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Standard Maintenance Procedure SHEM 03.02 SMP-SE-012

Rev. # ( 4 ) Date Jan, 2023

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Standard Maintenance Procedure

SMP/No.SMP-SE-012
Temporary Repair

Role Name Position & Department Signature Date

Prepared by Muhammad Shafi Mech. Maint. Engr 16/01/2023

Reviewed by Khaled Dulaim MTC manager 25/1/2023
Endorsed by -1 Moath Alsukhaiber Engineer, MTC-7 16/01/2023
Endorsed by -2
for
Approved by Khalaf AlDossari MTC-7 Sr. Manager 25/1/2023

Table of Change summary

Brief explanation of previous Brief explanation of new

Rational behind the change
requirement requirement

Kept all as orignal SMP Belzona Coating new method Belzona Coating added

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Purpose
Step 1: EHSS This procedure describes the requirements and for performing temporary repairs
requirement on plant equipment (pressure vessel, pumps, piping and pipeline) to address loss of

containment or reduced wall thickness. It is intended to be used by plant
personnel at all levels as a reference document to assist in efforts to ensure a
Step2: Technical systematic approach in planning and execution of temporary repairs
Requirements

Applicable to
For the following PETROKEMYA equipment:
Step 𝟑: Required  pressure vessel
tools & material   pumps
 piping
 pipeline
Step 4:
 of Activity
Type
Mandatory
materials Performing temporary repairs on plant equipment (pressure vessel, pumps, piping

and pipeline)

Boundaries
Step 5: Work
Instruction 
Applicable for the approved temporary repairs as per SHEM 09.
Any repairs involving In-service welding or Hot Tapping on active piping or
equipmento are not covered by this SMP.
Step 6: Startup References
Requirements
 • SHEM 03.00 , SHEM 03.01 , SHEM 03.02
 SHEM 08.00 , SHEM 08.03 , SHEM08.07 , SHEM 08.08 , SHEM 08.10
Step 7: Spare  SHEM09.00
Replaced  API 510: Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair
Additional and Alteration

spare  API 570: Piping Inspection Code: In-Service Inspection, Rating, Repair and
Step 8: Alteration
Observation &  ASME PCC-2: Repair of Pressure Equipment and Piping
findings

Equipment Tag # SAP Notification #

Step 9:
Refrences

Step 10:
Attachments

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Standard Maintenance Procedure SHEM 03.02 SMP-SE-012

Rev. # ( 4 ) Date Jan, 2023

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1.0 Safety, Health & Environment

Indicate any specific EHSS requirements for this particular job that must be included in the WP. This is
not waiving any WP requirements as per SHEM-08.10

QC requirements Confirmation
Sr. Safety, Health & Environment
by designated staff *
Kick of meeting need to be conducted with PETROKEMYA Operations
1 & maintenance, and contractor supervisor to share the temporary ☐
repair method of statement.
Appropriate permit received for the correct job.
The personal protective equipment requirements for the proposed
2 ☐
repair must be reviewed to ensure personnel safety and compliance
with local safe work practices.
3 Make sure the work area is barricaded properly ☐
Access to the leak must be provided, including scaffolding as needed. ☐
4 Two escape routes are required to enable safe evacuation of
personnel from the area if necessary
5 Ensure that tools and equipment are in good condition. ☐
6 Locate the nearest safety shower, eyewash and fire extinguisher. ☐
7 Clean or remove any slip and trip hazard. ☐
8 Look at surrounding activities and clear unsafe situation. ☐
9 Eliminate any exposure to chemicals. ☐
10 Follow the heat stress index. ☐
11 Compliance with LSR. ☐
12 Proper decontamination for the equipment. (if required) ☐
13 Reading MSDS and comply with the precaution. ☐
14 Insure LOTO done as per the SHEM-08 (0.2 – 0.9). (if required) ☐
15 Comply with method of statement steps. ☐
Proper Communication tools need to be available with maintenance,
16
operation & contractor supervisor. ☐
17 Comply with injection pressures as per engineering calculations. ☐

I acknowledge that all pre activity EHSS requirement are met.

