Project -

Utility & Auxiliary Pipeline for Desalination Plant

IREL,OSCOM, Chatrapur, Odisha, INDIA
Document Title – Erection Procedure for Steam Transfer Pipeline
 

Contents

1. Purpose
2. Scope
3. Responsibility
4. Specification
5. Equipment
6. Procedure
7. Environmental Health and Safety

MSME UNIT FOR MANUFACTURING OF MECHANICAL SPARES & INDUSTRIAL FABRICATION

FCI Road, Nalco Nagar, Angul – 759 145, Odisha, India
Phone +91 6764 220605, Email: info.works@indfab.in, Web: www.indfab.in
 Project -
Utility & Auxiliary Pipeline for Desalination Plant
IREL,OSCOM, Chatrapur, Odisha, INDIA
Document Title – Erection Procedure for Steam Transfer Pipeline
 

1. PURPOSE:

The Purpose of this procedure is to provide the guidelines to carryout fabrication and erection of
piping and to ensure that proper quality and documentation are maintained as per the requirements.

2. SCOPE:
This procedure covers fabrication, erection, Inspection, testing and record keeping for all piping
systems at site. For any changes required due to exigency/design changes, a written approval is
to be obtained from OWNER/PMC before proceeding for any action.
In Case of conflict between this procedure and contract job Specification/SCC/GCC/Material
Specification the later shall govern.

3. RESPONSIBILITY:
Resident Construction Manager

Shall be responsible for proving resources to implement this procedure, Control supervision and
direction for implementation and execution of Construction plans.

Fabrication Engineer

Shall be reporting to construction Manager. He shall be responsible for indenting required quantity
and type of consumable from stores. He shall also be responsible for overall control of all proper
usage of consumables in order to get desired output on field.

QA/QC Engineer

Will report to Project Quality Manager. Ensure proper implementation of this procedure. Check
and verify the activity. Will verify and countersign all the field inspction reports.

Welding Engineer

Shall be reporting to Project Quality Manager. He shall be responsible for overall control of
consumable and shall guide personals handling the consumables. He shall also be coordinating
with stores for proper record keeping.

Safety Engineer
Shall be reporting to Safety Manager. He shall Oversee implementation of safety procedures and
train workmen and staff towards safe working practices. He shall also guide the team in Promotiong
safe working culture.

MSME UNIT FOR MANUFACTURING OF MECHANICAL SPARES & INDUSTRIAL FABRICATION

FCI Road, Nalco Nagar, Angul – 759 145, Odisha, India
Phone +91 6764 220605, Email: info.works@indfab.in, Web: www.indfab.in
 Project -
Utility & Auxiliary Pipeline for Desalination Plant
IREL,OSCOM, Chatrapur, Odisha, INDIA
Document Title – Erection Procedure for Steam Transfer Pipeline
 

4. SPECIFICATION & REFERENCES

• Piping and Instrument diagram.
• Approved Drawings.
• General Requirements of welding.
• Approved Procedure.
• Procedure for welding consumable control.
• Submission for Welding of manufacturer procedures.
• Engineering Specification for piping material.
• Protective Coating system.
• Painting Specification.
• General Requirement for pipework fabrication.
• ASME SEC V
• ASME B31.3
• ASME SEC IX
• API RP 582
• NDT Procedure
• Line schedule
• Pipe Material Specification .
• Submission of welding and manufacturing procedure.
• Other Codes And Standard Are Referred To Where Applicable.
• Piping Material Traceability-revised
• Positive Material Identification at Site.
• Welder Qualification Test.

