REPORT

On
Design Training
&
Site training

ACKNOWLEDGEMENT

CONTENT

PART 1 : Design Training

Training in Static Equipment Department.

Training in Piping Department.
Training in Rotating Equipment Department.
Training in Packaged Equipment Department.
Training in Heat And Mass Transfer Division.
Common Classroom training in Procurement
Services, Planning, Costing & Projects.

PART 2 : Site Training

Introduction
.
..
.
.
Learnings
Conclusion
Annexures(If Any)

PART 1 : Design Training

Static Equipment Deptt.
Design of Columns:
Preface: Normally Vertical Vessels with height/diameter ratio more than 5 can be taken
as columns, columns are normally used for the process of distillation, fractionation etc.
Purpose: 1. Design requirements as per ASME Section VIII Division I.
2. Design of columns for imposed load like Wind, Seismic, Dynamic
Analysis.
3. Design of supports and Anchor Bolts.

Inputs:

1. Process data Sheet.

2. Engineering basis design.

Design of self supporting Columns:

Design considerations:

1. Design code: ASME Section VIII Division 1(Edition 2001).

2. Materials: a) SA 283 Gr C (Skirt)- Typical.
b) SA 516 Gr 60 or 70 (Shell, Bottom & Head).
3. Design Conditions:
Design Pressure(kg/cm2) : Internal- P
External- 1.055
Design Temperature
Inside Diameter
Corrosion Allowance(mm)
Wind Pressure
Horizontal Seismic Coefficient
4. Design Calculations:
a. Thickness of Shell for internal Pressure (Clause UG-27):
Ts=PR/(SE-0.6P) + Corrosion Allowance
Where S: Allowable stress shall be taken from ASME section II Part D.
(Note: Criteria for allowable stress- smaller of UTS/3.5 or YP/1.5)
b. Thickness of Head (Clause UG-32): Type of Head
c. Thickness of Shell for external Pressure(Clause UG-28)
d. Size of Stiffener
e. Design of Head for external Pressure(Clause UG-33)
f. Nozzle Design
Neck (Clause UG-45)
RF Pads(Clause UG-37)

g. Wind Design
h. Skirt Design
i. Hydrotest Pressure
j. Seismic design
k.Loading data for foundation design
l. Calculation of Deflection for Wind
m. Dynamic analysis of the column

Design of Horizontal Vessels:

Preface: Horizontal Vessels constitute a substantial part of process Equipment. The
main types are
Knock out Drums
Separator
Drums
Catalytic Reactors
Type of Support: Saddle Support
Advantage: Horizontal vessels having a larger base are much more stable against wind
or seismic force as compared to vertical vessels. However the selection type of vessels is
based on process considerations.
Purpose: 1. Design Requirements as per ASME Section VIII Division I
2. Design of horizontal vessels for imposed load like wind, seismic.
3. Design of supports
Input:
1. Process Data Sheet
2. Engineering Design Basis
3.Site Wind Data
4. Site Seismic Data

Design of Horizontal Vessel Supported on Saddle

Support:
Design Consideration:
I.
Design of Shell thickness/head thickness due to internal/external design
pressure and design temperature as per ASME section VIII Division I.
II.
Zick analysis.
III.
Design of support for the wind and seismic loading.
1. Design code: ASME section VIII division I(Edition 2001)
2. Material: SA 283 Gr C(Saddle)- Typical
SA 516 Gr 70(Shell., Bottom & head)- Typical
3. Design Conditions :
a) Design Pressure(kg/cm2): internal- P, External-1.055
b) Design Temperature
c) Wind pressure
d) Horizontal Seismic Coefficient
4. Design Calculations:

a) Thickness of shell for internal Pressure : (Clause UG-27)

Ts = PR/(SE-0.6P) + C.A.
Where S: Allowable Stress Shall Be taken
from ASME Section II Part D
b) Thickness of Head(Clause UG-32)
c) Thickness of shell for external Pressure(Clause UG-28)
d) Size of Stiffener
e) Design of head for external Pressure(Clause-UG-33)
f) Nozzle Design: Neck(Clause UG-45)
RF Pads (Clause UG-37)
g) Weight Calculation
h) Hydro test Pressure
i) Loading data for foundation design
Zick analysis: Zick analysis is used for evaluating the stresses due to saddles induced
on the shell of a horizontal vessel.

Design of Anchor bolts:

Shear load per bolt (Lb) = Greater of Fl or Ft/No. of Bolts
Shear Stress= lb/Area of bolts
Allowable shear stress may be taken as 800 kg/cm2
Selection of materials: there are no. of materials, which are approved and listed by
various codes that can be utilized for design and construction of Columns, Reactors,
Pressure Vessels, Welded steel tanks. These materials are selected based on economy,
service and limitations. The broad classification of these materials can be done in two
ways:
1. Boiler quality material
2. Structural quality material
Carbon Steel: SA 516 Gr 60, SA 516 Gr 70, SA 537 CL 1, SA 204

Storage Tanks:
Preface: Storage tanks constitute a substantial part of process equipment. Most of the
storage tanks are found in offsites & utilities where either feed or the products are stored.
Main types:
a) Cone roof storage tank
b) Floating roof storage tank
c) Cone cum floating storage tank
Classification with respect to storage Pressure:
a) Atmospheric & low pressure storage tanks designed with API 650
b) Pressurized storage tank designed with API 620

Design of API 650 Storage Tanks:

Purpose: Design requirements as per API 650
Design of storage tanks for imposed loads like wind , seismic
Input: Process data sheet

Engineering design basis

Site wind data
Site seismic data
Design considerations:
a) Design of shell thickness, bottom & roof thickness.
b) Design of wind girders
c) Design of anchor bolts
d) Design of tanks for seismic loads
1. Material : SA 283 Gr C
2. Design conditions:

Design pressure : Atmospheric

Design temperature
Inside diameter(in feet)
Height of tank(in feet)
Wind pressure
Horizontal seismic coefficient

Heat exchangers:

Heat exchanger is a equipment for exchange of heat between

two fluids one hot and other cold. It has two distinct compartments namely shell side and
tube or channel side.
Heat exchanger types:
a) Shell and tube
b) Air cooler
c) Plate
d) Brazed Aluminum
e) Electric heater
f) Vaporizer
g) Tubular reactor
Shell and Tube heat exchangers: Heat exchanger codes
ASME section VIII Division I
TEMA
EJMA
IBR
Heat exchangers
TEMA-R: For severe requirement of petroleum & related process
Application
TEMA-B: For chemical process services
TEMA-C: For moderate process requirement

Heat exchangers frequently used type:

Floating head
U tube

Fixed tube sheet

Kettle

Features of a floating Heat Exchanger:

Removable tube bundle

Cleaning possible both side of tubes
Permits thermal expansion
Cost is highest
Maximum joints- Possibility of leakage
Features of a U Tube heat exchangers:
Removable tube bundle
Cleaning possible only on outside of tubes
Cost is lowest
Features of a fixed tube sheet heat exchanger:
Tube bundle cannot be removed.
Cleaning possible only on inside of tubes.
Does not permit thermal expansion.
Cost is lower than floating head.
Heat exchanger Materials:
Carbon steel/ LTCS
LAS
Stainless steel
Non ferrous- Brass, CuNi
Duplex/Super Duplex
Monel
Inconel
Titanium
Heat exchanger tube layout:
Tubes- numbers, Tube Pitch, Passes
Baffle cut
Sealing strips
Sliding strips
Impingement plate
Tie rods, Dummy rods/Tubes
Pulling eye bolts
Heat exchanger tube layout on the basis of Pass:
1 Pass Tube layout
2 Pass tube layout
4 pass tube layout
6 pass tube layout
Heat exchanger Baffles:

 Provided to define fluid path thus helping in heat transfer

Provide support to tube thus help check vibration
Baffle thickness and outer diameter is as per TEMA
Diameter of tube holes in baffle is as per TEMA

Baffle cuts: Horizontal

Vertical
Rotated
Baffle cuts for multi-segmental baffles: Double Segmental
Triple segmental

Heat exchangers cathodic protection (for coolers/condensers):

Normally provided on channel where there is dissimilar metallurgy or
CLAD constant
Painting on tube sheet & channel
Anodes
Weld overlay on gasket faces
Details & Specs furnished by SMMS
Shell and tube heat exchangers:
Interface: HMTD- Review of baffling, first and last baffle space
Piping For nozzle and Davit orientation
Structural For support detail
Instrumentation-for instrument connections, Stab in bundles, column
supported Reboiler, Direct column mounted condensers.
Testing Accessories: Test Ring
Test flange
Dummy shell

Maintenance: Bundle and cover Removal Space

Air cooled

Pulling eyebolts on removable bundles

Lifting Lugs & Trunnions
Monorails
Hydro Extractors
Heat exchangers:

Advantages:

Availability
Location flexibility
No scale built up
No water treatment
Low corrosion problem
No waste water disposal
Low running cost

Disadvantages:

Sizes are higher than S&T heat exchangers

Noise level is high

Highly susceptible to seasonal changes. Effected by rain & sunshine also.
Not suitable for gaseous stream
Extent of cooling is limited

Type of air cooled heat exchanger: Depending on the location of fan they are
classified as

Forced draft type: Designed with tube bundle located in the discharge side of fan
Induced draft type: Designed with tube bundle located in the suction side of fan.
Forced draft type:

Advantage
Less power consumption.
Ease in maintenance.
Fans are unlikely to reach high
temperature.
Erection procedure is simple

Disadvantage
Under-slung walkway is required.
Susceptible to cross wind effect
inducing external recirculation
around the cooler.
Air flow distribution is difficult
The bundle is exposed to solar
radiation.

Plenum chamber: Provided either below or top of tube bundle for air distribution
depending upon induced draft type or forced draft type construction of air cooler.
Types of plenum chambers: 1. Conical type
2. Rectangular type

Design of Air cooled heat exchangers:

Design codes: a) ASME section VIII division 1
b) API-661(international standard)
c) IS 800
d) IS 875
e) IS 1893
Design of air cooled heat exchanger requires two stage design:
1. Thermal design by HMTD.
2. Mechanical design by static equipment department.
Output of thermal design:
Bundle size, number of tubes.
Type of fins
Air flow rate/bundle
Pressure drop
Motor power requirement
Inputs required for mechanical design: 1. Thermal data sheet
2. Engineering design basis.
MR of ACHE contents:1. Job specifications.
2. GA, tube bundle & frame drawing.

3. Typical motor data sheet.

4. Standard and specification for air cooled heat exchanger.
5. Specification for MV motors.
6. VSD datasheet, if any.
7. Structural standard

Piping department
Plant layout: It is planning the location and arrangement of various
facilities/blocks/process units etc within a available plot, as per recommended practice.

Equipment layout: It refers to the layout of various equipment like Columns,

Vessels, Drums, Pumps, Compressors, Furnaces, Reactors, Exchangers including
structure like Pipe rack, Tech. Structure, Platform etc. in a particular process unit or block
of the plant
Basis of Equipment layout:
P & ID
Overall plot plan
OISD guidelines
Wind direction
Equipment data sheet
Indicative equipment layout from process licensor/EIL process.
Process package
Dimensions of package equipments
Criteria for developing a good equipment layout:
Process requirement
Economy of piping materials
Erection and construction requirements
Safety requirements(OISD-118)
Operation and Maintenance requirement
Aesthetic appearance
Grouping of equipments:
Grouping as per process flow
Similar equipment grouping
Functional equipment Grouping
Combination of above
Guidelines for Equipment placing:
Wind direction
Pipe rack
Towers and Vertical vessels
Reboilers
Horizontal vessels

Pump
Exchanger
Air coolers
Furnace
Compressors
Clearance and accessibility

Unit piping:
Basis of unit piping:
Piping and instrument diagram(P & ID)
Equipment layout
Equipment data sheet & setting plan
Line list
Instrument data sheet
Structure & building drawings
Topography of the plant
Piping material specification
Overall plot plan
Guidelines for piping:
Pipe ways/ Rack piping
Column/Vessel piping/Control valves
Exchanger piping
Heater / Furnace piping
Pump piping
Compressor piping
Relief/Blowdown system piping
Steam piping: Piping is done as per IBR guidelines. It consist of steam supply/return
headers, stem tracing system and steam jacketing system.
Underground piping: underground piping system is designed based on the general civil
design basis for U/G services like OWS, CRWS, CBD etc.

Piping material specification (PMS): PMS gives detail about all piping items. It
consist of material details, dimension details, type of ends, schedules/thickness, branch
offs, NDT requirements, applicable code/standards etc. for all piping items.
The PMS consists of various classes, each with the following specified:
Services and corrosion allowance
Pressure and temperature rating
NDT and other special requirements
Connection details for Vents, Drains and instrument connection
Branch connection table

Detail of material, Dimension standard, Ends, Thickness, Ratings etc. for

piping items like pipes, flanges, fittings, valves, gaskets, bolting, traps and
strainers.
PMS is divided into various classes and the class designation comprises of
four alpha-numeric characters e.g. B41A.
The first letter indicates pressure rating. e.g.: A-150 class
The second character indicates the difference in the process services within
the same rating and material. e.g.: 2 for cryogenic
The third character indicates difference in corrosion allowance within the
same process services, rating and material. For e.g.: 1-1.5 mm corrosion
allowance.
The fourth letter indicates type of material e.g. : A- carbon steel
Piping specification:
Type of pipe(seamless, Electrode fusion welding(E.Fs.W)/Electrode
resistance welding(ERW)/welded).
End(plain end, bevel, screwed)
Schedule/thickness in mm
Dimension standard (B 36.10/ B 36.19)
Material specification
Pipe thickness/branch reinforcement calculations:
Code : B31.3
Class pr-temp rating/line conditions
Corrosion allowance
Mill tolerance
Joint efficiency factor depending on material specification and type of pipe.
Flange group specifications:
Type of flange(WN/SW/SO/Lap joint(LJ)/Blind/FIG. 8/SPCR &BLN)
Dimension standard (B16.5/B 16.47A/AWWA-C207)
Rating(150/300/600/900/1500/2500)
Facing and face finish(FF/RF/RTJ &125AARH)
Material specification
Fitting specification:
Type of fitting(90 degree Elbow/ Equal Tee/Eccentric reducer, concentric
reducer)
Dimension standard(B16.9/B16.11/MSS SP43 etc)
Ends(SW/SCRF/SCRM/BW/FLGD)/Thickness(BW)
Facing & face finish(FLGD)
Material specification

Valve specification in PMS:

Type of valve(Gate/Globe/Check/Ball etc.)

