prevent maintenance feedback -equipment no mp-0755-v5 plant name kop - 1-31-2016

SHEM-07 MECHANICAL INTEGRITY OIMS 6.4 MECHANICAL INTEGRITY / OIMS 6.3A Critical Equipment (COVERS SHEM-07.00 , 01.01, 07.031

Issue No.: 9

Date: September 2013

Rev. No.: 1 Date: June 2014

Next Revision

Date: September 2018

Page

1 of 1

APPENDIX-Al

P/F P/S AL-JUBAIL PETROCHEMICAL COMPANY

SHE CRITICAL EQUIPMENT PROGRAM

FUNCTIONAL FEEDBACK FORM TEST / PM

I I.% I LDPE UOD i.• ..

krruje.1 KOP X Others

1 SCD Function Test / PM Activity: ❑ Function Test/ PM ❑ Function Test \I-2')M

To be filled by MTCE Planner & Printed.

Procedure Number: KICV05-00 Revision No. 0 2_— Work Order # 937010940 Tag Number: MP-0755-V5 Area: KOP Instrument

Actual Trip Occur - Value N+ Pass

"As-Found" Result: Fail / Malfunction (Issue a Nearmiss incident report. Incident No. )

Previous Result 'zi Pass / Fail

Actual Trip Occur - Value Pass "As-Left" Result:

T 1 i < ' , "-"unction: Specialist to iss, - m4 notification

2 Safety Health Environmental Critical Ch∎, .c.,-. ! System

bt.i: Test Equip kE nf KTR Sr.i, 1 Expiry Date Remarks

1 'Ya Ce- s r; c4-ik,'-‘4- • Y VI C_ --r1A7 i

41- D e L— I c ov____ 2

Summary oi i.:i nngs "As Found":

ID OW-- (7\7 C-3-Tc - riS--A -ca. \I Av e_ ---V-sa-k_v\_ A c .

Summary ti Endings "As Left":

Tested by IA CO"v`yi7e)-v■V\ Sign: L-k-540;̀'2._____ Date: 1 s--- o \ — 2_ .. vc,

Witnessed By Equipment Owner 1-cPoi \ r-8( Sign: I' ' _ _ Date: \15 e) S „ 7 oli CI

3 MTCE Supervisor Name ivp Z7 Sign: Date: 1 y-___ k _ tc

4

Maintenance Specialist action in case of:

(1) As-Found fail: Testing frequency shall be reduced to 1/2 of current frequency. ■ Done

(2) As-Found fail: Raise Bad actor Report. • Done / EN NIA

(3) As-Left Fail: M4 notification need to be raised.. • Done / E N/A

(4) Previous two tests pass: Increase test frequency by 2 times that of current frequency

I • N/A (attach evidence if NIA)

ME Done / ❑ N/A

Remarks:

Specialist Name I I Sign: I Date I

5 ORIGINAL: To PM (SCD) Administrator Planning Office for filling in SCD file and closing SAP orders

MTCE Doc. Controller Name 1 3,,,,e„,s .1-4( I Sign 6\k 1 Date 12,3 - oi,(t, CC: In case of failure or malfunction, Ik4ep the copy in bad actor report file for future use by Specialist / Engineer

52W_SCI_SD INST PM MD-07F-OHL KICV05-02

AL-JUBAIL PETROCHEMICAL CO. PREVENTIVE MAINTENANCE

KICV05 CONTROL VALVE (INSPECTION & OVERHAULING)

"1 echnical ID: oe-07s-s—vs--- W.O. Number: 9 SlOI ° 94 0 Actual Man Hours: 2 X,

Procedure start date \ c — a — tra

1.0 OBJECTIVE & BASIS:

Time 0 ° i•11

1.1

The key objective of this procedure is to provide a complete service for the control valves and actuators including physical inspection for the external and internal parts.

1.2

Provide a preventive maintenance and a complete valve overhauling including valve seat leakage pressure testing. This procedure establishing consistence technique for checking the reliability of control valve.

1.3

The procedure ensures that the Inspection / overhauling is conducted in an established method and followed by calibration and stroke check on control valve. Performing this procedure will enhance control valves performance and reduce the unplanned outage.

