N6820-M04-2E-S2xxx

METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

Rev.: 00

Date: 18.01.2011
Page: 1

METHOD STATEMENT

INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2XXX

04.08.10

00

First Issue

UNNII
Mech.Eng.

Date

Revision

Description of Revision

Prepared by

MOHAMAD
HAMDY
M&E COORD.. Project Manager.
Reviewed by

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

Approved by

. Project Manager.2011 Page: 2 REVISION RECORDING Date Revision Description of Revision Prepared by 04.10 00 First Issue UNNII Mech.Eng.N6820-M04-2E-S2xxx METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR Rev.: 00 Date: 18.01. Reviewed by Approved by MOHAMAD HAMDY M&E COORD.08. This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law .

REFERENCE SPECIFICATION/ DRAWING 4. PARTIES INVOLVED 5. SCOPE 2. FOUNDATION SURFACE PREPARATION 9. PURPOSE 3. SAFETY PROCEDURES 11.01. EQUIPMENT INSTALLATION AND LEVELLING 10. MATERIAL RECEIVING 8. RESPONSIBILITIES 7. SCOPE This procedure applies to air compressor station to be purchased and installed at This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law . PLANT AND EQUIPMENTS 12. DESCRIPTION OF EQUIPMENT 6. ATTACHMENTS 1.METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev.2011 Page: 3 INDEX 1.: 00 Date: 18.

quality control of resource input and task activities.1 Flow sheet Gas and Flow sheet Water from Atlas copco 3. reciprocating type manufactured by M/S Atlas copco . PARTIES INVOLVED Various parties involved for this procedure TRANSCO – Owner ILF – Owner consultant TORISHIMA Main contractor NAEL ENERGY – Sub Contractor Atlas Copco – Air compressor manufacturer 5.: 00 INSTALLATION OF AIR COMPRESSOR Date: 18. responsibilities. one for Um Al Gaffa line and one will be common spare The compressor to be installed are of multi stage.N6820-M04-2E-S2xxx METHOD STATEMENT Rev.4 ADWEA Standards Specification . REFERENCE DOCUMENTS / DRAWING 3. which are planned and shown in sequence on the prepared Inspection & Test Plan (ITP) 3. There will be 3 identical compressor station .3 M6820-I01-4E-D005 – P&ID Air compressor package surge system 3.W-M-SS-007 Rev0 Package 3. DESCRIPTION OF EQUIPMENT As Part of Contract N6820. acceptance criteria. verifying test and inspection documents. PURPOSE This section describes the specific work quality plan to be implemented for the installation of air compressor station at Al Ain receiving pump station as part of TRANSCO contract N6820. This compressor station is utilised to feed compressed air to non vented type surge vessel during initial filling and during normal operation incise for loss of air mass .2 N6820-M05-2E-D005 drawing 3. The compressor and other ancillaries will be This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law .5 IOM manual compressor / assembly instruction canopy – Air compressor station General arrangement for Air Compressor 4.01.2011 Page: 4 Al Ain receiving pump station as part of TRANSCO contract N6820 2. and inspection points. out which one compressor for surge vessel plant for GIC line . It covers procedures. Air compressor systems will be installed at AARC Pumping station. oil free .

multi stage water cooled .N6820-M04-2E-S2xxx METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR Rev. Reciprocating . Cooling Tower model CTE50 This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law .01. oil free air compressor Model 3HX2T 2.2011 Page: 5 installed inside noise and sound proof canopy except cooling tower The main components in compressor system are 1.: 00 Date: 18. High Pressure Ancillary Equipment:     Dryer model HFD130W Activated Carbon Filter model HQD16 Fine Filter model HDDP160 Water Pump Skid model WPS16HAT 3.

