KOC STANDARD

Page 2 of 35

STRUCTURAL STEEL WORK -

FOR

YATERIALS, FABRICATION AND ERECTION C DOC. NO. KOC-C-007 / FORMERL Y 0 75-MH- 7002 )

ISSUING AUTHORITY:

STANDARDS DIVISION

Page 3 of 35 REV. 1

I 1.0 SCOPE 1 2.0 APPLICATION

3.0 TERMINOLOGY 3.1 Definitions 3.2 Abbreviations

TABLE OF CQNTENTS

Page No.

4.0 REFERENCE STANDARDS AND CODES 4.1 Conflicts 4.2 List of Standards and Codes 4.3 KOC Standard Drawings

1 5.0 ENVIRONMENTAL CONDITIONS HEALTH, SAFETY AND ENVIRONMENT

7.0 BASIC ENGINEERING INFORMATION

8.0 MATERIALS REQUIREMENTS 8.1 General 8.2 Structural Shapes 8.3 Structural Plates 8.4 Steel Pipes 8.5 Structural Bolts 8.6 Electrodes

FABRICATION REQUIREMENTS 9.1 General 9.2 Connections - Generally 9.3 Review of Fabrication Drawings 9.4 Shop Details 9.5 Fabrication Drawings 9.6 Erection Markings 9.7 Fabrication Tolerances

WELDING 10.1 General 10.2 Welding Requirements 10.3 Workmanship 10.4 Acceptance of Welds

ERECTION REQUIREMENTS 1 1 .I General 11.2 Setting Out 1 1.3 Alignment and Fit-up 11.4 Bracings 1 1.5 Field Holes and Openings 1 1.6 Site Welding 1 1.7 HSFG Bolted Connections 1 1.8 High Strength Bolts 1 1.9 Permissible Deviations

12.0 MISCELLANEOUS METAL WORK 12.1 General 12.2 Steel Flooring 12.3 Stairways 12.4 Spiral Stairways

, 12.5 Ladders 128 Handrails and Toe Plates 12.7 Ramps

1 13.0 PAINTING I GALVANIZING 30 I 14.0 INSPECTION AND TESTING

14.1 General 14.2 Quality Plan 14.3 Material and Equipment lnspection 14.4 Shop lnspection 14.5 Visual lnspection 14.6 Non-destructive Tests

15.0 QUALITY ASSURANCE

16.0 PACKING AND MARKING

17.0 DOCUMENTATION 17.1 General 17.2 Work Records and Reports 1 7.3 Deliverables

ACKNOWLEDGEMENT

This document " KOC Standard for Structural Steel Work - Materials, Fabrication and Erection " (KOC-C-007) is intended to address the need for consistent and practical requirements for material selection, fabrication and erection of structural steelwork within KOC Facilities (Onshore). This KOC Standard has been approved by Standards Division in consultation wi th the Standards Technical Committee for use throughout the corporate engineering and operational functions of Kuwait Oil Company (K.S.C) This Standard sets out to achieve the following objectives :- a. To provide the basic specifications of applicable materials for weldable, non

alloy structural steel and miscellaneous metal work by use of hot rolled sections, which are widely used for general structural engineering purposes.

b. To specify various practical technical requirements of fabrication, welding, erection, inspection and testing with a view to achieving safe, reliable and economical construction of structural steelwork.

To furnish general technical inputs for developing project specifications and 9' design / construction drawings in order to ensure a consistent approach for D material selection and workmanship in structural steelwork.

d. To set out minimum requirements to monitor compliance of material, fabrication, welding and erection with a contract.

Feedback as well as any comments or suggestions from the application of this Standard derived at any stage of conceptual design, engineering, fabrication, field erection or maintenance are encouraged and should be directed to:

The Supdt. Standards Division (Chairman, Standards Technical Committee) Loss Prevention Group, KOC P.O. Box - 9758, Ahmadi 61 008 State of Kuwait

/ Task Force Responsible for this Standard I I The preparation' of this Standard has been entrusted by the Standards Technical I I Committee (STC) t o the Task Force No. (TF-Cl03) comprising of the following members: I ,$$Ar. S, Kumar Standards Div. - Team IeaderIAuthor Tel. No. 61 407 I '"r. AIAzir H.Akbar Proj. Mgmt Div.(N) - Member Tel. No. 61 197 i Mr. J. Masood Engg Design Div. - Member Tel. No. 61 322 Mr. Maged M.Madi Ahmadi Svcs.,Dept. - Member Tel. No. 66389

SCOPE

This Standard specifies the basic technical requirements of materials, fabrication and erection including welding, inspection, testing, painting and galvanizing of Structural Steel and Miscellaneous Metal Work for installation at t he KOC onshore facilities within Kuwait. -

This Standard covers only the use of weldable non-alloy; hot rolled structural steel shapes and plates etc. for general structural and engineering purposes ; and shall not be applicable t o cold formed and light gauge steel sections for any structural work.

APPLICATION

The materials and workmanship o f structural steelwork shall conform t o the requirements o f this Standard and the reference standards and codes mentioned herein.

Any exceptions or deviations from this Standard, along with their merits and justifications, shall be brought to the attention o f KOC Controlling Department for their review, consideration and amendment by Standards Division (if required). Compliance with this Standard does not o f itself confer immunity from legal or statutory obligations.

TERMINOLOGY

Definitions

F o r the purposes of this Standard, the following definitions apply.

Contractor

Person or persons, f irm or company contracted by KOC, who are undertaking the execution of the structural steel and miscellaneous metal work related t o engineering, procurement, fabrication, erection, welding, testing and painting.

Fabricator

Person or persons or firm contracted by the Contractor, w h o prepare the fabrication drawings andior fabricate the various comporlents of structural steel by connections through welds / bolts.

Faying Surface

The mating surface of a member that is in contact or in close proximity wi th another member to which it is to be joined. ,

I 4 Friction Grip Connection 1 A bolted connection which transmits shear by friction between I components. I I 3.1.5 Lamellar Tearing Separation in highly restrained base metal caused by through-thickness strains induced by shrinkage of adjacent weld metal. I

3.1.6 Shielded Metal Arc Welding (SMAW)

An arc welding process that produces coalescence of metals by heating them w i th an arc between a covered metal electrode and the work pieces. Shielding is obtained from decomposition of the electrode covering. Pressure is not used and filler metal is obtained from the electrode.

3.1.7 Submerged Arc Welding (SAW)

An arc welding process that produces coalescence of metals by heating wi th an arc between a bare metal electrode or electrodes and the work pieces. The arc and molten metal is shielded by a blanket of granular, fusible material on the work pieces. Pressure is not used, and filler metal is obtained from the electrode and from welding rod, flux, or metal granules.

I 3.1.8 Steel Designation System (as per BS) I Structural steel grades conforming to BS to be designated as illustrated below :

LL . b lmpact Properties (J), min. at specified temp. (*I Minimum Yield Strength (N/mmz) for t 21 6 mm Symbol . . . for Structural Steel b Designated Standard ( e.g. BS EN 10025 ) ( * ) JR = lmpact energy in Joules at room temp. of +20C

JO = lmpact energy in Joules at temp. of OC J2 = lmpact energy in Joules at temp. of - 20C

Weldability

,a The capacity of a metal to be welded under the imposed fabrication conditions into a specific, suitably designed structure and to perform satisfactorily in the intended service.

