Iocl Shut Down Presentation

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DATE: 26 - 03 - 2009
KICK OFF MEETING

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DATE JOB LOCATION OWNER CONSULTANT CONTRACTOR FAX OF ACCEPTANCE NO DATE PERIOD SCHEDULE COMPLETION DATE
26.03.2009 MECHANICAL WORKS FOR PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. PANIPAT M/s. INIDAN OIL CORPORATION LIMITED, PANIPAT M/s. ENGINEERS INDIA LIMITED M/s. IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED, MUMBAI PJ/CC/MECH/PRAEP/2008-09 17.03.2009 12 MONTHS 16.03.2010
STATUS OF REQURIED 3 DOCUMENTS FOR KOM

SR. NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ITEM Power of Attorney H.O. & Site Organization Chart Posting of RCM Deployment Plan of Engineers Safety Plan (HSE) Site QAP, ITP & Job Procedure WPS/PQR & Welder Qualification Execution Philosophy, Methodology Compliance to Mandatory requirements Mobilization Plan for Manpower & Machinery Erection schedule for DHDT Reactor/ Scheme Site Infrastructure (Site Office, Power, Water) Overall Construction Schedule Site Reporting format
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STATUS Shall be submitted. However nomination letter given. Enclosed. Complied. Mr. A. P. Singh Vice President as RCM. Enclosed. Please refer C-40P-15/DS-01/STAFF/REV 0 Shall be submitted 07.04.2009 Enclosed to be reviewed & approved. List of WPS enclosed. WPS shall be submitted by 30.03.2009. PQR shall discussed & established subsequently. Welder qualification will follow. Enclosed Shall be complied. Documentary evidences shall be submitted. Request for issue of form V submitted. Enclosed. Enclosed erection schedule. Scheme shall be submitted by 28.03.2009. Proposal enclosed. To be established jointly with M/s. EIL based on material & front availability. Enclosed.
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400 076 H.O. ORGANIZATION CHART
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DOC. NO. : OC-01
Job Description : Fabrication & Erection of Equipment, Piping, Structure, Insulation and Painting work
Project: Panipat Refinery Additional Expansion Project Owner: Indian Oil Corporation Ltd., Panipat Consultants: Engineers India Ltd. Contractor : IOT Infrastructure & Energy Services Limited.
Sheet No. : 1 of 1 Revision : 0 Date : 25.03.2009
Location : Panipat Refinery FOA Ref. No. : PJ/MECH/PRAEP/2008-09 DATE : 17.03.2009 JOB No. : 6698 Contract No. : C-040
P. G. Vaidhyanathan Managing Director
K. K. Ranade Directior (Operation)
Y. A. Rane Director (Technical)
Dominic N. G. M. (Finance)
Bharatbhushan Dy. Mgr. (HRD)
S. K. Banerjee Sr. V. P. (Project Manager) Vivek Kumar C.M. (QA/QC) L. V. Rao Pres. (E & I) S. Nag Pres. (Civil) Puneet Khanna Sr. V. P. (Proc.) H. M. Naikar D.G.M. (Contracts) U. P. Konar D.G.M (F/A)
A. Patil Dy. Mgr. (Elec.)
A. P. Singh V.P. (RCM) at Site
D. K. Chakraborty V. P. (Civil)
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400 076 SITE ORGANIZATION CHART
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DOC. NO. : OC-02
Sheet No. : 1 of 1 Revision : 0 Date : 25.03.2009
Location : Panipat Refinery FOA Ref. No. : PJ/MECH/PRAEP/2008-09 DATE : 17.03.2009 JOB No. : 6698 Contract No. : C-040 A. P. Singh V. P. (RCM)
V.Bakthavathsalan / P. Maulik
Planning Incharge
M. Sengupta Safety Incharge
B. Karan Store / Warehouse
Indu Shekhar Execution Incharge
Vijith M. Welding & NDT Mgr.
K. K. Bhowmik QA/QC Incharge
A. K. Sarkar Admn. Officer
D. S. Mishra & G. Moinuddin Safety Sup.
S. N. Mondal Lead Engr.
N. Panivel / S. I. Ali Lead Engineer
Painting & Insulation
CDU / VDU
OHCU
SRU
MECH.
DHDT
OFFSITE
CIVIL / STRL.
S. Sharma Painting Inch.
A. Kamraj Manager
R. C. Bhatt. Manager
Romee S. Manager
Ansari Manager
Neeraj Kr. Manager
Parwez Ehsan Manager
Pawan Pandey Manager
B. K. Sharma Painting Sup.
Shashikant Kr. Manager
Sanjay Singh Engineer
A. Rana J r. Mgr.
Sanjeeb Supervisor
B. Chaterjee J r. Mgr.
Sushil Tiwari Engineer
Anchal Lead Engineer
DEPLOYMENT SCHEDULE OF ENGINEERS & SUPERVISORY PERSONNEL

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DOC. NO. : C-40/P-15/DS-01/STAFF/ REV 0 Sheet No. : 1 of 1 Date : 25.03.2009
Project: Panipat Refinery Additional Expansion Project Owner: Indian Oil Corporation Ltd., Panipat Consultants: Engineers India Ltd. Contractor : IOT Infrastructure & Energy Services Limited. Location : Panipat Refinery FOA Ref. No. : PJ/MECH/PRAEP/2008-09 DATE : 17.03.2009 JOB No. : 6698 Contract No. : C-040
SR. NO.
MONTH DESCRIPTION
Apr-09 May June July August September October November December January February March
1 2 3 4 5 6 7 8 9
Resident Construction Manager Lead Engineer Lead/Planning Engineers Lead/Piping Engineers Lead/Civil/Structural Engineers Lead/ Mech./Equipment Erection Engineers Supervisors/Foremen Lead/Quality Control Engineers/Supervisors Lead/Safety Engineers/Supervisor
1 4 4
6
1 6 4
10
1 6 4
10
1 6 4
10
1 6 4
10
1 6 4
10
1 6 4
10
1 6 4
10
1 6 4
10
1 12 8
20
12
20
3 3 15 6 6 3 51
3 4 25 8 8 4 73
3 4 25 10 10 4 77
3 4 25 10 10 4 77
3 4 25 10 4 7 74
3 4 25 10 10 4 77
3 4 25 10 10 4 77
3 4 25 10 10 4 77
3 4 25 10 10 4 77
5 6 40 18 16 8 134
5 6 40
18
5 1 2 2 19
16
10 Materials Management Supervisors TOTAL :
134
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED

I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. DOC. NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : 6698 : MSC-001, Rev. 0
BRIEF DESCRIPTION OF MEASURE ITEM AS PER SCOPE
1) Erection of two nos. Reactor weighing 516 MT Each 2) Above ground Piping 441603 Inch-Dia. 3) Erection, Alignment of Equipments a) Rotary b) Static 636 MT 3723 MT
4) Fabrication, Erection of Structure 757 MT 5) Painting & Insulation 6) Civil Work

I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. : : : : : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT INDIAN OIL CORPORATION LTD. ENGINEERS INDIA LTD. PJ/MECH/PRAEP/2008-09 6698
DOCUMENT NAME
QUALITY ASSURANCE PLAN
DOC. NO.
: QAP-001, Rev. 0
DATE
: 25.03.2009
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400076 QUALITY ASSURANCE PLAN Scope: Fabrication & Erection of Equipment, piping, structure, Insulation, and Painting work. Project: Panipat Refinery Additional Expansion Project. Owner: Indian Oil Corporation Ltd., Panipat Consultant : Engineers India Ltd. Contractor: IOT Infrastructure & Energy Services Limited.
SR ACTIVITY DESCRIPTION NO A 1 2 3 4 5 6 7 8 9 10 B 1 2 3 4 5 PRIOR FABRICATION OF STRUCTURE WORK. Receipt of approved draw ings Withdraw l of client materials WPS / PQR Welder Qualification and certif ication NDT procedures as applicable Procedures other than NDT as applicable Calibration of measuring instruments Test certificates of lifting tools and tackles Erection scheme Lifting arrangement DURING FABRICATION OF STRUCTURE Material Identification Fit up and dimensional check w ith proper alignment Field w elding including visual check Surface Prepration and Painting Final Inspection and acceptance Approved draw ings Approved draw ings Approved draw ings Approved procedure Approved procedure Approved draw ings Approved draw ings Approved draw ings Client specification Approved procedure Approved draw ings Inspection Report Inspection Report Inspection Report Inspection Report P P P P P R W W W W Approved draw ings Approved draw ings Client specification Client specification Material test certificates ASME Sec IX ASME Sec IX ASME Sec V Client specification Transmital Note Material test certificates Inspection Report Inspection Report Approved procedure Approved procedure Calibration certificates Test reports Erection scheme P P P P P P P P P P R W W W R R R R R R REFERENCE DOCUMENT ACCEPTANCE CRITERIA VERIFYING DOCUMENT IOT
QD Format : QAP - 01 Sheet no: 1 of 5 Revision: 0 Date: 24/03/2009
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Location: Panipat Refinery. FOA Ref. No. : PJ/MECH/PRAEP/2008-09 DATE : 17-03-2009 JOB No : 6698 Contract No: C - 040
INSPECTION BY EIL REMARK
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400076 QUALITY ASSURANCE PLAN Scope: Fabrication & Erection of Equipment, piping, structure, Insulation, and Painting work.
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Project: Panipat Refinery Additional Expansion Project. Owner: Indian Oil Corporation Ltd., Panipat Consultant : Engineers India Ltd. Contractor: IOT Infrastructure & Energy Services Limited.
SR NO C 1 2 3 4 5 D 1 2 3 4 5 6 7 8 9 10 ACTIVITY DESCRIPTION REFERENCE DOCUMENT ACCEPTANCE CRITERIA VRIFYING DOCUMENT
INSPECTION BY IOT EIL R W W W W REMARK
DURING ERECTION OF STRUCTURE Material Identification Fit up and dimensional check Weld visual check Painting final touch up as applicable Final Inspection and acceptance PRIOR FABRICATION OF PIPING WORK. Receipt of approved drawings Withdrawl of client materials WPS / PQR Welder Qualification and certification NDT procedures as applicable Procedures other than NDT as applicable Calibration of measuring instruments Test certificates of lifting tools and tackles Erection scheme Lifting arrangement Approved drawings Approved drawings Client specification Client specification Material test certificates ASME Sec IX ASME Sec IX ASME Sec V Client specification Transmital Note Material test certificates Inspection Report Inspection Report Approved procedure Approved procedure Calibration certificates Test reports Erection scheme P P P P P P P P P P R W W W R R R R R R Approved drawings Approved drawings Approved drawings Approved procedure Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Inspection Report Inspection Report Inspection Report Inspection Report P P P P P
E 1 2 3 4 5 6 7 8 F 1 2 3 4 5 6 7 8 9 G 1 DURING FABRICATION OF PIPING Material Identification Fit up and dimensional check with proper alignment Field welding including visual check PWHT as Applicable NDT as applicable PMI as applicable Surface Prepration and Painting Final Inspection and acceptance DURING ERECTION OF PIPING Material Identification Approved drawings Fit up and dimensional check with proper alignment Approved drawings Field welding including visual check Approved drawings PWHT as Applicable Approved drawings NDT as applicable Client specification PMI as applicable Client specification Hydrotestatic Presure Testing Approved procedure Final Painting as applicable Approved procedure Final Inspection and acceptance Approved procedure DURING ERECTION OF EQUIPMENT (STATIC & ROTARY) Correction of location, orientation & level of foundation including chipping and pocket cleaning Installation of equipment with proper alignment, orientation, levelling, bolt tightening and testing Final Inspection and acceptance Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Code B-31.3 ASME Sec V Approved drawings Inspection Report Inspection Report Inspection Report P P P P P P P P P R W W W W W W W W Approved drawings Approved drawings Approved drawings Approved drawings Client specification Client specification Approved procedure Approved procedure Approved drawings Approved drawings Approved drawings Code B-31.3 ASME Sec V ASME Sec II, PartA Client specification Approved procedure Approved drawings Inspection Report Inspection Report Inspection Report Approved procedure Approved procedure Inspection Report Inspection Report P P P P P P P P R W W W W W W W
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Approved procedure ASME Sec II, PartApproved A procedure Approved Inspection Report drawings Client Inspection Report specification Approved Inspection Report procedure Approved drawings Approved drawings Approved drawings Inspection Report
2 3
Inspection Report Inspection Report
P P
W W
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400076
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QUALITY ASSURANCE PLAN Scope: Fabrication & Erection of Equipment, piping, structure, Insulation, and Painting work. Project: Panipat Refinery Additional Expansion Project. Owner: Indian Oil Corporation Ltd., Panipat Consultant : Engineers India Ltd. Contractor: IOT Infrastructure & Energy Services Limited.
SR NO H 1 2 3 4 5 6 ACTIVITY DESCRIPTION REFERENCE DOCUMENT ACCEPTANCE CRITERIA VRIFYING DOCUMENT
INSPECTION BY IOT EIL REMARK
DURING INSULATION WORK Marking of studs Weld visual check Fixing of spacer rings/support ring and check their spacing Application of Insulation including cladding Sealing of cladding joints Final Inspection and acceptance Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Approved drawings Inspection Report Inspection Report Inspection Report Inspection Report Inspection Report Inspection Report P P P P P P R W W W W W
SR NO I 1 2 3 4 ACTIVITY DESCRIPTION REFERENCE DOCUMENT ACCEPTANCE CRITERIA VRIFYING DOCUMENT
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INSPECTION BY IOT EIL R R W R REMARK
GENERAL Treaciability of Identified materials Safety Non conformance Final documentation Safety Manual Approved drawings Approved drawings Approved drawings Approved drawings Inspection Report Safety Records Non conformance report Overall document P P P P
LEGEND: P - PERFORM, W - WITNESS, R - REVIEW
PREPARED BY ( SAJAL SARKAR )

IOT INFRASTRUCTURE & ENERGY SERVICES LTD.
CHECKED BY ( P. MAULIK )
APPROVED BY ( A. P. SINGH )
IOT INFRASTRUCTURE & ENERGY SERVICES LTD.OT INFRASTRUCTURE & ENERGY SERVICES LTD. I

I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. DOCUMENT NAME DOC. NO. DATE : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : : PJ/MECH/PRAEP/2008-09 6698
: INSPECTION & TEST PLAN FOR ABOVE GROUND PIPING : ITP-001, Rev. 0 : 25.03.2009
15
QD Format: ITP-01
IOT INFRASTRUCTURE&ENERGY SERVICES LIMITED
Sheet no:1 of 5 Revision:0 Date:25-03-2009
I N SPECTI ON & TEST P LAN FOR ABOVE GR OUND PI P I NG W OR K

