LKT-PROC-6-03

PT. LANGGENG KARYA TEKNIK

REV: A

PROCEDURE FOR STEEL STUCTURE WORKS

FABRICATION & INSTALLATION OF BOP FL3B

DOCUMENT NO. LKT-PROC-6-03

Issued to:

Controlled Copy Uncontrolled Copy

A 15 April 21 FAZ NIW MIF Issued for Approval

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Rev. Date Prep’d Chk’d App’d Description

CONTENT

1. SCOPE
2. OBJECTIVE
3. REFERENCES
4.DEFINITIONS
5. RESPONSIBILITIES
6. MATERIALS
7. PROCEDURES
8. EQUIPMENTS & TOOLS
9. DOCUMENTATION
10. HSE INSTRUCTIONS
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1. SCOPE

This document covers the sequence of activities for Fabrication and Erection procedure for
Steel Structure Works and to ensure the compliance to the above activities with the contractual
applications and HSE requirements in Steel Structure works of FL3B Project.

2. OBJECTIVE

The purpose of this generic work instructions is to define the procedure for Fabrication and
Erection for Steel Structure works of FL3EB Project.

3. REFERENCES

3.1PROJECT DRAWINGS
. Applicable layout drawings
. Detail drawings.
. Arrangement Drawing from Vendor or Manufacturer Recommendation.
. Others.
3.2 PROJECT SPECIFICATION
. Steel Structure Specifications,
. Other related Specifications.
3.3 CODE AND STANDARD
. AWS D1.1 Structural Welding Code
. VL1B-LSVI-K107 Sateri's Structural Steel work

4. DEFINITIONS

APRIL : Asia Pacific Resources International Holdings Ltd

SMP ; PT. Langgeng Karya Teknik
ITP : Inspection Test Plan
QC : Quality Control
PPE : Personal Protection Equipment
HSE : Health Safety & Environment
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5. RESPONSIBILITIES

5.1 The following Site Personal shall be involved as responsible for the
Assembly/Installation/Erection of Steel Structure:
-Site Manager
-Engineer
-Rigging Supervisor
-Steel Structure Supervisor
-QC Engineer
-QC Inspector
-Surveyor
-HSE Safety Officer

5.2 The Site Manager is responsible to implementing the provisions of this procedure. He shall
ensure that the Quality Inspector/Engineer the client or vendor technica! service witness
and approved the alignmen check of the inspection required by this procedure and Quality
Inspection scope list.

5.3 Section Engineer is over all responsible for monitoring steel structure erection operation
in accordance with the procedures, specification and construction drawing.

5.4 QC Inspectors in conjunction with the QC Engineer are responsible for the inspection in
accordance with specification and procedure of the steel structure erection and the
compilation of steel structure reports and records as per required ITP.

5.5 The Steel Structure Supervisor shall be responsible for the safe operation and quality of
work and shall ensure that the procedures are adhered to and that technical standard is
maintained.

5.6 The Rigging Supervisor is responsible for all rigging operation that includes off loading,
transporting, and erection and for the selection of proper crane capacity and rigging gear.

5.7 The Surveyor is responsible for checking elevations and verticality as per construction
drawing.

5.8 HSE Team Shall be responsible for the implementation of the HSE procedures before and
during execution of Fabrication & Erection. And responsible for check for any unsafe
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conditions on the working areas and liaise with field Supervisor ensuring that the work is
carried out as per approved Project safety plan and procedure.

6. MATERIALS

6.1 MATERIAL RECEIVAL

6.1.1 All material received at site shall be inspected in accordance with vendor's instruction
for storage, fabrication/erection and site preservation.

6.1.2 Material shall be off loaded from trailer using the vendor recommended lifting point and
approved techniques.

6.1.3 All loose items that are not required for immediate installation shall be suitably identified
and retained in the stores.

6.1.4 Protective covers on all Materials shall be removed if they appear damage and material
inspected Betore replacing the cover, if any damage has occurred discrepancy report
shall be issued with Photograph showing damages as necessary.

