Method Statement For Steel Erection

ORIGINATING COMPANY: RENCO-KAT

DOCUMENT NUMBER:

PROJECT: KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM

KE01-A1-000-RK-C-TT-0004-000

CONTRACT DESCRIPTION: SIS BUILDING CONSTRUCTION PROJECT AGIP KCO CONTRACT NO:

CONTRACTOR’S JOB NO:

2007-0757 DOCUMENT TITLE:

HOLDS

N/A

SHEET NO.

1 OF 15

CONTRACTOR’S DOCUMENT NUMBER:

METHOD STATEMENT FOR STEEL ERECTION

ABSTRACT: This document defines the Method Statement for Steel Erection for KEP SIS (Kashagan Experimental Program – Satellite Instrument Station) Building (Oil, Gas & Sulphur) Construction Project

C01

11.01.2008

Issued for Construction

AHD

A.Dhakan

D.Belpassi

P01

13.12.2007

Issued for Review

AHD

A.Dhakan

D.Belpassi

REV

DATE

REASON FOR ISSUE

PREPARED

CHECKED

APPROVED

REVISION DESCRIPTION SHEET

COMPANY

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 2 of 15

Rev.

Para.

Revision Description

P01

-

Issued for Review

C01

-

Issued for Approval

Para.

Description of Hold

Hold No.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 3 of 15

AGIPKCO KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM

RENCO-KAT METHOD STATEMENT FOR STEEL ERECTION KE01-A1-000-RK-C-TT-0004-000 rev C01

January 2008

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 4 of 15

LIST OF CONTENTS

1.0

PURPOSE........................................................................................................................................................................5

2.0

SCOPE.............................................................................................................................................................................5

3.0

REFERENCES................................................................................................................................................................5

4.0

DEFINITIONS AND ABBREVIATIONS....................................................................................................................5

5.0

ROLES AND RESPONSIBILITIES.............................................................................................................................5

6.0

HSE..................................................................................................................................................................................6

7.0

MATERIAL.....................................................................................................................................................................7

8.0

WORK SEQUENCE......................................................................................................................................................7

8.1 8.2 8.3 8.4

WELDING:.........................................................................................................................................................................7 PRE-ERECTION:...................................................................................................................................................... 8 ERECTION:.............................................................................................................................................................. 8 TIGHTENING OF THE BOLTS:................................................................................................................................... 9

9.0

QUALITY ASSURANCE AND CONTROL PROCEDURE...................................................................................10

10.0

ATTACHMENTS..........................................................................................................................................................10

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 5 of 15

1.0

PURPOSE The purpose of this Method Statement is to illustrate how Steel erection is to be carried out with safe implementation.

2.0

SCOPE The Method Statement defines the methodology of all kind of steel erection Works related to Satellite Instrument Buildings (Oil, Gas & Sulpher). This Method Statement also addresses the type and extent of inspections ITP must be submitted separately to be carried out to verify that all operations involved in the steel erection works conform to the specified requirements.

3.0

REFERENCES KE01.A0.000.KD.C.SP.0008.000 SNiP RK 5.-04.-18-2002 SNiP 3.01.01-85 GOST 12.1.003-83 SNiP RK A.3.2.5-96

KE01.A0.650.KD.C.SP.0010.000

4.0

Specification for erection of Structural Steelwork Metalwares, Production and acceptance of work rules Building Codes and Rules for Construction Management Occupational Safety Standards Labor Safety and Safety Technique in Construction Architectural Specification for Building Materials and Finishes

DEFINITIONS AND ABBREVIATIONS All the definitions are given KE01.A0.650.KD.C.SP.0010.000- Architectural Specification for Building Materials and Finishes

5.0

ROLES AND RESPONSIBILITIES Project Manager : Has ultimate responsibility of compliance of work to, relevant methodologies,

standards, specifications listed, while assuring adequate organization

resources to conduct the work. QA/QC Manager : Responsible for controlling and directing the activities complying with the quality requirements given in the references. He reports to the Project Manager. HSE Manager: Responsible for the implementation of the HSE Plan and management system. He reports to the Project Manager. Structural Steel Manager: shall plan the schedule of works and inform Project Manager for the resource requirements to conduct the work. He organizes structural steel supervisors and reports to Project Manager.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 6 of 15

Structural Steel Supervisor: shall be in charge of crew, equipment and material to conduct the work at his responsibility area. Furthermore, he will be in contact with COMPANY to rise RFI's. He organizes efforts of foreman and reports to Structural Steel Manager. Dimensional check shall be carry out by company survey department joint to with contractor. Foreman: shall be in charge of crew, equipment and material to conduct the work. He shall be instructed by Structural Steel Supervisor for the duration and sequence of work.

