SERVICES FOR SERVICING/OVERHAULING OF CONTROL VALVES (METSO)

 

Scope of Contracted Services

 

  1. General Scope of Work

 

Out-contracted services for the supply of labor, tools, test equipment, technical supervision and expertise for the complete Servicing/Overhauling and Testing of NCP Control Valves (METSO)

 

The contractor shall also actively participate in the development of work packages. This should include, but is not limited to the following:

 

  1. Provide Expertise in the development of detailed repair and testing procedures
  2. Provide Safety execution plan and risk analysis
  3. Provide Quality Assurance Plan for the testing and acceptance of work

 

  1. Detailed Scope of Work

 

a.) Activities

The scope of work shall include the following:

 

SN Activity Responsibility

  1. Dismantling/Hauling to Contractor’s Temporary shop

1 Process Isolation, Depressurization and Draining JGSPG

2 Isolation of signal and IA including venting of residual IA from pneumatic system.

Note: Signal isolation at marshaling panel shall be done by JGS Technician Contractor- Services (IED)

3 Dismantling of pneumatic system components and accessories Contractor- Services (IED)

3.1 Cleaning of instrument accessories (regulator, solenoid valve, pilot valve, trip valve, etc.)

Note: To be done during temporary storage of components during valve overhauling Contractor- Services (IED)

3.2 Cleaning and inspection of positioner internal pneumatic parts

Note: To be done during temporary storage of components during valve overhauling Contractor- Services (IED)

3.3 Cleaning of positioner micro filter

Note: To be done during temporary storage of components during valve overhauling Contractor- Services (IED)

3.4 Purging of instrument air tubing

Note: To be done during temporary storage of components during valve overhauling Contractor- Services (IED)

4 Dismantling

Note: Contractor-Services shall participate and witness in the dismantling to ensure proper valve pull-out Contractor- Services (MED) / Contractor- Services (IED)

5 Blinding

Note: Endorse to Kevin and Neil for blind list Contractor- Services (MED)

6 Hauling to Vendor’s temporary shop Contractor- Services (MED) / Contractor- Services (IED)

 

  1. Repair and overhauling

7 Disassemble of actuator/valves Contractor- Services (IED)

8 Initial quality assurance check

Note: JGS to verify As-Found Condition and Review of Material Identification Certificate JGS-IED QA Team

9 Inspection/cleaning/corrosion removal/painting/ Lapping or minor machining/repair of actuator Contractor- Services (IED)

10 Replacement of actuator corroded parts Contractor- Services (IED)

11 Replacement of actuator soft parts (diaphragms, O-ring, packing) Contractor- Services (IED)

12 Reassembly of actuator Contractor- Services (IED)

13 Actuator bench setting Contractor- Services (IED)

14 Replacement/Cleaning of valve’s corroded parts Contractor- Services (IED)

15 Replacement of gland packing Contractor- Services (IED)

16 Replacement of gaskets and seals Contractor- Services (IED)

17 Replacement of plug and seat assembly Contractor- Services (IED)

18 Lapping or minor machining/repair Contractor- Services (IED)

19 Reassembly of valves Contractor- Services (IED)

20 Reassembly of valve and actuator Contractor- Services (IED)

  1. Testing

Note: JGS Work Administrator along with Valve vendor to prepare testing procedure corresponding to related standard. i.e pressure rating, time/duration during testing

21 Seat leakage test (Using Contractor Valve Tester)  Contractor- Services (IED)/ JGS-IED QA Team

22 Shell test (Using Contractor Valve Tester) Contractor- Services (IED)/ JGS-IED QA Team

23 Stroke test (Using Contractor Valve Tester) Contractor- Services (IED)/ JGS-IED QA Team

 

  1. Hauling to Site and Reinstatement

24 Hauling to site

Note: Contractor to participate in the hauling to ensure that there is no damage incurred during the transport.  Contractor- Services (MED) / Contractor- Services (IED)

