Flow Synergy Technics Sdn Bhd was awarded static equipment HPWJ cleaning and mechanical work for EVYAP SABUN SHUTDOWN 2017 DOSH INSPECTION.

The maintenance scope covered :

• To provision qualified technician, 12 blaster and machineries 4 units of UHP diesel driven machine @ 30000 psi and 15000psi pump to lancing and cleaning c/w cross jet & polishing nozzles to remove the scaling 100%
• Dismantle & refit all related end cover to ease the cleaning operation
• After proper housekeeping & inspection to box back and hand over

1.0 Fractionation plant

(Tube internal lancing) – 4160 tubes – 15 KPSI

• Feed Preheater x 3 units  x 701 tubes
• Cooler x 10units x 2315 tubes
• Feed exchanger x 3units x 372 tubes
• Steam Generator x 3units x 372 tubes
• Condenser x 2 units x 200tubes
• Cold trap x 5 units x 200tubes

(Washing + Flushing ) – 25units

• Column x 5units – washing
• Evaporator x 7units – washing, open overhead & bottom flushing
• Light tank x 1unit – Flushing
• Flash vessel x 11units – Washing & flushing
• Air receiver x 1unit – washing

2.0 Hydrogenation plant

(Tube internal lancing ) – 1063tubes

• Cooler x 2 units  x 397 tubes (30KPSI)
• Preheater x 1unit x 110tubes (15KPSI)
• Exchanger x 4 units x 400tubes
• Condenser x 2 units x 156tubes

(Washing + Flushing ) – 7units

• Drier x 1unit – washing
• Reactor x 1unit – washing
• Tank x 3unit – washing
• Vessel x 2units – washing

The 10500 men hours shutdown was successfully handed over on the estimated schedule within 24hrs rotation shift. upon leak testing and final by DOSH & IRISH inspection the plant shutdown was handed over successfully .

LOTTE CHEMICAL TITAN AWARDED FLOW SYNERGY TECHNICS SDN BHD A 3″ PIPE INTERNAL PIGGING WORK TO FLUSH THROUGH THE HARDEN/ STICK POLYMER FORMATIONS.

1^st Stage – Pipe line internal pigging – 1300m(1.3km)

• All opening for entry required air purge and ventilation is required to provide sufficient ventilation duct, inductor, hose, air compressor, tools and other equipment required for the ventilation work.
• To install blinds at the starting point of the work activity and other isolation points as requested and indicated by PE2.
• To clean HP pipe line internal (as per the piping isometric and remove sludge, grease, dirt, flakes, rust, etc., by mean of conventional pigging method using Pig Launcher and Encapsulated Pig Receiver/Collector to bare metal finish.
• Schematic lines need to be pig :

1. TRAIN A : From the 1^st stage discharge of cylinders #1,2, & 3 through the jacketed intercoolers E-1150, E-1151, E-1154 & E-1155 to the 2^nd stage suction of cylinders #7,8 & 9. Total length of pipe in TRAIN A is 680.712 meters.
2. TRAIN B: From the 1^st stage discharge of cylinders #4,5, & 6 through the jacketed intercoolers E-1152, E-1153, E-1156 & E-1157 to the 2^nd stage suction of cylinders #10,11 & 12Total length of pipe in TRAIN B is 679.114 meters
3. Total length of pipe in TRAIN A & B together is 1359.826 meter

• Total length of pipe in TRAIN A & B together is 1359.826 meters
• After identify the pipe discharge point 550bar min pressure will be purged approx 250mtrs to dilute/break the hardened polymer. The process of purging will be prolonged till a discharge is found at another end. A HP pump at 40 000psi with applied in this pigging process, the pressure will be gradually increased based on the cleaning ratio & quickness.

2^nd Stage – Pipe line internal pigging – 120m

• Pigging from 2^nd stage discharge of cylinders 10, 11, 12 through HV1153 & E-1401(1^st Side Stream Cooler) up to SR1.
• Pigging from 2^nd stage discharge of cylinders 7,8,9 through HV1154 & E-1402 (2^nd Side Stream Cooler) up to SR40.
• Total 1300mtrs piping will be divided into 4 openings at 500mtrs each, will be cut and reweld using qualified 6g welders and fitters after cleaning process.
• While pre & post cleaning process all inspection will be done with a LCTM representative
• Bolting work shall be done by using a manual/hydraulic torch range which approve by LCTM
• After final pressure testing at 3000bar the reactor system was successfully handed over.

