The document contains lessons learned from various piping, support, and equipment installation projects. Key lessons include: properly communicating scope and ensuring drawings are accurate and detailed to avoid rework; finalizing specifications before starting work; and considering erection feasibility when designing supports. Frequent changes from clients increased costs and delays. Ensuring drawings are clear and issues are caught early can save time and money on installation projects.

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Lessons Learnt
Design & Engineering - Piping
MANIKANDAN BABU
Oct 22, 2022

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Title: Systemized for Steam Tracing Field routed piping
Details : Steam tracing drawings not received from LE.
Causes/Reason : It was difficult to monitor work progress.
Solution: Drawing prepared by LTEH & systemized in Ealps system as
Field routed piping to ease of As built documentation, Material
reconciliation & Erection sequence.
Learning: To be systemized to ease Erection sequence , Material reconciliation & Invoice.
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Victaulic coupling for Galvanized lines in Stick built piping
Details : Stick built drawings were issued as s spool with allowance.
Causes/Reason : Welding is not allowed on Galvanized lines as due to welding inner side of
pipe coating of galvanized removed due to temperature of welding
Solution: Proposed to use Victaulic coupling for Galvanized lines in Stick built piping
Learning: Where Green length has been specified on galvanized lines there Victaulic coupling shall be required at site as
field weld is forbidden in Pipe.
Impact: Victaulic pipe couplings can be installed faster than welding & flanging.
Remarks:
Positive / Negative

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Title: Support drawing prepared from LE Standard
Details : Individual support drawing not received from LE, Complication in
understanding the pipe support fabrication & Erection.
Causes/Reason : LE support standard details includes a combination of 3 to 4
standards of Each support. This leads to tedious to fabricate pipe supports.
Solution: Ident wise drawing prepared to ease of fabrication & Erection.
Learning: Ident wise drawing to be received from client
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Secondary support drawing Preparation
Details : Secondary support drawing not received from LE,
Causes/Reason : Complication in Fabrication & Installation of Sec.
support.
Solution: Snap was prepared from 3D model with combination of
Drg. no + Ident wise. Coordinates provided from near Colum
reference.
Learning: Secondary support drawing to be included in Structural
drawing.
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Piping GA drawing Preparation
Details : : Piping GA drawing not received from LE,
Causes/Reason : Complication in Erection of Piping.
Solution: GA drawing were prepared pancake wise from 3D model
with adequate details.
Learning: Piping GA drawing to be received from client
Impact: save in time & cost
Remarks:
Positive / Negative

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Title: Split of Piping Isometric Drawings
Details : Isometric drawings is being issued in smaller Length even for Straight line and Header line.
Causes/Reason : Isometric drawings received from client as splitted more drawings for Straight line / Header line.
Solution: Isometric drawings to be issued as single or minimum for Straight line / Header line
Learning: Drawings to be ensured before Issuing to minimize the field scope/ To be proposed to client to issue drawings as
single or min.
Impact: This leads to extra cost , Material & Delay in Schedule for Increasing field scope. Coordinates issue for branch
lines.
Remarks:
Positive / Negative

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Title: Piping Drawing Preparation - size below 2” lines
Details : Piping Isometric drawing is being issued as Spool drawing for size below 2” lines
Causes/Reason : lot of modification at site, damages of spool & Misplacement of spool
Solution: No spooling required, to be issued as loose item.
Learning: This leads to lot of modification at site, damages of spool & Misplacement of spool.
Impact: Extra cost , Material & Delay in Schedule
Remarks:
Positive / Negative

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Title: Piping Stick built – Welded valve scope
Details : Isometric drawing prepared, valve as erection item for Stick built drawings.
Causes/Reason : Communication mismatch with LE/LTEH
Solution: Scope to be freezed through proper communication from client.
Learning: Stick built welded scope to be finalized / Ensured before issuing drawing.
Impact: This leads lot of rework, extra cost & Delay in schedule.
Remarks:
Positive / Negative

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Title: Painting system & NDT Detail change in CLL
Details : Change in Painting system & NDT details due to frequent revision of Construction Line list by Client
Causes/Reason : Cross checking latest construction line list with older revision for Painting system and NDT details and
incorporating the changes in Isometric drawing and Ealps.
Solution: To be avoided certain time of revision from client. Revision shall be minimum not bulk.
Learning: Construction line list to be finalized from client. To be avoided frequent revision.
Impact: Spool wrongly painted due to discrepancy.
Remarks:
Positive / Negative

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Title: Valve handwheel orientation Missing
Details : Valve handwheel orientation detail missing in Piping Isometric drawing received from client
Causes/Reason : Misunderstanding in valve installation. valve handwheel not matching with Isometric orientation by
default received from vendor.
Solution: Proper valve handwheel orientation detail to be provided from client.
Learning: Valve handwheel orientation to be ensured before issuance of drawing.
Impact: This leads to lot of rework changing the valve handwheel orientation.
Remarks:
Positive / Negative

