EXHIBIT I - Project Execution Plan F
July 19, 2022 | Author: Anonymous | Category: N/A
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JEC 2000 Home Lot Development
China Communication Construction Company Ltd. Saudi Branch
EXHIBIT I Project Execution Plan
CONTENT
1.
General... General............. .................... .................... ..................... ..................... .................... ..................... ................................................ ..................................... 4 1.1 Introduct Introduction.. ion............ ..................... ..................... .................... .................... ..................... ..................... .................................... .......................... 5 1.2 Scope Scope of Works... Works.............. ..................... .................... .................... ..................... ..................... .................... ..................... ................... ........ 5 1.3 Referenc References.... es.............. .................... ..................... ..................... .................... ..................... ..................... .................... ..................... ............... ....5 5 1.4 Company Company Requirem Requirements ents.......... ..................... ..................... .................... ................................................. .......................................5 5 1.5 Contracto Contractors rs Procedur Procedures.... es.............. .................... .................... ..................... ..................... .................................... .......................... 5 1.6 Definitio Definitions.... ns.............. .................... ..................... ..................... .................... .................... ..................... ..................................... .......................... 5 1.7 Project Project Duration Duration and Critical Critical Milestone.. Milestone............ .................... ..............................................7 ....................................7 1.8 Mobiliza Mobilization tion plan............... plan.......................... ..................... .................... ..................... ..................... ................................... ......................... 7 1.8.1
Direct Direct Manpower.. Manpower........ ............ ............ ........... ........... ............ ............ ............ ............ .............. ........................... ........................7 .....7
1.8.2
Indirect Indirect Manpower. Manpower....... ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ ............. ....................7 .............7
1.8.3
Equipment Equipment and Material Materials..... s........... ............ ............ ............ ............ ........... ........... ............ ............ ........... ............... ............7 ..7
1.8.4
Laydown Laydown yards yards / c contrac ontractor tor camps / batch batch plants....... plants............. ............ ...................... ..................8 ..8
1.8.5
Sources Sources of potable potable water, water, utilities utilities & waste waste disposal.. disposal........ ............ ............ ........... ..............8 .........8
1.8.6
Access Access and egress egress to the project project site..... site.......... ........... ............ ............ ........... ........... ............ ............ ...........8 .....8
1.9 Demobilization...............................................................................................8 1.10 Project Closeout Phase.................................................................................8 2.
Procurem Procurement ent Program.. Program............ ..................... ..................... .................... ..................... ..................... .................................. ........................ 9
3.
Construct Construction ion Methods..... Methods............... ..................... ..................... .................... ..................... ..................... ............................... .....................9 9 3.1 Survey...... Survey................ ..................... ..................... .................... ..................... ..................... .................... ..................... ..................... ................... .........9 9 3.1.1
Survey Survey Instrument. Instrument....... ............ ............ ........... ........... ............ ............ ............ ............ ................. ............................. ....................9 ..9
3.1.2
Establishme Establishment nt of of Survey Survey Control Control Points.. Points........ ............ ............ ........... ........... ............. .....................9 ..............9
3.1.3
Establishme Establishment nt of Const Constructi ruction on Survey Survey Control Control Netwo Network.............. rk.........................10 ...........10
3.1.4
Setting Setting Out......... Out............... ............ ........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ ...........10 .....10
3.1.5
Displaceme Displacement nt Monitori Monitoring.... ng.......... ............ ............ ........... ........... ............ ............ ........... ........... ............... .................10 ........10
3.2 Site Clearanc Clearance e Work............. Work....................... ..................... ..................... .................... ........................................ .............................. 10 3.2.1
General Descript Description.... ion......... ........... ............ ............ ............ ............ ............ ........... ........... ............ ............ ............. .............10 ......10
3.2.2
Constructio Construction n Process.... Process.......... ........... ........... ............ ............ ............ ............ ............ .................... ...........................10 .............10
3.2.3
Constructio Construction n Methods..... Methods........... ........... ........... ............ ............ ........... ........... ............ ............ ........... ............ ................1 .........11 1
3.3 Excavatio Excavation n and Backfilli Backfilling..... ng............... .................... ..................... ..................... .................... .................... .................... ..........1 11 3.3.1
Preparation Preparation Works.... Works.......... ............ ............ ........... ........... ............ ............ ............ ............ ............ .................... ....................1 ......11 1
3.3.2
Backfilling Backfilling Wor Works.... ks.......... ............ ............ ............ ............ ............ ........... ........... ............ .............. .......................... ....................12 ..12
3.3.3
Excavation. Excavation....... ............ ........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ..................... ...................13 ....13
Page 1 of 54
3.3.4
Transiti Transition on Constr Construction uction...... ............ ........... ........... ............ ............ ............ ............ ............ ........... ........... ............ ............13 ......13
3.4 Substatio Substation n Work......... Work................... ..................... ..................... .................... ..................... ..................... .................... .................... .......... 15 3.4.1
General General Description... Description......... ........... ........... ............ ............ ........... ........... ............ ............ ............ ............ ............ ..............15 ........15
3.4.2
Constructio Construction n Flow Flow Chart..... Chart........... ............ ............ ........... ........... ............ ............ ........... ........... ................. .................15 ......15
3.4.3
Constructio Construction n Method...... Method............ ............ ............ ............ ........... ........... ............ ............ ...................... ..........................15 ..........15
3.5 Motor Motor Control Control Center(MCC Center(MCC)......... )................... .................... .................... ..................... .................................. ....................... 22 3.5.1
Locating Locating the MCC....... MCC............ ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ .............. ..............22 ......22
3.5.2
MCC Alignment.. Alignment........ ........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ ............ ...........22 .....22
3.5.3
MCC Alignment.. Alignment........ ........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ ............ ...........22 .....22
3.5.4
Positioning Positioning the MCC..... MCC........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ .................23 ...........23
3.5.5
Joining Joining Corner Corner Channe Channels.... ls.......... ............ ............ ........... ........... ............ ............ ........... ........... ............... .................24 ........24
3.5.6
Joining Joining Section Section side Channels.... Channels......... ........... ............ ............ ........... ........... ................. ..........................25 ...............25
3.5.7
Securing Securing Stucture Stuctures s to the Floor... Floor......... ............ ............ ............ ........... ........... ............ ............ ...................26 .............26
3.5.8
Seismic Seismic Hazard Hazard Designated Designated Locations.... Locations.......... ............ ............ ........... ........... ............ ............ .............26 .......26
3.5.9
Splicing Splicing Power Bus........ Bus.............. ............ ........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ...........27 .....27
3.5.10 Ground Bus Spilicing.. Spilicing........ ............ ............ ............ ............ ........... ........... ............ ............ ........... ............... ...................28 .........28
3.6 Cable Cable Pulling & Cable Cable Gland........ Gland.................. .................... ..................... ..................... .................... .......................29 .............29 3.6.1
Cable Installa Installation.. tion........ ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ ............... ...................29 ..........29
3.6.2
Pre-install Pre-installation ation Activities Activities of Cable Cable Gland..... Gland........... ............ ............ ........... ........... ............ ............ .........30 ...30
3.6.3
Assembly Assembly Instruction Instruction for Cable Gland........ Gland.............. ............ ........... ........... ............ ......................31 ................31
3.6.4
Epoxy Compound Compound Preparation.. Preparation........ ............ ............ ............ ........... ........... ............... ...........................32 ..................32
3.6.4
Conduit Conduit and and Cable Cable Seal Application.. Application....... ........... ............ ............ ........... ........... ............... ....................34 ...........34
3.7 I UPS System System Energizatio Energization....... n................. ..................... ..................... .................... .................... .......................... ................ 35 3.7.1
Material Material Requirement Requirement & Constr Construction uction Procedure.... Procedure......... ........... ............ ............ ...............35 .........35
3.7.2
Method of Energizati Energization..... on........... ........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ........35 ..35
3.8 PLC Testin Testing g and Energization Energization.......... .................... .................... ..................... ..................... ............................. ................... 36 3.8.1
Before Starting......... Starting.............. ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ ............ ...........36 .....36
3.8.2
Testing Inputs Inputs and Outputs.... Outputs......... ........... ............ ............ ........... ........... ............ ............ ........... ........... ...............36 .........36
3.8.3
Testing Software........ Software.............. ............ ........... ........... ............ ............ ........... ........... ............ ............ ............. ....................37 .............37
3.9 Installat Installation ion of Pumps and Motors....... Motors................. ..................... ..................... .....................................37 ...........................37 3.9.1
Installation Installation Sequence..... Sequence........... ............ ........... ........... ............ ............ ............ ............ ............ ...................... ....................37 ....37
3.9.2
Installation Installation Preparatio Preparation..... n........... ............ ........... ........... ............ ............ ........... ........... ............ ............ .............. .............38 .....38
3.9.3
Pad for Jack Bolts Installatio Installation...... n........... ........... ............ ............ ........... ........... ..................... .........................38 ..........38
3.9.4
Base Plate Plate Leveling.... Leveling......... ........... ............ ............ ............ ............ ............ ........... ........... ............ ............ ............. .............39 ......39
3.9.5
Preliminar Preliminary y Pump to Driver Driver Alignment.... Alignment......... ........... ............ ............ ........... ........... ............ ............ .........39 ...39
3.9.6
Baseplate Baseplate Grouting..... Grouting........... ............ ............ ............ ........... ........... ............ ............ ........... ........... ............ .............. .............39 .....39
3.9.10 Final Alignment... Alignment........ ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ............ ......................40 ................40
3.10 Storage of GRE Piping UG & AG................................................................40
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3.10.1 Storage Storage Piping...... Piping........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ .............. ....................40 ............40 3.10.2 Packaged Packaged Loads....... Loads............. ........... ........... ............ ............ ............ ............ ............ ........... ........... ............ ............ ...............41 .........41 3.10.3 Single Pipes.............................................................................................41 3.10.4 Handling Handling of Nested Pipes...... Pipes............ ............ ............ ........... ........... ............ ............ ........... ........... ....................42 ..............42 3.10.5 Package Package Removal Removal and de-nesting... de-nesting......... ............ ............ ........... ............... ............................ ......................43 ....43 3.10.6 Transporting Pipe at site..........................................................................43
3.11 Assembly Assembly and and installation of GRE Piping(UG Piping(UG & AG)....... AG)............ .......... .......... .......... ........... ........43 ..43 3.11.1 3.1 1.1 General General Instruction. Instruction...... ........... ............ ............ ........... ........... ............ ............ ........... ........... ................. ........................43 .............43 3.11.2 3.1 1.2 Pipe Laying Preparation Preparation and Installatio Installation...... n............ ............ ............ ........... ........... ............. ..............45 .......45
3.12 Piping Testing..............................................................................................48 3.12.1 General General Guidelines. Guidelines....... ........... ........... ............ ............ ........... ........... ............ ............ ........... ........... ............ ................ ............48 ..48 3.12.2 Visual Visual Inspection.. Inspection........ ........... ........... ............ ............ ........... ........... ............ ............ .................... ...............................49 .................49 3.12.3 Preparation prior hydrostatic Test............................................................50 3.12.1 Water Water Filling Filling and Pressuriza Pressurization... tion......... ............ ........... ........... ............ ............ ........... ........... ................. .............50 ..50 3.12.2 Post Hydrostatic Test...............................................................................51 est...............................................................................5 1 3.12.3 Backfilling Backfilling...... ............ ........... ........... ............ ............ ........... ........... ............ ............ ........... ............... ............................ .......................51 .....51
3.13 Installation of uPVC Drianage Pipe & Fittings………… Fittings………………………… ……………… ……..52 3.13.1 External External Drainage Drainage Pipe Installation. Installation....... ............ ........... ........... ............ ............ ........................ .....................52 ...52 3.13.2 Internal Internal Drainage Drainage Pipe Installation.... Installation.......... ............ ............ ........... ................. .............................. ...................52 .52 3.13.3 Vertical ertical Drainage Drainage Pipe Installation. Installation....... ............ ............ ............ ............ ........... ........... ............ ............ ...........53 .....53
4.
Testing, Testing, Commissio Commissioning ning and Closeout/H Closeout/Hando andover.... ver.............. ..................... ..................... .................53 .......53
5.
Logistics Logistics and Interface Interfaces s betwee between n Project Project Phase Phase Progra Program........ m............................54 ....................54 5.1 Manpowe Manpowerr for facilities.. facilities............. ..................... .................... .................... ................................................ ......................................54 54 5.2 Interface Interface with other Contractor. Contractor............ ..................... .................... .................... ..................... ........................... ................ 54
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1. General 1.1 Introduction The purpose of this plan is to provide a Project Execution Plan (PEP) of CONTRACT for successful completion of the Jazan Economic City, Port and Infrastructure (JECPI) project, Package 8 (JEC 2000 Home Lot Development) three Pumping Stations (Irrigation, Waste and Potable & Fire). JECtown is located in theapproximately south western corner Saudi Sea toBaish the west of the of Baish, 80 km of north of Arabia Jazanalong City. the TheRed existing Road connects Baish municipality to JEC. The distance from JEC to the neighboring city of Baish is approximately 20km in the t he eastward direction.
