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METHOD STATEMENT No : 04
METHOD STATEMENT No: 04 FABRICATION AND INSTALLATION OF STEEL STRUCTURE SUPPORT (SPS-B065-099) FOR 52-K0624
00
JER
MIS
Rev.
Comments
Date
Prepared by
Checked by
Approved by QG
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INDEX
1. 2. 3. 4. 5. 6. 7. 8.
PURPOSE SCOPE REFERENCES DEFINITIONS RESPONSIBILITIES PROCEDURE TOOLS AND EQUIPMENTS SAFETY INSTRUCTIONS
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2.
SCOPE The scope of this method statement covers following activities of shop fabrication and installation of steel structure: Material handling Lay Out and Marking Off Cutting Grinding Fit Up Welding Painting
3.
REFERENCES 3.1 PROJECT DRAWINGS 3.2 Shop drawings. Supporting structure detail drawing.
3.3
PROJECT QUALITY PLAN Inspection / testing shall be done in accordance with ITP.
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3.4
4.
RESPONSIBILITIES
It is overall responsibility of PM to organize resources to perform fabrication activities as per project specification, in compliance with quality, schedule & safety requirements. DESCON will ensure that all the works are performed safely as per latest Approved for Construction (IFC) drawings & specifications. The relevant Engineer and Supervisor will ensure that all the work is conducted in accordance with this method statement and project specification. The QC Inspector will ensure that all work is executed according to QCP and that requirements of quality dossier are full filled. Safety and Construction supervision will be carried out under responsibility of Contractor and Company may provide guidance if necessary.
5.
warehouse and placed on wooden supports. The material will be properly marked to identify the structure for which it is intended.
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Material handling shall be carried out in a manner to maintain identification When raw steel material is delivered, material controller shall confirm that
and to prevent damage. there is no shortage/damage of material as given in the packing list and that there is no damaged items. All materials shall be inspected and reviewed as per Company procedure. A logbook shall be maintained for all materials received showing following information:
Member identification marks and quantity. Quantity of fasteners, classified in accordance with designations, size, length etc. All fasteners shall be delivered in boxes and clearly marked with labels as per the requirements and specifications. Bags with tags can be used in case of small quantities of fasteners.
5.2
STRAIGHTENING Steel structure raw material shall be checked as per standards and specifications for straightness before shifting from warehouse to fabrication shop. Any damaged or distorted material shall not be shifted. Steel may be repaired or corrected subject to the prior approval of the client.
The marking off of steel structure will be done according to the shop drawings. In case a large number of identical items are required then templates can be used. The use of chisels or center punches for marking on materials shall be such that the material is not damaged. Completed member shall be tagged with drawing no. and member no.
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5.8 ASSEMBLING The component part shall be assembled in such a manner that they are neither twisted nor damaged.
5.9 TOLERANCES Tolerances for shop fabrication of steel structure shall be according to the design drawing and steel structure specifications.
6. WELDING Production welding/ workmanship and finishing shall be performed by utilizing following: -
Under control condition. In accordance with approved (WPS) welding procedure specification. By qualified welders approved by client.
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cracks and other discontinuities that affect the quality or strength of the weld. Surfaces to be welded and adjacent areas shall be free from loose or thick scale, slag, moisture, grease, rust, paint, and other foreign material.
6.0.2 DISTORTION AND SHRINKAGE In assembling and joining parts of a member or in welding reinforcing parts to member, the sequence and procedure shall be adopted so as to minimize distortion and shrinkage. Welds shall be made in a sequence that will balance the applied heat of welding while the welding is in progress. Before welding starts, welding sequence shall be established for members or structure.
Two welder will be used where the continuous welding all around the member
to avoid bending.
6.0.3
EXECUTION OF WELDING
Welding electrodes shall be properly handled at all the times. Electrodes having defects such as peeling of coating materials, stains, degradation, humidity, rusts, etc shall not be used. Welding electrodes shall be used as per the manufacturer recommendations. Welding shall be done continuously without incomplete penetration around the corner.
6.0.4
WELD CLEANING
Before welding over previously deposited metal, all slag shall be removed and
adjacent base metal shall be brushed clean properly. Slag shall be removed from all completed welds by wire brush. Spatter remaining after the cleaning operation shall be removed by chipping.
6.0.5
Die stamp markings are sometimes difficult to see, painted marking shall also be applied to all completed members prior to shifting so that they will become easily recognizable.
6.0.6
Testing and inspection shall be according to the approved Inspection test plan
(ITP). After welding 10% MPI will be carried out for piping supports / structure.
6.0.7 GALVANIZING
After final acceptance of structure by quality control shall be released for
8. SAFETY INSTRUCTIONS
During execution of the job all safety measure shall be adopted to ensure safe working. All personnel involved will use necessary PPE as required. The workers will be made aware of safety requirements related to this activity Safety notice board will be installed. All equipment will be inspected by HSE (Descon) prior to use. During transportation of the steel structure the members shall be properly During lifting of steel structure no body shall be allowed to work underneath. All lifting tackle will be inspected by HSE (DESCON) according to project requirement. Access and good housekeeping should be maintained at site. Fire extinguisher should be available in working area. All cylinders shall be kept in trolleys and in an upright position. Welding sets should be checked and maintained regularly for wear and tear.
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