026-pro-structural steel assembly and erection.pdf

Pearl GTL Project

LINDE ENGINEERING

Contractor Project No: 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.250.907 Project Rev.:A Page 2 of 22

Purchase Order Number: 2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

Doc. Title : GAM-PRO-QAC-GTL-026 QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL ASSEMBLY AND ERECTION

Date : 24.04.08 REV-D QQQ AAA TTT AAA RRR

T-4.250.907 Rev. A Page 3 of 22

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

D A 24.04.08 Ready For Construction BR UA ZG RFC

C O 03.12.2007 Issued for Company Comments BR AU/MC ZG ICC

B 22.11.2007 Issued for Review BR AU/MC ZG IFR

A 20.11.2007 Issued for Internal Review BR AU/MC ZG IIR

Approved By

GAMA Project Rev

Rev. Date Description Prepared

By Checked

By Status

No. No. ORIGINATOR

Document Title:

LINDEGINEERING AG

QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL ASSEMBLY AND ERECTION

Document No.

GAM PRO QAC GTL 026 D LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T-4.250.907 Rev No: A


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 4 of 22

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TABLE OF CONTENTS

1. SCOPE ________________________________________________________________________5 2. PURPOSE _____________________________________________________________________5 3. HSSE _________________________________________________________________________5 4. REFERENCE __________________________________________________________________5 5. DEFINITIONS _________________________________________________________________6 6. RESPONSIBILITIES ____________________________________________________________6

6.1. SITE MANAGER__________________________________________________________________6 6.2. CONSTRUCTION MANAGER ______________________________________________________6 6.3. EQUIPMENT MANAGER __________________________________________________________6 6.4. SITE ENGINEER__________________________________________________________________7 6.5. SITE SUPERVISOR/FOREMAN_____________________________________________________7 6.6. QA/QC ENGINEER________________________________________________________________7 6.7. QA/QC INSPECTOR_______________________________________________________________7 6.8. HSE MANAGER __________________________________________________________________7 6.9. HSE OFFICER ____________________________________________________________________7

7. PROCEDURE __________________________________________________________________7 7.1. PRELIMINARY CHECKS __________________________________________________________7 7.2. FABRICATION ___________________________________________________________________8 7.3. BEVELLING AND FITTING________________________________________________________8 7.4. WELDING, AND NDE _____________________________________________________________8 7.5. REPAIR__________________________________________________________________________8 7.6. CLEANING AND PAINTING _______________________________________________________8 7.7. PREASSEMBLY & ERECTION _____________________________________________________9 7.8. ERECTION______________________________________________________________________10

8. QUALITY ASSURANCE_________________________________________________________11 9. ATTACHMENTS/FORMATS ____________________________________________________11


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 5 of 22

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1. SCOPE This Quality Control Procedure relates to the verification of construction activities for steel Structure Erection.

2. PURPOSE The purpose of this quality control procedure defines the documentation to be collated and the inspections to be carried out in order to verify and record that all steel erection activities are conformant to the requirements of the project specification.

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have through LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required. At a minimum a Risk Assessment will have been prepared by the Risk Assessment Team (RAT) ranking the hazards associated with project works and control measures to be taken to mitigate the hazards to an acceptable level. Each work scope or task will have a completed and approved Job Safety Analysis (JSA) identifying the potential hazards and control measures that will be implemented to protect people and environment. Supervisor as the basis of conducting his daily Pre-Task meeting and his weekly Tool Box Talk (TBT) will use the JSA.

In addition to the above, employees conducting survey works will wear required PPE and highly visible vest where traffic or other hazards may exist. For additional safety requirements for a particular or specific task please refer to the JSA prepared for that task.

4. REFERENCE T.4.115-071: Fabrication & Assembly of Steel Structure T-4.234.542: Project Quality Plan GAM-PRO-QAC-GTL-012: HSSE Plan T-13-376-359 Rev-E: Steel Structures SSPC-SP 14/NACE No. 8: Industrial Blast Cleaning T-4.250. 917: ITP For Structural Steel 34-00-01-30: Minimum Requirements For Structural Design & Engineering


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 6 of 22

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GZ00-C-SY2005.013: Metal Works and Fencing. T.4.250.896 : Method Statement for structural steel assembly and

Erection.

