PLANNING NORMS FOR TURNAROUND - EQUIPMENT JOB BASIS Direct Manhour Resources FT SS RG HLP HJT Small

No

Task Description

Unit

TARGET TIME (Hours/Min) Small Medium (Hrs) Large (Hrs) (Hrs)

Total (Mhrs) Medium Large

A). General A1 A2 A3 A4 Fit Ventilator Fit Lighting Remove Lighting Remove Ventilator per manhole per manhole per manhole per manhole 15 Min 15 Min 15 Min 15 Min 1 1 1 1 1 1 1 1 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours

B). Column B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 Open Tray Manway Refit / Reinstate Tray Manway Packing Removal /Unloading Reload Packing Clean Internal Shell - SSPC-SP2 - CS Clean Internal Shell - SSPC-SP2 - SS/Others Clean Internal Shell - SSPC-SP3 - CS (Weldment area) Clean Internal Shell - SSPC-SP3 - SS (Weldment area) Clean all gasket seating surface @manhole - power brush & scrapping Wire brush all bolts (full length) & apply antisieze compound - replace defective bolts per trays per trays per Drum per Drum S/M/L S/M/L S/M/L S/M/L per equip per equip per equip per equip per equip per equip per equip per equip per equip per equip per equip 15 min 15 min 0.5 Hours 15 min 15 min 15 min 15 min 15 min 15 min 15 min 15 min 15 min 15 min 15 Min 15 Min 0.5 Hours 0.5 Hours
0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 1 Hours 1 Hours 1 Hours 1 Hours

1 1 2 2
-

1 1
-

1 1 1
-

4 4 3
3

0.5 Hours 0.5 Hours 3.5 Hours 4 Hours

3
3

0.5 Hours 0.5 Hours 0.5 Hours 15 min 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 1 Hours

1 1 1

1 1 1

B11 Pre Inspection - Internal (Confined Space Entry) B12 Pre Inspection - External B13 Post Inspection - Internal (Confined Space Entry) B14 Post Inspection - External B15 NDT - Internal (Confined Space Entry) B16 NDT - External B17 DOSH Inspection B18 Final Inspection prior to Box up B19 Housekeeping C). H/Exchanger C1 C2 C3 C4 C5 C6 C7 C8 C9 Remove Spool Reinstall Spool Remove Channel Cover Refit Channel Cover Pull Tube Bundle (Critical) Pull Tube Bundle (Non Critical) Refit Tube Bundle (Critical) Refit Tube Bundle (Non Critical) High Pressure Water Jetting

1 -

1 1 2 -

per equip per equip per channel per channel per equip per equip per equip per equip per tube hole (Min) per bundle per tube hole (Min) per tube hole (Min) S/M/L S/M/L S/M/L S/M/L per cover S/M/L S/M/L S/M/L S/M/L per unit per unit per equip per equip per equip per equip per equip per equip per equip

15 min 30 min 2 Hours 2 Hours 0.5 Hours 1Hours 0.5 Hours 1Hours

0.5 Hours 1 Hours 4 Hours 4 Hours 1 Hours 1.5 Hours 1 Hours 1.5 Hours 3 min

1 Hours 1.5 Hours 6 Hours 7 Hours 1 Hours 2 Hours 1 Hours 2 Hours

2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1

1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 1 2

24 Hours 28 Hours

2 Hours 2 Hours 2 Hours 2 Hours 2 Hours

1 1 15 min 1 Hours 3 Min 3 Min

C10 High Pressure Water Jetting external bundle cleaning C11 Air Blow (HEX Tube) C12 Air Blow (after HPWJ) C13 Surface Cleaning for Internal shell (SSPC-SP2) CS C14 Surface Cleaning for internal shell (SSPC-SP2) SS C15 Weldment Cleaning -Int. Shell (SSPC-SP3) CS C16 Weldment Cleaning -Int. Shell (SSPC-SP3) SS C17 Clean Channel Cover - Hydrojet C18 Clean Internal Channel Cover (SSPC-SP2) CS C19 Clean Internal Channel Cover (SSPC-SP2) SS C20 Clean Internal Channel Cover (SSPC-SP3) CS C21 Clean Internal Channel Cover (SSPC-SP3) SS C22 Cleaning Tube Sheet (SSPC-SP3) CS C23 Cleaning Tube Sheet (SSPC-SP3) SS C24 Leak Test (H/Exchanger-Pull Bundle) C25 Leak Test (H/Exchanger-Fixed Tube) C26 C27 Clean all gasket seating surface @channel head, flanges power brush & scrapping Wire brush all bolts (full length) & apply antisieze compound - replace defective bolts

