414 Column Procedure - Rev 1

ZPEC DOCUMENT No.
PE-0414-RP-01
METHOD OF STATEMENT
Rev. No. 1
FOR
COLUMN SHELL REPLACEMENT
QA/QC DATE: 22th Oct 2019
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
Page 1 of 5
ZPEC DOCUMENT No. PE-0414-RP-01
METHOD OF STATEMENT
Rev. No. 1
FOR
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.
2.0 DETAIL OF ITEM UNDER REPAIR:

Owner: SAUDI ARABIAN OIL COMPANY
Name of Original Manufacturer: As Per SIS Data Sheet
Item Identification: 110-C-6; 110-C-9; 110-C-11
Original Code of Construction / Edition: As Per SIS Data Sheet
G.A.DRAWING NO./ REV NO. :
3.0 REFERNCE DOCUMENTS/CODES/STANDARDS
Construction Code: ASME SEC VIII Div. 1 Ed. 2017

Aramco Specification: 32-SAMSS-004; SAES-W-010; SAES-D-008
Process Industry Practice: VEFV 1100M
ZPEC Welding Procedure Specification (WPS): ZPEC-414-WB
ZPEC PT Procedure: ZPEC-0414-PT, Rev. 0
ZPEC MT Procedure: ZPEC-0414-MT, 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
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; 110-C-9; 110-C-11)
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 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.
Page 2 of 5
METHOD OF STATEMENT
Rev. No. 1
FOR
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.
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.
9.
4.2 Fabrication of New Shell Segments (Column # 110-C-06; 110-C-09 & 110-C-11)
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; 110-C-9; 110-C-11) 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 fitup as per drawing# and
welding of long seam, cir-seam and nozzle welds as per approved weld book no. ZPEC-0414-WB
(Weld map shall be prepared and submitted as built after full column assessment)
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
Page 3 of 5
METHOD OF STATEMENT
Rev. No. 1
FOR
4.3 Assembly of New Shell Segments with Column(Column # 110-C-06; 110-C-09 & 110-C-11)
Note: Assembly of New shell segment shall follow requirements of 32-SAMSS-004 & 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 fitup completion (Closing joints # ), 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 &
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.
4.4 Hydro Static Examination of Column(Column # 110-C-06; 110-C-09 & 110-C-11)

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.
4.5 Painting and Insulation (Column # 110-C-06; 110-C-09 & 110-C-11)

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.
Page 4 of 5
METHOD OF STATEMENT
Rev. No. 1
FOR
4.6 Painting and Insulation (Column # 110-C-06; 110-C-09 & 110-C-11)
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.
Page 5 of 5

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ZPEC DOCUMENT No.

ZAMIL PROCESS EQUIPMENT COMPANY

Issued for Review and

2.0 DETAIL OF ITEM UNDER REPAIR:

3.0 REFERNCE DOCUMENTS/CODES/STANDARDS

Construction Code: ASME SEC VIII Div. 1 Ed. 2017

4.0 DESCRIPTION OF WORK:

S. No Joint Category NDE to be Carried out

4.4 Hydro Static Examination of Column(Column # 110-C-06; 110-C-09 & 110-C-11)

4.5 Painting and Insulation (Column # 110-C-06; 110-C-09 & 110-C-11)

4.6 Painting and Insulation (Column # 110-C-06; 110-C-09 & 110-C-11)

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