Location of the project
1.2 Scope of Works The scope of works is as listed below:
Page 4 of 54
1.3
(i)
Aramco Aramco Home Home Owners Ownership hip(AH (AHO) O) three three Pumpin Pumping g Station Station((I ((Irri rriga gatio tion, n, Wa Waste ste and and Potable & Fire)
(i (iii)
Wet iin nfras frastr tru uctur cture e
(ii (iii) i)
Potabl Potable e and and Fire Fire wate waterr Pumpi Pumping ng stat station ion
(i (iv) v)
Ir Irri riga gati tion on Pum Pumpi ping ng Sta Stati tion on
(v (v))
Was aste te Water ater Pu Pump mpin ing g Sta Stati tion on
(vi)
Dry infrast infrastructu ructure re MCC room, room, and an an on-site on-site electrol electrolytic ytic chlori chlorinatio nation n (OSEC) (OSEC) plant
References This procedure will be read in conjunction with the following other guidelines.
1.4
Company’s Requirements Paragraph 5.3 of SCHEDULE “B”
1.5
Project Execution Plan
Contractors Procedures CT-ORG-0001 Project Organization Chart AD-PLN-0001 AD-PLN-000 1 Manpower Staffing Staffing Plan AD-GEN-0002 Administrative Administrative P Procedures rocedures DC-DRS-0001 Drawing Control and Review Procedure GE-INV-0001 Cost Reporting CT-PMP-0001 Project Risk Management Plan AD-PLN-0001 AD-PLN-000 1 Coordination Coordination Plan PR-MPP-0003 Material Procurement Plan (IK) PR-MPP-0002 Material Procurement Plan (OOK) PR-MPP-0004 Plan for Coordinating Coordinating the Transport, Staffing & Storage of Materials GE-CPL-0001 Construction Execution Plan PR-PLA-0001 Material Logistics Plan QA-QAD-0001 Inspection Log Book and Report Format GL-FQR-00 GL-FQ R-0001 01 Deve Developm lopment ent and Prepare Prepare of Project Project Support Support Buildin Buildings gs and Site Laydown Area CI-MST-0001 Geotechnical Investigation
1.6
Definitions
“COMPANY” “COMP ANY” means Saudi Arabian Oil Company, Company, Saudi Aramco and Companies afliated thereto, thereto, including but not limited to Aramco Overseas Company (AOC) and/or Aramco Services Company (ASC). “CONTRACTOR” Means the organisaon that has a contractual arrangement or a prospecve contractual arrangementt with the COMP arrangemen COMPANY ANY to perorm Design, Engineering, Procuremen Procurementt and Construcon services under this project proposal.
Page 5 of 54
“SUBCONTRACTOR(S)“ Means an organisaon or organisaons contracted by and wholly responsible to CONTRACTOR or execung a specic part o the WORK. “VENDO “VE NDOR” R” Means Means an org organi anisa saon on that that has a contr contract actual ual arrang arrangeme ement nt with with CONTR CONTRAC ACTO TOR R or a prospecve contractual arrangement with CONTRACTOR to supply equipment, materials and/or services including documentao documentaon. n. “WORK “W ORK”” Means Means all the work work and servic services es to be peror perorme med d by CONTR CONTRAC ACTO TOR R und under er a contr contract actual ual arrangement with the COMPANY. “Must “ Denes a mandatory contractual or legal requirement or acon. “Shall” Denes a mandatory contractual contractual requirement or acon. “Should” Denes a desirable or recommended outcome or acon; “Will” Denes an intended outcome or acon; “May” Denes reedom o choice. “Afliated Afliated Contract” Contract” means a contrac contractt under under which an Afliated Afliated Contractor Contractor is required required to perorm perorm services related to the FACILITIES. FACILITIES. “Afliated Contractor” means a CONTRACTOR Afliate responsible or perorming services related to the FACILITIES FACILITIES outside o Saudi Arabia under an Afliated Contract as applicable. “Approval” means SAUDI ARAMCO's prior wrien approval. "Company Representave" means a party or pares duly authorized by SAUDI ARAMCO to act on behal o SAUDI ARAMCO. “Eecve “E ecve Date” shall mean the date specied in the rst Paragr Paragraph aph o the Signature Sheet. "Laydo "La ydown wn Yard" ard" means means the loca locaon on or loca locaons ons where where certai certain n com compon ponent entss and Mate Materia rials ls o orr the FACILITIES FACILITIES shall be temporarily stored, abricated or assembled or pre constructed constructed by CONTRACTOR. CONTRACTOR. “Project Support Buildings” means CONTRACTOR supplied habitable portable and/or xed buildings that are provided or contractor, subcontractor and/or SAUDI ARAMCO personnel to support execuon o WORK (or example example,, but not restrict restricted ed to, accommoda accommodaons, ons, assembly build buildings, ings, abr abrica icaon on shops, shops, workshops, site and project ofces, storage, mechanical, security, shower/Wes shower/Western tern and Eastern toilet and recreaon recrea on buildings; kitchen/dining/mess halls; medical/clinics/rst aid buildings). "SAUDI ARAMCO" means the Saudi Arabian Oil Company. "WORK Site" means all locaons at which CONTRACT CONTRACTOR OR perorms any construcon, abricaon, Materials handling, or similar poron o the WORK, including Laydown Yards.
1.7 Project Duration and Critical Milestone The following constitutes the Critical Milestone Dates and Scheduled Completion Date, as referenced in the following table.
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Item
Crical Milestone Events
No. o Consecuve Calendar Days aer the Eecve Date o the Contract
GENERAL 1.1 1. 1.2 2
Mobilizaon Plac Pl acem emen entt o Pu Purrchas chase e Or Orde derrs
30 60
1.3
Submission and approval o Project Execuon Plan (PEP) and Method Statements
45
INSTALLATION 1.4
Tan anks ks & pump pump hou house se o orr the the ir irrig riga aon on ser servi vices ces
100
1.5
Tanks anks & pump pump hous house e or the re re and and portab portable le servic services es
150
1.6
Tan anks ks & pum pump p hou house se o orr the the wast waste e ser servi vice cess
240
1.7
MCAN MCAN or or a all ll p pump umpss ssta taon onss & associ associat ated ed piping piping syst system em
300
COMPLETION & CLOSING OUT 1.8 1.8 1.9 1.10
Is Isssue Mechan chaniical cal Com Compl ple eon on Comple Complete te "As Bui Built' lt' Drawin Drawings gs & all all hand hand ove overr docu documen ments ts Demobilizaon
340
350 360
1.8 Mobilization plan
1.8.1
Direct Manpower
After the contract has been awarded, the direct Manpower (field staff) mobilization mobilization will be started immediately. immediately. Most of the manpower will be mobilized from the other Projects in KSA, so that the mobilization period will be very short and the Project can be started as soon as possible. 1.8.2 Indirect Manpower Normally, the Indirect Manpower (office/support staff) will be initially mobilized to the site within one week to start the preparation works. Part of skilled workers will be mobilized initially to start the construction of temporary facilities within one month. Other skilled labors and semi labors will be mobilized subsequently basing on the construction schedule. Some unskilled labors will be recruited locally in KSA.
1.8.3
Equipment and Materials
The mobilizatio mobilization n of the equipment equipment and material materials s will will also be started started early. And the earth work equipment that are carrying out the construction in KSA will be initially mobilized to the site very soon. After obtaining the construction permission and consents, the earth work will be started immediately. immediately. Several ongoingand project Port Dredging and Reclamation project Sea Water System project JEC like City JEC Commercial Port project are just located in the same area, ，
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which whic h is an ob obvi viou ous s adva advant ntag age e for for our our comp compan any y to mobi mobili liza zati tion on th the e manp manpow ower er and and equipment soon for this project.
1.8.4 1)
Laydown yards / contractor camps / batch plants
Laydown ya yards Prior to the mobilization of the survey team, the task force will start to set up the Site office on location with the approval by Engineer near the Site. CCCCmaterials will purchase constructloading contractor’s dining rooms, warehouse, storage yard, yard,and temporary wharf,office, and relevant electric, water, sewage, communication communicati on and fire services. The prayer room will be set up for Musalla.
2)
Contr trac acto torr cam camps ps CCCC will use the JEC Port project camp for project management and workman. The big bus and minibus will be used to transport personnel from such accommodation facilities to the construction site. Fence will be set around the site to guarantee the security. Project office will be put in to service within days.
3)
Batch pl plants Concrete will will be supplied from our our concrete batching batching and mixing plant plant located within the JEC Development area, which is about 10Km to the project site. The batch plants will meet the requirement. requirement.
4)
Precast Ya Yard Due to the limited quantity of precast I beam, the I beam will be precast on the same location of the bridge or the adjacent area. And the other precast items will be precasted on our JEC Commercial Port precast yard. The arrangement for the above temporary facilities is shown on the below map.
1.8.5
Sources of potable water, utilities & waste disposal
The po potab table le water water supply supply will will be do done ne by local local suppl supplier ier;; po power wer suppl supply y shall shall be from from generator. The fill materials will take from borrow pit and waste debris will be transported to the area Saudi Aramco approval. A temporary access road will be built with flexible aggregate pavement to fulfill hauling requirement. Access and egress to the project site A temporary access road will be built with flexible aggregate pavement to fulfill hauling requirement.
1.8.6
1.9 Demobilization The Equipment Equipment and some Personnel Personnel will be demobili demobilized zed accordin according g to the Construc Construction tion Schedule when phased Completion requirements are met and Works are accepted by the Engineer or SAUDI ARAMCO. 1.10
Project Closeout Phase
The tasks in this t his phase include:
Preparation of as-built documents; Settlement of project variation requests; Site clearance.
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2. Pr Proc ocur urem emen entt P Pro rogr gram am Please refer to Attachment 1 “Procuremen “Procurementt Program”.
3. Co Cons nstr truc ucti tion on Me Meth thod ods s 3.1 Survey In this project, electronic total station, level instrument, GPS will be used for survey control, setting out and displacement monitoring.
3.1.1
Survey Instrument
S.N.
INSTRUMENT
MODEL
ORGIN
PRECISION
QTY.
1
Electronic Station
Leica TCR1201+
Switzerland
1″
2
2
Leveling instrument
Topcon AT-G2
Japan
2mm
8
3
GPS base station
Trimble 5800
U.S.A.
5mm+1ppm
2
4
GPS station
Trimble 5800
U.S.A.
5mm+1ppm
2
Total
movement
Establishment of Survey Control Points Surv Survey ey Prep Prepar arat atio ion n
3.1.2 1)
All the survey equipment equipment proposed to be used in this project will be calibrated prior to survey sur vey work, work, and calib calibrat ratio ion n certif certifica icates tes will will be submit submitted ted to Clien Clientt for ap appro proval val.. Coordinate with Client to obtain original survey data, design drawing and other related documents and data. 2)
Survey Survey Control Control Points Points Confi Confirmat rmation ion and Verifica Verification tion The name, coordinates, elevation of the control points provided by Client should be site turnover to contractor. The stability, visibility etc. of provided points should be verified, and accordingly the points that can be used for survey control network will be selected.
3)
Hori Horizo zont ntal al Cont Contro roll The survey control network provided by Client will be calibrated and calibration results are to be submitted to Engineer for approval. Once the submitted results are approved, the co contr ntract actor’ or’s s survey survey ne netwo twork rk can be estab establi lishe shed. d. Verifi Verificat catio ion n method method to Clien Clientt provided control points is as flowing: Use static survey to conduct site survey and compare the survey results with the value required in project specification and other acceptable standards.
4)
Elev eva ati tio on Con Control trol Verify the Client provided elevation by using the method specified in project specification specification and other acceptable standard, and then reflect the elevation to construction area.
3.1.3
Establishment of Construction Survey Control Network
Base on the Client provided control points and construction requirement; the verified points will be used to establish GPS static network. The calculated accuracy should satisfy project specification and related standard requirement. Trimble 5800Business GPS will Center be used static survey andofthe survey data shall be processed with Trimble tofor obtain coordinates each point.
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Elevation Control Network: According to Client provided elevation, the accurate point should be selected to compose annexed traverse that satisfying project specification an and d rel relate ated d stand standard ards s requir requirem ement ent an and d then then survey survey will will be starte started. d. The metho method d specified in project specification and related standards will be used for establishing elevation control network. Surveying route shall be circuited route and then take the average value. On the compl completi etion on of est establ ablish ishmen mentt of horizo horizonta ntall and elevat elevation ion contro controll netwo network, rk, veri verifi fica cati tion on shal shalll be cond conduc ucte ted d by surv survey eyor ors s to ensu ensure re it meet meets s spec specif ific icat atio ion n requirement, requireme nt, and then survey report and survey data shall be submitted to Engineer and Client for approval. All the data can be used only until approved by Engineer or Client. The reference station shall be set up upon the submitted survey report is approved, and then the GPS-RTK dynamic survey points verification shall be conducted to obtain the factor for coordinates conversion in the area required to be surveyed. The obtained factor shall be saved in GPS and computer and to be utilized as the guidance for setting out. Survey control network shall be regularly verified, in case verified results does not meet proje pro ject ct specif specifica icatio tion n or rel relate ated d standa standard rd requi requirem rement ent,, and it shall shall be report reported ed to Engineer and Client immediately.