1 3.1 . I 0' Welding Consumables i' Materials comprising of welding electrodes, wires and fluxes; t o be specified as per AWS classification system with the following notations : For S M A W electrodes, symbols E70XX starrd for example E7015, E7016, E7018 & E7028, as

Coating Characteristics ( * *) Position Code (*)

70,000 psi Tensile Strength ( Min.) Electrode

(* ) 1 = All flat, vertical, overhead and horizontal 2 = Flat and horizontal only

("1 5, 6, 8 = Low hydrogen . -

3.2 Abbreviations

HSE Health, Safety and Environment ITP Inspection and Test Plan KOC Kuwait Oil Company ( K.S.C ) NDE Non-Destructive Examination PQR Procedure Qualification Record QAIQC Quality Assurance / Quality Control WPS Welding Procedure Specification

1 4-0 REFERENCE STANDARDS AND CODES 1 4.1 Conflicts 4.1 .I In the event o f conflicts between this Standard and the standards / codes

referenced herein, or other contractual requirements, the most stringent requirement shall apply. In case further clarifications are required, the subject shall be brought t o the attention of KOC Controlling Department.

I 4.1.2 In general, the order of precedence shall be followed as : a. Kuwai t ~ o v e r n m e n t a l Rules and Regulations b. KOC Technical Specifications c. This KOC Standard ( KOC-C-007 1 d. International codes and standards

"") e. Contractor's standards and specifications

DOC. NO. KOC-C-007 I Page 9 o f 35 I REV. 1 &,be2 List o f Standards and Codes

The latest edition of the following standards, codes and specifications shall apply:

I 4.2.1 Internationa! / National Standards AlSC Specification for Structural Steel Buildings - Allowable

Stress Design and Plastic Design

AlSC Manual of Steel Construction - Working Stress Design

AlSC Manual o f Steel Construction - Load and Resistance Factor Design (Vol. I)

I AlSC Manual of Steel Construction (Vol. II) - Connections ANSI A 1 0.1 3 construction and Demolition Operations - Steel Erection -

Safety Requirements

API 5L Specification for Line Pipe

ASME 01 8.22.1 Plain Washers

ASTM A 6 / 6 M Specification for General Requirements for Rolled Structural Bars, Plates, Shapes and Sheet Piling

I ASTM A36136M Specification for Structural Carbon Steel ASTM A 5 3 Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless

ASTM A 1 5 3 Specification for Zinc Coating (Hot-Dip) on' Iron and Steel Hardware

I ASTM A 3 0 7 Carbon Steel Bolts and Studs, 6 0 0 0 0 psi Tensile Strength ASTM A 3 2 5 Specification for Structural Bolts, Steel, Heat-treated, 1 20

1 105 ksi Minimum Tensile Strength

ASTM A 4 4 9 Specification for Quenched and Tempered Steel Bolts and Studs -

ASTM A 4 9 0 Specification for Heat-Treated Steel Structural Bolts, 1 5 0 ksi Minimum Tensile Strength

ASTM A 5 0 1 Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing

I ASTM A 5 6 3 M Specification for Carbon and Alloy Steel Nut's (Metric) I

DOC. NO. KOC-C-007 I Page 10 of 35 I Rw.1 ASTM B695 Specification for Coatings.of Zinc Mechanically Deposited

on Iron and Steel

ASTM F436 Specification for Hardened Steel Washers

ASTM F1554 Specification for Anchor Bolts, Steel, 36, 55, and 105 ksi Yield Strength

ASTM F1637 Standard Practice for Safe Walking Surface

I AWS D1. l Structural Welding Society - Steel BS 4 Structural Steel Sections : Part 1 : Specification for

Hot-Rolled Sections

BS' 449 Specification for The Use of Structural Steel in Building: Part 2 : Metric Units

BS '1 387 Sere-wed and Socketed Steel Tubes and Tubulars and for Plain End Steel Tubes Suitable for Welding or for Screwing to BS 21 Pipe Threads

I BS 2853 Design and Testing of Steel Overhead Runway Beams BS 3692 IS0 Metric Precision Hexagon Bolts, Screws and Nuts -

Specification (Metric Units) BS 41 9 0 IS0 Metric Black Hexagon Bolts, Screws and Nuts -

Specification (Metric Units) BS 4320 Specification for Metal Washers for General Engineering

Purposes. Metric Units

BS 4395 High Strength Friction Grip Bolts and Associated Nuts and Washers for Structural Engineering. Metric Series Part 1 : General Grade

BS 4592 Industrial Type Metal Flooring, Walkways and Stair Treads Part 1 : Specification for Open Bar Gratings

BS 4 6 0 4 Use of High Strength Friction Grip Bolts in Structural Steel Work. Metric Series : Part 1 : General Grade

I BS 5531 Code of Practice for Safety in Erecting Structural Frames fl?# BS 5950 Structural Use of Steel Work in Building : Part 2 :

Specification for Materials, Fabrication and Erection : Hot Rolled Sections

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DOC. NO. K~C-C-007 Page I 1 of 35

i' BS 7668. Weather Resistant Weldable Structural Hollow Sections BS EN 499 Welding Consumables - Covered Electrodes for Manual Metal Arc Welding of Non Alloy and Fine Grain Steels - Classification BS EN 101 1 Recommendations for Welding of Metallic Materials -

Part 1 : General Guidance for Arc Welding Part 2 : Arc Welding of Ferritic Steels

I BS EN 10020 Definition and Classification of Grades of Steel BS EN 10025 Hot Rolled Products of Non-Alloy Structural Steels -

Technical Delivery Conditions

BS EN 1 0 0 2 9 Specification for Tolerances on Dimensions, Shape and Mass for Hot Rolled Steel Plates 3 m m Thick or Above

BS EN 1 0 0 3 4 Structural Steel I and H Sections -Tolerances o n Shape and Dimensions

BS EN 10056 Specification for Structural Steel Equal and Unequal Leg Angles Part 1 : Dimensions Part 2 : Tolerances on Shape and Dimensions

BS EN 1 0 1 6 3 Delivery Requirements for Surface Condition o f Hot Rolled Steel Plates, Wide Flats and Sections Part 1 : General Requirements Part 2 : Plates and Wide Flats Part 3 : Sections

BS EN 1 0 2 1 0 Hot Finished Structural Hollow Sections o f Non-Alloy and Fine Grain Structural Steels Part 1 : Technical Delivery Requirements Part 2 : Tolerances, Dimensions and Sectional Properties

BS EN 22553 Welded, Brazed and Soldiered Joints - Symbolic ( IS0 2553) Representation on Drawings

BS I S 0 8 8 5 General Purpose Bolts and Screws - Metric Series - Radii under the Head

BS EN I S 0 8 9 8 Mechanical Properties of Fasteners made of Carbon Steel and Alloy Steel - Part 1 : Bolts, Screws and Studs

BS EN I S 0 1461 Hot Dip Galvanized Coatings on Fabricated !ron and Steel Articles

BS EN IS01 2944 Paints and Varnishes - Corrosion Protection of Steel Structures by Protective Paint Systems - Part 1 : General Introduction

BS EN IS01 471 3 Protection Against Corrosion of Iron and Steel in Structures - Zinc and Aluminum Coating

I IS0 272 Fasteners - Hexagonal Products - width Across Flats I IS0 888 Bolts, Screws and Studs - Nominal Lengths and Thread

Lengths for General Purpose Bolts I IS0 4759 Tolerances for Fasteners

SSPC-SP Steel Structures Painting Council - Surface Preparation Specifications

SSPC-PA2 Measurement of Dry Coating Thickness wi th Magnetic Gages

4.2.2 KOC Standards

1 KOC-C-001 KOC Standard for Basic Civil Engineering Design Data I KOC-C-027 KOC Standard for Materials and Workmanship - Fire

Proofing of Structural Steel Work

KOC-G-002 KOC Standard for Hazardous Area Classification

I KOC-G-004 KOC Standard for Packing, Marking and Documentation I I KOC-G-007 KOC Standard for Basic Design Data I I KOC-L-025 KOC Standard for Scaffolding I KOC-P-00 1 KOC Standard for Painting and Coating of Metal

Surfaces - New Construction

KOC Fire & Safety Regulations

4.3 KOC Standard Drawincls

15-1 9-1 3 Car Park Shelters - Standard Details

1 5-30-1 1 1 Standard Platforms and Crossovers Details

1 5-30- 1 20 Standard Steel Anchor Bolts

15-35-1 2 Base Plate Detail for Pipe Support \ I

DOC. NO. KOC-C-007

Reinforced Base Plate for Pipe Support

Anchor Skirt Detail for Pipe Support

Standard Ladder Details

Standard Handrail Details

Standard Circular and Rectangular Platforms Typical Details

Standard Steel Stair Details

Standard Stiles and Walkways

Standard Car Park Shelters

Typical Sunshade for Mobile Fire Monitor

ENVIRONMENTAL CONDITIONS

The environmental conditions in Kuwait are severe. Due regard should be given t o the consistently high levels of solar radiation experienced in Kuwait, which may develop surface temperatures of over 80' C (176' F) in exposed metals.

