specifications of steel works

File name: PE-D-DJ1784-CS-SPC-002-F0-E.docx

Contractor: FRAMEWORK AGREEMENT FOR ENGINEERING,

PROCUREMENT SERVICES AND CONSTRUCTION MANAGEMENT FOR SURFACE

FACILITIES

Company:

Framework Agreement no.: 84600146009 Company Job. No.: DJ1784

Contractor doc. no.: Contractor Job. No.: 11J01917 Company doc. no.:

11J01917-CIV-SP-000-002 Sheet 1 of 29 PE-D-DJ1784-CS-SPC-002-F0-E

FRD OIL PROJECTS STANDARDS

GENERAL SPECIFICATION FOR

EXECUTION OF STEEL WORKS

F0 12-11-2012 Final Issue N. Cristian M. Popa W. Ricciatti

D0 30-10-2012 Issued for Company Approval N. Cristian M. Popa W. Ricciatti

C0 29-06-2012 Issued for Company Review N. Cristian M. Popa W. Ricciatti

REV. DATE REVISION TITLE EN. PREP. EN. CHECK. EN. APP. COMP. APP.

FRD OIL PROJECTS STANDARDS GENERAL SPECIFICATION FOR EXECUTION OF STEEL WORKS

Contractor doc. no.: Rev.: C0 D0 F0 Company doc. no.:



INDEX

1 Preface ......................................................................................................................................... 4

2 General ......................................................................................................................................... 5

2.1 Scope of Document ............................................................................................................... 5

2.2 Definitions .............................................................................................................................. 5

2.3 Applicable Codes and Standards ........................................................................................... 6

2.4 Legislation of Labour Safety and Health ................................................................................ 6

2.5 Conflicting Requirements, Exceptions .................................................................................... 8

2.6 Unit of Measurement ............................................................................................................. 8

2.7 Language............................................................................................................................... 8

3 Steel Structures Execution ............................................................................................................ 9

3.1 General .................................................................................................................................. 9

3.2 Important Category and Class of Steel Structure ................................................................... 9

3.3 Materials ................................................................................................................................ 9

3.3.1 Materials for profiles ....................................................................................................... 9

3.3.2 Materials for connections .............................................................................................. 10

3.3.3 Materials for grating ...................................................................................................... 11

3.3.4 Materials for welds ........................................................................................................ 11

3.4 Category of Execution for Steel Structures .......................................................................... 12

3.5 Technical Documentation for Execution and Installing ......................................................... 12

3.5.1 Detail Design Documentation........................................................................................ 12

3.5.2 Technical Documentation to be Prepared by Factory .................................................... 13

3.5.3 Technical documentation prepared by Company who install the steel structure ............ 14

3.6 Technical Conditions for Shop execution ............................................................................. 14

3.6.1 General ......................................................................................................................... 14

3.6.2 Preparation of Rolled .................................................................................................... 15

3.6.3 Tracing ......................................................................................................................... 15

3.6.4 Rolled Processing ......................................................................................................... 15

3.6.5 Quality control after cutting, straightening and edges processing .................................. 16

3.6.6 Assemble ...................................................................................................................... 17

3.6.7 Pieces assembling in order to welding (temporary assembly) ....................................... 17

3.6.8 Quality control after assembly and temporary clamping ................................................ 17

3.6.9 Welding steel assemblies ............................................................................................. 17

3.6.10 Welding operation ......................................................................................................... 19

3.6.11 Manual welding ............................................................................................................. 19

3.6.12 Automatic welding ......................................................................................................... 20





3.6.13 Quality conditions of pieces, elements, assemblies and seams .................................... 20

3.6.14 Other works after assembly .......................................................................................... 21

3.7 Technical Conditions for Site execution ............................................................................... 21

3.7.1 Assembly and installation of steel structures made in workshop ................................... 21

3.7.2 Welded Connections ..................................................................................................... 21

3.7.3 Bolted Connections ....................................................................................................... 22

3.7.4 High-strength bolted connections .................................................................................. 22

3.7.5 Check of execution ....................................................................................................... 24

3.7.6 Records specification to installation of metal structures ................................................ 24

3.8 Reception of construction works .......................................................................................... 24

3.9 Final provisions .................................................................................................................... 24

3.10 Corrosion Protection ............................................................................................................ 25

4 Measures for compliance with safety and health during work ...................................................... 27

5 Quality tracking program concept ............................................................................................... 28

5.1 General ................................................................................................................................ 28

5.2 Quality Tracking Program Concept of Civil Works ................................................................ 28





1 PREFACE

This specification has been prepared by Contractor within a standardization program that has been introduced by Company with the aim of harmonising the design of steel structures for all the FRD Oil Projects. Being not submitted for approval to the Company Committee, this specification CAN NOT be considered as Company Standards and its validity is therefore limited to the FRD Oil Projects, for which it has been prepared, that will be developed by Contractor within the Framework Agreement Contract.





2 GENERAL

2.1 Scope of Document

This Specification defines general requirements for the supply, construction, testing, delivery of steel works to be installed in OMV Petrom S.A. production facilities in Romania.

The steel structures shall be designed, manufactured, inspected, tested and supplied in accordance with this specification and the referenced applicable codes and standard. This specification shall be read in conjunction with the latest revision of the applicable project documents.

The General Contractor must demonstrate the ability to achieve quality work in conditions required by law and provisions of this specification.

These Specifications were developed in accordance with Law 10/1995 on the quality of construction works to achieve adequate quality.

2.2 Definitions

The following definitions will be used in this document without the need of any further explanation: Company/Principal: OMV Petrom S.A. Contractor: ENERECO Spa. The Engineering Firm awarded by the

Company for the Framework Agreement for Engineering, Procurement Services and Construction Management for Surface Facilities

Contract: the Framework Agreement for Engineering, Procurement

Services and Construction Management for Surface Facilities

Project: is any FRD Oil Project who this specification applies to. Job: is any Job within the FRD Oil Project who this

specification applies to. Package Contractors: any third Party/Entity that will be charged by Company for

the Design, Fabrication, Site Erection, Commissioning and Start-Up of packaged process units and utility systems.

