procedure for fab, erec & testing of abovegroud piping

8/13/2019 Procedure for Fab, Erec & Testing of Abovegroud Piping

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CAIRN ENERGY INDIA PTY LIMITEDMANGALA PROCESSING TERMINAL (MPT)

MANGALA ASSOCIATED FACILITIES PROJECT (EPC-1)TANKS AND EXPORTS SYSTEMS - PROJECT NO: M201

M201TPL-MPT-L-PRO -6001

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TATA PROJECTS LIMITEDCAIRN ENERGY INDIA PTY LIMITED

MANGALA ASSOCIATED FACILITIESPROJECT (EPC-1)

WORK PROCEDURE FOR PIPING FABRICATION ERECTION &TESTING ( ABOVE GROUND PIPING)

SL.NO DESCRIPTION PAGE NO

1 Purpo! "

# S$op! "

" R!%!r!$! Do$u'! "

D!%***o "

+ ,!-/ -0 S-%!

2 E3*ro'!-

4 Tr-**5 -0 $o'p!!$ o% p!ro!

6 Pro$!

7 Ip!$*o 1"

18 F*- Ip!$*o 1"

11 Do$u'!-*o 1"

1# P!ro! 1

1" A!9ur! 1

M201TPL-MPT-L-PRO-6001 REV.A22


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1. PURPOSE

The purpose of this work procedure is to provide guide lines to carry out aboveground piping

fabrication, erection works and to ensure that proper quality control and documentation are

maintained at site.

#. SCOPE

The scope of this procedure covers fabrication, installation and relevant inspection for all

above ground piping works including relevant civil works at Phase II-Mangala Process Terminal

!ssociated facilities pro"ect # $P% & Pro"ect of %!I'( $($')* I(+I! td. This procedure is to

describe various activities such as 'eceipt of material from store, Identification mark transferring in

all pipes, Marking %utting as per Isometric +rawing, $dge preparation, it-up of "oints, /elding,

P/0T, (+T, 1urface preparation, painting and erection.

". REFERENCE DOCUMENTS

DECO:R;:L:SP:#88+

DECO:R;:M:SP:#88"

DECO:R;:L:SP:#88"

DECO:R;:M:SP:#8#8

M#81TPL:MPT:?:PLN:8881

DECO:R;:C:SP:#887

DECO:R;:C:SP:#811

M#81TPL:MPT:C:PRO:188#

M#81TPL:MPT:?:ITP:888"

M#81TPL:MPT:?:ITP:888

M#81TPL:MPT:R:PLN:881


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NDT : No:D!ru$*3! T!*5

,SE :,!-/ S-%! -0 E3*ro'!

WPS : W!0*5 Pro$!0ur! Sp!$*%*$-*o

P?R : Pro$!0ur! ?u-*%*$-*o R!$or0

ITP : Ip!$*o & T! P-

?C : ?u-* Coro

?A : ?u-* Aur-$!

PW,T : Po W!0 ,!- Tr!-'!

GTAW : G- Tu5! Ar$ W!0*5

,SE : ,!-/ S-%! & E3*ro'!

DPT : D! P!!r- !

MTC : M-!r*- T! C!r*%*$-!

7 8EALT8 9 SAFETY

2.& !s per 01$ Plan, the following system to be followed

2.3 !ll relevant elements of 01$ Plan shall be followed.

2.4 $mergency and response Plan shall be followed in case of any emergency. 'oad

Transport safety procedure shall be strictly adhered while transportation of manpower

or formwork materials by vehicles.

2.5 +aily pep talk shall be conducted prior to proceed for the work.

2.2 irst !id arrangements shall be followed as per procedure.

67 EN.IRONMENTAL

6.1 Refer to Environment Management instructions.

6.2 A activities s!a com"# $it! Environment Management Pan.

7 TRAINING AND COMPETENCY OF PERSONNEL

%.1 &ai# Too 'o( ta) s!a *e con+ucte+ *# ,o* su"ervisor an+ $ee)# too *o(

ta) s!a *e con+ucte+ *# res"ective area in-c!arge.



