WORK INSTRUCTION FOR DOC.

NO:
PLL/PSPL/QC/P17
MAINLINE VALVE / INSULATION JOINT
INSTALLATION REV. NO.: 0
PUNJ LLOYD LTD.
PROJECT: PUNE SOLAPUR PIPELINE PROJECT
ISSUED TO
NAME:
CONTROLLED COPY NO.: DESIGNATION:
ISSUED BY

SIGNATURE/DATE:

PUNJ LLOYD LIMITED

NEW DELHI
______________________________________________________________________

WORK INSTRUCTION

FOR

MAINLINE VALVE / INSULATION JOINT

INSTALLATION

Issued for Review M.Thaha S.C.Rana

0 12.01.06 & Approval PM
Engr. QC Sr. Engr. QC

DESCRIPTION PREPARED BY CHECKED BY APPROVED BY REVIEWED BY APPROVED BY

REV DATE
OF REVISION (PLL) (PLL) (PLL) (EIL) (EIL / HPCL)
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 WORK INSTRUCTION FOR DOC.NO:
PLL/PSPL/QC/P17
MAINLINE VALVE / INSULATION JOINT
INSTALLATION REV. NO.: 0
PUNJ LLOYD LTD.
PROJECT: PUNE SOLAPUR PIPELINE PROJECT

TABLE OF CONTENTS

1.0 PURPOSE............................................................................................................................................3

2.0 SCOPE.................................................................................................................................................3

3.0 REFERENCES....................................................................................................................................3

4.0 TERMS & DEFINITIONS..................................................................................................................3

5.0 RESPONSIBILITIES..........................................................................................................................4

6.0 METHODOLOGY..............................................................................................................................5

7.0 HEALTH, SAFETY AND ENVIRONMENT......................................................................................6

8.0 QUALITY ASSURANCE / QUALITY CONTROL............................................................................7

9.0 APPENDICES / FORMATS................................................................................................................7

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 WORK INSTRUCTION FOR DOC.NO:
PLL/PSPL/QC/P17
MAINLINE VALVE / INSULATION JOINT
INSTALLATION REV. NO.: 0
PUNJ LLOYD LTD.
PROJECT: PUNE SOLAPUR PIPELINE PROJECT

1.0 PURPOSE

The purpose of this procedure is to lay guidelines and requirements and to

establish a method to control the main line valve and insulation joint
installation in accordance with drawings and standards to be used in the
14”/12” Pune - Solapur Pipeline Project Construction Work by Punj Lloyd
Limited.

2.0 SCOPE

The scope covers defining of norms for installation of valve installation,

insulation joints for construction of Pune – Solapur Pipeline project.

3.0 REFERENCES

Following documents in totality or in part shall form the reference

documents:

 Specification For Fabrication and Erection (Onshore) 6-44-0012 Rev 02

 Contract document no. 6545/T-210/04-05/VKB/02.
 Design and Construction Requirements For Cross Country Hydrocarbon
Pipelines OISD B 141
 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia, and Alcohols ASME B 31.4
 HSE Manual

4.0 TERMS & DEFINITIONS

 For the Purpose of this document, the term “shall” indicates a mandatory
requirement and “should,” indicates a recommended practice.

 All terms used in the development of this procedure are defined in

a) Quality Assurance Manual

b) EIL’s Specification

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 WORK INSTRUCTION FOR DOC.NO:
PLL/PSPL/QC/P17
MAINLINE VALVE / INSULATION JOINT
INSTALLATION REV. NO.: 0
PUNJ LLOYD LTD.
PROJECT: PUNE SOLAPUR PIPELINE PROJECT
5.0 RESPONSIBILITY

Project Manager - Shall report to Project Director.

- Shall provide all necessary resources to
implement this procedure.

Resident Project Manager - Shall report to the Project Manager.

- Shall be responsible for quality of the job
and shall provide adequate resources, tools
and infrastructure to implement this
procedure.

Resident Construction Manager - Shall report to the Resident Project

Manager.
- Shall be responsible for overall
implementation, monitoring and control of
construction and commissioning activities

QA/QC Manager / In-charge - Shall report to Project Manager and Head

QA/QC at H.O.
- Shall be responsible for the compliance of
this procedure.

QA/QC Engineer - Shall report to QA/QC Manager / In-charge.

- Shall ensure proper implementation of this
procedure.
- Shall checks and verifies the
Valve/Insulation joint Installation activities.
- Verifies and countersigns Restoration report

Erection Engineer - Shall report to the Resident Construction

Manager.
- Preparation of schedule addressing specific
issues and characteristics of each spread.
- Responsible for overall control and safety
management and for the implementation of
procedure and supervises the activity.
- Generates reports during the activity and
records data.
- Shall be responsible for erection of all
piping, rotatory and static equipment as per
the approved drawings and standards.

