kirby_prequalifications_-_rev_1311 ตัวอย่าง

7/29/2019 Kirby_Prequalifications_-_Rev_1311

1/82

Structural Steel

Prequalification Document (R2)

Page 1 of 82

KIRBYStructural Steel

Prequalification Document


2/82

Structural Steel


Page 2 of 82

I N D E X

Introduction 4

Market Sectors & Products 6

Vision & Mission Statement 7

Legal Status 8

Iso Certificate 16

Design and Engineering 17

Piece Monitoring System 19

The Project Structure 22

General Description of Work Flow Procedures 23

EngineeringDesign OutputDesign ReviewDesign ValidationDesign Changes

SoftwareR F I sPre-Production Planning

Example 27

Material PreparationIdentificationHandling, Storage and StackingConsumable StorageFabrication DrawingsBeam Processing

Beam Preparation EquipmentPlate ProcessingPlate Processing EquipmentAssemblyWeldingCurving and StraighteningNon-Destructive TestingSurface Preparation and PaintingDelivery of Finished Product


3/82

Structural Steel


Page 3 of 82

I N D E X (continued)

Attachments 32

Process Flow ChartChange Procedure Flow Chart sChange Procedure DocumentationProject Quality Plan (Sample)Inspection and Test Plan (Sample)PMS Sample Schedules and QC ReportsWelding Procedure Specifications

Organisation Chart 75

Customer Base 76

Typical Projects 78


4/82

Structural Steel


Page 4 of 82

Introduction

Kirby Steel Engineering emerged as a natural extension to the ever expanding Kirby steel

fabrication network, as well as in response to the continuous requests from the market and

satisfied customers.

Kirby Steel Engineering complements Kirby Building Systems by providing services and

customized Hot Rolled steel structures to industrial market sectors such as Oil & Gas,

Petrochemical Industry, Heavy Industries, Cement Plants, Aluminium smelters etc

The company also offers its services, expertise and products in other sectors such as

Commercial sectors where it contributes, alongside its sister company Kirby Building

Systems, in providing a complementary and wider range of products to clients whose projects

may include a combination of heavier structural steel requirements, as well as Pre-engineeredbuildings.

Kirby Steel Engineering is managed by a team of professionals with an average experience of

twenty to thirty years experience in the structural steel industry and known to have executed a

number of prestigious and high-profile projects in the GCC and Middle East.

The engineering department uses the latest versions of internationally renowned industry

standard 3D and 2D software for designing as well as drafting.

Kirby Steel Engineering is affiliated to Kirby Building Systems, which in turn is part of Al

Ghanim Industries having the Head Office in Kuwait.

Kirby Building Systems - Kuwait is the premier producer of steel buildings and structures in

the Middle East. In operation since 1976, Kirby maintains a strong reputation for providing

cost effective solutions for buildings manufactured to the highest standards. Kirbys network

includes 24 offices in the GCC countries (Kuwait, Saudi Arabia, Qatar, Oman, Bahrain and

the UAE), the Middle East, Africa, and the Far East to service customers locally. Kirby

manufacturing facilities produce hundreds of custom made steel buildings each year.

Kirby upholds its position at the cutting edge of the industry due to its commitment to quality

and customer satisfaction. Skilled structural engineers using the very latest in computerized

engineering design and drafting systems permit the selection of the most economical,

accurate and efficient framing and cladding systems.

Kirbys customer base covers thousands of satisfied clients including General Motors,

AT&T, PepsiCo and Coca Cola , Ministries of Defense, Oil companies and Petrochemical

projects and other key international organizations over the world.


5/82

Structural Steel


Page 5 of 82

Alghanim Industries has consistently maintained its position as a leading private sector

trading and industrial group both in Kuwait and the GCC during the past 60 years. It is a

privately owned, professionally managed holding company. The executive management iscomposed of professionals with international education and experience in varying areas of

expertise. Overall, with the companys wholly owned subsidiaries, joint ventures and

associations, Alghanim Industries employs over 12000 men and women from over

40 different countries around the world.

The groups major areas of activity are trading and distribution of consumer electronics, food

and consumables, automotive vehicles and products, industrial manufacturing, engineering,

technology, travel, shipping and transportation services, advertising, insurance and

contracting.

Furthermore each of Alghanims separate businesses employs operating autonomy with its

own general manager, marketing managers and finance managers. Corporate policy mattersremain centrally controlled and direction is provided through strategic business planning

processes, quarterly operating review meetings and long term forecasting.

Multinational in both outlook and operation, Alghanim Industries has offices in countries that

span four continents. The diverse nationalities of the employees contribute to the companys

strength and widen its perspective. Alghanim Industries has successfully fused progressive

business procedures, local market place requirements and international resources.