3.1.4
Setting Out
Appropriate survey instruments have to be selected based on project specification and Appropriate related standards requirement, requirement, and then setting out per the data provided in drawings.
3.1.5
Displacement Monitoring
For settle settlemen mentt that that mig might ht occ occur ur durin during g constr construct uctio ion, n, displ displace acemen mentt monit monitori oring ng is requi req uired red.. Genera Generall lly, y, level level will will be use used d for settle settlemen mentt monito monitorin ring g an and d total total statio station n equipmentt for displacement equipmen displacement monitoring. 3.2 Site Clearance Work
3.2.1
General Description
This work mainly includes cleaning and dismantling all original weeds, surface floating soil, signs and building boundaries within the scope of the project.
3.2.2
Construction Process
3.2.3
Construction Methods
1)
Cons Constr truc ucti tion on Prep Prepar arat atio ion n Land acquisition, demolition and pipeline relocation will be completed with the approval of the local government and the owner's engineers. There should be safety warning signs, roadblocks and safety enclosures to protect the public and on-site personnel. Joint investigation with the owner's engineer and surveyor should be conducted on site to measure the underground structures, and the plan to remain or remove the structures
Page 10 of 54
shall be approved by the Engineer. A deep pit should be excavated before removing the underground undergrou nd structures. Protect the structures, pipelines and etc. that need to be protected. 2)
Cl Clea eani ning ng an and d Exca Excava vati tion on According to the design requirements, requirements, the surface plants, roots, rot plants and other construction wastes shall be removed.
Remove garbage
Remove surface soil
3.3 Excavation and Backfilling
3.3.1
Preparation Works
1)
Selec Selectt approp appropria riate te source source and storag storage e yard yard (pref (prefera erabl bly y the area area where where the surface surface cleaning has been accepted.
2)
After the the completi completion on of inspectio inspection n and accepta acceptance nce on surface surface cleani cleaning, ng, the ground ground shall shall be leveled and the steps shall be dug in the undulating section.
3)
Accordin According g to the characteris characteristics tics of the project project and and the work efficien efficiency, cy, select select appropri appropriate ate equipmen equi pmentt model model and quantity shall be determin determined, ed, and the mobiliza mobilization tion plan plan and rel relate ated d in infor format matio ion n especi especiall ally y the da data ta of the operat operators ors and eq equip uipmen mentt shall shall be prepared.
Determination Determinati on of filling materials: According to the actual situation on site, the source of the filling materials shall be chosen cho sen nearby nearby,, borrow borrow ea earth rth or reusab reusable le mater materia ials ls shall shall be used. used. The fil filli ling ng materials should meet the requirements stated in the specifications and classified according to the specification specifications. s.
Standard compaction test: After the roadbed fill is mixed, the fill should be sampled under the witness of the consultant. The soil sample shall be sent to the site lab for standard compaction tests to determine the maximum dry density at the optimum moisture content. The op opti timu mum m mois moistu ture re cont conten entt K and and maxi maximu mum m dry dry dens densit ity y MDD MDD of th the e fi fill ll are are determined by experiments.
3.3.2 1)
Backfilling Works
General The amount of ramp foundation f oundation fillin filling g in this t his project.
2)
Cons Constr truc ucti tion on Pro Proce cess ss
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Construcon procedure of roadbed lling
Preparaon
B a c k f il li n g z o n e
s u r v e y
3)
Treatment and inspecon
Construcon
S u r f a c e c le a n
B a c k if ll in g i n l a y e r s
C o m p a c it o n z o n e
L e v e li n g z o n e
P a v in g a n d l e v e li n g
W a t e r in g
C o m p a c it o n
T e s t z o n e
T e s t
in s p e c it o n
T r e a t m e n t a n d
Cons Constr truc ucti tion on Meth Method od In the process of roadbed filling, the principal of "four sections and eight processes" have always been adhered to. The “four sections” are filling area, leveling area, rolling area and inspectio inspection n area; area; “eight “eight pro processe cesses” s” are preparat preparation ion for construct construction, ion, base treatment, layer filling, paving and leveling, drying, rolling compaction, reporting and inspection permit, and roadbed renovation. The layer layer thickn thickness ess of the emb embank ankme ment nt sh shall all be strict strictly ly contro controll lled ed to en ensur sure e the compactness of each layer bottom; and the compactness shall be controlled to ensure the embankment filling quality and post-construction settlement does not exceed the standard; the road camber shall be controlled to ensure timely discharge of rainwater; as well, the flatness shall be controlled to ensure the embankment being rolled evenl evenly y to prevent flooding when raining.
Filling section The embankment shall be divided into construction sections at every 200m or between two structures and be filled by layers and horizontally with mechanized operation and method of lengthways horizontal filling and compaction along the overall width of the cross-section of the subgrade. The layer thickness shall be strictly controlled according to the technological parameters determined by the test section. When the terrain terrain is undulate, undulate, it shall be filled by layers layers from the lower part part and also filled from two sides to the center to ensure the compactness of the full face of the embankment embankment is uniform. The space between the backfill mounds shall be calculated based on the capacity of the dump truck so that a uniform layer thickness can be controlled during leveling.
Filling thickness The filling work shall be executed by layers from bottom to top; the thickness of each layer shall be marked on the control pile to ensure that the filling thickness is not too high or too low. Before filling filling the upper layer, layer, it is necessary to verify verify that
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the compactness and compaction height of the lower layer meet the requirements and pass the acceptance of the t he Engineer.
Paving and leveling The paving work shall be executed by bulldozers for initial leveling and the land leveler for final leveling to control that the layer surface is flat and the thickness is uniform and ensure ensure the rolling effect. At the time of paving, the drain drainage age slope shall be made according to the design for road surface drainage. While leveling by the bulldozer, roadrolling. shoulder shall be pre-compacted to ensure that the roller is free of landslidethe when
Control the optimal water content For some subgrade that may be filled with soil, the best control water content should be selected. When the water content exceeds the optimum water content, the soil should be properly aired for drying to reduce the water content of the fill. When the water content is lower than the optimum water content, it should be suitably watered.
Testing
3.3.3
Excavation
The quantity of earth excavation of this work is about 36,592m3, mainly concentrated in individual excavation and semi-filled or semi-excavated sections. The excavation shall be executed by excavators or bulldozers. Since the excavation is not deep, firstly after setting out, it shall be carried out based on de desig sign n de depth pth,, dimen dimensio sion n an and d slope slope;; the unqual unqualifi ified ed excava excavated ted mater materia iall shall shall be transported to the spoil area, and the suitable material shall be transported to the nearest backfill storage area for later use.
3.3.4
Transition Construction
The transition section mainly consists of the transition section between the embankment an and d the ab abutm utmen ent, t, and the sectio section n betwe between en the emban embankme kment nt and the ho horiz rizont ontal al structure. The transition section with anchor wall shall be constructed together with the anchor wall. The length of the transition section shall be determined by final design requirements, requireme nts, and the foundation base should meet the technical requirements. 1)
Cons Constr truc ucti tion on meth method od
Cleaning the foundation pit and compacting When the foundation pit is too small, it shall be excavated and cleaned to the re requ quir ired ed si size ze,, then then be comp compac acte ted d the the base base by th the e roll roller er.. Acco Accord rdin ing g to th the e specification, the compaction within a certain range behind the abutment shall be tamped by small hand-pushing vibratory rammer. For the founda foundatio tion n pi pitt with with con concre crete te fillin filling, g, the concre concrete te shall shall be mixed mixed in the concrete batching plant and then be transported by concrete mixer truck to the site
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to be poured by layers and manually vibrated by insert or fflat lat vibrator.
Paving and compacting The transi transitio tion n sectio section n an and d the joint joint emban embankme kment nt shall shall be paved paved and rol rolle led d simult sim ultan aneou eously sly;; the pavin paving g thickn thickness ess and rol rollin ling g passes passes shall shall be contro controll lled ed according to the construction parameters after the test. When it is difficult to use large equipment equipment to roll in the vicinity of the structure, it can be sufficiently tamped by smal sm alll mach machin ine. e. Fo Forr the the corn corner ers, s, elec electri tric c tamp tampin ing g ramm rammer er shal shalll be used used to stren str ength gthen en the the com compac pactio tion nand to specifications. ensure ensure that thans. t the compac compactio tion n qu quali ality ty of the fil fillin ling g section meeting design specificatio
2)
Cons Constr truc ucti tion on pro proce cess ss Transition Construction
Ground leveling and compacon NO
test
YES
Selected material backlling
inverted trapezoidal zone backlling
Embankment backlloing
Compacon in layers
Paving by paver NO
Test and modiy YES
Next step
3.4 Substation
3.4.1
General
The substation mainly consist of base slab, square column, top slab and other facilities. There are 2 base slabs, the length of each base slab is 37.1m and 34.7m, 34. 7m, constr construct uction ion joint joint for bas base e slab slab will will be made made accord accordin ing g to the lat latest est drawing and between 2 base slabs there is a 30mm EXP joint. There are 36
Page 14 of 54
square columns and each square column size is about 0.4m width, 0.6m length and 8.05m high; the same length, the construction joint & EXP joint of the top slab is same to base slab.
3.4.2
Construction Flow Chat
Figure 5.2-1: Construction flow chart of substation
3.4.3
Construction Method
3.4.3.1
Blinding Construction
Firstly, the site engineer will ask the survey to layout the limit and the elevation of the blinding by using the GPS. 5cm*10cm wooden batten will be manually installed as blinding formwork. Concrete used for blinding will be ready mixed concrete, supplied by approved concrete supplier, delivered to construction site by concrete mixer, poured by concrete pump and flattened by manpower. The surface of poured concrete will be smoothened with wooden trowels and then covered by poured geotextile, sprayed with with water for curing (1 day water curing).
Note that before pouring concrete the medicine of prevention termite will be sprayed on the surface of soil base because the construction area is an active termite zone and the substation inside have some wood devices. MTA of the medicine will be submitted to Aramco for approval, then medicine spraying will be implemented by a professional company. 3.4.3.2
Reinforcement Assemble
(1) Base slab slab rebar rebar
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Set out edge lines lines for reinfor reinforcem cement ent assembl assembly y and constru constructio ction n joints joints on casted casted concrete blinding first. Line maker will be provided in order to setting out the work limit. Epoxy rebar will be used for substation. Cutting and processing rebar will be conducted in a steel workshop located in the fabrication yard near batch plant, then finished rebar will be moved to the site by trailer. Distribute rebar and perform rebar wi will ll be assem assembl bled ed ac acco cord rdin ing g to the the ap appr prov oved ed dr draw awin ings gs.. In th thee co cour urse se of rebar rebar assembly, UPVC spacer cushion matched the requirement of the specification will be set at 1.2m interval under the reinforcement net in order to secure the thickness of reinforcement protection layer. The spacer made of UPVC need to be compatible with structure concrete. When fixing the rebar, a small passage made by wood board will be provided for the steel fixer to transport the material manually. “Quincunx” spacing will be adopted to tie rebar tightly by steel wire fully coated with epoxy or another polymer. Reinforcement nets will be supported by holder made of concrete, metal, or plastic. In addition, square column reinforcement shall be embedded before base slab pouring.
Base slab rebar
“Quincunx” spacing
(2) Square column rebar Scaffolding will be performed for the square column rebar. This scaffolding is just an auxiliary device to assist the construction of square column, so it will be finished by CHEC self and checked by Inspector/Superviser with Aramco certification. A simple sketch will be shown below (high of scaffolding will be adjust according to the requirement of site). When using the scaffolding, base slab concrete will be finished first, and the scaffolding will work on the base slab. Before using the scaffolding, scaffolding tag will be hanged on the scaffolding. 1200
1000
1200
400
Figure 5.3-2 Scaffolding plan layout
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400
Figure 5.3-3 Scaffolding section
(3) Top slab & beam rebar Top slab & beam rebar will be supported by the scaffolding which is shown as below sketch. This scaffolding will be designed and implemented by Kaefer Saudi Arabia Company from Aramco GBS. In order to describe the construction method Conveniently and clearly, below sketches have been added to this method statement, but CHEC will construct as per the approved design drawings of scaffolding from Kaefer.
Figure 5.3-4 Top slab support transverse section
Figure 5.3-5 Top slab support longitudinal section
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Figure 5.3-6 Beam support diagram
3.4.3.3
Formwork for the Structure
Scattered wooden formwork will be used to construct the substation. The sequence of formwork installation is different and depended on the position of components. Formwork Formw ork of squa square re column will be installed after rebar fixing is comp completed leted,, but the formwork of the top slab and beams will be installed before fixing rebar because rebar must be fixed on the top of formwork. To install the formwork, a 6 -10m wide working area will be provided in order to satisfy using the crane and other machine. Scattered wooden formwork:
(1) Base slab Use scattered wooden formwork for the substation base slab & walls & top slab. When casting the base slab, the retaining walls will also casting 150-450mm above the base slab (only for the base slab) for the convenient of the retaining wall concrete placement next time.
