009-METHOD STATEMENT - MAIN ERECTION SEQUENCE FOR ACC.pdf
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Pearl GTL Project LINDE ENGINEERING
Shell Project No: HP-3000-QAT Project Document Number: T- 4.250.904
Contractor Project No : Project Rev.: A
Purchase Order Number:
2MH127
Tag/Item Number(s):
1A-2121, 1A-2221, 1A-2321, 1A-2421, 2A-2121, 2A-2221, 2A-2321, 2A-2421
Unit(s):
1-2100, 1-2200, 1-2300, 1-2400, 2-2100, 2-2200, 2-2300, 2-2400
PCWBS:
Z
Page 2 of 65
5887
QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION
F
A
24.11.08
Company Comments Incorporated (with Preservation)
RT
UO/MK
AG
CCI
E
A
12.11.08
Company Comments Incorporated (with PMC)
OK
UO/MK
AG
CCI
D
A
30.07.08
Company Comments Incorporated
OK
UO
AG
CCI
C
O
10.04.08
Issued for Company Comments
RT
EE
ZG
ICC
B
17.03.08
Issued for Review
RT
EE
ZG
IFR
A
21.02.08
Issued for Internal Review
RT
EE
ZG
IIR
Date
Description
GAMA Rev. No.
Project Rev No.
Prepared Checked Approved By By By ORIGINATOR
Status
Document Title:
LINDE ENGINEERING AG
METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC Document No.
Contractor
LOC470 Gama Qatar Co. W. L. L.
GAM
MTS
MEC
GTL
009
F
Org. Code
Doc. Type
Disc. Code
Geogr. Area
Seq. No
Rev. No
Project Document Number: T- 4.250.904
Vendor Code
Rev No: A
Q A T A R
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Table of Content 1
PURPOSE _____________________________________________________________________5
2
SCOPE________________________________________________________________________5
3
HSSE _________________________________________________________________________5
4
DEFINITIONS __________________________________________________________________6
5
REFERENCES _________________________________________________________________7
6
RESOURCES _________________________________________________________________20 6.1
Responsibilities ___________________________________________________________________ 20 Site Manager __________________________________________________________________________ 20 Mechanical Erection Manager ___________________________________________________________ 20 Site Engineer__________________________________________________________________________ 20 Site Supervisor (SS) ___________________________________________________________________ 20 Piping Supervisor (PS) _________________________________________________________________ 20 Artisans ______________________________________________________________________________ 20 QA/QC Officer / Inspector _______________________________________________________________ 21
6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7
6.2
Equipment & Manpower __________________________________________________________ 21 Equipment ____________________________________________________________________________ 21 Manpower ____________________________________________________________________________ 21
6.2.1 6.2.2
7
METHOD OF EXECUTION _____________________________________________________23 7.1
General _________________________________________________________________________ 23
7.2
Pre-Commencement Works ________________________________________________________ 23 Foundation Seats ______________________________________________________________________ 23 Logistical Materials and Equipment _______________________________________________________ 23 Barricades and safety Sign Boards _______________________________________________________ 23 Positioning and Lifting Equipment ________________________________________________________ 24 Main Erection Sequence ________________________________________________________________ 28 Special Technical Procedures ___________________________________________________________ 40
7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6
8
QUALITY ASSURANCE________________________________________________________42
9
ATTACHEMENTS _____________________________________________________________43 9.1
Job Safety Analysis _______________________________________________________________ 43
9.2
Installation of Life Line for Bundles Erection at ACC __________________________________ 43
9.3
Lifting of Fan Deck Plates __________________________________________________________ 43
9.4
Design Calculation Notes for Horizontal Lifeline System ________________________________ 43
T-4.250.904 Rev. A
Page 4 of 65
Q A T A R 1
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
PURPOSE This document describes the methods proposed to be used for the Erection Operations that will be carried out as part of ASU Construction Works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City (RLIC) of Qatar including similar works in TSF Area.
2
SCOPE This method statement identifies the general steps, arrangements and precautions for the assembly and erection works of one ACC at the following site; FD at C2 area. Since the sites are identical to FD; this method statement shall also apply to other sites as FA, FB, FC and GA, GB, GC, GD at C2 area. This method statement also defines piping erection of all SPX equipment at the site which is developed for installation of steam condensed piping, extraction, cleaning systems and instrumentation. ACC consists of four streets with four modules per street with fan units and associated equipment which will be erected on top of the steel structures. The scope of the ACC starts from the turbine exhaust steam turbine outlet with the main steam duct, which feeds to the Air Cooled Condenser (ACC). The latter is equipped with drain pot that collects the condensate to the condensate tank which is located at module N of street # 4. The steel structure will be erected at site according to the ACC Construction Manual T4.121.350, by means of crane and/or certified lifting equipment utilizing equipment specified in section 6.2, with competent personnel. The works will also include the erection, installation and alignment of equipment above the steel structure as follows: fan screen and stack, motor bridge with drive and blades/impellers, condensate and steam manifolds, bundles (heat exchangers), associated steel structures, pipe works for steam recovery, and other amenities for access and walkways necessary for maintenance. The sequence of construction by street will be 3,4,2 then 1 taking into consideration to specific requirement on the erection of condensate tank, steam ejectors and associated equipment which will be located with separate steel structure beneath the module N of street 4 (please refer to drawing T-4.149.204). The sequence of activities will be applicable to other sites. Scaffolding will be required during the duration of the works. Scaffolding shall be inspected by HSE before work starts. Periodic scaffolding inspection will be required.
3
HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards/codes, and Company and Contractor requirements and instructions. All personnel will go through Gama, Linde and Company Safety Induction courses as well as other trainings as identified by their supervisor. Please refer Document T-4.219.615 for details. A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared as per Gama procedure T-4.219.606 and is attached herein. Such JSA addresses the hazards
T-4.250.904 Rev. A
Page 5 of 65
Q A T A R
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
associated with each task within the scope of this Method Statement and introduces the controls that will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks. All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves, double lanyard full body harness) at site at all times as required. In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all employees are out of danger. The supervision will report this to Contractor Emergency Contact numbers for Company, Contractor and Gama will be posted onsite. All vehicles and equipment used for the subject work will be inspected and certified as required. Drivers and operators will be competent and will have attended all required trainings set forth in the project procedures and specifications.
4
DEFINITIONS Company Contractor Subcontractor Contract QCP ITP QA/QC HSSE JSA Street SDM CCM SS ACC PTW LP RA FSI NDT TSTI TSTO PPE RLIC SPX
T-4.250.904 Rev. A
QSGTL and/or its PMC Linde Engineering AG Gama Qatar Co. W. L. L. QSGTL Pearl Project – C2 ASU Construction Works (2MH127) Quality Control Procedure Inspection and Test Plan Quality Assurance / Quality Control Health, Safety, Security and Environmental Job Safety Analysis Location of condensers and accessories Steam Distribution Manifold Condensate Collecting Manifold Site Supervisor Air Cooled Condenser Permit to Work Lifting Plan Risk Assessment Flawless Start-up Initiative Non-Destructive Test Total Safety Task Instruction Total Safety Task Observation Personnel Protection Equipment Ras Laffan Industrial City Vendor
Page 6 of 65
Q A T A R 5
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
REFERENCES ASME B 31.3 ASME Sec II; ASME SEC. IX ASME SEC.V DEP 34.28.00.31 DEP 70.10.70.11 DEP.30.8.60.18 DEP.31.38.01.11 DEP.31.38.01.31 T-13.377.360
Process Piping Specification for Welding Rods, Electrodes & Filler Metals Welding And Brazing Qualification Non Destructive Examination Technical Specification Steel Structures Preservation Of Old And New Equipment And Piping Standing Idle Welding Of Metal (Amendments/Supplements To Api Rp 582 Piping General Requirements Shop & Field Fabrication Of Steel Piping Amendment T.13.376.796e Flawless Start-Up Initiative (FSI)
T-13.377.438
Specification For Traceability, Alloy Verification And Material Substitution
T-13.377.441 T-4.095.303 T-4.095.723 T-4.116.905 T-4.116.909 T-4.116.910 T-4.116.970 T-4.121.193 T-4.121.194 T-4.121.212 T-4.121.213 T-4.121.214 T-4.121.215 T-4.121.226 T-4.121.227 T-4.121.228 T-4.121.230 T-4.121.231 T-4.121.232 T-4.121.233 T-4.121.234 T-4.121.235 T-4.121.236 T-4.121.237 T-4.121.238 T-4.121.239 T-4.121.240 T-4.121.241 T-4.121.244 T-4.121.245 T-4.121.246
