Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No: 5887

Project Document Number: T- 4.251.018 Project Rev.: A Page 2 of 11

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

E A 07.01.09 Ready for Construction SB EO AG RFC

D O 24.07.08 Issued for Company Comments SB EO AG ICC

C O 05.07.08 Issued for Company Comments RT MK AG ICC

B 03.07.08 Issued for Review RT MK AG IFR

A 02.07.08 Issued for Internal Review RT MK AG IIR

GAMA Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDEGINEERING AG

Document Title:

PROCEDURE - STRUCTURAL STEEL REPAIR WORKS AT SITE

Contractor

Gama Qatar Co. W. L. L.

Document No. LOC470 GAM PRO GEN GTL 035 E

Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T-4.251.018

Rev No: A

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 4 of 11

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TABLE OF CONTENTS

1 SCOPE.......................................................................................................................................5

2 PURPOSE .................................................................................................................................5

3 HSSE ..........................................................................................................................................5

4 REFERENCE & DEFINITIONS: ............................................................................................5

5 RESPONSIBILITIES ...............................................................................................................6

5.1 SITE MANAGER ......................................................................................................................... 6

5.2 MECHANICAL ERECTION MANAGER ................................................................................ 6

5.3 SITE ENGINEER ......................................................................................................................... 6

5.4 SITE SUPERVISOR .................................................................................................................... 6

5.5 QC INSPECTOR .......................................................................................................................... 7

The QC Inspector will be responsible for, ............................................................................................... 7

5.6 WELDING ENGINEER .............................................................................................................. 7

The Welding Engineer will be responsible for, ....................................................................................... 7

6 DESCRIPTION AND MEASURES ........................................................................................7

6.1 PRECAUTIONS ........................................................................................................................... 7

6.2 DESCRIPTION OF FAULTS ..................................................................................................... 8

6.3 MEASURES .................................................................................................................................. 8

6.4 REPAIR AND MODIFICATIONS ............................................................................................. 8

6.5 SURFACE PREPARATION ....................................................................................................... 9

6.6 REPAIR OF DAMAGED GALVANISING ............................................................................... 9

6.7 EQUIPMENT ............................................................................................................................. 10

7 CALIBRATION .......................................................................................................................10

8 INSPECTION ..........................................................................................................................10

8.1 TESTING .................................................................................................................................... 10 8.1.1 VISUAL INSPECTION ......................................................................................................................... 10 8.1.2 REPAIR OF PAINTING ....................................................................................................................... 10

9 RECORDING ..........................................................................................................................10

10 QUALITY ASSURANCE...................................................................................................11

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 5 of 11

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1 SCOPE

This Procedure covers mainly for the Minor and Major modifications or repair of structural members for Pipe Racks, Air Cooled Condenser and other project Substructures to be carried out as part of the Construction Works at C2 ASU Pearl GTL Project by GAMA Qatar situated in Ras Laffan Industrial City (RLIC) in Qatar.

2 PURPOSE

The main purpose of this Procedure is to describe the minimum requirements and responsibilities of activities associated with the modification or repair works of steel structures to ensure that the activities are carried out according to the project requirements.

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 go 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 Construction Group 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.

4 REFERENCE & DEFINITIONS:

a) Reference: DEP 34.28.00.31 : Structural Steel. DEP 30.48.00.10 : Painting and Coating of new Equipment. T-4.132.876 : Tech. Specifications for Metal works. T-4.250.927 : Material Handling, Storage and Preservation Procedure T-4.250-915 : Calibration Procedure T-4.250.900 : Method Statement for Painting and Repair Works. T-4.250.896 : Method Statement for Steel Structure Assembly & Erection. T-4.250.917 : ITP for Steel Structure. AWS D1.1 : Structural Welding Code Steel EN ISO 1461 : Metallic hot-dip galvanized coatings on Fabricated Products

SSPC-SP1 : Solvent cleaning SSPC-SP2 : Hand tool cleaning SSPC-SP3 : Power tool cleaning

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 6 of 11

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b) Definitions :

Company : QSGTL/or its PMC Contractor : LINDE ENGINEERING AG Sub Contractor : GAMA QATAR Contract : C2 ASU PEARL GTL Project ITP : Inspection and Test Plan QA/QC : Quality Assurance / Quality Control TPI : Third Party Inspection

5 RESPONSIBILITIES

5.1 SITE MANAGER

The Site Manager will provide inputs to the project execution plan to ensure that strategies & philosophy of the project are properly addressed.

