MS For Heat Exchangers

OMEGA TRADERS &
ENGINEERING SERVICE
PROJECT :
CLIENT :
CONTRACT No :
MAIN CONTRACTOR :
AIP PROJECT :
TITLE:
METHOD STATEMENT FOR INTERNALL INSPECTION & SERVICING OF HEAT
EXCHANGERS
Doc. No:
Prepared By Approved By Approved By Client

Rev Date Description
DE CM
Area Contract Management
Sub Area Quality Management Omega Traders &

Sub Doc Type Method Statement
Engineering Service
Area Facility Originator Doc Sequence
Method Statement for Internal Code Code Code
Discipline
Type No.
Sheet
Title / Description Inspection & Servicing of Heat
Exchangers
OMEGA TRADERS & ENGINEERING SERVICE
Method Statement for Internal Inspection & Servicing of Heat
Exchangers
INDEX
1. PURPOSE
2. WORK PERMIT REQUIRED
3. SAFETY
4. QA/QC
5. PRE-SHUTDOWN/PREPARATORY WORK
6. BLINDING, INSPECTION, MAINTENANCE, CLEANING & BOX-UP
7. HOUSEKEEPING
8. REFERENCE DOCUMENTS
Document No. Revision No. Page No.

Page 2 of 6
Exchangers
1. PURPOSE:
The purpose of this method statement is to describe execution procedure for Inspection and Maintenance
of Heat Exchanger as per scope.
2. WORK PERMIT REQUIRED
2.1 Cold Work Permit(Main Permit) 
2.2 Confined Space Entry Certificate 
2.3 Gas Test Certificate 
2.4 Hot Work Category 1 
3. SAFETY
1. All the workforce shall have basic PPE like hard hat with chin strap, safety glasses, coverall with long
sleeves, safety shoes, H2S mask, H2S personal gas detectors and ear plugs (other PPE as required
to be worn as per job requirement).
2. A valid work permit for the job to be carried out shall be obtained.
3. Approved HIRA shall be attached with work permit.
4. HIRA discussion and toolbox talk on the specific job to be carried out.
5. Follow emergency procedure incase of emergency alarm at the plant. This procedure should be
available at the work location, indicating the escape route, emergency assembly point, emergency
call out numbers etc.
6. Follow Gasco emergency plan (Facility Response Plan).
7. All incidents and accidents shall be reported to Gasco Operations/HSE immediately.
8. Return permit at the end of shift or on completion of the work to PCF GASCO.
9. Sign and close work permit upon completion of job.
10. Ensure proper housekeeping at all times of the activities and avoid any tripping hazards/ blocking of
emergency access points.
11. Scaffolding supervisor should inspect all scaffolding and he shall put Scaffolding Tag on it when
found satisfactory with date and time/removal.
12. No scaffolding should be used that doesn’t bear a Green Tag signed by Certified Scaffolding
Inspector.
13. Any modification of scaffolding shall be recertified.
14. Separate PTW shall be used for scaffolding.
4. QA/QC
1. TES QA/QC shall prepare and get approved the Inspection and Test Plan (ITP).
2. TES QA/QC to ensure all the inspection to be done as per the ITP and scope.
3. Where required as Gasco hold point, TES QA/QC to ensure activity to proceed after Gasco
inspection and clearance.
4. TES QA/QC to submit all the signed ITP’s, inspection report and box-up certificates as Dossier after
completion and handing over of equipment.
5. Index for QC dossier shall be attached as below.
i. Scope of work.

Page 3 of 6
Exchangers
ii. Equipment Drawing.

iii. P & ID
iv. GA Drawing.
v. Signed ITP.
vi. Preliminary Inspection.
vii. Detailed Visual Inspection.
viii. NDT Report.
ix. Repaired area Inspection, IWS’s Inspection Pack ( If Required)
x. Hydro test Report (If required).
xi. Box-up certificate.
xii. WPS & Material certificates using in repair & replacement activities.
5. PRE-SHUTDOWN/PREPARATORY WORKS
1. TES Supervisor shall arrange the scaffolding material, blinds, temporary and permanent gaskets near
the Heat Exchanger.
2. TES Supervisor shall ensure that all blinding points are tagged as per the blind lists approved by the
Gasco.
3. TES subcontractor shall build external scaffolding for all the blinding points and man way’s if no
access. (Refer approved method statement/procedure for scaffolding )
4. Obtain permit for removal of insulation from the flanges. Remove insulation from all tagged locations
for blinding. Use dust masks while handling insulation in addition to the already identified PPE’s
above.
5. Support Gasco operations to lay down nitrogen hoses for the complete loop.
6. Carry out Hot bolting if required with operation clearance
6. BLINDING, INSPECTION, MAINTENANCE & CLEANING:

Blinding of Heat Exchangers:-
Upon receiving the work permit shell inlet/ outlet and tube side inlet/outlet shall be blinded off as per blind
list/P&ID's and operation requirement. All the standard blinds shall be used. Tube side shall be blinded off
somewhere after the channel nozzles to facilitate for the removal of channel head. Site Supervisor shall
ensure that these blinds/spades shall be used during the hydro testing at the required pressure.
As the unit is under Nitrogen purging alternate bolts can be removed subject to Operations approval.
Opening of Heat Exchanger

