Pearl GTL Project Shell Project No: HP-3000-QAT Project Document Number: T- 4.250.897
Purchase Order Number:
2MH127
Tag/Item Number(s):
N/A
LINDE ENGINEERING
Contractor Project No: 5887
Project Rev.: G
Page 2 of 18
QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION J
G
03.12.08
Ready For Construction
SB
EO
AG
RFC
I
F
15.11.08
Issued for Review
SB
EO
AG
IFR
H
E
16.10.08
Issue for Review (Site Comments Incorporated)
SB
EO
AG
IFR
G
D
14.07.08
Ready For Construction
SB
EO
AG
RFC
F
C
24.05.08
Issued for Company Comments
FB
EO
AG
ICC
E
B
06.05.08
Issued for Company Comments
SB
SB
ZG
ICC
D
A
15.04.08
Issued for Company Comments
BR
UA
ZG
ICC
C
O
24.11.07
Issued for Company Comments
BR
AU/MC
ZG
ICC
B
22.11.07
Issued for Review
BR
AU/MC
ZG
IFR
A
20.11.07
Issued for Internal Review
BR
AU/MC
ZG
IIR
Date
Description
GAMA Rev.
Project Rev
No.
No.
Prepared Checked Approved By By By ORIGINATOR ORIGINATOR
Status
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
TABLE OF CONTENTS 1.
PURPOSE PUR POSE _____________________ _________________________________ _______________________ ______________________ _______________________ ______________ __ 5
2.
SCOPE ______________________ __________________________________ _______________________ ______________________ _______________________ ________________ ____ 5
3.
H SSE SSE ______________________ _________________________________ ______________________ ______________________ _______________________ __________________ ______ 5
4.
REF RE F ERE N CES _____________________ ________________________________ ______________________ ______________________ ______________________ ___________ 6
5.
D EF I NI TI ONS ON S _____________________ ________________________________ ______________________ ______________________ ______________________ ___________ 6
6.
TOOL TOO L S & PL AN TS ______________________ _________________________________ ______________________ ______________________ __________________ _______ 6
7.
RESP RE SPON ONSI SIBI BI L I TY ______________________ _________________________________ ______________________ ______________________ __________________ _______ 7
8.
PROJECT REQU I REM EN TS ________ ____________ ________ ________ ________ ________ ________ ________ ________ ________ ________ ________ _____ _ 8 8.1.
MATERIAL: _____________________________ ___________________________________________________________________ _________________________________________ ___ 8
PROCE DU RE ______________________ _________________________________ ______________________ ______________________ ______________________ ___________ 9
9.
9.1.
PRE ASSEMBLY INSPECTION ______________________________________ _____________________________________________________ _______________ 9
9.2.
TORQUE WRENCHES___________________________________ _____________________________________________________________ __________________________ 9
10 .
STRUCT URAL STEE L BOL T REQUI REM EN TS _____ ________ ______ _____ _____ ______ ______ _____ _____ ______ ______ _____ __ 9
10.1.
PREASSEMBLY & ERECTION ERECTION ____________________________________________________ ____________________________________________________ 10
10.2.
STRUCTURAL STRUCTURAL ERECTION ___________________________________ _______________________________________________________ ____________________ 10
11
JOI NT T I GH TE NI NG PROCED URE
11
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
1. PURPOSE The purpose of this method statement is to clarify the tightening & torque of high, ordinary strength bolts for structural works at the Qatar Shell GTL Pearl Project by GAMA Qatar located inside the Ras Laffan Industrial City in Qatar.
2. SCOPE This method statement identifies the basic structure of the Tightening & torque of high, ordinary strength bolts works used for the successful completion of the structural steel erection works, by using the FSI Procedure stage by stages will be followed.
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 QSGTL site safety induction, LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
4. REFERENCES DEP 34.28.00.31
:
34-00-01-30
:
T-4.234.542
:
T-4.250.917
:
T.13.377.578G
:
T-13.377.454
:
Steel Structures (Ammendments-T-13-376-359E) Minimum Requirements For Structural Design Engineering (Ammendments-T.13.376.3 ( Ammendments-T.13.376.351G) 51G) Project Quality Plan
&
ITP For Structural Steel Project specification PART IV Procedures and Requirements Chapter 10 - Flawless Start-Up Preservation of Old and New Equipment Standing Idle
5. DEFINITIONS Company
: QSGTL/or its PMC
Contractor
: LINDE ENGINEERING AG
Sub Contractor
: GAMA QATAR
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
MANPOWER
Supervisor Engineer QA/QC Engineer Site Supervisor/Foreman HSE officer Crew Leader Steel Erector Bolt Tightener.