Quality Control Requirement For Welding HSSE Plan Construction General Layout Plan Air Seperation Plants General Arrangement Drawing (C Bundle) Primary Fin Tube Bundle (D Bundle) Secondary Fin Tube Bundle PEFS ACC 03 – Condensate System General Arrangement Condensate Tank Parts list for Condensate Tank Piping Tie-In Drawing And List Piping Layout – Condensate Piping Piping Layout – Air Take Off System Piping Layout – Cleaning System Support Condensate Piping Support Drain Piping Cleaning Water Piping Arrangement Steam Duct Fabrication Main Steam Duct Part 1 Fabrication Main Steam Duct Part 02 DN3820 Fabrication Main Steam Duct Part 03 DN3820 Fabrication Main Steam Duct Part 04 DN3820 Fabrication Main Steam Duct Part 05 DN2820 Fabrication Main Steam Duct Part 06 DN2820 Fabrication Main Steam Duct Part 7 DN2820 Fabrication Main Steam Duct Part 8 DN2820 Fabrication Main Steam Duct Part 9 Fabrication Main Steam Duct Part 10 DN2020 Fabrication Main Steam Duct Part 11 Duct Support BN3800 P1 Duct Support DN3800 P2 & P3 Duct Support DN2800 P4 & P5
T-4.250.904 Rev. A
Page 7 of 65
Q A T A R T-4.121.257 T-4.121.261 T-4.121.262 T-4.121.264 T-4.121.265 T-4.121.266 T-4.121.270 T-4.121.271 T-4.121.272 T-4.121.273 T-4.121.274 T-4.121.275 T-4.121.276 T-4.121.277 T-4.121.278 T-4.121.281 T-4.121.282 T-4.121.284 T-4.121.287 T-4.121.298A T-4.121.304 T-4.121.305 T-4.121.323 T-4.121.350 T-4.121.350 T-4.121.350 T-4.121.350 T-4.121.357 T-4.129.656 T-4.129.850 T-4.129.852 T-4.129.853 T-4.129.854 T-4.129.855 T-4.129.856 T-4.129.857 T-4.129.859 T-4.129.860 T-4.129.861 T-4.129.864 T-4.129.865 T-4.129.866 T-4.129.867 T-4.129.868 T-4.129.871
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
(ASM) Fan Units (ASM) Columns and Bracings - Item Id A0080111, Page 4 of 4 Parts List Columns and Bracings Parts List Main Steel Truss (ASM) Windwall – Item ID A0080734 (sheet 1 of 4) Part List Windwall (Steelwork) Part List A-Frame Part List Motor Bridge Type 1 – 3 (ASM) Motor Bridges Complete Type 1 (ASM) Motor Bridges Complete Type 2A (ASM) Motor Bridges Complete Type 2B (ASM) Motor Bridges Complete Type 3 (ASM) Motor Bridge Type 3 Stair Tower General Arrangement Part List Stair Tower (ASM) Fan Screen Support Parts List (ASM) Fan Screen Escape Routes General Arrangement Condensate Tank Substructure General Arrangements General Instruction For Site Storage And Preservation General Arrangement Condensate Pump General Arrangement Drain Pump Outline Drawing Fan Motor Construction Report: Piping Foundation (D0007603) General Instructions : Preservation of ACC (D0042190) General Instructions for Site Storage and Preservation (D0042191) ACC Construction Manual Piping Class SPX 001 Construction Waste Management Plan Accident/Incident/Near Miss Reporting And Investigation Entry Into Confined Space Personal Protective Equipment Risk Assessment Emergency Response Welding And Flame Cutting Road Safety Procedure Lifting Operations Manual Handling Working With Electricity Safe Use Of Compressed Gases Portable Power Tools Use of Grinding Machines And Abrasive Wheels Hand Tools Work At Height – Scaffolding Environment Accounting
Page 8 of 65
Q A T A R T-4.129.872 T-4.131.762 T-4.131.763 T-4.133.661 T-4.133.662 T-4.133.665 T-4.133.666 T-4.133.667 T-4.133.970 T-4.149.204 T-4.149.213 T-4.149.274 T-4.149.277 T-4.149.295 T-4.184.595 T-4.184.826 T-4.186.019 T-4.193.137 T-4.193.139 T-4.193.298 T-4.193.303 T-4.193.304 T-4.193.320 T-4.193.323 T-4.193.324 T-4.193.325 T-4.193.326 T-4.198.504 T-4.198.505 T-4.198.506 T-4.198.509 T-4.198.510 T-4.200.135 T-4.200.144 T-4.200.145 T-4.200.146 T-4.200.152 T-4.200.159 T-4.200.160 T-4.200.163 T-4.200.164 T-4.200.165 T-4.200.166 T-4.200.167
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Heat Stress Disorder Prevention Piping Class SPX 002 Piping Class SPX 003 PEFS ACC 04 - Air Evacuation Unit PEFS ACC 06 - Detail Pump and Fan Motors PEFS ACC 01 - ACC Unit PEFS ACC 02 – Drain System PEFS ACC 05 Cleaning System PEFS Acc 03 – Condensate System General Layout Plan ASU Duct Support BN3800 P1 Arrangement Connecting Turbine Support Fabrication DN3800 Type QAR 01 Evacuation And Condensate Piping Details Land Road Transport HSSE Case Motor – Storage Procedure Flawless Start Up Initiative Packing And Preservation – Bundles Fin Tube Bundle Name Plate Packing and Preservation Procedure Fan Stack Protection Cage for ACC Handrail Axis A1 Protection Cage for ACC Handrail Axis A5 Structural Steelwork Erection Tolerances & Torques Relieve Valve Preservation Pipe work Preservation Instrument Preservation Cleaning System For Bundles Condensate Collecting Manifold, Sheet 1 of 2 Condensate Collecting Manifold, Sheet 2 of 2 Parts List Fabrication Steam Duct Manhole DN 600 / 150 Lbs Horizontal Manhole DN 600 / 150 Lbs Vertical Gear Box – Electrical Connection Diagram Operation And Maintenance Manual – Coupling Operation And Maintenance Manual – Gear Unit Including Attachment Parts And Lubrication List Gearbox – Outline Drawing Gear box - Procedure Preservation Stair tower Main Structure Part 01 Stair tower Main Structure Part 02 Stair tower Staircase Type 2a Stair tower Staircase Type 2b Stair tower Staircase Type 3a Stair tower Staircase Type 3b Stair tower Staircase Type 4a
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Q A T A R T-4.200.168 T-4.200.169 T-4.200.170 T-4.200.171 T-4.200.172 T-4.200.179 T-4.200.180 T-4.200.182 T-4.200.183 T-4.200.184 T-4.200.189 T-4.200.190 T-4.200.191 T-4.200.192 T-4.200.193 T-4.200.194 T-4.200.195 T-4.200.196 T-4.200.197 T-4.200.198 T-4.200.199 T-4.200.200 T-4.200.201 T-4.200.202 T-4.200.203 T-4.200.204 T-4.200.205 T-4.200.206 T-4.200.207 T-4.200.208 T-4.200.209 T-4.200.210 T-4.200.211 T-4.200.212 T-4.200.213 T-4.200.214 T-4.200.215 T-4.200.216 T-4.200.217 T-4.200.218 T-4.200.219 T-4.200.220 T-4.200.221 T-4.200.222 T-4.200.223
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Stair tower Staircase Type 4b Stair tower Staircase Type 5a Stair tower Staircase Type 5b Stair tower Staircase Type 6a Stair tower Staircase Type 6b Escape Routes Ladders LD1 LD4 Fabrication Details Escape Routes Ladders LD2 LD3 Fabrication Details Escape Routes Platforms Fabrication Details Part 01 Escape Routes Platforms Fabrication Details Part 02 Escape Routes Platforms Fabrication Details Hand rails (ASM) Column 1 – Item ID A0080112 (ASM) Column 1 – Item ID A0080123 (ASM) Column 1 – Item ID A0080124 (ASM) Column 1 – Item ID A0080125 (ASM) Column 1 – Item ID A0080126 (ASM) Horizontal Bracing – Item ID A0080133 (ASM) Horizontal Bracing – Item ID A0080136 (ASM) Columns and Bracings – Item Id A0080111, Page 1 of 4 (ASM) Horizontal Bracing – Item ID A0087511 (ASM) Horizontal Bracing – Item ID A0087493 (ASM) Horizontal Bracing – Item ID A0087495 (ASM) Horizontal Bracing – Item ID A0087496 (ASM) Horizontal Bracing – Item ID A0087499 (ASM) Horizontal Bracing – Item ID A0087501 (ASM) Horizontal Bracing – Item ID A0087503 (ASM) Horizontal Bracing – Item ID A0087505 (ASM) Horizontal Bracing – Item ID A0087506 (ASM) Horizontal Bracing – Item ID A0087507 (ASM) Horizontal Bracing – Item ID A0087508 (ASM) Horizontal Bracing – Item ID A0087512 (ASM) Horizontal Bracing – Item ID A0087558 (ASM) Horizontal Bracing – Item ID A0087577 (ASM) Horizontal Bracing – Item ID A0087576 (ASM) Horizontal Bracing – Item ID A0087578 (ASM) Horizontal Bracing – Item ID A0087585 (ASM) Horizontal Bracing – Item ID A0087587 (ASM) Horizontal Bracing – Item ID A0087586 (ASM) Horizontal Bracing – Item ID A0087588 (ASM) Horizontal Bracing – Item ID A0087581 (ASM) Horizontal Bracing – Item ID A0087582 (ASM) Column I – Item ID A0087668 (ASM) Column I – Item ID A0087670 (ASM) Column I – Item ID A0087696 (ASM) Column I – Item ID A0087697 (ASM) Column I – Item ID A0087701
Page 10 of 65
Q A T A R T-4.200.224 T-4.200.225 T-4.200.226 T-4.207.344 T-4.207.345 T-4.207.346 T-4.207.347 T-4.207.348 T-4.207.349 T-4.207.350 T-4.207.351 T-4.207.352 T-4.207.353 T-4.207.354 T-4.207.355 T-4.207.356 T-4.207.357 T-4.207.358 T-4.207.359 T-4.207.360 T-4.207.361 T-4.207.362 T-4.207.363 T-4.207.364 T-4.207.365 T-4.207.366 T-4.207.367 T-4.207.368 T-4.207.369 T-4.207.370 T-4.207.371 T-4.207.372 T-4.207.373 T-4.207.374 T-4.207.375 T-4.207.376 T-4.207.377 T-4.207.378 T-4.207.379 T-4.207.380 T-4.207.381 T-4.207.382 T-4.207.383 T-4.207.384 T-4.207.385
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
(ASM) Column I – Item ID A0087703 (ASM) Column I – Item ID A0087705 (ASM) Column I – Item ID A0087707 (ASM) Column I – Item ID A0087709 (ASM) Column I – Item ID A0087910 (ASM) Column I – Item ID A0087913 (ASM) Column I – Item ID A0087982 (ASM) Column I – Item ID A0087998 (ASM) Column I – Item ID A0087999 (ASM) Column I – Item ID A0088015 (ASM) Column I – Item ID A0088021 (ASM) Column I – Item ID A0088022 (ASM) Column I – Item ID A0088023 (ASM) Column I – Item ID A0088025 (ASM) Column I – Item ID A0088027 (ASM) Column I – Item ID A0088058 (ASM) Column I – Item ID A0088079 (ASM) Column I – Item ID A0088062 (ASM) Column I – Item ID A0088074 (ASM) Column I – Item ID A0088077 Pressure Locked Grating – Item ID A0090478 Pressure Locked Grating – Item ID A0090509 Pressure Locked Grating – Item ID A0090541 Plate – Item ID A0091017 Plate – Item ID A0091039 Plate – Item ID A0091103 Plate – Item ID A0091104 Plate – Item ID A0091105 (ASM) Support Beam – Item ID A0089688 (ASM) Support Beam – Item ID A0089516 (ASM) Support Beam – Item ID A0086913 (ASM) Support Beam – Item ID A0086912 (ASM) Support Beam – Item ID A0086911 (ASM) Column Head (I) – Item ID A0081806 (ASM) Column Head (O) – Item ID A0081809 (ASM) Longitudinal Beam (O) – Item ID A0079841 (ASM) Transversal Beam (O) – Item ID A0079848 (ASM) Longitudinal Beam (I) – Item ID A0079847 (ASM) Transversal Beam (I) – Item ID A0079857 (ASM) Platform End Profile – Item ID A0079878 (ASM) Fandeck Diagonal Beam – Item ID A0079890 (ASM) Fandeck Diagonal Beam – Item ID A0079894 (ASM) Fandeck Diagonal Beam – Item ID A0079896 (ASM) Fandeck Diagonal Beam – Item ID A0079898 (ASM) Fandeck Cross Beam – Item ID A0079900
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Q A T A R T-4.207.386 T-4.207.387 T-4.207.388 T-4.207.389 T-4.207.390 T-4.207.391 T-4.207.392 T-4.207.393 T-4.207.394 T-4.207.395 T-4.207.396 T-4.207.397 T-4.207.398 T-4.207.399 T-4.207.400 T-4.207.401 T-4.207.402 T-4.207.403 T-4.207.404 T-4.207.405 T-4.207.405 T-4.207.406 T-4.207.407 T-4.207.408 T-4.207.409 T-4.207.410 T-4.207.411 T-4.207.416 T-4.207.423 T-4.207.432 T-4.207.446 T-4.207.447 T-4.207.448 T-4.207.466 T-4.207.483 T-4.207.484 T-4.207.485 T-4.207.485 T-4.207.486 T-4.207.487 T-4.207.488 T-4.207.500 T-4.207.888 T-4.207.890
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