5.2 Refer t o KOC Standard for " Basic Design Data " (KOC-G-007) which provides the detailed design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC facilities.

1 6.0 HEALTH, SAFETY AND ENVIRONMENT /

6.1 The Contractor shall fo l low the necessary Health, Safety and Environment procedures, which are acceptable t o KOC, to protect i ts personnel and surrounding env i ronmntdu r i ng any site work.

Al l relevant safety requirements o f Health and Environment (HE) Guidelines, KOC Health, Safety and Environment (HSE) Policy and KOC Fire & Safety Regulations shall be adhered to, by the Contractor, while performing the Work wi th in KOC areas.

Hot work permits are essential prior to any field welding in any hazardous areas in compliance w i th "KOC Standard for Hazardous Area classification" (KOC-G-002) and relevant hazardous area classification drawings, as well as in any other areas within KOC facilities in accordance w i th Fire and Safety

I Regulations. i

1 7.0 BASIC ENGINEERING INFORMATION I Structural steelwork shall comply with the relevant technical requirements as specified in ;' KOC Standard for Basic Civil Engineering Design Data " (KOC-C-001) and shall be designed in accordance with AlSC or BS 449 along with other applicable British standards.-

7.2 Fireproofing requirements of structural steel shall also be considered for the fire protection of structures, wherever specified by KOC; and shall be provided in accordance with " KOC Standard for Materials and Workmanship - Fireproofing of Structural Steel Work " (KOC-C-027).

7.3 Structural steelwork shall be designed in the simpler forms of construction for general maintenance, easy access for painting and operation; and therefore, lattice type structures other than towers and roof trusses are not generally acceptable.

7.4 Structural steelwork shall be generally shop fabricated by weldingi and field assembled and erected by bolting at Site. .

7.5 Contractor should take into consiaeration the available facilities for transporting, handling, shipping, storing and erecting fabricated components of steelwork.

l"38-0 MATERIAL REQUIREMENTS General I

8.1 .I All Structural Steel materials shall be new, free from all defects that impair appearance, strength or durability; and shall-conform to the r e l _ e s B S or ASTM standards as referenced in clause 4.2 of this Standard.

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All materials shall be kept free from dirJ, grease and other foreign matter and shall be protected from corrosion.

8.1.2 In case, steel sections manufactured to the specified standard(s) are to be substituted wi th sections manufactured in other countries to different standards, Contractor shall submit at the time of inquiry all the technical data in English including geometrical, chemical and mechanical properties of

- the steel sections proposed, with the applicable national standards such as JIS, DIN or equivalent.

8.1.3 Mill certificates covering chemical, physical, charpy V-notch ~roperties, and the heat treatment data as applicable with heat number of all steel materials shall be submitted by Contractor for KOC approval prior to fabrication.

9 2 Structural Shapes

8.2.1 Structural steel (rolled shapes) shall be in accordance with the requirements of BS EN 10025 Grade S275JR or ASTM A36 or equivalent. \

.2.2 Structural steel (hollow sections) shall be in accordance wi th the requirements o f BS EN 1021 0 Grade S275JOH or ASTM A 3 6 or equivalent.

8.2.3 Structural members shall be supplied w i t h the dimensions and tolerances in conformity with BS 4, BS EN 10034, BS EN 113056 and BS EN 1021 0 (Part 2) or ASTM A6. The surface conditions shall conform t o BS EN 101 63.

I 8-3 Structural Plates 8.3.1 Structural plates shall be in accordance wi th BS EN 10025 S275JR or

ASTM A 3 6 or equivalent.

I 8.3.2 Plates shall have dimensions and tolerances in conformity w i th BS EN 1 0 0 2 9 or ASTM A6. 8.4 Steel Pipes

8.4.1 Structural steel pipes shall conform t o Grade 3 6 as per API 5L, Grade B, or t o ASTM A 5 3 Grade B.

1 8.4.2 Structural steel pipes, when designated as Grade 42, shall conform API 5L, ( Grade X42 .

8.4.3 Steel pipes shall be seamless or submerged arc welded (SAW), or electric resistance welded (ERW). ERW pipes shall be heat treated after welding in accordance w i th API 5L.

I 8.4.4 Pipes for handrails shall conform to ASTM A53, Grade B. I 1 8.5 Structural Bolts I 8.5.1 Structural bolts shall be high strength conforming t o either BS 3692 Grade

8.8 or ASTM A 3 2 5 1 A490. Nuts shall be as per BS EN I S 0 8 9 8 or ASTM A 5 6 3 and washers as per ASTM F436 respectively.

A 4 9 0 bolts shall not be hot dip galvanized and shall not be used in highly corrosive environments.

8.5.2 High strength fr ict ion grip (HSFG) bolts w i th associated nuts and washers shall comply w i t h the requirements o f either BS 4395, Part 1, General Grade or ASTM A 4 4 9 w i th A 5 6 3 nuts and F436 washers.

8.5.3 High-strength bolts, nuts, and washers shall be mechanically galvanized in

i.9 accordance w i th BS EN I S 0 1461 or class 5 0 of ASTM B695. 8 . 5 . 4 Ordinary bolts shall be IS0 metric black bolts wi th nuts and screws, and

strength shall conform to either BS 4 1 9 0 Grade 4 .6 or t o ASTM A307 . Nuts shall be as per BS EN IS0 898.

i

8.5.5 Ordinary steel washers shall comply w i th B S 4 3 2 0 for Metric Series o f bolts or ASME B18.22.1. Tapered washers shall be used where appropriate.

8.5.6 Ordinary bolts, nuts and washers shall be hot-dipped galvanized in accordance w i th BS EN I S 0 1461 or ASTM A1 53.

8.5.7 All fasteners shall be galvanized when used w i th galvanized or painted structural steel.

8.5.8 Mechanical and chemical properties of bolts and nuts shall be in compliance w i t h BS EN 1 0 0 2 5 / BS EN I S 0 898, ASTM A307, ASTM A325 or ASTM A490. For variation of forms, dimensions and tolerances of bolts and nuts refer t o IS0 272, I S 0 885, IS0 8 8 8 and IS0 4759.

Arc welding electrodes shall be in accordance with AWS as follows:

a. For manual shielded metal arc welding (SMAW) : E70XX as per AWS

b. For automatic or semi-automatic submerged arc welding (SAW) : F7X- EXXX as per AWS A5.17.

FABRICATION REQUIREMENTS

9.1.1 The Contractor / Fabricator shall prepare the fabrication drawings and shall be fully responsible for the accuracy of all the shop and I or field details o f structural steelwork.

9.1.2 Any substitution of shapes and built-up members shown on the KOC approved drawings shall be made only to expedite the work wi th full knowledge and prior approval o f KOC.