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*7 PROCESS

*71 MATERIALS

Eac! "iece of "i"es fittings vaves or an# ot!er com"onent s!a *e cear#i+entifie+ *# egi*e mar)ing on t!e "art as "er /AR "ecification AME ATM "ecification "ecification Manufacturers.

/oour co+ing s#stem s!a *e foo$e+ for eas# i+entification an+segregation.

A t!e incoming materia s!a *e ins"ecte+ *efore issuing. Refer Proce+urefor incoming materia recei"t an+ ins"ection an+ 4are !ouse Proce+ure.

On# ins"ecte+ 5 ceare+ materias s!a *e s!ifte+ to site for fa*rication.

T!e +imensions of t!e fa*ricate+ s"oos s!a *e c!ec)e+ against t!e+ra$ings. T!e ,ointing en+s s!a *e c!ec)e+ an+ ensure+ t!at t!e# are freefrom an# +amages.

*72 PIPING SPOOL FARICATION

*7271 Ge&e#$

After recei"t of +ra$ings +etaie+ fa*rication s)etc! or isometric $or)sc!e+ue s!a *e $or)e+ out *# Pi"ing Engineer.

Prior to start of $or) a +ocuments reate+ to t!e "i"ing suc! as 4e+ing

Proce+ure "ecification7 Proce+ure 8uaification Test Recor+s7 an+met!o+ statement s!a *e esta*is!e+ an+ +u# a""rove+ *# /AR.

After +iscussion $it! a concerne+ e9uence of fa*rication of t!e "i"ings"oo s!a *e +eci+e+ *# t!e concerne+ Engineer an# c!ange from t!ese9uence can *e ma+e on# after +iscussion an+ a""rova from concerne+Engineer.

A fa*rication +ra$ings s!ou+ *e a""rove+ issue+ for constructioncategor#.

*7272 ;e$ J"%&' Ie&'%!%4'%"&

:oint um*ering $i *e +one *# Pi"ing Engineer. :oint num*ering s!a *emar)e+ in t!e Master O +ra$ing. T!e ,oint num*er $i *e assigne+ to a t!e$e+ ,oints vi;. 123 etc. T!e se9uence of ,oint num*er s!a *e in t!e fo$+irection. T!e fie+ ,oints an+ t!e s!o" ,oints s!a *e i+entifie+ an+ mar)e+ int!e O +ra$ings i)e 4- !o" 4e+


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'- 'ranc! 4e+

MT- Mitre :oint

O- i" on fange ,oint

M- Mec!anica ,oint ? E=e P#e/#'%"&

Pi"ing materia s!a *e cut to si;e *# gas cutting or *# cutting too grin+ingmc.

T!e e+ges to *e $e+e+ s!a *e "re"are+ *# foo$ing met!o+s.

/ar*on teeD =as cutting foo$e+ *# grin+ing s!a *e use+ for e+ge

"re"aration. After gas cutting o(i+es s!a *e remove+ *# grin+ing u" to1.6 mm from t!e +ee"est "oint. 'eveing mac!ines s!a aso *e use+ fore+ge "re"aration.

tainess teeD '# Pasma cutting grin+ing mac!ine or *# sa$ cutting.

After "asma cutting cut surfaces s!a *e groun+ smoot! u" to 1.6 mmfrom +ee"est "oint.

T!e en+s to *e $e+e+ s!a *e "ro"er# ceane+ to remove "aint oi

grease rust +ust an+ ot!er foreign materias.



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E(terna an+ nterna surface at t!e cutting e+ges of t!e "i"e ,oint s!a *eceane+ for a minimum +istance of 2> mm from t!e ine of fusion to"revent contamination in t!e !eat affecte+ ;one of t!e $e+.

T!e en+s s!a *e com"ete# +r# *efore $e+ing.

T!e e+ge "re"aration "rofie s!a *e as "er a""rove+ an+ reevant 4P.

*727 ;e$ F%'-u/:


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4!ere a fie+ fit u" is re9uire+ one s"oo "iece s!a !ave a "ain en+ 100

mm onger t!an t!e +imension in+icate+ on t!e "i"ing +ra$ing fora+,ustment on site.