Supplier/Vendor: any third Party/Entity that will be awarded by the

Company for manufacturing and/or supplying of equipment and goods for the Project.

General Contractor: any third Party/Entity that will be charged by Company for

the Construction, Commissioning and Start-Up of the Balance of Plant (BOP), being this to be intended as the part of the Project not covered by the Package Contractors.





2.3 Applicable Codes and Standards

SR EN 1990:2004 Eurocod: Bases of structures design

SR EN 1990:2002/A1:2005 Bases of structures design, Annex 1

SR EN 1990/NA Bases of structures design, National Annex

SR EN 1993-1-1 Design of steel structures. Part 1-1: General rules and rules for buildings

SR EN 1993-1-8 Design of steel structures. Part 1-8: Design of joints

SR EN 1993-1-10 Eurocod 3: Design of steel structures. Part 1-10: Choice quality grades of steel.

SR EN-1998-1 & SR EN 1998-1/NA Eurocod 8: Design of structures for earthquake resistance. Part 1: General rules, seismic actions and rules for buildings.

P100-1/2006 Code of structures design for earthquake resistance

STAS 767/0-88 Civil, industrial and agricultural structures. Constructions of steel. General technical quality

STAS 767/2-78 Civil, industrial and agricultural structures. Bolted and swaged connections for steel structures

SR EN 15048-1:2007 Assembly with non-tensioned bolts for steel structures. Part 1: General requirements.

SR EN 10025/05 Hot rolled products of structural steel.

SR EN 25817/93 Arc welded connections of steel. Guidelines for acceptance of faults levels

SR EN 1090-1:2009 Execution of steel structures and aluminum structures. Part 1: Requirements for conformity assessment of structural elements

C150-1999 Normative about quality of welded connections for steel structures

C56-1985 Standard for quality check and reception of construction works and related equipment

STAS 9398-93 Welded Connections. Quality Classes

STAS 565-86 I shape steel. Hot formed steel

STAS 564-86 U shape steel. Hot formed steel

STAS 424-91 Equal angle steel

STAS 395-88 Hot rolled steel. Wide steel

STAS 2350-91 Anchor bolts for foundations

SR EN ISO 2560/2010 Welding. Coated electrodes for manual welding using electric arc of non-alloy and with fine granulation.

2.4 Legislation of Labour Safety and Health

1. Law no. 319/2006 Law of labour safety and health.

2. Law no. 346/2002 related to insurance for labour accidents and occupational health, modified and completed by OUG 91/2007.





3. Law no. 130/1999, re-publicated and completed by Law 403/2005 related to some measures to protect employed persons.

4. Law no. 245/2004 re-publicated, related to general product security.

5. Law no. 608/2001 re-publicated, related to evaluation of product confirmation.

6. Law no. 101/2008 for modified and completed Law no. 50/1991 related authorization the civil engineering.

7. Government Directive no. 300/2006 modified and completed by HG 601/2007, related to minimum safety and health requirements for temporary and mobile sites.

8. Government Directive no. 1425/2006 Methodological Norms for the application of Law of labour safety and health - 319/2006 with subsequent amendments.

9. Government Directive no. 1091/2006 related to minimum safety and health requirements for workplace.

10. Government Directive no. 1048/2006 related to minimum safety and health requirements for use of individual protection equipment by the workers at workplace.

11. Government Directive no. 1049/2006 related to minimum safety and health requirements from the surface or underground mining industry.

12. Government Directive no. 971/2006 related to minimum requirements for safety and/or health signaling at workplace.

13. Government Directive no. 1051/2006 related to minimum safety and health requirements for manual handling of weights with risks for workers, especially dorsal lumbar affection.

14. Government Directive no. 1058/2006 related to minimum requirements to improve safety of the workers who may be exposed to a potential risk due explosive location.

15. Government Directive no. 1876/2006 modified and completed by HG 601/2007, related to minimum safety and health requirements for workers exposed to vibration generating risks.

16. Government Directive no. 493/2006 modified and completed by HG 601/2007, related to minimum safety and health requirements for workers being exposed to noise generating risks, safety and/or health signalling at workplace.

17. Government Directive no. 1022/2006 related to administration policy for products and services jeopardizing life, health, labour safety and environment protection.





2.5 Conflicting Requirements, Exceptions

The General Contractor shall notify the Company of any conflict between this specification, the Codes and Standards and any other specification included as part of the procurement documentation for any equipment.

2.6 Unit of Measurement

The International System (SI) shall be used. When necessary for a specific application, alternative units may be indicated in brackets behind the SI units.

Length: m; mm

Area: m2; mm2

Force: kN; N

Mass: kg

Pressure: kN/m2; MPa

Specific Weight: kN/m3

2.7 Language

All documents will be done in English language excluding the manuals which must be in English language.





3 STEEL STRUCTURES EXECUTION

3.1 General

This Specification is applied for execution, control and reception of steel structures.

Execution, reception, storage, both in plant and on site, transportation, packaging, assembly, painting and finishing construction and steel building parts shall comply with the provisions of standards and actual technical regulations and instructions and provisions of this Specification.

This specification does not substitute actual normative provisions, but it completes and specifies some details and how to interpret.

The compliance of the existing norms, applicable to construction works in all phases of manufacturing and assembly of the investment, specified or not in the documentation and present specification shall be obligatory and shall be base of preliminary and final reception of the work.

Contractor will make required instruction to all execution staff, in factory and on site, regarding the project, norms, technical instructions and these specifications so that each of staff that participate to work must know perfectly their duties in compliance with technical conditions of work quality.

3.2 Important Category and Class of Steel Structure

Important Category, as per HG 766/1997 is C Important Class, as per Cod P100-1/2006 is III.

For a steel structure that complies with a higher category than above, shall be prepared an Annex to this specification with specific requirements of that category.