FLOW SYNERGY TECHNICS SDN BHD  : WAS AWARDED A FEED (FRONT & END ENGINEERING DESIGN) GLYCOL DUPLEX & CARBON STEEL LINE’S( 3”, 2” & 1”) ONBOARD SK 316 NC 3 GAS FIELD by TMJV

ONSHORE FABRICATION  : 

Deluge nozzle modification

• To provision proper repair procedure adhere to obtain an approval for repair as per original provided drawing as mentioned. To provision qualified CUNI 90/10 AWS welder at site (onshore) to weld and to renew the new nozzles as provided by TMJV and to braised the old material before installation – 26 joints

Glycol leakage line repair & modification

• To fabricate the newly provided pipes based on the P&Id by qualified 6G welder and fitter to weld by mean to provide all related welding machine, consumables, tools. To ensure competent welder to handle A312/316 Stainless steel material with weld process GTAW
• Pipe dimension : 3″ TP 316 sus x minimum 4 weld supports / with NDT inspection on welding seams – DPI

Glycol Recirculation Line fabrication 

• To fabricate the newly provided pipes based on P&Id by qualified 6G welder and fitter  to handle A106 carbon steel material with weld process GTAW
• Pipe dimension : 1″ & 2″ Carbon steel
• 3-GL-95817-91412 – 412mm x 6Joints
• 3-GL-95818-11412 – 13286mm x 15Joints
• 3-GL-95818-11412 –5451/924mm x 17Joints
• 3-GL-95818-91412 – 413mm x 6Joints\
• After fabrication process the external surface will be blasted with SA2.5 standard finish coated with FST provided weather resistance PU coating – Joton

OFFSHORE INSTALLATION  : 

• SUS 3″ LINE
• To field weld extra length for considering pipe length site adjustment, to modify pipe support and to weld new L type support on the secondary structure fabrication the pipe spools. To perform the fabrication & installation on board of Sk316 at offshore to adhere with proper Boiset & medical certs.
• Welding done by Habitat close measure welding method with tech
• CS 1″ & 2″ falnge to flange installation and to weld pipe support

Job successfully hand over to owner (PCSB)  & client (TMJV) after proper inspection on board SK 316 NC 3 field on 18.11.16. Max 11 crew was onboard for the said project

FST, awarded a internal ROTOFAN flushing job for Lotte Chemical Titan (M) Sdn Bhd located at Pasir Gudang Johor.

Workscope :

1. To provision 12 000psi high pressure diesel driven unit with high flow 185lpm capacity to hydro flushing internal of related SAJ line from battery point.
2. Flushing self rotating 3d nozzle system to cater id 100mm – 250mm equipped with roto track, speed controller & hose protector system to flush down the internal of pipe to remove any foreign matter which formed and to ensure 100% cleanliness. A T4 nozzle was used to flush the wide dia pipe which consisted 10 bend and the pipe lenght appeox 250meters.
3. To perform mechanical work on flanges and fittings opening, blinding & de blinding work during the maintenance cleaning.
4. Job completed successfully box back after all related sludge/mud was thoroughly house keeping and hand over upon satisfactory of LCTM own flushing.

Technology Applied :

1. High pressure flushing pump at 12000psi /390HP cater 185lpm with self rotating 3d concrete cutting nozzle with applied back pushers nozzle system for ID 250mm
2. Roto track with 175cfm air supply  T4 pneumatic hose driven system for 35meters height

FABRICATION OF CATION VESSEL DISH & RUBBER LINING – DOSH INSPECTION

Flow synergy technical team propose to Lotte Chemical for prefabrication of a dish end for cation vessel at PS 2 Cogent plant. The work scope covers DOSH preparation and submission for the named vessel. Provision qualified 6G welder, third party welding inspector (CSWIP 3.2) to monitor on welding, grove preparation and fit-up test.  To hire qualified NDE – RT company to perform 10% sport RT on the subjected weldment.

