CEYLON PETROLEUM CORPORATION

Project Title:

CONSULTANCY SERVICES FOR FEASIBILITY STUDY ON CONSTRUCTING

A JET A-1 TRANSFER PIPELINE FROM MUTHURAJAWELA TO BIA AND
ASSOCIATED DEVELOPMENTS

Document Title:

STRUCTURAL STEEL FABRICATION

Project Owner: CEYLON PETROLEUM CORPORATION (CPC)

Consultant: Consortium of ASPROFOS S.A. and RDC Ltd

Project No.: AF-11-7258

Contract No.: CPC/P&S/SER/21/2015

Document No.: 7258-1400/14

Revision: 0

Date: 15/01/2016
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Project Title: Consultancy Services of a Jet A-1 Transfer Pipeline and Jet A-1 Storage Tanks

Document Title: Structural steel fabrication

SUMMARY OF CHANGES

CHANGES LOG

There are changes in the following pages:

.....................................................................................................................…

Revisions log

0 15/01/2016 First Issue for Comments PNG GSA

Revision Date Reason of change Made by Approved by
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Project Title: Consultancy Services of a Jet A-1 Transfer Pipeline and Jet A-1 Storage Tanks

Document Title: Structural steel fabrication

CONTENTS

1 SCOPE 4

2 CODES, STANDARDS & JOB SPECIFICATIONS 4

3 TECHNICAL CONTENTS 6
3.1 Materials 6
3.2 Definition of design and detailing responsibilities 7
3.3 Design & detailing requirements for structural steel 8
3.4 Shop connections 9
3.5 Field connections 10

4 PROTECTIVE COATINGS 11

5 DOCUMENTATION PREPARED BY SUPPLIER 11

5.1 Documents to be produced 11
5.2 Assembly erection drawings 11
5.3 Shop fabrication drawings 12
5.4 Bill of materials and quantities, quantity summary tables 12

6 INSPECTION 12

7 SHIPMENT AND ERECTION 13

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Document Title: Structural steel fabrication

1 SCOPE

This Engineering Standard, with the codes and documents referenced herein, shall govern
the design where required, shop detailing, fabrication, inspection and supply of structural
steel to be built in the CPC Land at Muthurajawela for the Jet A-1 Storage Tanks &
Associated Facilities.

2 CODES, STANDARDS & JOB SPECIFICATIONS

7258-STD-46-01 Steel standard typical details

7258-STD-46-01 Safety steel barriers
BS EN 1990 [Eurocode 0: Basis of structural design]

BS EN 1991 [Eurocode 1: Actions on structures]

BS EN 1993 [Eurocode 3: Design of steel structures]

BS EN 1994 [Eurocode 4: Design of composite steel and concrete structures]

BS EN 1998 [Eurocode 8: Design of structures for earthquake resistance supplemented

by the Hellenic National Code EAK 2003]

BS EN 1011-2 Welding - Recommendations for Welding of Metallic Materials -Part 2: Arc

Welding of Ferritic Steels

BS EN 10025 Hot rolled products of structural steels; technical delivery conditions

BS EN 10034 Structural steel I and H sections; tolerances on shape and dimensions

BS EN 10055 Hot rolled Steel Equal Flange Tees with Radiuses Root and Toes- Dimensions
and Tolerances on Shape and Dimensions

BS EN 10056-1 Structural Steel Equal and Unequal Leg Angles – Part 1: Dimensions

BS EN 10058 Hot rolled flat steel bars for general purposes - Dimensions and tolerances
on shape and dimensions
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Document Title: Structural steel fabrication

BS EN 10279 Hot rolled steel channels - Tolerances on shape, dimensions and mass

BS EN 13479 Welding consumables - General product standard for filler metals and
fluxes for fusion welding of metallic materials

BS EN 14399 High-strength structural bolting assemblies for preloading

BS EN 15048 Non-preloaded structural bolting assemblies

BS EN 20898-2 Mechanical Properties of Fasteners Part 2: Nuts with specified Proof Load
Values - Coarse Thread

BS EN ISO 898-1 Mechanical properties of fasteners made of carbon steel and alloy steel -
Part 1: Bolts, screws and studs with specified property classes – coarse
thread and fine pitch thread

ISO 888 Fasteners - Bolts, screws and studs; Nominal lengths, and thread lengths

BS EN 1090 Execution of steel structures and aluminum structures

BS EN 5950 Design, fabrication and erection of structural steelwork

BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles –
Specifications and test methods

BS EN ISO 12944 Paint and varnishes – Corrosion protection of steel structures by protective
paint systems

BS EN ISO 14122,
Parts 1 – 4 Safety of machinery – Permanent means of access to machinery
BS EN 10210 – 2 Hot finished structural hollow sections of non – alloy and fine grain steels –
Part 2: Tolerances, dimensions and sectional properties

BS EN ISO 4014 Hexagon head bolts – product grades A and B

Where the subject is not covered by the previous codes the following international codes
shall be applied.
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AISC Steel Construction Manual, 14th Edition