5. EQUIPMENT

• Crane I Hydra
• Trailer
• Welding machines
• Flame Cutting Sets
• Grinding Machine
• Hydro test Pumps

MSME UNIT FOR MANUFACTURING OF MECHANICAL SPARES & INDUSTRIAL FABRICATION

FCI Road, Nalco Nagar, Angul – 759 145, Odisha, India
Phone +91 6764 220605, Email: info.works@indfab.in, Web: www.indfab.in
 Project -
Utility & Auxiliary Pipeline for Desalination Plant
IREL,OSCOM, Chatrapur, Odisha, INDIA
Document Title – Erection Procedure for Steam Transfer Pipeline
 

6. PROCEDURE

The Complete Piping work shall be carried out as per AFC (Approved for Construction) drawings.
Everything should fulfill the requirements of the IBR regulations for example pipe, pipe fittings,
Flanges, Valves, gaskets, studs and bolts etc. Used in a given system shall comply with the
approved Piping Material Specification for the piping class specified on the drawings. All materials
shall be inspected prior to start the fabrication activities.

After Receipt of approved drawings, detailed fabrication schedule shall be worked out by concern
engineer based on the availability of the drawings and materials. Based on the approved GAD,
ISO will be indicating weld joint Numbers both shop and field prior to start the fabrication. Weld
joint numbers shall be done as per the respective procedure.

Permitted redial misalignment of adjacent butt weld preparation shall be no greater than 1.5 mm
for thickness up to 15mm no greater than 2.5mm for thickness greater than 15mm.
Internal misalignment in excess of that permitted shall be corrected by machining pipe ends in
accordance with ASME B31.3.
FIT-UP:
Pipes shall be placed along the trench line with the skids to enable too easy fit. Pipe materials like
carbon steel, Low alloy steel, stainless steel, etc. Shall be cut size by suitable cutting process.
Finished cut edges shall be smooth and free from oxides, slag or other cutting marks.
Fit-up shall be done by qualified welder/tack welder as per approved procedure. All pipe "fit up"
welds attaching clips or bridge pieces, shall be performed by welder. All temporary welds to be
removed by cutting or grinding and always to be ground smooth with metal surface. All piping
spools shall be marked and identification like line no, joint No. spool No, with proper paint and
hard punch/ Tag plate. After completion the same shall be inspected as per guidelines.
PRE HEATING:
Preheat wherever required. Preheat will be applied by hand held torch or electrical resistance
heating coils. Temperature stick of suitable measuring instrument will be use to check the
temperature. In any case minimum preheat temperature shall be I 0 degree heating will be
maintained by suitable means throughout the weld cycle. Verification will be done by suitable
thermo chalk or digital thermometer at various locations of joint. For any weld the inter pass
temperature shall not be allowed to fall below specified preheat temperature until completion of not
less than 30% of final weld depth. Where inter pass temperature falls below specified preheat
temperature the preheat level shall always be restore before welding continues.

WELDING:
All welding shall be carried out by qualified welders. Welding technique, process etc. shall be
governed approved PMC. Before start of welding activities, WPS has to be approved, followed by
welder qualification test and welder has to pass the same. Before start welding edge and a
minimum of 25mm of adjacent material to be thorough cleaned. ·

MSME UNIT FOR MANUFACTURING OF MECHANICAL SPARES & INDUSTRIAL FABRICATION

FCI Road, Nalco Nagar, Angul – 759 145, Odisha, India
Phone +91 6764 220605, Email: info.works@indfab.in, Web: www.indfab.in
 Project -
Utility & Auxiliary Pipeline for Desalination Plant
IREL,OSCOM, Chatrapur, Odisha, INDIA
Document Title – Erection Procedure for Steam Transfer Pipeline
 

The Multiple pass shall be done as per the approved WPS. The multiple pass to be decided based
on the material thickness and groove.

