and still can be used.
4.2.1.2. Clean the thread of dirt by using the Screw Thread Insert (Hand tap)
corresponding to thread (1 1/8” – 12 UNF).
5. ACCEPTANCE CRITERIA
1. Result of the tap must match the thread to be used.
2. All thread must be free of dirt.
6. DOCUMENTATION
Result of thread repair shall be reported and verified
Pages 4 of 4
Document Number:
PT. BHUMI PHALA SOP-BPP-EXP-13-

AFCST
PERKASA
EXPAND PROCEDURE
DOCUMENT NUMBER : SOP-BPP-EXP-13-AFCST
DOCUMENT TITLE : EXPAND PROCEDURE
EQUIPMENT NAME : AFC and Shell and Tube
CLIENT : N/A
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
Fabricator
Rev Issue Date Prepared Cheked Approved Issue Purpose Owner Signature
by by by
A 09/08/2018 DYN ISSUED FOR REVIEW
REVISION SUMMARY

Page 2 of 7
Table of Contents
Revision Summary ........................................................................................................................... 2
Table of Contents ............................................................................................................................. 3
1. General......................................................................................................................................... 4
2. Applicable Specification, Code & Standard ................................................................................. 4
3. Applicable Item............................................................................................................................. 4
4. Application Of Expansion ............................................................................................................. 4
5. Tube Wall Reduction Calculation ................................................................................................. 5
6. Acceptance Criteria ...................................................................................................................... 7
7. Documentation ............................................................................................................................. 7
Pages 3 of 7
1. GENERAL
This procedure covers minimum requirements for tube expansion of Bundle Cooler for Air
Cooled Heat Exchanger 042-E-1010
2. APPLICABLE SPECIFICATION, CODE AND STANDARD

a) ASME code section VIII Division 1 2010 edition.
b) ASME code section II Part A, B, C 2010 edition.
c) ASME code section VIII Division 1, NONMANDATORY APPENDIX HH
th
d) API 661, 6 Ed Air Cooled Heat Exchanger For General Refinery
3. APPLICABLE ITEM
- Air Cooled Heat Exchanger and Shell and Tube
4. APPLICATION OF EXPANSION
4.1. Expander
4.1.1.Electrically operated expanders and accessories with torque control or pneumatically
operated expanders are also permissible if a reliable torque control is provided and
the driving air can be completely drawn.
4.1.2.Expander's tool
4.1.3.Tube end facer.
4.2. Cleaning
4.2.1.Tube
Clean the outside and inside of the tube and wipe them with a clean, white and lint
free cotton cloth before and during tubing.
4.2.2.Tubesheet
All contamination in the holes of the tubesheet such as rust, dirt, grease ; oil (etc.) to
be removed before tubing.
4.2.3.Expander Tool
Cleaning shall be done before and during the usage of tool.
4.3. Expanding Procedure

4.3.1 All tube ends and tube sheet holes shall be greased, cleaned and shall be dried and
free from contaminants
4.3.2 Parametric of expanding:
1) Tool driver Type
2) Number and length of overlapping steps
3) Speed of Rotation
4) Tool Type
5) Cage and pin length
Pages 4 of 7
6) Number of pins in the cage
7) Frequency of verifying percent wall reduction
4.3.3 Make sure the tube sheets, which have been machined as required tolerances,
special closed fit as specified in API 661 6ed table II, in accordance with relevant
drawings. The inside edges of tube sheet holes shall be free of burrs and sharp
corners to prevent cutting of tubes.
4.3.4 Cleaning shall be accomplished through the use of compressed air, power brush
with iron free type, etc.
4.3.5 The tube sheet holes and tube shall be checked for over-sizing and tolerances prior
to installation in to position. Over sizing report shall submit to client for information.
4.3.6 Align of tube sheet horizontally on the bundle to prevent relative movement in any
direction.
4.3.7 Stay tube sheet and specified arrangement in position by light rolling a few tubes
with heavy expand.
4.3.8 Insert all tubes carefully with correct protrusion at the ends as requirements as
shown on drawings.
4.3.9 Check the torque at the expander display indicator, base on input of percentage of
reduction that shown on the expander display.
5. TUBE WALL REDUCTION CALCULATION

