C5.8.

3 – Method of Construction of
Wastewater Treatment Plant
Project Name Organic Resources Recycling Centre Phase 2
Contract Number EP/SP/86/15
Document Number OWTF2-JEC-07-00-XX-DP-ME-0002
Revision Number 3
Author Samson Tam
Issue Date 15/06/2021
Security Classification Confidential

Authorisation
Name: Date:
Prepared by: Samson Tam 15 Jun 2021
Reviewed by: Bonnie Liao/ George Ng 15 Jun 2021
Approved by Eros To 15 Jun 2021

Revision History
Revision Status Approval
Rev Date Purpose Originator Reviewed Approval
0 03/04/2020 New Document ST BL/MS ST
1 11/05/2020 Internal Reviewed ST DI AW
2 05/10/2020 Issue with DDS Rev 2 ST BL AW
3 15/06/2021 Issue with DDS Rev 6 ST BL/ GN ET

UNCONTROLLED COPY UNLESS ACCESS FROM PROJECT DATABASE

 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

Figure 1.8 Construction Zone – WWTP Roof Floor

Contents Figure 1.9 Organisation Chart for E&M Installation of WWTP
Figure 1.10 Delivery Route, Temporary Storage and Site Area
1 Introduction ........................................................................................................................................ 2
Figure 2.1 Overhead Crane General Arrangement over DAF Equipment
1.1 Scope of Work ............................................................................................................................. 2
Figure 2.2 Equipment Delivery – Views on Building
1.2 Limitations ................................................................................................................................... 2 Figure 2.3 Overhead Crane Service Area
1.3 General Plant Equipment Layout ................................................................................................. 2 Figure 2.5 Lifting Route of Equipment to RO Room
1.4 Scope of Application for this Method Statement ......................................................................... 4
1.5 Construction Zones ...................................................................................................................... 4
1.6 Construction Organisation ........................................................................................................... 7
1.7 Construction Work Resources ..................................................................................................... 7 List of Tables
1.8 Dimension and Weight of Major Equipment ............................................................................... 8 Table 1 Construction Zones
1.9 Transport of Materials to Site ...................................................................................................... 9 Table 2 Work Forces
1.10 Delivery of Equipment ............................................................................................................... 10 Table 3 Equipment Dimensions and Loading
2 Construction Program ..................................................................................................................... 11
Table 4 Construction Program
2.1 Installation Preparation .............................................................................................................. 12
Table 5 Installation Tools
2.2 Erection/ Installation sequence .................................................................................................. 12
2.3 Equipment Delivery Route ........................................................................................................ 13
2.4 Lift Planning .............................................................................................................................. 14
3 Installation Method of Major Equipment ..................................................................................... 15
3.1 Installation of Pipework ............................................................................................................. 15
3.2 Hydrostatic Test of Pipes ........................................................................................................... 15
3.3 Environmental Issues ................................................................................................................. 15
3.4 Safety Measures ......................................................................................................................... 15
3.5 Installation Tools ....................................................................................................................... 16
4 QUALITY CONTROL.................................................................................................................... 16
5 APPENDICES .................................................................................................................................. 17

List of Figures
Figure 1.1 Installation Site Layout
Figure 1.2 Plant Equipment Layout Plan – Basement Tanks
Figure 1.3 Plant Equipment Layout Plan – Ground Floor Equipment
Figure 1.4 Plant Equipment Layout Plan – Roof Floor UF/RO Equipment
Figure 1.5 Construction Zone – Basement
Figure 1.6 Construction Zone – WWTP Ground Floor
Figure 1.7 Construction Zone – WWTP Mezzanine Floor

DDS C5.8.3 Method of Construction for WWTP (Rev.3)

Page No. i
 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

1 Introduction
1.2 Limitations
The Wastewater Treatment Plant (WWTP) plant is located on the ground and roof level of the
The contents of this document are shown as Construction Planning, Methods and Approaches for
granulation building between grid lines NA-NE and N2- N7 of the site of Organic Waste Treatment
construction of wastewater treatment plant equipment, as an isolated system. Other services and such as
Facilities Phase 2, as shown in below site plan.
potable water supply, plant drains, etc are to be covered by other design scope packages. This method
statement does not replace the Safe Work Method Statement of individual equipment or plant, as there are
plenty, and equipment specific. This Construction Method will be subject to review during the works and
may be amended if so required to suit actual site progress. Any changes of scope shall be reassessed and
confirm with individual construction risk assessment and job safety analysis.