1.4

This control valve procedure will cover: • Control valve inspection and overhauling • Control valve seat leakages pressure testing

2.0 REFERENCE BASES AND DOCUMENTATION:

2.1 P & I Diagram Refer, Loop Folders / EDMS 2.2 Instrument Loop Diagram Refer, Loop Folders / INTOOL 2.3 Specification sheet / Calibration Data Refer, Loop Folders / INTOOL 2.4 Standard Maintenance Procedure Refer SMP Manual

(SMP) SMP Procedure # SMP-KIN02, 13, 30 & 55.

3.0 SAFETY, HEALTH & ENVIRONMENT:

3.1 Caution must be taken while removing / installing the valve from process line.

3.2 Avoid Hand injury, more precaution to be taken while working on the valve.

3.3 One focal technician should lead the activity, and unwanted personal should be away from the working area.

3.4 If any abnormality observed while inspection, followed the repair / recondition the device as needed and should be document all the works.

4.0 EQUIPMENT & SPECIAL CONSUMABLE:

4.1 Multimeter 4.2 Hand Tools

4.3 Communication RADIO

NOTE: ■ Refer Vendors Instruction operating maintenance manual for control valve & actuator,

etc. ■ Do not exceed maximum air supply pressure. ■ After performing pressure test / functional Test, If an internal problem is suspected then

go for "valve disassembly and Reassemble — Overhauling".

Revision: 02, Date: 12/10/2014

Page 1 of 8 Issue: 01, Date: 04/11/2012

Next Issue Date: 04/11/2017



5.0 PROCEDURE:

5.1 Control valve inspection and overhauling:

Sr. # Steps to be followed (Activity Descriptions) Complete?

5.1 Job Preparation

5.1.1 ■ Obtain a cold work permit filled with a proper JSA.

■ Review the procedure.

■ Get complete clearence from console as well field operator before starting any job on the valve. \.--

5.1.2 • Operation has to be ready with Alternative procedure.

• Ensure good communication among the team.

5.2 Process Isolation & Depressurization

5.2.1 NO-Ensure process/system has been isolated completely and process is controlled through by-pass system. (if applicable).

Z1 Apply tag out lock out procedure for all isolated equipment.

4-Er-Operator should drain / depressurized the isolated valve, if applicable.

5.3 Preparation for the valve removal if required

5.3.1 ■ Make the loop 'INACTIVE'.

■ Remove power (knife switch) and ensure that signal is cut-off.

■ Remove instrument control signal wiring from positioner, limit switches and from solenoid valve for EBVs.

■ Remove the ground cable.

■ Isolate control valve instrument air supply and then disconnect the tubing.

VVVV

■ Remove the Control Valve with help of Mechanical support and bring to workshop.

OR Use the 3rd Party services for to complete overhauling/calibration / testing and certification.


Page 2 of 8

Issue: 01, Date: 04/11/2012





5.4 Reconditioning / calibration & Pressure Test / Record

5.4.1

• Inspection on Valve & Actuator

irInspect for corrosion, rust or any damage of material on the valve. Record 'As Found' observation.

...Er-Verify hand wheel is functioning and it is in idle position.

tErfnspect packing for leaks or wear.

a-Ensure all covers bracket and bolts are in place and they are secured.

(12rInspect stem, pin and guides for wear, warp age, corrosion and tightness.

fel-Inspect the actuator breather filter form any plugged dust or dirt. (if applicable)

1214eplace the breather filter if it is rusty and damaged. (if applicable)

• Inspection on Positioner / Repair as recommended & check Air Supply

.17D For pneumatic positioner, ensure bleed port and air flow are unrestricted.

4T-inspect positioner mechanism for loose, binding, wear or corrosion.

1,...17-Confirm all gauges are working and readable.

nspect electrical connections and positioner housing for tightness, corrosion or presence of moisture.

spect regulator for proper output setting as per valve specification sheet.

a-nsp.

ect Tubing for bending, leak and support.

• Inspe ion on limit switch / Repair as recommended

Inspect limit switch mechanism for loose.

•Jainspect the micro-switch & all other accessories for corrosion / vibration.

kJ:1'6- spect the gland cable & wire termination of limit switch for any damage.

N-Ettlieck the functioning of limit switch & verify the indication in DCS.

5.4.2

Reference: SMP Procedure # SMP-KIN02, 13, 30 & 55 for Recondition / calibration and pressure, leak test on control valve)

,J2rkecord your observation on calibration, Use control valve calibration certificate form.

,'Check / verify any leak/passing. Record the reading.

