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FIELD INSPECTION
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INSPECTION TYPE
WORK No.
ITEM No
AREA / LOCATION
SIGNATURE
INSPECTION NOTICE No
OWNER
CONSORTIUM
CONTRACTOR
OWNER'S INSPECTOR
CONSORTI UM'S INSPECTOR
CONTRACTOR'S INSPECTOR
REFERENCE Drawing. No
I'IGHTENING METHOD
I
INSPECTION
LOCATION
2. VERTICALITY
3. HEIGHT
4 HORIZONTALITY
5. FOUNDATION AND ANCHOR BOLT
6. SHIMMING
7 WELDING
B, BOLT I"ORQUI NG/I'IG HTEN'NG
9. GIlOUTING
1O PAINTING (TOUCH-UP)
OTHERS
COMMENTS
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REFERENCE Drawing. No
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WORK No.
INSPECTION TYPE:
SIGNATURE
CONSORTIUM
OWNER
INSPECTION NOTICE No
CONTRACTOR
OWNER'S INSPECTOR
CONSORTI UM'S INSPECTOR
CONTRACTOR'S I NSPECTOR
REFERENCE Drawing. No.
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VISUAL INSPECTION
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ACCESSORIES
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. Platform
2. Ladder
3. Grating
4. Checker Plate
5. Handrail
6. Stair
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COMMENTS
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REMARKS
Document Description
Client
On Shore JV
Document No.
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TABLE OF CONTENTS
1.0 SCOPE ................................................................................................................ 3
2.0 REFERENCE DOCUMENTS .............................................................................. 3
2.1 ABBREVIATIONS ........................................................................................... 3
2.2 CODES ........................................................................................................ 3
2.3 CONTRACTOR'S DOCUMENTS ....................................................................... 4
2.4 ASSOCIATED PETROJET PROCEDURES ......................................................... 4
3.0 RESPONSIBILITY .............................................................................................. 4
3.1 CONSTRUCTION MANAGER ........................................................................... 4
3.2 QA/QC MANAGER........................................................................................ 4
4.0 MATERIAL AND EQUIPMENT........................................................................... 4
4.1 STEEL STRUCTURES ................................................................................... 5
4.2 W ELDING FILLER METAL .............................................................................. 5
4.3 EQUIPMENT AND TOOLS .............................................................................. 5
5.0 PLANNING OF ACTIVITIES AND MONITORING OF PROGRESS ................. 5
6.0 ERECTION DRAWINGS .................................................................................... 5
7.0 RECEIVING, HANDLING AND STORING MATERIAL ..................................... 6
8.0 CHECK FOR FOUNDATIONS........................................................................... 6
9.0 PRELIMINARY CHECKS .................................................................................. 6
10.0 MATERIAL WITHDRAWAL............................................................................... 7
11.0 ERECTION .......................................................................................................... 7
11.1 GENERAL ..................................................................................................... 7
11.2 MOUNTING GUIDELINES ................................................................................ 8
11.3 INTERMEDIATE INSPECTION ..........................................................................10
11.4 FINAL INSPECTION ....................................................................................... 10
11.5 TOLERANCES .............................................................................................. 10
11.6 REPAIR OF GALVANIZED STEEL.................................................................... 10
12.0 TESTING AND INSPECTION ............................................................................. 11
13.0 GROUTING ........................................................................................................ 12
14.0 QUALITY RECORDS......................................................................................... 12
15.0 APPENDIX ......................................................................................................... 12
Document Description
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1.0
SCOPE
This procedure describe the minimum requirements that shall be observed at site for handling and
storing materials, erection of hot dip galvanized primary and secondary steel structure to be installed .
It also covers the tests and inspections that are to be carried out during the execution of the
assembly works.
And this procedure covers Steel Structures, Steel from Building, Supporting Steel, Steel Pipe Rack,
and Miscellaneous Structure Steel.
The objective is to ensure that all the activities are carried out:
2.0
Using special working and control process which have been previously qualified;
using material which are kept under control from receiving throughout entire
working cycle;
REFERENCE DOCUMENTS
2.1
ABBREVIATIONS
ITP
QC
2.2
=
=
AWS D1.1
(B S)
British Standard.
