EPCC FOR BALANCE OF PLANT REVAMP AREA 200

DURING SOHAR REFINERY TURNAROUND 2019

Document Title
METHOD STATEMENT - FABRICATION & ERECTION OF
PIPING

Document no. : S-200-1666-001

By Aiman Al Adawi at 9:36 am, Jul 07, 2019

This document is the property of Oman Gas Company. S.A.O.C. Neither the whole nor any part of this
document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any
form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written
consent of the owner.

P.O Box: 799, Postal Code: 133, Al Khuwair, Sultanate of Oman

Tel: 24681600 / Fax: 24681678
Website: www.oman-gas.com.om E Mail: info@oman-gas.com.om

Doc. No.: S-200-1666-001 Rev. A Page 1 of 23

 Contractor:
Client :

COMMENT RESOLUTION SHEET (CRS)

PROJECT NAME: EPCC FOR BALANCE OF

PLANT REVAMP AREA 200 DURING SOHAR
CONTRACT / PROJECT NO.: 4600003673 Date:03.07.19
REFINERY TURNAROUND 2019.

DOCUMENT TITLE: Method Statement -

Document No: S-200-1666-001/ Rev. A Page 1 of 1
Fabrication & Erection of Piping

Sr. No. ORPIC COMMENT AIP REPLY ORPIC RESPONSE STATUS

9.1.2 Add “by grinding till the surface becomes smooth and even.” Noted and incorporated in revised MS.
“All tack welding shall be done by qualified welders only. In
cases where "Bridge Tacks" are used, the Bridge tack pieces
9.1.3 shall be removed by grinding and the surfaces shall be visually Noted and to be executed with extra care
inspected.”

“To ensure cover all nearby OWS within 15 meter ground

radius with Fire blanket. Cover all other drainage, ditches and Noted and to be executed with extra care
9.1.4
sewage with Fire blanket”

“Use fire blankets and the area should be covered properly

9.1.4 (Make proper fire booth).” Noted and to be executed with extra care

9.2.2 Add “by grinding till the surface becomes smooth and even.” Noted and incorporated in revised MS.

9.3.3 Add “by grinding till the surface becomes smooth and even.” Noted and incorporated in revised MS.
 EPCC for balance of plant revamp area 200 during Sohar refinery turnaround 2019

Document Name : METHOD STATEMENT - FABRICATION & ERECTION OF PIPING

INDEX

Sl. Page
CONTENTS
No. No.
1 PURPOSE 4
2 SCOPE 4
3 DEFINITIONS 4
4 REFERENCES 4
5 RESPONSIBILITIES 5
6 TOOLS & EQUIPMENTS 6
7 PROCEDURE FOR MATERIAL CONTROL 6
PRE FABRICATION OF PIPES / SPOOLS (SHOP
8 7
FABRICATION)
9 PROCEDURES FOR FIELD WORK 7
10 HYDROTEST PROCEDURE 19
11 FLANGE MANAGEMENT PROCEDURE 21
12 SAFETY PRECAUTIONS 22

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 EPCC for balance of plant revamp area 200 during Sohar refinery turnaround 2019

Document Name : METHOD STATEMENT - FABRICATION & ERECTION OF PIPING

1.0 PURPOSE

The purpose of this method statement is to control, execute & monitor all activities related
to the installation of above ground piping on pipe racks and around equipment, also to
ensure that all such works comply with project specifications and technical standards.

2.0 SCOPE

This method statement is applicable for “EPCC For Balance of Plant Revamp (Area 200)
During Sohar Refinery Turnaround project piping installation activities such as: material
receiving, storage, lifting arrangements, erection of Pipe & Pre-fabricated spools on pipe
racks, fit-up and welding, painting, installation of supports and other erection items., those
are within the scope of works.

3.0 DEFINITIONS

AIP Arabian Industries Projects LLC

ORPIC Oman Oil Refineries and Petroleum Industries Company
AFC Approved for Construction.
ASME American Society of Mechanical Engineers.
HEMP Hazards and Effects Management Process.
HSE Health Safety Environment
PEFS Process Engineering Flow Scheme
PTW Permit to Work
PPE Personal Protective Equipment
QCP Quality Control Procedure
CS Carbon Steel
WPS Welding Procedure Specification.
MIR Material Issue Request
MIV Material Issue Voucher
NDE Non Destructive examination
GA General Arrangement
ITP Inspection and Test Plan

4.0 REFERENCES

ASME B31.3 (2016) Process piping

ASME B16.25 (2017) Butt welding Ends
ASME B16.5 (2017) Pipe Flanges and Flanged Fittings.
ASME Sec - V (2017) Nondestructive Examination.
API RP-582 (3rd, May 2016) Welding Guidelines for the Chemical, Oil, and Gas
Industries.
S-000-1650-003-R-0001 General Welding Requirements for Field Welding.

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Document Name : METHOD STATEMENT - FABRICATION & ERECTION OF PIPING

S-200-1560-102 ITP for Fabrication, Welding & Hydro Testing of On-plot

Piping.

