PROCEDURE FOR

Consortium of Punj Lloyd Limited SHEET 1 OF 9

FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

INDEX

1.0 GENERAL

2.0 STRUCTURAL FABRICATION SEQUENCE

3.0 INSPECTION

4.0 APPLICABLE ENGINEERING DRAWINGS

5.0 FABRICATION SCHEDULE

6.0 ORGANOGRAM

7.0 FABRICATION FLOW CHART

8.0 APPENDICES

ANNEXURES

ANNEXURE - I : SCOPE OF WORK

ANNEXURE - II : FABRICATION SCHEDULE

ANNEXURE - III : ORGANOGRAM

ANNEXURE - IV : SEQUENCE OF FABRICATION FLOW CHART

ANNEXURE - V : FORMATS
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 2 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

GENERAL SPECIFICATION FOR MATERIAL, FABRICATION

AND INSTALLATION OF STRUCTURE

1.0 GENERAL

1.1 Scope

This procedure covers the general plan for Structural fabrication and
assembly related to top side modification for Heera Redevelopment
Project.

Scope of work for Structural work is enclosed at Annexure – I.

1.2 Working Area

All works shall be carried at W-168, MIDC, Pawane, Navi Mumbai in

two shifts.

1.3 Application of Specifications

1.3.1. Governing Specifications

General specifications and standards for steel fabrication will be

in accordance with following latest edition.

 ONGC Specifications 6001 F and 6002 F.

 API RP2A
API recommended and practice for planning, designing and
constructing fixed offshore platforms.

 AWS D1.1
Structural Steel welding code steel.

1.3.2. Materials

Materials shall be as per bid specifications and approved

Design Drawings.

Material for each member to be used shall be shown on the

structural shop fabrication drawings.
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 3 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

1.3.3. Applicable Welding Process as per “Approved Welding

Procedure”

- Shielded Metal Arc Welding (SMAW)

1.3.4. Welding electrodes as per “Approved Welding Procedure “

- SMAW E-7018.

Batch test certificates shall be submitted during production

welding.

1.3.5 Welding Procedure

Refer to the approved “Welding Procedure Specification”

prepared by Punj Lloyd Ltd. /OHCS & duly approved by DNV or
BV or ABS or GLIS. All welding shall be carried out using the
same.

1.3.6 Welder List

List of the qualified & Valid (Running) welders shall be

submitted separately.

2.0 STRUCTURAL FABRICATION SEQUENCE

2.1 Marking

Identified Beams, Channel and Plates to be fabricated shall be marked

in accordance with AFC drawings and cutting plans. It shall be ensured
that heat nos. from the manufacturer are transferred by punching them
to each cut length for ease of correlation.
The Beam, Channels and Plates shall be numbered for identification.
Marking to be done in a way that cutting is done in the most economic
manner to minimize wastage.

2.2 Cutting

Marked Beams, Channels, Angles and Plates etc. shall be cut to

respective size by flame cutting or whenever possible by mechanically
guided tool.
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 4 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

2.3 Edge Preparation

All edges shall be visually examined to ensure freedom from slag,

burns, loose, scale, rust, paint, grease and any other foreign material.

Any beveled edge that has been damaged shall be restored.

Sharp rises of edge shall be removed by light grinding and visually

checked for exposed lamination.

2.4 Tubular

Profile of the tabular shall be cut using Template.

2.5 Shop Drawing

Shop drawings including the splicing, longitudinal joints at suitable

location shall be as per API-RP-2A.

2.6 Fit-up and Tack Welding

Marking shall be carried out in accordance with shop drawings and

technical specifications.

Wherever practical clamps, magnets, holding devices, welding dogs,

shims, wedge or setting up fixtures shall be used in assembling parts
of the structures for tack welding.
Tack welding shall be done by qualified welders.

2.7 Inspection

Inspection shall be carried out as per section 3.0.

2.8 Welding

The welding shall be carried out in accordance with approved “Welding

Procedure Specification”.

2.9 Copper slag / Grit Blasting / Painting

Copper slag / Grit Blasting / Painting shall be carried out for all
Structural as per ONGC Specification 2005 & approved procedure
HRP-QP-12.
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 5 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

3.0 INSPECTION

3.1 Relevant Code, Specification and Standard used for Inspection

This inspection program based on Bid Doc Structural specification is

as follows:

3.1.1 Material

The material will be in compliance with following codes,

standards and specifications, latest edition, to the extent
applicable:

API 5L Gr.B, IS-2062, Grade-A, ASTM-A36, API Spec.2B, API-

5L-Gr.B, Sec-4 of Bid Doc .

3.1.2 Welding

AWS D1.1,

3.1.3 Fabrication

AWS D1.1, Edition 2004 & ONGC Spec. 6001 F / 6002 F.

3.2 Material Inspection

This section covers the inspection for receipt material.

3.2.1 Material Inspection shall be carried out in accordance with

ONGC Specification 2004 B. Receiving inspection for QA
Engineer shall carry out materials in accordance with purchase
specification and documents supplied by vendor.