JD-Krii-cord the as-found condition

-‘_

Revision: 02, Date: 12/10/2014 Page 3 of 8 Issue: 01, Date: 04/11/2012 Next Issue Date: 04/11/2017

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5.5 Control valve seat leakage pressure test procedure:

5.5.1 Control Valve size: 2 " Leakage class: ' ‘-----

5.5.2

Pressure Test / Record

Make the set-up for pressure test. Ensure the Emergency Block Valve is close (100%)

Slowly, Apply the pressure at inlet of the valve as per specification and hold it.

Check / verify any leak/passing. Record the reading.

Note: certification of calibration and pressure test shall be provided for the tested valve.

Test Pressure Holding Time Passing Test Test Result

33° s' o

As found

'--C. Minute 0

,----- Pressure Test: Pass Fail Kg/ Bubble/Minute.

As left 3co r

`S- Minute 0 _

Pressure Test: Pass Kg/Cm2 Bubble/Minute.

5.5.3 Refer to the attachments A and B for valve seat pressure test reference. V

5.5.4 If the valve seat pressure test is FAIL, do valve overhauling as per next steps 1,1R-

Revision: 02, Date: 12/10/2014 Page 4 of 8

Issue: 01, Date: 04/11/2012 Next Issue Date: 04/11/2017



5.6 Full Shop Maintenance, valve and actuator overhauling:


Full Shop Maintenance, valve and actuator overhauling

5.6.1

Nlaf'erform valve seat leakage pressure test to record the "As Found" result including seat, plug, packing and stem condition. (part three of this procedure)

SkDisassemble actuator & perform cleaning.

\/ /r.......----

■ Replace all internal consumable parts.

■ Paint and assemble the actuator.

■ Replace all the control valve accessories (Booster, Lock up relay). (if applicable)

IR-Inspect stem, stem seal and diaphragm.

El‘-spect positioned and linkage, mounting. Change the regulator as require.

■ Disassemble body, sub assembly and make it clean.

■ Install new seat ring or rings in body.

■ Inspect bonnet gasket and blind plate gasket area.

Ednspect flange gasket area.

■ Check concentricity of plug guide post, bushing and run out of stem.

■ Inspect packing box.

■ Replace all gaskets and assemble body. '

■ Replace packing as per specifications.

■ Pe rm Hydrostatic test for the valve body.

pect the gland packing for any leak during the Hydrostatic test with considering different valve opening of 0%,25%, 50%,75%,100% and tight the gland packing if leaking.

\p'For PSA Valtek valves:

1 . Replace the actuator spring every two years.

\p-Perform seat leak test and record the result in the "As Left " result. (part two of this procedure)

rFerform Hydrostatic test for the valve body.

J2-Replace gauges as needed.

n-EPerform valve calibration and fill out the valve calibration certificate.

\Er6onfirm the travel as per specification sheet.

Check full stroking, ensure valve is operating smoothly.


Page 5 of 8 Issue: 01, Date: 04/11/2012


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5.6.2

Overhauling hazards

■ Be aware of the actuator spring tension during overhauling. ■ Release the spring tension slowly before dismantling the actuator.

• Always keep your hands or fingers away from the valve disc or stem during valve functioning. ■ Synchronize the function test of the valve with your partner in such a way that you

know when the valve will close and open.

5.6.3

Control Valve Reinstallation

iInst%

all the reconditioned valve with mechanical support.

spect, flush and connect back the instrument air tubing and line it up.

--if-Connect back instrument control signal wiring and ground cable.

Note: Ensure Proper Closure of Solenoid Valve & Proper Tighten of Gland Cable.

--15&nnect back the knife switch

-ErAsk console operator to put the loop ACTIVE

'Stroke the valve through DCS and/ or from Triconex. Operation witness is require.

,-0—Check / verify its calibration, smoothness and linkages, etc.

aConfirm the travel as per specification sheet.

11 For PSA unit control valves:

i. Adjust the close indication to be between 15% to 19%

ii. Adjust the opening indication to be between 20% to 25%

iii. Adjust the Valtek valves to start opening @ 4.8 mA.

\Z-1

\--77"---- 5.7 Close out work permit. ■ Write your comments regarding PM in SAP feedback form and to be acknowledged by

Instrument Supervisor / Area Instrument Specialist.


