Nuclear Power Corporation of India Ltd

Plant Water System Package –Kakrapar Atomic Power Project 3&4

Document Acceptance Note

Procedure Number: IVRCL/PWSP/KAPP3&4/PM/14 Rev: 00

Name of Procedure: PROCEDURE FOR ERECTION OF PIPING AND

STRUCTURE.

Submitted By: IVRCL Infrastructures & Projects Ltd

WO/Contract No: CMM/MEQ/23-71-2-1016/PO-6030 Dated: 6th Oct.2010

Name of Work: Plant Water System Package-KAPP 3&4

ABOVE WORK PROCEDURE /PROPOSAL HAS BEEN REVIEWED AND FOUND

CONFORMING TO THE REQUIREMENT OF NPCIL SPECIFICATION AND
RELEVANT CODES, HENCE ACCEPTED.

REGISTRATION NO: KAPP 3&4/Piping/71120 Date:

NAME & DESIGNATION SIGNATURE

REVIEWED BY

CONCURED BY

APPROVED BY
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PROJECT: NUCLEAR POWER CORPORATION OF INDIA LIMITED

KAKARPARA ATOMIC POWER PROJECT ( 2 X 700MWe)
GUJARAT STATE
PLANT WATER SYSTEM PACKAGE

CLIENT
NUCLEAR POWER CORPORATION OF INDIA LIMITED

EPC CONTRACTOR

IVRCL INFRASTRUCTURES & PROJECTS LIMITED -

HYDERABAD
TITLE

PROCEDURE FOR ERECTION OF PIPING AND STRUCTURE

.

This Document is the property of IVRCL Infrastructures &Projects Limited; it should not be used,
copied or reproduced without their written permission.

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WORK ORDER NO: CMM/MEQ/23-71-2-1016/PO-6030. Dated: 6th Oct.2010

DOCUMENT NO: IVRCL/PWSP/KAPP 3&4 /PM/14 Rev: 00

PREPARED BY:

(Bappadittya Nandi)
Sr. Engineer(QC-Mech)

REVIEWED BY:
(Anil C Nadgir) / D. Satish Reddy
Assistant Manager (Projects) / Manager (Projects)

APPROVED BY:
(L. Srinivas)
RCM

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REVISION CONTROL SHEET

WORK ORDER NO: CMM/MEQ/23-71-2-1016/PO-6030. Dated: 6th Oct.2010

DOCUMENT NO: IVRCL / PWSP/ KAPP3&4/PM /14

APPROVED NO.OF
SL.NO REVISION NO. DETAIL DATE
BY PAGES
01 R0 First Issue 10

CONTENTS

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1. Purpose
2. Scope of work
3. Applicability and References
4. Responsibility
5. Pre-Requisites
6. Procedure
7. Acceptance criteria
8. Checklist
9. Health, Safety & Environment
10. Records
11. Distribution
12. ITP for Erection of Piping and Structure – Encl.
13. Erection of Piping and Structure’s Report-Format-Encl.

1.0 PURPOSE

This purpose of this procedure is to lay down specific guide lines and requirements for
piping and structural erection which has been fabricated at the shop in accordance with
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the approved drawings and standard for mechanical construction of piping, piping
structures, supports, cross over, platforms, gratings, and associated pipeline works at
Plant Water System Package – Kakrapar Atomic PowerProject-3&4.

2.0 SCOPE OF WORK

The scope covers the following activities for installation of piping and all types of
mechanical works in line with the subject work procedure as per the approval of
NPCIL approved procedures of piping and structural works fabrication and other
specials and fittings on line as per the approved drawings and welding process qualified
at project.

3.0 APPLICABILITY & REFERENCES:

i) Technical Specifications;
PC-P-285
PC-P-344
ii) Relevant Indian and international standards;
iii) IS: 3589 / IS: 800 / IS: 816 / IS: 2062 – latest revisions.
iv) Relevant approved work procedures.

