009-METHOD STATEMENT - MAIN ERECTION SEQUENCE FOR ACC.pdf

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Pearl GTL

Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT

_{Contractor Project No :}

₅₈₈₇

Project Document Number: T- 4.250.904 Project Rev.: A Page 2 of 65

Purchase Order Number: _2MH127

Tag/Item Number(s): 1A-2121, 1A-2221, 1A-2321, 1A-2421,

2A-2121, 2A-2221, 2A-2321, 2A-2421

Unit(s): 1-2100, 1-2200, 1-2300, 1-2400,

2-2100, 2-2200, 2-2300, 2-2400

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C2 AIR SEPARATION UNITS CONSTRUCTION

F A 24.11.08 Company Comments Incorporated

(with Preservation) RT UO/MK AG CCI

E A 12.11.08 Company Comments Incorporated

(with PMC) OK UO/MK AG CCI

D A 30.07.08 Company Comments Incorporated OK UO AG CCI

C O 10.04.08 Issued for Company Comments RT EE ZG ICC

B 17.03.08 Issued for Review RT EE ZG IFR

A 21.02.08 Issued for Internal Review RT EE ZG IIR

GAMA Rev.

Project

Rev Date Description

Prepared By Checked By Approved By Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

METHOD STATEMENT - MAIN ERECTION SEQUENCE

for ACC

Contractor

Gama Qatar Co. W. L. L.

Document No.

LOC470

GAM MTS MEC GTL 009 F

Org. Code Doc. Type Disc. Code Geogr. Area Seq. No Rev. No Vendor Code

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T-4.250.904 Rev. A Page 4 of 65

Table of Content

1 PURPOSE _____________________________________________________________________5 2 SCOPE________________________________________________________________________5 3 HSSE _________________________________________________________________________5 4 DEFINITIONS __________________________________________________________________6 5 REFERENCES _________________________________________________________________7 6 RESOURCES _________________________________________________________________20 6.1 Responsibilities ___________________________________________________________________ 20 6.1.1 Site Manager __________________________________________________________________________ 20 6.1.2 Mechanical Erection Manager ___________________________________________________________ 20 6.1.3 Site Engineer __________________________________________________________________________ 20 6.1.4 Site Supervisor (SS) ___________________________________________________________________ 20 6.1.5 Piping Supervisor (PS) _________________________________________________________________ 20 6.1.6 Artisans ______________________________________________________________________________ 20 6.1.7 QA/QC Officer / Inspector _______________________________________________________________ 21

6.2 Equipment & Manpower __________________________________________________________ 21 6.2.1 Equipment ____________________________________________________________________________ 21 6.2.2 Manpower ____________________________________________________________________________ 21 7 METHOD OF EXECUTION _____________________________________________________23 7.1 General _________________________________________________________________________ 23 7.2 Pre-Commencement Works ________________________________________________________ 23 7.2.1 Foundation Seats ______________________________________________________________________ 23 7.2.2 Logistical Materials and Equipment _______________________________________________________ 23 7.2.3 Barricades and safety Sign Boards _______________________________________________________ 23 7.2.4 Positioning and Lifting Equipment ________________________________________________________ 24 7.2.5 Main Erection Sequence ________________________________________________________________ 28 7.2.6 Special Technical Procedures ___________________________________________________________ 40

8 QUALITY ASSURANCE________________________________________________________42

9 ATTACHEMENTS _____________________________________________________________43

9.1 Job Safety Analysis _______________________________________________________________ 43

9.2 Installation of Life Line for Bundles Erection at ACC __________________________________ 43

9.3 Lifting of Fan Deck Plates __________________________________________________________ 43

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T-4.250.904 Rev. A Page 5 of 65

1 PURPOSE

This document describes the methods proposed to be used for the Erection Operations that will be carried out as part of ASU Construction Works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City (RLIC) of Qatar including similar works in TSF Area.

2 SCOPE

This method statement identifies the general steps, arrangements and precautions for the assembly and erection works of one ACC at the following site; FD at C2 area. Since the sites are identical to FD; this method statement shall also apply to other sites as FA, FB, FC and GA, GB, GC, GD at C2 area.

This method statement also defines piping erection of all SPX equipment at the site which is developed for installation of steam condensed piping, extraction, cleaning systems and instrumentation.

ACC consists of four streets with four modules per street with fan units and associated equipment which will be erected on top of the steel structures.

The scope of the ACC starts from the turbine exhaust steam turbine outlet with the main steam duct, which feeds to the Air Cooled Condenser (ACC). The latter is equipped with drain pot that collects the condensate to the condensate tank which is located at module N of street # 4.

The steel structure will be erected at site according to the ACC Construction Manual T-4.121.350, by means of crane and/or certified lifting equipment utilizing equipment specified in section 6.2, with competent personnel.

The works will also include the erection, installation and alignment of equipment above the steel structure as follows: fan screen and stack, motor bridge with drive and blades/impellers, condensate and steam manifolds, bundles (heat exchangers), associated steel structures, pipe works for steam recovery, and other amenities for access and walkways necessary for maintenance.

The sequence of construction by street will be 3,4,2 then 1 taking into consideration to specific requirement on the erection of condensate tank, steam ejectors and associated equipment which will be located with separate steel structure beneath the module N of street 4 (please refer to drawing T-4.149.204).

The sequence of activities will be applicable to other sites.

Scaffolding will be required during the duration of the works. Scaffolding shall be inspected

by HSE before work starts. Periodic scaffolding inspection will be required.

3 HSSE

All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards/codes, and Company and Contractor requirements and instructions.

All personnel will go through Gama, Linde and Company Safety Induction courses as well as other trainings as identified by their supervisor. Please refer Document T-4.219.615 for details.

A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared as per Gama procedure T-4.219.606 and is attached herein. Such JSA addresses the hazards

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T-4.250.904 Rev. A Page 6 of 65 associated with each task within the scope of this Method Statement and introduces the controls that will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks. All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves, double lanyard full body harness) at site at all times as required.

In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all employees are out of danger. The supervision will report this to Contractor Emergency Contact numbers for Company, Contractor and Gama will be posted onsite.

All vehicles and equipment used for the subject work will be inspected and certified as required.

Drivers and operators will be competent and will have attended all required trainings set forth in the project procedures and specifications.

4 DEFINITIONS

Company QSGTL and/or its PMC

Contractor Linde Engineering AG

Subcontractor Gama Qatar Co. W. L. L.

