TURNAROUND MAIN MECHANICAL &

STS EDAC ENGINEERING SDN BHD MAINTENANCE MECHANICAL STATIC (TA4MS)

Document No:STS / CLIENT / 2020 / TP001 / WP01 Revision: 00 Date: 09 March 2020

SPECIFIC REPAIR PROCEDURE

PETRONAS REFINERY & PETRO CHEMICAL CORPORATION SDN.BHD .

UTILITIES & FACILITIES

FOR APPROVAL √

FOR REVIEW

FOR CONTRUCTION

Name / Designation Signature Date Rev

Originator Mohd As Shahiddin Jafri
(STS EDAC) QAQC
09 Mac 2020

Reviewed
00
(PRPC UF)
Approved
(PRPC UF)
 TURNAROUND MAIN MECHANICAL & MAINTENANCE
MECHANICAL STATIC (TA4MS)
STS EDAC ENGINEERING SDN BHD

Document No:STS / CLIENT / 2020 / TP001 / WP01 Revision: 00 Date: 09 Mac 2020

TABLE OF CONTENTS

1. SCOPE

2. REFERENCE

3. SPECIFICATION

4. WELD SUMMARY

5. PREPARATION

6. FABRICATION PROCEDURE

7. RECORD & DOCUMENTATION

8. SAFETY

9. ATTACHMENT
 TURNAROUND MAIN MECHANICAL & MAINTENANCE
MECHANICAL STATIC (TA4MS)
STS EDAC ENGINEERING SDN BHD

Document No:STS / CLIENT / 2020 / TP001 / WP01 Revision: 00 Date: 09 Mac 2020

1. Scope
This procedure provide To replace with a new gate valve as per original specification 4200-P-001E.

2. Reference
2.1 ASME B 31.3 Process Piping
2.2 ASME B 16.5 Pipe Flanges and Flange Fittings.
2.3 ASME IX, 2015 Ed Welding and Brazing Qualification
2.4 ASME V, 2015 Ed. Non Destructive Examination
2.5 PTS 12.30.05 Shop & Field Fabrication Of Piping
2.6 PTS 15.12.01 Welding For Chemical Oil And Gas Industries
2.7 HBFE-4200M00150-00001-32 Isometric Drawing Number
2.8 STS / CLIENT / 2020 / TP001 / WP01 Repair Procedure

3. Specification
3.1 EQUIPMENT No : 4200-P-001E (Gate CS Body 316SS/ST6 Trim FB RATE: 1500# )
3.2 Line No: 50-HBFW-4200-00001-9C139DA-H
3.3 NPS: 50mm
3.4 THK: SCH80
4. Preparation
4.1 Site visit prior to confirming dimension
4.2 Prior to start work at site, STS shall apply Permit to Work (PTW) from Area Owner for scaffolding, lifting and pipe
installation.
4.3 Submit Welding Inspection Control Sheet (WICS) together with WPS,WQT & Specific Repair Procedure to SRAIM
UF for review and approval
4.4 Identify all the areas on flange for weld build up and repairs.
4.5 Clean up the surfaces by power brushing (or wire brushing for areas non-accessed by power tool).
4.6 All rusts and scales shall be removed.
4.7 Perform Dye Penetrant Test after completed smooth grinding.
4.8 To grind off the whole weldment and produce new seal weld to the original geometry.
4.9 Proceed with welding on area to be repaired. Perform Dye Penetrant Test after completed welding.
5. Repair Procedures
5.1 Welding Consumable
5.1.1 Welding to be carried out as per approved repair procedure by qualified welder.
5.1.2 Acceptance criteria ASME B31.3.
5.1.3 Process : GTAW .Filler : ER70S-G
5.1.4 WPS No: STS/WPS/(M)001 (Single V)
5.1.5 Production welding shall comply to all essential & supplementary variables as per approved WPS.
 TURNAROUND MAIN MECHANICAL & MAINTENANCE
MECHANICAL STATIC (TA4MS)
STS EDAC ENGINEERING SDN BHD

Document No:STS / CLIENT / 2020 / TP001 / WP01 Revision: 00 Date: 09 Mac 2020

5.2 Visual Inspection

5.2.1 Shall be performed after completed welding work.
5.2.2 See Table 341.3.2, ASME B31.3 for visual inspection acceptance criteria.
5.2.3 Machining or grinding methods shall be used. After cutting, cut surface shall be machined or ground
smooth.
5.3 Non Destructive Testing
5.3.1 Inspection and testing shall be carried out according to Inspection Test Plan (ITP).
5.3.2 Acceptance criteria as per Table 341.3.2, ASME B31.3.
5.3.3 100% visual examination on butt welded connection.
5.3.4 100% surface examination (DPI/MPI)
5.3.5 If the result of NDT is unacceptable, remove the defect by grinding, repair and carry out NDT again.
5.4 Safety
5.4.1 Safe Operating Procedure For Grinding work
5.4.2 Stand-by fire extinguishers, fire water and a signage at the area of works.
5.4.3 Use proper tools, barricaded area, fire blanket and wear a proper PPE especially face shield and glove.
5.4.4 Supervisor / foreman must ensure that the work can only be started when no more hazardous gases
detected around the work and covered by approved permit.
5.4.5 Welding machine, gen-set, electrical power hand tools, torches, hoses and other electrical & fire producing
equipment must be checked and safe to use.
5.4.6 Welders and his assistant must wear a complete PPE.
5.4.7 Welders and his assistant must handle carefully the compressed gas cylinders.
5.4.8 When leaving the work area, turn-off the gas and all other electrical equipment.

5.5 Record & Documentation

5.5.1 After completion fabrication & final acceptance of the repair work an inspection shall be made. The
Contractor's QAQC inspectors and the third party inspector / SRAIM UF representative shall both be
represented and they shall sign an agreed inspection report.
 TURNAROUND MAIN MECHANICAL & MAINTENANCE
MECHANICAL STATIC (TA4MS)
STS EDAC ENGINEERING SDN BHD

Document No:STS / CLIENT / 2020 / TP001 / WP01 Revision: 00 Date: 09 Mac 2020

6. Sketch
a. Clean up the surfaces by power brushing (or wire brushing for areas non-accessed by power tool).
b. All rusts and scales shall be removed.
c. Perform Dye Penetrant Test after completed smooth grinding.
d. Carry out grinding to remove weld metal on the flange.

5.54mm

Figure 1: Joint Preparation GTAW welding process