Date of

Sr. No. Contractor Observation in Short Observation in Detail Typ of Observation

Observation
During routine surveillance in Offshore piping fabrication yard
(BS-VI Project) it has been observed that no flange serration
protection carried out at site further all piping spools and
flanges directly laying on ground. Please refer attached photo’s.
Flange face protection & pipe spool stacking
1 08-Mar-18 Offshore Desired Action : Major-SOQ-001
not carried out properly by M/s OIL
1) Serration protection tape or cardboard sheet shall be
provided at flange face.
2) Pipe & piping spool shall be properly stored on wooden
plank.
During routine surveillance in Offshore piping fabrication yard, it was
observed that electrode E7018 & E7018-1(NACE) were kept in same
Observed mixing of electrodes 7018 & 7018-1 in oportable oven, welding in NACE service line 6"-P-2225-D63A,SJ-5&SJ-
2 06-Apr-18 Offshore portable oven while welding on NACE line at M/s 6 was being carried out with the electrodes from the same oven. Major-SOQ-002
offshore fabrication yard BS-VI project. Hence there is a strong possibility of doing welding with Non-NACE
electrode (E-7018) on NACE line.welding was done by welder no.PW-
38

SOQ regarding welding by non-qualified welders

It is observed that in Offsite Piperack-61 area , Gas Cutter carrying out
at offsite area of BS-VI.
3 16-Apr-18 Offshore RF pad welding in line no. 24"-WCS-567-1165-A91A) near joint no-FJ- Major-SOQ-003
Gas Cutter carrying out RF pad support welding in
1.
24"pipe.

During routine surveillance in Offshore fabrication yard it has been

observed that distortion occurred in pipe spool no.8590, line no:3"-P-
607-1510-B1A sht 1/2 due to improper spool storage.
Found Bend on Piping Spool in offshore fabrication
4 19-May-18 Offshore Cut & Reweld the pipe spool. M/s EIL & M/s OIL quality personnel as Major-SOQ-004
yard
well as execution personnel ensure that spool shall be handled &
stored properly.

During routine surveillance in Offshore fabrication yard it has been

observed that distortion occurred in below line & spool no.
1) 2"-SL-607-5806-A1A-SPL-2440.
Found Bend on Piping Spool in offshore fabrication
5 24-May-18 Offshore 2) 2"-FL-607-2910-A11A-SPL-8849. Major-SOQ-005
yard
3) 2"-FL-607-1501-A11A-SPL-8832.
4) 4"-V-8038-A96A-SPL-5562.

During routine surveillance in cooling tower area, below observation

noted.(Repeated Observation)
1. Helper (Amit Kumar, Emp ID-52941) doing welding in 24" cooling
water 45 deg. mitre joint.
2. E-7018 electrodes used without baking.
Helper doing welding & unbaked electrode also
3. Marking not found on mitre joint for line identification.
6 06-Jun-18 Offshore used during fabrication of mitre joint in Cooling Major-SOQ-006
water line 24" x STD
Cut & Reweld the mitre joint. M/s EIL & M/s OIL quality personnel as
well as execution personnel ensure that all welding activity shall be
performed by EIL approved welder only. M/s Offshore quality
personnel shall do regular field surveillance to avoid such discrepancy.
Kindly refer attached photos for reference.

During routine surveillance in Offshore DHDT Pipe rack area, it was

observed that electrode E7018 & E7018-1 (NACE electrode) were kept
in same portable oven. Welding in NACE service line 12”-P-2203-B68A-
SHT1/2-SPL-2229, J-15, Welder No.10, VASUDEV PANDA & at another
location line no. 8”-P-607-2251-D63A-SHT-1/1-Z-D-SPL-7223-FJ-8
Welder No.23, ANIL THAKUR was being carried out with the mix-up
Electrode E7018 & E7018-1 (NACE electrode) were
7 28-Jul-18 Offshore electrodes from the same oven. It cannot be ensured that welding in Major-SOQ-007
kept in same portable oven.
NACE line has been carried out with E7018-1. Welding was being done
by welder's.
it is recommended to Cut & Re-weld the joints mentioned above in
observation. M/s EIL & M/s OIL quality personnel shall ensure that the
welding activities are being carried out as per approved welding
procedure specification.

