026-Pro-Structural Steel Assembly and Erection PDF
026-Pro-Structural Steel Assembly and Erection PDF
026-Pro-Structural Steel Assembly and Erection PDF
Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.250.907
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Page 2 of 22
5887
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
24.04.08
BR
UA
ZG
RFC
03.12.2007
BR
AU/MC
ZG
ICC
22.11.2007
BR
AU/MC
ZG
IFR
20.11.2007
BR
AU/MC
ZG
IIR
Date
Description
GAMA
Rev.
No.
Project
Rev
No.
Status
Document Title:
LINDEGINEERING AG
Contractor
LOC470
GAM
PRO
QAC
GTL
026
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
T-4.250.907 Rev. A
Vendor Code
Rev No: A
Page 3 of 22
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
TABLE OF CONTENTS
1.
SCOPE ________________________________________________________________________5
2.
PURPOSE _____________________________________________________________________5
3.
HSSE _________________________________________________________________________5
4.
REFERENCE __________________________________________________________________5
5.
DEFINITIONS _________________________________________________________________6
6.
RESPONSIBILITIES ____________________________________________________________6
7.
6.1.
6.2.
6.3.
6.4.
SITE ENGINEER__________________________________________________________________7
6.5.
SITE SUPERVISOR/FOREMAN_____________________________________________________7
6.6.
QA/QC ENGINEER________________________________________________________________7
6.7.
QA/QC INSPECTOR_______________________________________________________________7
6.8.
6.9.
PROCEDURE __________________________________________________________________7
7.1.
7.2.
FABRICATION ___________________________________________________________________8
7.3.
7.4.
7.5.
REPAIR__________________________________________________________________________8
7.6.
7.7.
7.8.
ERECTION______________________________________________________________________10
8.
QUALITY ASSURANCE_________________________________________________________11
9.
ATTACHMENTS/FORMATS ____________________________________________________11
T-4.250.907 Rev. A
Page 4 of 22
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
1. SCOPE
This Quality Control Procedure relates to the verification of construction activities
for steel Structure Erection.
2. PURPOSE
The purpose of this quality control procedure defines the documentation to be
collated and the inspections to be carried out in order to verify and record that all
steel erection activities are conformant to the requirements of the project
specification.
3. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras
Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG
and QSGTL and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will have
through LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety
induction for site safety, health, environmental and security prior to work activities.
Other training courses will be attended as required by LINDE ENGINEERING AG or
QSGTL and/or its PMC as required.
At a minimum a Risk Assessment will have been prepared by the Risk Assessment
Team (RAT) ranking the hazards associated with project works and control measures
to be taken to mitigate the hazards to an acceptable level.
Each work scope or task will have a completed and approved Job Safety Analysis
(JSA) identifying the potential hazards and control measures that will be implemented
to protect people and environment. Supervisor as the basis of conducting his daily
Pre-Task meeting and his weekly Tool Box Talk (TBT) will use the JSA.
In addition to the above, employees conducting survey works will wear required PPE and
highly visible vest where traffic or other hazards may exist. For additional safety
requirements for a particular or specific task please refer to the JSA prepared for that task.
4. REFERENCE
T-4.250.907 Rev. A
Page 5 of 22
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
5. DEFINITIONS
Company
Contractor
: LINDE ENGINEERING AG
Sub Contractor
: GAMA QATAR
Contract
CS
: Construction Supervisor
ITP
QCR
QCP
QCE
QCI
QA/QC
TPI
6. RESPONSIBILITIES
6.1.
SITE MANAGER
The site manager will provide inputs to the project execution plan to ensure
that lifting strategies & philosophy are addressed.
6.2.
CONSTRUCTION MANAGER
The construction manager is responsible for the overall management of the
project construction team to ensure that safe and effective operations are
conducted and properly documented.
6.3.
EQUIPMENT MANAGER
The equipment manager will be responsible for the transporting equipments
availability and good order.
