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JOB PROCEDURE FOR STRUCTURAL STEEL WORKS

TABLE OF CONTENTS

1.

PURPOSE

2. SCOPE 3. REFERENCE 4. 5. 6. 7. 8. GENERAL EQUIPMENTS METHODOLOGY INSPECTION AND TESTING OF WELD GROUTING QUALITY CONTROL

9. DOCUMENTS

PURPOSE
The purpose of this procedure is to form a systematic performance of activity so that the desired product and workmanship is achieved as per bid documents /customer specifications and drawings. 1.0 SCOPE This procedure covers the methodology to be followed during erection of all steel structures, fabricated at vendors shop like pipe rack, platforms including gratings / hand railing, technological structure, roof trusses, equipment structure etc, at site / work area pertaining to contract and project approved drawings / specification. Following are the activities for general structural works at refinery site Inspection of fabricated structural items received from the contractors shop. Erections of structures. Checking of alignment. Fixing of bolts / placing of packing / shim plates. Welding during erection. Painting Touch up & Final Painting.

2.0

REFERENCES The following documents in totally or in part shall be from the reference documents. IS 800-1984 (General Construction in Steel Structures), IS: 9595, IS: 2062 IS 7205-Safety code for erection in structural steel work. Customer Specifications. ASME Sec. II Part C ASME Sec. IX

4.0

GENERAL EQUIPMENT Following equipment shall be used for steel structures. Welding Machines Rectifiers, diesel welding generators. Oxy-Acetylene gas cutting equipment. Material handling equipment - Cranes, Chain pulley block, Wire ropes, Manila ropes, Piano wire, Wrenches, Slings of various sizes, Wooden sleepers, stairs etc. Air Compressors, jacks, ovens, welding accessories, electric grinding machine, hoses etc.

5.0 5.1

METHODOLOGY Fit-Up & Welding Fit-Up shall be made as per approved drawing using qualified welder for tack welding. Upon clearance of fit-up, all welding shall be done using approved welding procedure specification in accordance with customer Specification and other relevant codes. Proper care shall be taken for welding shrinkage and distortion so as to attain the finished dimension of the structure as per drawing. Erection Before commencement of any erection activity, foundation shall be checked for its elevation & centerline. Simultaneously location, orientation, size & length of foundation bolts shall be checked with column base plate holes and column orientation. The centre line should be marked suitably of each column before erection. By deploying suitable crane, the column shall be lifted from wooden sleep for placement on foundation. Only single identified person shall give the requisite signals. Other end of the column shall be tied with Manila rope, so that orientation can be changed before placement. Packing plates / shim plates of suitable size shall be placed under the base plate for final adjustments of elevation, which will be covered during grouting. Rope ladders / Aluminum ladders / steel ladders shall be used for approach to higher elevations of structures as per approval of safety department. Guy wires / Rope shall be used to hold tall structural column till the time other connecting members are erected and secured with bolts. After erection of sufficient nos. of columns and tie beams, the structure shall be aligned. The verticality of the structure shall be checked with plumb suspended at the end of piano wires and the level will be checked with the help of water level tubes. Nut shall be tightened immediately after placement before releasing the crane / hydra. Final tightening shall be done after checking & approval. Beams and other secondary beams shall be erected with help of hydraulic / mobile crane / hydra, orientation shall be checked. Scaffolding shall be erected as desired for the erection of structures. After final tightening of anchor bolts, at least two threads of the bolts shall protrude from top face of nut.

5.2

5.2.1 5.2.2 5.2.3

5.2.4 5.2.5 5.2.6

5.2.7

6.0

INSPECTION & TESTING OF WELD The method of inspection shall be according to the approved WPS and relevant applicable codes & standards and to be carried out during all stages of fabrication & erection, to check the conformity with the relevant specifications and Codes / standards.

7.0

GROUTING The area / location of grouting shall be cleaned of moisture, dirt and any oily substances. Grouting shall be carried out as per the approved drawings. The minimum thickness of the grout shall be 25 mm or as permitted / approved by customer. Grout material should be of approved quality.

8.0

QUALITY CONTROL Quality control of fabrication & erection will be as per Quality Plan and corresponding Inspection Test Plan. Following shall be checked while carrying out the job. a) Fabricated member shall be checked for measurement / dimensions from drawings / specifications. b) Foundation bolts must be true to vertical position. Their location, orientation shall be checked and must be matching with column base plate hole. Check shall be carried out for condition of the thread before erection of structure. c) To provide proper support / bracing to sections / members and other components in position during erection.

9.0

DOCUMENTS Inspection & Test Plan Surface Preparation & Painting