Contract QSGTL Pearl Project – C2 ASU Construction Works

(2MH127)

QCP Quality Control Procedure

ITP Inspection and Test Plan

QA/QC Quality Assurance / Quality Control

HSSE Health, Safety, Security and Environmental

JSA Job Safety Analysis

Street Location of condensers and accessories

SDM Steam Distribution Manifold

CCM Condensate Collecting Manifold

SS Site Supervisor

ACC Air Cooled Condenser

PTW Permit to Work

LP Lifting Plan

RA Risk Assessment

FSI Flawless Start-up Initiative

NDT Non-Destructive Test

TSTI Total Safety Task Instruction

TSTO Total Safety Task Observation

PPE Personnel Protection Equipment

RLIC Ras Laffan Industrial City

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T-4.250.904 Rev. A Page 7 of 65

5 REFERENCES

ASME B 31.3 Process Piping

ASME Sec II; Specification for Welding Rods, Electrodes & Filler Metals

ASME SEC. IX Welding And Brazing Qualification

ASME SEC.V Non Destructive Examination

DEP 34.28.00.31 Technical Specification Steel Structures

DEP 70.10.70.11 Preservation Of Old And New Equipment And Piping Standing Idle

DEP.30.8.60.18 Welding Of Metal (Amendments/Supplements To Api Rp 582

DEP.31.38.01.11 Piping General Requirements

DEP.31.38.01.31 Shop & Field Fabrication Of Steel Piping Amendment T.13.376.796e

T-13.377.360 Flawless Start-Up Initiative (FSI)

T-13.377.438 Specification For Traceability, Alloy Verification And Material Substitution

T-13.377.441 Quality Control Requirement For Welding

T-4.095.303 HSSE Plan Construction

T-4.095.723 General Layout Plan Air Seperation Plants

T-4.116.905 General Arrangement Drawing

T-4.116.909 (C Bundle) Primary Fin Tube Bundle

T-4.116.910 (D Bundle) Secondary Fin Tube Bundle

T-4.116.970 PEFS ACC 03 – Condensate System

T-4.121.193 General Arrangement Condensate Tank

T-4.121.194 Parts list for Condensate Tank

T-4.121.212 Piping Tie-In Drawing And List

T-4.121.213 Piping Layout – Condensate Piping

T-4.121.214 Piping Layout – Air Take Off System

T-4.121.215 Piping Layout – Cleaning System

T-4.121.226 Support Condensate Piping

T-4.121.227 Support Drain Piping

T-4.121.228 Cleaning Water Piping

T-4.121.230 Arrangement Steam Duct

T-4.121.231 Fabrication Main Steam Duct Part 1

T-4.121.232 Fabrication Main Steam Duct Part 02 DN3820

T-4.121.244 Duct Support BN3800 P1

T-4.121.245 Duct Support DN3800 P2 & P3

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T-4.250.904 Rev. A Page 8 of 65

T-4.121.257 (ASM) Fan Units

T-4.121.261 (ASM) Columns and Bracings - Item Id A0080111, Page 4 of 4

T-4.121.262 Parts List Columns and Bracings

T-4.121.264 Parts List Main Steel Truss

T-4.121.265 (ASM) Windwall – Item ID A0080734 (sheet 1 of 4)

T-4.121.266 Part List Windwall (Steelwork)

T-4.121.270 Part List A-Frame

T-4.121.271 Part List Motor Bridge Type 1 – 3

T-4.121.272 (ASM) Motor Bridges Complete Type 1

T-4.121.273 (ASM) Motor Bridges Complete Type 2A

T-4.121.274 (ASM) Motor Bridges Complete Type 2B

T-4.121.275 (ASM) Motor Bridges Complete Type 3

T-4.121.276 (ASM) Motor Bridge Type 3

T-4.121.277 Stair Tower General Arrangement

T-4.121.278 Part List Stair Tower

T-4.121.281 (ASM) Fan Screen Support

T-4.121.282 Parts List (ASM) Fan Screen

T-4.121.284 Escape Routes General Arrangement

T-4.121.287 Condensate Tank Substructure General Arrangements

T-4.121.298A General Instruction For Site Storage And Preservation

T-4.121.304 General Arrangement Condensate Pump

T-4.121.305 General Arrangement Drain Pump

T-4.121.323 Outline Drawing Fan Motor

T-4.121.350 Construction Report: Piping Foundation (D0007603)

T-4.121.350 General Instructions : Preservation of ACC (D0042190)

T-4.121.350 General Instructions for Site Storage and Preservation (D0042191)

T-4.121.350 ACC Construction Manual

T-4.121.357 Piping Class SPX 001

T-4.129.656 Construction Waste Management Plan

T-4.129.850 Accident/Incident/Near Miss Reporting And Investigation

T-4.129.852 Entry Into Confined Space

T-4.129.853 Personal Protective Equipment

T-4.129.854 Risk Assessment

T-4.129.855 Emergency Response

T-4.129.856 Welding And Flame Cutting

T-4.129.857 Road Safety Procedure

T-4.129.859 Lifting Operations

T-4.129.860 Manual Handling

T-4.129.861 Working With Electricity

T-4.129.864 Safe Use Of Compressed Gases

T-4.129.865 Portable Power Tools

T-4.129.866 Use of Grinding Machines And Abrasive Wheels

T-4.129.867 Hand Tools

T-4.129.868 Work At Height – Scaffolding

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T-4.250.904 Rev. A Page 9 of 65

T-4.129.872 Heat Stress Disorder Prevention

T-4.133.661 PEFS ACC 04 - Air Evacuation Unit

T-4.133.662 PEFS ACC 06 - Detail Pump and Fan Motors

T-4.133.665 PEFS ACC 01 - ACC Unit

T-4.133.666 PEFS ACC 02 – Drain System

T-4.133.667 PEFS ACC 05 Cleaning System

T-4.133.970 PEFS Acc 03 – Condensate System

T-4.149.204 General Layout Plan ASU

T-4.149.213 Duct Support BN3800 P1

T-4.149.274 Arrangement Connecting Turbine

T-4.149.277 Support Fabrication DN3800 Type QAR 01

T-4.149.295 Evacuation And Condensate Piping Details

T-4.184.595 Land Road Transport HSSE Case

T-4.184.826 Motor – Storage Procedure

T-4.186.019 Flawless Start Up Initiative

T-4.193.137 Packing And Preservation – Bundles

T-4.193.139 Fin Tube Bundle Name Plate

T-4.193.298 Packing and Preservation Procedure Fan Stack

T-4.193.303 Protection Cage for ACC Handrail Axis A1

T-4.193.304 Protection Cage for ACC Handrail Axis A5

T-4.193.320 Structural Steelwork Erection Tolerances & Torques

T-4.193.323 Relieve Valve Preservation

T-4.193.324 Pipe work Preservation

T-4.193.325 Instrument Preservation

T-4.193.326 Cleaning System For Bundles

T-4.198.504 Condensate Collecting Manifold, Sheet 1 of 2

T-4.198.505 Condensate Collecting Manifold, Sheet 2 of 2

T-4.198.506 Parts List Fabrication Steam Duct

T-4.198.509 Manhole DN 600 / 150 Lbs Horizontal

T-4.198.510 Manhole DN 600 / 150 Lbs Vertical

T-4.200.135 Gear Box – Electrical Connection Diagram

T-4.200.144 Operation And Maintenance Manual – Coupling

T-4.200.145 Operation And Maintenance Manual – Gear Unit Including Attachment

Parts And Lubrication List

T-4.200.146 Gearbox – Outline Drawing

T-4.200.152 Gear box - Procedure Preservation

T-4.200.159 Stair tower Main Structure Part 01

T-4.200.160 Stair tower Main Structure Part 02

T-4.200.163 Stair tower Staircase Type 2a

T-4.200.164 Stair tower Staircase Type 2b

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T-4.250.904 Rev. A Page 10 of 65

