Reliance

Recommended Practice
For
Welding Inspection of HMU Existing
Flare Line Shutdown Tie-in Job

25194-2-QM00-REC-ME-003

00 06.06.2013 Issued for Implementation PPP / ALJ KSS SNS

Prepared Checked Approved

Rev Date Revision
By By By
Reliance
Contents
1. Purpose .3

2. Scope 3

3. Abbreviations & Terms ..3

4. Responsibilities ..3

5. References ..3

6. Recommended Practices ..4

7. Attachments ..5

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1. Purpose

This guideline has been prepared as a step by step procedure for the
understanding of whoever connected with this job about specific requirements on
welding and NDT to avoid any miss out during execution of shutdown work there
by avoiding any rework.

2. Scope

Existing Flare Line at HMU in JERP.

3. Abbreviations & Terms

HMU : Hydrogen Manufacturing Unit

BA : Blow down Hydrocarbons (Flare)

NDT : Non Destructive Testing

MOC : Material of Construction

ITP : Inspection & Test Plan

WPS : Welding Procedure Specification

GTAW : Gas Tungsten Arc Welding

SMAW : Shielded Metal Arc Welding

QMD : Quality Management Department

HOD : Head of the Department

4. Responsibilities

Construction Manager / Engineer-In-Charge of Reliance is responsible for

ensuring that all modifications are carried out as per the latest revision of
approved drawings and fulfill the requirements of concerned specification, also
after the modification the same shall be tested and documented in accordance
with this procedure.
HOD QMD is responsible for maintaining this procedure.

5. References

25194-3PS-PL-006 : Piping Fabrication

25194-3PS-GAW-004 : Welding, NDE & PWHT for fabricated Piping
EPCMD-2-QM00-ITP-PP-010 : AG Piping fabrication & erection at field

25194-2-QM00-REC-ME-003, Rev.00 Page 3 of 5

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6. Recommended Practices
6.1 Details of existing flare line at HMU:

Main Header : Existing Flare Line

Service : BA (Non-Sour)
Pipe Class : EC 12 EA
Size : 30 NB x Sch. STD.
MOC : A671 CB60 EFW Pipe

6.2 Pre-shutdown Activities:

a) Ensure receipt of all ISOs with latest revision, welding, NDT & other related
documents related documents (if any).
b) Welders are to be qualified as per approved WPS.
c) ITP -2 QM 00 ITP PP 010 latest revision - A/G Piping fabrication & erection
at field to be followed.
d) During fabrication, location / orientation of the weld seam on the existing
line to be checked to ensure staggering of weld seam with the pup piece
(Refer specification no . 25194-3PS-PL-006 rev. 02, clause 5.6.2 & 25194-
3PS-GAW-004, Table of appendix 4, sl. No. 4). Same activity to be followed
during fit-up between pup piece & welded Tee.
e) Selection of WPS: Approved WPS with GTAW root + SMAW fill up and final
shall be used. In this case WPS No. 11110 shall be followed.
f) Before erection, ensure hydro test of the spools at fabrication shop.
g) All cleared spool sheet Xerox copies to be submitted before fit up at site.

6.3 Shutdown Activities:

a) Before cutting the existing line, check the thickness of existing line.

b) After cutting, check internal cleaning (approx. 50 mm from bevel edge) to

avoid any repair at root and to ensure the removal of cutting slag / spatters
from the inside portion.

c) During fit up and welding check the following:

- Root gap & bevel angle as per WPS.

- Mismatch if any.

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- Check any bevel edges by Dye Penetrant Test / Magnetic Particle Test for
any material defects. (Before fit-up activity).

- Check the welding parameters during welding.

d) Punch mark at 00 mm distances, on both side of the pipe, before root

welding to locate center of the weld, to facilitate Ultrasonic Test.

e) Check proper cleaning after each and every weld pass.

f) After completion of final weld, visual inspection of complete joint.

g) Check Dye Penetrant Test on final weld and cleat area.

h) Grinding & buffing approx. 150 mm to 200 mm to be done from both sides
of the weld edge (including flush grinding of the long seams).

i) Ultrasonic Test to be carried out on all Tie-in joints.

6.4 Post-shutdown Activities:

a) Restoration of removed items

b) Document handing over after final review for completeness & correctness.

7. Attachments
Nil

25194-2-QM00-REC-ME-003, Rev.00 Page 5 of 5

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