T-4.250.907 Rev. A
Page 6 of 22
Q A T A R
6.4.
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
SITE ENGINEER
Shall report to Construction Manager. Shall be responsible for planning,
execution and implementation of all site activities related to this procedure.
6.5.
SITE SUPERVISOR/FOREMAN
Shall report to Site Engineer. Shall be responsible for execution of
construction activity. Shall also prepare daily site construction records.
6.6.
QA/QC ENGINEER
Shall report to Manager (QA/QC) and shall be responsible for overall
implementation, monitoring and control of QC activities.
6.7.
QA/QC INSPECTOR
Shall report to QC Engineer.
Shall be responsible for attending all Inspection Stages as required by
ITP.
Shall be responsible of performing all checks and shall prepare necessary
Inspection Reports.
6.8.
HSE MANAGER
Shall report to Project Manager and shall be responsible for over all control
and inspection of HSE issues.
6.9.
HSE OFFICER
Shall report to HSE Manager.
Shall be responsible for all safety aspects for this procedure.
7. PROCEDURE
7.1.
PRELIMINARY CHECKS
According to the sequence and the schedule of construction activities, the
following preliminary verification shall be carried out before starting
prefabrication activities.
The availability of qualified personnels on site and suitable equipments to
carry out the works;
The availability on site of the necessary erection material and its status of
acceptance;
The status of approval of the assembly drawings and/or procedures
The availability of approved WPS and PQR, for carrying out welding;
T-4.250.907 Rev. A
Page 7 of 22
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
7.2.
FABRICATION
The Structural Steel shall be fabricated as per IFC Drawing. All Dimensions,
orientation bends etc. to be checked and reported in GAM-QCR-QAC-GTL035.
7.3.
7.4.
7.5.
REPAIR
Structural Steel Repair Works shall be carried out by as per the Repair welding
procedure & using Qualified Repair welder.
7.6.
Page 8 of 22
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
The prefabricated structural steel shall be sand blasted and painted by the
qualified painting personnel.
7.7.
T-4.250.907 Rev. A
Page 9 of 22
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
Workers working at height (above 1.2 meter from ground) will have at least
one lanyard connected to a stable/fix member on man lock Hole. Safety belt
used shall be double lanyard.
Centre of gravity of structural steel piece shall be calculated to prevent
security risks. But if the piece is symmetrical with regard to the centre line,
there is no need to calculate gravity centre.
A general cleanup of the work area will be conducted to ensure that no
unused materials are left on the erection site. All material retrieved will be
sent to the warehouse for proper storage.
7.8.
ERECTION
T-4.250.907 Rev. A
Firstly the surveyor will establish control lines will also be recorded on
the Surveyors Report.
Start the erection only after the Surveyor Report has been reviewed
by the Site Engineer and Construction Supervisor and it has been
agreed that on erection problems could be foreseen. Both Site
Engineer and Construction Supervisor will ensure that there are
sufficient copies of the "Specification for Structural Joints Using ISO
4014, ISO 4032, and ISO 888" latest edition at the Project site; to
ensure that inspectors and workmen have guidance to properly install
high strength bolts.
The Site Engineer and Construction Supervisor shall ensure that the
installation of high strength bolts shall be in accordance with
"Specification for Structural joints using ISO 4014,ISO 4032,and ISO
888", using Torque Wrench to indicate the correct tensioning of bolts.
Special attention shall be given for installation of galvanized hightension bolts.
Q A T A R
Doc. Title
GAM-PRO-QAC-GTL-026
QUALITY CONTROL PROCEDURE FOR STRUCTURAL STEEL
ASSEMBLY AND ERECTION
Date
24.04.08 REV-D
and only Steel Erection acceptance will grouting of steel column base
plates commence.
8.
QUALITY ASSURANCE
A Quality Assurance System shall be operated conforming to related standards.
Controls and checks shall be established and documented as per ITP T.4.250.917.
