Procedure for Fab, Erec & Testing of Undergroud Piping

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CAIRN ENERGY INDIA PTY LIMITEDMANGALA PROCESSING TERMINAL (MPT)

MANGALA ASSOCIATED FACILITIES PROJECT (EPC-1)TANKS AND EXPORTS SYSTEMS - PROJECT NO: M201

M201TPL-MPT-L-PRO -6002

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TATA PROJECTS LIMITEDCAIRN ENERGY INDIA PTY LIMITED

MANGALA ASSOCIATED FACILITIESPROJECT (EPC-1)

WORK PROCEDURE FOR PIPING FABRICATION ERECTION &TESTING ( UNDER GROUND PIPING)

S NO TITLE PAGE

1. PURPOSE 3

2. SCOPE 3

3. REFERENCE DOCUMENTS 3

4. DEFINITIONS 3

5. HEALTH & SAFETY 4

. EN!IRONMENTAL 4

". TRAINING AND COMPETENCY OF PERSONNEL 4

#. PROCESS 4

$. INSPECTION 1%

1%. DOCUMENTATION 1%

11. PERSONNEL 1%

12. EUIPMENT FOR CONSTRUCTION 1%

13. LIST OF ANNE'URE 1%

M201TPL-MPT-L-PRO-6002 REV.A22






1. PURPOSE

The purpose of this work procedure is to provide guide lines to carry out underground piping

fabrication and laying and to ensure that proper quality control and documentation are maintained

at site.

2. SCOPE

The scope of this procedure covers fabrication, installation and relevant inspection for all

underground piping works including relevant civil works at Phase II-Mangala Process Terminal

!ssociated facilities pro"ect # $P% & Pro"ect of %!I'( $($')* I(+I! td. This procedure is to

describe various activities such as surveying, ecavation, installation of manholes and catch

basins, fabrication, (+T, lowering, hydro test, "oint coating and back filling.

3. REFERENCE DOCUMENTS

• DECOR'LSP2%%5 P*+*,- F/0**,

• DECOR'MSP2%%3 G,06 W67*,-• DECOR'LSP2%%3 P*+*,- D8*-, ,7 M0*68

• DECOR'MSP2%2% E90,6 P*,*,- ,7 P0*: C*,-

• M2%1TPLMPTPLN%%%1 P0; <6*= P6,

• DECOR'CSP2%%$ U,70-0<,7 S0:*8 C,80<*,

• DECOR'CSP2%11 S+*>**, >0 ,0 W0?8

• M2%1TPLMPTCPRO1%%2P07<0 >0 S<0:= W0?8

• M2%1TPLMPTITP%%%3 ITP >0 0*,>0@, >0@0? & ,0*,-

0?8

• M2%1TPLMPTITP%%%4 ITP >0 S<0:= W0?8

• M2%1TPLMPTRPLN%%1 HSE M,-@, P6,

• D0*,- R>0,8.

4. DEFINITIONS

CEIL C*0, E,0-= I,7* P=. L*@*7(C6*,)

EIL E,-*,08 I,7* L*@*7 (PMC)

TPL TATA P0;8 L*@*7(EPC C,00)

NDT N,D80<*: T8*,-







*2 S;R/EYING

A surve# or)s s!a *e +one as "er t!e Proce+ure M201TPL-MPT-7-PRO-1002

As "er t!e +ra$ing8 t!e co or+inates s!a *e esta*is!e+ for t!e routing of t!eun+ergroun+ "i"ing8 ocation of man!oes an+ catc! *asins.

An# fouing or interru"tion in t!e routing s!a *e notice+ to TPLEngineering97EL.

An# c!ange in routing s!a *e +one after t!e a""rova of TPL Engineering97EL.

*, EXCA/ATION

'efore starting of e(cavation for trenc!8 t!e ocation an+ eevation for trenc!s!a *e verifie+ so t!at t!e trenc! for un+ergroun+ "i"ing can *e e(cavate+ tocorrect ocation an+ eevation. Trenc! !as to *e e(cavate+ $it! so"e to avoi+coa"se.

or 7atc! 'asin 9 Man!oe t!e E(cavation s!a *e +one after mar)ing a t!efour corners of catc! *asin 9 man!oe on groun+ *# ta)ing ao$ances for$or)ing cearance an+ so"es.