6/82

Structural Steel


Page 6 of 82

Market Sectors & Products

The following is an indication, but is not limited to, of the market sectors serviced and thetypes of structures undertaken by Kirby Steel Engineering.

The flexibility, expertise and equipment allows the company to customize and provide the

right products or mix of products as required by the clients projects.

Market Sectors Structures

Heavy Industries Oil & Gas Pipe Racks

Petrochemical Rectangular Platforms

Aluminum Smelters Circular Platforms

Fertilizer Plants Pipe Supports

Cement Plants Main Workshop Structures

Raw Material Storage

Buildings

Floor Gratings

Staircases

Handrails

Ladders

Temporary Structures

Infrastructure Bridges Steel Bridges

Power & Desalination

Heavy Duty Building

Structures

Airports & Seaports Platforms

Railways Equipment Support Structures

Passenger Terminals

Cargo Terminals

Aircraft Hangars

Buildings Segment Residential / Commercial Hi-rise Towers

Shopping Malls Tower CrownsLeisure Centres Atrium Structures

Multi-storey Car Parks

Roof Structures

Sports Centres


7/82

Structural Steel


Page 7 of 82

Vision & Mission Statement


8/82

Structural Steel


Page 8 of 82

Trade License - Kuwait


9/82

Structural Steel


Page 9 of 82

Commercial License - Kuwait


10/82

Structural Steel


Page 10 of 82

Chamber of Commerce Kuwait


11/82

Structural Steel


Page 11 of 82

Commercial Register Kuwait


12/82

Structural Steel


Page 12 of 82

Import License Kuwait


13/82

Structural Steel


Page 13 of 82

Trade License Ras Al Khaimah - UAE


14/82

Structural Steel


Page 14 of 82

Chamber of Commerce Ras Al Khaimah - UAE


15/82

Structural Steel


Page 15 of 82

Commercial Register Ras Al Khaimah UAE


16/82

Structural Steel


Page 16 of 82

ISO Certificate


17/82

Structural Steel


Page 17 of 82

Design and Engineering

Kirby Steel Engineering uses the latest computer software in both Engineering and Design

allowing both activities to be as fully integrated as possible.

All work undertaken in the Engineering / Design Department is closely monitored by the

Engineering Manager who is responsible for ensuring that the design conforms to the clients

requirements and is in accordance with the relevant Design Codes and Regulatory Authority

requirements

The Design / Engineering Department is fully computerized, utilising the latest software

packages to enable them to produce the most economical structures in the shortest time

possible. The software packages most frequently utilised are :


18/82

Structural Steel


Page 18 of 82

Design and Engineering Cont

The Drafting office is also fully computerised and utilises the following main software

packages :

Package Description Specifications / Code

AutoCad Preparation of GA Drawings &Fabrication Drawings Miscellaneous Works

N/A

BoCad 3D Modelling Detailing ofConnections AutomaticGeneration of Fabrication Drawings,Production & Material Listings

N/A

Strucad 3D Modelling Detailing ofConnections Automatic

Generation of Fabrication Drawings,Production & Material Listings

N/A


19/82

Structural Steel


Page 19 of 82


20/82

Structural Steel


Page 20 of 82

Piece Monitoring System What does it do ?

Maintains a full bill of quantities for each main and sub-assembly

Establish Production Priorities for each component

Automatically program each item of steel through the workshop to suit clientrequirements and production capacities

Issue production requirements for each stage of fabrication

Automatically maintain the independent KIRBY Steel Engineering quality assuranceprogramme

Real Time monitoring of production status

Piece Monitoring SystemThe Advantages

Each individual piece of steel is dynamically monitored at the stages of production toassure the client receives all the items on time

Monitors the effects of design changes etc to enable the client to incorporate intheir production schedules

A full set of reports is available under password control in the Web Server. Reportscan be downloaded by the user into spreadsheets, databases etc for later use


21/82

Structural Steel


Page 21 of 82

Piece Monitoring SystemHow does it work ?

The project is broken down into units of build-ability or client requirements

Project programmes are developed using Primavera Project Manager

Specialised CAD systems used to produce working drawings, also produce their ownbill of materials which is automatically fed into the Piece Monitoring System.

Drawings produced from other sources are taken off and entered manually.

The PMS automatically reviews the programme, type of fabrication and production

capacities to produce an individual fabrication programme for each item of steel. Full

manual modification control is maintained to allow further requirements to be incorporated

Production lists are produced for each stage of fabrication and production data re-entered into the system

Quality assurance inspection requests are generated automatically by the system andrecords maintained

Full status reports are produced, cross-checked between each function

The Web Server is automatically updated


22/82

Structural Steel


Page 22 of 82


23/82

Structural Steel


Page 23 of 82

Index to the General Description of Work Flow Procedures

The purpose of the following section is to describe in general each

activity executed during a project.

