002-bolt tightening (structural).pdf

Pearl GTL Project

LINDE ENGINEERING

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

Project Document Number: T- 4.250.897 Project Rev.: G Page 2 of 18

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

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

GAMA Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)

Contractor

Gama Qatar Co. W. L. L.

Document No. LOC470

GAM MTS MEC GTL 002 J

Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T- 4.250.897 Rev No: G

Doc. Title : METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)

Date : 03.12.2008 Rev. J

T-4.250.897 Rev-G Page 4 of 18

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TABLE OF CONTENTS

1. PURPOSE _____________________________________________________________________ 5

2. SCOPE ________________________________________________________________________ 5

3. HSSE _________________________________________________________________________ 5

4. REFERENCES _________________________________________________________________ 6

5. DEFINITIONS _________________________________________________________________ 6

6. TOOLS & PLANTS ______________________________________________________________ 6

7. RESPONSIBILITY ______________________________________________________________ 7

8. PROJECT REQUIREMENTS _____________________________________________________ 8

8.1. MATERIAL: ______________________________________________________________________ 8

9. PROCEDURE __________________________________________________________________ 9

9.1. PRE ASSEMBLY INSPECTION _____________________________________________________ 9

9.2. TORQUE WRENCHES _____________________________________________________________ 9

10. STRUCTURAL STEEL BOLT REQUIREMENTS ___________________________________ 9

10.1. PREASSEMBLY & ERECTION ____________________________________________________ 10

10.2. STRUCTURAL ERECTION _______________________________________________________ 10

11. JOINT TIGHTENING PROCEDURE ____________________________________________ 11

12. TRAINING FOR BOLT TIGHTENERS __________________________________________ 11

13. METHOD OF TIGHTENING OF BOLTS ________________________________________ 11

14. TORQUE VALUES ___________________________________________________________ 12

15. QUALITY ASSURANCE _______________________________________________________ 13

16. ATTACHMENTS _____________________________________________________________ 13

16.1. BOLT TIGHTENING INSPECTION REPORT _______________________________________ 13

16.2. JSA _____________________________________________________________________________ 13


Date : 03.12.2008 Rev. J

T-4.250.897 Rev-G Page 5 of 18

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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.


Date : 03.12.2008 Rev. J

T-4.250.897 Rev-G Page 6 of 18

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4. REFERENCES

DEP 34.28.00.31 : Steel Structures (Ammendments-T-13-376-359E)

34-00-01-30 : Minimum Requirements For Structural Design & Engineering (Ammendments-T.13.376.351G)

T-4.234.542 : Project Quality Plan

T-4.250.917 : ITP For Structural Steel

T.13.377.578G : Project specification PART IV Procedures and Requirements Chapter 10 - Flawless Start-Up

T-13.377.454 : Preservation of Old and New Equipment Standing Idle

5. DEFINITIONS

Company : QSGTL/or its PMC

Contractor : LINDE ENGINEERING AG

Sub Contractor : GAMA QATAR

Contract : QSGTL Pearl Plant - C2 ASU Project

ITP : Inspection and Test Plan

QCP : Quality Control Procedure

QCE : Quality Control Engineer

QCI : Quality Control Inspector

QA/QC : Quality Assurance / Quality Control

TPI : Third Party Inspection

6. TOOLS & PLANTS

Calibrated Torque wrenches

Feeler gage

Hammer

Spanners

Man Lift(Drop bar or chain is not used for bolt tightening work)

Trailers

Crane ( Approved Capacity)


Date : 03.12.2008 Rev. J

T-4.250.897 Rev-G Page 7 of 18

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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.


Date : 03.12.2008 Rev. J

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7.7. 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.

7.12. BOLT TIGHTENER

All the bolt tightening persons are to be trained and certified. They will be trained regarding relevant points of FSI.

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.


Date : 03.12.2008 Rev. J

T-4.250.897 Rev-G Page 9 of 18

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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. 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. 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.

