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1.0. PURPOSE
The purpose of this technical document is to explain the methodology in the Civil /Structural, Piping/tubes and Instrumentation works and to detail the steps to be taken to fulfil the specific requirements of the ongoing projects.
2.0. SCOPE
This Technical Methodology Document Highlights the work regarding the Civil/Structural, Piping/tubes and Instrumentation works such as:
1. Orbital/structural welding
2. Piping/tubes Installation
3. Road crossing Excavation
4. Pipe culvert/slab making and installation.
5. Painting
6. Backfilling
7. Final Tie-in
8. Testing and Dismantling work.
This this technical document highlights and explains the comprehensive details of as below:
- QHSE Requirements
- Equipment
- Methodology
- Inspection/testing requirements.
This Method Statement provides details on the following activities:
2.1.1. HSE Requirements
2.1.2. WPS Qualification (Welding Procedure Specifications)
2.1.3. Welder Qualification
2.1.4. Preparation
2.1.5. Fabrication
2.1.6. Field bending Procedure.
2.1.7. Orbital Welding
2.1.8. Trenching
2.1.9. Pipe Culvert/slab installation
2.1.10. Installation
2.1.11. Final Tie-in
2.1.12. Painting
2.1.13. Testing
2.1.14. Demolition Work
2.1.15. Final Documentation and Handover
Specification limits (breaks) are highlighted in the P&IDs and Isometric Drawings (IDs). The proper and authentic specification shall be referred for all activities including WPS qualification / Welder Qualification, NDT, Mechanical Testing, Fabrication and Erection following the specification breaks identified in the P&IDs. For precautions to be implemented for the road and transport safety such as crossings of roads and underground or above utilities, reference should be made to the following documents:
- Road Crossings
- Pipeline / Cable Crossings
- Isolation
- Final Tie-in
- Dismantling works
3.0. PREPARATION
3.1. Drawings for Piping/tubing installation works in “Approved for Construction” status shall be available before the start of fabrication. Drawings provide details of material (grade, type, size, shape, quantity etc), fabrication/welding requirements including weld type/size as applicable, fasteners and other information as necessary.
3.2. Field measurements as necessary will be made at the work site and pertinent dimensions/levels will be re-confirmed to ensure that the fabricated product will meet the erection site requirements.
3.3. Materials shall be inspected on receipt at the site for confirming their compliance with drawings and standards. Receipt inspection shall include characters such as type, grade, size, condition, availability of test certificates, identification, and traceability of materials against certification.
3.4. Cable/pipe detectors shall be used to detect the location of existing pipelines and other utilities. By liaison with the owner of the service and by digging trial holes manually, the location, depth and type of service shall be established. The details of the utility including type and size will be identified.
Continued…
4.0. PRODUCTION
FABRICATION
Methodology and measures for control of quality during the fit-up stage are as follows.
4.1. The material will be cut to size by cutting machine equipment. Measures necessary to prevent distortion during cutting operations shall be in place. The cut ends will be dressed up to sound metal to ensure that they are free from burrs/notches.
4.2. Fit-up of structural components will be done as per the dimensions specified in the drawings.
4.3. The surfaces of components that require to be welded together will be cleaned of any mill scale and other undesirable foreign material.
4.4. Assembly shall be tack welded (of adequate lengths/numbers), using approved WPS and a qualified welder.
4.5. Parts to be welded shall be carefully prepared and be firmly held before welding to avoid, as far as possible, warping, buckling and residual stresses.
4.6. Joints that require to be welded at the field (e.g., base plates or other members) will be identified clearly as field welds by the use of permanent markers.
4.7. The type / serial no of the fabricated component will be hard punched on the steel surface, preferably on the base plate of supports.
4.8. Structural members shall not be spliced unless specifically authorized.
4.9. The responsible foreman will check the fit up for verifying that the materials, orientation, dimensions, bevel preparation and other fit-up variables are following specified requirements. QC / Welding inspector will review the material's suitability and fit-ups.
Continued…
5.0. PIPE CULVERT & SLABS INSTALLATION
5.1. Understand the importance of culverts and their continuing performance in the RDX system.
5.2. Understand the key factors in properly evaluating and assessing an installed culvert.
5.3. Recognize critical differences in culvert material type for proper inspection and evaluation.
5.4. Understand basic load rating principles as they are applied to installed culverts.
Culverts must be properly inspected, assessed, and evaluated for structural and functional performance regularly as part of a logical RDX maintenance and inspection program. All those who inspect RDX must be trained to understand the key factors related to culvert inspection and maintenance.
5.5. The culvert's length, size, age, the height of cover, wheel loading and material type
5.6. Type and condition of end treatment, including end sections, headwalls, etc.
5.7. Inlet and outlet scour condition, including erosion parallel to the culvert.
5.8. Shape geometry of flexible culverts, requiring detailed measurements
5.9. Culvert wall thickness and condition, such as cracking, the extent of the corrosion, spalling and exposed rebar.
5.10. Infiltration and loss of structural backfill through joints, cracks or inlets.
5.11. Evidence of roadway settlement or repair, such as pavement distress, cracks or signs of recent repairs and repaving efforts.
Culvert inspection poses certain safety and risk issues. Tripping and slipping hazards exist. Conditions may be hazardous. Slope stability and negotiating embankments with potentially unstable footing and vegetation call for proper safety measures. Working in teams or tandem is recommended. This article will not attempt to list or describe all the relevant issues and necessary safety precautions. It is recommended that inspection personnel follow OSHA and other safety guidelines for such work.
5.12. Allowable Stress Rating (ASR) — uses unfettered loads and the allowable working stress of the construction material.
5.13. Load Factor Rating (LFR) — uses factored live and dead loads and a slight resistance factor applied to the capacity based on the construction material.
5.14. Load and Resistance Factor Rating (LRFR) — uses factored live and dead loads, and condition, system and resistance factors based on the construction material's nominal capacity.
Using outside firms that specialize in these services may prove to be the most logical and cost-effective approach to a comprehensive culvert inspection and load rating program.
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