Quality

Booklet
GGSPAP

Quality


 











































[2]
 GGSPAP
REFINERY PRODUCTS

NAPTHA LLDPE/HDPE LLDPE

1463 KTPA 2X400 KTPA
HDPE
Ethylene 1200
KEROSENE KTPA Butene-1
645 KTPA

Dual Feed
LPG HDPE
329 KTPA
Cracker Unit 1X450 KTPA HDPE
1200 KTPA
ROG Propylene 500 KTPA PP
423 KTPA 1X500 KTPA Polypropylene

[3]
Benzene
142 KTPA

CBFS/PFO
83 KTPA

H2
2 KTPA

Fuel gas
76 KTPA

C7-C8 pyrolysis
gas
171 KTPA

C9-180
48 KTPA
 Brief Information abut GGSPAP

[4]
 Quality Objectives for GGSPAP

Sr.
Objectives KPI Target
No

Calibration of
Conformance to
1 Measuring 100%
calibration
Equipment's

Technical Audit
No of Audits
of Contractors
2 conducted vs 100%
at 35%, 70% &
Planned
90% Progress.

Quality of Monthly Weld

3 <3.5%
welding Repair rate

NDT Backlog <10%

Progressive
Monitoring of
4
Weld Quality by Check Shots on
NDT Min 5 %
Radiographs

Control of Non- No of Non-

5 Zero
conformance Conformance

[5]
PIPING CLASS DESIGNATION CODE
PIPING CLASS DESIGNATION CODE
A 1 A

First letter Middle number Third letter indicates type of

indicates pressure indicates difference material:
rating in the specifications A: Carbon steel
A: 150 class within the same B: Carbon moly steel
B: 300 class rating and C: 1.0% Cr 0.5% Mo steel
C: 400 class Material. For more D: 1.25% Cr 0.5% Mo steel
D: 600 class details refer E: 2.25 % Cr., 1.0 % Moly.
E: 900 class specification B018- F: 5.0 % Cr., 0.5 % Moly.
F:1500 class 6-44-0005-A1. G: 9.0 % Cr., 1.0 % Moly.
G: 2500 class Few Examples from H: 3.5 % Ni.
J: 125/150 class Table: J: Nickel / Titanium
K: Tubing / 1: General Process K: Stainless steel type 304,
miscellaneous condensate 304H, 304L.
2: Steam & Boiler L: Aluminum
Feed Water(IBR) M: Stabilized stainless steel
3:Plant Air, type 316, 316H, 321, 347.
Nitrogen service N: 316L
water P: Monel / Alloy 20
4:LTCS Q: Hastalloy / Inconel /
5:H2 Service Incoloy
11: Mild Sour Flare R: Lead ZeCor / ZeCor Z
16: NACE/PWHT S: PVC & FRP, PP / FRP,
19:Caustic/Amine PVDF / FRP
PWHT T: Cast Iron / Silicon Iron
23:NACE V: Duplex Stainless Steel
46:HIC W: Cupro-Nickel
Y: Lined steel (Rubber Lined,
Teflon Lined, Cement lined
etc.).
Z: HDPE / PDVF / Teflon /
PVC

[6]
 Welding Specification Chart
Sr Piping Class P Consumables Preheat Interpass PWHT Charpy Hardnes Remarks
No No. Temp. Temp. Temp & Time V s
Notch
A1A,B1A,D1A,E1A,A7A,A9A, ER70S-2 -- -- -- 200 BHN Size 2” &
A20A,A21A,B21A,A22A,B22A,B2 & & Max below only
10 ̊C Min

1 4A,B25A,B26A,A27A,F28A,A32A, 1 E7016/E7018 100 ̊C for GTAW

A81A,B81A,A82A,B82A,A86A,B8 THK > 25
6A,A87A,B87A mm
ER70S-2 -- -- -- Size 2” &
& & 1 Hr/Inch (Min 1 Hr) below only
10 ̊C Min 595 ̊C-620 ̊C &

2 A2A,B2A,D2A,E2A,F2A 1 E7016/E7018 100 ̊C for for THK >20 mm GTAW

(IBR) THK > 25 ROH & ROC
mm 200 ̊C/Hr Max

[7]
ER70S-2 -- -- -- -- --
3 A3A,A91A,A92A,A94A,A95A, 1 & &
10 ̊C Min

A96A,A97A,J2A E7016/E7018 100 ̊C for

THK > 25
mm
ER80S-Ni1 315 ̊C -- 27 J at 200 BHN Consumable
& & Max -45 ̊ C Max shall be
10 ̊C Min

4 A4A,B4A,D4A,B41A,B42A,A48A, 1 E7016-1/E7018-1 100 ̊C for (Minus) tested at -

B48A,A49A,B49A THK > 25 45 C
̊ .
mm
ER70S-2 -- NA 200 BHN Size 2” &
& & 1 Hr/Inch (Min 1 Hr) Max below only
10 ̊C Min 595 ̊C-620 ̊C &

5 A5A,B5A,D5A,E5A,A52A,B52A, 1 E7016/E7018 100 ̊C for for THK >20 mm GTAW

D52A,E52A THK > 25 ROH & ROC
mm 200 ̊C/Hr Max
 ER70S-2 -- -- -- 200 BHN Size 2” &
& & Max below only
10 ̊C Min

6 A11A 1 E7016/E7018 100 ̊C for GTAW

THK > 25
mm
ER70S-2 -- -- 200 BHN PWHT shall
& & 1 Hr/Inch (Min 1 Hr) Max be carried
10 ̊C Min 595 ̊C-620 ̊C &

7 F65A 1 E7016/E7018 100 ̊C for for all THK

(NACE0103 THK > 25 ROH & ROC
Qualified) mm 200 ̊C/Hr Max
ER70S-2 -- -- 200 BHN PWHT shall
& & 1 Hr/Inch (Min 1 Hr) Max be carried
10 ̊C Min 595 ̊C-620 ̊C &

8 A19A,B19A 1 E7016/E7018 100 ̊C for for all THK

THK > 25 ROH & ROC
mm 200 ̊C/Hr Max
ER70S-B2L/ER80S- 150 ̊C -- -- 225 BHN PWHT shall
D2D,B2D B2 Min 1 Hr/Inch (Min 2 Hr) Max be carried
620 ̊C-660 ̊C &

9 (IBR) 4 & for all THK

[8]
E7016-B2L/E7018- ROH & ROC
B2L 200 ̊C/Hr Max
ER70S-B2L/ER80S- 150 ̊C -- -- 225 BHN PWHT shall
B2 Min 1 Hr/Inch (Min 2 Hr) Max be carried
705 ̊C-745 ̊C &

10 B5D 4 & for all THK

E7016-B2L/E7018- ROH & ROC
B2L 200 ̊C/Hr Max
ER70S-B2L/ER80S- 150 ̊C -- -- 225 BHN PWHT shall
B2 Min 1 Hr/Inch (Min 15 Max be carried
650 ̊C-705 ̊C &

4 & Minute) for all THK

11 B1D E7016-B2L/E7018-
B2L ROH & ROC
200 ̊C/Hr Max
 Ni+Mn<1.2
& Post-
F2G,G2G 15E ER90S-B9 250 ̊C- 300 ̊C -- 210-250 heating at
12 (IBR) & 300 ̊C Max 1 Hr/Inch (Min 2 Hr) BHN 300 ̊C for
705 ̊C-775 ̊C &

E9015-B91/E9016- Min Min 1 Hr

B91 ROH & ROC *PWHT
100 ̊C/Hr Max shall be
done for all
THK
13 A1K,B1K,D1K,A3K,A23K,A24K, 8 ER308L 10 ̊C Min 175 ̊C -- -- -- Size 2” &
A36K,A81K,B81K,A82K,B82K, & Max below only
A91K E308L-15/16 GTAW
10 ̊C Min 175 ̊C -- -- -- Consumable
Max shall be
14 A2K,B2K,D2K,B22K,D22K 8 ER308L tested at
& -196 ̊C for

[9]
E308L-15/16 Lateral
Expansion
0.38 mm
Min.
10 ̊C Min 175 ̊C -- -- -- During PQR,
Max Weld metal
15 B51K,D51K,E51K 8 ER308L Ferrite
& content
E308L-15/16 shall be
3 to 8%.
10 ̊C Min 175 ̊C -- -- -- For UNS
ER308L Max N06625,
16 A6K,B6K,D6K,A11K,A26K,A27K, 8 & Use
A29K,B27K,D27K,F28K E308L-15/16 ERNiCrMO-
3/ENiCrMO-
3
 NDE Requirements for Piping (Page 1 of 2)
Type of Weld Examined
Inspection Piping Class Types of
Girth Socket Attachment Fabricated Fabricated
Class Examination
Butt Weld Weld Branch Mitres/Reducer
Weld Weld
A3A,A3K,A91A,A92A, Visual 100% 100% 100% 100% 100%
Class I A94A,A96A,J2A
LPT/MPI - - - 5% 10%