3.3 Materials

Base materials must corresponded the described conditions into the project (mark, grade), must be accompanied by quality certificates of supplier materials and have marked on each plate, tape steel grade, quality class and punch the charged material suppliers QA.

Using unmarked laminate is not allowed.

3.3.1 Materials for profiles

Laminated profiles and plates could be made from following materials:

Grade S235

Grade S275

Grade S355





For other features that are not included in the above table, the delivery terms will be determined by the project, according to the normative SR EN 10025/2-2004.

The ratio between tensile strength "fu" and minimum yield resistance "fy" will be at least 1.20, and elongation at break will be at least 20%. Steels used in structural elements with dissipative role will have a distinctive yield landing, with specific elongation at the end of yield landing at least 1.5%.

Steels with yield design strength fy 350 N/mm2 can only be used if the plastic material properties are attested by experimental tests.

Plate elements with thickness exceeding 16 mm, required to tensile stress perpendicular to their plan, will be checked ultrasonic on all as loaded area. It will perform tensile tests on thickness direction (SR EN 10002-1) of the pieces from the rigid beam-column connections.

3.3.2 Materials for connections

Bolts - min. grade 4.6

High-tensile bolts - grade 8.8

Nuts, washers - according to SR EN 15048-1:2007

Bolt Class 4.6 4.8 5.6 5.8 6.8 8.8

fyb (N/mm2) 240 320 300 400 480 640

fub (N/mm2) 400 400 500 500 600 800





Grade 8.8 can be used with prior approval of Owner. Bolts, nuts and washers will be stored in specially marked boxes. All bolts, nuts and washers shall be galvanized.

Anchor bolts

The anchor bolts of columns bases will be made of steel from quality class 4.6, 5.6, 5.8 and 6.8. For very high loads, which would lead to constructive complicated solving of column bases, it is acceptable to use anchor bolts with physical and mechanical characteristics of the class as 8.8 (low alloy steel with heat treatment of normalization).

Anchor Bolts will be fitted with two nuts and a washer. Minimum distance of the center of the anchor bolts to the edge of the pedestal will be 100 mm or for times the bolt diameter which is greater.

All anchor bolts will be the embedded type, that is, placed in forms before the concrete poured. For particular installations, anchor bolts will be placed after construction of the foundations, in this case, adequate pockets will be provided in the foundation (before concreting), for anchor bolts to be installed later. Pockets will be used filled using non-shrink grout.

All instances will be specifically noted on the drawings. Anchor bolts and inserts will be set accurately with respect to position, orientation, verticality and projection.

Tolerance of anchor bolts for single equipment base frames will be:

distance between the bolts: maximum 2.0 mm

level of bolts: maximum 15.0mm

Anchor bolts will be protected throughout the construction works from physical damage and corrosion, until the installation of the supported facilities is complete.

The anchor plates are part of the concrete structure supply. On the steel structure drawing, the center-line and the top edge of the anchor plate is taken from the foundation drawings.

Deviation from the position of bolts shall be in accordance with manufacturer's specifications for equipment.

3.3.3 Materials for grating

Bearing bars and cross bars - S235 according to SR EN 10025-2/2004

Stair treads will be serrated grating with standard nosing unless otherwise specified on the drawings. The cross section bearing bars will be 30 mm 3 mm and will be spaced 30 mm center to center.

Contractor shall provide the opening dimensions on the design drawings. Non-dimensioned openings shall be cut in the field.

3.3.4 Materials for welds

Welding materials used must respect the quality requirements of Table 4, C150-99.

The supplier is responsible for executing the welded joints using the appropriate filler material fabrication technologies approved.

The electrodes for manual welding will choose depending on the brand steel and in accordance with SR ISO 2560-2010. It shall be considered the following:





During welding, electric arc is maintained as short as possible, making small oscillation perpendicular to the direction of welding. It is forbidden to carry out large oscillation, which for each deposited layer shall be covered the whole joint of welding. The last layer will be made with cover of whole joint.

At the corner joints, welding purposes shall be usually keep from the middle to ends of subassembly. It is recommended that long corner welds to be performed simultaneously by two welders starting from middle to ends.

In determining the welding system shall be consider the choice of electrode diameter so as to ensure good penetration to the root joint.

Manual welding of butt joints will be performed preferably horizontally.

Number of layers to butt joints will be determined by technological process and will be according to steel type.

For butt joints, each layer of weld shall deposit, obligatory, from one end to the other. It is not permitted to weld starting from both ends to center.

Each layer shall be deposited in the opposite direction of previous layer.

3.4 Category of Execution for Steel Structures

Steel structural elements are classified according to STAS 767/0-88 in execution category B.

Class or category of steel execution can be changed to Contractors proposal only with the designer approval.

3.5 Technical Documentation for Execution and Installing

3.5.1 Detail Design Documentation

Technical documentation should be developed by the designer, based on the FEED Documentation, these specifications and actual technical standards. Documentation shall include written and drawn parts specified in STAS 767/0-88 and the following information:

Execution category for each element shall be executed under Article 1.3 of STAS 767/0-88.

The welded elements shall be indicated, for each seam welded in part, the acceptance of welds according to technical instructions C 150-99.

Representation and dimensioning of welded connections shall be in accordance with SR EN 22553-1995 Welded and sticking connections. Symbolic representations on drawings and STAS 735/2-87 Notation on the drawing of nondestructive procedures for examination of welded connections.

If the execution drawings do not specify thickness corner stitches (a), it is now decided by workshop drawings in the thickness (t) of the rolled products which combines, in Table A.





TABLE A

Thickness of corner stitching

Thickness of plates

t (mm)

Thickness of corner stitching

a (mm) min.

4....8 3.5

9....15 4.0

16...20 4.5

21 ...30 5.0

31 ...40 6.0

> 40 8.0

3.5.2 Technical Documentation to be Prepared by Factory

Technical documentation for execution in factory shall be based on FEED documentation and detail design drawings and in accordance with these specifications and technical standards in force.

The supplier must prepare a documentation of technology design, which includes cutting and machining operations of parts and pre-assembly factories.