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Title: Steam tracing scope finalization
Details : Stick built coordination & Routing guidance not provided properly for Lead & tail of steam tracing.
Causes/Reason : Information are not clear from Steam tracing and jacketing schedule document and Specification
Solution: Proper details to be provided from client.
Learning: Lot of rework, Fouling with cable tray and other instrument connection.
Impact: Delay in schedule & cost.
Remarks:
Positive / Negative

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Title: Steam Jacketing Inlet/outlet connection
Details : Steam Jacketing Inlet/outlet connection small bore pipe drawing issued as spool.
Causes/Reason : small bore coordinates & Orientation mismatch with connecting line
Solution: small bore pipe to be issued as loose item/ allowances shall be given in x, y and z directions
Learning: lot of CRW, material waste
Impact: delay in Schedule & cost
Remarks:
Positive / Negative

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Title: Valve orientation VOR & HOR
Details : Some of the welded valve, valve orientation has been mentioned as HOR and
VOR reference like STEM HOR -125 DEG VOR -45DEG
Causes/Reason : It is extremely difficult to understand from drawings
Solution: Orientation to be provided as easy of method for better understanding.
Learning: Wrongly welded valve based on wrong interpretation.
Impact: . Delay in schedule & cost.
Remarks:
Positive / Negative

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Title: Cavity relief Gate Valve Flow direction missing
Details : Cavity relief Gate Valve Flow direction missing in Isometrics.
Causes/Reason : It was missed in LTHE spool isometrics and valves were wrongly welded.
Solution: Valve flow direction to be ensured before issuance of drawing
Learning: Special valve flow direction to be taken care in Isometrics.
Impact: delay in Schedule & cost.
Remarks:
Positive / Negative

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Title: Galvanized line support/ Shear plate welding
Details : Shear plate welding provided in Isometrics as Erection scope for GI pipe & Identified the issue & instructed to
weld shop itself.
Causes/Reason : Shear plate not welded on GI pipe in some of lines
Solution: All welding to be ensured before Galvanizing Drawing to be prepared properly.
Learning: Welding is not allowed on Galvanized lines. All welding to be ensured before Galvanizing
Impact: delay in schedule & cost.
Remarks:
Positive / Negative

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Title: Cut length short in Modified flange connection – Jacketed piping
Details : Cut length short in Modified slip on flange connection - Jacketed piping, welding not met as per code
requirement.
Causes/Reason : Special part shall not be properly customized as per drawing.
Solution: It was identified during early stage of fabrication and resolved.
Learning: Drawing to be checked as per special item dimensional standard.
Impact: This leads to rework of spool & cost
Remarks:
Positive / Negative

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Title: Moment free anchor support at Elbow
Details : Moment free anchor support at elbow - LS 544-01
Causes/Reason : Insertion of pipe to pipe & weld as trunnion, 30deg tap in second
trunnion is too tedious task to complete welding of support
Solution: Result to avoid 2nd trunnion pipe, Extra sch pipe can be added in main pipe of trunnion support.
Learning: Type of support to be changed/ Proposed at Initial stage
Impact: Cost & Time
Remarks:
Positive / Negative

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Title: Piping secondary support drawing
Details : Piping secondary support drawing issued as snapshot for not received from client.
Causes/Reason : Separate secondary support drawing leads to separate erection
sequences.
Solution: secondary support details to be provided in structural drawing.
Learning: Lot of cut & weld activities at work at height lead to more scaffolding access, Erected in pancake itself same can
be completed.
Impact: Extra manhours to Install
Remarks:
Positive / Negative

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Title: Shear plate weld
Details : Shear plate to be welded as Equivalent parent material
Causes/Reason : usage of shear plate discrepancy w.r.t. support specification & Purchase specification. Support spec.
Material – A36/304, as per purchase spec. Equivalent parent material.
Solution: Shear plate to be welded as Parent material
Learning: scope & Procurement material qty to be listed & prior approval will save cost & time.
Impact: wrong welding w.r.t. shear plate & Parent pipe lead to delay in MC and get it approval.
Remarks:
Positive / Negative

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Title: Support shipping attachment
Details : Shipping attachment bolting connection to be done. LS 545-91
Causes/Reason : Drilling hinderance on beam.
Solution: Shipping attachment stich weld to be done with column & beam.
Learning: Drilling hole during erection found hard.
Impact: This leads to extra stich weld, cost & time.
Remarks:
Positive / Negative

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Title: Special item procurement - Support
Details : Delay in Procurement Special item scope confirmation - support
Causes/Reason : usage of special item in piping support consolidated procurement are needs to be done in prior. like SS
plate / PTFE, Puf & Graphite plate etc.
Solution: Pipe support special item MTO to be received from client
Learning: based on client support special item procurement to be finalized earlier.
Impact: delay in schedule
Remarks:
Positive / Negative

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Thank You