A1A,B1A,D1A,A7A,A9A, Visual 100% 100% 100% 100% 100%

A11A,A20A,A22A,A32A,
Class II B32A,B22A,B26A,B32A, Radiography 5% - - - 20%
A4A,B4A,D4A,B41A,B42A,
A1K,A11K,B1K,D1K,A23K, LPT/MPI - 5% - 5% 20%
A24K,A26K,A29K,A6K,A91K,
B6K,D6K,A1M,A1N,B1N,D3M

[ 10 ]
Visual 100% 100% 100% 100% 100%

A95A,A97A, Radiography 10% - - - 50%

A2A,B2A,D2A
LPT/MPI - 10% - 10% -

Visual 100% 100% 100% 100% 100%

Class III
B1D ,B2D, Radiography 20% - - - 50%
D2D
LPT/MPI - 20% - 20% -

Visual 100% 100% 100% 100% 100%

A19A,B19A, A5A,A52A,B5A,B52A Radiography 20% - - - 50%
LPT/MPI - 20% 10% 20% -
 (Page 2 of 2)
Type of Weld Examined
Inspection Piping Class Types of
Class Examination Girth Socket Attachment Fabricated Fabricated
Butt Weld Weld Branch Mitres/Reducer
Weld Weld

Visual 100% 100% 100% 100% 100%

E1A,F28A,E2A, F2G,G2G
Radiography 100% - - - 100%

LPT/MPI - 100% 10% 100% -

[ 11 ]
A21A,A86A,A87A,B21A,B24A,B25A, Visual 100% 100% 100% 100% 100%
Class IV B86A,B87A,A27A,A48A,A49A,A81A,
A82A,B48A,B49A,B81A,B82A,
B5D,D5A,D52A,E5A,E52A,F65A Radiography 100% - - - 100%

LPT/MPI - 100% 10% 100% -

Visual 100% 100% 100% 100% 100%

B27K,D27K,A2K,B2K,B22K,D2K,D22K,
F1M,F28K,A27K,A81K,A81N,A82K,
B51K,B81K,B82K,D51K,E51K Radiography 100% - - - 100%

LPT/MPI - 100% 10% 100% -

 Material Specification Guide
Material Plate Pipe Forging Fittings Bolting
Stainless SA240-304,304L,316, SA312304,304L,316, SA182304,304L,316, SA403-
Steel 316L,347,347H 316L,347,374H 316L,347,347H 304,304L,316, SA320-B8 &
316L,347,347H SA194-8
9% Nickel SA-353(N+T) & SA333-Gr8 SA-522-Gr1 SA420-WPL8
SA553 (Q+T)

LTCS SA-516 Gr 55 & 60-N SA-333 All Grade SA-350-LF2 SA420WPL-6 SA320-L-7
SA-537-N,SA-537- &
Q&T SA194-4
Carbon SA516 All Grade SA-106 Gr B & C SA-105 SA234 WPB SA-193B7

[ 12 ]
Steel SA515 All Grade & SA194-2H
IS 2062 E 250/350
A,BR,B0,C
9Cr-1Mo SA387-Gr P91 SA335 Gr91 SA182-F91 SA-234-WP91 SA193-B5 &
SA194-B3

Ni-Alloys
25Cr-35Ni + Nb;
35Cr-45Ni+Nb;
20Cr-32Ni+Nb;
 Effect of Alloying Elements on Properties of Steel

[ 13 ]
 SS Family & effects of adding further alloys

[ 14 ]
[ 15 ]
[ 16 ]
[ 17 ]
[ 18 ]
CRITERIA FOR BOLT TENSIONING
Note: Not applicable for category D service

Nominal Bolt diameter Condition Remarks

When specified by the Process licensor/
All
vendor / project specifications
50 mm and above All joints
Class 600 and above
(See Note-1
Hydrogen service
below)
Refer ASME
38 mm and above, but Category 'M' fluid services
B31.3
less than 50 mm
(See Note-2
Joints with leakage potential
below)
(See Note-3
Critical joints with equipments
below)
(See Note-2
Joints with leakage potential
25 mm and above, but below)
less than 38 mm (See Note-3
Critical joints with equipments
below)
Note-1: Hydrogen Service
Hydrogen service is defined as service in contact with Hydrogen or gaseous
mixtures containing Hydrogen in which the partial pressure of Hydrogen is 7 bar
(100 psi) abs. or more.
Note-2: Joints with leakage potential shall include
a) Joints involving tapped holes.
b) Joints not subjected to hydro test e.g. joints for equipment manholes,
temperature connections, on line instrument joints like control valves and safety
valves, compressor volume bottles.
c) Items involving two sets of gaskets with one set of bolt e.g. orifice flange joint,
joints with spectacle blind, spacer, flangeless wafer check valve, wafer type
butterfly valves.
d) Tie-in joints with other contractors and package vendors.
e) High temperature (above 371°C) joints in hydrocarbon services.
Note-3: Critical joints with the equipments shall include the inlet and the outlet
flanges of pumps, compressors and turbines.
Criteria for Bolt Torque application
Service Joints
Hydrogen service All joints (Note-1)
Category 'M' services All joints (Note-1)
Other services Class 600 and above
Note-1: Joints, those qualify for hydraulic bolt tensioning as per cl. 5.1.1, shall not
be considered for torque application.

[ 19 ]
Torque application:
Torque should be applied using a minimum of following five
steps:
i. All the nuts should be made snug tight with a short wrench
(Criss-cross Pattern).
Flange should be bearing uniformly on the gasket (Distance
between mating flanges shall be uniform).
ii. Tightening to 30% of the final torque value (Criss-cross
Pattern).
Flange should be bearing uniformly on the gasket (Distance
between mating flanges shall be uniform).
iii. Tightening to 60% of the final torque value (Criss-cross
Pattern).
Flange should be bearing uniformly on the gasket (Distance
between mating flanges shall be uniform).
iv. Tightening to the final torque value (Criss-cross Pattern).
Flange should be bearing uniformly on the gasket (Distance
between mating flanges shall be uniform).
v. Tightening should be continued with the final torque in a
clockwise manner (bolt to bolt) until no further rotation is
observed.

Hydraulic bolt tension application:

a) Hydraulic pressure adequate to get the target bolt load can be

calculated dividing the bolt load by the load cell hydraulic seal
area. This pressure should be applied simultaneously to all load
cells.
b) 4 load cells equally spaced should be used.
c) Nuts should be run down to flange surface manually.
d) Load cells should be shifted following the Criss-cross Pattern
shown in Fig. 1 but in-groups of 4 bolts each (i.e. 1-2-3-4, 5-6-7-
8, 9-10-11-12 etc.) and the tensioning of all bolts should be
completed.
e) Tensioning operations should be repeated once again applying
the same pressure.

Typical criss-cross Bolt tightening / torque application

[ 20 ]
[ 21 ]
Recommended Gasket Contact Surface Finish for
Various Gasket Types
Gasket Description Gasket contact surface finish
(µm)
Spiral wound 3.2-6.4
Flexible graphite reinforced 3.2–6.4
with a metal interlayer insert
Soft cut sheet, thickness ≤1.6 3.2–6.4
mm
Soft cut sheet, thickness 1.6 3.2–13
mm
Note: Finishes listed are average surface roughness values and
apply to either the serrated concentric or serrated spiral finish
on the gasket contact surface of the flange.

Table 2: Allowable Defect Depth vs Width across

Fac e

Measurement Hard Faced Soft Face Gaskets

Gaskets
rd < w/4 < 0.76 mm < 1.27 mm
w/4 < rd < w/2 < 0.25 mm < 0.76 mm
w/2 < rd < 3w/4 Not allowed < 0.13 mm
rd > 3w/4 Not allowed Not allowed
Note:
1. Hard faced Gaskets: Gaskets having an assembly
compression less than 1.0 mm.
2. Soft faced Gaskets: Gaskets having an assembly
compression in excess of 1.0 mm. E.g. Spiral wound
gaskets, PTFE, fiber, etc.
3. See Figs. 1 and 2 for description of defect measurement.

[ 22 ]
 Fig 1: Flange Surface Damage Assessment: Pits and Dents

Fig 2: Flange Surface Damage Assessment: Scratches and Gouges

[ 23 ]
 Flange Seating Face Flatness Tolerances

Measurement Hard Gasket Soft Gasket

Acceptable variation T1 < 0.15 mm T1 < 0.25 mm
in circumferential
flange seating surface
flatness
Acceptable variation T2 < 0.15 mm T2 <.25 mm
in radial (across
surface) flange seating
surface flatness
Note: See Figs. 3 and 4 for description of T1 and T2
measurement methods.