(ASM) Fandeck Parallel Beam – Item ID A0079902 (ASM) Fandeck Parallel Beam – Item ID A0079904 Checkered Plate – Item ID A0079906 Fandeck Plate I – Item ID A0079916 Fandeck Plate II – Item ID A0079917 Fandeck Plate II – Item ID A0079918 (ASM) Column Head (O) – Item ID A0086822 (ASM) Column Head (O) – Item ID A0089614 (ASM) Column Head (O) – Item ID A0092800 (ASM) Checkered Plate – Item ID A0089538 (ASM) Fandeck Diagonal Beam – Item ID A0089652 (ASM) Fandeck Diagonal Beam (I) – Item ID A0089656 (ASM) Fandeck Diagonal Beam – Item ID A0089653 (ASM) Spring Support Beam – Item ID A0089654 (ASM) Platform End Profile – Item ID A0086452 (ASM) Platform End Profile – Item ID A0086973 (ASM) Spring Support Beam – Item ID A0092946 (ASM) Transversal Beam (O) – Item ID A0084631 (ASM) Transversal Beam (O) – Item ID A0084632 (ASM) Longitudinal Beam (O) – Item ID A0089657 Bellows – Installation, Maintenance And Safety Instruction, Hazardous Area Motors En12-2006 (ASM) Longitudinal Beam (O) – Item ID A0090155 (ASM) Columns and Bracings – Item Id A0080111, Page 2 of 4 (ASM) Columns and Bracings – Item Id A0080111, Page 3 of 4 (ASM) Main Truss – Item ID A0080733 (sheet 3 of 5) (ASM) Main Truss – Item ID A0080733 (sheet 4 of 5) (ASM) Main Truss – Item ID A0080733 (sheet 5 of 5) Bellows: Conservation and Storing at Site Procedure Bellows – Preservation Procedure Steelwork Preservation Procedure (ASM) Windwall – Item ID A0080734 (sheet 2 of 4) (ASM) Windwall – Item ID A0080734 (sheet 3 of 4) (ASM) Windwall – Item ID A0080734 (sheet 4 of 4) Condensate Tank substructure Escape Ladders - 1 Parts List Manhole Condensate And Evacuation Pipe work Evacuation and Condensate Piping Details ACC Condensate And Evacuation Piping Details Location On Platform +100.000 M Location On Platform +106.970 M Location On Platform +112.858 M Preservation And Storage Procedure Drain And Condensate Pump Parts List Steam Manifold Steam Manifold – Street 2 & 3
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Q A T A R T-4.207.891 T-4.207.892 T-4.209.301 T-4.209.302 T-4.209.303 T-4.209.304 T-4.209.305 T-4.209.306 T-4.209.307 T-4.209.308 T-4.209.309 T-4.209.310 T-4.209.311 T-4.209.312 T-4.209.313 T-4.209.314 T-4.209.315 T-4.209.316 T-4.209.317 T-4.209.318 T-4.209.319 T-4.209.320 T-4.209.321 T-4.209.322 T-4.209.323 T-4.209.324 T-4.209.325 T-4.209.326 T-4.209.327 T-4.209.328 T-4.209.329 T-4.209.330 T-4.209.331 T-4.209.332 T-4.209.333 T-4.209.334 T-4.209.335 T-4.209.336 T-4.209.337 T-4.209.338 T-4.209.339 T-4.209.340 T-4.209.341 T-4.209.342 T-4.209.343
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Steam Manifold – Street 4 Steam Manifold – Street 1 (ASM) Windwall Column – Item ID A0079935 (ASM) Windwall Top Beam – Item ID A0079945 Z-Profile – Item ID A0079950 (ASM) Z-Profile – Item ID A0079949 Bracing Anchor – Item ID A0079953 Windwall Bracing Connection – Item ID A0079954 (ASM) Windwall Bracing – Item D A0079952 Trapezoid Sheet – Item ID A0079956 (ASM) Windwall Modul Long – Item ID A0079934 (ASM) Windwall Column – Item ID A0079940 (ASM) Windwall Column – Item ID A0079958 (ASM) Windwall Column – Item ID A0079959 (ASM) Windwall Modul Long – Item ID A0079957 (ASM) Windwall Top Beam – Item ID A0079966 Trapezoid Sheet – Item ID A0079968 (ASM) Windwall Door Beam I – Item ID A0079989 (ASM) Windwall Modul Trans – Item ID A0079988 Trapezoid Sheet – Item ID A0086234 Trapezoid Sheet – Item ID A0086243 Z-Profil – Item ID A0086236 Z-Profil – Item ID A0087062 Z-Profil – Item ID A0087063 Z-Profil – Item ID A0087180 Z-Profil – Item ID A0087320 (ASM) Z-Profil – Item ID A0087066 (ASM) Z-Profil – Item ID A0087067 (ASM) Z-Profil – Item ID A0086237 (ASM) Z-Profil – Item ID A0087181 (ASM) Z-Profil – Item ID A0087325 (ASM) Door Beam – Item ID A0087303 (ASM) Windwall Column – Item ID A0079960 (ASM) Windwall Column – Item ID A0079971 (ASM) Windwall Column – Item ID A0079973 (ASM) Windwall Column – Item ID A0087768 (ASM) Windwall Column – Item ID A0087827 (ASM) Windwall Column – Item ID A0087885 (ASM) Windwall Door Beam II – Item ID A0087167 (ASM) Windwall Door Beam II – Item ID A0088780 (ASM) Windwall Door Beam II – Item ID A0092395 (ASM) Windwall Door Beam II – Item ID A0087165 (ASM) Windwall Door Beam II – Item ID A0088782 (ASM) Windwall Door Beam II – Item ID A0092398 (ASM) Windwall Modul Long – Item ID A0087777
Page 13 of 65
Q A T A R T-4.209.344 T-4.209.345 T-4.209.346 T-4.209.347 T-4.209.348 T-4.209.349 T-4.209.350 T-4.209.351 T-4.209.352 T-4.209.353 T-4.209.354 T-4.209.355 T-4.209.356 T-4.209.357 T-4.209.358 T-4.209.359 T-4.209.360 T-4.209.361 T-4.209.362 T-4.209.363 T-4.209.364 T-4.209.365 T-4.209.366 T-4.219.314 T-4.219.455 T-4.219.606 T-4.219.615 T-4.219.660 T-4.219.688 T-4.219.691 T-4.219.793 T-4.219.946 T-4.219.947 T-4.219.948 T-4.219.949 T-4.219.950 T-4.226.179 T-4.233.692 T-4.233.731 T-4.234.058 T-4.234.059 T-4.234.060 T-4.234.061 T-4.234.062 T-4.234.063
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
(ASM) Windwall Modul Long – Item ID A0087769 (ASM) Windwall Support Beam – Item ID A0088724 (ASM) Windwall Support Beam – Item ID A0088732 (ASM) Windwall Support Beam – Item ID A0088733 (ASM) Windwall Support Beam – Item ID A0088734 (ASM) Windwall Modul Trans II – Item ID A0086229 (ASM) Windwall Column – Item ID A0087733 (ASM) Windwall Column – Item ID A0088243 (ASM) Windwall Column – Item ID A0088278 (ASM) Windwall Column – Item ID A0088711 (ASM) Windwall Column – Item ID A0088712 (ASM) Windwall Column – Item ID A0088713 (ASM) Windwall Door Beam I – Item ID A0087235 (ASM) Windwall Door Beam I – Item ID A0087236 (ASM) Windwall Door Beam II – Item ID A0089486 (ASM) Windwall Door Beam III – Item ID A0089492 (ASM) Windwall Support I – Item ID A0080010 (ASM) Windwall Support I – Item ID A0089168 (ASM) Windwall Support I – Item ID A0089169 (ASM) Windwall Support I – Item ID A0089170 (ASM) Windwall Top Beam – Item ID A0086241 (ASM) Windwall Top Beam – Item ID A0086245 (ASM) Windwall Modul Trans III – Item ID A0086232 Cladding Preservation / Packing and Storage Procedure Handrail at ACC Platform Job Safety Analysis & Hazard Evaluation Training and Orientation Permit To Work Handover Implementation Plan Part List Central Walkways (D0032814) Steam Jet Air Ejector Condenser Preservation Fabrication Duct Part 1A Part List movable Ladder Top rail (D0032815) Part List Air Seals (D0032816) Movable Ladder Top Rail (Z0055127) Air Seals – Details (Z0055130) Central Walkways (Z0055131) Coupling Flange (Hub Flange Fan) Part List (ASM) Fan Stack (ASM) Fan Stack (ASM) Fan Screen Module A (ASM) Fan Screen Support (ASM) Fan Screen Support (ASM) Fan Screen Support (ASM) Fan Screen Module B (ASM) Fan Screen Module C
Page 14 of 65
Q A T A R T-4.234.067 T-4.234.080 T-4.234.084 T-4.234.104 T-4.234.105 T-4.234.106 T-4.234.107 T-4.234.108 T-4.234.109 T-4.234.110 T-4.234.111 T-4.234.112 T-4.234.113 T-4.234.114 T-4.234.115 T-4.234.116 T-4.234.117 T-4.234.118 T-4.234.119 T-4.234.120 T-4.234.121 T-4.234.122 T-4.234.123 T-4.234.124 T-4.234.125 T-4.234.126 T-4.234.127 T-4.234.128 T-4.234.129 T-4.234.130 T-4.234.131 T-4.234.132 T-4.234.133 T-4.234.542 T-4.245.162 T-4.245.163 T-4.247.910 T-4.247.911 T-4.247.912 T-4.247.913 T-4.247.914 T-4.247.915 T-4.247.916 T-4.247.917 T-4.247.918
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Method of Statement For Surveying Method of Statement For Scaffolding Method Statement Lifting (General) (ASM) Motor Bridge Type 1 (ASM) Motor Bridge Type 2 Pressure-locked Grating (Z0054934) Pressure-locked Grating (Z0054938) Pressure-locked Grating (Z0054945) Pressure-locked Grating (Z0054947) Shim Plate (Z0054949) Pressure-locked Grating (Z0054950) Shim Plate (Z0054952) Pressure-locked Grating (Z0054953) Pressure-locked Grating (Z0054954) Shim Plate (Z0054955) Pressure-locked Grating (Z0054956) Pressure-locked Grating (Z0054957) Shim Plate (Z0054958) Pressure-locked Grating (Z0055035) (ASM) Railing for Motor Bridge (ASM) Transversal Beam (Z0056215) (ASM) Transversal Beam (Z0056222) (ASM) Longitudinal Beam (Z0056257) (ASM) Gear Support (Z0056316) (ASM) Railing for Motor Bridge (Z0056323) (ASM) Railing for Motor Bridge (Z0056324) (ASM) Railing for Motor Bridge (Z0056325) (ASM) Railing for Motor Bridge (Z0056327) (ASM) Railing for Motor Bridge (Z0056328) (ASM) Stair for Motor Bridge (Z0056331) (ASM) Railing for Motor Bridge (Z0060049) (ASM) Railing for Motor Bridge (Z0060050) Pressure-locked Grating (Z0051995) Project Quality Plan General Assembly Fan Parts List Fan (ASM) A-frames Right Page 1 of 5 (ASM) A-frames Right Page 2 of 5 (ASM) A-frames Right Page 3 of 5 (ASM) A-frames Right Page 4 of 5 (ASM) A-frames Right Page 5 of 5 (ASM) A-frames Middle Page 1 of 5 (ASM) A-frames Middle Page 2 of 5 (ASM) A-frames Middle Page 3 of 5 (ASM) A-frames Middle Page 4 of 5
Page 15 of 65
Q A T A R T-4.247.919 T-4.247.920 T-4.247.921 T-4.247.922 T-4.247.923 T-4.247.924 T-4.247.926 T-4.247.927 T-4.247.929 T-4.248.106 T-4.249.856 T-4.249.889 T-4.249.890 T-4.249.891 T-4.249.892 T-4.249.893 T-4.249.894 T-4.249.895 T-4.249.896 T-4.249.897 T-4.249.898 T-4.249.899 T-4.249.900 T-4.249.901 T-4.249.902 T-4.249.903 T-4.249.904 T-4.250.896 T-4.250.902 T-4.250.907 T-4.250.916 T-4.250.917 T-4.250.921 T-4.250.930 T-4.250.931 T-4.250.932 T-4.250.938 T-4.250.940 T-4.250.944 T-4.250.954 T-4.250.957 T-4.250.958
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
(ASM) A-frames Middle Page 5 of 5 (ASM) A-frames Left Page 1 of 5 (ASM) A-frames Left Page 2 of 5 (ASM) A-frames Left Page 3 of 5 (ASM) A-frames Left Page 4 of 5 (ASM) A-frames Left Page 5 of 5 (ASM) Stiffening Plate (ASM) Connecting Angle Part List Escape Routes Preservation Procedure Fan Strainers Preservation Procedure End Profile (Z0050242) End Profile (Z0053751) End Profile (Z0053757) End Profile (Z0053765) End Profile (Z0053773) End Profile (Z0055879) End Profile (Z0055880) End Profile (Z0055881) Trapezoid Sheet (Z0050309) Trapezoid Sheet (Z0050310) Trapezoid Sheet (Z0050311) Trapezoid Sheet (Z0050312) Trapezoid Sheet (Z0050314) Trapezoid Sheet (Z0050315) Trapezoid Sheet (Z0050316) Trapezoid Sheet (Z0050317) Method Statement for Structural Steel Assembly & Erection Method of Statement For Structural Steel Assembly Warehouse, Workshop QCP For Structural Steel Procedure for Painting ITP For Structural Steel ITP For ACC Cleanliness Procedure Piping System Welding Consumable Control Quality Control Procedure For Preservation Of Piping Material And Equipment General Welding Procedure Weld Repair Procedure QCP For ACC Method Statement – Utilization of Hilti DX 76 Lifting Study for ACC Structures above 10 Tonnes for Dwg. # SPXCTOEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 (250T – 100T) Method Statement – Erection of Condensate Tank and Evacuation Unit