7. RESPONSIBILITY 7.1.
SITE MANAGER The site manager will provide inputs to the project execution plan to ensure that job strategies & philosophy are addressed.
7.2.
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.
7.3.
EQUIPMENT MANAGER
Q A A T A A R 7.7.
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
STEEL ERECTOR Shall erect steels structures as per site requirements and approved drawings in coordination with the Crew leader/Foreman.
7.8.
QC ENGINEER Shall report to Manager (QA/QC) and shall be responsible for overall implementation, monitoring and control of QC activities with releated to the Flawless start-up Initiative (FSI)
7.9.
QC INSPECTOR Shall report to QC Engineer Shall be responsible for attending all Inspection Stages as required by ITP &FSI Shall be responsible of performing all checks and shall prepare necessary inspection Reports.
7.10. HSSE MANAGER Shall report to Project Manager and shall be responsible for over all control and inspection of HSSE issues.
7.11. HSSE OFFICER Shall report to HSSE Manager Shall be responsible for all safety aspects for this procedure
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
All bolts, unless otherwise stated, shall be grade 8.8 or equivalent in accordance with ISO 898-1 and ISO 898-2. Standard washers Standard washers shall be used in all al l bolted connections.
9. PROCEDURE 9.1.
PRE ASSEMBLY PRE ASSEMBLY INSPECTION Bolt holes of mating surface shall be aligned using a spud wrench or similar tool. Lateral alignment shall be checked by ensuring that bolts can be inserted without force and that the alignment tool is not required to impart a significant force to achieve alignment. Two bolts shall be installed diagonally opposite each other, one bolt half way between the previously installed bolts, then the washer and nuts engaged The remaining bolts and nuts shall be installed and hand tightened. Care should be taken to assure proper seating of the structure within the allowable tolerances. Bolts shall be tightened by Torque wrench and inspected for tightness in accordance with Sec 11 this Method Statement.
9.2.
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
S.NO
Quality of bolts, 8.8 grade Dimensions
Bolt Load (KN)
1
M12
2
SPX values (KN)
Dry Torque (N-m)
35
40
93
M16
70
80
226
3
M20
110
120
399
4
M22
130
145
598
5
M24
150
165
798
6
M27
200
220
1197
7
M30
245
270
1596
8
M36
355
390
2730
Refer document T-4.193.320 T-4.193.320 for Grade 8.8, hot dip galvanized nuts and bolts from the vendor .
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
Structural bolt holes are clean and have been inspected to confirm there are no scratches, burrs, rust or any other defect on the seating surface. Physically check if fasteners & bolts are of correct length, diameter and material grade. Confirm if they are undamaged, free of any burrs. Dry t orque system will be executed. Bolts are installed in one direction with thread on one side. Bolt grade punch to be visible. The thread projection on end of the bolts shall be between be between 1 and 3 threads.
11. JOINT TIGHTENING PROCEDURE The assembly drawings will indicate the bolt length, diameter and material type and rating. Bolts shall be checked for correct length, diameter and conformance with material specification. The bolts and nuts shall be installed and hand tightened to the structural joints. Care should be taken to assure proper seating and centring of the structure within the allowable tolerances. Bolts shall be tightened by wrench and inspected for tightness in accordance with unique tightening sequence for equal distribution of stress.
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
two tradesmen working in tandem or in direct sequence. This procedure shall be repeated until all bolts have been tightened once. This sequence of tightening pairs of bolts is to be applied irrespective of whether the tightening is by torque or hand wrench/spanner. For torque wrench tightening, the bolts shall be tightened in wrench torque value steps that tighten the bolts to 80% then 100% of the bolt stress. After the connection has been tightened, the joint shall be inspected for uniform bolt loading by wrench testing each bolt in the same sequence specified above until all bolts are judged to have the same level of tightness. After 100% tightening of each joint, all the bolts will be marked with a red paint dot marking on each bolt. The bolts where ever possible will be installed head upside and nuts at bottom for horizontal joints and other joints where ever feasible. However, where this is not possible, bolts will also be installed head side down to ensure complete torquing of all bolts as per location and uniformity.
