IQWQ-CE1092-NPZZZ-00-0001 STEEL STRUCTURE INSTALLATION PLAN 14-Apr-2017

TABLE OF CONTENTS
1.0 PURPOSE.............................................................................................................................. 1
2.0 REFERENCE CODES, DRAWINGS AND DOCUMENTS .................................................... 1
3.0 PROCEDURE ........................................................................................................................ 1
3.1 Receive the shop prefabricated materials and inspect........................................... 1
3.2 Separate the marked materials in accordance with drawings ................................ 1
3.3 Assembling structural steel frame in the field ......................................................... 2
3.4 Lifting and erection of structural steel frame .......................................................... 2
3.5 Scaffolding erection ................................................................................................ 3
3.6 Connection and bolting of the beam or brace ........................................................ 3
3.7 Inspection ............................................................................................................... 3
3.8 Grouting the base plates ........................................................................................ 4
3.9 Hand over ............................................................................................................... 4
4.0 MANPOWER REQUIREMENT.............................................................................................. 4
5.0 MECHANICAL EQUIPMENT REQUIREMENT..................................................................... 4
6.0 PERMIT REQUIREMENTS ................................................................................................... 5
7.0 SAFETY AND RISK ASSESSMENT..................................................................................... 5

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 IQWQ-CE1092-NPZZZ-00-0001 STEEL STRUCTURE INSTALLATION PLAN 14-Apr-2017

1.0 PURPOSE
The purpose of this steel structure installation plan is to describe the construction procedure of
steel structure at the West Qurna-1 M-109 job site.

2.0 REFERENCE CODES, DRAWINGS AND DOCUMENTS

 Structural Design Specification

 Structural steel arrangement drawings and erection drawings

 Quality control procedure for equipment (Steel Structure) IQWQ-CE1092-QPQAC-00-0008

 ITP for steel structure installation IQWQ-CE1092-NPITP-00-0001

 AISC 303 Code of Standard Practice for Steel Buildings and Bridges

 ASTM A490M Standard Specification for High-Strength Steel Bolts, Classes 10.9 and
10.9.3, for Structural Steel Joints (Metric)

 ASTM Related Sections

3.0 PROCEDURE

Erection of structural steel should follow the procedure as below:

a) Receive the shop prefabricated materials and inspect

b) Separate the marked materials in accordance with drawings

c) Review and acceptance of structural steel foundation including pipe rack, pipe bridge,
platform etc.

d) Assembling structural steel frame in the field

e) Lifting and erection the structural steel frame

f) Scaffolding erection

g) Connection and bolting the beam or brace

h) Inspection

i) Grouting the base plates

j) Hand over

3.1 Receive the shop prefabricated materials and inspect

 All materials received at site related to the erection of the structural steel, shall be inspected and
stored in an open area such that the markings are clearly visible. All materials delivered to site
must be attached with the manufacturer’s certifications and shall be inspected in accordance
with drawings, purchase orders and packing lists to ensure their satisfaction to the requirements
of specifications and drawings. All the materials can be used after inspection and approved by
the company/contractor.

 Check arrangement drawing and painting of shop prefabricated elements by vender, which are
as per approved SP and approved drawings.

3.2 Separate the marked materials in accordance with drawings

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 Columns, breams and braces necessary for assembly and erection of different structural steel
frame (pipe rack, pipe bridge, platform) are to be separated with marked numbers, drawings and
shipping list.

 High strength bolts, nuts & washers and connection plates are to be separated with structural
steel frame (pipe rack, pipe bridge, platform).

 Miscellaneous members of structures (stairs ladders & platforms) related to specific structures
are to be separated with structural steel frame.

 Before starting the erection activity, the structural steel foundation shall be checked (axes,
elevation, level, slope, anchor straps position, etc.) and verified according to civil drawings and
the tolerances indicated. The foundation is of prime importance, inspection to be carried out with
care and subsequent repair, if any, shall be completed before the start of erection.

 Perform a visual inspection to ensure the foundation is without damage.

 Ensure diameter, length and center distance of anchor bolts conform to the requirements of
approved civil and structural drawing.

3.3 Assembling structural steel frame in the field

3.3.1 Truss assembly

 It is planned to pre-assemble the truss on the ground close to the point of installation. The steel
members will be laid in wooden sleepers to ensure that they are not damaged and will be lifted
and installed as a unit on the foundation. Where it is not possible to construct using this method,
the structure will be stick built.

3.3.2 Pipe rack

 The newly installed truss will be interconnected to the adjoining truss using manlift to execute the
bolt application and torquing.

 All steel members including: bolts, columns, breams and braces will be clearly marked in
accordance with their corresponding pipe rack axis number for easy identification.

3.3.3 Pipe bridge

 The pipe bridge will be constructed in the same manner as the pipe rack sections.

3.3.4 Platform

 The supports between two gantries shall be first assembled on the ground and then erected
integrally.

 All platform dimensions shall be in accordance with the drawings. Verticality and diagonal should
be checked and the inaccuracy should be within the allowed range.

3.4 Lifting and erection of structural steel frame

 Before the commencement of erection, all the erection equipment tools, shackles, slings etc
should be certified by lifting inspector, and lifting plan shall be prepared and approved. All
relevant parts shall be checked carefully for deformation.

 The lifting of truss sections frames shall start from the truss with bracing. The verticality shall be

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 IQWQ-CE1092-NPZZZ-00-0001 STEEL STRUCTURE INSTALLATION PLAN 14-Apr-2017

first roughly measured with a level, and then leveled with a magnetic plumb or theodolite to
ensure satisfactory to specification and drawing by checking.