10. STRUCTURAL STEEL BOLT REQUIREMENTS

Unless otherwise stated in Standard Drawings the minimum bolt diameters shall be:

For structural components 20mm 27mm

For walkway structures, joist etc. 16mm

For hand rails and ladders 12mm


Date : 03.12.2008 Rev. J

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S.NO Quality of bolts, 8.8

grade Dimensions

Bolt

Load (KN)

SPX values (KN)

Dry Torque (N-m)

1 M12 35 40 93

2 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 for Grade 8.8, hot dip galvanized nuts and bolts from the

vendor.

10.1. PREASSEMBLY & ERECTION

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.

10.2. STRUCTURAL ERECTION

During erection of Structure, each joint that shall be installed and checked by a qualified Bolt lightener/GAMA/LINDE QC inspector to confirm the following:


Date : 03.12.2008 Rev. J

T-4.250.897 Rev-G Page 11 of 18

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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.

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.

12. TRAINING FOR BOLT TIGHTNERS

The Bolt Tightening training will be made in presence of Gama QC Engineer /

Inspector and LINDE QC Engineer/ Inspector.

The Training will be with approved & calibrated torque wrenches and tools at

Gama pre-fabrication yard.

During training the torque will be observed in the stage of 50%, 80% and 100%.

The Successful candidates will be allowed to field for bolt tightening work after

issuing the ID card by Gama QC and Linde QC.

The method of bolt tightening is as per this method statement Clause 14 will be

followed.

13. METHOD OF TIGHTENING OF BOLTS

The following procedure shall be used for each successive step when wrench tightening bolts:

The bolts shall be torque tightened to the initial wrench torque value that applies 50% of the required bolt stress (see 15 below), either simultaneously in pairs by


Date : 03.12.2008 Rev. J

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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 steps. A typical torque table is shown below.

When completed the tables shall be reduced to pocket-size and issued to all Bolt tighteners, foremen and inspectors in a laminated format.

WRENCH TORQUE VALUES (Sample Table)

Bolt Size (mm)

TARGET TORQUE (N-m)

Initial Step (50% bolt stress)

Intermediate Step (80% bolt stress)

Final Step (100% bolt stress)

M12 46 74 93

M16 113 180 226

M20 199 319 399

M22 299 478 598

M24 399 638 798

M27 598 957 1197

M30 798 1276 1596

M36 1365 2184 2730


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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 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-T-4.250.907, ITP - T-4.250.917 and QCRs.

16. ATTACHMENTS

16.1. BOLT TIGHTENING INSPECTION REPORT

16.2. JSA

GAM-QCR-QAC-GTL-041

C2 ASU PEARL GTL PROJECT

RASLAFFAN INDUSTRIAL CITY

BOLT TIGHTENING INSPECTION REPORT

Subcontract Ref.: Report No.:

Item 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 Bolt Tightening (Torque Value)

Inspectors Signature Grade Size

ORGANIZATIONS DATE NAME SIGNATURE

Accepte

d B

y THIRD PARTY REP.

GAMA REP.

LINDE REP.

QSGTL OR its PMC REP.

JSA Number: T.4.250.897

Normal Approvals: Name Date

JSA by: Mr. Atila GUN 03.12.08

Job Supervisor: 03.12.08

Name Date

Discipline Superindent (LINDE)

HSSE Representative (LINDE)

2.Permit To Work.

LINDE EMERGENCY TELEPHONE NO. HSSE MANAGER 583 40 72

PEARL HOT LINE: 474 88 88

OTHERS(List Below):

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.

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.

Signature General job requirements / Common Personnal

Protective Equipment.

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.

Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager).

Signature

JOB SAFETY ANALYSIS / RISK ASSESSMENT

Page No: 1 of 4

Job being analysed: METHOD STATEMENT FOR BOLT TIGHTENING (STRUCTURAL)

Department/Section doing JSA:HSE & Mechanical Works JSA Members:Mr. Syd Osborne, Mr. Atila Gtn,

Job Performers:Mr. Atila Gtn,

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NEW REVISED

RISK

RANK

1 1.1 Hand and finger injury. 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.

1.2 Pinch point. Ensure that all hand tools are in

good condition.

Ensure qualified/ competent

employee to carry out the task.

Use the right tools for the job.

