SAUDI ARABIAN OIL COMPANY

NEAT KHUFF CONDENSATE FRACTIONATION PROJECT

METHOD STATEMENT
FOR
STRUCTURAL STEEL REPAIR

SUB CONTRACT NO: 308200

DOCUMENT NO: 308200-MST-STR-005 Rev. 4

Date:
Client: Project: Contractor:
03-11-02
SAUDI ARAMCO NEAT KHUFF CONDENSATE DODSAL & CO.
SNAMPROGETTI FRACTIONATION PROJECT

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 METHOD STATEMENT
FOR
STRUCTURAL STEEL REPAIR

REVISION CONTROL

Revision Date of Details of Prepared by Reviewed by Approved by Approved by

Status Issue Revision DODSAL DODSAL DODSAL SP

0 26.02.2002 Initial SKJ RON AB

Aramco comments
07-03-2002
1 incorporated coi incorporated V.K.SAMY S.V.RANGAN AB

2 03-11-2002 Incorporate 5.8.2 PB PB AB

Aramco comments
3 08.12.2002 PB PB AB
incorporated

Aramco comments
4 24.12.2002 PB PB AB
incorporated

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 INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 PROCEDURE

6.0 DOCUMENTATION

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1.0 PURPOSE

The purpose of this Method Statement is to provide a guideline for necessary steps to
be followed for structural steel repair job at Neat Khuff Condensate Fractionation
Project.

2.0 SCOPE

This Method Statement shall cover rectification of defects in structural steel members,
i.e defects are like weld repair, distorted members, mismatch due to wrong fabrication
of structural member, coating damage during shipping, handling and erection,
modification to suit field changes and misaligned bolt holes.

3.0 REFERENCES

3.1 INDUSTRIAL CODES & STANDARDS

AWS D1.1 -96 : Structural Welding Code for steel

PIP STS 05130 : Erection of Structural & Miscellaneous Steel Specification
Standard Specification For General Requirements for Rolled
Structural Steel Bars , Plates, Shapes and Sheet Piling.
AISC M 017 : Manual of Steel construction –Vol. II ,Connections
AISC : Engineering And Quality Criteria For Steel Structure
AISC : Code For Standard Practice For Steel Buildings And Bridges

ASTM A6 /A6M : Standard Specification for General Requirements

ASTM A36 /A36M : Standard Specification for Carbon Structural Steel

ASTM A153 : Standard Specification for Zinc Coating (Hot Dip) on Iron&Steel

ASTM A525,G90 : Zinc Coating for Gratings

ASTM A573/573M : Plates

3.2 SAUDI ARAMCO DOCUMENTS

SCHEDULE ‘Q’

Saudi Aramco Safety Manual

12-SAMSS-008 : Erection of Structural and Miscellaneous Steel

12-SAMSS-007 : Fabrication of Structural and Miscellaneous Steel

SAES-H-001 : Selection Requirements For industrial coatings

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 SAES-H-100 : Painting Requirements For industrial Facilities

SAES-H-101 : Approved Protective Coating Systems

SAES-M-001 : Structural Design Criteria For Non-Building structures

SAES-W-011 : Welding Requirements for On-plot Piping

SAES-A-204 : Preparation of Structural Calculations

SAES-M-100 : Saudi Aramco Building Code

3.3 SNAMPROGETTI DOCUMENTS

Quality Plan for I.K. Activity : J64-ZA-E-09601 Rev. D

General Requirement for Field Quality Control : J64- ZA-E-09607 Rev A
Field Quality Control Plan for Steel Structures : J64-ZA-E-09611 Rev. B

3.4 DODSAL DOCUMENTS

Weld Repair Procedure On Spliced Joint HP 14X 89 : JG-1044/CMS/QC/001 Rev
0
Method statement for General Painting : 308200-MST-CO-002 Rev
0
Inspection and Test Plan for General Painting : 308200-ITP-CO-002 Rev 0