Valve standard
Body and trim material

 Rating and End details

Tag number
Function-wise categories of valves:
On off valves: Gate, Ball, Plug, Butterfly, Diaphragm
Flow regulation: Globe, Butterfly
Non return valves: Check
Sample valves: Globe, Needle
Design and testing standards of valves:
+ Type of valves
Gate
<2
2
Globe
<2
2
Check
<2
2
Ball
Plug

Design standards
API 602
API 600
BS 5352
BS 1873
BS5352
BS 1868
BS5351/API 16D
BS 5353

Testing standards
API 598
API 598
BS 6755
BS 6755
BS 6755
BS 6755
BS 6755/API 607
BS 6755

Piping and instrumentation diagrams (P&IDs):

P&ID can be categorized as:
a) Standard symbol and nomenclature
b) General notes and typical symbols
c) Process P&ID(Licensor/EIL)
d) Utility P&IDs
P&ID is made by
a) Process department- for Units
b) POSD- for offsites
For utility services i.e. Steam, Air, Water, DM water, Nitrogen etc.
For loading/unloading systems(Loading/Unloading gantries)
Flare system
Process distribution/Interconnection
c) General civil- PFDS for oily water sewer, fire water etc.
P&ID shows inter connection of piping between different equipments & this is the
basis on which piping is done in the plant.
Each line is designated with a line number i.e.
Service line no.

24-P-114-3301-A1A-IHInsulation Type

Size Unit no. Specialisation

P&ID depicts the requirement of the following piping item.
Valves i.e. Gate, Globe, Ball, Check, Plug, Needle, Diaphragm, Butterfly etc.

 Strainers i.e. Temperature (Cone, Tee), Permanent (Tee, Y), Basket.

Motor operated valves (MOVs).
Steam traps, Air traps etc.
P&ID depicts the requirements of the following instrumentation tagged items:
Control valves, safety valves etc.
Pressure instruments i.e. TI, TE etc.
Flow instruments i.e. FE(orifice), Turbine meter, PD meter, Rotameter, Sonic
meter, Magnetic meter, Pitot tube, Annubar, Venturimeter, Straightening vanes
etc.
Level instruments i.e. LG, LC, LT etc.
Flame arrestor, rupture disc etc.

Piping supports: Piping supports are the mechanical devices which are used to take
the loads and reduce the concentration of stresses of the piping system.
Need of supports:
Carry weight of the piping system.
Limit the stresses in the piping system.
Limit the forces/Moments on terminal connection and Structures.
Limit the displacements.
Prevent/Minimize vibration effects.
Prevent joint leakage.
Different type of supports:
Pipe shoes/Pipe saddles: These are generally attached below pipe to rest pipe on
rack/structural supports for perfect insulation of the pipe resting on the rack/structure.
shoe support is used in smaller size pipe and saddle support is used in larger size pipe.
Low supports: Low support is a type of Y support which consist of a vertical pipe and
always comes below the pipe to support.
Guide: These are generally attached to the structure on either side of the pipe to restrain
pipe laterally on rack/structural supports.
Cross guide: These are generally attached below pipe to restrain pipe axially on
rack/structural supports.
Dummy pipe supports: It consist of a horizontal pipe element attached to pipe with in
turn rest suitably. It act always of bend/elbow.
Clamps: These consist of bent elements bolted to pipe and generally used in conjunction
with structure/other support elements to achieve a particular restraint function.
Bracket: It is a triangular or turn type structure extruded from the column to provide the
support to the pipe.
Hanger: It is used to hold the pipe and restrict deflection in downward direction.
Rigid hangers: These are generally attached above pipe to hang pipe from
Rack/Structural member. These have an advantage that they can be considered practically
frictionless for horizontal movement.
Variable spring supports: In this case spring effort increases with downward movement
of pipe and reduces with upward movement. It carries deflection due to weight not due to
pressure and temperature.

Constant spring supports: In this case spring effort remain almost constant with vertical
movement of pipe. It carries deflection due to temperature and pressure.

Piping Stress Analysis:

Piping systems carry fluids from one point to another in a process plant.
Operating conditions such as Temperature, Pressure etc., and loads such as Dead
weight, Wind etc. effect piping system causing stresses and loads at supports and
equipment terminations.
Design:
Thickness of piping is calculated and selected based on pressure requirements,
Corrosion Allowance and Mill Tolerance.
Piping system are analyzed for - Pressure
Dead weight
Thermal effects
Restraint/Terminal Displacements
Basic requirements: Piping system shall be designed to be suitably supported and have
sufficient flexibility to prevent:
Failure of piping/terminal connections/Support from overstress or fatigue.
Joint leakage.
Distortion in piping or valves or in connected equipment like Pumps, Turbines
etc. resulting from excessive forces and moments in the piping.
Stresses: Stresses develop in piping system due to Sustained load such as Pressure and Dead weight.
Thermal expansion/contraction of piping and movements of piping supports &
connected terminals.
Occasional loads such as wind/seismic.
Thermal displacement:
A piping system will undergo dimensional changes with any change in
temperature.
If it is constrained from free expansion or contraction by restraints, it will be
displaced from its unrestrained position in a different way.
Means of increasing flexibility in piping system:
Bends
Expansion loops
Expansion bellows
Springs
Special considerations:
Consider thermal expansion to decide shoe length.
Use Anchors/Guides/Cross guides to avoid interference with piping structure.
Consider Anchor bays for locating anchors in rack piping.
Provide symmetrical Anchors/Guides/Cross guides at expansion loops
(Preferably).
Provide Anchor at one end and Guide at other end at control valve manifold.

Use adjustable supports near sensitive machine connections.

CEASER II:
1. Need for analysis :
Stress analysis is required for designing new piping.
To estimate the forces exerted by piping on Equipments, Pumps, Turbines.
Behavior (like wind and dynamic condition).
2. Area of applications:
Mechanical design of new piping system.
Hot thermal strains & pressure pulsation.
To estimate the excessive loads and stresses due to water hammer.
To avoid low frequency vibrations.
Relief valve thrust loads.
Earthquake loads (system to resist).
Slug flow.
Eliminating low frequency vibrations formed in existing piping system.
3. Basic theories used in CEASAR II :
Stiffness method associated with associated piping codes/standards and
regulatory guide lines (generally almost all the softwares are based on the
stiffness method where basic unknown are displacements).
Flexibility approach (forces are unknown generally not used because of
complexity).
Empirical formulas based on standards/codes/hand books.
4. Numerical techniques used :
Converting mathematical models to matrix & solving them for approximation
solutions.
Matrix properties.
Solution techniques (inverting matrix, solution through banded matrix).
Time integration scheme in time domain(for dynamics).
5. Estimation of displacements, forces & Stresses on :
Equipment (check for allowable forces/stresses as per WRC297/WRC107).
Pumps/Compressor (checking as per API 610/API 617).
Turbines/heaters (check for NEMA-SM 23).
Stresses on bends, joints of various components, computed as per required
ASME B31.1/31.3/31.4 etc.
Check above forces/stresses as per other country codes (RCC, BS, JIS, DIN
etc.)
6. Load cases :
Primary loads (sustained, pressure & forces).
Secondary loads (thermal, displacements, cold pull).
Occasional loads (wind &dynamic(sustained, thermal, operating & occasional
and their combination) ).
7. How to make the design/ system safe :
Control the pressure/temperature.

Increase the thickness of pipe (review corrosion).

Properly design the support location to reduce the excessive loads on supports.
Placing hangers (constant, variable spring hangers).
Remove unwanted rigid supports and replace unidirectional & bi-directional
supports.
8. Modeling of various components :
Vertical vessels and horizontal vessels.
Expansion joints and skew restraints.
Closely & widely spaced miters.
Dummy leg support.
Concentric & eccentric reducer.
Value as rigid elements.
Flexibility factors (reinforced & unreinforced, tees, bends and mitres)
9. Command on the CEASER II:
Treating software as a bible/block/blackbox.
Using it conceptually
To reduce over design and make safer during system operational life
cycle.
To reduce the cost of project.

Piping design software (PDS):

3D modeling:

What id 3D modeling?
Integrated approach to plant design.
Design of various departments on one platform.
To the scale representation of plant in 3D with high resolution graphic
visualization.
Intelligent model components, not plain graphics.

Multiple types of output from same data.

Ability to detect interference.
Easy Graphical user interface (GUI) for fast learning.
Why 3D modeling?
Ease of visualization.
Skills for reading and interpreting the drawing not required.
Consistency in input and output.
Specification driven.
Reduces manual error.
P&ID consistency check.
To the scale model.
How 3D modeling works?

Graphics engine

 Parametric shapes.
Primitives.
Database
Specifications and catalogues.
Information regarding graphic elements (Equipment, Nozzles, Pipes, Pipe
component).
Link between graphics and database.
Query and report writing facility on database.
Drawing generation facility (isometrics, GADS, Structural drawings).

Graphics

Database

3D System

Administration

Structure of PDS: Microstation + Database

(Linkage through RIS)

PDS 3D Modules:
Piping: Routes pipelines and places components supplied by an extensive online
database.
Equipment modeling: Provides tool to build equipments by assembling basic 3D
elements and creating composite models automatically from an extensive library.
Structural modeling: Enables designer to model Steel framing, Floors, and walls;
produce drawings; and input model geometry into a structural analysis package, such as
GT STRUDL, STAAD-III and Larsa.
HVAC modeling: Provide interactive 3D tool to layout and model ducts and other HVAC
components.
Electrical raceway: Provides interactive 3D tools to design, layout, and model electrical
cable trays, conduits, wire ways, underground duct banks and cable trenches.
Interference checking: Identifies hard(Physical) clashes between design components
and pinpoints soft clashes, such as insufficient safety clearance or maintenance access.
Pipe support: Create pipe supports in the model, and revise existing pipe support, model
graphics and database information.

Interfaces:

Pipe stress analysis: Extract information from piping models for input to third- party
pipe stress analysis products.
Isometric drawing manager: Extract Isometric drawings from piping models and to
review or plot the created isometric drawings, PDS- isogen product is used to
generate isometric from interface files.
Design review integrator: extract information to form label files for use in design
review and to review data from a design review session.

Work flow in PDS:

Creation of project.
Finalization of attributes, color coding etc.
Setting of seed model to be updated.
Area / Zone division to be finalized.
Criteria for model division.
Piping specs creation, through interface with IPMCS and loading.
Short description, file creation and loading.
Branch tables creation and loading.
Temperature Pressure table loading.
Physical support libraries loading.
Table checker run for all the specs individually.
Creation and models in all disciplines.
Starting of modeling.
Updation of various components in spec and their corresponding table in database,
as per requirement.
Interference check.
Border file setting for isometrics.
Continuation zone settings for isometrics.

Plant design management system (PDMS): 3D

Walk through
Visualization

Text report

PDMS Module:

Design
Isodraft
Draft
Paragon
Specon
Propcon
ADMIN

PDMS Database

Engineering
Drawings

Lexicon

Rotating equipment department

Rotating equipment is an equipment that moves fluids (liquid or gases) through an
array of drivers (Turbines, Motors or Engines) from one place to another inside a process
plant.
The driven equipment (Compressors, Pumps) is supported by transmission devices
(Gears, Clutches, Coupling) and auxiliary equipment (lube and seal systems, cooling
systems, buffer gas system).

Functions of the department: The function of the department is to carryout

Engineering for procurement for all rotating equipment which include following major
equipments:
Compressors(Centrifugal, Reciprocating & Rotary), Gas/Steam turbines, Diesel/Gas
Engines, Expander-Compressors, Fans/Blowers, Process Pumps Of all kinds.

Key deliverables:
The department generates the following output:
Estimate of efforts.
Engineering design basis.
Material requisitions.
Departmental input to bid packages.
Technical memorandums.

Technical bid analysis.

Purchase requisitions.
Departmental input to contract documents.
Vendor data/drawings (duly reviewed/approved).

Centrifugal compressors: A centrifugal compressor is a dynamic machine used to

generating low to medium pressure for medium to large flow. The high speed rotating
impeller imparts kinetic energy to the gas and the kinetic energy is converted to the
pressure in the stationary diffuser section.

Family of compressors:

Principal of operation:
Standard followed for centrifugal compressor packages: API 610

Basic parameter of centrifugal compressors:

Range of Flow: 2000-150000 m3/hr
Head 3000 m/Stage
Surge: Surge is self oscillations of Pressure and Flow, often including a flow reversal.
Surge consequences:
Unstable flow and pressure.
Damage to Seals, Bearings, Impellers, Shaft.
Changed clearance.
Lower compressor output.
Less energy efficiency.
Shortened compressor life.

Compressor performance control:

Drivers for centrifugal compressors:
Electric motor.
Steam turbine.
Gas turbine.

