RESONANCE ENRGY PVT LTD

" Pursuing Knowledge Through Innovation”

Certificate Course on Health & Safety

Training Module-4
Stage Inspection Line Pipe to
Construction, Commissioning and Site
Audits
 Construction
• Staking & Stringing
• Welding
• Joint Coating
• Lowering
• Backfilling
• Cleaning
• Hydro-testing
• Dewatering
• Drying
• Intertisation
• Pre-Commissioning & Commissioning
 Stage Inspection
• Staking & Stringing:
➢Proper support- Sand pads, Soil filled gunny bags

➢ Staking Configuration

➢Check for end caps

➢ Check for any dents

➢Check for any coating damage

 Stage Inspection
• Welding:
➢ Selection of Electrodes
➢ Procedural Qualification
➢ Welder’s Qualification
➢ Check for pipe end bevel & lamination
➢ Pipe Alignment, Weld Geometry and gap between pipes
➢ NDT- Examination of root run, Final weld (No Root Crack, LF, LP, BT
not allowed in Indian Specs although API 1104 allows with limit for
them)
➢ Radiography
 Stage Inspection
• Joint Coating
➢ Selection of matching/ approved coating tape
➢ Cleaning of pipe end
➢ Apply Coating
➢ Holiday test
• Lowering
➢ Padding material (150 mm thk)
➢ Side boom requirement with belt
➢ Synchronized movements
➢ Cover Requirement
Cover requirement for Pipe laying
 Stage Inspection
• Backfilling
➢ Use of original/virgin soil
➢ See for gravel/stone free soil
➢ Use of warning tape/ OFC cable
• Cleaning
➢ Cleaning with Pigs
➢ Gauging plate (95% of ID ), Dent (1% of thickness)
➢ Removal of dust/ debris
 Stage Inspection
• Hydro-testing
➢ Water filling & Air removal
➢ Pressurizing in specified stages and holding time
➢ Correction for temperature rise & fall
➢ Hold time (24Hrs)
➢ Depressurization
• Dewatering
➢ Water disposal area
➢ Use of dewatering /cleaning pig
 Stage Inspection
• Drying (A) Air Drying
➢ Section wise drying with dry air having dew Point (-) 800C
➢ Continue floe of Air till you reach a dew point of (-) 400C
• Drying (B) Vacuum Drying
➢ Create Vacuum in the pipeline which lowers the vaporization
temperature of water
➢ Continue this till you get an absolute pressure of 50 mbarg
• Interstization
➢ Inertize with Nitrogen
➢ Continue filling N2 till O2 level comes down to 4-5%
➢ N2 pressure of 50 mbarg is required
 Stage Inspection
• Pre-Commissioning & Commissioning
➢ Check list of all activities
➢ Quench all outstanding issues
➢ Create a commissioning team
➢ Safety Precaution
➢ Commissioning team should comprise of
Construction team, Safety team, and O&M team
➢ Gas Charging with replacement of N2
 Site Audit
• To Start With
➢ ROU Cleared and opened
➢ Land for Dumping Yard and line pipe staking
➢ Contractor(s) in Place with predetermined list of
equipment (to be positioned in stages)
➢ Owner’s team in place
➢ All procedures in position
➢ PMC/TPI in position
➢ Safety team in position
 Site Audit
• During Construction
➢ Work assignment

➢ Office with equipment and IT support ,

Transportation and Residential arrangement

➢ Procedure Qualification for welders/ Joint Coating

➢Safety Procedure implementation

➢ All material availability schedule

 Site Audit
• During Pre-commissioning & Commissioning
➢ All Clearance and Work completion notification, in hand of
commissioning team (Comprising of Select Construction team,
Clearance (ROU etc) Group, Commissioning team, Safety team,
Medical team and the dedicated O&M team)
➢ Check list existing non compliance including by pass of any signal,
alarm or shutdown (ESD)
➢ Pipe Book preparation status
➢ TCP and PCP design & Installation
➢ Special instruction related to equipment suppliers or service providers
➢ Follow pre approved procedure (Inertization, Pigs geometry, Pig back
Pressure, Launcher and receiver area cordoning off.
 Site Audit
• Post Commissioning:
➢ Contractors Invoices settlement
➢ Clear site of all encumbrances
➢ Compensation paid (ROU, Land Crop etc)
➢ ROU Restoration (with virgin soil)
➢ Marker installation,
➢ GIS Mapping
➢ As built Pipe Book completion
➢ Demobilize site