Technician/Group leader Name & Signature: _______________________Date: ____________

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2.0 List of Specific technical requirements

List of requirements Prerequisite QA QC requirements Confirmation by

Sr.
Requirements designated staff

Inspection – DFT of applied coating system Ensure inspector authority ☐

with DFT gauge to perform the task and the
1 DFT gauge shall be having
3rd party calibration
certificate
Ensure inspector authority ☐
Inspection – Continuity Test using holiday to perform the task and the
2 tester High voltage/Low voltage – DC Spark Tester shall be having
operated instrument 3rd party calibration
certificate

2.0 List of Required Tools (other than standard tools)

QC requirements
Sr. List of Required Tools Confirmation by
designated staff
1 Hand tools ☐
2 Torque tools ☐
3 chain blocks ☐
4 Coating mixers ☐
5 Drilling machine ☐
6 MBX bristle blaster ☐
7 Grinding machine ☐

3.0 Mandatory Materials

QC requirements
Sr. List of Mandatory Materials Quantity Confirmation by
designated staff
1 Consumable materials. (Rags, contact cleaner, etc.)
2 Repair materials (sealant, coating, clamp, etc.)
3 Injections ports

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5.0 Work Instructions

5.1 Inspection and repair.

(Note: Legends: HP- Hold Point, WP- Witness Point, SP-Spot check Point)

5.1.1 Preparation & Observation

Measured QC
Sr. Description Category Expected Results By
Output Confirm.
Visit the job site and be ensure Equipment isolated
1 the equipment prepared for HP / free from the Sup. ☐
planned work obstruction
Received Work Order before All jobs should have
starting the job notification / Work
2 WP Order. Make sure Sup. ☐
the approved MOC
package is attached
Receive work permit as per Do joint site visit /
SHEM 08. See if any more
precautions are
3 HP
required. Comply
Sup. ☐
with PHA / RA
recommendations
Conduct the safety SHE checklist All required SHE
4
above
WP items done Planner ☐
Prepare the materials and tools All required tools as
5 and ONLY use the right tools for WP per shall be Sup. ☐
the right job as per SHEM 03 prepared at the site.
Ensure the area is clean. Avoid
6 HP contamination of oil Planner ☐
and grease
Before start the job ensure related Subject equipment
equipment isolated & LOTO should be ready for
7 WP
temporary repair
Sup. ☐
applied ( if required)
execution.

Final confirmation of Supervisor/designated staff that all QC requirements have been met (signature)

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5.1.2 Repair

QC
Expected Measure
Sr. Description Category By Confirm
Results d Output
.
Be sure follow the equipment
1 isolated ( if required) & prepared HP SUP. ☐
for repair activities
Make sure that team is aware of
2
method of statement.
HP SUP. ☐
Received Work Order before
3 starting the job with clear scope & WP SUP. ☐
QC/QA plan.
4 No change on leakage condition. WP SUP. ☐
Availability of temporary repair SUP.
5
materials
WP ☐
Application of the temporary SUP.
6
repair
WP ☐
7 Temporary repair completion HP SUP.
Final confirmation of Supervisor/designated staff that all QC requirements have been met (signature)

6.0 Startup Requirements

QC
Expected Measure
Sr. Description Category By Confir
Results d Output
m.
Housekeeping for the area
1 WP Tech. ☐
Ensure no leakage is remaining
5
after the repair
WP Sup. ☐

Final confirmation of Supervisor/designated staff that all QC requirements have been met (signature)

7.0 List of Additional Spare Replaced (filled by supervisor)

Description Quantity
Sr.