Scope: Fabrication & Erection of piping work.
Location: Panipat Refinery. FOA Ref. No. : PJ/MECH/PRAEP/2008-09
16
IOT EIL
DATE JOB No
: 17-03-2009 : 6698
Contract No: C - 040
Sl. No.
Activity Description
Documents
A PIROR TO FABRICATION
1 Incoming material a)Documents ; Review & acceptance b) physical verification ,thickness recheck etc. 2 Welding filler material approval a) Manufacturing test certificates/documents b) Testing if any I) Carbon steel ii) alloy steel iii) all other material including NACE, CS, CS FOR H2 service and LTCS 3 WPS/PPQ a) Reviewed of proposed procedure b) Testing I) Carbon steel ii) alloy steel iii) all other material including NACE, CS, CS FOR H2 service and LTCS c) Approval of final WPS/PQR 4 Welder's Performance qualification 4a Certification & approval of welders 5 NDT Procedure Qualification a) Reviewed of proposed procedure b) Witnessing of proposed procedure testing c) Approval of qualified procedure 6 Review of joint numbering in ISO Lines where Isometrics not avaliable
WC WC WC WC HP HP HP S Approved NDT Procedure AFC Isometric Drawing Proposed Procedure WC WC WC WC WC WC WC HP HP Rw W HP HP S HP Mechanical & Hardness Test Report Mechanical & Hardness Test Report Mechanical &Impact Test Report Approved WPS/PQR IOT/P-15/6698/MECH/ F-37 IOT/P-15/6698/MECH/F-03 IOT/P-15/6556MECH/F-01 & F-02 WC WC WC Rw W HP Chemical Analysis Report Impact Test Report for LTCS WC Rw MTC & MRIR WC WC Rw W MTC & IRN MRIR
7 a) Preparation of sketches b) Joint Numbering in sketches 8 Material traceability & Transfer of heat nos. a) CS piping <600# rating b) CS piping ,600# rating & above c) NACE piping, H2-Services
B. FABRICATION (SHOP & FIELD)
WC WC
S S
SKETCHES SKETCHES
WC WC WC
IOT/P-15/6698/MECH/F-38 IOT/P-15/6698/MECH/F-38 IOT/P-15/6698/MECH/F-38
17
HP W
Materials as per piping class( check 1 w.r.t approved colour coding procedure) a)Dimensional checks b)Fit up checks for butt & socket joints c)Fit up checks for branch joints 2 Pre-heat (if any) 3 Certificate of purity of purging/shielding gas (if any)
WC WC WC WC WC WC WC WC WC WC WC WC WC WC WC WC WC
S S S S S Rw S S S S S S S S S S S
Approved Procedure & Isometric Drawing AFC Drawing IOT/P-15/6698/MECH/F-09 IOT/P-15/6698/MECH/F-09
Purity Certificate
4 Purging rate (if any) and arrangement 5 Shielding rate (if any) 6 Baking of electrodes 7 Interpass cleaning & Temperature check
Backing Register
8 Visual check of completed welds 9 Monitring of PWHT Cycle 10 Review of time-temperature graph 11 Hardness check a) For CS & alloy material 12 PT/MT 13 Radiography marking (for Random Radiography)
IOTL/EPCC-8/6556MECH/F-10
PWHT CHART IOT/P-15/6698/MECH/F-15 IOT/P-15/6698/MECH/F-15 IOT/P-15/6698/MECH/F-13 IOT/P-15/6698/MECH/F-11
14 Radiography Interpretation / Review a) For CS piping & SS Piping (Type 304) b) For AS piping & others SS Piping c) For H2 ,NACE and low temp piping d) For Other material piping 14 Check Shot for Radiography 15 Surface cleaning & primer application
C ERECTION WC WC WC WC WC WC S W HP W W S IOT/P-15/6698/MECH/F-12 IOT/P-15/6698/MECH/F-12 IOT/P-15/6698/MECH/F-12 IOT/P-15/6698/MECH/F-12 IOT/P-15/6698/MECH/F-11 IOT/P-15/6698/MECH/F-14
Lifting arrangement ( for critical piping only) Location & Orientation of branch connections
WC WC WC WC WC WC WC
S Rw S S S S S
Lifting Scheme TEST CERTIFICATES AFC Isometric Drawing AFC Isometric Drawing AFC Isometric Drawing AFC Isometric Drawing AFC Isometric Drawing
2 Test certificates for lifting tackels 3
4 Provision of Inst. Tappings 5 Provision of vents and drains 6
Correctness of type of supports, anchors & guides Correctness of valves( NRV,Globe,
7 Correctness of gaskets/ fastners 8 Gate,control valves etc),steam traps &
WC
AFC Isometric Drawing
their direction of flow

9 Provision of cold pull, if any
D PROOF TESTING WC W
1 Procedure review 2 Correctness of testing arrangements
WC WC
HP W
Approved Procedure Testing Scheme
Check all valves kept open & confirm

3 that testing is not done against closed
WC W IOT/P-15/6698/MECH/F-23
valve seat Isolation of equipments, control

4 valves,instruments,bellows.Removal
WC W IOT/P-15/6698/MECH/F-23
of flappers from check valves
18
Scrutiny of test packs for mechanical & NDT clearance Positive material Identification as per
WC
HP
IOT/P-15/6698/MECH/F-18
6 specification after completion of
WC
installation. a) Review of calibration certificates of 7 pressure guages b) Field calibration , if any

8 Preparation of check list 9 Liquidation of check list. 10 Air/Water Flushing (preliminary) 11
19
Rw
IOT/P-15/6698/MECH/F-08
WC WC WC WC WC WC WC WC WC WC
HP S S HP S HP S S S S
Calibration certificate Calibration certificate IOT/P-15/6698/MECH/F-19
Test Pack Test Pack
Visual inspection of all weld joints for leak during Pneumatic/ Hydrotesting
12 Draining of Water & Air Drying 13
Removal of temporary blinds and temporary supports
14 Pickling of system, if required 15 16
Boxingup including reinstallation of flappers of check valves
IOT/P-15/6698/MECH/F-42
Review of records of fasteners & gaskets Torque tightening of flange 17 joints,whereever applicable
18 System testing 19 Setting of spring supports
WC WC WC WC
S S HP HP
IOT/P-15/6698/MECH/F-42
IOT/P-15/6698/MECH/F-20 IOT/P-15/6698/MECH/F-43
INSPECTION & TEST DOCUMENTS
Review Test and Inspection Documents.

Abbreviations: NDT WPS RT PWHT PT LEGENDS: HP: Hold Point
WC
20
Rw
A point which requires inspection / verification and acceptance by owner/EIL before any further processing is permitted. The contractor shall not Process the activity / item beyond a HOLD POINT without written approval by Owner/EIL except where prior writ W: Witness point A point which requires inspection / verification and acceptance by Owner/EIL when the activity is performed. After proper notification has been provided , the contractor is not obliged to hold further processing if Owner/EIL is not avaliable to witness. Rw: Review ofContractor's Documentation by EIL S: Surviellance inspection by Owner/EIL Monitoring or making observations to verify whether or not material / items or services conform to specified requirements. Surviellance activities may include audits,inspections,witness of testing, review of quality documents & records. WS: 100% Examination by Sub-Contractor WC: 100% Examination by Contractor NR: Not Required
(IOT NFRASTRUCTURE&ENERGY SERVICES LTD.)
Prepared by ( SAJAL SARKAR )
Checked by ( P . MAULIK )
Approved by ( A. P. SINGH )
21 IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED

I.O.C.L, PANIPAT
: INSPECTION & TEST PLAN FOR ROTARY EQUIPMENT : ITP-002, Rev. 0 : 25.03.2009
QD Format: ITP-02
I NSPECTI ON & TEST PLAN FOR R OTAR Y EQUI P M EN T W OR K S

Scope: Rotary Equipment work.
Location: Panipat Refinery.
22
IOT EIL
FOA Ref. No. : PJ/MECH/PRAEP/2008-09
DATE JOB No
: 25-03-2009 : 6698 Documents
Contract No : C - 040 Sl. No. Activity Description
A EQUIPMENT ERECTION(ROTARY) BEFORE ERECTION 1 Readiness for erection

a) Level of foundation( shims/packing with marking to be prepared & kept ready) b) Centre line marking on Equipment & foundation c) No/dia/length of anchor bolts, depth of pockets, verticality of pockets. d) Chipping , roughing & cleaning of pockets/top of foundation i) Normal equipments ii) Critical Equipments f) Avaliability of grouting material as per specifications/ Manufactures recommendations. WC WC WC S HP S
WC WC WC
S W S
B LIFTING TACKELS
Load test of cranes/lifting beams/slings/shackles/wire ropes etc. for weight of equipments to be handled WC W/Rw Load certificate
C VISUAL INSPECTION OF EQPT./TAG/IDENTIFICATION NO.

a) For any damage b) Free shaft rotation WC WC WC WC S S W HP
IOT/P-15/6698/MECH/F-35 Approved Procedure Non Conformating Report
D Drilling & tapping , holes in the base plate of equpt.( if reqd.) E

Approval of rigging procedure (for critical equipment)
F DURING ERECTION 1 Level/elevation of base frame 2 Checking of foundation bolts ( for location,threading,greasing etc.) 3 Checking Orientation of equipment 3 Placement of cranes , if applicable 4 as per AFC drawings
Elevation / level of equipment and placement of shims/packings WC WC WC WC WC WC WC WC WC WC S S W S S W S HP W S
IOT/P-15/6698/MECH/F-36 AFC Drawing IOT/P-15/6698/MECH/F-36 IOT/P-15/6698/MECH/F-36 IOT/P-15/6698/MECH/F-36 IOT/P-15/6698/MECH/F-36 IOT/P-15/6698/MECH/F-36
5 Distance between couplings 6 Rough alignment of equipment 7 Avaliability of vendors engineer at site (for critical equipments) 8 frame
Cleaning of pockets/grouting of foundation bolts/pockets/base
9 Erection of auxiliary equipment/accessories 10 Final alignment of equipment

i) Without piping ii) With piping ( After tightening the flange bolts)
WC WC WC
W HP W
11 All protection & safety guards installation
G POST ERECTION ACTIVITIES 1 Curing of grout 2 Auxiliary connections to be mounted on equpts as per drawing 3 Final tightening of bolts 4 Chemical cleaning of equipment parts/connected piping 5 Boxing up of equipment & connected piping 6
Log book maintenance (for rotating of shaft & any other activity to be performed as per vendors recommendation) WC WC WC WC WC WC WC WC WC S S S S S S W HP HP
IOT/P-15/6698/MECH/F-42A AFC Drawing IOT/P-15/6698/MECH/F-36
23
7 No load run of motors 8 supplied separately)

Installation of mechanical seals(whenever mechanical seals
9 Re-coupling of motor & reconfirmation of alignment H INSPECTION AND TEST DOCUMENTS

Review test and inspection documents LEGENDS: HP: Hold Point W: Witness point Rw: Review ofContractor's Documentation S: Surviellance inspection by PMC WS: 100% Examination by Sub-Contractor WC: 100% Examination by Contractor
WC
Rw

I.O.C.L, PANIPAT
: INSPECTION & TEST PLAN FOR STATIC EQUIPMENT : ITP-003, Rev. 0 : 25.03.2009
QD Format: ITP-03
Sheet no:1 of 2 Revision:0 Date: 25-03-2009
I NSPECTI ON & TEST P LAN FOR STATI C EQUI P M ENT W OR K S

Scope : Static Equipment work.
25

DATE JOB No
: 25-03-2009 : 6698
Contract No : C - 040 Sl. Activity Description No. A BEFORE ERECTION (STATIC) 1 Readiness for erection
a) Center line marking on equipment and foundation b) level of foundation (shims/packing with marking to be prepared & kept ready) c) Correctness of no. & size of foundation bolts d) Hole dia and no. of holes in base/structure of equipment columns e) matching equipment base bolt holes with actual foundation bolt layout f) marking orientation g) checking the threads of bolts & nuts h) chipping & roughening of foundation B. ERECTION SCHEMES FOR CRITICAL EQPTS a) Approval of rigging procedure. C SAFETY TEST a) Load test of cranes , lifting beams, slings & shackles , length & dia of sling & condition of wire rope. b) Placement of main & tailing crane D DURING ERECTION 1 Deployment of competent rigging crew 2 Orientation to be checked 3 Placement of packing as per AFC drawing Outside cleaning , coating/wrapping , painting ( for u/g 4 equipment only) 5 Orientation of equipment as per AFC drawing E AFTER ERECTION 1 Tightening of bolts & providing washers 2 Levelling & alignment of equipments a) Critical equipments/ODCs b) Others
IOT
EIL
Documents
IOT/P-15/MECH/F-34
WC WC WC WC
W S W W W Rw S S HP RIGGING PROCEDURE
WC
WC
WC WC
WC
WC WC WC WC WC WC WC WC WC WC WC WC WC WC WC WC WC WC
W/Rw Rw Rw W S W Rw S HP W W S Rw W S S
LOAD TEST CERTIFICATES
RIGGING PROCEDURE
IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34
3 nozzles in special cases. 4 Cleaning of sleeves before grouting 5 Grouting
Corresponding requirement elevation & distance between
6 F 1
a) Avaliability of specified grouting materials b) Placement of grouting c) Curing of grout Final tightening of bolts PACKED EQUIPMENTS Befor installation a) Identify the material, check thickness, dimensions, no. and angle of fingers of packing rings
IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34
Quality dossier
IOT/P-15/MECH/F-34
2 During Installation
a) Degreasing and cleaning of packing material b) Check packing support plate b) Check for stacked or dumped packing as per specifications c) Check for nesting b) check that packing are touching bed limiter INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents. LEGENDS: HP: W: Rw: S: WS: WC: Hold Point Witness point Review ofContractor's Documentation by EIL Surviellance inspection by Owner/EIL 100% Examination by Sub-Contractor 100% Examination by Contractor WC
26
WC WC WC
S S S S S Rw
IOT/P-15/MECH/F-34
IOT/P-15/MECH/F-34 IOT/P-15/MECH/F-34
( IOT NFRASTRUCTURE&ENERGY SERVICES LTD. )

I.O.C.L, PANIPAT
: INSPECTION & TEST PLAN FOR PAINTING WORK : ITP-004, Rev. 0 : 25.03.2009
QD Format: ITP-04
I N SP ECTI ON & TEST P LAN FOR SUR FACE P REP AR ATI ON & P AI NTI N G W ORK S
Scope: Surface Preparation & Painting work.
28
IOT
WC WC WC WC WC WC WC WC WC

DATE JOB No
: 25-03-2009 : 6698
Contract No : C - 040 EIL

HP HP Rw Rw Rw Rw Rw W S CERTIFICATE CERTIFICATE
Sl. No. 1
Paint material Inspection for approved supplier, expiry date, shelf life,MTC etc.
Documents MTC MRIR
2 Physical conditon and storage of paint material

a)Inspection for adequacy of blasting machine, abrasive used, airless spray equipment etc. b)Confirm identification /transfer of identificationof materialsbefor painting
3 a)Adequacy of blasting m/c capacity for blast cleaning

b)Type and quality of abrasive being used for blast cleaning c)Adequacy of airless spray equipment , air spray equipment and paint brushes Performance test of paint applicator and blast cleaning operator
5 Check quality of dry air fdr blast cleaning operator 6 Inspection of blast cleaning operation
a)Presence of chlorides befor and after blast cleaning by KAT-TATOR test kit b) Inspect for surface cleanliness by visual stds. Of ISO 8501/SSPC c) Measurement of surface profile by Micromater/Elkometer/stylus instrument We film thickness and over coating interval for each coat of paint during application
WC WC WC WC WC WC WC WC
W S W S W W S W IOT/P-15/6698/MECH/14 IOT/P-15/6698/MECH/14 IOT/P-15/6698/MECH/14 IOT/P-15/6698/MECH/14
8 Dry film thickness after final coat 9