5.1 The expansion shall be carried out by using an electric or pneumatic tube
expanding equipment.
5.2 The percentage wall reduction shall be set by adjusting the torque setting specified
minimum tolerance for 1” OD tube, and when hold measurement verifies that the
required wall reduction has been achieved the torque setting is noted and setting
fixed.
5.3 Roller expansion at inlet side to be done first. Expansion to bottom row, left to right.
Outlet/return side to be secured in position. Recheck and ensure tube protrusions of
all tubes are still within the 1.5 mm to 9 mm range. Protrusion should not exceed 3
mm. Roller expand all tubes from bottom side row, left to right.
5.4 The lubricant used for rolling shall be safe material without any effect to tubes. Lube
of tube rolling compound and its use shall be restricted to tube internal-to-expander
portion only.
5.5 The length of expansion shall be referred to drawing.
5.6 The final diameter of tube (See Table -2) of total wall thicknees and above the
tubesheet hole diameters to achieve for 100% bond. Over Expansion may cause
leaking, split or flakes tube. This percentage is calculated using the following
equation :
Pages 5 of 7
E = ( D – A ) + C + 2B%
Where :
A = Tube outside diameter (mm)
B = Tube wall thickness ( mm )
C = Tube inside diameter before expand (mm)
D = Tube hole diameter on tube sheet (mm)
E = Tube inside diameter after expand (mm)
% = Desired percent of wall reduction
Table-1. Allowable tubes wall thickness reduction for roller-expanded tubes to tubes sheet joints API 661 the
latest edition
Percentage Tube
` Tube Sheet Material
Wall Reduction
1 Carbon steel and low alloy steel 4 to 6 a

2 Stainless and high alloy steel 6 to 8 a
3 Non- ferrous 4 to 5 a
a. The upper limit may be increased by a further 2%, if approved by purchaser
• The tube shall not be over rolled. An inside tube gauge shall be used to check every
final dimension during the rolling operation.
• Check the horizontal dimensions while rolling to maintain proper measurement and
alignment. If it required being necessary to re-roll joint, it should be done lightly by
rolling several times. Heavy rolling that is likely to cause excessive deformation of
the affected tube to tube sheet material with a consequent reduction in strength and
stability of the jointed rolled.
• Dimensions of tubes must be recorded in a form for inspection and record.
Table-1. Table of Tube
TUBE OF EXPANSION TUBE MATERIAL JOINTING EXPANSION
FULL EXPANSION Tube 6% - 8%

SA 214
OD: 25.4 x THK.2.108
Pages 6 of 7
6. ACCEPTANCE CRITERIA
1. Result of expansions shall conform to Para 5.6, which applicable to selected material.
2. All tubes shall be full inspected by Inside Micrometer to check the reduction thickness.
3. Torque of heavy expand shall be inspected as per percentage of reduction at the
display of expander tools.
7. DOCUMENTATION
Result of expansion shall be reported and verified
Pages 7 of 7
Document Number:
PT. BHUMI PHALA SOP-BPP-TP-14-

AFCST
PERKASA
TUBE PLUGGING PROCEDURE

DOCUMENT NUMBER : SOP-BPP-TP-14-AFCST
EQUIPMENT NAME : AFC and Shell and Tube
CLIENT : N/A
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
Fabricator
by by by
REVISION SUMMARY

Page 2 of 7
1. Latar Belakang
Prosedur kerja ini berisikan langkah/panduan dalam melaksanakan pekerjaan tube plugging
pada HEX dengan model shell and tube dan Air Fan Cooler..
Penggunaan tube plugging ini jika ada di temukan kebocoran pada HEX model shell and tube
di antara tube sheet dan tube, pada model Air Fan Cooler di antara sisi header box dan tube
side.
2. Lingkup
Pekerjaan ini akan diaplikasikan pada setiap unit HEX yang ada di area CGS-1, CGS-3, CGS-
4, CGS-5 & CGS-10.
3. Standar Yang Digunakan

a) ASME code section V
b) ASME code section VIII Division 1 2010 edition.
c) ASME code section II Part A, B, C 2010 edition.
d) ASME code section VIII Division 1, NONMANDATORY APPENDIX HH
e) ASME PCC-2 2011
f) API 510 Pressure Vessel Inspection Code : Maintenance Inspection, Rating, Repair
and Alteration
g) API 660 Shell and Tube Heat Exchanger for General Refinery Services
h) API 661 Air Fan Cooler
4. Informasi Penting Kesehatan, Keselamatan dan Lingkungan