1.3 General Plant Equipment Layout

Below is a general layout plan of the CAPCS plant, which is the scope of installation described in this
Method of Construction document. WWTP occupies the basement (process tanks), ground floor (main
treatment equipment) and roof floor (UF/RO plant)

Figure 1.1 Installation Site Layout

1.1 Scope of Work

The scope of work includes the delivery and erection of WWTP, including but not limited to the all process
equipment, internal of concrete tanks, process tanks, chemical storage and delivery system, pumps and
aeration plant, ultrafiltration and reverse osmosis plant, all piping and association supports, all support
structures for pipes, access platforms, chemical pipes, transfer pumps, submersible pumps, valves,
instrument and analysers, as well as electrical installation. This method of construction describes the
procedures of installation for the major items of the Wastewater Treatment Plant.

DDS C5.8.3 Method of Construction for WWTP (Rev.3) Page No. 2

 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

Figure 1.2 Plant Equipment Layout Plan – Basement Tanks Figure 1.3 Plant Equipment Layout Plan – Ground Floor Equipment

The control room is located as a mezz floor over and above the Phospaq tank, whilst the MCC room is
located adjacent to the UF/RO room.

DDS C5.8.3 Method of Construction for WWTP (Rev.3) Page No. 3

 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

The mechanical and electrical installation works for the WWTP shall include the following major process
plants:

1) Raw feed water pipes from sumps and buildings to Buffer Tank at Granulation Building
2) Buffer Tank internals and Dissolved Air Flotation (DAP) equipment
3) PHOSPAQ tanks internal
4) Clarifier and internals
5) Anammox feed and effluent tanks, including heat exchangers
6) Anammox tanks internal
7) A/O bioreactors internal
8) MBR plant
9) RO plant
10) Compressed air plants, including all field pneumatic panels
11) Chemical plants, including Neutralization Tank
12) Polyelectrolyte preparation and dosing tanks
13) All chemical dosing skids and bunds
14) Overhead crane over and above MBR and DAF bays
15) Interconnection water pipes, including pipe supports, valves and instrumentations
16) Interconnecting chemical pipes
17) All pipe labels and equipment labels
18) Drainage pipes from process skids to floor channels
19) Installation and removal of temporary pipework for process commissioning
20) Electrical MCC installation and terminations
21) Electrical cabling and cable marking for the above process plants
22) Material take off for all installation supplies, including but not limited to pipes, fitting, supports,
cables, trays, and cable accessories.
23) All site tests, including but not limited to dimensional and level checks, hydro test, continuity and
earthing tests, alignment check, point-to-point check, instrument loops check, etc.

All equipment is fabricated in factory and designed to be skid mounted, therefore there will be minimal site
Figure 1.4 Plant Equipment Layout Plan – Roof Floor UF/RO Equipment fabrication required, and major site work will mainly be re-assembly and fitting out.

1.4 Scope of Application for this Method Statement 1.5 Construction Zones
The general requirements for electrical, mechanical, and piping installation works of the WWTP are The WWTP installation will be focused in the following zones:
described in the following documents:

(a) Contract Specification for Mechanical Installation

(b) Contract Specification for Piping Installation
(c) Contract Specification for Electrical Installation

DDS C5.8.3 Method of Construction for WWTP (Rev.3) Page No. 4

 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

Figure 1.5 Construction Zones - Basement

Figure 1.6 Construction Zones – WWTP Ground Floor

Figure 1.7 Construction Zones – WWTP Mezzanine Floor

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 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

Work implementation is based on design and engineering from DDS. Work will be executed for each work
area with the following activities:

• Analysis and planning of design and engineering outcome from lead designer and/or suppliers
• Temporary work design (if required for installation)
• Document Control
Figure 1.8 Construction Zones – WWTP Roof Floor • Material take off
• Procurement
• Off-site fabrication, pre-assembly, modular erection
The WWTP is consisted of the following key process areas. The Work Breakdown Structure (WBS), as • Manufacture of pipe supports and delivery to site
developed for the Project, forms the scope baseline for the execution of project construction. The main • Site resources planning
WBS elements are categorized as follows. • Work sequence and method statement for safe work
• Site lifting appliance and scaffolding
Table 1 – Construction Zones • Site labour health and safety
• Construction and installation
• Site tests
• Assist in process commissioning

Inspection and Test Plans (ITPs) for all site tests along with each work package will be targeted for
submission at least two weeks prior to site tests.

The ITPs of work packages prepared by the construction team will contain specific details, procedures and
forms as required by the work crews in carrying out the tasks allowing them to fully carry out and complete
the works. Each work package will be stand alone and related to the associated WBS to allow progressive
sign off to each WBS as the works progress.

