Installation & Maintenance Manual

CLIENT: MSET ENGINEERING PROJECT: KBB NORTHERN HUB VESSEL INTERNALS FOR: MP 2st Stage Compressor Suction Scrubber Vessel Tag: V-2414 and V-2424

Rev. No.

Description of Revision By

Prepared Date

Checked / Approved By Date

First Issue for Approval

MJA

110311

RN

280311

CDS Separation Systems Delta 101 6825 MN Arnhem The Netherlands Tel: +31 26 7999 100 Fax: +31 26 7999 119

Client Order Number Field / Platform End User Client Document Number -

MSET e 2011-0139 Rev1 KBB NORTHERN HUB KEBABANGAN PETROLEUM OPERATING COMPANY (KPOC) CDS Project No. P09-10075 Rev. No. 1 No. of Pages 9

CDS Document Number P09-10075-IMM7

Standard Document Code: CWF-2.11 Revision Date: 25-Jun-2010

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Table of Contents 1. 2. 3. Introduction ...................................................................................... 3 Preparations before Installation .......................................................... 3 Order of Installation........................................................................... 4
3.1.1 3.1.2 Evenflow HE (0910075A071A/B) ............................................................................ 4 Spiraflow Deck (0910075A072A/B) ........................................................................ 4

3.1 Installation ..................................................................................... 4 3.2 Bolting ........................................................................................... 5 3.3 Gasket............................................................................................ 5 3.4 Installation Check list ...................................................................... 5 4. Removal / Maintenance of the Separation System ............................... 5 5. Health and Safety Precautions ............................................................ 6

5.1 Equipment and tools ....................................................................... 6 5.2 Site procedures ............................................................................... 8 6. Recommended Tool List ..................................................................... 9

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1. Introduction
The purpose of this guide is to assist in the effective and satisfactory installation of the CDS internals into MP 2nd Stage Compressor Suction Scrubber with Tag No: V-2414 and V-2424 in the shortest possible time. It is vital that care is taken to ensure efficient handling and assembly of the separation system components. Also of importance is to refer to the specific drawings: 0910075G070A/B 0910075A071A/B 0910075A072A/B 0910075S070A/B Process General Arrangement Arrangement Evenflow HE Arrangement Spiraflow Deck Arrangement Supports

Please note that this booklet can be used only as a reference guide.

2. Preparations before Installation

1. 2. 3. 4. 5. 6. Make sure that all required scaffolding is placed inside and outside the vessel. Make sure that all required tools are near the vessel. Familiarize with the internals while unpacking / preparing installation. Make sure that all the items on the packing list / drawings are present and un-damaged. Display A1 drawings near the vessel. Check if all supports are welded in the vessel according to the drawings (elevations and orientations). 7. Cover the liquid outlet nozzle(s) in the bottom of the vessel.

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3. Order of Installation
The order of installation as stated below should be maintained. Before entering the vessel all health and safety precautions should be taken as described in section 5. All sections are designed to pass through a 762mm ID body flange. Prior to shipment, the complete package has undergone a complete trial assembly.

3.1 Installation 3.1.1 Evenflow HE (0910075A071A/B)

- Bolt end with double nuts to be installed outside the Evenflow HE for minimum flow obstruction. - Ensure Evenflow HE is centred in front of inlet nozzle (look through inlet nozzle). Procedure 1. Install the anti swirl sections (A01) with front bottom cover plate (A05) and spacers (A08 and A09). Grind anti swirl to tight fit in inlet nozzle. 2. Install vane ladders (A02 and A03) with back bottom cover plate (A07). Make sure that the end-vanes are interlocked. 3. Install top cover plates (A04 and A06). Bolting X20 X22, X37, X43 X22 Gasket -

3.1.2 Spiraflow Deck (0910075A072A/B)

Procedure 1. Install downcomers (B03 and B02). 2. Attach spiraflow box (B01) to downcomer (B02). 3. Install spiraflow box (B01). Bolting X26 X26 X29 Gasket Y15 Y15 Y03

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3.2 Bolting
All parts are supplied with interface bolting. 25% extra bolting has been added as installation spare. All bolts shall be double nutted for locking purposes. Note: the bolting used for the trial assembly and for transport is temporary bolting. Please use the bolting supplied in the boxes.

3.3 Gasket
10% extra gaskets or gasket material has been added as installation spare.

3.4 Installation Check list

1. 2. 3. 4. Check if every bolt has been secured properly by double nuts and washers. Check if gaskets are (properly) installed (use flash light). Check if all tools have been removed. Check if the vessel is clean.

4. Removal / Maintenance of the Separation System

The equipment supplied does not require regular maintenance. We would recommend that whenever the vessel is opened for inspection purposes or maintenance the internals should be visually inspected. For disassembling the separation system use the reversed order to the installation.

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5. Health and Safety Precautions

As in all construction operations, the installation of internals can be hazardous, and necessary precautions must be taken to ensure the health and safety of the installation personnel.

