EPCCOM FOR GAS PROCESSING PLANT

DETAIL DESIGN DOC.NO.: HFY-3800-0000-STR-SPC-0002 REV.: 1 PAGE 1 OF 28

HFY-CON/F&C0940-0964

SPECIFICATION FOR
STEEL WORKS

THIS DETAILED ENGINEERING DOCUMENT IS UPDATED FROM FEED

DOCUMENT - HFY3-GPP-STR-SP-00002_G UNDER THIS PROJECT AS
PER PMT/PMC REQUEST.

A. halim Doka 4.12.2020

1 Re-ISSUED FOR INFORMATION 16-Nov-2020 SB FWT ZY LJ

0 ISSUED FOR INFORMATION 08-Sep-2020 FWT SP ZY LJ / ZXR

REV. DESCRIPTION DATE PREP’D CHK’D REV’D APP’D

 SPECIFICATION FOR STEELWORKS

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REVISION DESCRIPTION SHEET

Rev. Page Para. Reason for Revision

A 28 ISSUED FOR INFORMATION

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0 28 ISSUED FOR INFORMATION

1 28 RE-ISSUED FOR INFORMATION

Rev. Page Para. Reason for Hold

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CONTENT

1.0 INTRODUCTION ........................................................................................................... 5

1.1 Purpose of Document ...................................................................................................... 5
1.2 Overview of the Project ................................................................................................... 5

2.0 CODES, REGULATIONS AND STANDARDS ..................................................................... 6

3.0 GENERAL ................................................................................................................... 14

3.1 Workmanship ................................................................................................................. 14

4.0 MATERIALS ............................................................................................................... 14

4.1 General ........................................................................................................................... 14
4.2 Structural Steel Materials............................................................................................... 14
4.3 Bolting ............................................................................................................................ 15
4.4 Welding .......................................................................................................................... 15
4.5 Solid Plate Flooring......................................................................................................... 15
4.6 Open steel flooring (grating) .......................................................................................... 16
4.7 Stairs, Ladders and handrails: ........................................................................................ 16
4.8 Fire Proofing ................................................................................................................... 17
4.9 Material Test Reports ..................................................................................................... 18

5.0 FABRICATION ............................................................................................................ 18

5.1 General ........................................................................................................................... 18
5.2 Material Fabrication Identification ................................................................................ 19
5.3 Connections .................................................................................................................... 19
5.4 Welding .......................................................................................................................... 20
5.5 Bolting ............................................................................................................................ 21

6.0 PAINTING AND COATINGS ......................................................................................... 22

6.1 General ........................................................................................................................... 22
6.2 Painting........................................................................................................................... 22
6.3 Galvanizing ..................................................................................................................... 23
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6.4 Coatings .......................................................................................................................... 23

6.5 SHIPPING AND HANDLING ............................................................................................. 23

7.0 ERECTION .................................................................................................................. 24

7.1 General ........................................................................................................................... 24
7.2 Bolting ............................................................................................................................ 24
7.3 Welding .......................................................................................................................... 24
7.4 Alignment and Fitting ..................................................................................................... 24
7.5 Setting Base Plates ......................................................................................................... 25
7.6 Erection Tolerances ........................................................................................................ 25
7.7 Repairs ............................................................................................................................ 26

8.0 INSPECTION .............................................................................................................. 26

8.1 General ........................................................................................................................... 26
8.2 Steelwork........................................................................................................................ 26
8.3 Painting and Coatings ..................................................................................................... 27

9.0 GUARANTEE .............................................................................................................. 28

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1.0 INTRODUCTION

1.1 Purpose of Document

This specification covers the minimum requirements for materials, fabrication and
delivery of structural steel.

1.2 Overview of the Project

The plant is situated in the southern part of Iraq, in the Missan Governorate, 35 km
southeast of Amarah city. The field is a NW-SE trending anticlinal structure about 30 km
long, 10 km wide, total area is about 288km2 .Location of Halfaya Oil Field is shown in
Figure 1.2.1.

Baghdad

AHDEB

Halfaya
Amarah

Basra
IRAQ

Figure 1.2.1 Location of Halfaya Oil Field

The Halfaya field was discovered in 1976. PetroChina (Halfaya) has completed FCP
(First Commercial Production) construction of Phase 1, in which CPF1 was constructed
with designed capacity of 70,000+ BOPD. Some facilities have been upgraded since
Y2012 to produce 100,000 BOPD as max. capacity.
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Central Processing Facilities No.2 (CPF2) with design capacity of 100,000BOPD and
relative facilities, which is defined as PHASE TWO and has been successfully put into
production in August 2014.

Central Processing Facilities No.3 (CPF3) with design capacity of 200,000BOPD and
relative facilities which is defined as PHASE THREE has been commissioned in
September 2018.

As part of Phase Four, CPF1 Upgrade is divided into three projects for ease of project
implementation. CPF1 Produced Water Treatment System Expansion Project, CPF1 Oil
Treatment System Upgrade and CPF1& CPF2 Gas Compression System Upgrade.

A Gas Processing Plant (GPP) is planned to be built in the third quarter of 2021 to treat
all the associated gas from Halfaya Oil Field CPFs. GPP will be built nearby CPF2 in
Halfaya Oil Field. GPP is defined as PHASE THREE. Gas processing capacity of GPP is
300 MMSCFD and 26000 BPD of condensate produced from all the CPFs.

At same time, Missan Oil Company (MOC) plan to gather the raw gas of Missan oil field,
Amarah oil field and Noor oil field, and transport to GPP to treatment in future.
Accordingly, GPP expansion in future should be considered. When GPP is expanded to
MGPP, Missan oil field, Noor oilfield and Amarah oil field raw gas will be sent to here,
and the total capacity of three oilfields expected is 450MMSCFD.