6.2 HANDLING OF MATERIAL

6.2.1 Any movement of material shall be under control of Material Control at all times and
repcrted to Client.

6.2.2 Unload and load trucks by using cranes or forklifts. Do not unload materials by free fall
from trailers or trucks.

6.2.3 To drag or tow material along the ground is prohibited.

6.2.4 Handle materials by utilizing tools and equipment of adequate safe сapecity.

6.2.5 Handle using installed lifting hooks, if any or other appropriate means.

6.2.6 All material surfaces shall be checked and applied with rust-
preventatives.

6.2.7 The material should not be placed directly on the earth, wooden blocks to be used.
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6.2.8 After checking the material and confirming discrepancies, material shall be stored or
delivered to fabrication/ that there are no installation site.

6.3 STORAGE

6.3.1 Lay down area to be established with clear marking unit wise.

6.3.2 Storage areas are to be properly graded, flattened and made free from water.

6.3.3 Secure all materials to prevent loss or damage.

6.3.4 Keeping all areas designated for storage in a clean, tidy and orderly manner is
mandatory. Easy access should be maintained for handling, identification and
inventory.

6.3.5 Separately store materials which have been found damage or defective, such
materials can be transported to site only after the defect and or the damage has been
repaired or eliminated. Store at designated locaticn all items which can not be
repaired.

6.3.6 Store materials aCcording to respective item classification. Do not store together
different elements, sizEs and shape.
6.3.7 Stack steel members on wooden planks, platforms, skids or other supports and keep
completely clear from the ground and water. Do not store steel members on uneven
supports.

6.3.8 Store materials in accordance with supplier's recommendations and in sheltered

area, especially those materials which are susceptible to deterioration.

6.3.9 High strength bolts, mild steel bolts and electrodes are to be stored in watertight and
dry place.
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7.PROCEDURES

7.1 GENERAL
7.1.1 The contractor shall provide all the necessary approved equipment and skilled
manpower to carry out the provision, fabrication, assembly & erection of
structural steel. The welders shall have to be approved by APR Quality Control
Department individually, before they are put on job.
7.1.2 The contractor shall fabricate the structural steel works as per the structural
steel drawings provided. From the structural drawings provided the contractor
shall prepare the fabrication or shop drawings and shall seek the approval of
the Engineer. However such an approval shall not absolve the contractor of
his responsibility to adhere to the structural drawings. Prior to starting the work
the contractor shall submit for approval a detailed plan & schedule for
stuctural steel work any inadequacies found in the plan or schedule shall be
referred to the contractor & the contractor shall change the planning
/scheduling of the job as per the directions given by the engineer.
7.1.3 All the erection work shall be the contractor's responsibility along with the
safety of workmen and equipment.
7.1.4 In addition to the requirement of section 3.2 and 3.3. the best practices shall
apply.
7.1.5 In case of any difficulty in fabrication or erection due to any reason, the
direction of the Engineer fabrication shall be sought.
7.1.6 Periodic inspections will be conducted jointly by the contractor & the Engineer
of the work completed (fabrication or erection).

7.2 FABRICATION

7.2.1 Ali the part of the steel structure shall be cut as per the drawing. The angle
between the part of a steel structure indicated or calculated from the drawing
shall be the angle between the center of gravity lines of the members.
7.2.2 The welding shall be of the thickness shown on the drawing and shall be
formed in at least two passes. All the slag shall be cleaned after the weld has
cooled & the welding inspected.
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7.2.3 The high strength friction grip bolts shall be of approved quality & shall be
provided & fixed as shown on drawings. The bolts shall be tightened fully to
realize their rated strength.

7.2.4 The fabrication of the base plates, gusset plates etc. shall be asper fabrication
drawings. No enlarging of holes for bolts, at site by any means shall be
permitted.
7.2.5 All part of the steel structure to be welded shall be ground by a grinding
machine to provide a smooth surface & then welded with approved electrode.
7.2.6 In case of hexagonal bolts, the bolts shall be tightened to achieve the required
strength.

