009-Method Statement - Main Erection Sequence For Acc PDF

Pearl GTL
Project
LINDE ENGINEERING
Shell Project No: HP-3000-QAT

Project Document Number: T- 4.250.904
Contractor Project No :
Project Rev.: A
Purchase Order Number:
2MH127
Tag/Item Number(s):
1A-2121, 1A-2221, 1A-2321, 1A-2421,

2A-2121, 2A-2221, 2A-2321, 2A-2421
Unit(s):
1-2100, 1-2200, 1-2300, 1-2400,

2-2100, 2-2200, 2-2300, 2-2400
PCWBS:
Page 2 of 65
5887
QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION
24.11.08
Company Comments Incorporated

(with Preservation)
RT
UO/MK
AG
CCI
12.11.08

(with PMC)
OK
UO/MK
AG
CCI
30.07.08
OK
UO
AG
CCI
10.04.08
Issued for Company Comments
RT
EE
ZG
ICC
17.03.08
Issued for Review
RT
EE
ZG
IFR
21.02.08
Issued for Internal Review
RT
EE
ZG
IIR
Date
Description
GAMA
Rev.
No.
Project
Rev
No.
Prepared Checked Approved

By
By
By
ORIGINATOR
Status
Document Title:
LINDE ENGINEERING AG
METHOD STATEMENT - MAIN ERECTION SEQUENCE

for ACC
Document No.
Contractor
LOC470
Gama Qatar Co. W. L. L.
GAM
MTS
MEC
GTL
009
Org.
Code
Doc.
Type
Disc.
Code
Geogr.
Area
Seq.
No
Rev.
No
Project Document Number: T- 4.250.904
Vendor Code
Rev No: A
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
METHOD STATEMENT - MAIN ERECTION SEQUENCE for ACC
Date
24 November 2008, Rev. F
TableofContent
1
PURPOSE _____________________________________________________________________5
SCOPE________________________________________________________________________5
HSSE _________________________________________________________________________5
DEFINITIONS __________________________________________________________________6
REFERENCES _________________________________________________________________7
RESOURCES _________________________________________________________________20
6.1
Responsibilities ___________________________________________________________________ 20
Site Manager __________________________________________________________________________ 20
Mechanical Erection Manager ___________________________________________________________ 20
Site Engineer__________________________________________________________________________ 20
Site Supervisor (SS) ___________________________________________________________________ 20
Piping Supervisor (PS) _________________________________________________________________ 20
Artisans ______________________________________________________________________________ 20
QA/QC Officer / Inspector _______________________________________________________________ 21
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.2
Equipment & Manpower __________________________________________________________ 21

Equipment ____________________________________________________________________________ 21
Manpower ____________________________________________________________________________ 21
6.2.1
6.2.2
METHOD OF EXECUTION _____________________________________________________23

7.1
General _________________________________________________________________________ 23
7.2
Pre-Commencement Works ________________________________________________________ 23

Foundation Seats ______________________________________________________________________ 23
Logistical Materials and Equipment _______________________________________________________ 23
Barricades and safety Sign Boards _______________________________________________________ 23
Positioning and Lifting Equipment ________________________________________________________ 24
Main Erection Sequence ________________________________________________________________ 28
Special Technical Procedures ___________________________________________________________ 40
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
QUALITY ASSURANCE________________________________________________________42
ATTACHEMENTS _____________________________________________________________43
9.1
Job Safety Analysis _______________________________________________________________ 43
9.2
Installation of Life Line for Bundles Erection at ACC __________________________________ 43
9.3
Lifting of Fan Deck Plates __________________________________________________________ 43
9.4
Design Calculation Notes for Horizontal Lifeline System ________________________________ 43
T-4.250.904 Rev. A
Page 4 of 65
Q A T A R
1
Doc. Title
GAM-MTS-MEC-GTL-009
Date
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.
SCOPE
This method statement identifies the general steps, arrangements and precautions for the
assembly and erection works of one ACC at the following site; FD at C2 area. Since the sites
are identical to FD; this method statement shall also apply to other sites as FA, FB, FC and
GA, GB, GC, GD at C2 area.
This method statement also defines piping erection of all SPX equipment at the site which is
developed for installation of steam condensed piping, extraction, cleaning systems and
instrumentation.
ACC consists of four streets with four modules per street with fan units and associated
equipment which will be erected on top of the steel structures.
The scope of the ACC starts from the turbine exhaust steam turbine outlet with the main
steam duct, which feeds to the Air Cooled Condenser (ACC). The latter is equipped with
drain pot that collects the condensate to the condensate tank which is located at module N of
street # 4.
The steel structure will be erected at site according to the ACC Construction Manual T4.121.350, by means of crane and/or certified lifting equipment utilizing equipment specified
in section 6.2, with competent personnel.
The works will also include the erection, installation and alignment of equipment above the
steel structure as follows: fan screen and stack, motor bridge with drive and blades/impellers,
condensate and steam manifolds, bundles (heat exchangers), associated steel structures,
pipe works for steam recovery, and other amenities for access and walkways necessary for
maintenance.
The sequence of construction by street will be 3,4,2 then 1 taking into consideration to
specific requirement on the erection of condensate tank, steam ejectors and associated
equipment which will be located with separate steel structure beneath the module N of street
4 (please refer to drawing T-4.149.204).
The sequence of activities will be applicable to other sites.
Scaffolding will be required during the duration of the works. Scaffolding shall be inspected
by HSE before work starts. Periodic scaffolding inspection will be required.
HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan
Industrial City and International standards/codes, and Company and Contractor requirements
and instructions.
All personnel will go through Gama, Linde and Company Safety Induction courses as well as
other trainings as identified by their supervisor. Please refer Document T-4.219.615 for
details.
A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared as
per Gama procedure T-4.219.606 and is attached herein. Such JSA addresses the hazards
T-4.250.904 Rev. A
Page 5 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
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.
DEFINITIONS
Company
Contractor
Subcontractor
Contract
QCP
ITP
QA/QC
HSSE
JSA
Street
SDM
CCM
SS
ACC
PTW
LP
RA
FSI
NDT
TSTI
TSTO
PPE
RLIC
SPX
T-4.250.904 Rev. A
QSGTL and/or its PMC

Linde Engineering AG
Gama Qatar Co. W. L. L.
QSGTL Pearl Project C2 ASU Construction Works
(2MH127)
Quality Control Procedure
Inspection and Test Plan
Quality Assurance / Quality Control
Health, Safety, Security and Environmental
Job Safety Analysis
Location of condensers and accessories
Steam Distribution Manifold
Condensate Collecting Manifold
Site Supervisor
Air Cooled Condenser
Permit to Work
Lifting Plan
Risk Assessment
Flawless Start-up Initiative
Non-Destructive Test
Total Safety Task Instruction
Total Safety Task Observation
Personnel Protection Equipment
Ras Laffan Industrial City
Vendor
Page 6 of 65
Q A T A R
5
Doc. Title
GAM-MTS-MEC-GTL-009
Date
REFERENCES
ASME B 31.3
ASME Sec II;
ASME SEC. IX
ASME SEC.V
DEP 34.28.00.31
DEP 70.10.70.11
DEP.30.8.60.18
DEP.31.38.01.11
DEP.31.38.01.31
T-13.377.360
Process Piping
Specification for Welding Rods, Electrodes & Filler Metals
Welding And Brazing Qualification
Non Destructive Examination
Technical Specification Steel Structures
Preservation Of Old And New Equipment And Piping Standing Idle
Welding Of Metal (Amendments/Supplements To Api Rp 582
Piping General Requirements
Shop & Field Fabrication Of Steel Piping Amendment T.13.376.796e
Flawless Start-Up Initiative (FSI)
T-13.377.438
Specification For Traceability, Alloy Verification And Material Substitution
T-13.377.441
T-4.095.303
T-4.095.723
T-4.116.905
T-4.116.909
T-4.116.910
T-4.116.970
T-4.121.193
T-4.121.194
T-4.121.212
T-4.121.213
T-4.121.214
T-4.121.215
T-4.121.226
T-4.121.227
T-4.121.228
T-4.121.230
T-4.121.231
T-4.121.232
T-4.121.233
T-4.121.234
T-4.121.235
T-4.121.236
T-4.121.237
T-4.121.238
T-4.121.239
T-4.121.240
T-4.121.241
T-4.121.244
T-4.121.245
T-4.121.246
Quality Control Requirement For Welding

HSSE Plan Construction
General Layout Plan Air Seperation Plants
General Arrangement Drawing
(C Bundle) Primary Fin Tube Bundle
(D Bundle) Secondary Fin Tube Bundle
PEFS ACC 03 Condensate System
General Arrangement Condensate Tank
Parts list for Condensate Tank
Piping Tie-In Drawing And List
Piping Layout Condensate Piping
Piping Layout Air Take Off System
Piping Layout Cleaning System
Support Condensate Piping
Support Drain Piping
Cleaning Water Piping
Arrangement Steam Duct
Fabrication Main Steam Duct Part 1
Fabrication Main Steam Duct Part 02 DN3820
Duct Support BN3800 P1
Duct Support DN3800 P2 & P3
Duct Support DN2800 P4 & P5
T-4.250.904 Rev. A
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T-4.121.257
T-4.121.261
T-4.121.262
T-4.121.264
T-4.121.265
T-4.121.266
T-4.121.270
T-4.121.271
T-4.121.272
T-4.121.273
T-4.121.274
T-4.121.275
T-4.121.276
T-4.121.277
T-4.121.278
T-4.121.281
T-4.121.282
T-4.121.284
T-4.121.287
T-4.121.298A
T-4.121.304
T-4.121.305
T-4.121.323
T-4.121.350
T-4.121.350
T-4.121.350
T-4.121.350
T-4.121.357
T-4.129.656
T-4.129.850
T-4.129.852
T-4.129.853
T-4.129.854
T-4.129.855
T-4.129.856
T-4.129.857
T-4.129.859
T-4.129.860
T-4.129.861
T-4.129.864
T-4.129.865
T-4.129.866
T-4.129.867
T-4.129.868
T-4.129.871
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date
(ASM) Fan Units