Safety and Operations to ensure that all work activities are completed in a safe and efficient manner in accordance with this procedure and standards referred herein. MATERIAL RECEIVING This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law . He shall be responsible for obtaining the following as a minimum for the safe erection/installation of equipments under this scope:    Shipping Net Weights of each separate components of compressor system Manufacturers’ drawings indicating the location of lifting lugs and the centre of gravity. He ensures that all pertinent QC records are in order and finally handed-over to Client/Consultant in organized manner. Canopy 6. He ensures that all activities are being performed in compliance with this Method Statement. Manufacturers’ recommendation for the lift including the use of spreader bars. 6. turnbuckles and so forth. applicable ADWEA Standards and established procedures. and other related activities covered under this job and raise Request for Inspection (RFIs) for Witnessing and Hold Points as per approved ITP.01. RESPONSIBILITIES 6. 6. slings.2011 Page: 6 4.: 00 Date: 18. They shall be also responsible for the Installation of vessel in accordance with the issued AFC drawings. Mechanical. 7. They coordinate with Client/Consultant. They coordinate with QC Inspectors for the necessary inspection during each phase of job execution and completion.2 Mechanical / Civil Foremen They report directly to the Concerned Discipline Supervisor for direct supervision of his craftsmen involved in the job execution.3 QC Inspectors Discipline QC Inspectors shall conduct Quality Control Inspection for.1 Mechanical/ Civil Site Engineers Reports directly to Project Engineer.METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev.

LIFTING 9.3 Verify that shipping protection has been applied and is still in effect 7.METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev.4 Verify that shop inspection has been completed and that the vendor had supplied all necessary documentation and other disposition procedures. 7.6 Verify proper identification of all components 7.8 Verify that protective caps and plugs are in place. This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law . Inspectors and storekeepers are responsible for the implementation of the preservation actions as per the recommendations of the manufacturer and/or by applicable OWNER Standard Specifications. 7.: 00 Date: 18.7 Verify components against the provide delivery note 7. FOUNDATION SURFACE PREPARATION Compressor station required a plane industrial slab of minimum 300 mm thickness without special preparation. Machine/equipment is lubricated as required 7. 7. preservation and protection of all machineries and their accessories at site. Completion of this minimum requirement shall be verified before the commencement of installation works 9.1 Discipline Supervisors. and other industry standards governing receiving.1 Lift the compressor using Slings and shackles of appropriate capacity 9.2 Shackles only to be connected to lifting lugs provide on compressor skid as per the below fig.2 Visually inspect all components for physical damage or contamination by opening packages and crates 7. Defect/failure shall be reported to OWNER /ENGINEER for all client supplied items 8.01.9 Report defects/failures to the manufacturer regarding the machine/equipment supplied.2011 Page: 7 7.5 Verify loose components with the package that they match the packing list and is complete.

METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev. 9. steel sling diameter for a compressor must be a minimum of 14 mm). electrical cabinet).6 The sling diameter must be appropriate to the load to be lifted (For guidance. 9. even better. or.7 Comply with safety instructions applicable to handling and lifting.2011 Page: 8 9.4 Do not allow the slings to come into contact with and damage paintwork. This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law . water pipes. and especially not on compressor components which are not sufficiently resistant to take them (coolants. a spreader (stiffened spreader) 9. allow for local protection over contact points.01.3 Do not let slings bear on the equipment.5 Avoid using steel slings with bare cables .In such cases. 9.: 00 Date: 18.

The chemical bolt may be laid in wet supports.10 Visual inspection while filling up. This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law .(speed ≤ 750 tr/min).4 Drill fixing holes into the foundation slab by following the erection instructions below.9 Position threaded studs (rotation -percussion).01. 10.METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev. 10. 10.5 Erection instructions and Operation Drill hole. 10.7 The resin must flow into the capsule (warm to the touch). 10. EQUIPMENT INSTALLATION AND LEVELLING 10. 10. 10. 10.2011 Page: 9 10.8 Place the capsule in the drill hole. (Diameter = 25 mm / depth = 170 mm).1 10. 10.6 Clean drill hole.3 Position the drilling jig (delivered with the compressor) to the ground and mark fixing points.: 00 Date: 18.11 Comply with the delay before tightening the lock-nuts.2 Compressor Check the completion concrete foundation accordance with manufacturer recommendation / approved GA drawing Adjustment and bolting down (chemical bolting) Use the chemical bolts delivered with the compressor. In such case just make sure to evacuate all water collected in the drill hole.