14. TORQUE VALUES GAMA shall develop a table for each type of bolt specified for the project that indicates for every bolt size, the required torque value for each of the tightening
Q A A T A A R
Doc. Title
:
METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Date
:
03.12.2008
Rev. J
15. QUALITY ASSURANCE The Quality checks and Quality Assurance shall be ensured by the following steps. a)
Each joint and bolts shall be checked for full tightening and marking by GAMA and LINDE QC. b) Overall alignment of structure shall be checked. c) Cleanliness of modules will be ensured. d) Overall inspection as per drawing shall be made. e) QC-Inspection will be made made with with Client for any deficiency (at lifting points & support points) during transportation of pre-assembled steel structure at site before erection of structure. A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented through relevant QCP -T4.250.907, ITP - T-4.250.917 and QCR’s.
16. ATTACHMENTS 16.1. BOLT TIGHTENING INSPECTION REPORT 16.2. JSA
C2 ASU PEARL GTL PROJECT RASLAFFAN INDUSTRIAL CITY
BOLT TIGHTENING INSPECTION REPORT
Subcontract Ref.:
Report No.:
Item Description: Description:
Inspection Date:
Item Location / Area:
Test Code No.:
Subsystem:
ITP No.:
Ref. DWG / Docs: Used Measuring and test equipment ref. (if applicable): INSPECTIONS
Item No/Spool No
Mark No./Joint No
Bolting Grade
Size
Bolt Tightening (Torque Value)
Inspector’s Signature
Q Q A A T T A A R
JOB SAFETY ANALYSIS / RISK ASSESSMENT
JSA Number: T.4.250.897
NEW
Page No: 1 of 4
REVISED
Job being analysed: METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL) Department/Section Department/Section doing JSA: HSE & Mechanical Works JSA Members:Mr. Members:Mr. Syd Osborne, Mr. Atila Gtn, Job Performers:Mr. Performers: Mr. Atila Gtn, General job requirements / Common Personnal Normal Approvals: Name Signature Date Protective Equipment. JSA by: Mr. Atila GUN 03.12.08 Job Supervisor:
03.12.08
Additional Approvals Approvals (Determined (Determined by Job Supervisor Supervisor in correlation correlation with LINDE HSSE Manager). Manager). Name Signature Discipline Superindent (LINDE)
Date
HSSE R epresentative epresentative (LINDE) OTHERS(List Below):
1. The following Personal Protective Equipment shall be worn while tightening & torqueing bolts in structural steel members: Approved coveralls, safety glasses, safety helmet, safety shoes, safety gloves & safety harness. 2.Permit To Work.
Approval required for hazardous work detailed in the LINDE work permit procedure. Changing conditions and emergency procedures: Stop work. Switch of equipment.Supervisor equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning returning to work. LINDE INDE EME EMERGEN RGE NCY CY TELEP ELEPHO HONE NE NO. NO.
H HS SSE SE MANA MANAGE GER R PEARL HOT LINE:
583 40 72 474 88 88
Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Industrial Hygienist must also approve the work. 2) Use additional sheets as necessary. 3) Details on safety (PPE,Hazard etc) and environment al requirement s can be found in LINDE and SHELL Safety and Environm ent Procedures.
Q Q A A
T T A A
JOB SAFETY ANALYSIS / RISK ASSESSMENT T.4.250.897
R R
SCOPE : METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Initial Risk ITEM
1
ACTIVITY
HAZARD / POTENTIAL CONSEQUENCES
Bolts tightening 1.1 during pre-assembly of structural steel members
P
C
Residual Risk
CURRENT CONTROLS
RISK RANK
Hand and finger injury.
1.1.1 B
2 #####
1.1.2 1.1.3
1.2
Pinch point.
1.2.1 1.2.2 B
2 #####
ADDITIONAL CONTROLS
P
C
R
A
3 #####
Do not use wrenches if the jaws are sprung. Do not use tools with loose, cracked, splintered. Ensure all bolt holes shall be aligned during insertion of bolts. Ensure that all hand tools are in good condition. Ensure qualified/ competent employee to carry out the task.
1.2.3 1.2.4
1.3
Improper use of tool.
B
2
Bolts torqueing final 2.1 tightening after erection of structural steel members
Falls of materials & tools.
