Pearl GTL

Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.251.018

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

LINDE ENGINEERING

Contractor Project No:

Project Rev.: A

Page 2 of 11

5887

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION

07.01.09

Ready for Construction

SB

EO

AG

RFC

24.07.08

Issued for Company Comments

SB

EO

AG

ICC

05.07.08

Issued for Company Comments

RT

MK

AG

ICC

03.07.08

Issued for Review

RT

MK

AG

IFR

02.07.08

Issued for Internal Review

RT

MK

AG

IIR

Date

Description

GAMA
Rev.
No.

Project
Rev
No.

Prepared Checked Approved

By
By
By
ORIGINATOR

Status

Document Title:

LINDEGINEERING AG

PROCEDURE - STRUCTURAL STEEL REPAIR WORKS

AT SITE
Document No.

Contractor

Gama Qatar Co. W. L. L.

LOC470

GAM

PRO

GEN

GTL

035

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T-4.251.018

Vendor Code

Rev No: A

Q A T A R

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

TABLE OF CONTENTS

SCOPE.......................................................................................................................................5

PURPOSE .................................................................................................................................5

HSSE..........................................................................................................................................5

REFERENCE & DEFINITIONS: ............................................................................................5

RESPONSIBILITIES ...............................................................................................................6
5.1

SITE MANAGER ......................................................................................................................... 6

5.2

MECHANICAL ERECTION MANAGER ................................................................................ 6

5.3

SITE ENGINEER ......................................................................................................................... 6

5.4

SITE SUPERVISOR .................................................................................................................... 6

5.5

QC INSPECTOR .......................................................................................................................... 7

The QC Inspector will be responsible for, ............................................................................................... 7

5.6

WELDING ENGINEER .............................................................................................................. 7

The Welding Engineer will be responsible for, ....................................................................................... 7

DESCRIPTION AND MEASURES ........................................................................................7

6.1

PRECAUTIONS ........................................................................................................................... 7

6.2

DESCRIPTION OF FAULTS ..................................................................................................... 8

6.3

MEASURES .................................................................................................................................. 8

6.4

REPAIR AND MODIFICATIONS ............................................................................................. 8

6.5

SURFACE PREPARATION ....................................................................................................... 9

6.6

REPAIR OF DAMAGED GALVANISING ............................................................................... 9

6.7

EQUIPMENT ............................................................................................................................. 10

CALIBRATION .......................................................................................................................10

INSPECTION ..........................................................................................................................10
8.1

TESTING .................................................................................................................................... 10

8.1.1
8.1.2

9
10

VISUAL INSPECTION ......................................................................................................................... 10

REPAIR OF PAINTING ....................................................................................................................... 10

RECORDING ..........................................................................................................................10
QUALITY ASSURANCE...................................................................................................11

T-4.251.018, Rev. A

Page 4 of 11

Q A T A R
1

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

SCOPE
This Procedure covers mainly for the Minor and Major modifications or repair of structural
members for Pipe Racks, Air Cooled Condenser and other project Substructures to be
carried out as part of the Construction Works at C2 ASU Pearl GTL Project by GAMA Qatar
situated in Ras Laffan Industrial City (RLIC) in Qatar.

PURPOSE
The main purpose of this Procedure is to describe the minimum requirements and
responsibilities of activities associated with the modification or repair works of steel structures
to ensure that the activities are carried out according to the project requirements.

HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL
and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will go through LINDE
ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety,
health, environmental and security prior to work activities. Other training courses will be
attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required.
At a minimum a Risk Assessment will have been prepared by the Construction Group ranking
the hazards associated with project works and control measures to be taken to mitigate the
hazards to an acceptable level.
Each work scope or task will have a completed and approved Job Safety Analysis (JSA)
identifying the potential hazards and control measures that will be implemented to protect
people and environment. Supervisor as the basis of conducting his daily Pre-Task meeting
and his weekly Tool Box Talk (TBT) will use the JSA.
In addition to the above, employees conducting survey works will wear required PPE and
highly visible vest where traffic or other hazards may exist. For additional safety requirements
for a particular or specific task please refer to the JSA prepared.

REFERENCE & DEFINITIONS:

a) Reference:
DEP 34.28.00.31
DEP 30.48.00.10
T-4.132.876
T-4.250.927
T-4.250-915
T-4.250.900
T-4.250.896
T-4.250.917
AWS D1.1
EN ISO 1461
SSPC-SP1
SSPC-SP2
SSPC-SP3

T-4.251.018, Rev. A

: Structural Steel.
: Painting and Coating of new Equipment.
: Tech. Specifications for Metal works.
: Material Handling, Storage and Preservation Procedure
: Calibration Procedure
: Method Statement for Painting and Repair Works.
: Method Statement for Steel Structure Assembly & Erection.
: ITP for Steel Structure.
: Structural Welding Code Steel
: Metallic hot-dip galvanized coatings on Fabricated Products
: Solvent cleaning
: Hand tool cleaning
: Power tool cleaning
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Q A T A R

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

b) Definitions :
Company
Contractor
Sub Contractor
Contract
ITP
QA/QC
TPI

5
5.1

: QSGTL/or its PMC

: LINDE ENGINEERING AG
: GAMA QATAR
: C2 ASU PEARL GTL Project
: Inspection and Test Plan
: Quality Assurance / Quality Control
: Third Party Inspection

RESPONSIBILITIES
SITE MANAGER
The Site Manager will provide inputs to the project execution plan to ensure that
strategies & philosophy of the project are properly addressed.