2.0 CODES, REGULATIONS AND STANDARDS

Contractor shall meet or exceed the requirements of the latest edition of the following
codes, regulations and standards, except as superseded herein. In cases where more
than one code, regulation or standard apply to the same condition, the most stringent
shall be followed. In the event of a conflict between this specification and other
specifications or correspondence, the COMPANY shall be consulted and a ruling, in
writing, shall be obtained before any work is started.
American Society of Civil Engineers（ASCE）
ASCE 7-05 Minimum Design Loads in Buildings and Other Structures
American Welding Society (AWS):
AWS D1.1/D1.1M Structural Welding Code – Steel
AWS A5.1/A5.1M Specification for Carbon Steel Electrodes for Shielded Metal Arc
Welding
American Institute of Steel Construction (AISC):
Manual of Steel Construction (Allowable Stress Design)
S303 Code of Standard Practice for Steel Buildings and Bridges
S360 Specification for Structural Steel Buildings
S348 Specification for Structural Joints Using ASTM A325 or A490 Bolts
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American Petroleum Institute (API):

Spec 2B Specification for Fabricated Structural Steel Pipe
American Society for Testing Material（ASTM）
AISC 360-10 (LRFD) Specification for Structural Steel Buildings

IBC 2012 International Building Code

AISC 303 Code of Standard Practice for Steel Buildings and

Bridges

AISC 325 Manual of Steel Construction – 13th Edition

AISC 326 Detailing of Steel Construction (2nd Edition)

AISC 348 Specification for Structural Joints Using ASTM A 325 or A

490 Bolts

ASTM A6 Specification for General Requirements for Rolled Steel

Plates, Shapes, Sheet Piling and Bars for Structural Use

ASTM A36 Standard Specification for Carbon Structural Steel

ASTM A53 Standard Specification for Pipe, Steel, Black and Hot-
Dipped, Zinc-Coated, Welded and Seamless

ASTM A123 Standard Specification for Zinc Coating (Hot-Dip) on Iron

and Steel Products

ASTM A143 Recommended Practice for Safeguarding Against

Embrittlement of Hot-Dip Galvanized Structural Steel
Products and Procedures for Detecting Embrittlement

ASTM A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron

and Steel Hardware

ASTM A193 Specification for Alloy-Steel Bolting Material for High

Temperature Service

ASTM A307 Standard Specification for Carbon Steel Bolts and Studs,
60000 PSI Tensile Strength

ASTM A325 M Standard Specification for Structural Bolts, Steel, Heat

Treated 830 Mpa Minimum Tensile Strength (Metric)

ASTM A490 M Specification for High-Strength Steel Bolts, Classes 10.9

and 10.9.3 for Structural Steel Joints (Metric)
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ASTM A500 Specification for Cold-Formed Welded and Seamless

Carbon Steel Structural Tubing in Rounds and Shapes

ASTM A529 Standard Specification for High-Strength Carbon-

Manganese Steel of Structural Quality

ASTM A563M Standard Specification for Carbon and Alloy Steel Nuts
(Metric)

ASTM A572 Standard Specification for High-Strength Low-Alloy

Columbium-Vanadium Structural Steel

ASTM A588 Standard Specification for High-Strength Low-Alloy

Structural Steel, up to 50 ksi (345 Mpa) Minimum Yield
Point, with Atmospheric Corrosion Resistance

ASTM A653 Standard Specification for Steel Sheet, Zinc-Coated

(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by
the Hot-Dip Process

ASTM A709 Standard Specification for Structural Steel for Bridges

ASTM A786 Specification for Rolled Steel Floor Plates

ASTM A830 Specification for Plates, Carbon Steel Structural Quality,

Furnished to Chemical Composition Requirements

ASTM E709 Standard Guide for Magnetic Particle Testing

ASTM F436M Standard Specification for Hardened Steel Washers

ASTM F959 Specification for Compressible-Washer-Type Direct

Tension Indicator for use with Structural Fasteners

AWS D1.1 Structural Welding Code- Steel

ANSI A14.3 Safety Requirement for Fixed Ladders.

ASSA A1264 Requirements for Fixed Industrial Stairs

TIA -222.G-2 Structural Standards for Antenna supporting structures

and Antennas Addendum -2

SNT-TC-1A Recommended Practice No. SNT-TC-1A, 2016 Edition,

and ASNT Standard Topical Outlines for Qualification of
Non-destructive Testing Personnel (ANSI/ASNT CP-105-
2016).
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British Standards

BS 4 (Part 1) Structural Steel Sections, Specification for Hot Rolled

Sections

BS 499-1 Welding terms and symbols. Glossary for welding, brazing

and thermal cutting

BS 499-2 Welding Terms and Symbols Part 2: Specification for

Symbols for Welding

BS 2573 Rules for design of cranes

BS 3692 Specification for ISO metric precision hexagonal bolts,

screws and nuts (Metric Units)

BS 4190 ISO metric black hexagonal bolts, screws and nuts (Metric
Units)

BS 4320 Specification for metal washers for general engineering

purposes. Metric series

BS 4592 (Part 1) Industrial type flooring and stair treads, metal open bar
gratings

BS 4592 (Part 2) Industrial type flooring and stair treads, expanded metal
gratings

BS 5395 (Part 1) Code of practice for the design of stairs with straight flights
and winders

BS 5493 Code of practice for Protective coatings of iron and Steel

Structures against Corrosion.

BS 5950 (Part 1) Structural use of steel in buildings, Code of practice for

design – Rolled and Welded Sections

BS 5950 (Part 2) Specification for materials, fabrication and erection – Rolled

and Welded Sections

BS 5950 – Section 3.1 Design in composite construction - Code of Practice for

Design of Simple and Continuous Composite Beams

BS 5950 (Part 4) Code of practice for design of composite slabs with profiled
steel sheeting

BS 5950 (Part 5) Code of practice for design of cold formed sections

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BS 5950 (Part 7) Specification for materials and workmanship, cold formed

sections

BS 5950 (Part 8) Code of practice for fire resistant design

BS 6072 Method for Magnetic Particle Flaw Detection

BS 7419 Specification for holding down bolts

BS 7668 Specification for Weldable structural steels, Hot finished

structural hollow sections in weather resistant steels

BS EN 612 Eaves Gutters with bead stiffened fronts and Rainwater

Pipes with seamed joints made of Metal Sheet.