4 DEFINITIONS

COMPANY : SAUDI ARAMCO

CONTRACTOR : SNAMPROGETTI

SUB CONTRACTOR : DODSAL & CO

WPS : WELDING PROCEDURE SPECIFICATION

JCC : JOB CLEARANCE CARD

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 5.0 PROCEDURE

5.1 RESPONSIBILITIES

5.1.1 Material controller/ QC Inspector are responsible for receiving/inspecting

materials.
5.1.2 Fabricator /Structural foremen shall be responsible for identification of
distorted and coating damaged materials.
5.1.3 QC Engineer / structural Engineer is responsible for verifying the
effectiveness of the repair method while being applied.
5.1.4 Welding inspector is responsible for weld repair inspection and
documentation.
5.1.5 Erection Engineer is responsible for repair of mis aligned bolt holes
5.1.6 Structural foreman and certified Rigger are responsible for careful handling
of materials while at fabrication and erection.
5.1.7 Structural Engineer shall be responsible for cold repair of steel.
5.1.8 Erection engineer/Safety Engineer is responsible for all the safety aspects.
5.1.9 Painting foremen is responsible for repairing the paint damaged.
5.1.10 Painting QC Inspector is responsible for painting repair inspection and
documentation.
5.2 Safety
ANSI A 10.13 -Steel Erection- Safety requirements

5.3 Material

5.3.1 The materials shall be free of injurious defects and shall have a workman
like finish for plates, structural size shapes, bar size, shapes.

5.3.2 Approved Electrodes for welding

5.3.3 ARAMCO approved paints

5.3.4 Non Abrasive Choker.

5.4 Equipments & Tools

 Magnetic / Ratchet drilling machine.
 Welding rectifier/generator
 Hydraulic Jack.
 Grinding Machine / Flexible Grinding Machine
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  Emery Paper
 Spirit Level
5.5 STRUCTURAL STEEL DEFECTS

5.5.1 Classification Of Defects:

Structural defects can be broadly classified as,

(a) Structural defects like distortions

(b) Dimensional variations due to wrong fabrication of structure

(c) Weld repair

(d) Misaligned bolt holes

(e) Repair of painting and Galvanized steel coating

5.6 REPAIR / CORRECTIVE ACTION FOR STRUCTURAL STEEL DEFECTS.

5.6.1 STRUCTURAL WELD REPAIR

5.6.1.1 The QC welding engineer will advise the structural engineer to

repair the defective weld using correct method, qualified welder
and approved WPS.

5.6.1.2 The location of weld repairs shall be marked on the finished piece
with weather proof paint by the Structural Erection Foremen.

5.6.1.3 The QC welding engineer will advise the structural engineer to

repair the defective weld using qualified welder and approved
WPS.

The grinding, or chipping and grinding of structural size, shapes,

bar size, plates by the fabricator to remove imperfections shall be
subject to the limitations that the area ground is well faired without
abrupt changes in contour and depression, which does not exceed
below the rolled surface by more than

a) 1/32 in. (1mm), for material less than 3/8 in.(10 mm) in
thickness

b) 1/16 in. (2mm) , for material 3/8 to 2 in.(10 to 50 mm) inclusive

in

c) 1/8 in (3mm), for material over 2in. (50 mm) in thickness

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 5.6.1.4 The reduction of thickness of material resulting from removal of
imperfections prior to welding shall not exceed 30% of nominal
thickness at the location of the imperfections.

5.6.1.5 The welds and adjacent heat affected zone shall be sound and
free of cracks, the weld metal being thoroughly fused to all
surfaces and edges or undercut in any layer shall be removed
prior to deposition of the succeeding layer. Weld metal shall
project at least 1/16in.(2mm) above the rolled surface and to
produce a work man like finish.

5.6.1.6 The Welding Repair will be inspected, cleared and documented by

the Structural welding QC inspector

5.7.1 REPAIR OF PAINTING AND COATING

5.7.1.1 As per 12-SAMSS-007 coating repair shall be made in the shop when

a) The total damaged area is greater than 1% but less than 2% of

the total coated area of the member being repaired.

b) Any single repair is at least 1300mm in area

c) Any single repair is 300mm long or more

5.7.1.2 Cold repair using an organic zinc rich coating (APCS-26 Epoxy Mastic) is 3
allowed. If the total damaged area is less than 1% of the total coated area of
the member being repaired and no single repair is greater than 1300mm ² or
300mm long.The dry film thickness shall be .05 to .08mm (2 to 3mils)

5.7.1.3 Where damage has occurred to Shop applied coatings on metal deck, 3
field touch up shall be in accordance with General Method Statement for
painting.

5.7.1.4 Hot dip galvanized gratings shall be repaired in accordance with 3

SAES-H-001 using Epoxy Mastic APCS 26.

5.7.1.5 The painting and coating repair shall be inspected, cleared and
documented by the Painting QC Inspector.

5.8 .1 MIS ALIGNED BOLT HOLES

5.8.1.1 The base plate hole sizes permit a reasonable tolerance for mis
alignment in setting the bolts and more precision in the adjustment if the
base plate or column to the correct center lines.

5.8.1.2 Enlargement of holes to the required size will be decided by the

Structural engineer and he will instruct the structural Erection Fore
men.