- Peralatan ultra high pressure yang menggunakan engine driven – Pekerja dapat
terkena pressure tinggi pada saat proses pembersihan.
Lakukan langkah-langkah berikut ini agar pekerjaan dapat dilakukan dengan selamat.
- Pastikan anda dan kru dalam keadaan sehat dan fit dalam melakukan pekerjaan ini.
- Selalu pastikan izin kerja yang diperlukan (GPTW) telah disetujui sebelum pekerjaan
dimulai.
- Segera lakukan SWA apabila pekerjaan yang dilakukan berbahaya untuk diteruskan.
5. Peralatan Yang Digunakan
Pages 3 of 7
1. Hammer Bronze
2. Material Tappered Plug
6. Personel yang Terlibat

- 1 orang Teknisi dan 1 orang Machinist
- Supervisor
- Helper
- Safety standby
7. Peralatan Keselamatan
Keselamatan Lainnya
Safety Shoes
Safety Glasses
Digunakan Selama Bekerja
Pakaian Kerja & Rain coat
Face Shield
Hand Gloves Light Duty
2 Khusus N/A
N/A
8. Parameter & Kondisi Operasi Normal

Batasan yang
diizinkan
CO 0 ppm 10 ppm
Multi Gas Detector
H2S 0 ppm 5 ppm
Oxygen 19.5%-23.5% 19.5%-23.5%
Pages 4 of 7
9. Objek Yang Di Periksa
Object pemeriksaan adalah sebagai berikut:
Spesikasi Tube HEX (contoh)
Equipment Name
Tube Thickness Tube Total
OD
No Location Material (mm) length Tube
(mm)
Spect (mm)
Tag / Item No
HEX
1 CGS-1 SA 214 19.05 2.11 6090 534x2
A/B/C/D/E/F/G/H
HEX
2 SA 214 19.05 2.11 6090 534x2
A/C/D/E/F/G/H/J CGS-3
/K/L/M
HEX SA 214 19.05 2.11 6090 534x2
3 CGS-4
A/B/C/D/E/F/G/H
HEX
1/2/3/4/5/6/7/8 SA 214 19.05 2.11 6090 534x2
4 CGS-5
/9/10/11/12/13/14
/15/16/17/18/19/20
HEX A213-TP
19.05 1.65 6090 926
5 1/2/3/4/5/6/7 CGS-10 316L
10. Pelaksanaan
1 Persiapan
Semua crew mempersiapkan segala hal yang berhubungan dengan pekerjaan ini
yakni toolbox meeting dan mempersiapkan tools.
Potensi Bahaya
buas lainnya.
2 Persiapan Raw Material dan Machining
Material round bar di persiapkan oleh team PT. Bhumi Phala Perkasa dengan
spesifikasi atau grade material yang sudah di setujui oleh pihak CPI dan
selanjutnya raw material bisa di proses machining untuk di buatkan tapered plug.
Pages 5 of 7
Potensi Bahaya
Bahaya tersandung, terpeleset dan area kerja licin.
safety shoes, hand gloves, safety glass.
3 Persiapan Peralatan
Sebelum melakukan pekerjaan tube plugging agar di pastikan semua peralatan
seperti bronze hammer material plug sudah tersedia dengan jumlah yang tube
yang akan di lakukan proses penutupan.
Potensi Bahaya
buas lainnya.
4 Pemasangan Plug di Tube HEX
Pemasangan tapered plug di tube HEX berdasarkan dari hasil temuan atau
inspeksi pada tube yang di temukan bocor.
Langkah pemasangan seperti tempatkan tapered plug yang telah di marking oleh
team inspection dan kemudian tapered plug di pukul dengan menggunakan bronze
hammer.
Pastikan tapered plug tersebut pemasangannya sudah benar dan tight.
Pages 6 of 7
Potensi Bahaya
Finger injury, Bahaya tersandung, terpeleset, area kerja licin/berlumpur, terdapat
pipa panas diarea kerja, terpapar H2s & CO, adanya sarang tawon, lipan, ular dan
binatang buas lainnya.
5 Melakukan Pekerjaan Visual Inspeksi Terhadap Tube Yang Di Plug
Pekerjaan visual inspeksi di lakukan setelah pemasangan tapered plug di tube
sudah sesuai dan benar.
Pastikan tidak ada celah atau longgar pada tapered plug.
Lakukan joint inspeksi dengan filed representative dari pihak CPI dan SMBR.
Potensi Bahaya
buas lainnya.
Pages 7 of 7
11. Informasi Pengendalian Dokumen
Description Date
Approval Date