During routine surveillance in M/s Offshore fabrication yard (BS-VI

use of electrode E7018 (CS) instead of E7018-1 Project), it was observed that CS electrode E7018 used for welding in
8 13-Aug-18 Offshore Major-SOQ-008
(NACE) for welding in NACE service line NACE+H2 service line 20"P-607-2202-01-D63A-D-SHT-1/1-Spool No.-
9385,J-12A by Welder No.101, Sanjeet khushwaha.
 During routine site inspection in DHDT pipe rack area, observed that
Gas cutter Mr. Suresh Paswan, ID No. 63498, doing welding on 24"
Miter Joint in line number 24"-WCS-563-1165-A91A-Sht1/1-Joint no-
F1C, while welder No.PW-97 (Sanjay Singh) seating ideal engaging the
Gas Cutter doing welding in 24" Miter Joint while above gas cutter in miter joint welding.
9 24-Aug-18 Offshore welder is seating ideal engaging the gas cutter on Desired Action: Major-SOQ-009
job. As per EIL approved Offshore Job procedure for AG piping fabrication
and erection, Clause 3.2 only those welders who have been approved
by the EIL authorised Inspector shall be deployed for welding. Hence it
is recommended to Cut & Re-weld the joint in observation and take
necessary action against concern welder and gas cutter. M/s EIL &
M/s OIL quality personnel shall ensure that the welding activities are
being carried out by EIL qualified welder only.
Piping spools of Line No. 1-1/2”-TRM-607-EA201B-01-A68A-D and 1-
1/2”-TRM-607-EA201C-01-A68A-D , (intermixing of the material)
CS flange used instead of CS-NACE,Intermixing of
10 11-Sep-18 Offshore Carbon Steel Flanges is used in place CS-NACE flanges. Re- Major-SOQ-010
NACE & CS Fittings.
commendation given to Cut both Joints and re weld with Appropriate
Material ( CS NACE Flanges). M/s OIL.
In line no.3/4”-WCR-607-2902-B1A, 600# SW In line no.3/4”-WCR-607-2902-B1A, 600# SW Flange is used in place
11 12-Sep-18 Offshore Flange is used in place 300# SW(Fitting Rating(#) 300# SW flange. Re-commendation given to Cut both Joints and re Major-SOQ-011
not as per iso.) weld with Appropriate Material

During routine Surveillance in DHDT pipe rack observed protection

Shield is not provided and plate for support is directly welded to the
Header for vertical run pipe of the line no. 6”-WCS-607-1501-A91A-D
Support not installed as per approved
and 6”-WCR-607-1501-A91A , which is not as per Isometric and
12 20-Sep-18 Offshore drawing(.Protection Shield Required as per Major-SOQ-012
Support standards.
drawing)
As per conversation with EIL Execution Personnel , they are not able
to clarify it. Recommendation given to Provide protection shield as per
standard otherwise clarify it with reference document.

During routine Surveillance in DHDT pipe rack distortion observed in

In DHDT pipe rack distortion observed in the line
13 26-Sep-18 Offshore the line no. 2-WDM-607-9001-AIK from the joint near Column no. 20 Major-SOQ-013
no. 2-WDM-607-9001-AIK
in 1st tier of Pipe Rack. The Line alignment is Completed but not
Resting on Consecutive Column due to Bend from joint.
In Offsite Area no.62 pipe rack Observed two Consecutive
welds nearby , Pipe to Wear Pad and Pipe to Pipe found
adjacent to one other (observed distance 10mm between the
welds instead of 50mm ) joint near FJ-11, Grid no. 12 in 1st tier
In Offsite Area no.62 pipe rack Observed two of Pipe Rack of Line No-12"-P-561-12200-B1A.
Consecutive welds found adjacent.. Weld to weld
14 29-Oct-18 Offshore Major-SOQ-014
distance should be mimimum 50mm or 4T Recommended to Cut the Piece of Required length for Proper
whichever is greater. fit up of wear Pad and Maintain the Minimum distance of
50mm between the two Consecutive welds, offer for
inspection after fitup. M/s offshore instructed to check all pipe
rack area for any such type of discrepancies and take action
accordingly
During routine Surveillance in Offsite Area no.61 pipe rack Observed
butt joints welds, foul on beam directly , FJ-10 line no-4"-WS-563-
1661-A3A at grid no. 06 of 61A and FJ-17,line no-8"-P-561-12205-B1A
Weld joint are direct resting on the structural
at Grid no-61 . The Line alignment is completed but not Compiling the
beams and the gap between the weld joint and
Standard Engineering Practices.
beam to very near.
15 01-Nov-18 Offshore Major-SOQ-015
Recommended to modify the joints so that its avoid resting on beams
As per good engineering practice these are not
and offer for inspection after fitup. M/s offshore instructed to check
allowed and rectify the joints accordingly.
all pipe rack area for any such type of discrepancies and take action
accordingly .