A mac!ine surfaces s!a * "rotecte+ from +irt an+ mec!anica +amages

a t!rea+e+ connections s!a *e eit!er ca""e+ or s!a !ave t!rea+ "ugsinserte+.

o i9ui+s of an# )in+ $!et!er for ceaning testing for t!ese reasons s!a*e a+mitte+ to t!e "i"eines e(ce"t $!en aut!ori;e+ *# t!e Engineer.

Loa+ing an+ unoa+ing s!a *e of !oisting or s)i++ing to avoi+ +amage.

Hn+er no circumstances s!a materias *e +ro""e+ or roe+ against ot!er"i"es.

=enera# $e+e+ t#"e of Vaves s!a *e $e+e+ in suitI !o$ever

a++itiona s"oos on *ot! si+es of isoation Vaves s!a *e $e+e+ at s!o"+e"en+ing u"on t!e constructivit# of site.

To avoi+ +istortion +uring $e+ing tem"orar# su""orts s!a *e "rovi+e+

$it! s"oos. n a++ition $e+ing se9uence s!a *e suita*# controe+ reguate+ to minimise +istortion.

&imensions as "er +ra$ing materia s"ecification an+ fit u"s $i *eins"ecte+ an+ ceare+ for $e+ing *# 8/ "ersonne.

times t!e t!ic)ness of t!e t!ic)er "art.


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T!e reinforcing "a+s s!a *e s!a"e+ so t!at no ga" arger t!an 1.> mm is

measure+ *et$een t!e "eri"!er# of t!e "a+ an+ t!e "i"e to $!ic! it fits.

A *ranc! connection s!a *e of stu*-on t#"e as "er +ra$ing.

A 6 mm vent !oe s!a *e ma+e *efore $e+ing a reinforcing "a+san+ sa++es.

Coes s!a *e ma+e on# *# +riing.

A $ee" !oes s!a *e seae+ $it! siicon or e9uivaent to "revent

corrosion after "a+ "neumatic test.

*727* P%/e e&%&=:

Prior to *en+ing c!ec) for t!e ceaniness of "i"e to *e *en+.

Prior to *en+ing c!ec) t!e forme+ +ies man+re "rofie for t!e

smoot!ness.

4or) surfaces of a *en+ing eements t!at contact $it! "i"e s!ou+ *esmoot! an+ !ave no scratc!es *urrs etc.

C#+rauic $e+ge t#"e *en+ing mc s!a *e em"o#e+ in a *en+ing

o"eration.

T!e "i"e s!ou+ *e su""orte+ "ro"er# $!ie *en+ing.

T!e *en+ing $or) area !as to *e *arrica+e+.

'en+ing curvature s!a *e uniform an+ t!e surfaces s!a *e free fromcrac)s *uges $rin)es tooing +amage an+ ot!er +efects.

T!e *en+ "ortion of t!e "i"e s!ou+ not !ave an# circumferentia $e+

,oint.

Pi"e $it! ongitu+ina $e+s s!a *e *ent in suc! a $a# t!at t!e $e+

seam s!a *e "assing t!roug! t!e neutra a(is.

At an# section of t!e force+ *en+ "i"e t!e +ifference *et$een t!e

ma(imum an+ minimum outsi+e +iameters at an# section s!a not *ee(cee+ing JK of t!e nomina "i"e.

Ma( O& Min O& F 100 J

omina &ia

T!e *en+ s!a *e ins"ecte+ for its ovait# Ange of *en+ Re+uction in$a t!ic)ness an+ visua ins"ection.

*727? ;e$%&=

*727?71 ;e$%&= P#"4eu#e S/e4%!%4'%"& 9 @u$%!%4'%"&

4e+ing "roce+ure s"ecification s!a *e +eveo"e+ in accor+ance $it! AME

ec F an+ t!e "ro,ect s"ecification.4P an+ P8R s!a *e a""rove+ *# /EL.

