Pipe Rack Erection modified and Presentation

(1)

PIPE RACK ERECTION

Using

Precast

Concrete Elements

and Structural Steel:

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Erection of columns

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Erected Columns

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Erection of

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Types of

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Continuation: (

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Erection of

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Grouting of beam

-

_-

column

_column

connection:

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Grouting with Non

-

_-

shrink

_shrink

grout:

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Grout Mixing:

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Grouted beam

-

_-

column

_column

connection:

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Erection of Structural Steel Module

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Steel Columns

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Structural Steel Columns:

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Continuation:

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Erection of one complete structural steel

module:

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During Erection:

CHECK FASTENING MATERIALS (12

CHECK FASTENING MATERIALS (12--SAMSSSAMSS--007 SEC. 4.6)007 SEC. 4.6)

-- HIGH STRENGTH BOLTS, ASTM A325, TYPE 1 , GALVANIZED.HIGH STRENGTH BOLTS, ASTM A325, TYPE 1 , GALVANIZED.

-- HEAVY HEX NUTS, ASTM A563 GR DHHEAVY HEX NUTS, ASTM A563 GR DH

-- WASHER, ASTM F436WASHER, ASTM F436

•

• THE MINIMUM NUMBER OF BOLTS IN A FRAMED CONNECTION SHALL BE TWO THE MINIMUM NUMBER OF BOLTS IN A FRAMED CONNECTION SHALL BE TWO

BOLTS (12

BOLTS (12--SAMSSSAMSS--007 SEC. 6.2.5.7)007 SEC. 6.2.5.7)

•

• MINIMUM DIAMETER OF BOLT 20 MM SHALL BE USED IN ALL BOLTED MINIMUM DIAMETER OF BOLT 20 MM SHALL BE USED IN ALL BOLTED

STRUCTURAL CONNECTION (12

STRUCTURAL CONNECTION (12--SAMSSSAMSS--007 SEC. 6.2.5.3)007 SEC. 6.2.5.3)

•

• ERECTION SHALL BE IN ACCORDANCE WITH THE DRAWINGS AND OTHER ERECTION SHALL BE IN ACCORDANCE WITH THE DRAWINGS AND OTHER

CONTRACT DOCUMENTS

•

• DURING ASSEMBLY, ALL JOINT SURFACES, INCLUDING THOSE ADJACENT TODURING ASSEMBLY, ALL JOINT SURFACES, INCLUDING THOSE ADJACENT TO

THE BOLT HEADS, NUTS OR WASHERS, SHALL BE FREE OF BURRS, DIRT AN

THE BOLT HEADS, NUTS OR WASHERS, SHALL BE FREE OF BURRS, DIRT AND D OTHER FOREIGN MATERIALS THAT WOULD PREVENT SOLID SEATING OF

OTHER FOREIGN MATERIALS THAT WOULD PREVENT SOLID SEATING OF

PARTS (12

PARTS (12--SAMSSSAMSS--008 PAR. IV, MOD. PIP STS05130 SEC. 6.5.8)008 PAR. IV, MOD. PIP STS05130 SEC. 6.5.8)

•

• ALL PREASSEMBLIES SHALL BE LIFTED IN A MANNER THAT WILL NOT IMPAALL PREASSEMBLIES SHALL BE LIFTED IN A MANNER THAT WILL NOT IMPAIR IR

THE STRUCTURAL INTEGRITY OF THE MEMBERS. ASSEMBLED STRUCTURAL

MEMBERS SHALL BE LIFTED IN A COMPLETE FRAME.

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INSPECTION OF STRUCTURAL ALIGNMENT

DURING ERECTION:

IMPORTANT CHECK POINTS:

VERTICAL TOLERANCES FOR STRAIGHT COMPRESSION STRUCTURAL VERTICAL TOLERANCES FOR STRAIGHT COMPRESSION STRUCTURAL MEMBERS

MEMBERS < 1/1000 OF THE AXIAL LENGTH, (AISC PAR. 6.4.2 & PIP STS05130 1/1000 OF THE AXIAL LENGTH, (AISC PAR. 6.4.2 & PIP STS05130

PAR. 6.2.1)

THE STRUCTURE SHALL BE PLUMBED, LEVELED, AND BRACED BEFORE ANY THE STRUCTURE SHALL BE PLUMBED, LEVELED, AND BRACED BEFORE ANY FINAL BOLTED OR WELDED CONNECTIONS ARE MADE, PIP STS05130 PAR.