5.2 MECHANICAL ERECTION MANAGER

The Mechanical Erection Manager is responsible for the overall management of the Project Construction team to ensure that safe and effective operations are conducted and properly documented.

5.3 SITE ENGINEER

The Site Engineer will be overall responsible for safe execution of the whole job including:

Confirming the installation location from schedule of approved construction drawings.

Organizing of equipments and tools needed for the job.

Assigning skilled personnel for the job.

Sequence of activities to be carried out for the work as per this procedure

Conduct inspection and surveillance.

Notify to Contractors engineer for inspection as applicable.

Ensure that all Contractor and Company regulations are followed.

Ensure that all personnel involved are in safe working condition at all times.

5.4 SITE SUPERVISOR

The Site Supervisor will be responsible for safe execution of the following activities:

Conduct TSTI with the concerned work force prior to start of work.

Ensure that relevant work permits for the job are obtained prior to start of work.

Conduct daily toolbox talks for the entire work force prior to start day work.

Assigning a competent work crew for specific activities, details of activities and task information will be given to the work crew.

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 7 of 11

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Organizing tools and equipment needed to the work site.

Inspection and supervision of work.

Ensure that all Contractor and Company safety regulations are followed as applicable.

5.5 QC INSPECTOR

The QC Inspector will be responsible for,

Verify identification of paint and correct preservation

Perform inspection on the surface before and after touch up according to procedure, specification and GAMA QATAR ITP requirements.

Notification to contractor 24 hours before the touch up operation indicated in the ITP.

Issue and sign the record and providing for contractor inspector signature of record as required.

Verify batch number, expire date, shelf life against Material Certificates and Material Data Sheets.

Ensure that the paint is not used after expiry date or shelf life.

Ensure that climatic conditions are suitable for surface preparation and painting.

Assigning a competent work crew for specific activities, details of activities and task information will be given to the work crew.

Organizing tools and equipment needed to the work site.

Inspection and supervision of work.

Ensure that all Contractor and Company safety regulations are followed as applicable.

5.6 WELDING ENGINEER

The Welding Engineer will be responsible for,

Ensure that the hot works are carried out according to the WPS procedure

6 DESCRIPTION AND MEASURES

6.1 PRECAUTIONS

Upon receipt of materials or structures, numbers and markings of components against the packing list or erection drawings and will be visually inspected all the components for damage or other unacceptable conditions; these are hole size and number and dimensions not matching as per drawing

When deficiencies are found on the components, structure shall be immediately segregated from the construction/erection work to prevent inadvertent use until repaired and/or re fabricated. The same shall be applicable for site revision requirements

Materials shall be handled by means of cranage or any suitable and acceptable equipment for material handling

Materials shall never be dragged or towed on the ground during full phase of the loading and unloading sequence

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 8 of 11

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All structures shall be handled by utilizing tools and equipment of adequate safe capacity

Prior to erection, all material surfaces shall be checked for cleanliness and cleaned of any mill scale, dust, oil etc.

The Contractor will be informed before starting any repair activity at site. Required forms will be filled up and documented

6.2 DESCRIPTION OF FAULTS

The following cases are normally encountered but not limited to:

Repair of structural member or members which are damaged during transportation

Repair of steel structure surfaces which are damaged during transport and/or mechanical or chemical reason

Repair of structural members which are damaged during erection

Repair is required if there is a mismatch as plan during fabrication stage

Repair is required if there is a mismatch during erection stage

6.3 MEASURES

Minor Modification modification or repair if the steel member or members requires minor repairs e.g. cutting of plates and welding as replacement for the member; building up or patch up, and re drilling for bolt holes, surface preparation prior to touch up etc.

Major Modification modification or repair if the structural member and/or members require extending or shortening and require complete replacement.

Ensure that the option of either repairing on welded areas due to damage or removing and replacing the entire weld except as modified by AWS D1.1 clause 5.26.3.

The repaired or replaced weld shall be retested by the method originally used, and the same technique and quality acceptance criteria shall be applied.

6.4 REPAIR AND MODIFICATIONS

When additional new holes are required for the erection of column, beam, girder, connecting plates will be performed at site or workshop with the correct equipment

When bracket, end and connecting plate or cleat are required to be cut; or additional piece will be fabricated, and welded in-situ by qualified welder

When new plates are to be cut and welded, edges has to be grinded and smoothen prior for touch up.

