ZPEC DOCUMENT No.

PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

ZAMIL PROCESS EQUIPMENT COMPANY

QA/QC DEPARTMENT

Revision History
Reviewed/
Prepared By
Approved By Approved By
ZPEC
Rev. No. Date Purpose of Revision AI End User
Sign/Date
Sign/Date Sign/Date

Issued for Review and

0 22.10.2019 DHK Saudi Aramco
Acceptance
Revised to include
1 22.10.2019 DHK Saudi Aramco
Aramco comments
Revised to include
2 29.10.2019 PAK Saudi Aramco
Aramco comments
Revised & Issued for review
3 19.11.2019 DHK Saudi Aramco
and acceptabce

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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

1.0 PURPOSE:
This procedure describes the method of statement for rectification work with detailed activities to
be followed to shell replacement along with nozzle, tray support, internal, external attachments
and repair of base metal & weld metal.

2.0 DETAIL OF ITEM UNDER REPAIR:

Owner: SAUDI ARABIAN OIL COMPANY
LOCATION OF INSTALLATION: Abqaiq Plant / Abqaiq, Saudi Arabia
NAME OF ORIGINAL MANUFACTURER: South Western Engineering Co. & Hoogovens, Holland and
Const. Metalliques De Province
Item Identification: 110-C-06 (STABILIZER COLUMN)
ORIGINAL CODE OF CONSTRCUTION / EDITION-ADDENDA: 1948 & 1960
G.A.DRAWING NO./ REV NO. : NA-446658 Rev 5

3.0 REFERNCE DOCUMENTS/CODES/STANDARDS

Construction Code: ASME SEC VIII Div. 1

Aramco Specification: 32-SAMSS-004; SAES-W-010; SAES-D-008
Process Industry Practice: VEFV 1100M
ZPEC Welding Procedure Specification (WPS): PED-414-WB
ZPEC PT Procedure: ZPEC-0414-PT, Rev. 0
ZPEC MT Procedure: ZPEC-0414-MT, Rev. 0
ZPEC UT Procedure: ZPEC-0414-UT, Rev. 0
Petrochem RT Procedure: PETROCHEM/RT/01, Rev. 11.1
Sievert Arabia RT Procedure: SAL/TECH/SOP/ERT/002/2011 Issue 3 Rev.02
Heat treatment Procedure: ZPEC-414-HT Rev.0
Hardness Procedure: ZPEC-414-HM Rev.1
Hydrostatic test Procedure: ZPEC-414-HP Rev.0
Painting Procedure: ZPEC-414-SP Rev.0
ITP# ZPEC-0414-01-ITP Rev 0;

4.0 DESCRIPTION OF WORK:

4.1 Removal of Damaged portion From Existing Column.
1. Identify the Equipment Tag No. (Column Tag No. 110-C—6)

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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

2. Blast (Sweep blast) the equipment completely from both inside and outside so that no
traces of corrosion, paint or insulation left on column.
3. Carryout thickness mapping (Corrosion mapping) on complete equipment so the verification
method shall include both minimum and maximum thickness as per Saudi Aramco
specification Manual Ultrasonic Thickness Testing (SAEP – 1146 dated 9th July 2014)
4. Perform Visual inspection on complete column and Magnetic particle inspection on
complete column pressure boundaries (Long weld joints, circumferential weld joints, nozzle
joints, etc.) from both internal and external side.
5. Mark Reference line (By punch) & Orientation mark and reference point before cutting the
damaged portion so that those references shall be used during fit-up of new replacement
shell segments.
6. Carry out UT covering distance minimum 100 mm on either side of punch mark before
cutting to ensure no cracks, lamination or inclusions.
7. Cut the shell segment along the punch marks
8. After cutting the shell carryout bevel preparation as per the sketch shown in weld map, the
cut section shall be completely free from HAZ formed during oxy-acetylene cutting. Further,
perform MPI on prepared bevel edge to ensure the base metal is free from lamination.

4.2 Removal of defect by Grinding and followed by welding (Column # 110-C-06)

Note : Repair as per para 3.3.2 (e) (2) of NBIC part 3 & §6.7 of SAES-D-008

The cracks on the surface or subsurface shall be removed by grinding and subsequent welding.
1. Any repair depth ≤ 3mm shall be repaired using the WPS provided with SMAW process
(0302-M 11 A0-01, CSD Log # F-397 & RT-2151) & GTAW Process (0302-TM 11 A0-01, CSD
Log # F-400 & RT-2151) as applicable.
2. Any repair depth >3mm and remaining base material thickness <6mm shall be reported to
CSD for further course of action.
3. Any surface repair crack exceed 6mm after grinding shall be repair or replaced by new
material based on CSD recommendation.