FINAL BOLTED OR WELDED CONNECTIONS ARE MADE, PIP STS05130 PAR.

6.3.2.

LEVELING PLATES, LEVELING NUTS AND WASHERS, LOOSE BASE PLATES ANLEVELING PLATES, LEVELING NUTS AND WASHERS, LOOSE BASE PLATES AND D

BEARING PLATES ARE SET IN ITS CORRECT ALIGNMENT AND ELEVATION.

VARIATION IN ELEVATION RELATIVE TO THE ESTABLISHED GRADE

VARIATION IN ELEVATION RELATIVE TO THE ESTABLISHED GRADE < +/+/--3 MM 3 MM (AISC PAR. 7.6 & PIP STS05130 PAR. 6.4.1)

(AISC PAR. 7.6 & PIP STS05130 PAR. 6.4.1)

ALL COLUMN SPLICES SHALL BE FIELD BOLTED AND CONFORM TO AISC ALL COLUMN SPLICES SHALL BE FIELD BOLTED AND CONFORM TO AISC DETAILING FOR STEEL CONSTRUCTION APPENDIX D (12

DETAILING FOR STEEL CONSTRUCTION APPENDIX D (12--SAMSSSAMSS--007 PAR. 007 PAR. 6.2.5.20)

6.2.5.20)

REFERENCE REFERENCE

-- AISC CODE OF STANDARD PRACTICE FOR STEEL BUILDING AND BRIDGESAISC CODE OF STANDARD PRACTICE FOR STEEL BUILDING AND BRIDGES

-- PROCESS INDUSTRY PRACTICES PIP STS05130, ERECTION OF STRUCTURAPROCESS INDUSTRY PRACTICES PIP STS05130, ERECTION OF STRUCTURAL L

AND MISCELLANEOUS STEEL SPECIFICATION

<

(20)

REPAIR/CORRECTION OF ERRORS OF STRUCTURAL ALIGNMENT

DURING ERECTION

IMPORTANT CHECK POINTS:

FITFIT--UP BOLTS AND DRIFT PINS SHALL NOT BE USED TO BRING IMPROPERLY UP BOLTS AND DRIFT PINS SHALL NOT BE USED TO BRING IMPROPERLY FABRICATED MEMBERS AND PARTS INTO PLACE (SPRINGING). (PIP STS051

FABRICATED MEMBERS AND PARTS INTO PLACE (SPRINGING). (PIP STS05130 30 PAR. 6.7.1)

PAR. 6.7.1)

STANDARD BOLT HOLES SHALL NOT BE ENLARGED BY MORE THAN 1 MM TO STANDARD BOLT HOLES SHALL NOT BE ENLARGED BY MORE THAN 1 MM TO MAKE CONNECTIONS RESULTING FROM MINOR MISFIT (PIP STS05130 PAR.

MAKE CONNECTIONS RESULTING FROM MINOR MISFIT (PIP STS05130 PAR.

6.7.2).

METHOD OF CORRECTING BOLT HOLE CONNECTIONS THAT MISFIT BY MORE METHOD OF CORRECTING BOLT HOLE CONNECTIONS THAT MISFIT BY MORE THAN 1 MM MUST BE APPROVED BY SAUDI ARAMCO.

THAN 1 MM MUST BE APPROVED BY SAUDI ARAMCO.