Reciprocating compressors:
Type of reciprocating compressor:
Vertical and horizontal.
Lubricated and non lubricated.
Labyrinth diaphragm.
Single acting, Double acting.
Applicable Indian standards:
API 618 for process gas compressor (slow speed and for refineries and
petrochemicals).
API 680 for plant and instrument air (packaged type).
API 11P for high speed reciprocating compressors (for gas gathering,
boosting, fueling and injecting).
Parts of reciprocating compressor system:
Driver.
Pulsation dampeners at suction and discharge.
Distance piece purging system.
Lubricating system for frame.
Cylinder lubricating system.
Drive system (Flywheel, Gear, Coupling, V-belt etc).
Base plate/sole plate.
Control system.

 Safety and protection monitoring system (instrumentation).

Materials of construction:
Part
Cylinder
Piston
Piston ring and packings
Pulsation dampers
Cooler tubes
valves

MOC
CI, CS, Forged Steel
CI, CS
Teflon
Steel
Admilarity brass
SS

Inspection and testing:

Material testing.
Hydrostatic testing.
Non destructive testing- Radiography, Ultrasonic, Dye penetration test.
Helium leak test.
Pneumatic pressure test.
Mechanical run test (4 hr) at full speed.
Dismantling inspection.
Complete unit testing.

Typical services:
Plant and instrument air compressors.
Recycle gas compressors in PP plants.
Hydrogen compressors in LLDPE plant (diaphragm).
Make-up gas compressors in hydrocracking and hydrotreating.

Positive displacement pump: Increase the pressure of the incompressible fluid by

reducing the volume till discharge valve opens.
Advantage of PD pumps over centrifugal pumps:
Flow is independent of pressure. We can change the flow without upsetting
the pumps efficiency.
The pump can handle high viscosity fluid efficiently.
The pump is self priming.
We can get the desirable high head flow combination that is need in many
high pressure applications.
They give us a non-shearing act that will not degrade sensitive petrochemicals
and polymers.
Type of positive displacement Pumps:

Displacement pumps are divided into reciprocating and Rotary.

Type depending on the nature of movement of the pressure producing
members.
A.
Reciprocating: Piston
Plunger
Diaphragm
B.
Rotary: Single screw (Progressive cavity)
Twin Screw
Gear
Vane
Lobe (Two, Three lobes)

Rotary type pumps:

Screw pumps: Screw pumps are operating on the principal of progressively moving a
fluid between sets of counter rotating screws. Screw pumps have been traditionally
chosen to pump viscous fluid and impart minimum shear force on the fluid with low
discharge pressure.
Main features of rotary positive displacement pump:
Positive displacement.
Slow and medium speed.
Self priming.
Fairly constant discharge.
Less vibration.

Gear pumps: gear pump traps the fluid between the gear teeth on the suction side and
carry it around to the discharge side from where it forced out into the discharge pipe.
Application of gear pump:
Industrial and mobile application.
Fuel and lubrication.
Metering.
Mixing and blending (double pump).
Hydraulic applications.
Precise metering application.
Low- volume transfers.
Light or medium duty.

Steam turbine:
Working principles:

Rankine cycle is a heat engine with vapor power cycle. The common working fluid is
water. The cycle consists of four processes:

1 to 2: Isentropic expansion (Steam turbine)

2 to 3: Isobaric heat rejection (Condenser)

3 to 4: Isentropic compression (Pump)

4 to 1: Isobaric heat supply (Boiler)

Work output of the cycle (Steam turbine), W1 and work input to the cycle (Pump), W2
are:
W1 = m (h1-h2)
W2 = m (h4-h3)

where m is the mass flow of the cycle. Heat supplied to the cycle (boiler), Q1 and heat
rejected from the cycle (condenser), Q2 are:
Q1 = m (h1-h4)
Q2 = m (h2-h3)
The net work output of the cycle is:
W = W1 - W2
The thermal efficiency of a Rankine cycle is:
The efficiency of the Rankine cycle is not as high as Carnot cycle but the cycle has less
practical difficulties and more economic.
Heat rate of turbine = (Net heat input to turbine)/(Electrical output from generator).
Turbine components:

Trip and throttle valve/Stop valve.

Inlet control valves
Single inlet control valve.
Multi valve.
Nozzles/Blades.
Exhaust casing.

Gas turbine: Gas turbines produce high quality heat that can be used for industrial
district heating steam requirements.Alternatively,the high temperature heat can be
recuperated to improve the efficiency of power generation or used to generate steam and
drive a steam turbine in a combined-cycle plant.
Basics of gas turbine: Gas turbine works on brayton cycle.Simple cycle gas turbines
convert a portion of input energy from the fuel to electricity and use the remaining energy
to produce heat,which is normally rejected to the atmosphere.

TYPES OF GAS TURBINE:

1. Aeroderivative gas turbine.
2. Industrial gas turbine.
ISO rating of gas turbines: The continuous power devloped by the gas turbine when it
is operated at ISO rated firing temperature and speed under the following standard
operating conditions:

Inlet temperature of 15 degree Celsius.

Inlet total pressure 1.0133 bar.
Exhaust (Static) pressure 1.0133 bar.
Inlet relative humidity 60 %.
This power and speed is measured at output shaft of the gas turbine.
Site rating of gas turbine:
KW = ISO X ALT Factor X Inlet factor X Exhaust factor X Inlet Temperature
factor X humidity Factor
Basic components:

Starting device

Accessories gear box

Compressor

Turbine

Load gear box

Couplings
Starting system:Different types of starting equipments are available:
Electric motor
Diesel motor

Hydraulic motor

Packaged equipment department

PED packages/Items:

Items handled
Packages
Major refinery Packages/Equipments:

Hydraulic decoking system

Heading/ Unheading system
Hydrocyclone
Tertiary separator system
FCCU slide valve
FCCU Cyclones
Flue gas cooler
Catalyst loading system
Feed filter
Amine filtration package
Refrigeration package
Filter, Seperator, Coalescer

Major Petrochemical Equipments/Packages:

Extruder and pelletizing system

Bagging and pelletizing lines
Pneumatic conveying system

Equipments

Additive unloading system

Additive dosing system
Gag filters
Rotary valves
Pallet vibrating screen
Flaking machine
Metering system
Spin dryer
Filter, Seperator, Coalescer

Major Offshore Packages:

Chlorinator Package
Water maker
Produced water conditioner package
Swage treatment plant
Deck Crane
Survival craft
Filter, Seperator, Coalescer

Major Material handling Equipments:

Belt conveyor
Air slides
Bridge Crane
E.O.T CRANE
HOT CRANE
Electric Hoist
Chain pully block
Lift
Mobile cranes
Fork lift truck

Major Offsites and Utilities packages:

PSA Nitrogen plant

Cryogenic Nitrogen plant
Instrument Air Dryer
Flare stack components
Loading arms
Weigh bridge
HVAC

Pressurization and ventilation

Start of Project:

Client
Place the order on EIL

EIL Marketing
Allocate the job no. of Project
Division

EIL Project
Allocate the Job to Concern Engineering
departments

Brief overview of Engineering cycle:

PDS,

PFD and P& ID issued

for comments to
Engineering process

Engineering gives their

comments on process
documents

Revised process
documents issued for
Engineering

Preparation of

RFQ

floated

MR/T
ender

by

C&P

HVAC and Refrigeration System:

HVAC (Heating, Ventilation & Air Conditioning): The Process of controlling the
temperature, humidity, cleanliness and distribution of the air based on some set
parameters.
HVAC parameters:

Packaged air conditioners

Vapor absorption machines
Air handling units
Cooling tower

Packaged air-conditioners:

Range 5.5 TR to 22 TR
Air cooled and water cooled options
Scroll compressor
Microprocessor based control panel
Multi-compressor in 11 TR, 15 TR,17 TR, & 22 TR models.

Water chilling package- Reciprocating series

Air cooled: Open-type compressor
Range: 30 TR 105 TR
Water cooled: open type compressor
Range: 30 TR-120 TR
Vapor absorption machines: range: 80 TR-1250 TR
Heat source: Saturated stem at 8 kg/cm2 g
Air handling units:

Single skin and double skin construction.

Horizontal, Vertical and Ceiling mounted configuration.
Reliable and energy efficient units.
Wide choice of air quantities and static pressure.

Pipeline design and Engineering

Modes of Transportation:

Road tankers.
Railway tankers.
Sea tankers.
Pipelines.

Benefits of transportation by pipelines:

Safer mode of transportation.

Environment friendly.
Least energy required.
Lowest maintenance cost.
Minimal impact on land use pattern.

Negligible loss of product in transit.

High reliability.
Multi-product transportation.

Stages of pipeline project:

Conceptualization:

Establish Requirement.

Evaluate Alternatives.

Finalize the Concept.

Feasibility Study:

Pipeline Route Study and Selection.

Hydraulic Studies and Optimization.

Establish Project Cost.

Project Implementation Scheme.

Environmental Impact Assessment & Risk Analysis.

Basic Engineering:
Process design and sizing.
Optimization studies.
Route survey and investigations.
Detailed Engineering:
Engineering Design Basis.
Route engineering and engineering analysis.
Specification and job standards.
Engineering for procurement.
Installation engineering.

Major pipeline components:

Line pipe and coating.

Scraper trap and coating.
Low radius bends.
Insulating joints.

Flow tees.
Sectionalizing valves.
Pumps/Compressors.
Filters and Meters.

Line pipe selection:

Thickness and grade selection.

Handling and transportation (d/t ratio).
Manufacturing considerations.
Installation requirements.
Testing conditions.

Type of line pipes:

Seamless (SMLS).
Electric welded (EW).
Longitudinal seam submerged- Arc welded(LSAW).
Helical seam submerged-Arc welded(HSAW).

Major engineering deliverables:

Design reports:
Design basis.
Route selection report.
Wall thickness selection.
Seismic analysis.
Crossing design report.
Support index.
Drawings:
Route maps.
Pipeline schematic.
Alignment sheets.
SV station layouts.
Crossing drawings.
Equipment layouts & Piping GADs.
Tenders/ Procurement:
Survey tender.
Line pipe & pipeline components.
Coating tender.
Pipeline installation tender.

Material specifications.

Design interface:

Process.
POSD.
PFD/RED/SED.
SMMS.
ETDD.
Civil & Structures.
Electrical/ Instrumentation.
Environmental.
Inspection.
Construction.
Process, Operations & Safety.
Mechanical.
Civil & Structures.
Electrical/ Instrumentation/ Telecom/ SCADA.
Environmental.
Inspection.
Construction.

Welding/NDT Methods

Edge Preparation.
Internal / External Line-up Clamps.
Manual / Automatic Welding.
NDT (X-Ray / UT / MPI etc.).

Field Joint Coating

Heat Shrink tapes.

Cold applied tapes.

Heat and Mass transfer division

Thermal design of heat exchangers:

General:
Shell and tube heat exchanger is the most common of various types of unfired
heat transfer equipments used in industry.
Word exchangers are used to denote the equipment where heat transfer takes
place between two process sreams.
Standards developed by Tubular Exchanger Manufacturers Association,
TEMA are universly used for design of shell and tube heat exchangers.
Most popular and reliable software used for the design of the shell and tube heat
exchanger are of:
HTRI- Heat transfer research institute, USA (Used by us).
HTFS-Heat Transfer fluid flow services, UK.
HEI- Heat exchanger institute, USA.
Classification of heat exchangers:
HEAT
EXCHANGERS

TUBULAR

SHELL & TUBE

AIR COOLERS

NON TUBULAR

DOUBLE PIPE

PLATE TYPE

FIXED TUBE
SHEET

PLATE FRAME

U-TUBE

PLATE FIN

FLOATING
HEAD

Selection of heat exchanger types:

Based on construction, shell and tube exchangers can be : Fixed Tube sheet
U-Tube
Floating Head

HYBRID

PACKINOX

S.
No

Cleaning Possible

Fixed
Tube-sheet

U-Tube

Floating Head

1.

Inside Tube

Possible

Not Possible in
U-Bend

Possible

2.

Outside Tube

Not Possible

Possible

Possible

3.

Costing

Moderate (depending
on use of bellows)

Least Expensive

Most Expensive

If the temperature difference between mean shell and the mean

tube-wall is large (say>50oC), fixed tube exchanger may require a bellow
( expansion Joint). However, such an exchanger may still be cheaper than a
floating head exchanger.
If substantial condensation/vaporization occurs on clean tube side fluid, U-tube
construction is preferred. Use of U-Tube exchanger eliminates the possibility of
misdistribution of fluid from exit of one pass to the entry of the next pass.
When hot oil is on the tube side, many licensors prefer to employ U-tube
exchangers as the potential leakage points are minimum in a U-tube exchanger as
a result of only one tube-sheet.
As mechanical cleaning like rodding and hydro-blasting are more prevalent than
chemical cleaning the following is the basic selection criterion:-

S. No

Service

Type

1.

Shell Side Fluid Clean

Tube Side Fluid Dirty

Fixed tube-sheet

2.

Shell Side Fluid Dirty

Tube Side Fluid Clean

U-tube Exchanger

3.

Shell Side Fluid Dirty

Tube Side Fluid Dirty

Floating Head

4.

Shell Side Fluid Clean

Tube Side Fluid Clean

Fixed Tube-sheet or U-Tube

Where:- Clean service Fouling Resistance <= 0.0002 (metric)

Dirty service Fouling Resistance > 0.0002 (metric)
Allocation of fluid sides:
S. No.

Property

Side

1.

Higher viscosity

Shell side

2.

Dirtier fluids

Tube side

3.

Higher pressure fluids

Tube side

4.

Higher temperature fluids

Tube side

5.

Corrosive fluids

Tube side

6.