ANSI / AISC 360 – 10 Specification for Structural Steel Buildings

AISC 303 -05 Code of Standard Practice for Steel Buildings and Bridges

ASCE Guidelines for Seismic Evaluation and Design of Petrochemical

Plants

ASCE Wind loads and anchor bolt design in petrochemical facilities

ASW American Welding Code Standards

API American Petroleum Institute Standards

ASTM A123 Standard Specifications for Zinc (Hot Dip Galvanized) Coatings on Iron
and Steel Products

ASTM A143 Recommended Practice for Safeguarding Against Embrittlement of

Hot Dip Galvanized Structural Steel Products and Procedures for
Detecting Embrittlement

3 TECHNICAL CONTENTS

3.1 Materials
Materials shall conform to the following, unless indicated otherwise in the drawings:

- Material for structural steel shall be Fe360 as per EN 10025 or an equivalent material.
For special high stressed members or elements Fe510 as per EN 10025 may be used (in
limited application and after approval by COMPANY).

- Grating shall be galvanized steel welded. Bearing bars shall be 30x3, mesh 30x50.
Other types of galvanized gratings, available on local market, may be used subject to
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approval by COMPANY. Floor plate shall be galvanized and it shall have raised pattern
and 6 mm nominal thickness.

- High strength bolts shall be type class 10.9 as per EN 20898. Bolts type class 8.8 shall be
used only after COMPANY's written approval for certain cases.

- Bolts for minor connections may be of class 4.6 or 5.6 as per EN 20898.

3.2 Definition of design and detailing responsibilities

DOCUMENTATION MANAGEMENT

- The CONTRACTOR shall provide the design drawings with the sizes of structural
members, base plates, and connections; connections shall be referred to standard
construction details or, if these are not applicable, to details shown on the drawings.

- On the basis of the documents received, the SUPPLIER shall prepare his documents in
accordance with the requirements of this section within the times scheduled in the
order, and shall send the required number of copies to the CONTRACTOR.

- Assembly erection drawings and shop fabrication drawings, although they need not be
approved by the CONTRACTOR since the SUPPLIER is responsible for their compliance
with the design, shall be sent to the CONTRACTOR before starting shop fabrication.

- The CONTRACTOR may require the total or partial redrawing of the shop drawings if
these do not ensure sufficient quality of the product.

- Any approval, if required in written CONTRACTOR's instruction, may be provided

officially by fax or - when considered strictly necessary by the CONTRACTOR – by
returning the SUPPLIER's shop drawing stamped with approval. This approval does not
relieve the SUPPLIER from his responsibility for compliance of his documents with
contractual drawings and specifications.
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Document Title: Structural steel fabrication

- The SUPPLIER may, by written request, propose alternative solutions different from
those shown on the design drawings, subject to prior approval by the CONTRACTOR
who reserves the unquestionable right to accept or reject them in writing.

- The design drawings issued by the CONTRACTOR may be revised during the supply
to include any design modification or completion. In this case the SUPPLIER shall update
his drawings, highlight the latest revision number of the design drawing, and send the
required number of copies to the CONTRACTOR.

- Within the time agreed in the purchase order, the SUPPLIER shall send the
CONTRACTOR a reproducible copy of all final documents, including bills of materials
and quantities and quantity summary tables.

"QUALITY CONTROL" SYSTEM

The SUPLIER shall provide his own quality control program together with inspection
procedures that ensure the compliance of his products with the requirements contained in
this document, with the design drawings, the other specifications and contractual
requirements, and with his own documents valid for construction.

3.3 Design & detailing requirements for structural steel

GENERAL SPECIFICATION
Reference shall be made to General Specification 1400/13 "Structural Steelworks" and to
relevant Steel Standards.

ADDITIONAL REQUIREMENTS

- For welded truss-work, working lines not more than 15 mm greater than the offset to
the gravity axis of the member shall be used.

- On welded trusses, splices shall be detailed to ship the largest possible section as shop
assembled units.
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Document Title: Structural steel fabrication

Splices for bolted joints shall also be detailed. Field welding shall not be used for splices
unless specifically shown and noted on the arrangement drawing.

- Grating shall be banded at all ends and cut-outs. All banding bars shall be of the
same size as the bearing bars.

Grating shall be fastened to supporting members by bolts and clip assemblies designed
not to protrude above the deck elevation.

At least one grating hold down clip shall be installed at each corner of a grating panel.

- Grating penetrations for pipes, electrical, etc. shall be as follows:

 Field cut, but do not band, all holes smaller than 200 mm in diameter.

 Shop cut and band all holes 200 mm in diameter and larger.

 For holes larger than 400 mm in diameter, split grating and band.

- All platforms, including circular platforms, ladders and cages shall be shop
assembled including posts, handrail, mid-rail and toe plate.

- Weld beads shall be carefully cleaned and slag deposit removed.

TOLERANCES

- Tolerances on sections, plates, and other structural members shall be in accordance

with the codes and standards that are applicable to the project.

- Fabrication tolerances shall be in accordance with BS EN 1993-1-1 "Eurocode 3" chap.