BS EN 1011-2 Welding - Recommendations for welding of metallic

materials. General Guidance for Arc welding

Execution of steel structures and aluminium structures.

BS EN 1090-2
Technical requirements for steel structures

Non-destructive testing – Terminology - Terms used in

BS EN 1330-3
industrial radiographic testing

Non-destructive testing – Terminology - Terms used in

BS EN 1330-7
magnetic particle testing

BS EN 1462 Brackets for Eaves Gutters. Requirements and Testing

Eurocode 3: Design of steel structures - Part 1-1: General

BS EN 1993 - 1-1
rules and rules for buildings

Eurocode 3: Design of steel structures - Part 1-2: General

BS EN 1993 - 1-2
rules - Structural fire design

Eurocode 3 - Design of steel structures - Part 1-3: General

BS EN 1993 - 1-3 rules - Supplementary rules for cold-formed members and
sheeting

Eurocode 3 - Design of steel structures - Part 1-5: Plated

BS EN 1993 - 1-5
structural elements

Eurocode 3: Design of steel structures - Part 1-8: Design of

BS EN 1993 - 1-8
joints

Eurocode 3: Design of steel structures - Part 1-10: Material

BS EN 1993 - 1-10
toughness and through-thickness properties
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BS EN 1993-6 Eurocode 3 - Design of steel structures - Part 6: Crane

supporting structures

Eurocode 4: Design of composite steel and concrete

BS EN 1994 - 1-1
structures - Part 1-1: General rules and rules for buildings

BS EN 10020 Definition and Classification of Grades of Steel

BS EN 10025-1 Hot rolled products of structural steels Part 1: General

technical delivery conditions

BS EN 10025-2 Hot rolled products of structural steels Part 2: Technical

delivery conditions for non-alloy structural steels

BS EN 10029 Specification for Tolerances on Dimensions and Shape for

Hot-rolled Steel Plate 3mm Thick on above

BS EN 10034 Structural Steel I and H Sections on Tolerance of Shape

and Dimensions

BS EN 10051 Specification for Continuously Hot-rolled strip and

Plate/Sheet cut from wide strip of Non-alloy and Alloy
Steels – Tolerances on Dimensions and Shapes

BS EN 10056-1 Specification for structural steel equal and unequal angles.

Dimensions

BS EN 10056-2 Specification for structural steel equal and unequal angles.

Tolerances on shape and dimensions

BS EN 10067 Hot Rolled Bulb Flats. Dimensions and Tolerances on

Shape, Dimensions and Mass

BS EN 10079 Definition of Steel Product

BS EN 10160 Ultrasonic testing of steel flat product of thickness equal or

greater than 6 mm (reflection method)

BS EN 10163 Part 1 Delivery Requirements for surface Conditions of Hot Rolled

Steel Plates , Wide Flats and Sections - General
requirements

BS EN 10163 Part 2 Delivery Requirements for surface Conditions of Hot Rolled

Steel Plates , Wide Flats and Sections - Plates and Wide
Flats

BS EN 10163 Part 3 Delivery Requirements for surface Conditions of Hot Rolled

Steel Plates , Wide Flats and Sections – Part 3 Sections
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BS EN 10204 Metallic Products – Types of Inspection Documents

BS EN 10210 Part 1 Hot Finished Structural Hollow Sections of Non Alloy and
Fine Grain Structural Steels - Technical Delivery
Requirements

BS EN 10210 Part 2 Hot Finished Structural Hollow Sections of Non Alloy and
Fine Grain Structural Steels - Tolerances , Dimensions and
Sectional Properties

BS EN 10279 Hot rolled steel channels. Tolerances on shape, dimension

and mass

BS EN 10365 Hot rolled steel channels, I and H sections — Dimensions

and masses

BS EN 20898 – Part 1 Mechanical Properties of Fasteners – Bolts, Screws and

Studs

BS EN 20898 – Part 2 Mechanical Properties of Fasteners – Nuts with Specified

Proof Load Values. Coarse Thread

BS EN 22553 Welded, brazed and soldered joints - Symbolic

representation on drawings

BS EN 24063 Welding, Brazing, Soldering and Braze Welding of Metals -

Nomenclature of Processes and Reference Numbers for
Symbolic Representation on Drawings

BS ISO 888 Fasteners. Bolts, screws and studs. Nominal lengths and
thread lengths

Mechanical properties of fasteners made of carbon steel

BS EN ISO 898-1 and alloy steel, bolts screws and studs with specified
property classes coarse thread and fine pitch thread

BS EN ISO 898-2 Mechanical properties of fasteners made of carbon steel

and alloy steel, nuts with specified property classes.
Coarse thread and fine pitch thread

BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles, Specifications and test methods

Welding and allied processes — Symbolic representation

BS EN ISO 2553
on drawings — Welded joints

Non-destructive testing. Penetrant testing. General

BS EN ISO 3452-1
principles
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BS EN ISO 4014 Hexagon Head Bolts - Product Grades A and B

BS EN ISO 4016 Hexagon Head Bolts - Product Grade C

BS EN ISO 4032 Hexagon Regular Nuts (Style 1) - Product Grades A and B

Welding and allied processes - Nomenclature of processes

BS EN ISO 4063
and reference numbers

Non-destructive testing. Magnetic particle testing. General

BS EN ISO 9934
principles

Tolerances for Fasteners - Part 1: Bolts, Screws, Studs and

BS EN ISO 4759-1
Nuts - Product Grades A, B and C

Tolerances for Fasteners - Part 3: Washers for Bolts,

BS EN ISO 4759-3
Screws and Nuts - Product Grades A, C and F

BS EN ISO 10684 Fasteners - Hot dip galvanized coatings

BS EN ISO 11600 Building construction. Jointing products. Classification and

requirements for sealants

Non-destructive testing — Magnetic particle testing —

BS EN ISO 12707
Vocabulary

BS EN ISO 17637 Non-destructive testing of welds. Visual testing of fusion-

welded joints

BS EN ISO 17640 Non-destructive testing of welds. Ultrasonic testing.