ENLARGEMENT OF HOLES SHALL BE MADE BY REAMING OR DRILLING ONLY ENLARGEMENT OF HOLES SHALL BE MADE BY REAMING OR DRILLING ONLY (PIP STS05130 PAR. 6.7.3)

(PIP STS05130 PAR. 6.7.3)

THE ERECTOR SHALL MAKE NO MODIFICATIONS OR REPAIRS TO STEEL THE ERECTOR SHALL MAKE NO MODIFICATIONS OR REPAIRS TO STEEL JOIST, AND CORRECTION OF FAULTY WORKS SHALL REQUIRE APPROVAL

JOIST, AND CORRECTION OF FAULTY WORKS SHALL REQUIRE APPROVAL

FROM SAUDI ARAMCO (PIP STS05130 PAR. 6.7.4 & 6.8.2)

ONE FILLER PLATE UP TO 1/8 INCH (3 MM) THICKNESS MAY BE USED AS ONE FILLER PLATE UP TO 1/8 INCH (3 MM) THICKNESS MAY BE USED AS REQUIRED IN SPACES BETWEEN MEMBERS TO BE BOLTED (PIP STS05130

REQUIRED IN SPACES BETWEEN MEMBERS TO BE BOLTED (PIP STS05130

PAR. 6.7.5)

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HIGH STRENGTH BOLTS TIGHTENING INSPECTION &

TESTING:

IMPORTANT CHECK POINTS:

BOLTS SHALL HAVE FULL THREAD ENGAGEMENT WITH THE NUT.

THE BOLT LENGTH USED SHALL BE SUCH THAT THE END OF THE

BOLT EXTENDS BEYOND OR IS AT LEAST FLUSH WITH THE OUTER

FACE OF THE NUT WHEN PROPERLY INSTALLED (AISC SPECS. FOR

STRUCTURAL JOINTS USING ASTM A325 or A490 BOLTS PAR. 2.3.2)

ALL NUTS FOR HIGH STRENGTH BOLTS SHALL BE WAX-DIPPED TO

REDUCE TORQUE DURING INSTALLATION (12-SAMSS-007 PAR.

6.2.5.22).

THE ERECTOR SHALL COLOR CODE, DIE PUNCH, OR OTHERWISE

MARK THE ENDS OF TORQUED BOLTS INDICATING THAT THE BOLTS

HAVE BEEN PROPERLY TENSIONED AND ARE READY FOR

INSPECTION (PIP STS05130 PAR. 6.5.7)

FAYING SURFACES AND SURFACES ADJACENT TO THE BOLT HEAD

AND NUT FOR SNUG-TIGHTENED OR PRETENSIONED JOINTS SHALL

BE FREE OF DIRT AND OTHER FOREIGN MATERIAL (AISC SPECS. FOR

STRUCTURAL JOINTS USING ASTM A325 or A490 BOLTS PAR. 3.2.1 &

PIP STS05130 PAR. 6.5.1)

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THREE TYPES OF BOLTED JOINT:

(MUST BE CLEARLY IDENTIFIED & INDICATED IN THE IFC

OR ERECTION DRAWINGS)

1.) ST – SNUG-TIGHTENED JOINT, A

CONDITION WHERE FAYING

SURFACES IN A BOLTED JOINT

ASSEMBLY ARE IN FIRM CONTACT

AFTER A FEW IMPACTS OF AN IMPACT

WRENCH OR WITH THE FULL EFFORT

OF A WORKER USING A SPUD

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2.) PT – PRETENSIONED JOINT:

A JOINT THAT TRANSMIT SHEAR AND/OR

TENSILE LOAD, WHERE THE BOLT

ASSEMBLY IS FULLY TIGHTENED TO WHICH

THE TENSION IN THE BOLT WILL BE EQUAL

TO A MINIMUM OF 70 PERCENT OF THE

SPECIFIED TENSILE STRENGTH (AS PER

TABLE 8.1 & COMMENTARY – SPECS. FOR

STRUCTURAL JOINTS USING ASTM A325

OR A490 BOLTS).

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3.) SC – SLIP CRITICAL JOINT:

SIMILAR TO PRETENSIONED JOINTS BUT THE FAYING

SURFACES HAVE BEEN PREPARED TO PROVIDE A

CALCULABLE RESISTANCE AGAINST SLIP.