6.0

HSE  All work shall be carried out in accordance to AGIP KCO and Renco-KAT safety regulations & policies.  Team coordination shall be implemented by the work supervisor.  Crane should be transported across cleared construction site with dropped boom.  While lifting a structural steel element, swing and rotation must be prevented with tag line.  In the case of adverse weather conditions (snowfall, fog or rain), and in poor visibility as conditions lifting operation will be stopped. Lifting operation shall not be carried on during electric storms.  Lifting operation shall stop when wind velocity exceeds 10 m/s or as per risk assessment.  All personnel related to work shall wear PPE.  Stop signs will be provided to warn vehicles, when required.  Valid certification of all lifting equipment will be verified prior to operation.  Certified and color coded rigging gear shall be used.  When working at height (height more that 1,5 m. from ground level), safety belt shall be fixed to a safety life line, fixed on beams or a rigid steel element.  All heavy transport and plant to be fitted with audible reverse alarm.  Wind speed meter to be provided.  Work area to be barricaded.  Rigging study/lifting plan to be approved for non-routine and critical lifts.  When manlifts are used, no person will be allowed to exit the manlift to get onto the structure.  All manlifts, and other plant and equipment shall not be allowed to moved unless assisted by a landsman.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 7 of 15

7.0

MATERIAL It should be ensured that the material is approved for use and the certificates are available. The fabricated structure should be stored on wooden logs above flat and solid surface free of water deposition. All other materials shall be transported and stored before execution of work in the manner to prevent any defect to the physical or chemical quality of them and according the safety procedures. The area of operation where erection is ongoing will be barricaded as per safety rules. All materials (steel components, bolts, nuts, washers) shall be in accordance with the requirements of the applicable specifications and drawing requirements with regard to type, grade and required certification. Fasteners and small fittings shall be stored in dry conditions.

8.0

WORK SEQUENCE 8.1

Welding: The steel structure is free issue from Company and The welding shall be limited to piping supports and/or modifications as required by the construction drawings or COMPANY direction. If welding is required in such manner, it shall be performed only after the thorough removal of the paint.

Welding in the field shall conform to the related codes and standards as well as to the corresponding drawings. All parts to be welded shall be clean of paint, rust and other materials that may affect the welding.

After the completion of the welding, all slag and spatter shall be removed from the welded area. Visual inspection shall be carried out to ensure that weld is visually acceptable and weld profile is adequate in accordance with approved welding procedure and specification. NDT to be performed in accordance with WPS.

The welding shall be performed in line with the approved & applicable welding procedures and the welders shall be qualified to the ASME IX code and/or local regulations.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 8 of 15

8.2

Pre-Erection: Before erection works start, the concrete surfaces of the foundations shall be scabbled, cleaned and checked by the Renco-KAT QC Inspector. Surveyors shall also check the coordinates and levels of these foundations and paint the marks on the foundations denoting these axis and levels. These target marks shall be colored red/white to facilitate their visibility. Structural steel may be erected in individual pieces or in pre-assembled in transversal as rigid sections, which have been assembled on the ground. The dimensional (KE01-A0-000-KD-C-SP-0008-000) checks shall be carried out on beams, columns, base plates, cross members, etc. of these pre-assembled sections by foremen and spot checks shall be made by the Renco-KAT QC Inspectors. Preliminary tightening of all bolts used for the pre-assembly shall be carried out using appropriate hand tools. The work permit shall be taken before starting of the erection work.

8.3

Erection: All structural steel shall be erected in accordance with the AFC (Approved for Construction) of the erection drawings. By means that no activity shall be done before AFC issued drawings received to site. Anchor bolts and connection points shall be inspected for damage. The erection of the steelwork shall not start until the concrete foundations and slabs have cured as specified by the relevant specifications and obtained minimum requirement of concrete strength at 28 days. The methods of lifting and fixing shall be determined so that the members are not damaged during the handling process. The structural components shall be lifted by means of mechanical lifting equipments. During erection, all work shall be securely bolted, however no permanent bolting and welding shall be done unless the correct positioning and alignment of the member has been obtained. All completed work shall be within the required

dimensional

tolerances

and

all

materials

shall

be

free

of

twists

or

distortions that are likely to affect the structural integrity. All the members shall be checked about damaged paint and if required, touch-up paint shall be done as per specifications. It shall be checked to ensure that the correct bolt type as indicated by the manufacturer’s stamp is used and the bolt length is correct.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 9 of 15

Friction surfaces shall not be painted and adequate protection shall be provided during the painting of the structural element at the workshop or at the site before the erection.

Columns shall be positioned on the concrete foundations, with the nuts on the fixing bolts left loose. These nuts shall be tightened using electric operated or manual wrenches and special care shall be taken to provide surfaces that are free from loose mill scale, dirt, oil, burrs or any other defect which would prevent tight sealing.

Nuts and bolts shall also be left loose for beams that are assembled between two structural steel columns. After this fit- up, the positioning shall be checked, and if required, adjustments shall be made in order to obtain the required tolerances and the nuts and bolts shall be permanently tightened.

Each part of the structure shall be aligned as soon as possible after it has been erected. Permanent connections shall not be made between members until sufficient sections of the structure have been aligned, leveled, plumbed. After ensuring that members will not be displaced during subsequent erection or alignment of the remainder of the structure, permanent fixing will be done. Fixed elements shall be braced to each other safely.

Tolerances for out of plumb and levels shall be as specified in the specifications and drawings.

