PREPARED BY APPROVED BY

Signature: Signature:
Name: Name:
 STANDARD WORK PROCEDURE
PROJECT
DESCRIPTION
DATE PROCEDURE NO.

Position: Position:
Date: Date:

1.0 Purpose

This procedure is written to explain the method involved during install liner plate on vertical
sterilizer dish head.

2.0 Scope

This procedure applies to the overall process control of liner plate installation on vertical
sterilizer dish head.

3.0 Reference Document

4.0 Machine and Tools Equipment

4.1 Welding set (FCAW/SMAW)

4.2 Tubular scaffolding/staging
4.3 Grinder machine
4.4 Chain block
4.5 Lever chain block
4.6 Set of hand tools
4.7 PPE
4.8 Set of Hydro test tools and equipment

5.0 Procedure

5.1 Workshop Activity

5.1.1 QC Inspector shall perform an incoming material inspection for purchased liner
plate and shall review the material test certificate.
5.1.2 Liner plate shall be marked and cut into size according to cutting plan. QC shall
check the cut plate and give his acceptance either accept or not.
5.1.3 After cut, each liner plate shall be marked with a number according to the liner
arrangement in the design drawing.
5.1.4 The plug hole shall be made on each liner plate as per design drawing after cutting.
5.1.5 Chamfering or bevelling shall be made for each liner plate as per weld detail in the
design drawing after cutting.
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5.1.6 The liner plate shall be forming into the radius curvature specified in the design
drawing after cutting. QC then shall check the inside radius of liner plate against
the template provided.

5.2 Site Activity at Carotino POM

5.2.1 Reporting to Mill Manager and to be brief the safety rules and regulation as well as
the area of work complying to mill procedures. Team Leader shall then conduct a
brief meeting with all workers involved in this work activity. Discussion shall be
the scope of work, safety procedures, PPE, method, and HIRARC.
5.2.2 Team Leader shall conduct an internal inspection of VS to make sure it is clean
from oil fruit, fiber, etc before starting any work.
5.2.3 Team Leader shall check the powerpoint at the distribution box assisted by the mill
personnel in order to ensure that all electrical connections adhere to the mill safety
procedure for usage during this work activity.
5.2.4 The mill personnel shall make sure that all steam inlets are blank off by removing
the valve and blank it with a blank flange. The team leader shall inspect and make
sure it is done for the safety of his workers at the site. The mill personnel shall
remove all electrical connection that is connected to the VS for example Augur and
Arch Breaker Motor/Gear Reducers. The mill personnel shall also remove the augur
and arch breaker from the VS and put it outside of the VS.
5.2.5 The mill personnel shall remove the top insulation at dish head area.
5.2.6 Team Leader shall also make sure that all Charging Door and Discharging Door is
in open position all time during the work activity. All electrical and hydraulic
control shall be dismantled for safety purposes. The Doors must be tied up with a
rope so that it won’t close while working inside.
5.2.7 Use ventilation portable exhaust fan to make sure there no fume or steam trapped
inside the VS.
5.2.8 Mill personnel shall erect the tubular scaffolding/staging properly inside the vertical
sterilizer. The scaffolding or staging shall be erect in a safe condition and shall suit
the site condition.
5.2.9 Fitter or helper then bring inside the liner plate from the outlet QAD (bottom) and
lift up to the top using chain block and lever chain block piece by piece.
5.2.10 The liner plate then will be attached piece by piece to the dish head and shall be fit-
up as per liner arrangement in the design drawing accordingly.
5.2.11 After completing the fit-up, the team leader then shall perform the fit-up inspection.
The fit-up shall follow as per design drawing with hi-lo not more than 3mm.
5.2.12 Once the fit-up is accepted, then the qualified welder shall start to weld the plug
weld and long seam weld with overhead position (4G) complying with their
Welders Performance Qualification Test (WPQT).
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5.2.13 Once the welding work is finished, the team leader shall check the weld joint
visually. All welded joint shall be free from any surface defect. If found any visible
surface defect, that area shall be repaired accordingly.
5.2.14 The team leader shall mark and drill the vent hole area at dish head outside surface.
The team leader then shall fit up the vent hole nozzle as per design drawing and
qualified welder shall start weld the vent hole nozzle with 1F position.
5.2.15 After welding activity is completed and the team leader is satisfied with the quality
of the weld, the team leader then shall prepare the air leak test equipment to check
the possible leak at liner area or welded joint. Air leak test shall be conducted as per
the approved procedure (TNR/012/08/19).
5.2.16

5.2.17 The leader shall make sure that all the installation and welding work is to the best
quality and satisfaction to the Mill Manager and his sub coordinates involve in the
work activity.
5.2.18 Fitter or helper shall then dismantle the augur and cantilever after aligned and
prepare the VS for Hydrostatic Test.
5.2.19 Fitter or helper shall blank and insert the gasket at all flange connection. This shall
suit the site and blanking shall be done to the nearest connection of the shell.
5.2.20 Fitter or helper together with mill personnel shall carry out all the doors
adjustments, replace new door seals and shall be closed to the maximum.
5.2.21 Fitter or helper together with mill personnel shall prepare the HT Pump and its
connection and do all the HT preparation work accordingly.
5.2.22 Fitter or helper shall assist mill personnel to fill the water into the VS and prepare
the water to be pump into the VS until it is full.
5.2.23 The HT pressure shall be 65 Psi (4.48 Bar) and the duration shall be 20 to 30 min.
5.2.24 Trial HT shall be conducted and witnessed by the Leader and Mill Manager or his
sub-coordinates.
5.2.25 Upon satisfactorily by all persons and to witness the final HT, Mill Manager or his
sub-coordinates shall arrange with DOSH Sarawak office for their officer.
5.2.26 After final HT was accepted by DOSH Sarawak officer, fitter or helper together
with mill personnel shall release the water and pressure gradually until there is no
pressure inside the VS.
5.2.27 Fitter or helper then shall open all door and blank at all flange before continue to
reinstall the dismantle cantilever, arch breaker and augur.
5.2.28 Fitter or helper then shall ensure the alignment of the arch breaker and augur are
in the appropriate position before closing all door and fasten all the steam
connection.
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