Techniques, testing levels, and assessment

Other Codes:
 National Fire Protection Association (NFPA)
 Uniform Building Code
 International Building Code
 Codes, Regulations and Statutes of Authorities having jurisdiction in location of
installation.

The following General Specifications shall be used in conjunction with this specification
where applicable:
 HFY-3800-0000-STR-SPC-0001 Specification for Concrete Works
 HFY-3800-0000-STR-SPC-0004 Specification for Structural Design
 HFY-3800-0000-STR-SPC-0005 Specification for Platforms, Stairs, Ladders and
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Hand railings

Any deviation from this specification must be approved, in writing, by COMPANY. Such
written approval must be obtained prior to the commencement of any work which would
constitute such a deviation.

3.0 GENERAL

3.1 Workmanship

Work shall be carried out in accordance with code requirements and industry standards.

4.0 MATERIALS

4.1 General

4.1.1 All material shall be of new stock and shall conform to the requirements of this
specification and the applicable Codes.

4.1.2 No material other than that specified shall be used unless approved in writing, by
COMPANY.

4.2 Structural Steel Materials

All materials shall be of new stock.

All materials shall be of single grade/standard for the whole structure.
Structural steel shall be mild steel and comply with the requirements of ASTM A572
1 Grade 50 / ASTM A992(yield stress 345Mpa) / ASTM A36 or BS EN 10025 Grade
S335JR / S275 JR/J0 or equivalent subject to the prior approval of COMPANY.
Profiles, Channels (Parallel Flange Channel-PFC) shall conform to BS 4-1. Angles shall
conform to BS EN 10056-or equivalent subject to the prior approval of COMPANY.
Structural plates shall conform to the requirements of BS EN 10025 Grade S275 JR/J0
or equivalent subject to prior approval of COMPANY.
All materials shall be free of seams, cracks, flaws, laminations, injuries and other defects
of any kind.
A minimum thickness of 6mm shall be considered for any structural shapes constituting
main structural frames of steel pipe racks, steel structure, heavy pipe support. the
minimum thickness of plate material used for structural connection shall be 6mm.
Hot rolled structural steel member specification for tolerances, shape and dimensions
shall be as follows:
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 Universal beams, Universal columns, Channels, Joists and Tees to conform to BS 4:

Part 1 and BS EN 10034
 Equal and Unequal leg angles to conform to BS EN 10056-2
 Plates shall conform to BS EN 10029

4.3 Bolting

4.3.1 High Strength Bolt Assembles:

1
Bolt ASTM F3125/F3125M Grade A325/A325M
Washer ASTM F436M (or F959M)
Direct Tension Indicator Washer ASTM F959M
Heavy Hex Nut ASTM 563M Grade C3, DH3, A194M Gr 2H

4.3.2 Standard Bolt Assemblies:

Bolt ASTM A307 Grade A & C, Heavy Hex

Washer ASTM F436M
Heavy Hex Nut ASTM 563M

4.3.3 Bolt for Low Service Temperatures

For service temperature under -20ºC, bolts and nuts shall be conform to ASTM 320L7
and ASTM 194M (connection of steel works on cold equipment).

4.4 Welding

Welding filler metal shall be accordance with AWS D1.1 and AWS A.5.1, section 4.1
(including table 4.1) with electrode strength of 58ksi minimum yield strength at 70ksi
minimum tensile strength. E70XX electrodes may be used for tack welding.
4.5 Solid Plate Flooring

4.5.1 Solid plate flooring shall be raised diamond pattern

 Floor plates shall be hot-dip galvanized unless otherwise stated on the design
drawings, to coating weight of 600 g/m². Steel for checkered plates shall be Grade
S235JR to EN 10025 or approved equivalent; minimum thickness shall be 6+2 mm.
 Checkered plates shall be bolted unless otherwise specified
 Thickness: 6mm excluding height of the raised pattern.
 Raised pattern sizing:
Length: 25/30mm approx.
Wide: 8/10mm approx.
Height: 1.7/2mm approx.
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 Mesh of raised pattern: 23/32mm approx.

 Steel: yield point between 235N/mm²and 355N/mm²
 Solid plate flooring shall meet the requirements of ASTM A786, pattern 4 or 5.’

4.6 Open steel flooring (grating)

4.6.1 Open steel flooring shall be supplied and galvanized to a coating weight of 600 g/m².

4.6.2 Grating shall not allow a sphere 19mm diameter to pass through.

1 4.6.3 Open steel flooring shall be serrated rectangular open grid type with load bearing bars
30mm deep x 3mm thick at 20mm cross centers with 5mm diameter twisted square
cross bars at 50mm centers

4.6.4 Steel shall be Grade S235JR to EN 10025 or approved equivalent.

4.6.5 Gratings shall be hot dip galvanized as per ASTM A123.

1 4.6.6 Maximum span between supports of the gratings shall not be more than 1.2m.

4.6.7 Flooring panel perimeters shall be bound with edge strips. Edge strips shall be extended
to provide kick plate where shown on Engineering drawings.

4.6.8 Panel shall be prefabricated within the tolerance 0 to ±4mm.

4.6.9 A nominal gap of 8mm is to be provided between installed panels.

4.7 Stairs, Ladders and handrails:

4.7.1 Stair treads shall be Grade S235JR to EN 10025 or approved equivalent fabricated,
supplied and galvanized to a coating weight of 600 g/m².

4.7.2 Stair treads shall be bolted to the stair stringer.

1 4.7.3 Grating shall consist of load bearing bars 30x3mm with serrated top edge spaced at
20mm C/C & 5m SQ. cross bars spaced at 50mm C/C pitch.