25 De-blinding Contractor- Services (MED) / Contractor- Services (IED)

26 Replacement of old bolts and nuts and gaskets

Note: Work Administrator to submit to JGS-MED the tags of valves to service for bolts/nuts/gasket prep Contractor- Services (MED) / Contractor- Services (IED)

27 Re-instatement of valve-actuator assembly Contractor- Services (MED) / Contractor- Services (IED)

28 Re-instatement of accessories Contractor- Services (IED)

29 Re-termination of signal at Marshalling panel JGS-IED

 

  1. Onsite Calibration & Commissioning

30 Calibration JGS-IED/ Contractor- Services (IED)

31 Stroke Checking / Loop Checking

Note: This should be done after line cleaning. JGS-IED/ Contractor- Services (IED)

32 Valve Software Benchmark (Diagnostic/Offline Tests) JGS-IED

33 QA/QC Inspection Contractor- Services (IED) / JGS-IED (QA)

 

b.) Resources Required

 

Repair Materials

1 Actuator and Valve Repair Kits JGS-IED

2 Gasket, Seals and Diaphragms JGS-IED

3 Anti-Seize compound Contractor- Services (IED)

4 Lapping compound Contractor- Services (IED)

5 Flange gaskets, bolts and nuts JGS-MED

6 Leak testing fluid Contractor- Services (IED)

7 Grease Contractor- Services (IED)

8 Graduated cylinder (for leak measurement) Contractor- Services (IED)

9 Pressure Gauges Contractor- Services (IED)

10 Sealing tape Contractor- Services (IED)

11 Paint (Restoration to original Color- High Temperature for Valve body) Contractor- Services (IED)

12 Contact cleaner Contractor- Services (IED)

13 Rags Contractor- Services (IED)

 

Repair Tools and Equipment

14 Chain block and A frame Contractor- Services (IED)

15 Repair table Contractor- Services (IED)

16 Hand tools Contractor- Services (IED)

17 Torque wrench Contractor- Services (IED)

18 Power brush Contractor- Services (IED)

19 Drill and drill bit set Contractor- Services (IED)

20 Handtap Contractor- Services (IED)

21 Seat leak and shell test equipment Contractor- Services (IED)

22 Hauling equipment (cart/truck/crane) JGS-MED

Temporary Shop/shelter

23 Temporary Site Repair Shop

Note: JG Summit to identify location for the TempFacil

        : Same Temporary shop for both NCP and Polymer Contractor- Services (IED)

24 Shop Air (at 7 bar) Contractor- Services (IED)

25 Power (excluding the socket, contractor to provide)

Note: Contractor to provide extension cables JGS-IED

 

III. Terms and Conditions / Acceptability notes

 

1) Accredited Contractor to conduct site and equipment survey prior to submission of quotation.

2) Duration of repair/servicing shall be within the schedule defined by JG Summit. Contractor may opt and is allowed to work on 24-hour shifting schedule to complete the scope within specified duration.

3) Contractor shall execute the repair based on control valve’s repair manual (JG Summit to Provide). All other performance test/parameters result must conform to equipment manufacturer and/or JGSPC standards.

4) Bolt torque for bonnet/body stud bolt/nut shall be as control valve’s repair manual (see attached). Failure to perform the specified torqueing may result to premature damage of bonnet/seat gaskets and seals and contractor shall be held liable and shall replace this immediately.

5) External specified parts shall be painted and rust/corrosion cleaned.

6) Contractor shall allot multiple repair team (2 to 4 teams) working with separate tools and equipment

7) Upon awarding, Contractor shall have site walkdown for familiarization at least seven (7) days prior the SD. Contractor shall setup Valve Servicing Shop/Staging Area at least 2 days before actual SD schedule.

8) Contractor shall provide a one (1) year warranty against workmanship and one (1) year warranty against material defect.

9) Contractor shall be penalized if unable to complete work within specified duration.