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 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

1.6 Construction Organisation

The erection of the WWTP will be directed by an AJA JV Site Installation Manager and assisted by two site
supervisors in charge of mechanical installations and electrical & instrumentation installations, respectively.
The engineering and technical support will be managed by three site engineers in charge of mechanical,
electrical and equipment installations, respectively. The installation team will be assisted by the Site Safety
and Compliance Team. Installation verifications will be approved and signed off by Design Team Leads or
their delegated team representative, each of whom will liaise with the Independent Checker and Employer’s
Representative.

AJA JV will employ subcontractor workers to carry out erection of plant equipment, pipes and electrical
installations. It is anticipated that subcontractors will be awarded to one single mechanical installation
contractor and other subcontractors for electrical installation. Erection riggers will be employed from time
to time when required for lifting tasks. The erection riggers will be expected to supply suitable lifting
appliance and equipment for the lifting tasks.

Steel works, including pipe supports, clarifier tank and access platforms, will be procured separately from
fabrication vendors, who will supply from off-site fabrication workshops.

Equipment will be procured by Supply Agreements, whilst metal pipes will be prefabricated as pipe spools
at off-site fabrication workshops. Plastic pipes will be supplied directly to site for site assembly by Figure 1.9 Organisation Chart for E&M Installation of WWTP
mechanical contractor.

Chemical tanks, valves, instrument, pump sets and skids will be supplied to site in batches for use. 1.7 Construction Work Resources
The site team organisation chart for the installation of WWTP is illustrated in below figure. Work Forces
The following work force will take part in construction phase:

Table 2 Work Forces

Human Resources Duties and Responsibilities

Installation manager (1)
• Receive, check and accept ITP from civil on foundation slab for
installation
• Plan, direct and organize installation
• Review, approves method statement, safe work method statement and
lifting plan
• Conduct risk assessment workshop
• Approve all installation materials
• Liaise with safety officer for all safety matters
• Notify IC/ER related site staff for the works
• In charge of site setting out and accept surveyors report
• Sign off and accept E&M installation ITPs

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 Contract No. EP/SP/86/15
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Project Engineer (M&E) • Support installation supervisor to provide technical details to - Will be in-charge of the installation
(2) installation subcontractors - Ensure all the installation work is carried in a safe manner.
• Check and ensure all equipment available on site
• Check and tick off equipment compliance with design specification Material supply:
• Quality control of all work FRP chemical tanks will be delivered as complete tank assembly..
Installation Supervisor • Supervise subcontractors and liaise with subcontractors foreman
(M&E) (1) • Direct labour when required Foundation and Civil Work:
The foundation where the equipment will be installed shall be ready, surveyed and inspected before the
• Ensure installation are conducted in accordance with approves SWMS,
commencement by all parties to ensure the compliance to the relevant specification.
JSA, etc.
• Assist IC/ER personnel to witness site tests
Material delivered on site:
• Witness and signed off all installation ITP steps Once the material is delivered to site the site engineer will allocate the material to a designed location at site
• Daily reporting of site activities in a controlled manner.
Subcontractor(s) (8) • Supply of installation foreman and labour (skilled or general skill)
Erection Labour • Supply and management of mobile installation plants – forklifts, Material transportation on site:
(1) Foreman (1) scaffolding, mobile cranes) The subcontractor will be responsible in transporting all the required material to construction area by crane
(2) Rigger and crane • Supply and installation of assembly materials including gaskets, lorry/ truck following the site road map. Protection of material and traffic control shall be taken care off.
operator (2 +1) glands, blanks, minor pipe supports (Unistrut), cable trays, temporary
(3) Fitter (2) supports, etc Water and temporary electrical:
(4) Welder (1) • Lifting of all equipment Sufficient water supply and electrical power points shall be provided on site for contractor’s activities.
(5) Electrician (1) • Assembly of equipment, pipes, valves, labels, cubicles, steel structure,
(6) FRP-tank and erection Lifting equipment
technician • Electrical installation Lifting appliance/ gear shall be certified and set-up by subcontractor at the working area for safety personnel
and engineer for approval before using. Subject to the actual site condition, protection work may be required
Safety Officer (1) • Safe Induction with subcontract labour in the construction area.
• Daily tool box talk
• Safe method assessment and site policing for compliance Wind condition for lifting:
• Safety report Lifting under windy condition shall refer to the crane operation manual. Generally, lifting activities shall not
• Accident report be undertaking at a high wind situations or when high wind warnings have been issued by the Observatory.
• Safety statistics
Work site housekeeping:
Plant and Equipment Construction site shall always be in good order and in clean and tidy condition. Proper housekeeping shall
- 1 - 100 tonnes mobile crane always be maintained in the designated walkway. Construction waste, debris shall be disposed in the
- 1 – 25 tonnes Hiab type truck crane designated area.
- 1 – 4 tonnes forklift truck
- 1 – set of scaffolding (demountable, aluminium)
- 1- scissor lift (11 m height) 1.8 Dimension and Weight of Major Equipment
- MIG welder
- Tripod (Topcon or similar) survey equipment The dimension and lifting weight of equipment are listed in the below table:
- Hand tools.