(ISO)
ANSI
ASTM
Document Description
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QC Procedure.
ED-9999-PJM-PEP-000-006[1]
ITP NO:20
3.0
PJ-EEP2-MRI-PRO-0001
PJ-EEP2-NR-PRO-0001
PJ-EEP2-NDT-PRO-0001
RESPONSIBILITY
3.1
CONSTRUCTION MANAGER
The Construction Manager is responsible for the implementation of this procedure for
the over all direction and coordination with the QA/QC Manager for monitoring,
coordinating
and control of all the erection activities.
3.2
QA/QC MANAGER
The Site QA/QC Manager is responsible to verify the proper implementation of the quality
systems and to implement quality control activities related to erection.
4.0 MATERIAL AND EQUIPMENT
4.1
STEEL STRUCTURES
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4.2
When required for any modification Welding filler metal shall conform now to BS 5135,
BS 639 and ISO 5182 /E7018 welders and welding WPS as per BS4871 & BS 4872
4.3
All tools and equipments to be used for erection shall be standard (not allow any
fabricated or hand made fouls) in good order, safe condition and sufficient quantity.
Examples of tools and equipment are:
5.0
Cranes
Plastic Ropes to be used as guide only during lifiting not for any lift.
Transportation Trucks
Torque Wrenches
The Project Planner is responsible to plan the sequence of erection of steel structure
according to the Construction Master Schedule.
He is also responsible to monitor the progress of the work and to keep informed the
Construction Manager and Project Manager for any deviation from the original schedule.
Planning of steel structure erection shall be made according to erections priority
and material availability.
6.0
ERECTION DRAWINGS
The Technical Office (TO) receive the steel structures drawings from engineering department.
Based on the availability of drawings, material after fabrication, specifications and in
congruence with planning, TO shall issue detailed drawings for erection and copy to all the
concerned departments (AFC DWGS & Last Rev).
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7.0
The Material Control Manager (MCM) shall receive all steel structures in accordance with the
procedure and shall be responsible for checking quantity and type of materials indicated in
the packing list and QC inspector checks for quality. The damages shall be immediately
notified to take the required measures.
The materials shall be stored, handled and preserved in accordance with the procedure.
8.0 CHECK FOR FOUNDATIONS
Before commencing work, center lines, locations, orientation, chipping and
elevations of foundations shall be checked for prescribed tolerances.
Support shims shall be located after marking the centre lines on the plinths.
At least 3/4 shims packs with levelling mortar shall be provided for the base plates of each
column. Centre lines marked on plinths shall have a tolerance of 1 mm and elevation
of 1 mm.
The foundation bolt surface that will come in contact with concrete shall be free from
dirty and oily matters or points. Foundation surface shall be chipped prior to erection activity.
9.0
PRELIMINARY CHECKS
According to the sequence and schedule of erection, the following preliminary checks
shall be carried out before erection activities begin, in order to verify:
The availability of experienced, qualified personnel and equipment necessary to
carry out the works;
The availability of fabricated steel structure and its status of acceptance.
The status and availability o f approved for Construction drawings and
/or specifications.
All tools and equipments used for erection are calibrated as per Calibration of
Inspection and Testing Equipment procedure
The status of torque wrench calibration the above preliminary checks shall be
jointly made by all the concerned as i n responsibility matrix.
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Document Description
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The contact surfaces of bolted elements shall be free from rust, mill scale, grease, etc. Bolts
already used and previously tightened shall not be re-used.
All site bolted connections shall be assembled and torque tightened in accordance with Appendix
A. After the torque tightening of bolts shall be identified by the paint on the bolt head.
All material, plant and equipment used shall be of sound construction and free from flaws.
Bolts designed for transmitting forces in structural member connections, shall have a minimum
diameter as follows:
Minimum diameter
20mm
16mm
2mm
o Up to 24 mm bolt diameter
4mm
o 24 to 32 mm bolt diameter
6mm
8mm
The spacing of bolts in the direction in which the force is applied shall be at least three bolt
diameters (measured in the direction of the force).