Lower flow rate fluid

Shell side

Selection of shell types: Shell and tube heat exchanger shell types designated in TEMA
are as follows:

Shell Style
E

Single Pass

Two Pass

Split Flow

Double Split Flow

Divided Flow

Kettle

Cross - Flow

Baffle design:
Types of baffles:
Longitudinal baffles: Used in F, G, and H type shells.
Cross baffles: Single segmental, Double segmental, rod baffle, helical baffle etc.
Baffling to reduce pressure drop: In order to limit the shell side pressure drop within
the permissible value, the following combination of shell and baffle style should be
considered, in order indicated:
Order
1.
2.
3.
4.
5.
6.

Combination
E shell and single segmental baffles.
E shell and double segmental baffles.
J shell and single segmental baffles.
J shell and double segmental baffles.
E shell and no-tubes in window (NTIW) baffles.
X shell

Baffles:
Baffles in condensers:
Vertical cut baffles are used in condensers to permit the separation of the
condensate from un-condensate vapor.
Horizontal cut baffles may be used in partial condensers where the two- phase
stream leaves together.

Baffles in vaporizers:
There is always a problem of phase separations and flow oscillations. Hence it is
advantageous to vaporize on tube side.
Never use vertical cut baffles for vaporization on shell side.

Fouling: Fouling is a general term that include any kind of deposit of extraneous
material that appears upon the heat transfer surface during the life time of heat exchanger.
It results in undesirable decline in heat transfer and/or an increase in pressure drop. It is
inescapable consequences of the process of indirect heat transfer across a building wall.

Air coolers: Air cooler heat exchangers (ACHEs) are heat transfer equipment usually
employing finned tubes where ambient air is forced across the outside of the tubes in
order to cool and/or condense the fluid inside the tubes.
The basic components are one or more tube bundles served by axial flow fans, fan
drivers, speed reducers and an enclosing and supporting structures.
Types of Air Coolers:
Forced draft: Air cooled exchangers are classified as forced draft which uses axial
flow fans to force the air across the finned tube bundle. The fans are positioned
below the bundle thus not exposing the mechanical section to hot exhaust air flow.
Forced draft is generally preferred as maintenance is much simpler. Here the tube
bundle is located on the discharge side of the fan.
Induced draft: In induced draft, the tube bundle is located on the suction side of the
fan, since ID fans throw the air to higher altitude than the FD fans. Induced draft is
preferred when difference between the process fluid outlet temperature and air inlet
temperature is low, say 7 degree Celsius.

Mass transfer
Equipment handled:

Mass transfer equipment.

Seperators (Three phase/Two phase).
Gas dehydration units.
Dearators.
Desalters.
De-ox systems.
Flue gas dehydration units

Mass transfer contacting devices:

TRAY
Packing

Major segments of Tray:

Area.
Active area- where Valves/Holes/Caps are provided.
Downcomer area- where fluid flows to the tray below.
Calming zone.
Weir.
Downcomer.
Under downcomer flow clearancev(UDFC).

Packings: 1. Random
2.Structured

Application of packings:

Mass transfer.
Heat transfer.
Potential to handle high throughput at high efficiency.
Extensive use in revamp application.
Offer low p/Unit theoretical stage.

Purpose of distributors:
Distributor:
Required when external liquid flow is introduced.
Provides uniform flow over the bed.
Liquid redistributor:
Remix liquid phase before the next bed.
Intercept all liquid flowing down the column.

Liquid
redistributor
Spray type
distributor

Gravity distributor

Recommendation ISL/ PBO

Evaluation of Price Bids
Recommendation for Award
Formulation of Draft LOI/PO/PR/ Contract
Award of Contracts / Purchase Orders By Respective Clients/EIL
To Cost Engg, To Inspection, To Construction

Purchase
Methods of purchase:
International competitive bidding (ICB)
Domestic competitive bidding
Limited enquiry
Crash procurement
Basic Requirements for issuing RFQs:

Projects Input Sheet along with Material requisition (MR) which contains
delivery period, cost estimate, type of MR (India / Foreign / Global) and other
special requirements.

Item code on MR as per PDD item code list

Approved vendor list in line with procedure.

Contracts:
Type of Contracts
Item Rate

EPCC (Engineering, Procurement, Construction & Commissioning)

ITEM RATE CONTRACT

Conventional Mode of Execution
Schedule of Rates with detailed description of item, Qty. and Units (In some cases rates
are specified & %age increase / decrease is asked)

Contract value is estimated as variation in Qty. thereby in Contract value can

take place during execution.

This is applied where design & detailed engg. is done by EIL.

Generally bids are invited on Domestic tender basis.

EPCC:
Engineering, Procurement, Construction, Commissioning.

Utility Packages:- such as Cooling Tower, DM Plant, Raw Water Treatment Plant,
Waste Water Treatment Plant, Captive Power plant, etc.

Process Packages: - Where whole Unit / Offsite are executed on EPCC mode like
Panipat Naphtha Cracker Project, MRPL Phase-III.

Complete Scope of work defined.

One Lump sum Price with Break-up of Prices for Engineering, Procurement and
Construction

Detailed Billing schedule after award

Generally Process Package on ICB/Utility Package on Domestic.

Contents of bidding Document:

Commercial section:
Letter Inviting Tender (LIT) /Notice Inviting Tender(NIT).

Instructions to Bidders (ITB)

Proposal Forms

General Conditions of Contract (GCC)

Special Conditions of Contract (SCC) and its annexures

Schedule of Rates (SOR)-short description in excel file generated from ICMS

package (in case of item rate tenders)

Schedule of Price (SOP)-in case of package tenders-SOP prepared by C&P and

vetted by engg. dept.

Technical section:
Job Specifications
Schedule of Rates-Detailed description (in case of item rate tenders)
Technical Specifications
Standards Specifications applicable for the work
Inspection Test Plan applicable for the work
Datasheets/Drawings

Integrity Pact:
Bidding document shall also include Integrity Pact as per procedure. Integrity
pact porforma shall be provided by Owner.
2. INSPECTION AND EXPEDITING:
INSPECTION:
EIL inspection department provides specialized inspection and expediting
services for EILs own projects in the field of
Petroleum Refining
Petrochemicals
Pipelines
Onshore Oil & Gas
Offshore Oil & Gas
Mining & Metallurgy
Terminals & Storages
Infrastructure

Undertakes independent certification and third party inspection assignments also.

10 Regional procurement offices (RPOs) across India and three foreign inspection
offices at London, Milan and Shanghai.

Functional set up:

Commercial
Directorate
Inspection

PDD

Shipping

Inspection /
Expediting

Service portfolio:
Source Inspection.
Site fabrication Inspection.

Project
Monitoring &
Expediting

Surveillance Audit.
Expediting and Monitoring.
Vendor evaluation - Capability and capacity assessment.

Inspection is needed:
To ensure quality of material / equipment before dispatch to site.

To ensure compliance with agreed specifications and to take care of special

requirements as per Purchase Requisition over and above the National/inter
national standards.

To prevent any rejections at site which may lead to delays in Project

completion and to prevent problems during plant operation.

To provide interface between engineering/projects and Suppliers and provide

feed back which helps in revision of our specifications from time to time.

To provide 3.1/3.2 certification as per EN 10204 standard which is insisted by

many clients.

It generates additional confidence in client and helps in smooth

commissioning at site.

Stage wise inspection for critical equipment, Review of welding procedures,

Quality plans, Checking of raw material helps in building the quality from
first stage itself.

Last but not the least, inspection helps to put a check to avoid deviations
which as a human being sometimes we tend to take lightly.

Inspection engineer from concerned RPO is responsible for all inspection

activities at Suppliers works

Deployment of Inspection engineer is based on Qualification, experience and

skill through competency analysis.

Inspection engineer is provided with relevant Job specification, drawings and

other relevant documents.

Inspection Methodology:
On satisfactory inspection/document review, inspection engineer issues Inspection
certificate.

Items inspected are stamped by Inspection Engineer and Inspection Certificate

issued.

Quality of Inspection Services is Continually Monitored and improved.

Continuous on job training of inspection engineers.

Head Inspection
at H.O.

Head RPO

Inspection
engineer

Monitors RPOs,
Sets Quality
Objectives for
the Department,
implements the
same through
RPOs
Deploys
inspector, selects
inspector by
competency
analysis,
Monitors quality
of Inspection
Services of RPO
Inspects , stamps
items with Unique
identification
stamp

Inspection Service:
Inspection at Supplier works, Yards, Offshore Platforms and onshore Project:
Source Inspections are tailored to meet a specific need and may include
Review and Approval of QAP / ITP

Review and Approval of WPS/PQR/WPQ/Welding data sheet /PWHT

procedure/NDT plan and other Inspection procedures.

Review of Material Test Certificates

Witnessing Mechanical tests, FAT, hydrostatic & performance tests.

Review of suppliers inspection documents

Issue of Final Inspection Certificate

[PQR: Procedure Qualification Record; PWHT: Post Weld Heat Treatment

WPS: Welding Procedure Specification; WPQ: Welders Performance Qualification]

Range of activities performed / services provided include:

Category A : Complete Inspection
Progressive inspection of equipment or materials as production /
manufacturing / fabrication proceeds. The inspection activities typically
include Pre Inspection Meetings, stage inspection & final inspection.
Category B : Final Inspection
Minimum inspection of materials or equipments to verify critical
dimensions, final inspection, material test certificates
Category C :
Review of test certificates, suppliers internal reports
Expediting is needed:
To ensure completion of orders within contractual delivery so as to meet
project schedule.
To minimize cost overruns of projects and prevent revenue loss to clients
due to delays.
To avoid heavy penalties on EIL for LSTK jobs and to earn bonus when
targets are achieved.
Most of EIL projects are of National Importance and directly monitored by
PMO office. Clients have to honor MoU signed with ministry for
completing the projects.
Typical progress statistic:
SL No

Discipline

% age Weightage

Engineering

3-5 %

Ordering

12-15%

Tendering

8-10%

Manufacturing /Delivery

35-45%

Construction

20-25%

Commissioning

2-3%

Field expediting methodology:

Client

Monitor /
Central
Coordinator
at HO

Expediting
visits by
RPO
Engineer

MSR /
Constrai
nt
Reports

Expediti
ng
Reports

3.PLANNING, SCHEDULING & MONITORING :

PLANNING:
Planning is the devising of a workable scheme of operations designed to
achieve an established objective when put into action.

Following steps constitute planning

Determination of job steps or activities that must be performed in
order to construct the projects.
Ascertainment of the sequential relationship among these
activities.
Presentation of the above information in network or in any other
form.
Establishment of strategy or a set of priorities for accomplishment
of the objectives.

SCHEDULING:

Scheduling is the preparation of a time table for implementation of an

agreed plan.

Following steps constitute scheduling

Rational grouping of activities.

 Determining weightage of activities.

Preliminary fixation of work on a time scale.
Computation of manpower requirement and re-fixation of work on
time scale either for manpower restrictions or for balance.
Establishment of scheduled progress curve.
MONITORING
Monitoring is close watching of the progress of the job and identifying and
highlighting deviations from schedules.

Following steps constitute monitoring

Reminding the activities to be completed during a month.
Obtaining feedback regarding accomplishment, slippage and hold
ups.
Computation of progress and comparison with schedule.
Analysis and appraisal of performance.
Identifying and recommending areas for corrective actions.

MONITORING CYCLE:
As the project is executed as per set targets, periodically, say, every month the
actual progress is compared with the schedule and in case of slippages/ holdups,
preventive/ corrective actions are highlighted for resetting the targets till the
project is completed.

In the EIL System of Planning, Scheduling & Monitoring, this is achieved by

what can be called Top to Bottom scheduling and Bottom to Top actual
progress measurement/ monitoring.

ACTIVITY AND MILESTONE:

Activity

An element of work performed during the course of a project, that has an

expected duration.

Milestone

A significant event in the project, usually the start or completion of a

major activity or phase of a project. A milestone has zero duration.

BAR CHART:
Bar Chart

A graphical display of activities showing activity start, finish and duration.

It does not show the logical relationships between the various activities.

Bar Chart with Milestones

A bar chart showing milestones.

Linked Bar Chart

A bar chart showing logical relationships of project activities. However, it

does not indicate critical path(s).

A graphical display of activities that shows critical path(s).

Network analysis is a method used for calculating a projects critical path,

activity dates and float.

Network

Float
. The difference in time between an activitys earliest and latest dates
Critical Path
Sequence of activities through a network from start to finish, the sum of
whose durations determines the overall project duration. It is the longest
continuous path of activities through the network.

There may be more than one such path.

Critical activity
Activity lying on critical path.

Activity with zero or negative total float.

Steps for making a schedule:

Breaking the project into identifiable items/ activities and finalization of Work
Breakdown Structure (WBS).

Defining the interrelation among activities.

Allocating time for each activity.

Defining priorities for activities.

Drawing a Bar chart/ Network.

Allocation of resources and leveling.

Finalizing and distributing weightages for activities.

Development of progress curve.

Software Used:

PROJECT MATERIAL MANAGEMENT SYSTEM (PMMS)

Used for project Material Control System at HO i.e. for keeping
track from project material identification stage to release of
materials from vendor shop.

COMPUTERISED ONLINE SYSTEM FOR MATERIAL ALLOCATION

AT SITE (COSMAS)
Used at construction sites for piping material allocation to the
contractors.

CONSTRUCTION PLANNING SYSTEM (CPS)

Used for preparation of contractor schedules, weekly progress
reports, monthly progress reports and monthly programmes for
contractors.