(ASM) Columns and Bracings - Item Id A0080111, Page 4 of 4
Parts List Columns and Bracings
Parts List Main Steel Truss
(ASM) Windwall Item ID A0080734 (sheet 1 of 4)
Part List Windwall (Steelwork)
Part List A-Frame
Part List Motor Bridge Type 1 3
(ASM) Motor Bridges Complete Type 1
(ASM) Motor Bridges Complete Type 2A
(ASM) Motor Bridges Complete Type 2B
(ASM) Motor Bridges Complete Type 3
(ASM) Motor Bridge Type 3
Stair Tower General Arrangement
Part List Stair Tower
(ASM) Fan Screen Support
Parts List (ASM) Fan Screen
Escape Routes General Arrangement
Condensate Tank Substructure General Arrangements
General Instruction For Site Storage And Preservation
General Arrangement Condensate Pump
General Arrangement Drain Pump
Outline Drawing Fan Motor
Construction Report: Piping Foundation (D0007603)
General Instructions : Preservation of ACC (D0042190)
General Instructions for Site Storage and Preservation (D0042191)
ACC Construction Manual
Piping Class SPX 001
Construction Waste Management Plan
Accident/Incident/Near Miss Reporting And Investigation
Entry Into Confined Space
Personal Protective Equipment
Risk Assessment
Emergency Response
Welding And Flame Cutting
Road Safety Procedure
Lifting Operations
Manual Handling
Working With Electricity
Safe Use Of Compressed Gases
Portable Power Tools
Use of Grinding Machines And Abrasive Wheels
Hand Tools
Work At Height Scaffolding
Environment Accounting
Page 8 of 65
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T-4.129.872
T-4.131.762
T-4.131.763
T-4.133.661
T-4.133.662
T-4.133.665
T-4.133.666
T-4.133.667
T-4.133.970
T-4.149.204
T-4.149.213
T-4.149.274
T-4.149.277
T-4.149.295
T-4.184.595
T-4.184.826
T-4.186.019
T-4.193.137
T-4.193.139
T-4.193.298
T-4.193.303
T-4.193.304
T-4.193.320
T-4.193.323
T-4.193.324
T-4.193.325
T-4.193.326
T-4.198.504
T-4.198.505
T-4.198.506
T-4.198.509
T-4.198.510
T-4.200.135
T-4.200.144
T-4.200.145
T-4.200.146
T-4.200.152
T-4.200.159
T-4.200.160
T-4.200.163
T-4.200.164
T-4.200.165
T-4.200.166
T-4.200.167
T-4.250.904 Rev. A
Doc. Title
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Date
Heat Stress Disorder Prevention

PEFS ACC 04 - Air Evacuation Unit
PEFS ACC 06 - Detail Pump and Fan Motors
PEFS ACC 01 - ACC Unit
PEFS ACC 02 Drain System
PEFS ACC 05 Cleaning System
PEFS Acc 03 Condensate System
General Layout Plan ASU
Duct Support BN3800 P1
Arrangement Connecting Turbine
Support Fabrication DN3800 Type QAR 01
Evacuation And Condensate Piping Details
Land Road Transport HSSE Case
Motor Storage Procedure
Flawless Start Up Initiative
Packing And Preservation Bundles
Fin Tube Bundle Name Plate
Packing and Preservation Procedure Fan Stack
Protection Cage for ACC Handrail Axis A1
Protection Cage for ACC Handrail Axis A5
Structural Steelwork Erection Tolerances & Torques
Relieve Valve Preservation
Pipe work Preservation
Instrument Preservation
Cleaning System For Bundles
Condensate Collecting Manifold, Sheet 1 of 2
Condensate Collecting Manifold, Sheet 2 of 2
Parts List Fabrication Steam Duct
Manhole DN 600 / 150 Lbs Horizontal
Manhole DN 600 / 150 Lbs Vertical
Gear Box Electrical Connection Diagram
Operation And Maintenance Manual Coupling
Operation And Maintenance Manual Gear Unit Including Attachment
Parts And Lubrication List
Gearbox Outline Drawing
Gear box - Procedure Preservation
Stair tower Main Structure Part 01
Stair tower Main Structure Part 02
Stair tower Staircase Type 2a
Stair tower Staircase Type 2b
Page 9 of 65
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T-4.200.168
T-4.200.169
T-4.200.170
T-4.200.171
T-4.200.172
T-4.200.179
T-4.200.180
T-4.200.182
T-4.200.183
T-4.200.184
T-4.200.189
T-4.200.190
T-4.200.191
T-4.200.192
T-4.200.193
T-4.200.194
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T-4.200.203
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T-4.200.207
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T-4.200.216
T-4.200.217
T-4.200.218
T-4.200.219
T-4.200.220
T-4.200.221
T-4.200.222
T-4.200.223
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date

Escape Routes Ladders LD1 LD4 Fabrication Details
Escape Routes Ladders LD2 LD3 Fabrication Details
Escape Routes Platforms Fabrication Details Part 01
Escape Routes Platforms Fabrication Details Part 02
Escape Routes Platforms Fabrication Details Hand rails
(ASM) Column 1 Item ID A0080112
(ASM) Horizontal Bracing Item ID A0080133
(ASM) Columns and Bracings Item Id A0080111, Page 1 of 4
(ASM) Column I Item ID A0087668
Page 10 of 65
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T-4.200.224
T-4.200.225
T-4.200.226
T-4.207.344
T-4.207.345
T-4.207.346
T-4.207.347
T-4.207.348
T-4.207.349
T-4.207.350
T-4.207.351
T-4.207.352
T-4.207.353
T-4.207.354
T-4.207.355
T-4.207.356
T-4.207.357
T-4.207.358
T-4.207.359
T-4.207.360
T-4.207.361
T-4.207.362
T-4.207.363
T-4.207.364
T-4.207.365
T-4.207.366
T-4.207.367
T-4.207.368
T-4.207.369
T-4.207.370
T-4.207.371
T-4.207.372
T-4.207.373
T-4.207.374
T-4.207.375
T-4.207.376
T-4.207.377
T-4.207.378
T-4.207.379
T-4.207.380
T-4.207.381
T-4.207.382
T-4.207.383
T-4.207.384
T-4.207.385
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date

Pressure Locked Grating Item ID A0090478
Plate Item ID A0091017
(ASM) Support Beam Item ID A0089688
(ASM) Column Head (I) Item ID A0081806
(ASM) Column Head (O) Item ID A0081809
(ASM) Longitudinal Beam (O) Item ID A0079841
(ASM) Transversal Beam (O) Item ID A0079848
(ASM) Longitudinal Beam (I) Item ID A0079847
(ASM) Transversal Beam (I) Item ID A0079857
(ASM) Platform End Profile Item ID A0079878
(ASM) Fandeck Diagonal Beam Item ID A0079890
(ASM) Fandeck Cross Beam Item ID A0079900
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T-4.207.386
T-4.207.387
T-4.207.388
T-4.207.389
T-4.207.390
T-4.207.391
T-4.207.392
T-4.207.393
T-4.207.394
T-4.207.395
T-4.207.396
T-4.207.397
T-4.207.398
T-4.207.399
T-4.207.400
T-4.207.401
T-4.207.402
T-4.207.403
T-4.207.404
T-4.207.405
T-4.207.405
T-4.207.406
T-4.207.407
T-4.207.408
T-4.207.409
T-4.207.410
T-4.207.411
T-4.207.416
T-4.207.423
T-4.207.432
T-4.207.446
T-4.207.447
T-4.207.448
T-4.207.466
T-4.207.483
T-4.207.484
T-4.207.485
T-4.207.485
T-4.207.486
T-4.207.487
T-4.207.488
T-4.207.500
T-4.207.888
T-4.207.890
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Doc. Title
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Date
(ASM) Fandeck Parallel Beam Item ID A0079902

(ASM) Fandeck Parallel Beam Item ID A0079904
Checkered Plate Item ID A0079906
Fandeck Plate I Item ID A0079916
Fandeck Plate II Item ID A0079917
Fandeck Plate II Item ID A0079918
(ASM) Checkered Plate Item ID A0089538
(ASM) Fandeck Diagonal Beam (I) Item ID A0089656
(ASM) Spring Support Beam Item ID A0089654
(ASM) Spring Support Beam Item ID A0092946
Bellows Installation, Maintenance And Safety Instruction, Hazardous
Area Motors En12-2006
(ASM) Main Truss Item ID A0080733 (sheet 3 of 5)
Bellows: Conservation and Storing at Site Procedure
Bellows Preservation Procedure
Steelwork Preservation Procedure
Condensate Tank substructure Escape Ladders - 1
Parts List Manhole
Condensate And Evacuation Pipe work
Evacuation and Condensate Piping Details ACC
Condensate And Evacuation Piping Details
Location On Platform +100.000 M
Preservation And Storage Procedure Drain And Condensate Pump
Parts List Steam Manifold
Steam Manifold Street 2 & 3
Page 12 of 65
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T-4.207.892
T-4.209.301
T-4.209.302
T-4.209.303
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T-4.209.306
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T-4.209.343
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Doc. Title
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Date
Steam Manifold Street 4

Steam Manifold Street 1
(ASM) Windwall Column Item ID A0079935
(ASM) Windwall Top Beam Item ID A0079945
Z-Profile Item ID A0079950
(ASM) Z-Profile Item ID A0079949
Bracing Anchor Item ID A0079953
Windwall Bracing Connection Item ID A0079954
(ASM) Windwall Bracing Item D A0079952
Trapezoid Sheet Item ID A0079956
(ASM) Windwall Modul Long Item ID A0079934
(ASM) Windwall Door Beam I Item ID A0079989
(ASM) Windwall Modul Trans Item ID A0079988
Z-Profil Item ID A0086236
(ASM) Z-Profil Item ID A0087066
(ASM) Door Beam Item ID A0087303
(ASM) Windwall Door Beam II Item ID A0087167
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T-4.219.314
T-4.219.455
T-4.219.606
T-4.219.615
T-4.219.660
T-4.219.688
T-4.219.691
T-4.219.793
T-4.219.946
T-4.219.947
T-4.219.948
T-4.219.949
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Date

(ASM) Windwall Support Beam Item ID A0088724
(ASM) Windwall Modul Trans II Item ID A0086229
(ASM) Windwall Door Beam III Item ID A0089492
(ASM) Windwall Support I Item ID A0080010
(ASM) Windwall Modul Trans III Item ID A0086232
Cladding Preservation / Packing and Storage Procedure
Handrail at ACC Platform
Job Safety Analysis & Hazard Evaluation
Training and Orientation
Permit To Work Handover Implementation Plan
Part List Central Walkways (D0032814)
Steam Jet Air Ejector Condenser Preservation
Fabrication Duct Part 1A
Part List movable Ladder Top rail (D0032815)
Part List Air Seals (D0032816)
Movable Ladder Top Rail (Z0055127)
Air Seals Details (Z0055130)
Central Walkways (Z0055131)
Coupling Flange (Hub Flange Fan)
Part List (ASM) Fan Stack
(ASM) Fan Stack
(ASM) Fan Screen Module A
(ASM) Fan Screen Module B
(ASM) Fan Screen Module C
Page 14 of 65
Q A T A R
T-4.234.067
T-4.234.080
T-4.234.084
T-4.234.104
T-4.234.105
T-4.234.106
T-4.234.107
T-4.234.108
T-4.234.109
T-4.234.110
T-4.234.111
T-4.234.112
T-4.234.113
T-4.234.114
T-4.234.115
T-4.234.116
T-4.234.117
T-4.234.118
T-4.234.119
T-4.234.120
T-4.234.121
T-4.234.122
T-4.234.123
T-4.234.124
T-4.234.125
T-4.234.126
T-4.234.127
T-4.234.128
T-4.234.129
T-4.234.130
T-4.234.131
T-4.234.132
T-4.234.133
T-4.234.542
T-4.245.162
T-4.245.163
T-4.247.910
T-4.247.911
T-4.247.912
T-4.247.913
T-4.247.914
T-4.247.915
T-4.247.916
T-4.247.917
T-4.247.918
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Method of Statement For Surveying

