Method Statement for Improve Anchorage Mechanism of

TOTAL 7 PAGES
11kV Capacitor Bank Enclosure with Foundations (Including Cover)

Purpose
PROJECT NAME. : Khabat Thermal Power Plant Units1&2 and
Bazyan 400KV Substation □ For Information

TITLE. : Method Statement for Improve □ For Review

Anchorage Mechanism of 11kV ☒ For Approval

Capacitor Bank Enclosure with □ For Construction

Foundations □ As-Built

DOCUMENT NO. : BS-80+++-CY712-B0046

OWNER. : Ministry of Electricity (MOE) of
Kurdistan Regional Government

A.H.
0 7th May.2017 Issued for Approval J.D. Jin S.J. Lee K. I. Kim
Mohammed

Rev.No. Date Description Prepared Checked Reviewed Approved

Owner

Ministry of Electricity (MOE)

Of Kurdistan Regional Government

Contractor

POSCOENGINEERING
&CONSTRUCTIONCO.,LTD.
 Khabat Thermal Power Plant Units1&2 and
DOC.NO. : BS-80+++-CY712-B0046
Bazyan 400KV Substation
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Proposal to Improve Anchorage Mechanism of
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11kV Capacitor Bank Enclosure with Foundations

Table of Contents
1 Purpose ................................................................................................................................... 3
2 Current Status ........................................................................................................................ 3
3 Search of Robust Solution ..................................................................................................... 4
3.1 Force Analysis Study Case ............................................................................................. 4
3.2 Study Anchorage Options .............................................................................................. 4
3.3 Characteristic of the selected material ......................................................................... 4
3.4 Work Procedure ............................................................................................................. 5
4 Conclusion .............................................................................................................................. 5
5 References ............................................................................................................................... 6
6 Risk Assessment……………………………….…………………………………………..…………6
 Khabat Thermal Power Plant Units1&2 and
DOC.NO. : BS-80+++-CY712-B0046
Bazyan 400KV Substation
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Proposal to Improve Anchorage Mechanism of
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11kV Capacitor Bank Enclosure with Foundations

1 Purpose
The purpose of this document is to propose a solution to improve the mechanism of
anchorage 11kV Capacitor Bank Enclosure with the foundations using additional 4 off
HIT-V-R M12x280mm Threaded rod embedded into mortar Hilti HIT-RE 500-SD
Epoxy resin system for every base plate.

2 Current Status
Currently, 2 off M20x200mm stud anchor bolts are used to fasten the 11kV Capacitor
Bank enclosure to concrete foundations.
O/OE have raised a concern that used 2 off M20x200mm stud anchor bolts are
insufficient to anchorage the enclosure securely to the concrete foundations.
 Khabat Thermal Power Plant Units1&2 and
DOC.NO. : BS-80+++-CY712-B0046
Bazyan 400KV Substation
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11kV Capacitor Bank Enclosure with Foundations

3 Search of Robust Solution

3.1 Force Analysis Study Case
POSCO E&C Structure team has modelled the 11kV Capacitor Bank enclosure using
Midas Gen Program to analysis the reaction forces applied on the structure. Civil team
have measured the minimum depth that can be embedded using of current stud in the
current status, which is 60mm. Maximum forces that can be generated from Self-
weight of the enclosure and from the action of 165km/h Wind loads forces were
calculate to determine critical forces applied on 2 off M20x200mm stud anchor bolts
embedded 60mm in concrete:
• Maximum tensile load per anchor in tension area, Nu: 29kN
• Maximum shear load per all applied anchor, Vu: 4kN
See attached BS-80UAA-EC115-E0024/ BS-80UAA-EC115-E0025/Design Criteria

3.2 Study Anchorage Options

POSCO E&C Civil and Mechanical teams had several meetings to find better Fastening
Options. Based on the results obtained from above experiment, the best option that can
be used is HIT-V-R M12x280mm Threaded rod with injection mortar HIT-RE 500-SD
Epoxy resin system with aggregate.