"Fabrication and erection"

3.4 Shop connections

- Generally shop connections shall be welded

Primary steel members shall be shop painted according to relevant General

Specification.
Only secondary members (i.e. gratings, floor plates) shall be galvanized.
For the galvanized steel, welding shall be done before galvanization.
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Document Title: Structural steel fabrication

- All welds shall be in accordance with latest revision of the relevant AWS Specifications.

3.5 Field connections

- Field connections shall be made with high strength steel bolts, except where field
welding is indicated in Engineer arrangement drawings:
- The minimum size of bolts shall be 16 mm diameter.
- Field connections using high strength bolts shall be bearing type connection.
- All bolted connections shall be tightened to the snug tight conditions.

No full tensioning condition is required unless otherwise indicated in the drawings or in

Material Requisition.

Snug tight is defined as tightness that exists when all plies are in firm contact, which will
vary from joint to joint depending on thickness and desire of parallelism of the
connected material.

In most joints the plies will pull together; however, in some joints, it may not be
possible at snug tight to have contact throughout the paying surface area.

Full tensioning is defined as tightening connections beyond snug tight under a

controlled procedure to produce a minimum specified tensile force on each bolt in the
connection.
- No friction type connection shall be used unless approved by Engineer.
- Where field welding is required, the Supplier shall provide erection clips as required.
- All fields welding shall be indicated on the erection drawings. Field welds are allowed
only if indicated in the arrangement drawings.
- Overages on field bolts shall be 5% on both high strength steel and unfinished bolts.
Hardened washers, including bevel washers, shall be provided where required.
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Project Title: Consultancy Services of a Jet A-1 Transfer Pipeline and Jet A-1 Storage Tanks

Document Title: Structural steel fabrication

4 PROTECTIVE COATINGS

- For galvanizing, painting and other coatings see the relevant General Specifications.

- Surface treatment is also required on loose and spare materials.

- Any touch-ups of surface treatments shall be performed in accordance with the

applicable codes and standards.

- All bolts (screws, nuts and washers) shall be galvanized in accordance with the
requirements of contractual documents.

5 DOCUMENTATION PREPARED BY SUPPLIER

5.1 Documents to be produced

The Supplier shall prepare the following documents:

 Assembly erection drawings

 Shop fabrication drawings

 Bills of materials and quantities

 Quantity summary tables.

5.2 Assembly erection drawings

Assembly drawings for erection of steelwork shall include, in addition to all indications for
correct assembly, the following information:

 Identification mark for each piece or structural member composed by several pieces

 Welds to be performed at site

 Diameter, length, class, and bolt tightening torque (the latter when specified on design
drawings)

 Erection sequences (if any)

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Document Title: Structural steel fabrication

 Reference to design drawings

 Reference to the shop fabrication drawings correlated to the assembly erection

drawing.

5.3 Shop fabrication drawings

Shop fabrication drawings shall include, in addition to all indications for correct
construction, the following information:

 Marks and positions

 Indications about chamfers for welding

 Type and location of shop welds

 Material used for each piece

 Reference to the relevant assembly erection drawing.

5.4 Bill of materials and quantities, quantity summary tables

Bills of materials and quantities shall be prepared and subdivided according to shop
fabrication drawings. The Supplier shall prepare a summary table of the quantities of each
shop fabrication drawing. The quantity summary table shall include all the necessary
references for correlation with the assembly erection drawing of the respective structure.

6 INSPECTION

The materials and workmanship covered in this Specification can be subject to inspection in
the field or shop by a qualified Inspector.

However, such inspection shall not relieve the SUPPLIER of his responsibility to furnish
materials and workmanship in accordance with the Contract requirements.
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Document Title: Structural steel fabrication

The Inspector shall have the option to make, but shall not be limited to, the following types
of tests and inspections.

- Determine chemical composition of steel.

- Determine mechanical properties of steel.

- Inspect shop-fabricated structural steel members and assemblies for conformance with
the requirements specified.

- Inspection of shop assembled.

- Make inspection of shop welds as follows:

 Visual inspection of all shop welds.

 Liquid penetrant inspection.

 Magnetic particle inspection.

 Radiographic testing.

 Ultrasonic testing.

Extent and cost charge for testing shall be specified in the relevant Material Requisition.

7 SHIPMENT AND ERECTION

- Sufficient bolt or connectors of the proper size and length to suit the material shipped
with each shipment shall accompany all shipments, including partial shipments.

- Prior to shipment, the Manufacturer shall transmit the necessary details.

- Ladders with ladder cages, handrails, platforms and trusses shall be shop assembled as
permitted by shipping limitations and with assurance of no damage.

- All steel erection shall be carried out without delay in a first class workmanlike
manner, in accordance with Codes and Standards (see Section 2) and as specified
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Document Title: Structural steel fabrication

elsewhere in this Specification. The Construction Contractor shall plumb level,

thoroughly fasten, brace, and guy the structure before welding or bolting starts so as to
keep it plumb and true during erection.