During format Inspection of several process loop discrepancies

Hydotest done in Process Loop not as per design
observed as follow:-
16 11-Mar-19 Offshore pressure in LDT, Loops not mechanically Major-16
1. Hydrotest pressure mention in HT Report not matches with LDT.
completed & Format-I raised.
2. Loops not mechanically completed as line alingment balan ce,
primary & secondary support(G3,G2,L1A) installation pending.
3. Support welding not proper.
During Format Inspection of the Loop: 607-P-10-85, It has been
observed that Primary support welding with parent pipe incomplete ,
17 24-Jan-19 Offshore Hot work pending & Format-I raised by EIL Major-17
Which is not acceptable. Instruction given to weld & Re-hydro, after
that offer for format Inspection..

During Routine survillance in DHDT it has been observed that in Loop

no: 607-P-10-95 ,Butt Weld joint Foul with wear pad Which is not
18 5-Jan-19 Offshore Pipe to pipe Butt joint foul with wear Pad. Major-18
compiling good engineering practices.M/S OIL instruted to cut the
joints & offer for inspection after correctifying the action.
 During routine surveillance in Offshore piping fabrication yard, DHDT
offsite Pipe-rack (BS-VI Project) it has been observed that following
welders who were already qualified by welder qualification, First
production joint and on job qualification for higher thickness range,
however don’t have welder ID card and they are deployed on
welding activities. Kindly do needful
Welder do not have welder ID card and deployed 1) Ashok Yadav (No Welder ID).
19 04-Apr-18 Offshore Minor-1
on welding activities. 2) Anil Kumar PW-14(Higher thickness qualification not incorporated
in welder ID card)
3) Vijay Kumar Sharma (No welder ID)
4) Parvesh Kumar PW-48 (Welder ID not signed by M/s EIL)
5) Nirbhay Pratap -Tacker welder (No welder ID)
6) Pappu Yadav -Tacker Welder (No welder ID)

Hardnes found 238 in HAZ of Spool No.8485-J-2

Hardness result for HAZ has been observed 238 BHN in line no. 6"-P-
Hardness found above then required hardness in 607-2264-D63A-D-SPL-8485-SHT1/1-J-2.
20 04-Apr-18 Offshore Minor-2
HAZ in spool No.8485-J-2
Rework has been carrried out for the joint and hardness value found
in range for HAZ area.
During routine surveillance in Offshore piping fabrication yard & HGU
Plant following observation found.
1) Tacker welder TW-9 Mr.Bishnu Phukan doing fit-up in line no.4”-
WCR-511-6261-A91A without baking electrode, further discussed with
1) Tacker welder using non baked electrode. tacker welder it has been found that they are not aware the baking
2) AS & SS Pipes has been stored with CS procedure.
21 05-Apr-18 Offshore Minor-3
Pipe.(Non-Proper Material Stacking) 2) Material Storage & handling-Alloy steel & SS pipe has been stored
3) Mechanical damage found on 8"x SS321 Pipe. along with carbon steel pipe. M/s Offshore shall store CS, SS and AS
material separately.
3) 8" size SS-321 pipe found with mechanical damage during loading &
unloading activities. same has been informed to concern for future
precaution.
Random PMI has been checked for Heater Components (V Anchor,
Bolted & Welded Y shape Anchor, Stud for refractory, Retainer Plates,
Random PMI has been checked for DHDT Heater
22 06-Apr-18 Thermax Nozzle 1.5", 2", 4 ", Clips, Nut & SS 304 Foils). PMI shall be checked for Minor-4
Components.
Heater Coil after received at site.