3.3 Characteristic of the selected material

HIT-V-R M12x280mm Threaded rod is longer than the current 200mm anchor stud by
80mm. Therefore, minimum actual embedded length that can be achieve using HIT-V-
R M12x280mm Threaded rod is about 120mm.
From Hilti Datasheet, typical drilling depth is 110mm whereas the minimum depth of
drilling to work within effective anchorage range is 48mm.
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DOC.NO. : BS-80+++-CY712-B0046
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11kV Capacitor Bank Enclosure with Foundations

At 110mm depth and with injecting mortar HIT-RE 500-SD Epoxy resin system with
aggregate, each HIT-V-R M12x280mm Threaded rod can withstand the following
forces According to European Technical Approval ETA-07/0260:
1- 59kN Tension resistance for static and quasi-static loading.
2- 30kN Shear resistance for static and quasi-static loading.

3.4 Work Procedure

Upon complete enclosure adjustment, the current 2 off M20x200mm stud anchor bolts
will be fasten it to the foundation.

In addition another 4 off holes will be drilled at least 110mm depth. Compressed air will
be used to clean the drilled holes. The mortar HIT-RE 500-SD Epoxy resin system
with aggregate will be injected to the cleaned holes and embed each HIT-V-R
M12x280mm Threaded rod to let it secure in the mortar material. Upon curing process
completed, nuts will be added to fasten the structure to the foundation.

Concrete Base Plate

Foundation of Column
TOP VIEW

110mm
SIDE VIEW

Drilling
Depth
Minimum

Location of Current M20x 200mm Bolts

Location of HIT-V-R M12x280mm Threaded Rod

Finally, at least 30mm grouting material will be added to improve foundation function
and surface appearance finishing.

4 Conclusion

In addition to the current 2 off M20x 200mm anchor bolts, additional 4 off HIT-V-R
M12x280mm Threaded rod can be used to improve fastening mechanism of the 11kV
Capacitor Bank enclosure to the concrete foundations significantly.
 Khabat Thermal Power Plant Units1&2 and
DOC.NO. : BS-80+++-CY712-B0046
Bazyan 400KV Substation
REV. : 0
Proposal to Improve Anchorage Mechanism of
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11kV Capacitor Bank Enclosure with Foundations

5 References
• Calculation report about anchorage_11kV Substation Area Fence & Gate/ BS-
80UAA-EC115-E0024/ BS-80UAA-EC115-E0025/Design Criteria
• Hilti HIT-RE 500-SD with HIT-V rod_RE-500-SD_FTM_2012-09

