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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 MIS

(For Train-06)

Rev. Comments Date Prepared by Checked by Approved by


QG

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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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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:

 Material handling

 Lay Out and Marking Off

 Cutting

 Grinding

 Fit Up

 Welding

 Painting

3. REFERENCES

3.1 PROJECT DRAWINGS

 Shop drawings.
 Supporting structure detail drawing.

3.2 PROJECT SPECIFICATION

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


 Approved material certificates.

3.3 PROJECT QUALITY PLAN

Inspection / testing shall be done in accordance with ITP.

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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)

 ASNT-TC-1A recommended practice.

4. 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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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.

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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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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.

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METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE


SUPPORT (SPS-B065-099) FOR 52-K0624

6.0.5 MEMBER IDENTIFICATION MARKS


 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.

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METHOD STATEMENT No : 04

FABRICATION AND INSTALLATION OF STEEL STRUCTURE


SUPPORT (SPS-B065-099) FOR 52-K0624

 Safety Goggles
 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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