During routine surveillance at M/s offshore piping fabrication yard, it

Fitup & wedling Inspection instrument not has been observed that no inspection gauges (Hi-Lo & welding Gage)
23 10-Apr-18 Offshore Minor-5
available with M/s Offshore. available whereas job under progress. Now Fit check carried out with
a template
During random witness of Hardness for DHDT piping in line no. 16”-P-
607-1802-D5A-IH-E, H2 service, hardness found between 245-270
BHN (Parent Metal) in M/s offshore fabrication yard. Hardness found
is higher than acceptable range, hence hardness test has been cross
verified with instruments of M/s IRC Engineering and found below 200
Hardness testing Instrument found with BHN which is acceptable.
24 10-Apr-18 Offshore Minor-6
inaccurate Test Result for M/s Offshore
Hardness testing Instrument used by M/s B. Tech Engineering sub-con
of M/s Offshore shall be recalibrated or, new hardness instrument
shall be arranged for further hardness testing of Weld, HAZ & Parent
Metal.

During routine surveillance in Offshore DHDT Pipe rack near coluumn

Helper doing welding in guide support with E-7018 no-6, it has been observed that Helper (Nirbhay kumar Pathak) Emp
25 12-Apr-18 Offshore electrode however portable oven was not in Code-50117, doing welding in guide support with E-7018 electrode Minor-7
working condition. however portable oven was not in working condition

Electrode baking log is maintained at the site, howover M/s EIL needs
26 17-Apr-18 Offshore Electrode baking register signoff by EIL Minor-8
to sign off the electrode baking register.
Observed damage on wrapping & coating of UG piping near grid no.
E12, E13 & E15. M/s B&R to repair & offer holiday testing for the
27 28-Apr-18 Bridge & Roof Damage on wrapping & coating Minor-9
same.(Open). Damaged wrapping & coating has been repaired by M/s
B&R.

Observed civil Sleeper/pedestral support has been settled down from

Settle down of Civil sleeper pedestral in 16" fire
28 28-Apr-18 VRC its original location in line no.16"WF-6074-5105-A95A, M/s VRC to Minor-10
water line
rectify the same in three location for proper resting of piping. (Open)

During routine surveillance in Offshore fabrication yard it has been

observed that Helper (Vikas Thakur) Emp Code-49869, doing tack
welding during Fit-up in line no:12”-P-607-3104-A68A-IS,Joint no-5.
29 08-May-18 Offshore Helper doing tack welding Minor-11
EIL is ensuring that only thier approved Tack welder will carry out
tacking in spools. (Closed)

Observed mechanical damage (scratch mark) on Observed mechanical damage (scratch mark) on pipe spool (Line
pipe spool. no.12"-P-561-12207-B1A) due to improper handling of fabricated
30 09-May-18 Offshore Minor-12
Action taken thickness checked after blassting spool.
result within acceptable range
 Welder Number found punched in fitup joint prior to welding (line no.
Found advance punching of welder no in fitup 6"-MS-511-4386-B5A-IH-SPL-H3350). The number removed and
31 09-May-18 Offshore Minor-13
joint in HGU piping spool. further fabrication crew to be sensitized in Tool box talk so as not to
repeat in the future.
M/s Offshore Welder no.53 carrying out partial root welding at
adjacent three weld joints of a spool (line no.10"-R-511-4395-A11A-IS-
Welder no.53 carrying out partial root welding at
J,2-J-3,J-4 ) instead of completing one full joint. Recommended for
32 13-May-18 Offshore adjacent weld locations one after another instead Minor-14
Radiography for all three joints and in future regular tool box shall be
of completing one full joint.
conducted for welders in this regard.

No proper stacking of fabricated spools, protection of flange faces

33 13-May-18 Offshore Improper stacking of fabricated spools Minor-15
leading to damage of pipe & flange face
it has been observed that metal debris created during plasma cutting.
Welding has been carried out in line no.24”-P-607-1902-E25M-IH, line
Metal debris present inside pipe and welding size 10”joint no-SJ-23 without inside cleaning of debris. Recommeded
34 15-May-18 Offshore Minor-16
carried out without cleaning. for inside cleaning by wire brush, buffing and filing and regular tool
box to be conducted for Fitter (Closed)

During routine surveillance in Offshore piping fabrication yard

following observation found.
1. Non IBR Welder Mr. Ajit Kumar(Welder No.5) carrying out welding
in line no.6”-SM-607-8701-IH-Spool No.-5448-Joint No.62 & 63
Non-IBR welder carrying out wedlding on IBR without IBR welding certificate.
35 24-May-18 Offshore Minor-17
piping job 2. Welder Mr. Bijay Kumar Sharma carrying out welding on Stainless
Steel (SS304) piping spool from last 4 days without having any Welder
Card.
Vendor shall take necessary action for preventive & corrective action
for not repeat of the same in future.