9.1.3 All frames, platforms, stairways, ladders, cages and handrails shall be shop assembled in the largest sections suitable for handling and transporting t o the installation Site, while minimizing site installation wrk.

9.Y.4 All fabricated frames shall be suitably braced and packed t o prevent distortion during transit.

9.1.5 When structures are fabricated or assembled in the open area, they shall be supported on f irm and level ground; and there shall be no settlement of the ground during assembly.

DOC. NO. KOC-C-007

Connections - Generally

Unless otherwise specified, the Contractor shall comply with the following:

9.2.1 Generally, structural steelwork shall be fabricated in the shop. All shop connections shall be by welding; and bolting may be used if shown specifically on the design drawings. All field connections shall normally be bolted at Site during erection.

9.2.2 HSFG bolts shall be used for moment connections in structures supporting vibrating or moving loads. Friction type connections shall be provided for crane girder, crane girder supports and wherever specifically indicated.

9.2.3 High-strength bolts shall be used for all main bearing type and moment connections. Main connections shall include main beam-to-beam, main beam-to-column, column splices, main bracing, crane brackets and all beams carrying equipment loads except as noted on the approved drawings.

9.2.4 Ordinary bolts shall be used for connections of secondary beams, purlins, light bracings, platforms, railings and similar members,'except as noted on the approved drawings.

.2.5 All connections shall be made with minimum t w o (2) bolts w i th minimum bolt sizes as indicated below :-

a. For main connections : M20 high-strength bolts. b. For secondary connections : M16 ordinary bolts. c. For ladder cages : M I 2 ordinary bolts.

9.2.6 Washers parallel or tapered to suit rolled steel sections being connected, shall be provided under each nut.

1 9.2.7 A11 welding symbols shall conform to AWS D l . I or BS EN 22533. 9.2.8 All strength welds shall be continuous fillet welds of minimum six (6) mm

size (leg length), unless otherwise indicated on the drawings.

9.2.9 Butt welds shall be used, where specifically indicated on the drawings. Splices in structural steel shall be full penetration butt welds and shall be subject t o KOC acceptance.

9.2.10 Gusset plates and stiffeners shall be minimum 10 mm thick. Welded end plates shall be minimum 12 mm thick.

-2.1 1 Runway beams and structural members to be periodically removed for maintenance purposes shall be connected to main framework with bolts BS 3692, Grade 8.8 or equiv.alent. Lock nuts shall be provided for all bolts securing runway beams to main framing.

Review o f Fabrication Drawinns

9.3.1 The Contractor shall submit all fabrication drawings with shop and field a) connection details t o KOC for review. Fabrication shall commence only after KOC has completed the review and informed the Contractor in writ ing t o proceed w i th the work.

9.3.2 The review and approval of fabrication drawings by KOC .does not, however, relieve the Contractor o f his responsibility t o furnish the materials and construction in ful l compliance with the project drawings and the requirements o f this Standard.

9.3.3 Fabrication drawings shall indicate for KOC review, all details of fabrication, information about materials, sizes, exact cut lengths, methods of assembly, welding details, location o f hardware fastenings, shop and field splices, joint preparation and weld procedures.

1 9.4 Shop Details I 9.4.1 All columns, except angle columns, shall be milled t o bear on base plates

and a t the contact surfaces of column splices.

9.4.2 All columns shall be welded to the base plates and at the column splices unless noted otherwise o n the drawings.

9.4.3 If crane girders are t o be spliced, rails shall not be spliced at the same points. Crane rails shall have staggered joints, i f any, along the runway beam.

9.4.4 All beams w i th moving loads shall have a pair of 1 0 mm thick stop angles bolted on the flange at each end.

9.4.5 Bolt holes shall be cut, drilled, or punched at right angles t o the surface of the metal and shall not b e made or enlarged by burning. Holes shall be clean cut wi thout torn or ragged edges.

9.4.6 For bol ts not exceeding 24 m m diameter (inclusive), holes shall be not more than 2 m m greater in diameter than the bolt, and for bolts over 24 m m diameter, holes shall be n o t more than 3 m m greater i n diameter than the bolt, except in steel base plates or where otherwise specified. Holes should be perfectly circular and n o t oblong, unless otherwise specified.

9.4.7 Beam t o column connections shall be arranged to facilitate erection without 1 the t i l t ing of columns. I

I At any seated connections, t h e beam set-back shall not exceed 12 rqm. I

Where seated connections are used, the bottom flange o f the beam shall be connected to the seat angle. The beam web shall be connected.with a side c l ~ p t o the column.

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DOC. NO. KOC-C-007

Y .4.8 A t equipment support beams with bolsters, the web shall be stiffened wi th stiffeners t o match the stiffeners in the bolster above the beam, stiffener length shall be one-half of the nominal depth with the top milled. 9.4.9 Camber shall be provided for trusses of span exceeding 30 m and wherever

indicated on the drawings. Large span welded trusses shall be detailed with splice connection to the largest possible section for ease of shipping.

9.4.10 Vertical bracing shall be connected to both beam and column at the intersection of column, beam and bracing.

9.4.1 1 Horizontal bracing shall be connected to both column and beam where the inside face of the column is used as a working point.

When the center of a column is used as a working point with beams framing to the flange and the web of the column, horizontal bracing in plane of the beams shall be connected to both beams.

9.4.1 2 All platforms, including circular platforms, shall be shop assembled including posts, handrail, mid-rail and toe plate to the maximum extent permitted by shipping limitations.

.4.13 Where the shop attachment of handrail assembly to platforms is limited by shipping constraints, both straight and bent sections of top'rail, mid-rail, toe plate, and post shall be supplied in shop fabricated assemblies for field bolting or welding to platform steel to minimize the field work.

Removable sections of handrail shall be provided with posts at each end of the removable section for bolted connection to supporting clip. I

9.4.14 Open grid flooring shall be attached to the supporting members wi th the saddle type clips, field fastened with 6 m m diameter self tapping screws at each end of panel and one at middle of panel at each intermediate support.

I 9.4.1 5 Removable floor plates shall be fastened with M I 2 bolts. I 1 9-5 Fabrication Drawinqs I

9.5.1 As a part of fabrication procedure, the Contractor shall prepare the erection plans with erection marks shown thereon in letters of at least 3 m m high, preferably on the reproductions of the approved project or construction drawings.

Each structure shall have an index sheet for the steel details. On small jobs, the index may be included to the erection plan, where convenient.

9.5.3 A bolt list specifying the number, size, type of conr:ector, grip and ordered length of connector for each connection shall be f~lrnishsd by the Contractor

!

I / Fabricator. This listing shall be divided into categories and tiers as below :- 1 a. Beam to column connections. b. Beam to beam connections. c. Column splices. d. Bracing to column connections. e. Bracing to beam connections.

I A summary of all field connectors by size and length shall also be included. I 9.5.4 A bill of material in standard format shall be the integral part of each

fabrication drawing(s) listing all material and fittings with weight(s) of each member summarizing into actual "weighing up" of the structure. Otherwise, a separate bills of material shall be furnished by the Contractor.

1 9-6 Erection Marking 9.6.1 The Contractor / Fabricator shall be responsible t o furnish an erection

marking system identifying all members for KOC review prior to fabrication.

9.6.2 Beam marks shall be painted on beams at the same end as they are shown on the plan view of the framing plan.

9 9.6.3 All unsymmetrical beams, girders, or trusses, shall have a direction painted I on one end, preferably "North" or "East".

9.6.4 All members shall be marked "Top" where the member may be erected inverted.

9.6.5 All columns shall have the mark painted "North" or "East" on the outside face of the flange.

I 9.6.6 All vertical bracings shall be marked with paint on the lower end. . I 9.6.7 Where a member is shipped in t w o or more pieces, each piece shall have a

different mark.