ORPIC Approved Welding Procedure Specifications (WPS), Quality Control Procedure and
Approved Construction drawing.
5.0 RESPONSIBILITIES

Construction Manager
Responsible for co-coordinating with Site Engineer and organizing the necessary
resources and ensures the work is carried out in accordance with the latest revision of
document deliverables, meeting progress schedule, Safety and Quality as per the
Project requirements.

Site Engineer
Responsible for Planning, execution and control of Piping Erection activities and lead
the construction team for the safe work execution at site meeting the Production
Targets. Focal Point for interface with Company / Contractor's safety department for
all related matters and interface with supervisors, and other discipline Engineers.
Planning Engineer
For providing and monitor the schedule target to be achieved daily / weekly /Monthly
in terms of "Inch dia" (Inch Diameter) and number of spools erected. He shall also
monitor the status of Spool Prefabrication, Erection, NDT & Painting, if require
priorities the necessary stage or brought the notice of Project Control Manager for
necessary action.

Piping Supervisor/ Foreman

Job allocation to the fitter/rigger crews. Their responsibilities includes but not limited
to the verification and materials delivered to the Site, report any shortages or damages
to the Site Engineer, Issue of Isometrics to various fitter gangs, Initiation of Field
Traceability Record, during installation of piping, if any interface /field modification
require shall be notified to Site Engineer, installation of prefabricated pipe supports,
Checking the markings on individual spool pieces, verification of the dimensions and
rolling after fit up, Preparation of fit-up progress report, Final dimensional Inspection.

QA/QC Engineer
He shall be responsible for all inspection activities related to piping at field and
coordinate with contractor welding/piping inspectors to clear any discrepancies. He
shall be organized for preparing traceability records, necessary NDE requests upon
clear of weld visuals and handover to NDE coordinator for further updating of NDE
reports in traceability.

QC Mechanical Inspector
Verification of all the materials confirming to the Isometric Drawings / Standard
Drawings, transfer heat nos. on to the material traceability records, checking of fit-ups,

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Document Name : METHOD STATEMENT - FABRICATION & ERECTION OF PIPING

preheats, inter pass temperatures final weld visuals, Weld Visual Inspection, In
process inspection & surveillance of all welding activities in field and shall interface
with supervisor/Forman.

HSE Advisor
HSE officer shall be responsible for successful implementation of safety systems
through different training and inspection as per the construction HSE Plan.

6.0 TOOLS & EQUIPMENTS

• Cranes, Fork Lifts / boom loader, Hiab, Chain blocks, chain pulleys, lifting belts,
slings, D shackle and other necessary tools and tackles for rigging & material
handling operation. All Cranes shall be certified by 3rd Party and all lifting
equipment certified (e.g. slings, shackles, chain blocks, wire, chain pulls etc.) and
color coded with current color as per Project HSE Requirements.
• Pipe stands, Pipe clamps, fixtures, angle grinding machines & pencil grinders etc.
• Gas cutting, and Bevel cutting machines.
• Pipe Fitting and Inspection Tools, General Workshop tools
• Pipe support trestles.
• Welding machines, High frequency sets, Argon cylinder & regulator set.
• Electrode baking and holding ovens (With valid calibration certificate).
• Hydrotest pump and Manifold.
• Torqueing (Manual & Hydraulic)

7.0 PROCEDURE FOR MATERIAL CONTROL

Material Receipt, Handling & Storage:

• Material receipt and storage will be carried out in accordance with Handling
Procedure.
• Materials will be stored in safe manner either off ground in open fenced area as in
the case of pipe spools, large pipe fittings, large valves, etc., or under cover inside
the warehouse for smaller and sensitive items, etc.
• Materials of different grade will be segregated and stored in designated areas.
• Materials under storage will be monitored to ensure that all end covers / caps / or
other vendor supplied means of protection is maintained in order to prevent
ingress of contaminants.

Material Issue

• Details of materials available for erection (Isometric wise) will be made available
to the Field erection team upon request.
• Site Engineer or supervisor shall request the issue of all or part of the materials by
completing a "Materials Request Form". All or part of the materials as detailed on

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Document Name : METHOD STATEMENT - FABRICATION & ERECTION OF PIPING

the applicable isometric will be listed on the form eg pipe spools, stud-bolts c/w
nuts, gaskets, valves and other in-line & on-line items, and supports etc.
• The Material Control department will then prepare the available materials as
listed on the MIV (Material Issue Voucher) ready for collection by the site
erection team. The Piping Supervisor or delegate will check the issued materials
for conformity against the MIV and sign for receipt of same.

Material Storage

The Material Handling at site erection location includes but not limited to:

• Segregation and stacking the field erection materials in the site racks.
• Segregation of materials to avoid cross contamination.
• Ensuring the spools are stored off the ground during temporary storage at site and
ensuring end caps and flange covers are maintained to avoid ingress of foreign
matter.
• Off ground storage of valves etc., ensuring that caps are fitted.
• Flange protection and capping for all valves.

