Pipe Rack Erection modified and Presentation

PIPE RACK ERECTION Using Precast Concrete Elements and Structural Steel:

Erection of columns

Erected Columns

Erection of Precast Beams

Types of Precast Beams

Continuation: (Precast Beams)

Erection of Precast Beams

Grouting of beam-column connection:

Grouting with Non-shrink grout:

Grout Mixing:

Grouted beam-column connection:

Erection of Structural Steel Module

Steel Columns

Structural Steel Columns:

Continuation:

Erection of one complete structural steel module:

During Erection: CHECK FASTENING MATERIALS (12-SAMSS-007 SEC. 4.6) - HIGH STRENGTH BOLTS, ASTM A325, TYPE 1 , GALVANIZED. - HEAVY HEX NUTS, ASTM A563 GR DH - WASHER, ASTM F436 •

THE MINIMUM NUMBER OF BOLTS IN A FRAMED CONNECTION SHALL BE TWO BOLTS (12-SAMSS-007 SEC. 6.2.5.7)

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MINIMUM DIAMETER OF BOLT 20 MM SHALL BE USED IN ALL BOLTED STRUCTURAL CONNECTION (12-SAMSS-007 SEC. 6.2.5.3)

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ERECTION SHALL BE IN ACCORDANCE WITH THE DRAWINGS AND OTHER CONTRACT DOCUMENTS

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DURING ASSEMBLY, ALL JOINT SURFACES, INCLUDING THOSE ADJACENT TO THE BOLT HEADS, NUTS OR WASHERS, SHALL BE FREE OF BURRS, DIRT AND OTHER FOREIGN MATERIALS THAT WOULD PREVENT SOLID SEATING OF PARTS (12-SAMSS-008 PAR. IV, MOD. PIP STS05130 SEC. 6.5.8)

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ALL PREASSEMBLIES SHALL BE LIFTED IN A MANNER THAT WILL NOT IMPAIR THE STRUCTURAL INTEGRITY OF THE MEMBERS. ASSEMBLED STRUCTURAL MEMBERS SHALL BE LIFTED IN A COMPLETE FRAME.

INSPECTION OF STRUCTURAL ALIGNMENT DURING ERECTION: IMPORTANT CHECK POINTS: „

VERTICAL TOLERANCES FOR STRAIGHT COMPRESSION STRUCTURAL MEMBERS < 1/1000 OF THE AXIAL LENGTH, (AISC PAR. 6.4.2 & PIP STS05130 PAR. 6.2.1)

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THE STRUCTURE SHALL BE PLUMBED, LEVELED, AND BRACED BEFORE ANY FINAL BOLTED OR WELDED CONNECTIONS ARE MADE, PIP STS05130 PAR. 6.3.2.

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LEVELING PLATES, LEVELING NUTS AND WASHERS, LOOSE BASE PLATES AND BEARING PLATES ARE SET IN ITS CORRECT ALIGNMENT AND ELEVATION. VARIATION IN ELEVATION RELATIVE TO THE ESTABLISHED GRADE < +/- 3 MM (AISC PAR. 7.6 & PIP STS05130 PAR. 6.4.1)

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ALL COLUMN SPLICES SHALL BE FIELD BOLTED AND CONFORM TO AISC DETAILING FOR STEEL CONSTRUCTION APPENDIX D (12-SAMSS-007 PAR. 6.2.5.20)

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REFERENCE - AISC CODE OF STANDARD PRACTICE FOR STEEL BUILDING AND BRIDGES - PROCESS INDUSTRY PRACTICES PIP STS05130, ERECTION OF STRUCTURAL AND MISCELLANEOUS STEEL SPECIFICATION

REPAIR/CORRECTION OF ERRORS OF STRUCTURAL ALIGNMENT DURING ERECTION

IMPORTANT CHECK POINTS: „

FIT-UP BOLTS AND DRIFT PINS SHALL NOT BE USED TO BRING IMPROPERLY FABRICATED MEMBERS AND PARTS INTO PLACE (SPRINGING). (PIP STS05130 PAR. 6.7.1)

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STANDARD BOLT HOLES SHALL NOT BE ENLARGED BY MORE THAN 1 MM TO MAKE CONNECTIONS RESULTING FROM MINOR MISFIT (PIP STS05130 PAR. 6.7.2).