3.2.2 All received material certificates are to be submitted for review

and approval to TPIA / ONGC Representative as per approved
QA plan. Upon receipt of material at the fabrication shop, The
QA inspector shall verify whether the received material confirms
to the corresponding mill certificates and submit the same to the
TPIA / ONGC Representative for review and approval as per the
approved QA plan.
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 6 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

3.3 Fit-up Inspection

3.3.1 Fit-up inspection shall be based on ONGC Specification 2009 F,

and approved welding procedure specification.

3.3.2 Dimensional check & acceptable limit shall be as per approved

structural drawings & analysis for engineering & execution point
of view.

3.3.3 Preparation of the base metal shall be prepared in accordance

with AWS D1.1.

3.3.4 Surface shall also be free from loose or thick scale, slag, rust
moisture, grease and other foreign material that would prevent
proper welding or produce objectionable fumes.

3.3.5 Dimensional tolerance for fit-up and edge preparation shall be

complied with AWS D1.1.

3.3.6 The joints with proper angle of bevel, root gap and alignment
checked by using profile gauges.

3.3.7 TPIA / ONGC representative as per QA Plan shall carry out fit-
up inspection for all joints by Punj Lloyd/OHCS QA Inspector.

3.4 Welding Inspection

Welding works for Structural and Pipe Supports shall be performed

complying with AWS D1.1 & ONGC Specifications 6001 F & 6002 F.

3.4.1. Welding Consumables

 All low hydrogen flux coated electrodes shall be heated

before use by holding in dry-oven for at least 30 – 60
minutes between 300 C and 350 C before they are used.

 A welder shall be issued electrodes that will be used in 4

hours from the time of issue. These electrodes will be kept
in heating quivers at a temperature of 70C (AWS D1.1)

 Welding consumables shall be used, which complies with

the approved welding procedure.
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 7 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

3.4.2. ln-process of Welding

 Welding works including tack weld shall be performed by

qualified welders. QA Dept. shall check the welders to
ensure that qualified welders are working in accordance
with the approved welding procedure specification.

 Before welding over previously deposited metal, foreign

materials, e.g. slag, refractory inclusions, de-oxidation
products, grease and moisture shall be removed by sharp
tool, chisel, and chipping hammer, or other suitable means
so as to prevent inclusion of impurities in the weld metal.

3.4.3. Pre-heating

 Pre-heating if required shall be performed by gas flame. The

range shall be up to 150OC depending upon thickness of
material (for detail refer AWS D1.1)

 Thermo crayons shall be used to measure all preheat

temperature requirements.

3.4.4. Completion of weld

 Weld profiles and quality of welds shall be inspected by QA

inspector and witnessed by TPIA / ONGC Representative
as per approved QA plan in compliance with AWS D 1.1.

 Welded bead surface shall be free from defects such as

cracks, porosity, roughly ground area and injurious defects.

3.4.5. Weld repair

 Weld repairs shall be performed in accordance with

approved repair welding procedure.

WPS / WPQR for weld repair is as per approved

Procedure.
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 8 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

3.5 Distribution of Inspection Report

3.5.1 Dimensional Record of fabricated structure

After completion of welding, NDT & Heat Treatment (if

applicable) of Sub assembly / Final assembly which shall be
witnessed by TPIA / ONGC Representative as per approved
QAP, the records for the same shall be submitted to TPIA /
ONGC Representative for verification.

3.5.2 NDE Report

The NDT reports shall be done as per QA plan & the report shall
be submitted to TPIA / ONGC for review & approval .

3.5.3 Original mill certificates for all materials shall be submitted to

TPIA / ONGC for review and acceptance.

3.6 Inspection Plan

Approved QA plan shall be referred .

4.0 APPLICABLE ENGINEERING DRAWINGS

Approved drawings shall be used for fabrication.

5.0 FABRICATION SCHEDULE

Schedule for Fabrication of Structural is enclosed at Annexure – II.

6.0 ORGANOGRAM & MANPOWER FOR THE WORKS

Organogram developed for Structural Fabrication along with manpower

deployment schedule is enclosed at Annexure – III.

All NDT related works shall be carried out by M/s. Offshore Testing &
Inspection Services (I) Pvt. Ltd..
 PROCEDURE FOR
Consortium of Punj Lloyd Limited SHEET 9 OF 9
FABRICATION OF STRUCTURE
& P. T .Sempec
PROJECT : HEERA REDEVELOPMENT PROJECT CONTRACT NO. :

DOC. NO. : HRP-PROC-13 REV. 0

7.0 FABRICATION FLOWCHART

Sequence of Fabrication Flow Chart is enclosed at Annexure – IV.

8.0 APPENDICES

Document Formats to be used (as attached) at Annexure - V

 Structural Clearance Report

 Painting Inspection Report
 Structural Fit-up & Weld visual inspection Report.
 Material identification report.