4.7.4 Lateral restraint shall be welded to the upper edge of the loading bearing bars.

4.7.5 Treads shall be supplied with end plates and slip resistant front edge.

4.7.6 Nominal tread size shall be 800x292mm (or as indicated on engineering drawings).

4.7.7 Stair treads materials meeting the requirements of ASTM A569 may be used in
packaged equipment, pressure vessels and tanks.
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4.7.8 Hand railing shall extend around the edges of all platforms, landings, walkways,
stairways and openings except at stair and ladder accesses or as shown on the
drawings.

4.7.9 Where not dimensioned, the spacing at handrail posts shall not exceed 1500 mm.

4.7.10 Handrails at the bottom of stairways shall terminate at the bottom post or completely turn
and attach to the post.

4.7.11 Kick plates shall extend around the edges of all platforms, landings, walkways, stairways
and openings protected by hand railing.

4.7.12 All flooring and stair treads shall be hot dip galvanized in accordance with ASTM
A123/A123M.

4.8 Fire Proofing

4.8.1 Fire proofing of structural steel shall comply with fireproofing specification

 API PUBL2218 Fireproofing Practices in Petroleum and Petrochemical Processing

Plants.
 HFY-3800-0000-SAF-SCH-0001 PFP Schedule

4.8.2 Structural members to be fireproofed shall be clearly indicted on Contractor drawings.

Such members shall be supplied with surface preparation, in accordance with
Specification.

4.8.3 All accessories for the fire proofing required by the Engineering drawings or Specification
shall be supplied by the Subcontractor.

4.8.4 Fire rating for columns of Gas Compressor Shelters shall be not less than 30 minutes.
And for pipe racks within a fire-scenario envelope the fire rating shall be not less than 2.0
hours, and the fire-resistant area shall be from ground to 9.1m high. Where air fin-fan
coolers are installed on top of a pipe rack within a fire-scenario envelope, fireproofing
should be considered for all vertical and horizontal support members on all levels of the
pipe rack.

4.8.5 Lightweight Cementitious Fireproofing coating shall be used for steel structure, such as
pipe rack, pipe support, equipment support structure etc.

4.8.6 Intumescent epoxy coatings will be used for some place that cementitious coating is
hard to apply, such as equipment skid base structure.

4.8.7 Test standard of fireproofing material shall be followed UL-1709 Rapid Rise Fire Tests of
Protection Materials for Structural Steel and ISO 22899 Determination of the resistance
to jet fires of passive fire protection material.

4.8.8 PFP requirement and rating (duration) of fireproofing for pool fire and jet fire shall follow
HFY-3800-0000-SCH-0001 PFP Schedule and API2218.
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4.8.9 Thickness of PFP to be decided based on duration of fire and Vender’s products
specification.

4.8.10 The selected fire proofing material shall be suitable for the primer coat, and if the fire
proofing material will be used for galvanized surfaces, the fire proofing shall be applied
for the galvanized surfaces.

4.8.11 The selected fire proofing material shall be suitable for field climatic conditions.

4.9 Material Test Reports

4.9.1 All material shall be first quality, free of defect and imperfections of recent manufacture,
unused and of the grade specified, as a minimum.

4.9.2 Contractor shall supply all certificates and tests reports on any material supplied at all
fabrication shops.

5.0 FABRICATION

5.1 General

5.1.1 Fabrication shall be carried out in accordance with the drawings, the applicable codes
listed in this specification and the requirements of this specification.

5.1.2 Fabrication shall commence only after shop drawings are approved by COMPANY.

5.1.3 Substitutions of sections and material or modifications of design details shall be made
only as approved by COMPANY.

5.1.4 Platforms, stairways and handrails shall be shop-assembled in the largest units suitable
for handling and shipping.

5.1.5 Steelwork shall be shop fitted and shop assembled as far as practicable to minimize site
work and to meet transportation restrictions. Parts not completely assembled in the shop
shall be secured insofar as possible to prevent damage during transit.

5.1.6 All burrs and sharp edges shall be removed from structural steel, handrails, ladders and
safety cages.

5.1.7 Base plates over 0.3 m2 shall be provided with bleed holes for grouting.

5.1.8 All members shall be clearly marked for field assembly with designating numbers or
letters corresponding to the field erection drawings.

5.1.9 Precautions shall be taken to prevent damage to protective coating.

5.1.10 Shop trial assembling shall be performed as required by the Contractor.

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5.1.11 Shop splice is not permitted without prior written approval of the Contractor. In case of
Contractor approval, the shop splices shall develop 100 percent of the member capacity.
Butt weld shall be full penetration and 100 percent soundness established by
radiographic or ultrasonic inspection.

5.1.12 Process submitted to restriction:

 GMAW process for welding structural components is prohibited.

 FCAW process is submitted to COMPANY approval

5.1.13 Joint preparation:

Joint preparation and execution properties shall be in accordance with those defined in
the welding procedure descriptions.
Special attention shall be paid to risks associated with the metallurgical weld-ability of
the construction sheets, in the other words, hot cracking, cold cracking and lamellar
tearing.

5.1.14 Preheating:

This shall extend to an area of at least 75mm on each component of the base metal.
Throughout the preheating period, the temperature must be able to be checked by
thermocouple, pyrometer or temperature indication stick on the side opposite to the
receiving the heat source and in all cases at right angles to the first pass.
The preheating temperature shall be maintained throughout the welding period, unless
the procedure provides different inter-pass temperature.
5.2 Material Fabrication Identification

5.2.1 The following documentation shall be carried out and transmitted by the Subcontractor to
the Contractor:

 Certified procedure of welding

 List of certified welders
 Non-destructive control report including Radiographic films
 Sizing control report including shop trial assembling report

5.3 Connections

5.3.1 Connections shall be as shown on the drawings and as specified herein.

5.3.2 Connections not shown on the drawings shall be designed as follows:

(a) Moment connections shall be designed to develop the factored moment

resistance of the weakest connected member.
(b) Shear connections shall be designed to develop one and half of the factored
shear resistance of the member being connected, unless the shear is shown on the
drawing.
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(c) Splices shall be designed to develop the factored tensile resistance of the
weakest connected member.
(d) Bracing members shall have their axis of gravity meet at one point if practicable
and if not, provisions shall be made for additional stresses due to the eccentricity.