Subcontractor

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 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

Table 3 Equipment Dimensions and Loading 16 RO Skid (in 2 x skids) 6.5 L x 2.4 W x 2.1 H (m) 3000 kg

Item Equipment Dimension (Approx.) Operation 17 CIP Skid 2.8 L x 1.2 W x 2 H (m) 2000 kg
Weight (kg）
18 PLC panel 3 W x 0.8 D x 2.5 H 2500 kg
(Approx.)
19 MCC Panels TBC 12000 kg
1 Dissolved Air Flotation units 4.8 L x 2.4 W x 2.8 H (m) 5,000 kg
(2)

2 DAF Flocculation Tube (1) 3 L x 0.8 W x 2 H (m) 400 kg 1.9 Transport of Materials to Site
3 Phospaq Internal Module (2) 5.8 L x 2.3 x 3 H (m) 12,000 kg Transport of materials include the following major deliveries:

4 Clarifier (1) Bridge 8 L x 1.5 W x 2 H (m) 4,500kg (a) DAF Units and flocculation tube skid
(b) Phospaq internal modules including support steel structure
(c) Anammox internal module including support structure
5 Anammox Internal Modules (2) 5.8 L x 2.3 x 3 H (m) 12,000 kg (d) Clarifier internal and scraper bridge and motor/gearbox
(e) MBR membrane modules
6 MBR Modules (12) Modules 2.3 W x 3 H x 0.7 W (m) Each 200 kg (f) A/O tank aeration ejectors and air pipes assembly (pre-fabricated)
Miscellaneous Steelwork 2500 kg (g) Air blowers for A/O and Phospaq
7 A/O Tank internal Pipes and ejectors 12,000 kg (h) Air blowers for MBR
(i) Air blowers for Anammox
8 Air Blower for A/O 3.5 L x 2 W x 2.8 H (m) 5,000 kg (j) Pumps including all submersible, centrifugal end suction and well pumps
(k) Bulk chemical tanks
9 Air Blower for MBR 2.5 L x 2 W x 2.1 H (m) 2800 kg (l) UF skid
(m) RO skid including CIP skid
10 Chemical Tanks Largest dia 2.3 x 4.5 H (m) 6000 kg (n) Pipe supports prefabricated
(o) Pipe spools prefabricated
11 Injection Pump Skid (4) 2.3 L x 1.3 W x 1.2 H (m) 850 kg (p) Miscellaneous equipment including chemical pipes, water pipes.
(q) Electrical control panel, local panel and electrical cabling accessories.
12 Other Pump Skids Various 350 kg
For items (a), (b), (c), (g), (h), (i), (k), (l) and (m), as well as the MCC and PLC panels, because they are
bulky structures and are supplied to site in modular forms, therefore they will not be required to store on
13 RAS Pump Skids (4) 1.6 L x 0.7 W x 1.5 H (m) 300 kg
site. The modules will be directly delivery to site from off-site storage yard, and directly lifted into
installation locations at the same time. Installation methods refer to the Section 1.8 of this document. The
14 MBR return to Anoxic Pump 1.6 L x 0.7 W x 1.5 H (m) 300 kg
delivery routing of these modules will follow the route as shown in Figure 1.7-1.
Skid (4)
For items (d), (e), (f), (j) and some of the pump skids, they will require on site assembly, therefore would
15 UF Skid 6.5 L x 1.3 W x 3 H (m) 5000 kg have to be stored in the laydown area, and assembled in smaller units, and move to their location of
installations.

DDS C5.8.3 Method of Construction for WWTP (Rev.3) Page No. 9

 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

For items (n) to (q) they are relatively small items and require safe storage. A temporary storage area inside
the granulator building as shown in Figure 1.7-1 will be employed for temporary storage in the duration of
flare construction. The storage time is expected to be short-terms and may be up to a period of two to three
months.