Keep away hand & finger from any

pinch point hazard.

1.3 Improper use of tool. All tools shall be inspected &

colour coded with the approved by

LINDE.Use the right tool for the job.

Operate tools according to

manufacturers instruction.Use appropriate personnel

protective equipment.

Perform maintenance on tools

regularly.

Cheater bar are not allowed use as

an extension for tightening bolts.

Falls of materials &

tools.

2.1.1 Install barricades "exclusion zone"

and secure the area with sign

boards to prevent unauthorized

entry.

2.1.1.1 Ensure to provide safety nets,

toe boards.

2.1.2 All materials shall be safety

lowered from one level to the next

either by hand-to-hand or by

securily attaching a rope and

hauling.

2.1.3 Tools shall be tied by a retaining

rope attached to the harness.

#####3A

#####2B

B 3 #####

ITEM

SCOPE : METHOD STATEMENT FOR BOLT

TIGHTENING (STRUCTURAL)

Initial Risk Residual Risk

ACTIVITY P CCONTROLS

ADDITIONALR


T.4.250.897

CONSEQUENCES

HAZARD / POTENTIAL

CONTROLS

CURRENTP C

Bolts tightening

during pre-assembly

of structural steel

members

2.1Bolts torqueing final

tightening after

erection of structural

steel members

2

1.1.1

1.1.2

1.1.3

1.2.1

1.2.2

1.2.3

1.2.4

1.3.1

1.3.2

1.3.3

1.3.4

1.3.5

1.3.6

#####

#####2B

B 2

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Page 2 of 4

RISK

RANKITEM





ADDITIONALR


T.4.250.897

CONSEQUENCES

HAZARD / POTENTIAL

CONTROLS

CURRENTP C

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2.2 2.2.1 Ensure all materials, tools,and

equipment are kept secure at all

times.2.2.2 Install lifting apparatuses such as

gin wheel and hoisting rope for

lifting pieces of materials.

2.2.3 Full body harness and lanyards

shall be inspected.

2.2.4 All employees shall wear inspected

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.

2.2.5 Ensure housekeeping is done

regularly to maintain walkway free

of hazards.

2.3.1 Monitor wind speed using

Anemometer. Crane operations

should be stopped if wind speed

exceeds 25 knots or as stipulated

by crane manufacturer, which ever

is lower.

2.3.2 Employees should be aware of the

affect of weather conditions on the

operation.

B #####4A

Ensure 100% fall protection.

Ensure that all employees

working at height are properly

trained.

Discuss working at height

hazards at daily TSTI.

2.2.1.1

2.2.1.2

2.2.1.3

2.3

Fall of working

personnel at height.

B

Wind hazards.

4

#####2

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Page 3 of 4

RISK

RANKITEM





ADDITIONALR


T.4.250.897

CONSEQUENCES

HAZARD / POTENTIAL

CONTROLS

CURRENTP C

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3.1.1Ensure equipment reliability &

complete inspection

3.1.1.1 Duly certified equipment will be

used

3.1.2

Check conditions of instruments at

regular intervals

3.2 Overturning 3.2.1 Prevent from over loading 3.2.1.1 Proper Training and

Certification of the operators

handiling the equipment

3.2.2 Avoid too much inclination of the

Boom

3.2.1.2 Lifiting plan submitted &

approved

3.3 Collision with other

object

3.3.1 Operate within the working range 3.3.1.1 Only trained personnel will

oprate the equipment

3.3.2 Maintain specific area around the

aerial work platform

3.3.1.2 Proper supervision during

operation

3.4 Utilizing equipment for

other purpose

C 3 MED 3.4.1 Use equipment for sole purpose

only

LOW2B

B 2 LOW

B 2 LOW

3 Operation Of Areial

work Platform

(ManLift)

C 4

3.1 Structural Filure

C 4

C 3 MED

MED

MED

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Page 4 of 4

002-bolt tightening (structural).pdf

Documents

project requirements

qat contractor project

method of tightening

review sb eo ag ifr

review br aumc zg ifr

construction sb eo ag

project rev date description

construction sb eo ag