Ispection of final curing /drying, adhesion, hardness, surface finish, sagging , hiding and pinhole detection
10 Painting identification band/code, etc. 11

Acceptance prior to shifting to fabrication shop, if applicable
B After Installation
1 Confirm completion of
a)Hydro testing of pipe b) Mechanical clearance of structure & equipments WC WC WC WC WC WC WC WC Rw Rw Rw S W Rw S HP IOT/P-15/6698/MECH/24 Certificate IOT/P-15/6698/MECH/24 IOT/P-15/6698/MECH/24
2 a)Adequacy of surface preparation tools and tackles

b)Check the quality of surface preparation a)Performance test for paint applicator for spray application b) Adequacy of airless spray equipment and air spray equipment and paint brushes and qulity of dry air for paint aplication coat of paint during application
4 We film thickness and over coating interval for each 5

Dry film theckness after final coat
Inspection of final curing/drying, adhesion, hardness, surface finish, hiding and pinhole detection
WC WC WC
W S
IOT/P-15/6698/MECH/24
7 Identification of colour bands, direction marking 8 Acceptance

F INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents. LEGENDS: HP: Hold Point
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HP
WC
Rw
A point which requires inspection / verification and acceptance by IOCL before any further processing is permitted. The contractor shall not Process the activity / item beyond a HOLD POINT without written approval by IOCL except where prior written approv W: Witness point A point which requires inspection / verification and acceptance by IOCL when the activity is performed. After proper notification has been provided , the contractor is not obliged to hold further processing if IOCL is not avaliable to witness. Rw: Review ofContractor's Documentation S: Surviellance inspection by IOCL Monitoring or making observations to verify whether or not material / items or services conform to specified requirements. Surviellance activities may include audits,inspections,witness of testing, review of quality documents & records. WS: 100% Examination by Sub-Contractor WC: 100% Examination by Contractor NR: Not Required

I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. DOCUMENT NAME : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : : PJ/MECH/PRAEP/2008-09 6698
: INSPECTION & TEST PLAN FOR STRUCTURAL WORK
DOC. NO. DATE
: ITP-005, Rev. 0 : 25.03.2009
QD Format: ITP-05
INSPECTION & TEST PLAN FOR STRUCTURAL STEEL WORKS

Scope: Structural Steel work.
31
Location
: Panipat Refinery.
DATE JOB No
: 25-03-2009 : 6698
Contract No : C - 040 IOT EIL Documents
Sl. No.
A PRIOR TO FABRICATION 1 testing equipments

a)Review of calibration certificates of instruments / b) Field calibration , if any WC WC WC HP W RW
Calibration certificates
Calibration report
MTC & MRIR
Checking of structural steel material supplied by contractor / manufacturers test certificates /testing (as applicable)
3 Welding filler material approval / qualification

a) Manufacturing test certificates/documents b) Testing , if any WC WC WC WC WC WC WC Rw Rw W W S S Rw AFC Drawings
IOT/P-15/6698/MECH/F-04 & F-05 IOT/P-15/6698/MECH/F-06
MTC
4 WPS / PQR 5 Welder's Performance qualification 6 Layout checking 7 Welding equipment & accessories 8 Preparation & approval of fabrication drawings B FABRICATION ACTIVITIES 1 Materials as per design drawing 2 Check straightness and non-warping of members 3 of slopes for deflection whereever required 4 Visual check for welding 5
Grinding including surface preparation for painting and application of primer Dimensional and fit-up checks including provision
WC WC WC WC WC WC WC
Rw S S S Rw S W
6 Checking paint as per spec , shelf-life , etc. 7 etc

Application of specified paint, painting thickness,
Batch certificate of paints
C FIELD ERECTION ACTIVITIES 1 lifting tackels

Lifting arrangements including test certificates of WC WC WC WC WC WC WC WC S/Rw S S
Test certificates
AFC Drawings AFC Drawings IOT/P-15/6698/MECH/F-17 IOT/P-15/6698/MECH/F-17 IOT/P-15/6698/MECH/F-17 IOT/P-15/6698/MECH/F-24
2 Correctness of location 3 Orientation of bracing , lugs 4 Alignment & levels 5 Field welding (if any) 6 Grouting 7 Final coat of paint thickness of paint etc. 8 Preparation of As-built drawings D INSPECTION & TEST DOCUMENTS
Review test and Inspection documents
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S W S W Rw
As built drawings
WC
Rw
LEGENDS: HP: Hold Point A point which requires inspection / verification and acceptance by Ownerr/EIL before any further processing is permitted. The contractor shall not Process the activity / item beyond a HOLD POINT without written approval by Ownerr/EIL except where prior wr W: Witness point A point which requires inspection / verification and acceptance by Ownerr/EIL when the activity is performed. After proper notification has been provided , the contractor is not obliged to hold further processing if Ownerr/EIL is not avaliable to witness. Rw: S: Review ofContractor's Documentation by EIL Surviellance inspection by Ownerr/EIL Monitoring or making observations to verify whether or not material / items or services conform to specified requirements. Surviellance activities may include audits,inspections,witness of testing, review of quality documents & records. WS: WC: NR: 100% Examination by Sub-Contractor 100% Examination by Contractor Not Required

I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : : PJ/MECH/PRAEP/2008-09 6698
DOCUMENT NAME DOC. NO. DATE
: LIST OF WPS & PQR : : 25.03.2009
IOT Infrstructure & Energy Services Limited
Date : 25.03.2009
LIST OF WPS & PQR

Client: Indian Oil Corporation Limited PMC: Engineers India Limited LSTK Contractor : IOT Infrastructure & Energy Services Limited Project : P-15 PREAP,IOCL PANIPAT Sl No. WPS No. Process(es) Base Material Filler Material Thickness Range
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Piping Class A1A,A10A,B1A,D1A, A22A,A26A,B26A, A27A,B27A,A32A, A93A,B93A,B2A,D2A,F2 A,A91Y,A92Y A19A,B19A,B29A PWHT A10A,A11A,A1A,D1A,B2 A,D2A PWHT A4A,B4A A1K,A28K,B28K A1N A1A,A10A A2K,B2K,D2K B25A A4A,B4A G22G A1A,A10A,A11A A2K,B2K,D2K ------AS to CS (P4 to P1) A4A,B4A G22G Dissimilar LTCS to CS
Others
Submission date
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
IOT/PIPING/CS/WPS-01 Rev 01 IOT/PIPING/CS/WPS-02 Rev 0 IOT/PIPING/CS/WPS-03 Rev 0 IOT/PIPING/CS/WPS-05 Rev 2 IOT/PIPING/CS/WPS-06 Rev 0 IOT/PIPING/CS/WPS-07 Rev 0 IOT/PIPING/CS/WPS-08 Rev 0 IOT/PIPING/CS/WPS-09 Rev 0 IOT/PIPING/CS/WPS-10 Rev 0 IOT/PIPING/CS/WPS-11 Rev 0 IOT/PIPING/AS/WPS-12 Rev 0 IOT/PIPING/CS/WPS-13 Rev 0 IOT/PIPING/SS/WPS-14 Rev 0 IOT/PIPING/DISS/ WPS-15 Rev 0 IOT/PIPING/DISS/ WPS-16 Rev 1 IOT/PIPING/CS/WPS-17 Rev 1 IOT/PIPING/CS/WPS-18 Rev 0 IOT/PIPING/DISS/ WPS-19 Rev 0
GTAW + SMAW GTAW + SMAW GTAW + SMAW GTAW GTAW GTAW GTAW GTAW + SMAW GTAW + SMAW GTAW GTAW + SMAW GTAW + SMAW GTAW SMAW SMAW GTAW + SMAW GTAW GTAW + SMAW
A106 Gr.B A106 Gr.B A106 Gr.B A 333 Gr. 6 A 312 TP 304 A 312 TP316L A106 Gr.B A 312 TP 304 A106 Gr.B A 333 Gr. 6 A335 P91 A672B60Cl 12 A312 TP 304 SS to CS A335 P11 + IS2062A A 333 Gr. 6 A335 P91 A333 Gr.6 + A106Gr. B
ER 70S-2 + E7018 ER 70S-2 + E7018 ER 70S-2 + E7018 ER 80S-Ni1 ER 308 ER 316L ER 70S-2 ER 308L ER 70S-2 + E7018-1 ER 80S-Ni1 ER 90S-B9 + E9018-B9 ER 70S-2 + E7018 ER 308L E 309-16 E7018 ER 80S-Ni1 + E7018-1 ER 90S-B9 ER 70S-2 + E7018
1.6 - 16.36 mm 5.0 - 27.8 mm 19.0 - 27.8 mm 7.11 - 13.11 mm 1.6 - 8.38 mm 1.6 - 8.0 mm 1.6 - 8.0 mm 1.6 - 10.98 mm 1.6 - 14.22 mm 2.74 - 11.89 mm 5.0 - 76.2 mm 5.0 - 20.0 mm 8.18 - 14.18 mm FILLET ALL FILLET ALL 7.11 - 13.11 mm 1.5 - 11.12 mm 1.5 - 14.22 mm
30-03-2009 30-03-2009 30-03-2009 30-03-2009 30-03-2009 30-03-2009 FULL GTAW CRY (-) 196C HYDROGEN SERVICES LTCS (- )46.5C P91 ---CRY (-) 196C --------P91 Support-Hardness 225 BHN (Max) LTCS (- )46.5C ------------30-03-2009 30-03-2009 30-03-2009 30-03-2009 02-04-2009 02-04-2009 02-04-2009 02-04-2009 02-04-2009 02-04-2009 02-04-2009 02-04-2009
LTCS (- )46.5C
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19 20 21 22 23 24 25 26 27 IOT/PIPING/DISS/ WPS-20 Rev 0 IOT/PIPING/DISS/ WPS-21 Rev 0 IOT/PIPING/CS/WPS-22 Rev 0 IOT/P-15/PIPING/WPS-01 Rev 0
IOT/P-15/STR TANKAGE/WPS-25 Rev 0 IOT/P-15/STR TANKAGE/WPS-25A Rev 0 IOT/P-15/STR TANKAGE/WPS-26 Rev 0 IOT/P-15/STR TANKAGE/WPS-35 Rev 0 IOT/P-15/STR WPS-36 Rev 0
GTAW GTAW + SMAW GTAW SMAW SMAW SMAW SMAW SMAW SMAW
A333 Gr.6 + A 312 TP 304 A 106 Gr. B + A 312 TP 304
ER 309 L 7.11 - 13.11 mm ER 309 L + E30916 1.5 - 19.05 mm ER 80S-Ni1 2.74 - 11.5 mm 5.0 - 19.0 mm 1.6 - 10 mm FILLET ALL 4.8 - 20.0 mm 5.0 - 50 mm 12.5 - 150 mm
Dissimilar LTCS to SS Dissimilar CS to SS A4A,B4A (Group 2) ----------------------------------------
IMPACT
(- )46.5C
04-04-2009 04-04-2009 04-04-2009 04-04-2009 04-04-2009 04-04-2009 04-04-2009
Hardness - 200 BHN(Max)on CS side
A537 Cl. 1
LTCS (- )46.5C
E6010 + E7018 A106 Gr.B SA283 Gr C + IS 2062A E6013 E6013 IS 1239 Gal SA283 Gr C + IS 2062A E7018 A 537 CL1 A 537 CL1 E7018 E7018-1
RPG tanks PWHT + Impact (- )45C
04-04-2009 04-04-2009
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO.
: PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/001 REV - 0 : 6698 : 01 of 03
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JOB PROCEDURE
JOB PROCEDURE FOR ABOVE GROUND PIPING FABRICATION & ERECTION WORK
IOT INFRASTRUCTRE & ENERGY SERVICES LIMITED Prepared by Approved by
ENGINEERS INDIA LIMITED Reviewed by Approved by
V. Bhaktabhatsalan
A. P. Singh

PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/001 REV - 0 : 6698 : 02 of 03
37
1. PURPOSE The purpose of this procedure is to provide the guidelines to carryout Fabrication, Erection, Inspection, Testing & Record keeping of above ground piping work. 2. SCOPE This procedure covers the method statements for various stages of pipe fabrication, ere ction & testing of piping system as per contract specification, standards and AFC Drawings. In case of conflict between this procedure & contract specification, The letter shall govern. 3. CONTROLLING SPECIFICATION ANSI B-31.3, ASME-Sec-IX & EIL specification No.6-44-0012. In case of any conflict between this procedure & contract specification, later shall govern. 4. PROCEDURE 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7. 4.8. 4.9. 4.10. 4.11. 4.12. 4.13. 4.14. 4.15. 4.16. 4.17. 4.18. 4.19. 4.20. Drawings shall be received from EIL as per the Transmittal and shall be issued to QA/QC dept.,Fabrication Dept. and erection dept. one copy each. One copy shall be kept as a master copy in planning department. Material receiving inspection shall be done as per Q.A.P. Enough field weld shall be marked for site adjustment. Spool No. shall be marked on Isometrics. All pipes, pipe fittings & flanges shall be withdrawn from store as per the specifications & color coding. Welding procedure shall be prepared according to the mate rials and submitted to EIL for the approval. PQR shall be done for the same, if required. WPS & PQR shall be approved by Inspection Authority. Welder performance Qualification shall be done & Records to be maintained. All piping materials specification shall be checked and confirmed with isometricsbefore marking cutting. Isometrics shall be checked for dimensions & Orientations w.r.t GAD. Pipe shall be cut & fabricated as per isometrics. Before cutting, identification mark i.e, Heat No. & Material specification shall be transferred to spool pieces for all critical servic like Alloy Steel materials, SS materials, IBR, es Hydrogen services, etc. An extra pipe length 100mm over and above the dimensions indicated in the drawing may be left on one side of the pipe at each of the field welds. Edge preparation shall be done as per WPS. Daily fit-up report shall be submitted & offered for inspection. List of parameters to be checked during Fit-up inspection to be indicated. All prefabricated spools shall have the line no/ size / Joint No. / SpoolNo. and & welder no X-ray nos to be punched on the spool near the joint. Fit-up shall be checked for materials, dimensions & orientation as per Specification & isometric drawings. Before Welding the Welder Identification No. shall be marked, Preheating shall be done if required. Welding shall be completed as per Conditions of WPS within the limits of welder qualification with approval welding consumables. Daily weld visual inspection Report shall be submitted & offered forinspection. Line-wise history sheet shall be prepared during fabrication work and regular updating shall be carried out. Non Destructive testing shall be done stage wise as per the inspection class. Before pipe erection, secondary supports shall be completed. Level Orientation & Welding shall be checked w.r.t. G.A.D. Piping Spools shall be erected as per GAD after cleaning with necessary slopesspecified in the drawing/PID. Fit-up & alignment shall be checked for field joints. Field joints welding shall be completed.