ONLY

ST & PT

JOINT TYPES ARE USED IN THE

STRUCTURAL STEEL PIPE RACKS

PRETENSIONING METHOD ACCEPTED BY SAUDI ARAMCO:

- TURN-OF-NUT PRETENSIONING

- CALIBRATED WRENCH PRETENSIONING

- DIRECT TENSION INDICATOR (DTI) PRETENSIONING

PRIOR TO PRETENSIONING OF BOLTS, THE BOLTED JOINT

ASSEMBLY WAS BROUGHT TO A SNUG TIGHT CONDITION.

WHEN IMPACT WRENCHES ARE USED; IT SHALL BE OF

ADEQUATE CAPACITY WITH SUFFICIENT AIR SUPPLY TO

PERFORM THE REQUIRED TIGHTENING OF EACH BOLT

(12-SAMSS-008 SEC. IV)

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TURN-OF THE NUT PRETENSIONING

METHOD:

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Direct Tension Indicator

Specially designed washers,

called direct tension indicators,

or load-indicating devices, have

a series of protrusions that

compress during tightening of

the bolt. When you tighten the

nut fully, the washer

compresses and the protrusions

will flatten, leaving a small gap

under the head or nut. You

verify the amount of tightening

by inserting a thin metal stick

into the gap. This method is the

least preferred by Saudi Aramco

for tightening and verifying the

installation of high-strength

bolts.

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CALIBRATED WRENCH PRETENSIONING

METHOD

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CALIBRATED WRENCH PRETENSIONING METHOD

TORQUE VALUE CALCULATION (USING AISC TABLE 8.1):

TV = db X Tm X COEFF. FACTOR X1000

SAMPLE CALCULATON FOR 1-1/2” DIA. BOLT

TV = 1.5/12 X 103 X 0.21 X1000 = 2700 FT.-LBS.

TO CONVERT TO NEWTON-METER:

2700 FT.LBS. / 0.7376 = 3660 N-M

WHERE; TV = TORQUE VALUE IN FT.-LB. db = BOLT DIAMETER IN FT. Tm = MINIMUM BOLT TENSION ( Table 8.1) PRETENSION IN KIPS COEFFICIENT OF FRICTION (Nut Factor) = 0.21 1 KIP = 1000 LBS.

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CALIBRATED WRENCH PRETENSIONING METHOD

(AS PER SAUDI ARAMCO REQUIREMENT` - VERIFICATION

OF TORQUE VALUES)

THE TORQUE REQUIRED FOR TIGHTENING SHALL BE

DETERMINED IN THE PRE-INSTALLATION PROCEDURE

VERIFICATION TESTING OF THE FASTENER ASSEMBLY AS PER

(12-SAMSS-008 SEC. I)

A CALIBRATED TENSION CALIBRATOR SHALL BE ONSITE WHEN

TIGHTENING IS TO BE PERFORMED ON PRETENSIONED JOINTS

AND SLIP-CRITICAL JOINTS.

A REPRESENTATIVE SAMPLE OF THREE COMPLETE FASTENER

ASSEMBLIES OF EACH COMBINATION OF DIAMETER, LENGTH,

GRADE AND LOT TO BE USED IN THE WORK SHALL BE CHECKED

AT THE SITE OF INSTALLATION IN A TENSION CALIBRATOR.

THE PRETENSION THAT DEVELOPED DURING THE

PRETENSIONING METHOD SHALL BE EQUALTO OR GREATER

THAN 1.05 TIMES THAT SPECIFIED FOR INSTALLATION AND

INSPECTION IN TABLE 8.1

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TENSION CALIBRATOR (SKIDMORE)

How The Tension Calibrator Works:

Tightening a fastener inserted into the calibrator creates pressure, which is transmitted through

hydraulic fluid to a gauge. The gauge gives a direct reading equivalent to fastener tension in pounds.

Bolt Tension Calibrator Allows You To Verify:

That your fasteners meet minimum bolt tension specifications.

That your impact wrenches are properly calibrated.

That your bolting crew understands how to achieve proper tension in all types of