Method of Statement For Scaffolding
Method Statement Lifting (General)
Pressure-locked Grating (Z0054934)
Shim Plate (Z0054949)
(ASM) Railing for Motor Bridge
(ASM) Transversal Beam (Z0056215)
(ASM) Transversal Beam (Z0056222)
(ASM) Longitudinal Beam (Z0056257)
(ASM) Gear Support (Z0056316)
(ASM) Railing for Motor Bridge (Z0056323)
(ASM) Stair for Motor Bridge (Z0056331)
Project Quality Plan
General Assembly Fan
Parts List Fan
(ASM) A-frames Right Page 1 of 5
(ASM) A-frames Middle Page 1 of 5
Page 15 of 65
Q A T A R
T-4.247.919
T-4.247.920
T-4.247.921
T-4.247.922
T-4.247.923
T-4.247.924
T-4.247.926
T-4.247.927
T-4.247.929
T-4.248.106
T-4.249.856
T-4.249.889
T-4.249.890
T-4.249.891
T-4.249.892
T-4.249.893
T-4.249.894
T-4.249.895
T-4.249.896
T-4.249.897
T-4.249.898
T-4.249.899
T-4.249.900
T-4.249.901
T-4.249.902
T-4.249.903
T-4.249.904
T-4.250.896
T-4.250.902
T-4.250.907
T-4.250.916
T-4.250.917
T-4.250.921
T-4.250.930
T-4.250.931
T-4.250.932
T-4.250.938
T-4.250.940
T-4.250.944
T-4.250.954
T-4.250.957
T-4.250.958
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date

(ASM) A-frames Left Page 1 of 5
(ASM) Stiffening Plate
(ASM) Connecting Angle
Part List Escape Routes
Preservation Procedure Fan
Strainers Preservation Procedure
End Profile (Z0050242)
Trapezoid Sheet (Z0050309)
Method Statement for Structural Steel Assembly & Erection
Method of Statement For Structural Steel Assembly Warehouse,
Workshop
QCP For Structural Steel
Procedure for Painting
ITP For Structural Steel
ITP For ACC
Cleanliness Procedure Piping System
Welding Consumable Control
Quality Control Procedure For Preservation Of Piping Material And
Equipment
General Welding Procedure
Weld Repair Procedure
QCP For ACC
Method Statement Utilization of Hilti DX 76
Lifting Study for ACC Structures above 10 Tonnes for Dwg. # SPXCTOEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 (250T 100T)
Method Statement Erection of Condensate Tank and Evacuation Unit
Page 16 of 65
Q A T A R
T-4.250.980
T-4.251.018
T-4.256.989
T-4.256.990
T-4.256.991
T-4.256.992
T-4.256.993
T-4.256.994
T-4.256.995
T-4.256.996
T-4.256.997
T-4.256.998
T-4.256.999
T-4.257.000
T-4.257.005
T-4.257.014
T-4.257.015
T-4.271.404
T-4.271.405
T-4.271.406
T-4.271.407
T-4.271.408
T-4.271.409
T-4.271.410
T-4.271.411
T-4.271.412
T-4.271.413
T-4.271.414
T-4.271.415
T-4.271.416
T-4.271.428
T-4.271.429
T-4.271.430
T-4.271.431
T-4.271.432
T-4.271.433
T-4.271.434
T-4.271.435
T-4.271.436
T-4.271.444
T-4.271.463
T-4.271.464
T-4.280.107
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Lifting Study for ACC Structures above 10 Tonnes for Dwg. # SPXCTOEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 (Optional 120T
100T)
Procedure for Structural Steel Repair Works at Site
Part List Windwall Claddings
Part List Partition Wall Claddings
Packing and Preservation Loose Ball Valves
Metso Automated Control Valves Preservation Instructions
Neway Check and Gate Valves Packing and Preservation Procedure
(ASM) Bracing (Z0050821)
(ASM) A-frame Beam (Z0055838)
(ASM) Hanger (Z0056446)
(ASM) A-frame Head (Z0050445)
(ASM) Sealing Beam (Z0055343)
(ASM) Partition Wall and Monorails (Z0050344)
(ASM) Partition Beam (Z0050286)
(ASM) Door Frame (Z0050334)
(ASM) Door Side Beam (Z0050345)
(ASM) Door Side Beam (Z0050347)
(ASM) Partition Wall II (Z0050356)
Part List Partition Wall (Steel Work) (D0050792)
Part List (ASM) Fan Units (D0042211)
Instrument mountion Support (Z0072213)
(ASM) Distance Angle (Z0065166)
Page 17 of 65
Q A T A R
T-4.280.108
T-4.280.109
T-4.280.110
T-4.280.111
T-4.280.112
T-4.280.113
T-4.280.114
T-4.280.115
T-4.280.116
T-4.280.117
T-4.280.118
T-4.280.119
T-4.280.120
T-4.280.121
T-4.280.122
T-4.280.123
T-4.280.124
T-4.280.125
T-4.280.126
T-4.280.127
T-4.280.128
T-4.280.129
T-4.280.130
T-4.280.131
T-4.280.132
T-4.280.133
T-4.280.134
T-4.280.135
T-4.280.136
T-4.280.137
T-4.280.138
T-4.280.140
T-4.280.141
T-4.280.142
T-4.280.143
T-4.280.144
T-4.280.145
T-4.280.146
T-4.280.147
T-4.280.148
T-4.280.149
T-4.280.150
T-4.280.151
T-4.280.152
T-4.280.156
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date

(ASM) Outrigger (Z0055333)
(ASM) A-frame Top Girder II (Z0055322)
(ASM) A-frame Top Girder I (Z0055299)
(ASM) Monorail II (Z0055324)
(ASM) Rail Support (Z0050819)
(ASM) Hanger (Z0050788)
(ASM) Monorail (Z0050782)
(ASM) Top Steam header Support Beam (Z0050439)
(ASM) A-frame (Type I) (Z0050456)
(ASM) A-frame Head (Z0050453)
(ASM) Monorail II (Z0056618)
(ASM) Rail (Z0056594)
(ASM) Rail (Z0056595)
(ASM) Rail (Z0056598)
(ASM) Column I (Z0060537)
(ASM) Horizontal Bracing (Z0060581)
(ASM) Horizontal Bracing (Z0060582)
(ASM) Platform End Profile (Z0057667)
Cover Plate (Z0057796)
Pressure Locked Grating (Z0057832)
Page 18 of 65
Q A T A R
T-4.282.688
T-4.282.689
T-4.282.690
T-4.282.691
T-4.282.692
T-4.282.693
T-4.282.694
T-4.282.695
T-4.282.696
T-4.282.697
T-4.282.698
T-4.282.699
T-4.282.737
T-4.282.738
T-4.282.739
T-4.282.740
T-4.282.741
T-4.282.742
T-4.282.743
T-4.282.744
T-4.282.745
T-4.282.746
T-4.282.747
T-4.282.748
T-4.282.749
T-4.282.750
T-4.282.751
T-4.282.752
T-4.282.793
T-4.282.845
T-4.282.920
T-4.305.053
T-4.305.085
T-4.305.144
T-4.305.149
T- 4.318.527
T-4.318.571
T-4.318.572
T-4.318.585
T-4.368.020
T-4.250.904 Rev. A
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Part List Hand and Cages at ACC Platform

(ASM) Windwall Column (Z0062738)
(ASM) Windwall Modul Trans (Z0062754)
(ASM) Windwall Modul Trans III (Z0062758)
(ASM) Monorail Bracing (Z0063067)
(ASM) Ladder for Windwall (Z0063621)
(ASM) Door Beam (Z0063710)
(ASM) Windwall Modul trans (Z0072330)
(ASM) Windwall Modul trans II (Z0072342)
Angle (Z0050282)
Angle (Z0050283)
Angle (Z0050284)
Angle (Z0050285)
Angle (Z0050286)
Angle (Z0050287)
Angle (Z0050288)
Angle (Z0050301)
Angle (Z0050302)
Angle (Z0050338)
Angle (Z0050339)
Angle (Z0050340)
Angle (Z0050341)
(ASM) A-Frames
(ASM) Sealing Beam
Tyco Valves Preservation Procedure
IOM Lifting Devices
Lifting Study for ACC Structures above 10 Tonnes for Dwg. # SPXCTOEO2-N-ZV-1001.001, 1001.002, 1001.003 & 1001.004 (Optional
120T 70T
Lifting Procedure for Condensate Tank and Evacuation Unit
Lifting Procedure for A Frame of ACC
Lifting Procedure For Acc- Motor Bridge Assembly Structures
Above 10 Tonnes for Dwg. # SPXCT-OEO2-B-ZE-1008 (120T Crane)
Lifting Procedure for Steam Distribution Manifold at ACC (Typical)
Lifting Procedure for Erection of Steam Ducts
Procedure for Preservation at ACC
Method Statement for Erection of Fan Deck Plates at ACC
List of Equipment ASU
Page 19 of 65
Q A T A R
6
Doc. Title
GAM-MTS-MEC-GTL-009
Date
RESOURCES
6.1
Responsibilities
6.1.1 Site Manager

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

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

Site Engineer is responsible for safe execution of the whole job including:
Confirming the installation location from schedule of approved construction drawings.

Organizing of equipments and tools needed for the job.
Assigning skilled personnel for the job.
Sequence of activities to be carried out for the work as per this method of statement.
Conduct inspection and surveillance.
Notify to Contractor engineer for inspection as applicable.
Ensure that all Contractor and Company regulations are followed.
Ensure that all personnel involved are in safe working condition at all times.
6.1.4 Site Supervisor (SS)

Site Supervisor is responsible for safe execution of the following activities:
Conduct TSTI with the concerned work force prior to start of work.
Ensure that relevant work permits for the job are obtained prior to start of work.
Conduct daily toolbox talks for the entire work force prior to start day work.
Assigning a competent work crew for specific activities, details of activities and task
information will be given to the work crew.
Organizing tools and equipment needed to the work site.
Inspection and supervision of work.
Ensure that all Contractor and Company safety regulations are followed as applicable.
6.1.5 Piping Supervisor (PS)

Piping Supervisor is responsible for the erection of pipes that will be performed in
accordance to the method of statements
6.1.6 Artisans
Group of skilled and semi skilled workers who will be responsible for the execution of
works and other jobs related to the completion of construction of ACC at C2 area.
T-4.250.904 Rev. A
Page 20 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
6.1.7 QA/QC Officer / Inspector

QA/QC Officer/Inspector is responsible for:
6.2
Inspecting and Certifying of all foundations, alignments, etc. will be in coordination

with the Contractor representative as per conformance of the specifications
Assurance of approved methods and materials are being used and conformance of
the specifications
Stage inspections and surveillance in accordance with ITP and assurance of quality of
work as per specification and erection procedures
Incoming material inspection and review of test certificates
Equipment & Manpower