Fig 3: Flange Circumferential Variation Tolerance, T1

[ 24 ]
Fig 4: Flange Radial Variation Tolerance, T2

[ 25 ]
Permissible Imperfections in Flange Facing Finish
for Raised Face and Large Male and Female
Flanges as per ASME B16.5

[ 26 ]
 COLOUR CODES FOR PIPES, FITTINGS AND FORGING

S. Pipe Elbows, Reducers, Tee’s Flange/Blind Colour Name Colour Shades

No Caps Flange
1. A-234 Gr WPB/WPBW-IBR Post Office Red
A-234 Gr WPB/WPBW- A-105
2. None
NON IBR
3. A-182 None
A-234 Gr WPBW- NON IBR
& NORMALISED

[ 27 ]
4. API 5L Gr B- ----- ----- None
Seamless
5. API 5L Gr B-EFSW ----- ----- None
6. API 5L Gr B-ERW ----- ----- Navy Blue &
India Brown
7. A-106 Gr B ----- ----- Deep Orange
8. A-106 Gr B A-234 Gr WPB(N) ----- Deep Orange &
(Normalized) Sea Green
A-234 WPBW(N) ----- Deep Orange &
Sea Green
9. IS 1239/IS 3589 ----- Light Purple
Gr 410 Brown
10. IS 3589 Gr 330 ----- Light Purple
 6. API 5L Gr B-ERW ----- ----- Navy Blue &
India Brown
7. A-106 Gr B ----- ----- Deep Orange
8. A-106 Gr B A-234 Gr WPB(N) ----- Deep Orange &
COLOUR CODES FOR PIPES, FITTINGS AND
(Normalized)
FORGINGS
Sea Green
A-234 WPBW(N)(CONTINUED…)----- Deep Orange &
S. No Pipe Elbows, Reducers, Flange/Blind Sea
Colour
GreenName Colour
9. IS 1239/IS 3589 Tee’s Caps -----
Flange Light Purple Shades
16. Gr 410A 335 Gr P11 A-234 WP11 A 182 F11 BrownLincoln Green
10. IS 3589A 691
Gr Gr
3301.25 Cr A-234 WP11W -----
---- Light Purple
Lincoln Green
CL.42 (EFW) Brown & Navy
17. A 335 Gr P12 A-234 WP12 A 182 F11 Blue Canary Yellow
11. A 333 Gr 6 A-420 WPL
A-2346 WP12W -----
---- Maroon
Canary Yellow
18. A 335 Gr P22 A-420 WPL A-2346WWP22 A -----
182 F22 Maroon
Sea Green

[ 28 ]
12. A 335A Gr691PIGr 2.25 CrA-234 WP1
A-234 WP22W A 182----F1 Salmon Pink
Sea Green
CL.42 (EFW) A-234 WP1W ----- Salmon Pink
A 335 Gr P5
19. Austenitic
13. A-234 WP5 182 F5
A ----- Navy
No Blue
Paint
Stainless Steel A-234 WP5W ---- Navy Blue
20. A 335 Gr P9 A-234 WP9 A 182 F9 Dark Violet
14. For Hydrogen White Colour
A-234 WP9W ---- Dark Violet
Service Band
15. For IBR Material Post Office Red

COLOUR CODES (POWDER COATING)-STUDS/BOLTS & NUTS

 COLOUR CODES FOR PIPES, FITTINGS AND FORGINGS
(CONTINUED…)
S. No Pipe Elbows, Reducers, Flange/Blind Colour Name Colour
Tee’s Caps Flange Shades
16. A 335 Gr P11 A-234 WP11 A 182 F11 Lincoln Green
A 691 Gr 1.25 Cr A-234 WP11W ---- Lincoln Green
CL.42 (EFW)
17. A 335 Gr P12 A-234 WP12 A 182 F11 Canary Yellow

[ 29 ]
A-234 WP12W ---- Canary Yellow
18. A 335 Gr P22 A-234 WP22 A 182 F22 Sea Green
A 691 Gr 2.25 Cr A-234 WP22W ---- Sea Green
CL.42 (EFW)
19. A 335 Gr P5 A-234 WP5 A 182 F5 Navy Blue
A-234 WP5W ---- Navy Blue
20. A 335 Gr P9 A-234 WP9 A 182 F9 Dark Violet
A-234 WP9W ---- Dark Violet
 COLOUR CODES (POWDER COATING)-STUDS/BOLTS & NUTS
S. No Nuts/Bolts ASTM Designation Colour Name Colour Shades
1. Bolt A 193 GR B 7 Canary Yellow
2. Nut A 194 GR 2 H Canary Yellow
3. Bolt A 307 GR B India Brown
4. Nut A 307 GR B India Brown
5. Bolt A 193 GR B 16 Lincoln Green

[ 30 ]
6. Nut A 194 GR 4 Lincoln Green
7. Bolt A 320 GR L 7 Chocolate
8. Bolt A 320 GR B 8 Light Purple
Brown
9. Nut A 194 GR 8 Light Purple
Brown
Spiral wound Gaskets

[ 31 ]
 Gasket Piping Class
Gasket
SS316+GRAFIL Piping
A20A (0.5" Class
to 24"), A95A (300#)
SS316+GRAFIL A20A (0.5"
A20A (26"to 28"), to 24"),
A11A A95A300#
(150#, (300#)
& 600#),
A11K,(26"to
A20A A19A,28"),
A1A, A11A
A1K, A1M,
(150#,A2A,
300#A3A, A3K
& 600#),
(300#),
A11K,A48A,
A19A,A49A, A4A,A1M,
A1A, A1K, A52A,A2A,
A5A,A3A,
A6K,A3KA7A,
SS316+GRAFIL+ I A82A, A86A
(300#), A48A,(150#),
A49A, A87A, A91A A5A,
A4A, A52A, (300#A6K,
& 600#),
A7A,
RING
SS316+GRAFIL+ I A96A
A82A,(300#), A9A, B19A,
A86A (150#), A87A, B1A, B1D
A91A (0.5"&to
(300# 24"),
600#),
RING B1K, (300#),
A96A B4A, B51K,
A9A,B52A,
B19A,B5A,
B1A,B5D,
B1D B82A, B86A,
(0.5" to 24"),
B87A,B4A,
B1K, D1A, D1K,B52A,
B51K, D2A, D2D,
B5A, D4A, D51K, B86A,
B5D, B82A, D52A
(600#),
B87A, D1A, D1K, D2A,D5A
D2D,(600#)
D4A, D51K, D52A
UNS (600#), D5A (600#)
A6K (0.75") - Inconel (Gold) with Graphite (Grey)
N06625+GRAFIL+I
UNS Filler with Graphite (Grey)
A6K (0.75") - Inconel (Gold)
RNG
N06625+GRAFIL+I
Filler
RNG A86A (300#), A21A, A27A, A27K, A81A, A81K,
SS316+GRAFIL+
A82K, B21A, B25A
A86A (300#), A21A,(0.5"
A27A,to A27K,
24"), B26A
A81A,(0.5" to
A81K,
SS316 I RING
SS316+GRAFIL+
A82K,20"),
B21A,B48A,
B25AB49A,
(0.5"B81A, B81K,
to 24"), B26AB82K
(0.5" to
SS316 I RING
SS316L+GRAFIL+ I 20"),toB48A,
B1D (26" 60"), B49A, B81A,B1N,
A1N, A81N, B81K,B2AB82K(300# &
RING
SS316L+GRAFIL+ I B1D (26" to 60"), 600#),
A1N,B2D,
A81N, D6K
B1N, B2A (300# &
RING
SS316+TEFFIL+ I 600#), B2D, D6K
B41A
RING
SS316+TEFFIL+ I
B41A
SS316L+GRAFIL
RING B6K
SS321+GRAFIL+
SS316L+GRAFILI B6K
D3M
RING
SS321+GRAFIL+ I
D3M
RING
SS316+GRAFIL+
A2K, B22K, B27K, B2K, D22K, D27K, D2K
SS316 I/O RING
SS316+GRAFIL+
A2K, B22K, B27K, B2K, D22K, D27K, D2K
SS316 I/O RING
SS316+TEFFIL+
A22A, B22A, B24A, B42A
SS316 I RING
SS316+TEFFIL+
A22A, B22A, B24A, B42A
SS316 I RING