5.3.3 Shop connections shall be welded, or equivalently bolted, and field connections shall be
bolted (at least 2 bolts)or welded as shown on the drawings.

5.3.4 Shop splices shall be made by full penetration butt welding.

5.3.5 All columns over 250 mm, all column splices, and loose bearing stiffeners shall be milled
to give full bearing over the entire cross-section. Columns 250 mm and under at base
plates and welded bearing stiffeners may be square cut.

5.4 Welding

5.4.1 Welding shall be in accordance with AWS D1.1 as applicable.

5.4.2 Welding procedures shall be in accordance with AWS D1.1 as applicable. (GMAW
process is prohibited).

5.4.3 At least one month before weld work starting, the Subcontractor shall submit welding
procedure specification and welding qualification records to COMPANY or its
representative for review.

5.4.4 Welding sequence on procedure shall be such as to minimize distortion and war-page.

5.4.5 Minimum size of fillet weld shall be 6mm except as otherwise required.

5.4.6 Full penetration weld shall be carried out according to the relevant code and submitted to
the COMPANY.

5.4.7 All welding shall be performed by the manual shielded arc, submerged arc, or flux cored
arc welding process. The latter process may be used provided a shielding gas is
employed and the current is in the spray transfer range.

5.4.8 All application of gas metal arc welding with solid wire electrodes are subject to approval
by COMPANY, and in no case will such application be allowed in the fabrication or
erection of main structural members.

5.4.9 Welding procedures, conforming in all respects to the applicable codes, specifications
and recommended practices listed in Section 2, shall be deemed as pre-qualified and
are exempt from tests for qualification.

5.4.10 Other procedures shall be qualified by tests as prescribed in the applicable codes,
specifications and recommended practices listed in Section 2. The written welding
procedures and the qualification test records shall be submitted to the COMPANY for
approval.
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5.4.11 Firms undertaking welding shall be currently certified by the authorities having
jurisdiction in the location of installation and certification shall be made available to
COMPANY.

5.4.12 Welding shall be performed only by welders or operators who are qualified in
accordance with the applicable codes, specifications and recommended practices listed
in Section 2. Welder's certificates shall be made available to Contractor, and a copy shall
be submitted to COMPANY.

5.4.13 Surfaces to be welded shall be free from loose scale, rust, grease, paint and other
foreign material. A light film of linseed oil may be disregarded. Joint surfaces shall be
free from fins and tears.

5.4.14 Each weld shall be uniform in width and size throughout its full length. Each layer of
welding shall be smooth and free of slag, cracks, pinholes and undercut, and shall be
completely fused to the adjacent weld beads and base metal. In addition, the cover pass
shall be free of coarse ripples, high crown, deep ridges and valleys between the beads,
and shall blend smoothly and gradually into the surface of the base metal.

5.4.15 Butt welds shall be slightly convex, of uniform height, and shall have full penetration.

5.4.16 Fillet welds shall be of specified size with full throat and the legs of uniform length.

5.4.17 Repair, chipping, or grinding of welds shall be done in such a manner as not to gouge,
groove, or reduce the base metal thickness.

5.4.18 Structures that are galvanized shall be continuously seal welded.

5.4.19 All welding shall be completed prior to painting or galvanizing.

5.4.20 Non-destructive testing of welds, where shown on the drawings, shall meet the
provisions of the applicable codes, specifications and recommended practices listed in
Section 2. The method of testing shall be shown on the drawings.

5.5 Bolting

5.5.1 Unless otherwise specified bolts 20 mm diameter and smaller shall be ASTM A307
Grade A. Bolts shall be installed and tightened so that all surfaces of the joint are in snug
1 contact.

5.5.2 Unless otherwise specified bolts greater than 20 mm diameter shall be ASTM F3125
Grade A325M installed and tightened using load indicator washers in accordance with
the applicable codes, specifications and recommended practices listed in Section 2 and
this specification.

5.5.3 Methods of installing bolts shall conform to the applicable codes, specifications and
recommended practices listed in Section 2.
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5.5.4 Either the "Turn-Of-Nut" or "Calibrated Wrench" method may be used for bolt tightening.
The calibration shall be performed using an approved device capable of indicating actual
bolt tension to assure that the minimum required bolt tensions are being obtained in
accordance with the applicable standards.

5.5.5 Where friction-type joints are specified on the drawings, the contact surfaces of the joints
shall be free of loose rust, oil and dirt and shall be prepared as specified on drawings.
Contact surfaces of galvanized members shall be scored with a wire brush prior to
assembly.

5.5.6 Beveled washers shall be installed under the heads of bolts or nuts when bearing on the
tapered flange of structural members. Beveled washers shall also be used to provide flat
bearing of diagonal tie-rod bracing.

5.5.7 Bolts, nuts and washers shall be free of scale, dirt or damaged threads and shall have
alight coating of lubricant prior to installation.

6.0 PAINTING AND COATINGS

6.1 General

6.1.1 Structural steel members shall be painted, galvanized or coated as shown and specified
in the specifications and drawings.

6.1.2 Painting, galvanizing and coating of structural steel shall be in accordance with the
codes, standards and General Specifications listed in this specification.

6.1.3 Repairs to painted or galvanized areas caused by handling, field welds, etc., may be
accepted if repair to be made by a method which; provide equal protection and also to
be approved by COMPANY; however, finished piece will be re-inspected.

6.1.4 Painting and surface preparation shall be in accordance with General Specification HFY-
3800-0000-CPR-SPC-0005 for External Coating of Equipment and Piping.