All welding consumable such as electrodes, filler wires, flux and gas shall be stored, handled and
used in accordance with manufacturer's recommendation.
Welder shall be in work only approved by PMC certified identity card and welder certificate. Root
must be completed by one or more welders as continuous operation. Each layer of deposited weld
shall be ground free profile irregularities. Particular attention shall be given to the toe of the each
layer of welding at the junction to the fusion face of the joint to avoid slag traps or lack of fusion in
sub sequent passes and penning is prohibited on all passes. All fillet joints shall be welded with
proper weld profile and shall have minimum two layers. At least 30% of the weld thickness to be
filled up before discontinuing the weld. Before restart the inter pass temperature will be maintained
as per the approved WPS.
FILLER MATERIALS:
Welding electrodes and filler wires used shall be as per approved WPS and MTC of electrode.
Before use of all low hydrogen electrodes, shall be baked in a baking oven as per the
manufacturer's recommendation. Low hydrogen electrodes issued for fabrication shall be
transferred to portable ovens in working areas. After the working period welders shall return all
unused electrodes from working areas into the main holding oven. Each welder will be provided
with one portable oven. Handling, storage and usage of filler must comply with approved
consumable control procedure.
All welding filler wires issued to welding shall be handles in strictly accordance with the
manufacturing recommendation. Particular attention shall be given to wire used in working areas,
welding filler wires shall be kept covered at all items while in the fabrication shop to avoid
contamination by oil, grease etc., prevent moisture to form rust on the wire. All filler wires shall be
identified by color coding system on both ends to avoid mixing of filler wires at the time of welding.
SIDEDLDING AND PURGING GAS:
Shielding and purging gases shall be procured from approved vendor with purity certificate. During
welding purging and shielding shall be maintained as specified respective WPS. Initial purging
shall be made for sufficient period of time so entrapped air is completely removed. No purging
masking taps shall be allowed local purging inside the pipe pertaining to the lines flowing in
pneumatic category. For austenitic stainless steel the inert gas shall not contain more than 2%
oxygen.

VISUAL INSPECTION ON WELDS:

For visual inspection welds shall be carried upon completion of the joint. During final inspection,
all temporary attachments (if any) to parent metal shall be removed by suitable means. All piping
spools shall be checked for proper identification like as line no, welder no, spool no etc.
Finished weld joints shall be free from any surface defect. Finished butt welds joints must have
proper reinforcement. In case of fillet weld, proper leg length and throat thickness shall be
MSME UNIT FOR MANUFACTURING OF MECHANICAL SPARES & INDUSTRIAL FABRICATION
FCI Road, Nalco Nagar, Angul – 759 145, Odisha, India
Phone +91 6764 220605, Email: info.works@indfab.in, Web: www.indfab.in
 Project -
Utility & Auxiliary Pipeline for Desalination Plant
IREL,OSCOM, Chatrapur, Odisha, INDIA
Document Title – Erection Procedure for Steam Transfer Pipeline
 

maintained. Acceptance criteria for visual shall be as per project specification and ASME B3 l .3
and relevant codes and standards.
HEAT TREATMENT OF WELD JOINTS:
PWHT/Post heating, whenever required for weld joints, shall be carried out as per the specification
approved procedure. No hot work shall be permitted on heat treated welds. PWHT shall be done
by electrical resistance coil heating method. Heating/cooling rate .soaking temperature & soaking
time shall be as per approved Specification. Acceptance of PWHT cycle is subjected to the
acceptance of the final hardness value. PWHT is required when weldment are in close proximity
than permitted, such weld shall be heat treated together.
NDT AND TESTING:
All Inspections and testing shall be carried out in accordance with the approved inspection test
plan and inspection test records shall be generated in approved formats.
NDT shall be carried out as per the approved procedures. All NDT works like as RT, DPT, and UT
& MPT shall be carried out by experienced & qualified personnel. The weld to be examined shall
cover each pipe size and each welder, including the first five production weld by each welder: The
application of above NDT for welding shall be as per inspection class mentioned in the contract
document by PMS.
Repair area of the weld will be removed by grinding according to the size, depth, and location of
the defect. The completed repair portion will be subjected to NDT as per the procedure. Welding
repairs made on PWHT joints, shall subject to complete the PWHT cycle once again. Maximum
number of attempts to repair a weld shall be in accordance with project fabrication spec. The
deciding criteria for no. of repairs performing to any weldment will be as per the no. repair cycles
incorporated in the PWHT cycle and the contract documents.
After re-PWHT, the hardness value on the weld, HAZ and parent metal shall be measured by
suitable hardness machine as per the approved procedure.