Page 16 of 65
Q A T A R T-4.250.980 T-4.251.018 T-4.256.989 T-4.256.990 T-4.256.991 T-4.256.992 T-4.256.993 T-4.256.994 T-4.256.995 T-4.256.996 T-4.256.997 T-4.256.998 T-4.256.999 T-4.257.000 T-4.257.005 T-4.257.014 T-4.257.015 T-4.271.404 T-4.271.405 T-4.271.406 T-4.271.407 T-4.271.408 T-4.271.409 T-4.271.410 T-4.271.411 T-4.271.412 T-4.271.413 T-4.271.414 T-4.271.415 T-4.271.416 T-4.271.428 T-4.271.429 T-4.271.430 T-4.271.431 T-4.271.432 T-4.271.433 T-4.271.434 T-4.271.435 T-4.271.436 T-4.271.444 T-4.271.463 T-4.271.464 T-4.280.107
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Lifting Study for ACC Structures above 10 Tonnes for Dwg. # SPXCTOEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 (Optional 120T – 100T) Procedure for Structural Steel Repair Works at Site Trapezoid Sheet (Z0050318) Trapezoid Sheet (Z0050320) Trapezoid Sheet (Z0050321) Trapezoid Sheet (Z0050322) Trapezoid Sheet (Z0050323) Trapezoid Sheet (Z0050325) Trapezoid Sheet (Z0050326) Trapezoid Sheet (Z0050327) Trapezoid Sheet (Z0050348) Trapezoid Sheet (Z0050349) Part List Windwall Claddings Part List Partition Wall Claddings Packing and Preservation Loose Ball Valves Metso Automated Control Valves Preservation Instructions Neway Check and Gate Valves Packing and Preservation Procedure (ASM) Bracing (Z0050821) (ASM) A-frame Beam (Z0055838) (ASM) A-frame Beam (Z0055834) (ASM) A-frame Beam (Z0055846) (ASM) A-frame Beam (Z0055848) (ASM) A-frame Beam (Z0055868) (ASM) A-frame Beam (Z0055875) (ASM) A-frame Beam (Z0050456) (ASM) Hanger (Z0056446) (ASM) A-frame Head (Z0050445) (ASM) Sealing Beam (Z0055343) (ASM) Sealing Beam (Z0055342) (ASM) Sealing Beam (Z0055341) (ASM) Partition Wall and Monorails (Z0050344) (ASM) Partition Beam (Z0050286) (ASM) Partition Beam (Z0050298) (ASM) Partition Beam (Z0050300) (ASM) Door Frame (Z0050334) (ASM) Door Side Beam (Z0050345) (ASM) Door Side Beam (Z0050347) (ASM) Partition Wall II (Z0050356) Part List Partition Wall (Steel Work) (D0050792) Part List (ASM) Fan Units (D0042211) Instrument mountion Support (Z0072213) (ASM) Distance Angle (Z0065166) (ASM) Sealing Beam (Z0055340)
Page 17 of 65
Q A T A R T-4.280.108 T-4.280.109 T-4.280.110 T-4.280.111 T-4.280.112 T-4.280.113 T-4.280.114 T-4.280.115 T-4.280.116 T-4.280.117 T-4.280.118 T-4.280.119 T-4.280.120 T-4.280.121 T-4.280.122 T-4.280.123 T-4.280.124 T-4.280.125 T-4.280.126 T-4.280.127 T-4.280.128 T-4.280.129 T-4.280.130 T-4.280.131 T-4.280.132 T-4.280.133 T-4.280.134 T-4.280.135 T-4.280.136 T-4.280.137 T-4.280.138 T-4.280.140 T-4.280.141 T-4.280.142 T-4.280.143 T-4.280.144 T-4.280.145 T-4.280.146 T-4.280.147 T-4.280.148 T-4.280.149 T-4.280.150 T-4.280.151 T-4.280.152 T-4.280.156
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
(ASM) Sealing Beam (Z0055336) (ASM) Outrigger (Z0055333) (ASM) Outrigger (Z0055332) (ASM) Outrigger (Z0055331) (ASM) Outrigger (Z0055330) (ASM) A-frame Top Girder II (Z0055322) (ASM) A-frame Top Girder II (Z0055311) (ASM) A-frame Top Girder I (Z0055299) (ASM) A-frame Top Girder I (Z0055288) (ASM) Monorail II (Z0055324) (ASM) A-frame Top Girder I (Z0055286) (ASM) A-frame Top Girder I (Z0054310) (ASM) A-frame Top Girder II (Z0055300) (ASM) A-frame Top Girder II (Z0051967) (ASM) Rail Support (Z0050819) (ASM) Bracing (Z0050616) (ASM) Hanger (Z0050788) (ASM) Monorail (Z0050782) (ASM) Outrigger (Z0050441) (ASM) Top Steam header Support Beam (Z0050439) (ASM) Bracing (Z0050438) (ASM) A-frame (Type I) (Z0050456) (ASM) A-frame Head (Z0050453) (ASM) A-frame (Type I) (Z0050454) (ASM) A-frame (Type I) (Z0050450) (ASM) A-frame (Type I) (Z0050448) (ASM) A-frame (Type I) (Z0050446) (ASM) Monorail II (Z0056618) (ASM) Rail (Z0056594) (ASM) Rail (Z0056595) (ASM) Rail (Z0056598) (ASM) Column I (Z0060537) (ASM) Column I (Z0060545) (ASM) Column I (Z0060547) (ASM) Column I (Z0060548) (ASM) Horizontal Bracing (Z0060581) (ASM) Horizontal Bracing (Z0060582) (ASM) Platform End Profile (Z0057667) (ASM) Platform End Profile (Z0057674) (ASM) Platform End Profile (Z0057676) Cover Plate (Z0057796) Cover Plate (Z0057797) Pressure Locked Grating (Z0057832) Cover Plate (Z0058237) (ASM) Main Truss – Item ID A0080733 (sheet 2 of 5)
Page 18 of 65
Q A T A R T-4.282.688 T-4.282.689 T-4.282.690 T-4.282.691 T-4.282.692 T-4.282.693 T-4.282.694 T-4.282.695 T-4.282.696 T-4.282.697 T-4.282.698 T-4.282.699 T-4.282.737 T-4.282.738 T-4.282.739 T-4.282.740 T-4.282.741 T-4.282.742 T-4.282.743 T-4.282.744 T-4.282.745 T-4.282.746 T-4.282.747 T-4.282.748 T-4.282.749 T-4.282.750 T-4.282.751 T-4.282.752 T-4.282.793 T-4.282.845 T-4.282.920 T-4.305.053 T-4.305.085 T-4.305.144 T-4.305.149 T- 4.318.527 T-4.318.571 T-4.318.572 T-4.318.585 T-4.368.020
T-4.250.904 Rev. A
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Part List Hand and Cages at ACC Platform (ASM) Windwall Column (Z0062738) (ASM) Windwall Column (Z0062753) (ASM) Windwall Modul Trans (Z0062754) (ASM) Windwall Modul Trans III (Z0062758) (ASM) Windwall Column (Z0062898) (ASM) Monorail Bracing (Z0063067) (ASM) Ladder for Windwall (Z0063621) (ASM) Door Beam (Z0063710) (ASM) Windwall Column (Z0063984) (ASM) Windwall Modul trans (Z0072330) (ASM) Windwall Modul trans II (Z0072342) Angle (Z0050282) Angle (Z0050283) Angle (Z0050284) Angle (Z0050285) Angle (Z0050286) Angle (Z0050287) Angle (Z0050288) Angle (Z0050301) Angle (Z0050302) Angle (Z0050338) Angle (Z0050339) Angle (Z0050340) Angle (Z0050341) Cover Plate (Z0050350) (ASM) A-Frames (ASM) Sealing Beam Tyco Valves Preservation Procedure IOM Lifting Devices (ASM) Main Truss – Item ID A0080733 (sheet 1 of 5) Lifting Study for ACC Structures above 10 Tonnes for Dwg. # SPXCTOEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 – (Optional 120T – 70T Lifting Procedure for Condensate Tank and Evacuation Unit Lifting Procedure for A – Frame of ACC Lifting Procedure For Acc- Motor Bridge Assembly Structures Above 10 Tonnes for Dwg. # SPXCT-OEO2-B-ZE-1008 (120T Crane) Lifting Procedure for Steam Distribution Manifold at ACC (Typical) Lifting Procedure for Erection of Steam Ducts Procedure for Preservation at ACC Method Statement for Erection of Fan Deck Plates at ACC List of Equipment ASU
Page 19 of 65
Q A T A R 6
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
RESOURCES 6.1
Responsibilities
6.1.1 Site Manager The Site Manager will provide overall inputs to the project execution plan to ensure that strategies & philosophies of the project are properly addressed.
6.1.2 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.
6.1.3 Site Engineer Site Engineer is 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 method of statement. Conduct inspection and surveillance. Notify to Contractor 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.
6.1.4 Site Supervisor (SS) Site Supervisor is 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. 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.
6.1.5 Piping Supervisor (PS) Piping Supervisor is responsible for the erection of pipes that will be performed in accordance to the method of statements
6.1.6 Artisans Group of skilled and semi skilled workers who will be responsible for the execution of works and other jobs related to the completion of construction of ACC at C2 area.
T-4.250.904 Rev. A
Page 20 of 65
Q A T A R
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
6.1.7 QA/QC Officer / Inspector QA/QC Officer/Inspector is responsible for: • • • •
6.2
Inspecting and Certifying of all foundations, alignments, etc. will be in coordination with the Contractor representative as per conformance of the specifications Assurance of approved methods and materials are being used and conformance of the specifications Stage inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and erection procedures Incoming material inspection and review of test certificates
Equipment & Manpower All equipment will be inspected and approved by the Contractor, when required, and all personnel will be inducted and trained before and during mobilization.
6.2.1 Equipment • • • • • • • • • • • • • • • •
Crane – (1) each for 250 T, 120, 100 T, 80 T, 70 T and 50 T lifting capacities hydraulic or crawler type will be utilized Forklift – 15 and 5 T capacity Boom Truck – 5 T capacity Aerial Work Platform (man lift equipment) – capable to 45 meters reach, (2) numbers either telescopic and /or folding hydraulic type Man basket for 3 persons Trailer – for transport of materials from lay down area to assembly site Rigging and lifting equipment – approved, certified and color -coded Scaffolding – as per requirement Gas cutting torch with arrestors and welding machines Grinding machine with correct grinding wheels and tool speed Survey and level instruments Portable diesel generator and portable lights – to service night works Hilti DX 76 – Fastening tool Air compressor Hand and electric tools – Note: No prefabricated tools will be allowed and shall be in good working order Paints and accessories – Only for repair and touchup
6.2.2 Manpower • • • • • •
Management Site Engineer Foreman HSSE personnel Certified Crane operator Certified Forklift operator
T-4.250.904 Rev. A
Page 21 of 65
Q A T A R • • • • • • • •
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Certified Articulated man lift operators Banks man and slingers Erectors Mechanical fitters Scaffolders Fire watchers Associated vendors Driver
If the above-listed equipment or manpower proves not sufficient for the timely completion of the facilities and project; additional will be provided to complete the works on time and in line with rules, regulations and specifications of Contractor, Company and RLIC.
T-4.250.904 Rev. A
Page 22 of 65
Q A T A R 7
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
METHOD OF EXECUTION 7.1
General
This chapter explains the methods to be used for the erection of all structural steel works, piping and duct works, installation of air cooled condensers with associated equipment, and steam recovery at the following site; FD at C2 area. This method shall also apply to the other sites FA, FB, FC, and GA, GB, GC, GD at C2 area.
