Reliance

Case Study
On
Structural Steel Beam Failure
EPCMD-2-QM00-CAS-GE-004

01

17.12.2010

00

16.10.2001

Rev

Date

Revised to EPCM
standard
Issued for
information
Revision

DD/DSK

SNS/TSR

AJV

DSK

AJV/APC

SCG

Prepared By

Checked By

Approved
By

Reliance
Contents
1. Purpose 3
2. Scope..3
3. Case Study and Analysis 3
4. Lessons Learned 5
5. Recommendations 6
6. Attachments (Only With The Hard Copy) .6
6.1
6.2
6.3
6.4
6.5
6.6

Dwg. No.C63-RD311-501 Rev. 02.

Dwg. No.C73-RD300-001 Rev. 00
Dwg. No.C63-RD311-570 Rev. 03
Dwg. No.C73-RD311-026 Rev. 02
ITP No. 2 00 ITP CL 013 Rev.00
Form No. FM-CIV-0030 (Doc. No. 22960-ITP-230)

EPCMD 2 QM00 CAS GE 004_00.doc

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Reliance
1.

Purpose
The purpose of this case study is to document

The cause and analysis of failure

Preventive measures taken to avoid recurrence of such failures in future.

2.

Scope
The scope of this case study is limited to the study details adopted at
Jamnagar Refinery; analysis and conclusion arrived for dealing with such
issues. This study is for internal use of Reliance only for facilitating the
decision-making process.

3.

Case Study and Analysis

The case under study is combination of both RCC and Structural Steel.
Structural steel is connected to RCC through insert plates or with the help
of anchor fasteners mechanical / chemical. In this case structural steel
connection plate was supposed to be welded to insert plate embedded in
RCC column and bolted to the beam. This being a expansion joint, slotted
holes were provided in the beam. After approximately one year of
commissioning of plant one beam of section UC254 X 73, collapsed at
Crude Unit 311 between column A-23 and A-24 (Ref. Dwg. No.C63RD311-501 Rev. 02). There were several brainstorming sessions among
the team members of construction, FDC, and CES departments for
analyzing cause and implementing corrective measures. This case study
gives the details of analysis and conclusion arrived for dealing with such
cases to avoid similar failures in other areas.

3.1

Observations made during this case study

3.1.1

It was expansion Bay of the main pipe rack. The joining connection
plate between beam and insert plate had slotted holes to provide
expansions. Instead these got anchored because the connection
plate was tack welded with beam and the bolts were missing.

3.1.2

It was a connection providing support to a) 10 dia expansion loop

of diesel to feed filter 311-PA-184-10-EC34EA-HC-75 insulated line
and b) 6 dia expansion loop of RICH OIL FROM UNIT 321, 321-PA086-6-EC12EA-HC-50 insulated line.

3.1.3 The case under study is combination of both RCC and Structural Steel.

Structural steel is connected to RCC through insert plates or with the help of
anchor fasteners mechanical / chemical. In this case structural steel
EPCMD 2 QM00 CAS GE 004_00.doc
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Reliance
connection plate was supposed to be welded to insert plate embedded in RCC
column and bolted to the beam. This being a expansion joint, slotted holes
were provided in the beam. After approximately one year of commissioning of
plant one beam of section UC254 X 73, collapsed at Crude Unit 311 between
column A-23 and A-24 (Ref. Dwg. No.C63-RD311-501 Rev. 02). There were
several brainstorming sessions among the team members of construction,
FDC, and CES departments for analyzing cause and implementing corrective
measures. This case study gives the details of analysis and conclusion arrived
for dealing with such cases to avoid similar failures in other areas.
Out of four hold fastener bars welded to insert plate on RCC side
found sheared at weld joint, three were rusted and one was fresh,
indicating that separation occurred some time back. (Ref. Dwg. No.
C73-RD300-001 Rev. 0).

10

As per drawing

Change proposed through this case study

Connection between insert plate and hold fastener rod

Comparison matrix
Sl.
No.
1

Requirement

Observation

In stud type connection as per

Connection between insert plate and each

drawing C73-RD300-001 Rev. 0

hold fastener should have been with at

weld length is limited to

least 160mm bearing and double-flare-

perimeter the cross section of

bevel groove welding between M.S. rod

the hold fastener rod.

and plate, as proposed in the above

schematic sketch.