Material Colour code

Metallic
Materialwinding material
Colour code
SS 316windingNo
Metallic color
material
SS 316 NoPink
color
SS 316L
Green
Pink
SS 316L
SS 321 Turquoise
Green
Nonmetallic
SS 321 filler material
Turquoise
Graphite filler material
Nonmetallic Grey
PTFE
Graphite White
Grey
PTFE White
[ 32 ]
SURFACE PREPARATION
VARIOUS INTERNATIONAL STANDARDS DESCRIPTION
(EQUIVALENT)
ISO 8501-1 / SIS- SSPC-SP, USA NACE, USA
05 59 00
ST. 2 SSPC-SP-2 - Manual or hand tool
cleaning
ST. 3 SSPC-SP-3 - Mechanical or
power tool cleaning
DRY ABRASIVE BLAST CLEANING
SA 3 SSPC-SP-5 NACE #1 White metal
SA 2 1/2 SSPC-SP-10 NACE #2 Near white metal
SA 2 SSPC-SP-6 NO. 3 Commercial blast
SA 1 SSPC-SP-7 NO. 4 Brush off blast

PAINT MATERIALS
TECHNICAL NAME DFT per Touch dry Hard Over
coat in at 30 C dry at coating
microns (minimum) 30 C interval
(max) (minimum)
PRIMERS
P-2 Chlorinated rubber 40-45 30 min 8 hrs 8 hrs
zinc phosphate
primer
P-4 Etch primer / wash 8-10 2 hrs 24 hrs 4-6 hrs
primer
P-6 Epoxy zinc 40-50 After 30 min 8 hrs 8 hrs
phosphate primer
P-7 Zinga Locktite or 40-50 10 min 24 hrs 4 hrs
ZRC cold galvanizing
FINISH PAINTS
F-2 Acrylic 30-40 30 min 8 hrs 12 hrs
polyurethane finish
paint
F-3 Chlorinated rubber 30-40 30 min 8 hrs Overnight
based finish paint
F-6 Epoxy High Build 100-125 3 hrs 16 hrs Overnight
A/B coating Max: 5 days
F-6C Solvent less epoxy 200-500 3 hrs 16 hrs 8 hrs
coating Max: 48 hrs
F-7 High build coal tar 100-125 4 hrs 48 hrs 24 hrs
epoxy coating Max: 5 days
F-8 Self-priming type 100-125 3 hrs 24 hrs 10 hrs
surface tolerant
high build epoxy

[ 33 ]
 coating (complete
rust control
coating).
F-9 Inorganic zinc 65-75 30 min 12 hrs 12 hrs (at 20
silicate coating C and 50 %
RH)
F-11 Heat resistant 15-20 3 hrs 12 hrs 24 hrs
synthetic medium
based two pack
aluminium paint
suitable upto 250 C
dry temp
F-12 Heat resistant 15-20 30 min 24 hrs 24 hrs
silicone aluminium
paint suitable upto
500 C dry temp
F-14 Polyamine cured 100-125 4 hrs 24 hrs 6 hrs
coal tar epoxy Max: 5 days
F-15 Two component 75-100 3 hrs 24 hrs 36 hrs
epoxy phenolic Max: 21
coating cured with days
polyamine adduct
hardener system
(primer +
intermediate coat +
finish paint)
F-16 Ambient 75-100 1 hrs 16 hrs 16 hrs
temperature curing
poly siloxane
coating / high build
cold apllied
inorganic
copolymer based
aluminium coating
suitable for under
insulation coating of
CS and SS piping for
high temperature
service
F-17 Two component 125-150 2 hrs 24 hrs 16 hrs
solvent free type Max: 21
high build epoxy days
phenolic / novalac
epoxy phenolic
coating cured with
polyamine adduct
hardner system

[ 34 ]
 COATING SYSTEM FOR OFFSITE AREA (Uninsulated and above
ground except flare line – for CS, LTCS & LAS)
Pre erection / shop Post erection / Field
primer coating system
Design Temp Surface No of No of Finish
in C preparation coats Primer DFT/Coat coats coat DFT/Coat Final DFT in microns
-90 to -15 SSPC-SP-10 1 F-9 65-75 None None None 65-75
-14 to 60 SSPC-SP-10 1 F-9 65-75 1 F-2 40 105-115
61 to 80 SSPC-SP-10 1 F-9 65-75 1 F-2 40 105-115
81 to 250 SSPC-SP-10 1 F-9 65-75 2 F-11 20 105
251 to 400 SSPC-SP-10 1 F-9 65-75 2 F-12 20 105-115

[ 35 ]
401 to 550 SSPC-SP-10 1 F-12 20 2 F-12 20 60

COATING SYSTEM FOR UNIT AREAS, DM, CPP, COOLING TOWERS

AND FLARE LINES (WITHIN UNIT OR OFFSITE) – UNINSUALTED
AND ABOVE GROUND – CS, LTCS AND LAS
Note: Flare lines, whether within unit or offsite area, shall be coated as per S No 3
(design temp: 81 to 400) of table.

Pre erection / shop

primer Post erection / Field coating system Final
Design Surface No of No of Finish DFT in
Temp in C preparation coats Primer DFT/Coat Primer coats coat DFT/Coat microns
 401 to 550 SSPC-SP-10 1 F-12 20 2 F-12 20 60

COATING SYSTEM FOR UNIT AREAS, DM, CPP, COOLING TOWERS

AND FLARE LINES (WITHIN UNIT OR OFFSITE) – UNINSUALTED
AND ABOVE GROUND – CS, LTCS AND LAS
Note: Flare lines, whether within unit or offsite area, shall be coated as per S No 3
(design temp: 81 to 400) of table.

Pre erection / shop

primer Post erection / Field coating system Final
Design Surface No of No of Finish DFT in
Temp in C preparation coats Primer DFT/Coat Primer coats coat DFT/Coat microns
-90 to -15 SSPC-SP-10 1 F-9 65-75 None None None None 65-75

[ 36 ]
1 coat of 2 F-6A 100
P-6 @ 40
micron
-14 to 80 SSPC-SP-10 1 F-9 65-75 DFT/coat 1 F-2 40 345-355
81 to 400 SSPC-SP-10 1 F-9 65-75 None 2 F-12 20 105-115
401 to 550 SSPC-SP-10 1 F-12 20 2 F-12 20 60
 COATING SYSTEM FOR UNDERGROUND CS PLANT PIPING
Post erection / Field coating system Final DFT
Design Surface
No of DFT/Coat No of Finish DFT/Coat in
Temp in C preparation Primer
coats (microns) coats coat (microns) microns

Coaltar 2 mm per
1 layer
tape layer
Synthetic
fast Synthetic
25 to 65 SSPC-SP-10 1 20 4 mm
drying fast
1 25

[ 37 ]
primer drying
primer
Coaltar 2 mm per
1 layer
tape layer
1 F-17 125
66 to 150 SSPC-SP-10 1 F-17 125 375
1 F-17 125
151 to 400 SSPC-SP-10 1 F-16 125 1 F-16 125 250

COATING UNDER INSUALTION – ALL UNIT AREAS AND OFFSITES –

FOR INSULATED PIPING
Pre erection / shop primer Post erection / Field coating system Final
Design DFT/Coa DFT/Coa DFT
 151 to 400 SSPC-SP-10 1 F-16 125 1 F-16 125 250

COATING UNDER INSUALTION – ALL UNIT AREAS AND OFFSITES –

FOR INSULATED PIPING
Pre erection / shop primer Post erection / Field coating system Final
Design DFT/Coa DFT/Coa DFT
Surface Primer /
Temp in No of t No of Finish t in
preparation Primer Intermediat
C coats (microns coats coat (microns micr
e
) ) ons
CS, LTCS AND LAS PIPING
1 coat of F-
-45 to 15 @ 75 225-
SSPC-SP-10 1 F-15 75 2 F-15 75

[ 38 ]
120 micron 250
DFT/coat
121-540 SSPC-SP-10 1 F-12 20 None 2 F-12 20 60
SS including Alloy-20 (incoloy) piping - blast cleaning shall be by aluminum oxide grits / shots or garnet

1 coat of
SSPC-SP-1 inert
inert
-180 to with Non polymeric 350-
None None None 2 polymeric 125
zero chloride matrix 400
matrix
solvent coating @
125 micron
 SSPC-SP-10 1 coat of F-
(15-25 micron 15 @ 80
0 to 125 1 F-15 80 1 F-15 80 240
surface micron
profile) DFT/coat

126 to
SSPC-SP-10 1 F-16 125 None 1 F-16 125 250
400
401 to Amercoat Amercoat
SSPC-SP-10 1 125 None 1 125 250
600 738 738