Equipment shall be dispatched to site in a controlled manner using store requisitions forms duly filled in and
signed off by the subcontractor and the engineer in charge of the works.

1.10 Delivery of Equipment

Figure below shows the delivery route of materials to site, laydown and storage area and site assembly area.

Figure 1.10 Delivery Route, Temporary Storage and Site Area

DDS C5.8.3 Method of Construction for WWTP (Rev.3) Page No. 10

 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

It is assumed that all equipment shall have completed Factory Acceptance Test in their respective 19 Install RO plant equipment 6 15 Oct 22 15 Dec 22
manufacturing facilities. FAT certificates and records must be provided to installation manager prior to
20 Pipe installation (first fix) Note 1 sitewide 1 June 22 30 Sep 22
delivery to site.
21 Install Electrical Trays Note 2 sitewide 10 Aug 22 30 Oct 22
2 Construction Program 22 Pipe Installation Note 3 sitewide 20 Sep 22 10 Nov 22

Key construction dates extracted from the Master Programme is shown as follows. Currently the earliest site Odour Pipe Installation (by CAPCS
23 Coordination 1 Aug 22 20 Sep 22
access date for installation is estimated in August 2021. The presented dates may be revised from time to work package)
time as site construction progresses. 24 Electrical Cabling and Terminations sitewide 1 Aug 22 15 Nov 22

Table 4 – Construction Program 25 Place in MBR modules 2 15 Feb 23 1 Mar 23

Final termination of field instrument,
Planned 26 All 15 Feb 23 10 Apr 23
Construction Activities Zones Planned Start electrical panels and MCC
Finish
27 Mechanical site tests All 12 Dec 23 15 Mar 23
1 Mobilization to site All 15 Oct 21 20 Oct 21
28 Electrical site tests All 15 Jan 23 30 Mar 23
2 Site setting out and check suitability All 15 Oct 21 31 Oct 21 Note 1 Pipe first fix included installation and adjustment, levelling of pipe supports and other accessories
3 Install overhead cranes 4 20 Oct 21 3 Nov 21 Note 2 Cable first fix include installation of cable trays and accessories (with cabling) on erected pipe supports
Note 3 Pipe installation second fix include installation of pipe trays and/or ladders, and pipe running for chemical pipes
4 Install clarifier tank 1 5 Sep 21 6 Nov 21
5 Install PHOSPAQ tank internal 1 20 Oct 21 30 Nov 21 The construction programme will display the construction activities in sequence order noting thatthere
may be a number of parallel activities in progress at the same time. It is expected that construction will
6 Install buffer tank internal 1 20 Oct 21 30 Nov 21 appoint labours for the following activities:
7 Install Anammox tank internal 1 15 Nov 21 30 Dec 21
(1) Off-Site labours
Install Anammox influent and effluent
8 1 15 Nov 21 15 Jan 22 (a) Pipe spools fabrication
tank internal
9 Install fixings in MBR tank 2 13 Dec 21 15 Jan 22 (b) Chemical dosing skids

10 Install internals of bioreactors 2 15 Dec 21 15 Feb 22 (c) LV switchboards/ MCC room construction subcontractors
(2) On-site labours
11 Install internals of sludge holding tank 2 15 Mar 22 15 Apr 22
(d) Lifting appliance, scaffolding and rigging labours,
12 Install MCC and Control Room 5 1 May 22 18 Sep 22
(e) Electrical installation labours,
13 Install pipes through openings All 20 Apr 22 10 July 22
(f) Mechanical installation labours,
14 All underground pumps and pipes 1&2 20 Mar 22 10 June 22
(g) Chemical storage and dosing facilities
15 Install air blowers + air compressors 4 15 May 22 5 July 22
16 Install DAF units 4 29 June 22 20 Aug 22
Other considerations include the erection of mobile plants consisting of a 2-tonne forklift truck, two 3.4
17 Install MBR cleaning tank 4 20 Aug 22 15 Sep 22 m scissor lifts, mobile scaffolding, and the overhead crane to be installed at the MBR andDAF bays.
18 Install chemical plant equipment 3 1 Sep 22 5 Nov 22 Tower crane, when available, will need to be used to lift equipment to first floor.

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 Contract No. EP/SP/86/15
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Electricity shall be provided to those areas and tank roofs for powering necessary tools and equipment
for installation works. Most, if not all installations, shall be in-door, and as such shouldnot be affected by
weather conditions. All subcontractors shall wear hearing protection where necessary for the works being
performed. All waste shall be disposed of to appropriate locationsor into waste skips.
2.2 Erection/ Installation sequence
Following the completion of the concrete structure of the underground tanks and hydro-tested by civil
construction to confirm water tightness, E&M works will commence on fitting out the various equipment
within and on top of the tanks.