E(cavation s!a *e +one manua#9 mec!anica# as "er suita*iit# to site.

'ottom of t!e "it s!a *e +resse+ to t!e re:uire+ eve an+ com"acte+manua#.

Trenc!es s!a *e e(cavate+ so as to "rovi+e a cover as s!o$n in t!e a""rove++ra$ing.

Re:uire+ +e"t! of cover s!a *e e(cavate+ un+er roa+s.

!en e(cavating near a+,oining *ui+ings or ot!er e(isting $or)s or structures8s"ecia "recautions against si"s8 si+es or settement of t!e e(isting $or)s orstructure s!a *e consi+ere+.

;o e(cavate+ materia s!a *e +e"osite+ $it! in 1. m from t!e e(cavate+trenc!. uita*e signs an+ *arrica+es s!a *e "rovi+e+ to "revent acci+ents.After e(cavation t!e *ottom of t!e trenc! s!a *e "ro"er# gra+e+ to ma)e t!etrenc! rea+# for a#ing un+ergroun+ "i"ing. Trenc! s!a *e roc) free as "er

&E7O-R<-7-P-2004 =>n+ergroun+ ervices 7onstruction?.

After trenc!ing t!e eevation s!a *e c!ec)e+ for t!e correct so"e if re:uire+as "er +ra$ing.

Trenc!es s!a *e of sufficient $i+t! to ao$ satisfactor# ,oining of "i"e an+tam"ering of *ac)fi un+er an+ aroun+ t!e "i"e.

T!e trenc! *ottom s!a *e firm an+ fu# ca"a*e of su""orting t!e "i"e to *einstae+. !ere unsta*e materia suc! as muc) or "eat is encountere+8 t!etrenc! *ottom s!a *e over e(cavate+ to a +e"t! at $!ic! sta*e materia isencountere+ an+ t!e over e(cavate+ s!a *e *ac)fie+ $it! t!e samee(cavate+ materia or ot!er suita*e materia.

T!e sta*iit# of a e(cavate+ faces is to *e maintaine+ in com"iance $it!s"ecifie+ e(cavation safet# stan+ar+s t!roug! fina acce"tance of t!e $or).







afet# *arrica+es s!a *e "rovi+e+ aroun+ a e(cavate+ areas unti t!e $or) iscom"ete+.

*< INSTALLATION OF MAN8OLES AND CATC8 =ASINS

*<1 =$%&%&> C"&5#e'e

After t!e +ressing an+ com"action t!e s!uttering for *in+ing concrete s!a*e +one using tim*er 9 "# $oo+.

f t!e +ea# *et$een com"action test an+ a#ing of concrete s!a *e moret!an 10 !ours8 t!e area s!a *e $atere+ "ro"er# *efore a#ing concrete.

T!e *in+ing concrete of a""ro"riate gra+e as "er +ra$ing s!a *e ai+ an+com"acte+ using vi*rators. 7oncrete to" s!a *e finis!e+ roug! using$oo+en foat. To" eve of concrete s!a *e c!ec)e+.

7oncrete s!a *e cure+ for minimum 3 +a#s.

*<2 C"&'#u5'%"& "! M&4"$es + 5'54 s%&s

7onstruction of a R77 man!oes an+ catc! *asin s!a *e "re-cast an+ $i*e +one as "er M16&TP-MPT-7-ITP-6662 =TP for reinforcement8 form$or)8 @concreting $or)s.

A vave "its s!a *e constructe+ in site. A masonr# $or)s s!a *e +one as"er M201TPL-MPT-7-PRO-100 =Proce+ure for Masonr# $or)s?.

*<, E#e5'%"& "! #e-5s' ?&4"$es + 5'54 s%&

Man!oes an+ catc! *asins s!a *e erecte+ after 2/ !r of P77.

