uic-qp-m-016 procedure for corrosion probe installation and removal

UIC-QP-M-016

Rev. 0, April 2004

PROCEDURE FOR CORROSION

PROBE REMOVAL AND INSTALLATION Page 1 of 9

MI & QA Eng & Const. Dept

PROCEDURE FOR CORROSION PROBE REMOVAL AND INSTALLATION

UIC QP M - 016

APPROVAL

T i t l e N a m e Signature D a t e Next Approval

Approved by Steve Adrianto SA

Checked by Suhartono SHN

Originator by Iman Sugi Im.S April 2004

UIC-QP-M-016

Rev. 0, April 2004




1.0. PURPOSE

The main purpose of this procedure is to provide guidance on removal and installation of Electronic Reading Probe used to monitor corrosion rate in the Unocal Indonesia Facilities

2.0 SCOPE

This Procedure cover ER Corrosion Probe installed on the UIC Plant facilities, both onshore and offshore.

3.0 REFERENCES

- NACE 1C187, Use of Galvanic Probe Corrosion Monitors in Oil and Gas Drilling and Production Operation

- API 14 J, Recommended Practice for Design and Hazard Analysis for Offshore Production Facilities

- UOT Corrosion Probe Installation Manual 4.0 RESPONSIBILITIES

4.1. Corrosion Technicians should assume the responsibility to perform removal and/or installation of corrosion probe in the field.

4.2. MIQA Specialist provides probe data prior to removal and/or installation

and should assume the supervision responsibility of removal and installation process.

4.3. Head of Production should provide any required access in removal and

Installation process related to his area. 4.4. Head of Maintenance should provide any required assistance, during

removal and/or installation process of the corrosion probe related to his responsibility area.

4.5. Field Safety Officer should assume the supervision role related to safety

aspect and environmental issue during removal and/or installation of the probe including safety guidance prior and during the process.

5.0 PROCEDURE

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Corrosion Technicians shall check and verify whether the retrieval/installer tool is in good condition prior taking to the field. Prior to perform removal and/or installation of corrosion probe, The Corrosion Technicians shall inform Production, Maintenance and Safety Officer in related field to get access and/or required support for the work to be done. The removal and/or installation of corrosion probe can be started after work permit being released. 5.1 Removal Process

1. Check to ensure proper equipment, (PPE, scaffolding, etc) and sufficient space to perform retrieval job.

2. Remove the protective cover of access fitting 3. Inspect the external threads and fitting shoulder, and clean as required 4. Slowly remove the pipe plug, hallow / solid plug internal thread

Protector and clean the threads as required. Note: Slowly remove the pipe plug as there may be some pressure trapped in the hole

5. Place the service valve onto the access fitting and thread the hammer nut Until the service valve is securely seated onto the access fitting shoulder 6. Turn the valve handle to close and open positions to ensure no Obstruction by any piping or equipment adjacent to the service valve, And adjust the valve position as required. 7. Tighten the service valve hammer nut with brass hammer 8. Open the service valve. 9. Place the retriever onto the service valve and thread the hammer nut Until the retriever is securely seated onto the service valve shoulder. 10. Extend and collapse the retriever body to ensure no obstruction by any Piping or equipment adjacent to retriever, and adjust the retriever Position as required. 11. Tighten the retriever hammer nut with brass hammer. 12. Close the bleed valve and equalizing valve 13. Lift the retriever outer barrel and slowly turn the barrel clockwise to Screw the socket adapter into the hollow / solid plug assembly internal Threads. 14. Slowly lift the outer barrel to ensure that the socket adapter is properly Screwed into the plug assembly threads. 15. Lower down the outer barrel onto the solid / hollow plug assembly Hexagonal head. 16. Slowly turn the barrel a little bit to ensure that the retriever socket Adapter pilot is properly locked onto the solid/hollow hexagonal head. 17. Slowly turn the barrel counterclockwise for one - three revolutions and Check if the barrel pressure starts to increase. Note: - Check and observe for any leak. - Under any circumstances, do not remove the plug more than 4

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Revolutions prior to the retriever pressure balancing. 18. Once the barrel pressure equals to the line pressure, slowly turn the Barrel counterclockwise until the solid / hollow plug is completely Removed from the access fitting. Note: Ensure that the adapter pilot is properly locked onto the

Hexagonal head at all time during the turning. 19. Extend the retriever to the maximum position and lock the inner barrel With a wood clamp. 20. Close the service valve. 21. Open the bleed valve to depressurize the barrel 22. Once the barrel pressure dropped down to zero, close the bleed valve And check if there is any pressure built up due to valve passing. 23. Re-open the bleed valve to full open position 24. Slowly loose the retriever hammer nut with brass hammer 25. Remove the retriever 26. Remove the retrieved corrosion probe or coupon from the retriever

5.2. Installation Process

1. Screw the solid / hollow plug assembly with a new set of corrosion

Probe or coupon onto the retriever socket adapter. Note: - Do not over tighten the plug assembly with the retriever

Socket adapter as it may cause difficulty during Disengaging the retriever.