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8.0 Observations and Findings

Finding in Step# Findings and observations (if any) Action Taken

Technician/Group leader Name & Signature: _______________________Date: ____________

Supervisor Name & Final signature: Date:

9.0 Reference

 SHEM 08.00
 SHEM 08.03
 SHEM08.07
 SHEM 08.08
 SHEM 08.10
 SHEM09.00

10. Attachments – Not Applicable

Sr. Description Attachment files Remarks

1 Pre-activity hand safety checklist To be filled before
Acrobat Document
execution

2 Tools & equipment inspection checklist

Tools & Equipment
inspection check list.pdf

3 Hand injury prevention procedure Only for reference.

Hand Injury
Prevention Procedure (CGPM-001).pdf

4 Heat Stress Checklist

Attachment 5 Heat
stress workplace inspection check list.pdf

5 Temporary repair methods

SMP-Belzona
(attachment).docx

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Attachment 5: trmporary repair methods

1. Temporary engineered enclosure clamp:

Clamp is a fabricated steel enclosure filled with sealing material. Used as a temporary repair to stop the
leak while system under operation on piping components.

These will require the competent engineering contractor company to provide mechanical engineering
design (both on pressure envelop calculations and clamp engineering drawings) on the enclosure and
also the sealant injection for the temporary repair to be executed.

• Clamps are usually used to stop the leak of the system while it is under operation.

• Clamp suites all process types with a condition of choosing the right sealant and material of the clamp
body.

• Clamps are used most commonly on the piping components such as, pipe lines, flanges and valves.

• The use of clamp helps in preventing the plant down time as well as allowing more time for planning the
permanent repair.

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Three most common types of clamps are the following:

• Engineered enclosure clamp:

It shall be installed by competent and approved engineering contractors.

It is used to cover heavy leaks and leaks of high pressure fluids.

It covers big area.

It rests on the pipe line or the flange body.

Maintenance Stationary Engineer shall review and approve the suitability of the clamp. Consideration
should be given to the additional weight of the enclosure clamp, specially, if thinning has occurred or a
potential degradation mechanism has been identified in the area affected by the leak. NDE is required in
all cases. Consult to AED Stationary Engineer shall be addressed, if required.

Maintenance Stationary Engineer shall review and approved, all injection or re-injection of leak sealing
fluids. Chemical compatibility of sealant to be injected shall be reviewed and approved by Process
Engineer.

Where a clamp encapsulates the flanges/bolting (for example wire clamp), an evaluation of the bolting
integrity shall be made in consultation with AED Stationary Engineer.

Injection points drilled on the clamp body.

After sealant has cured, the open end shall be sealed, and valve closed.

• Flange Clamp:

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Used commonly to seal flange leaks.

Installed to cover the opening between two flanges.

It rests on the pipe line or flange body.

Flange clamps shall be designed and installed by approved contractors.

Maintenance Stationary Engineer shall specify the type of flange clamp including injection re-injection of
leak sealant.

Maintenance Stationary Engineer shall review and approve the suitability and the injection or re-injection
of leak sealing fluids. Chemical compatibility of sealant to be injected shall be reviewed and approved by
Process Engineer.

Flange clamps have injection points drilled on the clamp body.

After sealant has cured, the open end shall be sealed.

• Wire Clamp:

Used to seal the leaks on flange in congested areas.

Installed as insertion between two mating flanges.

Injection points drilled on the flange body.

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Wire clamps shall be designed and installed by approved contractors.

Maintenance Stationary Engineer shall review and approve the suitability and the injection or re-injection
of leak sealing fluids. Chemical compatibility of sealant to be injected shall be reviewed and approved by
Process Engineer.

AED Stationary Engineer shall be consulted for the evaluation of the bolting integrity shall.

Sealant Injection Point

2. Inject sealant :

This kind of temporary repair used to stop the leak on the flanges or valves packing.

• The maximum injection pressure shall not exceed 120% of the line operating pressure. In case the
pressure need to be increased, PETROKEMYA approval is required.