8.0 PRE-FABRICATION OF PIPES/SPOOLS (SHOP FABRICATION)

• The pipe spools will be fabricated in accordance with the details shown on the
approved isometrics and spool fabrication drawings. All fabricated spools will be
tagged with a unique identification number. Straight lengths of pipe will also be
designated as spools and will be similarly tagged. The tags will comprise
aluminum strip with unique spool number hard stamped on it and which will be
secured to the spool by stainless wire.
• Whereas fabricated spools and pipe will be supplied as coated.

9.0 PROCEDURES FOR FIELD WORK

For the field work feasibility and identification the total piping scope divided in five
areas.

9.1 Depropanizer Reboiler area – Modification and Installation of new piping systems
for new heat exchangers.

Piping Scopes involved in this area are

 Modification of existing process piping (P27010304-16”-A2A1-IH, P27010305-

20”-A2A1-IH, P27010311-12”-A2A1-IH & P27010312-12”-A2A1-IH) system
during shutdown.
 Installation of primary and secondary supports.

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 Installation of new 4” condensate (SC27010330-4”-MS11-IH & SC27010331-4”-

MS12-IH) steam Line to new exchanger.
 Installation of new 8” LLP (LLS200241201-8”-MS11-IH) line from new
exchanger.
 Installation of new ¾” (HCC27010301-3/4”-MS11-IH) Line condensate from
steam trap to 6” condensate header
 Modification of existing fire water line.
 Installation of new fire water line (FW910113400-2”-MS02) for new heat
exchanger.
 Hydrotesting of all prefabricated spools on 8” and 4” new line prior to
shutdown.
 Hydrotesting of existing modified spools, existing fire water line and new fire
water line during shutdown.
 Golden joint of new 8”, 4” and ¾” line on pipe rack.
 Insulation works of all lines.

9.1.1 Setting up of Pipes on Pipe Rack

• The location of Pipes/ Spool on pipe rack shall be marked in accordance with the
line coordinates referenced on the Isometrics and GA (General Arrangement)
drawings prior to commencement of pipe erection.
• Before commencement of erection, the pipe spools shall be inspected for
cleanliness by piping supervisors or inspectors.
• Prior to erection, to ensure proper scaffolding to be erected and inspected by
approved scaffolding inspector.
• Proper scaffolding landings to be provided on pipe rack for inserting pipe and
spools to pipe rack.
• Prior to any lifting and pulling activities HSE and site supervisor to ensure, all
lifting tools and tackles are certified.
• Crane to be fixed in such a way that to access this landing stage.
• Once the crane set, then prefabricated spools and pipe to be lifted and positioned
in to pipe rack one after another.
• Inside the pipe rack spools and pipe are pulled in its actual position by using chain
blocks and web sling with proper care.
• Pipe spools will be prevented from uncontrolled rolling by use of temporary
restraints in the form of wooden wedges or rope.

9.1.2 Pipe Cutting & Edge preparation

• Once the pipe reach on position then by using Disc angle grinder or flame cutter
pipe to be cut as per the field dimension.
• End preparation for CS materials will be carried out using angle grinder.

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Document Name : METHOD STATEMENT - FABRICATION & ERECTION OF PIPING

• After flame cutting a min. of 2mm of material shall be removed from the cut
surface by grinding till the surface becomes smooth and even. A
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• Bevel edge shall be prepared as per approved WPS.
• Adjacent pipe and steel structure will be covered in order to protect surfaces
against damage and cross contamination between pipes of differing materials
when grinding etc. After grinding, the weld edges shall be visually examined to
ensure freedom from defects.
• Weld bevels for butt welds of pipe (and fittings) shall be in accordance with
ASME B16.25.

9.1.3 Alignment and Fit-up

• Pipes to be welded shall be joined with the use of jigs, clamps, bridges, or direct
tack welding, so as to be accurate with respect to their dimensions & direction as
specified in AFC drawings.
• Root spaces shall be checked by using spacers to confirm that their dimensions
are accurately maintained as specified in WPS.
• For butt welds, a uniform root gap shall be maintained.
• If misalignment due to unequal internal diameter exceeds the above value,
tapering of the internal diameter of the thicker member to a taper of 1:4 shall be
carried out or ASME B 31.3.
• All tack welding shall be done by qualified welders only. In cases where "Bridge
Tacks" are used, the Bridge tack pieces shall be removed by grinding and the
surfaces shall be visually inspected.
• Materials used for bridge tacking shall be the same as parent metal.
• The minimum distance between the edges of two pressure containing welds shall
be twice the wall thickness of the thicker pressure part and in any case shall be not
less than 2".

9.1.4 Welding

• Welding process to be done as per the ORPIC approved WPS and in compliance
with applicable approved Welding Procedure Specifications (WPS), and Welding
& Inspection Test Plan (ITP).
• All welding shall be performed in areas protected from rain, wind and air-borne
dust and sand.
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).

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• To ensure all butt welds & branch welds shall be full penetration welds. Partial
penetration groove welds shall not be allowed.
• GTAW process for all girth < 2", also all fillet welds shall be GTAW.
• Welds found unacceptable shall be repaired as per approved repair procedure and
re inspection as originally carried out.
• Last joints which is not feasible for hydrotest can be done later as golden joints.
• Welding consumables shall be controlled in accordance QCP for Handling of
welding consumables.