- Mark on the top of the hollow / solid plug assembly for the Direction required the probe or coupon to face with, prior to screwing in.

2. Place the retriever onto the service valve and thread the hammer nut Until the retriever is securely seated onto the service valve shoulder.

3. Adjust the retriever to a proper position and tighten the hammer nut With the brass hammer.

4. Close the retriever bleed valve. 5. Slowly open the equalizing valve and check if the barrel pressure starts

To increase. Note : Check and observe for any leak.

6. Once the barrel pressure equals to the line pressure, open the service valve to full open position.

7. Carefully remove the wooden clamp and slowly collapse the retriever. 8. Once the solid / hollow plug assembly is properly seated onto the top of

the access fitting assembly, slowly turn the outer barrel clockwise to screw the plug assembly into the access fitting assembly.

9. Once the plug is properly crewed into the access fitting, open the bleed valve to depressurize the retriever barrel.

10. Re-close the bleed valve and observe for any pressure built up. 11. Lift the outer barrel to remove the socket adapter pilot from the plug

UIC-QP-M-016

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hexagonal head. 12. Slowly turn the barrel counterclockwise to unscrew the socket adapter

from the plug assembly. Note : Observe for any pressure built up. Should the pressure built up, stop the turning. This may cause by unscrewing of the hollow / solid plug assembly, so turn the barrel clockwise to re-screw the plug assembly into the access fitting assembly. 13. Extend the retriever and clamp the inner barrel with the wooden clamp. 14. Open the bleed valve. 15. Slowly remove the retriever and the service valve. 16. Adjust the probe or coupon position to face to the required direction. 17. Screw in the pipe plug. 18. Re-install the protective cover.

6.0 SAFETY PRECAUTION

The following precaution shall be considered prior to perform retrieving and installing probe :

1. Make sure all equipment in good and reliable condition, by testing and Checking prior to use

2. The job shall be performed by 2 people as minimum 3. The job performer shall be well-trained in using the equipment 4. All plant safety/environment requirements shall be followed

5. Identify in service operation condition: work location fluid type, temperature and Pressure, take any necessary action to mitigate Potentials hazard 6. Always use proper and standardized PPE (Personnel Protective Equipment) 7. Ensure enough clearance for safe retrieve/installing operation 8.

7.0 ATTACHMENT

- Step by Step Checklist - Job Safety Analysis - Typical

UIC-QP-M-016

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Attachment

CHECK LIST FOR

RETRIEVAL AND INSTALLATION OF SOLID OR HOLLOW PLUG ASSEMBLIES (MELEPAS DAN MEMASANG SOLID ATAU HOLLOW PLUG ASSEMBLIES)

I. RETRIEVAL (MELEPAS) DATE BY/INITIAL 1. Check the retriever and service valve equipment before

used, be sure that the equipment working properly. (Periksa peralatan retriever dan service valve sebelum digunakan, yakinkan bahwa peralatan tersebut dapat bekerja dengan baik)

2. Adjust the socket adapter assembly. For solid or hollow plug assemblies, the socket adapter should be set in the third and fifth holes from hex end. (Atur posisi dari socket adapter assembly. Untuk solid dan hollow plug assemblies, socket adapter harus diset pada lubang ketiga dan kelima dari hex end).

3. Remove the access fitting cover. (Lepas tutup access fitting).

4. Looses the plug assembly by adjustable crescent whench, DO NOT loosens beyond the turn maximum. (Kendorkan plug assembly dengan kunci inggris. Jangan mengendori lebih dari putaran)

5. Remove the pipe plug from the plug assembly. (Lepas pipe plug dari plug assembly).

6. Connect the service valve assembly to the access fitting. (Hubungkan service valve assembly ke access fitting).

7. Tap the hammer nut tight using a brass hammer. (Kencangkan hammer nut dengan menggunakan palu kuningan).

8. Stroke the retriever to ensure it is lubricated, not binding and operating properly. (Naik turunkan retriever untuk meyakinkan peralatan terlubrikasi, tidak terjepit dan beroperasi dengan baik).