Cyclic service of CS, LTCS, LAS and SS

[ 39 ]
SSPC-SP-10 1 coat of F-
-40 to (15-25 micron 15 @
1 F-15 80 1 F-15 80 240
150 surface 80micron
profile) DFT/coat
CS: SSPC-SP-6
-180 to 1 coat of
commercial
650 inert
blast inert
polymeric 350-
SS: SSPC-SP-1 None None None 2 polymeric 125
matrix 400
with non- matrix
coating @
chloride 125 micron
solvent
No painting required for insulated, monel, nickel and alloy lines

Coating system for gratings, rolling & stationery ladders, spiral

 No painting required for insulated, monel, nickel and alloy lines

Coating system for gratings, rolling & stationery ladders, spiral

stairways & hand rails

Design Coating system Total DFT

No
Temp DFT/coat in microns
of Coating
in C (microns) (min)
coats
Hot Dip 1 P-6 40
galvanizing
to 80-85
micron 80

[ 40 ]
(600-610 (excluding
Upto
gm/m3) as thickness
60 1 F-2 40
per IS of
4759, galvanizing)
2629,
4736,
2633
 REPAIR OF PRE-ERECTION / PRE-FABRICATION OR SHOP PRIMER
AFTER ERECTION / WELDING
Note: In case the damages of primer are severe and spread over large area, entire
primer shall be removed by blasting to achieve SSPC-SP-10 and surfaces to be
primed again with F-9 or F-12 as applicable.
Coating system Total
Design
No DFT in
Temp Surface DFT/coat

[ 41 ]
of Coating microns
in C preparation (microns)
coats (min)
-90 to
SSPC-SP-3 1 F-9 65-75 65-75
400
401 to
SSPC-SP-3 1 F-12 20 20
550
 Guidelines for standard Blind Thickness-Hydro Testing
PLATE for HYDRO TESTING (Thickness in mm)
TEST PRESSURE
KG/CM2 Nominal Header Size (Inches)
2 3 4 6 8 10 12 14 16 18 20 24 30 36 42
7 6 6 6 9 13 13 13 13 13 19 19 19 25
14 6 6 6 9 13 19 19 19 19 19 25 25 31
21 6 6 6 9 13 19 19 19 25 25 25 31 38
28 6 6 9 13 19 19 25 25 25 31 31 38 38
35 6 6 9 13 19 25 25 25 31 31 31
42 6 6 9 13 19 25 25 25 31 38 38
49 6 9 9 16 19 25 25 31 31 38 38
56 6 9 9 16 19 25 31 31 38 38

[ 42 ]
63 6 9 12 16 19 25 31 31 38 38
70 6 9 12 16 25 31 31 38 38
77 6 9 12 16 25 31 38 38 38
84 6 9 12 16 25 31 38 38
91 6 9 12 16 25 31 38 38
98 9 18 12 16 25 31 38
105 9 18 12 16 25 31 38
112 9 18 18 25 25 31
119 9 18 18 25 30 38
126 9 18 18 25 30 38
133 9 18 18 31 30 38
146 9 18 18 31 30 38
 
QUALITY BULLETIN   

INTEGRITY ISSUES:
POOR HANDLING & PROTECTION OF FLANGE FACE AT SITE

Introduction:
The Integrity of Flanged connections is critical to
the containment of fluids in a piping system. Loss of
containment, whether in chemical lines such as
hydrocarbons and gas systems or water distribution
lines, will have significant environmental,
operational and commercial impact, and could
impose a serious safety risk.

Integrity Issues:
• Damage of face of the flange, its serration &
groove results in poor tightness between gasket &
flange face, providing escape route for contained
service fluid.
• The concentration of corrosive materials between
the gap of the sealing surface and gasket material
can initiate the corrosion on flange face resulting
into release of the product.

What We Can Do?

• All type of flanges & blind flanges shall be stored on pallets in single Layer.
• If space constraint, Flanges may be stacked in layers with timber spacers
between each layer.
• Ensure that flange protection is intact in all critical stages viz. shop pre-fabrication,
transit and site erection.

How We Can Do?

• Educate the piping QC Supervisor regarding
flange protection & its preventive measure and
create awareness during Tool box talk.
• Flange face protection can be done using suitable
methods such as Plastic flange covers tightened
with wires or plywood /cardboard sheet covered
with masking tape.
• Ensure above to be part of material handling checklist during fabrication & before
release to site for Erection.
• Enhance visual management by displaying relevant Quality posters at erection
sites.
HMEL QUALITY TEAM

[ 43 ]
 
QUALITY BULLETIN
   

INTEGRITY ISSUES:
WELD JOINT FOULING ON CIVIL & STRUCTURAL BEAMS


Introduction:
    
During piping fabrication & erection activities, there is
high probability that weld joints will foul on civil beams or
structural members. In the BS-VI project, similar issues
were observed during Format inspection. Typically weld
joints have an acceptable weld reinforcement or capping
at outside joint surface. This weld reinforcement will
always result in point contact with the surface while
resting. This condition has potential reliability issues
leading to leakages during operations.
Integrity Issues:
• Point contact with civil beams or structural members due to weld reinforcement
resulting in concentrated stresses at the point of contact.
• Damage to weld joint due to expansion and contraction movement of piping during
operations resulting in leakage.
• Potential crevice corrosion at weld joint location due to moisture ingress leading to
leakage.
• Not possible to inspect these weld joints during in-service inspection or repair activities.
• Not possible to carry out temporary (OLS) & permanent (welding) repairs in case of leak
due to inaccessibility.

What We Can Do?

• During Erection of piping, ensure that no weld joint is
fouling with civil beam or structural member.
• Ensure there is a minimum gap of 50T or 100mm,
whichever is greater, between toe of weld joint and
edge of civil beam or structural member, T is nominal
thickness of pipe.

 How We Can Do?

 • Educate the piping fitter regarding this reliability issues
 
    and its preventive measure and create awareness
during Tool box talk.
• In case, not possible to avoid weld joint fouling, insert a new piping spool piece to avoid
weld joint on beam or structure.
• Visual check during erection that no weld joint is fouling with civil beam or structural
member and minimum recommended gap is maintained.
• Enhance visual management by displaying relevant Quality posters at erection sites.
• Contact Quality experts in case of confusion before erection.

HMEL QUALITY TEAM

[ 44 ]
 GGSPAP/
QUALITY BULLETIN QUALITY/ 2019/03
DATE: 25/07/2019

HYDROTEST PRACTICES
WATER QUALITY AND FLUSHING PRACTICES
Introduction:
A hydrotest is an activity in which pressure vessels (pipelines, heat
exchangers, etc) are tested for integrity and leaks. The test involves
filling the equipment or pipe system with a liquid, usually water, and
pressurization to the specified test pressure. Pressure tightness is
then tested by shutting off the supply valve and observing whether
there is a pressure loss, deformation or visual leaks. Hydrotest is the
most common method employed for certifying newly manufactured
LEAKED WELD JOINT CUT SECTION
–ID SIDE SURFACE WITH WATER
pipes and equipments for in service use.
In a Refinery, 16” line (SS304L) few weld joints leaked during commissioning stage and reason
was attributed to left over stagnant water causing MIC.
Integrity Issues:
Inferior quality of water and left out water after hydrotest – It can cause Localized pitting leading to
in-service leakage of hydrocarbons. This pitting is attributed to below described damage
mechanism.
Microbiologically Induced Corrosion (MIC):
• A form of corrosion caused by living organisms such as bacteria, algae
or fungi. It is often associated with the presence of tubercles or slimy
organic substances.
• Such microbes can grow under severe conditions including lack of
oxygen, light or dark, high salinity, pH range of 0 to 12, and
temperatures from -18°C to 112°C in presence of inorganic / organic
substances along with water.
• Most common materials of construction including carbon and low alloy
steels, 300 Series SS and 400 Series SS, aluminum, copper and
some nickel base alloys are affected.
• MIC is found in equipments and pipes where the hydrotest water has
not beenremoved and dried or has been left outside and unprotected.

What We Can Do?

• Clean Build: Prevent ingress of foreign materials in pipe systems and equipment during
fabrication and erection. These substances become nutrients for microbes.
• Quality of water: Ensure quality of water used for hydrotest is within the spec (as recommended
for differentmaterials). For SS piping, demineralized water shall be preferred or water with
chloride < 20 ppm shall be used.
• Empty out hydrotest water as soon as possible. Blow dry air and prevent moisture intrusion. 

How We Can Do?

• Educate contractor supervisors regarding prevention of foreign material ingress in piping systems
during fabrication and erection & create awareness during Tool box talk.
• Water quality certificate to be ensured before hydrotest. Foul smelling water shall never be used
for hydrotest. Also, it is necessary to ensure tankers used for transportation and tanks used for
storage of hydrotest water are clean.
• Coordination between execution team and operations team to flush the hydrotested lines as soon
as possible, preferably within one week of hydrotest completion.