All equipment will be inspected and approved by the Contractor, when required, and all
personnel will be inducted and trained before and during mobilization.
6.2.1 Equipment
Crane (1) each for 250 T, 120, 100 T, 80 T, 70 T and 50 T lifting capacities
hydraulic or crawler type will be utilized
Forklift 15 and 5 T capacity
Boom Truck 5 T capacity
Aerial Work Platform (man lift equipment) capable to 45 meters reach, (2) numbers
either telescopic and /or folding hydraulic type
Man basket for 3 persons
Trailer for transport of materials from lay down area to assembly site
Rigging and lifting equipment approved, certified and color -coded
Scaffolding as per requirement
Gas cutting torch with arrestors and welding machines
Grinding machine with correct grinding wheels and tool speed
Survey and level instruments
Portable diesel generator and portable lights to service night works
Hilti DX 76 Fastening tool
Air compressor
Hand and electric tools Note: No prefabricated tools will be allowed and shall be in
good working order
Paints and accessories Only for repair and touchup
6.2.2 Manpower
Management
Site Engineer
Foreman
HSSE personnel
Certified Crane operator
Certified Forklift operator
T-4.250.904 Rev. A
Page 21 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Certified Articulated man lift operators

Banks man and slingers
Erectors
Mechanical fitters
Scaffolders
Fire watchers
Associated vendors
Driver
If the above-listed equipment or manpower proves not sufficient for the timely completion of the
facilities and project; additional will be provided to complete the works on time and in line with
rules, regulations and specifications of Contractor, Company and RLIC.
T-4.250.904 Rev. A
Page 22 of 65
Q A T A R
7
Doc. Title
GAM-MTS-MEC-GTL-009
Date
METHOD OF EXECUTION
7.1
General
This chapter explains the methods to be used for the erection of all structural steel works,
piping and duct works, installation of air cooled condensers with associated equipment, and
steam recovery at the following site; FD at C2 area.
This method shall also apply to the other sites FA, FB, FC, and GA, GB, GC, GD at C2 area.
7.2
Pre-Commencement Works
7.2.1 Foundation Seats
Prior to works commencement, all seating foundations are checked for load bearing
of all steel erection as per approved drawings issued by the vendor or the company.
Any deviations as per plan will be recorded and served as guideline during the
execution of works and shall be within the tolerances recommended by the
manufacturer
Survey report on the main level references from Civil will be generated and submitted
before start up of construction to anticipate problems which can be encountered
during construction and alignment stages. Any deviations from the general
arrangements, drawings shall be identified
7.2.2 Logistical Materials and Equipment
Materials and equipment required during the duration of works shall be available
nearby and checked
Lay down area for materials and equipment shall be located in such a place that
double handling can be minimized or can be totally eliminated. Due to space
limitations at the assembly area, a minimum supply of materials or structures for at
least three days will be maintained to assure continuous works without interruption.
This will also reduce risk for possible damage and distortion of materials from
handling and during assembly
Lifting procedures will be followed as per documents T-4.234.084 for Lifting General
Scaffolding will be followed as per separate method of statement and PTW (permit
to work) will be initiated before any works can commence; please refer to document
T-4.234.080. The use of scaffoldings will only be at selected area where height and
space have some limitations example as: pipe installation and welding works inside
the A-frame with bundles structures, piping below the fan deck; installation and
connection of condensate duct from turbine to the SDM
7.2.3 Barricades and safety Sign Boards
All works areas are to be secured, barricaded, and posted with signboards indicating
that works are in progress, and lifting operations are being conducted
Only authorized personnel's will be allowed to work within the perimeter
All barriers will be kept in place during the progress of works, and/or until the works
are completed
T-4.250.904 Rev. A
Page 23 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
7.2.4 Positioning and Lifting Equipment

7.2.4.1 Lifting and related equipment will be in position only by certified operators and banks
man; ground foundation checked for stability before setting up the outriggers or tracks
7.2.4.2 Correct colour coded and certified slings are to be used only
7.2.4.3 Aerial work platform/man-lift and construction cages are to be used for certified
erectors. When construction cages are being provided, dead man's control & inspection
certificate will be presented. The personnel must rope themselves into the cage. The
cage must be suspended in an insulated manner when welding work is to be performed
from the cage.
7.2.4.4 It is necessary to determine more or less the weights of the following sub-structures or
equipment due to limitations on space and height at the assembly area for its respective
lift, and they are as follows:
The assembly of two adjoining columns and braces (Step 1)

Member
1
2
3
4
5
6
Part no.
Description
Wt.
No.
Total Wt.
A0080123 Column 1
1864.4
2
3728.8
A0087913 Column 1
1920.8
2
3841.6
A0088074 Column 1
1164.4
2
2328.8
A0087511 Hor. Bracing
727.836
1
727.836
554.345
1
554.345
924.12
2
1848.24
Wt of two adjoining columns & braces 13029.621 Kg
13.03 T
Note: This shows how weight of the steel structure is calculated
T-4.250.904 Rev. A
Page 24 of 65
Q A T A R
2
3
4
5
6
7
8
9
GAM-MTS-MEC-GTL-009
Date
Part no.
A0087709
A0087701
A0088079
A0088025
A0088074
A0087511
A0087512
A0087506
A0080136
A0087493
A0087495
Description
Wt.
No.
Column
1745.3
1
Column
1745.3
1
Column
1838.4
1
Column
1838.4
1
Column
1164.4
2
Hor. Bracing
727.836
1
Hor. Bracing
554.345
1
Hor. Bracing
924.12
2
Hor. Bracing
312.166
2
Hor. Bracing
312.166
2
Hor. Bracing
330.493
2
Wt. of two adjoining columns & braces
Total Wt.
1745.3
1745.3
1838.4
1838.4
2329.8
727.836
554.345
1848.24
624.332
624.332
660.332
14536.617 Kg
14.54 T
The motor bridge with drive unit

Member
1
2
3
T-4.250.904 Rev. A
Assembly of two adjoining columns & braces (Step 2)

Member
1
Doc. Title
Part no.
Description
Wt.
No.
Total Wt.
A0087898 E. Motor
1700
1
1700
A0086149 Gearbox
1400
1
1400
A0091415 Motor Bridge Complete 5102.812
1
5102.812
Motor Bridge consists of the following: A0091417 Railings
A0091360 Gear Support
A0091352 Transversal Beam
A0091398 Press Lock Grating
A0075068 Fan Impeller
126.88
7
888.16
Wt. of Motor Bridge & Structure 9090.972 Kg
9.10 T
Page 25 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
One section of A-frame

Member
1
2
3
4
5
6
7
8
9
Part no.
A0080285
A0080291
A0080280
A0080330
A0084581
A0088149
A0080320
A0080316
A0080302
10
11
12
13
14
15
16
17
A0080309
A0089231
A0089232
A0080338
A0091097
A0091096
A0091101
A0091100
Description
A Frame
A Frame
A Frame
Bracing
Top Girder
Top Girder
Hanger
Monorail
Top Steam Header
Support Beam
Outrigger
Outrigger
Outrigger
Bracing
Sealing Beam
Sealing Beam
Sealing Beam
Sealing Beam
Wt.
1568
820
2322.5
260.215
938.37
689.2
55.267
195.4
237.63
No.
2
2
2
8
1
1
2
2
1
Total Wt.
3136
1640
4645
2081.72
938.37
689.2
110.534
390.8
237.63
69.138
61.81
63.423
2
138.396
2
123.62
2
126.846
2
33.801
95.801
1
95.801
95.801
1
95.801
95.801
1
95.801
95.801
1
95.801
Wt. of A Frame 14675.121 Kg
14.67 T
Note: Only for presentation
The sections of SM (Steam Manifold)

Member
1
2
3
4
5
T-4.250.904 Rev. A
Part no.
A0080519
A0080520
A0080521
A0086422
A0080522
Description
Spool
Spool
Spool
Spool
Spool
Wt.
No.
5420
1
4700
1
3700
1
3650
1
3323
1
Wt. of steam Manifold
Total Wt.
5420
4700
3700
3650
3323
20793 Kg
20.8 T
Page 26 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
3 Lifts to be carried out
CM (Condensate Manifold) sections per street
Consists of 5 spools @ 2,300 Kg each
One assembly of support and parallel beams at the upper deck

Member
1
2
3
4
5
6
7
8
9
10
11
12
T-4.250.904 Rev. A
Part no.
A0079847
A0079904
A0079900
A0079896
A0079898
A0079904
A0079902
A0092946
A0089654
A0084106
A0082543
A0082456
A0084105
A0081962
A0089614
A0089588
A0089516
A0086912
A0079878
A0098394
A0086912
A0086911
A0086973
Description
Wt.
No.
Total Wt.
Longitudinal Beam
328.664
2
657.328
Longitudinal Beam
328.664
2
657.328
Fan Deck Cross Beam 102.318
4
409.272
Diagonal Beam
180.388
2
360.776
Diagonal Beam
270.831
2
541.662
Parallel Beam
225.28
2
450.56
Parallel Beam
187.849
2
375.698
Spring Support Beam
68.225
1
68.225
Spring Support Beam
68.225
1
68.225
Beam
21.705
1
21.705
Beam
21.313
4
85.252
Beam
21.313
4
85.252
Beam
21.704
1
21.704
Beam
472.99
1
472.99
Column Head
520.149
2
1040.298
Support Beam
85.534
1
85.534
Support Beam
128.704
1
128.704
Support Beam
171.993
1
171.993
Platform End Profile
751.931
1
751.931
Support Beam
274.061
1
274.061
Support Beam
171.993
1
171.993
Support Beam
128.704
1
128.704
Platform End Profile
151.769
1
151.769
Wt. of Fan Deck Structure 7180.964 Kg
7.2 T
Page 27 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Lifting of structures/members & equipment to the upper deck will be performed by

the 250 T / or 120 T crane with counter weights.
For any single lifts greater than 10 Tonnes, individual rigging plans shall be
provided and approved before lifting can commence
Lifting procedures will be followed as per lifting method of statement documents
T.4.234.084
Avoid related equipment operate over or near pre-installed and covered lines.
Ensure such equipment access lifting area through identified access ways. (FSI
Ref.: Q1-1.3.1.)
Avoid related equipment cause over settling of concrete pits resulting shears at the
grip pipe connections. Following the lifting operations, ensure proper condition of
any nearby underground piping (with video cameras if necessary). (FSI Ref.: Q11.3.4.)
7.2.5 Main Erection Sequence

7.2.5.1 Under Structure Erection
Start works at street 3; Method of statement for structural steel assembly; refer
document T-4.250.902 also applies
Two vertical column frames will be assembled on the ground, will be erected on the
foundation plinths, using two cranes; and will be stabilized with 20 mm diameter wire
ropes as temporary supports for verticality. Minimum of two set of cables of hand
operated winch will be used to serve as guy ropes for stability. The bigger crane (100 T)
will lift the load and the smaller one (80T) will support the tail load during mounting the
structure to vertical position.
The temporary supports (ropes) will not be removed until twin column is erected and
horizontal bracings and other diagonal braces are secured or bolted in; continue until
one street is completed.
T-4.250.904 Rev. A
Page 28 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
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 colourcoded indicating that bolts are
properly checked and correct torque is applied.
All erection works will be done by competent and certified erectors, and banks man for
all lifting operations.
Grouting will be done on steel structure foundation with approved materials as per site
specifications after complete alignment and acceptance of fan deck assembly of each
street.
See illustration for similar installation for a similar project by other agencies: -
STEP 1
STEP 2
STEP 3
7.2.5.2 Upper Structure/Fan Deck