• Where subsequent number of sealant injection is required after the initial 3 days of sealant injection, this
shall be discussed with AED Stationary Engineer.

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3. Non- Metallic temporary repair:

Non-metallic wraps (e.g. Composite wraps) shall be installed by approved contractors, in consultation
with AED Stationary Engineer. Wrapping may be used to seal leaks and reinforce corroded areas.
Composite wraps are generally used in low risk leaks.

Careful consideration of system operating pressure, temperature, fluid/gas interaction and fire resistance
shall be made in consideration of the composite wrapping system.

a. Non-metallic composite wrap/coating repair (e.g. Belzona or NRI):

 Maintenance Stationary Engineer shall review operational and design conditions and
compatibility of wrap material (inclusive and not limiting to design pressure & temperature and
also process service) in consultation with Production Engineer and Process Engineer.

 Maintenance Stationary Engineer shall review existing material of equipment and/or piping
(consult with AED Stationary Engineer, when required).

 Vendor/contractor shall be specialist on non-metallic composite repairs.

 Data of above has to be send to engineering contractor as a request for quotation / technical
proposal.

 Contractor to submit technical proposal to cover wrapping/coating technical requirements,

including number of layers and wrap length based on defect dimension, in conformance with
ASME PCC-2.

 All non-metallic composite wrap/coating applicators will need to be proven competent by the
contractor company.

 Surface preparation and wrap/coating execution checklist to be prepared, verified and signed
off by Maintenance Stationary Engineer and also Stationary Equipment Inspector.

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 As minimum applicator contractor has to provide the supervision to ensure that substrate
(equipment/piping) to be repaired have the sufficient anchoring surface profile (since
contractor will be providing the warranty).

 If there is a hole/pitting, the same will be required to be sealed via a compatible non-metallic
putty before the layer up of non-metallic composite wrapping/coating.

 Allow time for curing as specified in technical proposal.

 Final inspection: DFT Check by using DFT gauge, Coating continuity test Holiday detectors (Low
voltage /High voltage DC operated instruments )- as instructed in Technical proposal, Shore
hardness and visual inspection (by contractor, witness PETROKEMYA SEI).

 See Attachment – 1, Surface Preparation and Wrap Application Check List.

 If non-metallic composite wraps/coating are as above procedures and only damage mechanism
applicable is from external. This repair will be considered as a permanent repair, after AED
Stationary Engineer approval.

b. Non-metallic material compound build-up (e.g. Belzona 1111):

Non-metallic composite compounds (e.g. Epoxy glass fiber or ceramic reinforced patch) shall be applied
by approved contractors, in consultation with AED Stationary Engineer. Repair compounds (e.g. Belzona
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1111) are typically multi-component repair composites based on metallic- or ceramic- reinforced
polymer systems. These are applied as paint-like coatings or putties and have been used in minor
repairs of tube sheets, flanges, pump and compressor casing, etc.

 The contractor shall visit the work site with the Maintenance Stationary Engineer for field
feasibility evaluation.

 Maintenance Stationary Engineer to obtain material and also operation process for
location/item to be repair, in order to send it to contractor.

 Contractor to submit technical proposal for review and approval.

 All applicators need to be proven competent by the contractor company.

 Maintenance Stationary Engineer to review process and material compatibility of the repair. To
consult AED Stationary Engineer, as required.

 Process Engineer and Production Engineer to evaluate the material compatibility.

 Surface preparation checklist (who to do / supervise) as minimum contractor to provide the

supervision to ensure that the substrate is having sufficient anchoring surface profile (since they
are providing the warranty).

 Allow time for curing as recommended in technical proposal.

 Machining where surface flatness is required.

 Final inspection by AED Stationary Equipment Inspector and final work acceptance, by
Maintenance Stationary Engineer.

QC Engineer / Supervisor / Foreman

Name: ______________ ID# ___________ Signature: _____________

QA Engineer / Supervisor / Foreman

Name: ______________ ID# ___________ Signature: _____________

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