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4.1.
All valves & instruments / In-line equipment shall be installed as per the flow direction if specified in P&ID / isometrics. 4.2. Vents & Drains shall be provided as per drawing. Additional drains / vent point shall be provided at heights / lowest point of Loop forming if required. 4.3. Records of all flange connections shall be maintained as per EIL Spec. 4.4. All gasket & fasteners shall be provided & all bolts shall be tightened as per piping material specification. 4.5. PMI and traceability of SS and AS piping materials shall be done before Mechanical Clearance and this should form a part of test pack.(PMI-during storage & fabrication should also be done). 4.6. Loop identification shall be done and Mechanical clearance shall be obtained from EIL. 4.7. Bolttorquing / Hydraulic torquing shall be done as per specification. 4.8. Release the loops for Hydro test. 4.9. After Hydro test restoration of the loops / systems-after removal of blinds. 4.10. Documentation and handing over. 1. SAFETY MEASURES 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. 5.8. All erected pipes shall be supported either with permanent support or proper temporary support. Proper access / platforms shall be provided while working at higher elevation. All DA Cylinders should be kept upright. All welding machines shall be properly earthed. All electrical cables if any should be insulated properly. All persons working at higher elevation should use safety belt. Gas Cutter / Grinder / Welders should use safety goggles while they are working. Proper guard should be fixed with grinding machines.
39
JOB PROCEDURE
JOB PROCEDURE FOR UNDER GROUND PIPING WORK
V. Bhaktabhatsalan
A. P. Singh

40
1) PURPOSE :The unit of this procedure is to cover the basic requirements for carrying out the U/G piping work at Panipat refinery Expansion project and to ensure proper control on documentation at site. 2) SCOPE: Procedure covers the detail steps of working method /quality steps to be maintained in testing of U/G piping work, surface preparation tape coat application etc. fabrication, erection,
3) Reference: As per contract document. 3.1. As per EIL specification 6-77-0001 Rev-2 3.2. As per EIL specification 6-77-0005 rev- 3 3.3. AWWA-C-203 (1991)-Coal tar protective coating 3.4. S/S05 5900 of ISO 8501 1988 (Pictorial surface preparation standard 3.5. SSPC SP 10 Surface preparation, Specification near White metal blast cleaning 4) Procedure: A) Prior to starting of fabrication: 1. Prier to fabrication work necessary isometric / hand sketches will be developed at site to facilitate the fabrication & erection work. 2. Materials are to be identified according to the EIL specification, ISO/GAD and shall be correctness of class /rating etc. before taking up fitment of work. 3. Approved welding procedures are to established by IOT. 4. Grit blasting and application of primer to be ensured before starting of fabrication work. B) Fabrication & Erection: 1. During fitment of work joint nos are to be marked on the joints as well as on ISO /Hand sketches including indication of fabrication of field joints. 2. For fitment and welding monitoring of inspection system shall be as per approved QAP/ITP 3. The fitment joint shall be identified with joint no and the spool shall bear the line no. / Area no. Before taken up for inspection by IOT and spool be selected for welding after approval by IOT & EIL as per ITP. 4. A fit up and welding inspection record shall be maintained as per approved ITP formats. 5. All prefabricated piping / spool are to be welded after clearance by IOT & EIL as per ITP. 6. After shop welding clearance, the spool / loops are allowed for hydro testing. 7. After hydro testing clearance, the spool shall be shifted to respective work place for tape coating as per EIL specification. 8. Some of the piping class which are not tape coated shall be blast cleaned and primed as per EIL specification and than pipe shall be shifted to respective work place for fit up and shop welding. 9. All spool /piping shall be checked to ensure that line no, pipe no. and area no etc. are properly marked prior to erection at work point. 10. Shifting arrangement shall be checked thoroughly prior to commencement of erection. 11. If provision of cold pull is indicated in the drawing fit-up of the same is to be carried out as per procedure detail in ITP and record shall be maintained . 12. After tape coating erection of pipe shall be carried out in trenches as per EIL specification. The field joints shall be fully radiographed as per contract. 13. The field joint area shall be tape coated and tested after radiography clearance.

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C) Welding: 1. WPS/PQR welding consumables and welder are to be approved by IOT & EIL before going for welding work. 2. Welding of job shall commence upon clearance by IOT and EIL. The exposing of root run to atmosphere is not allowed. Filler pass shall follow immediately after root run completion. However for alloy steel welding shall normally not to be discontinued till completion of joints. if stoppage occurred due to unforeseen circumstance adequate care should be taken as stated in specification . 3. Welding shall not be done, when the weather condition is bad, which includes moisture blowing same dust and high wind. 4. Before going to carryout the welding of joints, welder no, shall be noted near the joint no, on pipe for identification. Tack /Cleat shall be removed and grind smooth of weld joint for visual inspection / clearance of final weld quality. 5. A record of daily inspection weld report for welding shall be made by M/s IOT and submitted to M/s EIL for inspection and clearance. 6. Line wise record shall be maintained by as per ITP / format and shall be submitted to EIL for mechanical clearance before going for hydro test for respective line. The detail of line no , Area no, joint no, date of welding , type of weld , radiography status (Report no & date ), NDT status etc shall be furnished in the line wise record. 7. After completion of final weld , the requirement of RT/MT/DPT shall be identified as per contract byIOT and offer to EIL for marking and same shall be carried out as per ITP , DPT may be done at root of the joint als required) o(if 8. Prior to hydro of line , the complete weld visual check of all joints, LPT/RT wherever required PWHT / hardness (if any) as per line wise record pertaining to the above shall be submitted to EIL for review & approval of NDT clearance. D) Supporting & leveling: Fabrication erection and welding of pipe supports (if any) like shoe, saddle, guide, stops anchors, clips, hangers, supports fitures, brackets, cantilever, struts, tee pits etc. as per AFC drawing and standards. E) Preparation of test loops: 1. Test loops or test pecks shall be identified in convenient section and approved by M/s EIL 2. Test packs shall be prepared by taking care with other instrument to facilate the testing vessel of other equipment may be included in the system with prior approval of engineer-in charge. Seats of all values shall not subjected to a pressure in excess of examination cold working pressure of the values. 3. Test pressure shall be obtained from line schedule or as per contract for each test circuit / loop pack . In each case of verification of test pressure for different line in the test circuit in the test pack , the test pack shall be further segregated on individual test pack shall be tested as per the recommended test pressure. F) Mechanical & welding clearance: 1. Mechanical completion and NDT clearance shall be obtained by IOT for such test pack by submitted the relevant documents /record to EIL for Reviewed.. 2. Mechanical clearance shall consist of checking the specification location etc. of valves, gaskets, fasteners, supports used in the line & record are to be maintained in relevant format as per ITP. 3. Welding clearance shall consist of visual inspection of weld joint and acceptability of NDT carried out as per requirement of specification .

PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. 42 : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/002 REV - 0 : 6698 : 04 of 04
G) Hydro testing: 1. Before hydro testing of each line will be flushed with portable water / dry compressed air wherever water flushing is not desirable to the satisfaction of M/s EIL. 2. Pressure gauge used for testing should be calibrated by IOT shall be submitted any gauge 3. The test pressure should fall in between 40% to 80% of the gauge scale range. 4. Venting of the test circuit / packs / loop is to be properly done prior to pressuring the system. 5. After venting is over, vents shall be plugged elevation wise in order, starting from the maximum elevation. 6. Test gauges shall be installed as close possible to lowest point and highest point of the system being tested. 7. The testing pressure shall be applied by suitable pump. A duly calibrated pressure gauge shall be installed in pump discharge. For guidance in bringing the system up to desired pressure . 8. The system shall be kept pressurized for a period of time 3 Hrs. permit a inspection a system any leakage or sign of failure shall be required / rectified and rested to the required pressure . 9. Test pressure shall be released after approval from IOT & EIL . PECL shall ensure that all vents to be opened before opening the drains. H) Tape Coating: After hydro testing clearance of U/G pipe loop is to be shifted to relevant place for tape coating as per EIL specification , i.e. surface preparation , application of primer and tape coat inspection ,repair & handling of tape coat in site as per EIL speciation. In case of conflict between this procedure and contract specification, the latter shall govern. 06.06 .2003-2 Revision-2
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JOB PROCEDURE
PROCEDURE FOR HOT INSULATION OF VESSELS, PIPING & EQUIPMENT
V. Bhaktavatsalan
A. P. Singh

44
1.SCOPE: Scope of work covers supply of material requirement for above ground and external insulation of piping and equipment operating between ambient temp. and 5500 C for the purpose of heat conservation process stabilization, temperature maintenance, personnel protection and fire protection. The following project document should be verified before doing the insulation work. a) P&I Diagram and line list b) Piping G.A.D & Isometric c) Piping & Instruments schedule d) Equipment Insulation schedule e) Equipment manufacturer drawings 2.Insulation work for piping system: a) b) c) d) e) f) g) The insulation of piping system shall have straight pipe, bends, tees and pipe fittings completely insulated. All valves & flanged joints shall be completely insulated in Steam, condensate, hot oil, steam-traced and jacketed lines. All insulation shall be terminated 500mm before thermostatic and thermodynamic steam traps. The following instrumentation to be insulated including pipes, valves and fittings such as level gauges, level controllers, level switches. The following piping insulation work shall not be applied in pressure relief valves, vents, steam out let, snuffing steam flare and blow down system. Supports for piping covered by insulation. All piping and pipe supports insulation shall be provided a minimum clearance of 25mm between the outside surface of insulation finishing materials and adjacent surface.
3. Equipment insulation works: 1)Equipment support skirts of insulated vertical vessel above 1200mm diameter shall be insulated both internally and externally for a minimum distance of 600mm below the bottom tangent line and less than 1200mm shall be insulated externally. Bottom heads of vertical vessels enclosed by a support skirt shall be insulated when the outside diameter is greater than 1200mm. 2)Steam & turbine ends of reciprocating pumps shall be insulated. 3)Heat traced & jacketed pumps liquid ends shall be insulated. Materials: 1)All insulation materials shall be of high quality and good appearance as per EIL Spec.No.6-44-02. 2)Insulation material shall be randomly checks for density, thickness, shape and size as per the directions of EIL / Owner. 3)A minimum jacketing shall be used for weather protection over insulation. 4)All Al. cladding joints shall be sealed with seal compound for perfect water proofing.

PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO. Procedure: 1)All piping & equipment shall be hydro tested before application of insulation If any insulation installed before hydro . testing then all welds and flanged joints shall be kept open till completion of pressure test. 2)All surface shall be thoroughly cleaned, dried and made free from loose seal, oil and grease before applying insulati on. 3)All insulation work shall be finished with weather -proofed at all terminals to remove bolts with out damage to the insulation. 4)Equipment name-plated shall be visible after application of insulation. 5)All projected items shall be insulated with the same thickness of insulation as specified. 6)Two or more layer insulation shall be insulated in staggered in both longitudinal and circumferential way and secured in place with 1mm dia galvanized lacing wire. 7)To avoid any damage, rain and contamination all insulation materials shall be covered with protective cover. 8)The insulation shall be carried out with least number of materials and all unavoidable gaps, cavities and voids suitably filled with loose materials. 9)All horizontal pipe line insulation shall be provided 25x3 thk M.S. Spacer Ring at a distance of 900mm approx. 10)All vertical insulation shall be supported of 6mm thk. M.S / Alloy Steel Collar support. 11)Insulation material shall be mitered from the same materials, pipe size 6"Dia & below all insulaton materials shall be i secured by spirally wound 16SWG G.I Wire. 12)All flanged joints and valves shall be insulated with pre-fabricated removable Aluminum Covers. 13)Insulation shall be stopped a sufficient distance to the removal of bolts and nuts with out d amage to the insulating material. 14)All steam tracing piping shall be insulated with over size section of insulation to accommodate parent pipe and tracer with out damage to the insulation and also all instruments and fitting shall be totally enclosed by th insulation. e 15)All cladding support and insulator shall be checked before starting the insulation work. 16)Insulation Blanket shall be applied over the surface with joints tightly together with 1mm dia gal. wire. 17)All equipment projections shall have the jacketing sealed. 18)Horizontal cylindrical equipment shall be furnished with flat metal jacket. The insulated heads of vertical and horizontal equipment shall be fabricated from flat metal : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/003 REV - 0 : 6698 : 03 of 04
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PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. : INDIAN OIL CORPORATION LTD. 46 : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/003 REV - 0 : 6698 : 04 of 04
1)All projections from the heads shall be sealed using by metal flashing. The seal between the flashing and jacket shall be weather proofed. 2)Insulation at bottom heads of fully skirted equipment does not required weather proofing. Piping cladding: 1)Straight pipe run shall have metal jacketing cut & machine rolled, wrapped around with minimum 50mm overlaps on longitudinal & circumferential joints. 2)All overlaps shall be made metal to metal water tight and provided self tapping screws at 150mm center for both vertical and horizontal piping. 3)All overlaps shall be provided in a staggered way. Equipment cladding: 1)The metal jacket over vertical vessel shells shall be made by sheet metal panels as per EIL Std.7-12-25. 2)Each circumferential ring of Panel shall be tensioned by means of tensioning band until final joint is screwed tight. 3)The panels shall have a minimum overlap of one corrugation on vertical joints and 80 mm on horizontal joints. 4)The vertical and horizontal overlaps shall be screwed at 150 center to center.
47
JOB PROCEDURE
JOB PROCEDURE FOR PAINTING WORK
V. Bhaktabhatsalan
A. P. Singh