B
Use the right tools for the job. Keep away hand & finger from any pinch point hazard. 1.3.1 All tools shall be inspected & colour coded with the approved by Use the right tool for the job. 1.3.2 Operate tools according to 1.3.3 manufacturers instruction. Use appropriate personnel 2 ##### 1.3.4 protective equipment. Perform maintenance on tools 1.3.5 regularly. Cheater bar are not allowed use as 1.3.6 an extension for tightening bolts. 2.1.1 Install Install barrica barricades des "exclu "exclusion sion zone" zone" 2.1.1.1 2.1.1.1 and secure the area with sign boards to prevent unauthorized 2.1.2 All material materials s shall shall be safet safety y lowered from one level to the next 3 ##### either by hand-to-hand or by securily attaching a rope and hauling. 2.1.3 Tools Tools shall shall be tied by by a retain retaining ing rope attached to the harness.
Ensure Ensure to to provid provide e safety safety nets, nets, toe boards.
Page 2 of 4
Q Q A A
T T A A
JOB SAFETY ANALYSIS / RISK ASSESSMENT T.4.250.897
R R
SCOPE : METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Initial Risk ITEM
ACTIVITY
HAZARD / POTENTIAL CONSEQUENCES 2.2
P
Fall of working personnel at height.
RANK
2.2.1
Ensure all materials, tools,and equipment are kept secure at all times. 2.2.2 Install Install lifting lifting apparatus apparatuses es such such as as gin wheel and hoisting rope for lifting pieces of materials.
B
2.3
C
Residual Risk
CURRENT CONTROLS
RISK
Wind hazards.
B
4
2.2.3 Full body harness harness and and lanya lanyards rds shall be inspected. 2.2.4 All emplo employee yees s shall shall wear wear inspec inspected ted full body harness fitted with twin lanyards with shock absorbers, each lanyard shall be fitted with dual action self-locking safety hook to allow for 100% Tie-off.
ADDITIONAL CONTROLS 2.2.1.1 2.2.1.2 2.2.1.3
P
C
R
A
4 #####
Ensure 100% fall protection. Ensure that all employees employees working at height are properly trained. Discuss working at height hazards at daily TSTI.
2.2.5 Ensure Ensure housekee housekeeping ping is done regularly to maintain walkway free of hazards. 2.3.1 2.3.1 Monito Monitorr wind spe speed ed using using Anemometer. Crane Crane operations operations should be stopped if wind speed exceeds 25 knots or as stipulated by crane manufacturer, which ever 2 ##### is lower. 2.3.2 Employe Employees es shoul should d be aware of the the affect of weather conditions on the operation.
Page 3 of 4
Q Q A A
T T A A
JOB SAFETY ANALYSIS / RISK ASSESSMENT T.4.250.897
R R
SCOPE : METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)
Initial Risk ITEM
3
ACTIVITY Opera perati tio on Of Of Arei Areial al work Platform (ManLift) ManLift)
HAZARD / POTENTIAL CONSEQUENCES
P
C
Residual Risk
CURRENT CONTROLS
RISK RANK
3.1 Struct Structura urall Filure Filure 3.1.1 C
3.2
Overturning
4
Util Utiliz izin ing g equ equip ipme ment nt for for other purpose
C
3
3
MED
C
R
B
2
LOW
B
2
LOW
B
2
LOW
Proper Training and Certification of the operators handiling the equipment
3.2.2 Avoid Avoid too much inclinat inclination ion of of the Boom
3.2.1. 3.2.1.2 2
Lifiti Lifiting ng plan plan submit submitted ted & approved
3.3.1 3.3.1
Operat Operate e with within in the workin working g ran range ge
3.3.1. 3.3.1.1 1
Only Only traine trained d person personnel nel will will oprate the equipment
3.3.2 Maintain Maintain specific specific area around around the the aerial work platform
3.3.1.2 3.3.1.2
Proper Proper supervisi supervision on during during operation
MED 3.4.1
P
Duly certified certified equipmen equipmentt will will be used
MED
Coll Collis isio ion n with with othe otherr object C
3.4 3.4
MED
3.1.1.1 3.1.1.1
Check conditions of instruments at 3.1.2 regular intervals 3.2.1 Prevent from over loading 3.2.1.1
C
3.3 3.3
4
Ensure equipment reliability & complete inspection
ADDITIONAL CONTROLS
Use equipment fo for sole purpose only
Page 4 of 4