M201TPL-MPT-L-PRO-6001 REV.A2N


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List of a""rove+ 4P an+ P8R for t!e "ro,ect s!a *e maintaine+ at site.

A $e+ing mac!ines an+ ot!er e9ui"ments s!a *e in goo+ $or)ingcon+ition. T!e $e+ing mac!ines s!a !ave a+e9uate contro for currenta+,ustments.

*727?72 ;e$e# Pe#!"# ;e$%&= /#"u4'%"& C"&'#"$4e+ing s!a *e in accor+ance $it! a""rove+ 4P.

Hness ot!er$ise s"ecifie+ a *utt $e+s s!a *e fu "enetration $e+s. T!ee(terna surface of t!e $e+ s!a *e free from un+er cuts overa"s an+a*ru"t ri+ges or vae#s.

Prior to t!e $e+ing t!e $e+ fit-u" s!a *e c!ec)e+ *# t!e $e+ing engineerfor ceaniness of e+ge *eve ange en+ "re"aration etc. in accor+ance$it! t!e a""rove+ 4P. After tac) $e+ing t!e ,oints t!e ,oints s!a *ec!ec)e+ *# t!e $e+ing engineer for crac)s an+ s!a *e remove+ if foun++efective.

Tac)s to *e incu+e+ in t!e $e+ s!a *e "re"are+ *# grin+ing en+s tofeat!er e+ge for satisfactor# merge $it! $e+ meta.



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After t!e fit-u" is ceare+ for $e+ing t!e $e+ing Engineer $i c!ec) forre9uirement of "re!eating as "er 4P an+ ensure t!at t!e same is carrie+out. On com"etion of root "ass t!e $e+ing Engineer !as to ensurecom"iance to &E re9uirement at root if an#. An# com"etion of $e+ing

,oint visua ins"ection of ,oint $i *e carrie+ out $i *e reease+ for P4CT &T.

T!e reinforcement s!a *e cro$ne+ at t!e centre an+ s!a ta"er smoot!#to t!e surfaces *eing ,oine+.

'utt $e+s attac!ing orifice fange to "i"ing s!a !ave t!e interna surface oft!e root "asses groun+ smoot! an+ fus! $it! t!e insi+e +iameter of t!e

"i"ing.

Pre!eat inter"ass tem"erature tec!ni9ue s!a *e as "er a""rove+ 4P.

P4CT !ar+ness c!ec)ing s!a *e +one as "er M201TPL-MPT-L-PRO-600>Proce+ure for "re!eat 5 "ost $e+ !eat treatment of "i"e $e+7 an+ cares!ou+ *e ta)en +uring P4CT to avoi+ +istortion.

P4CT of ,oint $!erever re9uire+ as "er 4P /!arts of P4CT recor+s are to*e revie$e+ *# $e+ing Engineer *efore su*mission to /AR. Car+ness testof suc! ,oints $i t!en *e carrie+ out *# 9uaifie+ or e("erience+ "erson.

A a""ica*e &T $i *e +one as "er a""rove+ "roce+ures.

&T re9uirements s!a *e foo$e+ as "er a""rove+ "roce+ure.Ra+iogra"!# test s!a *e +one after P4CT com"ete+.

Eac! ,oint s!a *e i+entifie+ "unc!e+ $it! ,oint num*er an+ $e+er num*ernear t!e $e+.

&T s!a *e carrie+ out in accor+ance $it! a""rove+ "roce+ure an+ as "erre9uirements of /AR s"ecification. After cearance t!e ,oints s!a *ereease+ for furt!er o"eration.

After t!e com"etion of P4CT an+ &T t!e s"oo cearance s!a *e given.

*7, PIPING ERECTION 9 ;ELDING

T!e s"oo cearance s!a *e ta)en after com"etion of &T P4CT !ar+nessc!ec) an+ "ainting t!en t!e s"oos $i *e s!ifte+ to erection site. T!e erectionof "i"ing $i *e "anne+ in suc! a $a# t!at minimum num*ers of fie+ ,ointsare encountere+.