9. ATTACHMENTS/FORMATS
1. GAM-QCR-QAC-GTL-035
2. GAM-QCR-QAC-GTL-036
3. GAM-QCR-QAC-GTL-037
4. GAM-QCR-QAC-GTL-038
5. GAM-QCR-QAC-GTL-039
6. GAM-QCR-QAC-GTL-040
7. GAM-QCR-QAC-GTL-041
8. GAM-QCR-QAC-GTL-042
9. GAM-QCR-QAC-GTL-043
10. GAM-QCR-QAC-GTL-044
11. GAM-QCR-QAC-GTL-125
T-4.250.907 Rev. A
Page 11 of 22
Report No.:
Item Description:
Inspection Date:
Item No:
Subsystem:
ITP No.:
Fit up checked
3.
Orientations checked
4.
5.
6.
PT/MT verified
7.
Painting checked
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
GAM-QCR-QAC-GTL-035
DATE
ACC
REJ
NAME
Signature
Date
SIGNATURE
Subcontract Ref.:
Report No.:
Item Description:
Inspection Date:
Subsystem:
ITP No.:
3.
4.
5.
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
GAM-QCR-QAC-GTL-036
DATE
QC Inspector
Initial
Date
NAME
SIGNATURE
Report No.:
Item Description:
Inspection Date:
Subsystem:
ITP No.:
3.
4.
5.
6.
7.
8.
9.
Welding Acceptable.
QC Inspector
Initial
Date
The Installation of the above Steel has been Satisfactorily completed in accordance with the Drawings &
Specifications.
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
GAM-QCR-QAC-GTL-037
DATE
NAME
SIGNATURE
Subcontract Ref.:
Report No.:
Item Description:
Inspection Date:
Subsystem:
ITP No.:
Planned Level
Actual Level
Level/Difference
Plumb
0 Degree
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
GAM-QCR-QAC-GTL-038
DATE
NAME
90 Degree
SIGNATURE
Report No.:
Item Description:
Inspection Date:
Subsystem:
ITP No.:
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
GAM-QCR-QAC-GTL-039
DATE
NAME
SIGNATURE
Subcontract Ref.:
Report No.:
Item Description:
Inspection Date:
Subsystem:
ITP No.:
Ref. DWG /
Documents:
Used Measuring and test equipment ref. (if applicable):
INSPECTIONS
Item
Mark No.
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
GAM-QCR-QAC-GTL-040
Check of
Ladders
DATE
Check of
Handrail
NAME
Check of
Staircases
Check of
Grating
SIGNATURE
Subcontract Ref.:
Report No.:
Item Description:
Inspection Date:
Item Location /
Area:
Subsystem:
ITP No.:
Mark No./Joint No
Accepted By
ORGANIZATIONS
THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
GAM-QCR-QAC-GTL-041
Bolting
Grade
DATE
Size
NAME
Bolt Tightening
(Torque Value)
Inspectors
Signature
SIGNATURE
Test Report
Magnetic Particle Test (MT)
QSGTL PEARL PROJECT-QATAR
Testing Contractor
Testing
Data
General
Code, Standard
Test Equipment
Testing Consumables
Evaluation Standard
Magnetisation Current
Fieldstrength [kA/m]
Object Data
Test
No.
1)
Line No.
Sheet
Area
Weld
No.
Abbreviations
1) R Repair
N new after Rep.
G non pressure
tested weld
2) Type of Test
a = wet
b = dry
c = fluorescent
GAM-QCR-QAC-GTL-042
NPS
Thickness
Welder 1
Welder 2
3) Type of Defect
G = globular
L = in Line
Illumination [lx]
Current [A]
Testing Data
Piping
Testing
Contractor before/
after
PWHT
Electrode
Contact
Distance
4) Location of Defect
B = Base Material
T = Transition Area
W = Weld Metal
Type of
Test
2)
Testing Results
Examiner
5) Position of Defect
Distance to Reference
Point [mm]
Test
Date
no
Defects
no
Defects
after
grinding
Type
3)
Length
[mm]
Defect
Location
4)
Pos.