T-4.200.179 Escape Routes Ladders LD1 LD4 Fabrication Details

T-4.200.180 Escape Routes Ladders LD2 LD3 Fabrication Details

T-4.200.182 Escape Routes Platforms Fabrication Details Part 01

T-4.200.183 Escape Routes Platforms Fabrication Details Part 02

T-4.200.184 Escape Routes Platforms Fabrication Details Hand rails

T-4.200.189 (ASM) Column 1 – Item ID A0080112

T-4.200.194 (ASM) Horizontal Bracing – Item ID A0080133

T-4.200.196 (ASM) Columns and Bracings – Item Id A0080111, Page 1 of 4

T-4.200.219 (ASM) Column I – Item ID A0087668

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T-4.250.904 Rev. A Page 11 of 65

T-4.207.361 Pressure Locked Grating – Item ID A0090478

T-4.207.364 Plate – Item ID A0091017

T-4.207.365 Plate – Item ID A0091039

T-4.207.366 Plate – Item ID A0091103

T-4.207.367 Plate – Item ID A0091104

T-4.207.368 Plate – Item ID A0091105

T-4.207.369 (ASM) Support Beam – Item ID A0089688

T-4.207.370 (ASM) Support Beam – Item ID A0089516

T-4.207.374 (ASM) Column Head (I) – Item ID A0081806

T-4.207.375 (ASM) Column Head (O) – Item ID A0081809

T-4.207.376 (ASM) Longitudinal Beam (O) – Item ID A0079841

T-4.207.377 (ASM) Transversal Beam (O) – Item ID A0079848

T-4.207.378 (ASM) Longitudinal Beam (I) – Item ID A0079847

T-4.207.379 (ASM) Transversal Beam (I) – Item ID A0079857

T-4.207.380 (ASM) Platform End Profile – Item ID A0079878

T-4.207.381 (ASM) Fandeck Diagonal Beam – Item ID A0079890

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T-4.250.904 Rev. A Page 12 of 65

T-4.207.386 (ASM) Fandeck Parallel Beam – Item ID A0079902

T-4.207.387 (ASM) Fandeck Parallel Beam – Item ID A0079904

T-4.207.388 Checkered Plate – Item ID A0079906

T-4.207.389 Fandeck Plate I – Item ID A0079916

T-4.207.390 Fandeck Plate II – Item ID A0079917

T-4.207.391 Fandeck Plate II – Item ID A0079918

T-4.207.395 (ASM) Checkered Plate – Item ID A0089538

T-4.207.397 (ASM) Fandeck Diagonal Beam (I) – Item ID A0089656

T-4.207.399 (ASM) Spring Support Beam – Item ID A0089654

T-4.207.402 (ASM) Spring Support Beam – Item ID A0092946

T-4.207.405 Bellows – Installation, Maintenance And Safety Instruction, Hazardous

Area Motors En12-2006

T-4.207.409 (ASM) Main Truss – Item ID A0080733 (sheet 3 of 5)

T-4.207.416 Bellows: Conservation and Storing at Site Procedure

T-4.207.423 Bellows – Preservation Procedure

T-4.207.432 Steelwork Preservation Procedure

T-4.207.466 Condensate Tank substructure Escape Ladders - 1

T-4.207.483 Parts List Manhole

T-4.207.484 Condensate And Evacuation Pipe work

T-4.207.485 Evacuation and Condensate Piping Details ACC

T-4.207.485 Condensate And Evacuation Piping Details

T-4.207.486 Location On Platform +100.000 M

T-4.207.500 Preservation And Storage Procedure Drain And Condensate Pump

T-4.207.888 Parts List Steam Manifold

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T-4.250.904 Rev. A Page 13 of 65

T-4.207.891 Steam Manifold – Street 4

T-4.207.892 Steam Manifold – Street 1

T-4.209.301 (ASM) Windwall Column – Item ID A0079935

T-4.209.302 (ASM) Windwall Top Beam – Item ID A0079945

T-4.209.303 Z-Profile – Item ID A0079950

T-4.209.304 (ASM) Z-Profile – Item ID A0079949

T-4.209.305 Bracing Anchor – Item ID A0079953

T-4.209.306 Windwall Bracing Connection – Item ID A0079954

T-4.209.307 (ASM) Windwall Bracing – Item D A0079952

T-4.209.308 Trapezoid Sheet – Item ID A0079956

T-4.209.309 (ASM) Windwall Modul Long – Item ID A0079934

T-4.209.316 (ASM) Windwall Door Beam I – Item ID A0079989

T-4.209.317 (ASM) Windwall Modul Trans – Item ID A0079988

T-4.209.320 Z-Profil – Item ID A0086236

T-4.209.325 (ASM) Z-Profil – Item ID A0087066

T-4.209.330 (ASM) Door Beam – Item ID A0087303

T-4.209.337 (ASM) Windwall Door Beam II – Item ID A0087167

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T-4.250.904 Rev. A Page 14 of 65

T-4.209.345 (ASM) Windwall Support Beam – Item ID A0088724

T-4.209.349 (ASM) Windwall Modul Trans II – Item ID A0086229

T-4.209.359 (ASM) Windwall Door Beam III – Item ID A0089492

T-4.209.360 (ASM) Windwall Support I – Item ID A0080010

T-4.209.366 (ASM) Windwall Modul Trans III – Item ID A0086232

T-4.219.314 Cladding Preservation / Packing and Storage Procedure

T-4.219.455 Handrail at ACC Platform

T-4.219.606 Job Safety Analysis & Hazard Evaluation

T-4.219.615 Training and Orientation

T-4.219.660 Permit To Work Handover Implementation Plan

T-4.219.688 Part List Central Walkways (D0032814)

T-4.219.691 Steam Jet Air Ejector Condenser Preservation

T-4.219.793 Fabrication Duct Part 1A

T-4.219.946 Part List movable Ladder Top rail (D0032815)

T-4.219.947 Part List Air Seals (D0032816)

T-4.219.948 Movable Ladder Top Rail (Z0055127)

T-4.219.949 Air Seals – Details (Z0055130)

T-4.219.950 Central Walkways (Z0055131)

T-4.226.179 Coupling Flange (Hub Flange Fan)

T-4.233.692 Part List (ASM) Fan Stack

T-4.233.731 (ASM) Fan Stack

T-4.234.058 (ASM) Fan Screen Module A

T-4.234.062 (ASM) Fan Screen Module B

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T-4.250.904 Rev. A Page 15 of 65

T-4.234.067 Method of Statement For Surveying

T-4.234.080 Method of Statement For Scaffolding

T-4.234.084 Method Statement Lifting (General)

T-4.234.106 Pressure-locked Grating (Z0054934) T-4.234.107 Pressure-locked Grating (Z0054938) T-4.234.108 Pressure-locked Grating (Z0054945) T-4.234.109 Pressure-locked Grating (Z0054947) T-4.234.110 Shim Plate (Z0054949) T-4.234.111 Pressure-locked Grating (Z0054950) T-4.234.112 Shim Plate (Z0054952) T-4.234.113 Pressure-locked Grating (Z0054953) T-4.234.114 Pressure-locked Grating (Z0054954) T-4.234.115 Shim Plate (Z0054955) T-4.234.116 Pressure-locked Grating (Z0054956) T-4.234.117 Pressure-locked Grating (Z0054957) T-4.234.118 Shim Plate (Z0054958) T-4.234.119 Pressure-locked Grating (Z0055035)

