Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.250.897
2MH127
Tag/Item Number(s):
N/A
Unit(s):
ASU
PCWBS:
LINDE ENGINEERING
Page 2 of 18
5887
03.12.08
SB
EO
AG
RFC
15.11.08
SB
EO
AG
IFR
16.10.08
SB
EO
AG
IFR
14.07.08
SB
EO
AG
RFC
24.05.08
FB
EO
AG
ICC
06.05.08
SB
SB
ZG
ICC
15.04.08
BR
UA
ZG
ICC
24.11.07
BR
AU/MC
ZG
ICC
22.11.07
BR
AU/MC
ZG
IFR
20.11.07
BR
AU/MC
ZG
IIR
Date
Description
GAMA
Rev.
No.
Project
Rev
No.
Status
Document Title:
LINDE ENGINEERING AG
Contractor
LOC470
GAM
MTS
MEC
GTL
002
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Vendor Code
Rev No: G
Q A T A R
Doc. Title
Date
03.12.2008
Rev. J
TABLE OF CONTENTS
1.
PURPOSE _____________________________________________________________________ 5
2.
SCOPE ________________________________________________________________________ 5
3.
HSSE _________________________________________________________________________ 5
4.
REFERENCES _________________________________________________________________ 6
5.
DEFINITIONS _________________________________________________________________ 6
6.
7.
RESPONSIBILITY ______________________________________________________________ 7
8.
9.
MATERIAL: ______________________________________________________________________ 8
PROCEDURE __________________________________________________________________ 9
9.1.
9.2.
TORQUE WRENCHES_____________________________________________________________ 9
10.
10.1.
10.2.
11.
12.
13.
14.
15.
16.
ATTACHMENTS _____________________________________________________________ 13
16.1.
16.2.
JSA _____________________________________________________________________________ 13
T-4.250.897 Rev-G
Page 4 of 18
Q A T A R
Doc. Title
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
activities. Other training courses will be attended as required by LINDE ENGINEERING AG
or QSGTL and/or its PMC as required.
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 Total Safety Task
Instruction (TSTI) and his weekly Tool Box Talk (TBT) will use the JSA.
In addition to the above, employees conducting bolts tightening 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.
T-4.250.897 Rev-G
Page 5 of 18
Q A T A R
Doc. Title
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
&
5. DEFINITIONS
Company
Contractor
: LINDE ENGINEERING AG
Sub Contractor
: GAMA QATAR
Contract
ITP
QCP
QCE
QCI
QA/QC
TPI
Page 6 of 18
Q A T A R
Doc. Title
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
The equipment manager will be responsible for the transporting equipments
availability and good order.
7.4.
SITE ENGINEER
Shall report to Construction Manager
Shall be responsible for planning, execution and implementation of all site
activities related to this procedure
Shall train the Bolt Tightening persons and certificates are to be issued.
7.5.
SITE SUPERVISOR
Shall report to Site Engineer
Shall be responsible for execution of construction activity
Shall also prepare daily site construction records
7.6.
CREW LEADER/FOREMAN
Shall supervise the group of erectors and lead them as per site requirements.
Shall makes reports and keeps records of work accomplished and materials used.
Shall perform related work and will be reporting to the Site supervisor.
T-4.250.897 Rev-G
Page 7 of 18
Q A T A R
7.7.
Doc. Title
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.
8. PROJECT REQUIREMENTS
This method statements deals with tightening of bolt for various type of bolts used in
End Plate Moment Connection
Hanging Type Connections
Brace Connection
Column Splice Joints
And various types of steel cover plates as per DEP 34.28.00.31 & PQP
T.4.234.542
8.1.
MATERIAL:
Fixing bolts shall be of DIN 4017, Grade 8.8 and shall be galvanized. Nuts shall
be Grade 10 and shall be galvanized.
Bolts, nuts and threads shall comply with ISO 4014, ISO 4032 and ISO 888,
respectively. The use of other threads requires prior approval of the Principal.
T-4.250.897 Rev-G
Page 8 of 18
Q A T A R
Doc. Title
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 shall be used in all bolted connections.
9. PROCEDURE
9.1.
9.2.
TORQUE WRENCHES
Torque wrenches shall be calibrated and have a valid certificate that must be
revalidated after the wrench has been inspected and recalibrated on a monthly
basis. A validation sticker confirming inspection and last date of calibration shall
be attached to the torque wrench at all times.
