DOC No.

: GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

1.0 Introduction 2

2.0 General 2

3.0 Pre-Engineering Activities 3

4.0 Co-ordination with other department 3

5.0 Engineering Activities 4

6.0 Monthly Activities 5

7.0 Stress Analysis documentation 5

8.0 Handover Report 5

9.0 Close-out Report 5

10.0 Reference 5

Applicable Revision: R1
Prepared: BRT Checked: AKB Approved: RUD

Date: Date: Date:

First Edition: R0
Prepared: SRD Checked: BRT Approved: RUD

Date: 27/12/2001 Date: 27/12/2001 Date: 02/01/2002

A. File Name:Ref-1002 Server: Pune : KUMUS 402 VKO : KUMUS 209
 DOC No. : GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 2

1.0 Introduction
This document is prepared to guide the Lead Stress Engineer (LSE) in the execution of stress
analysis (SA) work of a project. It lists the various activities to be done, the procedures to be
followed and different engineering aids available. The matter listed in this document may vary
from project to project. LSE should decide the same in line with the contractual requirements in
the beginning of the project itself. LSE should consult the DM-SE/DSE whenever required.
Reference should be made to the latest revisions of all the documents mentioned herein.
LSE – SA should also refer LE-PI reference manual to make his design activities consistent with
the project requirements.

2.0 General
2.1 Calculation Index
All stress analysis calculations shall have a calculation number. LSE should consult LE-PI/DSE in
order to follow proper numbering system.
2.2 Filing System
All Documents / Drawings should be kept in the file. The File should have the File Number.
LSE should refer Piping Procedure Group No. 8.003 for giving the File Number.
2.3 Requirements of Master / Working/ Check Prints for SA work
Working copies and checkprints need not be maintained. Master copies shall be maintained in
plastic pouches. Master copies shall match with the latest electronic files except for few minor
changes that has no implication on the final results like loads and deflections.
All the major comments of the maker & checker shall be marked on title sheet of CAESAR input
printout and the same shall be preserved. The respective CAESAR input/output printouts of the
system under checking shall not be preserved. However the soft copies of all the intermediate
revisions shall be preserved and shall be kept in a project directory for reference.
2.4 Guidelines for Windows NT Server Usage
LSE shall give the list of the persons/PC numbers to LE (PI) to arrange for the access to the
project server directory.
To understand the Project Directory structure on the server, access privileges, data backup and
restoration refer Piping Procedure Group No. 9.013.

3.0 Pre-Engineering Activities

3.1 Contract study
Review of the contract shall be made for the following :
3.1.1 Scope for piping stress analysis
The LSE should read the contract document between UIL & the client and the sales offer given by
R1
PI so as to understand the total scope, inclusions & exclusions. LSE should find out the
deliverables required in the project and should also find out which documents shall need approval
 DOC No. : GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 3

/ review from the client / licensor. Important aspects of this scope should be included in project
specific GES.

3.1.2 Deviation in scope between contract document & sales offers

Any deviations in the scope of work with respect to the sales offer should be discussed with the
HOD and change request for deviation in scope from that in sales offer should be raised
immediately.
3.1.3 Control Estimation
Even for the scope in the contract that tallies exactly with the sales offer, LSE should make his
own estimate of hours required to complete the job. If this estimate is in variance with the hours
sanctioned for the project, LSE should inform the HOD about the same. Further course of action
in this regard shall be advised by the HOD to LE accordingly.
3.2 Project Schedule
LSE shall refer to the overall schedule as prepared by LE-(PI) and should make the schedule for
stress activities and forecast the man power requirement for the total duration of the project.
3.3 Quality and procedural documents
LSE should follow the Quality system of the company religiously. LSE should see to it that all QA
R1
procedures are strictly followed by the entire piping stress analysis team. LSE to refer CQM and
the project co-ordination manual for various procedures to be followed during project execution.
Specific quality procedures / checking guidelines required by licensor / client need to be referred
in the project specific GES for SA.