HMEL QUALITY TEAM

[ 45 ]
 GGSPAP/Quality/
QUALITY BULLETIN 2019/04
Date: 27-7-2019

INTEGRITY ISSUES:
PRIMARY PIPING SUPPORT
Introduction:
A pipe support is a designed element that transfer the
load from a pipe or the structural attachment to the
supporting structures. Structural attachments are
elements that are welded, bolted, or clamped to the
pipe, such as clips, lugs, clamps, clevises, and stops.
The load includes the weight of the pipe, the content
that the pipe carries, all the pipe fittings attached to
pipe, and the pipe covering such as insulation. Pipe
Supporting elements are so designed as to prevent:-
» Piping stresses in excess of those permitted in the Fig. Incomplete Welding of Primary Support
Construction Code of ASME B31.3
» excessive thrusts and moments on connected equipment (such as pumps and turbines)
» excessive interference with thermal expansion and contraction in piping
» excessive distortion or sag of piping under conditions of repeated Thermal cycling.
Basically, there are two types of pipe support structures, Primary and Secondary supports.
Primary
supports are directly attached to the piping, while secondary pipe supports are attached directly
to the foundation or structure supporting the pipe.
In BS-VI Project, and Refinery Projects; During Format Inspection of Loops, one of the major
observations was- Missing or Incomplete Welding of Primary Supports.

Integrity Issues:
• Both Absence of Primary Support and Incomplete welding will lead to both loss of time, and
resources at the time of Mechanical Clearance. Further causes metallurgical degradation of
weld joints due to multiple welding at the same location. A lack of support or stiffening allows
vibration and possible cracking problems that usually initiate at stress raisers or notches that
may lead to Vibration Induced Fatigue Cracking.
• Fabrication Stresses remain persistent in the weld joint of Primary Support welded to alloy
steel pipes such as P11, P22, and P91 etc., when Stress relieving is missed out.

What We Can Do?

• Supports has to be provided as mentioned in the approved isometric drawing before
mechanical clearance.
• Stage-wise Visual inspection and NDT needs to be done after Primary Support welding to
pipe. All welded supports to be fully welded, stress relieved if applicable.
• Any modifications in Primary supports arrangement needs to be closed prior to Hydro Test 

How We Can Do?

• Technical awareness: Educate contractor Supervisor and Field engineer regarding
importance of Primary Support by conducting Classroom programs and Tool Box Talk.
• In the final stage of piping erection and prior to mechanical clearance, both Quality and
Execution Team needs to carry out Walk through Survey in-order to ensure the placement
and fabrication of primary support with respect to approved isometrics.
HMEL QUALITY TEAM

[ 46 ]
 GGSPAP/QUALITY/
QUALITY BULLETIN 2019/05
DATE: 29/08/2019

INTEGRITYQuality Bulletin
ISSUE: GGSPAP/QUALITY/2019/05

Installation of Incorrect “Colour Code” and DATE: 29/08/2019

“Pressure
Integrity Class”
Issue – Installation of Spiral
of Incorrect “Colour Wound
Code” and “Pressure Gasket
Class” of Spiral Wound Gasket

Case1-SS 316L (Pink) with Graphite (Grey) filler - for class 150, 300 & 600 rating SS material
Wrong practice - 600# Gasket on 300# Flange
flanges (other than utilities)
Gasket outer ring
fouling with bolt
holes

Pink strip Grey strip

Case2- SS 321 (Turquoise) with Graphite (Grey) filler – for flanges in corrosive liquid, vapor and
Correct Practice -300# Gasket on 300# Flange
gas – flammable / nonflammable, toxic / nontoxic but non-lethal service

Turquoise Grey
strip Strip

Case3-SS 316/316L (Pink) with PTFE (White) filler – for flanges in ethylene service Wrong Practice -150# Gasket on 300# Flange
Even though Gasket
outer ring is not fouling
with bolt holes, but it is
not acceptable due to
lower pressure rating of
gasket

White strip Pink Strip

Case 4-SS 316L (Green) with PTFE (White) filler – for flanges in ethylene service Correct Practice -150# Gasket on 150# Flange

White strip
Green strip

Case 5-SS 316L (Green) with Graphite (Grey) filler – for class 150, 300 & 600 rating SS material
flanges (other than utilities)

Green strip Gray Strip

Case 6-SS 316 (No colour) with Graphite (Grey) filler – a) for class 150 CS & LTCS (Process &
Steam), AS (all services) flanges up to 371 deg C b) for class 300 & 600 CS flanges up to 427 deg C
c) for class 300 & 600 rating AS material flanges d) for class 150, 300 & 600 rating SS material
flanges (other than utilities)

Gray Strip No Color

HMEL Quality Team

HMEL QUALITY TEAM

[ 47 ]
 GGSPAP/QUALITY/
QUALITY BULLETIN 2019/08
DATE: 09/10/2019

INTEGRITY ISSUE:
Wrong Weld Design of Blind Flange to
Small Bore Threaded Piping Joint.
Introduction:
The refining industry has had a history of failures occurring in small
bore threaded pipe connections welded in end blind flanges. In such
connections, generally a nipple or small bore pipe is welded with
blind flange. Few Example of Such connections can be seen in drain
arrangement of pump strainers, Drain connection for Hydro test set
up end blind and Drain connection in drip legs to remove
condensate.
In Indian Refinery a leak was observed from Propylene feed Pump
Strainer drain weld joint (Blind flange to Nipple) and reason was
attributed to wrong Blind flange to Nipple weld joint design.
Strainer Blind Flange
to Nipple Joint

Integrity Issues:
• Failure of joint having lower strength due to incomplete insertion of nipple and lack of welding
from ID side
• Cracking of joint due to vibration in absence of supports or
stiffeners.
What We Can Do?
• Correct Configuration & Welding: Full penetration of the nipple in
the flange thickness & seal welding from service side and outer
side provides optimum strength to weld and ruled out the chances
of fluid ingress from inside.
• Quality Inspection: Stage-wise Visual Inspection and NDT needs
to be done.
• Provide Supports: Supports or orthogonal stiffener need to be
provided.  Lack of Penetration in
Flange to Nipple Joint
How We Can Do?
• Educate contractor supervisors regarding configuration of small bore connections in piping
systems during fabrication & create awareness during Tool box talk.
• Visual check during mechanical clearance for availability of orthogonal stiffeners for such
configurations.
• Enhance visual management by displaying relevant quality posters at erection sites.
• Contact quality experts in case of confusion before erection.
HMEL QUALITY TEAM

[ 48 ]
 GGSPAP/QUALITY/
QUALITY BULLETIN 2019/09
DATE: 16/10/2019

INTEGRITY ISSUE:
Improper Flushing/Cleaning of Piping
Systems Pre and Post Hydro test.
Introduction:
A Clean Build piping system is required for smooth and flawless commissioning of Petrochemical units.
Flushing of piping plays an essential role to achieve this clean build up system. Cleaning is required at two
stages:
a) Pre pressure testing
b) Post pressure testing.

Integrity Issues:
Cleaning of piping is essential for following reasons (not limited to below
mentioned reasons):
a) Requirement of service: Some services require pipe systems to be free
of contaminants. These contaminants can act as poison for process and
cause operating excursions.
b) Prevent blockages: Contaminants present in piping systems can cause
sticking and blockages of valves, small bore piping, small cavities, etc.
c) Reduce downtime: Foreign materials present in piping systems chokes
filters and strainers present in the system. Downtime is required to isolate
and clean these components and again taking them in line. Fig: Choked strainer
d) Prevent damages: Small debris can cause huge damages to process
critical equipment’s like pumps, compressors, heat exchanger tubes, etc.

What We Can Do?