Pages 8 of 7
Document Number:
PT. BHUMI PHALA SOP-BPP-EITB-15-ST
PERKASA
EXTRACTION AND INSTALL TUBE BUNDLE PROCEDURE

DOCUMENT NUMBER : SOP-BPP-EITB-15-ST
EQUIPMENT NAME : Shell and Tube
CLIENT : N/A
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
Fabricator
by by by
REVISION SUMMARY

Page 2 of 7
I. Tujuan
Prosedur Kerja ini berisi langkah langkah/panduan untuk melaksanakan pekerjaan
mengeluarkan dan memasang HEX tube bundle dengan tube bundle extractor.
II. Lingkup
Prosedur ini berlaku untuk semua pekerjaan menggunakan tube bundle extractor disetiap
HEX yang berada di CGS-1/CGS-3/CGS-4/CGS-5/CGS-10.
III. Informasi Penting Kesehatan, Keselamatan dan Lingkungan

a. Bahaya-bahaya umum
- Area licin apabila terjadi hujan – pekerja terpeleset.
b. Langkah Pencegahan
selamat
- Pastikan anda dan kru dalam keadaan sehat dan fit dalam melakukan pekerjaan
ini.
- Selalu pastikanizin kerja yang diperlukan (GPTW) telah disetujui
sebelumpekerjaan dimulai.
diteruskan.
IV. Peralatan Yang Digunakan
Peralatan dan perlengkapan yang digunakan untuk melaksanakan pekerjaan vacuum test:
- Tube bundle extractor
- Mobile Crane cap.40 T
- FOCO truck
- Wire/webbing sling
- Shackle
- Basket untuk tube bundle
V. Personel yang Terlibat

- Operator tube bundle extractor
- Operator crane
- Operator FOCO truck
- Rigger
Pages 3 of 7
- Helper
- Safety standby
VI. Peralatan Keselamatan

Keselamatan Lainnya
Safety Shoes
Safety Glasses
Pakaian Kerja
2 Khusus - -
VII. Parameter & KOndisi Operasi Normal

Batasan yang
diizinkan
CO 0 ppm 10 ppm
Multi Gas Detector
H2S 0 ppm 5 ppm
Oxygen 19.5%-23.5% 19.5%-23.5%
VIII. Uraian Pekerjaan