7.3 ERECTION
7.3.1 Provide / fabricate all the temporary hooks, bolts supports or other arrangements
required for erection After the erection is complete the all such arrangements
mentioned above shall be removed and make gooc the work to the
satisfaction of the Engineer. The foundation to be checked as per the drawing
dimensions b, the
7.3.2 The foundation to be checked as per the drawing dimensions by the surveyor
and mark the centerline and co-ordinates on the foundation
7.3.3 Check the anchor bolt for the corect location and straightness with respect to
the columns.
7.3.4 The surface of the foundation is to be cleaned of all dirt, oil, and any loose
materials and roughened by chipping with brush hammer before placing the
columns.
7.3.5 Documentation of top elevation of anchor bolts as well as concrete pedestals in
approved format.
7.3.6 Check the capacity of lifting equipment and rigging plan shall be prepared and
approved before lifting of the steel structure.
7.3.7 Each part of the structure shall be alignment as soon as practicable after it has
been erected. Permanent correction shall not be made between members
until adequate section of the structure have been aligned, leveled, plumbed
and temporarily connected to ensure that no member can displaced during
subsequent erection or alignment of remaining structure.
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7.3.8 After completion of alignment work of the columns and beams, tightening of bolts
by electric shear wrench or hand operated wrench according to the
specifications. The bolts tensioning value conform to the bolt specification
and or as per vendor/client specification.
7.3.9 The erection tolerances unless specified otherwise shall be within the following :
Item Tolerance
Verticality of Columns Length of Column/500 but not exceeding 25mm
Horizontal Levelling 1/2° variation from 90° but not exceeding 10mm
Position of Columns +5 mm
7.3.10 Column will be released for grouting after achieving the required alignment,
leveling, or verticality.

8. EQUIPMENT, TOOLS
A. FOR MATERIAL HANDLING, LOGISTIC, RIGGING & INSTALLATION WORKS:
 Trailers/Trucks
 Crane 25 Ton &45 Tons
 Truck mounted crane/ Hiab Crane 6 Ton
 e Forklift 7 Tons
 Hand trolleys/ hand pallets
 Mobile cranes
 Electrical winches
 Chain blocks/level blocks of various capacities
 Sling belts of varicus capacities.
 Wire rope slings/clamps of various capacities
 "D" Shackles of various capacities
 Puller units

B. FOR FITTING/GAS CUTTING/GRINDING/DRILLING

 Hammers(steel/rubber) of various sizes.
 Sledge hammers
 Crowbars
 Ring/Double end spanners of various sizes.
 Hammering spanners of various sizes.
 Screw drivers/cutting pliers of various sizes.
 Torque wrenches Pneumatic torque wrenches
 Pipe wrenches of various sizes
 Reaming sets of various sizes.
 Tapping and drilling sets of various sizes.
 Exhaust fan (Fan blowers) as required.
 Gas cutting set with hose and other accessories.
 Manila rope/Nylon ropes of various sizes.
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 Grinding machine of 4", 7" as required.
 Magnetic base drilling machine.
 Concrete drilling machine
 De watering pumps.
 Drill bits of various sizes.
 Scaffolding pipes and clamps.
 Flood lights/Halogen lamp units

C. FOR MEASUREMENT
 Precision Theodolites & Auto level (Calibration validity)
 Vernier calipers
 Rulers/steel scales/right angles
 Measuring tapes from 2 M up to 50 M long.
D FOR WELDING/CUTTING WORKS:
 Electrical distribution boxes
 Cabinet size electrical oven
 Portable size electrical oven
 Welding Rectifiers/Transformers

9. DOCUMENTATION

 All Inspection Records shall be filed and documented as per procedure.

 After construction works are finished as contract all original required documentations
as per contract shail be submitted to Client and copied for our file.

10. HSE INSTRUCTIONS

 Job safety analysis attached.

 All workers shall conduct orientation course.
 Work at height, full body harness shall be used with 100%Tie off.
 Make sure access completely safe on scaffolding with green tag.
 Hot work, a Gas/Oxygen level check through the use of gas detector shall be used prior
to any hot work (welding-gas cutting).
 Confined space ventilation using air mover is required for any vessel prior to entry for
any internal activity.
 Power lighting shall be used as required.
 Working area shall be barricaded (Crane operation area, erection or dismantling of
Scaffolding)
 All warning signs shall be fixed in proper location to ensure personnel safety.
 Rigging operation will be done under control of Rigging Supervisor all
using rigging study or lift plan as required for each lift.