The peripheral beams of the fan deck will be assembled on the ground and installed to
form the support structure; assuring that all bolts are tightened correctly. Temporary
detachable railings will also be integrated and fixed to the structure prior to lifting, as
safety measure for people to work at the upper deck later.
T-4.250.904 Rev. A
Page 29 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Aerial work platform (AWP) will be used by the erectors in connecting the structure to
the built columns. Proceed until the whole street is completed forming a complete
working table. Wherever necessary, man lifts will be also be used.
Inspection for the elevation and verticality will be done after it is determined and
conditions are acceptable within the given tolerances. It will serve as a guide or
reference in foregoing installation of equipment and structure to the adjacent streets
After completing the erection of the fan deck structures at street 3, erect the columns
and steel structures at N module of street 4 (south corner). Stairs and walkways will be
assembled and will serve as access going to the fan deck or upper structure. This will
provide us some leeway of maximizing the utilization of man lifts to other area and
eliminate expensive scaffoldings
One bracing is required to be temporarily removed to allow installation of condensate
tank and steam evacuation unit. Further study on the removal of the bracing will be
provided in ref. T-4.305.085
Note: It is not permitted to proceed with erection of other equipments as motor bridge,
A-frame, CCM and SDM until completion of condensate tank and steam evacuation unit
and installation of temporarily removed bracing is complete
Deck plates and gratings are to be secured by Hilti fastening tool; catch nets to be
provided and laid out on the fan deck screens to prevent materials, etc from falling and
other safety reasons.
Catch nets specification: PE or Polyester or PP perimeter debris netting for construction
industry (Mesh size 2.5 x 2.5 mm, width 2000mm) subject to approval by Linde
Engineering AG/PMC
Subject to prevailing conditions at site, an alternative scheme can be device to be able
to install the fan deck plates at the fan deck structure
After erecting the fan bell with screen into the structure, platform openings can only be
closed by fan deck plates during the course of construction, hence additional safety
measures for people working at height is mandatory. Additional lifelines aside from the
proposed will be provided i.e., lines installed midpoint from each cell. The latter will be
use for people to be positioned inside the fan bell assembly during the laying out &
fastening the fan deck sheets into the structure. They will be assisted by a third person
riding in the manlift
Lifting of the fan deck plates will be done according to attached procedure - Lifting ACC
fan deck plates & plate clamps lifter will not be allowed to be used
The Sequence will be repeated until the cell is covered by deck plates
It (deck plates) will be fixed permanently soon as activity 7.2.5.3 is completed
See illustration for similar installation by other agencies: -
T-4.250.904 Rev. A
Page 30 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
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 offset from the axis.
Final alignment of the fan stack with screen will be carried out once the motor bridge
with the drive unit installation is completed.
Lifting will be done by certified and competent riggers and banks man.
T-4.250.904 Rev. A
Page 31 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
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.
T-4.250.904 Rev. A
Page 32 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
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%.
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.
T-4.250.904 Rev. A
Page 33 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
7.2.5.7 Assembly of CCM, Bundles, SM, Piping Works and Wind wall
Erection of the remaining structures will be as follows: Condensate Collecting Manifold (CCM) first, secondary bundles and primary bundles,
and Steam Distribution Manifold (SDM) as third step
Assemble and weld two CCM spool on the ground, temporarily fixed with bolts after
lifting them at the upper deck. These bolts can be removed once the alignment and tack
welding of the CCM is done. Lift the next two joined spools, and join to the latter spools.
Final alignment of the joined spools and welding will be done at this stage, then
proceed to complete the street. Final welding on the manifold will be done as soon as
all the alignment of the manifold is achieved
Before erecting the bundles onto the A-frame, thorough inspection will be done for any
damages. The inspection shall be recorded and noted whether bundles are acceptable,
or require repairing
Lifting up of the bundles starts first with secondary, then the primary. Installation of
lifeline for people working in the bundle erection will be performed. Refer document
attached
Lifting up of the bundles will be alternate (to Left & to right side) to avoid unbalancing on
the structure. Bundles shall be lifted at the required A-frame slope, using offset sling
lengths.
Join two (2) opposite primary bundles with plate (A0080412) by welding after aligning
the bundles; taking into consideration on special procedures to avoid overheating of the
tube sheets. After welding completion and alignment, the steam distribution manifold
(SDM) will be installed.
The weight of the complete steam manifold exceeds 10 Tonnes, hence it is necessary
to have at least three (3) lifts; starting lift of spool 3 (A0080521) at the fixed point, which
is located on the top of the secondary bundle structure. Spool 4 (A0086422) & spool 5
(A0080522) will be assembled & welded on the ground prior to lifting; similarly with
spool 1 (A0080519) & spool 2 (A0080529). They will be joined with spool 3 after
erection at the structure. Lifting lugs will be provided for its joined spools, taking into
consideration of the centre of gravity. Seal plates at the end of manifold (spool 5) are to
be adjusted at the site after the bundles assembly & steam manifold installation is
completed and stitch welding of the manifold & bundle will commence.
Ensure all heat exchanger pipe protection covers removed before installation. (FSI Ref.:
Q2-2.1.)
Ensure pipes are internally clean before lifting into the structure (visual, air blow, liftingup at one end). (FSI Ref.: Q2-1.8.)
Ensure all open ends capped after work interruption or day end. (FSI Ref.: Q2-1.8.)
Condensate tank and structure will commence for erection after fan bell is erected at
module N of street # 4.
Condensate tanks, steam ejectors, the drain pump station and associated equipment
and instrumentation will be erected and piping will follow as soon as the upper
structures are done, then continue to work on the remaining streets.
T-4.250.904 Rev. A
Page 34 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
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.
T-4.250.904 Rev. A
Page 35 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
7.2.5.8 Steam Ducting

The steam ducting will be assembled and installed between the connection of the
turbine exhaust and the ACC with the construction sections as per drawings.
Steam ducting section certain sections are fabricated with additional fitting lengths.
These fitting lengths will be used for adjustment to site conditions. By means of a cutter
or blow torch; the sections will be cut to the exact length required during installation, the
cut edge will be ground smoothed, cleaned and prepared for welding in accordance
with specified WPS.
The expansion joints and ducting sections will be assembled and welded together to a
great extent at the ground level, before lifting them into position; however the weight of
the assembled parts and crane lifting capacity and the reach will be considered and
planned accordingly.
During installation of the expansion joints and the vane elbows special care and
attention will be taken to ensure that they are installed correctly for the direction of the
steam flow.
Beginning at the turbine, the remaining main steam ducts and risers are installed up to
the top steam distribution manifold.
T-4.250.904 Rev. A
Page 36 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
The Steam ducting installation will start at the duct fix point. Sequence refer sketch as
given below in (illustration A & A1): -
Connection
Point SM
Connection
Point SM
Fixed Starting
Point
Illustration A
Illustration A1
The steam ducting has to be assembled and installed starting from the turbine outlet at
machine house to the air cooled condenser inlet joining streets 3/4 and streets 2/1
respectively. The expansion joints and ducting sections can be assembled and welded
together to a great extent at the ground level before lifting them into position.
Spool 1 a (Drg. No.:Z0060956; T-4.219.793) and expansion joint to be welded on site to
the turbine piece before turbine installation.
T-4.250.904 Rev. A
Page 37 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Install complete part to the turbine flange and lift together with turbine into the turbine
table.
After adjustment at spool 1, fabricated duct part-01 DN3820 (Drg. No.:Z0055358; T4.121.231) to be welded with the expansion joint. During installation of the expansion
joints and the vane elbows, special care and attention shall be taken to ensure that they
are installed correctly for the direction of steam-flow.
Additional stiffening brackets may have to be welded to the steam duct risers in the
area of expansion bellows for safeguarding and preventing damages on the rings
convolutions of the expansion rings.
All sections of the ducting must be connected together free of any "forces and
moments" by means of using the correct procedure and respectively, the planned
sequence of erection. It is not acceptable to assemble or install together by force as this
would lead to lateral deformation or misalignment of the supports. Even in such cases;
uncontrolled forces and moments can occur to the turbine connection.
After full completion of the ducting and piping systems; all temporary stiffening or
locking devices must be removed.
Separate Method statement for ducting will be prepared and got approved prior to
commencement of the erection of ducting.
7.2.5.9 Preservation of ACC

Preservation of the Installed ACC. Due to the local conditions at Pearl site and long
period between the mechanical erection and final commissioning preservation methods
on site need to be considered. All parts, components and auxiliaries are to be
preserved after installation in accordance with the general instruction listed in Ref.: T4.121.350.
The scope of this procedure is to describe the measures to be undertaken for the
preservation of ACC (Air Cooled Condensers).
The measures will be undertaken in order to preserve the equipment & reticulations in
order to maintain the ACC performance to high degree. The measures to be undertaken
are divided into three gradations, each presenting different level of protection, as the
length of shut down in cases, a higher level of protection will be required and
economically justified.
Categories:
1. Short Term Shutdown
Short term shutdown is considered a period less than one week, with respect to
preservation of ACC, no specific requirements are to be fulfilled
2. Medium Term Shutdown
Medium term shutdown is considered a period of more than one week and less than
6 (six) weeks,
Dry air connection is to be made into the manhole (20) on steam duct near to hot
weld, Air evacuation to atmosphere through the hogging ejection silencer & holding
ejectors.
T-4.250.904 Rev. A
Page 38 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
Precautions:
All valves on steam, air extraction & condensate shall be open (except for vents and
drains)
Vent & drain on condensate tank can be partially open to improve air circulation in
the tank
Condensate pumps to be removed to create air circulation of dry air
Preservation with hot air cannot be considered for the ACC tube bindles since cooling
surface is high and air will cool down immediately, hence efficiency is limited. The
condenser, tanks, vessels and tubes to be drained. The condenser will be preferably
blown dry with air; if possible to be maintained under vacuum
3. Long term Shutdown
Long term shutdown is considered a period more than 6 weeks.
Alternative A: Dry air preservation

All condensate shall be drained in
Condensate tank
Hot weld on Steam Duct
Vacuum ejector units
Condensate pumps
After draining of all components, immediate drying of complete ACC will start
Dry air shall be blown into the steam duct and evacuated at hogging and holiday
ejector outlets.
A continuous dry air injection is to be foreseen
Alternative B: Preservation with Nitrogen