T!e centre ines s!a *e mar)e+ on t!e P77 to" in suc! a $a# t!at t!e# arevisi*e even after t!e erection of man!oes 9 catc! *asins.

T!e man!oes 9 catc! *asins s!a *e trans"orte+ to site *# suita*e means$it! "ro"er toos an+ tac)es.

T!e ca"acit# of ifting toos s!a *e at east 2 times t!an t!e e("ecte+ oa+on it.

T!e centre of man!oe 9 catc! *asin s!a *e mar)e+ on a its four si+es

*efore erection so as to "ace it in "ro"er aignment.Man!oes s!a *e instae+ an+ $!erever t!e o"enings are t!ere8 t!e "i"es!a *e inserte+ an+ secure+. Man!oe to" s!a *e covere+ *# suita*emeans.

*7 FA=RICATION

Prior to start of $or) a +ocuments reate+ to t!e "i"ing suc! as =e+ingProce+ure "ecification?8 =Proce+ure 5uaification Test Recor+s? an+met!o+ statements s!a *e esta*is!e+ an+ +u# a""rove+ *# 7AR;.

Pi"es s!a *e stretc!e+ near t!e trenc! area so as to faciitate fa*rication.

Pi"e fa*rication s!a *e +one as "er +ra$ings.







Materia s!a *e mar)e+ as "er t!e sie re:uirement. Mar)ing $i *eins"ecte+ an+ recor+e+ *# ins"ector an+ reease+ for cutting.

After cutting t!e "i"e "ieces8 e+ge "re"aration $i *e +one as "er +ra$ingan+ P re:uirement. it u" as "er +ra$ing s!a *e offere+ to ns"ection&e"t. An+ $!en ceare+ s!a *e reease+ for $e+ing. e+ers $i *e:uaifie+ as "er a""rove+ P 9P5R.

'efore fitting u" t!e $e+ ,oint8 t!e "rofie an+ +imensions of t!e $e+ en+"re"aration s!a *e c!ec)e+. f t!e s"ecifie+ toerances are e(cee+e+8 t!iss!a *e correcte+ *# grin+ing.

it-u" s!a *e +one *# using *ri+ge ceats of same materia for aignment of"i"e ,oints. f aternative# tac) $e+s are ma+e t!en it s!a *e incor"orate+into t!e fina $e+.

f tem"orar# $e+e+ attac!ments are use+8 t!en t!ese s!a *e of t!e samenomina c!emistr# as t!e *ase meta. Tem"orar# attac!ments s!a *eremove+ *# fame cutting8 arc gouging or grin+ing. ammering off s!a not*e +one. Location of remove+ tem"orar# attac!ments s!a *e e(amine+visua#.

e+ers s!a *e :uaifie+ as "er M201TPL-MPT-5-PRO-0001 =e+er5uaification Proce+ure?.

7onsuma*es contro an+ storage s!a *e as "er M201TPL-MPT-5-PRO-0031.

=Proce+ure for Eectro+e @ fier $ire torage 7ontro?.

>ness ot!er$ise s"ecifie+8 a *utt $e+s s!a *e fu "enetration $e+s. T!ee(terna surface of t!e $e+ s!a *e free from un+ercuts8 overa"s an+a*ru"t ri+ges or vae#s.

To avoi+ +istortion +uring $e+ing8 tem"orar# su""orts s!a *e "rovi+e+$it! s"oos.

A *ranc! connection s!a *e of stu* B on t#"e.

A a""ica*e ;&T $i *e +one as "er a""rove+ "roce+ures.

;&T re:uirements s!a *e as "er s"ecification or +ra$ings.

*6 8YDRO TEST@ FILL TEST ("#) SER/ICE TEST

#+ro test $i *e carrie+ out in accor+ance $it! 7AR; s"ecification an+"i"ing cass.

#+ro test s!a *e +one for ire $ater an+ fi test CorD ervice test s!a *e+one for o"en +rain an+ cose +rain s#stems.

#+ro test s!a *e +one in t$o o"tions

O"tion 1

#+rotest s!a *e carrie+ a*ove groun+ on t!e i+entifie+ sections an+ u"oncom"etion coating of fie+ ,oints8 !oi+a# test an+ o$ering s!a foo$.

