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Lesson Learnt

Tray modelling for air cooler vendor

The cable trays are running beneath the headroom level on the cooler access platform hence obstructing access to the
This had occurred due to,
1. Non modelling by electrical\instrument team since it was not included in their scope.
2. Lack of interaction by discipline engineer with the layout engineer.
Tray modelling for air cooler vendor

1. Sample modeling was done for 2 bays of air cooler to study the change.
2. RLM for all the affected coolers were prepared by EIT team & issued through coreworx to PDO.
Tray modelling for air cooler vendor

1. Tray modeling within packages shall be included in modelling scope. Layout shall be verified before IDIT is issued to civil.
2. EIT shall interface with layout team through model manager to ensure the integrity of layout.
Interference with Splice plate

Concern: Pipe supports directly resting \ welded on the beams where splice plates are

Resolution : Line to be rerouted \ support to be modified to clear splice plate location.

PDMS : Generally splice plate locations are mentioned in structure GA but not
modeled until TEKLA model comes out, hence depending on the schedule of iso
issuance, civil needs to model the splice plate as per GA from the initial stage itself
RF pad on galvanised pipes – 18011
As per PMS RF pad is not required but the option to include RF pad is available in PDMS.

Iso identified : 14 nos
Red line markup provided through coreworx to contractor.
Ref nos : IA-GEC-PECONTQ-MP-0712
Branch table of 18011 Lesson :
A rule can be included in PDMS to verify branch
connection & generate error while iso is extracted if
mismatch with the branch table.
Handwheel\Spindle orientation valve
Construction team requested
to specify the spindle & handwheel
in the iso for better understanding
to the layman.

Few valves had to be re oriented as

The layman had interpreted the
Drawing incorrectly.

Lesson : The orientation of spindle,

Handwheel \ gear \ lever shall be
Mentioned specifically in the iso
To avoid any misinterpretation
Irrespective to the valve type.
• Check length of spool provided post cutting the 45 deg angle on open vent lines wrt the fit up of bird screen.
• Extra care to be taken care for the large bore lines esp above 12” when the linear length of the 45 deg cut exceeds 300mm.
The bird screen at 4 locations had to be redone at site as per new dimension.
• KHF-00-PPFP003-ZV-C03-00001-0001_05_bird screen
Modelling of Nozzle as per GA

Concern : Nozzle touching the platform steel member.

Resolution: Platform was modified to provide clearance as per std.

Lesson : The modelling for esp. critical \ high pressure equipment shall consider the forge shape of the nozzle. PMDS shall provide the
Provision to include such graphics of nozzle to check for actual interference.
Centralizers for CS sleeves – UG
Centralizers are provided in iso as per Basis for placing centralizer at site:
Vendor requirement.
Calculation for Centraliser spacing as per method of
statement provided by the contractor based on
agreement with vendor :

Length of sleeve / ( nos of centralizer + 1 )

22465 / (7+1) = 2808mm or 2.8m

But while placing actually at site the sleeve began to sag due to various reasons such as,
1. Alignment not yet complete.
2. Temporary support was located far from GRE line.
3. Sand padding incomplete.
Centralizers for CS sleeves – UG
However as per SP-1208 (though a spec for pipe line) PDO
recommended to included additional spacers at either ends.

Action :
Additionally 866 nos of centralisers were identified & ordered

Lesson :
Since sleeve\centraliser requirement are project specific, the philosophy for requirement of centralizers from
constructability point of view shall be discussed with client & documented before or during 30% model review.
Need of couplers \ lamination joints on GRE pipes at
location where sleeve length exceeds the random
length of GRE pipe.
Based on method of statement, the GRE pipes are partially hydro tested & this will call for plugging
either ends of pipe. Post hydro testing the plugged ends are cut resulting in one side of pipe which
becomes a male end comes in contact with another male end

It was discussed that neither couplers nor lamination joints shall be used but unnecessary cutting of
pipe can be avoided by appropriate sequencing of bell\spigot pipes. The usage of lamination joints
shall be regulated by taking approval for case to case basis from the company by the construction

The hydro test plan can be discussed during construction review & the conclusion shall be minute
hence the same is included in the method of statement which shall be referred during the execution
MTO for encirclement pads:

The basis for WP\EP length considered in yibal

WP – 2 Nos of WP considered in one pieces of Pipe.
EP – 1 No of EP considered in one pieces of Pipe.

Full encirclement PAD requires two times the length than the dimension specified in the support drawing. From 360
degree we cannot cut two pieces and weld to the main pipe . There will be cutting wastes so second half shall be Cut
from other pipe.

2. Wear pad for elbow shall be considered in MTO as additional elbow qty
Cont. co ordinate error leading to
At site, it has been noticed that there is a discrepancy
in the coordinates for the drawing /line number
3101-29-8-F-380502-11422-NN-68. Spool to be modified
on the header 3101-29-F-380502-68 to suit with the
branch 3402-04-F-380580-51 location.

The path forward is placed here below:

The new location is depicted in green on the above
snapshot. In order to adjust at new location,
you may cut the line and rotate it as shown above,
re-weld and proceed with branching.
Please note that NDT requirements for new joints
shall be as per relevant specifications.
1. Lined pipes shall be captured with maximum length & profile in PDMS so that the maximum extent & flange qty does
not exceed the agreed spec..
2. Spacer ring shown in ROTO – GRE combination shall be for full face against what is shown in detail – 4 of roto std
issued for ykp.
4. Check the possibility to use clamped line stop for flanged spools to facilitate constructability changes if any.
5. Hydrotest vent \ drain missed - 3506-02-A-841161-51
6. Excess bolt length for GRE interface flange.
7. Bolt length not considered for plate on the stilling well nozzle for drain vessels
8. Debate to use pneumatic test instead of hydrotest on IA , flare lines, large OD pipes(80”,64”,48”etc).
9. All pump seal lines to be modelled to avoid any clash \ rework at site (P-8302A/B)
10. MTO for spacer ring for GRE to be checked to ensure the ring -1 & ring -2 are not missed.
11. Knowledge on bolt torque value required for non std combination apart from what is provided in SP-2020. (ex. Higher
flange size, gasket other than std rqd)
12. PWHT on valve- pipe spool shall be provided on either side of welded valve where PWHT needs to be carried out at
13. Elevation of equipment changed in PP area due to miscommunication between process & piping
14. CPP GRVE flange crack study.
15. SP-2051 – different test pressure within the same pipe class leads to creating more test pack breaks. In a same pipe
class all line sizes shall have same test pressure.
1. SP-2051 – Lack of clear details on activities to be carried out during pre comm.
2. Std pipe support on steel members – strength of the member to be verified to avoid shaky pipe supports
3. Orientation of NRV per system
4. Dissimilar welding on header-branch connection