This alternative is theoretically possible, but not practical due to huge quantity of
nitrogen requirement.
Blanketing plate is provided in part 1 of the steam duct, hence steam turbine
connection is isolated
The condenser, the steam duct, the vessels, exchangers and all connecting pipings
will be drained and filled with nitrogen
The purging of nitrogen will be controlled within 0.05 barg and 0.25 barg over
pressure. When it exceeds, the nitrogen has to be blown off
Note: Complementary to preservation; following interventions are especially
required:
Condensate Pump
Weekly by hand rotation
Gearboxes
Rotation of gearbox every 3 weeks
Greasing
Check every 3 months
In addition to the above a separate procedure on preservation will be presented and

approved. Refer doc # T-4.318.572
T-4.250.904 Rev. A
Page 39 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
7.2.5.10 Piping Erection Order

Condensed steam piping, air extraction piping, cleaning system and instrumentation
with related support and hangers will be erected according to approved SPX reference
drawings, only certified welders will be performing based on existing Welding Procedure
Specification.
Basic consideration will be given before any erection works can start and are as follows:
Steel structure will be built so far that the main pipe supports will be erected.
Main pipe supports will be made and assembled in right positions and level.
Equipment and devices will be available, assembled and fixed in right position
where pipe connections will be executed.
Required tools and materials will be made available so the works can continue
without interruptions.
Blind plates and plugs have to be kept in place during the progress of works.
Bigger and technically difficult pipes will be erected first before the small ones.
Non Destructive Test (NDT)
This activity is performed to check the correctness and soundness of the welded joints
performed at the site. A number of test can individually or in combination be applied
which includes but not limited to visual inspection; ultrasonic inspection, dye-penetration
check, magnetic particle check, eddy current check, radiography etc. the test will be
performed in accordance to NDT Procedure; ASME code Sec. V and related
specifications.
Leak Test and Cleaning of Pipes.
A separate method of statement will be prepared for the above test and procedure.
7.2.6 Special Technical Procedures

7.2.6.1 Bolting
The bolting applies for all subsequent description:
All high strength joints will be tightened to the specified torque indicated on the
drawings or attachments to manufacturing instruction respectively.
Correct bolt torque will be applied in accordance with the instruction given and will be
colour-coded to mark completion. Task completed will be recorded in site construction
records.
Employees doing bolt tightening shall bear a unique number in a similar manner to the
welder numbers and shall be certified appropriately. (FSI Ref.: Q1-1.1.1., 1.1.2., 1.1.3.)
The following table will be implemented for ACC Steel structure:
# dimensions
nominal preloading
Torque control
force (kN)
Method (Nm)
1
M 12
35
70
2
M 16
70
170
3
M 20
110
300
4
M 22
130
450
5
M 24
150
600
T-4.250.904 Rev. A
Torque value
(KN)
40
80
120
145
165
Page 40 of 65
Q A T A R
Doc. Title
GAM-MTS-MEC-GTL-009
Date
6
M 27
7
M 30
8
M 36
Refer document T-4.193.320
bolts from the vendor.
200
900
220
245
1200
270
355
2100
390
for Grade 8.8, hot dip galvanized and lubricated nuts and
The following table will be implemented for Motor & Gear Box, coupling's, fan blades
and other machine components: #
dimensions
Strength class 8.8
Strength Class 10.9
1
M6
10 Nm
14 Nm
2
M8
25 Nm
35 Nm
3
M 10
49 Nm
69 Nm
4
M 12
86 Nm
120 Nm
5
M 16
210 Nm
295 Nm
6
M 20
410 Nm
580 Nm
7
M 24
710 Nm
1000 Nm
8
M 30
1450 Nm
2000 Nm
9
M 36
2530 Nm
3580 Nm
10
M 42
4070 Nm
5720 Nm
11
M 48
6140 Nm
8640 Nm
12
M 56
9840 Nm
13850 Nm
13
M 64
14300 Nm
21000 Nm
Refer Document T-4.200.145 as provided by SPX/vendor.
Additional Reference: DEP 34.28.00.31
Any other bolts of different grades, the torque values will be followed in line with the
vendor's recommendations.
7.2.6.2 Site Welding Principles

On structures and parts of structures as well as all the items that are protected by hot
dip galvanization, welding is not allowed. Repair and/or adaptation of assembly parts
are subjected to a concession authorized by SPX site representative prior to
proceeding.
Welding will be performed by certified welders with approved WPS (Welding Procedure
specifications).
NDT shall be carried out on areas of lifting lug removal after dressing of affected area.
Welding map; each weld should be itemized with particular reference number and
recorded in the welding map drawing and listed on record sheets with location and
WPS that are done.
In case of bad weather conditions, special protection during welding must be taken to
avoid weld failure; such prevention will be listed before starting main welding operation
and must follow general welding recommendations.
Galvanized structures need to be shielded off during welding and/or grinding activities
in close proximity to avoid contamination or damage.
Whenever the galvanized portion or portions is damaged on the structure or corrosion
exist; repair can be done with the following procedure;
T-4.250.904 Rev. A
Page 41 of 65
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Doc. Title
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Date
o corrosion or damage shall be removed using light sweeps of an orbital grinder

o 25 mm band of sound galvanizing around the damaged area shall be carefully
feathered down to bare steel
o residual oil or grease shall be removed with degreaser
o on surface preparation completion, scrub and rinsed with fresh water
o the area shall be coated with rich zinc paint (or approved equal paint) for at least
100 microns, or
o the repair coating shall overlap onto the feathered edge of the existing galvanizing.
Following FSI Issues will be as follows with T-4.186.019: 1. Ensure welding of valves is carried out with closure member in open position as
required by Appendix 3, DEP 31.38.01.31 to avoid small bore valve internals be
damaged during welding. (FSI Ref.: Q1-1.2.5.) (T-13.377.360)
2. Ensure received rotating equipment drain connections are free of screwed and seal
welded screwed connections. (FSI Ref.: Q1-3.3.)
3. Ensure adequate supervision/QC during lifting & lug removal to avoid pin holes at
Column walls. (FSI Ref.: Q1-4.3.)
4. Apply GTAW (TIG) root run welding for all pipe welds on process piping works (no
internal slag generation) unless access to back weld is possible, (i.e.> 36" diameter)
to avoid instrument toppings and small bore piping plugged with weld slag. (FSI
Ref.: Q2-1.16)
5. Have tight control on GTAW root run backing gas dams. Avoid paper dams with
sticky tape. (FSI Ref.: Q2-1.16)
6. Ensure thorough inspection on internal cleanliness when any form internal dams for
backing gas are being applied. (FSI Ref.: Q2-1.16)
7. Root bulge of weld between nozzle and flange has to be removed by grinding to
ensure correct ID of manhole walls. (FSI Ref.: Q3b-59L)
8. Ensure the cleanliness be preserved after welding, cutting or grinding operations as
per T-4.250.930 Quality Control Procedure for Cleanliness Paragraph 12.2.
9. Ensure the cleanliness be preserved after welding, cutting or grinding operations as
per T-4.250.932 Quality Control Procedure for preservation of Piping Material and
Equipment.
10. Proper screening and training of the personnel shall be performed in accordance
with the T-4.219.615 Rev. C Training and Orientation.
7.2.6.3 Record of Deviation and Tolerance for Construction
Deviations and tolerances have to be strictly followed as per requirements specified by
associated Vendor's.
Refer Doc. T-4.121.350 records & protocols will be recorded, kept & maintained.
QUALITY ASSURANCE
A Quality Assurance System will be operated conforming to related standards and
vendor's recommendations.
T-4.250.904 Rev. A
Page 42 of 65
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Date
Controls and checks will be established and documented through relevant QCP T4.250.944 & ITP T-4.250.921 and QCR's.
FSI should also apply to this method of statement. Reference DEP 70.10.70.11
ATTACHEMENTS
9.1
9.2
9.3
9.4
Job Safety Analysis

Installation of Life Line for Bundles Erection at ACC
Lifting of Fan Deck Plates
Design Calculation Notes for Horizontal Lifeline System
T-4.250.904 Rev. A
Page 43 of 65
Page 44 of 65
Mr. Bilal
Mr. Ozkan Karlioglu
Name
2. Permit To Work.
1. The following Personal Protective Equipment

shall be worn:
Approved coveralls, high-visibility vests, safety
glasses, safety helmet, safety steel toe shoes
and gloves, harness with double lanyard
(lifeline).
RLIC EMERGENCY NO
583 40 72
474 88 88
Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work.
2) Use additional sheets as necessary.
3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and SHELL Safety and Environment Procedures.
LINDE EMERGENCY TELEPHONE NO.
Approval required for hazardous work detailed in the Linde Work Permit Procedure.
Changing conditions and emergency procedures: Stop work. Switch off equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing
employees are reported to Linde HSSE Dept. When all clear is given, check with Linde HSSE before returning to work.
OTHERS (List Below):
HSSE Representative (Linde)
Date
24.11.08
JSA Members: Mr. Syd Osborne, Mr. Renato Tabing

Job Performers: Mr. Ozkan Karlioglu, Mr. Ertan
General job requirements / Common Personal
Date
Signature
Protective Equipment.
24.11.08
Additional Approvals (Determined by Job Supervisor in correlation with Linde HSSE Manager).
Name
Signature
Discipline Superindent (Linde)
Job Supervisor:
JSA by:
Normal Approvals:
Department/Section doing JSA: HSSE & Mechanical works
Page No: 1 of 6
JOB SAFETY ANALYSIS FORM
JSA For: T-4.250.904

NEW
REVISED
Job being analysed: Methods Statement - Main Erection Sequence for ACC
Q A T A R
Page 45 of 65
ITEM
Mobilization of
structures and
equipment to site
laydown area
ACTIVITY
Q A T A R
Personnel observation at
work
Ensure safe distance from
the excavations
Injury due to muscle strain
or sprains while lifting
weights
1.3
1.5
1.4
Adequate Banksmen
1.2
HAZARDS / POTENTIAL
CONSEQUENCES
1.1 Lifting and transport
equipment movement
LOW
MED
Rank
Initial Risk
1.5.2
1.5.1
1.4.1
1.3.1
1.2.1
1.1.3
1.1.2
SCOPE : Methods Statement - Main Erection

Sequence for ACC
Residual Risk
ADDITIONAL
P C
Rank
CONTROLS
1.1.1.1 Only drivers/operator with Qatar
license & certified operator &
trained personnel are be allowed to
work on site.
Ensure the area is wide enough for the 1.1.2.1 Ensure that every vehicle and
slewing movement.
equipment is fitted with an
automatic reverse alarm and
beacon or strobe light.
1.1.3.1 Barricade working area and
Place the outriggers in level ground
B 2
LOW
provide warning signs.
surface and ensure ground
compaction report required to
accompany lift plan.
Ensure that an adequate number of
1.1.4.1 Proper determination of cg (center
Banksmen are assigned as necessary
of gravity) for each lifts
to control work.
All personnel to be vigilant of each
other and vehicle movements.
Ensure the area is wide enough in the
travelling range.
Ensure employee shall be trained in
safe methods of handling equipment,
assessed & qualified.
1.5.2.1 The weights of each structure or
Assessment of weight of equipment
LOW
B 1
equipment will be specified and
and structure to be noted and
noted before any lift
numbers of person required to be
defined. Rigging & lifting plan to be
submitted for approval.
MAIN
CONTROLS
1.1.1 Ensure that there are no obstacles in
the travelling range.
JOB SAFETY ANALYSIS / RISK ASSESSMENT