Concrete block
Figure 5.3-7 Base slab support (1) The sealing rod
The sealing rod
Page 18 of 54
Figure 5.3-8 Base slab support (2)
Figure 5.3-9: Construction joint at the wall
Figure 5.3-10: Scattered wooden formwork
2) Square column
Square column will use the scattered wooden formwork, which is reinforced by the steel pipe. The formwork of square column will be divided in three steps to install. First the formwork install at 0 to 4m high from the base slab, after concrete pouring and the bottom 4m concrete completed; then remove the formwork from bottom 4m to the upper part which is 4 to 7.05m high from the base slab; finally the last 1m square column will besketch. constructed with the beams and the top slab. For details, please refer to below 3) Beams and top slab Formworks for beams and top slab will be made together with top 1m of the square column and cast in one time. At the top of the scattered wooden wooden formwork, a working platform platform which is consist of guardrail, handrail, rail and steel board, will be provided for the masons to cast the concrete safely. At the same time, chamfer will be provided to meet the requirement of relevant or specification. 3.4.3.4
Concrete Pouring
Concrete will be poured in three ways: base slab, square column, top 1m of square column with top slab and beams. Use concrete pump trucks for pouring concrete. Concrete poring sequence please refers to 5.1 Construction sequence. When pouring concrete, a wood board will be provided for the masons to pouring concrete. Use the concrete pump pumping fresh concrete installed into the formwork and use immiscible i mmiscible concrete vibrator to vibrate throughout the entire process of concrete pouring. Attention shall be paid to avoid avoid hitting the formwork especially especially to the steel formwork. When casting concrete, the sequence should be clear that it’s from the corner to the center, and the concrete should be poured layer by layer. Thickness of each layer should not exceed 450mm and pouring time should not be too long for each layer to prevent the cold joint. Methods for pouring concrete:
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Considering mass concrete placement in accordance with ACI 301-10, ACI 304R and Hot Weather concerting requirements; Measures will be taken in place to thermally control the concrete setting, details shown below: a) Rebar and formwork should be fully wet to reduce their temperature before pouring concrete. b) Concrete should be mixed with ice to reduce the concrete temperature while flowing from mixing plant. c) During pouring concrete, we will employ the concept of staged segmental pouring and control the volume of concrete in the unit time. d) Select a suitable period of time for pouring (for example, night) when the weather is cool. Then timely curing should be implemented after finishing pouring. The poured concrete surface will be leveled with leveling rod and smoothened manually by wooden and metallic trowel. Then concrete will be covered with geotextile and sprayed with water. 3.4.3.5
Concrete Curing
The curing of the structural concrete will be in according with the Saudi Aramco Standard SAES-Q-001 Section 10, “Curing”. 1. Base slab Base slab will be cured by water and will be covered with geotextile overlain with plastic sheet. she et. The geotex geotextil tile e shall shall be kept kept wet wet thr throu ougho ghout ut concre concrete te cu curin ring g perio period d to meet meet the requirementt stated in specifications. requiremen specifications. 2. Square column Square column will be cured by curing compound. Spray the approved curing compound directly after concrete finishing and then no more water or curing compound is required during the curing period. 3. Beams and top slab Top slab and beams will be cured same as base slab. For slab construction, attention should be paid to protect the fresh concrete from damage cause by people walking on it. 3.4.3.6
Concrete Coating
The concre concrete te surfac surface e is to be fin finish ished ed as pe perr specif specifica icatio tion n an and d drawi drawings ngs.. All concre concrete te surfaces in direct contact with earth or sea water shall be coated by coating material approved by the Company. 6. Resources According to construction construction method, method, the necessary machinery schedule schedule refers to Table
Page 20 of 54
6-1.
Table 6-1: Machinery schedule
Items
No.
description
Quantity
Remarks
1
Crawler Crane
80t
1
Meet the requirement of site
2 3 4 5 6 7
Air Compressor Concrete Pump Concrete Mixer Roller Grader Tower Light
N/A 25t 10m N/A N/A N/A
1 1 3 1 1 4
Meet t he Meet the Meet the Meet t he Meet the Meet the
requirement requirement requirement requirement requirement requirement
of of of of of of
site site site site site site
According Accordin g to construction construc tion method, m ethod, the necessary nec essary manpower ma npower schedule refers to Table 6-2 below. Table 6-2: Manpower schedule No. 1 2 3 4 5 6 7 8
position site engineer operator foreman
mason
carpenter Steel fixer safety officer QC inspector
Quantity 1 7 1 6 10 8 Not full time Not full time
Remarks
Meet the requirement of site Meet the requirement of site Meet the requirement of site Meet the requirement of site Meet the requirement of site Meet the requirement of site Meet the requirement of site Meet the requirement of site
3.5 MOTOR CONTROL CENTER (MCC)
3.5.1
Locating the MCC
1) MCCs MCCs are designe designed d for use in non-ha non-hazard zardous ous locatio locations. ns. 2) Choose a location location for installation installation that is well well ventilated ventilated and free from excess humidity, dust, and dirt. 3) Protect Protect the enclos enclosure ure from the the entrance entrance of water water or any any moisture. moisture.
3.5.2
Space Requirements Page 21 of 54
1) Install MCCs MCCs in an area with a minimum of of 1500 mm of free space space in front of frontof-board construction. construction. 2) This free free space provid provides es adeq adequate uate room room to remove and and install install units. 3) Provide Provide at least least 13 mm of space betwee between n the back of front-offront-of-boar board d MCCs an and da wall. 4) MCCs MCCs require require a minimum minimum of 724 724 mm from the the top plate plate of the MCC MCC to the neares nearestt obstruction (minimum ceiling height of 3048 mm including base channel). 5) All spacing spacing requir requiremen ementt for LV, MV and MCC shall shall be as per SAES-PSAES-P-116 116..
Figure # CC
3.5.3
MCC Alignment
MCCs will be installed on a smooth, level surface to ensure proper alignment of all sections. An uneven foundation may cause misalignment misalignment of shipping blocks, units, and doors. The surface under an MCC must be of a non-combustible material, unless bottom plates are installed in each vertical section.
3.5.4
Positioning the MCC
1) MCCs are are constructed constructed in shipping blocks of of up to three vertical vertical sections. sections. This allows for ease of handling during transportation and installation. The main horizontal bus of all shipping blocks will be spliced together together at the job site with the use of captive horizontal splice bars.
Page 22 of 54
2) A joining joining hard ware kit is bagged bagged and tied to the right Corner channel of each shipping split. 3) Captive splice bars bars are pre-assembled pre-assembled on the horiz horizontal ontal bus on the left side of each shipping split. 4) To mount mount and splice splice a new MCC section to join factory shipping, shipping, follow these these steps. steps. i.
Re Remo move ve the uppe upperr and and lowe lowerr hori horizo zont ntal al wire wire trou trough gh cover covers s in all all se sect ctio ions ns,, providing access to each section’s front splicing bolts as in figure # DD.
ii ii..
To gain gain acces access s to each each secti section on’s ’s bus bus splic splicing ing prov provisi isions ons;; slide slide the panel panels s of the two-piece bus barriers (see Figure # EE) in the sections adjacent to a splice connection (the left and right sections).
ii iii. i.
Make Make provis provision ions s for fast fasteni ening ng the the struct structure ure(s) (s) tto o the flo floor or and and wall wall..
iv iv..
Suppor Supportin ting g the MCC MCC by its base base cha channe nnels ls and/o and/orr liftin lifting g angle angles s lift lift it into into place. place. The front edges of the base channels must be aligned to form a continuous front in a straight line. Use a chalk line, string or other method to align the front base channels in a straight line.
v.
Usin Using g the the notc notche hes s in th the e base base chan channe nels ls,, ca care refu full lly y mo move ve the the se sect ctio ions ns in to alignmentt with a crowbar (see Figure # FF). alignmen
Fig DD
Fig EE
Base Channel Notches Figure # FF
3.5.5
Joining Corner Channels:
1) The hardware hardware kit for joining joining sections sections (as in below Figure Figure # GG) is is bagged and tied to the right front corner channel of each shipping split.
Page 23 of 54
Figure # GG
2) Locate the four half-circle half-circle shaped shaped notches notches on the the inside inside surface of the corner corner channels (as in figure below Figure # HH). Hal Circle shaped notch
Figure # HH
3) Using four of the 3/4 3/4 in. x 1/4-20 hex hex head thread-forming thread-forming screws screws supplied supplied in the hardware kit, join the front vertical corner channels by inserting the screws through the clearance holes located within the half-circle shaped notches and into the mating thread-forming thread-formin g hole (as in figure below # II).
Figure # II 4) Tighten Tighten the the screw screws s (see (see in figure figure # JJ).
Page 24 of 54
Figure # JJ
5) Repeat Repeat steps steps 2-4 to conn connect ect the rear rear corner corner chann channels. els.
3.5.6
Joining Section Side Channels
1) Locate two clearance holes for for 1/4-20 hardware on the inside surface surface of the bottom section side channels as in figure # KK & LL. These can be accessed after removal of the bottom wire way cover.
Front Bottom Bottom Side Side Ch Channe annell Connecti Connection on Figure Figure # KK
Rear Botto Bottom m Side Channel Channel C Conne onnection ction Figure Figure # LL
2) Use two of of the four 1-1/4 1-1/4 in. in. x 1/4-20 1/4-20 hex head head thread-for thread-forming ming screws screws.. 3) Locate two clearance holes for for 1/4-20 hardware on the inside surface surface of the top section side channels. The front clearance hole is in the left section and is accessible after removal of the top wire way cover (see in figure # MM).
Top Front Side Channel Connection Figure # MM
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4) The rear clearance hole is in the right section. section. In most most cases, it will be necessary necessary to remove the section back plate or the top plate to gain access to the t he rear clearance hole and install the screw as in figure # NN.
3.5.7
# NN Top Rear Side Channel Connection (Shown with MCC back plates removed.)
Securing Structures to the Floor
Fasten each section to the floor (see in below figure ) using 1/2 in. or 3/4 in., grade 5 or higher, bolts, and flat washers (furnished by customer). 0.88 in. (22 mm) diameter base channel mounting holes provide clearance clearance for bolt expansion expansion anchors for 1/2 in. bolts.
Figure OO: Standard Base Channel Mounting
3.5.8
Securing Structures to Floor-Seismic Hazard1 Designated Locations
Each section must be anchored per detail supplied by engineer of record to the load-bearing path of the building structural system. For floor mounting locations, see Figure 14 (NEMA Type 1, Type 1 Gasket, and Type 12 enclosures) or Figure 16 on page 26 (NEMA Type 3R enclosures). Use 0.50 in. or 0.75 in. grade 5 or higher bolts and Belleville washers. Torque bolts to the value specified by the manufacturer of the anchor.
Page 26 of 54
Figure # PP
3.5.9
Splicing Power Bus
1) Remov Remove e the horizo horizontal ntal wire wa way y cover covers s and slid slide e the horizo horizontal ntal bus b barrier arriers s to gain access to the captive splice connectors as in figure # QQ.
Figure # QQ Horizontal Wire way Covers and Bus Barriers Removed
2) Remov Remove e all fou fourr bolts fr from om the in integra tegrall splic splice e bar Fig Figure ure # RR. 3) Move the s single ingle sp splice lice bar to th the e left and alig align n the two left ho holes les in the sp splice lice bar with the corresponding holes in the horizontal bus on the left section as in figure# SS.
Figure # SS Moving and Aligning the Splice Bar to the Bus Holes
Page 27 of 54
4) Rei Reinst nstall all the four bolt bolts s int into o the hor horizo izonta ntall bus bus on the left and right sect section ions s (see Figure 33). Make sure the original conical washers are reinstalled with the concave side facing the horizontal bus as in figure # TT.
Figure # TT Inserting Splice Bolts in the Left and Right Sections
5) Placi Placing ng a Co Conical nical Wa Washer sher u under nder th the e Bolt head head.. 6) Torque all bolts on b both oth ends to (41.87–43.22 N*m) as in figure below UU.
Figure # UU Torqueing the Bolts
7) Bef Before ore ener energiz gizing ing the eq equip uipme ment, nt, slide the horiz horizont ontal al bus bar barrie riers rs into the closed position and replace all covers. 3.5.10 Ground Bus Splicing To splice the ground bus, follow these steps 1) Remove ground bar bolts from the right and left sections as in figure # VV
Figure VV Ground Splice Bar as Shipped
Page 28 of 54
2) Slide the ground s splice plice bar into the right sec section, tion, aligning the mou mounting nting holes as in figure # WW. 3) Slide the ground s splice plice bar into the right sec section, tion, aligning the mou mounting nting holes as in figure # WW. 4) Repla Replace ce the gro ground und bar bo bolts lts as in figu figure re belo below w in the right a and nd left sec section. tion. 5) Torqu Torque e bo both th bo bolts lts to (6.75 – 8. 8.44 44 N N*M). *M).
