WORK INSTRUCTION FOR A/G DOC.

NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

ISSUED TO
NAME :
CONTROLLED COPY NO.: DESIGNATION :
ISSUED BY

SIGNATURE/DATE :

INDIAN OILTANKING LIMITED

WORK INSTRUCTION
FOR
A/G PIPING FABRICATION AND ERECTION

For approval

G.
SAMADDER S.
CHIEF CHAKRABARTI
0 MANAGER CHIEF
(WORKS) MANAGER
(PROJECT)
REV. DATE DSCRP'TN PREP’BY CHK’BY REV’BY (IOT) REV' BY APP’BY
No. OF (EIL) (EIL)
REVISION
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

TABLE OF CONTENTS

1.0 PURPOSE
2.0 SCOPE OF WORK
3.0 TECHNICAL REQUIREMENTS
4.0 METHODOLOGY
5.0 EQUIPMENT LIST
6.0 QA/QC
7.0 HSE

8.0 DOCUMENTATION
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

1.0 PURPOSE
The purpose of this procedure is to lay guidelines and requirements for piping
fabrication and erection in accordance with drawings and specifications.

2.0 SCOPE OF WORK

The scope covers the minimum requirements of installation of above ground piping at
all stations related to the MMMPL Augmentation Project.

3.0 TECHNICAL REQUIREMENTS

Following documents in totality or in part shall form the reference documents:

 ASME B31.4
 ASME B31.3
 ASME SEC – V
 ASME SEC –IX
 ASME SEC II PART C
 EIL Specifications

4.0 METHODOLOGY
The sequential activities and corresponding tasks are as follows:

4.1 Preparation of Isometrics

On receipt of piping GADs, isometric drawings shall be prepared based on the

same. The piping spools for site fabrication shall be marked in the isometric
drawings with spool numbering for identification. Each weld Joint shall be clearly
marked and identified on the isometric drawing. The joint numbers shall be done
in the flow direction in the ascending order. The erection joints shall be
separately marked and identified. Prefabrication shall be kept maximum and
field joints shall be minimized as far as possible. High point vents and low point
drains for the purpose of hydro testing shall be indicated in the isometric
drawings and the size shall be 0.75”, consisting of threadolet and plug (for
piping class up to 600#) and gate valve and blind flange assembly (for piping
class up to 900# and above) The plug shall be seal welded with threadolet after
hydro testing. Each isometric drawing shall have bill of materials. All isometric
drawing shall be approved by EIL before execution. One copy of the approved
isometric drawing shall be submitted to EIL for records.
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

4.2 Pre-fabrication

After preparation and approval of isometric drawings, pre-fabrication of the spool

shall be started. The length of the particular spool may not exceed 12 M. to ease
the handling and erection.

4.3.1 Issuance of Material from Store

After studying the isometric drawings, material shall be received from the store
as per the drawing BOQ. Before receiving the materials from store, all the
materials shall be checked for their heat no., material specification, grade,
physical condition and quantity.

4.3.2 Marking

Marking on the piping spools shall include line No.,Jt. No. and spool No. as
per isometric drawings. If original material identification marking is to be cut or
material divided into two or more pieces, the heat no. and pipe no. shall be
transferred to each of the pieces. Material treceability record shall be
maintained for S.S. materials.

The identification for each spool shall be painted using white paint. When fit-
up is completed the line No. shall be stamped on each piping spool and Jt.
Nos. stamped near the joints using a metal stamp. Metal stamping shall not be
done for pipes with wall thickness less than 3.5 mm. For pipes with wall
thickness less than 3.5 mm joint Nos. shall be marked with paint and the spool
identification shall be done using a corrosion resistant metal tag (50 mm x 15
mm) stamped with the marking attached with the piping spool by means of
corrosion resistant wire.
Minimum 100 mm of pipe length shall be kept for field tolerance at the free
end of pipe.

4.3.3 Cutting and Edge Preparation

Cutting of the pipe should be done by manual oxygen cutting/machine oxygen
cutting/plasma cutting/ hacksaw cutting or by cutting wheel to suit the type of
material and site conditions. Edge preparation shall be made either by
machine tool or machine oxygen cutting/manual oxygen cutting followed by
grinding. The bevel ends shall be reasonably smooth and uniform and
dimension shall be in accordance with the approved WPS. Surface shall be
free from tears, slag, rust and scale. Reinforcement pads for structural
attachments shall be provided with an untapped hole of 6mm diameter for
venting and the hole shall be filled with grease on completion of testing and
painting.
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

4.3.4 Fabrication
Only experienced fitters or fabricators shall be engaged for
fabrication .Welding procedure shall be established at site before the start of
piping fabrication and the required No. of welders shall be qualified
accordingly. For fit up of pipes of wall thickness 5 mm and above, the ends to
be welded shall be secured in position with the aid of couplers, yoke or C-
clamps to maintain alignment and the same shall be detached after completion
of weld. Offsets, if any, should be equally spaced. Tack welds for maintaining
alignment of pipe joints shall be made by qualified welders only using the
appropriate WPS. Minimum number of tacks shall be: 3 tacks for 2 ½” and
smaller dia pipes, 4 tacks for 3” to 12” dia pipes; 6 tacks for 14” and larger dia
pipes.