4.0 RESPONSIBILITY
The prime responsibility of implementation of the procedure lies with Project manager
supported by the QA/QC Manager, Procurement Manager and the subordinate staff
underneath them with project execution engineer and project quality engineer deployed
at site.

5.0 PRE-REQUISITES:
Availability of requisites tools & tackles for erecting pipe lines.

6.0 PROCEDURE:
6.1 Preparation of isometric drawings for and up to 40 mm dia. piping works:

On receipt of approved GAD, s and AFC drawings isometric drawings shall be prepared and
forwarded to NPCIL for their review. Copies of all approved drawings along with the erection
plan depending on the size, weight and equipments used in erection shall be submitted to
NPCIL, if required for their concurrence and clearance for erection. Other piping and structural
fabrication and erection works shall be as per guidelines of relevant technical specifications,
Indian relevant standards and good engineering practice.

6.2 Identification of weld Joints

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For identification of the weld joints for the particular piping line / position of the
structure, a number shall be given to each production weld joint. The joint number is
essential to keep the records of the welder performance and orderly preservation of
the films, whenever this is required for traceability. The erection joints shall be
separately marked or identified prior to pre-fabrication. Joint number should be
marked on the isometric drawings.
The particular pre-fabricated section of a line / position of structure shall be denoted
by spool / joint number etc., which consists of number of joints. Prefabrication shall
be kept maximum and field joints shall be minimized as far as possible.

6.3 Erection
After radiography clearance and shop priming as per NPCILs specification and
approved relevant procedure with manufacturer datasheet the erection shall be done.
Before the erection of the piping spools / structure with all the fittings, flanges and
valves etc. shall be made available on the site with their respective fastener and
gaskets .The actual size shall be calculated in accordance with the plan / elevation /
isometric drawing / P & I diagram .For proper pipe supporting the pipe support shall
be erected with adequate rigidity as per the detailed engineering drawing.

The fabrication and the welding procedure shall be same per the relevant approved
work procedures for fabrication and welding of piping and structures. The final
tightening of the bolts shall be done after field welding. During the welding all the
valves wherever are on the system line shall be in open mode. After the completion
of the welding, visual inspection and radiography of the welded joints shall be
performed.

Before erection all the prefabricated spools pieces / structural members, pipes fittings
etc shall be cleaned by the suitable means. Pipe to pipe structure /equipment
distance /clearance shown in the drawing shall be strictly followed as theses
clearances may be required for the free expansion of the piping equipment. Where
ever cold pull is specified the necessary gap shall be maintained as indicate in the
drawing. Slopes for various lines as indicated in the drawing shall be maintained. All
expansion joints /bellows shall be installing in accordance with the specification and
installation drawing supplied. On all of the above the erection teams shall specially
ensure the following for head wise items:

6.3.1 Flange connection:

While fitting up the flanges care shall be exercised to properly align the pipe and
check the trueness of the flanges, so that faces of the flanges can be pulled together,
without inducing any stresses in the pipes and the equipment nozzles. The assembly
of a flange joint shall be done in such a way that the gaskets between these flange
face is uniformly compressed. To achieve these both shall be tightened in a proper
sequence.

6.3.2 Vents and Drains:

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High point vents and low point drains shall be provided as per approved drawings.
The details of the vents and drain shall be as piping material specification / relevant
job procedure and standards

6.3.3 Valves:

Valves shall be installed with the spindle orientation as shown in the layouts
drawings. .Care shall betaken to ensure that the valves are installed with the “flow
direction arrow” on the valve body pointing the correct direction.

6.3.4 Instruments:

Installation of the inline instruments shall be from the part of the piping erection
work. Limits of piping instrument work shall be shown in the drawings
/orientations /locations of tap offs for temperature pressure, flow, level connections
etc shown in the drawings shall be maintained .Care shall be taken to avoid damages
and entry of the foreign material into the instruments line during transportation,
installation and testing.