48
1.SCOPE THIS PROCEDURE COVERS THE REQUIREMENTS FOR THE PAINTING INCLUDING SURFACE PREPARATION, PAINTS, EXECUTION AND INSPECTION OF PRAEP JOB. APPLICABLE CODES AND STANARDS. a.EIL PAINTING SPECIFIC AT ION NO. AND ADDENDUM OF PAINT ING SPEC IFIC ATION b.STEEL STRUC T URE PAINTING C OUNC IL (SSPC ) c .SWEDISH STANDARDS INST UT IT ION (SIS) 2.EXEC UT ION OF PAINTING WORK 2.1T F HE OLLOW ING W ORK SHALL BE CARRIED OUT PRIOR T S O URFACE PREPARAT ION a)REMO VE SLAG , FLUX AND SPATTER ADHERED TO WELD AREA AND STEEL SURFAC ES b)WHERE SUBSTANC ES SUC H AS GREASE AND M AC HINE OIL ARE FOUND ON THE SURFAC E, REMOVE THEM WITH C LEANING SOLVENT OR OTHER APPROPRIATE METHODS. c )REMOVE EXC ESSIVE RUST AND DIRT USING APPROPRIATE MET HODS. d)FOR M AINT ENANC E PAINIT ING OF ALREADY PAINTED SURFAC ES, REMOVE T EXISTING PAINT FROM T AREA HE HE TO BE PAINTED WITH T APPROPRIATE SURFAC E PREPARATION METHOD. HE 2.2EXECUT ION OF S URF ACE PREPARAT ION WORK SURFAC E PREPARAT ION SHALL BE C ARRIED OUT BY G RID BLASTING UPT SA 2 AND PROFILE OF 35 T 50 O O MIC RONS. APPROPRIATE METHODS T HAT WILL ENSURE THE REQUIRED G RADE OR FINISH. PROC EDURE AND DEG REE OF SURFAC E PREPARATION ARE SHO WN IN C LASSIFIC AT ION OF STEEL SURFAC E PREPARATION, REST RICT IONS CONCERNING S URFACE PREPARAT ION AND PROT IVE MEASURES : ECT a)SURFAC E PREPARATION SHALL NOT C ARRIED OUT OUT DOORS IN C ASE OF RAIN. b)WHEN SURFAC E SUBSTRATA IS WET, PREPARATION SHALL NOT BE C ARRIED OUT . c )WHEN RELATIVE HUMIDIT IF 85% AND ABOVE, SURFAC E PREPARAT Y ION SHOULD, BE AVOIDED. d)WHEN BLAST C LEANING IS T BE C ARRIED OUT, APPROPRIATE PRO T T O EC IVE MEASURES SHALL BE TAKEN. 2.3 DURING THE EXEC UTION OF PAINTING WORKS, ALL EQUIPMENT WALLS, FLOORS AND OTHER SURFAC ES SHALL BE , FULLY PROTEC T AG AINST DAM AG E, C ONTAMINATION, DUST, PAINT DROPPINGS, PAINT MIST ETC . DURING THE ED EXEC UT ION OF PAINT ING WORKS. S PECIAL CARE IS T B T O E AKEN T PROT O ECT ALL S AINLES ST MAT T S EEL ERIAL FROM Z INC/ ALUMINUM BASED PAINT S. 2.4 PAINT SHALL BE THOROUG HLY MIXED AND STIRRED, WITH SPECIFIC MIXING RATIOS IF ANY. SHELF LIFE SHALL BE OBSERVED.NO PAINT MATRIAL TO BE USED IF SHELF LIFE HAS EXPRIED. 2.5 APPLICAT ION 1)PAINT ING TOOLS SUITABLE FOR PROPERTIES OF THE PAINT SHALL BE USED AC C ORDING TO M ANUFAC TURERS REC OMMENDAT ION AND STUDYING WORK LOC AT ION. ENVIRONMENT, SHAPE O F ITEMS T BE PAINT O ED AND C ONDIT ION OF SURFAC E T BE PAINT O ED. 2)EAC H C O AT SHALL BE PAINTED IN ORDER OF THE SPEC IFIED TYPE OF PAINT. IN T HIS C ASE, FOR THE C O AT ING OF EAC H FILM, OBSERVE THE INTERVAL BETWEEN C O ATS AND FILM THIC KNESS SPEC IFIED AC C ORDING TO THE PROPERTIES AND PERFORMANC E OF THE PAINT. 3)WHERE EAC H C O AT IS APPLIED SUC C ESSIVELY, SUC H C ONTINUOUS WORK SHALL BE C ARRIED OUT AFTER T HE LAPS OF SPEC IFIED DRYING TIME AND DRYING OF PREVIOUS FILM HAS BEEN C ONFIRMED.

49
1.1RES RICT T IONS UNLESS SPEC IAL MEASURES ARE TAKEN, PAINTING SHALL NOT BE C ARRIED OUT UNDER THE FOLLO WING CO NDIT IONS. 1. WHEN THE PAINTING SURFAC ES ARE MOIST OR LIKELY TO BEC OME MOIST PRIOR TO THE SPEC IFIED DRYING T IME. 2. WHEN THE TEMPERATURE DURING PAINT ING IS BELOW 5C . 3. WHEN RELATIVE HUMIDIT IS 85% OR MORE. Y 4. WHEN A STRONG WIND IS BLOWING AND FOREIG N MATT SUC H AS SAND MAY ADHERE TO THE FILM. ER 1.2F IELD S ET AND HYGIENE AF Y SAFETY AND HYG EINE IN CONNEC TION WITH THE PAINT ING WORK SHALL BE C OTROLLED SUFFIC IENTLY. C ARE SHALL BE TAKEN WITH REG ARD TO THE FO LLOWING . 1)PROTEC TORS LIKE G OGGLES SHOULD BE USED WHILE SURFAC ES ARE PREPARED BY BLAST C LEANING OR THE USE OF PO WER TOOLS. 2)WHEN PAINTING IS TO C ARRIED OUT IN ENC LOSED SPAC E, APPROPRIATE VENTILATION AND LIGHTING EQUIPMENT SHOULD BE PRO VIDED. 3)AVOID FIRE OR NAKED FLAMES AROUND THE PAINTING SITE. 3.0F D ST IEL ORAGE AND CONT ROL OF PAINT . ST ORAGE 1)AS A RULE, PAINT SHALL BE STORED IN A WELL VENTILATED ROOM 2)WHEN A PAINT IS STORED OUTDOORS, IT SHALL BE PROTEC TED USING SHEETS OR OT HER APPROPRIATE MEASURES, IN O RDER TO PREVENT DAM AG E TO C ONTAINERS OR C HANG ES IN THE QUALITY OF T E PAINT. H 3)FOR STORAG E AREAS, PROVIDE PRESC RIBED PROTEC TIVE MEASURES AND SIGNS. PAINT EXCEEDING T HE PRESC RIBED AMOUNT SHALL NOT BE STORED. 4)WHEN PAINT IS TEMPORARILY STO RES IN THE WORKING AREA, THE AMOUNT EQUIVALENT TO ONE DAYS USE OR LESS SHALL BE STORED. PAINT SHALL BE PROTEC TED FROM RAIN ET . USING SHEETS ET . C C 3.1QUALIT CONT Y ROL OF ST ORED PAINT . 1)ALL PAINT AND THINNERS SHALL BE STORED IN SUC H A WAY THAT THE MANUFAC TURERS LABELS C AN BE READILY IDENT IFIED AND C AN BE CO-RELATED WITH BATC H C ERTIFIC ATES. 2)PAINT STOC KS SHALL BE C ONTROLLED SO THAT THEY C AN BE USED WITHIN T HEIR EFFEC TIVE PERIOD OF USE. 3)C ARE SHALL BE TAKEN WITH STORING AND HANDLING TO AVOID BREAKAG E OF MARKED DEFORM ATION OF CO NTAINERS. 4.0INSPEC TION THE PREPARED SURFAC ES SHALL BE C OMPARED WITH THE STANDARD PHOT OG RAPHS OF SIS, ISO OR SSPC . WHERE THE PREPARED SURFAC ES ARE DEEMED TO BE EQUIVALENT TO THO SE INDICATED IN T STANDARD HE PHOT GRAPHS, THEY SHALL BE DEEMED AC C EPTABLE, PROFILE G AUG E WILL BE USED TO C HEC K THE PRO FILE. O 4.1T HE PAINT FILM SHALL BE VISUALLY C HEC KED WITH REG ARD TO UNFINISHED SURFAC E, DRIPS WRINKLES, BLISTERING, PEELING , C RAC KING DISC OLORATION, ST RAINS, PINHOLES AND SPRAY DUST. WHERE THERE ARE NOT MARKED DEFEC TS IN APPEARANC E, THE PAINT FILM SHALL BE DEEMED AC C EPTABLE, SUBJ EC T TO MEET ING DFT REQUIREMENT. 4.2 PAINT FILM THICKNESS 1) FILM THIC KNESS SHALL BE MEASURE WITH APPROPRIATE MEASURING INSTRUMENTS 2) THE NUMBER AND POSIT ION OF MEASUREMENT SHALL BE DETERMINED WITH DUE C ONSIDERATION GIVEN S TO SIZ AND SHAPE O F IT E EMS TO BE PAINTED. 3) MEASUREMENTS SHALL BE C ARRIED OUT THREE T IMES AT EAC H MEASURING POINTS. THE AVERAG E O F THREE MEASUREMENTS SHALL BE TAKEN AS THE MEASURED VALUE FOR THE ITEM C ONC ERNED.

PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/004 REV - 0 50 : 6698 : 04 of 04
3.1 RATING OF MEASURED VALUE WHEN THE MEASURED VALUE SATIFY THE FOLLOWING REQUIREMENTS, T HEY SHALL BE DEEMED AC C EPTABLE. a)WHEN AVERAG E OF MEASURED FILM THIC KNESS IS EQUAL OR MORE PRESC RIBED FILM T HIC KNESS. b)MINIMUM OF MEASURED FILM THIC KNESS IS EQUAL OR MORE OF THE PRESC RIBED FILM THIC KNESS. 3.2TRANSPORTATION PAINTED PRODUC TS SHALL NOT BE TRANSPORT PRIOR TO T C OMPLETION OF THE PRESC RIBED C URING ED HE TIME. ALL T RANSPORTATION SHALL BE C ARRIED OUT WIT ADEQUATE PROTEC TIVE MEASURES, SO THAT, THE H FILM IS NOT DAM AG ED. 3.3 DESC RIPTION AND DEFINITION OF C LASSIFIC ATION OF STEEL PREPARATION IS GIVEN BELOW.
4.0 C LEANING 4.1C LEANING O F SURFAC E T BE PAINTED SHALL BE AS PER EIL STANDARD 6227-PT O -0642-03,Rev.-1, C LASS 5.1 & 5.2. Method of Cleaning Classification Procedure and degree of S teel surface finish SS PC SIS
Blast c leaning Method
Very thorough blast c lean. Mill sc ale, rust, and foreign matter shall be removed to the extent that only trac es Near White blast remaining are slight trains in the form of spots or strips. C lean Finally, the surfac e is cleaned with a c lean dry c ompressed air or c lean brush.
SP 10
SA 21/ 2
5.0 In case of c onflic t between this proc edure and c ontrac t specific ation, the latter shall govern. 6.0 C olor c ode is to be transfered before blast c leaning when pipes are painted before starting fabric ation. 7.0 In c ase of fabric ated spool, joints are to be c overed with tape. 8.0 DOC UMENTAION: Q UALITY FORMATS TO BE USED.
51
JOB PROCEDURE
JOB PROCEDURE FOR STATIC EQUIPMENT WORK
V. Bhaktabhatsalan
A. P. Singh

52
1.SC OPE This sc ope of work consists of preparing foundation, erection of equipment sub-assembly, final alignment, grouting & testing of equipment and records keeping as per c ontract. 2.C O NTRO L SPEC IFIC ATION Tec hnic al specific ation, vendors drawing, manual & owners G.A Drawings In case of any c onflict between this proc edure & contrac t spec ification, the later shall govern. 3.PRO C EDURE 3.1. C hec k foundation c enter line, elevation & pocket loc ation. C heck PC D of the foundation with that of equipment. 3.2. Identify all parts of equipment with Drawings. C heck whether all items are available. Also c heck all parts for any transit damage. 3.3. Prepare foundation for plac ing the packing plates & c hec k correctness of the base of hole with respec t to foundation bolts. 3.4. C heck the orientation of base plate with respec t to data sheet / Drgs. 3.5. C heck base plate for drilling & tapping if required. 3.6 Plac ement of packing plates shall be completed. Required number of pac king plates shall be used. 3.7 C alibration of measuring instruments shall be done. 3.8 C heck the lifting arrangements. Erec tion scheme shall be submitted (if required) for review. 3.9 Erec t the equipment in proper orientation w.r.t. Piping G.A Drawings. 3.10 C heck the vertic ality of the equipment & alignment at least in two right angles direc ti n. o 3.11 Tightening of all foundation bolts & nuts with washer. 3.12 Final alignment shall done. 3.13 G routing shall be done. 3.14 After c uring of grouting, Piping connec tion & all acc essories shall be erec ted. 3.15 Final acc eptance & doc umentation 4.SAFETY Before erection of equipment, lifting tools shall be selec ted acc ording to the weight of the equipment and the erection area shall be c ordoned. Proper ac c ess platforms and safety arrangements shall be provided for working. All person should wear safety belt while working at higher elevation and should tie it with existing members before the start of work. After erec tion, the equipment shall be sec urely bolted.
53
JOB PROCEDURE
JOB PROCEDURE FOR ROTARY EQUIPMENT WORK
V. Bhaktabhatsalan
A. P. Singh

PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. : INDIAN OIL CORPORATION LTD . : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/006 REV - 0 : 6698 : 02 of 03
54
1.SC OPE This sc ope of work consists of preparing foundation, erec tion of equipment sub -assembly, final alignment, grouting, trial run, testing & record keeping of Rotary equipment as per contract spec ification. 2.C ONTROL SPEC IFIC ATION a. b. c. Tec hnic al spec ific ation Vendors drawing, manual & G .A Drawings inc luding foundation. In c ase of any c onflict between this procedure & contract spec ification, the latter shall govern.
3.PRO C EDURE 3.1. Chec k foundation c enter line, elevation & pocket loc ation and other details w.r.t. Piping G AD/ Equipment Drg. 3.2. Identify all parts of equipment with Drawings. C heck whether all items are available. c hec k all parts for any transit damage. 3.3. Prepare foundation surface for placing the pac king plates. 3.4. Calibration shall be done for mea suring & testing instrument. 3.5. Erec t the equipment & bearing pedestal / base frame of motor & c omplete the leveling / alignment. 3.6 Inspection for pocket Grouting clearanc e. 3.7 Grout the bolts of the base frame / Equipment / bearing pedestal with the required material. 3.8 Level the base frame & bearing pedestal & tighten all foundation bolts. 3.9 Erec t the shaft assembly with bearing, runner & c oupling & c omplete the leveling. 3.10 Erec t & level the motor & chec k that nuts are properly tightene d. 3.11 Align the runner & motor and tighten all the foundation bolts. 3.12 Inspec tion for runner & motor alignment. initial Also

55
3.13 Erec t all protection & safety guards. 3.14 C omplete the final grouting. 3.15 Erec t the c ontrol system of motor & c hec k their operation properly. 3.16 Final alignment to be c hec ked with and without piping. 3.17 De c ouples the motor & takes no load trial run. 3.18 C hec k Oil / Grease in c oupling, bearing & other moving parts. Fill where nec essary. 3.19 C ouple the motor & take trial run. 3.20 Final ac c eptanc e and doc umentation. 1.SAFETY Before erec tion of equipment, lifting tools shall be selec ted ac c ording to the weight of the equipment and the erec tion area shall be c ordoned. Proper ac c ess platforms and safety arrangements shall be provided for working. All person should wear safety belt while working at higher elevation and should tie it with existing members before the start of work. After erec tion, the equipment shall be sec urely bolted. All toolc , tac kles, Hydra & c rane etc . should have a valid load test c ertific ate issued by the c ompetent authority.
56
JOB PROCEDURE
JOB PROCEDURE FOR STRUCTURAL WORK
V. Bhaktabhatsalan
A. P. Singh

57
1.SC OPE Supply, storage, preparation of fabrication dra wings, fabrication, assembly, material testing, transportation, erec tion and painting of all types of bolted and welded structural steel works. 2.Referenc e: EIL Specifications 6-68-0006, 6-68-0008 and bid documents. 3.Material specific ation All bought out materials shall conform to EIL spec .No.6-68-0002 and shall be supplied with relevant test certific ates. 4.Rec eipt of materials Receipt all materials will be c hec ked with referenc e to the purchase order & test c ertific ates, any defective materials will be removed from store / site. Steel should be proc ured from direct approved manufac tures or their authorized dealers. During rec eipt of material, joint inspec tion By QA/ QC Engineer & store personnel shall be conduc ted to ensure material quality as per spec . IMIR shall be submitted along with MTC . At the disc retion of EIL, Sample shall be drawn and tested to establish c onformanc e to relevant specific ation. 5.Storage of materials: a) All materials will be stored sec tion wise and size wise with proper identification . b) All welding elec trodes shall be kept in size & grade wise. c) All bolts, nuts & washers shall be kept in size & grade wise. 6.Preparation of detail drawings a) Preparation of fabrication & erection drawings to be made on the basis of design drawings. b) Fabric ation & erection drawings thoroughly chec ked & stamped "Approved for Construc tion" signed & submitted to EIL for comment, if any. 7.The following details are to be followed during detail Engg. a) Struc tural Lay out, orientation & elevation b) Members size, welding joint details. c) Reference design drg.No., Rev.No. d) Erec tion part marked of all members e) Detailing of shop / field joints / splic e joint. f) Location of welding / bolting. g) Shape & size of welding h) Matc hing of hole and joint. i) Bill of materials.