6.2 Painting

6.2.1 Painting and surface preparation shall be in accordance with HFY-3800-0000-CPR-SPC-

0005 Specification for External Coating of Equipment and Piping.

6.2.2 All structural steel shall be shop primary painted according to specification of painting.

6.2.3 Paint shall be excluded from areas within 50 mm of joints to be field welded or high
strength bolted.

6.2.4 After completing erection, Contractor shall clean and paint all surfaces where paint was
omitted for field welding; and shall repair, clean and paint all areas damaged subsequent
to shop painting so that all steel is completely covered by a sound coating equivalent to
the shop painting specified.
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6.3 Galvanizing

6.3.1 Where galvanizing of steelwork is called for, it shall be done after shop fabrication.
Welded joints in material to be galvanized shall be completely sealed with not less than
the equivalent of a 5 mm fillet weld in addition to the structural welding as shown. This
seal welding shall be provided whether or not shown on the drawings.

6.3.2 Weld slag or spatter, mill scale and other surfaces contaminants not removed by normal
caustic cleaning and pickling shall be removed by abrasive blasting.

6.3.3 Materials and facilities used in connection with the galvanizing work shall be subject to
inspection and approval by COMPANY.

6.3.4 Occasional bare spots or mechanical damaged caused by handling, etc., may be
accepted if repairs are made by a method which will provide equal protection, is
approved by COMPANY and the finished piece is re-inspected.

6.3.5 Warped or twisted structural shapes are not acceptable.

6.4 Coatings

All steel to be coated shall be coated as per section 4.1 in HFY-3800-0000-CPR-SPC-

1 0005 Specification for External Coating of Equipment and Piping. Coating to be applied
shall in accordance with manufacturer's instructions.
Some important steel structure shall be coated with fire protection coating, area and fire
rating shall be according to the specification and drawings. Coating shall be applied in
accordance with manufacturer's instructions and specification.
According to HFY-3800-0000-CPR-SPC-0005 Specification for External Coating of
Equipment and Piping, system EP1 will be used for structural steel and EP4 for
structural steel under fireproof.

6.5 SHIPPING AND HANDLING

All parts shall be thoroughly cleaned of loose scale, dirt or other foreign materials. They
shall be properly marked for identification to facilitate field erection. All parts shall be
protected from damage in shipment and loaded and unloaded in a manner ensuring that
no scratching of surfaces or distortion of components results.
No material shall be shipped until the shop coat of paint is thoroughly dry and clearly
marked with waterproof ink or paint.
Shipments shall only be made of sections of steelwork complete with connectors and
bolts which would allow erection of the steelwork upon delivery.
All Bolts, washers and nuts shall be packaged in separate, rigid, weatherproof
containers by size and length for each shop order, with each package properly identified.
Loose clips and other small parts shall be wired together to facilitate handling and to
prevent loss.
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Contractor shall receive, unload and stockpile all materials at the jobsite. Contractor
shall protect the steel against damage prior to erection, including protection of painted
surfaces during storage and handling.

7.0 ERECTION

7.1 General

7.1.1 Unless otherwise specified or shown on the drawings, the erection of structural steel
shall conform to the applicable codes, specifications and recommended practices listed
in Section 2.

7.1.2 Contractor shall furnish and install all temporary bracing as required during the erection
period.

7.1.3 Contractor shall supply all pre-fabricated structures, erection bolts, nuts, washers, load
indicator washers, shims, wedges and levelling plates required for proper fit-up.

7.2 Bolting

Bolts and the installation of bolts shall conform to this specification.

7.3 Welding

7.3.1 Welding shall conform to this specification.

7.3.2 Before field welding on galvanized or painted surfaces, remove the surface coating
within 50 mm of welds.

7.3.3 Field welding shall be in accordance with the shop drawings, erection drawings or other
contract documents.

7.3.4 Unless otherwise shown on the drawings, non-destructive testing other than visual
examination is not required. Where applicable, the drawings will indicate the welds to be
given non-destructive tests, the extent of each type of test for each weld, and the method
of testing.

7.4 Alignment and Fitting

7.4.1 Each part of a structure shall be properly aligned before completing field connections.

7.4.2 All members in completed frames shall be true to line and free from bends, twists and
open joints.

7.4.3 Fitting-up bolts and drift pins shall not be used to bring improperly fabricated members
and parts into place thus causing a strain on bolts in finished work. Drift pins shall not be
driven with such force as to injure adjacent metal.
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7.4.4 Packing, shimming, or wedging shall not be permitted to correct faulty work, unless so
directed by COMPANY.

7.4.5 Minor misfit, which can be remedied by a moderate amount of reaming and slight cutting
and chipping, may be corrected by Contractor when, in COMPANY's opinion, it will not
be detrimental to the strength or appearance of the structure.

7.4.6 Fastening of splices of compression members shall be done after the abutting surfaces
have been brought completely into contact. Splices shall be permitted only where
indicated on the drawings.

7.4.7 Erection bolts used in welded construction shall be either tightened securely and left in
place, or removed and the holes filled with plug welds.

7.5 Setting Base Plates

7.5.1 Column base plates shall be set and shimmed to correct positions and elevation shown
on the design drawings.

7.5.2 Anchor bolts shall be tightened only after grouting.

7.5.3 Grouting shall be in accordance with the General Specification for Grouting. The erection
of other portions of structural steel shall commence only when grouting and anchors are
in a condition that they can adequately support all the loads subjected to them and their
expected capacity will not be influenced due to the erection operation.

7.6 Erection Tolerances

7.6.1 Erection tolerances shall be in accordance with the applicable codes, specifications and
recommended practices listed in Section 2 and specific requirements of this specification.