Alignment for the fit up of the piping components shall be executed on a steel
stand. Pipe shall be properly supported and aligned by jig or clamps as
required precluding extraneous loads and minimizing strains during tacking.
Where reinforcing pads are fitted either for branches or structural attachment,
they shall be accurately shaped so that a good fit up is obtained before
welding.

Bolt holes of flanges shall straddle the normal centerlines unless specified
otherwise.

After completion of fit up, in order to protect bevel edges from damage
masking tape shall be wrapped around pipe and fitting ends.

Prior to performing main weld, tack weld, shall be done by either SMAW or
GTAW.

After fit up the spool shall be given for welding by qualified welder as per the
approved WPS.

4.4. Welding

Piping shall be welded by the SMAW and/or GTAW, to approved WPS,

process using suitable equipments. All welds shall be performed in
accordance with the approved WPS.

All edges of surface to be welded shall be cleaned to bright metal in a manner

suitable to remove any exudes, scale, grease, oil or contamination due to
flame cutting or machining. Any bevel edge of pipe that has been damaged
shall be resorted to minimum tolerance before welding. Back up ring shall not
be used.

Any cracks, blowholes, cold lap, unusual irregularities, slag, flux or other
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

impurities that appear on the surface of any bead of welding shall be removed
by grinding or chipping before depositing the successive bead. No welding
shall be done when weather conditions would impair the quality of the weld.

Reinforcement pads shall be added only after external visual inspection and
NDT if any of attachment area. Reinforcing pads shall be provided with 1/4”
vent holes.

All consumables shall conform to approved welding specification. The

welding procedures to be used shall be previously qualified according to
ASME Sec IX and approved by Consultant. Performance qualifications are
required for all welders & welding operators employed in the fabrication of all
piping. All welders shall wear identification cards with photograph and name
of the welders, welder No. duly signed by Consultant.

4.4.1 Pre-heating & Post Weld Heat Treatment

Pre-heating shall be performed according to approved WPS and shall extend

uniformly to at least three times the thickness of joint, but not less than 50mm
on both side of weld

4.4.2 Interpass Cleaning

When weld metal is deposited over a previously welded surface, all slag
cracks porosity and other irregularities shall be removed by a roughing tool,
chisel, air chipping hammer, power brush, grinding and or other suitable
means so as to prevent inclusion of impurities in the weld metal.

4.4.3 Joint Detail

All the piping joints shall be single V butt welded unless otherwise
stated/specified in Drg./WPS
No backing rings shall be used unless otherwise specified in approved WPS.

4.4.4 Welding Consumable

All the electrodes, filler wires and shielding gas should be used in accordance
with their approved WPS. The low hydrogen electrodes shall be rebaked at
the temperature of 350° C in the electrodes oven for 1 hour before transferring
it to portable oven for use on the job. Recommendations of electrode
manufacturer shall be followed.
Low hydrogen electrodes left exposed may be rebaked in ovens at an
approved temperature but only once.

4.4.5 Arc Strike

 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

Arc strike outside the area of permanent welds shall be avoided on any base
metal cracks or blemishes caused by ARC strike shall be ground to a smooth
contour and shall be visually inspected and subject to NDE, if required.

4.4.6 Cleaning of completed weld

Slag shall be removed from all completed weld, and the weld and adjacent
base metal shall be cleaned by brushing or other suitable means. Tightly
adherent spatter shall be removed. Weld joints shall not be painted until
welding has been completed and the weld accepted.

4.5 Visual Inspection

Inspection of all welds shall be carried out as per the latest editions of the
applicable codes and specifications. All the finished weld shall be visually
inspected for parallel and axial alignment of the work, excessive reinforcement
concavity of welds, shrinkage cracks, inadequate penetration, un-repaired
burn-through, under cuts, dimensions of the weld, surface porosity and other
surface defects. Undercutting adjacent to completed weld shall not exceed the
limit specified in the applicable standard/code.

4.6 Radiographic Inspection

After visual inspection radiography of welds shall be carried out as per the
procedure and specifications. Radiographic procedure shall be established at
site prior to start of production radiography. Type of radiation source and film
to be used shall be as per approved procedure at site.

4.6.1 Any welds found to be unacceptable according to acceptance / rejection

criteria stated in the governing specifications shall be repaired or replaced .No
of times repair welding could be done for the same weld before acceptance
shall be as follows:

C.S. upto 300# 3 or less

C.S above 300# 2 or less
Austenitic SS 2or less
The repaired joints shall be given a identification no. With joint no. (for
example J12-R1 Joint no. and R1 is the first repair of that joint) to separate
from the acceptable joints.
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

4.6.2 Acceptance Criteria

To be in accordance with ASME B 31.3, unless otherwise specified.