5. DEFINITIONS Company : QSGTL and/or its PMC Contractor : LINDE ENGINEERING AG Sub Contractor : GAMA QATAR Contract : QSGTL Pearl Plant-C2 ASU Construction Works CS : Construction Supervisor ITP : Inspection and Test Plan QCR : Quality Control Record QCP : Quality Control Procedure QCE : Quality Control Engineer QCI : Quality Control Inspector QA/QC : Quality Assurance / Quality Control TPI : Third Party Inspection

6. RESPONSIBILITIES

6.1. SITE MANAGER The site manager will provide inputs to the project execution plan to ensure that lifting strategies & philosophy are addressed.

6.2. CONSTRUCTION MANAGER The construction manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented.

6.3. EQUIPMENT MANAGER The equipment manager will be responsible for the transporting equipments availability and good order.


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 7 of 22

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6.4. SITE ENGINEER Shall report to Construction Manager. Shall be responsible for planning, execution and implementation of all site activities related to this procedure.

6.5. SITE SUPERVISOR/FOREMAN Shall report to Site Engineer. Shall be responsible for execution of construction activity. Shall also prepare daily site construction records.

6.6. QA/QC ENGINEER Shall report to Manager (QA/QC) and shall be responsible for overall implementation, monitoring and control of QC activities.

6.7. QA/QC INSPECTOR Shall report to QC Engineer. Shall be responsible for attending all Inspection Stages as required by ITP. Shall be responsible of performing all checks and shall prepare necessary Inspection Reports.

6.8. HSE MANAGER Shall report to Project Manager and shall be responsible for over all control and inspection of HSE issues.

6.9. HSE OFFICER Shall report to HSE Manager. Shall be responsible for all safety aspects for this procedure.

7. PROCEDURE

7.1. PRELIMINARY CHECKS

According to the sequence and the schedule of construction activities, the following preliminary verification shall be carried out before starting prefabrication activities. The availability of qualified personnels on site and suitable equipments to carry out the works; The availability on site of the necessary erection material and its status of acceptance; The status of approval of the assembly drawings and/or procedures The availability of approved WPS and PQR, for carrying out welding;


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 8 of 22

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The existence of valid certification for the personnel involved in special processes, when applicable,

7.2. FABRICATION The Structural Steel shall be fabricated as per IFC Drawing. All Dimensions, orientation bends etc. to be checked and reported in GAM-QCR-QAC-GTL-035.

7.3. BEVELLING AND FITTING Where necessary, structural steel shall be cut in order to reach the length indicated in the specified drawings after checking actual conditions on site. After cutting, the ends of the Steel to be grinded and make Butt or Fillet welding, accordance with the applicable WPS. The welding surfaces adjacent to the joint shall be free from all scale, rust, oil, grease, moisture or other foreign material that could prevent proper welding.

7.4. WELDING, AND NDE

All welding and PT/MT activities shall be carried out by qualified personnel(ASNT Level II) in compliance with approved procedures. Qualification of welders shall be made in accordance to approved Procedure and witness / approved by Contractor. Weld joints found defective during Non-destructive examinations shall be carried out in as per repair method.

7.5. REPAIR

Structural Steel Repair Works shall be carried out by as per the Repair welding procedure & using Qualified Repair welder.

7.6. CLEANING AND PAINTING

6.5.1 Cleaning of structural steel

The prefabricated structural steel shall be cleaned, to make them free from sand, weld slag and any other foreign material.

6.5.2 Painting of structural steel


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 9 of 22

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The prefabricated structural steel shall be sand blasted and painted by the qualified painting personnel.

7.7. PREASSEMBLY & ERECTION The preassembly and erection will be done in basically the following steps: preassembly on the ground, erection with crane(s), and stabilization of erected pieces, general cleanup. All erection works will be done with the latest approved IFC drawings. Before assembly of any structural steel element; position and level of anchor bolts will be checked. True level of a base plate will be obtained with the use of shimming plates.

Surveyors will paint marks on the foundations denoting the axes and levels to be used. These target marks will be colored for visibility.

When a damaged galvanized surface on a steel element is observed during the execution of the preassembly of the structural steel members, surface touch-up will be done in accordance to painting and coating of new Equipment DEP 30. 48.00.31 concerning repair of galvanized steel plates if necessary. Where possible, preassembly of the steel structure elements will be done close to the foundations to minimize handling needs preferably in a position where the crane used for the assembly can be used for the erection as is.

