FPC Manual-1 Rev.A

EVERSENDAI OFFSHORE RMC FZE

EVO Doc No. EVOQAMN002 FACTORY PRODUCTION CONTROL SYSTEM MANUAL Rev. 0

FACTORY PRODUCTION CONTROL SYSTEM MANUAL

EVOXXX Doc. No.: EVOXXXQAMN002Rev. 0

Originated By Reviewed By Approved ByNamePositionSignatureDate

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REVISION HISTORY

EVOXXX Doc. No. EVOXXXQAMN002 Rev. 0

Rev Revision Information Date

A Issued for review and comments 29th Feb 2016

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TABLE OF CONTENTS1 GENERAL..........................................................................................................................................4

1.1 Introduction...................................................................................................................................4

1.1 SCOPE...........................................................................................................................................5

1.2 Exclusions.....................................................................................................................................5

1.3 Responsibilities............................................................................................................................5

1.4 Manual revision control...............................................................................................................62 REFERENCES...................................................................................................................................6

3 TERMS, DEFINITIONS AND ABBREVIATIONS..............................................................................6

3.1 Terms and Definitions..................................................................................................................6

3.2 Abbreviations................................................................................................................................7

4 SPECIFICATION AND DOCUMENTATION......................................................................................7

4.1 Execution specification...............................................................................................................7

4.2 Constructor documentation........................................................................................................8

5 CONSTITUENT PRODUCTS.............................................................................................................8

6 PREPARATION AND ASSEMBLY...................................................................................................9

6.1 General..........................................................................................................................................96.2 Identification.................................................................................................................................9

6.3 Handling and storage...................................................................................................................9

6.4 Cutting...........................................................................................................................................9

6.5 Shaping(Forming or Bending)...................................................................................................10

6.6 Holing...........................................................................................................................................10

6.7 Cutouts........................................................................................................................................11

6.8 Full contact baring surfaces......................................................................................................11

6.9 Assembly.....................................................................................................................................11

7 WELDING........................................................................................................................................11

7.1 General........................................................................................................................................11

7.2 Welding plan...............................................................................................................................12

7.3 Welding process.........................................................................................................................12

7.4 Qualification of welding procedures and welding personals.................................................12

7.5 Welding coordination.................................................................................................................13 of 25



7.6 Preparation and execution of welding......................................................................................13

8 MECHANICAL FASTENING...........................................................................................................14

8.1 General........................................................................................................................................14

8.2 Use of bolting assemblies.........................................................................................................15

8.3 Tightening of non-preloaded bolts...........................................................................................16

8.4 Preparation of contact surface in slip resistant connection..................................................16

8.5 Tightening of preloaded bolts...................................................................................................16

9 ERECTION.......................................................................................................................................17

10 SURFACE TREATMENT.............................................................................................................20

11 GEOMETRICAL TOLERANCES.................................................................................................21

12 INSPECTION, TESTING AND ERECTION..................................................................................22

12.1 General........................................................................................................................................22

12.2 Constituent products and components...................................................................................23

12.3 Manufacturing: Geometrical dimensions of manufactured components............................23

12.4 Welding........................................................................................................................................23

12.5 Mechanical fastening.................................................................................................................24

12.6 Surface treatment and corrosion protection...........................................................................24

12.7 Erection.......................................................................................................................................24

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1 GENERAL 1.1 Introduction

EversendaiCOMPANY Name Corporation Berhad and Group of Companies including subsidiaries and associates (hereinafter called the ECB Group) Executive Chairman and Group Managing Director, Tan Sri A K Nathan's experience in the construction industry can be traced back to 1982 when he undertook his first project, the Dayabumi Building in Kuala Lumpur..

ECB EversendaiCOMPANY Name Oil & Gas (M) Sdn Bhd was established in 2010 by the Malaysian-listed EversendaiCOMPANY Name Group, a leading global organization in undertaking turnkey contracts; delivering highly complex projects with innovative construction methodologies for high-rise buildings, power & petrochemical plants as well as composite and reinforced concrete building structures in the Asian and Middle Eastern regions.

EversendaiCOMPANY Name Offshore RMC FZE (EVOXXX) is a part of ECB Group is an established Oil & Gas EPC contractor, specializing in complex fabrication projects, ranging from medium sized turnkey projects to large EPC projects from our facilities in the United Arab Emirates (UAE) covering the MENA , Asia Pacific, Australia & European markets as well as the United States of America (USA) & South America.

Our new fabrication facility in RAK Maritime City, Ras Al Khaimah in the United Arab Emirates (UAE) is one of the largest in the region, having a land area in excess of over 200,000m² with over 550m of exclusive quayside to specifically suit most onshore/offshore load out operations with capabilities extending beyond most fabrication companies in the region which complements our established ASME certified facility in Hamriyah Free zone, Sharjah, UAE as well as other fabrication facilities within the EversendaiCOMPANY Name Group in South East Asia, Qatar and India.

EversendaiCOMPANY Name Offshore’s core focus lies in the areas of construction of New Build Jack-up Rigs including Upgrade/Refurbishment Rigs, EPC Fabrication Onshore/Offshore, Wellhead and Production Platforms, Offshore Structures & Foundation, Process Modules (including Early/Central Production Facilities, Separation, Produced Water Treatment, Compressors, Chemical Injection and

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several others), Offshore Living Quarters, Multi-Purpose Jack-ups (Lift boats) as well as a range of Turnkey EPC Engineering services dedicated to the Oil & Gas sector.