Index

Engineering

Software

R F I s

Pre Production Planning

Example

Identification

Handling Storage and Stacking

Fabrication Drawing

Beam Processing

Plate Processing

Assembly

Welding

Curving and Straightening

Non Destructive Testing

Surface Preparation

Delivery of Finished Products


24/82

Structural Steel


Page 24 of 82

Engineering

All Technical information received from the client such as drawings, project specifications,

bills of quantity, agreed scope of work and any other pertinent information is forwarded to

the Design Department who review all relevant documentation to establish the designparameters. Any clarifications and requests for information are communicated to the

client in writing.

Should circumstance arise were the requested information is not available then the Design

Department clearly detail any and all assumptions they have made. This information is

forwarded to the client.

Design Output

The design output is expressed in the following formats :

Computer generated calculations prepared on propriety software Design sketches containing all the necessary information to allow drafting to generate

general arrangement drawings

The General Arrangement drawing package shall consist of but not be limited to:

Anchor Bolt Layout

Roof Framing Plan

Elevations

Connection Details (if requested)

Design Review

During the Design Sketch and calculation stage, the activities of the individual designer are

monitored by the Design Department Supervisor

On completion of the calculations the designer details in writing all parameters used in

the calculation, the Design Supervisor verifies that the design parameters are correct as

per contract documentation.

Should the contract require the formal submittal of the design calculations to the client then

the Design Supervisor forwards the package to the Engineering Manager for Approval.

All General Arrangement drawings developed from design sketches are reviewed by thedrafting department for drawing accuracy and signed as checked then the package is

forwarded to the Design Department for review by the Designer against his design sketches

to determine if they have been correctly interpreted. The design package is then forwarded

to the client for review and comment.


25/82

Structural Steel


Page 25 of 82

Design Validation

All design packages, as detailed in the contractual requirements are forwarded to the client

for review comment and approval prior to the start of fabrication. Should any comments or

status codes be applied to the submitted design package other than approved, these commentsare addressed and another submittal is made to the client. This process is repeated until the

design is acceptable to the client.

Design Changes

When a change or modification to the design is required, the originator of the change

documents the required modification and forwards written instructions to the relevant

departments. Depending on the source of the change notice, the information is transmitted as

follows :

Internal Change notice Information to be forwarded to the Design Supervisor for

review and action

External (Client) notice Information to be forwarded to the Design Supervisor forreview and action

All change notices either in the form of commented drawings or written instructions are filed

in the Project File for future reference.

Software

KIRBY Steel Engineering has standardized the computer software used in order to ensure

compatibility with clients and other third parties involved in the project:

Microsoft Office General Office

Primavera / Microsoft Project Planning

Autocad 2D Drafting

Strucad 3D modeling and drafting

Bocad 3D modeling and drafting

Staad Pro 2D & 3D Design

Master Key Connections Design

ProKon Connections Design

PMS system Production Tracking & Monitorng

RFI s

If during the review, engineering design, or drafting cycles, additional information or

clarifications are required, a formal RFI is raised and issued to the client. The issue and

return of the RFI is recorded.


26/82

Structural Steel


Page 26 of 82

Pre-Production Planning

On award of the contract the Planning Department review the overall structure to establish

the following :

Overall production requirements per week and month

Sequence of contract execution in order to support the clients program

Priority for each sub structure

Engineering and Drafting planning

Procurement planning

The 3D modeling & drafting systems utilized by KIRBY Steel Engineering produce a full

Bill of Quantities during the "3 D" modelling phase of the drafting cycle. This information is

transferred to the piece monitoring system where the pre-determined priority ratings for each

Sub-structure are automatically assigned to the individual item

This allows the Piece Monitoring System to automatically generate a detailed (item by item)

production program which is then grouped together to give the daily production requirements

for all fabrication activities.

Due to the modular format of the Piece Monitoring System the individual module and the

relevant information required to control a specific activity can be downloaded onto the

computer system of any associate company. This allows them to conduct their area of the

operation in parallel with the overall project requirements.


27/82

Structural Steel


Page 27 of 82

Example

Material Preparation

The relevant material preparation modules of the Piece Monitoring System is forwarded tothe relevant departments and all the production scheduling information downloaded.

The engineering department also issues the plates and beam shafts drawings in the format

required to program the CNC equipment used in the material preparation.

As the material is processed in accordance with the production schedule, the Piece

Monitoring System is regularly updated by the computer system controlling the CNC

equipment or by manual entry periodically through the shift. This updated informationallows monitoring the progress of the contract piece by piece.

This example is applicable to each individual stage of the fabrication process.