Erection of the preassembled parts like Cladding, Roofing Sheets, Gratings, Stair treads. Plat forms, Metal Cladding will be done with cranes.

Adequate safe lifting capacity of the cranes is to be confirmed from the load charts of the cranes. For cranes not herein attached, load charts Shall be submitted for approval, before the start of the respective work.

The area where the crane is positioned must be suitable for the purpose. There should not be deep excavations close enough to the crane to destabilize it and the ground must be firm enough to prevent the crane from sinking. To spread the load and further stabilize the crane steel sheets or pads will be used if required. A soft barricade will be erected around the crane and signs posted to clearly define the work area.

Before erection works start, the concrete surfaces of the foundations shall be checked & roughened by chipping. After checked by QA/QC Management and handed over, erection facilities shall begin.

During erection, temporary bracing and guys shall be used to maintain structural stability as necessary.


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 10 of 22

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Workers working at height (above 1.2 meter from ground) will have at least one lanyard connected to a stable/fix member on man lock Hole. Safety belt used shall be double lanyard.

Centre of gravity of structural steel piece shall be calculated to prevent security risks. But if the piece is symmetrical with regard to the centre line, there is no need to calculate gravity centre.

A general cleanup of the work area will be conducted to ensure that no unused materials are left on the erection site. All material retrieved will be sent to the warehouse for proper storage.

7.8. ERECTION

Firstly the surveyor will establish control lines will also be recorded on the Surveyors Report.

Start the erection only after the Surveyor Report has been reviewed

by the Site Engineer and Construction Supervisor and it has been agreed that on erection problems could be foreseen. Both Site Engineer and Construction Supervisor will ensure that there are sufficient copies of the "Specification for Structural Joints Using ISO 4014, ISO 4032, and ISO 888" latest edition at the Project site; to ensure that inspectors and workmen have guidance to properly install high strength bolts.

The Erection of the Structural Steel shall be supervised by the

Construction Supervisor who will ensure conformance with AISC "Code of Standard Practice for Steel Building and Bridges".

The Construction Supervisor will ensure that if erection bolts are

used, they are replaced with permanent bolts as soon as possible after plumbing the structure, and all connections shall be completed.

The Site Engineer and Construction Supervisor shall ensure that the

installation of high strength bolts shall be in accordance with "Specification for Structural joints using ISO 4014,ISO 4032,and ISO 888", using Torque Wrench to indicate the correct tensioning of bolts. Special attention shall be given for installation of galvanized high-tension bolts.

The Construction Supervisor will inspect the completed structure and

only after satisfactory completion will the Construction Supervisor raise the RFI and Check Sheet (Steel Erection) for the Surveyor to confirm Plump, Line & Level. All base plates will be shimmed to level


Date : 24.04.08 REV-D

T-4.250.907 Rev. A Page 11 of 22

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and only Steel Erection acceptance will grouting of steel column base plates commence.

8. QUALITY ASSURANCE A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented as per ITP T.4.250.917.

9. ATTACHMENTS/FORMATS

1. GAM-QCR-QAC-GTL-035 2. GAM-QCR-QAC-GTL-036 3. GAM-QCR-QAC-GTL-037 4. GAM-QCR-QAC-GTL-038 5. GAM-QCR-QAC-GTL-039 6. GAM-QCR-QAC-GTL-040 7. GAM-QCR-QAC-GTL-041 8. GAM-QCR-QAC-GTL-042

9. GAM-QCR-QAC-GTL-043 10. GAM-QCR-QAC-GTL-044 11. GAM-QCR-QAC-GTL-125

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY

STRUCTURES FABRICATION REPORT

Subcontract Ref.: Report No.:

Item Description: Inspection Date:

Item No: Test Code No.:

Subsystem: ITP No.:

Ref. DWG / Docs:

Used Measuring and test equipment ref. (if applicable): Check the following:

Item No.

Description ACC REJ Signature Date

1. Dimensional to be checked as per Drawing

2. Fit up checked

3. Orientations checked

4.

Various bends checked

5.

Welding Acceptable in visual

6.

PT/MT verified

7. Painting checked

ORGANIZATIONS DATE NAME SIGNATURE

THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y

QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-035

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY STRUCTURES RECEIVING INSPECTION



Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG / Docs:

Used Measuring and test equipment ref. (if applicable):

Check the following:

QC Inspector Item No.