Figure # WW Ground Bar Bolt Replaced
3.6 Cable pulling The cabl The cable e shou should ld be insp inspec ecte ted d care carefu full lly y befo before re cons constr truc ucti tion on to conf confir irm m if th the e specifications, specificatio ns, model, section and voltage level are in line with the design requirements, and the appearance is free from distortion and damage. 1. Ensur Ensure e lat latest est IFC copies copies of AG and UG Cabl Cable e routin routing g drawing drawings s are availa availabl ble e prior to commencement cable pulling. 2. Confirm Confirm procedu procedures res are approv approved ed and availab available le to relev relevant ant personne personnel. l. 3. Confirm Confirm adequat adequate e quantities quantities of correct correct size/typ size/type e of cables cables are availabl available e as per IFC documents. 4. Ensu Ensure re all all cabl cables es have have been been pass passed ed QC Mate Materi rial al Rece Receiv ivin ing, g, Cont Contin inui uity ty & Insulation 5. Resi Resista stance nce tests (on-Re (on-Reel el)) an and d Quali Quality ty record records s be been en prepar prepared ed,, pri prior or to cable cable pulling. 6. Ensure Ensure that the area/med area/medium ium of the cables cables to be laid/pul laid/pulled led (i.e., (i.e., conduits/cab conduits/cable le trays) have been completed, inspected and accepted in accordance with the IFC drawings, drawing s, prior to start the cable pulling. 7. Check Check and and ensure ensure that the cable cables s to be install installed ed are of correct correct size, size, type and length and are in conformance with cable list and cable drum Schedule and Project specification specification prior to cut any cable. 8. Ensure Ensure that safety safety barrie barriers rs have been been erected erected where where requi required. red. 9. QC Inspect Inspector or is respon responsib sible le to witne witness ss cable cable pulling pulling and record record results results on the inspection report. 10. Ensure Ensure all cables cables are identifie identified d by temporar temporary y markings markings on both ends just after cutting from reels. 11. Pull Pull cables cables and wires wires into conduits conduits,, usin using g suitable suitable ropes ropes or steel steel wire; this will will
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prevent its loss in the event should pulling be stopped in the middle of the conduit. 12. Care should should be taken not to strain, strain, twist, entangle entangle or undesira undesirably bly stretch the cable. Use an approved pulling compound. Cable pulling & installation activity sh shall all be do done ne in accord accordanc ance e with with the rel releva evant nt check check li lists sts.. Manuf Manufact acture urer1 r1 s specifications specificatio ns also shall be follows. 13. Cable and wires wires must not be spliced into conduit conduit fittings. 14. Leave Leave minimum free length length at all outlets, outlets, junction junction boxes, boxes, and lighting lightings s etc for final connections or as specified in drawings and specifications. 15. Splicin Splicing g of conductors conductors shall be kept to a minimum. minimum. Provide Provide approved approved terminal terminal lugs for terminations. terminations. 16. All cables cables shall be tagged, tagged, at each end and the cable-tags cable-tags with permane permanently ntly marked alphanumeric characters. The cable-tag shall be securely attached to the cable with cable ties. 17. Perform preliminary preliminary meggering of power power cables. After installation those fail failing ing to meet the required resistance as specified in the specification must be removed and replaced. 18. Ensure all the cable cable ends are properly sealed sealed after the testing. 19. Fix cables cables using approved approved cable cable ties. 20. Ensure Ensure that all activitie activities s at desi designat gnated ed areas are completed completed and RFI shall shall be pr prep epar ared ed in acco accord rdan ance ce wi with th the the Proj Projec ectt Qual Qualit ity y Cont Contro roll Pr Proc oced edur ure e and and submitted to the concerned Inspection Unit of Company. 21. Complete inspection inspection record and place in Project Certificatio Certification n dossier.
Cable install lla ation
3.6.1
Pre-installation Activities for Cable Gland Type
Verify / check the cable gland sealing materials as per Aramco / Manufacturer Specifications. Before glanding and sealing the cable, ensure that cables are completely tested, Inspected and accepted and the manufacturer’s instruction shall available at site. Dressed the cable as per required and install the cable gland as per Manufacturer procedure.
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3.6.2 Type
Assembly Instruction for Cable Gland
1) Cable Cable Gland Gland Prepar Preparati ation on i)
Back nut
ii)
Middle nut
iii)
Reversible Ar Armour Clamping Ring (RAC)
iv)
Armour Spigot
v)
Rubber Pot
vi)
Entry (with captive deluge seal)
2) Strip the cable cable to suit equip equipment ment as as shown shown above above and the expose the armour / braid ‘I’ removing all cable fillers. (Os to F implies as per Cable Gland Selection Table in
Page-
11) ‘I’ = 20mm for cable gland sizes Os to A
‘I’ = 25mm for cable gland sizes B to C2
‘I’ = 32mm for cable gland sizes D to F
‘II’ = to suit equipmen equipment, t, if required fit shroud
3) Push the the cable cable throu through gh the the armour armour spigot spigot 4. Spread Spread Armour/braid over over the armour spigot spigot 4 until the en end d of the Armour / braid is up up against the shoulder shoulder of the ar armour mour Cone. Position the armour clamping ring 3.
4) Remove Remove the rubber rubber pot pot 5 from from the entry entry 6, 6, place place the Entry 6 over the armour spigot 4. Move the sub-assembly sub-assembly 1 and 2 up to meet the entry 6.
5) Hol old d the the entr entry y 6 in posi siti tio on wi with a sp spann anner wren rench or Mo Monke key y pli plie er
to prev revent
rota rotati tio on. Hand and titighten ten the the Mid Middle nut 2 onto onto th the e en entry try 6 and tu turn a
fu furt rthe herr ½
to ¾ of a turn with a spanner / wrench.
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6)
Unscrew the middle nut 2 and visually inspect that the
armour /
braid has been successfully clamped between the armour spigot 4 and the armour clamping ring 3 if armour / braid not clamped repeat assembly.
7)
Remov Remove e the the entr entry y6 6,, sprea spread d the the cabl cable e core cores so out ut for the compound packing. Pack the compound between the cores.
3.6.3
Epoxy Compound Preparation
1) When handling handling this this materials, materials, the gloves gloves supplied supplied must must be worn. worn. The epoxy compound is supplied in the form of a two part package, these should be mixed into the ratio of 1:1 until both colours have blended into one, without any streaks. Rolling and folding is the most satisfactory method of obtaining an even blend. 2) Once mixed the compound compound must be used used within 30 minutes, minutes, after this time it will begin to stiffen. The compound shoul should d be kept at an ambient temperature of no less than 200C prior to using, at lower temperatures it becomes difficult to mix. 3) Any Compound Compound come into contact contact with the skin it should should be cleaned cleaned off off with skin skin cleaner and not allowed to dry on the skin. Only compound for immediate termination should be mixed. 4) The mixing mixing and installation of the compound compound at an ambient temperature temperature below 40C 40C is not recommended due to extended curing periods. 5) With all all gaps gaps and voids voids filled filled,, bring bring the conduc conductors tors Back together and pack more compound around the outside of the conductors, tape the conductors together to prevent disturbance of the compound seal, pass the rubber pot 5 over the armour spigot 4 and removed any surplus compound from the top of the rubber pot 5 and joint face as indicated.
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6) Replace the entry 6 over the rubber pot 5 ensuring ensuring that that compound compound does not cover cover the end of rubber pot 5 7) Locate and and hand tighten the sub-assembly sub-assembly 1 and 2 to the entry 6. The conductor conductor must not be moved for a minimum of four hours. 8) Allow Allow the compoun compound d to cure (See (See below below 6.3.10 6.3.10 for curing curing times) times).. Untighten the sub-assembly sub-assembly 1 and 2 from the entry 6 to enable inspection. The rubber pot 5 may be removed for inspection to ensure that the packing is satisfactory, add further compound if necessary. 9) Re-assemble the rubber pot 5 and the entry 6, hand tighten the
sub-
assembly 1 and 2 to the entry 6 and add half a turn with a spanner / wrench. Tighten the back nut 1 to form a seal around the cable, then tighten a further full turn using a wrench / spanner. Ensure that the middle nut 2 does not rotate when tightening the back nut, ensure that deluge seal is pulled down into position. Locate the shroud over the cable gland if applicable. 10) The compound may be adversely adversely affected by some solvent solvent vapours, if such vapours are likely to be present in the
vicinity
of the cable gland in service, suitable precautions may be necessary. The compound cures at a shore D hardness of 85 when it can be handled, the compound when fully cured is suitable for use at a temperature range of -60oC to +80oC. 11) The ‘Os’ and ‘O’ size cable gland gland when used with brai braid d is only suitable for use with fixed apparatus (See the Table) the cable for which must be effectively clamped elsewhere to prevent pulling or twisting, the cable gland has an operating temperature of -60oC to +80oC. A seal must be formed between the equipment and the cable gland to maintain the appropriate degree of protection against ingress of dust, solid objects and water.
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3.6.4
Conduit and Cable Seal Application
1) Using fiber, fiber, make a dam in each conduit hub, hub, leaving leaving a sufficiently sufficiently sized sized pour hole, so that fluid sealing compound compound cannot leak from the sealing chamber. Proceed as follows to pack proper fiber dam. A. Position the conductor conductor forward so they do not impede impede the work. B. Pack fiber fiber into into each condui conduitt hub behind behind the conduc conductors. tors. C. Position Position the conduc conductors tors backwa backward rd and spread spread them apart. apart. D. Pack fiber between and around around the conductors in each conduit hub. E. Pack fiber fiber into into each condui conduitt hub in front front of conductors conductors.. F. Caution: Remove all excess excess fibers fibers from the sealing sealing chamber chamber and and conductors. conductors. The complete dam and conduit stop shall be level. G. If the conduit conduit is a type or size that that has a separate separate work opening, this this should be closed by its cover before pouring the seal. 2) Compound Compound:: Follow Follow these these instruc instruction tion to to apply. apply. A. Use clean mixing mixing container container for every batch. B. The manufacturer’s manufacturer’s specified proportions by volume volume compound compound and clean clean water shall be strictly followed. C. Do not mix more than the quantity quantity that can be poured in 15 minutes after water is added. D. Stir immediat immediately ely and thoroughl thoroughly. y. E. Fill condui conduitt sealin sealing g compound compound to the level level recommen recommended ded by the manufacturer’s manufacturer’ s instructions.
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3) Specif Specific ic Instru Instructi ction ons: s: A. Conduits seal shall only be poured at temperatures temperatures between between 35 – 85 degrees degrees Fahrenheit. B. If a batch has has started started to set, set, do not attempt attempt to thin thin it by adding adding water water or by stirring. C. Discard Discard partial partially ly set materia materiall and take take up fresh fresh batch. batch. D. After pourin pouring, g, immediate immediately ly close the the pouring pouring open opening. ing. E. All poured poured condui conduitt seal fittings fittings shall shall be painte painted d red. 4) Rectif Rectifica icatio tion n if seali sealing ng fail fails s A. Clean the sealing sealing area by removing removing the sealing sealing compound compound which is fails fails secure the cable that it will not be damage. B. Check the inner sealing sealing compound compound that that are poured that that it was was failed if failed failed removed totally the failed sealing compound. C. Apply Apply by sealin sealing g compound compound as pe perr 6.6.2 6.6.2 3.7
3.7.1
UPS SYSTEM ENERGIZATION MATERIAL REQUIREMENTS& CONSTRUCTION PROCEDURES
1) Before the energization, energization, electrical electrical materials materials shall shall conform conform to all applicable applicable requirements, standards standards and specifications prior to release to be used as part of the work. 2) Material shall shall be traceable from manufacturer manufacturer and and supplier supplier through delivery, storage, erection, fabrication, installation, modification and use. 3) Material used used for energization energization shall be suitable suitable for the environment environment where where it was was located.
3.7.2
METHOD OF ENERGIZATION/SEQUENCE OF WORK
1)
The Ene Energi rgizat zatio ion n proc proced edure ure may may be incorp incorpora orated ted iinto nto the the Vendor Vendor’s ’s sta startrt-up up procedure, but activity shall be supervise by a Commissioning Engineer.
2)
Either Either at at ti time me of of and and part part of of in initia itiall startstart- u up p or as sepa separate rate procedur procedure e fol follow lowing ing Vendor start-up, the Scope of Work of final energization is as follows: 2.1)) 2.1
Observ Observe e an and d revie review w Vendor Vendor startstart-up up proced procedure ure..
2.2)
Instruct Instruct instal installer ler to conne connect ct load load banks banks of the size as previ previousl ously y decide decided d by Client.
2.3)
Follow Follow detail detailed ed Scope Scope of Work Work to insure insure a allll power power is is off at all all connec connection tion points points prior to load bank hook up.
2.4)) 2.4
With With UPS UPS runnin running, g, put put load load on UPS UPS via via load load bank bank in steps steps and and obser observe ve UPS UPS performance as load is increased to planned maximum.
2.5)) 2.5
Perfor Perform m the the test test as as deta detail iled ed on on the the Ven Vendor dor proced procedure ure..
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2.6)
Check Check all all UPS UPS input input and output output voltag voltage e and and curren currents ts for for accurac accuracy y with with Vendor Vendor’s ’s calibrated instrument.
2.7)
With battery battery fully fully charged, charged, perform perform a battery battery run down down te test st for for the designed designed run time to verify battery performance performance..
2.8)
Battery Battery shou should ld initi initially ally provide provide run time as purch purchased ased at 80% 80% of of design designed ed load load and will improve performance overtime after start up.
2.9)) 2.9
Take Take DC test test of of batter battery y amp ampera erage ge a and nd volta voltage ge meas measure uremen ments ts every every one one minute to establish an initial performance curve.