1 9.6.8 The suffixes like "R" or " L " for opposite hand marks shall not be used. I 9.6.9 All marks shall be painted on the steel in legible fashion, with letters and

numerals of minimum 40 m m high.

I 9.7 Fabrication Tolerances I I 9.7.1 The tolerances for materials (rolled sections & plates) shall be in accordance

with relevant standards as mentioned in clause 8.0 of this Standard.

9.7.2 However, tolerances for other features like length, straightness, camber, squareness, flatness and verticality of members and built-up members, shall be ~n compltance with BS 5950 Part 2 or AWS D l .l. \

1 10.1 General I

10.1 .I Welding shall be carried out in compliance wi th all requirements specified in A W S D 1 . l o r B S E N 1011.

10.1.2 Contractor shall prepare the Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) as per A W S D l .I requirements and submit t o KOC for approval at least one (1) month in advance before commencing fabrication works.

10.1.3 All welding work shall be carried out by the skilled and qualified welders. Welders shall be pre-qualified and approved by KOC through Welder Qualification tests as per AWS D l .I. Records o f all these qualification tests and certif icates o f qualification of personnel shall be maintained for the period o f fabrication work.

10.1.4 All welding shall be performed in areas protected f rom rain, wind and air- borne dust and sand.

Weldinn Requirements

10.2.1 All i tems o f electrodes, welding wires, fluxes and welding equipment shall be capable o f producing sound and satisfactory welds, when used by a qualified welder or welding operator using qualified welding procedures.

10.2.2 Structural fabrication shall generally be made by manual shielded metal arc welding (SMAW) with E70XX electrodes.

However, submerged arc welding (SAW) w i th F7X-EXXX electrodes may be used for automatic or semi-automatic welding of long runs o f welds for built-up sections and crane girders,

10.2.3 All S M A W electrodes t o be used shall be l ow hydrogen with E70 filler metals for fabrication of structural steel work.

10.3.1 All structural welds shall be made in accordance with the sizes and types of welds (fillet, bu t t or groove) as shown on the project or fabrication drawings.

, 3 1 0 . 3 . 2 All fillet welds shall be minimum 6 mrn equal leg size unless otherwise noted.

T 10 .3 .3 All but t welds shall be full penetration welds a ~ d shall be made in t w o or I more passes such that filler material is deposited over the whole thickness of the joint.

10.3.4 Suitable joint details for full penetration welds shall be selected based on the thickness of the base metals such that it will not cause lamellar tearing due to weld shrinkage.

10.3.5 All structural tubular members shall be connected with full penetration groove welds as shown on the drawings or in accordance with AWS pre- qualified tubular joints. Partial penetration groove welds shall not be

10.3.6 All tack welds shall be carried out by qualified welders andlor weld operators and shall be subject to the same quality requirements as the final welds as specified in AWS D l . I , Section 3. Tack welds may be used judiciously to retain the parts in alignment during welding and shall be removed, if not to be included in the final welds of the welded joint.

10.3.7 Seal welds except for building, shall be provided along all faying surfaces, not otherwise structurally welded, to 3 mm (118") minimum size.

10.3.8 All temporary assembly attachments shall be removed by flame cutting or gouging a minimum 3 m m above the surface of the base material; and shall be finished smooth and flushed by grinding, taking care so that base metal is not damaged.

10.3.9 All welds shall be deposited in a sequence which will minimize distortion and shrinkage. No welding shall be done on wet surfaces.

10.3.10 Any paint on surface adjacent to joints to be welded shall be thoroughly removed to expose clean steel within 50 mm from each side of the outside lines of welds.

10.3.1 1 Structural parts to be welded shall be properly prepared and shall be firmly held in position prior to welding to avoid warping and buckling.

10.3.1 2 If joined by fillet welds, the parts shall be brought as close as practicable to a separation distance for root opening not exceeding 5 mrn (3116"). If the separation is more than 1.6 mm (111 6") or greater, the leg of the fillet weld shall be increased by the amount of root opening.

10.3.13 If post-weld heat treatment is required, welds shall be stress relieved in accordance with AWS D l . 1.

10.3.14 Welding inspection and testing shall be in conformity with the relevant section of AWS D l .I and shall meet the requirements as specified in clause 14.0 of this Standard.

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DOC. NO. KOC-C-007

dl 0.4 ~ c c e p t a n c e of Welds 1 10.4.1 Welds shall be examined by visual inspection for inadequate penetration. I incomplete fusion, burned-through areas, slag inclusions, gas pockets. undercutting and improper weld geometry.

I f these or any other defects are found, which in the opinion o f KOC are detrimental t o the integrity o f the structure, all such welds shall be repaired , or replaced by the Contractor at no cost t o KOC.

10.4.2 The Contractor shall submit repair procedure(s1 to KOC for review and shall commence rectification cjf defective welds only after obtaining KOC approval t o proceed w i th the work. Routine repairs should no t need case b y case approval t o proceed.

10.4.3 The repaired welds, depending on the types, shall be tested for soundness as per methods of testing (UT, MPI or radiographic) as specified in clause 14.0 o f th is Standard.'

I 10.4.4 Welds shall be deemed t o be acceptable, when the results are found t o be satisfactory after random checks and tests in accordance with clause 14.0 I o f this Standard.

10.4.5 However, KOC has the right t o reject any weld under the conditions as below :-

a. Welds that do not conform t o AWS Dl .I and this Standard. b. Welds that do not conform t o the project or fabrication drawings. c. Welds that have caused distortion and shrinkage o f the adjoining

members. d. Any we ld that impairs the safety of the member or structure. I 11.0 ERECTION REQUIREMENTS I I 1 1 .I General i

1 1.1 .I Prior t o erection, all fabricated parts of structures shall be transported safely b y the Contractor f rom the fabrication yard t o the installation Site wi thout any visible abrasion, distortion, bending, buckling or other damage t o any o f the structural members. I i

I 1 1 .I .2 All miscellaneous materials like erection bolts, black bolts, high-friction grip b bolts with nuts, washers, load indicator washers, shims, wedges and leveling plates shall be furnished by the Contractor as necessary t o facilitate proper alignment and correct fit-up; and shall comply w i t h the relevant ASTM / BS standards as referenced in clause 4.2 of this Standard.

1 1 1 . I .3 The Contractor shall provide all labor, tools, equipment anc: scattolding t o I execute the erection work as per the KOC approved method statements and

i erection drawings. I

11 .I .4 All plant and equipment shall be of sufficient capacity and suitable for the loads and sizes of the structures or their parts to be erected. They shall be in sound condition, free from defects and shall be regularly tested as per the Factory Acts. The test certificates shall be always available at Site for inspection by KOC.

1 1.1.5 The Contractor shall be responsible to familiarize with all existing services above and below ground and shall take all necessary precautions to ensure that no damage will occur thereto during execution of the Work. No props or supports shall be attached or affixed to such services.

11.1.6 ANSI A10.13 for steel erection shall be adhered to for all safety requirements; and modern techniques & lifting equipmentk) shall be utilized.

I 1.2 Setting Out

11.2.: Before commencing erection of any major structures, all foundations including anchor bolts shall be checked for accuracy; and it shall be confirmed that the structure(s) shall be in place within the permissible deviations as specified in BS 5950 Part 2 or AISC.

1) 11.2.2 Setting out shall be carried out for all column bases and column tops for accurately positioning, plumbing, aligning and leveling of all other members of structures in accordance wi th KOC approved fabrication drawings and to KOC satisfaction.

1 1.3 Alignment and Fit-up

11.3.1 All structural members shall be erected in a sequential order which shall ensure safety as well as speedy progress of work. The method of handling, lifting and fixing shall be KOC approved.