58
1.Fabric ation: a) Fabric ation of struc tural shall be done as per approved for c onstruc tion drawings and latest design drawing. b) Fabric ation area to be paved, leveled before fabric ation. c ) Toleranc e for fabric ation of steel struc tural as per IS 7215 d) All material shall be straight & free from twists. e) All material shall be properly marked as per drg. before c utting. f) All bolt holes should be properly marked and punc h before drilling. g) Bolt holes are not to be formed by gas c utting proc ess. h) All bolt holes should be as per Drg. i) All joints shall be welded as per drawings. j) Welding shall be in ac cordanc e with IS:816,814,1029,1261,1323,9595 as appropriate. k) Adequate protec tion and supervision shall be required during welding operation. l) Splic ing of built-up sec tions shall be done in a staggered manner.
2.W elding Procedure and welding: a) T welding proc edure and c onsumables used for the job shall be approved as per 7307 & he IS 9595 b) All welder shall be qualified as per welding procedure. c ) All welding shall be c arried by ARC welding proc ess. d) Welding shall be c ompleted with correc t number of runs. e) All slag / spatters shall be removed and c leaned by wire brush and light c hipping. f) Any deviation for welding shall be by written approval from EIL. g) All finish welds shall be visually inspec ted. 3.S hop Painting: All fabric ated struc ture shall be given one c oat of inorganic zinc silic ate blast c leaning after surfac e preparation in acc ordanc e 4.Erection: a) C heck the foundation as per drawing b) Dressing of foundation c ) C leaning and greasing of foundation bolts. d) Erec tion of C olumns / Portals on the founda tion and align. e) Erec tion of tie beams, brac ing in between the portals / c olumns and alignment. f) Erec tion of platform, grating, ladder, stair c ase, hand railings etc . g) Inspec tion of final alignment of c omplete struc ture as per AFC Drawings. h) Grouting of struc ture. i) Final painting as per specific ation

j) Proc edure: 1.Load test of c ranes, lifting beams, slings and shac kles length & dia of slings, wire rope etc . 2.Deployment of erec tion tools & tac kles during erec tion. 3.Orientation to be c hec ked as per AFC drgs. 4.Pac king plates to be provided to matc h AFC Drawings 5.Proper sc affolding & platforms are required at all working level before erec tion & welding and bolting works. 6.Tightening of bolts and washers. 7.Leveling & Alignment of struc ture. 8.C leaning of sleeves/ poc kets before grouting. 9.Plac ement of grouting as per AFC Drawings. 10.C uring of grouting as per Spec ific ation 11.Final tightening of bolts & washers. 1.S afety During erec tion, the steel work shall be bolted / fastened or temporarily brac ed / guyed. Proper ac c ess platforms and safety arrangements shall be provided for working. All person should wear safety belt while working at higher elevation and should tie it with existing members before the start of work. 2.Inspection: a) Erec ted struc tures shall be c hec ked for its elev. Vertic ality c oordinates, size of weld, painting with respec t to drawings and related spec ifications. b) Handing over.
60
JOB PROCEDURE
JOB PROCEDURE FOR PIPING MATERIAL TRACIBILITY
V. Bhaktabhatsalan
A. P. Singh

61
a)SC OPE: Trac eability of piping materials
b)PROC EDURE: Piping materials are to be issued by c lient to c ontractors by MIV. T MIV shall be prepared as per his the line list. While lifting materials a thorough c hec k regarding c olor c oding / spec ification of materials have to be taken up. After lifting the materials from C lient Stores, the same shall be unloaded and stacked ac c ording to material spec ific ation / c olor c ode like C .S. NIBR, C .S Hydrogen Servic e, C .S IBR, SS, A.S etc . All the materials issued shall be used for the fabric ation of the respe c tive drgs. only, if due to some prac tic al diffic ulty or due to the priority of convenienc e or due to the requirement of owner. Some fittings may have to be used for other lines, then required approval from C lient's Engineer shall be taken prior to use.
All piping materials identific ation records (Heat nos) are to be maintained for Hydrogen servic es, A.S and S.S duly signed by IOTIES / EIL / Owner.
62
JOB PROCEDURE
JOB PROCEDURE FOR MECHANICAL CLEARANCE & PRESSURE TESTING
V. Bhaktabhatsalan
A. P. Singh

63
1.PURPOSE The main purpose of this proc edure is to establish the work procedure for mechanic al c ompletion and pressure testing of pipe lines. 2.SC OPE C odes / Standards EIL Spec ific ation 6-44-0017, 6-44-0013, 6-44-0012, ASME B 31.3 This proc edure c overs the method statements on exec ution, inspec tion, testing & rec ord keeping of mec hanic al c ompletion & pressure testing for piping as per contrac t spec ific ation and AFC Drawings. In c ase of any c onflic ts between this proc edure & the c ontrac t spec ific ation the later shall govern. 3.MEC HANIC AL CLEARANC E a. b. Identify the test pac kage from P&ID File of Test Pac kage shall be prepared with all nec essary drawings / doc uments with latest revision. It c omprises of Isometric drawings, P&ID, chec k list formats, flange c onnec tion formats. Material trac eability report wherever required, hydrotest formats, line history sheet flange joint history sheets and the formats as mentioned in Point No.6 The test pac kage shall be submitted to EIL for review. After getting bac k the EIL reviewed test pac k file, following ac tivities will be c arried out.
c. d.
1. On readiness of any loop file for mec hanic al c ompletion all the chec k points (ie. Items to c hec k) of enc losed format no.QD-2B(C hec k list for mec hanic al c learance) for the c onc erned loop will be c hec ked and will be signed against eac h point for ac c eptanc e. 2. Punc h list will be prepared by Petron for any minor left out jobs and will be enc losed in test pac k file. 3. Test pac k files with doc uments as in d(i) and d(ii) will be submitted to EIL for c hec king and punch listing. 4.On rec eiving bac k of test pac k files from EIL with EIL's punc h list, all punc h list points (both Petron punc h list & EIL punc h list) will be attended / resolved and will be signed in respec tive c olumns of punc h lists. 5. On attending / resolving & signing of all the punc h points, the loop files will be presented / resubmitted to EIL for obtaining mec hanical c learanc e. 6. NDT c ompletion for the loop will be obtained from EIL parallelly or after mec hanic al c ompletion. 7.PMI test of installed lines of SS & alloy steel pipes will be completed prior to mec hanical c learanc e as per spec ific ation. PMI report/print out will be enc losed in the test pack file.

64
1.Details of all the flange joints c oming in the loop will be inspec ted & rec orded in the format "History sheet for flange joints"(Format No.5-77-0120-F1). Bolt torquing or bolt hydraulic tensioning will be performed on all the permanent flange joints(ie. Flange joints which will be boxed up with permanent gasket & stud bolt/ nuts) wherever applic able as per spec ification No.5-7700-0120 and its addendum. Bolt torquing or bolt hydraulic tensioning of above flange joints will be performed prior to mechanic al c ompletion and hydrotest of the loop and will be rec orded ac cordingly. 2.On obtaining mechanical completion and NDT completion the loop will be released for pressure testing. Please refer enc losed Annexure A for bolt tensioning and Annexure -B for bolt torquing. Flange joints whic h are not subjected to hydrotest (i.e. not boxed up with permanent gasket & stud / nuts) will be rec orded as temporary flange joints in flange joint history sheet. These flange joints will be boxed up with permanent gaskets & stud/nuts and same will be torque tightened / bolt tensioned (which ever applic able) either after hydrotest or after flushing operation required for pre -commissioning. 1.PRESSURE TEST a. Flushing shall be done to remove the foreign materials. All inline instruments like c ontrol valves, orific e plate, rotameters, safety valve, thermowell pressure gauge etc . are to be dismantled before flushing / testing. The sc reen / mesh of permanent strainers are to be removed before flushing whic h will be reinstalled after fusing but before testing. All the nozzle openings shall be suitably blinded. The thickness of blind plate whic h shall with stand the required hydrostatic pressure shall be ensured. The drain connection with the valve shall be provided at the lowest point of loop forming and the vent c onnection with a valve at highest point of loop forming. At least two pressure gauges shall be provided one on the highest point and the other at lowest point or suitable location near to hydro test pump. All valves shall be kept open. All equipments, instruments & c ontrol valves shall be isolated before testing. Flanged type chec k valve will be reversed to suit pressure testing requirement and S.W c hec k valves plunger are to be removed to ensure socket welded joint of c heck valve. After testing these will be made set right as per Drg. Requirement and flanged type chec k valve joints will be considered as flange joints not tested and should mentioned in flange joint history sheet. Similarly the S.W c heck valve bonnet joint will be shown as untested joint in flange history sheet, or always it will be preferred to fill the water from disc harge side in both pumps during common discharge header. Pressure gauge selec ted shall be suc h that re quired test pressure shall fall within 40 to 80% range of the gauge needle. Pressure gauges to be used shall have calibration certific ates of approved laboratory or Inspection Authority. Rec alibration should be done after due interval
b. c. d. e. f. g. h.
i.

65
j.
1. T pipe line shall be filled up with potable water ensuring that there shall be no air he trap anywhere. The inlet valve shall be opened and the test pump sha ll be operated to pump in water. The potable water should satisfy minimum requirement of c hlorine ppm. In c ase of SS piping for hydro testing D.M water is required. 2. After air free water comes out from the vent, the vent valve shall be closed. T his pressure shall be raised to the required test pressure given in the line schedule. Onc e the required pressure is reac hed, the inlet valve shall be closed & pump assembly shall be isolated. The needle position shall be marked on the pressure gauge. All weld joints are to be c leaned with wire brush to remove for paints , fire proofing material, rust, grease etc . prior to start c hec king of leak test.
k.
All the weld joints shall be seen to confirm that there shall be no water leaking. T test he pressure shall be maintained for a suffic ient time, to determine if there are any leaks to notice whic h could be developed gradually.
1.
2. Following the application of the hydrostatic test pressure, an inspec tion shall be c arried out on all joints at the test pressure. If any leak / sweating notic ed shall be rectified by draining out the water and retesting will be done there after. Test period shall be maintained for a minimum of three hours. 3. On the satisfactory inspec tion, the vent valve shall be opened sli ghtly to release the pressure. It shall be ensured that air free water c omes out of the vent valve. The pressure gauge needles shall be brought to zero pressure gradually and same is to be ensured for c orrectness of c alibration of pressure gauge. l. Keeping the vent valve in open position, all the blind covers provided for hydraulic test shall be opened and also drain valve to drain out water and inside surface shall be dried by means of c ompressed air. m. Restoration: After completion of the testing & drying, all temporary blinds will be removed, box-up will be done with required gaskets, bolt / nuts etc. n. Flange joints which are not tested / tested with temporary gaskets are to boxed up with required gaskets and fasteners and to ensure tighte ning of these joints by bolt tensioning / bolt torquing as applic able. o. Air Test : When tested with air, pressure shall be supplied by means of compressor. The c ompressor shall be portable type with a rec eiver, after c ooler and oil separator. Piping to be tested by air shall be shall have joints c overed with a soap and water solution so the joints c an be examined for leaks. All other details shall remain same as per hydrotesting procedure as above. p. Final acc eptanc e & documentation q. Handing over
66
1.SAFETY The pressurising area shall be c ordoned. The system / loop under pressure shall be fixed with a Tag "Line Under Pressure" during pressure test. Ensure the thic kness of the Blind Plates which must to withstand the subjec t test pressure.
67
JOB PROCEDURE
JOB PROCEDURE FOR BOLT TIGHTENING
V. Bhaktabhatsalan
A. P. Singh

68
The specification for Bolt Tensioning covers under ASME B16.5 flange joints by hydraulic bolt tensioner or torque wrenches during testing and commissioning stage and used for indicated process as well as requirement of the project OWNER / VENDOR recommendation. The approval of the Hydraulic Tensioner equipment shall be taken before application. Tightening of the flange joints shall be done by skilled and qualified technicians. Identification of flange joints to be done by calculated bolt tension with bolt tensioner or bolt torque with torque wrenches. Hydraulic bolt tensioning shall be applied for all joints wherever the bolt size specified, indicated as below : 1. Specified by Process Licensor / Vendor / Project Specification. 2. Bolt dia. 50mm and above for all joints. 3. Bolt dia. 25mm to 50mm class 600# and above, Hydrogen service in which partial pressure of hydrogen 58 psig or more, equipment man holes, equipment mounted instrument joints, orifice flanges, spectacle blinds, spacers, valve flanges, tie-in joints, high temperature joints (i.e. above 3700c in hydrocarbon services), critical joints with pumps, compressors, turbines etc. Before tensioning use of gasket, fasteners etc. to be check as per piping material specification. Only the joint is open during testing and commissioning stage shall be required for bolt tensioning. Wherever the flange joints are tested should not be reopen for tensioning. Following visual inspection shall be done before bolt tensioning:1. Flange shall be free from dirt, scale, face pitting, tool marks or scratches etc. 2. Alignment of flanges should be proper. Flange faces shall be parallel and bolt holes shall match so that stud can be inserted properly. 3. Visual inspection of gasket should be done. 4. Position of gasket to be checked. 5. Studs & Nuts shall be free from dirt, burrs and chips. Stud shall be straight and nut shall turn freely on the stud. 6. If necessary, gasket seating faces to be cleaned by using wire brush or suitable solvent. No damaged gasket shall be use during tensioning. 7. Threads of studs & nuts to flange contact face should be lubricated with suitable solvent. Thread compound or lubricant may be used suitable for line temperature. The application of hydraulic bolt tensioning should be applied simultaneously and should be shifted in criss -cross pattern. Four bolts equally spaced should be used and nuts should be run down to flange surface manually and tensioning of all bolts should be completed. After completion of bolt tensioning, History Sheet for flange joints to be maintained as per approved format mentioning the names and signatures of person involved in execution and inspection of pf boxing up. All critical joints like interface joints and online instrument joints such as control valves, safety valves, flow meters etc. which are not subjected to hydro test shall be maintained separately
69
JOB PROCEDURE
JOB PROCEDURE FOR PMI WAREHOUSE
V. Bhaktabhatsalan
A. P. Singh