7.2
Pre-Commencement Works
7.2.1 Foundation Seats •
•
Prior to works commencement, all seating foundations are checked for load bearing of all steel erection as per approved drawings issued by the vendor or the company. Any deviations as per plan will be recorded and served as guideline during the execution of works and shall be within the tolerances recommended by the manufacturer Survey report on the main level references from Civil will be generated and submitted before start up of construction to anticipate problems which can be encountered during construction and alignment stages. Any deviations from the general arrangements, drawings shall be identified
7.2.2 Logistical Materials and Equipment • •
• •
Materials and equipment required during the duration of works shall be available nearby and checked Lay down area for materials and equipment shall be located in such a place that double handling can be minimized or can be totally eliminated. Due to space limitations at the assembly area, a minimum supply of materials or structures for at least three days will be maintained to assure continuous works without interruption. This will also reduce risk for possible damage and distortion of materials from handling and during assembly Lifting procedures will be followed as per documents T-4.234.084 for Lifting General Scaffolding – will be followed as per separate method of statement and PTW (permit to work) will be initiated before any works can commence; please refer to document T-4.234.080. The use of scaffoldings will only be at selected area where height and space have some limitations example as: pipe installation and welding works inside the A-frame with bundles structures, piping below the fan deck; installation and connection of condensate duct from turbine to the SDM
7.2.3 Barricades and safety Sign Boards • • •
All works areas are to be secured, barricaded, and posted with signboards indicating that works are in progress, and lifting operations are being conducted Only authorized personnel's will be allowed to work within the perimeter All barriers will be kept in place during the progress of works, and/or until the works are completed
T-4.250.904 Rev. A
Page 23 of 65
Q A T A R
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
7.2.4 Positioning and Lifting Equipment 7.2.4.1 Lifting and related equipment will be in position only by certified operators and banks man; ground foundation checked for stability before setting up the outriggers or tracks 7.2.4.2 Correct colour coded and certified slings are to be used only 7.2.4.3 Aerial work platform/man-lift and construction cages are to be used for certified erectors. When construction cages are being provided, dead man's control & inspection certificate will be presented. The personnel must rope themselves into the cage. The cage must be suspended in an insulated manner when welding work is to be performed from the cage. 7.2.4.4 It is necessary to determine more or less the weights of the following sub-structures or equipment due to limitations on space and height at the assembly area for its respective lift, and they are as follows: •
The assembly of two adjoining columns and braces (Step 1) Member 1 2 3 4 5 6
Part no. Description Wt. No. Total Wt. A0080123 Column 1 1864.4 2 3728.8 A0087913 Column 1 1920.8 2 3841.6 A0088074 Column 1 1164.4 2 2328.8 A0087511 Hor. Bracing 727.836 1 727.836 A0087512 Hor. Bracing 554.345 1 554.345 A0087506 Hor. Bracing 924.12 2 1848.24 Wt of two adjoining columns & braces 13029.621 Kg 13.03 T
Note: This shows how weight of the steel structure is calculated
T-4.250.904 Rev. A
Page 24 of 65
Q A T A R •
2 3 4 5 6 7 8 9
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Part no. A0087709 A0087701 A0088079 A0088025 A0088074 A0087511 A0087512 A0087506 A0080136 A0087493 A0087495
Description Wt. No. Column 1745.3 1 Column 1745.3 1 Column 1838.4 1 Column 1838.4 1 Column 1164.4 2 Hor. Bracing 727.836 1 Hor. Bracing 554.345 1 Hor. Bracing 924.12 2 Hor. Bracing 312.166 2 Hor. Bracing 312.166 2 Hor. Bracing 330.493 2 Wt. of two adjoining columns & braces
Total Wt. 1745.3 1745.3 1838.4 1838.4 2329.8 727.836 554.345 1848.24 624.332 624.332 660.332 14536.617 Kg 14.54 T
The motor bridge with drive unit Member 1 2 3
4
T-4.250.904 Rev. A
:
Assembly of two adjoining columns & braces (Step 2) Member 1
•
Doc. Title
Part no. Description Wt. No. Total Wt. A0087898 E. Motor 1700 1 1700 A0086149 Gearbox 1400 1 1400 A0091415 Motor Bridge Complete 5102.812 1 5102.812 Motor Bridge consists of the following: A0091417 Railings A0091360 Gear Support A0091352 Transversal Beam A0091358 Transversal Beam A0091357 Transversal Beam A0091398 Press Lock Grating A0091396 Press Lock Grating A0091395 Press Lock Grating A0091393 Press Lock Grating A0091394 Press Lock Grating A0091397 Press Lock Grating A0091399 Press Lock Grating A0075068 Fan Impeller 126.88 7 888.16 Wt. of Motor Bridge & Structure 9090.972 Kg 9.10 T
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
One section of A-frame Member 1 2 3 4 5 6 7 8 9
Part no. A0080285 A0080291 A0080280 A0080330 A0084581 A0088149 A0080320 A0080316 A0080302
10 11 12 13 14 15 16 17
A0080309 A0089231 A0089232 A0080338 A0091097 A0091096 A0091101 A0091100
Description A Frame A Frame A Frame Bracing Top Girder Top Girder Hanger Monorail Top Steam Header Support Beam Outrigger Outrigger Outrigger Bracing Sealing Beam Sealing Beam Sealing Beam Sealing Beam
Wt. 1568 820 2322.5 260.215 938.37 689.2 55.267 195.4 237.63
No. 2 2 2 8 1 1 2 2 1
Total Wt. 3136 1640 4645 2081.72 938.37 689.2 110.534 390.8 237.63
69.138 61.81 63.423
2 138.396 2 123.62 2 126.846 2 33.801 95.801 1 95.801 95.801 1 95.801 95.801 1 95.801 95.801 1 95.801 Wt. of A Frame 14675.121 Kg 14.67 T
Note: Only for presentation
•
The sections of SM (Steam Manifold) Member 1 2 3 4 5
T-4.250.904 Rev. A
Part no. A0080519 A0080520 A0080521 A0086422 A0080522
Description Spool Spool Spool Spool Spool
Wt. No. 5420 1 4700 1 3700 1 3650 1 3323 1 Wt. of steam Manifold
Total Wt. 5420 4700 3700 3650 3323 20793 Kg 20.8 T
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
3 Lifts to be carried out •
CM (Condensate Manifold) sections per street
Consists of 5 spools @ 2,300 Kg each •
One assembly of support and parallel beams at the upper deck Member 1 2 3 4 5 6 7 8 9 10
11 12
T-4.250.904 Rev. A
Part no. A0079847 A0079904 A0079900 A0079896 A0079898 A0079904 A0079902 A0092946 A0089654 A0084106 A0082543 A0082456 A0084105 A0081962 A0089614 A0089588 A0089516 A0086912 A0079878 A0098394 A0086912 A0086911 A0086973
Description Wt. No. Total Wt. Longitudinal Beam 328.664 2 657.328 Longitudinal Beam 328.664 2 657.328 Fan Deck Cross Beam 102.318 4 409.272 Diagonal Beam 180.388 2 360.776 Diagonal Beam 270.831 2 541.662 Parallel Beam 225.28 2 450.56 Parallel Beam 187.849 2 375.698 Spring Support Beam 68.225 1 68.225 Spring Support Beam 68.225 1 68.225 Beam 21.705 1 21.705 Beam 21.313 4 85.252 Beam 21.313 4 85.252 Beam 21.704 1 21.704 Beam 472.99 1 472.99 Column Head 520.149 2 1040.298 Support Beam 85.534 1 85.534 Support Beam 128.704 1 128.704 Support Beam 171.993 1 171.993 Platform End Profile 751.931 1 751.931 Support Beam 274.061 1 274.061 Support Beam 171.993 1 171.993 Support Beam 128.704 1 128.704 Platform End Profile 151.769 1 151.769 Wt. of Fan Deck Structure 7180.964 Kg 7.2 T
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
Lifting of structures/members & equipment to the upper deck will be performed by the 250 T / or 120 T crane with counter weights. For any single lifts greater than 10 Tonnes, individual rigging plans shall be provided and approved before lifting can commence Lifting procedures will be followed as per lifting method of statement documents T.4.234.084 •
Avoid related equipment operate over or near pre-installed and covered lines. Ensure such equipment access lifting area through identified access ways. (FSI Ref.: Q1-1.3.1.)
•
Avoid related equipment cause over settling of concrete pits resulting shears at the grip pipe connections. Following the lifting operations, ensure proper condition of any nearby underground piping (with video cameras if necessary). (FSI Ref.: Q11.3.4.)
7.2.5 Main Erection Sequence 7.2.5.1 Under Structure Erection Start works at street 3; Method of statement for structural steel assembly; refer document T-4.250.902 also applies Two vertical column frames will be assembled on the ground, will be erected on the foundation plinths, using two cranes; and will be stabilized with 20 mm diameter wire ropes as temporary supports for verticality. Minimum of two set of cables of hand operated winch will be used to serve as guy ropes for stability. The bigger crane (100 T) will lift the load and the smaller one (80T) will support the tail load during mounting the structure to vertical position. The temporary supports (ropes) will not be removed until twin column is erected and horizontal bracings and other diagonal braces are secured or bolted in; continue until one street is completed.
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
Proceed to erect the sub structures at the upper deck (see proceeding item, 7.2.5.2). The first street will be levelled and aligned before connecting any steel structures of another street. Final bolt torque should be completed after thorough inspection has been performed and found acceptable, and they are to be colour–coded indicating that bolts are properly checked and correct torque is applied. All erection works will be done by competent and certified erectors, and banks man for all lifting operations. Grouting will be done on steel structure foundation with approved materials as per site specifications after complete alignment and acceptance of fan deck assembly of each street. See illustration for similar installation for a similar project by other agencies: -
STEP 1
STEP 2
STEP 3
7.2.5.2 Upper Structure/Fan Deck The peripheral beams of the fan deck will be assembled on the ground and installed to form the support structure; assuring that all bolts are tightened correctly. Temporary detachable railings will also be integrated and fixed to the structure prior to lifting, as safety measure for people to work at the upper deck later.
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Aerial work platform (AWP) will be used by the erectors in connecting the structure to the built columns. Proceed until the whole street is completed forming a complete working table. Wherever necessary, man lifts will be also be used. Inspection for the elevation and verticality will be done after it is determined and conditions are acceptable within the given tolerances. It will serve as a guide or reference in foregoing installation of equipment and structure to the adjacent streets After completing the erection of the fan deck structures at street 3, erect the columns and steel structures at N module of street 4 (south corner). Stairs and walkways will be assembled and will serve as access going to the fan deck or upper structure. This will provide us some leeway of maximizing the utilization of man lifts to other area and eliminate expensive scaffoldings One bracing is required to be temporarily removed to allow installation of condensate tank and steam evacuation unit. Further study on the removal of the bracing will be provided in ref. T-4.305.085 Note: It is not permitted to proceed with erection of other equipments as motor bridge, A-frame, CCM and SDM until completion of condensate tank and steam evacuation unit and installation of temporarily removed bracing is complete Deck plates and gratings are to be secured by Hilti fastening tool; catch nets to be provided and laid out on the fan deck screens to prevent materials, etc from falling and other safety reasons. Catch nets specification: PE or Polyester or PP perimeter debris netting for construction industry (Mesh size 2.5 x 2.5 mm, width 2000mm) subject to approval by Linde Engineering AG/PMC Subject to prevailing conditions at site, an alternative scheme can be device to be able to install the fan deck plates at the fan deck structure After erecting the fan bell with screen into the structure, platform openings can only be closed by fan deck plates during the course of construction, hence additional safety measures for people working at height is mandatory. Additional lifelines aside from the proposed will be provided i.e., lines installed midpoint from each cell. The latter will be use for people to be positioned inside the fan bell assembly during the laying out & fastening the fan deck sheets into the structure. They will be assisted by a third person riding in the manlift Lifting of the fan deck plates will be done according to attached procedure - Lifting ACC fan deck plates & plate clamps lifter will not be allowed to be used The Sequence will be repeated until the cell is covered by deck plates It (deck plates) will be fixed permanently soon as activity 7.2.5.3 is completed See illustration for similar installation by other agencies: -
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
7.2.5.3 Erection of Fan Screen and Fan Ring These foregoing activities can commence in parallel with the above sequence. The sectional screens will be pre assembled at ground level with timber cribbage or fabricated supports below the corresponding location or module where they will be lifted into their final position. Each section will be supported underneath and levelled to prevent distortion and possible damages on the wire mesh during the assembly of the fan stack or bell. Fan stack segments will be assembled on top of assembled fan screen. After the guard grill is pre-assembled, the stiffening plates need to be installed on the connection plates on the outside edge from the guard grill. Here the fan bell segment can be connected into their position. The connection bolts have no torque value. They need to tighten in the most tightly possible way by hand, to consider that the fan bell material is fragile FRP glass fibre. The inspector for the bolt tightening needs to check every bolt for its tightness by hand. Before lifting; check the roundness and diameter of the fan bell on the top edge from the bell. In the positions from the stiffening plates they can use slings to adjust the roundness and diameter. Then lift the fan bell & guard grill into its position on the fan deck level. Attach stiffening plates to the small supports in the fan deck steel structure. The bolts which keep the fan bell in position can just be hand tight, because in later stage from the erection the fan bell needs to be aligned with the fan blades. This is the moment the connection bolts will be tightened according to the correct torque value. Then install the fan deck plates on the fan deck level. Drill holes at the top of the fan stack using the sealing angle plate as template, and install the sealing angle. Lifting of the assembled fan stack and screen will be performed using four point soft slings taking note on the correct and final orientation of the fan screen assembly which is 45 º offset from the axis. Final alignment of the fan stack with screen will be carried out once the motor bridge with the drive unit installation is completed. Lifting will be done by certified and competent riggers and banks man.
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
See illustration for similar installation by other agencies: -
7.2.5.4 Assembly of Motor Bridge with Drive unit and Fan Blades Pre assembly of motor bridge with drive unit will be done by mechanical fitters at the adjacent streets respectively to limit movement of lifting equipment. The latter structure will be laid horizontally and levelled along with fabricated support beams at 1.2 meters height. This will assure mobility of people working underneath for fan blade erection Secure and align the gearbox with correct bolts and shims for correct levelling on the motor bridge structure; then fasten the motors, taking note the orientation of the motor control box. At this stage, gearbox will not be filled with oil; this will be done during the commissioning stage. Refer to ACC construction manual T-4.121.350 Railings, grating materials and walkways will be installed before lifting the whole structure with blades at the upper deck. The fan blades will be installed in vertical position temporarily; to prevent damages during erection of other parts above the deck Observe correct torque value for bolts on the gearbox shaft coupling to motor plus the flanged connection to the fan hub plate, and then install and assemble the fan blades. Ref.: 7.2.6.1 Bolting. Torque bolts on joints, blades for flange with 70% torque value Prior to lifting, additional fasteners and/or soft ropes will be required to prevent movement and rotation of the fan blades during the lifting operation to the upper sub structure Lift the structure assembly and secure into final position at the upper deck Lifting of the motor bridge with drive unit and fan blades will be done by certified and competent riggers and banks man. See illustration for similar installation by other agencies: -
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
Following the erection, ensure proper preservation of rotating equipment (e.g. 4 weekly vertical shaft rotation, oil top-up/greasing) and refer to equipment manuals as necessary, for protection against heat, dust and humidity. (FSI Ref.: Q1-3.1.)
