Ms for Fabrication & Erection of Structures

PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624

METHOD STATEMENT No: 04 FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624

00

Issue for Approval

JUN 20, 2011

JER

Date

Prepared by

MIS

(For Train-06)

Rev.

Comments

Checked by

Approved by QG

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PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624

INDEX

1.

PURPOSE

2.

SCOPE

3.

REFERENCES

4.

DEFINITIONS

5.

RESPONSIBILITIES

6.

PROCEDURE

7.

TOOLS AND EQUIPMENTS

8.

SAFETY INSTRUCTIONS

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PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624 1.

PURPOSE. The purpose of this method statement is to define the procedure for shop fabrication and installation of steel structure for 52-K0624 Train 6

2.

SCOPE The scope of this method statement covers following activities of shop fabrication and installation of steel structure:

3.

•

Material handling

•

Lay Out and Marking Off

•

Cutting

•

Grinding

•

Fit Up

•

Welding

•

Painting

REFERENCES 3.1

3.2

3.3

PROJECT DRAWINGS •

Shop drawings.

•

Supporting structure detail drawing.

PROJECT SPECIFICATION •

Steel structure specifications. (QCS/50/00/ST/DB/NA/002)

•

Approved material certificates.

PROJECT QUALITY PLAN Inspection / testing shall be done in accordance with ITP. Page 3 of 11 REV: 00

PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624

3.4

CODES AND STANDARDS •

BS EN 10025 1993 grade S275 (ASTM A36)

American Welding Society (AWS) •

AWS D1.1 structural welding code.

American society for non-destructive testing (ASNT) •

4.

ASNT-TC-1A recommended practice.

RESPONSIBILITIES • It is overall responsibility of PM to organize resources to perform fabrication activities as per project specification, in compliance with quality, schedule & safety requirements. • DESCON will ensure that all the works are performed safely as per latest Approved for Construction (IFC) drawings & specifications. • The relevant Engineer and Supervisor will ensure that all the work is conducted in accordance with this method statement and project specification. • The QC Inspector will ensure that all work is executed according to QCP and that requirements of quality dossier are full filled. • Safety and Construction supervision will be carried out under responsibility of Contractor and Company may provide guidance if necessary.

5.

PROCEDURES – METHOD OF WORKS – INSTRUCTIONS 5.1 MATERIAL RECEIPT •

The steel structure approved material shall be received from Descon

warehouse and placed on wooden supports. The material will be properly marked to identify the structure for which it is intended.

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PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624 •

Material handling shall be carried out in a manner to maintain identification

and to prevent damage. •

When raw steel material is delivered, material controller shall confirm that

there is no shortage/damage of material as given in the packing list and that there is no damaged items. •

All materials shall be inspected and reviewed as per Company procedure.

• A logbook shall be maintained for all materials received showing following information:

-

Member identification marks and quantity.

-

Quantity of fasteners, classified in accordance with designations, size, length etc.

-

All fasteners shall be delivered in boxes and clearly marked with labels as per the requirements and specifications. Bags with tags can be used in case of small quantities of fasteners.

5.2

STRAIGHTENING •

Steel structure raw material shall be checked as per standards and

specifications for straightness before shifting from warehouse to fabrication shop. •

Any damaged or distorted material shall not be shifted.

•

Steel may be repaired or corrected subject to the prior approval of the client.

5.3 MATERIAL TRACEABILITY • Material traceability shall be according to the ITP

5.4 MARKING OFF •

The marking off of steel structure will be done according to the shop drawings. In case a large number of identical items are required then templates can be used.

•

The use of chisels or center punches for marking on materials shall be such that the material is not damaged.

•

Completed member shall be tagged with drawing no. and member no. Page 5 of 11 REV: 00

PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624 5.6 CUTTING •

Cut dimension shall be according to the drawings and specifications with due consideration given to allowance for finishing, shrinkage etc, which may occur during shop fabrication.

•

Steel shall be cut by friction saw, cold saw, mechanically guided flame. In case hand cutting is required, it shall be conducted with appropriate margins for removing notches and gouges in conformance with the specified shape and dimensions.