Identification

All material received either from the mill or merchants stock is inspected on receipt for:

Completeness of order

Compliance with Purchase Order requirements

Transport Damage

Identifiable to valid mill certificate

As the material is processed through the preparation stage of the fabrication process the heatnumber of the individual piece is logged onto the cutting schedule against its unique position

/ item number. This information is then transferred to the Piece Monitoring System

providing material trace-ability for each individual piece back to the mill certification

Handling, Storage and Stacking

Steel plates and sections are either delivered to the preparation facility on a JIT basis or

stored and stacked in a KIRBY Steel Engineering designated area. All material is stored and

stacked in such a manner as to prevent distortion twisting or bending.

Consumable Storage

All welding rods painting and blasting material are stored in accordance with the

anufacturer's recommendations.


28/82

Structural Steel


Page 28 of 82

Fabrication Drawings

Material preparation drawings are issued to the Preparation Facility in electronic format and

are identified by phase substructure and cutting schedule.

The assembly drawings are issued either in electronic format or paper copy again they are

identified by phase substructure and assembly schedule

Beam Processing

During the cutting operation each beam is marked with it's item / position number to allow

identification and trace-ability through the rest of the fabrication process.

After the beam has been marked and cut, and depending on the requirements, the beam is

either moved directly to the transit lay-down area or processed thorough the CNC drill

station.

Beam Preparation Equipment

Please refer to the list of equipment attached.

Plate Processing

Plates are processed using various methods depending on thickness contract requirements and

end usage

If the thickness of the plate is 12 mm or less, the plates can be sheared to the required size,

however the end usage and contract requirements are also considered before work is detailed

to these machines.

Once the plate has been cut to the correct size and shape the final operation is producing the

holes. This can be done either by drilling or punching. Again thickness, hole dia, and

contract requirements are considered before allocating the work to the various machines

During the cutting operation, each plate is marked with it's item / position number to allow

identification and trace-ability through the rest of the fabrication process.

All cut edges can be dressed to remove burrs, dross and irregularities. Holes are dressed

as required to provide a smooth contoured surface.


29/82

Structural Steel


Page 29 of 82

Plate Processing Equipment

Please refer to the list of equipment attached.

Once the preparation of the material has been completed the material is then ready forassembly.

Assembly

When the material has passed it's inspection, it is released to the assembly / welding yard

were it is segregated in the lay down yard prior to release to assembly.

The material is assembled in accordance with the fitting schedule issued by Piece Monitoring

System.

The material is assembled in accordance with the fabrication drawings in such a manner thatthey are not bent, twisted or otherwise damaged, and any deformation is within the stated

tolerances.

All items, after assembly, are fully dimensionally checked, any deviations are corrected

immediately.

The results of the dimensional check are logged onto the Piece Monitoring System.

Welding

All welding operations are carried out in accordance with KIRBY Steel Engineeringsapproved welding procedures by independently qualified welders.

All procedures and welder qualifications are in accordance with AWS D 1.1

During the welding operation all welders are continually monitored to ensure that the welding

parameters, as detailed in the relevant procedure, are adhered to and that the level of

workmanship is maintained.

All items, after completion of welding are visually inspected against the requirements of

AWS D 1.1 for compliance. Any visual discontinuity is marked and repaired immediately.

Only when the item has been fully passed and accepted will it be released to blasting and

painting

All welding inspections are entered onto the piece monitoring system.


30/82

Structural Steel


Page 30 of 82

Curving and Straightening

When it is necessary to curve or straighten components one of the following methods may be

used:

Mechanical - taking care not to cause indentations or changes in cross section

Local Application of Heat - ensuring that the temperature does not exceed 650C

Non-Destructive Testing

Non destructive testing is carried out in accordance with the contract requirements, all NDT

inspections are conducted by an independent 3rd party specialist company with AWS D1.1

acceptance standards used for determining the acceptability of the weld.

The results of all NDT examinations are entered on the Piece Monitoring System.

Surface Preparation and Painting

The surface preparation / blast cleaning produces the required anchor pattern and cleanliness

level as detailed by the paint manufacturer to ensure paint adhesion to the surface.

The Painting Inspector carries out profile checks at the start of each blasting run to ensure

that the required profile and cleanliness levels are met.

All material once blasted are primed within 4 hours to prevent rust bloom.

The painting operation is conducted ony if the following conditions are met:

(as specified by the paint manufacturer)

The surface temperature shall be at least 3 degrees centigrade above the dew point andthe Relative Humidity (RH%) 40% and 85%.

Visual checks on the surface shall be carried out to ensure none of the following pointexist oil, grease, dirt, loose paint, rust and other surface contamination.

There is protection from adverse weather conditions, such as wind that may blowsand, or other foreign bodies on the painted surface or it may disrupt the paint pattern

or cause dry spray.

Paint Strip shall be applied to all welds and corners if required.

Primers, intermediate coats and top coats shall be contrasting colours, if more thanone application is required to achieve the required film thickness, then the same

colour should be used. But reference to Client's specifications must be made before

implementation.