O"tion 2

M201TPL-MPT-L-PRO-6002 REV.A2%






#+rotest s!a *e carrie+ out *eo$ groun+ after o$ering of i+entifie+sections an+ *# )ee"ing a $e+e+ ,oints e("ose+. After com"etion of!#+rotest8 coating8 !oi+a# test of a ,oints an+ *ac)fiing s!a foo$.

n some cases i)e roa+ crossing8 $!ere t!e ine !as to *e *urie+ *efore!#+ro testing8 100 ra+iogra"!# s!a *e +one on fie+ ,oints. T!ese ,oints!as to get "rior a""rova from EL9 7EL.

Foints *et$een t$o !#+ro teste+ sections s!a *e consi+ere+ as tie-in ,oints.

T!e "ressure an+ !o+ing time are genera# 1. times t!e +esign "ressurean+ minimum 1 !our. ater must *e use+ form a""rove+ source as testingme+ium for !#+rostatic testing of "i"ing s#stem.

T!e "ressure gauges s!a !ave a vai+ cai*ration certificate.

*61 SER/ICE TEST + FILL TEST

T!is s!a *e +one for o"en +rain an+ cose+ +rain s#stems. T!e test s!a *ecarrie+ out using cean $ater as t!e testing me+ium. T!is s!a *e +one u"oncom"etion of a $e+ing an+ ;&T activities. T!e testing $i *e +one *eforecommissioning.

*. FIELD JOINT COATING

After acce"tance of !#+ro test8 t!e fie+ ,oints s!a * reease+ for coating.

*.1 S;RFACE PREPARATION T!e stee surface s!a *e free of mu+8 oi8 grease or an# ot!er foreignmateria. urface "re"aration can *e o*taine+ *# using "o$er $ire *rus!an+ t!e surface s!a *e ceane+ to a $e+is! tan+ar+ Association O-01T 2 G. A *urr an+ $e+s sag s!a *e remove+ from t!e "i"e surface. T!e"i"e surface s!a *e +r# an+ free of an# +ust "articuate "rior to t!e ,ointcoating s#stem. Mi a""ie+ "rimar# coating s!ou+ *e *evee+ at t!ecut*ac) area.

*.2 APPLICATION

After t!e surface "re"aration imme+iate# t!e "rimer s!ou+ *e a""ie+ to"i"e stee surface $it! *rus!. T!e "rimer s!a cover t!e entire e("ose+ steesurface incu+ing t!e raise+ circumferentia $e+ *ea+ an+ overa" onto t!emi a""ie+ "rimar# coating s#stem *# minimum four inc!es. T!e "rimers!a *e +r# to = tac)# to touc!? "rior to t!e a""ication of $e+ ,oint inner$ra". T!e corrosion "rotection inner $ra" s!a *e a""ie+ to t!e "rime+ fie+

,oint in s"ira.

T!e $ra""ing "rocess starts at minimum four inc!es *e#on+ t!e cut*ac)e+ge. T!e inner $ra" s!a *e a""ie+ un+er taug!t tension t!at $i resut ina smoot! $rin)e free coating. T!e minimum s"ira overa" s!a *e 0. T!emec!anica "rotection outer $ra" s!a *e a""ie+ to t!e to" of first a#er.

T!e outer $ra" s!a *e a""ie+ un+er taug!t tension t!at $i resut in asmoot! $rin)# free coating. T!e minimum s"ira overa" s!a *e 0 at t!een+ of t!e s"ira $ra" s!a *e cut on t!e +o$n site at t!e 3 or 4 HOI coc)"osition.







*., INSPECTION

7arefu ins"ection of t!e coating s!a incu+e visua o*servation. T!e coatings!a *e c!ec)e+ of an# !oi+a#s using 10 JV !oi+a# +etectors. A !oi+a#san+ a +amages coating s!a *e cear# mar)e+ an+ re"aire+ imme+iate#.