2.10)) 2.10
Perform Perform IR scan scan on battery battery to detect detect heat and and any possi possible ble hot hot spots. spots.
2.11)) 2.11
Vendor Vendor start up up procedure procedure should should includ include e the followi following ng at the minimum minimum;; a) b) c) d) e) f)
Test Test of of ala alarm rm functi function ons. s. Operatio Operation n of transfers transfers betwe between en bypass bypass and and inverter. inverter. IR scan scan of UPS UPS compone components nts during during full load load opera operation tion.. Conditi Condition on of room room enviro environmen nmentt at UPS UPS locatio location. n. Check Check of UPS an and d battery battery inpu inputt current current limit if appli applicabl cable e Efficien Efficiency cy measur measuremen ementt of UPS UPS wi with th battery battery fully fully charged charged or (disconnected) g) Inspect Inspect UPS room room for proper proper cleanline cleanliness ss and removal removal of installa installation tion materials by installer. h) Provide Provide final final report to Client Client noting noting any issues issues and recommend recommendation ations. s.
3.8
3.8.1
PROGRA PRO GRAMMABL ABLE ENERGIZATION
LOGI LOGIC C
CONTR ONTROL OLLE LER R
(PLC (PLC))
TEST ESTING ING
AND
Before Starting
1) Checking that all cable connections between the PLC and the plant are complete,
2) 3) 4) 5) 6)
3.8.2
safe, and to the required specification and meeting Project standard. Check that that all the incoming power supply supply matches matches the voltage setting setting for which the the PLC is set. Check Check that all protectiv protective e devices devices are set to their their appropria appropriate te settings. settings. Checking Checking that emergenc emergency y stop button button work. work. Checking that all input/output devices are connected connected to the correct correct input/output input/output points and giving the correct signals. Loadin Loading g and testi testing ng the the softwa software. re. Testing Inputs and Outputs
1) Input devices devices can be manipulated manipulated to give the open and and closed contact conditions conditions and and the corresponding LED on the input module observed. 2) Forcing also can be applied to test inputs and outputs. This involves software, rather than mechanical switching switching On or Off, being used with instructions to turn Off or On Inputs/Outputs.
3.8.3
Testing Software
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1) Most PLC’s PLC’s contain contain some software software checkin checking g program. program. This checks checks through through the installed program and provides a list on a screen or as print out with any errors detected. 2) Testing Testing shall shall be done to a Professi Professional onal Program Programming ming Engine Engineer. er.
3.9
3.9.1
Installation of Pump & Motors Installation Sequence
Installation shall be carried out in the following order.
Foundation
Drawings
Base Line Establishment
Foundation Surface Preparation
Pad For Jack Bolts Installation
Baseplate Levelling
Preliminary Pump to Driver Alignment
Baseplate Grouting
Pump to Driver Alignment
NOTE: IN CASE OF USING NON-SHRINK GROUT, FOLLOW THE INSTRUCTION OF
NON-SHRINK GROUT MANUFACTURER.
3.9.2 1)
Installation Preparation Obtain Obt ain the IFC Drawing Drawings. s. The IFC drawi drawing ng will will be distri distribut buted ed an and d
Page 37 of 54
controlled by Document controller to Site Construction Group and Quality Control personnel. 2)
Chec Check k prop proper er ori orien enta tati tion on mar marki king ng at at the the equi equipm pmen entt i.e. i.e. 0°, 0°, 90°, 90°, 180 180°° & 270° against orientation of IFC drawing.
3)
Arran Arrangem gement ent of lift lifting ing,, hoist hoisting ing,, and and const construc ructio tion n equip equipmen mentt durin during g lift lift..
4)
Revie Review w the the const construc ructio tion n draw drawin ings gs and and chec check k avail availabi abilit lity y of of the the follo followi wing: ng:
Lifting hoisting and construction equipment / tools.
Report of existing foundation and anchor bolts to ensure that they are ready to accept the equipment.
The calibration of measuring tools and gauges will be performed by an approved Aramco calibration shop qualified technician t echnician..
5)
In Insc scri ribe be benc bench h lines lines or benc bench h marks marks,, which which will will be the the refer referen ence ce for for installation,, at a site which will not shift or sink. installation
6)
Check Check that that the the floor floor level level an and d found foundati ation on Pock Pockets ets diame diameter ters so off the the pump pump
7)
floor conform to the requirements shown in “Pump Outline Drawing”. Mar ark k the the pump pump ce cen nter ter lines nes, fou foundati dation on height ght and and fo fou undati datio on bolt olt positions, etc. in accordance with “Pump Outline Drawing”.
8)
For bett tter er ad adh her eren ence ce of grou routing ting mort rta ar, chip hip th the e fo fou undat atio ion n fl flo oor surface except where the base lines are marked off.
9)
The The con concr cret ete e surfa surface ce and and found foundat atio ion n bolt bolt hole holes s shoul should d be clea cleane ned d with with compressed air, and all foreign matter removed
10)
Ensur Ensure e that that prepara preparatio tion n of founda foundatio tion n such as as Pocket Pockets s for Anchor Anchor Bolts Bolts,, Rough and Clean Surface for Grouting, Bench Mark Shifting near the Equip Eq uipme ment nt Instal Installa latio tion, n, These These Items Items checke checked d by civil civil sectio section n an and d released by QC.
3.9.3
Pad for Jack Bolts Installation
1)
For tight tight adhesi adhesion on o off concrete concrete,, clean clean tthe he founda foundation tion bolt holes holes to remove remove oil, oil, water, water, dirt, waste, material, material, etc. If there is oil, oil, paint, dirt, dirt, etc. on the foundation foundation bolts, the adhesion of the foundation bolts and grout to be poured will be poor. Wipe the bolts with a clean cloth or burn off off any oil, paint or similar substance. substance.
2)
Pl Place ace the the pads pads with with grout grout on the the concre concrete te found foundati ation on at the port portion ion o off eac each h jack jack bolts.
3.9.4 1)
Base Plate Leveling After confirmi confirming ng that that the p pump ump d disch ischarge arge direc direction tion is is correct correct accord according ing to the installation installati on marks, determine the centered height of discharge casing using a level
Page 38 of 54
or other tool, and install the Baseplate. Make sure that the distance between between the baseplate and the foundation foundation surface is between 25mm an and d 50mm. 2)
To prevent prevent misali misalignme gnment nt of the found foundation ation bolts bolts with with the baseplate baseplate holes holes durin during g the bolt fixing, fixing, suspend suspend the sole sole plate over the foundation bolt holes and insert the foundation bolts in the sole plate. Wrap several thickness of tape or paper around the bolts where they contact the sole plate hole. This tape to be removed later Fasten the nuts.
3)
The requirem requirements ents of API API 686 chap chapter-5 ter-5,, section section 3.9.4 will be follow follow
4)
Using Using a polys polystyren tyrene e form in place place o off the found foundatio ation n bolt Pockets Pockets frame frame is not not desirable desirabl e because it is difficult to completely completely remove. If such form is used, be very careful not to leave any polystyrene inside the bolt holes.
5)
Using Using oxygen oxygen gas gas or s simil imilar ar method methods s to remove remove remnants remnants by burnin burning g is not desirable because combusted gas will remain and bonding between the foundation concrete and grout will not be satisfactory.
6)
Pour Pour the the grou groutt when when the ambi ambient ent air air tempe temperat rature ure iis s 10℃ or higher. If frozen, the strength of the grout will be degraded.
7)
Inject Inject grout grout in the founda foundation tion bolt bolt holes holes to fix fix the founda foundation tion bolts bolts.. The grout grout should should be poured to a height of the surface of the t he grout foundation foundation to obtain adequate space for setting the pads for alignment of the sole plates. plates.
8)
Moreover Moreover,, the grout grout should should be poure poured d from one one directi direction on so that that air pocke pockets ts are not not formed, and once started, grout pouring should be continuous.
9)
After 7 days days curing curing,, place place a level level gauge gauge on on the upper upper surface. surface.
10) Tight the foundation foundation bolts bolts and adjust adjust the horizontal horizontal level level to within within 0.16 mm per per meter.
3.9.5 1)
3.9.6
Preliminary Pump to Driver Alignment Reverse Reverse rim rim alignm alignment ent method method shall shall be u used sed as as per API 686 686 chapter-7, chapter-7, Annex AnnexureureD, para D.1.
Baseplate Grouting
1)
Set Set the the form formwo work rk aroun around d the the basepl baseplate ate..
2)
Grout Grout the the basep basepla late te up tto o the bottom bottom of of the base basepla plate te
Page 39 of 54
3.9.7 1)
Final Alignment Prior Prior to star startt piping piping final final alig alignme nment nt to the the mac machin hinery ery:: The pi pipin ping g sys system tems s shall shall be hy hydro dro-te -teste sted, d, dri dried ed ou outt an and d all hydrohydro-tes testt bli blind nds s removed.
All permanent supports (fixed, sliding, spring supports and hangers) shall be installed and aligned.
Motor or driver solo run shall be completed and accepted.
2)
After After pipe pipe connect connecting ing reche recheck ck the 8.7 steps steps check check the Pump to Driver Driver Alig Alignme nment, nt, if exceeding the tolerance adjust it.
3)
Connec Connectt the coup couplin ling g and inst install all the the co coup uplin ling g guard. guard.
3.10
Storage of GRE Piping UG & AG
3.10.1 Storing Pipe It is generally advantageous to store pipes on flat fl at timber to facilitate placing and removal of lifting slings around the pipe. When storing pipe directly on the ground, be sure that the area is relatively flat and free of rock and other potentially damaging debris. All pipes should be chocked to prevent rolling in high winds. If It is necessary to stack pipes, it is best to stack on flat timber supports at maximum 6 meter spacing (3 meter for small diameter) with chocks (See Figure 2.4).
Page 40 of 54
Ensure the stack will be stable for conditions such as high winds, un-level storage area or other horizontal loads. 3.10.2 Packaged Loads Pipes 1400mm and smaller in diameter are packaged as a unit. Packages may be handled using a pair of slings as shown in Figure 2.1.
3.10.3 Single Pipes Single pipes must be unloaded and handled separately (one at a time). Use pliable straps, slings or ropes to lift single pipes. Do not use steel cables or chains to lift or transport the pipe. Pipe sections can be lifted with only one support point (Figure 2.2) although two support points placed as in Figure 2.3 make the pipe easier to control. Do not lift pipes by passing a rope through the section end to end.
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3.10.4 Handling of Nested Pipes 1) Propo Propose se to nest vari various ous diam diameter eter pipe pipes s during tra transpo nsportatio rtation. n. Always lif liftt nested bundles using at least two pliable ropes. Always keep nested Pipes on site in the original transporting package only. Stacking of these pipes is not advisable. 2) De-ne De-nesting sting of pip pipes es shou should ld be done car carefully efully at pre al allocat located ed statio station. n. Inside pipe May be removed by lifting it slightly with an inserted padded boom to suspend the section & carefully move it out without damaging the outer pipe.
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Nylon rope–with “C” Clamp Pulling Pipe on Roller Arrangement
“C”- Clamp Arrangement 3.10.5 Package removal and de-nesting Package removal and de-nesting of the inside pipe(s) is best accomplished at a de nesting station. Typically, this consists of three or four fixed cradles to fit the outside diameter of the largest pipe of the bundle. Inside pipes, starting with the smallest size may be removed by lifting slightly with an inserted paddle boom to suspend the section and carefully move it out the bundle without touching the other pipes (Figure 2.7). When weight, length and/or other equipment limitations preclude the use of this meth me thod od,, pr proc oced edur ures es for for slid slidin ing g th the e insi inside de pi pipe pe(s (s)) ou outt of th the e bu bund ndle le wi will ll be recommended for each project. 3.10.6 Transporting Pipe at site. If it is necessary to transport pipes at the job site, support all pipe sections on flat timber spaced on a maximum of 4 meters centers (3 meter for small diameter) with 2 meters maximum overhang. Chock the pipes to maintain stability and separation. Insure no pipes contact other pipes, so vibrations during transport will not cause abrasion (Figure 2.5).Strap pipe to the vehicle over the support points using pliable straps or rope – never use steel cables or chains without adequate padding to protect the pipe from abrasion.
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3.11
Assembly and Installation of GRE Piping UG & AG
3.11.1 General Instruction for Assembly and Installation 1) Chec Checking king d drawin rawings gs (IFC (IFC)) as pe perr lates latestt revi revision. sion. 2) Make sur sure e that all RTR (Fib (Fiberglas erglass) s) pipes fitt fittings ings and sp spool ool asse assemblie mblies s are free from defects prior to installation. 3) All safet safety y permits req required uired ar are e obtain obtained ed and prec precautio aution n must be establish established. ed. 4) The RTR (Fiberglass) pipe shall be kept near and parallel to the excavated trench within the minimum safe distance from the top edge of it. The minimum distance shall be 0.6 from the edge of the excavation.