EversendaiCOMPANY Name Offshore has completed several many major EPC projects to date and are currently expanding the workforce and capabilities for further expansion plans moving forward with a target to become the Oil & Gas construction company of choice in the Middle East.

1.1 SCOPE

This factory production control system manual (Here after called FPCSM) is in conjunction with EVOXXX QMS Manual (EVOXXXQAMN001).

The factory production control system manual applies Engineering, procurement, and fabrication/ construction of steel structures to European Standard specific requirements for execution class 1, 2, 3 and 4.

This Factory production Control System Manual applies to steel structures designed according to the relevant parts of EN 1993 and structures designed according to other design rules to provide that conditions for execution comply with them and any necessary additional requirements are specified.

This FPCMS does not applicable for any steel structural which requires water tightness or air permeability resistance of sheeting requirements.

The scope of this manual is carbon steel and stainless steel structural of Execution class EXC1, EXC2, EXC3 and EXC4.

1.2 Exclusions

This manual is not applicable for any aluminum structures with EXC1, EXC2, EXC3 and EXC4.

1.3 Responsibilities

The following additional responsibilities will be apply In addition to the responsibilities and authorities were stipulated in EVOXXX quality management system manual (EVOXXXQAMN0001)

CEO has nominated the QM as “Management Representative” for the company and has been provided with adequate authority, resources and facilities to manage the FPCS in order to establish, implement and maintain essential processes, in consultation with other departmental managers. The Quality Manager, reports directly to the CEO on all Quality performance and matters, including need for improvement and monitors all essential operations through audit, analysis and Management Review to ensure compliance.

Welding coordinator shall be report to QAQC Manager. Welding coordinator is responsible for all welding coordination throughout the project execution since beginning to final completion. His detailed responsibilities shall be as per ISO 14731.

1.4 Manual revision control

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The list of documents required by the FPCSM along with their current revision status is maintained by QM or his designee through online network server. This manual requires revisions if any scope of this manual addition or deletion.

2 REFERENCES

EVOXXXQAMN001 : Quality management system manualEN1090-1 : Execution of steel structures and aluminum structures Part-1

Requirements for conformity assessment of structural components

EN1090-2 : Execution of steel structures and aluminum structures Part-1 Technical requirements for steel structures.

EVOXXXQAPR021 : Control of nonconforming product

Other normative references as per BS EN 1090-2

3 TERMS, DEFINITIONS AND ABBREVIATIONS

3.1 Terms and Definitions

Constituent product: Material and product used for manufacturing a component and which remains as part of it, e.g. Structural steel product, stainless steel product, mechanical fastener, welding consumable

Component: Part of a steel structure, which may itself be an assembly of several smaller components

Execution class: Classified set of requirements specified for the execution of the work as a whole, of an individual component or of a detail component

Service category: Category that characterizes a component in terms of the circumstances of its use.

Production category: Category that characterizes a component in terms of the methods used for its execution.

Calibration: Comparison to a standard of known accuracy and making any needed adjustment(s).

Essential Tolerance: Basic limits for a geometrical tolerance necessary to satisfy the design assumption for structures in terms of mechanical resistance stability.

Functional Tolerance: Geometrical tolerance which might be required to meet a function other than mechanical resistance and stability. E.g appearance or fit up.

Special Tolerance: Geometrical tolerance which is not covered by the tabulated type types or values of tolerances given in BS EN 1090-2, and which needs to be specified in a particular case.

Manufacturing tolerance: Permitting range in the size of a dimension of a component resulting from component manufacturing.

3.2 Abbreviations of 25



For the purposes of this Manual, the following abbreviations will apply

FPCSM : Factory production control system manualEVOXXX : EversendaiCOMPANY Name Offshore RMC FZEEXC : Execution ClassISO : International Standards OrganizationBS EN : British Standard European NormQA : Quality assuranceQC : Quality controlHSE : Health Safety EnvironmentNDT : Non Destructive TestingPWHT : Post weld heat treatmentRWC : Responsible welding coordinatorWPS : Welding procedure specificationTRA : Task Risk AssessmentHOD : Head of the departmentQM : Quality manager

4 SPECIFICATION AND DOCUMENTATION

4.1 Execution specification

EVOXXX has established and implemented a quality management system manual (EVOXXXQAMN0001) to ISO 9001:2008 which states the responsibilities of design department, design, development planning, design development inputs and out puts, design development review, design development verification and final review, design development validation and approval, control of design development change requirements.

EVOXXX Design and Development procedure (EVOXXXQAPR006) shall be followed for the controls required to ensure that the design meets the specified product requirement. Where the original structural will have to undertake all the design shall be accordance to the relevant Eurocodes. In general this requires to use of the following technical codes.

a) BS EN 1090-1: Execution of steel structures and aluminum structures Part-1 Requirements for conformity assessment of structural components

b) BS EN 1090-2: Execution of steel structures and aluminum structures Part-1 Technical requirements for steel structures.

c) EN 1990: Basic structural designd) EN 1991, Eurocode 1: Actions on structures ( All relevant parts) e) EN 1991, Eurocode 3: Design steel structures (All relevant parts)f) EN 1991, Eurocode 4: Design of composite steel and concrete structures (All relevant parts for

steel parts in composite structures)g) EN 1991, Eurocode 8: Design for earthquake resistance(All relevant parts)

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EVOXXX will identify and agreed the necessary and technical requirements for execution of each part of the work, any additional information, testing, technical requirements regarding the safety of the works etc. prior to commencement of the works.

All the design documents and as built documents of design shall retain with EVOXXX for a period of 5 years.