6. Risk Assessment
JOB SAFETY ANALYSIS / RISK ASSESSMENT SCOPE : Improve Anchorage Mechanism of 11kV Capacitor Bank Enclosure with Foundations
JOB STEP POTENTIAL HAZARD Control Measures
Initial Risk Residual Risk
STEP (List the steps required to (Against each step list the potential / risk hazards that (Control measures have been identified using the Hierarchy of Control Elimination ->Substitution ->Engineering -> Admin -> PPE) Control
NO perform the task in the could cause injury / damage when the task step is Responsibility
L C Risk L C Risk
sequence they are carried out.) erformed.)
Material falling from truck during transport 1.1.1 Operators and Job Supervisor shall ensure that the vehicle is not overloaded
1.1 3 4 12 1.1.2 Ensure that all materials are properly secured by means of correct sling belt to prevent materials from falling during delivery POSCO 1 4 4
1.1.3 No overloading of materials on the trailers
Speeding 1.2.1 All drivers shall have valid driving licenses
1.2.2 Enforcement of traffic regulations
1 Transporting of Materials to Site 1.2 4 4 16 1.2.3 Strictly follow speed limit POSCO 1 4 4
1.2.4 Approved transportation route map for vehicle trafic in accordance with GAMA Khabat Project rules
1.2.5 Safe access shall be maintained at site for vehicles and equipment
Struck by Vehicle 1.3.1 All drivers shall have valid driving licenses
1.3 3 4 12 1.3.2 All vehicle movement shall be guided by competent banksmen vith HİVİ vest POSCO 1 4 4
1.3.3 Barricade and secure working area with signboard
2.1.1 Ensure all employees use proper PPE i.e. Helmet, safety glasses, gloves, safety shoes
Hand& Finger Injuries-Bruising-Cut while
2.1 2 3 6 2.1.2 One piece of material at one time during unloading POSCO 1 3 3
carrying/pulling materials
2.1.3 Ensure TBT is executed and monitored
Manual Handling of Materials at
2 3.2.1 Ensure employee use proper lifting techniqyes i.e. lift with their legs not their back
Site
Physical injuries back, muscle strains, sprains 3.2.2 Use the "Buddy System" to get help
2.2 2 3 6 POSCO 1 3 3
from lifting/carrying materials and tools 3.2.3 Provision for mechanical equipment i.e. Trolley, fork lift etc...
3.2.4 Break the job down into manageable portions
3.1.1 All work is to be completed with approved PPE, including safety glasses with side shields, safety helmet and steel toe footwear and gloves
3.1 Use of hand held power tools 2 3 6 POSCO 1 3 3
3.1.2 Ensure that all employees are properly trained to use the assigned tools
3.2.1 Approved PPE including face shield by employees working is close proximity of concrete pouring
3 Work for Chipping 3.2 Concreate particle splash (Eye injury) 3 3 9 POSCO 1 3 3
3.2.2 Eye wash required near the work area
3.3 Foot injury 2 2 4 3.3.1 Rubber type steel toed footwear POSCO 1 2 2
3.4 Vibration 2 3 6 3.4.1 Execution of short shifting period is necessary POSCO 1 3 3
(Drilling )and using of hydrolic Bursting of gaskets and hydraulic hoses. 4.1.1 Use safety glasses. Ensure that design pressure is not exceeded. Equipment should be pressure tested and certified regularly.
tools 4.1 2 5 10 4.1.2 Ensure that safety valves on pump sets are set properly and are corresponding with the design pressure on the equipment to be used. POSCO 1 5 5
4.1.3 Discard damaged hoses, repair should only be made by a certified workshop.
4
Thread damage on hydraulic ports, connections 4.2.1
and to bolt stretching inserts. Use safety glasses. Visually inspect threads before connecting hoses or equipment such as bolt stretching inserts.
4.2 2 5 10 POSCO 1 5 5
4.2.2 Discard equipment with damage to threads or sealing surfaces.
4.2.3 Stand clear of pressurized tools and equipment.
Setting up of anchor bolts and Pinch point injuries tightening of nuts to the 5.1.1 Ensure that all hand tools are in good condition.
bolt tightening. 5.1 anchor bolts. 2 3 6 POSCO 1 3 3
5.1.2 Ensure qualified/ competent employee to carry out the task.
Muscle strain or sprain while positioning of 5.2.1 Ensure employee use proper lifting techniques i.e. lift with their legs not their back.
5 5.2 frames into anchor bolts. 2 2 4 5.2.2 Use the "Buddy System" get help. POSCO 1 2 2
5.2.3 Break the job down into manageable portions.
Caught in between column base plate & 5.3.1 Only authorized & skilled workers for the task.
5.3 2 3 6 POSCO 1 3 3
foundation. 5.3.2 Ensure workers not to hold base plate.
Skin irritation. Use of PPE (gloves, safety goggles and mask)

6.1 3 2 6 6.1.1 POSCO 1 2 2

Preperation & Application of Material splash during mixing/ applying 6.2.1 Approved PPE including safety mask by employees working is close proximity of substrate concrete mixing or applying.
6
Substrate material ( Chemical ) 6.3.2 Competent personnel.
6.2 3 3 9 POSCO 3 1 3
6.3.3 MSDS communicated.
6.3.4 Eye wash available.
Environmental Pollution due to material spill 6,3,1 Employees must be trained about, chemical substances during the disposal of contaminated material throwed away seperate waste bins.
6,3 4 1 4 POSCO 3 1 3