The minimum distance from center of bolt edge of plate measured in the direction of force shall
be two bolt diameters, and measured at right angles to the direction of force, one and a half bolt
diameters.
Slotted hole connections are to be executed in such away, that these connections may perform
their design function, as indicated on the design drawings, and shall be provided with washers.
High-strength bolts shall be used for structural steel-to-steel connections.
High-strength bolts shall be used for in bearing-type connections and not as friction grip bolts
11.2 MOUNTING GUIDELINES
If required, additional drilling of beams, columns or other components shall be made to
remedy fabrication mismatch / faults. Magnetic base drills shall be used for such work.
Document Description
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Based on the defined priority, structural members shall be assembled prior to erection for
ease of construction with due consideration to lifting capability and study.
The following sequence shall be followed:
Prepare shim plate above concrete mortar and control the required bottom elevation
Document Description
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Document Description
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metal
and free of all visual rust, oil or grease. Any none adhering galvanizing shall be removed to the
extent that the surrounding galvanizing is integral and adherent.
12.0 TESTING AND INSPECTION
Inspection and test shall be carried out by qualified personnel, coordinated by SQM, according to
the Inspection & Testing Plan (ITP).
All structural steel material and fabrication shall be subject to inspection by client
Welds shall be inspected by contractor according to the previsions of regulatory requirements with
respect to technique, equipment, and acceptance criteria and personnel qualifications. All welds
shall be subject to random visual inspection by client .in addition, the following special
requirements shall apply to welding inspection.
Grating shall be tagged with metal plate having raised letters so that the mark shall be seal welded
to the grating prior to galvanizing.
Contractor may submit alternate proposal for marking galvanized members, subject to clients
written approval.
SQM shall manage all Witness and Hold Points shown on the ITP, including convocation to
Contractor.
The form worked out toyo shall be used for issue of the certificates listed in the Inspection and
Test Plan The Inspection mentioned in the Inspection and Test Plan shall be carried out using the
following calibrated instruments:
Optical levels, steel metric rollers, water levels, manual dial type torque wrench for torque read-out.
10% of all connections for each bolt size shall be randomly selected and inspected, of each
joint shall show the tightening value of high strength bolts. Such test shall be conducted on
minimum 2 bolts per each joint.
Tested bolts shall be clearly marked with paint.
Each high strength bolts assembly shall consists of one heavy semi-finished hexagon structure
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bolts one heavy semi-finished hexagon nuts and one hardened washer to be used the nut
In presence offload indication Washers ,turn-of nut tightening follow-up; one nut sample per each
size of bolts shall be unscrewed by at least 1/6 turn and then to check whether the prescribed torque
brings the nut back to its original position.
Galvanized bolts shall not be reused after unscrewed; bolts may be reused after repaint
by galvanize spray.
13.0
GROUTING
All bearing plates, loose lintels, beams and columns shall be shimmed to proper grade and
level before grouting.
Grout material as specified in the technical specification or on drawing shall be used.
The sand-cements mixture shall be combined with the least amount of water to produce a low
slump, place able grout.
Prior to setting structure, the concrete surface to receive grout shall be chipped to a depth of
6 mm to obtain a roughened surface.
After the structure is a place, positioned and shimmed immediately before grouting, the surface to
receive grout shall be cleaned and wetted. Excess water shall be removed.
Grout shall be placed and thoroughly worked to eliminate voids and provide a uniform bearing
surface under the base plate.
When specified on drawings, epoxy grout shall be used for grouting under heavy equipment
where large bearing and /or vibration stresses occur. Epoxy grout shall be mixed by mechanical
mixer and placed in accordance with manufacturer instruction.
14.0 QUALITY RECORDS
The following records shall be provided:
ITP and Procedure
Certificates of materials supplied
Dimensional reports
Bolt torque tightening reports
Surface treatment reports
Grouting reports
Final dossier containing the report of the test carried out
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15.0 APPENDIXB
1-
2-
3-
4-
Tightening Torque in NM
12
94
14
148
16
234
18
320
20
456
22
616
24
787
27
1150
30
1562
33
2125
36
2729
39
3532