11.3.2 Members shall not be permanently fixed before checking their correct positions and alignments. Minor misfits shall be remedied by means of drifting, moderate reaming, grinding, chipping or cold cutting of the members as necessary.

1 1.3.3 If any major misfits and misalignments of members occur due to fabrication errors, they shall be rectified t o a practical and satisfactory solution subject t o KOC approval.

11.3.4 If the safety of any part of structural work is in doubt due to these misalignments and misfits or the solutions outlined by the Contractor are not acceptable to KOC, that part of structural work or the individual affected

I members shall be removed and replaced by the new members..

2 1 1.4 Bracinqs' 1 1.4.1 Adequate numbers of temporary guys and bracings shall be provided

wherever necessary t o withstand all loads including erection load during erection. Such bracing(s) shall remain in place t o maintain the safety and stabil ity o f the structures until completion of erection and installation of permanent bracing systems.

11.4.2 Crane(s1 and heavy equipment shall not be erected on the structure, until permanent bracing systems (vertical and horizontal) w i th t ie members are f ixed t o the structure.

11.5 Field Holes and Openinqs

11.5.1 Field holes required t o be made shall be drilled, cleaned of burrs or rough edges and countersunk, i f necessary. No burning or punching shall be al lowed unless otherwise authorized.

11.5.2 Openings in gratingslopen grid floorings and floor plates n o t indicated on the drawings shall be cut and banded by the Contractor. Banding of field cut-outs (piping, conduit, equipment penetration etc.) shall be done as per the details shown on the drawings.

11.5.3 All f ield connections shall be wi th minimum t w o (2) Nos. M20 bolts, unless otherwise specified. 1 11.6 Site Weldinq

11.6.1 Site welding, whenever specified, shall be carried out in accordance with the details shown on the fabrication drawings after setting ou t and aligning the members t o their positions and providing the field connections.

11.6.2 All welds, except fillet welds, shall be full penetration welds unless noted otherwise.

11.6.3 No site welding shall be done on structural steelwork after surface preparation or painting has been carried out unless specifically permitted by KOC.

1 1.7 HSFG Bolted Connections

1 1.7.1 All connections using high-strength friction grip bolts shall comply w i t h the b requirements o f BS 4 6 0 4 Part 1 or AISC; and HSFG bolts shall be supplied in accordance w i t h clause 8.0 of this Standard. 1 11.7.2 HSFG bol ts shall be tightened to required tension using "Coronet" load I lndlcator washers or approved eau~valent. Hardened washers shall be

provlded as recommended by the manufacture of the load indicator washers.

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11.7.3 Contact surfaces shall be free of paint or other applied finish, oil, dirt, loose rust, scale, burrs or other defects. 8 1 1 1.8 Hiah Strength Bolts I High strength bolts, Grade 8.8 shall be tightened enough t o ensure that adequate contact is achieved between the parts assembled. The tightening shall be achieved by using a normal podger spanner or up t o a pbint where a power wrench starts to impact.

I 1 1.9 Permissible Deviations I The erection tolerances of steel framed structures shall comply wi th BS 5 9 5 0 Part 2 or AISC.

I 12.0 MISCELLANEOUS METAL WORK 12.1 .I Platforms shall be provided at locations above grade levels as operating

f loors and/or for access to equipment and their appurtenances for operations, servicing and maintenance as indicated on the drawings. Minimum width shall be no t less than 1000 m m for operating platforms and access around equipment(s1.

I a

12.1.2 Platforms, i f provided at various levels and around different items, shall be interconnected by walkways, stairways or ladders w i t h specific attention to escape routes in the event of fires.

12.1.3 Headroom clearance at all platforms shall not be less than 2150 m m considering the presence o f electrical fittings and all other obstructions thereon.

12.1.4 Platforms shall be installed in the form o f either open grid or solid checker plate steel flooring with stairways and ladders for access and exit; and shall be protected w i th handrails and toe plates as generally detailed in the clauses 12.2 t o 12.6 of this Standard.

12.1.5 Walkways shall be of open grid type and shall be provided wi th handrails and toe plates. Walkways shall not be less than 7 5 0 m m in width.

1 12.2 Steel F l o q r b I

12.2.1 Normally, steel flooring shall be o f open grid type and should be hot dip galvanized. However, checker plate flooring should be considered for safety where any chance of spillage exists from upper level t o lower'platforms or equipment.

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2.2.2 Open grid flooring shall be serrated rectangular type, with load bearing bars 30 mm deep x 5 mm thick @ 30 m m centers with 10 mm twisted cross bars @ 1 0 0 mm centers in transverse direction.

12.2.3 Open grid flooring shall be attached to the supporting steelwork with clips or by other effective means approved by KOC. Holes or cut-outs in panels shall b e stiffened around with welded strips prior t o galvanizing.

12.2.4 Checker f loor plates shall have raised pattern to provide a non-slip surface and shall be minimum 6 m m thick excluding the pattern.

12.2.5 Checker floor plates shall be attached t o the supporting frames w i th countersunk bolts, unless otherwise indicated on the drawings. Unsupported edges shall be stiffened wi th a 60 m m x 1 0 mm but t strap. rain age holes of 1 2 m m diameter shall be provided for every 1.5 mZ of floor plate, with a minimum of one (1) hole per panel.

12.2.6 lo or panel shall be limited to span (L) having deflections no t more than L l200 or 1 0 mm, whichever is smaller.

12.2.7 Steel flooring shall be provided to the extent as indicated o n the project i3 drawings and shall comply wi th all details shown on the KOC standard drawings listed in clause 4.2.3 of this Standard 1 12.3 Stairways I 12.3.1 Stairways shall be provided for access t o platforms serving equipment

which requires regular and frequent operational attendance or rapid escape or access in the event o f an emergency.

12.3.2 All stairs o n the same platform or in the same building should preferably be arranged with same slope, i f possible, and shall have handrails continuous with plat form handrails.

12.3.3 Stairways shall be arranged w i th the angle of slope between 30" t o 38" t o the horizontal. In some special cases, up t o 45' may be provided subject t o KOC approval.

i I

12.3.4 Generally, stairs shall be provided wi th at least 7 5 0 mm minimum clear ( w id th between stringers. Stairs shall have minimum 2 4 0 rnm tread width and maximum 1 9 0 m m riser height.

I

'"$2.3.5 However, main access and escape stairs shall have a t least minimum clear 1 widths of 1 0 0 0 m m and 1200 mm respectively between stringers. I ( 12.3.6 The maximum rise in a single flight of stairs shall be limited t o 3 0 4 0 m m or I

! ! i 16 risers wi thout landing. The n-lir~imurr) length of landing shall bs : 20C i 1 mm.

1 12.3.7 Headroom clearance over stairs shall be minimum 2 1 5 0 mm measured at t he nose o f a tread. 12.3.8 Treads for stairs and landings shall be galvanized open grid flooring t o the

sizes indicated on the drawings. For stair widths o f 1 0 0 0 mrn and 1200 mm, treads shall follow the same requirements given in clause 12.2.2 of th is Standard.

However, for stairs having 750 m m width, treads shall be made wi th 25mm deep x 5 mm bearing bars @ 30 mm clc with 10 mm diameter twisted bars @ 1 0 0 mm c/c in transverse direction. All treads at stairs and landings shall have full width anti-skid checker plate nosing.

12.3.9 Stairways shall be fabricated in accordance w i th KOC standard drawings 15-39-54 and 15-39-56.

1 12.4 S ~ i r a l Stairwavs I 12.4.1 Spiral stairways shall be generally provided t o the circular structures like

vessels and tanks for access to platforms.

12.4..2 Stair widths shall be a t least minimum 1 0 0 0 m m between stiingers and slope shall be decided on the basis of number of landings, depending on the diameter and height of the structures.