Pre Hydro test:-
• Flushing of all lines shall be done before pressure testing.
• Flushing shall be done by 'fresh potable water' or by 'dry compressed air wherever water flushing is not
desirable to clean the pipe of all dirt, debris or loose foreign material.
• Required pressure for water flushing shall meet Utility Water Pressure. For air flushing, the line/system
shall be pressurized by compressed air at the required pressure which shall be 3.5 kg/cm2g maximum. The
pressure shall then be released by quick opening of a valve, already in line or installed temporarily for this
purpose. This procedure shall be repeated as many times as required till the inside of the pipe is fully
cleaned.
• The screens/meshes shall be removed from all permanent strainers before flushing. Screens/meshes
shall be reinstalled after flushing but before testing.
• Records shall be prepared and submitted by the contractor for each piping system for the flushing done
in the proforma provided/approved by the Engineer-in-Charge.
• HMEL operation shall witness the flushing of line before Hydro test.
Post Hydro test:-
• After hydro test, lines / systems shall be drained & dried by air. In services like dry air, ethylene etc., small
traces of water can cause problem. For such lines hot air drying is to be done after hydro-test.
• Drying shall be continued for at least 10-15 minutes after the last drop of water is drained. This is to
ensure complete removal of moisture from piping system.
After Hydro test Flushing shall be hold point for HMEL operation, FIN/RFI shall be provided by Business
Associate.
How We Can Do?
• Ensure Flushing records present in loop files before hydro test witness.
• Isolate and keep the line covered until pre commissioning to prevent ingress of contaminants.
• Educate contractor supervisors regarding flushing of piping systems & create awareness during Tool box
talk.
• Enhance visual management by displaying relevant quality posters at erection sites.
• Contact operation experts in case of confusion. HMEL QUALITY TEAM

[ 49 ]
 GGSPAP/QUALITY/
QUALITY BULLETIN 2019/10
DATE: 13/11/2019
Quality Bulletin GGSPAP/QUALITY/2019/10
INTEGRITY ISSUE: DATE: 13/11/2019

Improper FitIntegrity
up and Welding
Issue: Improper ofof Branch
Fit up and Welding Branch ConnectionsConnections

Crotch of Back of Sloping

STUB
sloping branch branch

ON

WELDOLET

HALF COUPLING INSIDE VIEW

Flank

STUB
IN
tc = min of 0.7t &
6.4 mm

INSIDE VIEW

Crotch of Right
angle branch

Pipe branch fittings are installed in 2 configurations:

Pipe branch
1. Stub on:fittings are installed in 2 configurations:
1. Stub on:on, also known as set on / not breaking into, is to be used when branch is equal to or one pipe size smaller than main pipe.
a) Stub
b) All the “O Lets” (i.e Sockolet, Weldolet) also known as integrally reinforced fittings / forged fittings are stub on in nature.
a) c)Stub on, also
Half couplings known
are also asin set
installed onconfiguration.
stub on / not breaking into, is to be used when branch is equal to
or one pipe
2. Stub in: Stubsize
in, alsosmaller
known as setthan maininto,
in / breaking pipe.
is to be used when branch is more than one pipe size smaller than main pipe.
Note:
b) 1.AllRFthe “O Lets” (i.e Sockolet, Weldolet)
pad shall be obtained from pipe spool of the same schedule and also known
diameter as mainas integrally reinforced fittings /
pipe.
forged
2. Weep fittings are
/ Vent holes stub
of RF onbeinplugged
pads shall nature.
and welded after pneumatic testing .

c) Half couplings are also installed in stub on configuration. 2. Stub in: StubHMEL in, Quality
also known
Team
as set in / breaking into, is to be used when branch is more than one pipe size smaller than
main pipe.
Note:
1. RF pad shall be obtained from pipe spool of the same schedule and diameter as main pipe.
2. Weep / Vent holes of RF pads shall be plugged and welded after pneumatic testing.

HMEL QUALITY TEAM

[ 50 ]
 GGSPAP/QUALITY/
QUALITY BULLETIN 2019/11
DATE: 15/11/2019

INTEGRITY ISSUE: Poor Weld Fit-up

Introduction:
Majority of piping involves single bevel weld configuration. A schematic diagram of similar
configuration is as below.

Integrity Issues:
Improper Joint preparation makes it more difficult for the welder to make a sound weld and
results in weld discontinuities. Different types of dimensional faults during fit up and their
consequences are:

Dimensional Faults Consequences

Incorrect Bevel angle: Excessive Bevel Angle

• Weld Distortion
• Deposition of excess weld metal.
Lesser Bevel Angle
• Lack of Fusion
• Slag entrapment

Improper Root Face:

Undersize Root face :
• Excessive Penetration
• Burn - through

HMEL QUALITY TEAM

[ 51 ]
 GGSPAP/QUALITY/
QUALITY BULLETIN 2019/11
DATE: 15/11/2019

Dimensional Faults Consequences

•
Incorrect fit-up ( Mismatch ) • Stress Raiser Areas.
• Effective Thickness of Joint lesser
than Design Thickness
• Lack of Fusion at Root.
• Incomplete Penetration
• Root Undercut

Improper Root Gap:

Excessive Root opening
• Weld Distortion
Less Root opening
• Lack of penetration
• Lack of fusion
• Slag entrapment

Surface irregularities during weld edge

• Cracks
Preparation :
• Undercut
• Lack of Fusion
• Burn Through
• Incomplete Penetration

How We Can Do?

1. Ensuring weld configuration as per applicable approved WPS.
2. Dimension of Bevel angle, Root face and Root openings (gap) should be within the tolerance.

Sr.No. Description Tolerance limit (AWS )

1 Root face ±1.6 mm
2 Root opening of joints
( w/o backing ) ±1.6 mm
3 V Groove angle (750 ) +100 , -50
4 Root mismatch Up to 1.5 mm
HMEL QUALITY TEAM

[ 52 ]
 GGSPAP/QUALITY/
QUALITY BULLETIN 2019/11
DATE: 15/11/2019

3. Usage of different Weld gauges to measure different dimensions during fit up stage.

What We Can Do?

1. Tool Box Talk to fitters, grinders and welders.
2. Ensuring availability of measuring Tools/ weld gauges at all times during fabrication.
3. Validation required for Fitters and grinders along with welders.
4. Usage of Jigs/fixtures for good fit-up.

HMEL QUALITY TEAM

[ 53 ]
 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A
A) ABOVE GROUND PIPING
Monthly Audit for piping material at
1) Incoming Material at EIL warehouse - - S S - Random thickness checks on fittings
warehouse.
Monthly Audit for piping material at
2) Contractor's Supply including Check Testing WC HP HP S -
contractor warehouse.

3) Welding filler material approval / qualification

Review of Manufacture test certificate / documents &
i) WC HP HP S -
sampling Monthly Audit for filler material at
ii) EQT (Please see " NOTE" after serial no.7) - contractor warehouse.
iii) Carbon steel WC W W S -
iv) Alloy Steel / Stainless Steel WC W W S -

4) WPS/PQR
i) Review of proposed procedure WC HP HP S - Quarterly Audit of WPS/PQR for dissimlar
ii) Testing (Site) WC HP W S - and exotic material .

[ 54 ]
iii) Approval of final WPS/PQR WC HP HP S -

5) Certification & Approval of welders

180 welders revalidation shall be carried
i) Welder Performance Qualification WC W W W -
out by TPI (M/s LLOYDS)
Forthnightly audit for qualification test
ii) Welder Qualification Test Record. WC HP HP S -
record of welders

6) NDT Procedure Qualification

i) Review of proposed procedure WC HP HP S - Monthly Audit of validation of NDT
ii) Witnessing of proposed procedure testing WC HP HP S - procedure.
iii) Approval of qualified procedure WC HP HP S -

7) Preservation Audit of Piping Material . WC S S S - Monthly Audit for Preservation.

NOTE:
Not withstanding any other tests/documents required for qualification/approval of filler metals.
i) For alloy Steel & Stainless Steel welding filler metals chemical analysis to be carried out for every batch
ii) For LTCS welding filler metals. Impact test to be carried out for every batch.
iii) For NACE filler metals, corrosion tests like HIC, SSCC. Etc. to be carried out for every batch.
 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A

B) FABRICATION ( SHOP & FIELD )

1) Material Traceability & Transfer of Heat No

C.S. Piping below 600# rating WC S S S/W -
C.S. Piping 600# rating and above WC W W S/W - Monthly Audit of Material Traciability
A.S. Piping, S.S. piping, Nace piping , Hydrogen Service
WC HP HP S/W -
piping / NACE H2 (Transfer of Heat No's & Traceability
2) FIT UP CHECK
i) Dimensional checks WC W S W -
ii) Fit-up check for butt joints and Socket joints WC W S W -
10 nos joints per week per inspector for
iii) Fit-up checks for Branch joints WC W S W -
CAT A services
iv) WC HP S W -
A.S. Piping, S.S. piping, Nace piping , Hydrogen Service

v) For all piping class weldolets weld joint fitup WC HP HP HP - 100% weldolet fitup inspection .
piping / NACE H2 Incl. weldolets

[ 55 ]
100% weldolet root weld visual
For all piping class weldolets weld Root and final weld FIN/RFI Required for this activity
vi) WC HP HP HP - inspection and Random Boroscopy shall
visual
be carried out.
3) Visual check of completed welds WC S S W -
10 nos joints per week per inspector for
i)
A.S. Piping, S.S. piping, Nace piping , Hydrogen Service
WC HP S W - CAT A services

4) Monitoring of PWHT cycle WC S - - -

piping / NACE H2 Incl. weldolets

10 no's chart per month/per inspector to be

i) Review of time - Temperature graph WC RW RW RW -
reviewed and signed

5) Hardness check(if required)

i) For C.S. Materials WC S - S -
10 joints per week per inspector.
ii) For A.S. Materials piping WC W S W -

6) RADIOGRAPHY TEST
All Golden Joints Radiographs shall be
reviewed.
100 film monthly shall be reviewed by
i) Radiography interpretation / review WC RW RW RW -
TPIA
All Dissimilar Welds Radiographs to be
reviewed.