Finished coatings shall be free of runs, drips, dry spray etc. Areas that are cracked,damaged or below minimum thickness shall be repaired in prior to dispatch


31/82

Structural Steel


Page 31 of 82

All defective areas are to be cleaned with solvents, detergents or clean water as required

All repair areas blast cleaned to the metal surface, with the edges being feathered back at

least 50 mm beyond the clean metal surface. For areas less than 1000 mm2, brush coating

may be acceptable, but with reference to Client's specifications , areas greater than 1000 mm2the paint shall be applied as to the original specification.

Painted items shall be handled with proper care so that damage to the paint is minimised.

Structural steel items shall not be handled until paint has thoroughly dried.

Care shall be taken to avoid abrasions and other damage.

Nylon / Canvas slings shall be used for handling the coated steelwork or when steel slings are

to be used, they shall not be choked with wood to avoid / limit contact with coated steelwork.

Delivery of Finished Product

Each piece of steelwork shall be distinctly marked with Item No and bar code before dispatch

in accordance with the fabrication drawing . Steelwork shall be stacked on timbers in order to

provide easy handling

All attachments and fittings shall be securely attached. Loose plates and smaller items shall

be either boxed or wired together and then wired to larger parts.

Floor plates shall be bundled for shipment

Bolts, Nuts and Washers shall be packed in strong bags with the Nuts and Washers assembledon the Bolts.

The client should be informed of the time of delivery and delivery notes shall accompany all

deliveries.

The sequence of shipment shall be such as to expedite erection and minimise field handling

of material


32/82

Structural Steel


Page 32 of 82

Attachments

i. KIRBY STEEL ENGINEERING Process Flow Chart & Description

ii. KIRBY STEEL ENGINEERING Change Control Procedure & Description

iii. KIRBY STEEL ENGINEERING Steel Sample Project Quality Plan

iv. KIRBY STEEL ENGINEERING Steel Sample Inspection & Test Plan

v. P M S Sample Schedules & Q C Reports

vi. KIRBY STEEL ENGINEERING Welding Procedures


33/82

Structural Steel


Page 33 of 82


34/82

Structural Steel


Page 34 of 82

KIRBY STEEL ENGINEERING Change Procedure


35/82

Structural Steel


Page 35 of 82

KIRBY STEEL ENGINEERING Change Procedure

The attached logic chart details the standard method adopted by KIRBY STEEL

ENGINEERING for processing changes. This procedure may be amended to reflect ndividual

contract requirements.

Note: P = Project Management Team

FW = Fabrication Workshop

SAMPLE DOCUMENTATION ONLY

PROJECT QUALITY PLAN

Document No CGP-PQP-204Revision 0

15-9-01 0 Douglas Bevan Henry Nasr Henry NasrDate Revision Author Review Approval

Page 39 of 96KIRBY STEEL ENGINEERING Prequalification


36/82

Structural Steel


Page 36 of 82


PROJECT QUALITY PLAN

Document No. CGP-PQP-204

Revision 0


37/82

Structural Steel


Page 37 of 82


INDEX

1.0 Purpose

2.0 Scope

3.0 References

4.0 Definitions

5.0 Responsibilities

6.0 Procedure

6.1 Contract / Tender Review

6.2 Document Control and Quality Records

6.3 Procurement Procedure

6.4 Material Control

6.5 Identification and Tractability

6.6 Process Control

6.7 Inspection and Testing

6.8 Control of Inspection Measuring and Testing Equipment

6.9 Non Conforming Product Control

6.10 Corrective and Preventative Action

6.11 Material Handling Storage and Delivery

6.12 Audit Procedure6.13 Training

7.0 Exhibits


38/82

Structural Steel


Page 38 of 82


1.0 Purpose

The purpose of this Standard Project Quality Plan is to outline the applicableprocedures to be used for the execution of a project in conformance with KIRBY

STEEL ENGINEERING Quality system.

2.0 Scope

This procedure is applicable to all contracts where the generation of a specific Project

Quality Plan is not called for by the client.

3.0 References

KIRBY STEEL ENGINEERING's Quality Management System.

4.0 Definitions

KIRBY STEEL ENGINEERING KIRBY STEEL ENGINEERING

ITP Inspection and Test Plan

5.0 Responsibilities

As Detailed in the procedure

6.0 Procedure

6.1 Contract / Tender Review

6.1.1 All Tender Enquiry's Shall Be:

Logged as received and assigned a Tender Number

Reviews shall be carried out by Senior Management

The contract shall be priced by engineering


39/82

Structural Steel


Page 39 of 82


6.2 Document Control and Quality Records

6.2.1 Project Filing System

On the award of a contract, a contract specific identification number shall be allocated

by the Engineering Manager, and a Project File shall be generated All the in-coming

and out-going documents related to their project will be logged in the Project File.