0.5 Hours

1 Hours 3 Min 3 Min

15 min 15 min 30 min 30 min

1 Hours 1 Hours 1 Hours 1 Hours

1 1 -

15 min 15 min 15 min 15 min 15 min 0.5 Hours 0.5 Hours 1 Hours 1 Hours 0.5 Hours 0.5 Hours 15 min 15 min 0.5 Hours

1 Hours
0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 1 Hours 1 Hours 1 Hours 1 Hours 1 Hours 1 Hours 1.5 Hours 1.5 Hours

2 2 1 1

2 Hours 2 Hours 1 Hours 1 Hours 0.5 Hours 0.5 Hours

1 Hours

4 Hours 4 Hours

C28 Pre Inspection & deposit sampling C29 Post Inspection C30 NDT Inspection

1.5 Hours

PLANNING NORMS FOR TURNAROUND - EQUIPMENT JOB BASIS Direct Manhour Resources FT 1 1 1 SS RG HLP 1 2 1 2 HJT Small

No

Task Description

Unit

TARGET TIME (Hours/Min) Small Medium (Hrs) Large (Hrs) (Hrs) 5 min 0.5 Hours 15 min 0.5 Hours 0.5 Hours 1 Hours

Total (Mhrs) Medium Large

C31 NDT Inspection (IRIS/RFET/ECT) C32 DOSH Inspection C33 Final Inspection prior to Box up C34 Housekeeping D). Vessel D1 D2 D3 D4 D5 D6 D7 D8 D9 Remove Spool/top Elbow Refit Spool/top Elbow Remove Demister (Non Critical) Remove Demister (Critical)* - 2 layers demister Cleaning Demister Refit / Reinstate Demister Non Critical) Refit / Reinstate Demister (Critical) * Clean Internal Shell - SSPC-SP2 - CS Clean Internal Shell - SSPC-SP2 - SS/Others

per tube hole (Min) per equip per equip per equip

per equip per equip per equip per equip per equip per equip per equip S/M/L S/M/L S/M/L S/M/L per equip per equip per equip per equip per equip per equip per equip per equip per equip per equip per equip

15 min 30 min
1 Hours

0.5 Hours 1 Hours

2 Hours

1 Hours 1.5 Hours

3 Hours 2 Hours

2 2

1 1

1 1 1 2 2 1 2 3 3 1 1 2 2 1 1 1 1 1 1 1 1 2

2 2 2 2
-

1 -

0.5 Hours 0.5 Hours

1 Hours

1 Hours 1 Hours
2 Hours

1 Hours
3 Hours 2 Hours

0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours 0.5 Hours

1 Hours 1 Hours 1 Hours

1 Hours 1 Hours

1.5 Hours 1.5 Hours

2 Hours 2 Hours

D10 Clean Internal Shell - SSPC-SP3 - CS (Weldment area) D11 Clean Internal Shell - SSPC-SP3 - SS (Weldment area) D12 D13 Clean all gasket seating surface @manhole, flanges - power brush & scrapping Wire brush all bolts (full length) & apply antisieze compound - replace defective bolts

1 1 -

1 Hours 1 Hours 1 Hours 15 min

D14 Pre Inspection - Internal (Confined Space Entry) D15 Pre Inspection - External D16 Post Inspection - Internal (Confined Space Entry) D17 Post Inspection - External D18 NDT - Internal (Confined Space Entry) D19 NDT - External D20 DOSH Inspection D21 Final Inspection prior to Box up D22 Housekeeping E). AFC E1 E2 E3 E4 E5 Remove Tube Plug Air Blow (AFC Tube) High Pressure Water Jetting (tube cleaning) Refit Tube Plug Leak Test/ Hydrotest Vacuum debris inside fins tubes from external E6 E7 E8 E9 Pre Inspection & deposit sampling Post Inspection (After cleaning) NDT Inspection DOSH Inspection