Satisfied RT & HT(Hydro testing) result and witness by LCT PE and DOSH officer the vessel was sent to rubber lining internally. On success removal of rubber lining and new rubber lining was installed as per spec and successfully read through the spark test/Holiday test at 12 000 volt using an Elcometer.

On successful fabrication and its related test the vessel was installed at PS-2 plant as origin without an obstacle. Job delivered at owner’s satisfaction

TECHNIP BRUNEI SDN BHD – JOCON CONTRACTORS SDN BHD -On site beveling

On site beveling project been awarded by Jocon contractors, a local Bruneian contractor for on site beveling work for various diameter of process pipes to FLOW SYNERGY TECHNICS SDN BHD.

The diameters covers from 12″- 20″, 24″-30″ & 32″ – 42″ a new fabricated pipes at work site at Technip yard. Flow Synergy provided 3sets of onsite beveling machine with qualified operators at work site.

Project duration was proposed for 2 1/2 month for various dia meter, and the biggest OD covered was 42″ in diameter.

AUXILIARY BOILER SUNROD CPH 250 – OVERHAULING

Being awarded a contract for Auxiliary SUNROD CPH 250 water tube boiler for general overhauling for surveyor inspection onbord of FPSO BERANTAI (Engine Room).

The project successfully proceeded  with the collaboration of TGS MARITIME SDN BHD as the Main Contractor at Trengganu Offshore. Work duration was 7days.

The work scope generally covers :

Boiler fire side dry/mechanical cleaning, Water side high pressure wash down (2500psi), valve & fittings lapping, Water tube & drum internal washing and cleaning. Refractory repair, Safety valve 2nos servicing and popping test, generating tube bank internal boroscope inspection (random check). After final inspection a hydro test was performed for surveyor to witness.

Flow synergy Technics successfully purchased another unit of high flow diesel driven pump for pipe internal flushing, high pressure washing and hydro jetting purposes.

The ultimate purpose of this pump : ROTO fan internal of process pipes, lancing clogged condenser tubes,  sewage lines, underground & over head pipes (which hardly dismantle), long length pipes hardly have intermediate flanges.

Technical terms of the unit    : 12 000psi / 130Lpm / Diesel driven unit /   Electromagnetic sensors  / 4 unit hp                                                                     guns runs concurrently / 2 units lancing system runs concurrently

EVERSENDAI ENGINEERING – HIGH PRESSURE HYDRO TESTING – 1500BAR (UNIT 4)

To perform a high pressure hydro testing job for Ever Sendai Engineering at Tanjung Bin unit 4 boiler feed water lines, for duration of 3months.

Application of pressure from 800bar – 1200bar using a diesel driven high pressure pump at 20 000psi with 55lpm Hammelman pump. As for safety precaution a NRV non return safety valve al 20 000psi was used while the testing process.

A high pressure filling pump also used on the boiler water filling at 2000lpm with 10bar electrical driven at 3 months duration too.

Job done successfully while appreciated by Alstom & Malakoff site engineers.

LOTTE TITAN PE3 SHUTDOWN – CONDENSER CLEANING PROJECT

UHP cleaning :

Consisted 9 shell and tube heat exchangers need to be mechanically remove and refit channel heads. Apply UHP lancing 30 000psi with 3nos diesel driven pump to lance internal tube section for 9 nos shell & tube bundle. After all the internal residue / polymer being removed an inspection was carried out. Upon successful cleaning and inspection the units are ready for box up.

Finally a hydro testing carried out to satisfy owner.

Chemical cleaning :

3nos bearing jackets done internal shell side chemical cleaning using (REDLYME) industrial water based biodegreaser to circulate and flush internal shell side to remove the residue any oily surface till achieve 90% of cleanliness.

The coolers internal cleaning done in parallel for each jackets. The system was circulated for 2hrs with fresh water & 4hours with biodegreaser till achieve the required standard.

It took  36hours to complete the descaling process for 3 jackets.

Finally a hydro testing carried out to satisfy owner.