2.1 Installation Preparation

Checking shall be conducted to ensure that all devices are in good condition prior to installation. Welding
activities if any, shall be done by certified welders.
The following key success factors will be observed for the Project:

▪ Mobilization to site as early as possible

▪ Highest priority given to environment, work health and safety
▪ Site services connections for water, power, drainage, sewer
▪ Timely materials receipt and handling.
▪ Delivery of the equipment to be coordinated closely with civil contractor.
▪ Lifting plan considerations for heavy lifts, availability of cranes at site, crane access to and
positioning at job site. Unloading of equipment, lay down areas and movement of equipment
to installation locations will be identified and included in work method statements
▪ Interface with the other plants, both in pipework, tie in and electrical & control interfaces

The following are preparations prior to installation work.

Setting out
1. Check concrete slab levels and finish accuracy
2. Set out all installation location, anchor bolt setting for supports
3. Check all drain and bund finish and dimension
4. Set out centre line of each equipment and alignment
Preparation of installation of equipments and tanks will follow below procedures:
Figure 2.1 Overhead Crane General Arrangement over DAF Equipment
1. Clean site to remove residual concrete debris, and mark up on site equipment locations.
2. Check level tolerances of concrete slab to ensure they are within the required finish tolerance
3. Mark up location (and anchoring locations) to ensure equipment can be aligned to plan
The first installation task will have to install the overhead crane which services the areas over and above the
4. For equipment with plinths the position of plinths to be checked
MBR tank, the DAF, the anoxic tanks, the clarifier and the Anammox influent and effluent tank. This line
5. Pre-drill chemical anchors if possible so that equipment can be directly placed on these anchors
of installation equipment is the core part of the WWTP, and the overhead crane can be used both for lifting,
6. All wall mounted pipe and cable supports can be pre-installed before equipment are delivered.
handling and installation of the equipment.
7. When the above is completed the site is ready to receive equipment for installation.

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 Contract No. EP/SP/86/15
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The following tank internals (Zones 1 & 2) will be assembled:
1. Buffer Tank – installation of air ejector, submersible pumps, first fix of pipes
2. PHOSPAQ tanks – internal separation module support structure, first fix of aeration pipes
3. Assembly of clarifier tank modules, weld tank walls, and install tank internals including
scrapper, still well, influent pipe, access walk bridge and vertically mounted drive/ gearbox.
4. Anammox influent tank – submersible lift pumps, first fix of pipes
5. Anammox tanks – internal separation module support structure, first fix of aeration pipes
6. Anammox effluent tank – submersible lift pumps, first fix of pipes
7. A/O bioreactors – internal tank baffles, aeration pipe first fixing, tank vertical mixers
8. MBR tank – bottom track, support structure, pipe fixtures
9. Neutralization Tank – lift pump, pipes first fix,
10. Reuse water tank – guide pipe for well pump, first fix pipes
The major works within the tanks include assembling and installing pipe support brackets, mounting for
pumps, and preparing connections to puddles. All sub-assemblies will be prefabricated and require
minimum fabrication on site, except the clarifier tank, which will be supplied with a pre-assembled
bottom plate, and twelve wall modules. The modules will be assembled with bolt and nuts on site, then
finish weld for waterproof. Internal separation modules of PHOSPAQ and Anammox will not be
installed until the building is completely waterproof to avoid any accidental damages.
The tank internals installation then will have completed and will be protected, awaiting civil construction
to continue. During the construction when the building is still being erected with tower crane and the
building delivery slab opening is still opened for use, chemical tanks, which are supplied (complete with
nozzles and lifting lugs) in light weight as FRP or PE materials, will be lifted by tower crane to the ground
floor, which will be moved into the chemical storagearea (Zone 3). The tanks will then be protected from
damages due to overhead ongoing construction.
When the building construction works for the first floor are finally completed whereby all building and
civil work scaffolding and support probes would have been removed, electrical and mechanical
installation team will take over the site, including the control room area, for equipment installation.
Zones 3, 4 and 5 will be clear of building wastes and debris, as well as any other wet trade remains,
before installation. The following installation of equipment will take place:
Installation of overhead crane above the MBR tank, DAF and clarifier will be completed as soon as
possible to assist with material movement within the ground floor area.
DDS C5.8.3 Method of Construction for WWTP (Rev.3)
1. Zones 1 and 2 - PHOSPAQ and Anammox separation modules will be lifted down to tank,
positioned, levelled and anchored firmly. All second and final round of tank internal pipe fix
will take place at the same time. Aeration pipes at bottom of tank willbe set out and anchored
to ground. Pipes to pumps will then be installed. Electrical cabling to equipment where
required will commence.
2. Zone 3 – Chemical tanks position confirmed and fixed, chemical dosing skids installed,
followed by chemical pipe installation. Polyelectrolyte skids delivered to site and installed.
3. Zone 4 – Air blowers delivered to site and moved into installation position. Pipe supports and
pipes installation will commence at the same time. DAF units delivered tosite and will be
installed together with the MBR cleansing tanks.
4. Site wide pipe and cabling will continue at the same time.
5. Zone 5 – MCC and control room equipment will be delivered to site and electrical
installation will continue at full speed.
While tank installation continues at full speed in basement and ground levels, civil work is expected to
complete on first floor. When the roof level of the building is completed, and all building support
scaffolding removed, the RO room area (Zone 6) will be released forinstallation. It is expected that at
that time, just before the tower crane will be dismounted, the RO skids and associated tanks and
equipment will be delivered to site for lifting through the building slab opening and into the RO room.
At this time installation of RO plant equipment will commence.
2.3 Equipment Delivery Route
Following the completion of the concrete structure of the digester tanks, work will commence with
delivery of major equipment. The main equipment delivery routes are illustrated as follows.
There will be two main delivery routes anticipated for the transfer of equipment into positions, one on
north face of Granulation Building, and the other on the west face of Granulation Building. These openings
will be provided with roller shutter typically 4 m wide by 5 m high finished openings.
Equipment moves into the building from north opening will be handled by overhead crane to thelay down
area. Equipment to be transported to the WWTP works area from west opening shall be handled by mobile
crane or forklift truck to store in lay down area. Bulk-size equipment, such as chemical tanks, will be
supplied in one large size, typically 3 m diameter x 3.5 m high, shall be moved into their respective
installation locations with internal wall openings, shown as secondary delivery routes.
Equipment on first floor will share the building openings - both construction and permanent – to be used by
other building services plants.
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 Contract No. EP/SP/86/15
Organic Waste Treatment Facilities Phase 2

