1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. PROCEDURE
6. QUALITY CONTROL
7. SAFETY PRECAUTION
8. ATTACHMENT.
STEEL STRUCTURES INSTALLATION PROCEDURE AND METHOD STATEMENT
1.0 PURPOSE
The purpose of this method of statement is to provide a clear guidelines and specification for structural grating and miscellaneous structural steel installation procedures.
2.0 SCOPE
The scope of works covers under this procedure applies to the fabrication and installation of gratings and miscellaneous structural steel section required to complete installation of pipe-racks for commercial buildings, plants and refineries.
3.0 REFERENCES
SATIP-M-001-01 Structural Steel Pipe Rack, Steel Supports & Miscellaneous, * Steel Structure (*including Piping supports per specification).
12-SAMSS-007 Fabrication of Structural Steel & Miscellaneous Steel.
12-SAMSS-008 Erection of Structural and Miscellaneous Steel.
PIP-STS05120 Fabrication of Structural and Miscellaneous Steel Specification.
PIP-STS05130 Erection of Structural and Miscellaneous Steel Specification.
4.0 RESPONSIBILITIES
4.1 Construction Manager shall be responsible for implementing HSE, providing construction equipments, tools and manpower to carry out the work as per project drawing specification and schedule. Ensure that construction fabrication and installation activities are being carried out in conformance to drawing requirements and project specification.
4.2 Construction Supervisor shall be responsible in monitoring actual site works activities from fabrication to installation to ensure that each piece of fabricated steel structure is as per drawing specification. Ensure that equipments and manpower are enough necessary to complete the project schedule.
4.3 Quality Control Manager shall be responsible in the implementation of project quality management system and ensure that all project specifications and standards are monitored ,complied and documented.
4.4 Quality Control Inspector shall be responsible in monitoring compliance of all structural steel materials from fabrication to installation with complete inspection documentation records and with clients approval.
4.5 Construction Foreman shall be responsible in ensuring that work execution is as per approved drawing and standard and shall ensure that all manpower I workers are qualified to carry out the work effectively.
4.6 Safety Supervisor shall be responsible in monitoring and overseeing safety implementation activities from fabrication area to site installation area and ensure that all safety parameters are being complied by all working personnel.
5.0 PROCEDURE
General:
Fabrication & Installation of Miscellaneous Structural Steel shall conform with Saudi Aramco Standard to 12-SAMSS-007 and 12-SAMSS-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-M001-01 requirements. Any noncompliance shall be subjected to inquiry and shall be referred to SAUDI ARAMCO for approval.
5.1 Miscellaneous Structural Steel Fabrication and Installation
• Fabrication
5.1.1 Prior to any start of fabrication ensure that materials 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 installation.
5.1.3 Welding activities shall be as per AWS D1.1 WPS approved by client prior to any welding activity commencement. Only Certified Welders are allowed to weld.
5.1.4 Miscellaneous Structural Steel fabrication materials requirements shall conform with ASTM Standards and PIP STS05120.
5.1.5 Shop splices, substitutions of member sizes, or changes in details or dimension shall not be permitted without written approval from Engineering Department and Saudi Aramco.
5.1.6 All beams, except cantilevers, shall be fabricated with natural mill camber in the up position.
5.1.7 All re-entrant comers shall be shaped, notched-free, to a radius.
5.1.8 Base plate holes size for structural steel columns shall be in conformance with 12-SAMSS-007 item 6.1.13.
5.1.9 All pieces shall be clearly marked with a permanent identifying erection mark number. The fabricator shall obtain approval for the method and location of marking from Engineering section.
5.1.1 0 Before surface preparation, the fabricator shall remove all sharp edges and chamfer all comers, burrs (including bolt hole burrs), weld spatter, slag, weld flux, loose mill, and other foreign matter.
5 .1.11 Painting or galvanizing requirements for fabricated gratings shall be in conformance with SAES-H-100-Coating Material and Application Requirements for industrial facilities and SAES-H-101 -Approved Protective Coating.
5.1.12 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 .
• Installation / Erection
5.1.13 Any Installation and Erection activity shall be in accordance with and Saudi Aramco approved drawing.
5.1.14 Materials lifting activity shall be carried out by an approved Saudi Aramco Rigger from Fabrication to Site to avoid damage to materials and property. Lifting of painted structural members shall be done with a nonabrasive choker.
5 .1.15 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 references during installation and erection.
5.1.16 All miscellaneous structural steel fabrication with connection to main beams, columns and supports shall be as per approved design drawings. Connection installation are as per the following criteria specified under PIP STS05130 and 12-SAMSS-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
5.1.17 Before any erection and installation work commencement, the erector shall check foundations and other connection points to confirm their location, orientation, elevation, and condition.
5 .1.18 Erection and Shop drawing shall be available during installation to ensure that all parts, sizes, and fabricated materials is as per approved drawing.
5.1.19 Any circumstances discovered by the erector that affect 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 or unacceptable work of other contractors affecting the erector’s work shall be immediately reported to JGC/DEC Engineering Department and SAUDI ARAMCO for final disposition.
5.1.20 Any damage incurred caused during erection or installation shall be reported for disposition. Corrective measures shall be completed as directed by SAUDI ARAMCO.
5.1.21 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.
5.1.22 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 I installation operation.
5.1.23 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 of, off the premises all crating, waste materials, and other refuse that has accumulated as a result of the erector’s activities.
5.1.24 Lifting of painted structural members shall be done with nonabrasive choker.
5.1.25 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 cables requirement to counteract loading imposed during erection.
• When Setting of Base Plates, erector shall clean the top of bearing surfaces and the bottom of base plates. The erector shall set and shim column base plates to correct positions, elevations, and locations as shown on the erection drawing. If setting nuts are used, they shall be loosened before grouting.
• Check bolted connections in line with high strength bolt tensioning method using calibrated torque wrenches and approved torque value table.
• 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 Engineering.
6.0 QUALITY CONTROL
6.1 Quality Inspector shall ensure that all fabricated and installed, erected structural steel forms shall be in compliance with approved design drawing, standard and specification.
6.2 All inspection activities shall meet Saudi Aramco Inspection requirement as per SATIP.
6.3 QC Inspector shall coordinate with construction installer, erector any noncompliance found during inspection and shall ensure that corrective action is taken with approval of JGC/DEC Engineering.
7.0 SAFETY PRECAUTION
7.1 Safety requirements at site during field erection and installation shall be strictly monitored and an implementation of complete PPE shall be strictly observed.
7.2 Safety Barricades from the job site where installation and erection is on progress shall be installed.
7.3 Ensure that work permits shall be available prior to any site installation, erection commencement and that safety tool box meeting is conducted.
7.4 Ensure that Flagmen, whole watcher, riggers and operators shall have a competency training certificates or certified in their own field of works prior to start of any job site work activities.
7.5 Safety Officer shall have a close and strict monitoring implementation of safety at site before and after work is carried out and a house keeping shall be observe before and after work activities to avoid any accident or incident cause of negligence.
8.0 ATTACHMENT
Job Safety Analysis