3.4. Stress Analysis procedures & guidelines.

GENERAL ENGINEERING SPECIFICATION FOR PIPING FLEXIBILITY – Group No.7.020.
R1 - This shall be made project specific. Clients & Licensors requirements as per project design
basis shall be incorporated. Document need to be sent to client / licensor for their comment
/ approval.
GUIDE LINES FOR PIPE STRESS ANALYSIS – Group No.7.018
- This shall be used during engineering. If needed changes per GES will be done as mark-
up.
STRESS ANALYSIS (SA) CHECKING GUIDELINES – Group No.7.022
- This shall be used during engineering. Any changes as per GES to be done as mark-up.
PDMS-CAESAR TRANSFER SOFTWARE – USER MANUAL – Group No.7.023
- For use after obtaining consent of DM-SE / HOD.
 DOC No. : GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 4

4.0 Co-ordination with other departments during Stress Analysis Work

The following are the highlights of major activity where the inter-departmental discussions and
confirmations are necessary before the documents are released for execution.
4.1 Interface with MQ for nozzle load, piping clip load etc.
4.2 Interface with PI (Piping Layout) for line list, isometric, piping spec, support spec, special
support sketch, etc.
4.3 Interface with PE for offset conditions, fluid density & safety valves etc.
4.4 Interface with IC for control valve data
4.5 Interface with PR for enquiry, vendor evaluation, etc.
4.6 Interface with CI for special support, piping load, etc.
4.7 Interface with PM & Planning as needed.

5.0 Engineering activities

5.1 Stress Analysis / Supporting activity
LSE-SA shall prepare a concept note for stress analysis and support work before starting the
detail engineering. This note will briefly contain the following stages / steps to be followed for
completion of stress analysis work.
5.1.1 Review of basic engineering package to know the requirements for stress analysis & support
work.
5.1.2 Review of frozen P&IDs to mark and finalise the system for SA work and any special
requirement indicated on notes in P&IDs.
5.1.3 Preparation of stress critical line list (Gr.No.7.020) having category A, B, C & D taking line list
and P&IDs as the input document. This also specifies the scope of work for stress analysis.
5.1.4 Preparation of calculation index to know the list of lines in a particular system and the document
can be used to monitor the receipt of isometrics from layout group.
5.1.5 Finalisation of local & server directory path for smooth functioning.
5.1.6 Configuration set up for stress analysis.
5.1.7 Unit file set up.
5.1.8 Equipment modelling procedure set up in Caesar.
5.1.9 Analysis Load cases set up.
5.1.10 Finalise work steps to be performed by SE, PI & CI for preparation of special supports.
5.1.11 Handling of documents e.g. stress calculations reports, stress isometric, design data sheet &
vendor drg. etc. with PI layout group during SA work.
5.1.12 Checking & approval of documents. (Gr.No.7.022)
5.1.13 Documentation procedure with a copy of sample documentation.
5.1.14 Input data preparation set up.
5.2 Preparation of Technical specification for springs, expansion bellows, etc.
 DOC No. : GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 5

5.3 Bid Evaluation / Technical Recommendation / Order Specs. preparation for springs, expansion
bellows etc.
5.4 Assistance to Client / Project manager for IBR approval
LSE should give input assistance as required by LE-PI.

6.0 Monthly activities

6.1 Progress Report shall be submitted to LE-PI alongwith hold list, if any.
6.2 Drawing / document Index
The following index shall be prepared by LSE and shall be regularly updated to reflect the
changes undergone during project execution.
- Critical Line list document index
- Calculation index
- Spring index
- Expansion joint index
- Special support index
6.3 Change notices and extra work
During the execution of project additional work / wasteful work may be required to be done
which calls for additional hours which needs to be sent to EM / LE – PI / HOD either for
reference or action.

7.0 Stress analysis Documentation

This shall be done as per project requirement. Specific requirements by Licensor and/or client
R1
shall be incorporated in project specific GES.

8.0 Handover Report

Handover reports need to be made by LSE as per guidelines given in Annexure-2 (page 8) at
the time of completion of stress analysis & support activities.
R1
When any stress engineer is not available for more than two weeks, he shall prepare a list of
pending activities, in discussion with LSE.
Such reports shall be discussed with DM-SE before finalisation. Copies shall be forwarded to
DM-SE & HOD.

9.0 Close-out Report

Input, if any shall be furnished by LSE to LE(PI) for inclusion in close out report.

10.0 Reference
Annexure - 1 (Page 6 & 7) indicates the reference PI-Procedure & QA documents at a glance
in Lead Engineer’s Manual (GENL-PI-UZ-1001)
 DOC No. : GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 6

Annexure - 1
List of referred PI-Procedure & QA documents
in Lead Engineer's Manual

PI - Procedure Gr.No.