14 Lay the base plate over the 20 millimeter shims inserted on either side of the drill fixing holes 10.15 Use the levelling screws (Item 4) to level the compressor. (15 daNm).01. 10.: 00 Date: 18. Tolerance is 0. This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law .13 Bring the compressor to its position. insert the shims of varying thickness provided over the 20 millimetre shims (Item 3) previously inserted.2011 Page: 10 10.12 Place the torques. After the chemical bolts positioning 10.5 millimetres / metre. Once the compressor is level.METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev.

2011 Page: 11 10.18 Cooling tower to be fixed as per the approved GA drawing ( Fixing details shown below) 10.METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev. A high fluidity. shrink-proof concrete must be used. Fit and tighten lock-nuts (item 2).01.: 00 Date: 18.17 Pour finishing concrete between the slab (item 5) and the base plate (item 1). Cooling tower 10. 10. Clamp the compressor to the foundation slab.19 This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law .16 Allow the compressor frame to rest on the shims by releasing the levelling screws (item 4).

9 Check all tools /equipments for damage before use with daily equipment checklist This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law . 11.3 Wear appropriate Personnel Protective Equipment (PPE) 11.1 Observe all Safety Notices and Site Rules 11.01.7 Allow ample space for each employee to work safety 11.5 Avoid walking and working under suspended loads 11. uneven ground and other obstructions 11.23 All compressed air piping to be installer as per the GA dawning according to GA drawing and Manufacturer’s process diagram 10.21 Cooling water skid also to be fixed using chemical anchor bolt and levelled 10.25 Once completion of installation of All components inside the canopy .22 Air drier is to be placed on the foundation as per the approved GA drawing ( No anchor bolt is required ) 10.24 The piping system should be tight & leak proof.2 Follow the method statement 11.4 Be aware of crushing hazards and pinch points when handling and joining pipes 11.6 Be aware of loose material excavation /opening drop of .28 All the installation to be cross checked again and Air compressor installation QCR to be filled properly 11. Canopy installation to Carrie out according to the Canopy assembly instruction from manufacturer ( Attached for information) 10.2011 Page: 12 10.26 Cooling water piping ( uPVC ) to completed according to GA drawing and Manufacturer’s process diagram 10.METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev.27 Darin piping to be completed according to GA drawing and Manufacturer’s process diagram 10. SAFETY PROCEDURE 11.: 00 Date: 18.8 Use tools for the proper purpose.20 Cooling tower will installed on the top of “I” ( 75X75) section as show on the above drawing Other Auxiliaries 10. 10.

3 Hand tools 12.17 Risk assessment : Refer to attachments 12.11 Do not use any tools /equipments that is unsafe 11.2 Inspection QCRs N6820 M-C-QCR 006 – Air compressor Levelling Record N6820-M-QCR 005 – Air compressor installation completion check list 13.2011 Page: 13 11.2 Rigging gears 12.4 Process sheet Gas / Process sheet Water 13.15 Be available always adequate first aid supply in the site 11.8 Risk Assessment This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law . ATTACHMENTS 13.6 Assembly instruction -Canopy 13.: 00 Date: 18. 11.16 Be available all safe certificate and documents at work area 11.13 Earth all electrical generator for lighting 11.3 Drawings N6820-M05-2E-D005 – Air compressor station General arrangement M6820-I01-4E-D005 – P&ID Air compressor package surge system 13.N6820-M04-2E-S2xxx METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR Rev.7 Compressor Bottling down instructions 13.14 Keep the working area clean at all time.5 IOM Manual compressor 13.1 Inspection test Plan Air compressor installation – N6820-000-ITP-0055-00 13.1 Crane 12. 11.12 Check all lifting gear for capacity and condition before use. PLANT AND EQUIPMENTS 12.4 Industrial spirit level 12.01.5 Shims 13.10 Remove the damage tools /equipments immediately and affix the visible label 11.

2011 Page: 14 This document is the property of the Company who will safeguard its rights according to the civil and penal provisions of the law .METHOD STATEMENT INSTALLATION OF AIR COMPRESSOR N6820-M04-2E-S2xxx Rev.: 00 Date: 18.01.