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12.4.3 Structural steel shall conform to ASTM A36. Anchor bolts shall be ASTM A 3 0 7 or ASTM F1554, Grade 36. Nuts and washers shall be in conformity with ASTM A563, Grade A and ASTM F436, Type 1 respectively. Field connections shall be bolted wi th ASTM A325 bolts.

12.4.4 Stairs and landings of stairways shall be galvanized open grid flooring t o the sizes indicated on the drawings and shall follow the same requirements given in clause 12.2.2 o f this Standard. Treads of stairs and landings shall have full w id th anti-skid checker plate nosing.

12.4.5 All spiral stairways shall be provided with handrails in accordance w i th KOC Standard drawing 15-39-54.

1 2..5 Ladders I ,, I 12.5.1 Fixed ladders shall be provided for I a. access t o all platforms not served by a stairway ; b. an emergency escape from a platform which is already served by

a stairway ;

I c . access to locations where no piatforms are provided. 12.5.2 All ladders shall be generally vertical. If inclined ladders are to be provided,

the slope shall be not more than 15" to the vertical, but their use is subject

3 12.5.3 Changes in inclination of ladders shall not be allowed. Intermediate platforms shall be provided to avoid change of inclination within a flight. 12.5.4 Side access ladders shall be preferred to front access. Safety bars shall be

provided where ladders start close to the edge of an elevated platform. I

12.5.5 Ladder shall be provided with safety cage, when ladder height is 5.0 m o r , more above ground or platform level. Safety cage shall start in that case from a height of 2.1 m minimum but not exceeding 2.4 m maximum from the ground or platform level. Safety cage shall be circular shape in plan wi th a radius ranging from minimum 3 4 0 mm to maximum 380 mm as applicable.

12.5.6 Ladder rungs shall be fitted into holes in the stringers and secured by welding. Ladder width shall be not less than minimum 380 m m but not more than 4 6 0 m m for ease of climb.

12.5.7 Ladders shall be fabricated in accordance with the details shown on KOC Standard drawing 15-39-53.

Handrails and Toe Plates

12.6.1 Handrails shall be provided for safety around edges of all platforms and walkways which are 500 mm or more above ground or any operating level. Handrails shall be provided for stairways and all landings.

12.6.2 Toe plates shall be provided along all edges protected by handrails, at openings in flooring around equipment, but not across the entrance to platforms by stairs and ladders. Toe plate upstand shall be not less than 100 mm.

12.6.3 Handrails shall be made of either steel sections (equal angles) or pipes and shall be fixed t o steel posts (equal angles) or tubular sections b y bolts or by welding. Handrail posts shall be spaced not more than 1800 m m wi th railing height not less than 1100 mm with at least one mid-railing.

12.6.4 Handrails shall be fabricated in accordance with details shown on KOC Standard drawing 15-39-54.

I 12.7 Ramps 2.7.1 Ramps, if made of steel, shall be provided wi th adequate width a t I.' emergency escapes in hospitals and buildings; and shall be of solid checker plates wi th raised anti-skid patterns. Checker plate shall be minimum 8 mm thick excluding the raised patterns.

I ' 12 .7 .2 Ramps or inclines shall have slopes not more than 15" and should never I exceed 20" from the horizontal; and shall be laid over a smooth surface of

thoroughly compacted base.

PAINTING I GALVANIZING

All structural steel including miscellaneous metal items shall be prepared, and shop painted or galvanized in accordance wi th KOC Standard for "Painting and Coating of Metal Surfaces -New Construction" (KOC-P-001).

Painting shall be excluded from the areas within 5 0 m m of joints to be field welded.

The areas o f contact surface for friction type connections (HSFG) in crane girders and girder supports, and other friction type connections wi th high- tensile bolts, shall not be painted.

All surface preparation and shop coating application shall be carried out by the Contractor in compliance w i th KOC Standard KOC-P-001.

All steelwork for platforms, stiles, walkways including open grid flooring, handrails, stair treads, ladders, cages and safety guards shall be hot dip galvanized in accordance with BS EN I S 0 1461.

All steelwork for valve pits and trenches including checker plates cover, steel beams and appurtenances shall be hot dip galvanized in accordance w i th BS EN IS0 1461.

13.7 All bolts, nuts and washers shall be galvanized as specified in clause 8.5 of this Standard.

13.8 If any fabrication or welding is done after shop painting, damaged areas of coating shall be re-blasted and recoated.

13.9 Painted surfaces shall be free f rom pinholes, runs, sags, thin spots, dirt inclusions and other evidence o f poor workmanship. Care shall also be taken t o prevent damage t o the coated surfaces during handling and transportation.

1 14.0 INSPECTION AND TESTING 14.1 General

14.1 .I Contractor shall perform at all stages o f the Work, all the responsibilities and duties of Inspection and testing through his qualified and KOC approved inspectors, to meet fully the requirements o f fabrication, welding and erection as laid down in AWS D l .I and this Standard.

14.1.2 However, KOC reserves the right of independent inspection df the material and workmanship at all t imes t o assure conformance to the project drawings, approved fabrication drawings, standards and specificat;lons

referenced in clause 4.2 o f this Standard.

14.2 Quality Plan

Contractor shall prepare and submit a detailed quality plan for KOC approval prior t o implementation. The quality plan shall consist o f the following:

a) lnspection and Test Plan '(ITPI

The ITP shall list the sequence of all inspection and testing activities.

The plan shall include inspection & testing of fabrication, assembly, and packing for shipment in a chronological order, showing the frequency o f control, the acceptance criteria, the governing code and whether a document or report is produced for each activity.

I b) Pre-inspection Meeting (PIMI PIM shall be held by the Contractor wi th KOC before commencing of the fabrication work. During the PIM the Contractor and KOC will review and finalize the mark-up of the ITP, confirm the requirements for witnessing (W), surveillance (S), monitoring (MI, reviewing (R), in the plan. The approved quality plan shall be strictly adhered t o throughout the entire fabrication, assembly, inspection, and testing period.

I 14.3 Material and Equipment Inspection 14.3.1 All materials shall be inspected from t ime to time for safe keeping and shall

be properly laid ou t o n wooden supports clear of the soil and shall b e covered with plastic sheets. Care shall be taken t o ensure that no damage or harmful sand or water ingress occurs.

14.3.2 The Contractor shall keep the mill certificates and shop material test reports of all approved materials t o be used or used in the fabrication work available for KOC inspection whenever needed.

14.3.3 All equipment t o be used for site welding and field erection shall be inspected t o ensure compliance wi th the KOC Fire and Safety Regulations.

14.4 Shop lnspection

14.4.1 Shop fabrication inspection and tests shall be performed by the Contractor in accordance with ITP prior t o assembly, during assembly, during welding and after welding t o ensure that materials and workmanship shall meet the requirements of th is Standard and approved drawings.

! 14.4.2 KOC may additionally employ the services of inspectors, as deemed appropriate; t o witness the required inspection and testing of materials and

1 workmanship after gett ing proper advance notice from the Contractor.

14.4.3 Welds shall be inspected regularly by the Contractor I Fabricator according to AWS requirements with respect to technique, equipment, acceptance criteria and personal qualifications. All welds shall be subject to random visual inspection according to Section 8.1 5 of AWS Dl .I.

I 14.5 Visual Inspection I 14.5.1 All structural steel welding shall be subjected to close visual inspection by

the qualified welding inspectors of the Contractor as the work progresses; and all deficiencies, faults or bad practices shall be corrected as soon as possible. Miscellaneous steel welding shall also be visually inspected as per ITP as specified.

14.5.2 In particular, main structural welds shall be examined after thorough cleaning for faults such as lack of fusion, surface inclusions and undercutting.