1.SC OPE PMI testing to be performed as part of the receiving inspection at warehouse. 2.PROC EDURE The extent of PMI shall be done 100% on eac h c omponent including welding consumables and welding joints unless specified by owner / EIL. However if PMI testing has been carried out at vendor's / manufacturer's shop and relevant c ertific ate, records and c orrelation with incoming materials is available, PMI testing at warehouse need not be done. PMI testing within the warehouse shall not be regarded as an alternative to PMI testing of the installed system. However all non-pressure parts suc h as pipe supports, stud-bolts & washers shall be required random 10% of eac h lot.
71
JOB PROCEDURE
JOB PROCEDURE FOR LIQUID PENETRANT TEST
V. Bhaktabhatsalan
A. P. Singh

72
1.0REFERENCE CODE AND S PEC

Article 6 of ASME Sec. V- 2001, ASME Sec VIII Div 1, ANSI B 31.3, EIL SPEC. Method : Color contrast penetrant technique shall be used. 3.0 Operator and Interpreter : ASNT Level 1 operator shall be employed for testing. Interpretation shall be done by internal quality control engineer and inspection authority (I.A) with ASNT Level II certification. 4.0 Type : Solvent removable process using visible dye for the purpose of detecting surface defects. 5.0 Typical Discontinuity : 1. Rounded and liner indications. 2. Hair line cracks and lamination. 6.0 Chemical for use : Non-toxic chloride and surfur free penetrant cleaner and developer of recommended brand shall be used which meets the requirements of ASME code of practice shall be from approved vendor / Brand of EIL 7.0 Surface Preparation : Surface shall be free from dirt, oil, grease and other particles that would obstruct surface opening. 8.0 Pre-Cleaning : The area shall be thoroughly cleaned with wire brush or buffing wheel and lint linen cloth damped in cleaner. Adequate care shall be taken to ensure proper surface condition prior to testing. 9.0 Temperature : During testing the metal temperature shall be between 60 o F to 125o F (16o to 52o C) 10.0 Application of Penetrant : The liquid penetrant shall be applied by spraying over the area cleaned and dwell time of 5 to 7 minutes shall be allowed for penetration. 11.0 Penetrant Remover : The area sprayed with penetrant shall be wiped with clean lint free linen cloth. Cleaning shall be continued till all traces are removed. Final cleaning shall be carried out using lint free linen cloth damper with cleaner (solvent). Care shall be taken to avoid use of excess cleaner and deposition of any contaminating material, which shall lead to misinterpretation of the results. 12.0 Scope: LP Test shall cover Liquid Penetration test to be carried out on butt welds, filler welds, welding on branches etc. This will cover field and shop joints. 2.0
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED I.O.C.L, PANIPAT 73

1.0 Application of developer : Developer shall be applied by spraying at proper angle and from distance of 4 to 6 inches min. to fom a thin uniform single coat. Developer dwell time be 5 minutes minimum. Care shall be taken to avoid over spraying of developer. 2.0 Cleaning : On completion of testing, interpretation and recording the part shall be cleaned with lint free linen cloth for removing developer and penetrant. 14.0 Safety: Inspection personnel involved in L.P.T. shall take sufficient precaution due to inflammability nature of the chemicals. 15.0 Acceptance standard: Appendix 8 of ADME Sec, VIII Div. 1- 2001 16.0 Records : 1. I.A. approved copy of L.P.T. Procedure. 2. Liquid Penetrant interpretation reports.
74
JOB PROCEDURE
JOB PROCEDURE FOR MAGNETIC PARTICLE INSPECTION
V. Bhaktabhatsalan
A. P. Singh

75
1. Scope :- This is procedure is intended for wet continuous MPI examination, a non destructive method for detecting cracks and other discontinues in surface and up to 6mm in ferromagnetic materials. 2 Reference :- (1) ASME Section V & VIII (Division 1 & 2) (2) ASME B31.3 (3) EIL Specification 3 Equipment :- HWDC, electromagnetic yokes provide an effective means for near surface discontinues as well. The magnetizing force of a yoke will be tested by determining lifting power on steel plate. Lifting power of A.C Yoke is 4.5 Kgs (10 lb) and D.C. Yoke is 18 kgs (40 lb). The pole spacing will be 6 (inch) (maximum ). Magnetic current of A.C; H.W.D.C. D.C. will be applied to magnetize the material to be tested in direction as longitudinal.
SL .NO
PROD SPACING (INCHES)
UNDER INCH THICKNESS
INCH OVER THICKNESS
1 2 TO 4 2 4 TO 6 3 6 TO 8 400 TO 600 AMPS 600 TO 800 AMPS 300 TO 400 AMPS 400 TO 600 AMPS 200 TO 300 AMPS 300 TO 400 AMPS
Surface Preparation :- The surface to be examined should be clean, dry and free of oil grease , Rusts and scale , lint, thick paint and welding spatters . Surface may be accomplished by detergents, organic , solvents & by mechanical means. 5 Magnetic Particles :- The wet Particles employed will be black color powder will be suspended in water . The concentration will be 10 gram of particles in I liter of suspended liquid. 6 Sensitivity :- A Magnetic field indicator will be used as a check of the adequacy of field strength and direction of part magnetization. 7 Technique :- Yoke technique

After surface preparation as mentioned above a fine coating of white contrast paint will be applied . In wet continuous method the weld will be bathed by bath application simultaneously by with the initiation of magnetic current will be to 1 seconds. 8 Examination :- At least two separate examination shall be carried out on each area . During second examination the prod / Yoke are spaced so that line of flux is approximately perpendicular to those used the 1 st examination . 9 Interpretation :- All indication formed by magnetic particles examination are the result of magnetic flux leakage fields . Indication should be approved in perfect illumination ( Under minimum light intensity of 500 lux ) Temperature of the test surface should not be more than 57 F or 135 F. 10 Acceptance Criteria :- Will be as per ASME see V III DIV 1 . Appindix - 6 1 2 Linear indication is greater than three time of width . Rounded indication should not be greater than 3/16 (inch)
11 Reporting :- The MPI test result to be field in report formatted . 12 Calibration :- Ammeter of magnetic equipment shall be calibration at least once in a year, or after each times it has been subjected to major electrical repair , periodic overhaul or damage. If the equipment is not been in use for a year or more calibration shall be done prior to the first use .
77
JOB PROCEDURE
JOB PROCEDURE FOR POST WELD HEAT TREATMENT
V. Bhaktabhatsalan
A. P. Singh

78
1.0Scope:
The Heat Treatment is performed by electrical resistance heating for local stress relieving of weld mentis using electrical coils for piping weld Joints.
2.0
3.0
Controlling specification:
EIL specification (In case of any conflict between this procedure & the contract specification the later shall govern.), ASME B 31.3, ASME Sec VIII, welding specification chart as approved WPS. Method: Heating elements of Ni Cr, Wire of suitable gauge insulated with porcelain bends (i.e. heating coil) shall be all round the weld portion and heated electricity at 220 V supply. Heating elements are wrapped with sufficient mineral wool (50 mm thick) to shield the heat. Heat is controlled by varying the electrical energy manually as well as timer control.
4.0
Arrangement of elements:
Heating the circumferential joints of pipe by any appropriate means over a band having a width on each side of the centerline of not less than three the greatest width of the finished weld. The portion outside of the heater band shall be protected so that the temperature gradient is not harmful. (ASME sec. /VIII Div. 1 2001) Thermocouple : All thermocouples shall be of the chromel Vs. Alumel type to BS 4937 part 4 type K and having valid calibration certificate. Units used to tack weld thermocouples to parent joints shall be of the same materials as that of the joints being post-weld heat treated. Thermocouple positions: Pipe Dia. (O.D.) Thermocouple Up to and inclusive 6inch O/D Min. One No. From 8 inch up to 10 inch O/D Min. Two Nos. o From 12 inch & up above Min. Three 120 apart Procedure for Stress relieving of carbon steel. o Controlled from 300 C (Minimum 1 Hr. upto 300 C) o Rising rate 150 C per Hr. ( max.) Rising upto As per welding spec. charts. Soaking time 1 Hr. (Min.) and 1 hr./inch o Cooling rate 150 C per Hr. ( max.) o Controlled cooling upto 300 C Show exhibit of TC arrangement in various dia of pipe including coiling & TC arrangement for branch joints. Methodology for SR recorder sealing and initial chart verification to b e specified.
5.0
6.0
7.0

PROJECT OWNER CONSULTANT F.O.A. REF. NO. PROCEDURE NO. JOB NO. PAGE NO. 8.0 8.1 8.2 : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT. : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : IOT/C-40/JP/014 REV - 0 : 6698 : 03 of 03
79
Thermocouple extension cable : Copper constantan compensation cables shall be use. The copper lead (+ve) shall be connected to the chromel conductor (non-magnetic) and the nickel lead(ve) shall be connected to the alumel conductor (magnetic). 9.0 Thermal insulation: 9.1 The insulation consists of mineral wool 50mm thick wrapped around heating elements. 9.2 The insulation shall extended a minimum distance of 300 mm beyond the outer edges of heated band. 9.3 The total insulation covering will be such as to provide minimum heat loss and the temperature o out side the insulation coverings shall not exceed 300 C and the same should be established during procedure qualification. 10.0 Thermal recorders: 10.1 The recorders shall be six pointer suitable for 1000 oC & 1200oC having continuous recording chart having copper lead with color dots, scanning period 30 seconds/dot. 10.2 Each recording instrument will give information and immediate indication of a thermocouple open circuit condition. 10.3 Calibration certificate shall be available for review and such calibration can be witnessed by client if required. 11.0 Temperature control system : 11.1 The temperature control system shall guarantee a post weld heat treatment within the limits of the specification. 11.2 The power shall be controlled by times & manual control of electrical energy. 12.0 Identification. After PWHT joints should be identified by orange color band. White color box shall be marked on joints where hardness to taken. Hardness shall be recorded & report shall be submitted to inspection authority for review. 13.0 Hardness testing : Hardness (max) in BHN for CS shall be 238 or as specified in the welding chart of EIL Spec. Hardness test shall be carried out by Brinell hardness test. Whenever hardness increases to required value re- PWHT shall be carried out as per the above procedure. Hardness value shall be recorded for each welds in approval format. Hardness to be recorded on sm ooth weld surface. If required, surface to be prepared by grinding. Documentation :- The graph shall have individual identification such as line no, joint no & size. Starting time and completed time shall be counter signed by inspection Engineers immediately after commencement of heating. Soaking hold time must be marked. Submission of charts shall be done day to day basis for QA/QC verification. 14.0 Recorders to be submitted for review to inspection authority : S.R.Charts, Calibration Certificate of temperature Recorder.
80
JOB PROCEDURE
JOB PROCEDURE FOR PIPING JOINT NUMBERING
V. Bhaktabhatsalan
A. P. Singh

81
1.0
SCOPE This procedure outlines the method of joint numbering on the isometric drawings for EPCC -9 piping work. In case of any conflict between this procedure and Technical specifications, the Technical specifications shall govern.
2.0
PROCEDURE: After receipt of approved drawing, detailed fabrication & erection scope will be worked out by planning/ piping engineer based on availability of drawing and material. The approved ISO. Drg. Shall be marked with all the weld joints (shop/field) prior to fabrication in the flow direction with a number to identify each weld in the following sequence and one set of this marked ISO drawing shall be submitted to EIL for their reference.
2.1
PIPING: system for each line number in the Ascending order. Joint numbering shall follow a five digit system as given below. X X X X X S- Suffix A,B,C for Branch,Socket & Additional joints Serial number 01,02,03.99 Shall indicate the First 3 digits of AREA NUMBER
2.1.1 On the basis of approved drawings and sketches we shall follow the area wise numbering
2.2 2.2.1
MITER JOINTS Miter joints will be as per Line wise only. Joint numbering shall follow a three digit system prefix with M a suffix with nd A,B,C,D,.. Eg. M01A.,M02A..,M03A..,..
82
I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09
JOB NO.
6698
DOCUMENT NAME DOC. NO. DATE
: JOB EXECUTION METHODOLOGY : JEM-001, Rev. 0 : 25.03.2009

I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. DOC. NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : 6698 : JEM-001, Rev. 0
83
JOB EXECUTION METHODOLOGY

M/s. Indian Oil Corporation vide FOA PJ/MECH/PRAEP/2008-09 Dated: 17.03.09 placed order on M/s. IOT Infrastructure & Energy Services for carrying out the Mechanical works Panipat Refinery Additional Expansion Project at Panipat. M/s. IOT Infrastructure & Energy Services has already vide their letter no. IOT/PROJ/APAEPRKS06/23032009 dated: 23.03.09 communication to M/s. IOCL the acceptance of FOA & also nominated Mr. A. P. Singh, V.P. as Resident Construction Manager at Site and Mr. S. K. Banerjee, Sr. V. P. as Project Manager at H.O. Mumbai. The work will be executed by M/s. IOT Engg. Proj. Ltd. in totality on behalf of M/s. IOTIES. The organization chart at Head Office & Site for execution of this order is attached. To execute the work, IOTEP inform will engage some contractors for Radiography, Painting & Mechanical work. The erection of DHDT Reactor shall be carried out engaging M/s. Sanghvi Movers Cranes. The erection scheme shall be submitted for review & approval by EIL. Procurement of Permanent material to be supplied as per scope, will be procured by Head Office from approved vendor. In case of any deviation prior approval shall be taken.
84
I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. DOCUMENT NAME DOC. NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : : PJ/MECH/PRAEP/2008-09 6698
: COMMUNICATION PROCEDURE : CP-001, Rev. 0
DATE
: 25.03.2009

I.O.C.L, PANIPAT
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO. DOC. NO. : PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : 6698 : CP-001, Rev. 0
85
COMMUNICATION PROCEDURE
1) Communication from owner (IOCL) / Consultant (EIL) to IOT IES a) All communication if addressed to site, a copy to be sent to IOTIES, Head Office. All communication if addressed to IOTIES, Head Office, a copy should be sent to IOTIES Site. At IOTIES Site:Attention: Mr. A. P. Singh C/o. Napatha Cracker Project IOCL, Panipat Haryana Mob. No. 09896318432 Email ID - apsingh.iotep@gmail.com At IOTIES HO:Attention: Mr. S. K. Banerjee Plot No. 15, IOT House, 2nd Floor Ceat Tyre Road, Nahur (West) Mumbai 400076 (India) Phone No.: +91-22-67190810 Email ID iotepp@gmail.com 2) Communication from IOTIES to consultant / Owner EIL / IOCL to indicate
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400 076