4.PROJECT:
Zero Date:
This is the date from which EIL is committed to complete the project. This can be either
the date of clearance given from the government, signing of contract between EIL&
client, signing of contract between client & process licensor or receipt of process package
from licensor or the date specified by the client.
Start Date:
This is the date when the client asks EIL to start the job.
Pre Commissioning:

This is the preparation of the plant for commissioning after mechanical completion. This
includes mainly flushing & cleaning of pipes, loading of catalysts, loops checking & trial
run of auxiliary systems.
Commissioning/Start Up:
The commissioning activity will start with the introduction of raw materials and will
terminate with satisfactory completion of guarantee runs by licensor
Project execution methodology:

CONVENTIONAL METHOD

LSTK METHOD

In LSTK / EPCC a contractor has to perform a number of activities

Detail Design and engineering of the plant

OBE:

Procurement, Supply, Receipt and storage at the project site of the

required equipment and material

Construction of the plant, erection and installation

Pre-commissioning trial and test runs

Final commissioning

Handing over of the plant to owner / customer

Defect liability period

Stage 1
effective date upto conversion date
stage 2
conversion date upto completion of the work
Project is awarded to the contractor based on its lump sum price of
services/ various mark up fees, contractor and company collaborate to
develop the open book estimate
Mrs/ sub-contracts are floated & awarded in the first 10-12 months of the
project (stage 1- OBE phase). The LSTK price of the project is based upon
the value of finally awarded pos/ sub-contracts. The LSTK price is fixed
at the end of the OBE phase (conversion date)
For the items for which engineering could not be completed during the
stage 1 (OBE phase) or no formal enquiries issued for any material, eqpt
or works the price is based on in-house data/ budgetary quotes to finalise
the lst price, contingencies on these items are fixed in consultation with
the company

Commitment on project schedule & time savings

Bidding time is drastically cut contractor estimates its services for the project
like any consultancy job

Time required by client to select an PMC & EPC contractor is fruitfully utilised in
engineering & project execution

Cost efficient & accurate

Mode of execution is fair to both client & contractor

Risk & reward on account of market volatility on price are transparent and both
client & contractor derive the benefit of the same

This mode also permits mid course corrections upto first 6 to 8 months of
engineering which otherwise is difficult due to contractual commitments with
EPC contractor

Confidence level of vendors / sub-contractors is high, client gets best deals in

LSTK project on OBE basis

No hidden costs in the overall project

Contractor is assured of reasonable returns

Client has the benefits of both the modes of project execution (conventional as
well as LSTK)

Clear & transparent

Project material management:

Project material Management system keeps track of all project materials right
from identification / Material Take-off (MTO stage, till consumption (Actual put
to use) at site

It ensures that required project material is identified, requisitioned, ordered,

manufactures / Inspected / delivered, allocated / issued to contractors and
reconciled well in time, inline with the overall Project Requirement.

Project Materials can be broadly categorized as:

Tagged Items Equipment (16-CC-101, 18-VV-101A/B)

- Other Tagged (Control & Safety valves

(16-PSV-1421, 18-CV-1118).
Bulk materials Piping, Electrical / Instt. cables,

Project Materials further be categorized as:

Free Issue Materials (FIM)

Material Procurement by contractors scope

Project Material Management Stages:

Identification of Requirement / MTO-Tagged: Licensor / Process / POSD

Bulk: Engineering Disciplines

Requisition : Generation of MRs by respective Engineering disciplines.

Forwarding to C&P through Project.

Purchase:

Manufacturing/ Delivery:

Receive approved vendors list from PDD (Procurement

Development Department)
Issue RFQ (Request for Quotation) / NIT
Receive Bids and distribute technical portion to native Engineering
discipline
Coordinate for TQ/CQ, Vendor replies and Technical Bid Analysis
(TBA).
Price Bid Opening, and preparation of Commercial Bid analysis
(CBA) and necessary approvals.
Issue FOA, PO, PR etc.

Stage wise Inspection to ensure quality as per PR

Preparation / Submission / Review of vendor documents
Sub-ordering of materials.
Receipt of Sub-ordered items
Manufacturing / Assembly
Final Inspection
Packing / Dispatch

Receipt at site:

Receipt
Report)

of materials and preparation of DRR (Daily Receipt

Physical verification of materials w.r.t PR and preparation of MRR

(Material Receipt Report).

Preparation of OSRD (Over, Short, Reject & Damage) report.

Raising Insurance claims of damages in transit

Allocation to agencies:

Bulk: Planning to Allocate material to different contractors

depending on availability of drawings, access, Contractors
capabilities, Priority of the Job .

Tagged: Directly allocated to the specific contractor / agency

Issuance of Indents to contractors

Issuance to contractors:

Based on planning allocation, indents are issued authorization by

Area-Coordinators.
Materials are issued to the contractors by warehouse in the form of
MIVs (Material Issue Vouchers), signed by contractors as a token
of acceptance.

Reconciliation of materials:

Unused material is returned by contractors to warehouse through

MRVs (Material Return Vouchers).

Reconciliation statements are made with details of issue,

consumption, return for each contractor.

Warehouse prepares the Reconciliation statement of materials

received, consumed and balance stock at the end of the project for
handing over to client.

5. COST ESTIMATION:
An estimate is " an evaluation of all costs of the elements of a project or effort as defined
by an agreed upon scope ".
Estimation is required:
Establishing feasibility and initial budget for project

Arrange project financing

Study broad project options

Select optimal process with respect to feed, operating

conditions, product requirement.

Location

Replacement v/s revamp

Existing process v/s new process

Optimise operating conditions v/s equipment

Cost control

Cost estimating involves developing an approximation (estimate)

of the costs of the resources needed to complete project activities.

Cost estimation is different from pricing. Cost estimating involves

developing an assessment of the likely quantitative resulthow
much will it cost the organization to provide the product or service
involved.

Pricing is a business decisionhow much will the Pre

organization charge for the product or service

Cost estimation is a process used to predict uncertain actual costs

Goal of cost estimation process is to minimize the uncertainty of

the estimate given the level and quality of scope definition

Inputs for estimation:

Project Description

Project Location / Accessibility

Execution Philosophy

Process Description

Block Flow Diagrams

Material & Energy Balance - Raw Materials & Product

Profile P & IDs

Overall Plot Plan

Equipment List with Capacity, technical specs Utilities & Off-sites Requirement

Site Related Facilities & Infrastructure Requirement

Constructability - Availability of labor, building materials, requirement of

construction facilities etc.

Transportation of ODC Equipment

Extent of shop and site fabrication

Site training
Introduction:
PROJECT BACKGROUND:
In 2002 , GAIL (India) Limited commissioned Engineers (India) Ltd to prepare a
per-feasibility report for setting up a petrochemical complex at Assam, based on
the OIL & ONGC gas as feed stock, and converting the existing LAKWA LPG
plant into C2+ recovery plant and setup a 160000 TPA gas cracker complex along
with one downstream polymer unit.
Based on the pre-feasibility report and as directed by MPO&NG in AUG-2004,
GAIL has decided to prepare a detailed feasibility report for setting up an ethylene
cracker based on the gas available in Assam supplemented with naphtha.
FEED SCENARIO:
The feed commitment available for the complex is as under:
6 MMSCMD Natural Gas with C2+ content of 7.02 mole% Approx from OIL
INDIA LTD Duliajan.
1.35 MMSCMD Natural Gas with C2+ content of 7.74 mole% Approx from
ONGC at LAKWA up to 2012 and 1.0 MMSCMD thereafter.
160000 TPA Naphtha from Numaligarh Refinery.
Based on the above feed availability which can produce 220000 TPA Ethylene & 60000
TPA Propylene, the detailed feasibility report has been prepared for a configuration of a
220000 TPA & 60000 TPA cracker complex.

OIL
DULIAJAN

RICH GAS 18 49KM

6.0 MMSCMD
LEAN GAS 18-49KM
4.5 MMSCMD

LLDPE /HDPE
220,000 TPA

CRACKER COMPLEX, LEPETKATA

POLYPROPYLENE

GAIL, LAKWAC2+ LIQUID 4 47kmGSU- 6.0 MMSCMD 60,000 TPA

59,616 TPA
C2/C3 -5.9 MMSCMD
C2/C3 PLANT
ETHYLENE- 220,000PYRO
TPAGASOLINE 55,750 TPA
RICH LEAN
PROPYLENE-60,000 TPA
GAS* LAKWA
GAS
ONGC,
FUEL OIL
NRL

NAPTHA
160,000 TPA

12,500 TPA

TOTAL POLYMER PRODUCTION

* RICH GAS- 1.35 MMSCMD (upto March 2012),
1.0 MMSCMD thereafter

280,000 TPA

TECHNOLOGY SELECTION:
UNIT

CAPACITY

LICENSOR

GAS SWEETENING UNIT

6.0 MMSCMD

EIL

C2 + SEPARATION UNIT

6.0 MMSCMD

EIL

ETHYLENE CRACKER UNIT

USA

220,000 TPA

LLDPE / HDPE SWING UNIT

220,000 TPA

POLYPROPYLENE UNIT
GERMANY

60,000 TPA

A. AT LEPETKATA

UTILITIES & OFFSITES

(C2+SEPARATION UNIT)

LUMMUS TECHNOLOGY,
INEOS, UK
LUMMUS NOVOLEN,

EIL

B. AT LAKWA
GAS SWEETENING UNIT

1.35 MMSCMD

MODIFICATION OF LPG PLANT AS REQUIRED

EIL
EIL

C. AT DULIAJAN
GAS DEHYDRATION UNIT (GDU)

6.0 MMSCMD

RICH / LEAN GAS DESPATCH

RECEIPT TERMINAL

EIL
EIL

D. PIPELINES
1. C2+LIQUID PIPELINE (4 - 47 KM) LAKWA TO LEPETKATA

EIL

2. RICH GAS PIPELINE (18 - 49 KM) DULIAJAN TO LEPETKATA

EIL

3. LEAN GAS PIPELINE (18 - 49 KM) LEPETKATA TO DULIAJAN EIL

ESTIMATED COST: Rs. 5460 Crores (As per DFR)
PROJECT IMPLEMENTATION SERVICES (EPCM):

BCPL has appointed EIL as EPMC consultant. Project management services cover all the
activities leading to the execution of a project by carrying out engineering, procurement
and managing construction at site. The efforts of various agencies such as licensors,

vendors, clients, contractors / sub contractors and EIL's different departments are brought
together in a logical pattern to result in fruitful culmination of the project.
PROJECT KEY DATES
ZERO DATE :

09.04.2007

EFFECTIVE START DATE :

23.11.2009

Mechanical Completion Date:

TARGETED :

08.04.2012

CONTRACTUAL :

22.11.2013
(48 months from the date of receipt
of Licensor Package for Ethylene Cracker
Unit)

PROJECT DURATION

TARGET :

SCHEDULE DURATION :

53 Months

CONTRACTUAL DURATION :

48 Months from Receipt of ECU-BDEP

53 months (For Mechanical Completion)

Learnings
Construction department
Construction management services comes under directorate projects
Total management of the project system is controlled by directorate project.
Total no. of construction site EIL has right now = 44 and 891 working people.
EIL is ISO 9000 company in quality point of view and ISO 14000 in
environmental aspect.
ISO 18000 company in quality, environment and health.
OSA- Observation and safety aspect.
OQA-Observation and quality aspect.

Safety Induction & HSE management

Ensure compliance with requirements of health, safety and environment, during
design and delivery of product/services as per applicable national and
international codes, standards, procedures, engineering practices, statutory
requirements including customer requirements.
Ensure safety and health of employees, personnel of clients and associates.
Create awareness on health, safety and environment aspect for all employees and
associates.

HSE objectives:
Based on the HSE policy, the HSE objectives derived areas under
To maintain an HSE management system conforming to the principles of ISO
14001 and with guidelines as per BS 8800, and ensure its availability to all
parties of interest and compliance at all levels.
To promote the highest standard of safety and health and care of environment to
comply with all applicable laws, regulations and codes of practice.
To design and construct the plant and Equipment which is and does not have any
unacceptable impact on health, Environments and meets or exceeds customer
requirement for HSE.
To provide resources for employees essential for implementation, control and
improvement of HSE management system.
To strive for continual improvement by periodical reviews based on feedback
from performance measurement and monitoring trends in international HSE
system.
Reference documents:
EIL HSE manual : 1-0000-0011, REV 0.
EIL standard specification: 6-82-0001, Rev 4.
HSE procedure:5-1940-1940, Rev 4.
EIL procedure for technical audits: 5-1940-8020, Rev 3.
Safety aspect with owner/Contract between EIL and Customer.
General condition of contract(GCC).
Special case of contract (SCC).
Statutory requirements.

Few Definitions:
Safe: An entity is provisionally categorized as safe if its risk are deemed knownand, in
the light of that knowledge, judged to be acceptable.
Risk: The cumulative effect of the chances of predictable/unpredictable occurrences
which will adversely affect project activities.
Hazard: A set of condition which has potential of causing damage to property, injury of
person, or to environment.
Incident: Something occurring by chance, without intention, which interrupts the normal
line of events in process or construction activities.

Accident: An unforeseen, unintended event which causes personell injury or illness as a

result of unsafe conditions practices.
Site specific HSE plan:
Role of field engineers at site :
Review/approval of HSE documents prepared by contractor as per EIL standard
specification for HSE management at construction sites (6-82-0001-Rev 04).
Monitoring of implementation of HSE activities and generation of HSE records
and reports by contractors as per his approved HSE documents.
Stopping of unsafe acts considered potentially dangerous.
Recording of HSE violations and imposing penalty as applicable.
Resolution of HSE violations.
Implementation of corrective and preventive actions and submission of
compliance reports for audit observations.
Risk/Hazards Assessment: All the construction related activities are analyzed, hazards
identified with their effects and preventive measures suggested.
Areas where more attention required:
Working at height.
Structural/Equipment erection.
Scaffolding and barricading.
Excavation.
Electrical installation.
Welding/Gas cutting.
Radiation exposure.
Heavy lifts.
Demolition/dismantling.
Explosive/Blasting.
Vehicular movement.
Confined space.
Safe permit system:
Permit for working at height (above 2 meter).
Confined space entry permit.
Radiation work permit.
Demoltion/Dismantling work permit
Others- if required, as per site requirement.
PPES (personal protective equipments):
Safety helmet.
Safety shoes: leather shoe with steel toe.
Gum boot: For working in water, mud & casting of footings.
Safety goggles: For gas cutter, welding helper, grinder.
Hand gloves: For material handling, welding, gas cutting.
Full body harness: For all height work (above 2 meter).
Boiler suits: For entering into boiler drum, closed vessel.
Nose mask: For dust, welding gas.