Company that makes steel parts must check, before starting the execution plans. Special attention will be given to verification welded seams types and forms provided by the project.

The technological process of execution for each piece must include:

Drawings with odds for each item

Procedures for cutting and machining of parts of the edges, with changes class quality cuts marks and quality classes of steel to be welded;

Types and sizes welded stitching;

Shape and size of edges that are to be welded according to the project or, in their absence, according to SR EN 29692/94 and SR EN ISO 9692-2:2000;

Mark, adding features and quality materials: electrodes, wires and flection;

Mode and order of assembly of parts in assemblies;

The welding process;

Welding procedure;

Order of execution of welded stitching;

Order of application of layers of welding and crossings;

The processing of welded stitching;

Heat treatment if considered necessary;





Sequence of assembly of subassemblies;

Non-destructive control plan (Rntgen, gamma or ultrasonic) of the joints;

The sampling plan for testing specimens destructive;

Rules and methods for checking the quality of the execution phases, according to the head 4 of STAS 767/0-88 and the provisions of this specification.

Welding schemes shall be established by machining company on trial joints. These shall be considered corresponding only if the results of destructive tests and metallographic analyzes performed according to Table 5, normative C150-99 correspond to the provisions of Table 6 of respective normative.

3.5.3 Technical documentation prepared by Company who install the steel structure

Technical documentation for execution and installation of steel structure shall be produced by authorized company, based on FEED documentation and detail design drawings and in accordance with these specifications and technical standards in force.

Technical documentation of installation must include:

Spaces and measures on site storage and transport of construction elements;

Organization of pre-assembly platforms on the site, indicating that lifting vehicles and use;

Check the dimensions involved in obtaining required assembly tolerances;

Preparation and execution of assembly joints;

Check dimensions and elevations indicated in the project for structure installed;

Sequence of assembly of components;

Ways to support and ensure stability in intermediate stages of assembly components;

Heated winter schedule and size to fill the hall with some parts machined assemblies to be welded on site.

3.6 Technical Conditions for Shop execution

3.6.1 General

Supplier will prepare for each subassembly, a technological process of execution, in such way to ensure a good quality of work. Technological process should include:

Drawn pieces on parts with all dimensions

Cutting dimensions and process of the rolled steel

Quality of base material which must be used

Preparation mode of piece edges to be welded (chambering)

The pre-assembly of elements and subassemblies

Welding procedure indicating the widespread use of automatic and semi-automatic welding

Welding system

Type and dimensions welds





Order of welded execution to avoid non-admissible deformations and large internal stresses

Order of application of layers and the number of crossings, where appropriate;

The processing of welds

Order of assembly

Control plan Rontgen, gamma graphic or ultrasound

Welding grades shall be established by factory on samples. Samples are considered appropriate only after mechanical and physical tests of welding seams, which must comply with the provisions of this specification. Supplier is directly and only responsible for the preparation of execution processes and welding of subassemblies (which are shop executed), the choice of optimal welding grades, quality of chosen filler material and the quality of executed works, in accordance with execution drawings and this specification.

3.6.2 Preparation of Rolled

Rolled profiles must be checked in terms of quality, condition and their appearance, and possible defects of rolling. Based on the batch number printed on laminated as bulletins on analysis and mechanical tests shall be check the data correspondence with project requirements, standards and these specifications. The laminates rusty and dirty of mud, oil or paint shall be clean before processing.

Laminates with defects as stratifications, overlapping, murmurs, cracks, inclusions or other defects which are not acceptable, as those the dimensional deviations above those permitted by these specifications or standards shall not be used for execution of welded steel construction.

The processing of rolled without their prior straightening is accepted if their geometric shape deviations from correct, not exceeding tolerances contained in applicable standards (STAS 767/0 - 88) or as specified in the execution details. Rolled which shows deformations higher than those mentioned above, should be directed before tracing and cutting.

3.6.3 Tracing

Steel constructions will be executed according to the details of the project, using technology to every workshop. Tracing will be executed with precision 1.00 mm if the project does not provide greater accuracy. No accumulation is admitted on the same line more tolerances of rating.

Tracing is done with tools, tested and compared with control standards, officially checked or special installations. On templates are written: work symbol, drawing number, pieces position, hole diameter, same number of pieces, etc.

Before being cut shall be marked by stamping each drawn piece, cast which includes the steel plate. Also, the pieces will be marked by painting (or punching) with the track position number according to the project or plan of operations. Checking the correct execution of marking on the pieces will be performed by survey of quality authority, the shooter not being exempt from liability.

3.6.4 Rolled Processing

Cutting pieces are made with scissors, saws, oxygen flame or laser, using especially mechanized cutting. It is not permitted cutting and processing using electric arc.





Connections or circular recesses which are provided in the project will be executed obligatory only by drill using bit or by cutting using axial blow with compass.

For the pieces that are cut and processed with heat, for which no more processing of edge, it is imperative to clean the dross crust that forms on the bottom of the cut. The processing of pieces edges (chamfering) that must be joined by welding is obligatory and will be executed according to technological process execution.

It is not permitted manual processing of edges using the oxy flame.

Surfaces of cuts made by stamping or flame are processed by cutting to a depth of 2 - 3 mm. It is except the free edges of gussets or stiffeners. Edges of cuts made by flame, scissors or laser are not required processing by cutting, if by welding are completely melting or if to ensure cuts having quality class of 1.2.1 according to SR EN ISO 9013-1998.

On each piece, cut from a steel plate will be applied a mark by painting and stamping, which notes:

Track numbers according to mark of drawings and eventually indicative element that is used;

Mark and quality class of the steel plate;

The lot number comes from.

Connection type must be specified in the project. Factory should examine these types and make proposals for amendments to designer, if by these will facility the execution, without changing of stich quality.

Joint geometry (angle, size of nonwoven edges, joint openings, etc.) and processing form of edge for welding is chosen by the plant, depending on the connection type specified in the project, by used welding procedure and the pieces thickness, considering the provisions of SR EN ISO 9692-1/2004 for coated arc welding. These forms must be provided in welding technology prepared by the factory.