9.1.5 Ground Assembly of Spools.

• Pipe spools shall be checked against the relevant drawings and Specifications by
referring to their mark number (Tag numbers) to confirm their conformance to
relevant isometric drawings.
• Pipe spools shall be placed off the ground on temporary pipe stands or wooden
blocks during field fabrication.
• Pipe stands shall be rubber wrapped on the cross beam where pipes shall rest.
• Doubling of the straight pipes shall be done on the pipe stands.
• Pre-fabricated spools may also be assembled and welded at ground level prior to
erection
• Identification of piping segments after field fabrication shall be performed and
spool number / line number / field weld joint number shall be marked on pipes
• Bolt holes of flange joints shall be distributed to straddle the center-line of the
pipe, unless otherwise indicated on the drawings.
• The dimensional tolerances for pre-fabricated piping shall be according to the
drawing(s).
• Pre-fabricated pipe spools shall be cleaned and both the open ends shall be capped
properly to prevent any entry of sand / dust inside the spool.
• Except tie in joints remaining all joints of new 8”, 4” and ¾” lines, hydrotest to be
done prior to shut down.
• These lines tie in joints can do as golden joints.

9.1.6 Installation of Pipe Support.

• The location of Pipes supports shall be marked in accordance with GA (General

Arrangement) drawings.
• Prior to spool erection all secondary supports to be installed.
• Proper scaffolding required for elevated area support erection.
• Secondary supports which are welded to existing beam or column are erected with
proper care.

9.1.7 Fabrication and Installation of Existing and New Fire water line.

• Existing fire water line surrounding to old exchanger to be demolished for the
erection feasibility.

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• After Reboilers installation existing fire water line to be installed with proper
care.
• New fire water line for Reboiler (E-2720) to be installed.
• Threaded components and threaded ends are examined before assembly, for
cleanliness and continuity of threads.
• The threaded spools shall be shifted to site and jointed as per drawings.
• Applying sealant compound on the threaded fittings and tighten.
• When tightening with wrenches there should be no deep wrench teeth marks on
pipe if this happens then these shall be filed smooth and coated as above prevent
rust.
• Hydrotesting of new fire water line to be carried out.

9.1.8 Installation of Pipe Spools to Static & Packaged Equipment.

• Except existing spool modification all other prefabrication works to be completed

prior on shutdown.
• Installation / reinstatement of new spools and existing modified spools
(P27010304-16”-A2A1-IH, P27010305-20”-A2A1-IH, P27010311-12”-A2A1-IH
& P27010312-12”-A2A1-IH) on new Depropanizer Reboilers, E-2704 & E-2720
shall be carried out only on shutdown period.
• To ensure protective covers shall remain attached to all pipe flanges until bolt-up
connection is to be made.
• Piping supports shall be installed along with erected piping in order to achieve
correct alignment and elevation as per AFC drawings. This shall also prevent
undesirable vibration, sag and stress on erected piping.
• Prior to Piping hook up, the Equipment nozzle and corresponding pipe or valve
flange shall be inspected to verify no damage.
• Where there is a requirement for Spade / Spacer or Spectacle Blind at the nozzle,
the Spade or the Spectacle Blind in the closed position shall be installed to
prevent ingress of foreign matter.
• Where there is no requirement for Spade / Spacer or Spectacle Blind, temporary
spades (slip plate) shall be installed along with piping at all such equipment
nozzles to avoid ingress of foreign matter. Such temporary spades shall be easily
identifiable and tagged.
• Hydrotesting of modified spool to be carried out during shutdown.
• Once all painting and erection work done then insulation work to be completed.

9.2 Gulftronic Skid Area - Modification of Condensate lines.

Piping Scopes involved in this area are

 To lay new 4” (HCC21093501-4”-MS11-IH30) condensate header on pipe rack

for collecting condensate from Gulftronic skid. This header will connect
existing 12” header (HCC20025101-12”-MS11-IH30) on pipe rack.

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 1.5”& ¾” Condensate return from each condensate manifold and steam

manifold connected to new 4” header.
 Installation of supports.
 Hydrotesting of new line.
 Insulation work.

9.2.1 Setting up of 4” header Pipes on Pipe Rack and Support

• The location of header on pipe rack shall be marked in accordance with GA

(General Arrangement) drawings.
• Since area is congested, ensure there is no clashing with existing line.
• Prior to erection to ensure proper scaffolding to be erected and inspected by
approved scaffolding inspector.
• Proper scaffolding landings to be provided on pipe rack for inserting pipe and
spools to pipe rack.
• If any temporary support required for the erection purpose that should provide.

• Once the crane set, then prefabricated spools and pipe to be lifted and positioned
in to pipe rack one after another.
• Inside the pipe rack, spools and pipe are pulled in its actual position by using
chain blocks and web sling with proper care.
• Pipe spools will be prevented from uncontrolled rolling by use of temporary
restraints in the form of wooden wedges or rope.