Description Initial Date 1. Material is per Packing List No.:

2. Welds have been inspected visually

3. Painting visually inspected for transportation damages

4.

Quantity as per Packing List and drawings

5.

Material not damaged by transport


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


GAM-QCR-QAC-GTL-036


STRUCTURAL STEEL INSTALLATION PROCESS SHEET



Item Location/ Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG / Docs:



QC Inspector Item No.

Description Initial Date 1. Foundation complete and inspected

2. All structural members correctly Installed

3. Base supports are set at correct Elevation.

4.

Structure is plum in all directions and Members Aligned.

5.

All Bolts in & correctly Tightened.

6.

Length of Bolts correct.

7. All Washers correctly Mounted.

8. All Temporary construction materials Removed.

9.

Welding Acceptable.

The Installation of the above Steel has been Satisfactorily completed in accordance with the Drawings & Specifications.


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


GAM-QCR-QAC-GTL-037

C2 ASU PEARL GTL PROJECT RASLAFFAN INDUSTRIAL CITY

SETTLEMENT MONITORING REPORT




Subsystem: ITP No.:

Ref. DWG / Documents:


INSPECTIONS Plumb Column No Planned Level Actual Level Level/Difference

0 Degree 90 Degree


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


GAM-QCR-QAC-GTL-038


ALIGNMENT REPORT FOR STEEL STRUCTURE




Subsystem: ITP No.:

Ref. DWG / Docs:

Used Measuring and test equipment ref. (if applicable): Unit No.:

OUT OF PLUMBNESS


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


GAM-QCR-QAC-GTL-039

C2 ASU PEARL GTL PROJECT-RAS LAFFAN

INDUSTRIAL CITY CHECK LIST OF LADDER,

HANDRAIL, STAIRCASE & GRATING




Subsystem: ITP No.: Ref. DWG / Documents:


INSPECTIONS

Item Mark No. Check of Ladders

Check of Handrail

Check of Staircases

Check of Grating


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


GAM-QCR-QAC-GTL-040

C2 ASU PEARL GTL PROJECT RASLAFFAN INDUSTRIAL CITY

BOLT TIGHTENING INSPECTION REPORT


Item Description: Inspection Date: Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG / Docs:


INSPECTIONS Bolting Item No/Spool

No Mark No./Joint No

Grade Size Bolt Tightening (Torque Value)

Inspectors Signature


THIRD PARTY REP.

GAMA REP.

LINDE REP.

Acc

epte

d B

y


GAM-QCR-QAC-GTL-041

Test Report Magnetic Particle Test (MT)

QSGTL PEARL PROJECT-QATAR

Testing Contractor Testing Code, Standard Test Equipment Testing Consumables Illumination [lx] Surface Temperature [C] Data General Evaluation Standard Magnetisation Current Fieldstrength [kA/m] Current [A]

Object Data Testing Data Testing Results (a = accepted / na = not accepted)

Test Defect No. Line No. Area NPS Welder 1 Piping Testing Electrode Type of Examiner Test no no Type Length Location Pos. Comments a/na 1) Sheet Weld

No. Thick-ness

Welder 2 Contractor before/ after PWHT

Contact Distance

Test 2)

Date Defects Defects after

grinding

3) [mm] 4) 5)

Abbreviations GAMA REP Third Party 1) R Repair

N new after Rep. G non pressure tested weld

3) Type of Defect G = globular L = in Line

4) Location of Defect B = Base Material T = Transition Area W = Weld Metal

5) Position of Defect Distance to Reference Point [mm]

_______________________________________ Date Name Signature

_______________________________________ Date Name Signature

2) Type of Test a = wet b = dry c = fluorescent

LINDE REP _______________________________________ Date Name Signature

QSGTL OR its PMC REP _______________________________________ Date Name Signature

GAM-QCR-QAC-GTL-042

Test Report Liquid Penetrant Examination (PT)

C2 ASU Pearl GTL PROJECT -Qatar Testing Contractor Testing Consumables Doc No: Testing Code, Standard Ilumination [lx] System Trade Name Batch Data Penetrant General Evaluation Standard Surface Temperature [C] Cleaner Developer

Object Data Testing Data Testing Results (a = accepted / na = not accepted) Test Defect No. Line No. Area NPS Welder 1 Piping Testing Penetr. Develop. Test no no Type. Length Location Pos. Comments a/na