4.2 Constructor documentation

EVOXXX has established and implemented a quality management system manual (EVOXXXQAMN0001) to ISO 9001:2008 which specifies about the product quality plan and its development and implementation, management responsibilities, authorities, accountabilities and procedures for handling changes and modifications and procedures for handling nonconformities. In addition this requirements the following minimum factory production control documents need to established as required by the related execution class in Annexure –2

Defining project specific organization charts and managerial staff responsibilities for execution;

The procedures, methods and work instructions as applicable;

Inspection and test plans with applicable hold points, witness requirements with inspection frequencies as applicable.

Method statements giving detailed work instructions shall comply with the technical requirements relating to the safety of the erection works

Sufficient documentation shall be prepared during execution and as a record of the as-built structure to demonstrate that the works have been carried out according to the execution specification

5 CONSTITUENT PRODUCTS

EVOXXX has established and implemented a quality management system manual (EVOXXXQAMN0001) to ISO 9001:2008 which states the constituent products purchasing, purchase control, supplier evaluation, critical purchase, non-critical purchase, supplier re-evaluation, outsourcing, verification of purchased products or activities.

Structural steel products shall conform to the requirements of the relevant European product standards as listed in Tables 2, 3 and 4, unless otherwise specified. Grades, qualities and, if appropriate, coating weights and finishes, shall be specified together with any required options permitted by the product standard, including those related to suitability for hot dip zinc-coating, if relevant.

Steel products to be used in the manufacture of cold formed components shall have properties that conform to the required suitability for cold forming process. Carbon steels suitable for cold forming are listed in Table 3.

Other material thickness tolerances, surface conditions, special properties clause 5.3.2, 5.3.3 and 5.3.4 shall be use respectively as applicable. Steel casting clause 5.4 in ES EN 1090-2 shall be used.

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All welding consumables shall conform to the requirements to EN 13479 and the appropriate product standard as per clause 5.5 in BS EN 1090-2

6 PREPARATION AND ASSEMBLY

6.1 General

EVOXXX is maintaining a documented procedure (EVOXXXQAPR018) addresses the PreventiveMaintenance of the equipment used in the yard facility, procedure covers the type of equipment’s,Frequency of maintenance required, and responsible personnel. Records of the preventive to ensure any equipment failure do not cause significant inconsistency in the manufacturing process.

6.2 Identification

EVOXXX will maintain a documented procedure for ‘’ Material control and traceability” for each project at all stages of manufacturing to ensure the compliance of the requirements of BS EN 1090-2 as required by each execution class as per the annexure – 2 and customer specification.

This traceability or identification may be achieved by test certificates or batch number or serial number or any other identification.

6.3 Handling and storage

It is the responsibility of EVOXXX stores and production engineer to ensure all the material and storage of the constituent and steel products throughout the process. EVOXXX will maintain a documented procedure for ‘’ Material control and traceability” for each project at all stages of manufacturing to ensure the compliance of the requirements of BS EN 1090-2 and customer specification.

6.4 Cutting

EVOXXX will maintain a detailed project fabrication method statement or procedure which complies various requirements of fabrication activities such as cutting, shaping or forming, flame straightening, holing, cut outs, full contact baring surfaces, assembly, and assembly checks.

The cutting activity will be carried out in such a way that the requirements of geometrical tolerances, maximum hardness and smoothness of free edges, damage of painting while cutting of painted items as specified in the appropriate European standards and customer specification as applicable.

EVOXXX may adopt known and recognition cutting methods such as sawing, disc cutting, water jetting, and other thermal cutting if no practical usage of machine thermal cutting. Any cutting method can be unsuitable for components subjected to fatigue requirements shall not be adopted.

EVOXXX will verify the thermal cutting accuracy for mean height of the profile and perpendicularity or angularity to EXC4 as per BS EN 1090-2 and EN ISO 9013 on annually and cutting accuracy verification hardness as per BS EN 1090-2 when purchaser specified in specification. Hardness will be carried out as per BE EN 1090-2.

6.5 Shaping(Forming or Bending)

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EVOXXX will maintain a suitable detailed project forming and bending procedure and Heat straightening procedure which complies with BS EN 1090-2 and purchaser specification as applicable.

6.6 Holing

Holes for fasteners or pins may be formed by drilling, punching or thermal cutting through CNC method. Manual thermal cutting method for final holing purpose shall not be used.

Holes shall be made in such a way that all matching holes for fasteners or pins shall be suitable with each other so that fasteners can be inserted freely through the assembled members in a direction at right angles to the faces in contact

Punching method is performed provide that the nominal thickness of the component is not greater than the diameter of the hole or for a non-circular hole, its minimum dimension.

EXC1 and EXC2 items, holes may be formed by punching without reaming unless otherwise specified.

EXC3 and EXC4 items, punching without reaming is not permitted if the plate thickness is greater than 3 mm. For plate thickness greater than 3 mm, the holes shall be punched at least 2 mm undersize in diameter. For plate or sheet thickness less than or equal to 3 mm (i.e. Sheets), holes may be formed by full size punching.

The capability of holing processes for punching method for EXC 3 and EXC4 structural shall be checked annually as follows:

a) Eight samples shall be produced from any constituent product encompassing the range of hole diameters, constituent product thickness and grades processed;

b) Hole sizes shall be checked at both ends of each hole using go/no go gauges. Holes shall comply with the tolerance class as specified in ES EN 1090-2 clause 6.6.2

If the process does not conform it shall not be used until corrected. It may be used on a restricted range of constituent products and hole sizes that do produce conforming results

For cold formed components and sheeting, slotted holes may be formed by punching in a single operation, consecutive punching, or joining two punched or drilled holes by use of a jig saw.