T-4.234.120 (ASM) Railing for Motor Bridge

T-4.234.121 (ASM) Transversal Beam (Z0056215)

T-4.234.122 (ASM) Transversal Beam (Z0056222)

T-4.234.123 (ASM) Longitudinal Beam (Z0056257)

T-4.234.124 (ASM) Gear Support (Z0056316)

T-4.234.125 (ASM) Railing for Motor Bridge (Z0056323)

T-4.234.130 (ASM) Stair for Motor Bridge (Z0056331)

T-4.234.133 Pressure-locked Grating (Z0051995)

T-4.234.542 Project Quality Plan

T-4.245.162 General Assembly Fan

T-4.245.163 Parts List Fan

T-4.247.910 (ASM) A-frames Right Page 1 of 5

T-4.247.915 (ASM) A-frames Middle Page 1 of 5

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T-4.250.904 Rev. A Page 16 of 65

T-4.247.920 (ASM) A-frames Left Page 1 of 5

T-4.247.926 (ASM) Stiffening Plate

T-4.247.927 (ASM) Connecting Angle

T-4.247.929 Part List Escape Routes

T-4.248.106 Preservation Procedure Fan

T-4.249.856 Strainers Preservation Procedure

T-4.249.889 End Profile (Z0050242) T-4.249.890 End Profile (Z0053751) T-4.249.891 End Profile (Z0053757) T-4.249.892 End Profile (Z0053765) T-4.249.893 End Profile (Z0053773) T-4.249.894 End Profile (Z0055879) T-4.249.895 End Profile (Z0055880) T-4.249.896 End Profile (Z0055881) T-4.249.897 Trapezoid Sheet (Z0050309) T-4.249.898 Trapezoid Sheet (Z0050310) T-4.249.899 Trapezoid Sheet (Z0050311) T-4.249.900 Trapezoid Sheet (Z0050312) T-4.249.901 Trapezoid Sheet (Z0050314) T-4.249.902 Trapezoid Sheet (Z0050315) T-4.249.903 Trapezoid Sheet (Z0050316) T-4.249.904 Trapezoid Sheet (Z0050317)

T-4.250.896 Method Statement for Structural Steel Assembly & Erection

T-4.250.902 Method of Statement For Structural Steel Assembly Warehouse,

Workshop

T-4.250.907 QCP For Structural Steel

T-4.250.916 Procedure for Painting

T-4.250.917 ITP For Structural Steel

T-4.250.921 ITP For ACC

T-4.250.930 Cleanliness Procedure Piping System

T-4.250.931 Welding Consumable Control

T-4.250.932 Quality Control Procedure For Preservation Of Piping Material And

Equipment

T-4.250.938 General Welding Procedure

T-4.250.940 Weld Repair Procedure

T-4.250.944 QCP For ACC

T-4.250.954 Method Statement – Utilization of Hilti DX 76

T-4.250.957 Lifting Study for ACC Structures above 10 Tonnes for Dwg. #

SPXCT-OEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 (250T – 100T)

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T-4.250.904 Rev. A Page 17 of 65 T-4.250.980

Lifting Study for ACC Structures above 10 Tonnes for Dwg. # SPXCT-OEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 (Optional 120T – 100T)

T-4.251.018 Procedure for Structural Steel Repair Works at Site

T-4.256.989 Trapezoid Sheet (Z0050318) T-4.256.990 Trapezoid Sheet (Z0050320) T-4.256.991 Trapezoid Sheet (Z0050321) T-4.256.992 Trapezoid Sheet (Z0050322) T-4.256.993 Trapezoid Sheet (Z0050323) T-4.256.994 Trapezoid Sheet (Z0050325) T-4.256.995 Trapezoid Sheet (Z0050326) T-4.256.996 Trapezoid Sheet (Z0050327) T-4.256.997 Trapezoid Sheet (Z0050348) T-4.256.998 Trapezoid Sheet (Z0050349)

T-4.256.999 Part List Windwall Claddings

T-4.257.000 Part List Partition Wall Claddings

T-4.257.005 Packing and Preservation Loose Ball Valves

T-4.257.014 Metso Automated Control Valves Preservation Instructions

T-4.257.015 Neway Check and Gate Valves Packing and Preservation Procedure

T-4.271.404 (ASM) Bracing (Z0050821)

T-4.271.405 (ASM) A-frame Beam (Z0055838)

T-4.271.412 (ASM) Hanger (Z0056446)

T-4.271.413 (ASM) A-frame Head (Z0050445)

T-4.271.414 (ASM) Sealing Beam (Z0055343)

T-4.271.428 (ASM) Partition Wall and Monorails (Z0050344)

T-4.271.429 (ASM) Partition Beam (Z0050286)

T-4.271.432 (ASM) Door Frame (Z0050334)

T-4.271.433 (ASM) Door Side Beam (Z0050345)

T-4.271.434 (ASM) Door Side Beam (Z0050347)

T-4.271.435 (ASM) Partition Wall II (Z0050356)

T-4.271.436 Part List Partition Wall (Steel Work) (D0050792)

T-4.271.444 Part List (ASM) Fan Units (D0042211)

T-4.271.463 Instrument mountion Support (Z0072213)

T-4.271.464 (ASM) Distance Angle (Z0065166)

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T-4.250.904 Rev. A Page 18 of 65

T-4.280.109 (ASM) Outrigger (Z0055333)

T-4.280.110 (ASM) Outrigger (Z0055332)

T-4.280.111 (ASM) Outrigger (Z0055331)

T-4.280.112 (ASM) Outrigger (Z0055330)

T-4.280.113 (ASM) A-frame Top Girder II (Z0055322)

T-4.280.115 (ASM) A-frame Top Girder I (Z0055299)

T-4.280.117 (ASM) Monorail II (Z0055324)

T-4.280.122 (ASM) Rail Support (Z0050819)

T-4.280.123 (ASM) Bracing (Z0050616)

T-4.280.124 (ASM) Hanger (Z0050788)

T-4.280.125 (ASM) Monorail (Z0050782)

T-4.280.126 (ASM) Outrigger (Z0050441)

T-4.280.127 (ASM) Top Steam header Support Beam (Z0050439)

T-4.280.128 (ASM) Bracing (Z0050438)

T-4.280.129 (ASM) A-frame (Type I) (Z0050456)

T-4.280.130 (ASM) A-frame Head (Z0050453)

T-4.280.135 (ASM) Monorail II (Z0056618) T-4.280.136 (ASM) Rail (Z0056594) T-4.280.137 (ASM) Rail (Z0056595) T-4.280.138 (ASM) Rail (Z0056598) T-4.280.140 (ASM) Column I (Z0060537) T-4.280.141 (ASM) Column I (Z0060545) T-4.280.142 (ASM) Column I (Z0060547) T-4.280.143 (ASM) Column I (Z0060548)

T-4.280.144 (ASM) Horizontal Bracing (Z0060581)

T-4.280.145 (ASM) Horizontal Bracing (Z0060582)

T-4.280.146 (ASM) Platform End Profile (Z0057667)