On completion of the project, the Project files shall be filed for a minimum of 1 year.

After which they may be disposed of, at the discretion of Senior Management

6.2.2 Drawing Receipt Approval and Issue

All drawings received by KIRBY STEEL ENGINEERING relating to a specific

project shall be acknowledged and a copy of the acknowledgement shall be filed inthe project file

All drawings as detailed in the contract shall be issued to the client for approval

After approval Fabrication drawings shall be generated and issued to the relevant

personnel

Their issue and return shall be recorded in the Issue register maintained by the Head

of Drafting or his designated nominee.


40/82

Structural Steel


Page 40 of 82


6.2.3 Quality Records

The QC Engineer shall maintain the following records: -

Material Certification

Goods Inwards Inspection Reports

Plate / Beam Cutting Schedules

Consumable Certification (Electrodes, Paint, Bolts etc)

Fabrication Check Lists

NDE Reports if applicable

Welders Qualifications

Welders Records

Weld Procedure Specifications

Procedure Qualification Records Painting Release Forms

Painting Inspection Reports

Dimensional Check Reports

Final Inspection Reports

Copies of Delivery Notes

QC Fabrication Drawings

On completion of a Project the quality records relating to the project shall be

correlated by the QC Engineer into a Project Data Book. The quality records shall

consist of:

Material Certification Data Book

Plate / Beam Cutting Schedules Data Book

Fabrication Check Lists Data Book

NDE Reports if applicable Data Book

Painting Release Forms Data Book

Painting Inspection Reports Data Book

Final Inspection Reports Data Book

Copies of Delivery Notes Forwarded with each delivery

QC Fabrication Drawings Data Book

Bolt Certification Data Book

Paint Certification Data Book

On completion of the project the quality records will be archived for the minimum of

one year


41/82

Structural Steel


Page 41 of 82


6.2 Procurement Procedure

6.3.1 BOQ

The Engineering Manager through his designated nominee shall ensure that a BOQ is raised

for each project.

The Stores shall check the BOQ against the stock lists and raise the necessary requisition

orders for the balance material

The Commercial Director shall review the requisitions for cost quantity and technical

accuracy; if the requisition is acceptable he shall approve it and forward it to Procurement

who shall raise the order.

6.4 Material Control

6.4.1 Material Receipt

All material ordered by and delivered to KIRBY STEEL ENGINEERING shall be inspected

by the Goods Inwards Inspector in accordance with the relevant Work Instructions and

Procedures.

6.4.2 Traceability

Material trace-ability shall be maintained by heat number, which shall be logged on the

material cutting schedule against the relevant piece number.

6.4.3 Electrodes

All electrodes shall be inspected upon receipt, stored in accordance with KIRBY STEEL

ENGINEERING procedures and their issue, return and baking (if required) shall be recorded

by the Rod Storeman.


42/82

Structural Steel


Page 42 of 82


6.4.4 Paint

Paint shall be inspected upon receipt in accordance with KIRBY STEELENGINEERING's procedures; the paint shall be stored in the designated area, used

within its shelf life and rotated through the stores on a first in first out basis.

6.5 Identification and Trace-ability

All material shall be marked with its Project Number and position / piece number at

the material preparation stage.

The material heat numbers shall be logged on the Cutting schedule.

6.6 Process Control

6.6.1 Trace-ability of steel

All steel material shall have a valid mill certificate and the material shall be identified

to the mill certificate

6.6.2 Fabrication / Shop Drawings

All in house drawings shall be checked for accuracy before issue

The drawings shall contain all the necessary details for production to fabricate the

item.

Certain contracts may require specific information to be included on the drawing, the

head of drafting shall be informed of these requirements

6.6.3 Marking

All items shall be marked with their Project Number and their position / piece number

as detailed on the cutting schedule, at the preparation stage.

The Heat Number shall be transferred to the cutting schedule and logged against the

items position piece number.


43/82

Structural Steel


Page 43 of 82


6.6.4 Cutting Shaping Bending and Bolt Holes.

Beams plates and sections shall be cut in accordance with their cutting schedules

Cutting may be done by shearing, sawing, grinding and machine cutting. Hand flame

cutting may be allowed if all other methods are impractical.

Holes may be made by drilling or punching and slotted holes made by a combination

of drilling punching and cutting. All tolerances shall be in accordance with the

contract requirements as detailed on the ITP

6.6.5 Assembly

All components shall be assembled in a manner such that they are not bent, twisted or

otherwise damaged.

6.6.6 Curving and Straightening

When it is necessary to curve or straighten components, this may be done by

mechanical means or the local application of heat

6.6.7 Welding

All welding shall be in accordance with the requirements of AWS D1.1

When required by contract all applicable welding procedures shall be submitted to the

client for approval

Pre Qualified welding procedures shall be used unless specifically stated in the

contract documentation.