T!e re"air s!a *e carrie+ out *# fiing t!e +amage+ area $it! "atc! an+t!en $ra""ing aroun+ t!e circumference to e(ten+ 0 mm *e#on+ t!e+amage. Pee test s!a *e carrie+ out using !an+ "ee test gauge. T!efre:uenc# of "ee test $i *e one in fift# $e+e+ "ro+uction. t s!a *e +oneafter 2/ !ours after a""ication.

Te?e#'u#e(De> C)

Pee$K>+%54

Pee$ /$ue

(N+5?) s e#DIN,06.2

23 3. 1

30 3.0 12

3 2. 10

/0 2.0

/ 1.3

0 0.0 3

** LOERING OF PIPE SECTIONS

'efore o$ering8 100 !oi+a# test of "i"e sections s!a *e carrie+ out.

Pi"e s!a *e "rotecte+ +uring !an+ing against im"act s!oc)s an+ free fa.Pro"er faciities s!a *e "rovi+e+ for o$ering t!e sections of t!e "i"e to"revent +istur*ances of t!e *e+ an+ si+es of t!e trenc!.

T!e s)i+ mar)s an+ ot!er "aces of +amage s!a *e t!oroug!# e(amine+ toensure "ro"er "atc!ing $!erever necessar# *efore t!e "i"e is o$ere+ in to

trenc!.

T!e *arre of t!e "i"e s!a *e in contact $it! t!e :ua+rant s!a"e+ *e++ingt!roug!out its fu engt!.

To "revent s!ear faiure t!e *ranc!es of a fittings s!a *e su""orte+ *#granuar materia *ac)fie+ in t!e trenc! to "rovi+e su""ort e:ua to t!atfurnis!e+ t!e *arre of t!e "i"e.

En+s of t!e "i"e s!a *e )e"t secure# cose+ to "revent t!e entr# of an#foreign materia or moisture after o$ering in to t!e trenc!.

or s"acing "i"es of +ifferent +iameters8 t!e s"acing re:uirements for t!e

arger "i"e s!a *e use+.







!erever man!oes an+ catc! *asins are "rovi+e+ a singe "i"e s!a *einserte+ an+ ai+. T!e inserte+ ine s!a *e seae+ using a""rove+ seaantinsi+e t!e man!oe an+ catc! *asin.

* =ACK FILLING

'ac)fiing an+ com"action s!a *e +one as "er contract s"ecification &E7O-R<-7-P-2004 =>n+ergroun+ ervices 7onstruction?. Pro"er com"action s!a*e carrie+ out after *ac)fiing as "er t!e acce"ta*e met!o+ a""rove+ *#7EL.

After t!e ins"ection of t!e "i"eines Cafter !oi+a# test of coating or re:uire+test com"etionD8 t!e trenc! s!a *e *ac) fie+ $it! t!e e(cavate+ materia.'ac)fiing $it! t!e e(cavate+ materia s!a *e +one in a#ers8 *ac) fiingmaterias s!a *e free from roc)s $e $atere+ an+ ramme+ to avoi+ settingafter$ar+s.

0 INSPECTION

tages ise ins"ection +uring fa*rication an+ erection s!a *e as "er TPM201TPL-MPT-5-TP-6001.

100 DOC;MENTATION

&ocumentation of un+ergroun+ "i"ing s!a *e as "er t!e TP ;o. M201TPL-MPT-5-TP-6001.

110 PERSONNELI) Pe"$es %&"$e

1. 7onstruction Manager

2. Pro,ect 57 Manager

3. 57 Engineer

/. ite Engineer

. E Engineer

6. 57 Assistant

%. oreman

II) R"$es 9 Res"&s%%$%'%es B Re!e# P#"e5' u$%'3 P$&

M201TPL-MPT-5-PL;-0001- Res"onsi*iit# @ Aut!orit# section.

120 E;IPMENTS FOR CONSTR;CTION 9 TESTING

1. e+ing Mac!ines an+ its accessories.

2. itter *o( toos

3. 7rane of suita*e ca"acit#

/. Pro"er rigging toos suc! as ifting *ets etc

. ns"ection an+ testing toos


Procedure for Fab, Erec & Testing of Undergroud Piping

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