9.2.2 Pipe Cutting & Edge preparation

• Once the pipe reach on position then by using Disc angle grinder or flame cutter
pipe to be cut as per the field dimension.
• End preparation for CS materials will be carried out using angle grinder.
• After flame cutting a min. of 2mm of material shall be removed from the cut
surface by grinding till the surface becomes smooth and even. A
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• Bevel edge shall be prepared as per approved WPS.
• Adjacent pipe and steel structure will be covered in order to protect surfaces
against damage and cross contamination between pipes of differing materials
when grinding etc. After grinding, the weld edges shall be visually examined to
ensure freedom from defects.
• Weld bevels for butt welds of pipe (and fittings) shall be in accordance with
ASME B16.25.

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9.2.3 Alignment and Fit-up

• Pipes to be welded shall be joined with the use of jigs, clamps, bridges, or direct
tack welding, so as to be accurate with respect to their dimensions & direction as
specified in AFC drawings.
• Root spaces shall be checked by using spacers to confirm that their dimensions
are accurately maintained as specified in WPS.
• For butt welds, a uniform root gap shall be maintained.
• If misalignment due to unequal internal diameter exceeds the above value,
tapering of the internal diameter of the thicker member to a taper of 1:4 shall be
carried out or ASME B 31.3.
• All tack welding shall be done by qualified welders only. In cases where "Bridge
Tacks" are used, the Bridge tack pieces shall be removed by grinding and the
surfaces shall be visually inspected.
• Materials used for bridge tacking shall be the same as parent metal.
• The minimum distance between the edges of two pressure containing welds shall
be twice the wall thickness of the thicker pressure part and in any case shall be not
less than 2".

9.2.4 Welding

• Welding process to be done as per the ORPIC approved WPS and in compliance
with applicable approved Welding Procedure Specifications (WPS), and Welding
& Inspection Test Plan (ITP).
• All welding shall be performed in areas protected from rain, wind and air-borne
dust and sand.
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• To ensure all butt welds & branch welds shall be full penetration welds. Partial
penetration groove welds shall not be allowed.
• GTAW process for all girth < 2", also all fillet welds shall be GTAW.
• Welds found unacceptable shall be repaired as per approved repair procedure and
re inspection as originally carried out.
• Welding consumables shall be controlled in accordance QCP for Handling of
welding consumables.

9.2.5 Installation of Pipe Support.

• The location of Pipes supports shall be marked in accordance with GA (General

Arrangement) drawings.
• Prior to spool erection all secondary supports to be installed.
• Proper scaffolding required for elevated area support erection.

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• Secondary supports which are welded to existing beam or column are erected with
proper care.

9.2.6 Assembly / Reinstatement of Spools.

• Pre-fabricated spools may to be assembled and welded.

• Identification of piping segments after field fabrication shall be performed and
spool number / line number / field weld joint number shall be marked on pipes
• Bolt holes of flange joints shall be distributed to straddle the center-line of the
pipe, unless otherwise indicated on the drawings.
• The dimensional tolerances for pre-fabricated piping shall be according to the
drawing(s).
• Once the line complete then hydrotest to be done.
• Insulation to be done.

9.3 WGC condensate Pump (P-2210A/B) area – Installation of new LLS Steam Line
to WGC condensate pump turbine (KT-2210B).

Piping Scopes involved in this area are

 To install new 4” (LS22050203-4”-MS12-IH) separate LP steam header for

WGC condensate pump turbine from existing 8” steam header (LS20024102-
8”-MS12-IH) on pipe rack.
 Installation of new supports.
 Cutting and Blinding of existing 3” (LS200241200-3”-MS12-IH) steam inlet line
and provide new steam trap.
 Installation of 1” (HCC200241201-1”-MS12-IH) condensate return line from
new steam trap.
 Hydrotesting of new line prior to shutdown.
 Insulation of line.

9.3.1 Installation of Pipe Support.

• Prior to spool erection all secondary supports to be installed.

• The location of Pipes supports shall be marked in accordance with GA (General
Arrangement) drawings.
• Proper scaffolding to be erected.
• Welding area of existing column and beams, fire proof coating to be chipped.
• After support installation damaged or chipped fire proof coating to be rectified /
reinstated.

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9.3.2 Laying of 4” header through secondary Support

• The location of header shall be marked in accordance with GA (General

Arrangement) drawings.
• Prior to erection to ensure proper scaffolding to be erected and inspected by
approved scaffolding inspector.
• Proper scaffolding landings to be provided for inserting pipe and spools on rack
and support.
• If any temporary support required for the erection purpose that should be
provided.
• Once the crane set, then prefabricated spools and pipe to be lifted and positioned
one after another on newly added support.
• If required spools and pipe are pulled in its actual position by using chain blocks
and web sling with proper care.
• Pipe spools will be prevented from uncontrolled rolling by use of temporary
restraints in the form of wooden wedges or rope.