Burrs shall be removed from holes before assembly.

Other holing method may be adopt subjected to BS EN 1090-2 requirements as per the purchaser requirements.

6.7 Cutouts

During fabrication and assembly process EVOXXX production supervisor and foreman will ensure there will not be any remaining over-cutting of re-entrance corners. If thermal cutting method will use for hole marking clause 6.4 as per this manual shall be complied. Plate thickness over 16 mm the deformed material shall be removed by grinding. Punched cuts are not permitted for EXC4 and for thin gauge

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components and sheeting sharp re-entrant corners are not permitted and it will be smoothened to the specified radii

6.8 Full contact baring surfaces

All the contact baring surfaces are require to check for all dimensional inspection prior to any erection or installation. This shall be carried out as per the project dimensional inspection procedure and all the dimensional shall be comply with BS EN 1090-2 and purchaser specification as applicable.

6.9 Assembly

Fabrication superintendent, production engineer and QC personal shall be responsible for assemblies prior to erection inspection and clearance for erection. Precaution shall be taken so as galvanic corrosion produced by contacting different metallic material. Care shall be taken to avoid contamination of stainless steel.

EVOXXX project dimensional control procedure and Inspection test plan will be followed as per the ITP.

7 WELDING

7.1 General

It is the responsibility of the welding engineer and welding coordinator responsibility to ensure all the welding shall be undertaken in accordance with the requirements of the relevant part of EN ISO 3438 or EN ISO 14554 as applicable.

According to the execution class the following parts of EN ISO 3834 shall apply.

EXC1: Part 4 Elementary quality requirements

EXC2: Part 3 Standard quality requirements

EXC3 & EXC4: Part 2 Comprehensive quality requirements

Arc welding of ferritic steels and stainless steel should follow the requirements and recommendations of EN1011-1, EN 1011-2 and EN 1011-3 and EN ISO 1090-2 clause 7.7

7.2 Welding plan

A welding control plan/ procedure shall establish including the following as relevant

a) Welding consumable control, b) Measures to taken to avoid distortion, sequence of welding c) Requirements of intermediate weldingd) Details of restraints applicatione) Measures to be taken to avoid lamellar tearing as applicablef) Requirements of welding identificationg) Weld profile finish and cleanliness and acceptance criteriah) Welding inspection

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7.3 Welding process

EVOXXX have been adopted the following welding process as defined in EN ISO 4063 for fabrication and construction and activities. The following welding process application will be based on the project and yard requirements.

111: Manual metal-arc welding (metal-arc welding with covered electrode);

121: Submerged arc welding with one wire electrode

125: Submerged arc welding with tubular electrodes

131: Metal inert gas welding; MIG-welding

135: Metal active gas welding; MAG-welding

136: Tubular-cored arc welding with active gas shield

141: Tungsten inert gas welding TIG welding;

7.4 Qualification of welding procedures and welding personals

7.4.1 Qualification of welding procedures

The Welding Engineer shall be responsible for the preparation of Welding Procedure Specifications (WPS) and revisions to them.

All new qualifications, preparation, welding and testing of the specimen is performed in accordance to EN ISO 1090-2, EN ISO 15609 or EN ISO 14555 or EN ISO 15620 as relevant

If any specified, special conditions for tack welding shall be included in the WPS

The qualification of welding procedure, the parent material and the testing of the material shall be complies to EXC4

The Welding engineer supervises and witnesses the welding of procedure qualification test coupons, the actual welding variables used are recorded on a procedure qualification record and sends coupons to an independent laboratory for testing.

Only the non-essential variables of a qualified WPS may be changed to suit production requirements without re-qualification of the procedure. A new WPS is prepared and qualified if an essential or when required supplementary essential variable is changed.

The QC/Welding engineer reviews the test reports and, if acceptable, certifies the PQR, based upon acceptance of the PQR, the welding engineer issues the WPS to shop/site.

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The WPS along with the supporting PQR shall be submitted to EVOXXX appointed third party representative for review and acceptance, and shall be available for reference at any time.

7.4.2 Qualification of welders and welding operators

The Welding Engineer with Production engineer shall be responsible for the qualification and certification of welders and welding operators; Welding engineer shall witness the qualification and carry out necessary testing of the coupons as required by Code in house or by an external laboratory and maintain records.

All welders and welding operators used for the Code welding shall be qualified in accordance with EN 287-1 and EN 1418 respectively under the supervision of Welding engineer. He shall prepare and certify the welders/welding operator’s performance qualification record which shows the essential variable actually used for the test weld and range qualified for production welding by these variables.

The Welding Engineer shall assign each Welder and welding operators a unique number upon successful completion of his or her qualification.

The Welding Engineer and welding coordinator shall maintain a Welders/Welding Operators Qualification Register which consists of welder names, number, range qualified, etc. and he shall ensure proper welder continuity is maintained.

7.5 Welding coordination

The Project manager and QA/QC Manager is responsible to appoint responsible welding coordinator as specified in EN ISO 14731 and BS EN 1090-2 clause 7.4.3 for EXC2,EXC3 and EXC4 class projects.

The QA/QC Manager is responsible to confirm that RWC is competent enough to perform to the relevant Execution class requirements.

7.6 Preparation and execution of welding

The Supervisor shall ensure that all the joint preparation shall be carried out as per the approved drawing and welding procedure test. He shall also responsible to ensure the joints are free from any visual defects.

The Supervisor and QC Inspector are responsible for ensuring that all the joint are free from moisture, visual defects and requirements of any NDT test as applicable and pre hating requirements are being fulfilled as per the welding procedure specification.