All pieces, which in the process of cutting with flame have suffered higher deformations than those indicated in this specification, shall be subject to calibration. Straightening can be made to rolling mill or local heating. In local heating areas, temperature of steel plate shall be about 6000C. It shall be obligatory control.

Drilling is done after straightening and welding operations. It can be done before these operations, if are provided the conditions of quality and holes coincidence of pieces which overlap.

Dimensions of cut pieces should be such that after final welding not to exceed permitted deviations.

3.6.5 Quality control after cutting, straightening and edges processing

The staff of Quality Control has the obligation to check the following:

The existence of correctly marked and visible on pieces;

Dimensions of cut pieces within the limits of tolerances;

Complete cleaning of dross crust that forms on the bottom of the cut;

Surface flatness and edge straightness pieces after straightening within the limits tolerances;

Correct execution of chamfer to the pieces that need it.

Not allowed to move to other parts operations which:

Are inadequate dimensional;

Are not correctly marked and visible;

Cutting defects that cannot be remedied.





3.6.6 Assemble

The pieces that will be assembled must have clean and dry surfaces. It prohibits assembly of pieces wet, covered with ice, grease, dirt, rust, etc., showing exfoliation. Edges of pieces to be welded shall be polished on a width of 20 30 mm, on both sides for complete removal of mill scale and rust.

The pieces showing resulting bites from accidentally stopping of cutting process will be corrected prior to assembly.

3.6.7 Pieces assembling in order to welding (temporary assembly)

Assembling of the pieces will be performed using assembling and welding tools. The construction of these tools must ensure assembly accuracy of pieces, within allowed tolerances by this specification and do not prevent deformation of free parts and welding execution in good conditions.

Assembly must be made so as to result subassemblies with the correct size, after final welding. Potential deviations to welding assembly must fit within those specified in this specification.

Irregularities and local deformations presented by piece and exceeding those specified in this specification shall be removed by processing, achieving smooth connection from processed to that raw portion.

At assembly tolerances shall be those STAS 767/0 to 88.

3.6.8 Quality control after assembly and temporary clamping

Before welding operation shall be checked all sizes subassemblies. It will be controlled all welding fastenings. These will be controlled by quality control staff. It shall be proceeding to detailed examination of each fastening, using for this purpose electric lamps and magnifiers with magnification of 2.5 times.

If either are present cracks in fastening cords of head to head joints will be completely removed by air arc gouging followed by grinding until the complete removal of traces left by electric arc (from gouging) on base material.

For some cracks in the fastening cords of corner joints they will be removed by grinding or gouging mechanical (power cords to completely remove the cracks). Mechanical cleaning will be required followed by grinding.

3.6.9 Welding steel assemblies

Execution of high quality welded joints is conditioned by:

Use of high quality rolled, free from defects such as: stratifications, overlapping, murmurs, cracks, inclusions.

Cleaning by impurities (grease, paint, rust) to rolled steel in joint area.

Drying areas of steel plate on which apply welding.

Use of filler materials (electrodes, wire, flux) corresponding to the base material to be welded.

Horizontal welding of head to head joints or welding of corner joints in the gutter.

Welding of joints in unstiffening condition to avoid stress concentration, using a correct order of assembly and welding.





Welding steel assemblies will be performed closed warehouses to a minimum temperature of + 50C. The workplaces shall be without permanent air currents that influence the quality of welds.

If for some reason it is necessary to execute some manuals joints outdoor, in small length, it will be done under the guidance of welder engineer. Special measures should be taken to protect the welding place and welders, from wind, rain and snow, which would hinder the execution of the works.

In these conditions, welding of metal pieces is admitted to a temperature below + 50C, but not lower than - 50C and only for pieces under 24 mm thick, made by steel rolled with not more than 0.18% C. Before welding, the edges of pieces to be welded will be preheated to a temperature of 100 - 1500C.

For pieces with thicknesses greater than 24 mm and with carbon content less than 0.18%, the edges will be preheated to a temperature of 150-200C. Cooling the welded areas shall be such that the pieces temperature of 100C to turn off no earlier than 30 minutes after welding temperature.

For welding, shall be used electrodes that will dry to a greater temperature 250 300C, for at least 1 hour.

Purpose of establishing a system of normal welding is getting a good quality of welded joints. Mainly aims at:

Achievement of adequate mechanical characteristics;

Adequate penetration into the base material;

Penetration of the root;

Lack of defects (cracks, pores, inclusions, etc.).

Established regimes are maintained as long as one of the factors does not change: mark of base material, trademarks filler of materials, welding processes. Laboratory will communicate to welding sector and quality control person, optimum welding system for each type of bead.

All welds manual, automatic and semiautomatic are made using end plates.

For corner joints shall be provided at both ends of bead T-shaped end plates.

For butt joints will be placed, at both ends of the bead, end plates. End plates shall be chamfered so with pieces which are combined.

In cases where placement of end plates is not possible, must ensure filling of craters at the ends of the welds.

After finishing the welding operations, end plates should be removed and the ends of codons will be processed. Removal of end plates will be made only by flame cutting. It is not allowed to remove them by tapping.

Butt joints that will be used sample plates, for mechanical testing shall be agreed between the designer and supplier. Sample plates will have a number stamped on them to identify place where they were taken, a number that will correspond to that of the process.

Sample plates will be welded in the same condition in which joint is manufactured and shall be by the same welder that will punch the stamp on plate.

Not be allowed to start welding if:

Each piece of subassembly does not have marked its position number and the number of batch-wise from plan of operations.

Assemblies and enterprises do not comply with execution plans, with the technological process and the indications of this Specification.

Machining tolerances are exceeded, beveling or assembly specified in this Specification.





Edges to be welded and surrounding areas are not clean. It will check and clean the slag of spot welds.

End plates are not well placed or smaller than those shown in the process.