PRECAUTIONS TO BE FOLLOWED DURING RECTIFICATION WORK (in all cases)

1. If multiple cracks removed and the ground areas are in the close proximity, merge
these clusters of ground areas with each other in to a single area of boat shape with
shallow and wide dimensions.
2. CSD approved WPS only shall be used for rectification work (0302-M 11 A0-01, CSD
Log # F-397 & RT-2151 & 0302-TM 11 A0-01, CSD Log # F-400 & RT-2151) as
applicable.
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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

3. Welders qualified as per ASME Section IX only shall be used for any rectification
work including tack welding.
4. Minimum preheat of 95°C shall be maintained throughout the welding and shall be
measured by using temperature crayons or digital thermometers.
5. Minimum preheat shall be applied 102mm (4”) on each side of the groove
6. Maximum interpass temperature shall be 260°C and the minimum interpass
temperature shall not fall below the minimum preheat temperature (95°C).
7. Only the electrodes with a diffusible hydrogen designator of H4 or lower shall be
used for rectification work.
8. At least two layers shall be welded in the repair area.
9. Temper bead technique shall be followed as described below
9.1 Final layer shall be deposited at least 2mm inside the weld toe of previous layer
9.2 After completion of welding at least half of the top layer shall be removed and
merged smoothly with surrounding area.

DESCRIPTION OF WORK:
1. CRACKS IN SHELL / DISHED HEAD PLATE
1.1 Identify and mark the location of crack
1.2 First grind holes / notches 3mm from edges of crack to arrest the crack propagation
1.3 Remove the crack in base material by grinding. Ensure the complete removal of
crack by PT/MT
1.4 Verify the repair depth using a welding gauge and if repair depth is >3mm report the
same to CSD for further course of action.
1.5 Perform the weld buildup using WPS without PWHT, approved WPS No.: 0302-M 11
A0-01, Rev. 0 (CSD Log # F-397 & RT-2151) or 0302-TM 11 A0-01, Rev. 0 (CSD Log # F-400 &
RT-2151)
1.6 Interpass cleaning shall be performed carefully to ensure defect free weld build up.
1.7 Perform the visual inspection and dye penetrant test/Magnetic Particle Test after
completion of weld buildup
1.8 After completion of all NDE, grind smoothly the surface to merge with surrounding
area
1.9 Upon satisfactory inspection by ZPEC, offer the same to ARAMCO for final inspection
and acceptance

DEFECT REMOVAL FROM GASKET SURFACE

1. Identify the damaged area on the nozzles (Gasket surface)

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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

2. Firstly, remove the corrosive substance and any process deposits from the surface of the
nozzle by power wheel or if necessary by grinding
3. Ensure the complete removal of defect or corrosive substance removed by PT
4. Verify the repair depth using a welding gauge and if repair depth is >3mm report the same
to CSD for further course of action.
5. Perform the weld buildup using WPS without PWHT, approved WPS No.:
0302-M 11 A0-01, Rev. 0 (CSD Log # F-397 & RT-2151) or 0302-TM 11 A0-01, Rev. 0 (CSD
Log # F-400 & RT-2151)
6. Interpass cleaning shall be performed carefully to ensure defect free weld build up.
7. Perform the visual inspection and dye penetrant test after completion of weld buildup
8. After completion of all NDE, grind smoothly the surface to merge with surrounding area.
9. Upon satisfactory inspection by ZPEC, offer the same to ARAMCO-PID for final inspection
and acceptance

4.3 Fabrication of New Shell Segments (Column # 110-C-06)

Note: Fabrication of New shell segment shall follow requirements of 32-SAMSS-004 & SAES-W-010

1. Identify the Equipment Tag No. (Column Tag No. 110-C—6) applicable for each component
2. After clearance of receiving inspection, carryout material traceability and record the details in
traceability report for all pressure retaining components
3. Upon completion of material inspection, perform fit-up as per drawing and welding of long
seam, cir-seam and nozzle welds as per approved weld book no. ZPEC-0414-WB.
4. Carry out Following NDE as minimum