 

  1. Acceptance and Testing

 

Acceptance Test

1 Leakage Test ISO 5208/API 598/ API 6D/ MSS SP-61/ FCI 70-2

2 Shell Pressure Test ISO 5208 acceptance criteria as per API RP 6DR

3 Documentation, Forms and Certifications All findings and activities must be documented including:

  1. As found observations / findings including pictures
  2. As left / actions taken including pictures
  3. All parts that were replaced and those that were re-used (in case there is insufficient repair kits available) including pictures
  4. All other necessary observations, remarks and recommendations
  5. Repair/Servicing Summary

4 Submission of Report/Documentation

5 Submission of Material List To capture all materials that were turned-over to contractor (used and unused)

  1. Purpose

Servicing/Overhauling of Control Valves (METSO) for NCP Turnaround Maintenance October 2019

Published by: Sharon.B. Santos, Website Admin LCI

 

 

 

 

 

 

JG SUMMIT EXPANSION PROJECT PHASE 1

Fluor was awarded an engineering, procurement and construction management (EPCM) contract for the utilities, offsites and infrastructure scope of work for JG Summit’s petrochemical complex expansion in Batangas City, Philippines.

The JG Summit Petrochemicals Group will be increasing ethylene production by 160,000 tons per year and propylene production by 110,000 tons per year. The Group will also add four new units to the facility: 2nd stage pygas hydrogenation unit, aromatics and butadiene extraction units, and a new bimodal high-density polyethylene (HDPE) plant. The existing polypropylene (PP) plant will also expand its production capacity by 110,000 tons per year. The utilities and offsites project will therefore provide new and expanded utility systems to meet the demands of the complex, as well as upgrade the existing infrastructure.

JG Summit is the sole naphtha cracker operator in the Philippines and will continue to operate the facility during the construction phase. A 6-week turnaround has been scheduled for mid-2019, at which point all critical tie-in activities must be completed.

The challenge to the project will be to complete construction, perform the tie-in works and have the system pre-comm​issioned and ready for full expanded plant operations after the turnaround.​​

Fluor is executing EPCM for the complex’s utilities, offsites and infrastructure from our Manila office, which is located only 60 km from the facility, allowing for greater interaction between engineering and construction. In 2017, Fluor completed the simplified front-end engineering and design work for the expanded utilities and offsites systems.

Additionally, Fluor’s Manila office is also providing program management consulting services for the project, simplifying the interface process with the other EPC contractors.Fluor is executing the utilities, offsites and infrastructure scope for JG Summit’s petrochemical complex expansion. The project is expected to be completed in phases, with the cracker expansion, new 2nd stage pygas hydrogenation, and new aromatics and butadiene extraction units completed in mid-2019, and with the polypropylene expansion and new HDPE facility completed in mid-2020.

(Source: Fluor Website)

Re-Published by: S.B. Santos, LCI

http://www.fluor.com/projects/jg-summit-petrochemical-expansion

Track Record

 

SARANGGANI ENERGY CORPORATION II

 

JGC Awarded the Contract for a Power Plant Construction Project in the Philippines

Full-scale expansion into the energy infrastructure field under the new medium-term management plan

Yokohama-Japan- JGC Corporation announced today that, with JGC Philippines Inc., its subsidiary in the Philippines, it has been awarded a lump-sum turnkey basis contract for the Phase II construction work for a Coal-Fired Power Plant Construction Project planned in the Sarangani Province, Mindanao, Philippines, by Sarangani Energy Corporation (Capital subscribers:Alsons Consolidated Resources, Inc. 75%, Toyota Tsusho Corporation 25%).

The contract covers the engineering, procurement, construction and commissioning (EPCC) services for the Phase II construction work (105 MW x 1 train) for a coal-fired power plant with a capacity of 210 MW (105 MW x 2 trains).  The project is scheduled for completion in April, 2019.