7.6.2 Unless otherwise shown, runways for electric overhead cranes shall not exceed the
following tolerance limitations:

Lateral Tolerance:
±6 mm in centre distance between two crane rails
±12 mm maximum centre line shown
Both items are per 15 m of runway.
Vertical Tolerance:
±6 mm from the elevation shown at the top of the rail, in the unloaded condition, per 15
m of runway

7.6.3 Rail joints shall be tight and provided for a smooth transfer of the crane wheel from one
rail to another.
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7.7 Repairs

7.7.1 All field repairs or alterations must be approved by COMPANY.

7.7.2 Bolt holes shall be made by drilling or punching. Holes made by burning are not
permitted.

7.7.3 Any cut member shall be dressed and have a smooth edge and shall be re-galvanized or
repainted in accordance with this specification.

8.0 INSPECTION

8.1 General

8.1.1 Contractor shall provide access to the work at all times to COMPANY for checking
materials, and fabrication and installation procedures.

8.1.2 COMPANY shall have the right to stop work and require repairs or alterations if, in his
opinion, the materials or workmanship do not meet the required specification.

8.1.3 Any omissions or failure on the part of COMPANY to disapprove or reject any work or
materials must not be construed as an acceptance of any defective work or materials.

8.1.4 Contractor will bear the cost if repair and additional inspection resulting from faulty
material or workmanship.

8.1.5 Contractor shall provide facilities including platforms, ladders, tools and calibration
records for inspection of the erected steel work as requested by COMPANY.

8.2 Steelwork

8.2.1 COMPANY shall inspect the erected steel work and workmanship for conformance with
the requirements of this specification, including but not limited to checking for plumb-
ness, high strength bolting, field welds and touch-up painting.

8.2.2 Shop fabricated structural steel shall be subject to inspection and approval by
COMPANY. Facilities shall be provided for shop inspection of materials and
workmanship as requested by COMPANY.

8.2.3 All unloading, storage, erection, welding, bolting and painting of structural steel shall be
subject to COMPANY's inspection and approval as to conformity to this specification.

8.2.4 Contractor shall provide adequate inspection to ensure proper cleanliness and
preparation of the faying surfaces of friction type high-strength bolted joints.

8.2.5 Specific inspection shall be made to ensure that the load indicator washers are properly
installed in accordance with the manufacturers' instructions.
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8.2.6 Welds shall be inspected by COMPANY in accordance with the provisions of the
applicable codes, specifications and recommended practices listed in Section 2 with
respect to technique, equipment, acceptance criteria, and personnel qualifications.

8.2.7 All welding inspection shall meet requirements of AWS D1.1 as applicable.

8.2.8 All welds shall be visually inspected.

8.2.9 As a minimum, non-destructive testing shall be performed in accordance with the

following:

 All groove welds in splicing of plate girders or rolled section: 10% Radiographic Test
or 10% Ultrasonic Test for wall thickness higher than 20mm including the weld.
 All controls shall be covered by an inspection report. These reports must be able to
link unambiguously to areas inspection.
 When temporary attachments have been removed, the surface of the base metal
shall be carefully ground and the inspected by visual examination and in addition for
steels of Re>275Mpa, by magnetic particle analysis or dye penetrant test.
 All welds shall be visually inspected in all accessible parts.
 Additional examination: Any welds of doubtful appearance (excessive wide, irregular
width or area, scaled surface, excessive distortion, etc.) shall be inspected by
radiographic or ultrasound inspection. If this not possible, it shall be inspected by a
magnetic particle analysis or dye penetrant.
 All full penetration welds in tension and over 25mm in thickness used in beam
column moment connections and corner and T-joints:
 25% Ultrasonic Test of each weld with a length >=1m, 15% of welds of the same
type with a length <1m shall be Ultrasonic tested.
 All fillet welds 10mm (throat thickness) or over in size shall be inspected by
magnetic particle test or by liquid penetrate inspection for 10% of their length.
 10% MPI or LPI of each weld with a length >=2m. 10% of welds of the same type
with a length <2m shall be MPI or LPI tested.

8.2.10 Welding Rejection

 Inspection of acceptance criteria shall be based on AWS D1-1 as applicable.

 Rejection of any portion of weld inspected on a less than 100% basis shall require
inspection of 100% of this weld.

8.2.11 Welding Repair

 WPS shall be established for repairs and covered by specific PQR.

 Any repair by welding shall be identified and inventoried in the inspection file.

8.3 Painting and Coatings

8.3.1 Painting
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 Painting and surface preparation shall be in accordance with General Specification

HFY-3800-0000-CPR-SPC-0005 for External Coating of Equipment and Piping.
 All structural steel shall be shop primed.
 Paint shall be excluded from areas within 50 mm of joints to be field welded or high
strength bolted.
 After completing erection, Contractor shall clean and paint all surfaces where paint
was omitted for field welding; and shall repair, clean and paint all areas damaged
subsequent to shop painting so that all steel is completely covered by a sound
coating equivalent to the shop painting specified.

8.3.2 Galvanizing

 Where galvanizing of steelwork is called for, it shall be done after shop fabrication.
Welded joints in material to be galvanized shall be completely sealed with not less
than the equivalent of a 5 mm fillet weld in addition to the structural welding as
shown. This seal welding shall be provided whether or not shown on the drawings.
 Weld slag or spatter, mill scale and other surfaces contaminants not removed by
normal caustic cleaning and pickling shall be removed by abrasive blasting.
 Materials and facilities used in connection with the galvanizing work shall be subject
to inspection and approval by OWNER.
 Occasional bare spots or mechanical damaged caused by handling, etc., may be
accepted if repairs are made by a method which will provide equal protection, is
approved by OWNER and the finished piece is re-inspected.
 Warped or twisted structural shapes are not acceptable.

8.3.3 Coatings

 All steel to be coated shall be coated as per section 4.1 in HFY-3800-0000-CPR-

SPC-0005 Specification for External Coating of Equipment and Piping. Coating to be
applied shall in accordance with manufacturer's instructions.

9.0 GUARANTEE

Contractor shall guarantee the structural item, component and erected structure against
defective materials, poor workmanship and improper design for a period of one year
after the steel has been erected, the total period not to exceed eighteen months from the
date of receipt. Contractor shall repair and make good, at his own expense, any defects
noted during the guarantee period.