The Supervisor and RWC are responsible for ensuring adequate support provision and easy assessable to welding, inspection and testing

The Supervisor and RWC are responsible for ensuring proper preheat shall be undertaken according to applicable WPS and applied during welding, including tack welding and the welding of temporary attachments

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When assembly or erection requires the use of temporarily attached by welds, attachment material grade, and usage of applicable WPS for welding, removal, installation applicability with respect to EXC class shall be followed as per the applicable procedures.

All the tack welds shall be made using a qualified welder and welding procedure, tack welds not incorporated into the final welds shall be removed. Tack welds that are to be incorporated into the final weld shall have a suitable shape and be carried out by qualified welders. Tack welds shall be free from deposition faults and shall be cleaned thoroughly before final welding. Cracked tack welds shall be removed.

The Shop/Site welding supervisor, QC Inspector and RWC are responsible to ensure proper consumable is implemented and followed as per the project welding consumable control procedure.

The Supervisor, QC Inspector and RWC are responsible to ensure both welder and welding are adequately protected against the effect of wing, rain and snow

The QC inspector and RWC shall verify the implementation of WPS through weld audits.

Welders or Welding operators shall stamp each weld with their welder ID number adjacent to the welds.

The Supervisor, QC inspector and RWC shall be ensured for proper penetration, fusion, cleaning, removal of all temporary attachments, welds are free from defects or any masks etc.

During repair back weld material excavation shall be done to a sufficient depth to ensure full penetration into the previously deposited weld metal.

QC engineer and Inspector shall be responsible for inspection before welding, during welding and after welding and compliance of any PWHT and NDT inspection requirements with relevant EXC.

The acceptance criteria for welding shall be BS EN 1090-2, EN ISO 5817 and customer specification as applicable.

8 MECHANICAL FASTENING

8.1 General

The Supervisor and Production engineer shall be ensure proper alignment, appropriate fasteners, fastening and fixing, when any packing required for alignment the packing material shall be compatible corrosion behavior and mechanical strength of the connection.

EVOXXX will ensure that all personnel engaged in flange management, including sub-contractors, are suitably trained, experienced and competent for the activities in which they are involved. Training may include in house or third party instruction. All personnel, including sub-contractors, will attend the Tool Box Talks. Auditable records will be maintained to demonstrate the training and competence of all personnel.

8.2 Use of bolting assemblies

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All the fasteners and joints holes before inserting shall be clean and free form any foreign particles, ensure the joints are properly aligned with in the prescribed tolerances and free from any external stress.

The Supervisor shall ensure that the using the correct fasteners material, size, type, correct tooling, other measures to secure the nuts, vibration, lock nuts facility as applicable

Care shall be taken for preloaded and non-preloaded bolt requirements separately

The nominal fastener diameter used for structural bolting shall be at least M 12, unless otherwise specified together with the associated requirements. For thin gauge components and sheeting the minimum diameter shall be specified for each type of fastener

For preloaded bolts according to EN 14399-3, EN 14399-7 and EN 14399-10, at least four full threads (in addition to the thread run out) shall remain clear between the bearing surface of the nut and the unthreaded part of the shank.

For preloaded bolts according to EN 14399-4 and EN 14399-8, clamp lengths shall be in accordance with those specified in Table A.1 of EN 14399-4:2005

Check for nuts shall freely run on their penetrating bolt and during fasteners fixing and tightening process care shall be taken in such way that the material grade/ type markings shall not be damaged.

Prior to use any power tool, from each new batch - one normal bolt or nut for their compatibility and one mounted bolt assembly for free running may be verified by hand assembly. This may be done prior to use of the new batch

During installation location of washers (i.e. washers to be placed under the blot head or under the nut or both sides) care shall be taken to avoid parent material damage

Plate washers shall be used for connections with slotted and oversized holes. One additional plate washer or up to three additional washers with a maximum combined thickness of 12 mm may be used to adjust the grip length of bolt assemblies.

For preloaded bolt assemblies tightened by the torque control method (including system HRC) only one additional plate washer may be used on the side that is turned, alternatively an additional plate washer or additional washers may be placed on the side that is not turned. Otherwise, in preloaded and non-preloaded applications, an additional plate washer or additional washers may be placed either on the side that is turned or on the side that is not turned.

8.3 Tightening of non-preloaded bolts

Prior to tightening the gap between two components shall be ensure and shims may be used unless otherwise specified in the flange management procedure

Special attention shall be given to avoid over tightening. The tightening process shall be carried out from bolt to bolt of the group, starting from the most rigid part of the connection and moving

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progressively towards the least rigid part. To achieve a uniform snug-tight condition, more than one cycle of tightening may be necessary

8.4 Preparation of contact surface in slip resistant connection

This clause is not applicable to stainless steels for which any requirement related to contact surfaces shall be specified. This clause does not deal with corrosion protection

The contact surfaces shall be prepared to produce the required slip factor which shall generally be determined by test as specified in BS EN 1090-2 Annex G as necessary specified by engineering.

Precaution shall be taken prior to assembly for contact surfaces shall be free from all contaminants. Burrs that would prevent solid seating of the connecting parts shall be removed. Care shall be taken not to damage or smooth the roughened surface. Untreated areas around the perimeter of the tightened connection shall be left untreated until any inspection of the connection has been completed

Ensure for achieving the minimum slip factor as per the BS EN 1090-2 table-18 unless otherwise specified in the flange management procedure.

8.5 Tightening of preloaded bolts

Torque method shall be used for tightening unless otherwise specified.