All the radiography films shall be preserved and produced to the inspecting
agency whenever they demand.

4.7 ERECTION

After the radiography clearance and shop priming the erection of pipe spool
shall be done. Before the erection of pipe spool all the fitting and valves shall
be available at site with their respective fasteners and gaskets For proper pipe
supporting the pipe supports shall be erected along with spool erection. The
extra length of the pipe shall be cut to suit site requirement during fit up of field
welds.

The fabrication and welding procedures shall be the same as discussed

earlier for prefabrication. The final tightening of the fasteners shall be done
after erection welding. During the welding all the valves shall be in open
mode. After the completion of welding, visual inspection and radiography of
the welded field joints shall be performed.

Before erection all prefabricated spool pieces, pipes, fittings etc. shall be
cleaned inside and outside by suitable means.

Pipe to pipe / structure / equipments distances / clearances as shown in the

drawings shall be strictly followed as these clearances may be required for the
free expansion of piping / equipment.

Wherever cold pull is specified the necessary gap shall be maintained as

indicated in the drawing.

Slopes for various lines as indicated in the drawing shall be maintained.

All expansion joints / Bellows shall be installed in accordance with the
specification and installation drawing supplied.

4.8 Flange Connections

While fitting up mating flanges care shall be exercised to properly align the
pipes and to check the flanges for trueness, so that faces of the flanges can
be pulled together, without inducing any stresses in the pipes and the
equipment nozzles. The assembly of a flange joint shall be done in such a
way that the gasket between these flange faces is uniformly compressed. To
achieve these bolts shall be tightened in a proper sequence.
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

4.9 Vents and Drains

High point vents and low point drains shall be provided as per drawings. The
details of vents and drains shall be as per piping material specification / job
standards.

4.10 Valves

Valves shall be installed with spindle orientation as shown in the layout

drawings. Care shall be taken to ensure that valves are installed with the “
flow direction arrow “on the valve body pointing in the correct direction.

4.11 Instruments

Installation of inline instruments shall form part of piping erection work. The
limits of piping and instrumentation work will be shown in the drawings.
Orientation / locations of take offs for temperature, pressure, flow, level
connections etc. shown in drawings shall be maintained. Care shall be taken
to avoid damage and entry of foreign material into instruments during
transportation, installation & testing.

4.12 Line mounted Equipments

Installation of line mounted items like filters, strainers , steam

traps,desuperheaters, ejectors, samples coolers, mixers, flange arrestors,
sight glasses etc. including their supporting arrangements shall form part of
piping erection work.

4.13 Bolts and Nuts

Molycoat grease mixed with graphite powder shall be applied to all bolts and
nuts during storage , after erection .

4.14 Pipe Supports

For lines 3” and above pipe supports shall be installed as indicated in the
drawings. For below 3” lines PLL shall locate and design pipe supports in line
with EIL standards and shall obtain approval of EIL before start of fabrication.

Erection Inspection shall be carried out after complete alignment of line and
erection & welding of supports.
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

4.15 Painting

All piping spools shall be shop primed before erection and shall obtain
approval of EIL before start of erection.

4.16 Spool Protection and Preservation

Attaching plastic caps shall protect flange faces. Threaded connection shall
be wrapped with tape and closed with plastic caps beveled ends shall be
wrapped with tape and close with plastic cap (stock area only).

5.0 EQUIPMENT LIST

1.Welding Machine
2.Gas cutting sets
3.Cranes
4.Tractor and Trailer
5. Chain Pulley Bricks
6. Pumps
7. Air Compressor
8.DG Set,
9.Ovens
10.Hand Tools
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL

6.0 QA/QC
Quality Assurance will be maintained by systematic implementation of this procedure,
compliance to project specific Inspection & Test Plan and recording essential quality
parameters to establish trace ability.

7.0 HSE
Daily toolbox meeting will be performed. Risk assessment will be conducted and the
controls identified will be implemented

8.0 DOCUMENTATION
Inspection & Test Plan for Radiography : IOT/PPL/ 01, APPENDIX-1
Daily Fit-up Inspection Report Format No. : IOT/PPL/01/F-01
Daily Visual Inspection Report : IOT/PPL/01/F-02
Radiographic Offering Report : IOT/PPL/01/F-03
Radiography Interpretation Report : IOT/PPL/01/F-04
LPT Record : IOT/PPL/01/F-05
MPT Record : IOT/PPL/01/F-06
Line wise Record : IOT/PPL/01/F-07
Material Traceability Report : IOT/PPL/01/F-08
Material Receipt Inspection Report : IOT/PPL/01/F-09

Note: In case of conflict between this procedure and tender specifications the letter
shall govern
 WORK INSTRUCTION FOR A/G DOC. NO:
IOT/PPL/ 01
PIPING FABRICATION & ERECTION
Rev. – 0
PROJECT: COMPOSITE WORK FOR MMPL PIPELINE AUG. PROJ. OF BPCL