Ear plug/Muffs: For noise.

Face shield: For grinder.
Gauntlet and protective clothing for grit blaster.

Civil Structural and Architectural

Substructure: Any structural element that constructed below the ground floor level is
substructure. That could be range from a simple foundation to a basement floor, or more
complex structures such as subways or underground tunnels.
Superstructure: Super- Structures are that portions of a building or any structure that
are visible (from the ground level up). It could be a simple residential house to a multi
storey building or a complex structure.
Foundation: Foundation of a structure or equipment is like the roots of a tree without
which the tree cannot stand. The construction of any structure, be it residence or a
skyscraper, starts with the laying of foundations.
Before designing the foundation, the type of soil is determined. Depending on
whether the soil is hard or soft, a specific type of foundation is adopted.
Foundations are made in various materials. They could be reinforced cement
concrete foundations or brick foundations or stone rubble masonry foundations
etc.
The choice of material to be used in the construction of the foundation also
depends on the weight of the structure or Equipment on the ground.
Bearing capacity of the soil at BCPL Lepetkata is 10-15 ton/m2.

Pile foundation: Pile foundations are the part of a structure used to carry and transfer
the load structure to the bearing ground located at more depth below ground surface.
These are used in case of Soft/Silty/Clayey type of soils. These are pipe shaped:

When the load is tremendous high, most foundations are pile foundation.

 90% of civil works is concrete work.

Raft foundation: A raft foundation is essential a mat foundation. The purpose of mat
foundation is when a building built on a site with low soil bearing conditions. A raft is
used to distribute the building pressure over a large area so that soil can bear the stress.

Concrete: Concrete is a composite construction material, composed of cement and

other cementitious material such as fly ash and slag cement, Aggregate (generally a
coarse aggregate made of gravel or crushed rocks such as limestone, or granite, plus a
fine aggregate such as sand), water and chemical admixture.
M-30 grade cement is used in Lepetkata.
Crushing strength of concrete is tested by cube test. In this test cube is left to
settle for 28 days and after that it is compressed between two parallel faces. The
stress at failure is taken to be the compressive strength of the concrete.
Size of cube to be tested 150 mm X 150 mm X 150 mm.
95% of the cube should show more than 33 N/mm2 of compressive strength.

Type of connection in Steel Structure:

1. Moment connection
2. Shear connection
Moment connections: Moment connection keeps the steel from turning in a circle.
Moment connections are designed to transfer bending moments, shear forces and some
times normal forces.
Shear connections: shear connection is for resisting shear force only. It stops the two
connected members from sliding up and down or back and forth.
If the two members are connected by a single bolt, they cannot move up and down but
can move in a circle i.e. rotate, i.e. the connection has no resistance to turning i.e.
moment. If at this place we put two or more nails or bolts, the members will neither move
nor rotate. This is a moment connection.
Gusset plate: Gusset plates are thick sheet of steel that are used to connect beams and
girders to column or to connect truss members. A gusset plate can be fastened to a
permanent member either by bolts, rivets or welding or a combination of the three.
Underground piping can be of gravity line or pressure line but above grond
piping will be pressure line always.
Pressure inside the Fire water line- 10 kg/cm2.
Pressure inside the Drinking water line- 7 kg/cm2.

Compaction: Densification of soil by removing air voids using mechanical

equipment.
Objective for compaction:
Increasing the bearing capacity of the foundation.
Decreasing he undesirable settlement of structures.

 Control undesirable volume changes.

Reduction in hydraulic conductivity.
Increasing the stability of slopes.
Consolidation: It is another kind of densification with fluid flow away. Consolidation
is primarily for clayey soils. Water is squeezed out from its pores under load.
There are four control factors affecting the extent of compaction:
1. Compaction effort.
2. Soil type and gradation.
3. Moisture content.
4. Dry unit weight (dry density).
In soils compaction is a function of water content.
Water added to the soil during acts as a softening agent on the soil particle.
For better compaction
The dry unit weight increases as the moisture content increases to a point.
Beyond a certain moisture content, any increase in moisture content tends to
reduce the dry unit weight.
Moisture content of soil should be optimum.
Vibromax roller compactor is used to compact the soil.
Total area of the plant- 260 hectare.
Template: Used for placing the bolt on foundation.

I beam:

The web resists shear force while the flanges resist most of the bending moment
experienced by the beam.
ISMB: Indian standard medium weight beam.

ISWB: Indian standard wide flange beam.

ISJB: Indian standard junior beam.
ISLB: Indian standard light weight beam.
ISWPB: Indian standard wide panel beam.
Universal beam: I beam having uniform thickness throughout its flange and web is
called universal beam.

Grouting: Grouting involves injecting a grout material into generally isolated pore or
void space of which neither the configuration or volume are known and is often referred
to simply as grouting. The grout may be a cementitious, resinous or solution chemical
mixture material.
The greatest use of grouting is to improve Geomaterial (Soils and Rocks).
The purpose of grouting can be either to strengthen or reduce water flow through
a formation.
It is also used to correct faults in concrete or masonry structures.
Grouting has been performed on the foundation of virtually every one large
dams, in order to reduce the amount of leakage through the rock, and sometimes
to strengthen the foundation to support the weight of the overlaying
Structure/Equipment

Footings: Outdoor structures are supported by a base foundation called footings.

Footings eliminate setting and slippage, and help protect posts and beams from direct

contact with the earth. Posts and beams that come in direct contact with the earth will rot
more quickly and ultimately weaken the structure. Footing also prevent frost heave.
Nito bond: For bonding fresh wet cementitious materials to existing cementitious
surfaces.
Can be applied on to dry or damp substrates.
Exhibits high mechanical strength.
Positive adhesion-exceeds that of the tensile strength of the host concrete.
Slow curve allows time to erect steel reinforcement and formwork.
Solvent free- can be used in enclosed locations.
Admixtures: Admixtures are natural or manufactured chemicals which are added to
the concrete before or during mixing. The most often used admixtures are air-entraining
agents, water reducers, water reducing retarders and accelerators.
Admixtures are used to give special properties to fresh or hardened concrete.
Admixture may enhance the durability, workability or strength characteristic of a
given concrete mixture.
Admixtures are used to overcome difficult construction situations, such as hot or
cold weather placements, pumping requirements, early strength requirements or
very low water-cement ratio specifications

Planning, Scheduling and Documentation

Introduction:

Part project division under project directorate.

Planning, Scheduling and monitoring services are an integral part of project
management for helping in achieve completion of project within schedule time
frame through detail assessment of work, quantum, meticulous planning, micro
level scheduling and dynamic monitoring.

Major activities of field planning:

1. Overall construction schedule.
2. Contractor schedule.
3. Monthly construction program.
4. Weekly construction progress report.
5. Monthly construction progress report.
6. Preparation of drawing-material hold up report.
7. Piping material control.
8. Drawing and document control.
9. Job close out report.
10. Preparation of presentation material and conduct review meeting.

Key terminology:
Construction Network: Construction network is an extension of the overall project
schedule for construction part of the project.
Overall construction schedule: Based on the overall project schedule, site planning,
engineers develop an overall construction schedule Unit/Area wise and tender wise.
Workload for various tender is converted to equivalent man-hour using standard manhour productivity data from available data bank and skill factor for various elements.
The progress on the bars at any point of time multiplied by the weighted
value percentage shall provide overall construction progress curve (S-curve).
Contractor schedule: The contractor schedule is also prepared as soon as the contract
is awarded and as per signed and agreed document. Individual work items would be
assigned with weighted value in the same way as defined in the overall construction
schedule.

Progress Monitoring and Reporting:

1. Contractor schedule: Based on the construction schedule submitted by the
individual contractor with resource development plan, concern discipline engineer
review the same as per scope of the agreed contract.
2. Daily progress report: In the line with the approved contractor schedule, site
planning prepare and issue DPR formats to all contractors for implementation. As
the contractor submit DPR, Concern Area engineer verified the quality of work
load, front and actual progress as per agreed contractor schedule and arrange to
send the same site planning department. Based on the receipt of the verified DPR
of all contractors, weekly report is compiled.
3. Monthly construction program: The monthly construction program is weekwise quantitative program for each work item of the contract for the next month.

4. Drawings/materials hold up report: Drawings and materials required for

subsequent months program with respect to generation of work front is
highlighted in the report.
5. Weekly construction progress report: This is quantitative report reflecting
contractor wise weekly progress (Sunday to Saturday). The highlights, hold-up
and areas of concern are provided by individual area engineer/area coordinator.
6. Monthly construction report: Based on the issued WPR of individual
contractor, site planning compile the last four weeks data and prepare monthly
progress report as on the 15th of every month.

Quality plan:
Purpose: The purpose of this service is to describe the methodology to befollowed for
field planning services as per planning manual.

Drawings and Document control services:

Purpose: The purpose of this service is to describe the methodology to be followed for
drawings/document control services to be provided at construction sites by field planning
group.
Drawing control: Site planning circulate updated drawing index received from HO to
respective area coordinator/field engineer to ensure use of latest drawings.
Document control: On receipt of documents (Tenders/Contract/Vendor) from HO/RO,
site planning distribute the documents to EIL area coordinator through document issue
transmittal.
Material control:
Piping material control at site is under site planning department. Site planning is
executing
material
control
through
EIL
In-house
package
COSMAS(computerized online system of material allocation at site).
Piping material which is issued to contractors as Free issued material (FIM)
procured through EIL as well as the material agreed to be supplied by the client.

Equipment and bulk status:

HO planning role:
Identification of requirement / MTO stage.
Requisition stage.
Ordering stage.
Manufacturing/delivery stage.
Site warehouse role:
Receipt of material
Generating of DPR, MRR, OSRD report and issuance of the same to client, EIL
HO and site planning.
Monthly bulk material receipt status to be sent to site planning for generating
monthly progress report.

Site planning role:

Allocation of material: Material is allocated to the contractors from the available logical
stock of material by site planning after following consideration/analysis:
Priorities of different activities based on:
Availability of related drawing and access.
Balance material to be allocated to the individual contractor in line with monthly
program which is reviewed by EIL engineer.
Priority of different jobs.
Indents are handed over to respective contractor for lifting the material from ware
house after authorization and signing of each indent by respective area
coordinator.
Issuance of material to contractor: Warehouse issues the requisitioned material
to contractors after receiving the indent, duly authorized by area coordinator.
Detail of issued quantity is filled up by warehouse and copies are marked to
client, area coordinator & site planning.
Return on material: All unused material both usable and non usable are returned by
contractor to warehouse through MRVs.
Stock verification: Ware house periodically verify the physical stock of material by
comparing actual quantities available in the stock with the quantities indicated in bin
card. Discrepancy if any is reconciled by warehouse with vendor.

Electrical
Substation transfers power through panel boards which then transfer the power through
the feeder pillar boards.
There are three different types of clearance required for electrical items:
A- inspection at site/workshop
B- dispatch clearance
C- Verification of documents

Electrical job at site:

Earthing: In electricity supply systems, an earthing system defines the electrical
potential of the conductors relative to the Earth's conductive surface. The choice of
earthing system can affect the safety and electromagnetic compatibility of the power
supply, and regulations can vary considerably among countries. Most electrical systems
connect one supply conductor to earth (ground). If a fault within an electrical device
connects a "hot" (unearthed) supply conductor to an exposed conductive surface, anyone
touching it while electrically connected to the earth (e.g., by standing on it, or touching
an earthed sink) will complete a circuit back to the earthed supply conductor and receive
an electric shock.
Earth plates are used for individual instruments. These plates are made of galvanised iron.
Separate electrodes are provided for lighting protection.
Electrodes used are the directly driven electrodes which are driven till the moisturised
soil or in treated earth pit( filled with coal) to reduce the resistance. This is one of the cost
effective methods of earthing.
Cabling: Cables are conductors of power. There are three types of cables:
Power cables
Control cables
Lighting cables
Cables carrying a voltage of more than 1100V are called high tensioned cables.
Those carring voltages above 220V are called extra high voltage carrying cables. With
increase in voltage the insulation capacity increases. PVC (poly vinyl chloride) cables are
used for medium voltage and XLPE (cross linked poly ethylene) cables for high voltage.
As far as conduction is concerned copper cables carry 1.6 times the power than carried by
aluminum cables. However copper cables are more costly as compared to aluminum
cables.
INNER SHEET
FILLER
MATERIALS
(PVC PIPES)

ARMOUR (GI)
OVERALL SHEET

Above shown is the insulation design of the conductors. Three conductors are kept in a
triangular fashion to reduce the space between the conductors. The three conductors are
then surrounded by a PVC sheet for insulation. On the periphery of the PVC sheets we
have a mesh of GI called the armour over which we have a sheet of PVC again.
In case of XLPE, there is a thin semiconductor screen/film around the main conductor
which is again surrounded with copper film.
There are again two phases for conduction
TP: three phase: three-phase electric power systems have at least three
conductors carrying voltage waveforms that are 120offset in time.