All equipment will be in good working order and suitable for the scope of work. Damaged equipment shall be repaired or replaced to ensure that all activities can be completed safely. All Torque wrenches shall be calibrated and records of calibration maintained.

Torqueing wrenches accuracy, calibration and maintenance shall be done according to BS EN 1090-2 clause 8,Annex H or EN 14399-2 and EN ISO 6789 as appropriate and in case of pneumatic wrenches checked every time that the hose length is changed.

For torque wrenches used in the first step of the combined method these requirements are modified to ± 10 % for the accuracy and yearly for the periodicity. Checking shall be carried out after any incident occurring during use (significant impact, fall, overloading etc.) and affecting the wrench.

Burrs, loose material and excessive thickness of paint that would prevent solid seating of the connecting parts shall be removed before assembly

If a bolt assembly has been tightened to the minimum preload and is later un-tightened, it shall be removed and the whole assembly shall be discarded.

Bolt assemblies used for achieving initial fit up should not generally need to be tightened to the minimum preload or un-tightened, and would therefore still be usable in location in the final bolting up process.

NOTE: If the tightening process is delayed under uncontrolled exposure conditions the performance of the lubrication may be altered and should be checked

The supervisor shall ensure torqueing is properly carryout as per specified sequences at prescribed torque values the project flange management procedure.

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9 ERECTION

9.1 General

This clause gives requirements for erection and other work undertaken on site including those relevant to the suitability of the site for safe erection and for accurately prepared supports.

Work carried out on site which includes preparation, welding, mechanical fastening and surface treatment shall comply with the Clauses 6, 7, 8 and 10 respectively.

Inspection and acceptance of the structure shall be performed in accordance with the requirements specified in Clause 12.

9.2 Site conditions

The project manager is responsible to ensure that all the site for the construction works complies with the technical requirements with respect to the safety of the works the erection.

He need to make sure that any soil compactness, approval from purchaser for erection, details of any under and above ground services, any particulars of adjacent structures affecting or affected by the works as applicable.

Access routes to the site and within the site should be given on a site plan showing dimensions and level of access routes, level of the prepared working area for site traffic and plant, and areas available for storage.

If the works are inter-linked with other trades, technical requirements with respect to the safety of the works shall be checked for consistency with those for other parts of the construction works.

9.3 Erection method

The project manager is responsible for any kind of lifting/erecting and he shall ensure all the components/structural items are ready and site are is ready for erection.

Prior to lifting all the engineering drawings with proper sequence of lifting/erection and necessary design/load, center of gravity calculation are performed.

Simple/ uncomplicated lifts/erections which most of them are performed on a regular basis utilizing fixed, dedicated lifting equipment. Essentially this type of lift consists of routine crane or rigging operations within the yard (e.g. loading plate lines and cutting lines, unloading steel from lorry or trailer, moving items in fabrication shops using plate clamps and slings, erection of pipes on the erection area, etc.) or lifts/erections involving the use of basic hoisting equipment but not requiring specialist rigging skills (e.g. use of certified lifting equipment suspended from dedicated lifting points such as pad eyes or runway beams to handle a piece of equipment). The use of generic task risk assessments and toolbox talks is adequate for this level of lifting operation.

For complex Lifts/erections call for the lifting operations to be carried out within areas of restricted access or close proximity to unprotected parts of the facility structure. This requires lifting operations of a non-routine nature which call for specialist advice, and planning or other special conditions. These

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lifts, as listed below, require a separate Method statement/ rigging arrangement prepared by the concerned fabrication yard. Weather conditions and forecasts (wind speed, tide, sea conditions etc.) shall be monitored for such lifts. The areas of Complex Lifts shall be identified as exclusion zones and cordoned off when a lift is carried out.

The execution of these operations must not deviate from the rigging arrangements and any associated method statement where applicable. Complex Lifts shall be covered by Task Risk Assessment (TRA) sessions. Prior to making the lift, all personnel involved shall be thoroughly briefed as to their duties and responsibilities, via a documented Tool Box Talk.

The superintendent or supervisor / Sub Contractor (if the rigging is done by Sub Contractor’s, then they have to include their TRA) will issue a method statement and lift plan and drawing plan in accordance with the “Lifting Procedure”. A minimum of two (2) days prior to the Complex Lift coordination meeting shall be conducted. The method statement/lifting plan distribution shall include Project Manager, Construction Superintendent, Rigging Superintendent and HSE Manager. Refer to Safe Rigging and Material handling Procedure

Prior to the task taking place an inspection will be undertaken on all of the associated activity equipment, rigging and general area by each concerned PIC or his nominee involved in the activity. On verification of compliance to the procedure, drawing and Rigging & Lifting Risk Assessment concerned HSE personnel will sign off Risk Assessment allowing the activity to proceed.

Prior to a Complex Lifts or other selected tasks, each employee involved will attend a Safety briefing (Toolbox Talk) to review hazards previously identified and remind employees of precaution necessary to be taken during the activity.

Any unexpected problem that occurs during activities will be recorded by the HSE Department so they are included in future (TRA).

9.4 Survey

Relevant geotechnical survey campaign shall have been performed on sites where onshore lifting operations are to be executed. The ground parameters (reaction modulus, density, friction coefficient, bearing capacity) shall be assessed area by area and justified on the basis of the aforementioned geotechnical surveys. Onshore Lifting documentation shall include ground bearing pressure calculations / notes.

The ground bearing pressure calculations shall be based on the hook static loads increased by the crane(s) reeving and hook weights. The ground bearing pressure shall not exceed the assessed ground bearing capacity of the concerned area.