8.002 - Doc. / Drg. Numbering.

8.003 - File Numbering.
9.005 - Use of Stamps.
9.009 - Procedure for maintaining Master/Working/Check
Prints
9.010 - Presentation of Master/Working/Check Prints.
1.013 - List of software for PI-activities.
1.006 - Drg. List/Doc. List.
9.013 - Guidelines for Windows NT server
8.014/8.015 - PDMS proj. schedule/Non-PDMS proj. schedule.
6.013 - GES for Rubber lined piping.
6.014 - GES for PTFE lined piping.
6.020 - Std spec for utilities.
6.043 - GES for steam tracing.
7.006 - HDPE pipe support.
7.008 - Std support for Reinforced Plastic Piping.
7.018 - Guidelines for pipe stress analysis.
7.020 - GES for piping flexibility.
1.012 - Guidelines for nos. of sites in PDMS project.
9.012 - Standard project schedule.
4.001 - Civil Co-ordination Procedure.
4.002 - Co-ordination Procedure for Civil Design Info.
7.022 - Stress Analysis Checking guidelines.
6.030 - UIL Logic for Designation of pressure test system
for pipelines.
6.034 - Support Spec.
6.025
6.032
6.036 - Finalisation of Isometrics & BOM.
6.037
6.038 - Concept note for PI study for PDMS Modelling
6.031 - Preparation of Spec thru' IRP.
6.035 - 2D Model System for generating PI-doc.
1.010 - Model Review.

QA Documents
QA-08AR-A10 - Distribution of documents
QA-08AR-A16 - Drawing up the contract related QA Manual
QA-09PE-F04 - Design Basis.
09-PIR-F01 - Design Instructions - aboveground piping.
 DOC No. : GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 7

09-PIR-F11 - Pipe Supports & Layout Instructions for above

ground piping.
09-PIL-F01 - Technical Instructions - Instructions for Equipment
Arrangement
09-PIL-F02 - Technical Instructions - Preparation of overall & unit
Plot Plant (PIL)
 DOC No. : GENL- PI-UZ-1002
LEAD STRESS ENGINEER'S
Rev. : R1
REFERENCE MANUAL
Uhde India Limited Page : 8

Annexure - 2
HANDOVER REPORT
(A typical Sample)
Project No.:_____________
Date :_____________

STRESS ANALYSIS FOR PROJECT

The status of various STRESS ANALYSIS DOCUMENTS for the project is as follows :

1. CRITICAL LINE LIST :

The critical line list is issued for construction to Client / LE-PI. The critical line
list is attached herewith. (only for category A lines)

2. LIST OF SPRING SUPPORT :

The list is attached. All the spring supports enquiry / order specification are
sent to Client / LE-PI / Vendor etc. further action.

3. LIST OF EXPANSION BELLOWS :

The list is attached. All enquiry / order spec. are sent to Client / LE-PI / Vendor
for action.

4. ISO MARK UP WITH SA COMMENTS : The marked up ISO's with SA

comments are kept along with SA REPORTS.

5. DOCUMENTATION OF SA REPORTS :
The SA documentation is completed and sent to Client / Licensor / UIL records.
CRITICAL LINE LIST (soft copy) will be part of IRP documentation.

6. INTERNAL DOCUMENTATION :
- The DOCUMENTED as well as WORKING COPY OF SA REPORTS,
VARIOUS CORRESPONDENCE FILES between UIL / Client / Licensor are
handed over to LE-PI.
- All stress calculations are copied on a CD and handed over to UIL records.

7. DOCUMENTATION OF SOFT COPY

Location of soft file
SA FILES
Kumus 209/DATA/xxxx(Proj.#/CAESAR/FINAL (WORKING SA FILES)
Kumus 209/DATA/xxxx(Proj.#/CAESAR/Docu'n (WORKING SA FILES)

CRITICAL LINE LIST, DATA SHEETS / INDEX FOR SPRING etc.

Kumus 209/DATA/xxxx(Proj.#/CAESAR/GENERAL

8. HANDOVER
All documents, correspondence, calculation files are handed over to LE-PI.

Signed : ________________
O : LE-PI
cc : GM(PI) - Rud-Brt / EM - W/o Enclosures cc : BRT (with xerox of
enclosures)