T-4.280.149 Cover Plate (Z0057796)

T-4.280.150 Cover Plate (Z0057797)

T-4.280.151 Pressure Locked Grating (Z0057832)

T-4.280.152 Cover Plate (Z0058237)

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T-4.250.904 Rev. A Page 19 of 65

T-4.282.688 Part List Hand and Cages at ACC Platform

T-4.282.689 (ASM) Windwall Column (Z0062738)

T-4.282.691 (ASM) Windwall Modul Trans (Z0062754)

T-4.282.692 (ASM) Windwall Modul Trans III (Z0062758)

T-4.282.694 (ASM) Monorail Bracing (Z0063067)

T-4.282.695 (ASM) Ladder for Windwall (Z0063621)

T-4.282.696 (ASM) Door Beam (Z0063710)

T-4.282.698 (ASM) Windwall Modul trans (Z0072330)

T-4.282.699 (ASM) Windwall Modul trans II (Z0072342)

T-4.282.737 Angle (Z0050282) T-4.282.738 Angle (Z0050283) T-4.282.739 Angle (Z0050284) T-4.282.740 Angle (Z0050285) T-4.282.741 Angle (Z0050286) T-4.282.742 Angle (Z0050287) T-4.282.743 Angle (Z0050288) T-4.282.744 Angle (Z0050301) T-4.282.745 Angle (Z0050302) T-4.282.746 Angle (Z0050338) T-4.282.747 Angle (Z0050339) T-4.282.748 Angle (Z0050340) T-4.282.749 Angle (Z0050341) T-4.282.750 Cover Plate (Z0050350) T-4.282.751 (ASM) A-Frames

T-4.282.752 (ASM) Sealing Beam

T-4.282.793 Tyco Valves Preservation Procedure

T-4.282.845 IOM Lifting Devices

T-4.305.053

Lifting Study for ACC Structures above 10 Tonnes for Dwg. #

SPXCT-OEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 – (Optional

120T – 70T

T-4.305.085 Lifting Procedure for Condensate Tank and Evacuation Unit

T-4.305.144 Lifting Procedure for A – Frame of ACC

T-4.305.149 Lifting Procedure For Acc- Motor Bridge Assembly Structures

Above 10 Tonnes for Dwg. # SPXCT-OEO2-B-ZE-1008 (120T Crane)

T- 4.318.527 Lifting Procedure for Steam Distribution Manifold at ACC (Typical)

T-4.318.571 Lifting Procedure for Erection of Steam Ducts

T-4.318.572 Procedure for Preservation at ACC

T-4.318.585 Method Statement for Erection of Fan Deck Plates at ACC

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T-4.250.904 Rev. A Page 20 of 65

6 RESOURCES

6.1 Responsibilities

6.1.1 Site Manager

The Site Manager will provide overall inputs to the project execution plan to ensure that strategies & philosophies of the project are properly addressed.

6.1.2 Mechanical Erection Manager

The Mechanical Erection Manager is responsible for the overall management of the Project Construction team to ensure that safe and effective operations are conducted and properly documented.

6.1.3 Site Engineer

Site Engineer is responsible for safe execution of the whole job including:

• Confirming the installation location from schedule of approved construction drawings. • Organizing of equipments and tools needed for the job.

• Assigning skilled personnel for the job.

• Sequence of activities to be carried out for the work as per this method of statement. • Conduct inspection and surveillance.

• Notify to Contractor engineer for inspection as applicable.

• Ensure that all Contractor and Company regulations are followed.

• Ensure that all personnel involved are in safe working condition at all times.

6.1.4 Site Supervisor (SS)

Site Supervisor is responsible for safe execution of the following activities: • Conduct TSTI with the concerned work force prior to start of work.

• Ensure that relevant work permits for the job are obtained prior to start of work. • Conduct daily toolbox talks for the entire work force prior to start day work.

• Assigning a competent work crew for specific activities, details of activities and task information will be given to the work crew.

• Organizing tools and equipment needed to the work site. • Inspection and supervision of work.

• Ensure that all Contractor and Company safety regulations are followed as applicable.

6.1.5 Piping Supervisor (PS)

Piping Supervisor is responsible for the erection of pipes that will be performed in accordance to the method of statements

6.1.6 Artisans

Group of skilled and semi skilled workers who will be responsible for the execution of works and other jobs related to the completion of construction of ACC at C2 area.

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T-4.250.904 Rev. A Page 21 of 65 6.1.7 QA/QC Officer / Inspector

QA/QC Officer/Inspector is responsible for:

• Inspecting and Certifying of all foundations, alignments, etc. will be in coordination with the Contractor representative as per conformance of the specifications

• Assurance of approved methods and materials are being used and conformance of the specifications

• Stage inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and erection procedures

• Incoming material inspection and review of test certificates

6.2 Equipment & Manpower

All equipment will be inspected and approved by the Contractor, when required, and all personnel will be inducted and trained before and during mobilization.

6.2.1 Equipment

• Crane – (1) each for 250 T, 120, 100 T, 80 T, 70 T and 50 T lifting capacities hydraulic or crawler type will be utilized

• Forklift – 15 and 5 T capacity • Boom Truck – 5 T capacity

• Aerial Work Platform (man lift equipment) – capable to 45 meters reach, (2) numbers either telescopic and /or folding hydraulic type

• Man basket for 3 persons

• Trailer – for transport of materials from lay down area to assembly site • Rigging and lifting equipment – approved, certified and color -coded • Scaffolding – as per requirement

• Gas cutting torch with arrestors and welding machines

• Grinding machine with correct grinding wheels and tool speed • Survey and level instruments

• Portable diesel generator and portable lights – to service night works • Hilti DX 76 – Fastening tool

• Air compressor

• Hand and electric tools – Note: No prefabricated tools will be allowed and shall be in good working order

• Paints and accessories – Only for repair and touchup

6.2.2 Manpower

• Management

• Site Engineer

• Foreman

• HSSE personnel

• Certified Crane operator • Certified Forklift operator

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T-4.250.904 Rev. A Page 22 of 65 • Certified Articulated man lift operators

• Banks man and slingers • Erectors • Mechanical fitters • Scaffolders • Fire watchers • Associated vendors • Driver

If the above-listed equipment or manpower proves not sufficient for the timely completion of the facilities and project; additional will be provided to complete the works on time and in line with rules, regulations and specifications of Contractor, Company and RLIC.

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T-4.250.904 Rev. A Page 23 of 65

7 METHOD

OF

EXECUTION

7.1 General

This chapter explains the methods to be used for the erection of all structural steel works, piping and duct works, installation of air cooled condensers with associated equipment, and steam recovery at the following site; FD at C2 area.

This method shall also apply to the other sites FA, FB, FC, and GA, GB, GC, GD at C2 area.

