Method & Risk.docx

8/10/2019 Method & Risk.docx

1/7

METHODE STATEMENT & RISK ASSESSMENT

Client : PT.Sentra Usahatama Jaya

Unit : Tube Boiler

Schedule : November 2012

OBJECTIVE

The purpose of this project proposal is to propose our method of cleaning internal &

external Fire Tube Boiler during maintenace on PT.Sentra Usahatama Jaya at

Cilegon.

SYSTEM OF CLEANINGBased on our experience in cleaning internal & external tube boiler, we will use only

fresh water as the media of cleaning. We strongly not recommend the company to

use any chemical substance to clean the tube boiler due to its corrosive agent as

its natural excess. High Pressure water jet system was also applied at many power

plants around the world.

Our Water jet system of cleaning will be explained as follows:

1. We will split our team in 2 teams. First team will clean the internal tube and

second team will clean the external tube at INSITU which located in the

power block area and both teams will do the job at the same time.

2. First team will do the cleaning from bottom tube which had been cut off for

replacement using rotating Nozzle BANSHEE (see attachement 1) connected

to the flexible lance and our 2nd team will do the external cleaning tube using

a Fan Nozzle that is a 15 angle spray nozzle (see attachment 2) attached to the

dump style triggered gun (see attachment 3), so total working gun are 2 nozzles

work independly at the same time. This 2 nozzle splitted independent system

will work due to the Bi-mode Valve (see attachment 4) which make it possible.

The team will work long shift, 12 hours work per shift.

Each tube will have 30 minutes to be cleaned to its base metal surface. We

calculate that the first team will finish cleaning 60 internal tube in 2 days.

While the 2nd team will accomplished the job in 4 days. Adding 1 day for

preparation and 1 day for dismantling equipment, we are convident to

accomplish the job in 6 days.

3. But before the cleaning can be done, we will install sufficient lighting

mounted on scaffolds which we installed 1-2 days previousely, so our team

could enter the furnace and work in safely manner.


2/7

4. The working pressure to clean the internal tube will be around 10.000psi and

14gpm of water flow rate on each nozzle gun and cleaning can be jetted from

the top side of the layer to the bottom. This pressure was proven more then

enough to wash and clean the internal tube to its base metal surface.

5.

For the second team, the pressure applied will be around 5.000 to 7.000psi.

6. We will cover a plastic sheet underneath the working area in a cone manner to

cover the below area from splashing water.


3/7

METHOD OF CLEANING

As our Standard Operating Procedure for the job of internal & external tube cleaning,

we hereby submit the Method of Cleaning:

PREPARATION

When the Pump Unit arrived at the location, our supervisor will report to theCompany Representative in order to get access and position where the pump

unit will be placed

Our Crew will start to do the preparation for the job like connect discharge

pump to pipe, pipe to splitter, splitter to hose, hose to hose, hose to gun, the

connection gun to nozzle will be connected later after we do the Flushing.

Our Technical Supervisor will re-check all connection to make sure that allfittings are connected properly.

Our Technical Supervisor will inform our Pump Operator to Start the Engine

for 10 minutes with PTO in Neutral Position to heat up the engine.

Our Technical Supervisor will inform all Jeter to hold the gun in order to do

the Flushing.

Our Technical Supervisor will instruct the pump operator to start running thepump to do the Flushing for 3 minutes.

The Pump Operator will make a report to Technical Supervisor regarding the

Preparation Report.

IN SITU CLEANING (1ST

TEAM)

Technical Supervisor will conduct Tool Box Meeting with Safety Officer,

Pump Operator, Leader, Jeter and Helper to discussed safety issue and

technical condition for the job.

Internal tube will be cleaned by rotating nozzle which will be performed from

the bottom side and slowly inserted climb up to the top.

Each team will be supervised by 1 Leader/Foreman.

Each operator will wear proper PPE such as Helmet, Face Shield, Goggle,

Rubber Glove, Safety Shoes, Rain Coat and also Full Body Harness due to the

high elevation of work.

IN SITU CLEANING (2ND

TEAM)

Our operator will clean the external tube started from top end to the bottom

end of the tube.

Each tube boiler will take about 30 minutes to be cleaned properly.

We will set the working pressure from 5.000 psi and gradually raised to

7.000psi if there is necessary.

After the tube is visually clean, then our operator will move to the other dirty

tube.


4/7

INSPECTION

Every Work Shift completed, we propose the Companys Representativeto dothe Inspection using Boroscope for the internal tube area.

After each inspection, our Leader will make a written report to the company,

signed and acknowledged by our Technical Supervisor and Company

Representative.

CLEANING AREA

When all the jetting is done, all of our personnel will conduct a cleaning area

and our Project Manager will make a Completion Job Report acknowledged

by company representative.


5/7

RISK ASSESSMENT

Our method of cleaning would have very minimum environment impact due to use

only fresh water as the media of cleaning. How ever the risk that might occur with our

system is such mechanical risk has to be considered with all attention. Those risks

might be explained as follows:

Head Injury: Any fallen object from above. To minimize the risk, all our

personnel will use proper Safety Helmet.

Eye Injury: Dirty water splashed as a cause of high pressure cleaning. To

minimize the risk, all our personnel will use Safety Google.

Foot Injury: Step on a sharp object or hit by a heavy material will cause foot

injury. To minimize the risk, all our personnel will use Safety Shoes.

Fall from Height: Every personnel who work on elevation maximum 2 meters

will wear Full Body Harness.

We will use heavy equipment such as forklift to lift and move the basket from

and to the cleaning area, there for we will use registered heavy equipment with

valid license and a professional driver with licences and certification from

government.

As a safety standard for lifting equipment, we will provide a professional

Rigger to support and directing the forklift driver.

Our Safety Officer will conduct safety briefing which will be followed by

Tool Box meeting every day before start working.

Imani, Z

Director


6/7

ATTACHMENT

No.1 No.2

No.3 No.4


7/7

PICTURES

Method & Risk.docx

Documents

Transcript of Method & Risk.docx