Fillet welds size between Hold-

Fillet weld size actual found between

fastener to insert plate to be 10

5mm to 6mm.

mm as per drawing C73-RD300-

EPCMD 2 QM00 CAS GE 004_00.doc

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Reliance
001 Rev. 0.
3

Connection plate is required to

There was a gap between insert plate and

be directly welded to insert plate

connection plate. This gap was bridged

with no gap.

with additional plate. This additional plate

had incomplete welding all-round.

Connection plate at sliding

Connection plate tack welded to beam

connection with bolt nuts

section thus arresting the sliding

required to just snug-fitted and

movement and making it an anchor joint.

bolt threads peened to prevent

back-off nut for sliding action
during expansion.
5

As per ITP 22960-ITP-230,

Scope of inspection for structural steel

inspection record to be prepared

items / sliding joint not identified

for structural steel erection in

clearly.

form No FM-CIV-0030.

line with the ITP.

As per the above ITP most of the

check / hold points were left on

Quality records prepared were not in

Contractor Quality Control Engineer

Contractor Quality Control

(CQCE) failed to produce evidence that

Engineer.

all structures were inspected

religiously.

For key checkpoints we should not

have relied on CQCE.

Most of the left out punch points were

liquidated during first shut down of this
unit after commissioning of the unit.

3.2

Analysis
3.2.1 Being expansion joint one side of the beam was supposed to be
with sliding connection.. Bolts should have been at the center of
the slotted with nuts just snug-fitted to provide provision for
expansion. Instead connection plates were tack welded to beam
and thus making sliding joint as fixed one which caused additional
stresses in the whole assembly.
3.2.2 By this stressing, the weakest link i.e. holds fasteners and insert
plate gave away, leading to collapse of the beam.

3.3

Conclusion

EPCMD 2 QM00 CAS GE 004_00.doc

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Reliance
3.3.1 Sliding joint required in the expansion bay as per drawing was not
existing and this has exerted extra force on the connection and was
the cause of failure.
3.3.2 Rusted fracture of three hold fasteners of insert plate indicates that
failure started from this weakest link. Because hold fasteners were
just stud welded to insert plate.
3.3.3 Later on because of falling of the beam, connection plate connected
to insert plate through extended additional plate by welding also
failed and subsequently tack welds between connection plate with
beam section also gave away.

4.

Lessons Learnt
4.1

During erection of structural steel proper attention should be paid

for sliding joints and instructions given in the drawing should be
properly followed. For this we cannot rely on Contractor Quality
Control Engineer alone, key check points should also be HOLD
point for Reliance QMD.

4.2

Bolts in the slotted holes should be at the center of the slot at the
time of construction and have free movement in the direction of
expansion. As recommended by Designer expansion bay connection
shall have nuts snug-fitted and bolt threads peened to prevent
back-off of nut.

4.3

Proper quality control should be exercised during fabrication of

insert plates to ensure sound welding between hold fasteners and
plate.

4.4

Temporary tack welds between connection plates and beam shall

not be used as a practice at expansion bays, however if tack
welded during fabrication should be removed by grinding before
erection.

4.5

Welding between connection plate and insert plate should be sound

and as specified in the drawing.

4.6

5.

Quality record as per the relevant ITP shall be prepared.

Recommendation
5.1

Expansion joint shall be Hold Point for all concerned e.i. for
Execution

as

well

as

Quality

Control.

This

point

shall

be

incorporated in ITP for structural steel erection (Ref. 2 00 ITP CL

013 Rev.00).
5.2

Joint design between hold fasteners and insert plate shall be

double-flare-bevel groove weld type instead of stud type.

EPCMD 2 QM00 CAS GE 004_00.doc

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6. Attachment (only with the hard copy)
6.1
6.2
6.3
6.4
6.5
6.6

Dwg. No.C63-RD311-501 Rev. 02.

Dwg. No.C73-RD300-001 Rev. 00
Dwg. No.C63-RD311-570 Rev. 03
Dwg. No.C73-RD311-026 Rev. 02
ITP No. 2 00 ITP CL 013 Rev.00
Form No. FM-CIV-0030 (Doc. No. 22960-ITP-230)

EPCMD 2 QM00 CAS GE 004_00.doc

Confidential Reliance. All rights reserved

Page 7 of 7