9. Extend the retriever. (Perpanjang/tarik retriever (inner barrel)).

10. Connect the retriever to the service valve. (Hubungkan retriever dengan service valve).

11. Tap the hammer nut tight using a brass hammer. (Kencangkan hammer nut menggunakan brass hammer).

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12. Move the outer barrel toward the access fitting body until the socket adapter pilot contacts the plug assembly. (Solid or hollow plug). (Gerakkan outer barrel menuju access fitting sehingga socket adapter pilot berhubungan dengan plug assembly (solid atau hollow plug).

13. Turn the outer barrel clockwise about four turns to engage the socket adapter pilot threads to the female threads of the plug assembly. (Putar outer barrel searah jarum jam kira-kira empat putaran untuk memasukkan socket adapter pilot thread ke female thread pada plug assembly).

14. Close bleed valves. (Tutup bleed valve).

15. Connect the socket adapter hex by moving the retriever outer barrel toward the access fitting body while turning slightly clockwise until the socket adapter hex slides over the plug assembly hex. (Hubungkan socket adapter hex dengan menggerakkan retriever outer barrel menuju access fitting body kemudian putar sedikit searah jarum jam hingga socket adapter hex lebih masuk ke plug assembly hex).

16. Retriever pressure balancing. Turn the retriever outer barrel slowly counter clockwise. The pressurization will begin after to 2 turns of the outer barrel. (Menyeimbangkan tekanan pada retriever. Putar pelan-pelan retriever outer barrel berlawanan jarum jam. Pressurize akan mulai setelah sampai 2 putaran dati outer barrel).

17. Retrieving the plug assembly from the access fitting body, extend the retriever outer barrel counter clockwise approximately 15 or 16 turns. (Lepas plug assembly dari access fitting body. Putar retriever outer barrel berlawanan arah jarum jam kira-kira 15 atau 16 putaran).

18. After the plug assembly is removed from access fitting body, extend the retriever outer barrel with twisting, turning, sliding motion. (Setelah plug assembly terlepas dari access fitting body, tarik retriever outer barrel dengan gerakan ulir, putar).

19. Close the service valve bleed screw and the service valve ball. (Tutup service valve bleed screw and service valve ball).

20. Bleed-off retriever pressure gradually until zero. (Turunkan tekanan pada retriever pelan-pelan hingga nol).

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21. Close the retriever bleed valve. (Tutup retriever bleed valve).

22. Tap loose the retriever hammer nut using the brass hammer. (Kendorkan retriever hammer nut dengan menggunakan hammer kuningan).

23. Lift the retriever to remove from the service valve. (Angkat pelan-pelan retriever untuk melepas dari service valve).

24. Check and remove the solid or hollow plug from socket adapter pilot. (Periksa dan lepas solid atau hollow plug dari socket adapter pilot).

25. Check retriever condition. (Periksa kondisi retriever).

II. INSTALLATION (PEMASANGAN) DATE BY/INITIAL 1. Prepare the plug assembly, inspect the plug assembly

threads, replace all o-rings and packing and apply grease to the full length of plug assembly. (Persiapkan plug assembly, periksa ulir plug assembly, ganti semua o-ring dan packing, berikan grease pada plug assembly).

2. Connect the plug assembly to socket adapter pilot. (Hubungkan plug assembly ke socket adapter pilot).

3. Fully extend the retriever. (Tarik/perpanjang retriever (inner barrel)).

4. Connect the retriever to the service valve. Turn the hammer nut clockwise until the retriever is securely seated and tightened in place on the service valve. Use the brass hammer to tap a secure connection. (Hubungkan retriever dengan service valve. Putar hammer nut searah jarum jam hingga retriever tepat dan kencang pada posisinya di service valve. Gunakan brass hammer untuk mendapatkan sambungan yang baik).

5. Ensure that the retriever bleed valve is fully closed. (Yakinkan bahwa bleed valve dari retriever tertutup rapat).

6. Slowly open the service valve bleed valve to pressurize the retriever. (Buka pelan-pelan bleed valve dari service valve untuk pressurize retriever).

7. Open the service valve ball and close the service valves bleed valve.

UIC-QP-M-016

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(Buka ball service valve dan tutup bleed valve dari service valve).

8. Engage the plug assembly to the access fitting body. Slowly and gently thread the plug assembly into the access fitting body by turning the retriever outer barrel clockwise and check the plug assembly starts threading properly. (Masukkan plug assembly ke access fitting body. Ulir dengan pelan dan hati-hati plug assembly ke access fitting body dengan memutar retriever outer barrel searah jarum jam dan periksa plug assembly mulai terikat dengan baik).

9. To complete the engagement of the plug assembly to access fitting body, turn the retriever outer barrel 14 or 15 turns. (Untuk memasukkan plug assembly ke access fitting dengan sempurna, putar retriever outer barrel 14 atau 15 putaran).

