TECHNOLOGY EXPORTS

SERVICES CORPORATION WORK INSTRUCTION

REVISION No.: 0
DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
Page 1 of 5
TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

ORIGINATED BY REVIEWED BY APPROVED BY

NAME : ARNIE A. ALTERADO NAME : JAYSON AGUSTINO NAME : TEODORO

POSITION: OPERATION POSITION : SCO MANAGER MAGPANTAY
POSITION : GEN. MANAGER /
QMR
DCN AFFECTED
REV ORIGINATOR EFFECTIVITY NATURE OF CHANGE SECTIONS/
No. PAGES

MARCH 12,
0 A. ALTERADO ORIGINATION ALL
2022
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SERVICES CORPORATION WORK INSTRUCTION
REVISION No.: 0
DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

1.0 OBJECTIVE:

These specifications describe the requirements and critical procedures applying to the Disassembly,
fabrication, installation, inspection, and acceptance criteria for installation of new Balance Pipe. It shall be
conformed to the approved drawings, welding requirements, quality control specifications and other
related documents.

2.0 SCOPE:

This procedure will cover Balance Pipe replacement, Piping fabrication, Installation of new balance pipe,
Safety for lifting and other related activities for the project.

3.0 RESPONSIBILTY:

Field Supervisor – Must oversee all the process activities are properly implemented. Ensures that
the procedure is followed and performed it safely.

Safety Officer – implement all safety procedures as required.

Customer Representative/Single point of contact – ensure that all site requirements are all
prepared and good coordination to the contractor must be monitored.
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

Welder and Pipe Fitter – Responsible for performing Welding and Fitting activities.

NDT Technician- Responsible for the welding inspections, performs Nondestructive test on the
weldments.

NCT II Scaffolder – A qualified personnel which is responsible for assembling and dismantling
usually temporary scaffolding structures that allow worker to access specific portions of a plant or
buildings to perform needed work.

4.0 SAFETY:

This procedure will follow all safety requirements as required by the customer and government standards.
Accomplish all safety procedures that will cover on this operation (Risk assessment, JHA, JMP etc.)

5.0 SITE INSPECTION:

5.1 Inform customer regarding the schedule of site inspection prior for mobilization to site project.
5.2 Site inspection should involve Field Supervisor, Safety officer and SPOC/Representative.
5.3 TESCO representatives who will conduct the inspection should undergo plant orientation
(Security, Environment and Safety.) prior to proceed inside the plant. Complete PPE’S must be
worn during inspection.
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DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

5.4 Verify weather forecast before the schedule of site inspection.

5.5 Report or inform customer SPOC or project supervisor upon arrival at site.
5.6 Conduct Pre-job meeting together with SPOC to discuss concerns regarding the inspection.
5.7 Check the route if it is passable for trucks and light vehicles that carry the tools and equipment’s
needed for the project, note on JMP if there are some hazards or concerns such as low-lying
wires, community concerns, road problems or any other issues.
5.8 Site inspection checklist should be accomplished during inspection (Refer to mobilization checklist
FM-QP-TRD-04-01-02 REV. 2)

5.9 Conduct meeting after the inspection with the customer SPOC and other concern department.
Address all concern issues if necessary.

6.0 GENERAL WELDING REQUIREMENTS:

6.1 Contractor/Supplier shall be responsible for meeting the requirements of these specifications.
6.2 Welding procedure (WPS), Welders Qualification, consumables and consumables handling, and
storage shall be as per the requirements specified in TESCO Welding procedure (WI-QAD-13
General Welding Practices and Rules for Welding Procedure Qualification System).
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SERVICES CORPORATION WORK INSTRUCTION
REVISION No.: 0
DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

6.3 Regardless of the requirements of ASME IX, welder shall be tested and be qualified as per the
WPS to be used in this project. Ensure that welder is certified with Welding Procedure
Specification (WPS) for materials DN200, ASTM A335 Grade P11.
6.4 All weld joints must conform to client’s acceptance criteria.