Joints are local deviations higher than allowed.

Butt joints of pieces that are assembly and were welded before assembly were not controlled or do not meet the prescribed quality class.

3.6.10 Welding operation

Arc ignitions are prohibited on surfaces that are not covered after welding. Measures will be taken not to cause damage to the pieces by spraying molten metal.

Forced cooling of welds shall be prohibited. Welding slag should be removed only after their normal cooling. Automatic and semi-automatic welding, flux removal must be done at a distance of at least 1 m from voltaic arc.

To butt welds, before welding the second side, the first root welds will be cleaned by mechanical gouging or arc-air process to obtain a clean metal surface. When using air-arc process is mandatory to polish the joint surfaces until the complete removal of the burned material.

Attachment welds (spot welds) will always be totally covered with the cord itself to avoid the overlapping of several closure craters.

Welding begins and ends on end binding plates.

Welding layers will be deposited one after another avoiding the joint to cool.

However previously deposited layer temperature will not exceed 200C. (For the short joints will be left for cooling 5-6 minutes between two successive layers deposited).

3.6.11 Manual welding

Electrodes for manual welding will be chosen depending on steel mark.

Shall be considering the following:

During welding, the arc is maintained as short, making small oscillation perpendicular to the direction of welding. It is forbidden to carry out large oscillation, which at each deposited layer to be covered the whole joint of welding. The last layer will be made with whole joint coverage.

For corner joints the welding direction will be usually from the middle to the end subassembly.

In determining of welding system it will be considered the choice of electrode diameters so to ensure good penetration to the joint root.

Manual welding of butt joints will be performed preferably horizontally.

Number of layers at butt joints will be determined through the process and will be depending on steel type.

Each layer of butt welding joints shall be deposited mandatory from one end to the other. No welding is allowed at both ends to the center.

Each layer shall be applied in reverse order of the previous layer.





3.6.12 Automatic welding

Filler materials (wire, flux) shall fulfill the conditions provided by regulations.

Resulted thickening at the start and the end of the welding will be smoothed by grinding (if it has not been possible placement on plates at the ends of welds). Automatic welding corner joints will be executed horizontally in the gutter, ensuring the necessary penetration.

A layer of weld applied must ensure the execution of that layer without having to interrupt the welding process. If accidentally it is interrupted the welding process of a layer, it will be mandatory continued in the same direction as soon as possible.

At each seam of strength welding, the welder must print own stamp on the base metal in visible places at 50 mm distance from seam axis namely at the middle of length for cords of 1 m and the beginning and end of the cords longer than 1 m.

Welds shall be executed without pores, inclusions, melting gaps. Surface of seams should be as smooth and uniform. Shall be avoided notches melting the edges of welded seams. Welding craters shall be filled. Grinding of welds is not permitted.

All welded seams will be performed with the dimensions specified in the technological process in accordance with execution project.

3.6.13 Quality conditions of pieces, elements, assemblies and seams

Dimensions specified on shop drawings correspond to temperature + 20C.

For measurements made at other temperatures shall be made the necessary corrections, the coefficient of linear thermal expansion being = 12 x 106.

Limited deviations from the shape and dimensions of pieces and welded assemblies are specified in STAS 767/0 -88, with following limitations and specifications:

Limited deviations to length of secondary pieces: +2 -4 mm

Limited deviations to length of main beams:

o Up to openings of 9 m including: +0 -4mm

o For openings more than 9 m: +0 -6 mm

Limited deviations for milled columns

(Length between 4, 5 and 9 m): 2 mm

Limited deviations for columns with non-milled ends,

but processed for welding: +2 4 mm

If lengths result greater, they should be processed by grinding and if result smaller, shall proceed according to section 4.7.1.4.d and paragraph 2.3.5.2 of STAS 767/0-88.

Regardless of the joints type and seams shape, the quality of the welded seams is dimensionally checked, by visually external examination and using magnifying glass, knocked, dye penetrant, exceptional and by drilling.

Acceptance levels of defects in welded joints are shown in Table 6 of Norm C 150 -99 for head to head and corner seams.





3.6.14 Other works after assembly

Quality control of welded assemblies and their joints shall be made by the competent authorities of the supplier.

Checks shall be made by visual and dimensional measurements. This control should not be exceeded permissible tolerances STAS 767/0 -88. It will give special attention to compliance with tolerances in its joints with other elements.

For each part or subassembly that leaves the factory it will be issued a quality certificate attesting that the subassembly is properly quality and dimensional of the project and specification.

It will not receive any subassembly without having to accompany by quality certificate respectively.

Storage and transport of the subassemblies or finished spare parts, it will do so at the plant, as well as on the way to site, in such a way that these do not deformed, water does not stagnate on metal parts and the unprotected parts by painted will be device from rust.

Protection of metal surfaces is done immediately after surface preparation and should not exceed 3 hours after completion of cleaning every surface portions of the element that is protected.

In the plant priming of metal elements is made with two coats of primer.

Surfaces and holes of bolted connections and surfaces in the vicinity of welded joints are not painted and do not protect themselves with other products. After finishing of installing it will be applied the last exterior coat of paint.

3.7 Technical Conditions for Site execution

3.7.1 Assembly and installation of steel structures made in workshop

Supplier of site execution will not receive the steel assemblies made in workshop only if accompanied by a quality certificate.

Technical control authorities of the supplier will check by sampling quality of metal pieces made in plant and project compliance, this specification and technical regulations in force. Before assembly, subassemblies will be checked.

Outside the warehouse, near the place of mounting will be arranged platforms of prepared works for installation.

The technological process of assembling and welding of sections on site will be determined by technical authorities of the supplier in accordance with the design and specification.

3.7.2 Welded Connections

Steel welding, including fixed welding that incorporates the finished work, must comply with the provisions of C 150-99 "Standard quality steel welded joints of civil, industrial and agricultural."

The contractor shall prepare welding technology considering the quality of materials combined, welding type indicated in the project, continuity and seam length, composition and its mechanical qualities.