A Extracting Tube Bundle (Mengeluarkan Tube Bundle)
1 Persiapan
Pastikan semua crew telah menyiapkan semua hal yang berhubungan dengan
pekerjaan extracting tube bundle, lakukan toolbox meeting dan persiapan tools.
Potensi Bahaya
Bahaya tersandung, terpeleset, area kerja licin/berlumpur, terdapat pipa panas diarea
kerja, terpapar H2s & CO, adanya sarang tawon, lipan, ular dan binatang buas
lainnya.
Posisikan tubuh anda pada posisi aman, gunakan PPE standar,safety helmet, safety
Pages 4 of 7
shoes, hand gloves, safety glass, periksa kadar gas H2S dengan gas detector,
pastikan area kerja terbebas dari binatang berbisa & buas.
2 Posisikan Peralatan
Sebelum memulai pekerjaan, posisikan semua peralatan seperti FOCO truck,
Mobile Crane dan Tube Bundle Extractor yang akan digunakan sesuai
perencanaan.
Potensi Bahaya
Pihak yang tidak berkepentingan memasuki area kerja, Mobile Crane & FOCO
truck yang mundur/maju, area kerja licin/berlumpur, terdapat pipa panas di area
kerja, terpapar H2S & CO, adanya sarang tawon, lipan, ular dan binatang buas
lainnya.
Baricade area kerja sebelum memulai pekerjaan, perhatikan langkah dan posisi
tubuh, posisikan tubuh anda pada posisi aman, gunakan PPE standar, safety
helmet, safety shoes, hand gloves, safety glass, periksa kadar gas H2S dengan gas
3 Membuka Cover & Head Cover Channel
- Membuka cover & head cover channel dilakukan stelah pekerjaan chemical
cleaning selesai dilakukan.
- Pelepasan cover dan head cover channel dari shell dibantu dengan FOCO truck
untuk proses pengangkatannya.
- Letakkan cover & head cover channel di tempat yang aman yang telah
ditentukan.
Potensi Bahaya
Pihak yang tidak berkepentingan memasuki area kerja, komunikasi yang buruk antara
rigger dan operator FOCO truk, Bahaya tersandung, terpeleset, area kerja
licin/berlumpur, terdapat pipa panas diarea kerja, terpapar H2S& CO, adanya sarang
tawon, lipan, ular dan binatang buas lainnya.
Baricade area kerja sebelum memulai pekerjaan, membuat komunikasi yang baik
antara rigger dengan operator FOCO truk, posisikan tubuh anda pada posisi aman,
gunakan PPE standar,safety helmet, safety shoes, hand gloves, safety glass,
periksa kadar gas H2S dengan gas detector, pastikan area kerja terbebas dari
binatang berbisa & buas.
4 Persiapan Penarikan Tube Bundle
- Mempersiapkan penampungan/lantai kerja yang mampu
menampung/menahan liquid yang terdapat dalam shell agar tidak
Pages 5 of 7
langsung terkena tanah pada saat pelepasan tube bundle.
- Posisikan crane dengan perhitungan yang matang agar kapasitas angkat
dari crane bisa memenuhi persyaratan dengan beban yang akan diangkat.
- Posisikan tube bundle extractor sejajar dengan shell dengan bantuan
mobile crane dengan posisi pengait tube bundle extractor berada dibagian
belakang shell flange sebagai penahan.
Potensi Bahaya
rigger dan operator FOCO truk, Bahaya tersandung, terpeleset, area kerja
licin/berlumpur, terdapat pipa panas diarea kerja, terpapar H2S& CO, adanya sarang
tawon, lipan, ular dan binatang buas lainnya.
antara rigger dengan operator FOCO truk, posisikan tubuh anda pada posisi aman,
gunakan PPE standar,safety helmet, safety shoes, hand gloves, safety glass, periksa
kadar gas H2S dengan gas detector, pastikan area kerja terbebas dari binatang
berbisa & buas.
5 Penarikan Tube Bundle
- Tarik keluar tube bundle perlahan dengan bantuan wire sling yang dikaitkan
dengan hydraulic extractor, setelah dirasa cukup lepaskan wire sling dan kaitkan
hydraulic extractor dengan tube sheet, kemudian tarik perlahan sampai tube
bundle keluar dari shell dan dengan mengatur keseimbangan tube bundle
extractor.
Pages 6 of 7
Tube bundle yang ditarik menggunakan wire sling
Tube bundle ditarik dengan hydraulic extractor
Tube bundle ditarik keluar shell