As the unit is declared gas free by GASCO operations and ready for maintenance activities, the supervisor
shall get the work permit from the GASCO operations for the removal of channel cover. The channel cover shall
be removed by using appropriate crane and certified lifting tackles and shall be placed on ground on wooden
pallets for further cleaning and inspection activities as per scope of work. After the removal of channel cover the
exchanger shall be offered for initial inspection by GASCO. All the removed items shall be kept separately on
the wooden blocks! planks to avoid any possible damages to their gasket surfaces. A separate cleaning
crew shall be deployed for of channel cover welding seams and nozzles by power brush and shall be offered
for final inspection. All the gasketted surfaces shall be cleaned and made ready for reinstallation.
High Pressure Water Jetting

An independent crew shall be deployed for the high pressure water jetting and all the necessary
HSE requirements to be fulfilled and approved by GASCO HSE department. Once the external hydro blasting
is completed the bundle will be shifted to the next bay for internal tube cleaning using the tube lancing
machines. The bundle positioned for internal tube cleaning shall be slightly inclined to ensure no water is
present inside the tubes. After completion of internal cleaning the bundle will be shifted to the next bay for the
visual inspection and NDT works. Area of the jetting yard shall be barricaded and marked for the safe
operation. Proper draining and cleaning will be done to keep the jetting area clean and avoid dust or water
clogging.
Cleaning Machines

Page 4 of 6
Exchangers
Adequate number of high-pressure water jetting machines shall be deployed as per the requirement.
Automatic multi lance for tube internal cleaning and shell side machines shall be required for the internal
eternal cleaning of the bundle.
Shell Cleaning
As per the scope of work shell should be thoroughly cleaned water washing and manually. The area under
the shell shall be covered well to avoid spillage of water directly on the other equipment. Proper draining and
cleaning will be done to keep the jetting area clean and avoid dust or water clogging. After completed cleaning
with water the welding seams and flange nozzles would be power brushed cleaned and offered to GASCO
inspections for further inspection and acceptance. Temporary scaffolding and lighting arrangement inside the
Shell will be made as per requirement.
Hydro Testing of Exchanger

Tube bundle testing:- After inspection and approval from the client, the tube bundle shall be made ready for
hydro testing by fixing the channel cover to the tube bundle. The test blinds shall be installed at the inlet and
outlet of the channel. Only the rated blinds shall be used. Calibrated pressure gauges as per the test pressure
shall be fixed at both inlet and outlet. Water to be filled keeping the vent open to remove all the air present in
the water and the tubes. Once the water is filled and found no air bubbles at the vent close the vent and start
pressurizing. The pressure tested shall be 1.5 times the design pressure in general, otherwise as stated in the
name plate detail or the data sheet of the exchanger. Hold the pressure for 1 hour and observe any drop in
pressure.
Shell side Testing: After completion of the tube testing, the bundle shall be inserted in the shell using bundle
puller and the tube sheet to be tightened new gasket to be provided between tube sheet and shell side . Close
all the nozzle with rated blinds or spades and install two pressure gauges in both inlet and outlet. Fill the water
from bottom and open the vent to remove air bubbles. Once all the bubbles are removed and water is filled
close the vent and start pressurizing the shell and hold at the test pressure for 1 hour and observe for any
pressure drop. During shell pressurized the tubes shall be leak tested internally by air one by one after one Hr.
to confirm no leakage . This way we can also identify tube which is defect and leaking if identified in the tube
testing. Do the necessary repairs/ plugging as required and found during the testing. Then fix the channel
cover and carry out combined test the tube side test and shell side test to ensure the gasket integrity leak test
to be done with nitrogen during start up.
6.4 CLOSING/BOX-UP:
1. After GASCO inspection approval, connect the associated piping spools, de-spading
2. Box up with new gaskets.
3. Tighten the bolts to proper torque values as per GASCO approved procedure.
4. Carry out the leak test during start up and retighten the bolts as required in close co-ordination with
operation department.
5. Restore /renew insulation and cladding
6. Remove external scaffolding & proper house-keeping
7. HOUSEKEEPING
1. TES Supervisor shall ensure to remove all scaffolding, unwanted material and tools from the work
area for proper housekeeping.
2. Masking tape shall be removed from flanges after satisfactory start up prior to demobilization.
8. REFERENCE DOCUMENTS
i. Approved Blind list with P & ID
ii. Approved ITP
iii. Approved subcontractor method statement for scaffolding & Insulation
iv. Approved subcontractor Bolt Torqueing procedure

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Exchangers

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OMEGA TRADERS &

Prepared By Approved By Approved By Client

Area Contract Management

Sub Area Quality Management Omega Traders &

2. WORK PERMIT REQUIRED

6. BLINDING, INSPECTION, MAINTENANCE, CLEANING & BOX-UP

Document No. Revision No. Page No.

2. WORK PERMIT REQUIRED

2.1 Cold Work Permit(Main Permit) 

2.2 Confined Space Entry Certificate 

2.3 Gas Test Certificate 

2.4 Hot Work Category 1 

Document No. Revision No. Page No.

ii. Equipment Drawing.

6. BLINDING, INSPECTION, MAINTENANCE & CLEANING:

Opening of Heat Exchanger

High Pressure Water Jetting

Document No. Revision No. Page No.

Hydro Testing of Exchanger

Document No. Revision No. Page No.

Document No. Revision No. Page No.

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