5.2

MECHANICAL ERECTION MANAGER

The Mechanical Erection Manager is responsible for the overall management of the
Project Construction team to ensure that safe and effective operations are conducted
and properly documented.

5.3

SITE ENGINEER
The Site Engineer will be overall responsible for safe execution of the whole job
including:
Confirming the installation location from schedule of approved construction
drawings.
Organizing of equipments and tools needed for the job.
Assigning skilled personnel for the job.
Sequence of activities to be carried out for the work as per this procedure
Conduct inspection and surveillance.
Notify to Contractors engineer for inspection as applicable.
Ensure that all Contractor and Company regulations are followed.
Ensure that all personnel involved are in safe working condition at all times.

5.4

SITE SUPERVISOR
The Site Supervisor will be responsible for safe execution of the following activities:
Conduct TSTI with the concerned work force prior to start of work.
Ensure that relevant work permits for the job are obtained prior to start of work.
Conduct daily toolbox talks for the entire work force prior to start day work.
Assigning a competent work crew for specific activities, details of activities and task
information will be given to the work crew.

T-4.251.018, Rev. A

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Q A T A R

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

Organizing tools and equipment needed to the work site.

Inspection and supervision of work.
Ensure that all Contractor and Company safety regulations are followed as
applicable.
5.5

QC INSPECTOR
The QC Inspector will be responsible for,
Verify identification of paint and correct preservation
Perform inspection on the surface before and after touch up according to procedure,
specification and GAMA QATAR ITP requirements.
Notification to contractor 24 hours before the touch up operation indicated in the
ITP.
Issue and sign the record and providing for contractor inspector signature of record
as required.
Verify batch number, expire date, shelf life against Material Certificates and Material
Data Sheets.
Ensure that the paint is not used after expiry date or shelf life.
Ensure that climatic conditions are suitable for surface preparation and painting.
Assigning a competent work crew for specific activities, details of activities and task
information will be given to the work crew.
Organizing tools and equipment needed to the work site.
Inspection and supervision of work.
Ensure that all Contractor and Company safety regulations are followed as
applicable.

5.6

WELDING ENGINEER
The Welding Engineer will be responsible for,
Ensure that the hot works are carried out according to the WPS procedure

6
6.1

DESCRIPTION AND MEASURES

PRECAUTIONS
Upon receipt of materials or structures, numbers and markings of components against
the packing list or erection drawings and will be visually inspected all the components for
damage or other unacceptable conditions; these are hole size and number and
dimensions not matching as per drawing
When deficiencies are found on the components, structure shall be immediately
segregated from the construction/erection work to prevent inadvertent use until repaired
and/or re fabricated. The same shall be applicable for site revision requirements
Materials shall be handled by means of cranage or any suitable and acceptable
equipment for material handling
Materials shall never be dragged or towed on the ground during full phase of the loading
and unloading sequence

T-4.251.018, Rev. A

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Q A T A R

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

All structures shall be handled by utilizing tools and equipment of adequate safe capacity
Prior to erection, all material surfaces shall be checked for cleanliness and cleaned of
any mill scale, dust, oil etc.
The Contractor will be informed before starting any repair activity at site. Required forms
will be filled up and documented
6.2

DESCRIPTION OF FAULTS
The following cases are normally encountered but not limited to:
Repair of structural member or members which are damaged during transportation
Repair of steel structure surfaces which are damaged during transport and/or
mechanical or chemical reason
Repair of structural members which are damaged during erection
Repair is required if there is a mismatch as plan during fabrication stage
Repair is required if there is a mismatch during erection stage

6.3

MEASURES
Minor Modification modification or repair if the steel member or members requires
minor repairs e.g. cutting of plates and welding as replacement for the member; building
up or patch up, and re drilling for bolt holes, surface preparation prior to touch up etc.
Major Modification modification or repair if the structural member and/or members
require extending or shortening and require complete replacement.
Ensure that the option of either repairing on welded areas due to damage or removing
and replacing the entire weld except as modified by AWS D1.1 clause 5.26.3.
The repaired or replaced weld shall be retested by the method originally used, and the
same technique and quality acceptance criteria shall be applied.