Figure 2.2 Equipment delivery – Views on Building

Figure 2.3 Overhead Crane Service Area
In order to facilitate handling the laydown area as shown below are covered by the overhead crane, which
can assist assembly and installation of small parts, such as pumps, minor structures and detail assembly.
2.4 Lift Planning
Lifting and placing of vessels and equipment will be achieved with use of a 75 tonnes mobile cranes to lift
and bring the UF and RO skids to the RO room, through a temporary opening reserve foe the same purpose.
It is expected that with this opening all equipment, including tanks, pipes, steel work and CIP skids will all
be transported to the RO room through this temporary opening. Below plan shows the location of this
opening.

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 Contract No. EP/SP/86/15
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For pipe installation the following installation sequence shall be taken:

• Pipe laying and support
• Pre-alignment of pipe
• Installation of pipe and support
• Final Alignment (connection to equipment/ welding/ bolting)
• Cable trays and containments will usually follow the pipe routing and usually stack up as
the top layer of the same pipe support

The pipework installation shall be designed and arranged to provide for ease of erection and future
dismantling. Pipes may only be supported from existing structural steel works where it can be arranged.
Pipes crossing roads shall be designed and constructed with necessary pipe bridges or run together with
other road crossing structures. Sufficient dismantling joints, flange adaptors or flexible couplings shall be
provided to enable removal for replacement, cleaning and maintenance. Removable pipe take-down fittings
(Gibault, Straub or similar) and cleanouts shall be provided on sludge lines to facilitate cleaning and
maintenance.

3.2 Hydrostatic Test of Pipes

After installation activities have been carried out, hydrostatic test will be conducted as soon as possible. The
Figure 2.4 Lifting Route of Equipment to RO room
pipework shall undergo a pressure test of 1.5 times the maximum working pressure.

After the equipment have been lifted and placed into the RO room, it may be required to shift the equipment
horizontally to their installation locations. 3.3 Environmental Issues
Refer Environmental Management Plan for general measures and check list.

- All waste materials will be disposed at the designated areas.