7.2.5.5 Alignment of Fan Ring After the motor bridge is aligned and levelled to its position, alignment of the fan stack with angle sealing plates will be done accordingly, and fixing the fan deck plates permanently. The blades pitch angle will be set to 12.7 ° as recommended by the manufacturer; and the gap between stack and fan tips will be noted. Alignment will be done by mechanical fitters. Final settings of the blade angle will be performed prior to trial operation & bolts torque to 100%. See illustration for similar installation by other agencies: -
7.2.5.6 Upper Structure: Pre assembly and Erection of A – Frame Pre assembly of the A – frame will be done on the ground with complete support, with partition walls sub structure, with cladding, supports and braces are lifted to the upper deck and fastened to the main steel structure. Alignment of the upper and lower sections of the A – frame for the street will be controlled with shims to obtain same elevations. Structures like the sliding and fixed supports at the top of the beam, bracings between A – frame and motor bridge, and hoisting beams will be installed before any installation of the foregoing structures. See illustration for similar installation by other agencies: -
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
7.2.5.7 Assembly of CCM, Bundles, SM, Piping Works and Wind wall Erection of the remaining structures will be as follows: Condensate Collecting Manifold (CCM) first, secondary bundles and primary bundles, and Steam Distribution Manifold (SDM) as third step Assemble and weld two CCM spool on the ground, temporarily fixed with bolts after lifting them at the upper deck. These bolts can be removed once the alignment and tack welding of the CCM is done. Lift the next two joined spools, and join to the latter spools. Final alignment of the joined spools and welding will be done at this stage, then proceed to complete the street. Final welding on the manifold will be done as soon as all the alignment of the manifold is achieved Before erecting the bundles onto the A-frame, thorough inspection will be done for any damages. The inspection shall be recorded and noted whether bundles are acceptable, or require repairing Lifting up of the bundles starts first with secondary, then the primary. Installation of lifeline for people working in the bundle erection will be performed. Refer document attached Lifting up of the bundles will be alternate (to Left & to right side) to avoid unbalancing on the structure. Bundles shall be lifted at the required A-frame slope, using offset sling lengths. Join two (2) opposite primary bundles with plate (A0080412) by welding after aligning the bundles; taking into consideration on special procedures to avoid overheating of the tube sheets. After welding completion and alignment, the steam distribution manifold (SDM) will be installed. The weight of the complete steam manifold exceeds 10 Tonnes, hence it is necessary to have at least three (3) lifts; starting lift of spool 3 (A0080521) at the fixed point, which is located on the top of the secondary bundle structure. Spool 4 (A0086422) & spool 5 (A0080522) will be assembled & welded on the ground prior to lifting; similarly with spool 1 (A0080519) & spool 2 (A0080529). They will be joined with spool 3 after erection at the structure. Lifting lugs will be provided for its joined spools, taking into consideration of the centre of gravity. Seal plates at the end of manifold (spool 5) are to be adjusted at the site after the bundles assembly & steam manifold installation is completed and stitch welding of the manifold & bundle will commence. Ensure all heat exchanger pipe protection covers removed before installation. (FSI Ref.: Q2-2.1.) Ensure pipes are internally clean before lifting into the structure (visual, air blow, liftingup at one end). (FSI Ref.: Q2-1.8.) Ensure all open ends capped after work interruption or day end. (FSI Ref.: Q2-1.8.) Condensate tank and structure will commence for erection after fan bell is erected at module N of street # 4. Condensate tanks, steam ejectors, the drain pump station and associated equipment and instrumentation will be erected and piping will follow as soon as the upper structures are done, then continue to work on the remaining streets.
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
At this stage, the steam duct connecting the turbine exhaust and the ACC can commence simultaneously with other works in the ACC; and it is necessary to start works at each fixed points. Installation of walkways and rails at street 4 going to the upper deck will be done to minimize utilization of man-lift equipment during installation of structures on the remaining streets. Soon as the entire street installations are completed, panel sheeting of the interior will be done. The pre-assembly of the wind wall will be done on the ground level, lifting and installation will be parallel and commence with A-frame erection at the upper structure. The wind wall section will be connected and bolted to the main structure (fan deck) and connected to the steam manifold bracings. See illustration for similar installation by other agencies: -
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
7.2.5.8 Steam Ducting The steam ducting will be assembled and installed between the connection of the turbine exhaust and the ACC with the construction sections as per drawings. Steam ducting section – certain sections are fabricated with additional fitting lengths. These fitting lengths will be used for adjustment to site conditions. By means of a cutter or blow torch; the sections will be cut to the exact length required during installation, the cut edge will be ground smoothed, cleaned and prepared for welding in accordance with specified WPS. The expansion joints and ducting sections will be assembled and welded together to a great extent at the ground level, before lifting them into position; however the weight of the assembled parts and crane lifting capacity and the reach will be considered and planned accordingly. During installation of the expansion joints and the vane elbows special care and attention will be taken to ensure that they are installed correctly for the direction of the steam flow. Beginning at the turbine, the remaining main steam ducts and risers are installed up to the top steam distribution manifold.
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
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24 November 2008, Rev. F
The Steam ducting installation will start at the duct fix point. Sequence refer sketch as given below in (illustration A & A1): -
Connection Point SM
Connection Point SM
Fixed Starting Point
Illustration A
Illustration A1
The steam ducting has to be assembled and installed starting from the turbine outlet at machine house to the air cooled condenser inlet joining streets 3/4 and streets 2/1 respectively. The expansion joints and ducting sections can be assembled and welded together to a great extent at the ground level before lifting them into position. Spool 1 a (Drg. No.:Z0060956; T-4.219.793) and expansion joint to be welded on site to the turbine piece before turbine installation.
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Install complete part to the turbine flange and lift together with turbine into the turbine table. After adjustment at spool 1, fabricated duct part-01 DN3820 (Drg. No.:Z0055358; T4.121.231) to be welded with the expansion joint. During installation of the expansion joints and the vane elbows, special care and attention shall be taken to ensure that they are installed correctly for the direction of steam-flow. Additional stiffening brackets may have to be welded to the steam duct risers in the area of expansion bellows for safeguarding and preventing damages on the rings – convolutions of the expansion rings. All sections of the ducting must be connected together free of any "forces and moments" by means of using the correct procedure and respectively, the planned sequence of erection. It is not acceptable to assemble or install together by force as this would lead to lateral deformation or misalignment of the supports. Even in such cases; uncontrolled forces and moments can occur to the turbine connection. After full completion of the ducting and piping systems; all temporary stiffening or locking devices must be removed. Separate Method statement for ducting will be prepared and got approved prior to commencement of the erection of ducting.
7.2.5.9 Preservation of ACC Preservation of the Installed ACC. Due to the local conditions at Pearl site and long period between the mechanical erection and final commissioning preservation methods on site need to be considered. All parts, components and auxiliaries are to be preserved after installation in accordance with the general instruction listed in Ref.: T4.121.350. The scope of this procedure is to describe the measures to be undertaken for the preservation of ACC (Air Cooled Condensers). The measures will be undertaken in order to preserve the equipment & reticulation’s in order to maintain the ACC performance to high degree. The measures to be undertaken are divided into three gradations, each presenting different level of protection, as the length of shut down in cases, a higher level of protection will be required and economically justified. Categories: 1. Short Term Shutdown Short term shutdown is considered a period less than one week, with respect to preservation of ACC, no specific requirements are to be fulfilled 2. Medium Term Shutdown Medium term shutdown is considered a period of more than one week and less than 6 (six) weeks, Dry air connection is to be made into the manhole (20”) on steam duct near to hot weld, Air evacuation to atmosphere through the hogging ejection silencer & holding ejectors.
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Precautions: •
All valves on steam, air extraction & condensate shall be open (except for vents and drains)
•
Vent & drain on condensate tank can be partially open to improve air circulation in the tank
•
Condensate pumps to be removed to create air circulation of dry air
Preservation with hot air cannot be considered for the ACC tube bindles since cooling surface is high and air will cool down immediately, hence efficiency is limited. The condenser, tanks, vessels and tubes to be drained. The condenser will be preferably blown dry with air; if possible to be maintained under vacuum 3. Long term Shutdown Long term shutdown is considered a period more than 6 weeks. •
Alternative A: Dry air preservation All condensate shall be drained in
•
-
Condensate tank
-
Hot weld on Steam Duct
-
Vacuum ejector units
-
Condensate pumps
-
After draining of all components, immediate drying of complete ACC will start
-
Dry air shall be blown into the steam duct and evacuated at hogging and holiday ejector outlets.
-
A continuous dry air injection is to be foreseen
Alternative B: Preservation with Nitrogen This alternative is theoretically possible, but not practical due to huge quantity of nitrogen requirement. Blanketing plate is provided in part 1 of the steam duct, hence steam turbine connection is isolated The condenser, the steam duct, the vessels, exchangers and all connecting piping’s will be drained and filled with nitrogen The purging of nitrogen will be controlled within 0.05 barg and 0.25 barg over pressure. When it exceeds, the nitrogen has to be blown off Note: Complementary to preservation; following interventions are especially required: •
Condensate Pump
-
Weekly by hand rotation
•
Gearboxes
-
Rotation of gearbox every 3 weeks
•
Greasing
-
Check every 3 months
In addition to the above a separate procedure on preservation will be presented and approved. Refer doc # T-4.318.572
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
7.2.5.10 Piping Erection Order Condensed steam piping, air extraction piping, cleaning system and instrumentation with related support and hangers will be erected according to approved SPX reference drawings, only certified welders will be performing based on existing Welding Procedure Specification. Basic consideration will be given before any erection works can start and are as follows: • Steel structure will be built so far that the main pipe supports will be erected. • Main pipe supports will be made and assembled in right positions and level. • Equipment and devices will be available, assembled and fixed in right position where pipe connections will be executed. • Required tools and materials will be made available so the works can continue without interruptions. • Blind plates and plugs have to be kept in place during the progress of works. • Bigger and technically difficult pipes will be erected first before the small ones. Non – Destructive Test (NDT) This activity is performed to check the correctness and soundness of the welded joints performed at the site. A number of test can individually or in combination be applied which includes but not limited to visual inspection; ultrasonic inspection, dye-penetration check, magnetic particle check, eddy current check, radiography etc. the test will be performed in accordance to NDT Procedure; ASME code Sec. V and related specifications. Leak Test and Cleaning of Pipes. A separate method of statement will be prepared for the above test and procedure.
7.2.6 Special Technical Procedures 7.2.6.1 Bolting The bolting applies for all subsequent description: All high strength joints will be tightened to the specified torque indicated on the drawings or attachments to manufacturing instruction respectively. Correct bolt torque will be applied in accordance with the instruction given and will be colour-coded to mark completion. Task completed will be recorded in site construction records. Employees doing bolt tightening shall bear a unique number in a similar manner to the welder numbers and shall be certified appropriately. (FSI Ref.: Q1-1.1.1., 1.1.2., 1.1.3.) The following table will be implemented for ACC Steel structure: # dimensions nominal preloading Torque control force (kN) Method (Nm) 1 M 12 35 70 2 M 16 70 170 3 M 20 110 300 4 M 22 130 450 5 M 24 150 600
T-4.250.904 Rev. A
Torque value (KN) 40 80 120 145 165
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
6 M 27 7 M 30 8 M 36 Refer document T-4.193.320 bolts from the vendor.
200 900 220 245 1200 270 355 2100 390 for Grade 8.8, hot dip galvanized and lubricated nuts and
The following table will be implemented for Motor & Gear Box, coupling's, fan blades and other machine components: # dimensions Strength class 8.8 Strength Class 10.9 1 M6 10 Nm 14 Nm 2 M8 25 Nm 35 Nm 3 M 10 49 Nm 69 Nm 4 M 12 86 Nm 120 Nm 5 M 16 210 Nm 295 Nm 6 M 20 410 Nm 580 Nm 7 M 24 710 Nm 1000 Nm 8 M 30 1450 Nm 2000 Nm 9 M 36 2530 Nm 3580 Nm 10 M 42 4070 Nm 5720 Nm 11 M 48 6140 Nm 8640 Nm 12 M 56 9840 Nm 13850 Nm 13 M 64 14300 Nm 21000 Nm Refer Document T-4.200.145 as provided by SPX/vendor. Additional Reference: DEP 34.28.00.31 Any other bolts of different grades, the torque values will be followed in line with the vendor's recommendations.
7.2.6.2 Site Welding Principles On structures and parts of structures as well as all the items that are protected by hot dip galvanization, welding is not allowed. Repair and/or adaptation of assembly parts are subjected to a concession authorized by SPX site representative prior to proceeding. Welding will be performed by certified welders with approved WPS (Welding Procedure specifications). NDT shall be carried out on areas of lifting lug removal after dressing of affected area. Welding map; each weld should be itemized with particular reference number and recorded in the welding map drawing and listed on record sheets with location and WPS that are done. In case of bad weather conditions, special protection during welding must be taken to avoid weld failure; such prevention will be listed before starting main welding operation and must follow general welding recommendations. Galvanized structures need to be shielded off during welding and/or grinding activities in close proximity to avoid contamination or damage. Whenever the galvanized portion or portions is damaged on the structure or corrosion exist; repair can be done with the following procedure;
T-4.250.904 Rev. A
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GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
o corrosion or damage shall be removed using light sweeps of an orbital grinder o 25 mm band of sound galvanizing around the damaged area shall be carefully feathered down to bare steel o residual oil or grease shall be removed with degreaser o on surface preparation completion, scrub and rinsed with fresh water o the area shall be coated with rich zinc paint (or approved equal paint) for at least 100 microns, or o the repair coating shall overlap onto the feathered edge of the existing galvanizing. Following FSI Issues will be as follows with T-4.186.019: 1. Ensure welding of valves is carried out with closure member in open position as required by Appendix 3, DEP 31.38.01.31 to avoid small bore valve internals be damaged during welding. (FSI Ref.: Q1-1.2.5.) (T-13.377.360) 2. Ensure received rotating equipment drain connections are free of screwed and seal welded screwed connections. (FSI Ref.: Q1-3.3.) 3. Ensure adequate supervision/QC during lifting & lug removal to avoid pin holes at Column walls. (FSI Ref.: Q1-4.3.) 4. Apply GTAW (TIG) root run welding for all pipe welds on process piping works (no internal slag generation) unless access to back weld is possible, (i.e.> 36" diameter) to avoid instrument toppings and small bore piping plugged with weld slag. (FSI Ref.: Q2-1.16) 5. Have tight control on GTAW root run backing gas dams. Avoid paper dams with sticky tape. (FSI Ref.: Q2-1.16) 6. Ensure thorough inspection on internal cleanliness when any form internal dams for backing gas are being applied. (FSI Ref.: Q2-1.16) 7. Root bulge of weld between nozzle and flange has to be removed by grinding to ensure correct ID of manhole walls. (FSI Ref.: Q3b-59L) 8. Ensure the cleanliness be preserved after welding, cutting or grinding operations as per T-4.250.930 “Quality Control Procedure for Cleanliness” Paragraph 12.2. 9. Ensure the cleanliness be preserved after welding, cutting or grinding operations as per T-4.250.932 “Quality Control Procedure for preservation of Piping Material and Equipment”. 10. Proper screening and training of the personnel shall be performed in accordance with the T-4.219.615 Rev. C “Training and Orientation”. 7.2.6.3 Record of Deviation and Tolerance for Construction Deviations and tolerances have to be strictly followed as per requirements specified by associated Vendor's. Refer Doc. T-4.121.350 records & protocols will be recorded, kept & maintained.
