PETROFAC PROJECTS _SERVICES PVT. LTD. - 2022-2023

• Erection of Structural, Mechanical & Piping (SMP) Work with Pre-Fabrication for Well Pads

  Project Scope and Objective
  The scope of this work involves the comprehensive erection of Structural, Mechanical, and Piping (SMP) systems along with detailed piping pre-fabrication activities. This is carried out for the newly developed Well Pad-02 and includes tie-in works and upgrades for the existing Well Pads 1, 4, 5, and 7. The primary objective is to achieve mechanical completion of all systems, ensure accurate and secure integration with existing infrastructure, and make the entire facility ready for hook-up and commissioning. The project focuses on high standards of quality, safety, and technical compliance, following project specifications, applicable codes, and industry best practices to ensure a robust and efficient installation.

  Structural, Mechanical & Piping Execution
  Structural erection activities include the installation of essential steel frameworks such as pipe racks, equipment foundations, access platforms, walkways, handrails, and ladders. This process involves lifting, aligning, and securing beams, columns, and structural supports in accordance with general arrangement (GA) drawings and structural layout plans. Equipment erection covers both static and rotary machines including vessels, manifolds, skids, separators, and electrical/control panels. This is done using cranes, chain blocks, jacks, and certified rigging tools. All mechanical equipment is anchored, aligned, and grouted as per the manufacturer's specifications to ensure optimal functioning and durability.

  Piping works are executed in two key phases: pre-fabrication and erection. During the pre-fabrication phase, spools are prepared based on isometric drawings with activities including pipe cutting, beveling, precise fit-up, and welding of CS/SS pipes. Welders work under approved WPS and PQR, ensuring consistency and quality in every joint. Flange connections, valve fittings, and branch welds are installed with accuracy, followed by Non-Destructive Testing (NDT) methods such as Radiography (RT), Ultrasonic Testing (UT), and Dye Penetrant Testing (DPT). Dimensional inspections confirm compliance with tolerances. Each completed spool is properly tagged and marked before being transported to its respective well pad. Erection involves site installation of various pipelines such as flowlines, injection lines, test lines, and drain/vent systems. On-site flange bolting, field welding, alignment, and tie-in connections are executed precisely following the isometric drawings. The pipeline installation is completed with hydrotesting or pneumatic testing, flushing, and final leak checks to ensure pressure integrity and cleanliness.

  QA/QC, Safety & Final Deliverables
  All SMP works are governed by robust Quality Assurance and Quality Control procedures. This includes adherence to Inspection Test Plans (ITPs), weld mapping, NDT documentation, and full material traceability. Every phase of fabrication and erection is supported with documented inspection reports and compliance records. Safety is embedded into every stage of the job through mandatory use of Personal Protective Equipment (PPE), daily toolbox talks, lifting plans, confined space protocols, and continuous risk assessments. Permit-to-work systems and activity-specific safety briefings ensure a controlled and hazard-free working environment. Upon successful completion, the project achieves full mechanical readiness for commissioning. The final deliverables include updated as-built drawings, detailed inspection reports, and a complete dossier of documentation for client approval and operational handover. This ensures that New Well Pad-02 is fully prepared for integration and operation, while existing Pads 1, 4, 5, and 7 are successfully upgraded to meet current production and safety requirements.