1) Sheet No. Weld No. Thick-ness Welder 2 Contractor

before/ after PWHT

Time [min]

Time [min] Date Defects

Defects after grinding 2) [mm] 3) 4)

Abbreviations GAMA REP Third Party

1)

R1 Repair N new after Rep. G non pressure tested weld

2)Type. Of Defect G = globular L = in Line

3)

Location of Defect B = Base Material T = Transition Area W = Weld Metal

4)Position of Defect Distance to Reference Point in [mm]

Date Name Signature

Date Name Signature

LINDE REP _______________________________________ Date Name Signature

QSGTL OR its PMC REP _______________________________________ Date Name Signature

GAM-QCR-QAC-GTL-043

Test Report Radiographic Examination (RT)

C2 ASU PEARL GTL PROJECT-QATAR

Testing Contractor Film Class Source Position

Testing Code, Standard Penetrameter IQI Systemclass C3 C4 C5 Expos.No. Data Trade Name 120 vertic. 90 EL General Evaluation Standard Density Screen Type EN 1435 5 8 2 14 11 12 Screen Thickn. ASME-V A B C D E F G

Object Data Testing Data Testing Results Test No.

Line No.

Area

NPS

Welding

Welder 1

Source Source

Size Distance

FF Tube Volt.

[kV] Expo-sure

Film

Source

Date

of

No. of Films

Imper-fections

Pos. IQI

Comments

a/na

1) Sheet No.

Weld No.

Thick-ness

contract. Welder 2 Activity [Ci]

[mm] [mm] Tubecur. [mA]

Time [min,sek]

System Pos. Test Film size 2) Sen-sitivity

Repair from - to

1) 2) Imperfections GAMA REP Third Party R1,2 N F

Repair new after Rep. Tracer Shot

101 102 2011

Ea Eb Aa

Crack long. Crack transv. Pore

304 401 402

H C D

Foreign Materials Lack of Fusion Lack of Penetration

__________________________________________Date Name Signature

______________________________________________ Date Name Signature

G K T

RT instead of Pressure Test Control Shot T-Joint, 1Film

2013 2016 301

Ad Ab Ba

Porosity Wormhole Slag inclusion

5011/12 5013 504 515

F Da Dc Db

Notch Root Notch Root Reinforcement Root suck-back

LINDE REP __________________________________________Date Name Signature

QSGTL OR its PMC REP ______________________________________________ Date Name Signature

GAM-QCR-QAC-GTL-044

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY STRUCTURES PRE ERECTION

REPORT

Report No.: Inspection Date:

Area : RFI No:

Location : Test Code No.:

Grid No : ITP No.:

Ref. DWG / Docs:


Item No.

Description ACC REJ N/A REMARK

1. Foundation handing over (Civil to Mechanical)

2. Preparation for Grouting

3. Checking for Anchor Bolt

4.

Shim Plate fixed as per RFC Drawing and Work Instructions

5.

Ready for Erection

ORGANIZATIONS DATE NAME SIGNATURE GAMA QATAR.

LINDE.

QSGTL OR its PMC

GAM-QCR-QAC-GTL-125

PRO -STEEL.pdfPRO -STEEL.pdfPRO .pdfThe purpose of this quality control procedure defines the documentation to be collated and the inspections to be carried out in order to verify and record that all steel erection activities are conformant to the requirements of the project specification.

PRO -STEEL.pdfPRO -STEEL-03.12.2007.docThe purpose of this quality control procedure defines the documentation to be collated and the inspections to be carried out in order to verify and record that all steel erection activities are conformant to the requirements of the project specification.

QCR-035-STRUCTURES FABRICATION REPORT.pdfQCR-036-STEEL STRUCTURES RECEIVING INSPECTION REPORT.pdfQCR-037-STRUCTURAL STEEL INSTALLATION PROCESS SHEET.pdfQCR-038-SETTLEMENT MONITORING REPORT.pdfQCR-039-ALIGNMENT REPORT FOR STEEL STRUCTURE.docQCR-040-DIMENSIONAL CHECK FOR LADDER ,HANDRAIL REPORT.docQCR-041 BOLT TIGHTENING INSPECTION REPORT.pdfQCR-042-MT REPORT.pdfQCR-043-PT REPORT.pdfQCR-044-RT REPORT.pdf

125-STRUCTURES PRE ERECTION REPORT.pdf

026-pro-structural steel assembly and erection.pdf

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