7) PNEUMATIC TEST FOR REINFORCING PADS. WC HP S W - 10 Pads per month/ inspector.

 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A
8) Support fabrication 10 nos joints per week per inspector for
i) Welding NDT WC S S W - CAT A services

C) ERECTION

Cleanliness of pre-fabricated piping spools prior to Operations to witness internal cleanliness of

1) HP HP -
erection all Critical Piping.
WC W

For Class # 600 (inlet/outlet/Manway

2) Correctness of gaskets / fasteners nozzle flange joint ) of
SS/Alloys/NACE/Hydrogen service.
i) C.S. Piping, NACE Piping WC W S S/W W Gasket to be checked for color coding.
Fastners to be checked for correct
ii) A.S. Piping, SS Piping WC HP HP S/W W Metallurgy and Short Bolting

For Class # 600 (inlet/outlet/Manway

nozzle flange joint ) of
3) Flange Alignment WC HP S W -
SS/Alloys/NACE/Hydrogen service.

[ 56 ]
Mechanical & NDTclearance before Hydrotest of
2) WC HP W W - 100% For CAT A services.
piping loop
FIN/RFI required for this activity

10 no's Lines for CAT A services per week,

3) PMI as per specification after completion of installation WC RW - W -
per inspector

4) Review of calibration certificates of pressure gauges WC RW RW RW - 100% For CAT A services.

5) Liquidation of check list WC HP HP W - 100% For CAT A services.

Operations-All Critical Piping Internal

6) Air/Water flushing (preliminary) WC S S - W All Pipings /Systems
Clealiness to be witnessed.

Page 3 of 8
 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A

It is to be ensured that, all SS Piping have

been flushed and dried after hydro testing.
Visual inspection of all weld joints for leak during
7) WC HP W W - 10% For CAT A Services
pneumatic / hydrotest.
Gap betrween Hydrotesting and Flushing
shall not be more than 15 days.
FIN/RFI is required for this activity

10% CAT A Services for QA team.

8) Pickling and Passivation of System, if required WC W S W HP However passivation will be Hold point

[ 57 ]
for Operation. FIN/RFI is required for this activity

9) System testing WC HP HP - HP All Pipings Systems based on service FIN/RFI is required for this activity
 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A
D) SURFACE PREPARATION & PAINTING

1) SHOP FABRICATION
10 nos spool For CAT A Services per week
i) Dry film thickness after primer WC W W W -
per inspector.

2) AFTER INSTALLATION
10 nos spool For CAT A Services per week
i) Dry film thickness after final coat WC W W W -
per inspector.
Target per Day( TML spot)
DFCU- 90
3) Base Line thickness survey. - - - W - 100% For CAT A Services
Polymer-60
OS&U-60
UG Piping
1) Scrutiny of test packs for Mechanical & NDTclearance WC HP W W - 100% For CAT A services.

[ 58 ]
Operations- To witness all internal
2) Air /Water Flushing (Preliminary) WC S S - W
Cleanliness of Critical Piping .
3) Pneumatic / Hydrostatic Testing WC HP W W - 10% For CAT A Services
4) Calibration of Holiday Tester WC HP HP W -
5) Holiday Testing WC W W W - 10% Piping to be witnessed.
6) Peel test WC HP S W - 10% of Total no's of Peel Tests
Checking of wrapping & coating for damages during
7) WC S S W - 10% Piping to be witnessed.
lowering, their repair, Holiday Testing etc.
8) Backfilling WC Rw Rw W 10% For CAT A services.

Heater Package
E) Radiant Coil Support

1) Fixing of Radiant coil support - - - S - 5 No.s of coil support / Heater

F) Coil Erection and Welding in Radiant Section

1) Fixing of coil support castings WC S - S - 2 No.s of coils / Heater

-
2) Alignment of complete coil work WC W - W - 100% - Straightness of tubes to be checked
-
 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A
3) Welding procedure Specification WC RW - RW - Review of all WPS
-
4) Welder Qualification WC W - W - 5% - pertaining to coil welders
-
5) Fit up and weld visual WC S - S - 10 Joints / month
-
Review of
6) WC - -
Radiography of coil butt joints films 100% S 10% review of films

100%, To check adequecy of expansion for

7) -
Adequecy of expansion of coils W coil

G) Assembly , Erection & Welding of convection Box

[ 59 ]
1) Welding procedure Specification WC RW - RW - Review of all WPS
-
2) Welder Qualification WC W - W - 5% - pertaining to coil welders
-
3) Fitup & Weld Visual WC W - S - 10 Joints / month
-
4) PWHT WC S - S - 10 charts per month
-
Review of
5) WC - -
Radiography of coil butt joints films 100% S 10% review of films
-
6) Scrutinity of test packs for mechanical & NDT clearance WC H - W - 100% before Hydrotest
-
7) PMI as per specification after completion and installation WC RW - S - 10 lines / month
-
Visual inspection of all weld joints for leak during
8) WC - -
pneumatic / hydrotesting H W 100%, No leakage & sweating at joints

9) Review of records of fasteners and Gaskets WC W - S - Manufacturer's Test certificate

100%, To check adequecy of expansion for

10) - - - W -
Adequecy of expansion of coils coil
 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A
G) Refractory Application

Inspection of refractory Castable lining ( Visual &

1) WC RW - S -
Hammer Test ) of individuL Layer To check the Healthiness of Refractory
-
2) Dry out referactory Lines - RW - RW - Chart Review
Equipment

Random Witness by HMEL Quality and

OPS -
Internal Visual Inspection prior to box up of
1) WC HP HP HP HP All static Equipment PMI of Internals
equipment.
Internal weld joint smoothness, surface
finish , Painting of equipment specifically
applicable in Polymer Unit.
FIN/RFI required for this activity

[ 60 ]
2) External Visual Inspection prior to box up of equipment. - - - W W All static Equipment

, g
have been immediately flushed and dried
Witness of Predetermined Heat Exchanger and static after hydro testing.
3) - - - W - 10% All static Equipment CAT A services
equipment Hydro test. FIN/RFI required for this activity

Target per Day( TML spot)

DFCU- 45
4) Base Line thickness survey. - - - W - All static Equipment,
Polymer-25
OS&U-25

PSVs
Equipment connected to CAT A Piping
1) Calibration of PSVs W 10% of Critical PSVs
Single Line PSVs.

Page 7 of 8
 Guru Gobind Singh Petrochemical Addition Project.

Inspection & Test Plan for A/G, UG Piping Works , Heater, Equipments and PSVs
HMEL HMEL
EIL
Sl. No. Activity Contractor Quality Operations Frequecny of Inspection Remarks
CAT A CAT B CAT A CAT A
Legend :- WC : 100% Examination by contractor HP : Hold point W : Witness point RW : Review
RW : Review of contractors documentation.
An activity which requires witnessing/inspection/verification by HMEL/EIL when the activity is performed. After proper notification has been provided (notification
W: modalities and period shall be finalized before hand),The contractor is not obliged to hold further processing if HMEL/EIL is not available towitness the activity or
does not provide comments before the date notified. Basis of acceptance shall be as per relevant technical Specification
Survellance Inspection by HMEL /EIL.
S: Monitoring or making observation to verify whether or not material/items or services conform to specified requirements. Surveillance activity may include audit,
Inspections,withness of testing, review of quality documentation & personal qualifications, etc.
Hold Point :
HP : A point which requires witnessing/ acceptance / inspection / verification by HMEL / EIL before any further processing is permitted.
The Contractor shall not process the activity / item beyond a hold point without written approval by HMEL / EIL except where prior written permission further processing is available.
CAT A: All services involving hydrogen and hydrogen bearing fluid., , all SS, AS,NACE,LTCS ,clad Inconel, piping ,SHP/HP Steam piping. All CS piping for process lines all Steam lines under purview of IBR and
Note: excluding category Jacketed piping.

[ 61 ]
CAT B: Piping for “D” class fluid, Non IBR portion of condensate & steam lines
PREPARED BY REVIEWED BY APPROVED BY REV.
Signature
Kishlaya Kishore Ranjeet Singh Antonio Barletta
Name 1
Manager-QA AGM-QA General Project Director
Date 25.07.2019 25.07.2019 25.07.2019
[ 62 ]
[ 63 ]
 03

01 05

OUR
CORE
VALUES
02 04

03