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METHOD OF CORRECTING BOLT HOLE CONNECTIONS THAT MISFIT BY MORE THAN 1 MM MUST BE APPROVED BY SAUDI ARAMCO.

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ENLARGEMENT OF HOLES SHALL BE MADE BY REAMING OR DRILLING ONLY (PIP STS05130 PAR. 6.7.3)

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THE ERECTOR SHALL MAKE NO MODIFICATIONS OR REPAIRS TO STEEL JOIST, AND CORRECTION OF FAULTY WORKS SHALL REQUIRE APPROVAL FROM SAUDI ARAMCO (PIP STS05130 PAR. 6.7.4 & 6.8.2)

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ONE FILLER PLATE UP TO 1/8 INCH (3 MM) THICKNESS MAY BE USED AS REQUIRED IN SPACES BETWEEN MEMBERS TO BE BOLTED (PIP STS05130 PAR. 6.7.5)

HIGH STRENGTH BOLTS TIGHTENING INSPECTION & TESTING: „

IMPORTANT CHECK POINTS:

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BOLTS SHALL HAVE FULL THREAD ENGAGEMENT WITH THE NUT. THE BOLT LENGTH USED SHALL BE SUCH THAT THE END OF THE BOLT EXTENDS BEYOND OR IS AT LEAST FLUSH WITH THE OUTER FACE OF THE NUT WHEN PROPERLY INSTALLED (AISC SPECS. FOR STRUCTURAL JOINTS USING ASTM A325 or A490 BOLTS PAR. 2.3.2)

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ALL NUTS FOR HIGH STRENGTH BOLTS SHALL BE WAX-DIPPED TO REDUCE TORQUE DURING INSTALLATION (12-SAMSS-007 PAR. 6.2.5.22).

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THE ERECTOR SHALL COLOR CODE, DIE PUNCH, OR OTHERWISE MARK THE ENDS OF TORQUED BOLTS INDICATING THAT THE BOLTS HAVE BEEN PROPERLY TENSIONED AND ARE READY FOR INSPECTION (PIP STS05130 PAR. 6.5.7)

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FAYING SURFACES AND SURFACES ADJACENT TO THE BOLT HEAD AND NUT FOR SNUG-TIGHTENED OR PRETENSIONED JOINTS SHALL BE FREE OF DIRT AND OTHER FOREIGN MATERIAL (AISC SPECS. FOR STRUCTURAL JOINTS USING ASTM A325 or A490 BOLTS PAR. 3.2.1 & PIP STS05130 PAR. 6.5.1)

THREE TYPES OF BOLTED JOINT: (MUST BE CLEARLY IDENTIFIED & INDICATED IN THE IFC OR ERECTION DRAWINGS)

1.) ST – SNUG-TIGHTENED JOINT, A CONDITION WHERE FAYING SURFACES IN A BOLTED JOINT ASSEMBLY ARE IN FIRM CONTACT AFTER A FEW IMPACTS OF AN IMPACT WRENCH OR WITH THE FULL EFFORT OF A WORKER USING A SPUD WRENCH.

2.) PT – PRETENSIONED JOINT:

A JOINT THAT TRANSMIT SHEAR AND/OR TENSILE LOAD, WHERE THE BOLT ASSEMBLY IS FULLY TIGHTENED TO WHICH THE TENSION IN THE BOLT WILL BE EQUAL TO A MINIMUM OF 70 PERCENT OF THE SPECIFIED TENSILE STRENGTH (AS PER TABLE 8.1 & COMMENTARY – SPECS. FOR STRUCTURAL JOINTS USING ASTM A325 OR A490 BOLTS).

3.) SC – SLIP CRITICAL JOINT: SIMILAR TO PRETENSIONED JOINTS BUT THE FAYING SURFACES HAVE BEEN PREPARED TO PROVIDE A CALCULABLE RESISTANCE AGAINST SLIP. ONLY ST & PT JOINT TYPES ARE USED IN THE STRUCTURAL STEEL PIPE RACKS PRETENSIONING METHOD ACCEPTED BY SAUDI ARAMCO: - TURN-OF-NUT PRETENSIONING - CALIBRATED WRENCH PRETENSIONING - DIRECT TENSION INDICATOR (DTI) PRETENSIONING PRIOR TO PRETENSIONING OF BOLTS, THE BOLTED JOINT ASSEMBLY WAS BROUGHT TO A SNUG TIGHT CONDITION. WHEN IMPACT WRENCHES ARE USED; IT SHALL BE OF ADEQUATE CAPACITY WITH SUFFICIENT AIR SUPPLY TO PERFORM THE REQUIRED TIGHTENING OF EACH BOLT (12-SAMSS-008 SEC. IV)