A detailed survey shall be conducted considering erection bed position, temporary supports arrangements, suitability of supports, any grouting and sealing requirements and survey report shall be provided to the concern person for review and approval as required.

9.5 Supports, anchors and bearings

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The condition and location of the supports shall be checked using appropriate visual and measurement means before the commencement of erection.

All foundations, foundation bolts and other supports for the steelwork shall be suitably prepared to receive the steel structure. Installation of structural bearings shall comply with the requirements of EN 1337-11.

Erection shall not commence until the location and levels of the supports, anchors or bearings comply with the acceptance criteria.

The compliance survey used to check the positions of the supports shall be documented.

If foundation bolts are to be pre-stressed, provision shall be made accordingly. Proper sleeves should be provided as per the drawings

Whilst erection is proceeding, the supports for the steelwork shall be maintained in an equivalent condition to their condition at the commencement of erection.

Any shims or other supporting devices used as temporary supports under base plates shall present a flat surface to the steel and be of adequate size, strength and rigidity to avoid local crushing of the substructure concrete.

If packings are subsequently to be grouted as specified. Proper adjustments shall be done prioe to erection, in case any adjustment bolts/shim plates will have to be left under the structure that packing material shall be similar to the contact point area.

When any grouting required under the structure proper grouting material shall be selected. Mixing and pouring shall be carryout as a per the manufacturer recommendations.

Care shall be taken so that no voids will exist after pouring and vent shall be provided for air release.

Care shall be taken that the external profile of grouting allows water to be drained away from structural steel components and If there is a danger of water or corrosive liquid becoming entrapped during service, the grout around base plates shall not be surcharged such that it rises above the lowest surface of the base plate and the geometry of the concrete grout shall form an angle from the base plate.

If no grouting is needed, and the edges of the base plate are to be sealed, the method shall be specified.

9.6 Erection and work site

All the erection drawing shall be shall be prepared with proper sequence, lifting arrangements, type of fasteners to be used, mounting and attachments, crane positions, and design calculation.

Components that are individually assembled or erected at the site shall be allocated an erection mark. A component shall be marked with its erected orientation if this is not clear from its shape.

10 SURFACE TREATMENT

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Engineering is responsible to derive the preparation of steel grades and paint specification base on the corrosion protection and corrosivity category as per BS EN 1090-2, EN ISO 12944 and EN ISO 14713-1 as relevant.

The painting engineer and Painting QC Inspector is responsible to complying the stage inspections, necessary quality checks like raw material inspection, blast profile quality checks, salt contamination, paint adhesion test, holiday tests, Paint manufacturers and purchaser representatives involvement during inspection as per the project inspection test plan.

All the paint surface shall be preparation, application and quality checks shall to meet the criteria of BS EN 1090-2. Prior to blasting and paint works a painting procedure and inspection and test plan shall be prepare with complete guidelines, it shall comply with the BS EN 190-2 requirements and purchaser specification as applicable. The paint specification shall approve from purchaser and paint manufacturer.

Unless otherwise specified steel preparation grade P1 shall apply EXC2, EXC3 and EXC4. The thermal cut surfaces, edges and welds shall be suitably smooth and able to achieve the specified roughness are subsequent steel preparation.

During galvanizing sufficient pickling is to be used prior to galvanizing, all welds shall be clean, smooth and free from any defects.

During galvanizing proper vents and drains shall be provided and any internal surfaces or enclosed surfaces galvanizing requirement shall be clearly specified prior to galvanizing.

Proper protection and identification shall be provided for areas where the paint shall not be carried out.

Surfaces that are to be in contact with concrete including the undersides of baseplates shall be coated with the protective treatment applied to the steelwork, excluding any cosmetic finishing coat, for a minimum of the first 50 mm of the embedded length unless otherwise specified and the remaining surfaces need not be coated unless specified. If uncoated, such surfaces shall properly cleaned by applicable cleaning method.

Areas which cannot cover any painting after assembly shall be carried out prior to assembly and for any slip resistant connections faying surfaces paint protection shall be consider for corrosion protection. Unless specified otherwise, bolted connections including the perimeter around such connection shall be treated with the fill full corrosion protection system specified in the reminder area.

All the repair area shall be identified prior to paint repair. Appropriate paint repair procedure or original painting procedure may be used for this purpose.

Stainless steel surface preparation and painting works shall be established additional precautions in addition to the above stipulated guidelines.

11 GEOMETRICAL TOLERANCES

11.1 Tolerance Types

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The following types of geometrical tolerances shall be follow during steel structures fabrication, assembly and erection as applicable.

a) Essential tolerances: Dimensions for those applicable for range of criteria that are essential for mechanical resistance and suitability of the completed structure.

b) Functional tolerances: Dimensions for those required to fulfill other criteria such as fit-up, pre assembly and appearance.

In addition, special tolerances may be specified either for geometrical deviations already defined with quantitative values or for other types of geometrical deviations. If special tolerances are required the following information shall be given as appropriate:

a) Amended values for functional tolerances already defined;b) Defined parameters and permitted values for the geometrical deviations to be controlled;c) Whether these special tolerances apply to all relevant components or only to particular

components that are specified.

In each case, the requirements are for final acceptance testing. If fabricated components are to form parts of a structure that is to be erected on site, the tolerances specified for the final checking of the erected structure shall be met in addition to those for the fabricated components.

a) Essential Tolerances

Essential tolerances shall be in accordance with BS EN 1090-2 Annex D.1. The values specified are permitted deviations. If the actual deviation exceeds the permitted value, the measured value shall be consider as a non-conformity.