After the alignment and bolting of the steel structure, but before grouting, all anchor bolts and nuts shall be tightened while the shims are checked with regard to their tight fit. After the hardening of the grouting compound, the anchorage shall again be checked and, if required, the nuts shall be tightened once again.

8.4

Tightening of the bolts: Bolts shall be tightened to bring the surfaces together using a normal effort with a podger spanner or power wrench. After bringing the bolt and nut to the right position by normal hand power, Bolts and Nuts positions shall be marked with identification marks visible showing the reference to the steel structure. Marking will be done by non-erasable type marker.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 10 of 15

The bolt shall be turned 2 quarters of one full rotation against the tightened nut by a long moment arm wrench.

9.0

QUALITY ASSURANCE AND CONTROL PROCEDURE Request for Inspection (RFI) shall be submitted to QA/QC section prior to commencing the erection work. The Engineer in-charge in collaboration with the QC Section shall inspect all the necessary requirements prior to erection work, thus ensuring the readiness of the work. 

Check all Applicable Documents & Specifications if available & approved.



Inspection of Tools and Equipment.



Check all materials required for the work.



Check application as the work progresses.

10.0 ATTACHMENTS 1 Request for Inspection 2 Risk Assessment

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 11 of 15

ATTACHMENT 1 REQUEST FOR INSPECTION

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 12 of 15

REQUEST FOR INSPECTION ЗАПРОС НА ПРОВЕДЕНИЕ ИНСПЕКЦИИ Client: AGIP KCO

Contractor:

Заказчик: АДЖИП ККО

Подрядчик:

Project:

KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM Проект: Проект разработки восточного месторождения Кашагана

Discipline:

RFI No.

№ контракта.

№ ЗНИ

Location/Местонахождение:

Date: Дата:

Karabatan/ Карабатан

Hold Point  Witness Point 

ITP No. :

Дисциплина:

Contract No.

№ ППТ:

ITP activity code: Код деятельности ППТ:

Description of inspection: Описание инспекции:

INSPECTION DATE ДАТА ИНСПЕКЦИИ

INSPECTION TIME

LOCATION/AREA

ВРЕМЯ ИНСПЕКЦИИ

МЕСТОНАХОЖДЕНИЕ

Ref. DOCs / DWGs

Ссылка на Документы/ Чертежи

The above mentioned work activity has been final inspected and accepted. Вышеуказанная работа была проинспектирована и принята.

RENCO-KAT/ QA/QC

RENCO-KAT/ CONSTRUCTION

RENCO-KAT / OTHER

Ренко-КАТ / ОТДЕЛ КОНТРОЛЯ КАЧЕСТВА

Ренко-КАТ/ СТРОИТЕЛЬНЫЙ ОТДЕЛ

Ренко-КАТ / ДРУГИЕ

Name Имя

Name Имя

Name Имя

Date Дата

Date Дата

Date Дата

Signature Подпись

Signature Подпись

Signature Подпись

Received by AGIP KCO Получено АДЖИП ККО

AKCO / CONSTRUCTION Date & Time:

Name:

Signature:

AKCO / QA-QC Date & Time:

Name:

Signature:

RFI Acceptance & Inspection Result ACCEPTED

REJECTED A) Work is not ready at the inspection time.

See AKCO comments attached

B) Result of inspection is not acceptable. RFI shall be issued. C) See AKCO comments attached.

AKCO / QA-QC Name

Date & Time

Signature

New

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 13 of 15

ATTACHMENT 2 RISK ASSESMENT ФОРМА ОЦЕНКИ РИСКА

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 14 of 15

RENCO Risk Assessment Worksheet TASK/ACTIVITY

PROJECT/LOCATIO N

GENERAL HAZARD TYPE

REPORT NO

STEELSTRUCTURE ERECTION

KEPSIS/KARABATAN

EQUIPMENT

RA-021

RISK ASSESSMENT (NO CONTROLL) S.N

HAZARD

TARGET

UNDESIRABLE EVENTS

CONTROL MEASURES SEVE RITY

P 1

Material Handling

A

Injury of personnel and damage of equipments Slips, Trips & Falls

LIKELIH OOD

RISK

 2

2

M

  

All personnel will wear PPE including safety glasses All crew will be familiar with the content of the method of statement A Superintendent will supervise the work Proper house keeping to be maintained.

RISK ASSESSMENT (WITH CONTROLL) SEVER LIKE ITY LIHO OD

1

1

OVER ALL RISK

L

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-C-TT-0004-000 KEP SIS Method Statement for Steel Erection January 2008 Page 15 of 15

2.

Scaffolding use

P A

Dropping tools and objects, dropping of the crew, Scaffolding collapse, overturn

  2

2

M   

3.

Erection

P A

Cutting hazards. Falling collapses of steel structure itself. Falling from Height. Falling object due to high wind.

2

2

M

Always follow safe work practices Scaffolding shall be assembled by certified worked and supervised according to the specific procedure Toe- boards need to be used Egress/Ingress points always need to be assigned Scaffolding to be inspected by HSE Engineer.



Adequate access and egress arrangements and suitable working plat forms at the place of work



R/A Safety training awareness



Use of proper PPE/safety harness



Avoid lifting in high wind

1

1

L

1

1

L