T!e +ocuments $i *e c!ec)e+ for i+entif#ing t!e s"oos t!at are rea+# forerection *# suita*e i+entification mar)s.

A fa*ricate+ "i"e s"oos s!a *e c!ec)e+ for t!e interna ceaniness an+ ifre9uire+ it s!a *e ceane+ *# suita*e means.

As far as "ossi*e "i"e su""orts s!a *e assem*e+ an+ instae+ *efore t!eerection of "i"es. Co$ever tem"orar# su""orts s!a *e "rovi+e+ $ere

"ermanent su""orts are im"ractica*e.



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After erection "acing of s"oos in "osition it $i *e aigne+ to meet t!ere9uirement of its orientation eves sto"s su""ort ocation co+ "ue("ansion etc. n case of c!ec) go*e an+ R vaves t!e +irection of fo$ $i*e c!ec)e+ as "er isometric +ra$ings.

Pi"e su""orts $i *e "rovi+e+ as "er "i"ing isometric +ra$ing. Pi"e su""orts$i *e $e+e+ as "er a""rove+ 4P.


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Pre!eating an+ "ost $e+ !eat treatment s!a *e as "er t!e M201TPL-MPT-L-PRO-600> Proce+ure for Post $e+ Ceat Treatment7.

&T s!a *e carrie+ out as "er foo$ing "roce+ures.

Htrasonic Testing M201TPL-MPT-8-PRO-000>Ra+iogra"!ic Testing M201TPL-MPT-8-PRO-0006Magnetic Partice Testing M201TPL-MPT-8-PRO-0003e Penetrant Testing M201TPL-MPT-8-PRO-000

*7> ;ELDING REPAIR

T!e $e+ +efect i+entification s!a *e mar)e+ outsi+e t!e "i"e.

&efective $e+ing s!a *e com"ete# remove+ *# c!i""ing or grin+ing.

T!e e(cavate+ area s!a *e e(amine+ *# i9ui+ "enetrant test met!o+ toassure com"ete remova of t!e +efects.

4e+ un+ercutting re"aire+ *# *en+ grin+ing "rovi+e+ t!e *ase meta is notre+uce+ *eo$ t!e minimum re9uire+ t!ic)ness.

T!e "i"e +efect area s!a *e *evee+ accor+ing# to t!e a""rove+ 4P.

T!e re"air $e+ing s!a *e +one as "er t!e 4P use+ in t!e origina $e+.

On# 9uaifie+ $e+ers s!a *e engage+ in t!e $e+ing.

4e+ re"air s!a *e re-e(amine+ *# t!e &T met!o+ origina# use+ to +etectt!e +eficienc# $e+.

Pre!eat an+ P4CT s!a *e +one as "er t!e 4P.

*7 8YDRO TEST

times t!e $or)ing"ressure an+ minimum 1 !our. /onstruction $ater $i *e genera# t!e testingme+ium for !#+rostatic testing of "i"ing s#stem uness ot!er$ise s"ecificinstruction is avaia*e.

Pre- C#+ro test c!ec) ist s!a *e "re"are+ for *aance $or) com"etion*efore !#+ro test.

*76 SRFACE PREPARATION AND PAINTING

urface "re"aration an+ "ainting s!a *e as "er t!e M201TPL-MPT-M-PRO->00% Proce+ure for urface Pre"aration an+ Painting for structuraan+ "i"ing7.

Pi"e en+ *eves $e+ ,oints fange face s!a *e covere+ $it! mas)ing ta"e to"revent from "ainting.

Painting s!a *e +one *ot! in s!o" an+ 00 ' +ia. "i"es an+ a*ove.



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00' "i"es $!ic! are cut to ma)e "i"e s"oos s!a *e fa*ricate+as s"oos first an+ t!en *aste+ an+ "ainte+ $it!out finis! coat at s!o".


15/16




Peo"es invove+

1. /onstruction Manager

2. Pro,ect 8/ Manager

3. 8/ Engineer

. ite Engineer

>. CE Engineer

6. 8/ Assistant

%.


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procedure for fab, erec & testing of abovegroud piping

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