10. Bleed the retriever. (Turunkan tekanan di retriever).

11. Disengage the socket adapter from the plug assembly. (Keluarkan socket adapter dari plug assembly).

12. Retriever bleed-off to zero. (Turunkan tekanan retriever hingga nol).

13. Loosen the retriever hammer nut and remove the retriever. (Kendorkan retriever hammer nut dan lepas retriever).

14. Loosen the service valve hammer nut and remove the service valve. (Kendorkan service valve hammer nut dan lepas service valve).

15. Install the stainless steel pipe plug. (Pasang plug stainless steel).

16. Install the protective cover of access fitting. (Pasang tutup pelindung access fitting).

JOB SAFETY ANALYSIS WORKSHEET

JOB TITLE OR OPERATION Retrieval and installation of Corrosion and Scale Coupon

DATE

PAGE ____ OF JSA NO. _____

NEW REVISED

COMPLETED BY

EMPLOYEE/OPERATOR

SUPERVISOR

REVIEWED BY

COMPANY/ORGANIZATION Unocal Indonesia Co.

WORK SECTION/ DEPARTMENT MI & QA

APPROVED BY

REQUIRED/RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT / SAFEWORK PERMITS Minimum requirement PPE is safety shoes, safety hat, safety glasses, hand gloves have to be worn during perform the work. BASIC JOB STEPS, IN SEQUENCE POTENTIAL HAZARDS RECOMMENDED PREVENTIVE MEASURES Mobilization Handling the retriever & service valve equipment

Personnel injury 1. To lift the equipment shall be two persons 2. Take a rest for a minute to fit up handling. 3. Do not drop the tools. 4. Use proper PPE required 5.

Preparation Simulation of the equipment

Personnel injury, Equipment Damage

1. check the handle, pressure gauge, 2. lubricate the barrel with the lube oil 3. try to pull and push the barrel smoothly 4. use proper PPE required 5. Required Well-trained technicians 6. Request Work Permit from Plant

7. Having enough Clearance for Safe Operation

Removing Process Personnel injury, Equipment damage, Hydrocarbon release

1. Five minutes Safety Talk 2. Use Proper PPE 3. Follow Step by Step SOP / Equipment Manual 4. Follow Plant Safety Regulation

Installation Process Personnel injury, Equipment damage, Hydrocarbon release

1. Five minutes Safety Talk 2. Use Proper PPE 3. Follow Step by Step SOP / Equipment Manual 4. Follow Plant Safety Regulation

V

INSTRUCTIONS FOR JOB SAFETY ANALYSIS FORM The following lists the columns on the form and explains how to complete each. JOB TITLE OR OPERATION List the title of the job or operation being analyzed. For example, Pipefitter, Warehouseman, or Changing a Flat Tire. DATE The date the JSA is being completed. PAGE ____ of JSA NO. ____ - Indicate which page of the JSA for this job this page this is and the number assigned to the JSA, if one has been assigned. NEW/REVISED If this is the first time this job has been analyzed, check NEW. If this is a revision of a previous JSA for the job, check REVISED. COMPLETED BY The typed or printed name of the person who completed the JSA. This will usually be the supervisor of the employee whose job is being analyzed. EMPLOYEE/OPERATOR This will be the name of the person whose job is being analyzed. If there is more than one employee in the same position, list the one who was used to demonstrate the steps of the job for you. SUPERVISOR The immediate supervisor of the employee whose job is being analyzed. This will often be the same as the COMPLETED BY person. REVIEWED BY If someone in your organization or unit is assigned to review the completed JSA, his typed or printed name should be included here. When he has reviewed it, he should initial next to his name. COMPANY/ORGANIZATION The name of your company or organization. WORK SECTION/DEPARTMENT This could be, for example, Maintenance Section, Electrical Section, Fabric Repair Department, or so on. In some cases, it will not be necessary to complete this block. APPROVED BY If someone in your organization has been designated to approve the JSA, his name should go here. When he has approved it, he should initial next to the name. REQUIRED/RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT List any PPE or protective clothing that should be used by the employee. Be specific. For example, do not simply say gloves. Instead, list a specific type of gloves. BASIC JOB STEPS, IN SEQUENCE List the major steps taken in performing the job, in their chronological order. POTENTIAL HAZARDS Next to each Basic Job Step, list the hazards associated with that step. Be complete and specific. Use action verbs, such as Cut by blade of knife, or Struck by spinning handle of machine. RECOMMENDED PREVENTIVE MEASURES For each Potential Hazard, list control measures to eliminate or mitigate the hazard. For additional information regarding the proper completion of a JSA, see the MANSCEN Safety Office slide show entitled Job Safety Analysis.

uic-qp-m-016 procedure for corrosion probe installation and removal

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