Potensi Bahaya
operator tube bundle extractor dengan signalman, tube bundle Bahaya tersandung,
terpeleset, area kerja licin/berlumpur, terdapat pipa panas diarea kerja, terpapar H2S&
CO, adanya sarang tawon, lipan, ular dan binatang buas lainnya.
Pages 7 of 7
antara operator tube bundle extractor dengan signalman, posisikan tubuh anda
pada posisi aman, gunakan PPE standar,safety helmet, safety shoes, hand gloves,
safety glass, periksa kadar gas H2S dengan gas detector, pastikan area kerja
terbebas dari binatang berbisa & buas.
6 Pengangkatan Tube Bundle Kedalam Basket
Angkat tube bundle dari tube bundle extractor ke dalam basket yang sudah
disiapkan dengan crane.
Potensi Bahaya
rigger dan operator crane, Bahaya tersandung, terpeleset, area kerja licin/berlumpur,
terdapat pipa panas diarea kerja, terpapar H2S& CO, adanya sarang tawon, lipan,
ular dan binatang buas lainnya.
antara rigger dengan operator crane, posisikan tubuh anda pada posisi aman,
7 Pengangkatan Basket Tube Bundle ke FOCO Truck
Basket tube bundle diangkat menggunakan crane ke FOCO truk untuk kemudian
dimobilisasi ke area cleaning CGS-3.
Potensi Bahaya
8 Housekeeping
Semua crew melakukan pembersihan area kerja setelah pekerjaan telah selesai
dilakukan
Pages 8 of 7
Potensi Bahaya
kerja, terpapar H2S& CO, adanya sarang tawon, lipan, ular dan binatang buas
lainnya.
Tindakan Pencegahan
posisikan tubuh anda pada posisi aman, gunakan PPE standar,safety helmet, safety
B Install Tube Bundle (Memasang Tube Bundle)
1 Persiapan
Pastikan semua crew telah menyiapkan semua hal yang berhubungan dengan
pekerjaan install tube bundle, lakukan toolbox meeting dan persiapan tools.
Potensi Bahaya
lainnya.
2 Posisikan Peralatan
Sebelum memulai pekerjaan, posisikan semua peralatan seperti FOCO truck,
Mobile Crane dan Tube Bundle Extractor yang akan digunakan sesuai
perencanaan.
Potensi Bahaya
Pihak yang tidak berkepentingan memasuki area kerja, Mobile Crane & FOCO
truck yang mundur/maju, area kerja licin/berlumpur, terdapat pipa panas di area
kerja, terpapar H2S & CO, adanya sarang tawon, lipan, ular dan binatang buas
lainnya.
Baricade area kerja sebelum memulai pekerjaan, perhatikan langkah dan posisi
tubuh, posisikan tubuh anda pada posisi aman, gunakan PPE standar, safety
helmet, safety shoes, hand gloves, safety glass, periksa kadar gas H2S dengan gas
3 Pengangkatan Tube Bundle Ke Tube Bundle Extractor
Lakukan pengangkatan tube bundle dari basket ke tube bundle extractor, pastikan
Pages 9 of 7
posisi tube bundle pada posisi yang baik pada tube bundle extractor.
Potensi Bahaya
4 Mengatur Posisi Tube Bundle Extractor
Set up tube bundle extractor dan atur keseimbangan tube bundle extractor dengan
menggeser hanger puller. Pasang dan posisikan puller unit ke shell dengan dua buah
wire sling pengikat dengan kokoh.
Potensi Bahaya
berbisa & buas.
5 Memasukan Tube Bundle ke Dalam Shell
Dorong tube bundle dengan hydraulic extractor kedalam shell secara perlahan-lahan
hingga tube bundle bisa masuk dan duduk dengan sempurna.
Potensi Bahaya
Pages 10 of 7
berbisa & buas.
6 Melepas Tube Bundle Extractor Dari Shell
Sebelum melepas tube bundle extractor dari shell atur keseimbangan unit terlebih
dahulu kemudian lepaskan wire sling pengikat, dan tube bundle extractor dapat
diangkat.
Potensi Bahaya
7 Install Cover & Head Channel
Pemasangan cover &Head channel dilakukan setelah tube bundle terinstall dengan
benar. Lakukan pemasangan cover & head channel dengan bantuan crane.
Potensi Bahaya
8 Housekeeping
Pages 11 of 7
Semua crew melakukan pembersihan area kerja setalah pekerjaan telah selesai
dilakukan.
Potensi Bahaya
kerja, terpapar H2S& CO, adanya sarang tawon, lipan, ular dan binatang buas
lainnya.
Tindakan Pencegahan
posisikan tubuh anda pada posisi aman, gunakan PPE standar,safety helmet, safety
IX. Informasi Pengendalian Dokumen

Description Date
Approval Date
Pages 12 of 7
Document Number:
PT. BHUMI PHALA SOP-BPP-VT-16-ST
PERKASA
VACUUM TEST PROCEDURE

DOCUMENT NUMBER : SOP-BPP-VT-16-ST
EQUIPMENT NAME : Shell and Tube
CLIENT : N/A
REVISION :A
APPROVAL SHEET
A – Approved
Date :
(……………………..) (……………………..)
Revision Status
Fabricator
by by by
A 09/08/2018 ASP JS DYN ISSUED FOR REVIEW
REVISION SUMMARY