0.5 Hours

1 Hours 15 min

0.5 Hours

1 Hours 0.5 Hours

0.5 Hours 15 min 1 Hours

1 Hours 30 min 1.5 Hours

per plug (Min) per tube hole (Min) per tube hole (Min) per plug (Min) per equip per equip per equip per equip per tube hole (Min) per equip per equip per equip

5 min 5 min 5 min 5 min 4 Hours

1 1 1

1 1 2

0.5 Hours 0.5 Hours 1 Hours 0.5 Hours 0.5 Hours 1 Hours

1 1 1 1 1 1

E10 Final Inspection prior to Box up E11 Housekeeping F). Filter F1 F2 Remove Filter Element Refit / Reinstate Filter Remove wire mesh screen Refit wire mesh screen F3 F4 F5 F6 Unloading Media Reloading Media Clean all gasket seating surface @manhole, flanges - power brush & scrapping Wire brush all bolts (full length) & apply antisieze compound - replace defective bolts

per equip per equip per layer per layer per Drum per Drum per equip per equip

0.5 Hours 0.5 Hours 15 min 0.5 Hours

1 Hours 1 Hours 0.5 Hours 1 Hours 0.5 Hours 0.5 Hours

1 1

1 1 -

1 1 1 1 1 1 2 2

1 1 1 1 -

0.5 Hours 0.5 Hours

1 Hours 1 Hours

Note: Use "Vessel" as guideline for cleaning, inspection, box-up & housekeeping. G). Furnace/Boiler. G1 G2 G3 G4 Opening / Closing access door Power brush for tube external cleaning Wire brush & cotton rag for tube external cleaning Burner removing / cleaning (incl.tubing) Reformer - Propose for direct loading supply resources per access door S/M/L S/M/L per burner tip
0.5 Hours 0.5 Hours

0.5Hours
1 Hours 1 Hours 1.5 Hours 1.5 Hours

1 1

1 1 1

1 1 -

1 Hours

PLANNING NORMS FOR TURNAROUND - EQUIPMENT JOB BASIS Direct Manhour Resources FT 1 1 1 SS RG 1 1 HLP 1 1 1 HJT Small

No

Task Description

Unit

G5 G6 G7 G8 G9

Burner installation (incl.tubing) Opening convection header box cover Closing convection header box cover Debris Removal - normal removal by scooping Vacuum cleaning

per burner tip per panel per panel S/M/L S/M/L

TARGET TIME (Hours/Min) Small Medium (Hrs) Large (Hrs) (Hrs) 0.5 Hours 0.5 Hours 0.5 Hours

Total (Mhrs) Medium Large

Note: Use "Vessel" as guideline for inspection, box-up & housekeeping. H). Scaffolding - to propose volume/unit rate - For scheduling purpose only H1 H2 H3 H4 Erection External Scaffolding Erection Internal Scaffolding Dismantle External Scaffolding Dismantle Internal Scaffolding I). Insulation I1 I2 Insulation Removal Insulation Reinstatement Note: Equip. size category Medium Small 0.5m < M < 1.5m Heat Exchanger (Diamater) < 0.5m 1m < M < 2.5m Column/Vessel (Diameter) <1m Furnace/Boiler/Reformer : 10m x 10m < M < 25m x 25m a) Area < 10m x 10m 10m < M < 20m b) Height < 10m 5m < M < 20m c) Diameter < 5m Safety watch - Ratio base on total man entry Fire watch - Ratio base on requirement Deblinding/Close Manhole = included factor for MTW Method Target time Planned time allows for breaking the joint, inspect & clean flange faces. Large > 1.5m > 2.5m > 25m x 25m > 20m > 20m 1m 2 1m
2

1m 3 1m 1m
3

10 min 15 min 10 min 15 min

1 1 1 1

1m 3
3

10 min 15 min. `

1 1

1 1

1 2 3

4 5 6 7

PLANNING NORMS FOR TURNAROUND - BLINDING/DEBLINDING/MANHOLE & END FLANGE BASIS

Flange Rating & Size Category No of Bolt 150# 300# 600# 900# 1500# 2500# BLINDING / BREAKING JOINTS TARGET TIME (Min) DEBLINDING / MAKING JOINTS OPEN CLOSE MANHOLE/END MANHOLE/END FLANGE FLANGE RESOURCES