TPN: Three-phase neutral: Three-phase systems may have a neutral wire. A

neutral wire allows the three-phase system to use a higher voltage while still
supporting lower-voltage single-phase appliances. In high-voltage distribution
situations, it is common not to have a neutral wire as the loads can simply be
connected between phases (phase-phase connection). The neutral is basically
black in colour. The size of the neutral wire is half the size of the main conductor.

CONDUICTOR SIZES: 1.5,2.5,4,6,10,16,25,35,50,70,95,120,150,185,240,300,400.(all

in mm2).
For conductors of size 1.5-16mm2 we use copper conductors and foe higher sections we
use aluminium conductors.
TYPES OF CONTROL CABLES DEPENDING ON THE NUMBER OF CORES: 3
core, 5 cores, 7 cores, 10 cores, 12 cores, 14 cores, 16 cores, 20 cores( where one core =
one number of conductor). As the number of signals increases the number of cores
increases.
Cables are normally measured in gauge. There are two types of instrument cables:
Pad cables
Triad cables.
On the basis of safety there are two cables:
Intrinsically safe: in case of any failure the circuit is electrically quenched.
Non- Intrinsically safe.
Different systems under electrical are:

a
b
c
d
e
f

Fire alarm system

Telecommunication system
Plant communication system
Pressurization and ventilation system.
Air conditioning system
Clean agent system

For a switch on-off cable minimum 3 b=core cable is required

For lighting 3 core cable is used
For high voltage transformers single core cables are used
Glands are provided to isolate the cables from moisture and rodents but mechanical
protection is achieved through armours only.
Lighting: the different lighting fixtures are
o Industrial fixtures
o SFD
o RSD
o FLP
o Bulk heating fittings
o HV
o MV
o FDR
o AFD
Lighting phases: 3 phase-red, yellow, blue. Black for neutral and green for earthing
Size of wires: 6 mm2 for split AC, 2.5 mm2 for lighting (single socket), 4 mm 2 for series
of sockets.
ELCB: Earth leakage circuit breaker. It is a safety device. Whenever it detects a current
of 30mA it trips the circuit.
Area classification:
Prevaillance of hazardous materials
Type of gas to be used
Decides the types of zone:
Zone 0: presence of gas all the time, non ventilated enclosed spaces. Eg:
Mining areas.
Zone 1: strong likelyhood of gas being available but is ventilated
Zone 2: free ventilation. No gas at all
Gas Group: 1- coal dust, flammable
2A & 2B- General Hydrocarbon gas
2C
- hydrogen.
Magger is an instrument to measure the insulation resistance. Minimum
Insulation = 1 mega-ohm
Equipment safety groups:
EX-increase safety

EX e- for gas group 2A- zone II

EX d- explosion proof
EX I- intrinsically safe
EX p- pressurized
EX ns- restricted ventilation
For the control of motors LCS-local control stations are used.
EQUIPMENTS:
Voltage grade: 33kV or down
High tensioned switchboard
Medium voltage switchboard
o PCC- power control center- to distribute powers
o PMCC- power motor control center-breaker controls.capacity>55kW
o MCC- motor control center- contactors controls. Capacity unto 55 kW.
Transformers
o Power transformers: Steps down the Voltage from 33kV to 6.6 kV or 3311kV
o Distribution Transformers
Battery rechargers- DCDB: direct current distribution board: this is used for
constant power supply.
Pressurization and Ventilation System:
From the incoming cable the power goes to the HT panels from there to transformersand
then to the equipments. The transformers are not loaded unnecessarily. So in case the load
increases the fans are switched on automatically for cooling the room.
Mechanical devices for transformer protection:
o PRV: Pressure Relief Valves
o Bucholz relay
o Gas sensing device
o Oil device
o Marshalling Box- For Indication
o Space heater- for keeping the moisture of the marshalling box less
o Deluge valve. To protect in case of fire by spraying water.
Switchgear panels
Cable trays motors
Electrical heat tracing

Welding and NDT Inspection

Arcing temperature of stainless steel above 300 degree Celsius.
Chemical composition of electrode is responsible for the strength of the weld.
To improve the impact property we add extra material to the electrode.

Electrical characteristics :
Current-DC
Amp (range) 80-110 A
Voltage(range) 22-24 V
Tungsten electrode 2 mm
Welding positions: The welding progression, (vertically upwards or downwards), must
always be stated and it is an essential variable for both procedures and performance
qualifications.
Welding Positions For Groove welds:Welding Position

Test Position

Flat

1G

Horizontal

2G

Vertical Upwards Progression

3G

Vertical Downwards Progression

3G

Overhead

4G

Pipe Fixed Horizontal

5G

Pipe Fixed @ 45 degrees Upwards

6G

Pipe Fixed @ 45 degrees Downwards

6G

Welding Positions For Fillet welds:Welding Position

Test Position

Flat (Weld flat joint at 45 degrees)

1F

Horizontal

2F

Horizontal Rotated

2FR

Vertical Upwards Progression

3F

Vertical Downwards Progression

3F

Overhead

4F

Pipe Fixed Horizontal

5F

E601 Electrode: Celulose type coating

It is high penetration electrode.

Do not put in light and moisture.
Used in pipeline in root.
E6013 electrode: Rutile (mainly Titanium oxide) type coating
Low penetration electrode.

E7018:

Low hydrogen potassium type.

Iron powder is used for deposition.
Kept free from moisture.
Baking at 250, 300 degree Celsius for two hour for removal of moisture otherwise
arcing temperature is high and hydrogen from moisture will come out and get
intact with welding forming hydrogen induced crack.

E7016:

Used for carbon steel material.

To remove sulphar induced cracks.
Kept in oven at 100 degree Celsius to remove moisture.

GTAW (Gas tungsten arc welding) :

Tungsten electrode 2% Thoriated or 2.5% Ceriated electrode.

Tungsten electrode is used to produce heat at the junction.
Electrode-Cathode
Metal-Anode
Root will get fused fast.
Coating is not used on the filler wire, so there is need to protect molten filler wire
from being oxidize. The tungsten electrode holder has got a passage to send
shielding gas along the non consumable electrode. In case of carbon steel we
shield the pool with the help of welding torch only, But in stainless steel and high
alloy steel we shield whole pipe. SS & AS forms stable oxide which prevent the
metal to melt. This shield is created with the help of purging gas.
Purging gas- Inert gas (Generally Argon because it is cheap and can be available
easily).
Flow rate of purging gas- 3-4 litre/min
Purging gas is flowed to three to four times of volume of pipe, so that
oxygen gets out.
Purging : Inside the pipe 2-3 l/min
Outside the pipe- 6-8 l/min
Material deposition rate is not fast in case of GTAW.
Pipe of diameter below 2- GTAW is used
In case of A19A, A11A used for flare lines, GTAW is used and Ar is used for
shielding 100% radiography (now EIL is using 20%).

SMAW (Shielded metal arc welding): Electrode-Anode

Metal-cathode

Electrode will get fused fast.

Coating serve the purpose to shield the weld by forming slag (after reacting with
O2). Slag is removed by chipping.
SAW (Submerged arc welding):
Used only for tankages.

Code of welding:
IS 7307- Qualification of welding procedure.
IS 7310- Qualification of welders.
IS 9595- Joint design
For civil and structure work because in IS qualification for a single position does not
qualify WPS or the welder for other positions. WPS for horizontal position, qualified for
horizontal position only.
ASME welding code : ASME section 9 for qualification of welding procedure and
welder- both for Welding and Brazing.
ASME section II part A- For ferrous material.
ASME section II part C- For welding consumables.
ASME section V for (non destructive test)
NDT Radiography
Ultrasonic testing
Dye penetration test
Magnetic particle testing
Penetrate testing
Eddy current testing
Hydro testing
For flare line Pneumatic testing (at low pressure).
Pneumatic testing pressure- 1.1 times of design pressure.

Safety in welding : I.For fumes of welding

II.For the electrical hazards.
Destructive test: Tensile test(done by UTM)
Bent test
Impact test
Weld hardness is more than the base metal(Tensile property is good).
Stress relieving (Post weld heat treatment) is done to decrease hardness.

Stress relieving for Carbon steel:

Cooling and heating rate: 200 degree Celsius per hour (maximum limit)
Soaking temperature- 500 degree, Celsius keep for sometime at this temperature

For alloy steel Slow heating and slow cooling.

Radiography: To locate the defect and measure the defect for acceptance of welded
joint.
Radiography and dye penetration test is done at site.
Radiography acceptance criteria for piping ANSI 31.3
Acceptance criteria for welder on the basis of joint welded by welder is given in ASME
section 9.

Radiograp
hy

Gamma
Ray
X- Ray

Gamma ray is mainly produced by Ir 192.

High energy source is used for high thickness (e.g. in sphere) Co 60 is generally
used for this.
For higher energy source (high penetrating power), higher radius of safety is used.
Radiation from the radioactive source falls on the object being radiographed. It is
partially absorbed and rest of energy falls on the film.
Film: Plastic base upon which zilletin layer. In zilletin layer there is silver bromide
solution. Radioactive energy ionizes the AgBr to Ag+ & Br- ions.Br- ions are absorbed by
the zilletin and Ag+ ins are attracted towards a particular location. when the films are
developed by the developing solution which gives extra electron to Ag+ ions into metallic
silver and silver looks black, rest of the bromine ions are dissolved in fixer solution and
later washed. Whenever there is defect in the object this thickness
So the energy passing through the defect is more than the energy which is passing
through the adjacent area where is the more defect. More energy produces more silver. So
the area of the film where the energy has come through the defect will be darker.
Welding machine- Rectifier
Passes of V groove:
I.
Root pass
II.
Hot pass
III.
Filler pass
IV. Capping pass
Root and capping is done with two separate electrode
E 6010 Used for root (Rutile type)
Internal spatter.
Deep penetration.
490 MPa tensile strength.
Big X-ray machine
Ir 192 75 mm Penetration
Co 60 200 mm penetration (Half life 30 years).
AERB (Atomic Energy regulatory board)

 Surveymeter: Portable radiation detection and measurement instrument used to

check personnel, Equipment and facilities for radioactive contamination, or
ambient ionizing radiation.

Welding defect recognition in radiography:

I.

Undercut:

II.

Porosity:

III.

Incomplete fusion:

IV.

Overlap:

V.

Underfill:

VI.

Spatter:

VII.

Incomplete Penetration and Excessive Penetration :

Cracks are not allowed in welding. Generally cracks develop in Alloy Steel.

Limitation of radiography testing:

1. Inline defect cannot be detected. Example porosity
2. Only suitable trained and qualified personnel can practice this type of testing.

Instrumentation
Role of Instrumentation:
I.
II.

Better process control.

Maintain good quality of product.
Process parameter: Flow, level, temperature and pressure.
Viscosity measuring Instrument Special Instrument.

Differential pressure flowmeter: Fluid flow rate by reading the pressure loss across a
pipe restriction is most commonly used flow measurement technique.
Flow rate is directly proportional to square root of differential pressure.
Signal conditioning : signal conditioning means manipulating an analog signal in such
a way that it meets the requirement of the next stage for further processing. Signal
conditioning can include amplification, Filtering, Converting, Range matching, Isolation
and any other processes required to make sensor output suitable for processing after
conditioning.
Flow measuring Devices: Flow orifice, Pitot tube, Venturimeter, Turbine flow meter,
Coriolis mass flow meter and ultrasonic flow meter.
Displcer: A Displcer is a device is a device based on the Archimedes principle. The
displacer rod, which attached to a measuring spring using a chain, immerse into the
liquid and is subjected to buoyant force proportional to the mass of the displaced liquid.
Every change in the weight of the rod corresponds to the change in the length of the
spring and is therefore a measure of the liquid level.
Level measuring devices: Differential pressure transmitter, Displacer, Radar.

Temperature measurement: I. Thermocouple

II. RTD (Resistance temperature Detector)
RTD: RTD is used to measure temperature by correlating the resistance of the RTD
element with temperature.
Common resistance materials of RTDs:
Platinum (most popular and accurate).
Nikel
Copper
Balco(rare)
Tungsten(rare)
Benefits of using RTD: 1. Most Accurate
2. Excellent Stability and repeatability
Pressure switch: A pressure switch is a form of switch that makes electrical contact
when a certain set pressure has been reached on its input. This is used to provide on/off
switching from a pneumatic or hydraulic source.
Vibration switch: A device that that
1. Recognize the amplitude of vibration to which it is exposed
2. Provides some sort of response when this amplitude exceeds a predetermined
Thresold value.
Temperature Switch: A switch that is responsive to temperature changes. Temperature
switches are generally provided with a temperature responsive element which will open
or close a switch when a predetermined minimum temperature or pressure is sensed by
the responsive element.
Electrical switching: Use to fixed the current at a particular level
All instrument output is 4-20 mA, except turbine flowmeter.
Output of the turbine flowmeter is frequency.
All signals are converted into voltage from current at control room.

Liquid level indicating controller/Level indicating controller (LIC):

Pneumatic type indicating controller which are used to measure and control various type
of process variables such as temperature, pressure, flow and liquid level.

Programmable logic controller (PLC): PLC meets the following requirement:

Simple programming
Program changes without system intervention (no internal rewiring)
Smaller, cheaper and more reliable than corresponding relay control system.
Simple, low cost maintenance.

Control valve positioners: A positioner ensures that there is linear relationship

between the signal input pressure from the control system and the position of the control
valve. This means that for a given input signal, the value will always attempt to maintain

the same position regardless of changes in value differential pressure, stem friction,
diaphragm hysteresis and so on.

Actuators: Control valves need actuator to operate.

