CAREER EPISODE 3

C.E.3.1 INTRODUCTION:

C.E.3.1.1 DURATION: April 2008 to February-2009

C.E.3.1.2 LOCATION: Cairn India Limited, Viramgam, District:

Ahmadabad, State: Gujarat, India.

C.E.3.1.3 COMPANY: Cairn India Limited.

C.E.3.1.4 POSITION: Senior Engineer Mechanical (2011 to till now)

C.E.3.2 BACKGROUND:

C.E.3.2.1 EMPLOYER PROFILE:

Cairn India Limited is a subsidiary of Vedanta Resources. Cairn India
Limited is an Oil and gas exploration and production company. CIL is
engaged in both the upstream and midstream business. CILs this
hydrocarbon block is Indias second largest discovery as crude oil
reserve. CIL has crude oil processing terminal at Rajsthan, India and
worlds longest continuously heated crude oil pipeline of dimension 24
inch diameter and 670 kilometer long. Pipeline starts from dessert area
Bramer of Rajsthan, India to coastal area Bhogat of Gujarat, India. CIL
also operates 8 inch diameter natural gas pipeline. Pipeline includes
terminals, spur lines, above ground installation, custody transfer meter
and interconnections throughout the way. Terminal includes various
facilities like main line pumps, crude oil storage tanks, gas turbine
generator, pig launcher/receiver, dual fuel fired fire tube boiler, fire
water network etc. CIL supplies crude oil to various government owned
and private sector oil refinery for further processing of crude oil.
Furthermore, CIL supplies Natural Gas to fertilizer plant too. This
project contributes more than 23% of Indias domestic production.

C.E.3.2.2 OBJECTIVE:

After achieving handsome experience with Reliance Gas Transportation

Infrastructure Limited, I got an opportunity to work with another major
Oil and Gas company, Cairn India Limited. This company is involved in
prime hydrocarbon business, Crude Oil and Natural Gas. I was given an
assignment for modification and extension of existing fire water
network for terminal premises. This project was quite different from my
previous experience. Therefore, it was a challenging task for me. Main
purpose for this project is to cover crude oil storage tank dyke,
hazardous chemical storage building and leaving quarters for fire
fighting, in case of any emergency. I learned many things by executing
this crucial project. Various activities were included in this project like
project planning, bill of material preparation, purchase requisition of
BOM, service contract finalization, welding procedure preparation and
approval, welder test perform, excavation, installation, non destructive
test as per procedure, hydro test, backfilling etc. This project was great
learning opportunity for me in field of pipe welding, pipe and fitting
material selection and its specification and many more.
C.E.3.2.3 ORGANIZATION CHART:

General Manager-Field Pipeline Operation

DGM- Pipeline Operation

Maintenance Manager

Maintenance Superintendent

Senior Engineer (My Position)

Supervisor Contractor

Fitter, Welder, Grinder, Rigger, Helper

C.E.3.2.4 PROJECT RESPONSIBILITY:

As terminal is in its fully operational state, as crude oil is normally kept

stored in buffer storage tank, various activities were planned in view
not to disturb pipeline operation and uninterrupted crude oil sales to
customer. I was responsible for below mentioned activity.

Fire water network Pipeline isometric drawing

understanding and ensuring approval by joint operation and
maintenance field visit.
Bill of Material preparation for pipeline laying.
Purchase requisition creation in SAP MM module for
pipeline bill of material and pipe wall external wrapping
coating/painting material as per material specification and
standard.
Scope of work preparation and ensuring approval from
higher management for further course of action.
Pipeline laying service quotation arrangement by asking
competitive rate to reputed service provider and creating
purchase requisition.
Technical bid evaluation for Service contract finalization.
Job planning activity to be done in coordination with
operation and contractor team.
Pipeline and coating material inspection once received at
warehouse and acceptance.
Pipeline welding procedure preparation.
Welder test perform at site for skill check and to minimize
weld defect and downtime.
 Job safety analysis and Lifting plan preparation for the job.
Lifting tools and tackles healthiness checks.
Daily tool box talk providing to site excavation, pipeline
fabrication team and job supervision during execution to
ensure safety and job progress.
Excavation to lay pipeline.
Pipeline fabrication and installation in excavated trench.
Radiography activity for pipe weld joint.
Hydro test of entire fabricated pipeline.
Cold wrapping coating and painting on fabricated piece of
pipeline section.
Trench backfilling and land restoration.
Fire water network handing over to operation team.
Further documentation for processing on time payment to
contractor.
Piping and instrument diagram update.

C.E.3.3 PROJECT ENGINEERING ACTIVITIES:

C.E.3.3.1 Due to further expansion of crude oil buffer storage tanks, it

was an obvious requirement of fire water net work to cater any
emergency.

C.E.3.3.2 After receiving all pipeline isometric drawing, I, along with

operation department representative, made joint field visit for job
execution planning.

C.E.3.3.3 Operation team is responsible for any process isolation.

Isolation is decided jointly by operation and maintenance team. As part
of maintenance team, I mentioned primary requirement for process
isolation on P & ID and submitted to operation for their further
approval, preparation and planning from operation point of view.

C.E.3.3.4 I prepared bill of material as per isometric drawing and ASME-

American society for mechanical engineers. Bill of material includes
number of pipes as per standard length, pipe fittings such as 90 and
45 elbows, equal and unequal tees, slip on and weld neck flanges, stud
bolts & nuts, spiral wound gaskets and gate valves of various sizes.