Page 2 of 7
I. Tujuan
Prosedur kerja ini berisikan langkah/panduan dan menjadi panduan dalam
melaksanakan pekerjaan uji kebocoran Vacuum Test shell tube heat exchanger. Vacuum
test bertujuan untuk mendeteksi kebocoran pada tube dengan cara membuat udara
didalam tube yang akan diuji menjadi hampa udara, kebocoran akan terdeteksi lewat alat
ukur yang terpasang pada test gun.
II. Lingkup
Pekerjaan ini akan diaplikasikan pada setiap unit Heat Exchanger.
III. Standard yang digunakan

1. ASME Code Sec. VIII div.1. 2004 edition. Addenda 2005
2. TEMA
3. BPP’s Safety manual
IV. Informasi Penting Kesehatan, Keselamatan dan Lingkungan

selamat
- Pastikan anda dan kru dalam keadaan sehat dan fit dalam melakukan pekerjaan
ini.
- Selalu pastikan izin kerja yang diperlukan (GPTW) telah disetujui
sebelumpekerjaan dimulai.
diteruskan.
V. Peralatan Yang Digunakan

Peralatan yang digunakan untuk melaksanakan pekerjaan vacuum test:
1. Test Gun
2. T-handle
3. Seal Set
4. Air instrument
Pages 3 of 9
5. Hose Angin
VI. Personel yang Terlibat

- Dua orang operator vacuumtest gun
- QC
- Helper
- Safety standby
VII. Peralatan Keselamatan


Keselamatan Lainnya
Safety Shoes
Safety Glasses
Pakaian Kerja
2 Khusus - -
VIII. Parameter & Kondisi Operasi Normal

Batasan yang
diizinkan
CO 0 ppm 10 ppm
Multi Gas Detector
H2S 0 ppm 5 ppm
Oxygen 19.5%-23.5% 19.5%-23.5%
IX. Uraian Kerja

A. Persiapan
1. Pastikan crew telah mempersiapkan semua hal yang berhubungan dengan pekerjaan
vacuum test yakni toolbox meeting & mempersiapkan tools
Pages 4 of 9
Potensi Bahaya
lainnya.

2. Pastikan tube yang akan diuji sudah bersih, jika tube tidak bersih saat operasi
pengujian akan berakibat rusaknya test gun bahakan dapat melukai operator karena
tube yang masih terdapat kotoran.
Potensi Bahaya
lainnya.

shoes, hand gloves, safety glass, periksa kadar gas H2S dengan gas detector, pastikan
area kerja terbebas dari binatang berbisa & buas.
3. Pilih dan pastikan ukuran seal dan nozzle yang terpasang sudah tepat untuk dimensi
tube yang akan diuji. Pasang seal dan nozzle pada Vacuum test gun dan T handle.
Pages 5 of 9
Potensi Bahaya
lainnya.

4. Memasang selang angin pada vacuum test gun untuk dihubungkan dengan air
instrument yang terdapat diarea kerja. Test gun akan dioperasikan dengan suplai
udara antara 40 sampai 130 psi.
Potensi Bahaya
lainnya.

B. Pelaksanaan
1 Plugging Both Ends of The Tube
Plug kedua ujung tube dengan T handle dan Vcuum Test Gun.
Pages 6 of 9
Potensi Bahaya
lainnya.
2 Membuka Valve Vacuum
Buka valve vacuum test gun dengan memutarnya kekanan untuk mulai menghasilkan
vakum, sampai vacuum level pada gauge berhenti. (Vacuum pressure ditentukan 5-7
Psi).
Potensi Bahaya
lainnya.

3 Mengamati Vacuum Gauge
Tutup valve vacuum test gun dengan memutarnya kekiri dan kemudian amati
Pages 7 of 9
vacuum gauge pada vacuum test gun. Setiap kebocoran pada tube akan
diidentifikasi dengan penurunan pembacaan pada vacuum gauge.
Potensi Bahaya
lainnya.
4 Pengujian Tube yang Lain
Jika tidak ada tube yang bocor, lepaskan vacuum test gun dan T-handle plug
dari ujung tube, masukan kembali ke ujung tube yang akan dilakukan
pengujian berikutnya. Tandai tube yang terdeteksi bocor untuk diperbaiki.
Potensi Bahaya
lainnya.
5 Housekeeping
Lakukan pembersihan area kerja setelah semua pekerjaan telah selesai dilakukan.
Potensi Bahaya
Pages 8 of 9
lainnya.