7.0 SCAFFOLDING ERRECTION REQUIREMENTS:

7.1 Scaffold must be structurally sound and sturdy enough to support its own weight plus four times
the max intended load. It should do all of this without settling or any displacement.
7.2 Unsteady objects should never be used to support planks or scaffolds. Such objects might include
loose bricks, boxes, barrels, and the like.
7.3 A competent person (NCII scaffolder) must supervise workers as scaffolds are erected,
dismantled, moved, or altered in any way.
7.4 All scaffolding must be equipped with toe boards, mid rails, and guardrails.
7.5 Scaffolding platforms should be tightly planked. Ensure the scaffolding plank grade material or
equivalent is used.
7.6 Scaffolding may be accessed by way of stairwells and ladders. Do not access via unsteady
objects.
7.7 Scaffolding must rest at least 10 feet away from electrical power lines during all times.
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DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

7.8 Provide fall protection for every personnel who work on scaffold more than 10 feet above a lower
level.

8.0 PROCEDURE INSTRUCTION:

8.1 MOBILIZATION

8.1.1 Field Supervisor must conduct a safety meeting before the start of mobilization. All
personnel that are involved in the project must be present at the meeting.
8.1.2 Safety check-up shall impose by the field working supervisor/Safety officer after the
safety meeting.
8.1.3 Documents and records needed on the project must gather by the Field supervisor.
8.1.4 Preparation of all tools and equipment shall be done by each working crew and to be
check by field supervisor.
8.1.5 All TESCO personnel/work party must undergo plant safety orientation conducted by
the client’s assigned personnel before proceeding to site location.
8.1.6 All Tools, Equipment’s, gadgets etc. must be declared to guard on duty and make a
copy of item declaration list form prior entering to plant gate.
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DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

8.2 SAFETY CHECK-UP ON SITE/PREPARATION

8.2.1 The Field Supervisor must initiate/conduct safety meeting/toolbox before the start of
the activities.
8.2.2 As necessary, make or construct temporary shelter/temfacil allocated in a safe
distance from the work area.
8.2.3 The assigned safety officer must ensure that all required permits are complete and
available at work area. Ensure that all hazards present on the working area have
identified and mitigation plan must be implemented.
8.2.4 Before doing any activities, make sure that all safety requirements must be
implemented and place all safety gadgets in an accessible location. (Fire
Extinguishers, barricade tape, barriers/warning signs etc.).
8.2.5 All involved personnel must know how to evacuate, and the location of Master point
must be identified in case of any emergencies that may happen during the duration of
project.
8.2.6 Field Supervisor should check all necessary materials; equipment’s, PPE’S and
consumables needed especially supplied materials by client prior for installation.
8.2.7 Gas monitoring must be conducted by safety officer to ensure no harmful and
combustible gases are present before and during operation.
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SERVICES CORPORATION WORK INSTRUCTION
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DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

8.3 DISASSEMBLY OF OLD PIPES

7.3.1 Make sure that the entire power source connected on the pipe are disconnected and
piping line must be isolated prior for disassembly. Ensure that the system (pipeline)
has been shut down or a lock-out & tag-out (LOTO) is being done prior to cutting and
welding.
7.3.2 Provide or erect scaffolding on a higher location where cutting is to be performed.
7.3.3 Always wear Personal Protective Equipment (Safety Shoes, Helmet, Safety glass,
gloves etc.) when performing a job.
7.3.4 Prior for any lifting activities, a lifting plan must be clearly define especially the load to
be lift, lifting points, lifting method and operation of lifting. Also, all lifting equipment’s
must be check (hook, Slings, shackle, etc.) for any visible defects before using. It
should have a third-party inspection and inspection tag must be visible.
7.3.5 Put Barricade or caution tape on the work area, assign rigger to assist the operator
for lifting activities. No worker shall be under the suspended load and proper
communication must be follow. Put tag lines on object to be lifted to control its
movement during lifting.
7.3.6 By using available lifting equipment such as 5 Tons Chain Block, Boom truck (if
available), lift the cut pipe to designated transfer location.
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DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

7.3.7 Prior for Hot Work activities such as cutting, welding and any activities that involved
using open flames, it is important to identify hot work hazards and control measures
to reduce risks and keep worker safe.
7.3.8 Remove existing cladding, old pipes, fittings using power tools 7” Grinder or hot
cutting using oxyacetylene cutting torch.
7.3.9 Secure all the dismantled items in a safe location and coordinate to client for proper
disposal.