FOR T-4.250.904
Page 46 of 65
Unloading of
structures and
equipment prior to
erection
Erection of structure
and equipment
ACTIVITY
ITEM
Q A T A R
Working at heights
Working in confined space
Trippping & Slipping
3.2
3.3
Injury due to muscle strain

or cuts while lifting
3.1
2.2
HAZARDS / POTENTIAL
CONSEQUENCES
2.1 Lifting and transport
equipment movement
LOW
MED
HIGH
LOW
LOW
Rank
Initial Risk

Sequence for ACC
3.3.1 Adequate walkways and railings are

required
3.3.2 Lighting shall be set up to prevent
shadows.
3.2.2 Adequate ventilation and lightings are

required when performing welding at
the steam manifold
3.2.3 Ensure working with buddy system
3.2.1 Ensure that personnel are properly

educated and confined space trained
to do the erection works.
3.1.2 Ensure scaffoldings and ladders are

used when applicable.
3.1.2.2 Scaffold to be erected by qualified

persons.
3.1.2.1 Harness to be checked before use
3.1.1 Ensure that personnel are properly

3.1.1.1 Proper PPE (personal protective
educated and trained to do the
equipment) are required. TSTI to
erection works, safe work procedures.
be completed daily.
2.2.1 Ensure that materials handled are free 2.2.1.1 Proper PPE (personal protective
equipment) required.
from splinters or rough surfaces which
can contribute and affect harm.
LOW
LOW
MED
LOW
Residual Risk
ADDITIONAL
P C
Rank
CONTROLS
2.1.1.1 Only drivers/operator with Qatar
license & certified operator &
trained personnel are be allowed to
work on site.
B 1
LOW
2.1.2 Ensure the ground are level to prevent 2.1.1.2 Area to be barricaded off with sign
boards mwntioning lifting in
structures and equipment from
progress.
distortion
MAIN
CONTROLS
2.1.1 Ensure that no obstacle within the
laydown area

FOR T-4.250.904
Page 47 of 65
ITEM
ACTIVITY
Q A T A R
Tampering Electrical
equipment
Slip, trip, fall on same

level.
Risk of Fall
3.5
3.6
3.7
HAZARDS / POTENTIAL
CONSEQUENCES
3.4 Electrical hazard.
HIGH
LOW
LOW
MED
Rank
Initial Risk
3.6.1 Keep cables, materials, tools neatly

organised.
3.6.2 Area shall be properly maintained all
equipment and materials must be
properly stored and picked up.
3.6.3 Removed unnecessary materials in
the work place. Proper house-keeping
to be done at work place.
3.7.1 Ensure Proper education & training of 3.7.1.1 Use of Proper PPE. Harness to be
personnel doing erection works.
checked before use.
3.7.2 To provide temporary detachable post 3.7.1.2 Harness to be properly fixed at 2
(two) points above the head level.
and railings for clamping full body
harness to the structure attached or
secured.
3.7.3 To provide catch to cover the exposed 3.7.1.3
area at the fan deck structure during
Harness to be colour coded every
the initial stage.
month.
3.5.2 Work will be properly supervised at all

times.
3.5.3 Equipment will be checked by a
competent electrician after installation.
3.5.1
3.4.4
3.4.2
3.4.3
3.4.1
MED
LOW
LOW
LOW
Rank
Residual Risk

Sequence for ACC
MAIN
ADDITIONAL
CONTROLS
CONTROLS
3.4.1.1 Ensure all electrical equipment
Check electrical equipment prior to
were properly grounded and built
use. Ensure it is properly inspected,
with ELCB at their source.
color coded for the month and properly
documented.
Ensure good electrical connection.
Dont allow any live electrical parts to
touch the ground.
Dont touch electrically live parts with
skin or wet clothing.
Ensure that only qualified and trained
electrical technician will carry out in
setting up lights in work area.

FOR T-4.250.904
Page 48 of 65
Improper use of hand 7.1

tools
6.1
Right tools for the right

job.
Provide suitable ladder for

safer access
Utilizing equipment for

other purpose.
5.4
Personnel or Tools
falling
Collision with other object
5.3
Overturning
5.2
5.1
Utilizing
Utili i equipment
i
t ffor
other purpose.
Structural Failure
4.4
44
Operation of Crane
Collision with other object
4.3
Overturning
4.2
Operation of Areial
work platform
ACTIVITY
LOW
HIGH
MED
MED
MED
MED
MED
MED
MED
MED
Rank
Initial Risk
4.3.1.1 Only trained personnel will operate

the equipment.
4.3.1.2 Proper supervision during
operation.
4.2.1.1 Proper Training and certification of

the operators handling the
equipment.
4.2.1.2 Lifting plan submitted & approved.
ADDITIONAL
CONTROLS
4.1.1.1 Duly certified equipment will be
used.
6.1.3 Approved and color coded body

harness to be worn.
7.1.1 Never use defective tools.
6.1.2 Rigid barrier shall be provided.
6.1.1 Display warning signs.
5.3.2 Maintain specific area around the

aerial work platform.
5.4.1 Use equipment for sole purpose only.
5.3.1 Operate within the working range.
5.2.2 Avoid too much inclination of Boom.
5.2.1 Prevent from overloading.
6.1.3.1 Prior to use check the harness.

7.1.1.1 All tools to be inspected prior to
use and color coded.
6.1.1.1 Practice 3 point of contact.
5.3.1.1 Only trained personnel will operate

the equipment.
5.3.1.2 Proper supervision during
operation.
5.2.1.1 Proper Training of the operators

handling the equipment.
LOW
LOW
LOW
LOW
LOW
LOW
LOW
LOW
Rank
Residual Risk

Sequence for ACC
5.1.1 Ensure equipment reliability &

5.1.1.1 Duly certified equipment will be
complete inspection.
used.
5.1.2 Maintenance & Instrumentation failure.
4.3.2 Maintain specific area around the

aerial work platform.
4.4.1
4 4 1 Use
U equipment
i
t for
f sole
l purpose only.
l
4.2.2 Avoid too much inclination of the

Boom.
4.3.1 Operate within the working range.
4.1.2 Check conditions of instruments at

regular intervals.
4.2.1 Prevent from overloading.
MAIN
CONTROLS
4.1.1 Ensure equipment reliability &
complete inspection.

FOR T-4.250.904
HAZARDS / POTENTIAL
CONSEQUENCES
4.1 Structural Failure
ITEM
Q A T A R
Page 49 of 65
ACTIVITY
Operation of HILTI
DX76 fastening tool
Permit Holders
ITEM
Q A T A R
9.1
Unqualified PTW Holder's

(Supervisors)
HAZARDS / POTENTIAL
CONSEQUENCES
8.1 Utilizing of the unit.
LOW
HIGH
Rank
Initial Risk
8.1.5 Attention is required & could cause

hazard if incorrectly used; as damage
to property & tool.
9.1.1 All Supervisors will be trained by
GAMA/Linde on PTW procedures.
procedures
8.1.4
8.1.3
8.1.2
8.1.1
LOW
LOW
Rank
Residual Risk

Sequence for ACC
MAIN
ADDITIONAL
CONTROLS
CONTROLS
Ensure the users are trained to
8.1.1.1 Training is required for all user.
operate the tool.
Only authorised users have to operate
the unit.
8.1.1.2 Proper PPE for operator
The operator has to understand what
the tool is cabable off.
8.1.1.3 Discuss in TSTI.
Proper attention is required & could
cause hazard if incorrectly used; as
personal injury.

FOR T-4.250.904
Q A T A R
INSTALLATIONOFLIFELINEFORBUNDLESERECTIONAT
ACC
Doc.Title
Date
: 12thNovember2008,RevE
1. SCOPE:
The procedure applies to the installation or erection of the secondary & primary bundles for ACC at
C2 Area.
2. PURPOSE:
The main purpose is to describe the procedures on how the bundles will be erected & to ensure that
it is carried out in accordance with the project requirement and philosophy.
3. DESCRIPTION OF BUNDLES:
Secondary Bundles:
L x W = 10600mm x 2193mm
Wt.
= 3.403 Tonnes
Total number to be erected per ACC
= 24 nos.
Primary Bundles
L x W = 11100mm x 2193mm
Wt.
= 3.597 Tonnes
Total number to be erected per ACC
= 168 nos.
4. INSTALLATION OF LIFELINE ON TOP OF A-FRAME:
12 mm wire rope will be used

Two standard scaffolding beam clamps will be installed in two ends of the A-Frame
One end of the rope will be fixed in the structure at the fan deck i.e.; the motor bridge
The rope will run into the installed beam clamps and will be resting on top of the girder
The other end will be tensioned below by an appropriate tool or chain block or a hand winch
The system will be utilized by the erector during alignment & setting of the bundle & remove of
the tackles from the crane
The erector sitting on the A-Frame will brace himself in the installed lifeline & will straddle as
the next bundle is being erected
5. PROCEDURE
Bundles will be erected in the following sequence; first secondary & then the primary
bundles
Ensurethatallheatexchangerprotectivecoversareremoved&cleanedbeforeinstallation
BundleswillbeliftedfromthegroundusingthecraneavailableatACCarea
Bundles will be lifted in 30 inclination and to be placed into the erected AFrame. The
wholeweightwillbesupportedbytheinstalled(CCM)collectingcondensatemanifoldatthe
bottom & anchored on top of the AFrame. The two opposite bundles will be joined by
weldingonthelatestage
Sequence of lift will be alternate i.e. starting from the left to the right; or right to left
whicheverapplicabletopreventunbalancingatthestructure
During primary bundles erection, the lifeline system will be bolted into the edge of the
bundles & will cover the entire length of the street. This will provide access to trained
personnelintheexecutionoftheirworksi.e.joining,alignmentandweldingofbundles
Page 50 of 65
Q A T A R
INSTALLATIONOFLIFELINEFORBUNDLESERECTIONAT
ACC
Doc.Title
Date
: 12thNovember2008,RevE
The lifeline will be later removed during the erection of the (SDM) steam distribution
manifold
Manliftwillbeutilizedtofastenthemobilepostforlifelineandwillbespacedmorethan4
meter or at two bundles interval. At least two lines will be erected; & wire rope will be
minimum10mm.
6. ATTACHMENT:
Lifeline arrangement on top of A- Frame

Lifting sequence for bundle
Safe working procedure for exiting man basket or man lift in elevated position
Page 51 of 65
Page 52 of 65
Page 53 of 65
DESIGN CALCULATION NOTES