External Visual Inspection for ten nos. Heat Exchanger has been
Mechanical damage observed on Lean Amine Pre
carried out & observed N2 Purging not intact in shell side for 4 nos.
36 11-Jun-18 Offshore Heater 607-E-302 & N2 Purging not intact for Shell Minor-18
and 3nos. in tube side Mechanical damage has been observed in dish
& Tube side for 4 Exchanger.
end of HP Lean Amine Pre Heater- 607-E-302.

During routine surveillance inspection we observed in M/s Offshore

new DHDT BS -VI Pipe rack no edge preparation and bevel smoothing
done for drain hole which were made by gas cutting ( Metal Burr
found inside the main header pipe) in line no-6”-P-607-1102-B1A-IH
no edge preparation and bevel smoothing done
near joint no-MJ-30. Please refer attached photos for your further
37 03-Jul-18 Offshore for drain hole which were made by gas cutting ( Minor-19
action.
Metal Burr found inside the main header pipe)
The inside metal particles are to be removed before installing the half
coupling with nipple fit up and welding.

Reactor feel/ Effluent Exchanger No.2 607-E-103B shell side Nozzle

38 13-Jul-18 VRC Minor-20
Exchanger nozzle fouling with cvil foundation fouling with civil foundation.
During random thickness surveillance of piping items in fabricated
spool at BS VI project, thickness found lesser (4.14) then minimum
required thickness(6.02) in carbon steel elbow near Joint no.20, line
Thickness found lesser (4.14) then minimum no. 4"-FL-607-4401-A11A-Sht-3/3-Spl-68.
39 23-Aug-18 Offshore Minor-21
required thickness(6.02) in carbon steel elbow
Elbow Details - Manufacturer - Tube Turn India , Heat No.- 6652 (4" x
Sch.STD)

1. Offsite pipe rack area no- 61 observed that helper Mr. Kundan
Kumar, ID No. 50698, doing tack welding in line number 12”-P-561-
12207-B1A. As per EIL approved Offshore Job procedure for AG piping
40 06-Sep-18 Offshore Non-qualified tack welder deployed in job Minor-22
fabrication and erection ,only those welders who have been approved
by the EIL authorized Inspector shall be deployed for welding.

Offshore Fabrication Yard Stainless Steel pre- fabricated Spool

Stainless Steel piping spools layed on carbon Steel Directly Lay On Resting on Carbon Steel Spools , segregate the
41 06-Sep-18 Offshore Minor-23
Spools metallurgy wise and not mixing with SS to carbon steel spools.

Non -qualified welder Mr. Rakesh Mahto (emp.ID-40281) of M/s B&R

doing tack welding in line no. 6”WF-511-0031-A97A, which is not
42 10-Sep-18 Bridge & Roof Helper doing tack welding Minor-24
accepted, as per EIL Specification only EIL qualified welders should be
engaging in welding activity.
DHDT Pipe Rack , we observed that Spool No-143 of Line no- 4”-V-607-
8005-A96A found bend from the Joint due to proper support is not
43 14-Sep-18 Offshore Erected Pipe spool found bend from the weld joint Installed in vertical vent line , during erection of piping spools provide Minor-25
proper clamping or resting supports immediately to avoid such
incidents.
 HGU Area, Line No- 10”-PG-511-5704-D1E-IH , J-12A Welding is
started without reaching Pre Heat Temperature of 200®C , Temp. of
the joint location is physical checked by pyrometer and found 124®C
instead of required pre heat temperature of 200®C and Welder and
Preheating for As field joint not carried out
44 14-Sep-18 Offshore OIL QC Personnel don’t have no temperature stick for Verification of Minor-26
properly at HGU Unit
Pre- Heat Temperature.
(Provide the temperature sticks to welders those involved in alloy
steel piping welding they verify the required temperature before
starts the welding.)
Spools found bend and hanged with cleats and 1).line no. 8”-AM-607-4301-A2A- IS-E-Sht-1/2- SPL-12075 hanged
supported with scaffolding pipes which is not a with cleats and supported with scaffolding pipes which is not a
standard practice. standard practice. Not forwarded to
45 18-Sep-18 Offshore
2).Spools found bend 2”-WS-607-8944-A3A-Z-G-SPL-18094-SHT-1/2, contractor
2”-FL-607-1305-A11A-D-Sht-1/7-SPL-9363 and 2”-P-607-4512-B65A-Z-
C-SPL-5293-Sht-1/4.
Elbow chekced at Offshore Storage yard, below elbow found less then
minimum required thickness.
PO No. 3903 - 6" x STD (CS-NACE) Tube Turn India - Batch No..7084 - 3
nos.
Thickness found lesser then minimum required
46 25-Sep-18 Offshore PO No. 4127 - 6" x STD (CS-NACE) Tube Turn India - Batch No..7084 - 2 Minor-27
thickness in carbon steel elbow
nos.
6" x XS Tube Turn BatCh No.7085 (CS-H2)-2 Nos.
Observation shown to Mr. Vijay Rathore EIL for necessary correction
& corrective action.