3 Installation Method of Major Equipment
- The site work activities must be done at 07:00 to 19:00 hours. However, should the progress demand
Major equipment installation will be separately prepared as each of the equipment has its own for the works be undertaken beyond normal working hours or on public holidays, a construction
manufacturer’s installation procedures. Before erection of these equipment installation, (i) Risk noise permit (CNP) shall be applied at least 2 weeks in advance, as necessary. Portable noise barriers
Assessment, (ii) Safe Work method Statement (SWMS), (iii) Job Safety Analysis (JSA) will be conducted will be considered for erection to minimize the noise from breaking work and/ or other heavy
and recorded prior to any site work. machines if necessary
Major equipment will the list of equipment / system as stated in Section 1.8.
- Site cleaning tidiness and housekeeping shall be carried out for environmental purpose.

3.1 Installation of Pipework 3.4 Safety Measures

Pipes in stainless steel will generally be prepared with pipe isometrics – for pipe sizes larger than DN150, Refer Health and Safety Plan for general measures, procedures and check list.
pipe spools will be pre-fabricated as practicable as possible off-site and deliver to site for assembly.
Pre-fabricated pipe spools will be marked with identification as per ISO drawings.

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 Contract No. EP/SP/86/15
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- All works within the construction site will be checked by the Site Engineer; ensure that the site work Safe Work Method Statement (SWMS)
will be carried out with compliance to both statutory and in-house requirements: Prior to work on site, a step-by-step procedure Safe Work Method Statement (SWMS) will be prepared,
- All hand tools are in safe working order; ensuring every construction/installation steps are considered and safe work methods are to be planned and
- All portable electric tools comply with safety requirements and in safe working order, while extension implemented on site. The SWMS for flare installation is included in the appendix of this document.
leads are not;
- There is adequate temporary lighting if applicable; Job Safety Analysis (JSA)
- Temporary power source is available for contractor at the designated location; Whilst SWMS studies the planning and implementation of the construction activities, it is acknowledged
- All works will be supervised by Site Engineer; that specific work details may require careful planning, as well specific job procedures analysis to ensure
- All site staffs, subcontractors, and workers should wear the required PPE such as safety helmet with the job can be completed safely and correctly. Examples of specific work that requires JSA will include
Y-type chinstrap, reflective vest and safety boots; (i) Heavy lifting at height for installation (lifting plan, traffic management, laydown area defined)
(ii) Installation of particular skid modules with manufacturer’s instructions
(iii) Installation of pressure relief valves
3.5 Installation Tools (iv) Installation of specific instruments which require attentions, for example, gas detectors and
sensors,
Table 5 Installation Tools …..etc.

Item Description
1. Hand-tools e.g. screw drivers, spanner, zips The above three control documents are for planning, methods and risk mitigations. They will require
approvals prior to work.
2. Crane Truck
3. Survey equipment For actual construction and erection activities on site, it is important to control work and check for
4. LA & LG compliance to requirements. This will be controlled by establishing,
5. Hydraulic Jack Inspection and Test Plans (ITP)
6. PPE Inspection and test plans are prepared for each block of activities, so that work procedures and outcomes are
7. Pressure Gauge anticipated, checked, verified and approved as completion. An overall ITP summary sheet will be prepared
for the flare construction and erection. It is expected that the ITP will be progressively filled and signed off
8. Drilling Machine as works are being conducted on site, ensuring each work will be checked and signed off prior to advancing
9. Electrical tools to the next step.

The ITP summary sheet is included in the Appendix to this document.

4 QUALITY CONTROL
The following quality control document shall be required for completions and signed off to confirm
construction work to the requirements of design. The quality assurance document will be consisting of the
overall Construction Risk Assessment which is specific for the Flare Construction.
Risk assessment
Risk assessment provides an overall construction/installation risk and mitigation measures to be instituted
to minimise or removal of identified risk. Risk assessment form is appended to this document.
The ITP log book will include check sheets of work done. As an example, the following Check Forms are
included as demonstration of the details required.
Check Form – Concrete Work Inspection – this form will be filled and signed off prior to accepting the
concrete foundation slab for installation
Check Form – Structural Steel Installation – this form will be used and signed off prior to accepting
installation of the stair tower to the flare.

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 Contract No. EP/SP/86/15
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There will be other check forms, currently under development as site wide installation, which will be used.
These check forms will include, for example, installation of pumps installation of equipment, motor
installation. Check forms will also be used for site testing, prior to construction completion. These will
include pipe hydro-tests, alignment checks, etc

5 APPENDICES
(The following forms will be prepared when closer to time and prior to installation)

Risk Assessment Form

Safe Work Method Statement
Job Safety Analysis
Inspection and Test Plan
Check Form – Concrete Foundation Inspection
Check Form – Structural Steel Inspection

DDS C5.8.3 Method of Construction for WWTP (Rev.3) Page No. 17