8
QUALITY ASSURANCE A Quality Assurance System will be operated conforming to related standards and vendor's recommendations.
T-4.250.904 Rev. A
Page 42 of 65
Q A T A R
Doc. Title
:
GAM-MTS-MEC-GTL-009 METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
:
24 November 2008, Rev. F
Controls and checks will be established and documented through relevant QCP – T4.250.944 & ITP – T-4.250.921 and QCR's. FSI should also apply to this method of statement. Reference DEP 70.10.70.11
9
ATTACHEMENTS 9.1 9.2 9.3 9.4
Job Safety Analysis Installation of Life Line for Bundles Erection at ACC Lifting of Fan Deck Plates Design Calculation Notes for Horizontal Lifeline System
T-4.250.904 Rev. A
Page 43 of 65
Page 44 of 65
Mr. Bilal
Mr. Ozkan Karlioglu
Name
2. Permit To Work.
1. The following Personal Protective Equipment shall be worn: Approved coveralls, high-visibility vests, safety glasses, safety helmet, safety steel toe shoes and gloves, harness with double lanyard (lifeline).
RLIC EMERGENCY NO
583 40 72 474 88 88
Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work. 2) Use additional sheets as necessary. 3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and SHELL Safety and Environment Procedures.
LINDE EMERGENCY TELEPHONE NO.
Approval required for hazardous work detailed in the Linde Work Permit Procedure. Changing conditions and emergency procedures: Stop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.
OTHERS (List Below):
HSSE Representative (Linde)
Date
24.11.08
JSA Members: Mr. Syd Osborne, Mr. Renato Tabing Job Performers: Mr. Ozkan Karlioglu, Mr. Ertan General job requirements / Common Personal Date Signature Protective Equipment. 24.11.08
Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager). Name Signature Discipline Superindent (Linde)
Job Supervisor:
JSA by:
Normal Approvals:
Department/Section doing JSA: HSSE & Mechanical works
Page No: 1 of 6
JOB SAFETY ANALYSIS FORM
JSA For: T-4.250.904 NEW REVISED Job being analysed: Methods Statement - Main Erection Sequence for ACC
Q A T A R
Page 45 of 65
1
ITEM
Mobilization of structures and equipment to site laydown area
ACTIVITY
Q A T A R
Personnel observation at work Ensure safe distance from the excavations Injury due to muscle strain or sprains while lifting weights
1.3
1.5
1.4
Adequate Banksmen
1.2
HAZARDS / POTENTIAL CONSEQUENCES 1.1 Lifting and transport equipment movement
C
C
P
1
3
C
LOW
MED
Rank
Initial Risk
1.5.2
1.5.1
1.4.1
1.3.1
1.2.1
1.1.3
1.1.2
SCOPE : Methods Statement - Main Erection Sequence for ACC
Residual Risk ADDITIONAL P C Rank CONTROLS 1.1.1.1 Only drivers/operator with Qatar license & certified operator & trained personnel are be allowed to work on site. Ensure the area is wide enough for the 1.1.2.1 Ensure that every vehicle and slewing movement. equipment is fitted with an automatic reverse alarm and beacon or strobe light. 1.1.3.1 Barricade working area and Place the outriggers in level ground B 2 LOW provide warning signs. surface and ensure ground compaction report required to accompany lift plan. Ensure that an adequate number of 1.1.4.1 Proper determination of cg (center Banksmen are assigned as necessary of gravity) for each lifts to control work. All personnel to be vigilant of each other and vehicle movements. Ensure the area is wide enough in the travelling range. Ensure employee shall be trained in safe methods of handling equipment, assessed & qualified. 1.5.2.1 The weights of each structure or Assessment of weight of equipment LOW B 1 equipment will be specified and and structure to be noted and noted before any lift numbers of person required to be defined. Rigging & lifting plan to be submitted for approval.
MAIN CONTROLS 1.1.1 Ensure that there are no obstacles in the travelling range.
JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.250.904
Page 46 of 65
Unloading of structures and equipment prior to erection
Erection of structure and equipment
3
ACTIVITY
2
ITEM
Q A T A R
Working at heights
Working in confined space
Trippping & Slipping
3.2
3.3
Injury due to muscle strain or cuts while lifting
3.1
2.2
HAZARDS / POTENTIAL CONSEQUENCES 2.1 Lifting and transport equipment movement
B
C
C
B
B
P
3
4
5
2
2
C
LOW
MED
HIGH
LOW
LOW
Rank
Initial Risk
SCOPE : Methods Statement - Main Erection Sequence for ACC
3.3.1 Adequate walkways and railings are required 3.3.2 Lighting shall be set up to prevent shadows.
3.2.2 Adequate ventilation and lightings are required when performing welding at the steam manifold 3.2.3 Ensure working with buddy system
3.2.1 Ensure that personnel are properly educated and confined space trained to do the erection works.
3.1.2 Ensure scaffoldings and ladders are used when applicable.
3.1.2.2 Scaffold to be erected by qualified persons.
3.1.2.1 Harness to be checked before use
3.1.1 Ensure that personnel are properly 3.1.1.1 Proper PPE (personal protective educated and trained to do the equipment) are required. TSTI to erection works, safe work procedures. be completed daily.
2.2.1 Ensure that materials handled are free 2.2.1.1 Proper PPE (personal protective equipment) required. from splinters or rough surfaces which can contribute and affect harm.
B
B
B
B
1
3
4
1
LOW
LOW
MED
LOW
Residual Risk ADDITIONAL P C Rank CONTROLS 2.1.1.1 Only drivers/operator with Qatar license & certified operator & trained personnel are be allowed to work on site. B 1 LOW 2.1.2 Ensure the ground are level to prevent 2.1.1.2 Area to be barricaded off with sign boards mwntioning lifting in structures and equipment from progress. distortion MAIN CONTROLS 2.1.1 Ensure that no obstacle within the laydown area
JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.250.904
Page 47 of 65
ITEM
ACTIVITY
Q A T A R
Tampering Electrical equipment
Slip, trip, fall on same level.
Risk of Fall
3.5
3.6
3.7
HAZARDS / POTENTIAL CONSEQUENCES 3.4 Electrical hazard.
C
C
5
2
2
3
C
C
C
P
HIGH
LOW
LOW
MED
Rank
Initial Risk
3.6.1 Keep cables, materials, tools neatly organised. 3.6.2 Area shall be properly maintained all equipment and materials must be properly stored and picked up. 3.6.3 Removed unnecessary materials in the work place. Proper house-keeping to be done at work place. 3.7.1 Ensure Proper education & training of 3.7.1.1 Use of Proper PPE. Harness to be personnel doing erection works. checked before use. 3.7.2 To provide temporary detachable post 3.7.1.2 Harness to be properly fixed at 2 (two) points above the head level. and railings for clamping full body harness to the structure attached or secured. 3.7.3 To provide catch to cover the exposed 3.7.1.3 area at the fan deck structure during Harness to be colour coded every the initial stage. month.
3.5.2 Work will be properly supervised at all times. 3.5.3 Equipment will be checked by a competent electrician after installation.
3.5.1
3.4.4
3.4.2 3.4.3
3.4.1
B
B
B
B
P
5
2
2
2
C
MED
LOW
LOW
LOW
Rank
Residual Risk
SCOPE : Methods Statement - Main Erection Sequence for ACC
MAIN ADDITIONAL CONTROLS CONTROLS 3.4.1.1 Ensure all electrical equipment Check electrical equipment prior to were properly grounded and built use. Ensure it is properly inspected, with ELCB at their source. color coded for the month and properly documented. Ensure good electrical connection. Don’t allow any live electrical parts to touch the ground. Don’t touch electrically live parts with skin or wet clothing. Ensure that only qualified and trained electrical technician will carry out in setting up lights in work area.
JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.250.904
Page 48 of 65
Improper use of hand 7.1 tools
7
6.1
Right tools for the right job.
Provide suitable ladder for safer access
Utilizing equipment for other purpose.
5.4
Personnel or Tools falling
Collision with other object
5.3
6
Overturning
5.2
5.1
Utilizing Utili i equipment i t ffor other purpose. Structural Failure
4.4 44
Operation of Crane
Collision with other object
4.3
5
Overturning
4.2
Operation of Areial work platform
ACTIVITY
C
C
C
C
C
C
C
C
C
C
P
2
5
3
3
4
4
3
3
4
4
C
LOW
HIGH
MED
MED
MED
MED
MED
MED
MED
MED
Rank
Initial Risk
4.3.1.1 Only trained personnel will operate the equipment. 4.3.1.2 Proper supervision during operation.
4.2.1.1 Proper Training and certification of the operators handling the equipment. 4.2.1.2 Lifting plan submitted & approved.
ADDITIONAL CONTROLS 4.1.1.1 Duly certified equipment will be used.
6.1.3 Approved and color coded body harness to be worn. 7.1.1 Never use defective tools.
6.1.2 Rigid barrier shall be provided.
6.1.1 Display warning signs.
5.3.2 Maintain specific area around the aerial work platform. 5.4.1 Use equipment for sole purpose only.
5.3.1 Operate within the working range.
5.2.2 Avoid too much inclination of Boom.
5.2.1 Prevent from overloading.
6.1.3.1 Prior to use check the harness. 7.1.1.1 All tools to be inspected prior to use and color coded.
6.1.1.1 Practice 3 point of contact.
5.3.1.1 Only trained personnel will operate the equipment. 5.3.1.2 Proper supervision during operation.
5.2.1.1 Proper Training of the operators handling the equipment.
B
B
B
B
B
B
B
B
P
2
2
2
2
2
2
2
2
C
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
Rank
Residual Risk
SCOPE : Methods Statement - Main Erection Sequence for ACC
5.1.1 Ensure equipment reliability & 5.1.1.1 Duly certified equipment will be complete inspection. used. 5.1.2 Maintenance & Instrumentation failure.
4.3.2 Maintain specific area around the aerial work platform. 4.4.1 4 4 1 Use U equipment i t for f sole l purpose only. l
4.2.2 Avoid too much inclination of the Boom. 4.3.1 Operate within the working range.
4.1.2 Check conditions of instruments at regular intervals. 4.2.1 Prevent from overloading.
MAIN CONTROLS 4.1.1 Ensure equipment reliability & complete inspection.
JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.250.904
HAZARDS / POTENTIAL CONSEQUENCES 4.1 Structural Failure
4
ITEM
Q A T A R
Page 49 of 65
ACTIVITY
Operation of HILTI DX76 fastening tool
Permit Holders
ITEM
8
9
Q A T A R
9.1
Unqualified PTW Holder's (Supervisors)
HAZARDS / POTENTIAL CONSEQUENCES 8.1 Utilizing of the unit.
C
C
P
1
5
C
LOW
HIGH
Rank
Initial Risk
8.1.5 Attention is required & could cause hazard if incorrectly used; as damage to property & tool. 9.1.1 All Supervisors will be trained by GAMA/Linde on PTW procedures. procedures
8.1.4
8.1.3
8.1.2
8.1.1
B
B
P
2
2
C
LOW
LOW
Rank
Residual Risk
SCOPE : Methods Statement - Main Erection Sequence for ACC
MAIN ADDITIONAL CONTROLS CONTROLS Ensure the users are trained to 8.1.1.1 Training is required for all user. operate the tool. Only authorised users have to operate the unit. 8.1.1.2 Proper PPE for operator The operator has to understand what the tool is cabable off. 8.1.1.3 Discuss in TSTI. Proper attention is required & could cause hazard if incorrectly used; as personal injury.
