method statementINSTALLATION of air compressor

N6820-M04-2E-S2xxx

Rev.: 00Date: 18.01.2011

Page: 13

METHOD STATEMENT

INSTALLATION of AIR COMPRESSOR

N6820-M04-2E-S2xxx

04.08.1000First Issue UNNIIMech.Eng.MOHAMADM&E COORD..HAMDYProject Manager.

DateRevisionDescription of RevisionPrepared byReviewed byApproved by

Revision recording

DateRevisionDescription of RevisionPrepared byReviewed byApproved by

04.08.1000First Issue UNNIIMech.Eng.MOHAMADM&E COORD..HAMDYProject Manager.

INDEX

1. SCOPE

2. PURPOSE

3. REFERENCE SPECIFICATION/ DRAWING

4. PARTIES INVOLVED

5. DESCRIPTION OF EQUIPMENT

6. RESPONSIBILITIES

7. MATERIAL RECEIVING

8. FOUNDATION SURFACE PREPARATION

9. EQUIPMENT INSTALLATION AND LEVELLING

10. SAFETY PROCEDURES

11. PLANT AND EQUIPMENTS

12. ATTACHMENTS

1. SCOPE

This procedure applies to air compressor station to be purchased and installed at Al Ain receiving pump station as part of TRANSCO contract N6820

2. PURPOSE This section describes the specific work quality plan to be implemented for the installation of air compressor station at Al Ain receiving pump station as part of TRANSCO contract N6820. It covers procedures, responsibilities, quality control of resource input and task activities, acceptance criteria, verifying test and inspection documents, and inspection points, which are planned and shown in sequence on the prepared Inspection & Test Plan (ITP)

3. REFERENCE DOCUMENTS / DRAWING Flow sheet Gas and Flow sheet Water from Atlas copco N6820-M05-2E-D005 Air compressor station General arrangement drawing M6820-I01-4E-D005 P&ID Air compressor package surge system ADWEA Standards Specification - W-M-SS-007 Rev0 for Air Compressor Package IOM manual compressor / assembly instruction canopy

4. PARTIES INVOLVED

Various parties involved for this procedure

TRANSCO Owner ILF Owner consultant TORISHIMA - Main contractor NAEL ENERGY Sub Contractor Atlas Copco Air compressor manufacturer

5. DESCRIPTION OF EQUIPMENT

As Part of Contract N6820, Air compressor systems will be installed at AARC Pumping station. This compressor station is utilised to feed compressed air to non vented type surge vessel during initial filling and during normal operation incise for loss of air mass . There will be 3 identical compressor station , out which one compressor for surge vessel plant for GIC line , one for Um Al Gaffa line and one will be common spare

The compressor to be installed are of multi stage, oil free , reciprocating type manufactured by M/S Atlas copco . The compressor and other ancillaries will be installed inside noise and sound proof canopy except cooling tower

The main components in compressor system are

1. Reciprocating , multi stage water cooled , oil free air compressor Model 3HX2T 2. High Pressure Ancillary Equipment:

Dryer model HFD130W Activated Carbon Filter model HQD16 Fine Filter model HDDP160 Water Pump Skid model WPS16HAT 3. Cooling Tower model CTE50 4. Canopy

6. RESPONSIBILITIES

6.1 Mechanical/ Civil Site Engineers

Reports directly to Project Engineer. They coordinate with Client/Consultant, Safety and Operations to ensure that all work activities are completed in a safe and efficient manner in accordance with this procedure and standards referred herein. They coordinate with QC Inspectors for the necessary inspection during each phase of job execution and completion.

They shall be also responsible for the Installation of vessel in accordance with the issued AFC drawings, applicable ADWEA Standards and established procedures.

6.2Mechanical / Civil Foremen

They report directly to the Concerned Discipline Supervisor for direct supervision of his craftsmen involved in the job execution. He ensures that all activities are being performed in compliance with this Method Statement.He shall be responsible for obtaining the following as a minimum for the safe erection/installation of equipments under this scope:

Shipping Net Weights of each separate components of compressor system Manufacturers drawings indicating the location of lifting lugs and the centre of gravity. Manufacturers recommendation for the lift including the use of spreader bars, slings, turnbuckles and so forth.

6.3QC Inspectors

Discipline QC Inspectors shall conduct Quality Control Inspection for, Mechanical, and other related activities covered under this job and raise Request for Inspection (RFIs) for Witnessing and Hold Points as per approved ITP. He ensures that all pertinent QC records are in order and finally handed-over to Client/Consultant in organized manner.