During Routine Surveillance at BS VI project Pipe rack distortion

47 10-Oct-18 Offshore distortion observed from the joint no-FJ-1C Minor-28
observed from the joint no-FJ-1C of the line no. 6”-SM-563-1821-B2A
due to not properly use of leveling tools and tackles during fit- up.

During routine site inspection in DHDT pipe rack area below

discrepancies observed.
Elbow found bend & welding with cold electrode 1. Spool found bend due to elbow ovality changed between joint No.SJ-
Not forwarded to
48 3-Nov-18 Offshore & weldor doing welding in higher than qualified 34 & 35 in line no.3”-BCR-607-8619-A91A-D, Spool No. 8589.
contractor
thickness range. 2. Welding in progress with use of cold electrode in Line No.10”-607-
1705-E1A-IH-F-SPL-15009-Sht-2/3, Rev.1, FJ-14 –Thickness-15.09 (Pipe
to Flange Joint) also Welder No.PW-100, Name-Jai Hind doing welding
in higher than qualified thickness range.
Appropriate action shall be taken by OIL as well as EIL to stop this type
of non-standard work practices repeatedly observed at site.
During Loop inspection for loop no. 607-P-27-344, observed that Cross
Guide for Bare Pipe (G3 Type Support) not installed which require hot
work.
Format-I shall be raised after completion of
49 29-Nov-18 Offshore Format-I shall be raised after completion of support welding and Minor-29
support welding and hydrostatic test.
hydrostatic test.
M/s OIL/ EIL to ensure completion of all hot work prior to hydrostatic
test and raise Format-I.

During Routine survillance in DHDT it has been observed that in Loop

no: 607-P-10-95 ,Butt Weld joint Foul with wear pad Which is not
50 5-Jan-19 Offshore Pipe to pipe Butt joint foul with wear Pad. Major-16
compiling good engineering practices.M/S OIL instruted to cut the
joints & offer for inspection after correctifying the action.

During survillance in Offsite Area it has been observed that spool bend
Spool bend from joint due to sequence of welding from joint due to Welding sequence not proper. In Long length pipe
51 4-Feb-19 Offshore Minor-27
in Doubling(Long length). welding to be done in consecutives passes such as Root, Hot Pass &
Fill up of all neaby joints simultaneously.Tool Box given to Fitter &
Welder to Maintain it.
During fit up inspection in DHDT in Line no-3-IG-607-2101-A3A-F-
SS321 Weldolet installed instead of Inconel 625 which is not as per iso.
52 23-Mar-19 Offshore SS weldolet used instead of Inconel 625. minor-28
M/S Oil instruted to cut the fit up & installed inconel weldolet as per
drawing.

During format Inspection in DHDT it has been observed that at Several

Stiffner installation balance at LPDs & HPVs in location stiffener installation pending. As per iso stiffener Must be
53 28-Mar-19 Offshore Minor-29
High pressure Loop. installed for 600# & above , two phase flow in 1.5" branch & Below.
Instruction given to M/S EIL to provide stiffeners at all branches which
compiling above mention Criteria & after that re-hydro to be done.