C.E.3.3.5 Piping, fittings, wrapping/coating and painting material

quotation was arranged from reputed supplier for purchase requisition
creation through SAP MM module system for further procurement
action by purchase and supply chain management team.

C.E.3.3.6 For this project, I made scope of work as per companys

standard procedure and forwarded further for higher managements
review and approval.

C.E.3.3.7 In mean time, I arranged quotation for pipeline fabrication

and laying service from piping fabrication contractor.

C.E.3.3.8 After receiving approval of SOW and quotation, I created

purchase requisition in SAP MM module for further service contract
finalization action by purchase and supply chain management team.

C.E.3.3.9 Once material received at site warehouse, I inspected all

materials and confirmed by checking all test certificates including heat
number, material composition and various test performed etc.

C.E.3.3.10 After receiving request for technical bid evaluation for

service contractor finalization from PSCM department, I thoroughly
understood all partys technical service offer and concerns. And
selection was made based on acceptance criteria. I cleared all vendors
eligible for the job and left rest on PSCM department for final purchase
order processing.

C.E.3.3.11 After final selection of service provider, I asked vendor to

visit our premises for Minutes of Meeting. So that major points and
concerns can be discussed to avoid unwanted issues during job.
Specially, I emphasized to follow safety rules as I give utmost priority to
safety.

C.E.3.3.12 I prepared welding procedure in coordination with

contractor supervisor as per standard.

C.E.3.3.13 I asked vendor to mobilize their team along with all tools and
tackles for further activity. Tools and tackles include welding machine,
welding electrodes, electrode Owen, grinding machine and wheel, gas
cutting set, lifting web slings, D-shackle, chain pulley block etc.

C.E.3.3.14 I prepared job safety analysis for excavation job and got
approval from senior authority for field implementation.

C.E.3.3.15 In mean time, I started excavation for underground road

crossing section and RCC support for above ground piping. Also I
arranged hard barricade around the excavated trench for safety point
of view.

C.E.3.3.16 I gave tool box talk to excavation team for hazards involved
in the job on daily basis and ensured excavation to be performed in
reverse bell fashion to avoid excavation collapse.
C.E.3.3.17 Once, contractor mobilized all tools and tackles at site, I
performed joint inspection with electrical engineer for healthiness
checks of all mechanical and electrical equipments. My major concern
was valid load test certificate of all lifting tools and tackles.

C.E.3.3.18 Welders test is the first step to start the fabrication job.
Therefore, I asked vendor to perform welder test on 4 inch pipe piece
and sent to laboratory for testing.

C.E.3.3.19 I prepared job safety analysis for fabrication job in

coordination with senior authority and contractors team to understand
job, hazards involved and control measures.

C.E.3.3.20 I started withdrawing piping material from warehouse and

shifted to site to start welding job.

C.E.3.3.21 On primary basis, I prepared isolation mark up drawing on P

& ID for operation department review.

C.E.3.3.22 I started job by applying work permit in SAP system to

perform hot work.

C.E.3.3.23 It was my daily schedule to apply and receive work permit.

Also, after receiving permit, I used to reach at site on time and provided
tool box talk to fabrication team on daily basis.

C.E.3.3.24 Pipe end beveling machining and welding job were started.
Grinding machine was used for beveling. Before grinding of pipe
started, I inspected grinding machine for electrical department check
and grinding wheel healthiness checks by filling check sheet.

C.E.3.3.25 For pipe end root welding, tungsten inert gas welding was
performed for better joint and arc welding was performed to fill up.
C.E.3.3.26 After completion of pipe welding job, I inspected welding
joint visually and by using die penetration kit test for finding presence
of any welding crack.

C.E.3.3.27 Also I arranged radiography test of 10% inch diameter of

total welding joint inch diameter. I selected most of the weld joint
which were about to buried underground for road crossing.

C.E.3.3.28 Hydro test was also arranged after clearance received from
quality department by inspecting radiography films.

C.E.3.3.29 Hydro test of entire fabricated pipeline was performed at 1.5

times for its design pressure. Also I used pressure recorder for
recording purpose.

C.E.3.3.30 After successful hydro test, I commenced cold wrapping

coating followed by external pipe wall scarping and cleaning. These
sections were underground road crossing which were to be buried.
Also, I asked to start painting on aboveground pipe line.

C.E.3.3.31 Also, I kept PTFE teflon sheet packing inside pipe support
clamp and PTFE teflon rod at the bottom of pipe and metal plate
support at every RCC support to prevent crevice corrosion.

C.E.3.3.32 Officially, I handed over the fire water system to operation

department.

C.E.3.3.33 Once, all activity completed, I asked to our companys draft

man to modify the existing P & ID.

C.E.3.3.34 Making payment to contractor was also my responsibility. I

received payment invoice from vendor along with all job detail and
measurement sheet. I processed contractors payment in SAP system
by attaching all job detail and measurement sheet.

C.E.3.3.35 I learned many things specially pipe and fitting material,

design standard, welding procedure and many more.

C.E.3.4 SUMMARY:

I believe that learning is a continuous process. In engineering

field, by executing different kind of project, I can have excellent
knowledge. This project was an opportunity for me to explore
new things as pipe line installation is also a vast subject to learn
like piping codes, standards and many more. In this project, I had
a chance to learn civil engineering also.
In this away, I completed this project in safe manner.