Fitter

Semi skill

1/2" 3/4" 1" 1-1/2" 2" 3" 4" 2" 3" 4" 6" 8" 10" 12" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 20" 24" 14" 16" 14" 16" 18" 20" 12" 14" 8" 10" 12"

A B C D

1"

45 min

30 min

45 min

30 min

6" 8" 10"

70 min 170 min

60 min 170 min

70 min

60 min

3 2

12

12" 14" 16" 18"

170 min 170 min

16

215 min

240

215 min

240

20

24" 26" 28" 30" 32" 34" 36" 38" 18" 20" 20" 24" 24" 26" 28" 30" 32" 34" 36" 38" 40" 42" 44" 46" 48"

240 min

280

240 min

280

20

24

24" 20" 24" 28" 30" 32" 26" 28" 30" 32" 34" 20" 24" 34"

300 min

330

300 min

330

28

330 min

370

330 min

370

H I J K L

32 36 40

36" 38" 40" 42" 44" 46" 48" 50" 52" 54" 56"

44

48

58" 60"

NOTE: 1. Deblinding/Close Manhole = included factor for MTW Method Target time 2. Planned time allows for breaking the joint, inspect & clean flange faces. 3. Close Manhole = included factor for Box up Target time 4. Special Lens Ring Joint = if found badly defect, required for lapping (~8hrs).

PETRONAS AMMONIA SDN BHD PASB - 4th TURNAROUND 2010 PLANNING NORMS FOR TURNAROUND - REMOVAL & REINSTATEMENT PRESSURE SAFETY VALVES (PSVs)
Flange Rating & Size Category No of Bolt 150# 300# 600# 900# TARGET TIME (Min) REMOVAL OF PSVs REINSTATEMENT OF PSVs Fitter RESOURCES Semiskill Rigger

A B C D

1/2" 3/4" 1" 1-1/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24" 2" 3" 4" 6" 8" 10" 12" 14" 16" 12" 14" 16" 18" 20" 24" 26" 28" 30" 32" 34" 36" 38" 14"

70

80

1 1 2 2 2

1 2 1 2 2

1 1 2

100 120

110 120

8 12 16

180 210

200 260

20

340

400

NOTE: 1. Deblinding/Close End Flange = included factor for MTW Method Target time 2. Planned time allows for breaking the joint, inspect & clean flange faces.

Prepared By:

Reviewed By:

Approved By:

Name : Ahmad Azliza Mat ali Mushtari Maintenance services

Name : Petronas Ammonia Sdn Bhd

Name : Petronas Ammonia Sdn Bhd

MECHANICAL VALVE (CHECK VALVE, GLOBE VALVE)

Flange Rating & Size Category No of Bolt 150# 300# 600# 900# 1500# 2500# REMOVAL OF Vlvs TARGET TIME (Min) REINSTATEMENT OF Vlvs Fitter RESOURCES Semiskill Rigger

A B C D

4
2" 3"

1/2" 3/4" 1" 1-1/2"

60

70

1 1 1 1

1 1 2 2

110
2" 3" 4" 6" 8" 10" 6" 8" 10" 12" 14" 16" 18" 20" 24" 8" 10" 12"

120 160

8 12

4" 6" 8" 10" 12" 14" 16" 18"

2" 3" 4"

140

220

300

12"

16

420

450

20" 24"

14" 16"

12" 14" 16" 18" 20" 24" 26" 28" 30" 32" 34" 36" 38" 14"

20

460

480

18"

20" 24"

40" 42" 44"

20"

24

24" 20" 24" 26" 28" 30" 32" 34" 20" 24" 24" 26" 28" 30" 32" 34" 36" 38"

46" 48"

G H I J K
NOTE:

28" 30" 32"

28

32 36 40 44

34" 36" 38" 40" 42" 44" 46" 48" 50" 52" 54"

480 560 640

530 600 680

2 2 2 -

4 4 4 -

3 3 3 -

1. Deblinding/End Flange = included factor for MTW Method Target time 2. Planned time allows for breaking the joint, inspect & clean flange faces.