DEPLOYMENT SCHEDULE OF WORKMEN
86
DOC. NO. : C-40/P-15/DS-02/WM/ REV 0 Sheet No. : 1 of 1 Date : 25.03.2009
Location : Panipat Refinery FOA Ref. No. : PJ/MECH/PRAEP/2008-09 DATE : 17.03.2009 JOB No. : 6698 Contract No. : C-040
SR. NO.
MONTH DESCRIPTION
Apr-09 May June July August September October November December January February March
1 2 3 4 5 6 7 8 9
PIPE WELDERS
10
20 4 25
8
40 4 50
8
40 4 50
10
40 4 50
10
40 10 50
10
40 10 50
15
50 10 65
15
50 10 65
15
75 10 85
15
75 10 85
15
75 10 85
15
75 10 85
15
85 10 90
15
85 10 90
15
105 10 110
15
110 10 110
15
110 10 110
15
110 10 110
15
150 10 160
15
200 20 180
30
250
250
STRUCTURAL WELDERS
20
20
PIPE FITTERS
15
180
180
STRUCTURAL FITTERS
40
40
MILLRIGHT FITTERS
2 40 10 60 70 239
4 40 15 70 100 331
4 60 30 100 110 408
4 60 30 100 110 408
4 65 35 120 110 444
4 65 40 120 110 454
4 70 50 140 130 534
4 70 50 140 130 534
4 80 60 150 170 649
6 80 60 160 170 661
6 85 60 190 170 696
6 85 60 200 170 706
6 100 65 210 200 781
6 100 65 210 200 781
6 100 80 250 200 876
6 110 80 250 200 891
6 110 80 250 210 901
6 110 80 250 210 901
6 130 80 250 250 1051
10 180 100 400 300 1420
10 180 100
400
10 180 100
400
GRINDERS
10
20
GAS CUTTERS
4 30 30 95
6 40 30 129
RIGGERS
HELPERS / KHALASI
300
300
TOTAL :
1480
1480
IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400 076 EQUIPMENT DEPLOYMENT SCHEDULE DOC. NO. : C-40/P-15/DS-03/P&M/ REV 0 Sheet No. : 1 of 1 Job Description : Fabrication & Erection of Equipment, Piping, Structure, Insulation and Painting work Project: Panipat Refinery Additional Expansion Project Owner: Indian Oil Corporation Ltd., Panipat Consultants: Engineers India Ltd. Contractor : IOT Infrastructure & Energy Services Limited. SI. NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 DESCRIPTION
Apr-09 May June July August
87
MONTH
September October November
Date : 25.03.2009 Location : Panipat Refinery FOA Ref. No. : PJ/MECH/PRAEP/2008-09 DATE : 17.03.2009 JOB No. : 6698 Contract No. : C-040
December
January
February
March
HEAVY DUTY CRANE FOR REACTORS 450 MT CRANE 300 MT CRANE 150 MT CRANE 75 MT CRANE 40 MT CRANE HYDRA 10/12 MT TRAILOR 20 MT WELDING RECTIFIERs PORTABLE GRINDING SETS GAS CUTTING SETS DIESEL POWER GENERATOR 125 KVA STATIONARY ELECTRODE OVENS MIXER M/C (MIXER M/C IS ALLOWED ONLY FOR SMALL PEDESTALS FOR PIPE SUPPORTS, PCC, FIRE PROOFING WORKS) AIR COMPRESSOR(7KG/CM2 & 350 CFM) LIFTING AND RIGGING EQUIPMENT WEIGH BATCHER SPRAY PAINTING M/C - AIR LESS HYDRO TEST PUMP (MOTORISED) BLAST CLEANING EQUIPMENT X-RAY M/C 250 AMPS GAMMA RAY SOURCES OF REQUIRED CURIE U.T. MACHINE S.R. MACHINES WITH RECORDER PORTABLE ALLOY ANALYSER (PAA) WELDERS TOOLKITS FITTERS TOOLKITS MW FITTER TOOL KIT PORTABLE ELECTRODE OVENS CHAIN PULLEY BLOCKS 10T/5T/3T/2T HAND TOOLS MOTORISED TEST PUMP
DEPLOYMENT SCHEDULE SEPACATELY ENCLOSED 1 1 1 4 3 13 8 450 200 140 10 5 3 3 2 3 3 3 3 1 1 1 4 3 13 8 450 200 140 10 5 3 2 2 3 3 3 3
1 1 1 30 20 12 1 1 1 1 1 1 1 1 1
1 1 10 7 100 30 20 2 3 1 2 2 1 1 1 2
1 2 10 7 100 40 40 6 2 2 2 2 2 2 2 2
1 2 10 7 130 60 50 8 3 2 3 2 2 2 2 2
1 2 10 7 150 80 50 10 3 2 3
1 2 10 7 200 100 60 10 4 2 3
1 3 10 7 210 100 80 10 5 2 3
1 3 10 7 250 120 100 10 5 3 3
1 3 10 7 250 140 100 10 5 3 3 2 3 3 3 3
1 3 10 7 250 170 100 10 5 3 3 2 3 3 3 3
2 2 2 2 2 2 2 3 2 2 2 3 2 2 2 3 2 2 2 3 SHALL BE DEPLOYED AS AND WHEN REQUIRED SHALL BE DEPLOYED AS AND WHEN REQUIRED SHALL BE DEPLOYED AS AND WHEN REQUIRED SHALL BE DEPLOYED AS AND WHEN REQUIRED SHALL BE DEPLOYED AS AND WHEN REQUIRED AS REQUIRED AS REQUIRED AS REQUIRED AS REQUIRED AS REQUIRED AS REQUIRED AS REQUIRED

PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO.
: : : : :
PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT INDIAN OIL CORPORATION LTD. ENGINEERS INDIA LTD. PJ/MECH/PRAEP/2008-09 6698
88
FACILITIES REQUIRED FOR JOB.

A FABRICATION YARD. i ii iii B AREA REQUIRED POWER REQUIRED WATER FACILITIES
: : :
250 M X 100M ( 25, 000 M ) 2000 AMPS To be provided
AT VARIOUS UNITS. i ii AREA REQUIRED FOR SITE OFFICE POWER REQUIRED
: :
2 Nos Porta cabin to be mobilised. In addition Brick masonary offices to be allowed near units. CDU/ VDU 500 AMPS OHCU 400 AMPS SRU 400 AMPS DCU 500 AMPS DHDT 500 AMPS OFFSITE 500 AMPS
Power requirement during shut down to be indicated well in advance of start of shut down. iii WATER
To be provided

DAILY PROGRESS REPORT PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO.
89
: PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT : INDIAN OIL CORPORATION LTD. : ENGINEERS INDIA LTD. : PJ/MECH/PRAEP/2008-09 : 6698
CDU / VDU OHCU SCOPE FRONT PROGRESS TO-DAY CUMM SRU SCOPE FRONT PROGRESS TO-DAY CUMM DCU SCOPE FRONT PROGRESS TO-DAY CUMM DHDT UOM
Data Date: Report Date:
UTILITIES & OFFSITE PROGRESS TO-DAY CUMM
TOTAL SCOPE FRONT PROGRESS TO-DAY CUMM
S. No. 1 2
Activities
SCOPE FRONT
PROGRESS TO-DAY CUMM
SCOPE FRONT TO-DAY CUMM SCOPE FRONT
Mitre/ Reducers Nos. A/G Piping
37
50
23
56
160
326
2.1 CS NIBR Fabrication Erection ID IM 132205 249390 59880 70160 57435 71025 55655 80563 424 378 57067 267275 362666 738791
2.2 CS IBR Fabrication Erection ID IM 3000 3140 4350 2640 12505 10705 8792 11990 0 0 9352 35807 37999 64282
2.3 SS Fabrication Erection ID IM 4181 6520 1016 1388 7390 5760 193 295 1563 2697 0 0 14343 16660
2.4 AS Fabrication Erection ID IM 19025 33780 640 124 0 0 6930 3287 0 0 0 0 26595 37191
3.
STEAM TRACING Mtr.
17000
11095
9865
8345
26475
72780
4.
ERECTION OF VALVES
Nos
1063
702
877
840
68
99
3649
90
CDU / VDU Activities UOM S. No. PROGRESS SCOPE FRONT TO-DAY CUMM 5. 5.1 5.2 5.3 PIPE SUPPORT CS SS AS MT MT MT 55 1 9 60 9 7 14 3 37 1 2 4 4 28 198 18 18 SCOPE FRONT TO-DAY CUMM OHCU PROGRESS SCOPE FRONT TO-DAY CUMM SRU PROGRESS SCOPE FRONT TO-DAY CUMM DCU PROGRESS SCOPE FRONT TO-DAY CUMM SCOPE FRONT TO-DAY CUMM DHDT UTILITIES & OFFSITE PROGRESS SCOPE FRONT TO-DAY CUMM TOTAL PROGRESS
6.
RADIOGRAPHY
ID
41727
15698
40704
20698
1922
26943
147692
7.
PWHT
ID
21588
4854
40535
15210
17740
99927
8. 8.1 8.2
EQUIPMENT ERECTION Static Rotary
MT MT
1465 174
393 223
638 148
115 91
1112 0
0 0
3723 636
9.
Strl. Fabn. & Eren. Gratings Installation Handrailing
MT
552
76
61
34
13
21
757
10.
MT
10
20
42
11.
Mtr.
230
880
810
145
25
55
2145
PROJECT OWNER CONSULTANT CLINET REF. NO. JOB NO.

I. MANPOWER
: : : : :
PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT DAILY MENPOWER & MACHINERIES PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT INDIAN OIL CORPORATION LTD. ENGINEERS INDIA LTD. PJ/MECH/PRAEP/2008-09 6698
Management & Supervision

Sl.No. Category Deployed
91
Present Strength
II.
EQUIPMENT & MACHINERY

Category Deployed Present Strength
Sl.No.
1 2 3. 4. 5. 6. 7. 8. 9. 10.
Manager Planning Engineer / Asst. Engr. QA/QC Engineer / Supervisor Execution Engineer Administration Officer / Asst. Site Supervisor Safety Officer / Supervisor Store Keeper / Asst. PMD Supervisor Electrical Supervisor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
DG Set (65 & 75 KVA) DG Set (125 KVA) DG Set (250 KVA) Trailer Tractor Trolly Crane - 35 Ton Crane - 40 Ton Crane - 150 Ton Hydra Crane Welding Rectifiers Grinding M/c Drilling Machine Air Compressor Hopper Automatic Blasting Machine Pug Cutting M/C
Total WORKMEN STRENGTH PIPING WORK

S.No. Category Deployed Present Strength
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

17
Foremen / Chargehand Pipe Fabricator Fitter - Pipe Fitter Pipe Support Welder - Pipe Tack Welders Sarang Rigger Khalasi Gas Cutters Grinders Electrician Chaser Helper Mechanic Mail Nurse Operator/Driver Total 0 BLASTING & PAINTING WORK
Category Deployed S.No.
STRUCTURE WORK Category Foremen / Chargehand Fabricator Structural Fitter Gas Cutter Grinder Helper Rigger Welder Khalasi Total
0 0
Deployed Present Strength
1 2 3 4 5 6 7 8 9
RADIOGRAPHY WORK 1. 2. Radiographer

Technician
0
Present Strength
S.No.
1 2 3 4 5 6 7
1 2 3
1 2 3
Painters Blasters Supervisor Foremen Helper Comp. Operator Rigger Total INTERMEDIATE / FINISH PAINTING WORK Brush Painter Helper Supervisor Total EQUIPMENT ERECTION WORK M/W FITTER RIGGER / KHALASI HELPER Total
Total Radiography Source (G-RAY) Radiography Source (X-RAY)
REMARKS:-
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1

KICK OFF MEETING

STATUS OF REQURIED 3 DOCUMENTS FOR KOM

Sheet No. : 1 of 1 Revision : 0 Date : 25.03.2009

P. G. Vaidhyanathan Managing Director

K. K. Ranade Directior (Operation)

Y. A. Rane Director (Technical)

Bharatbhushan Dy. Mgr. (HRD)

A. Patil Dy. Mgr. (Elec.)

A. P. Singh V.P. (RCM) at Site

Sheet No. : 1 of 1 Revision : 0 Date : 25.03.2009

M. Sengupta Safety Incharge

B. Karan Store / Warehouse

Indu Shekhar Execution Incharge

Vijith M. Welding & NDT Mgr.

K. K. Bhowmik QA/QC Incharge

A. K. Sarkar Admn. Officer

D. S. Mishra & G. Moinuddin Safety Sup.

S. N. Mondal Lead Engr.

N. Panivel / S. I. Ali Lead Engineer

Painting & Insulation

S. Sharma Painting Inch.

Neeraj Kr. Manager

Parwez Ehsan Manager

Pawan Pandey Manager

B. K. Sharma Painting Sup.

Shashikant Kr. Manager

Sanjay Singh Engineer

Sushil Tiwari Engineer

Anchal Lead Engineer

DEPLOYMENT SCHEDULE OF ENGINEERS & SUPERVISORY PERSONNEL

10 Materials Management Supervisors TOTAL :

IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED

BRIEF DESCRIPTION OF MEASURE ITEM AS PER SCOPE

4) Fabrication, Erection of Structure 757 MT 5) Painting & Insulation 6) Civil Work

IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED

QUALITY ASSURANCE PLAN

QD Format : QAP - 01 Sheet no: 1 of 5 Revision: 0 Date: 24/03/2009

QD Format : QAP - 01 Sheet no: 2 of 5 Revision: 0 Date: 24/03/2009

QD Format : QAP - 01 Sheet no: 3 of 5 Revision: 0 Date: 24/03/2009

Inspection Report Inspection Report

IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED MUMBAI - 400076

QD Format : QAP - 01 Sheet no: 4 of 5 Revision: 0 Date: 24/03/2009

QD Format : QAP - 01 Sheet no: 5 of 5 Revision: 0 Date: 24/03/2009

LEGEND: P - PERFORM, W - WITNESS, R - REVIEW

PREPARED BY ( SAJAL SARKAR )

IOT INFRASTRUCTURE & ENERGY SERVICES LIMITED

IOT INFRASTRUCTURE&ENERGY SERVICES LIMITED

Sheet no:1 of 5 Revision:0 Date:25-03-2009

I N SPECTI ON & TEST P LAN FOR ABOVE GR OUND PI P I NG W OR K

Location: Panipat Refinery. FOA Ref. No. : PJ/MECH/PRAEP/2008-09

Contract No: C - 040

IOT/P-15/6698/MECH/F-38 IOT/P-15/6698/MECH/F-38 IOT/P-15/6698/MECH/F-38

Approved Procedure & Isometric Drawing AFC Drawing IOT/P-15/6698/MECH/F-09 IOT/P-15/6698/MECH/F-09

PWHT CHART IOT/P-15/6698/MECH/F-15 IOT/P-15/6698/MECH/F-15 IOT/P-15/6698/MECH/F-13 IOT/P-15/6698/MECH/F-11

2 Test certificates for lifting tackels 3

4 Provision of Inst. Tappings 5 Provision of vents and drains 6

Correctness of type of supports, anchors & guides Correctness of valves( NRV,Globe,

7 Correctness of gaskets/ fastners 8 Gate,control valves etc),steam traps &

AFC Isometric Drawing

their direction of flow

1 Procedure review 2 Correctness of testing arrangements

Approved Procedure Testing Scheme