6.3.5 Line Mounted Equipment:

Installation of line mounted items like fitter’s strainers, stream traps, super heater
ejectors, sample collectors, mixers, vents and drains, flame arrestors, sight glasses etc
.including their support shall form their piping arrangement erection details as per the
P&I drawings / isometric drawings..

6.3.6 Bolts and Nuts:

Grease mixed with graphite powder shall be applied to all bolts during storage and
during erection.

6.3.7 Pipe Supports:

Pipe supports shall be installed as indicated in the drawings for the all the piping
supports drawings and specifications duly approved by NPCIL.IVRCL shall in turn
carry out the complete alignment of the line erection and welding of the pipe supports
in pipeline and with the necessary structural works with the approved WPS and PQR
for welding of structural pipe supports for the project and in line with the approved
piping and related structural drawings.

6.3.8 Painting:

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All piping spools and structural members shall be shop primer before erection. The
weld joint shall be masked by the masking tape so that the primer does not cover the
weld joints .After drying the paint, such mask shall be removed before erection of the
spool .Shop priming and painting shall be done as per approved procedure separately
shall be submitted in line with the contact specifications.

6.3.9 Pipeline Hydro Testing:

After completion of erection, hydro testing of process piping shall be carried out
as per approved specific hydro testing procedure separately shall be submitted in line
with the contact specifications.

7.0 ACCEPTANCE CRITERIA:

QA/QC of IVRCL & NPCIL both should be accepted as per specification of NPCIL
& ASME Boiler Pressure Vessels codes (section-II-C / V / VIII / IX)

8.0 CHECKLIST:

Following activities should be checked

i) Material Identification MRN / MTC / ITP

ii) All erection materials available as per drawing & specification
iii) Fit-Up check as pre specification
iv) Hydro Testing check as pre specification

7.0 HEALTH, SAFETY & ENVIRONMENT

This is an environment friendly project. Following safety points shall be shall be

followed:

 Referred approved HSE plan for complete details

 Entire working area shall be barricaded.
 All utilities shall be identified and protected so that they do not foul with
the execution work. All lifting tools and tackles shall be periodically
inspected against any damage.
 All heavy equipments shall be maintained in good condition as per
maintenance schedule. All workmen shall use proper personal protection
gears.

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 All employees shall follow the Employee Occupational Health & Safety
Rules.
 Environment protection shall be followed.

10.0 RECORDS:

The formats/records that shall be used as evidential records of the site activities that have
been carried out shall be recorded and preserved in the below mentioned subsequent
formats given as below:

11.0 DISTRIBUTION
 NPCIL ACE(PIPING)
 NPCIL PIPING
 NPCIL QA
 NPCIL FE
 IVRCL- Execution
 IVRCL-QA

12.0 ITP FOR ERECTION OF PIPING AND STRUCTURE. ANNEXURE-I, Encl.

Submitted separately in Excel Format.
12.0 ERECTION OF PIPING AND STRUCTURE’S REPORT-FORMAT: Encl
Submitted separately in Excel Format as per list enclosed.

1) Doc.No.: IVRCL/PWSP/KAPP3&4/PM/14/ITF-01 Rev. No. : 0

- FIT UP inspection report piping and structure ANNEXURE-II
2) Doc.No.: IVRCL/PWSP/KAPP3&4/PM/14/ITF-02 Rev. No. : 0
- Piping Support Installation Report ANNEXURE-III
3) Doc.No.: IVRCL/PWSP/KAPP3&4/PM/14/ITF-03 Rev. No. : 0
- Radiography Inspection Report Piping ANNEXURE-IV
4) Doc.No.: IVRCL/PWSP/KAPP3&4/PM/14/ITF-04 Rev. No. : 0
- Radiography Offering Report ANNEXURE-V
5) Doc.No.: IVRCL/PWSP/KAPP3&4/PM/14/ITF-05 Rev. No. : 0
- Weld Visual Inspection Report ANNEXURE-VI

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