Erection of Platforms and Access Ways (Miscellaneous Steel Structure)

1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. PROCEDURE
6. INSPECTION AND TESTING
7. SAFETY PRECAUTION
8. ATTACHMENT

1.0 PURPOSE

The purpose of this document is to establish and provide detailed guidelines for construction and inspection personnel engaged in the erection of platforms and access ways including its miscellaneous steel structure activity in plants and refineries.

2.0 SCOPE

The scope of works cover under this method statement applies to the sequence of work instructions that utilize for the erection of platforms and access ways including its miscellaneous steel structure activity in plants and refineries.

3.0 REFERENCE

• SATIP-M-001-01 Structural Steel-Piperack, Steel Supports & Miscellaneous’ Steel Structures ( Incl Piping Supports per Specification)
• 12-SAMMS-007 Fabrication of Structural and Miscellaneous Steel

12-SAMMS-008 Erection of Structural and Miscellaneous Steel
• SAES-H-100 Coating Materials and Application Requirements for Industrial Facilities
• SAES-H-101 Approved Protective Coating
• Pl P-STF05530 Grating Fabrication Details
• PIP-STS05120 Fabrication of Structural and Miscellaneous Steel Specification
• PIP-STS05130 Erection of Structural and Miscellaneous Steel Specification
• PIP-STF05501 Fixed Ladders and Cages
• PIP-STF05521 Details for Angle Railings for Walking and Working Surfaces
• PIPI-STF05535 Vessel Circular Platform Details
• AWSD1.1 Structural Welding Code

• Construction drawings and related design drawing (IFC)

4.0 RESPONSIBILITIES

Site Manager:

Ensure the full implementation of this Method Statement and identifies the HSE requirements and maintained
sufficient resources for the effective accomplishment of the erection of platforms and access ways.

Steel Structure Supervisor

Ensure full compliance of all foremen, steel erectors and helpers regarding with the execution of work in accordance with Saudi Aramco Project requirements and specifications. Confirm the availability of all materials, tools, equipment, and required personnel who will carry out the work.

Quality Control Manager

Ensure the full implementation of the required minimum quality control procedures and maintain the required documentation as per applicable Saudi Aramco Inspection and Test Plan for the final acceptance and handover of the system.

Quality Control Inspector

Conducts daily surveillance and inspections as necessary in accordance with this procedure and prepares quality control records and secure final acceptance documentation which is required for final handover.

Construction Manager

Secure that the work areas are in safe working condition and monitor properly from time to time the implementation of safety procedure, requirements and assuring that all safety equipments and tools are present at working site and shall be in proper and good condition.

5.0 PROCEDURE

Fabrication and installation of platforms and access ways including its miscellaneous steel structure shall conform with Saudi Aramco Standard to 12-SAMMS-007 and 12-SAMMS-008 and Process Industry Practices to structural works as per STS05120 and STS05130. Required painting process shall conform to SAES-H-001, SAES-H-100 and SAES-S-101.
Materials handling prior to any fabrication and installation shall comply with SATIP-M-001-01 requirements. Any non compliance shall be subjected to inquiry and shall be referred to JGC/DEC and SAUDI ARAMCO approval.

5.1 Platforms and Access Ways including its Miscellaneous Structural Steel Fabrication and Erection.

o Fabrication

5.1.1 Prior to any start of fabrication, ensure that material receiving inspection record is available and classification or type of materials shall be the same as per approved drawing requirements and material specification.
5.1.2 Thickness and size requirements of materials shall be monitored prior to any fabrication to avoid any mismatch during erection.
5.1.3 Welding activities shall be as per AWS D1.1. WPS shall be approved by the client prior to any welding activity. Only certified welders are allowed to weld.
5.1.4 Grating fabrication shall conform to Saudi Aramco referred PIP.STF05530.
5.1.5 Grating fastening method shall be as specified in the drawing standard and as per PIP­ STS05120 par. 6.3.10.
5.1.6 Grating and checkered plate fabrication details shall conform to the approved drawing and standards and it shall conform to PIP-STS05120 par. 6.3.11, 6.3.12, 6.3.13.
5.1.7 Miscellaneous structural steel fabrication materials and requirements shall conform to ASTM standards and PIP-STS05120.
5.1.8 Shop splices, substitution of member sizes or changes in details or dimension shall be not be permitted without the written approval of JGC/DEC Engineering Department and Saudi
Aramco.
5.1.9 AI beams except cantilevers shall be fabricated with natural mill camber in the up position.
5.1.10 All re-entrant corners shall be shaped and notched free to a radius.
5.1.11 Base plate holes size for structural steel columns shall be in conformance with 12-SAMMS­-007.
5.1.12 All pieces shall be clearly marked with a permanent identifying erection mark number.