TURN-OF THE NUT PRETENSIONING METHOD:

DTI PRETENSIONING METHOD:

Direct Tension Indicator „

Specially designed washers, called direct tension indicators, or load-indicating devices, have a series of protrusions that compress during tightening of the bolt. When you tighten the nut fully, the washer compresses and the protrusions will flatten, leaving a small gap under the head or nut. You verify the amount of tightening by inserting a thin metal stick into the gap. This method is the least preferred by Saudi Aramco for tightening and verifying the installation of high-strength bolts.

CALIBRATED WRENCH PRETENSIONING METHOD

CALIBRATED WRENCH PRETENSIONING METHOD TORQUE VALUE CALCULATION (USING AISC TABLE 8.1): TV = db X Tm X COEFF. FACTOR X1000

SAMPLE CALCULATON FOR 1-1/2” DIA. BOLT TV = 1.5/12 X 103 X 0.21 X1000 = 2700 FT.LBS. TO CONVERT TO NEWTON-METER: 2700 FT.LBS. / 0.7376 = 3660 N-M

WHERE; TV = TORQUE VALUE IN FT.-LB. db = BOLT DIAMETER IN FT. Tm = MINIMUM BOLT TENSION ( Table 8.1) PRETENSION IN KIPS COEFFICIENT OF FRICTION (Nut Factor) = 0.21 1 KIP = 1000 LBS.

CALIBRATED WRENCH PRETENSIONING METHOD (AS PER SAUDI ARAMCO REQUIREMENT` - VERIFICATION OF TORQUE VALUES)

THE TORQUE REQUIRED FOR TIGHTENING SHALL BE DETERMINED IN THE PRE-INSTALLATION PROCEDURE VERIFICATION TESTING OF THE FASTENER ASSEMBLY AS PER (12-SAMSS-008 SEC. I) A CALIBRATED TENSION CALIBRATOR SHALL BE ONSITE WHEN TIGHTENING IS TO BE PERFORMED ON PRETENSIONED JOINTS AND SLIP-CRITICAL JOINTS. A REPRESENTATIVE SAMPLE OF THREE COMPLETE FASTENER ASSEMBLIES OF EACH COMBINATION OF DIAMETER, LENGTH, GRADE AND LOT TO BE USED IN THE WORK SHALL BE CHECKED AT THE SITE OF INSTALLATION IN A TENSION CALIBRATOR. „

THE PRETENSION THAT DEVELOPED DURING THE PRETENSIONING METHOD SHALL BE EQUALTO OR GREATER THAN 1.05 TIMES THAT SPECIFIED FOR INSTALLATION AND INSPECTION IN TABLE 8.1

TENSION CALIBRATOR (SKIDMORE) How The Tension Calibrator Works: „ Tightening a fastener inserted into the calibrator creates pressure, which is transmitted through hydraulic fluid to a gauge. The gauge gives a direct reading equivalent to fastener tension in pounds.

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Bolt Tension Calibrator Allows You To Verify: That your fasteners meet minimum bolt tension specifications.

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That your impact wrenches are properly calibrated.

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That your bolting crew understands how to achieve proper tension in all types of fasteners.

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That you have the right installation tools and equipment.

HIGH STRENGTH BOLTS TIGHTENING, INSPECTION & TESTING CALIBRATED WRENCH PRETENSIONING METHOD DURING PRETENSIONING OF BOLT ASSEMBLY: THE TORQUE WRENCH IS CALIBRATED IN IN A DAILY BASIS. AN ASTM F436 WASHER SHALL BE USED UNDER THE TURNED ELEMENT. THE TORQUE DETERMINED IN THE PRE-INSTALLATION VERIFICATION IS APPLIED TO ALL BOLTS IN THE JOINT, PROGRESSING SYSTEMATICALLY FROM THE MOST RIGID PART OF THE JOINT IN A MANNER THAT WILL MINIMIZE RELAXATION OF PREVIOUSLY PRETENSIONED BOLTS.

CALIBRATED WRENCH PRETENSIONING METHOD

End of Part II