SURFACE PREPARATION & PAINTING:

Before taking into erection or as the case may be, pipes & piping spools will be blasted and coated.
It is recommended that pipes are coated before erection leaving sufficient bare portion on the
edges for field welding purpose. For fittings, edges and a minimum of 25 mm of adjacent material
shall be thoroughly cleaned of contaminants. Which could adversely affect weld quality. All
activities pertaining to surface preparation and painting shall be performed as per the approved
procure & Project specification.
FIELD PAINTING:
Field painting shall be done as per the project specification, approved surface preparation and
painting procedure.

ERECTION, ALIGNMENT & SUPPORTING:

Prior to erection spools, in ready to erect condition, shall be identified by suitable identification
marks (Isometric no, spool no, tag plate etc.).All identified spools shall be shifted to the respective
MSME UNIT FOR MANUFACTURING OF MECHANICAL SPARES & INDUSTRIAL FABRICATION
FCI Road, Nalco Nagar, Angul – 759 145, Odisha, India
Phone +91 6764 220605, Email: info.works@indfab.in, Web: www.indfab.in
 Project -
Utility & Auxiliary Pipeline for Desalination Plant
IREL,OSCOM, Chatrapur, Odisha, INDIA
Document Title – Erection Procedure for Steam Transfer Pipeline
 

location. Erection of piping spools shall be aligned properly to meet the requirements and its
orientation, levels, slopes, supports location, expansion shall be checked. Pipe supports shall be
provided at every required location as per the approved drawings & support standard. Spools shall
be clearance & witness by execution prior to lifting.
Vents and drains ,instrument tapings and line mounted equipment's & items shall be erected in
position as per the approved drawings & P & ID and shall be checked for their tag.no, flow direction,
orientation, location ,etc.
NDT activity of field weld joint shall be performed in accordance with procedure and relevant
codes.Spool cleaning shall be done by compressed air.
PRESSURE TESTING:
Prior to pressure testing, the entire piping network shall be divided into several test loops according
to their piping class and operating procedure. Pressure test shall be carried out upon mechanical
completion of test loop which includes NDT completion and completion of all A Category punch
points pertaining to the loop. The test medium, test pressure and holding time shall be specified in
project specification & line schedule/ pressure testing procedure and shall comply with the
requirements of the project specification, ISO & IBR as applicable.
Mechanical / NDT clearance of piping loops will be given after the acceptance of all a category
punch points pertaining of the same.
After pressure testing, the loop shall be depressurized and water shall be drained off safely and
dry the system by dry compressed air. All temporary arrangements shall be removed.
The quality of water, flushing & re-instalment shall be done as per approved Pressure testing
procedure.
.

7. ENVIRONMENTAL HEALTH AND SAFETY:

• Full PPE Such as helmet, safety shoes/gum boots, googles shall be used.
• Proper work instruction and tool box talk to be given workman before
commencement of the activity on daily basis.
• All personnel involved shall be made aware of hazard identification & Risk assessment.
• All lifting tools and tackles and lifting equipment to be used shall be certified by
competent person.
• Equipment I machines shall only operate by authorized personnel.
• Good housekeeping shall be maintained in working areas.
• Evacuation plan, emergency telephone numbers available at site.
• Periodic safety training shall be arranged for all concern persons to
improve their consciousness towards safety.

MSME UNIT FOR MANUFACTURING OF MECHANICAL SPARES & INDUSTRIAL FABRICATION

FCI Road, Nalco Nagar, Angul – 759 145, Odisha, India
Phone +91 6764 220605, Email: info.works@indfab.in, Web: www.indfab.in