5)
Comments
a/na
GAMA REP
Third Party
_______________________________________
Date
Name
Signature
_______________________________________
Date
Name
Signature
LINDE REP
_______________________________________
Date
Name
Signature
_______________________________________
Date
Name
Signature
Test Report
Liquid Penetrant Examination (PT)
C2 ASU Pearl GTL PROJECT -Qatar
Testing Contractor
Code, Standard
Testing
Data
Evaluation Standard
General
System
Line No.
1)
Sheet No.
Area
Weld
No.
NPS
Thickness
Trade Name
Testing Data
Welder 1
Piping
Welder 2
Contractor
Testing
before/
after PWHT
Penetr.
Time
[min]
Develop.
Time
[min]
no
Date
Defects
Abbreviations
1)
R1 Repair
N new after Rep.
G non pressure
tested weld
GAM-QCR-QAC-GTL-043
Batch
Penetrant
Cleaner
Developer
Object Data
Test
No.
Doc No:
Testing Consumables
Ilumination [lx]
no
Defects after
grinding
Type.
Length
2)
[mm]
Defect
Location
GAMA REP
Type. Of Defect
2) G = globular
L = in Line
Location of Defect
B = Base Material
3)
T = Transition Area
W = Weld Metal
Position of Defect
4) Distance to
Reference Point in [mm]
Date
3)
Pos.
Comments
a/na
4)
Third Party
Name
Signature
Date
Name
Signature
LINDE REP
_______________________________________
Date
Name
Signature
_______________________________________
Date
Name
Signature
Test Report
Radiographic Examination (RT)
C2 ASU PEARL GTL PROJECT-QATAR
Testing Contractor
Testing
Data
General
Film Class
Code, Standard
Penetrameter IQI
Evaluation Standard
Density
Systemclass
Trade Name
Screen Type
Screen Thickn.
C3
Source
Position
C4
C5
120 vertic.
EN 1435
ASME-V
Object Data
Test No.
1)
1)
R1,2
N
F
G
K
T
Line No.
Area
NPS
Welding
Welder 1
Source
Sheet
No.
Weld
No.
Thickness
contract.
Welder 2
Activity
[Ci]
Repair
new after Rep.
Tracer Shot
RT instead of
Pressure Test
Control Shot
T-Joint, 1Film
GAM-QCR-QAC-GTL-044
2) Imperfections
101
Ea Crack long.
102
Eb Crack transv.
2011
Aa Pore
2013
Ad Porosity
2016
Ab Wormhole
301
Ba Slag inclusion
Expos.No.
Source
Size
Distance
FF
Tube Volt.
[kV]
Testing Data
Exposure
[mm]
[mm]
Tubecur.
[mA]
Time
[min,sek]
GAMA REP
304
401
402
5011/12
5013
504
515
H
C
D
F
Da
Dc
Db
Foreign Materials
Lack of Fusion
Lack of Penetration
Notch
Root Notch
Root Reinforcement
Root suck-back
5
A
8
B
Film
Source
System
Pos.
2
C
Date
of
Test
14
E
D
No. of
Films
Imperfections
Film size
2)
90 EL
11
F
12
G
Testing Results
Pos.
IQI
Comments
Sensitivity
a/na
Repair
from - to
Third Party
__________________________________________ ______________________________________________
Date
Name
Signature
Date
Name
Signature
LINDE REP
__________________________________________ ______________________________________________
Date
Name
Signature
Date
Name
Signature
Inspection
Date:
Area :
RFI No:
Location :
Grid No :
ITP No.:
ACC
2.
3.
4.
5.
ORGANIZATIONS
GAMA QATAR.
LINDE.
QSGTL OR its PMC
GAM-QCR-QAC-GTL-125
DATE
REJ
NAME
N/A
REMARK
SIGNATURE