JOB SAFETY ANALYSIS / RISK ASSESSMENT FOR T-4.250.904
Q A T A R
INSTALLATION OF LIFE LINE FOR BUNDLES ERECTION AT ACC
Doc. Title
:
Date
: 12th November 2008, Rev E
1. SCOPE: The procedure applies to the installation or erection of the secondary & primary bundles for ACC at C2 Area.
2. PURPOSE: The main purpose is to describe the procedures on how the bundles will be erected & to ensure that
it is carried out in accordance with the project requirement and philosophy.
3. DESCRIPTION OF BUNDLES: Secondary Bundles: L x W = 10600mm x 2193mm Wt. = 3.403 Tonnes Total number to be erected per ACC
= 24 nos.
Primary Bundles L x W = 11100mm x 2193mm Wt. = 3.597 Tonnes Total number to be erected per ACC
= 168 nos.
4. INSTALLATION OF LIFELINE ON TOP OF A-FRAME: • • • • • •
•
12 mm Ø wire rope will be used Two standard scaffolding beam clamps will be installed in two ends of the A-Frame One end of the rope will be fixed in the structure at the fan deck i.e.; the motor bridge The rope will run into the installed beam clamps and will be resting on top of the girder The other end will be tensioned below by an appropriate tool or chain block or a hand winch The system will be utilized by the erector during alignment & setting of the bundle & remove of the tackles from the crane The erector sitting on the A-Frame will brace himself in the installed lifeline & will straddle as the next bundle is being erected
5. PROCEDURE • • • •
• •
Bundles will be erected in the following sequence; first secondary & then the primary bundles Ensure that all heat exchanger protective covers are removed & cleaned before installation Bundles will be lifted from the ground using the crane available at ACC area Bundles will be lifted in 30º inclination and to be placed into the erected A‐Frame. The whole weight will be supported by the installed (CCM) collecting condensate manifold at the bottom & anchored on top of the A‐Frame. The two opposite bundles will be joined by welding on the late stage Sequence of lift will be alternate i.e. starting from the left to the right; or right to left whichever applicable to prevent unbalancing at the structure During primary bundles erection, the lifeline system will be bolted into the edge of the bundles & will cover the entire length of the street. This will provide access to trained personnel in the execution of their works i.e. joining, alignment and welding of bundles
Page 50 of 65
Q A T A R
INSTALLATION OF LIFE LINE FOR BUNDLES ERECTION AT ACC
Doc. Title
:
Date
: 12th November 2008, Rev E
• •
The lifeline will be later removed during the erection of the (SDM) steam distribution manifold Man lift will be utilized to fasten the mobile post for lifeline and will be spaced more than 4 meter or at two bundles interval. At least two lines will be erected; & wire rope will be minimum 10mm Ø.
6. ATTACHMENT: • • •
Lifeline arrangement on top of A- Frame Lifting sequence for bundle Safe working procedure for exiting man basket or man lift in elevated position
Page 51 of 65
Page 52 of 65
Page 53 of 65
DESIGN CALCULATION NOTES FOR HORIZONTAL LIFELINE SYSTEM
FOR CONSTRUCTION 0 03.11.2008 N.KUMAS Rev. Date Description Prepared Customer Engineering
A.GÖKDALAY F.TİNİŞ Approved Checked
G PEARL-GTL PROJECT
INDUSTRIAL PLANT MANUFACTURING &
QATAR
ERECTION CORP.
Document Title HORIZONTAL LIFELINE SYSTEM DESIGN CALCULATION NOTES
Document No. 000-101-S0041-CN01
Rev. 0
Page 54 of 65
PEARL GTL PROJECT - QATAR Document Title: Calculation Notes for Horizontal Lifeline System
Document No: 000-001-S0041-CN01
Page No:
Rev
i
0
TABLE OF CONTENTS Page No Table of Contents 1.0 GENERAL
i 1-5
1.1 Scope
1
1.2 System
1
1.3 Units
6
1.4 Materials
6
1.5 Reference Codes, Standards & Specifications
6
2.0 CALCULATIONS
7
3.0 CONCLUSION
10
Page 55 of 65
PEARL GTL PROJECT - QATAR Document Title: Calculation Notes for Horizontal Lifeline System
Document No: 000-001-S0041-CN01
Page No:
Rev
1
0
1. 0 GENERAL 1.1. SCOPE This report is prepared for the design of the mobile post and horizontal lifeline system at Fan Deck Sub-structure of ACC. The system is checked for the safety of wire ropes for a factor of safety greater than 2 as well as the mobile posts to resist for the cable force. Assuming some type of shock-absorbing/self-retracting lanyards are used; 410 kg (900 lbs) force for one worker is applied at midspan of the horizontal lifeline system for design/analysis purposes and it is assumed that both top or mid-rail of the system could be used. As can be seen on the drawing at the next page; the support system is designed as braced for both top and mid-rail at the corners as well as at the ends where the lifelines coincide. The horizontal distance of the bracing form the vertical supports are considered as 1.2 m providing an angle of 25.15° for the top rail with vertical support. The bracings profiles are the same as the vertical supports of pipes with 38.1 mm diameter and 4.1 mm wall thickness.
1.2. SYSTEM System of the structure is indicated at the following page.
Page 56 of 65
Page 57 of 65
Page 58 of 65
Page 59 of 65
Page 60 of 65
PEARL GTL PROJECT - QATAR Document Title:
Document No:
Calculation Notes for Horizontal Lifeline System
000-001-S0041-CN01
Page No:
6
Rev
0
1.3. UNITS Throughout this report the following units will be used. Length
:
m and mm
Area
:
m2
Force
:
ton, kg, newton
Pressure
:
kN/m2 (kPa)
Stress
:
N/mm2 (MPa)
Elevations
:
m
1.4. MATERIALS Structural Steel
: S235JR
1.5. REFERENCE CODES, STANDARTS & SPECIFICATIONS Throughout the design the following design codes, standards & specifications are used: •
OHS Guidelines Part 11 Fall Protection - Mon Nov 3, 2008
•
Eurocode 3-Design of Steel Structures-1993 Part1-1: General rules and rules for buildings
Page 61 of 65
Page 62 of 65
= 600.44 cm
By doing iteration for t2 until the difference btw L2 and L22 converge to zero (see the next page); Tangential cable tension at mid-span under its own weight and concentrated load t2 is calculated as t2: 3690 kg
⎞ ⎟⎟ ⎠
16.82 kg
16.73 kg
⎛ 8 f 12 S .⎜⎜1 + 3s 2 ⎝
w .s 2 8 . f 1 2 ⎛ w.s ⎞ 2 t1 + ⎜ ⎟ ⎝ 2 ⎠
Length of cable under its own weight L1
Cable tension at supports T1
Tangential cable tension t1
Nominal diameter, d: Cross-sectional area, A: Distance btw. anchor points,S: Cable weight: Modulus of elasticity: Mid-span applied concentrated load for 3 workers: Minimum breaking load: Sag of cable under its own weight:
1.20 cm wire rope 6x7 1.13 cm2 600.00 cm 0.006 kg/cm 630000 kg/cm2 410 kg 10.30 ton 10.00 cm
000-001-S0041-CN01
CALCULATION NOTES FOR HORIZONTAL LIFELINE SYSTEM
2.0 CALCULATIONS
Document No:
Document Title:
PEARL GTL PROJECT - QATAR 7
Page No
0
Rev
Page 63 of 65
s
301.52326 301.50848 301.4939 301.47954 301.46538 301.45143 301.43767 301.42411 301.41073 301.39755 301.38455 301.37173 301.35908 301.34661 301.33432 301.32219 301.31022 301.29841 301.28677 301.27528 301.26394 301.25275 301.24171 301.23082 301.22007 301.20946 301.19899 301.18865 301.17844 301.16837 301.15842 301.1486 301.13891 301.12934 301.11988 301.11055 301.10133 301.09223 301.08323 301.07435
0.9041143 0.8661115 0.8285369 0.7913823 0.7546397 0.7183013 0.6823595 0.6468066 0.6116356 0.5768391 0.5424103 0.5083424 0.4746287 0.4412628 0.4082382 0.3755489 0.3431887 0.3111517 0.2794321 0.2480243 0.2169227 0.186122 0.1556167 0.1254018 0.0954722 0.065823 0.0364491 0.0073461 -0.021491 -0.050066 -0.078385 -0.10645 -0.134267 -0.16184 -0.189173 -0.216269 -0.243133 -0.269769 -0.29618 -0.322369
603.04654 603.01697 602.98782 602.95909 602.93078 602.90287 602.87535 602.84823 602.82148 602.79511 602.76911 602.74347 602.71818 602.69324 602.66865 602.64438 602.62045 602.59684 602.57355 602.55057 602.52789 602.50552 602.48344 602.46165 602.44015 602.41893 602.39798 602.37731 602.3569 602.33675 602.31686 602.29722 602.27783 602.25868 602.23978 602.22111 602.20267 602.18446 602.16648 602.14872
L2
602.142429 602.150856 602.159283 602.16771 602.176138 602.184565 602.192992 602.201419 602.209846 602.218273 602.2267 602.235128 602.243555 602.251982 602.260409 602.268836 602.277263 602.28569 602.294117 602.302545 602.310972 602.319399 602.327826 602.336253 602.34468 602.353107 602.361535 602.369962 602.378389 602.386816 602.395243 602.40367 602.412097 602.420524 602.428952 602.437379 602.445806 602.454233 602.46266 602.471087
L22 2040 2050 2060 2070 2080 2090 2100 2110 2120 2130 2140 2150 2160 2170 2180 2190 2200 2210 2220 2230 2240 2250 2260 2270 2280 2290 2300 2310 2320 2330 2340 2350 2360 2370 2380 2390 2400 2410 2420 2430
t2 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600
S 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131 1.131
A 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558 0.00558
w
000-001-S0041-CN01
CALCULATION NOTES FOR HORIZONTAL LIFELINE SYSTEM
L2-L22
Document No:
Document Title:
630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000 630000
E
PEARL GTL PROJECT - QATAR
410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410 410
F 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425 25.098425
t1 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444 600.4444444
8 L1
Page No
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
0 f1
Rev
Page 64 of 65
S ( 2 F + ws ) 8t 2
T2=
→
102.93 kN
The safety factor = Allowable load / Actual Load =
Allowable load of steel supports, fy*A:
- Reaction on the vertical support N= T2.sin(θ) + q. cos(α)= 6202.16 kg
T2.cos(θ)= q. sin(α) α= 31.61º - Reaction on the inclined support q = 7040.76 kg
1.46
- Reaction due to cable force on the anchor supports For the equilibrium at anchorage, the sum of horizontal forces should be equal to zero.
→
= 16.73 cm
2
⎛ F + ws ⎞ t22 + ⎜ ⎟ 2 ⎠ ⎝ S cos(θ)= 2 = 0.99845 s
= 603.54 cm
→ θ=
= 3695.78 kg
Wire rope factor of safety: Min. Breaking Load / q = 2.79
Sag of the cable under its own weight and concentrated load f2=
= 300.47 cm
3 ⎛ S ⎞ ⎤⎥ ⎜ ⎟ .⎜ 2 ⎟ ⎥ ⎜ s ⎟ ⎥ = 600.93 cm ⎜ ⎟ ⎥ ⎝ ⎠ ⎥⎦
(t 2 − t1).L1 + L1 AE
⎡ ⎛S⎞ w 2 .⎜ ⎟ ⎢ ⎝2⎠ 2.⎢ s + ⎢ 24.t 2 2 ⎢ ⎢⎣
s 2 ⎛ S ( 2 F + ws ) ⎞ +⎜ ⎟ 4 ⎝ 8t 2 ⎠ 3
L22=
Length of cable under its own weight and concentrated load L2=
The chord length btw support and center deflected cable s=
000-001-S0041-CN01
CALCULATION NOTES FOR HORIZONTAL LIFELINE SYSTEM 2
Document No:
Document Title:
PEARL GTL PROJECT - QATAR
3.19º
→
L2 - L22 -= 2.61 cm
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>
Length of the weld for tension resistance , lv= 119.69 mm Design tension strength of weld= 13262.17 kg 7040.76 kg
3690.05 kg
As a result, the horizontal lifeline with the support system is found to be safe.
1 - The cable tension load is less than the cable breaking load with a factor of safety equal to 2.79 2 - The axial load on tubular column is less than allowed load with a factor of safety equal to 1.46 3 - The baseplate weld capacity of the is greater than the applied load with a factor of safety equal to 1.80
The horizontal lifeline fall arrest system has been analyzed using the principle described above and the following results are gathered.
3.0 CONCLUSION:
>
= 277 Mpa
Length of the weld for shear resistance , lv= 59.85 mm Design shear strength of weld= 6631.09 kg
f vw.d= ( fu / √ 3 )/( βw * Ύ M2 )
000-001-S0041-CN01
CALCULATION NOTES FOR HORIZONTAL LIFELINE SYSTEM
- Baseplate welds;
Document No:
Document Title:
PEARL GTL PROJECT - QATAR Page No 10
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