Level of acceptance for welded connections is B and is in accordance with Table 2 of C150-99 - Standard for quality of steel welded connections to civil, industrial and agricultural structures. The acceptance of weld defects will be the "C".





Site welds must be performed only with authorized welders, with tools, devices and corresponding equipment, taking all necessary measures to ensure welds quality. The acceptance of fault welds is C in accordance with the norm C150-99, except the acceptance of welds marked B.

Steel welding is forbidden for temperatures below +50C.

Welders who perform the assembly of sections and welding assembly on site, will be schooled and trained and then they will subjected to practical tests, performed in a position where they welded on site. They will be authorized to perform only those seams which have proven acquisition of theoretical and practical knowledge.

Each certified welders will have a punch with a number, registered by the Quality Assurance (AQ), which will mark each weld performed by him.

It is not allowed to use in execution of unauthorized welding welders or not to use punch mark.

3.7.3 Bolted Connections

Bolted connections used for installing of steel structure shall be indicated on the details drawings. Surface of pieces in contact does not require special training, having the same corrosion protection as the item meets.

Contractor will provide all holes required for installation of equipment, as indicated on the drawings. Contractor will furnish all erection bolts and washers, including all those necessary to connect steel work to other items. For sliding connections, Contractor will provide two nuts per each bolt.

All shop connections should be welded and all field connections should be bolted, unless otherwise specified on the drawings.

For bolted connections, high-strength bolts will be used unless normal bolts are noted on the drawings. All bolted connections will have a minimum of two 16 mm bolts unless otherwise noted on the drawings. The holes will be 2 mm larger than bolt diameter.

The execution of connections using high-strength bolts will be made only with certified workers.

Assembly pieces for these connections must be conforming to SR EN 15048-1: 2007. Alternatively, these could be supplied according to SR EN 14393-3: 2005 (bolts and nuts) and SR RN 14399-6:2005/AC: 2006 (washers).

3.7.4 High-strength bolted connections

High-strength bolted connections are made according to the "Technical Instructions C133-82". In general, these work in tension in the rod bolts or pressure on the hole. Holes are 2 mm larger than the screw diameter.

Pre-tensioning of Bolts is made by tightening the nuts at a moment equal to 50% of tightening moment, for the final stage, the tightening moment which is indicated in the C133-82.

Quality of connections can be checked by measurement of tightening moments with a torque wrench, and the survey with method "grip angle" as defined in the "Technical Instructions" C 133-82.





Surfaces of pieces, which will be in contact after performing high-strength bolted connections, shall be protected against corrosion as full metal construction (no special requirements for finishing).

Execution of high-strength bolted connections shall be made only with certified workers. Certification refers to the leader of the work and the foreman, team leader and skilled workers who perform such connections.

Tighten of high strength bolts shall be made in one phase, in accordance with the provisions of C133-82 "Technical Instructions for joining elements of metal structures using pre-stressed high strength bolts."

No

Item Nominal Diameter Class

Final tightening moment

(daNm)

50% of Final tightening moment

(daNm)

1 M12 10.9 2550 12.525

2 M16 10.9 5080 2540

3 M20 10.9 80110 4055

4 M24 10.9 140190 7095

5 M27 10.9 185 92.5

6 M12 8.8 1025 512.5

7 M16 8.8 2540 12.520

8 M20 8.8 5075 2537.5

9 M24 8.8 85125 42.5 62.5

10 M27 8.8 - -

According to the normative technical instructions of C133/82, checking of tightening moment shall be made on at least one screw in each characteristic area of the joint.

After tightening the pre-stressed high strength bolts, joint grouting will not be made because surfaces that come in contact are protected against corrosion by priming and painting the entire confection like metal.

Current standards are:

High strength bolts:

o Screws SR EN 14399-3/2005 - grade 10.9 or 8.8

o Nuts SR EN 14399-3/2005 - grade 10.9 or 8.8

o Washers STAS 8796/3-89

Precise bolts:

o Screws SR EN ISO 4014-2003

o Nuts SR EN ISO 4032-2002

o Washers STAS 2241/1-82





3.7.5 Check of execution

Supplier shall ensure through competent staff, continuous technical supervision of assembly and installation operations and reception of each subassembly or component assembly, both on the ground and mounting.

Control of assembly and installation will be done by visual and dimensional measurements. Should be checked the size, shape and quality of welds at each joining element, and respect the assembly tolerances and the mounting.

Assembly and of welding works on site shall be pursued and received, on execution phase by a permanent representative of the client.

3.7.6 Records specification to installation of metal structures

Works supplier is obliged to prepare and keep up to date, "Specification for evidence of steel structures". It is preferable that this book will be prepared by one person.

This book is an indispensable part for receiving partial or full operation of the work.

After receiving this book will be delivered to Client and will keep it attached to "Construction Book".

3.8 Reception of construction works

At the reception of construction works will be checked:

Correct execution of welded joints

Correct assembly of steel sections on the site

It shall be verified correctness the execution of corrosion protection to steel construction.

The reception will be made in accordance with C 56-85. During the execution stage, shall be keeping all necessary information in preparing the technical book of structure, namely: the project which was the basis, site provisions issued by the designer during the execution of work, minutes of quality reception and hidden works prepared during execution and quality certificates of materials, testing.

Any necessary corrective actions will be executed only with the approval or support of the designer. During reception of the construction works shall be checked: correct execution of welds, accuracy of steel sections assembled on site, quality documents and specifications for all the materials and structural elements.

Also, shall be verified correct execution of corrosion protection for steel structures.

3.9 Final provisions

During the work execution shall be retain all documents necessary for compiling the construction book, namely:

The project which was the basis for execution

Site provisions issued during the execution of construction work





The minutes of quality reception and hidden works, prepared during execution

Quality Certificates of materials used

Test reports

Any necessary corrective actions will be executed only with the approval and support of the designer.

During of exploitation, the beneficiary will follow that construction elements will not be loaded beyond the limits allowed in the project.