X. Informasi Pengendalian Dokumen

Description Date
Approval Date
Pages 9 of 9

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Document Number:

PT. BHUMI PHALA PERKASA

PROCEDURE MECHANICAL CLEANING AIR FAN COOLER

REV DATE DESCRIPTION OF CHANGE

Doc. No. 001/AFC/2018 Rev (A) Page 2 of 8

Doc. No. 001/AFC/2018 Rev (A) Pages 3 of 8

2. APPLICABLE SPECIFICATION, CODE, STANDARD and OTHER REFERENCES

Doc. No. 001/AFC/2018 Rev (A) Pages 4 of 8

4.2 Draining & Free gas

4.3.1.2 Permit To Work , Lifting Plan and ITP

Doc. No. 001/AFC/2018 Rev (A) Pages 5 of 8

4.3.3 OPEN HEXAGONAL PLUG

4.3.4 MECHANICAL CLEANING WITH HIGH PRESSURE PUMP

4.3.6 RE-INSTALL HEXAGONAL PLUG

4.3.7 Bolt Tightening Plug Sheet and Nozzle

Nozzle Size Bolt Dia Wrench Size Torque NM

Doc. No. 001/AFC/2018 Rev (A) Pages 6 of 8

Size Bolt Dia Wrench Size Torque NM

4.4 Purging & Test Leak

4.5 Waste Management & House Keeping

5. Attachment & Table

Doc. No. 001/AFC/2018 Rev (A) Pages 7 of 8

Doc. No. 001/AFC/2018 Rev (A) Pages 8 of 8

PT. BHUMI PHALA PERKASA

PROCEDURE MECHANICAL CLEANING AIR FAN COOLER

REV DATE DESCRIPTION OF CHANGE

Doc. No. 001/AFC/2018 Rev (A) Page 2 of 8

Doc. No. 001/AFC/2018 Rev (A) Pages 3 of 8

2. APPLICABLE SPECIFICATION, CODE, STANDARD and OTHER REFERENCES

Doc. No. 001/AFC/2018 Rev (A) Pages 4 of 8

4.2 Draining & Free gas

4.3.1.2 Permit To Work , Lifting Plan and ITP

Doc. No. 001/AFC/2018 Rev (A) Pages 5 of 8

4.3.3 OPEN HEXAGONAL PLUG

4.3.4 MECHANICAL CLEANING WITH HIGH PRESSURE PUMP

4.3.6 RE-INSTALL HEXAGONAL PLUG

4.3.7 Bolt Tightening Plug Sheet and Nozzle

Nozzle Size Bolt Dia Wrench Size Torque NM

Doc. No. 001/AFC/2018 Rev (A) Pages 6 of 8

Size Bolt Dia Wrench Size Torque NM

4.4 Purging & Test Leak

4.5 Waste Management & House Keeping

5. Attachment & Table

Doc. No. 001/AFC/2018 Rev (A) Pages 7 of 8

Doc. No. 001/AFC/2018 Rev (A) Pages 8 of 8

PT. BHUMI PHALA PERKASA

PROCEDURE MECHANICAL CLEANING AIR FAN COOLER

REV DATE DESCRIPTION OF CHANGE

Doc. No. 001/AFC/2018 Rev (A) Page 2 of 8

Doc. No. 001/AFC/2018 Rev (A) Pages 3 of 8

2. APPLICABLE SPECIFICATION, CODE, STANDARD and OTHER REFERENCES

Doc. No. 001/AFC/2018 Rev (A) Pages 4 of 8

4.2 Draining & Free gas

4.3.1.2 Permit To Work , Lifting Plan and ITP

Doc. No. 001/AFC/2018 Rev (A) Pages 5 of 8

4.3.3 OPEN HEXAGONAL PLUG

4.3.4 MECHANICAL CLEANING WITH HIGH PRESSURE PUMP

4.3.6 RE-INSTALL HEXAGONAL PLUG

4.3.7 Bolt Tightening Plug Sheet and Nozzle

Nozzle Size Bolt Dia Wrench Size Torque NM

Doc. No. 001/AFC/2018 Rev (A) Pages 6 of 8

Size Bolt Dia Wrench Size Torque NM

4.4 Purging & Test Leak