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1) Initia Initially lly dewa dewatering tering of the tre trench nch shall shall be done by the civi civil. l. During ins installa tallation tion of RTR (Fiberglass) pipes the dewatering shall be done by the mechanical subcontractor if necessary. 2) Before in install stalling ing the pipe pipes s in the trench trench,, the beddin bedding's g's comp compactio action n and its testing shall be done. 3) Pipes shall be lifted b by y crane using 2 fl flexible exible nylon web slings at equal s space. pace. The lifting space shall be minimum 150 mm wide. 4) The elev elevation ation of pi pipe pe bedd bedding ing has to be c check heck a as s per IFC dra drawing wing pri prior or to lying down of pipes. 5) Surve Survey y instru instrument ment sh shall all be use used d to make su sure re that the la laid id pipes d do o not deviate from the established line. Pipe elevation shall be maintained in accordance to IFC plan and isometric drawings. 6) All refere reference nce poi points nts have to be cert certified ified an and d establ established ished fo forr verifica verification. tion. Pipe line shall be in a straight line both horizontal and perpendicular plane. 7) Pipes sh shall all prop properly erly alig align n and fit up as perfec perfectly tly as poss possible. ible. Bes Bestt effort shal shalll exert to eliminate the lateral offset. The maximum permissible lateral offset is 10 mm. 8) Installation of s scaffolding caffolding if necessary s shall hall be d done one as an acces access s to the joint preparation for fit up and external lamination, or for adhesive bonding of big diameter pipe. 9) Reque Request st and notic notice e for closin closing g of roads if neces necessary sary dur during ing RTR (Fib (Fibergla erglass) ss) materials lay down and piping installation shall be done by contractor and approved by safety department. The routing plan shall be made by the contractor safety department. 10)Prior to commence the job activity qualified pipe assembler assembler shall carry out the work. Bounder’s lamination shall be certified by the manufactures installation of piping as per approved procedure and specification.
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3.11.2 Pipe Laying Preparation and Installation I nstallation 1)
Ens Ensure ure tthat hat a allll re relev levant ant d doc ocume uments nts a and nd ma mater terial ial have have b been een a appr pprove oved d by
2)
ARA ARAMCO MCO p prio riorr to co comme mmence ncemen mentt of th the e wo work rk an and d tha thatt the llate atest st re revis vision ions s of IFC drawings, specifications including approved procedure are disseminated to concerned personnel who carry out the work.
3)
Pri Prior or to c comm ommenc encing ing tthe he in insta stalla llatio tion n wor work, k, an any y dam damag age e suc such h as ex exter terior ior scratch mark, impact mark, bulges, projections, blisters, indentation, curvature of pipes, coupling and flanges shall be inspected visually.
4)
Int Intern ernal al in inspe specti ction on s shal halll als also o be pe perfo rforme rmed d to ch check eck for d dama amage ge of iinsi nside de surface, such as scratch or impact marks and to verify drainage of water and removal of foreign materials. Qualification for RTR (Fiberglass) piping Installation personnel shall be trained and qualified in accordance with RTR (Fiberglass) ARAMCO & manufacturer's requirements.
5)
All RT RTR R (Fib (Fiberg erglas lass) s) fit fittin tings gs an and d spo spool ol as asse sembl mblies ies s shal halll be tra transf nsferr erred ed to th the e
6)
working area nearer to the trench. All R RTR TR (F (Fibe ibergla rglass) ss) m mate ateria rials ls sh shall all b be e han handle dled d in ac accor cordan dance ce w with ith tthe he manufacturer's recommendation.
7)
Sto Storag rage e of RT RTR R (Fi (Fiber bergla glass) ss) m mate ateria rials ls ne near ar th the e wor workin king g are area a sh shall all a also lso b be e considered to avoid being contacted with contaminants.
8)
Dam Damage age c comp ompone onents nts s shal halll be ma marke rked d an and d seg segreg regate ated d and s shou hould ld no nott be brought in the vicinity of the working area.
9)
Th The e de depth pth o off the tre trenc nch h sh shall all b be e du dug g de deep ep e enou nough gh tto o pro provid vide e a mi minim nimum um round cover above the top of the pipe and ground bed of at least 150mm in depth below the bottom of the pipe. The width of the trench should be wide enough to allow room for jointing.
10) Tren Trench ch exca excavati vation on and be bedding dding d details etails a and nd proc procedure edure s shall hall be in ac accord cordance ance with SAES-S-070. 11) In stab stable le soil c conditi ondition, on, the tr trench ench e excav xcavation ation s shall hall be m made ade as s shown hown in tthe he below figure. 12) In uns unstable table s soil oil co conditio ndition, n, the tre trench nch wid width th shal shalll be exte extended nded tto o minim minimum um half of pipe diameter at each side.
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13) The tr trench ench b bottom ottom s shall hall be c contin ontinuous uous,, smoo smooth, th, and ffree ree of roc rocks ks and tto o the line and grade shown on the installation drawings. The pipe shall have essentially continuous support and not rest on the joint. For RTR, (Fiberglass) piping, the trench contour shall not cause the joint j oint angular deflection or the pipe bending radius to exceed the manufacture's limit. 14) Unre Unrestrain strained ed ga gasket sket jo joint int pip piping ing mus mustt be join joined ed tog together ether in the tre trench. nch. 15) Adhe Adhesive sive b bonde onded d and rest restraine rained d gask gasket et joint pi piping ping of 25 250 0 mm nom nominal inal pip pipe e size and less may be assembled next to or in the trench. Piping larger than 250 mm nominal pipe size shall be assembled in the trench. 16) Fo Forr trenc trenches hes 2 m deep or less less,, pipe ass assemb embled led ne next xt to the tren trench ch sha shallll not be moved within three pipe lengths of an uncured joint. The pipeline shall be lowe lowere red d into into th the e tre trenc nch h prog progre ress ssiv ivel ely y to av avoi oid d ex exce cess ssiv ive e jo join intt an angu gula lar r deflection. 17)) Fo 17 Forr tr tren ench ches es dee deepe perr th than an 2 me mete terr pipe pipe sha shall ll be as asse semb mble led d in the tr tren ench ch.. Table 2 – Trench Width SAES-S-070.
18) Aft After er lying the sp spool ools, s, plac place e the sand sandbag bags s besi beside de of pip pipes es to supp support ort from any movement.
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19) Aft After er comp complet leting ing the lay laying ing of the initi initial al spoo spools. ls. Dim Dimens ension ional al chec check k on the trench shall be done to ensure that the pipe length's measurement is correct including its fitting's location and that no interference from the pipe rack foundation existed. 20) Pipe Pipe's 's join jointt port portion ion sh shall all be m made ade pr prior ior to p pipe ipe la laying ying works works.. 21)) This ex 21 exc cava vate ted d port rtio ion n on th the e tr tre enc nch h will will be th the e wor orki king ng ar are ea of th the e lamina lam inator tors s dur during ing joi jointi nting ng of big dia diame meter ter pip pipe e lam lamina inatio tion n or adh adhesi esivevebonding activity. 22) Cran Crane e shall b be e used fo forr big siz size e of pipe la laying ying ac activitie tivities s in the wo working rking p place. lace. Therefore the pipes can be lowered only on the vacant or open area. 23) In this s situat ituation, ion, rol rollers lers o orr carts s shall hall be used to facil facilitate itate th the e layin laying g down o of f the pipes in their respective locations. 24) Plac Place e the ro rollers llers o orr carts o on n the tre trench. nch. M Make ake s sure ure tha thatt the ver vertical tical c center enter o of f the pipe and the roller/cart is identical. After checking the position of the rollers/carts, gently place the pipe on it. 25) Pul Pulll the pipe wit with h the use of a chai chain n bloc block k or lever bl block ock un until til it rea reache ches s the location.
3.12
TESTING
3.12.1 General Guidelines 1)
Under Undergro ground und p pipi iping ng shall shall be be pa parti rtiall ally y backfi backfill lled ed with with all all joints joints expo exposed sed durin during g the hydro test. The exposed joints shall be shaded from direct sunlight, and the hydro test shall be performed so that the t he temperature of the piping material or the temperature of the test water does not exceed 40°C during the test period.
2)
If the the test test wate waterr is not not avail availabl able e at or or be below low 40 40°C °C,, the resu resulti lting ng hyd hydros rostat tatic ic tes testt pressure shall be calculated at the available test water temperature in accordance with the respective ASTM standards.
3)
It shou should ld be be noted noted,, that that varia variatio tion n of temper temperatu ature re of of the the wate waterr with with in the pi pipe pe could affect the pressure significantly. As per the manufacturer's specifications, any change (increase / decrease) in water temperature by amount of 5.5°C can cause a change in pressure (increase / decrease) by an amount of 275Kpa (2.75 bar).
4)
Hydr Hydros osta tati tic c test testin ing g flu fluid ids s shal shalll be be as foll follow ows: s:
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5)
Potabl Potable e water water (drin (drinkin king g water water an and d raw raw wate water) r) pip piping ing system system shall shall be be hydro hydro tested with fresh potable water
6)
Other Other util utility ity pipin piping g sha shall ll be be hydro hydro tested tested with with pota potable ble water water,, wel welll water water or sea sea water.
7)
No ther thermop mopla lasti stic c pipi piping ng shal shalll be pres pressur surize ized d until until itit has has cured cured for 24 24 hours hours at a surface temperature of 10°C or higher or 48 hours at a surface temperature
8)
below 10°C. No adh adhesi esiveve-bon bonde ded d RTR RTR (Fibe (Fibergl rglass ass)) pipin piping g shall shall be pres pressu suriz rized ed unti untill it has has cured in accordance with manufacturer's instructions. instructions.
9)
Upon Upon comp comple letio tion n of insta installa llatio tion n of piping piping system system,, part part of of inspe inspecti ction on requ request est shall be raised by the construction crew for punch list.
10)
Test package package to be be prepa prepared red and submitted submitted for approval approval for the the partic particular ular portion of line including all documents such as P&ID, IFC, drawing, hand over report from civil, daily fit layer inspection report, installation check list, field inspection record, deflection record, punch list and pressure test record.
11)
Upon Upon the syste system m or part of system system is clear cleared ed from from punch punch list list items items and and have have clearance for testing, a hydro test pack for the loop or section to be tested
12)
shall be submitted to company for approval. All hi high gh po point ints s sha shall ll be provi provided ded with with vent vents. s.
13)
If the the line line does does not include include flanges flanges and end caps, caps, it will will be necessar necessary y to connect temporary flanges and end caps or testing purpose.
14)
The sectio sectional nal pipin piping g to be be tes tested ted shoul should d be partiall partially y backfill backfilled ed inclu including ding pipe pipe to fitting joints to ensure a proper support. All filled joints shall be left fully exposed for inspection during the test.
15)
Remove Remove the the connect connecting ing instru instrument ment if any any such such as valve, valve, bellow bellow,, strai strainer, ner, flow meter and others where the blind flange is to be connected to the RTR (Fiberglass)) or Thermoplastic (CPVC) flange. (Fiberglass
16)
Clean Clean the face face of fla flang nges, es, bli blind nd fla flange nges s and and gaske gaskets. ts.
17)
All temporar temporary y gaskets gaskets,, nuts, nuts, washe washers rs and and bolts bolts used used for hydro hydro test shall shall be replaced as per specification after final hydro test.
18)
Install Install the the manufa manufacture cturer's r's gaske gaskett or "O"-ri "O"-ring ng gaske gaskett and blind blind flanges flanges includin including g bolts, nuts and washers to its appropriate location.
19)
Require Required d temporar temporary y piping piping a arrang rrangemen ements ts like like blind blind flang flanges es and and dummy dummy spool spools s will be installed in appropriate location.
20)
Test Test manifo manifold lds s are to be be tested tested to the the sp speci ecifie fied d system system test test press pressure ure requirements.
21)
Pressure Pressure gauges gauges with with appro appropria priate te ranges, ranges, such that the the test test pressu pressure re is is within within 30 - 80 % of the full range of the gauges.
22)
A minimu minimum m of two pres pressur sure e gauge gauges s (one (one at the the view view of the the pressu pressuriz rizin ing g equipmentt operator and the other at the high point also in the view of the equipmen
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operator, if possible, otherwise in view of a designated signal man) shall be used per test. 23)
Piping Piping sectio section n to be Hydro Hydro-tes -tested ted shall shall be fill filled ed from from the lowest lowest point point if possible. Vents or other high point connections shall be opened to expel air from the line prior to t o filling commencement.
24)
All valve valves s in the te test st sy system stem shall shall be in the the fully fully open open positi position. on. Vents Vents shall shall be closed only when clear water with no air bubbles comes through the vent. All air shall be removed from the piping system by venting before hydrostatic test pressure is applied.
25)
After After clo closin sing g all all vents vents the wate waterr fill filling ing will will b be e stopp stopped. ed.
26)
The pressure pressure test shall shall be maintain maintained ed for for a maximum maximum of requir required ed time time for for Thermoplastic Thermoplas tic (CPVC) pipes, while the joints are inspected for leakage. If for justifiable safety safety reasons the line line must be back-fil back-filled, led, the joints joints shall remain exposed during testing, otherwise the test shall be recorded test. Do not pressurize the CPVC pipes, until the responsible engineer is present to witness the test.
27)
For RTR (Fibergl (Fiberglass) ass) pipes pipes th the e test test press pressure ure shall shall be maintain maintained ed for for a minimum period of time. The test pressure and holding time will be decided with reference to SAES-B-017, SAES-A-004.