The plant is located in the province of Sarangani, about 1,100 km south of Manila, and the electric power generated is intended to serve the needs of the province, including its major city of General Santos, thereby increasing the potential for industrial growth in the province and contributing to an improved standard of living for the population.  With a growing population and steady economic growth, the Philippines is facing an increasing demand for electric power, and this situation is of particular concern on the island of Mindanao, where the shortage of power has been especially severe.

Minimizing the environmental impact of this project is also a high priority.  This has been addressed by the use of a circulating fluidized bed boiler that makes possible two stage combustion at low temperatures, which inhibits the generation of atmospheric pollutants, such as Nitrogen Oxide (NOx) and Sulfur Oxide (SOx).  This, combined with removal of the particulates contained in the off-gas, ensures that the effects of the operation of this plant on the environment are kept to a minimum.

JGC Philippines was established in 1989 and initially undertook detailed design work for JGC projects, but in recent years, it has applied its expertise gained through that experience to carry out EPC work independently for domestic projects within the Philippines.  In this project, the combination of JGC Philippines’ knowledge of local conditions and JGC’s project management skills not only will lead to the successful completion of this project but will also open the door to further expansion of the JGC Group’s activities in other areas, as well.

JGC’s new medium-term management plan, “Beyond the Horizon,” announced in May of this year, directly targets JGC’s basic goal of expanding its business beyond projects in the oil and gas sector to other energy infrastructure, industrial infrastructure and social infrastructure projects.  Under that plan, with this project, JGC is taking a large step into the field of power generation, and further, JGC anticipates that this project will contribute to the growth expected in the ASEAN region.

(Source: JGC Corporation Archives)

 

PETRON BATAAN REFINERY RMP2 PROJECT

The Petron Bataan Refinery (PBR) is the country’s largest integrated crude oil refinery and petrochemicals complex. Inaugurated in 1961 with a capacity of 25,000 barrels per day, it has grown to its current rated capacity of 180,000 barrels-per-day.

Located in the province of Limay, Bataan, PBR processes crude oil into a full range of petroleum products including gasoline, diesel, liquefied petroleum gas (LPG), jet fuel, kerosene, and industrial fuel oil. PBR also produces petrochemical feedstock benzene, toluene, mixed xylene, and propylene.

PBR is at the heart of Petron’s operations. For over 50 years, the facility has served the country’s demand for quality fuel products, ensuring a reliable and continuous supply to power the nation forward. Run by Filipino refining experts, PBR is a showcase of the world-class technical capability of our countrymen as well as first-rate technology.

Through the years, PBR has achieved several firsts in the industry including the production of revolutionary and environment-friendly fuel products, international certifications (e.g. International Management Systems), and safety milestones among others.

Petron continues to invest in its refinery to better serve the nation. In the past decade, it has employed its refinery to formulate petroleum products that fit the lifestyles of Filipinos. It has also commissioned units that allow the local production of fuels that meet the requirements of the Clean Air Act.

Petron is the only local producer of petrochemical feedstock. Petrochemical production is strategic since it is one of the pillars of an industrialized nation. Petrochemicals are raw materials used in a wide variety of applications, including food packaging, rope, sacks, plastic parts, home appliance, automotive parts, reusable containers, etc.

In 2011, Petron embarked on the Refinery Expansion Project (RMP-2) in celebration of PBR’s golden anniversary. Targeted for completion in the next few years, RMP-2 will make the refinery more competitive in the Asia-Pacific region by significantly increasing its production rate, thus improving the country’s oil supply security.

The decision to undertake this massive project was born out of the vision to make the Petron Bataan Refinery one of the most modern integrated oil refining and petrochemical complexes in Asia.

Furthermore, RMP-2 is a reflection of Petron’s belief in the country’s prospects and staunch partnership with the Filipino towards nation-building. As it grows its refinery, Petron hopes to contribute in the growth of its motherland.

Note: Products involves MTL Surge Protection and Metso Control Valves

Re-Published By: S.B. Santos, LCI

(Source: Petron Website)