In some cases there is a possibility that the uncorrected deviation of an essential tolerance can be justified in accordance with the structural design when the excess deviation is included explicitly in a recalculation. If not, the nonconformity shall be corrected.

b) Functional Tolerances

Functional tolerances in terms of accepted geometrical deviations shall be in accordance with one of the following two options:

a) The Tabulated valuesb) The alternative criteria

If no option is specified by designer or purchaser the tabulated values shall apply

Tabulated values:

Tabulated values for functional tolerances shall be followed as per BS EN 1090-2 Annex D table D.2. Generally values for two classes are shown. The choice of tolerance class may be applied to individual components or selected parts of an erected structure.

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NOTE How D.2 can be applied would be to invoke tolerance class 2 for part of a structure to which a glazed facade was to be fitted, in order to reduce the amount of clearance and adjustability required at the interface.

If tabulated values are used, and the choice of class is not specified by design or purchaser, then tolerance class 1 apply.

Alternative values:

If specified the following alternative criteria may be applied

a) Welded structures, the following classes according to EN ISO 13920 apply: Class C for length and angular dimensions; Class G for straightness, flatness and parallelism;

b) Non-welded components the same criteria as in (a);

c) In other cases, for a dimension d, a permitted deviation ± Ll equal to the greater of d /500 or 5 mm is allowed.

Where full contact bearing is specified, the fit-up between surfaces of erected components shall be in accordance with Table D.1 after alignment.

For bolted splices shims may be used where the gap exceeds the specified limits after initial bolting-up, to reduce the gaps to within the permitted deviation, unless otherwise specified in. the execution specification.

Shims shall be used at any point. If necessary, the shims may be held in place by means of either fillet welds or a partial penetration butt weld extending over the shims.

Proper care shall be taken during welding of large/ heavy sections welding to avoid distortion. If any components are identified beyond specified dimension, heat straightening procedure shall be applied to correct the dimensions.

The supervisor and dimensional surveyor shall be responsible for all dimensional inspection as per the specified intervals in inspection and test plan.

12 INSPECTION, TESTING AND ERECTION

12.1 General

Inspection, testing and corrections shall be undertaken on the works against the specification and within the quality requirements set out in BS EN 1090-2.

All inspection and testing shall be undertaken to a predetermined plan with documented procedures. Specific inspection testing and associated corrections shall be documented.

12.2 Constituent products and components

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All the constituent products (Raw material) shall be inspected and necessary documents shall be generated.

The inspection of the surface of product for defects revealed during surface preparation are repaired using proper methods as per BS EN 1090-2, the repaired product may be used provided that it complies with the nominal properties specified for the original product.

In case purchase will supply any pre-fabricated components contractor shall verify all the documents prior to proceed further.

If the documentation supplied does not include a declaration from the supplier that the products conform to the specifications, they shall be treated as non-conforming products until it can be demonstrated that they meet the requirements of the inspection and test plan.

If any products are first designated as nonconforming and are subsequently proved to be in conformity by test or retest, the testing shall be recorded.

12.3 Manufacturing: Geometrical dimensions of manufactured components

Inspection test plan shall be developed prior to execution. This inspection plan shall consider the requirements and the checks necessary on prepared constituent steel products and manufactured components.

Dimensional measurements of components shall always be taken. Methods and instruments used shall be selected, as appropriate. Accuracy shall be assessed in accordance with the relevant part of ISO 17123. The frequency of measurements shall be specified in the inspection plan.

The acceptance criteria shall be in accordance with essential tolerances in clause 11 in this FPCS manual. The deviations shall be measured with respect to any specified camber or preset.

If acceptance inspection results in the identification of nonconformity, the action on such nonconformity shall be deal as per Control of nonconforming product (EVOXXXQAPR021)

12.4 Welding

Inspection shall be carried out before, during and after welding as per relevant EN ISO 3834 standard

NDT shall be carried out as per the approved procedure and NDT procedure shall be complied with BS EN 1090-2.

Visual inspectional personal and NDT personal shall be qualified to minimum level-2 as per EN 473 or any equivalent internal standard.

Prior to NDT minimum holding time shall be followed for specified steel grades. Extent of NDT shall be carried out as per BS EN 1090-2

All the welding shall be visually inspected throughout the length and friction surfaces as applicable and necessary repairs shall be carried out.

All the repair welding shall be carried out as per the qualified repair procedure and welder only.

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When required by the purchaser production test coupon shall be carried out for EXC3 and EXC4 steel structural of each welding process used

12.5 Mechanical fastening

All the connection with non-preloaded mechanical fasteners shall be visually inspected. If any non-conformity found shall be rectified and re inspection shall be carried. All the calibration of equipment shall be verified.

All the connections with preloaded mechanical fasteners shall be visually checked after they are initially bolted up with the structure aligned locally and before the commencement and after completion of tightening.

EXC2, EXC3 and EXC4, the tightening sequence shall be as per the procedure.

12.6 Surface treatment and corrosion protection

All the blasting and painting inspections shall be carried out as per inspection and test plan. If any non-conformance found against the acceptance criteria shall be rectified and re-inspection shall be carried out.

12.7 Erection

All the pre-fabricated or assembly steel structure shall be inspected prior to release for erection.

A survey of completed structure shall be made for EXC3 and EXC 4 and this survey shall be recorded. This survey shall be consider all the inspection aspects as per BS EN 1090-2.

In any non-conformance observed correction shall be carried out as per BS EN 1090-2

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FPC Manual-1 Rev.A

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Transcript of FPC Manual-1 Rev.A