7.2 Pre-Commencement Works

7.2.1 Foundation Seats

• Prior to works commencement, all seating foundations are checked for load bearing of all steel erection as per approved drawings issued by the vendor or the company. Any deviations as per plan will be recorded and served as guideline during the execution of works and shall be within the tolerances recommended by the manufacturer

• Survey report on the main level references from Civil will be generated and submitted before start up of construction to anticipate problems which can be encountered during construction and alignment stages. Any deviations from the general arrangements, drawings shall be identified

7.2.2 Logistical Materials and Equipment

• Materials and equipment required during the duration of works shall be available nearby and checked

• Lay down area for materials and equipment shall be located in such a place that double handling can be minimized or can be totally eliminated. Due to space limitations at the assembly area, a minimum supply of materials or structures for at least three days will be maintained to assure continuous works without interruption. This will also reduce risk for possible damage and distortion of materials from handling and during assembly

• Lifting procedures will be followed as per documents T-4.234.084 for Lifting General • Scaffolding – will be followed as per separate method of statement and PTW (permit

to work) will be initiated before any works can commence; please refer to document

T-4.234.080. The use of scaffoldings will only be at selected area where height and

space have some limitations example as: pipe installation and welding works inside the A-frame with bundles structures, piping below the fan deck; installation and connection of condensate duct from turbine to the SDM

7.2.3 Barricades and safety Sign Boards

• All works areas are to be secured, barricaded, and posted with signboards indicating that works are in progress, and lifting operations are being conducted

• Only authorized personnel's will be allowed to work within the perimeter

• All barriers will be kept in place during the progress of works, and/or until the works are completed

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T-4.250.904 Rev. A Page 24 of 65 7.2.4 Positioning and Lifting Equipment

7.2.4.1 Lifting and related equipment will be in position only by certified operators and banks man; ground foundation checked for stability before setting up the outriggers or tracks

7.2.4.2 Correct colour coded and certified slings are to be used only

7.2.4.3 Aerial work platform/man-lift and construction cages are to be used for certified erectors. When construction cages are being provided, dead man's control & inspection certificate will be presented. The personnel must rope themselves into the cage. The cage must be suspended in an insulated manner when welding work is to be performed from the cage.

7.2.4.4 It is necessary to determine more or less the weights of the following sub-structures or equipment due to limitations on space and height at the assembly area for its respective lift, and they are as follows:

• The assembly of two adjoining columns and braces (Step 1)

Member Part no. Description Wt. No. Total Wt.

1 A0080123 Column 1 1864.4 2 3728.8

2 A0087913 Column 1 1920.8 2 3841.6

3 A0088074 Column 1 1164.4 2 2328.8

4 A0087511 Hor. Bracing 727.836 1 727.836

5 A0087512 Hor. Bracing 554.345 1 554.345

6 A0087506 Hor. Bracing 924.12 2 1848.24

Wt of two adjoining columns & braces 13029.621 Kg

13.03 T

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T-4.250.904 Rev. A Page 25 of 65 • Assembly of two adjoining columns & braces (Step 2)

1 A0087709 Column 1745.3 1 1745.3

A0087701 Column 1745.3 1 1745.3

2 A0088079 Column 1838.4 1 1838.4

A0088025 Column 1838.4 1 1838.4

3 A0088074 Column 1164.4 2 2329.8

4 A0087511 Hor. Bracing 727.836 1 727.836

5 A0087512 Hor. Bracing 554.345 1 554.345

6 A0087506 Hor. Bracing 924.12 2 1848.24

7 A0080136 Hor. Bracing 312.166 2 624.332

8 A0087493 Hor. Bracing 312.166 2 624.332

9 A0087495 Hor. Bracing 330.493 2 660.332

Wt. of two adjoining columns & braces 14536.617 Kg

14.54 T

• The motor bridge with drive unit

Member Part no. Description Wt. No. Total Wt.

1 A0087898 E. Motor 1700 1 1700

2 A0086149 Gearbox 1400 1 1400

3 A0091415 Motor Bridge Complete 5102.812 1 5102.812

Motor Bridge consists of the following: -

A0091417 Railings

A0091360 Gear Support

A0091352 Transversal Beam

A0091398 Press Lock Grating

4 A0075068 Fan Impeller 126.88 7 888.16

Wt. of Motor Bridge & Structure 9090.972 Kg 9.10 T

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T-4.250.904 Rev. A Page 26 of 65 • One section of A-frame

1 A0080285 A Frame 1568 2 3136

2 A0080291 A Frame 820 2 1640

3 A0080280 A Frame 2322.5 2 4645

4 A0080330 Bracing 260.215 8 2081.72

5 A0084581 Top Girder 938.37 1 938.37

6 A0088149 Top Girder 689.2 1 689.2

7 A0080320 Hanger 55.267 2 110.534

8 A0080316 Monorail 195.4 2 390.8

9 A0080302 Top Steam Header

Support Beam 237.63 1 237.63 10 A0080309 Outrigger 69.138 2 138.396 11 A0089231 Outrigger 61.81 2 123.62 12 A0089232 Outrigger 63.423 2 126.846 13 A0080338 Bracing 2 33.801

14 A0091097 Sealing Beam 95.801 1 95.801

15 A0091096 Sealing Beam 95.801 1 95.801

16 A0091101 Sealing Beam 95.801 1 95.801

17 A0091100 Sealing Beam 95.801 1 95.801

Wt. of A Frame 14675.121 Kg

14.67 T

Note: Only for presentation

• The sections of SM (Steam Manifold)

1 A0080519 Spool 5420 1 5420 2 A0080520 Spool 4700 1 4700 3 A0080521 Spool 3700 1 3700 4 A0086422 Spool 3650 1 3650 5 A0080522 Spool 3323 1 3323 Wt. of steam Manifold 20793 Kg 20.8 T

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T-4.250.904 Rev. A Page 27 of 65 3 Lifts to be carried out

• CM (Condensate Manifold) sections per street

Consists of 5 spools @ 2,300 Kg each

• One assembly of support and parallel beams at the upper deck

1 A0079847 Longitudinal Beam 328.664 2 657.328

2 A0079904 Longitudinal Beam 328.664 2 657.328

3 A0079900 Fan Deck Cross Beam 102.318 4 409.272

4 A0079896 Diagonal Beam 180.388 2 360.776

5 A0079898 Diagonal Beam 270.831 2 541.662

6 A0079904 Parallel Beam 225.28 2 450.56

7 A0079902 Parallel Beam 187.849 2 375.698

8 A0092946 Spring Support Beam 68.225 1 68.225

9 A0089654 Spring Support Beam 68.225 1 68.225

10 A0084106 Beam 21.705 1 21.705

A0082543 Beam 21.313 4 85.252

A0082456 Beam 21.313 4 85.252

A0084105 Beam 21.704 1 21.704

A0081962 Beam 472.99 1 472.99

11 A0089614 Column Head 520.149 2 1040.298

12 A0089588 Support Beam 85.534 1 85.534

A0089516 Support Beam 128.704 1 128.704

A0086912 Support Beam 171.993 1 171.993

A0079878 Platform End Profile 751.931 1 751.931

A0098394 Support Beam 274.061 1 274.061

A0086912 Support Beam 171.993 1 171.993

A0086911 Support Beam 128.704 1 128.704

A0086973 Platform End Profile 151.769 1 151.769

Wt. of Fan Deck Structure 7180.964 Kg

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T-4.250.904 Rev. A Page 28 of 65

Lifting of structures/members & equipment to the upper deck will be performed by the 250 T / or 120 T crane with counter weights.