 To prevent door frames from deformation, as many lifting points as possible shall be used and
lifting and movement shall be slowly performed when they are lifting.

3.5 Scaffolding erection

 The scaffolding erection of steel structure is in accordance with IQWQ-CE-CSMTH-00-0925

Method Statement For Scaffolding.

3.6 Connection and bolting of the beam or brace

 During installation, strict inspections shall be performed for each step of installation, and the next
step of work shall not proceed until the preceding step of work has been inspected and accepted.
The steel work should be securely bolted or fastened and braced to take care of the stresses
from erection equipment or the loads carried during erection. In addition, adequate provisions to
resist lateral forces and wind loads during erection should also be made according to local
conditions.

 Fitting-up bolts and drift pins shall not be used to bring improperly fabricated members and parts
into place thus causing a strain on bolts in finished work. Drift pins shall not be driven with such
force as to injure adjacent metal.

 For erection of gantries, the verticality shall be first measured roughly with a level, and then
leveled with a theodolite. The records shall be made and the results shall be in conformance with
specifications and drawings.

 The bracing between two frames shall be connected with bolts first and all bolts shall be
tightened in accordance with specifications, the bolt connection area shall be free of paint, oily,
dirt, etc.

 The correct size and type of bolts shall be used in field connection as per approved specifications
and approved drawings, the bolt shall be tightened from the center outwards one by one.

 The high strength bolt shall be tightened by calibrated torque wrench and the torque value of
torque wrench conform to approved specification.

 Final bolt tightening shall be taken after checking the accuracy of the assembled frames, and
final tightening torques of high strength bolts are rechecked as per approved specification.

 After connection beams are installed, the verticality of columns shall be rechecked. Safety
precautions shall be taken whenever overhead operations are performed.

 Man-lift can be used as a temporary platform for connection and bolting of beams or braces.

3.7 Inspection

 Ensure column is in plumb, applicable to transverse and longitudinal direction, is as per

approved SP and approved drawings.

 The quality records and inspection reports shall be prepared simultaneously with performance of
construction activities.

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3.8 Grouting the base plates

 Grout the base plates after completing the steel structure inspection by the company/contractor
as per approved SP and approved drawings.

 Method for grouting shall be in conformance with specifications and drawings

IQWQ-CE-KSMTH-00-0908 Method Statement for General Foundations.

3.9 Hand over

 Collect and collate all the documents signed during erection and hand over to company.

 Hand over shall be in accordance with Company handover procedures.

4.0 MANPOWER REQUIREMENT

SL.No Manpower Requirement QTY

1 Team leader 1

2 HSE engineer 1

3 Supervisor 1

4 Mechanical fitter 20

5 Riggers 3

6 Driver/Operators 3

7 Scaffolding worker 10

8 Electrician 1

5.0 MECHANICAL EQUIPMENT REQUIREMENT

SL. No Mechanical Equipment Requirement QTY

1 Mobile crane 25T 2

2 Manlift 2

3 Chain block(2t) 2

4 Chain block(5t) 2

5 Torque wrench 2

6 Electric wrench 4

7 Hand wrench 4

8 Theodolite 2

9 Level 1

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10 Magnetic plumb 1

6.0 PERMIT REQUIREMENTS

Permits to Work
Description
CSE Critical General Critical Temporary Hot works
Works Works Lift Defeat

Cutting and welding x

Assemble of steel
trusses on the x x
ground

Lift door frame for

erection x

Scaffolding x
Connection and
bolting beam,
working at heights x
(scaffolding
platform or Man-lift)

Survey x
Grouting x

7.0 SAFETY AND RISK ASSESSMENT

 Occupational and health hazards will be carefully observed and mitigated. Hazards will be
managed in accordance with the hierarchy of control elimination, engineering, transfer, paper,
PPE.

 Risk assessment will be submitted for the scope of works related to the Steel structure
Installation.

 All lifting and erection activities will be controlled by PTW, which includes lifting method
statement, check of lift parameters.

 Crane configuration and location to be checked per permit basis.

 Transportation of materials shall be carried out safely. - Include in Mobile Equipment Procedure.

 Scaffolding Plan and Procedure to be developed for the elevated works.

 Only one person will be designated to give signals to the crane operator.

 In case of strong wind no course to be free without installation.

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 ground

Survey

heights
heights

welding
Man-lift)
Grouting
ENL

Working at
Scaffolding
for erection

Cutting and
Assembly of
Equipment

Description

trusses on the

(scaffolding or
Lift door frame

Bolting beam at

X
X
X
X
X
X
X
X
JSA's

X
X
X
X
X
X
X
Risks Assess
IQWQ-CE1092-NPZZZ-00-0001

X
X
X
X
X
X
Method Statement

X
X
X
X
X
X
X
Plot Plan

P&ID drawing

CPECC
CSE/exit checklist

CS entry stand by
person check list
General lift check

X
X
X

list
Machine-ries check
X
X

list

Rigging study

Job Specific
checklist

Page
X

Ladders check list

6/6
Scaffolding check
X

list
X

Scaffolding study

Health check list

Steel Structure Installation Plan

UXO completion
X

report
X

UXO check list

UG clearances
excavation
Hot work
X

Check list
Rev. 0

Job specific Evac.

X

Plan
Confined space
X

Rescue plan
General Emergency
X

X
X
X
X
X
X

Evac. Plot Plan

Gas Test
X
X

X
X
X
X
X
X

MSDS
X
14-Apr-2017