The preparation and fit up of all parent metal shall be in accordance with the

requirements of AWS D1.1 and the approved welding procedure.

6.6.8 Electrodes and Automatic Coils

Electrodes and automatic coils shall be procured, stored, issued and controlled in

accordance with KIRBY STEEL ENGINEERING's procedure


44/82

Structural Steel


Page 44 of 82


6.6.9 Preheat and Interpass Temperature

Minimum Preheat and Interpass Temperature shall be exercised as detailed in theapproved WPS.

6.6.10 Inspection

These activities shall be controlled in accordance with procedure KIRBY STEEL

ENGINEERING Inspection and Testing procedures. And governed by the Test and

Inspection Plan

6.6.11 Surface Preparation, and Painting

All surface preparation, priming and top coating, will be in accordance with the

KIRBY STEEL ENGINEERING' procedure of Paint Control

6.7 Inspection and Testing

6.7.1 Inspection and Test Plan

KIRBY STEEL ENGINEERING standard Inspection and Test Plan shall be adhered

to unless a project specific Inspection and Test Plan is required by the contract in

which case the QA Manager shall draft, submit for approval and issue the relevant

Project Specific Inspection and Test Plan.

6.7.2 Receipt Inspection

All incoming material shall be checked by the Goods Inwards Inspector for

conformance to KIRBY STEEL ENGINEERING's requirements.

6.7.3 In-process Inspection and Testing

All stage inspections shall be carried out by the designated inspection personnel and

the findings reported to the QC Engineer.

6.7.4 Non-destructive Examination

The QC Engineer shall call up such NDT as required (10% MPI + Radiography of

Splice Welds. KIRBY STEEL ENGINEERING normal in-house requirement) to

ensure the quality of KIRBY STEEL ENGINEERING's fabrication.


45/82

Structural Steel


Page 45 of 82


6.7.5 Records

Records of all inspections shall be filed with the QC Engineer as objective evidenceof the inspection.

6.8 Control of Inspection Measuring and Testing Equipment

All inspection Measuring and testing equipment utilised by KIRBY STEEL

ENGINEERING shall maintain a current calibration status that is traceable back to

the national standards at all times

6.9 Non Conforming Product Control

6.9.1 Non-conformance of Procured material

If purchased material is found not to conform to KIRBY STEEL ENGINEERING's

requirements, then the material shall be returned to the supplier. The materials

controller shall inform the supplier for the reason for rejection and the supplier may

re-supply material that conforms to KIRBY STEEL ENGINEERING's requirements

or the Materials Controller shall inform procurement who shall place the order with

an alternate supplier.

6.9.2 Non-conformance during Production

When a Non-conformance is noted during production the Inspector shall quarantine

the material and an NCR shall be raised.

The QC engineer shall evaluate the Non-conformance and decide on the relevant

course of action to correct the non-conformance.

Should corrective action be outside the specification requirements then a concession

request shall be forwarded to the client for their recommendation and approval.

Rejected material shall be removed from the production area and either down graded

or scraped


46/82

Structural Steel


Page 46 of 82


6.10 Corrective and Preventative Action

6.10.1 Customer Complaints

The QA manager shall record investigate and respond to any formal complaint from

the client.

6.10.2 Quality System Deficiencies

When a deficiency is identified in the Quality System, then the deficiency shall be

reviewed against the relevant procedure. Should it be found necessary to amend the

procedure this shall be done in accordance with Procedure Preparation Style and

Format procedure and the eview and issue procedure as detailed in the Quality

Manual.

6.11 Material Handling Storage and Delivery

6.11.1 Before and After Fabrication

All material shall be stacked in such a manner as to minimise damage and distortion.

The material during fabrication shall be laid out clear of the ground and in such a

manner as to acilitate inspection

6.11.2 After Painting

All painted material shall be stacked in bundles, with wooden strips in between

adjacent members these bundles shall then be metal strapped before loading. Alllifting operations of painted steel shall be done with nylon / canvas slings so as to

minimise damage. Paint touch-up is acceptable before dispatch.

6.11.3 Delivery of Finished Product

All items shall be marked with their item number as detailed on the erection drawings

All loose items shall be securely fastened, bundled or bagged before dispatch.


47/82

Structural Steel


Page 47 of 82


6.12 Audit Procedure

The QA Manager or his designated nominee shall carry out periodic audits of thequality system to access its effectiveness and the level of compliance to the Quality

Management Procedure.