• •

In all flame or plasma cutting, the rough-cut surface shall be ground. The cut edge of a member shall be free of gouges, notches, and other defects.

•

5.8 ASSEMBLING •

The component part shall be assembled in such a manner that they are neither twisted nor damaged.

5.9 TOLERANCES Tolerances for shop fabrication of steel structure shall be according to the design drawing and steel structure specifications.

6. WELDING Production welding/ workmanship and finishing shall be performed by utilizing following: -

Under control condition.

-

In accordance with approved (WPS) welding procedure specification.

-

By qualified welders approved by client.

6.0.1 EDGE PREPARATIONS

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PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624 • Surfaces and edges shall be welded smooth, uniform and free from fins, tears,

cracks and other discontinuities that affect the quality or strength of the weld. •Surfaces to be welded and adjacent areas shall be free from loose or thick scale, slag, moisture, grease, rust, paint, and other foreign material.

6.0.2 DISTORTION AND SHRINKAGE •In assembling and joining parts of a member or in welding reinforcing parts to member, the sequence and procedure shall be adopted so as to minimize distortion and shrinkage. •Welds shall be made in a sequence that will balance the applied heat of welding while the welding is in progress. •Before welding starts, welding sequence shall be established for members or structure. • Two welder will be used where the continuous welding all around the member

to avoid bending.

6.0.3

EXECUTION OF WELDING

•Welding electrodes shall be properly handled at all the times. •Electrodes having defects such as peeling of coating materials, stains, degradation, humidity, rusts, etc shall not be used. •Welding electrodes shall be used as per the manufacturer recommendations. •Welding shall be done continuously without incomplete penetration around the corner.

6.0.4

WELD CLEANING

• Before welding over previously deposited metal, all slag shall be removed and

adjacent base metal shall be brushed clean properly. •Slag shall be removed from all completed welds by wire brush. Spatter remaining after the cleaning operation shall be removed by chipping.

6.0.5

MEMBER IDENTIFICATION MARKS Page 7 of 11 REV: 00

PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624 •The correct identification of each structure component will be done covering its member identification mark, direction marks etc. and shall be verified with erection plan, shop drawings, floor arrangement drawings etc. • All member/ components shall be marked with punch mark or die stamp.

•Die stamp markings are sometimes difficult to see, painted marking shall also be applied to all completed members prior to shifting so that they will become easily recognizable.

6.0.6

TESTING AND INSPECTION

• Testing and inspection shall be according to the approved Inspection test plan

(ITP). After welding 10% MPI will be carried out for piping supports / structure.

6.0.7 GALVANIZING • After final acceptance of structure by quality control shall be released for

Galvanizing as per QG specification 003/00/00/SP/TS/00/014.

7. TOOLS & EQUIPMENTS 7.1

EXECUTION •

Cutting / grinding machines.

•

Hand Tools

•

Gas Cutter set

•

Auto cutter set

•

Cranes

•

Welding machines

•

Welding generator

•

Trailer

7.2

SAFETY •

Safety helmet.

•

Safety Goggles Page 8 of 11 REV: 00

PMT OPEN ENGINEERING ITEMS MODIFICATION JOBS METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624 •

Safety Shoes

•

Escape hood

•

Gloves

•

Welders Helmet

•

Fire Extinguishers (if required)

8. SAFETY INSTRUCTIONS During execution of the job all safety measure shall be adopted to ensure safe working. •

All personnel involved will use necessary PPE as required.

•

The workers will be made aware of safety requirements related to this activity

through daily, weekly and monthly toolbox and safety talks. •

Safety notice board will be installed.

•

All equipment will be inspected by HSE (Descon) prior to use.

•

During transportation of the steel structure the members shall be properly

supported and tied on the Trailer. •

During lifting of steel structure no body shall be allowed to work underneath.

•

All lifting tackle will be inspected by HSE (DESCON) according to project requirement.

•

Access and good housekeeping should be maintained at site.

•

Fire extinguisher should be available in working area.

•

All cylinders shall be kept in trolleys and in an upright position.

•

Welding sets should be checked and maintained regularly for wear and tear.

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