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 WORK INSTRUCTION FOR DOC.NO:
PLL/PSPL/QC/P17
MAINLINE VALVE / INSULATION JOINT
INSTALLATION REV. NO.: 0
PUNJ LLOYD LTD.
PROJECT: PUNE SOLAPUR PIPELINE PROJECT
HSE Officers - Shall report to Resident Construction
Manager.
- Implementation of all safety requirements
during erection of pipe & valve installation
activity.
- Ensuring that the communication system is
working properly and that emergency
equipment is in place

6.0 METHODOLOGY

INSTALLATION OF VALVES & VALVE STATIONS

Valves shall be installed in line with the AFC drawings. The civil and
structural works shall be carried out with relevant specification for the
purpose and in accordance with the approved drawings. This work as a
minimum shall include cleaning, grading, fencing, foundations etc. All
above ground structures shall be painted as per approved procedure.
Pedestals shall be cast at valve locations after embedding an insulating
hard PE Sheet of at-least 5-mm thick of equivalent as indicated in the
respective drawing. Block and SV units shall be completely assembled,
tested and made fully functional including all related instruments.

Clamping of pipes shall be done as indicated in the approved

drawings/standards. An insulating sheet of at least 5-mm thick hard PE
sheet shall be installed under pipe clamps.

Valves with flow arrows shall be installed according to the normal flow in
the pipeline. During welding, the valves shall be in fully open position. In
addition all manufacturer instruction shall be followed. Care shall be taken
to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.

Valves shall be installed on section of pipeline in horizontal position or

within an inclination not greater than that allowed by valve manufacturer.
Valve with flow arrows shall be installed according to the normal flow in the
pipeline.

For valves and piping, installed the anti-corrosion coating/painting shall be

done as per the requirement of the relevant specifications issued for this
purpose. The anti-corrosion below ground coating shall extend upto 300
mm above grade at the lowest point.

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 WORK INSTRUCTION FOR DOC.NO:
PLL/PSPL/QC/P17
MAINLINE VALVE / INSULATION JOINT
INSTALLATION REV. NO.: 0
PUNJ LLOYD LTD.
PROJECT: PUNE SOLAPUR PIPELINE PROJECT
All valves always be handled using equipment and method to avoid impact,
shaking and stresses. The equipment and tools for lifting and handling shall
never be done through hand wheels, valve stem, flange point and other
parts, which may suffer damage.

All sectionalizing valves and other on line assemblies shall be

prefabricated with a pretested pup piece of 1 mtr minimum length welded
on either side of the valve and tested hydrostatically ex-situ as per the
applicable specifications. The test pressure shall be as per valve
manufacturer and as per the instructions of EIL. All such assemblies shall
be installed at the locations shown in the drawing only after successful
completion of the hydrostatic test and dewatering just prior to pre-
commissioning The ends of the valve assembly shall be closed off during
transportation to site. All tie-in joints shall be 100% examined by
radiographic and ultrasonic testing. Tie in of valve assembly shall be done
as per approved tie-in procedure just prior to pre-commissioning.

INSULATION JOINTS

Insulation joints shall be installed at locations shown in the approved

drawings. Prior approval from the company shall be taken before the
installation of insulation joint.

Handling and installation of the insulating joints shall be carried out with all
precautions required avoiding damage and excessive stresses and
ensuring that original pipe length is not reduced. External coating as per
relevant specifications issued for the purpose shall protect the insulating
joints and the welded joints.

During the execution of the in line connection welding, the propagation of

heat shall be avoided. To achieve this, the joint shall be kept cold by means
of rags continuously wetted.

Insulation joint shall be electrically tested before welding into the pipeline.
The electrical conductance test shall be carried out using a megger.
Measurement of insulation resistance across the joint shall be
approximately 1 mega ohm. The test shall be repeated after installation
and welding of the joint into the pipeline to verify that assembly is not
damaged.

7.0 HEALTH, SAFETY AND ENVIRONMENT

 PLL shall ensure that the machine operator Involved must be an

experienced person.
 PPE is a must in this activity.

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 WORK INSTRUCTION FOR DOC.NO:
PLL/PSPL/QC/P17
MAINLINE VALVE / INSULATION JOINT
INSTALLATION REV. NO.: 0
PUNJ LLOYD LTD.
PROJECT: PUNE SOLAPUR PIPELINE PROJECT
 Personnel around the machine must be cautious about overhead falling
objects.
 During the movement of earth moving equipments the operator must
blow horn to caution the people around.
 All Measuring & Test Equipments used must be well maintained.
 All lifting devices & Tolls used shall be well maintained and approved
by a competent authority.
 Regular awareness program shall be arranged.

8.0 QUALITY ASSURANCE / QUALITY CONTROL

Mainline Valve installation / Insulation joint installation activities shall be

executed in accordance with the requirements of this procedure.
Quality Records of Valve / Insulation joint installations shall be retained.
The respective department shall retain original quality records. The
company shall forward copies of all quality records to the QA/QC
department for review.

9.0 APPENDICES AND FORMATS

Appendix : 1 Inspection and test plan

(PLL/PSPL/QC/P17 Rev 0)

Format : 1 Daily Inspection Report Format No.

(PLL/PSPL/QC/P17/F01 Rev 0)

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