5.1.13 Before surface preparation, the fabricator shall remove all sharp edges and chamfer all corners, burrs (including bolt hole burrs), weld spatter, slag, weld flux, loose mill and other
foreign matter.
5.1.14 Painting or galvanizing requirements for fabricated gratings shall be in conformance with SAES-H-100 and SAES-H-101.
5.1.15 Prior to construction hand over for installation/erection, all fabricated materials shall be inspected and accepted by JGC/DEC Quality Control Department and approved by Saudi Aramco PID.
o Installation / Erection

5.1.16 Any installation/ erection activity shall be in accordance with JGC/DEC and Saudi Aramco approved drawing.
5.1.17 Materials lifting activity shall be carried out by a qualified and approved Rigger from fabrication to site to avoid damage to materials and property. Lifting of painted structural members shall be done with a non abrasive choker.
5.1.18 Evidence of materials quality inspection documentation such as receiving inspection and fabrication approval drawing shall be available prior to installation and erection for easy site
reference during installation/erection.
5.1.19 All miscellaneous steel structure labrication with connection to main beams, columns and supports shall be as per approved design drawings by JGC/DEC. Connection installation are as per the following criteria specified under PIP-STS05130 and 112-SAMMS-007.
• Engineer-Designed Connections
• Fabricator-Selected Connections
• Fabricator-Designed Connections
• Bolted Connections
• Welded Connections
• Shop and Field Connections
• Bracing Connections
• Connections for Concrete Fireproofed Members

5.1.20 Before commencement of any installation and/or erection work, the erector shall check foundations and other connection points to confirm their location, orientation, elevation and condition.
5.1.21 Erection and shop drawings shall be available during installation to ensure that all parts, sizes and fabricated materials are as per the approved drawings.
5.1.22 Any circumstances discovered by the erector that affects progression, performance or completion of the erector’s work activities such as discrepancies between the erection shop
drawing and the delivered steel members, incorrectly fabricated steel members or incomplete/unacceptable work of other contractors, it shall be immediately reported to JGC/DEC for final disposition.
5.1.23 Any damage incurred caused during erection or installation shall be reported to JGC/DEC for disposition. Corrective measures shall be completed as directed by Saudi Aramco.
5.1.24 Temporary erection loads or permanent loads during installation shall not be place on any incomplete portions of the structure being erected unless the erector can demonstrate by
analysis that the contemplated action is safe.
5.1.25 Loose timbers, metal sheeting, bolt buckles, tools, debris and temporary scaffolding shall be kept restrained or removed from work areas. The erector shall be responsible for securing all equipment and materials within the erector’s care, custody and control during the erection/installation operation.

5.1.26 Before and after erection and installation activities is carried out, job site shall maintain a clean and safe condition environment at all times and shall dispose from premises all crating, waste materials and other rubbish that has accumulated as a result of the erector’s activity.
5.1.27 Erectors and installers shall verify the following crucial activities prior to commencement of any erection and installation as per PIP-STS05130 standard as follows:
• Check and verify the Structural Stability of the installed or erected structures in connections with temporary bracing adequacy and guy cable requirements to counteract loading imposed during erection.
• When setting of base plates, erector shall clean the top of bearing surfaces and the bottom of the base plates. The erector shall set and shim column base plates to correct positions, elevations and locations shown on the erection drawing.  If setting nuts are used, it shall be loosened before grouting.
• All welded connections shall be as per approved AWS D1.1 WPS.
• Any kind of error corrections on fabrication during assembly and erection shall be approved by JGC/DEC.
5.1.28 AI grating and floor plate installation that requires cutting at field shall be as required on the design and approved drawing.
5.1.29 The erector shall fasten the grating and floor plate as specified on the design drawings. A minimum of four fasteners per panel shall be used.
5.1.30 Repair of galvanized steel shall be in accordance to PIP-STS05120 par. 6.4.6

6.0 INSPECTION AND TESTING

Inspections and testing shall be conducted and recorded in accordance with the Saudi Aramco Typical Inspection Plan. Reports and record shall be documented as per the applicable Saudi Aramco Inspection and Checklist/Test Report.

7.0 SAFETY PRECAUTION

7.1 Approved work permit shall be obtained prior to the start any structural works.
7.2 Work execution shall be carried out in accordance with this method of statement.
7.3 Erection crew must carry out a safety risk assessment prior to the start of any new activities.
7.4 During any lifting works, signalman must be assigned full-time.
7.5 The necessary manpower inclusive of supervisory staff, tools, equipment, materials, and other resources required must be made available and ready to use.
7.6 Workers shall be provided with and wear their PP E’s needed for work.
7.7 A Fire Watcher with fire Extinguisher shall assign for any hot work activity.
7.8 Certified permit receiver, firewatcher, traffic/flagman and work-in-charge should be at work site during the execution of the work.
7.9 Man lift equipment shall be tested and certified by the Saudi ARAMCO Equipment Inspection Division.
7.10 Only certified man lift operator(s) shall be allowed to operate the man lift equipment
7.11 Sufficient lightings shall be provided if work is done at night time. Work at night shall be approved by client.