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 5.8.1.3 Enlarging the holes shall be by reaming or drilling only. Flame cutting,
burning, gouging, chipping or drift punching shall not be permitted as per
PIP STS 05130 Para. 6.7.3.

4 5.8.1.4 PMT may have the right to reconsider case by case flame cutting and
shall submit each case to CSD for approval.

2
5.8.2 REPAIRING OF MISALIGNED HOLES:

The misaligned holes in Light Steel Structures of Equipment shall be plugged by

welding using the following method.

1. Preparation: Clean the paint and dirt in and around the holes by brushing /
filing.

2. Welding Process: SMAW

3. WPS: WPS-STR-02

4. Electrode: E 7018

5. Welder: Qualified and Saudi Aramco Approved Pipe / Structural Welder

5.8.2.1 Welding Technique:

5.8.2.1.1 Plug Welds

5.8.2.1.1.1 Flat Position Welding: Each pass shall be deposited around the root of
the joint and then deposited along a spiral path to the center of the hole,
fusing and depositing a layer of weld metal in the root and bottom of the
joint. The arc is then carried to the periphery of the hole and the
procedure repeated, fusing and depositing successive layers to fill the
hole to the required depth. The slag covering the weld metal should be
kept molten until the weld is finished. If the arc is broken or the slag is
allowed to cool, the slag must be completely removed before restarting
the weld.

5.8.2.1.1.2 Vertical Position Welding: The arc is started at the root of the joint at
the lower side of the hole and is carried upward, fusing into the face of
the inner plate and to the side of the hole. The arc is stopped at the top
of the hole, the slag is cleaned off, and the process is repeated on the
opposite side of the hole. After cleaning slag from the weld, other layers
should be similarly deposited to fill the hole to the required depth.

5.8.2.1.1.3 Overhead Position Welding: The procedure is the same as for the flat
position, except that the slag should be allowed to cool and should be
completely removed after depositing each successive head until the hole
is filled to the required depth.

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5.8.2.2 Slot Welds:

Slot welds shall be made using techniques similar to those specified in 6.1.1 for
plug welds, except that if the length of the slot exceeds three (3) times the width,
or if the slot extends to the edge of the part, the technique requirements of 6.1.3
shall be apply.

5.8.2.3 Weld Finish: The weld shall be grinded smooth after the completion for QC
inspection.

5.8.2.4 N D T: Visual Inspection for finding out the weld shall contain free of crack,
pinholes & slag inclusion.

5.8.2.5 Final Finish: With approved procedure, touch-up painting shall be carried out
on the completed and QC cleared welds.

5.8.2.6 Modification / Rectification:

If welding is required for increasing / shortening of the handrail posts, flats then
the above WPS and Qualified Welder shall be made use of. Cleared welds shall be
touch-up painted with approved procedure.

5.8.2.7 Providing & Enlarging Holes by Gas Cutting:

Wherever the drilling machine cannot be engaged for making holes in the steel
structural parts of Heater Box, Exchanger, Housings, Component Casing like base
plates, slide plates, etc., the following procedure shall be adopted.

1. Procedure:
1.1 Remove the paint in and around where the holes has to be made by brushing /
filing.
1.2 Make a layout for the holes, which are to be driven and mark the outline by
punch.
1.3 Use the cutting torch for making the holes (1-2 mm inside the outline punch) in
the prepared layout.
1.4 Reamers / pencil grinders of suitable size shall be used for smoothening the
inside of the holes made by gas cutting.
1.5 Grinder shall be used on the outside surface for cleaning.
1.6 Approved paint shall be used for touch-up in and around the made holes.
1.7 The completed holes finally checked for visual inspection.

5.9.1. FIELD CHANGE MODIFICATIONS

5.9.1.1 Approved field changes will be carried out as per the approved
construction drawings.
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 5.9.1.2 Cutting and welding of the structural member modifications shall be
as per the approved fabrication procedure.

5.9.1.3 All fields cut floor plate or grating openings, toe plate protection or
beading shall be installed as required on the approved design
drawings.

5.9.1.4 Whatever field changes made shall be reflected in As Built drawings.

5.9.1.5 Any difference(s) in the material dimension, section properties shall

be recorded in the log book, informed to the contractor and the
member will be changed.

5.9.1.6 Non conforming Materials will be marked with weatherproof marker

paint and kept in the designated area.

6.0 DOCUMENTATION

WELDING REPAIR INSPECTION REPORT :308200/DOD/F-070

PAINTING REPAIR INSPECTION REPORT :308200/DOD/F-005

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