When plates or brackets are bend, it will be hammered or hydraulic press can be applied to align the component/s

When brackets, end plates, cleats are to be cut or additional new piece will be fabricated, they will be welded at site by qualified welders

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 9 of 11

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Ensure that the welding flux and spatter remaining shall be removed by grinding or other suitable company mechanical means.

When new materials have to be used for the modification and or repair of structural steel, these materials shall be identical to the material of the structural steel and a certificate to prove this is required.

There shall further be in place / available for the repair and or modification works an approved welding procedure , approved welding consumables , approved (qualified) welders and last but least:

1) All site repairs shall be approved by the Contractors Structural Steel Engineers.

2) All site modifications shall be approved by the Structural Steel Design Engineers.

3) The flaw register shall be maintained for repair and or modification works including material certificates for new materials, galvanizing repair details, and related drawings indicating the location of repair.

4) All bolt holes not used, due to repair and or modification shall be fill welded and made smooth surface.

6.5 SURFACE PREPARATION

The surfaces shall be cleaned with following operations:

For structural steelwork which has sustained mechanical damage during either transportation or erection:

Solvent cleaning: all the surfaces shall be removed from foreign matter as oil, grease, soil, salts or other contaminants by solvents, emulsions, fresh water or other suitable method. Compressed air can also be used to remove hard headed stains etc.

The surface can be cleaned by electric or air operated power wire brushes and or power disc or needle guns.

Sand blasting treatment shall not be used for cleaning.

Ensure that the surface finish shall be as per BS 7079 and to a visual standard.

Surface preparation shall extend onto the undamaged galvanized coating for approximately 25mm overlapping. After cleaning dry air shall be blown on the surfaces.

6.6 REPAIR OF DAMAGED GALVANISING

Damaged hot dip galvanised coating shall be repaired as follows:

Corrosion or other damage shall be removed using light sweeps of an orbital sander.

A 25mm band of sound galvanizing around the damaged area shall be carefully feathered down to bare steel.

Residual oil or grease within the repair zone will be removed using a patent degreaser in accordance with the manufacturers recommendations.

On completion preparation surfaces shall be scrubbed and rinsed with fresh water.

When the areas to be repaired for coating are fully dry.

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 10 of 11

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Zinc rich paint (RESISTEX L722 or approved equal) shall be brush applied in accordance with the manufacturers instructions to achieve the same thickness as that of the original galvanizing (minimum 100 microns DFT).

The repair coating shall be overlapped onto the feathered edge of the existing galvanising

Ensure that the compatibility of the coating material, when the materials shall be purchased from different manufactures.

When items of steel work are difficult to repair after complete erection (or) when the program of erection work is such that, the repairing treatment may perform prior to erection. This shall be implemented after getting approval from company.

6.7 EQUIPMENT

Suitable equipment for cutting, drilling, grinding and other machine shop works shall be in correct capacity

For touch-up or repairs to the localised damaged areas, weld or other irregular surfaces, provided that the manufacturer considers the painting material suitable for brush or roller shall be used for small areas in accordance with the Manufactures recommendations.

Spray equipment shall be in compliance with the painting manufacturer's instructions (e.g. nozzle tips, spray angle, pressure etc.).

7 CALIBRATION

All inspection, measuring and test equipment shall be calibrated in accordance with Gama-Qatar Equipment and instrument calibration procedure T-4.250-915.

8 INSPECTION

All materials, components of structure covered will be subject for further inspection and in concurrence by the Contractor, whether works carried out are in accordance to this procedure and applicable ITPs. If found any damage during Transportation, handling and / during erection that shall be rectified as per company specification & DEP 34.28.00.31

8.1 TESTING

8.1.1 VISUAL INSPECTION

Painting film should be inspected visually after application in order to verify that the whole surface is free of defects as: blister, forces, flaking mechanical damage, sags.

8.1.2 REPAIR OF PAINTING

Defective or damaged paintings shall be removed by hand tools or power tool until a surface is cleaned and the new layer of paint can apply.

9 RECORDING

Accordingly, the activities shall be recorded in QCR Forms mentioned relevant Method Statement and GAM-QCR-QAC-GTL-031- Painting Coating Check List & GAM-QCR-QAC-GTL-097- Welding Repair Authorization

Doc. Title GAM-PRO-GEN-GTL-035

Procedure - Structural Steel Repair works at site

Date / Rev. 07 January 2009

/ Rev - E

T-4.251.018, Rev. A Page 11 of 11

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10 QUALITY ASSURANCE

A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented through relevant QCP-T-4.250.916, ITP- T-4.250.919 and QCRs.