S. No Joint Category NDE to be Carried out

1 Category A & B VT; MT; RT & UT
2 Category C VT; MT;RT& UT as accessible
3 Category D VT; MT & UT as accessible

5. Up on completion of All NDE and inspection from all parties, the shell segment shall be heat
treated as per approved heat treatment procedure# ZPEC-414-HT
6. After completion of PWHT repeat all NDE as same as before PWHT, additionally hardness shall
be ensured as per ZPEC-414-HM procedure

4.4 Assembly of New Shell Segments with Column (Column # 110-C-06)

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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

Note: Assembly of New shell segment shall follow requirements of 32-SAMSS-004, SAES-D-008 &
SAES-W-010

1. After inspection completion by all party, the newly fabricated segment shall be fitup with old
column.
2. Care shall be take while performing fitup the heat-treated area shall not be subject to any kind
of welding or heating.
3. Upon fit-up completion, verify the column for water level, straightness (verticality) and other
dimension from previously marked reference line.
4. After successful inspection from all party, closing joint shall be welded as per approved WPS of
mock-up PQR & Weld map.
5. On completion, perform VT, MT, UT & RT of closing joints as applicable.
6. Where minor damage observed less than T/3 and not exceeding 100 Sq. mm in size shall be
welded/ repaired and MT/UT to be performed. Such spots shall be welded using WPS (without
PWHT, except newly fabricated shell segments)
Note: Repair once the defects are detected by appropriate NDE.
7. Verify the Internal Tray support rings, if any damage is observed the same need to rectify with
same thickness with approved WPS as mentioned above. Upon final weld completion perform
the weld visual and MT examination.
8. Perform final visual and dimensional inspection of complete column for its suitability.

4.5 Hydro Static Examination of Column (Column # 110-C-06)

1. After Successful inspection completion, the complete column shall be subject to Hydrostatic
examination as per procedure no. ZPEC-414-HP
2. Holding time followed shall meet Saudi Aramco specification 32-SAMSS-004 and to the
satisfactory limit of all inspectors to complete pressure test inspection.
3. Hydro pressure shall be followed based on newly established MAWP after assessment and
design of complete column.

4.6 Painting and Insulation (Column # 110-C-06)

1. Upon finish of Hydro pressure test, the column shall be thoroughly inspected for
complete draining of water and also drying of equipment prior to box up the equipment.
2. Further blasting and painting shall be carried out as per procedure # ZPEC-414-SP
3. Verify final DFT of equipment and release for insulation.

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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

4.7 Final Certification (Column # 110-C-06)

After completion, preservation shall be perform as per 32-SAMSS-004, Para $ 19.2.

4.8 Final Certification (Column # 110-C-06)

1. After complete verification of documents and equipment’s, equipment shall be certified with R-
form as per the latest design condition for which hydrostatic examination carried out.

Records
1. Thickness mapping report
2. MPI report for all pressure retaining joints
3. RT report for newly welded category A, B & C joints
4. UT report for newly welded category A, B, C & D joints
5. Shop Hydrostatic report
6. Painting report
7. Traceability records for newly welded Pressure items
8. Alignment Verification & Dimensional report
9. Visual inspection report for complete column
10. Signed R2 Form for Alteration.

Attachments
1. MT Procedure (ZPEC-0414-MT Rev.0)
2. PT Procedure (ZPEC-0414-PT Rev.0)
3. RT Procedure (ZS-PE-0414)
4. UT report for newly welded category A, B, C & D joints (0414-UT Rev.0)
5. Shop Hydrostatic report (ZPEC-0414-HP Rev. 0)
6. Hardness Measurement Procedure (ZPEC-0414-HM-Rev. 1)
7. Post weld heat treatment procedure (ZPEC-0414-HT_Rev. 0)
8. Weld Book
8.1 Weld Book with PWHT (PED-0414-WB-Rev. 0)
8.2 Weld Book without PWHT (PED-0414-WB-Rev. 0)
8.3 Weld map for 110-C-06 (PED-0414-C6-WM-Rev. 0)
8.4 WPS & PQR for closing seam with mock-up test report
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ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
FOR Rev. No. 3
COLUMN SHELL REPLACEMENT
TAG No. # 110-C-06 DATE: 19th Nov 2019
QA/QC

9. Painting report

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