FOR
HORIZONTAL LIFELINE SYSTEM
FOR CONSTRUCTION
0
03.11.2008
N.KUMAS
Rev.
Date
Description
Prepared
Customer
Engineering
A.GKDALAY
F.TN
Approved
Checked
G
PEARL-GTL PROJECT
INDUSTRIAL PLANT MANUFACTURING &
QATAR
ERECTION CORP.
Document Title
HORIZONTAL LIFELINE SYSTEM
DESIGN CALCULATION NOTES
Document No.
000-101-S0041-CN01
Rev.
0
Page 54 of 65
PEARL GTL PROJECT - QATAR

Document Title:
Calculation Notes for Horizontal Lifeline System
Document No:
000-001-S0041-CN01
Page No:
Rev
TABLE OF CONTENTS
Page No
Table of Contents
1.0 GENERAL
i
1-5
1.1 Scope
1.2 System
1.3 Units
1.4 Materials
1.5 Reference Codes, Standards & Specifications
2.0 CALCULATIONS
3.0 CONCLUSION
10
Page 55 of 65

Document Title:
Document No:
000-001-S0041-CN01
Page No:
Rev
1. 0 GENERAL
1.1. SCOPE
This report is prepared for the design of the mobile post and horizontal lifeline system at
Fan Deck Sub-structure of ACC. The system is checked for the safety of wire ropes for a
factor of safety greater than 2 as well as the mobile posts to resist for the cable force.
Assuming some type of shock-absorbing/self-retracting lanyards are used; 410 kg (900
lbs) force for one worker is applied at midspan of the horizontal lifeline system for
design/analysis purposes and it is assumed that both top or mid-rail of the system could
be used.
As can be seen on the drawing at the next page; the support system is designed as
braced for both top and mid-rail at the corners as well as at the ends where the lifelines
coincide. The horizontal distance of the bracing form the vertical supports are considered
as 1.2 m providing an angle of 25.15 for the top rail with vertical support. The bracings
profiles are the same as the vertical supports of pipes with 38.1 mm diameter and 4.1 mm
wall thickness.
1.2. SYSTEM
System of the structure is indicated at the following page.
Page 56 of 65
Page 57 of 65
Page 58 of 65
Page 59 of 65
Page 60 of 65

Document Title:
Document No:
000-001-S0041-CN01
Page No:
Rev
1.3. UNITS
Throughout this report the following units will be used.
Length
m and mm
Area
m2
Force
ton, kg, newton
Pressure
kN/m2 (kPa)
Stress
N/mm2 (MPa)
Elevations
1.4. MATERIALS
Structural Steel
: S235JR
1.5. REFERENCE CODES, STANDARTS & SPECIFICATIONS

Throughout the design the following design codes, standards & specifications
are used:
OHS Guidelines Part 11 Fall Protection - Mon Nov 3, 2008
Eurocode 3-Design of Steel Structures-1993 Part1-1: General rules and rules for
buildings
Page 61 of 65
Page 62 of 65
= 600.44 cm
By doing iteration for t2 until the difference btw L2 and L22 converge to zero (see the next page);
Tangential cable tension at mid-span under its own weight and concentrated load t2 is calculated as
t2: 3690 kg
16.82 kg
16.73 kg
8 f 12
S .1 +
3s 2
w .s 2
8 . f 1
2
w.s
2
t1 +
Length of cable under its own weight L1
Cable tension at supports T1
Tangential cable tension t1
Nominal diameter, d:
Cross-sectional area, A:
Distance btw. anchor points,S:
Cable weight:
Modulus of elasticity:
Mid-span applied concentrated load for 3 workers:
Minimum breaking load:
Sag of cable under its own weight:
1.20 cm wire rope 6x7

1.13 cm2
600.00 cm
0.006 kg/cm
630000 kg/cm2
410 kg
10.30 ton
10.00 cm
000-001-S0041-CN01
CALCULATION NOTES FOR HORIZONTAL LIFELINE SYSTEM
2.0 CALCULATIONS
Document No:
Document Title:

7
Page No
Rev
Page 63 of 65
301.52326
301.50848
301.4939
301.47954
301.46538
301.45143
301.43767
301.42411
301.41073
301.39755
301.38455
301.37173
301.35908
301.34661
301.33432
301.32219
301.31022
301.29841
301.28677
301.27528
301.26394
301.25275
301.24171
301.23082
301.22007
301.20946
301.19899
301.18865
301.17844
301.16837
301.15842
301.1486
301.13891
301.12934
301.11988
301.11055
301.10133
301.09223
301.08323
301.07435
0.9041143
0.8661115
0.8285369
0.7913823
0.7546397
0.7183013
0.6823595
0.6468066
0.6116356
0.5768391
0.5424103
0.5083424
0.4746287
0.4412628
0.4082382
0.3755489
0.3431887
0.3111517
0.2794321
0.2480243
0.2169227
0.186122
0.1556167
0.1254018
0.0954722
0.065823
0.0364491
0.0073461
-0.021491
-0.050066
-0.078385
-0.10645
-0.134267
-0.16184
-0.189173
-0.216269
-0.243133
-0.269769
-0.29618
-0.322369
603.04654
603.01697
602.98782
602.95909
602.93078
602.90287
602.87535
602.84823
602.82148
602.79511
602.76911
602.74347
602.71818
602.69324
602.66865
602.64438
602.62045
602.59684
602.57355
602.55057
602.52789
602.50552
602.48344
602.46165
602.44015
602.41893
602.39798
602.37731
602.3569
602.33675
602.31686
602.29722
602.27783
602.25868
602.23978
602.22111
602.20267
602.18446
602.16648
602.14872
L2
602.142429
602.150856
602.159283
602.16771
602.176138
602.184565
602.192992
602.201419
602.209846
602.218273
602.2267
602.235128
602.243555
602.251982
602.260409
602.268836
602.277263
602.28569
602.294117
602.302545
602.310972
602.319399
602.327826
602.336253
602.34468
602.353107
602.361535
602.369962
602.378389
602.386816
602.395243
602.40367
602.412097
602.420524
602.428952
602.437379
602.445806
602.454233
602.46266
602.471087
L22
2040
2050
2060
2070
2080
2090
2100
2110
2120
2130
2140
2150
2160
2170
2180
2190
2200
2210
2220
2230
2240
2250
2260
2270
2280
2290
2300
2310
2320
2330
2340
2350
2360
2370
2380
2390
2400
2410
2420
2430
t2
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
S
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
1.131
A
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
0.00558
000-001-S0041-CN01
L2-L22
Document No:
Document Title:
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
630000
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
410
F
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
25.098425
t1
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
600.4444444
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L1
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f1
Rev
Page 64 of 65
S ( 2 F + ws )
8t 2
T2=
102.93 kN
The safety factor = Allowable load / Actual Load =
Allowable load of steel supports, fy*A:
- Reaction on the vertical support N= T2.sin() + q. cos()= 6202.16 kg
T2.cos()= q. sin()
= 31.61
- Reaction on the inclined support q = 7040.76 kg
1.46
- Reaction due to cable force on the anchor supports

For the equilibrium at anchorage, the sum of horizontal forces should be equal to zero.
= 16.73 cm
F + ws
t22 +
S
cos()= 2
= 0.99845
s
= 603.54 cm
= 3695.78 kg
Wire rope factor of safety: Min. Breaking Load / q = 2.79
Sag of the cable under its own weight and concentrated load f2=
= 300.47 cm
3
S

. 2
s = 600.93 cm

(t 2 t1).L1
+ L1
AE
S
w 2 .
2
2. s +
24.t 2 2
s 2 S ( 2 F + ws )
+
4
8t 2
L22=
Length of cable under its own weight and concentrated load L2=
The chord length btw support and center deflected cable s=
000-001-S0041-CN01

2
Document No:
Document Title:
3.19
L2 - L22 -= 2.61 cm
Page No
Rev
Page 65 of 65
>
Length of the weld for tension resistance , lv= 119.69 mm

Design tension strength of weld= 13262.17 kg
7040.76 kg
3690.05 kg
As a result, the horizontal lifeline with the support system is found to be safe.
1 - The cable tension load is less than the cable breaking load with a factor of safety equal to
2.79
2 - The axial load on tubular column is less than allowed load with a factor of safety equal to
1.46
3 - The baseplate weld capacity of the is greater than the applied load with a factor of safety equal to 1.80
The horizontal lifeline fall arrest system has been analyzed using the principle described above and the following results are gathered.
3.0 CONCLUSION:
>
= 277 Mpa
Length of the weld for shear resistance , lv= 59.85 mm

Design shear strength of weld= 6631.09 kg
f vw.d= ( fu / 3 )/( w * M2 )
000-001-S0041-CN01
- Baseplate welds;
Document No:
Document Title:

Page No
10
Rev

009-Method Statement - Main Erection Sequence For Acc PDF

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Pearl GTL

Shell Project No: HP-3000-QAT

Purchase Order Number:

1A-2121, 1A-2221, 1A-2321, 1A-2421,

1-2100, 1-2200, 1-2300, 1-2400,

QATAR SHELL GTL PROJECT (PEARL)

Company Comments Incorporated

Company Comments Incorporated

Company Comments Incorporated

Issued for Company Comments

Issued for Review

Issued for Internal Review

Prepared Checked Approved

METHOD STATEMENT - MAIN ERECTION SEQUENCE

Project Document Number: T- 4.250.904

24 November 2008, Rev. F

Equipment & Manpower __________________________________________________________ 21

METHOD OF EXECUTION _____________________________________________________23

Pre-Commencement Works ________________________________________________________ 23

Job Safety Analysis _______________________________________________________________ 43

Installation of Life Line for Bundles Erection at ACC __________________________________ 43

Lifting of Fan Deck Plates __________________________________________________________ 43

Design Calculation Notes for Horizontal Lifeline System ________________________________ 43

24 November 2008, Rev. F

24 November 2008, Rev. F

QSGTL and/or its PMC

24 November 2008, Rev. F

Specification For Traceability, Alloy Verification And Material Substitution

Quality Control Requirement For Welding

24 November 2008, Rev. F

(ASM) Fan Units

24 November 2008, Rev. F

Heat Stress Disorder Prevention

24 November 2008, Rev. F

Stair tower Staircase Type 4b

24 November 2008, Rev. F

(ASM) Column I Item ID A0087703

24 November 2008, Rev. F

(ASM) Fandeck Parallel Beam Item ID A0079902

24 November 2008, Rev. F

Steam Manifold Street 4

24 November 2008, Rev. F

(ASM) Windwall Modul Long Item ID A0087769

24 November 2008, Rev. F

Method of Statement For Surveying

24 November 2008, Rev. F

(ASM) A-frames Middle Page 5 of 5

24 November 2008, Rev. F

24 November 2008, Rev. F

(ASM) Sealing Beam (Z0055336)

24 November 2008, Rev. F

Part List Hand and Cages at ACC Platform

24 November 2008, Rev. F

6.1.1 Site Manager

6.1.2 Mechanical Erection Manager

6.1.3 Site Engineer

Confirming the installation location from schedule of approved construction drawings.

6.1.4 Site Supervisor (SS)

6.1.5 Piping Supervisor (PS)

24 November 2008, Rev. F

6.1.7 QA/QC Officer / Inspector

Inspecting and Certifying of all foundations, alignments, etc. will be in coordination