9.3.3 Pipe Cutting & Edge preparation

• Once the pipe reach on position then by using Disc angle grinder or flame cutter,
pipe to be cut as per the field dimension.
• End preparation for CS materials will be carried out using angle grinder.
• After flame cutting a min. of 2mm of material shall be removed from the cut
surface by grinding till the surface becomes smooth and even. A
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• Bevel edge shall be prepared as per approved WPS.
• Adjacent pipe and steel structure will be covered in order to protect surfaces
against damage and cross contamination between pipes of differing materials
when grinding etc. After grinding, the weld edges shall be visually examined to
ensure freedom from defects.
• Weld bevels for butt welds of pipe (and fittings) shall be in accordance with
ASME B16.25.

9.3.4 Alignment and Fit-up

• Pipes to be welded shall be joined with the use of jigs, clamps, bridges, or direct
tack welding, so as to be accurate with respect to their dimensions & direction as
specified in AFC drawings.
• Root spaces shall be checked by using spacers to confirm that their dimensions
are accurately maintained as specified in WPS.
• For butt welds, a uniform root gap shall be maintained.

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• If misalignment due to unequal internal diameter exceeds the above value,

tapering of the internal diameter of the thicker member to a taper of 1:4 shall be
carried out or ASME B 31.3.
• All tack welding shall be done by qualified welders only. In cases where "Bridge
Tacks" are used, the Bridge tack pieces shall be removed by grinding and the
surfaces shall be visually inspected.
• Materials used for bridge tacking shall be the same as parent metal.
• The minimum distance between the edges of two pressure containing welds shall
be twice the wall thickness of the thicker pressure part and in any case shall be not
less than 2".

9.3.5 Welding

• Welding process to be done as per the ORPIC approved WPS and in compliance
with applicable approved Welding Procedure Specifications (WPS), and Welding
& Inspection Test Plan (ITP).
• All welding shall be performed in areas protected from rain, wind and air-borne
dust and sand.
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• To ensure all butt welds & branch welds shall be full penetration welds. Partial
penetration groove welds shall not be allowed.
• GTAW process for all girth < 2", also all fillet welds shall be GTAW.
• Welds found unacceptable shall be repaired as per approved repair procedure and
re inspection as originally carried out.
• Welding consumables shall be controlled in accordance QCP for Handling of
welding consumables.

9.3.6 Assembly / Reinstatement of Spools.

• Pre-fabricated spools may to be assembled and welded.

• Identification of piping segments after field fabrication shall be performed and
spool number / line number / field weld joint number shall be marked on pipes
• Bolt holes of flange joints shall be distributed to straddle the center-line of the
pipe, unless otherwise indicated on the drawings.
• The dimensional tolerances for pre-fabricated piping shall be according to the
drawing(s).
• Once the line complete then hydrotest to be done.
• All possible insulation scope to be completed prior to shutdown. Final finishing
work will do during shutdown..

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9.3.7 Cutting and Blinding of existing 3” (LS200241200-3”-MS12-IH) steam inlet line

and provide new steam trap.

• All prefabricated spools are hydro tested prior to install.

• During shutdown existing 3” team line to be cut.
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• Newly fabricated 3” spool with steam trap to be welded on this existing 3” line
with proper care. This 3” joint on existing header will consider as Golden joint.
• From steam trap new 1” condensate return line connected to 2” header on rack.
• All welding jobs to be carried out with proper care.

9.4 CAT Cooler area – Installation of New UVs

Piping Scopes involved in this area are

 Cutting of existing 3” (A20012901-3”-A1A1-PP & A20012902-3”-A1A1-PP)

Airline and Weld new modified spool on line.
 Welding of new supports.
 Hydrotesting of line.
 Installation of new UV.
 Insulation.

9.4.1 Pipe Cutting & Edge preparation

• By using Disc angle grinder pipe to be cut as per the field dimension.
• End preparation for CS materials will be carried out using angle grinder.
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• Bevel edge shall be prepared as per approved WPS.
• Adjacent pipe and steel structure will be covered in order to protect surfaces
against damage and cross contamination between pipes of differing materials
when grinding etc. After grinding, the weld edges shall be visually examined to
ensure freedom from defects.
• Weld bevels for butt welds of pipe (and fittings) shall be in accordance with
ASME B16.25.

9.4.2 Alignment and Fit-up

• Pipes to be welded shall be joined with the use of bridges, or direct tack welding,
so as to be accurate with respect to their dimensions & direction as specified in
AFC drawings.

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• Root spaces shall be checked by using spacers to confirm that their dimensions
are accurately maintained as specified in WPS.
• For butt welds, a uniform root gap shall be maintained.
• If misalignment due to unequal internal diameter exceeds the above value,
tapering of the internal diameter of the thicker member to a taper of 1:4 shall be
carried out or ASME B 31.3.
• All tack welding shall be done by qualified welders only. In cases where "Bridge
Tacks" are used, the Bridge tack pieces shall be removed by grinding and the
surfaces shall be visually inspected.
• Materials used for bridge tacking shall be the same as parent metal.
• The minimum distance between the edges of two pressure containing welds shall
be twice the wall thickness of the thicker pressure part and in any case shall be not
less than 2".