6.4

REPAIR AND MODIFICATIONS

When additional new holes are required for the erection of column, beam, girder,
connecting plates will be performed at site or workshop with the correct equipment
When bracket, end and connecting plate or cleat are required to be cut; or additional
piece will be fabricated, and welded in-situ by qualified welder
When new plates are to be cut and welded, edges has to be grinded and smoothen prior
for touch up.
When plates or brackets are bend, it will be hammered or hydraulic press can be applied
to align the component/s
When brackets, end plates, cleats are to be cut or additional new piece will be
fabricated, they will be welded at site by qualified welders

T-4.251.018, Rev. A

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Q A T A R

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

Ensure that the welding flux and spatter remaining shall be removed by grinding or other
suitable company mechanical means.
When new materials have to be used for the modification and or repair of structural
steel, these materials shall be identical to the material of the structural steel and a
certificate to prove this is required.
There shall further be in place / available for the repair and or modification works an
approved welding procedure , approved welding consumables , approved (qualified)
welders and last but least:
1) All site repairs shall be approved by the Contractors Structural Steel Engineers.
2) All site modifications shall be approved by the Structural Steel Design Engineers.
3) The flaw register shall be maintained for repair and or modification works including
material certificates for new materials, galvanizing repair details, and related
drawings indicating the location of repair.
4) All bolt holes not used, due to repair and or modification shall be fill welded and
made smooth surface.
6.5

SURFACE PREPARATION
The surfaces shall be cleaned with following operations:
For structural steelwork which has sustained mechanical damage during either
transportation or erection:
Solvent cleaning: all the surfaces shall be removed from foreign matter as oil, grease,
soil, salts or other contaminants by solvents, emulsions, fresh water or other suitable
method. Compressed air can also be used to remove hard headed stains etc.
The surface can be cleaned by electric or air operated power wire brushes and or power
disc or needle guns.
Sand blasting treatment shall not be used for cleaning.
Ensure that the surface finish shall be as per BS 7079 and to a visual standard.
Surface preparation shall extend onto the undamaged galvanized coating for
approximately 25mm overlapping. After cleaning dry air shall be blown on the surfaces.

6.6

REPAIR OF DAMAGED GALVANISING

Damaged hot dip galvanised coating shall be repaired as follows:
Corrosion or other damage shall be removed using light sweeps of an orbital sander.
A 25mm band of sound galvanizing around the damaged area shall be carefully
feathered down to bare steel.
Residual oil or grease within the repair zone will be removed using a patent
degreaser in accordance with the manufacturers recommendations.
On completion preparation surfaces shall be scrubbed and rinsed with fresh water.
When the areas to be repaired for coating are fully dry.

T-4.251.018, Rev. A

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Q A T A R

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

Zinc rich paint (RESISTEX L722 or approved equal) shall be brush applied in
accordance with the manufacturers instructions to achieve the same thickness as
that of the original galvanizing (minimum 100 microns DFT).
The repair coating shall be overlapped onto the feathered edge of the existing
galvanising
Ensure that the compatibility of the coating material, when the materials shall be
purchased from different manufactures.
When items of steel work are difficult to repair after complete erection (or) when the
program of erection work is such that, the repairing treatment may perform prior to
erection. This shall be implemented after getting approval from company.
6.7

EQUIPMENT
Suitable equipment for cutting, drilling, grinding and other machine shop works shall be in
correct capacity
For touch-up or repairs to the localised damaged areas, weld or other irregular surfaces,
provided that the manufacturer considers the painting material suitable for brush or roller
shall be used for small areas in accordance with the Manufactures recommendations.
Spray equipment shall be in compliance with the painting manufacturer's instructions
(e.g. nozzle tips, spray angle, pressure etc.).

CALIBRATION
All inspection, measuring and test equipment shall be calibrated in accordance with GamaQatar Equipment and instrument calibration procedure T-4.250-915.

INSPECTION
All materials, components of structure covered will be subject for further inspection and in
concurrence by the Contractor, whether works carried out are in accordance to this
procedure and applicable ITPs.
If found any damage during Transportation, handling and / during erection that shall be
rectified as per company specification & DEP 34.28.00.31

8.1

TESTING

8.1.1 VISUAL INSPECTION

Painting film should be inspected visually after application in order to verify that the whole
surface is free of defects as: blister, forces, flaking mechanical damage, sags.

8.1.2 REPAIR OF PAINTING

Defective or damaged paintings shall be removed by hand tools or power tool until a
surface is cleaned and the new layer of paint can apply.

RECORDING
Accordingly, the activities shall be recorded in QCR Forms mentioned relevant Method
Statement and GAM-QCR-QAC-GTL-031- Painting Coating Check List & GAM-QCR-

QAC-GTL-097- Welding Repair Authorization

T-4.251.018, Rev. A

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Q A T A R

Doc. Title

GAM-PRO-GEN-GTL-035
Procedure - Structural Steel Repair works at site

Date / Rev.

07 January 2009 / Rev - E

10 QUALITY ASSURANCE
A Quality Assurance System shall be operated conforming to related standards. Controls and
checks shall be established and documented through relevant QCP-T-4.250.916, ITPT-4.250.919 and QCRs.

T-4.251.018, Rev. A

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