14.5.3 Visual inspection shall be aided by a strong light, magnifiers or such devices which are helpful to detect visually cracks in welds, and base metals and other discontinuities in the welding.

14.6 Non-destructive Tests

14.6.1 Non-destructive examinations (NDE) of structural welds, whenever required, shall be conducted by means of ultrasonic (UT), magnetic particle (MP), dye penetrant (DP) or radiography tests to evaluate the soundness of weld metal for the integrity of structural welded connections and critical joints. I

14.6.2 Testing shall be in random spots and as per AWS Dl . I . Location of the spot testing shall be determined by KOC.

14.6.3 Fillet welds shall be inspected by MP or DP tests as per Part A, Section 6 and shall be accepted based on Part D, Section 8 o f AWS D l -1,

14.6.4 All full penetration welded corner and T-joints used in beam column connections shall be inspected by ultrasonic tests in accordance with the thickness schedule as per Table I :

Table I : Tests for Weld Lennth I I Thickness of Thinnest Section to be Welded 11 Weld Lenclth to be Tested 11 I

14.6.5 All full penetration butt welds used in splicing members shah have visual inspection and shall also be inspected by non-destructive tests, either by ultrasonic or radiographic tests as follows:-

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( No. 1 1 1 by UT - (%I 20 5 0

1 2 3

I Over 5 0 mrn (2" ) 5 0 mm (2 " ) to 25 mm (1 "1

Less than 25 mm (1")

a. Ultrasonic tests shall be carried out on the entire length of butt weld including the webs as per Part C, Section 6 of AWS Dl .l.

b. Radiographic tests shall be made by one spot radiograph per 500 mm (20") of butt weld including radiographs on the tlange sections of the beam w i th a minimum one radiograph per welded connection in accordance with Part B, Section 6 of AWS Dl .l .

14.6.6 Welds shall be acceptable, when they are found to be satisfactory meeting ' all the requirements of visual inspection and the specified tests in accordance wi th relevant sections of AWS Dl .1 to assure the soundness of weld metal.

14.6.7 Welds, i f found to be unsatisfactory and unacceptable, shall be subjected to the requirements of clause 10.4 of this Standard and shall be repairea'as per Section 3.7 of AWS Dl .I.

I 15.0 QUALITY ASSURANCE The Contractor shall operate a quality system preferably based on IS0 .go00 series of standards t o satisfy the requirements of this Standard. The Contractor shall demonstrate compliance by providing a copy of the accredited certificate or i ts quality manual. Verification of the Contractor quality system is normally part of the pre-qualification procedure and is, therefore, not detailed in the core text of this Standard.

16.0 PACKING AND MARKING

For packing and marking of materials, refer to " KOC Standard for Packing, Marking and Documentation " (KOC-G-004).

I 17.0 DOCUMENTATION 17.1.1 All correspondence, instructions, data sheets, drawings or any other written

information shall be in English language. In case of dual languages, one language shall be English.

1 17.1.2 All dimensions, units of measurement, physical constants etc. shall be in SI I units unless otherwise specified. (Nominal bore pipe sizes to be generally 1 mentioned in inches ).

P . I . 3 All documents (text, data sheets, specifications etc.) shall be provided wi th electronic files in the approved and widely used software ( MS Word, Excel, Auto Cad etc.). All calculations shall be submitted in approved and widely used software(s) agreed upon by KOC. I

i 17.2 Work Records and Re~or ts 17.2.1 Contractor shall operate a detailed recording and reporting system on all

aspects of structural steelworks including inspection and testing. All relevant information shall be set out on a Site Record for fabrication and erection within 2 4 hours of carrying out a specific work.

17.2.2 All test results and certificates of materials required for ,satisfactory execution of the Works shall be submitted to KOC for review and approval within the stipulated period as specified in the Contract documents.

17.2.3 All equipment and machinery, associated with cutting, welding, handling, transporting, erecting and painting the structural steel, shall have the latest fitness test reports certifying that they are in good working conditions and shall be submitted to KOC for further inspection, i f necessary, as per KOC regulations.

17.2.4 All inspection reports including NDE tests shall be submitted to KOC for review and acceptance within 72 hours of completion of tests.

1 7.3 Deliverables

17.3.1 Contractor shall submit the necessary documents as a minimum to KOC for review and acceptance as below, but is not limited to the following only:

a. Structural analysis and design calculations for all frames, primary and secondary load bearing members, trusses, girders, built-up sections, bracings, connections and support structures.

b. Designfconstruction drawings of plan, elevations and details outlining sizes, dimensions, materials and connections.

c. Fabrication drawings showing member sizes and exact cut lengths, connection details including bolt sizes and lengths, type of welds and weld lengths with shop and field weld symbols, erection markings and bill of materials for all fabricated items.

d. Erection plans including list of equipment and tools to be used. e. Certified mill test and shop test reports for all steel materials specified. f. Material safety data sheets for paintsfgalvanizing and safety precautions

t o be taken. g. Welding Procedure Specifications (WPS) and Procedure Qualification

Records (PQR). (For approval) h. Inspection and test plan (ITP) and QAfQC procedures. (For approval &

mark-up) i. Welder qualification test records. (For review only) j. lnspection and nondestructive examination (NDE) records. k. \Weld quality surveillance records. I. Repair procedures. m. As-built drawings.

17.3.2 ContractorfFabricator shall submit the relevant calculations for any splice connections by bolts/welds to KOC for review, whenever required.

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DOC. NO. KOC-C-007 REV.l

ACKNOWLEDGEMENT

This Standard has been approved by the Standards Technical Committee (STC) consisting of the following:-

Mr. Ali H. Baba (Standards Div.) Chairman Mr. Mohd. Emam (Insp. & Corr. Dept.) Deputy Chairman Mr. S. Kumar (Standards Div.) SecretaryIMember Dr. Mohammad llyas (Standard Div.) Member Mr. Khalid S. AI-AIi (Gen. Proj. Div.) Member Mr. Henry S. Hill (Opn. Svcs. Dept. S&E) Member

The draft of this Standard has been circulated to the KOC user departments for their review and responses were received from the following:- I ENGINEERING GROUP OPERATIONS GROUP (S&E) Gen. Supdt. Proj. Nlgmt. Dept.(S&E) Gen. Supdt. Opn. Svcs. Dept.(S&E) Gen. Supdt. Proj. Mgmt. Dept.(N&W) Gen. Supdt. Opn Dept. (El Gen. Supdt. Engg. Svcs. Dept. Gen. Supdt. M&EO Dept.

L3 AJOR PROJECTS GROUP OPERATIONS GROUP (N&W) I Gen. Supdt. Engg. Proj. Dept.(S&W) Gen.Supdt. Opn. Svcs. Dept.(N&W) I INDUSTRIAL SERVICES GROUP LOSS PREVENTION GROUP Gen. Supdt. Ahmadi Svcs. Dept. Gen. Supdt. Insp.& Corr. Dept. Gen. Supdt. Transport & Plant Dept. Gen. Supdt. Fire & HSE Dept.

I DRILLING OPERATIONS GROUP DIVIDED ZONE GROUP Gen. Supdt. Drill. Engg. & Supp. Svcs. Dept. Supdt. Proj. Engg. & Faciljties Div.

This KOC Standard for " Structural Steel Work - Materials, Fabrication and Erection " has been prepared by the Task Force (TF-C/03) comprising of the following members:

Mr. S, Kumar Standards Div. - - Team IeaderIAuthor Tel. No. 61 407 Mr. AIAziz H.Akbar Proj. Mgmt Div.(N) - Member Tel. No. 61 197

r. J. Masood Engg Design Div. - Member Tel. No. 61 322 ! Maged M.Madi Ahmadi Svcs. Dept. - Member Tel. No. 66389