9.4.3 Welding

• Welding process to be done as per the ORPIC approved WPS and in compliance
with applicable approved Welding Procedure Specifications (WPS), and Welding
& Inspection Test Plan (ITP).
• All welding shall be performed in areas protected from rain, wind and air-borne
dust and sand.
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• To ensure all butt welds & branch welds shall be full penetration welds. Partial
penetration groove welds shall not be allowed.
• GTAW process for all girth < 2", also all fillet welds shall be GTAW.
• Welds found unacceptable shall be repaired as per approved repair procedure and
re inspection as originally carried out.
• Welding consumables shall be controlled in accordance QCP for Handling of
welding consumables.

9.5 Replacing of 2” Equal split with Normal 2” Equal tee.

 Cutting of existing 2” (BFW20025102-2”-MS12-N) line and Weld new equal.

 Due to the construction feasibility welding joints on header to be considered as
golden joint.
 Insulation to be done.

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10 HYDROTEST PROCEDURES

10.1 Identification of Piping Test Documents

• Prior to hydro testing a system test pack shall have been submitted and approved.
• The test pack consists of all testing records and pretest, punch list, mark ups and
line list information within the test limits.
• The PEFS mark ups will show the test limits for testing a system/sub-system with
the type and test pressure to be applied.

10.2 Pre-Test Piping Walk Down

• On completion of piping installation, the system will be walked down by the

Supervisor with QC Inspector. The walk down shall be performed with PEFS and
isometrics included in the test pack. The system shall be punched and all
outstanding items will be documented in Pre-Test punch list.
• Punch items shall be classified as either "A", "B" or "C".
• "A" items refer to outstanding items that must be completed prior to pressure
testing. "B" items can be completed either before testing or after testing, but
before pre-commissioning. "C" items to be completed before commissioning.
• Any punch items identified by ORPIC shall be issued to AIP, these punch items,
once completed by construction, requires to be signed off by ORPIC.
• QC Inspector checks the line for correct installation, welding completion, PWHT,
NDT, completion of support welding etc and signs the original reports in the test
pack once all the 'A' punch items are cleared.
• QC signed off test packs shall be submitted to ORPIC for review and obtain
clearance for hydro test. Once the test pack is accepted, QC department of AIP
shall inform construction that the test pack is released for testing.

10.3 Preparation for Flushing and Pressure Testing

• Temporary blind flanges and Test blinds will be installed at locations shown on
the marked up PEFS included in Pressure Test Pack. Test blinds would be of the
same line ratings.
• Piping shall be thoroughly vented of air during introduction of the test water.
High point vents to be provided as required and to conform to the relevant line
class. All lines shall be checked to ensure that entire system can be completely
drained prior to and after testing.
• Flow restriction orifice plates will be removed prior to pressure test.
• Tubing from instrument block valves is to be disconnected and positively isolated.
Blind flange will be used for flange connections.
• Check valves, remove internals or complete valve and spacer fitted.
• Test breaks shall be given at flanged joints.
• Control valves, thermometers and thermal element from thermo wells, orifice
plates, strainer baskets, filter elements, in-line instruments and all other

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components unable to withstand the test pressure or liable to damage by the test
medium or by the impact of foreign matter during the flushing or testing process
shall be removed and replaced with temporary spools or spacers/blinds.
• Pressure and thermal relief valves and rupture disc will not be included in system
during pressure tests.
• All weld joints, bolted connections in the system to be tested shall be inspected
during testing.
• All items removed for the duration of pressure testing shall be labeled and the
location to which they belong or the position in the line from which they were
removed shall also be labeled to ensure correct reinstallation after the testing.
• All valves, except as excluded specifically herein, Shall be included in the
pressure tests, all valves would be in the half open position.
• All permanent piping supports welded to the pipe shall be installed prior to
pressure testing.
• Temporary support if required to restrain the pipe during testing shall be provided
in consultation with field engineering. These supports shall be removed after
testing.

10.4 Test Medium and Pressure

• Test medium and pressure will be as specified in the piping line list/Isometric
drawing.
• Water will be provided with test certificates prior to initial use.
• Water quality requirements is as given below

PH 6.5 to 10.5
Total dissolved solids less than 1.5 Kg/m3
H2S Nil
Suspended Solids Nil
Appearance Clear with no visible sediment.

10.5 Pressure testing & Acceptance.

• All high points shall be open during filling. The filling hose from the pressure
pump shall be connected to the lowest point of the system to be tested.
• The pressure pump shall be disconnected immediately after the test pressure has
been reached.
• The pressure pump shall be disconnected if the inspector leaves the equipment for
any reason.
• The area around the system to be tested will be cleared of unauthorized personnel
and warning notices posted during that the piping system is pressurized for test.
• During the test, Pressure shall be increased in steps of 25%, 50%, 75% and 100%
of the test pressure to allow for equalization of strain during the test and to allow
for leak check and inspection of the system.
• Test duration shall be min. 2hrs or as long as it shall take to inspect all joints.

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• All pressure gauges should have calibration sticker with latest calibration date.
Minimum of two pressure gauges shall be used for testing.
• The gauge shall be not less than 125 mm in diameter. All gauges shall have a
range such that the test pressure is within 50% to 75% of the full range.
• One pressure gauge shall be installed on lowest point and one shall be installed on
highest point. Test pressure shall be read at or near the lowest point of the system.
• The actual pressure shall not exceed the test pressure by more than 2%. The actual
pressure exceed the test pressure by more than 2% the system shall be vented to
reduce the pressure to the test pressure.
• If a leak found, the pressure shall be reduced to zero and the leak rectified when a
leak is discovered, bolts shall not be tightened with the system under pressure.
The test shall be repeated.