There are various types of tools available to achieve the proper torque value. The
manufacturer's instructions shall be followed for the operation and maintenance of
all Torque wrenches used to perform tightening procedure.
T-4.250.897 Rev-G
Page 9 of 18
Q A T A R
Doc. Title
Date
03.12.2008
Rev. J
S.NO
Bolt
Load (KN)
M12
SPX values
(KN)
35
40
93
M16
70
80
226
M20
110
120
399
M22
130
145
598
M24
150
165
798
M27
200
220
1197
M30
245
270
1596
M36
355
390
2730
Refer document T-4.193.320 for Grade 8.8, hot dip galvanized nuts and bolts from the
vendor.
10.1.
Erection of steel structure shall conform to AISC Code of Standard Practice for
Steel Building and Bridges. Dimension control will be performed i.e. bolt holes,
bolt size, grade, washers and other fasteners.
The preassembly and erection will be done in basically the following steps:
preassembly on the ground, erection with crane(s), stabilization of erected pieces
with guy wires & tri-fore, and/or by crane; installation of the diagonals and purling,
installation of side materials, installation of roof material, then general cleanup.
A maximum of the steel structure will be preassembled on the ground, if
applicable. Preliminary tightening of all nuts and bolts will be carried out using
appropriate hand tools and subsequently with torque wrench for full tightening.
Pre-assembled units will be inspected & certified at the pre-assembly yard by QC
of GAMA and LINDE before erection.
T-4.250.897 Rev-G
Page 10 of 18
Q A T A R
Doc. Title
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 torque 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 1 and 3 threads.
Page 11 of 18
Q A T A R
Doc. Title
Date
03.12.2008
Rev. J
T-4.250.897 Rev-G
Page 12 of 18
Q A T A R
Doc. Title
Date
03.12.2008
Rev. J
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 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 QCRs.
16. ATTACHMENTS
16.1. BOLT TIGHTENING INSPECTION REPORT
16.2. JSA
T-4.250.897 Rev-G
Page 13 of 18
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
Q A T A R
NEW
Page No: 1 of 4
REVISED
03.12.08
Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager).
Name
Signature
Discipline Superindent (LINDE)
HSSE Representative (LINDE)
OTHERS(List Below):
Date
Approval required for hazardous work detailed in the LINDE work permit procedure.
Changing conditions and emergency procedures: Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work.
LINDE EMERGENCY TELEPHONE NO.
HSSE MANAGER
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 Hygienist must also approve the work.
2) Use additional sheets as necessary.
3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and SHELL Safety and Environment Procedures.
Q
Q A
A T
T A
A R
R
Initial Risk
ITEM
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
Bolts tightening
1.1
during pre-assembly
of structural steel
members
Residual Risk
CURRENT
CONTROLS
RISK
RANK
1.1.1
B
2 #####
1.1.2
1.1.3
1.2
Pinch point.
1.2.1
1.2.2
B
2 #####
1.2.3
1.2.4
1.3
1.3.1
1.3.2
1.3.3
B
2 #####
1.3.4
1.3.5
1.3.6
2.1.1
2.1.2
B
3 #####
2.1.3
ADDITIONAL
CONTROLS
3 #####
Page 2 of 4
Q
Q A
A T
T A
A R
R
Initial Risk
ITEM
ACTIVITY
HAZARD / POTENTIAL
CONSEQUENCES
2.2
Residual Risk
CURRENT
CONTROLS
RISK
RANK
Fall of working
personnel at height.
2.2.1
2.2.2
2.2.3
B
2.2.4
2.2.5
2.3
Wind hazards.
2.3.1
2 #####
2.3.2
ADDITIONAL
CONTROLS
2.2.1.1
2.2.1.2
2.2.1.3
4 #####
Page 3 of 4
Q
Q A
A T
T A
A R
R
Initial Risk
ITEM
ACTIVITY
Operation Of Areial
work Platform
(ManLift)
HAZARD / POTENTIAL
CONSEQUENCES
Residual Risk
CURRENT
CONTROLS
RISK
RANK
3.2
3.1.2
3.2.1
3.1.1.1
MED
LOW
LOW
LOW
3.2.2
3.2.1.2
3.3.1
3.3.1.1
3.3.2
3.3.1.2
MED 3.4.1
MED
3.4
MED
Overturning
3.3
ADDITIONAL
CONTROLS
Page 4 of 4