Industrial deposits shall be removed at regular intervals so that these do not exceed the limits. Removal of dust deposits shall be made based on a program developed for this purpose by customer. It shall be made periodically a technique checking to status of construction. After the events of exceptional (earthquakes, fires, explosions, damage due to exploitation process, and so on) it will be necessarily checking the technical condition of the building.

3.10 Corrosion Protection

The execution and installation of metal structures will be complying with GP 111-2004, "Guide for the design, implementation and operation of corrosion protection of steel constructions.

The life of anticorrosion coating must be at least 15 years which corresponds to a high durability "R" as paragraph 5.1.2 of GP 035-98. The performance of corrosion protection systems shall be in accordance with Chapter 4 Table 4.2 of GP 035-98.

Coating application will be painted before installation construction elements. It can accept the last layer to be applied after installation. Layers of primer and at least one layer of paint component coating system on the entire surface can be applied before mounting only. The overlapping areas will apply the total number of layers of paint coating system.

The surfaces of all steel items shall be blast to grade 2, according to STAS 10166/1-77, surface preparation being performed in accordance with SR EN ISO 8501-1:2002, SR EN ISO 8504:2002, EN ISO 8504-2:2002 and SR EN ISO 8504-3:2002.

For the application of paint coating systems must be created following ambient conditions:

The lack of dust

Reduced gas concentration as aggressive

Air temperature and of protected piece between 5 and 400C, unless the manufacturer specifies other values protective material

Relative humidity below 70%, according to STAS 10702/1-83, unless otherwise specified by the material manufacturer.

The first layer of paint coating system will be applied after 3 hours of surface preparation of steel elements. Successive layers of paint coating system will be applied only on clean surfaces, free from water, dust or dirt. Each layer of coverage should be continuous, without wrinkles, male here or peels, cracks, irregularities.

Except where special preparation is required, all steelwork shall be delivered primed. Parts to be encased in concrete shall not be painted, oiled or galvanized, except for parts that shall be primed when concrete encasement is to provide fireproofing.





For shop connections using high-strength bolts, holes shall have all paint, dirt and other deleterious matter removed.

On receipt of the construction works will be checked: correct execution of welded joints and correct assembly of metal sections on the site. Check correct execution of the construction steel corrosion protection.

Class of corrosive of structural elements is provided in the following table:

Structural Elements Class of corrosive as per SR ISO 9223, SR EN ISO 12944-2

Columns, beams and vertical and horizontal bracings located inside the structure (superstructure)

C1





4 MEASURES FOR COMPLIANCE WITH SAFETY AND HEALTH DURING WORK

General Contractor shall comply with all norms of safety and health at work, as well as other specific norms to the site, existing at the date of the works. General Contractor shall provide the necessary safety and health measures by specialized person or entity authorized. If the General Contractor will sub-contract some work, he shall obligatorily complete with specialized sub-contractor an agreement to provide measures of safety and health at work.





5 QUALITY TRACKING PROGRAM CONCEPT

5.1 General

This concept was prepared according to the provisions of Law 10/1995 Article 22 letter c paragraph 7 for quality control in constructions and will be developed at the DE phase.

This control program is info having the scope to determine quality levels for works execution according to Law 10/1995. The final checking program will be part of the technical report.

Participants in the program:

COMPANY/PRINCIPAL: OMV PETROM S.A.

CONTRACTOR: ENERECO Spa.

1. According to GD 272/1994 before starting work, the beneficiary will send a copy of the quality control plan (PCC) at the Inspectorate for Constructions, who will decide what the acceptance phases to be witnessed are.

2. According to art. 14 of HG 272/1994, the beneficiary and the constructor shall have the designer notified in writing at least 2 days before reaching the progress status indicated in the plan, regarding the acceptance phase required to be attended. Thus the quality of construction works shall be verified and the necessary conditions for quality control shall be created.

3. The acceptance phase represents the progress status when the construction works cannot continue without the written approval of the beneficiary, designer and contractor.

Upon the acceptance of works a copy of Quality Control Plan accompanied by all the documents indicated (project, test reports that certify the quality of materials, reports of hidden works, acceptance reports, notes etc.) shall be attached to the Construction Technical Book.

5.2 Quality Tracking Program Concept of Civil Works

Job name: DETAIL DESIGN FRDP - Only for info

No

Acceptance Phases for the control of the construction quality

Control methods

Participants Documents for quality certification

Documents to be produced

0 1 2 3 4 5

I. CIVIL WORKS FOR PREPARATION OF FOUNDATION SOIL AND ACCESS ROAD

1. Axis marking and location handover.

Topographic B,E Construction project P.V

2.

Excavation bottom compaction and filling compaction (ballast and ground). Foundation ground type.

Compacting report

B,E,G Construction project P.V P.V.L.A

3. Geomembrane layer. Visual, measurements

B,E Construction project P.V P.V.L.A

4. Final acceptance of works Visual, measurements

B,E,P,G Construction project P.V.R

II. CIVIL WORKS FOR FOUNDATIONS AND STRUCTURES





1 Handover of facilities Measurement (theodolite, level gauge)

B,E

Construction project P.V

2 Checking of excavations at foundation depth and determination of the possibilities to continue works

Visual, measurements

B,E,G

Construction project P.V.L.A

3 Acceptance of formwork and reinforcement execution

Visual, measurements

B,E,P Construction project P.V.L.A

4 Checking of the location of metal parts to be embedded in concrete

Visual B,E

Construction project P.V

5 Checking of concrete appearance after release

Visual B,E Construction project P.V.

6 Final acceptance of works Visual Measurements

B,E,P,C Construction project, Compaction measurement sheet, Lab tests

P.V.R

Legend:

PV: official report

PVLA: official report of hidden works

PVR: official report of acceptance

CC: quality certificate

B: Company

E: Contractor

P: Designer

C: ISC delegate

G: Geotechnical specialist

specifications of steel works

Documents

11j01917 company

company job

c0 d0 f0 company

company approval

company review

dj1784 contractor

execution of steel works

contractor job