7.4 PRE-FABRICATION OF PIPE SPOOLS (SHOP)

7.4.1 Prepare all needed consumables, tools, equipment’s, and materials for the
fabrication; Pipes, fittings (elbow, flange etc.) on designated shop fabrication area.
7.4.2 Marking shall be done according to drawing requirement and the same shall be
checked by onsite supervisor/welding inspector prior to cutting.
7.4.3 The project supervisor shall ensure and defined set of quality management criteria to
ensure the accuracy of fabrication to achieve the proper fit at site.
7.4.4 The cutting shall be done as follows:
Carbon steel pipes – By Gas cutting or grinding
Alloy steel pipes – By Grinding or Flammable
Stainless Steel Pipe cutting – By Grinding or Plasma
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

7.4.5 Edge preparation of pipe shall be done at shop as per the approved Specifications
and WPS. Edge preparation shall be done by grinding and it should be free from
tears, grease, oil slag and scale.
7.4.6 Pipes and fittings for fit-up will be placed on temporary pipe bed and will make sure
that support is secured properly.
7.4.7 Welds, including addition of weld metal for alignment shall be made in accordance
with a qualified procedure and by qualified welders or welding operators.
7.4.8 All pipe joints should be tack welded only. Welding of the joint will be done after
getting QC fit-up inspection clearance.
7.4.9 After welding, spool number and joint number will be marked with paint marker for
traceability. Fabrication completed spools shall now be subject for NDT inspection as
required by project specification.
7.4.10 Pre-Heating and PWHT shall be done at shop as per specification requirements
accordance with the approved WPS.
7.4.11 All completed spools that are passed for the NDT inspection will be shifted from shop
to allocated lay down area.

7.5 INSTALLATION AND WELDING OF BRANCH PIPE (ON SITE)

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DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

7.5.1 All piping work shall be in accordance with approved drawing such as plot plans,
sections, isometric drawing, standard, special support details and other specified by
client as applicable.
7.5.2 Internal and external surfaces to be thermally cut or welded shall be clean and free
from paint, oil, rust, scale, and other material that would be detrimental to either the
weld or the base metal when heat is applied.
7.5.3 Pipe supports shall be in accordance with the relevant pipe support detail drawings.
7.5.4 The root opening and fit-up tolerances shall be specified. Parts to be joined (pipe,
fittings) shall not exceed the maximum gap of 1/8”. Ensure no misalignment during fit-
up, and measurement should be follow as specified on the issued drawing.
7.5.5 Upon fit-up is done, an inspection on the joint pipe shall be conducted by the
assigned inspector to verify the accuracy of the actual dimension and leveling of the
pipe.
7.5.6 Before welding, pre-heat the weld joint to its required temperature as specified on the
WPS by using heating torch or by other method. Full weld joints by qualified
personnel and with the given Welding Procedure Specification.

7.5.7 Inspection on the finished weld joints will be conducted by a third-party inspector by
means of Radiographic Test. Defective welds shall be repaired in accordance with
the original WPS or as applicable.
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

7.5.8 After Passing NDT, Post Weld Heat treatment shall be performed following the given
and required temperature as specified on the Welding procedure.
7.5.9 Put additional scaffold if necessary for the preparation of cladding installation.
7.5.10 Installation of insulation and cladding shall be performed by competent personnel
assigned for this activity. Pipes must be free of contamination grease, rust, scale prior
for installation of cladding.

7.6 PROJECT COMPLETION

7.6.1 Project as completed and done after advised from client’s representative and final
confirmation by client’s project head.
7.6.2 Accomplish Service Operation Report and Customer Survey Form and must be
signed by client’s representative.
7.6.3 Clear the area/Housekeeping and secure all tools and equipment’s.
7.6.4 Return and closed all issued permits to client’s safety officer prior for demobilization.

7.7 DEMOBILIZATION
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SERVICES CORPORATION WORK INSTRUCTION
REVISION No.: 0
DOC No.: WI- TRD- 48 EFFECTIVITY: MARCH 12, 2022
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TITLE: BALANCE PIPE REPLACEMENT STEAM LINE

7.7.1 The Field Supervisor must initiate inspection of all tools and equipment’s.
7.7.2 Make sure that all tools and equipment are properly loaded and secure.
7.7.3 Check service vehicle before demobilization.

9.0 REFERENCES:
ASME 31.3 Power Piping
ASME IX Qualification Standard for Welding and Brazing Procedures
American Welding Society D1.1
OSHA Construction Scaffolding Safety

10.0 APPENDECIES:
FM-QP-TRD-04-01-02 REV. 2 - Mobilization Checklist
FM-QP-TRD-04-01-01 REV.1 - Service Operation Report
FM-QP-QAD-01-04-01 REV. 0 – Customer Satisfaction Survey