For any single lifts greater than 10 Tonnes, individual rigging plans shall be provided and approved before lifting can commence

Lifting procedures will be followed as per lifting method of statement documents

T.4.234.084

• Avoid related equipment operate over or near pre-installed and covered lines. Ensure such equipment access lifting area through identified access ways. (FSI Ref.: Q1-1.3.1.)

• Avoid related equipment cause over settling of concrete pits resulting shears at the grip pipe connections. Following the lifting operations, ensure proper condition of any nearby underground piping (with video cameras if necessary). (FSI Ref.: Q1-1.3.4.)

7.2.5 Main Erection Sequence 7.2.5.1 Under Structure Erection

Start works at street 3; Method of statement for structural steel assembly; refer document T-4.250.902 also applies

Two vertical column frames will be assembled on the ground, will be erected on the foundation plinths, using two cranes; and will be stabilized with 20 mm diameter wire ropes as temporary supports for verticality. Minimum of two set of cables of hand operated winch will be used to serve as guy ropes for stability. The bigger crane (100 T) will lift the load and the smaller one (80T) will support the tail load during mounting the structure to vertical position.

The temporary supports (ropes) will not be removed until twin column is erected and horizontal bracings and other diagonal braces are secured or bolted in; continue until one street is completed.

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T-4.250.904 Rev. A Page 29 of 65 Proceed to erect the sub structures at the upper deck (see proceeding item, 7.2.5.2). The first street will be levelled and aligned before connecting any steel structures of another street.

Final bolt torque should be completed after thorough inspection has been performed and found acceptable, and they are to be colour–coded indicating that bolts are properly checked and correct torque is applied.

All erection works will be done by competent and certified erectors, and banks man for all lifting operations.

Grouting will be done on steel structure foundation with approved materials as per site specifications after complete alignment and acceptance of fan deck assembly of each street.

See illustration for similar installation for a similar project by other agencies: -

STEP 1 STEP 2

STEP 3

7.2.5.2 Upper Structure/Fan Deck

The peripheral beams of the fan deck will be assembled on the ground and installed to form the support structure; assuring that all bolts are tightened correctly. Temporary detachable railings will also be integrated and fixed to the structure prior to lifting, as safety measure for people to work at the upper deck later.

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T-4.250.904 Rev. A Page 30 of 65 Aerial work platform (AWP) will be used by the erectors in connecting the structure to the built columns. Proceed until the whole street is completed forming a complete working table. Wherever necessary, man lifts will be also be used.

Inspection for the elevation and verticality will be done after it is determined and conditions are acceptable within the given tolerances. It will serve as a guide or reference in foregoing installation of equipment and structure to the adjacent streets After completing the erection of the fan deck structures at street 3, erect the columns and steel structures at N module of street 4 (south corner). Stairs and walkways will be assembled and will serve as access going to the fan deck or upper structure. This will provide us some leeway of maximizing the utilization of man lifts to other area and eliminate expensive scaffoldings

One bracing is required to be temporarily removed to allow installation of condensate tank and steam evacuation unit. Further study on the removal of the bracing will be provided in ref. T-4.305.085

Note: It is not permitted to proceed with erection of other equipments as motor bridge, A-frame, CCM and SDM until completion of condensate tank and steam evacuation unit and installation of temporarily removed bracing is complete

Deck plates and gratings are to be secured by Hilti fastening tool; catch nets to be provided and laid out on the fan deck screens to prevent materials, etc from falling and other safety reasons.

Catch nets specification: PE or Polyester or PP perimeter debris netting for construction industry (Mesh size 2.5 x 2.5 mm, width 2000mm) subject to approval by Linde Engineering AG/PMC

Subject to prevailing conditions at site, an alternative scheme can be device to be able to install the fan deck plates at the fan deck structure

After erecting the fan bell with screen into the structure, platform openings can only be closed by fan deck plates during the course of construction, hence additional safety measures for people working at height is mandatory. Additional lifelines aside from the proposed will be provided i.e., lines installed midpoint from each cell. The latter will be use for people to be positioned inside the fan bell assembly during the laying out & fastening the fan deck sheets into the structure. They will be assisted by a third person riding in the manlift

Lifting of the fan deck plates will be done according to attached procedure - Lifting ACC fan deck plates & plate clamps lifter will not be allowed to be used

The Sequence will be repeated until the cell is covered by deck plates

It (deck plates) will be fixed permanently soon as activity 7.2.5.3 is completed See illustration for similar installation by other agencies: -

(34)

T-4.250.904 Rev. A Page 31 of 65

7.2.5.3 Erection of Fan Screen and Fan Ring

These foregoing activities can commence in parallel with the above sequence.

The sectional screens will be pre assembled at ground level with timber cribbage or fabricated supports below the corresponding location or module where they will be lifted into their final position. Each section will be supported underneath and levelled to prevent distortion and possible damages on the wire mesh during the assembly of the fan stack or bell.

Fan stack segments will be assembled on top of assembled fan screen.

After the guard grill is pre-assembled, the stiffening plates need to be installed on the connection plates on the outside edge from the guard grill. Here the fan bell segment can be connected into their position. The connection bolts have no torque value. They need to tighten in the most tightly possible way by hand, to consider that the fan bell material is fragile FRP glass fibre. The inspector for the bolt tightening needs to check every bolt for its tightness by hand.

Before lifting; check the roundness and diameter of the fan bell on the top edge from the bell. In the positions from the stiffening plates they can use slings to adjust the roundness and diameter.

Then lift the fan bell & guard grill into its position on the fan deck level. Attach stiffening plates to the small supports in the fan deck steel structure.

The bolts which keep the fan bell in position can just be hand tight, because in later stage from the erection the fan bell needs to be aligned with the fan blades. This is the moment the connection bolts will be tightened according to the correct torque value. Then install the fan deck plates on the fan deck level.

Drill holes at the top of the fan stack using the sealing angle plate as template, and install the sealing angle.

Lifting of the assembled fan stack and screen will be performed using four point soft slings taking note on the correct and final orientation of the fan screen assembly which is 45 º offset from the axis.

Final alignment of the fan stack with screen will be carried out once the motor bridge with the drive unit installation is completed.

(35)

T-4.250.904 Rev. A Page 32 of 65 See illustration for similar installation by other agencies: -

7.2.5.4 Assembly of Motor Bridge with Drive unit and Fan Blades

Pre assembly of motor bridge with drive unit will be done by mechanical fitters at the adjacent streets respectively to limit movement of lifting equipment. The latter structure will be laid horizontally and levelled along with fabricated support beams at 1.2 meters height. This will assure mobility of people working underneath for fan blade erection Secure and align the gearbox with correct bolts and shims for correct levelling on the motor bridge structure; then fasten the motors, taking note the orientation of the motor control box. At this stage, gearbox will not be filled with oil; this will be done during the commissioning stage. Refer to ACC construction manual T-4.121.350

Railings, grating materials and walkways will be installed before lifting the whole structure with blades at the upper deck. The fan blades will be installed in vertical position temporarily; to prevent damages during erection of other parts above the deck Observe correct torque value for bolts on the gearbox shaft coupling to motor plus the flanged connection to the fan hub plate, and then install and assemble the fan blades. Ref.: 7.2.6.1 Bolting. Torque bolts on joints, blades for flange with 70% torque value Prior to lifting, additional fasteners and/or soft ropes will be required to prevent movement and rotation of the fan blades during the lifting operation to the upper sub structure

Lift the structure assembly and secure into final position at the upper deck

Lifting of the motor bridge with drive unit and fan blades will be done by certified and competent riggers and banks man.