8.0 ATTACHMENT

Job Hazard and Risk Assessment (JHRA)
Grating/Floor Plate/Guardrail Removal Checklist

Grating/Floor Plate/Guardrail Removal Checklist

1. Before removing any grating, floor plate, or guardrail, inform the client, project engineer, or other. (If yes, circle which is/are applicable.)
2. Is the removal/installation crew trained/experienced to perform this task?
3. Conduct a JSA meeting on the hazards and risk mitigation with the removal/installation crew.
4. Walk down the area with the removal team and reinforce the points made at the Toolbox meetings.
5. Place a sign at the bottom access way of the platform to alert workers that grating/floor plate/guardrail sections are removed.
6. Barricade the area below grating to be removed and ensure that no one enters the barricaded area.
7. Ensure that the removal crews have their PPE, full body harness, proper tools, and equipment for the job – especially barricades and barrier tape.
8. Conduct a pre-work TSTI meeting.
9. Remove the grating panels carefully and place them in a safe place (according to floor- loading limits) to avoid tripping and falling.
10. Tag and bag the clips, screws, etc., and then tie the bag securely to the removed panels.
11. Construct barricade or guardrail system around the opening and highlight with barrier tape.
12. If the work is incomplete at the end of the shift, the grating must be reinstalled at end of workday, or provision is made to construct/place hole covers to protect the holes.
13. Reinstall the removed section as soon as possible and inform the client, project engineer, or other (circle as applicable) to inspect the workmanship.
14. After inspection, remove all signs and barricades and complete housekeeping of the area.
15. Complete a post-work TSTI meeting.

WELDING SAFETY CHECKLIST FORM

1. PERSONAL PROTECTION

A. Helmets; welding hoods and goggles worn.
B Proper welding gloves used.
c Safety boots and legging worn.
D Protective clothing and sheilding.
E Screen/covering provided and placed soas not to restrict the flow of air for ventilation purposes

2. FIRE PREVENTION CONTROL

A. Combustible materials removed from the work area.
B. Correct fire extinguisher provided.
c Remove oil spills/leaks from welding machine.
D Welding machine motor stopped before refueling.
E. A firewatch has been provided if the work is inside GOSP # 3 Plant.
r Metal bins provided for spent electrode stubs.
G. A standby man has been provided inside confined space.

3. WELDING CONNECTIONS

A Welding cables being checked for any damage.
B. Welding machine properly grounded.
c Splice in welding cables.
D. Welding grounds and returns securely attached to the work by cables lugs or clamps.
E. Electrode holder in good condition.

4. PROTECTIVE MEASURES

A. Welding machine in good condition and has an approved operator.
B. Doors; covers and panels in place when operating the machune.
C. Welding and ground cables and connection maintained in good condition.
D. Correct/proper cable size and lengths.
E. The full length of the cable is streched out and not coiled on the machine.
F. Welding cables properly laid out in order to prevent tripping hazards.
G. GFCI”s provided for portable hand tools using approved cables.

HOT WORK FIRE WATCH CHECKLIST

1. There is no evidence of burning or smoldering material.
2. Familiarize yourself with the Emergency Evacuation Plan, exit routes and alarm locations in the working area where hot work operations are being performed.
3. Ensure that an appropriate fire extinguisher is readily available in the hot work area.
4. Verify with the Hot Work Operator what type of activity they will be doing and take necessary precautions prior to the start of the work.
5. Verbally communicate to all employees that hot work activities are being conducted in the area.
6. Ensure that there are no flammable materials near the work area. Flammable materials must be relocated from the work area.
7. Ensure that materials which cannot be relocated from the work area are covered with a fire blanket prior to conducting hot work.
8. Assist the Hot Work Operator with identifying holes in the floor or walls where hot sparks and slag can enter. Ensure that these locations are covered prior to conducting work.
9. Position yourself in a manner that allows you to remain visible to the Hot Work Operator and other employees and personnel who may enter the work area.
10. Monitor sparks and slag produced by the hot work and ensure that they do not land near flammable materials or other employees working in the area.
11. Detain anyone attempting to pass through the work area until the hot work can be suspended.
12. Alert the Hot Work Operator if anyone enters the work area. Suspend hot work activities until the area is clear again.
13. DO NOT leave your post until you are relieved by another trained fire watch. In the event ofan emergency all hot work activities must be suspended.
14. Remain in the work area for least 30 minutes after hot work is completed.