10.6 Draining and Disposal of water

• After completion of hydro testing, the system will be depressurized in steps and
system will be thoroughly drained off water by first opening high point vents and
then the drains.
• The drained water can be disposed off via normal sewer systems. Adequate
precautions shall be made to keep animals away.

10.7 Reinstatement

• When draining is completed, all items removed for the test system will be
reinstated. Reinstatement of piping component and in-line instrument will be
carefully carried out to ensure that they are installed in the correct place.
• Flange joints opened for the purpose of testing shall be tightened with new
gaskets.

11 FLANGE MANAGEMENT PROCEDURE

11.1 General requirements

• Controlled torque wrenching shall be carried out using either manual or hydraulic
torque wrenches. The method chosen is dependent upon bolt loading, access,
clearance and tooling availability, which can be determined by the site personnel.
• To achieve uniform joint load /stress distribution the bolts shall be tightened in
three stages, representing 30%, 60% and 100% of the total torque values at each
stage of tightening, bolts shall be tightened in a controlled sequence as follows:

(Bolts numbered clockwise around the flange)

4 bolt flange 1,3,2,4.
8 bolt flange 1,5,3,7,2,6,4,8.
12 bolt flange 1,7,4,10,2,8,5,11,3,9,6,12.

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16 bolt flange 1,9,5,13,3,11,7,15,2,10,6,14,4,12,8,16.

20 bolt flange 1,11,6,16,3,13,8,18,5,15,10,20,2,12,7,17,4,14,9,19

24 bolt flange 1,13,7,19,4,16,10,22,2,14,8,20,5,17,11,23,6,18,12,24,3,15,9,21

28 bolt flange 1,15,8,22,4,18,11,25,6,20,13,27,2,16,9,23,5,19,12,26,3,17,10,24,7,21,14,28.

1,17,9,25,5,21,13,29,3,19,11,27,7,23,15,31,2,18,10,26,6,22,14,30,8,24,16,32,4,20,1
32 bolt flange
2,28

Finally the bolts shall be chased round using the 100% torque value, until no nut movement occurs.

• Flanges and associated system equipment must be adequately supported and not
subject to excessive vibration, pulsation, or shock impact loading.
• The gasket area must not show sign of leakage and the piping, flanges and bolt
and nuts must not be significantly corroded.
• Existing flange bolts nuts must be the correct size and grade and must be tight.
• No simultaneous hot work operations are being conducted in the near vicinity.
• Only competent and qualified personals are allowed to execute.

11.2 Identification and Record.

• Once the required bolt torqueing activity is completed, flange tightening report
shall be prepared which shall include the details like flange location,
size/rating/type, verification of correct bolt/ nut / gasket and alignment, torque
value, test pack reference etc.
• The flanges which are facilitated with bolt torqueing shall be identified in a
diagram (to be highlighted in isometric drawings for on-plot/hook up piping) and
this diagram to be attached along with the flange tightening report in the test
packages.
• Physical identification is to be provided to the flanges in field after torqueing.
ORPIC Flange Management Tagging (Blinding / De-Blinding& Equipment)
procedure (TA-TAG-Pcoc-2018Oct31R0) to be followed in field.
•
12 SAFETY PRECAUTIONS

• All personnel involved in the construction activities shall follow the requirements
of approved Project HSE Plan & ORPIC PTW Systems
• JSA for Construction activities are carried out and all hazards identified and
mitigation measures addressed as per worksheets.
• Distribute necessary warning signs / strips / barriers in areas of work.
• All Cranes shall be certified by 3rd Party and all equipment certified (e.g. slings,
shackles, chain blocks, wire, chain pulls etc.) and color coded with current color
as per Project HSE Requirements.

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• Lifting / handling, loading, unloading of pipes spools shall be done in a safe

manner taking into consideration nearby existing utilities and specified speed
limit.
• Pipe off-cuts, welding rod butts, used grinding &. Cutting discs, end protection
caps & covers will be contained and removed from work place site on a regular
basis.
• Adjacent pipe flanges will be covered in order to protect when grinding and
welding.
• To ensure cover all nearby OWS within 15 meter ground radius with Fire blanket.
Cover all other drainage, ditches and sewage with Fire blanket
• Use fire blankets and the area should be covered properly (Make proper fire
booth).
• Only trained personnel and experienced shall be engaged for carrying out
hydrostatic testing
• Movement of personnel not involved with the testing shall be restricted. It shall be
ensured that all personnel involved are provided with suitable personal protection
equipments and they are familiar with its operations.
• Only competent and qualified personals are allowed to execute torqueing activities.
• Activity specific safety tool box talks will be carried out on daily basis.
• For NDT safety precautions need to follow approved Radiation Safety procedure.
• Good housekeeping on site will be maintained at all times.

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