6.13 Training

While it is not generally KIRBY STEEL ENGINEERING's policy to employ then

train personnel but to employ already trained personnel. Should the need for training

of personnel be identified then this training shall be accomplished in one of the

following manners

Verbal Instruction

Tool Box Talks Work Instructions

In House Training

Training Agency (outside the Company)

7.0 Exhibits

Inspection and Test Plan


48/82

Structural Steel


Page 48 of 82


49/82

Structural Steel


Page 49 of 82


50/82

Structural Steel


Page 50 of 82


51/82

Structural Steel


Page 51 of 82


52/82

Structural Steel


Page 52 of 82


53/82

Structural Steel


Page 53 of 82


54/82

Structural Steel


Page 54 of 82


55/82

Structural Steel


Page 55 of 82


56/82

Structural Steel


Page 56 of 82


57/82

Structural Steel


Page 57 of 82


58/82

Structural Steel


Page 58 of 82


59/82

Structural Steel


Page 59 of 82


60/82

Structural Steel


Page 60 of 82


61/82

Structural Steel


Page 61 of 82


62/82

Structural Steel


Page 62 of 82


63/82

Structural Steel


Page 63 of 82


64/82


65/82

Structural Steel


Page 65 of 82


66/82

Structural Steel


Page 66 of 82


67/82

Structural Steel


Page 67 of 82


68/82

Structural Steel


Page 68 of 82


69/82

Structural Steel


Page 69 of 82


70/82

Structural Steel


Page 70 of 82


71/82

Structural Steel


Page 71 of 82


72/82

Structural Steel


Page 72 of 82


73/82

Structural Steel


Page 73 of 82


74/82

Structural Steel


Page 74 of 82


75/82

Structural Steel


Page 75 of 82

Organisation Chart


76/82

Structural Steel


Page 76 of 82

Customer Base

Kuwait United Arab Emirates

Snamprogetti/Equate National Food Co.

Al Hamra / MOD System Construct

Jahra Mega Warehouse Choithram & Sons

PIC/Kuwait Fertilizer Plant System Construct

Public Warehousing Sharjah Airport

RECAFCO System Construct

Kuwait Co.for Processing Plant C Fawaz Al Khateeb

Ministry of Defence Orion Engineering

TOYO Sheikh Saleh Bin Ham.

Kuwait Airways Corporation (KAC) Abu Dhabi Municipality

Ahmadi Governorate Gulf Erection / EMC

Kuwait Free Trade Zone System Construct

Coca Cola Boskin Factory

Kuwait Oil Co. Dubai Municipality

National Guard

Bahrain

Qatar Jawid Textile Mill

Al Jaber Engg. Manama Textiles

J.G.C. Daewoo Desalination Project

Qapco/Snamprogetti Rolls Royce / Chrysler

Qatar Clay Bricks Co. Bahrain Airport Service

Naseer Enterprise

NBKS Saudi Arabia

Qatar Steel Co. (QASCO) Ministry of Defence, S.A.

Al Madar Cont. Trdg. Al Owaidah / Ministry of Awkahf

NADA

Oman Al Othman Agri Products

Khimji Textile Mill Al-Othaim Central Warehouse Pro.

Oman Ceramics Ministry of Education

Qurum Contractors Sahara Building Cont.

Steel Service Centre Hussain Bakri Gazzaz & Partners

Raysyt Cement Co. Nesma & Al Fadel Cont. Co.

Al Turki Trdg. Cont. Co.

Yemen Saudi BinLaden Group

Canada Dry TADCO

Yemen Co. For Ind. Invest. Ltd. Saudi National Guard

H.S.A. - (YCFM)


77/82

Structural Steel


Page 77 of 82

Customer Base Ctd.

Syria Jordan

Rubi Eco. Group Jordan Royal Airforce

Deiri Group International Arabian Dev. Co.

Arab Agri. Mfg. Co.

Granada Ceramic Ind. Egypt

Arab Brothers

Lebanon Inglen

Sukom Misr Al Amria

Liban Lait Sal Al Safadi Group

Misr Al Amria

Sudan

Sudan Railway Corporation Tanzania

Coldair P.B. Power / Rolls Royce

Ethiopia Libya

H'rena Pvt. Ltd. F.L. Smidth

Summit Partners Alimaz

Burayu Spring

Sri Lanka

Vietnam Industrial & Commercial dev. Co.

Indochina Ceramics Factory Complex/Star Packaging

American Standard Cotton Line

Triumph International

Nestle Korea

Toforby Corporation

Bangladesh

Spinning Mill/Silver Line Composite Romania

Al Muhaidib & Sons

Pakistan

Adam Motor Co./Car Plan Cambodia

Manitel / Pochentong Airport

Guam

S.H. Behbehani


78/82

Structural Steel


Page 78 of 82

Typical Structural Steel Projects


79/82

Structural Steel


Page 79 of 82



80/82

Structural Steel


Page 80 of 82



81/82

Structural Steel


Page 81 of 82



82/82

Structural Steel



kirby_prequalifications_-_rev_1311 ตัวอย่าง

Documents