Page 6 of 8

Issue: 01, Date: 04/11/2012




6.0 ATTACHMENTS: A. Control valve leakage classification overview part-1:

Port Diameter Bubbles per

minute ml per minute

inches Millimeters

1 25 1 0.15

1 1/2 38 2 0.30

2 51 3 0.45

2 1/2 64 4 0.60

3 76 6 0.90

4 102 11 1.70

6 152 27 4.00

8 203 45 6.75

10 254 63 9

12 305 81 11.5


Page 7 of 8

Issue: 01, Date: 04/11/2012




B. Control valve leakage classification overview part 2:

Leakage Class Designation

Maximum Leakage Allowable Test Medium Test Pressure Testing Procedures Required for

Establishing Rating

I x x X No test required

II 0.5% of rated capacity

Air or water at 50 - 125° F

(10 - 52°C)

45 - 60 psig or maximum operating differential whichever is lower

45 - 60 psig or maximum operating differential whichever is lower

III 0.1% of rated capacity As above As above As above

IV 0.01% of rated capacity As above As above As above

V

0.0005 ml per minute of water per

inch of port diameter per psi

differential

Water at 50 to125°F (10 to

52°C)

Maximum service pressure drop across

valve plug not to exceed ANSI body rating

Maximum service pressure drop across valve plug not to exceed ANSI body rating

VI Not to exceed

amounts shown in the table above

Air or nitrogen at 50 to 125° F (10

to 52°C)

50 psig or max rated differential pressure

across valve plug whichever is lower

Actuator should be adjusted to operating conditions specified with full normal

closing thrust applied to valve plug seat

7.0 RATIONALE BEHIND PROCEDURE REVISION:

7.1 Procedure Updated.

Procedure End date: I o — LAC Time: 'a o PO

Done by: \-10A‘triv:i /D lr\ Signature:


Page 8 of 8

Issue: 01, Date: 04/11/2012


II 2 II% 1 411", AL-JUBAIL PETROCHEMICAL COMAPNY

CALIBRATION CERTIFICATE

CONTROL VALVE rrs k ye.i

CALIBRATION CERTIFICATE : CV-001A Rev. 0 PAGE 1 OF 1

INSTRUMENT TAG.NUMBER Pi — ° 7S-S- — V S-- INSTR ∎UMENT SERVICE ■ e s A — ∎ -'i),

INPUT RANGE AS PER SPECS. --ro 20 K A VALVE FAILURE POSITION Clo S CI_ CAM Nos. & TYPE

•••::!'

., ,:i....- :.-,, :..,;

- . ,v

' - - oil . lilii0

" - CALIBRATION RESULTS

INPUT RANGE REFERENCE

VALVE "TRAVEL INDICATION

USED FOR CALIBRATION

BEFORE CALIBRATION

AFTER CALIBRATION

mA OPEN CLOSE % OPEN CLOSE OPEN CLOSE.

LA 0 _:: • b. 5

:,;'7;,7. k 0 D

iMPITOEHESEEELVA21,111:BMSM, iii! 11 0 co

S '2.,fc- r-15-- 25 (-7 5— —7

I S r7=5

- 5— o

r

I L 75- _ ) 75 22 ,coo 5 ) 100 Do 0

I C. IS- 2 75 7 -5---- 25-- IL 5-73 'S---;2 50 c., 5-D a (2_ S-- '2_ S--- r7 5-

IA 0 i o o 0 6 too

ADJUSTMENT CONTROL VALVE ACTION RESULT mA DEAD BAND °/0

START- OPENING l'i ' 9 ZERO

YES START- CLOSING

,..., .. „ NO S R TEST EQUIPMENT: MFG KTR Sr.# Cal. Date Exp. Date

SPAN

YES 1 0 I -50C.e.S5 (146-Yr;-6( 14-4-1■1?"-e--- II-E-3 87 ir—pec- 15- I k-- 2_c----1,4 NO . 2

3

CALIBRATION DONE BY k- x46.4 ( T)Ot U‘') DATE 1 S. ---/ o( / 2-°1 C

SIGN '/NC4Pi-----

NOTE: > DCS INDICATION AS REFERENCE FOR FINAL CALIBRATION. > USE ONLY CERTIFIED TEST EQUIPMENT FOR CALIBRATION.

REFER, CONTROL VALVE SPECIFICATION DATA SHEET. > THE ALLOWABLE % ERROR, ACCORDING VENDOR'S RECOMMENDATION.

prevent maintenance feedback -equipment no mp-0755-v5 plant name kop - 1-31-2016

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