Types of actuators: 1. Electric
2.Pneumatic
Actuator accepts signal from the control system and, in response, move the valve to
fully open or fully closed position, or a more open or more closed position (depending on
whether on/off or continuous control action is used).
Pneumatic actuators: Pneumatic actuators are commonly used to actuate control valves
and are available in two main forms; Piston actuators, and Diaphragm actuators.
Electrical actuators: Where a pneumatic supply is not available or desirable. It is
possible to use an electrical actuator to control the valve.
Instrument air is required to actuate the actuator.
Shutdown valve: A shutdown valve is an actuated valve designed to stop the flow of a
hazardous fluid upon the detection of a dangerous event.
Solenoid valve: A solenoid is an electromechanical device which allows for an electrical
device to control the flow of a gas or liquid. The electrical device causes a current to flow
through a coil located on the solenoid valve. This current flow in turns results in a
magnetic field which causes the displacement of a metal actuator.
Junction box: junction boxes are devices that contain the wiring junction or
intersection that allow the wiring in home or public building to interface with the main
power supply provided by a local utiliy.
An instrument air line goes through the pipe rack.
Instrument air tapping should be vertically.
Type of junction box:
1. JBN for signal cables
2. JBT for thermal cables
3. JBA for alarm
4. JBS for shutdown normally solenoid signals
5. JBG for gas detector.
Calibration of instrument should be done before installation.
Field instrument: Instrument used for getting the information Smoothly, Quickly,
Accurately and Securely. Measurement of key element of process control like Pressure,
Temperature, Flow and level is done by field instrument.
Some of the field instruments are:
Pressure transmitter (PT)
Magnetic flow transmitter
Coriolis flow meter
Differential pressure transmitter
Vortex flow meter
Mass flow meter
Maximum pressure instruments are calibrated with hand.

 Oil temperature bath is used to calibrate the temperature.

Pressure safety valve is calibrated by safety valve.

Loop checking: For the type of inputs

1. Analog input
2. Analog output
3. Digital input
4. Digital output
Loop: 1. Open loop
2. Closed loop
Flow element
(P & ID no.)
Instrument index: XXX-FE-3502

Unit no.
Tag no.
FV- Flow valve
II- Instrument Index
LAH- Level Alarm high
TE- Temperature element
LG- level gauge
LT- level transmitter
LAL- level alarm low
AI- analyser indicator(gas detector)
Mother equipment of Instrument index is P&ID.
For corrosive liquid we use pressure type filter.
Transmitter is installed at 1.5 m from the equipment.
For gas- Transmitter is installed above the vessel.
For liquid- Transmitter is installed below the vessel.
Duct: In duct we can put one wire over another.
Cable tray: one wire at a time.
There are three satellite rack room and one control room for every unit.
Smart instrument gives more data.

Ware house management system

A warehouse management system or WMS is a key part of the supply chain and primarily
aims to control the movement and storage of material within a ware house and process
the associated transactions, including shipping, Receiving, Put away and picking.
From the client side order is placed by EIL and this is done by HO.
Two type of inspector for the material:
1. EIL: Inspect every material.
2. IBR: 5-6 % material needs IBR clearance. Some equipment for example
vessels connected to boiler needs IBR clearance.
Heat exchanger: Body- Inspected by EIL
Tubes- Inspected by IBR
WAMS (warehouse management system)- used for record of material.
Material issue voucher (MIV): Document issued to the contractor for issuing the material.
Material return voucher (MRV): Document given by contractor for returning the material.
Elbow, fittings If damaged cannot repairable.
Valve-if damaged can be repaired.
Types of issue of material:
I.
Free issue material- 99% material is free issue material.
II.
Chargeable
III.
Loan
Inhouse management system develop by EIL- WAMS
Item code 17 digit code develop by EIL.
Daily receipt report (DRR)
Material receipt report (MRR)
STV- stock transfer voucher
STV is given to client at the end of the project/transfer to other project.
DRR- 2247-144-UV-30

Pipeline works
Natural gas, LPG, ores can be transported from one place to another by pipeline.
Duliajan to BCPL Lepetkata twin pipeline 18 pipeline, thickness 6.4, 7.1, 8.5 mm
and length 47.04 km.
Raw water pipeline- River to site 6.2 km and diameter 28.
Naphtha from numaligarh-5.2 km and 20 diameter.
Thickness of line pipe from lakwa to BCPL Lepetkata 7.1 mm.
In survey three routes are proposed for the pipeline, away from the village.
20 m land is taken into acquisition.
Right of use (ROU) 10 % of land cost is given to owner.
Right of way (ROW) Land is bought.
Typical ROU (right of use):

Sectionizing valve station(SV Station): To control the flow.

Types of pipeline: 1. Offshore
2. Onshore
Deadstock: Initial amount of product required to get the output from another end.
Pipe material for line pipe API 5L X 70
100% radiography is done for every line pipe.

Anti-corrosive coating:
Coal tar ENAMEL coating (BS 4164, AWWA C203):
Primer
Two layer of coal tar enamel and glass fibre inner rap
One layer of coal tar impregnated outer wrap.
Coating thickness 4.7 mm.

3 layer PE/PP coating:

First layers of fusion bonded epoxy.
Second layer of extruded adhesive.
Third layer of extruded PE/PP.
Coating thickness 2.0 to 3.7 mm.
Fusion bonded epoxy coating:
350-500 micron thick single layer coating.
600-800 micron thick dual layer coating.

Peel test:
Done to check the adhesion of coating.
Should be done for every 50 joints or for coating done in one day whichever is
least.
Lowering activity hold point
For normal land depth of pipe from the ground level should be 1 m and for road
crossing it is 1.2m.
Only cropping should be done on the land from where pipeline is passing.
Crawler crane having side boom is used to lower the line pipes.
25 kv current is used for holiday test (5.5 mm thick layer).
Lowering should not be done at night but for road crossing activity it should be done
at night.
Concrete coating pipe:
Used for river crossing, concrete balance the buoyant force.
2 mm of wire mesh is used in this case and after that 70 mm of concrete coating
is done.

Horizontal direction drilling (HDD): HDD is a trenchless methodology that

provides an installation alternative that can offer a number of benefits over traditional
open-cut. HDD can be implemented with very little disruption to surface activities,
requires less working space, and may be performed more quickly than open-cut method.
This is done generally in case of road and railway.
Casing pipe material CS
Railway crossing minimum depth of pipe 2.2 m
Hydrotest limit length 50 km (mximum)
For class I and II (Location based class):
Hydrotest pressure 1.25 X design pressure.
82.5 kg/cm2 for Dulijaan Pipeline.
49 kg/cm2 for lakwa pipeline.
For class IIIhydrotest pressure- 1.4 X design pressure.

Cathodic protection: It is a technique used to control the corrosion of a metal

surface by making it the cathode of an electrochemical cell. The simplest method to apply
CP is by connecting the metal to be protected with another more easily corroded
sacrificial metal to act as the anode of the electrochemical cell.

 Two SV station in Duliajaan pipeline route and four SV station in Lakwa route.
Number of SV station in a Particular pipeline route depends on the population and
land in that route

Quality management system

Quality objectives of construction division:
1. Delivery of services/ Deliverables on schedule.
2. Improvement in Systems/Process/Technologies-improvement in quality of
services/Deliverables and Economical service or reduction in cost of project.
3. Achieve full customer satisfaction on all parameters.
Improvement in Systems/Process:
5 numbers of QMS document shall be revised and one new document shall be
introduced to bring about the improvement in Systems/Process/Deliverables.
Procedure for field purchasing (5-1940-4030).
Procedure for field tendering (5-1940-9120).
Procedure for closing the sites (5-1940-9180).
Procedure for manpower planning in construction division.
CPES system (Contractor performance evaluation system): Area coordinators to
evaluate performance rating of respective contractors on half yearly basis i.e. July to
December and January to June.

QA/QC in Civil, Structural, Mechanical and Electrical works:

Quality assurance plan

Job procedure
Inspection and test plan
Formats
(All the above documents are to be prepared by the contractor and approved by
PMC before starting the work)
Quality assurance of inputs i.e.
a. Material(IMIR) TPIA(Third party inspection agency), MTC(material test
certificate), QAP(Quality assurance plan)
b. Manpower (Skill check, qualification etc.)
Quality assurance of output i.e. product quality.

Inspection test plans (ITPs): It provides the details of activities for various works,
sequentially and indicates the stage wise roles of verification/inspection by contractor,
PMC/owner and the records/formats to be maintained.
Types of Verification/Inspection:
WC: 100% Examination by contractor.
RW (Random vigilance): Review of contractors documentation.

S (surveillance)- Inspection by owner/EIL.

W (Witness point)
HP (Hold point)

Mechanical
Two major activities: 1. Piping (consists above ground and underground)
3. Equipment
All process lines are above ground.
Utility lines are underground. E.g.- Cooling line, OWS, CWS, CBD line.
Underground piping is done during civil works and is under Structural scope.
Corrosion protection is done by either of the two methods:
1. Wrapping coating
2. Cathodic protection (Done for pipelines)

Piping system is classified on the basis of characteristic of flowing fluid.

Different services (Corrosion allowance)

A3AMaterial of construction

Pressure rating
Piping specification A1A, A2A, A10A
1st character:
A 150 #
D 600 #
G 2500 #
B 300 #
E 900 #
J 150 # (for GI pipe)
C 400 #
F 1500 #
2nd character:
A Carbon Steel
D one quarter chrome moly (alloy Steel)
3rd character:
1-10 non corrosive Hydro-carbon.
2- IBR
5 Hydrogen
4- Cryogenic
16 NACE
3- non corrosive utilities (Air, nitrogen)
20 jacketed line (Steam tracing to Keep the process fluid hot)
On the basis of services, lines are classified as:
IBR
Non IBR
Process fluid having pressure more than 3.5 kg/cm2 is termed as IBR service fluid.
Jacketing does not come under IBR, only parts upto tapping come under IBR.
Mechanical Drawings, Specifications and Works:
1. Piping material specifications (PMS).
2. Isometric Routing, Dimension, Material, in 3-D picture.

3. GAD (General arrangement Drawing): Arrangement of lines, equipments with

respect to each other.
4. Fitup, Welding
Pre-heating, Intermediate heating and post heating is done for different
requirements.
Preheating: Crack develops at room temperature when Alloy steel is heated during
welding. So pre-heating is required.
5. NDT (non destructive test), Radiography, DPT (Dye penetration test), MPT
(Magnetic partical test), UT (Ultrasonic test), Stress Relieving (SR).
6. Supporting of pipes
Types of support is indicated in Isometric.
Types of support:
I. Resting support (on structure or paddestle base, pipe is reted)
II.Guiding
III.
Saddle support
IV.
Clamp type support (no component is welded to pipe)
V.Spring support (procured item)
Lines are supposed to vibrate or having variable load
Supplied in locked postion, unlocked before commissioning.
7. Positive material inspection (PMI):
Done for AS & SS
PMI is done on the vendor shop before mechanical completion.
PMI has to be done on site also.
PMI should be done for joints (for AS & SS joint)

NDT is done after mechanical clearance.

P&ID is the mother drawing and we should achieve the work completion according
to it. Changes should be done in Isometric not in P&ID.
Type of pressure test:
I. Pneumatic test Air, Inert gas
II. Hydrotest Water
Purpose of hydrotest:
Detect the leakage if any.
Can withstand that pressure.
Pneumatic test pressure 1.25 X design pressure.
Soap solution is used in case of pneumatic testing.
Hydrotest pressure has to be retained for four hour.
Water has to be drained out and dried with the help of compressed air.
Equipment:
Static equipment a. columns
b. vessels
c. Exchanger, Filter
2. Rotating equipment Compressors, Pumps, Blowers.
Erection:
I.
Orientation of equipment with respect to nozzles*, vessels. (* to be preffered)

II.
Elevation
Alignment: level and verticality by
Hanging a plumb
Thredolite
Rotating equipment:
I.
Elevation of nozzle and orientation of nozzle.
II.
Grouting of pocket.
III.
Pump and motor is aligned with the help of dial gauge.
IV.
Entire grouting.
V.
Final alignment
With pipe
Without pipe
Single skid pump: Pump and motor in one package.
Double skid pump: Pump and motor in two package.
Assembly of compressor is done at site.
Column internals:
Trays:
Used in fractionation columns.
Trays supporting rings (TSR) are used to support the trays.
Trays are bolted to TSR.
Drawing used:
1 Isometric (3D).
2 P&ID (piping and instrument diagram)
3 PFD (process flow diagram)
4 GAD(general arrangement drawing)
Standard length of fabricated pipe 6 m
For beams, structural steels and pipe of smaller diameter like 2 and below we can
find pipe having length 12 m.
Flanges: Flanges shall be in accordance with the following codes except where otherwise
noted
Upto 24 (150# - 1500#) ASME B16.5
Upto 12 2500#
- ASME B16.5
Above 24
- ASME B 16.47series
Spectacle blinds are used for complete isolation.
PCV Pressure control valve
TRV- Temperature regulating valve
PRV Pressure regulating valve
PDT Pressure differential transmitter
Priority 1 work before Hydrotest
Priority 2 work after hydrotest
Volume of Naphtha tank 5000 kilolitre
Naphtha is pumped to ECU from Naphtha tank.
Naphtha tank diameter 18 m
Height 11.5 m

Five core of primer is used in tank. Two core of Epoxy primer and three core of final
primer.
Alcometer is used to measure the thickness of the primer.(Dry film thickness (DFT))
Tank :
Bottom-full radiography
Sides-10% radiography
In case of tank fabrication of tank is done on site and blasting is done after welding (of
all the material including tank plates).
Because of rain problem, overhead cabeling is suggested for the Lepetkata site.
We should do fire proofing of steel structure which is used in RCC structure.