Upright Engineering Limited

N2 Plant Building Project –

Construction Procedure
For

Moment Energy Limited

Nigeria

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 Table of Content
Purpose 3

Scope 3

References 3

Fabrication to Quality 3

Blasting and Painting 9

Documentation 9

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Purpose:
This document addresses the different areas involved during the fabrication activities that provides
structural members for the N2 plant building and erection with the purpose for quality.

Scope:
To build the shelter of N2 plant for Moment Energy Limited. The Fabrication covers the process of
making the individual elements of the steel framed building from the rolled steel sections and plates.
The provision of the framed parts are completed in-line with quality in fabrication from processes of
making drawings showing details required for use by shop fabrication, measuring and marking out,
cutting into shapes, fitting, drilling or welding, blasting and painting, to delivery.

References:
AWS D1.1

Fabrication to Quality:
Measuring and marking out

In Upright Engineering Limited, measurement is taken as significant to enable a proper mark out of
components, to check components whilst we make them to ensure that they finally end up the correct
size and shape. We measure to be able to inspect the finished component to make sure they have been
correctly manufactured.

During linear measurement in our fabrication, steel rule either rigid or flexible is frequently used in our
workshop and on site for measuring components of limited accuracy quickly. Our rule are engraved with
both systems of imperial and metric systems. For accuracy of measurement, a visual alignment of a
mark or surface on the work with the corresponding graduation on the rule is paramount. Possible
errors are minimized by using a thin rule and keeping eyes directly above and at 90 deg to the mark on
the work. We measure linear distances between two lines, and or between two surfaces and or between
two combination of line and surface. The use of suitable measuring device is always selected for the job
at hand.

Calipers in conjunction with rule to transfer the distance across or between the faces of a component is
used in such a way as to reduce sighting errors which converts from end measurement to line
measurement. We also use vernier caliper or micrometer caliper to check the thickness of plates and
diameter of drills and always avoid its loose of initial accuracy by observing some precautions eg wiping
the work-piece and anvils of the micrometer before making a measurement, less force when making
measurement (two clicks of the micrometer ratchet is sufficient), not leaving the anvil faces of
micrometer in contact when not in use, not measuring whilst drilling
Right angles are made using Try square to ensure that angles made are squared. We keep squares clean
and protect the edges of the blade and stock and are checked for squareness at regular intervals. Other
tools like; scriber, nipple punches, divider and trammels, scribing block, etc are used by us to meet
quality

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Cutting into shapes
- After adequate surface preparation by removal of oil, grease and loose materials from surfaces
of structural sections and thick plate of ferrous metals, we flame cut and beveled with pure
oxygen of 99.5% or better for a faster cutting speed with acetylene as fuel gas. The ratio of
acetylene to oxygen shall be 1:1.1. Carbon steel above 0.25% carbon will be preheated over a
wide area of 250 to 300 deg C. The hardened surface after flame cutting shall be grinded before
welding.

Fitting
Rolled Steel Sections made of low carbon steel are type of materials used for the structural building. The
connection of the members are made by welding and or bolting of drilled members. The steel structure
is designed such that the sizes of various members are determined by their ability to withstand the
effects of applied loads in service. The size of the member are as near as to the design size as possible,
and greater than design size for safety. Connections for structural steel work include but not limited to;
stanchion bases, stanchion splices, beam-stanchion connections, beam-beam connections.
Stanchion bases
The vertical members are the stanchions or columns. The Stanchion bases transmit the downward
thrust on the stanchion to the foundation upon which the stanchion and its load are supported. The
stanchion base also spreads the load so that the stanchion does not cut into and / or crush the concrete
foundation. During installation, except the slap less that 50 mm, top surface of the base slab need be
machined to ensure close contact with the end of the stanchion. The foot of the stanchion shall be
machined square to the axis of the stanchion to ensure it stands vertically. This ensures that the load is
carried directly onto the base plate or slab and into the foundations. If the foot of the stanchion or column
is not square to the base plate, then the total load on the stanchion would be carried through the bolt or
rivet shanks where these are used to secure the assembly.

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Stanchion Splices
Splices in stanchions or columns shall be arranged at a position above the adjacent floor level so that the
joint, including any splice plates, are well clear of any beam (horizontal member) connection. Splices shall
never be made on a connection, otherwise the bolts or rivets making the joint would be subjected to
double loading.
Below shows some typical stanchion splices.

Beams to Splices

Beams are horizontal members that are connected at right angles to the vertical stanchions or columns
and supports the building floor though, beams may be inclined or arched for some applications. Below
are connection using seating cleats and fittings

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Beam to Beam

With beam to beam connections as shown below, loads are transmitted from the secondary beams to
the main beams using web cleats or welded-on end plates

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The roof frame

Sloping rafters usually to support roof in conjunction with purlins are plane frames designed to meet at
the ridges as trusses and lattice frames. The joining could be by bolting or welding. The main horizontal
tie connects with the lower ends of the rafters, and the internal bracing members. The purlins are
secondary members laid horizontally across the rafters on which the roof covering is laid. See below
lattice girders which have plane frames of open web construction. They have parallel chords or booms
which are connected with internal web bracing members. The framing of the lattice girders are
triangulated, with consideration of the span and the spacing of the applied loads. The booms are divided
into panels of equal length and, as far as possible, the panel points are arranged to coincide with applied
loads.

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Mechanical connections

Fabricated components by Manskhu for this N2 plant building are assembled together using high
strength friction grip bolting type. The drilled holes shall have clearance up to 1.6mm. The bolts shall be
provided with two hardened washers which shall be fitted under the head of the bolt and under the nut.
The bolts shall be tightened with torque spanners in order that they exert a specified clamping force on
the members making up the connections. When using these bolts, no outer ply in the connection shall
be smaller in thickness than half the diameter of the bolt or 9.525mm, whichever is less. The bolt must
be square to the bearing surfaces under the bolt head and nut. The corners of the nut shall not bite into
the structural member and washer of correct size shall be fitted. Similarly, bolt that is too short so that
the full length of the connection is not achieved shall not be used. The taper of the washer and the taper
of the member must match.

Alignment of holes

Manskhu apply the use of drifts to assemble connections for bolting of fabricated components. The drift
ranging from taper to barrel and parallel drift, assist specifically in aligning parts coming together so that
the holes will be faired to admit bolts while, barrel drift is used to align holes in confined spaces by
hammering until it passes through the hole especially where the amount of movement required to bring

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the members into alignment is minimal, parallel drift is used to maintain alignment of members during
bolting operations

Welding

The welding process selected by Upright Engineering Limited for the fabrication of the building
components for the N2 plant is the manual metal arc welding process. It is a reliable process for welding
thicker sections successfully. A qualified welding procedure specification meeting AWS D1.1
requirements shall be provided and welders shall demonstrate ability to produce sound welding
according to the specification on the qualified WPS. High weld quality shall be the ultimate goal of the
selected process and all discontinuities resulting from penetration, lack of fusion, crack, slag inclusions,
undercut, spatters and porosity shall be avoided. The weld profile shall meet acceptance criteria of
ASME section V. All weld shall be 100% inspected visually and reported accordingly. Further NDT
inspection using MPI at 30% is recommended.

Blasting and Painting:

The fabricated item shall be blasted and painted according to the approved procedure. Inspection of the
blasting and painting work shall be meet nace requirements.

Documentation:
Proper documentation shall be provided and reports shall include but not limited to;

1. WPS
2. Welders Qual
3. MTC / Batch certs
4. Weld map
5. Visual Inspection Report
6. Weld Summary report
7. Blasting and Painting procedure and report
8. Original and As-built drawing