3.12.2 Visual Inspection 1) 2) 3) 4)
All All la lami mina nati tion on w wor orks ks a and nd a adh dhes esiv ive e bo bond nded ed jjoi oint nt sha shall ll be vi visu sual ally ly inspected. Allo Allowa wabl ble e def defec ectt is ap appl plie ied d to sma small ll lo loca cali lize zed d are areas as an and d sha shall ll not be averaged over larger areas. All All la lami mina nate ted d jo join ints ts s sha hall ll b be e co comp mple lete tely ly c cur ured ed p pri rior or to ttes estin ting. g. Testing shall be wit itn ness and approved by contractor and company.
3.12.3 Preparation Prior to Hydrostatic Test 1)
All jo joint ints s shal shalll be expose exposed d for for visua visuall inspe inspecti ction on of of leaks leaks..
2)
All tes testin ting g equipm equipment ent’s ’s to be inst instal alled led s sha hall ll be che checke cked, d, verif verified ied and and have have obtained the required certificates. SAES- S-070 Para. 18.5 & Para. 18.6 shall be used as reference.
3)
This This Method Method of stat stateme ement nt for for Hydros Hydrostat tatic ic te testi sting ng shall shall be be availa available ble with with full full understanding understandi ng to the test team.
4)
Each Each branch branch shal shalll have have an allo allowan wance ce to mo move ve freel freely, y, withi within n limits limits duri during ng the the hydrostatic test.
5)
Check Check tha thatt the vent vent valv valves es shal shalll be full fully y open open and and drain drain valve valves s closed closed..
6)
All fla flang nges es are are tig tighte htened ned to the the spe specif cified ied torque torque sequen sequence. ce.
7)
An inter internal nal w wal alk k throug through h inspec inspectio tion n of the bac backfi kfill lled ed pipi piping ng was was done. done.
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8)
Upon Upon the the verifi verificat cation ion of of the inspe inspecto ctors, rs, when when the the findi finding ngs s are all all judge judged, d, acceptable and recorded, manhole covers/openings shall be closed.
9)
All safety signboards signboards and precautions precautions are established established.
3.12.4 Water Filling and Pressurizing 1) 2) 3) 4) 5) 6) 7) 8)
9) 10) 11) 12) 13)
14)
15)
Beg Begin in th the e wa water ter filling filling thr throug ough h a ttemp empora orary ry pr press essure ure hos hose e an and d pump at the lowest point. Pum Pump p ca capa pacit city y sh shall all b be e ch chose osen n ac accor cordin ding g to tthe he pip pipe e di diame ameter ter a and nd linear length. Wa Water ter fill filling ing sha shallll c comp omplet lete e af after ter the wat water er is c comp omplet letely ely (no bubbles) coming out in the highest point of the open vent valve. Sto Stop p th the e wa water ter pum pump p an and d ch check eck the fla flange nges, s, va valve lves, s, jo joint ints s an and d connected accessories for any leakage Wh Whil ile ek kee eep ping ing tthe he ven entt o ope pen n. Whe When n no sig sign n of lea leakag kage e on fitt fitting ings s an and d jo joint ints s are pres present ent dur during ing the visual inspection proceed with pressurizing the system. Sta Start rt pre press ssuri urizin zing g tthe he sys system tem thr throug ough hp pres ressur sure ep pump ump.. Onc Once e th the e wa water ter com comes es o out ut iin n th the e hi highe ghest st p poin ointt ve vent nt v valv alve, e, c clos lose e it. Place the pressure gauge onto the vent valve and fully open it again. Pre Pressu ssure re g gage ages s sh shall all b be e in insta stalle lled d on tthe he h high ighest est and low lowest est poi point nt of the system. Safety valve shall be likewise installed and open. The p pressu ressure re in increme crement nt sh shall all be maint maintained ained at 0. 0.5Bar/ 5Bar/10 10 minutes. Any u unusu nusual al sha shallll be im immedia mediately tely re reporte ported d to th the e team lleader eader.. Unles Unless s the there re are no fin finding dings s whi which ch pr preven eventt the test from continuing, the system shall be further pressurized. Shou Should ld be tthere here n no o unu unusual sual o orr findi findings ngs to prev prevent ent th the e test ffrom rom continuing, the system shall be pressurized to the required test pressure. For R RTR TR (Fi (Fibergl berglass) ass) p pipes ipes tthe he tes testt pres pressure sure s shoul hould d not e excee xceed d 1.5 times of the work pressure. For fire water, main network shall be hydraulically tested with a condition of 1.5 times of design pressure in accordance with the requirement of ASME B31.3. The te test st sha shallll be co conside nsiderr pass if ther there e is no decr decrease ease in pressure, no leakage or water traces in the vicinity in laminated joint, adhesive bonded bonded joint, flange joint, pipe or fittings are observed.
3.12.5 Post Hydrostatic Test 1)
Af Afte terr com compl plet etio ion n of the te test st,, slo slowl wly y ope open n the ve vent nt va valv lve e to re rele leas ase e the pressure inside the pipe.
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2) 3)
4) 5) 6)
On Once ce th the e pre press ssur ure e is fu full lly y rel relea ease sed, d, gr grad adua ually lly o ope pen n the dra drain in valve to flush out the filled water from the pipe line. Hy Hydr dros osta tatic tic ttes estt wat water er mu must st be d dis ispo pose sed d of in ac acco cord rdan ance ce wi with th th the e requir req uireme ements nts of SAE SAEP-3 P-327, 27, SAE SAES-A S-A-10 -103. 3. (Re (Refer fer SAE SAES-A S-A-00 -007 7 Para. 9.1.) Ven entt val valve ves s sh shal alll be re rema main ined ed o ope pen n un until til a all ll wate waterr in th the e pi pipi ping ng system is drained out to prevent vacuum. Wh When en tthe he ffill illed ed w wat ater er is c com ompl plet etel ely y flu flush shed ed o out ut,, pre prepa pare re to remove the end cap or temporary flange as per standard procedure. Wat ater er sh shal alll be com compl plet etel ely y flu flush shed ed ou outt fro from m the pi pipe pe li line ne af afte terr th the e hydro static testing.
3.12.6 Backfilling 1)
Upo Upon nc comp omplet letion ion/ac /accep ceptan tance ce of p pipe ipe tes testt pr press essure ure and a afte fterr drying of line, conduct housekeeping properly and submit for inspection prior to backfilling. Start backfilling using an approved material and backfill following the project specification SAES-A- 114.
2)
Bac Backfi kfillll d deta etails ils a and nd p proc rocedu edure re s shal halll be in a acco ccorda rdance nce wit with h SAES-S-070 Para. 21. Unless prevailing conditions or regulations require full backfilling of the pipe prior to the hydrostatic test, underground piping shall be partially backfilled with all the joints exposed during the hydro test. The exposed joints shall be shaded from direct sunlight.
3.13
Installation of uPVC Drainage Pipe & Fittings
Perform the piping work as per following sequence: seque nce:
Highlighted coordinated drawings for selected pipeline are studied. All the material is shifted to appropriate location. Support marking is done at the location as per the drawing. Enough safety care like safety belts, eye protection is taken in case of work at the heights. Drilling of suitable size is done to fix the rawel bolt. Anchor bolts / raw bolts are fixed and threaded rod of suitable length is fixed. Specified clamps are fitted in the threaded rod. Straight Pipes, cleaned from inside, with fittings are inserted and the properly clamped. Pipeline thus erected are plugged from both ends at the end of the day work. Check request is made for the same and consultants approval taken. Pipes are painted with red oxide except joints. The straight portions are insulated as per specification and the remaining pipeline is released for the pressure testing. After pressure testing the joints are painted with red oxide.
I nstallation 3.13.1 External Drainage Pipe Installation
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Before start of the work, make sure that, all the HSE measures have been taken and obtain all the necessary PPEs.
Mark the drainage pipe route with lime powder for excavation of trench as per the approved drawings. Check the trench bottom level with leveling instrument to match the invert level of the pipe line as per the approved drawings. Provide concrete base with required gradient for a firm base for pipe installation. Install the pipe between the manholes as per the specification and approved drawings. Provide head vent on the first or starting Manhole. Make sure that the maximum distance between manholes should be only 25 to 30mtrs. Check the invert level of the pipes after installation. Make proper supports after the installation and checking of the level. After the checking the level of the installed pipes arrange for testing. Fix 2 No’s of 90 deg bends on both the ends of the pipe line and fix about 3 meter height vertical pipe. Fill the pipe line with water up to the height of 3 metre. Check the pipe joints for any leakage. If found any leakage repair it. Make inspection request for Consultant/ client approval.
3.13.2 Internal Drainage Pipe Installation Before start of the work, make sure that, all the HSE measures have been taken and obtain all the necessary PPEs.
Obtain clearance from the civil contractor for installation of Pipes. Remove the sleeve box provided in slab / wall for opening. Mark the pipe route as per the approved drawings. Fix the brackets / supports / clamps as per the specification with proper intervals with required gradient for a proper slope. Fix an approved quality Floor trap for waste drainage system with pipes and required fittings as per the approved drawing and connect to the Gully trap. Fix a 90 deg Bend for soil drainage system with pipes and fittings and connect it to a nearest manhole. Fix the uPVC waste lines from the wash basin, bath tub and bidet and connect to the floor trap with boss connector. Provide cleanouts at every 20mtr and every turning point. Provide Vent pipe for each system. Fix flexible connectors on the building expansion joints. Fill water for leakage test of all the drainage pipes. If found any leakage repair it. Make inspection request for Consultant/ client approval.
3.13.3 Vertical Drainage Pipe Installation Before start of the work, make sure that, all the HSE measures have been taken and obtain all the necessary PPEs.
Obtain the Civil clearance from the main Contractor for the shafts/ducts where the piping works to be carried out. Inspect the shafts/ ducts for wall plastering & water proof treatment etc. if any Mark the pipe location as per the approved coordinated shop drawing.
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Fix the supports/brackets in proper intervals as per the standard with approved quality materials. Install the vertical Soil pipes with “T” or “Y” provision for Water closet branch connection from Toilets Install the vertical Waste pipes with “T” or “Y” provision for Waste pipe branch connection from Kitchen / Baths Rooms & Traps. Terminate the vertical stack 1 meter above the parapet wall and install vent cowl on the top. Check with plumb level for Verticality of the pipes after installation. Make the supports rigid after checking of the Plumb level. Connect the branch lines to the Vertical stack. Provide cleanout points at 1.20 meter height from the finish floor level. Close all the branch lines for Smoke/Water leak test up to 2 levels or 6 meter height. Fill the pipe line with Water or Smoke. Inspect the joints for any visible leakage or with soap water. If found any leakage repair it. Make inspection request for Consultant/ client approval.
4. Test esting ing,, Com Commis missio sionin ning g and Close Closeout out/Ha /Hando ndover ver CCCC will develop and issue to Company Representative Commissioning data packages inclusive, without limitation to: Electrical devices and Equipment, Mechanical devices and eq equip uipme ment, nt,without instru instrumen ments ts an and d con troll system sys tems, s, we wet t utilit utilities ies ne netwo tworks rks inclu inclusiv sive eholes/ of all its elements limitation to contro pipelines networks/ manholes/ chambers/ hand gate valves/ joints & fittings and valves), traffic signalized Ducts system, MV and LV network inclusive without limitations to (substations and transformers, cabling) … etc. Commissioning Data Packages shall include the following:
Potable Water Network
Sewerage Network
Irrigation Network
Storm Network
Firefighting Network and fire Extinguishers
Surge Protection Bladder Vessels
Potable Water Storage Tanks Chlorination Packages
Odor Control Units
Pumping System
Fire Protection Equipment System
Plumbing Sanitary System
Air Balance and and HVAC Equipment, Equipment, Ducts with associated associated Accessories Accessories System
Traffic Signalized Signalized Ducts System System
Potable Pumping Stations
Sewerage Lifting Stations
Irrigation Pumping Stations Sewerage Force Main Line
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Electrical Generators and Complete Genset
Transformers
FAT & SAT for Remote Terminal Terminal Unit (RTU)
Mechanicall Tie-In for Potable Water, Sewerage, Mechanica Sewerage, Irrigation and TSE transmission lines
Unit Substation (13.8/0.4-0.23kV Transformer + LV panel)
13.8kV Ring Main Unit 13.8/0.4-0.23kV 13.8/0.4-0.23k V Distribution Distribution transformer
Medium Mediu m Volta Voltage ge Cabl Cables es an and d associ associate ated d access accessori ories es such such as MV termin terminati ation on and Joining Kit Ducts
Low Voltage Cables and associated accessories such as LV termination and Joining Kit Ducts
5. Logi Logistics stics and Inter Interfaces faces betwe between en Proje Project ct P Phase hase Prog Program ram 5.1 Manpower for facilities Around 25 people worked for two months for facilities work, including remove and relocation work. This work start while the mobilization completed, to ensure the main work going on smoothly. 5.2 Interface with other Contractor According to the project organization, an interface department will be set during the project phase, this team will work for cooperation with other contractor and authority. authority. Please refer to EXHIBIT XII - Interface Management Plan. Plan.
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