7. MATERIAL RECEIVING

Discipline Supervisors, Inspectors and storekeepers are responsible for the implementation of the preservation actions as per the recommendations of the manufacturer and/or by applicable OWNER Standard Specifications, and other industry standards governing receiving, preservation and protection of all machineries and their accessories at site.Visually inspect all components for physical damage or contamination by opening packages and cratesVerify that shipping protection has been applied and is still in effectVerify that shop inspection has been completed and that the vendor had supplied all necessary documentation and other disposition procedures.Verify loose components with the package that they match the packing list and is complete.Verify proper identification of all components Verify components against the provide delivery note Verify that protective caps and plugs are in place. Machine/equipment is lubricated as requiredReport defects/failures to the manufacturer regarding the machine/equipment supplied. Defect/failure shall be reported to OWNER /ENGINEER for all client supplied items

8. FOUNDATION SURFACE PREPARATION

Compressor station required a plane industrial slab of minimum 300 mm thickness without special preparation, Completion of this minimum requirement shall be verified before the commencement of installation works

9. LIFTING

Lift the compressor using Slings and shackles of appropriate capacity Shackles only to be connected to lifting lugs provide on compressor skid as per the below fig.

Do not let slings bear on the equipment, and especially not on compressor components which are not sufficiently resistant to take them (coolants, water pipes, electrical cabinet).

Do not allow the slings to come into contact with and damage paintwork.

Avoid using steel slings with bare cables .In such cases, allow for local protection over contact points, or, even better, a spreader (stiffened spreader)

The sling diameter must be appropriate to the load to be lifted (For guidance, steel sling diameter for a compressor must be a minimum of 14 mm).

Comply with safety instructions applicable to handling and lifting.

10. EQUIPMENT INSTALLATION AND LEVELLING

Compressor Check the completion concrete foundation accordance with manufacturer recommendation / approved GA drawing Adjustment and bolting down (chemical bolting)Use the chemical bolts delivered with the compressor.Position the drilling jig (delivered with the compressor) to the ground and mark fixing points.

Drill fixing holes into the foundation slab by following the erection instructions below.Erection instructions and Operation Drill hole. (Diameter = 25 mm / depth = 170 mm).Clean drill hole. The chemical bolt may be laid in wet supports. In such case just make sure to evacuate all water collected in the drill hole.The resin must flow into the capsule (warm to the touch).Place the capsule in the drill hole.Position threaded studs (rotation -percussion).(speed 750 tr/min).Visual inspection while filling up.Comply with the delay before tightening the lock-nuts.

Place the torques. (15 daNm).After the chemical bolts positioningBring the compressor to its position. Lay the base plate over the 20 millimeter shims inserted on either side of the drill fixing holes

Use the levelling screws (Item 4) to level the compressor. Tolerance is 0.5 millimetres / metre. Once the compressor is level, insert the shims of varying thickness provided over the 20 millimetre shims (Item 3) previously inserted.

Allow the compressor frame to rest on the shims by releasing the levelling screws (item 4). Clamp the compressor to the foundation slab. Fit and tighten lock-nuts (item 2).Pour finishing concrete between the slab (item 5) and the base plate (item 1). A high fluidity, shrink-proof concrete must be used.

Cooling tower

Cooling tower to be fixed as per the approved GA drawing ( Fixing details shown below)

Cooling tower will installed on the top of I ( 75X75) section as show on the above drawing

Other Auxiliaries

Cooling water skid also to be fixed using chemical anchor bolt and levelled Air drier is to be placed on the foundation as per the approved GA drawing ( No anchor bolt is required ) All compressed air piping to be installer as per the GA dawning according to GA drawing and Manufacturers process diagram The piping system should be tight & leak proof.Once completion of installation of All components inside the canopy , Canopy installation to Carrie out according to the Canopy assembly instruction from manufacturer ( Attached for information)Cooling water piping ( uPVC ) to completed according to GA drawing and Manufacturers process diagram Darin piping to be completed according to GA drawing and Manufacturers process diagram All the installation to be cross checked again and Air compressor installation QCR to be filled properly

11. SAFETY PROCEDURE

Observe all Safety Notices and Site RulesFollow the method statement Wear appropriate Personnel Protective Equipment (PPE)Be aware of crushing hazards and pinch points when handling and joining pipes Avoid walking and working under suspended loads Be aware of loose material excavation /opening drop of , uneven ground and other obstructions Allow ample space for each employee to work safety Use tools for the proper purpose.Check all tools /equipments for damage before use with daily equipment checklist Remove the damage tools /equipments immediately and affix the visible label Do not use any tools /equipments that is unsafe Check all lifting gear for capacity and condition before use.Earth all electrical generator for lighting Keep the working area clean at all time.Be available always adequate first aid supply in the site Be available all safe certificate and documents at work area Risk assessment : Refer to attachments

12. PLANT AND EQUIPMENTS

CraneRigging gears Hand toolsIndustrial spirit levelShims

13. ATTACHMENTS

Inspection test Plan Air compressor installation N6820-000-ITP-0055-00Inspection QCRsN6820 M-C-QCR 006 Air compressor Levelling Record N6820-M-QCR 005 Air compressor installation completion check list DrawingsN6820-M05-2E-D005 Air compressor station General arrangement M6820-I01-4E-D005 P&ID Air compressor package surge system Process sheet Gas / Process sheet Water IOM Manual compressorAssembly instruction -Canopy Compressor Bottling down instructions Risk Assessment

This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law