5.1 Equipment and tools

The installation of internals involves the moving of heavy components through a confined space, down the length of a vessel, whilst people are waiting to receive them at the particular point in the vessel where the internal installation is taking place. This is potentially a very dangerous situation and the following defines the equipment and procedures necessary to ensure that the proper precautions are taken to avoid injury: 1. Checklist of equipment: Lifting pulleys, slings, shackles, rope ladders, scaffolding, safety harness, helmets, gloves, goggles, protective footwear, and a first aid kit. 2. Description of equipment: 2.a. The lifting pulleys, slings and shackles must be in prime condition and of sufficient capacity to handle the heaviest component. It is the Supervisors responsibility to decide which type of lifting and lowering gear is to be used for each individual item that will be handled. The Supervisor must ensure that the chosen gear has sufficient capacity for its intended use. At the outset of each day, the Supervisor should check the condition of any ropes, to ensure that they have not been attacked by chemicals or damaged through fraying, etcetera. 2.b. Wherever possible, when lowering and raising parts within the vessel `D' shackles shall be used rather than slinging, as there is always a danger of components slipping out of the sling. Due to the large numbers of holes in internal components, it will be possible to use the `D' shackles in most cases. The `D' shackle, when used, must be in the proper position and properly bolted for fixing rope to the component being raised or lowered. The `D' shackles should be stamped and be officially certified as suitable for the maximum load involved. If slinging has to be used, then installation teams and managers should be aware of the dangers of slinging in confined spaces, and those directly concerned should have adequate recognised experience in slinging. It is the Supervisors' responsibility to check the loads being handled before work commences and, to ensure that the equipment has the adequate capacity for the job. 2.c. Access to internal installation areas should be by means of a ladder or scaffolding, which should be kept in prime condition and be regularly inspected by the Supervisor. 2.d. Safety harnesses (in accordance with registered safety standards) should be used whenever necessary and it is the Supervisors' responsibility to decide when this is so, and to make sure that they are in fact used.

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2.e. All personnel working on internal installations must wear safety helmets. It is the Supervisors' responsibility to ensure that this is carried out. 2.f. Particularly within vertical vessels, when items are being raised or lowered, there is a danger that foreign bodies, nuts, bolts, clamps, etcetera, can fall from above. At these times, and during other times judged by the Supervisor to be equally dangerous, safety glasses shall be worn to protect the eyes. 2.g. Because of the manufacturing processes and the need for proper functioning of the equipment, it is inevitable that there are sharp edges on the internal parts that are handled. The wearing of suitable gloves is therefore essential to ensure freedom from small and more serious cuts and abrasions. The Supervisor is responsible for ensuring the proper wearing of safety gloves. 2.h. Footwear is extremely important from the safety aspect. The use of proper protective and safety footwear (usually with re-enforced toe caps) can prevent injury to feet. No one should be allowed to work inside a vessel without the appropriate footwear as above. 2.i. A small First Aid Kit must be carried with the tools into the vessel to deal with small abrasions, etcetera.

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5.2 Site procedures

Examination of the job site environment is necessary, prior to the work commencing. This ensures that any local safety measures are fully met when work is underway. Advice on site conditions should be sought whenever possible, from the Site Safety Officer. 1. 2. 3. 4. Checklist of site inspection procedures: First Aid Station, Site and Working Environment Hazards. Description of Site Check Procedures - Precautions to be taken before commencing work in a vessel. First Aid Station - The Supervisor should immediately, on arrival at the site, find out the location of the First Aid Station, and should familiarise him/herself with the procedures involved in summoning First Aid assistance. Where the vessel has been previously operating with chemicals, the Supervisor must familiarise him/herself with the necessary precautions for handling that particular fluid, particularly from a health aspect. The necessary safety equipment, i.e. glasses, gloves, overalls, etcetera, of the correct material, should be provided before work commences. 4.1 The Supervisor should ascertain from the Plant manager, or other responsible officials on the plant, what safety precautions have been taken with regard to making sure that the vessel is safe for working, and should not commence work unless satisfaction is obtained. 4.2 There may be a risk of fire or explosion, either in or in the vicinity of the vessel, and full instructions should be received from the operating personnel with respect to restrictions on smoking, welding, burning, and the use of non-sparking spanners, non-sparking type footwear, and etcetera. The Supervisor should ensure in these circumstances that he/she learns from the Plant Supervisor or Manager, which equipment/procedures are necessary, and should take steps to ensure that all personnel employed use them.

NOTE: Working in hazardous areas is often subject to the issue of work permits by the operating company.

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6. Recommended Tool List

Description X X X X X X X Scaffolding Outside Vessel Scaffolding Inside Vessel Oxygen Meter Gas Detector Compressor Exhauster (vent) Fan Air Header for Air Hoses X X X Barrier Tape Tape for Instrument Marking Vessel Lighting Torchlight Grinder Grinding Discs Cutting Discs Plasma Cutter Welding Equipment Mill for grinding out Holes Hack Saw Drilling Machine Drill Bits 5 8 11 14 19 Impact Wrench with Long Sockets M8 (No.13) M10 (No.17) X M12 (No.19) X M16 (No.24) Remarks X X Description Spanners M8 (No.13) X M12 (No.19) M10 (No.17) X M16 (No.24)

Screwdrivers, Normal & Cross Allan Key (set) X X X X X X X Pair of Wire Cutters Measuring Tape Fiberglas Hammer Centering Rod Water Proof Pencils Spirit Level Punch Chisel Rope Ladder Pulley Block Jack X Personal protection (PPE) X Overalls X Helmet with Ear Protectors X Safety Glasses X Gloves X Safety Shoes

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