(36)

T-4.250.904 Rev. A Page 33 of 65 Following the erection, ensure proper preservation of rotating equipment (e.g. 4 weekly vertical shaft rotation, oil top-up/greasing) and refer to equipment manuals as necessary, for protection against heat, dust and humidity. (FSI Ref.: Q1-3.1.)

7.2.5.5 Alignment of Fan Ring

After the motor bridge is aligned and levelled to its position, alignment of the fan stack with angle sealing plates will be done accordingly, and fixing the fan deck plates permanently.

The blades pitch angle will be set to 12.7 ° as recommended by the manufacturer; and the gap between stack and fan tips will be noted.

Alignment will be done by mechanical fitters. Final settings of the blade angle will be performed prior to trial operation & bolts torque to 100%.

See illustration for similar installation by other agencies: -

7.2.5.6 Upper Structure: Pre assembly and Erection of A – Frame

Pre assembly of the A – frame will be done on the ground with complete support, with partition walls sub structure, with cladding, supports and braces are lifted to the upper deck and fastened to the main steel structure.

Alignment of the upper and lower sections of the A – frame for the street will be controlled with shims to obtain same elevations.

Structures like the sliding and fixed supports at the top of the beam, bracings between A – frame and motor bridge, and hoisting beams will be installed before any installation of the foregoing structures.

See illustration for similar installation by other agencies: -

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T-4.250.904 Rev. A Page 34 of 65 7.2.5.7 Assembly of CCM, Bundles, SM, Piping Works and Wind wall

Erection of the remaining structures will be as follows: -

Condensate Collecting Manifold (CCM) first, secondary bundles and primary bundles, and Steam Distribution Manifold (SDM) as third step

Assemble and weld two CCM spool on the ground, temporarily fixed with bolts after lifting them at the upper deck. These bolts can be removed once the alignment and tack welding of the CCM is done. Lift the next two joined spools, and join to the latter spools. Final alignment of the joined spools and welding will be done at this stage, then proceed to complete the street. Final welding on the manifold will be done as soon as all the alignment of the manifold is achieved

Before erecting the bundles onto the A-frame, thorough inspection will be done for any damages. The inspection shall be recorded and noted whether bundles are acceptable, or require repairing

Lifting up of the bundles starts first with secondary, then the primary. Installation of lifeline for people working in the bundle erection will be performed. Refer document attached

Lifting up of the bundles will be alternate (to Left & to right side) to avoid unbalancing on the structure. Bundles shall be lifted at the required A-frame slope, using offset sling lengths.

Join two (2) opposite primary bundles with plate (A0080412) by welding after aligning the bundles; taking into consideration on special procedures to avoid overheating of the tube sheets. After welding completion and alignment, the steam distribution manifold (SDM) will be installed.

The weight of the complete steam manifold exceeds 10 Tonnes, hence it is necessary to have at least three (3) lifts; starting lift of spool 3 (A0080521) at the fixed point, which is located on the top of the secondary bundle structure. Spool 4 (A0086422) & spool 5 (A0080522) will be assembled & welded on the ground prior to lifting; similarly with spool 1 (A0080519) & spool 2 (A0080529). They will be joined with spool 3 after erection at the structure. Lifting lugs will be provided for its joined spools, taking into consideration of the centre of gravity. Seal plates at the end of manifold (spool 5) are to be adjusted at the site after the bundles assembly & steam manifold installation is completed and stitch welding of the manifold & bundle will commence.

Ensure all heat exchanger pipe protection covers removed before installation. (FSI Ref.: Q2-2.1.)

Ensure pipes are internally clean before lifting into the structure (visual, air blow, lifting-up at one end). (FSI Ref.: Q2-1.8.)

Ensure all open ends capped after work interruption or day end. (FSI Ref.: Q2-1.8.) Condensate tank and structure will commence for erection after fan bell is erected at module N of street # 4.

Condensate tanks, steam ejectors, the drain pump station and associated equipment and instrumentation will be erected and piping will follow as soon as the upper structures are done, then continue to work on the remaining streets.

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T-4.250.904 Rev. A Page 35 of 65 At this stage, the steam duct connecting the turbine exhaust and the ACC can commence simultaneously with other works in the ACC; and it is necessary to start works at each fixed points.

Installation of walkways and rails at street 4 going to the upper deck will be done to minimize utilization of man-lift equipment during installation of structures on the remaining streets.

Soon as the entire street installations are completed, panel sheeting of the interior will be done.

The pre-assembly of the wind wall will be done on the ground level, lifting and installation will be parallel and commence with A-frame erection at the upper structure. The wind wall section will be connected and bolted to the main structure (fan deck) and connected to the steam manifold bracings.

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T-4.250.904 Rev. A Page 36 of 65

7.2.5.8 Steam Ducting

The steam ducting will be assembled and installed between the connection of the turbine exhaust and the ACC with the construction sections as per drawings.

Steam ducting section – certain sections are fabricated with additional fitting lengths. These fitting lengths will be used for adjustment to site conditions. By means of a cutter or blow torch; the sections will be cut to the exact length required during installation, the cut edge will be ground smoothed, cleaned and prepared for welding in accordance with specified WPS.

The expansion joints and ducting sections will be assembled and welded together to a great extent at the ground level, before lifting them into position; however the weight of the assembled parts and crane lifting capacity and the reach will be considered and planned accordingly.

During installation of the expansion joints and the vane elbows special care and attention will be taken to ensure that they are installed correctly for the direction of the steam flow.

Beginning at the turbine, the remaining main steam ducts and risers are installed up to the top steam distribution manifold.

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T-4.250.904 Rev. A Page 37 of 65 The Steam ducting installation will start at the duct fix point. Sequence refer sketch as given below in (illustration A & A1): -

Illustration A Illustration A1

The steam ducting has to be assembled and installed starting from the turbine outlet at machine house to the air cooled condenser inlet joining streets 3/4 and streets 2/1 respectively. The expansion joints and ducting sections can be assembled and welded together to a great extent at the ground level before lifting them into position.

Spool 1 a (Drg. No.:Z0060956; T-4.219.793) and expansion joint to be welded on site to the turbine piece before turbine installation.

Fixed Starting Point Connection Point SM Connection Point SM

009-METHOD STATEMENT - MAIN ERECTION SEQUENCE FOR ACC.pdf

Pearl GTL

Project

Shell Project No: HP-3000-QAT

Contractor Project No :

5887

C2 AIR SEPARATION UNITS CONSTRUCTION

METHOD STATEMENT - MAIN ERECTION SEQUENCE

for ACC

LOC470

GAM MTS MEC GTL 009 F

Table of Content

1 PURPOSE

2 SCOPE

3 HSSE

4 DEFINITIONS

5 REFERENCES

6 RESOURCES

7 METHOD

OF

EXECUTION

_{Contractor Project No :}

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