Erection Procedure For Preacast Pipe Rack (HGU-EPCC-06) 2 Reveivewed

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The key takeaways from the document are that it describes the methodology for erecting precast pipe racks, including the materials, preparatory work, erection sequence, quality control processes, and safety precautions to be followed.

The scope of work described is the erection of precast pipe rack columns and beams in their final locations as per design drawings for a hydrogen generation unit project in Visakhapatnam, India.

Safety precautions that need to be followed during erection include using appropriate PPE like safety shoes, helmets, gloves and goggles, barricading the surrounding area, checking lifting tools and documents, and ensuring workers at height use fall protection.

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TP/CONS./HGU/077015C/MS/005A

HYDROGEN GENERATION UNIT (EPCC-06


PROJECT : PACKAGE) FOR VISAKH REFINERY
MODERNISATION PROJECT, HPCL

LOCATION : HPCL VISAKHAPATNAM, ANDHRA PRADESH

OWNER PMC LEPCC

JOB PROCEDURE FOR PRECAST PIPE RACK


ERECTION
TP/CONS./HGU/077015C/MS/005A

Document Category Document Review Status (by Owner / PMC)

1 Approved / Reviewed
Approval
2 Approved / Reviewed with comments as marked
Review
3 Not Approved / Resubmit

Information 4 Retained for Information / Records

Date: Name:
This approval does not absolve the Contractor from meeting their
contractual obligations of delivering a complete, safe and
efficiently operating units/facilities meeting all requirements of the
contract.

Pages modified under this revision:


Kumar
israo@tec
Digitally signed by
2018.12.26 israo@technip.com
Digitally signed by arkumar@technip.com DN: cn=israo@technip.com
17:12:04 +05'30'
hnip.com
DN: cn=arkumar@technip.com
Date: 2018.12.26 15:35:42 +05'30' Date: 2019.01.03 15:06:27
+05'30'

ISSUED FOR
0 13.12.2018 ARVIND KUMAR P KUMAR IS RAO
IMPLEMENTATION
Date
Rev STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MM/YYYY

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the margin

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.

CONFIDENTIAL – Not to disclose without authorization


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REVISION HISTORY

REV NO DATE DESCRIPTION

0 13.12.18 For Implementation

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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TABLE OF CONTENTS

1. SECTION 1: SCOPE

2. SECTION 2: MATERIAL

3. SECTION 3: REFERENCE

4. SECTION 4: PREPARATORYWORK(METHODOLOGY,EQUIPMENT,
MATERIAL, FABRICATION)

5. SECTION 5: ERECTIONSEQUANCE

6. SECTION 6: QA/QC

7. SECTION 7: FORMATS

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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SECTION 1: SCOPE
The Procedure describes the methodology to have firm, techniques understanding and
guidance for the erection of Pre-Cast pipe rack (Columns & Beams) in their final location
as per IFC Drawing for construction of LEPCC-6, HGU Unit at HPCL Visakh Refinery
(Andhra Pradesh)

2 MATERIALS: -

a) Pipe Rack precast elements, Pad plates, Neoprene pads, Pin Rod, Non-Shrink Grout GP-
2, Guy
Ropes & wedges for holding in position, tools & tackles.
b) Machinery & Manpower.
c) Crane used for lifting & shifting and erection.
 Hydraulic/crawler cranes of 80 MT& 150MT capacity.
 Trailers / tractors of suitable capacity.
 Standard Scaffolds.
 Man lift/Cherry picker
 Skilled riggers and erection gang.

3 REFERENCE: -

3.1 Contract Civil Drawings for Pre-Cast Pipe racks (IFC)


3.2 077015C-ITP-1710-01 Reinforced concrete materials and construction
3.3 077015C-505-DW-1741-0205 rev. 1 Pipe Rack 105/205
3.4 TP-CONS-HGU-077015C-MS-002 Method Statements for Concrete Works
3.5 TPFMC/HPCL VISAKH REFINERY/CIVIL/HSE/001Site HSE Plan.
3.6 Approved ITP.
3.7 Approved Rigging plan

4 PREPARATORY WORK: -

 All precast member & cast-in-situ concrete member to be cleaned properly. Surface
preparation of the precast column (in situ portion) to be done by chipping and making the
surface rough.
 Anchor bolts, insert plates (if any) to be fixed and inspected before erection and inspection
clearance shall be recorded on the format

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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 Before installation of any precast frame, pad to be installed inside pedestal with non-shrink
grout (conbextra-GP-2). The top level of the liner plate should install within ± 5mm of the
specified level.
 The fixing of the pad plate should be done before commencement of column erection.
 Generally, if enough space is available for a man to go inside of the column pedestal, then
liner plate can be fixed after of the final lift, otherwise, before casting of the final lift of the
pedestal. The liner plate must be fixed.
 Transportation of the precast members from cast yard to erection site shall be done only
after achieving the required strength by capable trailer.
 Precast member already marked with identification no will be shifted to the erection
location from stacking yard to erection site shall be done only after achieving the required
strength.
 Precast member already marked with identification number, will be shifted to the erection
location by from stacking yard generally all columns for a particular pipe rack will be
transported as per erection site.
 Crane lifting the precast member at the pre-cast bay should have sufficient capacity as
per the crane load chart. Longitudinal beams and cross beams which are already been
casted after achieving the required strength to be transported to erection site as per Tag
no. of the erection sequence.
 At erection site all members should be unloaded with proper capacity of crane and should
be stacked near pedestal.

N.B.: - All lifting equipment shall be got verified for the validity of the lifting tools.

5 ERECTION SEQUENCE: -

 Crane with adequate capacity (main crane) along with hydra or crane) depending on the
weight of the column will be used for making Precast frame in vertical position. Before
lifting the precast frame, rope ladder / aluminum ladder will be fixed for removal of slings
as well as fixing of guy rope for subsequent operation. Subsequently column will be placed
inside pedestal’s liner plate.
 Subsequently longitudinal beam will be placed on respective precast frame brackets
starting from bottom one ending to top one and bolted/tied firmly to the frames.
 Subsequently respective main beam will be erected on precast frame bracket and
alignment shall be done to the line & levels. Then after completing one unit, non-shrink
grout will be poured on the pedestal and will be cured as per recommendation. Lastly all
interconnection of precast frame and respective beams will be joined by coupling/welding
and cast in-situ. Erection group will decide the sequence of group grouting. At the end
steel cross bracing will be fixed.
 Arrangement of scaffolding, Man lift, access ladder, life line etc., on all elevations and get
it cleared by the TPFMC safety personnel.
 Further work on erected members shall only be taken up after erection & grouting is
completed in all respect.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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5.1 TRANSPORTATION OF THE PRECAST ELEMENTS (Columns & Beams)

5.1.1 Loading/Unloading of columns & beams at the prefabrication stockyard and


at work place, on long bed (40’) trailer permanently fitted with support
under each lifting anchors by using capable cranes or F-15.
5.1.2 Transportation & shifting the material to site location along selected itinerary
routes (curves and humps control) after getting the required permission
from approving authority.
5.1.3 Trailer details: Type of trailer: Payload flatbed semi-TRLR., Capacity: 40
Ton
5.1.4. Unloading in the erection site on a proper graded & levelled area, the head
near the location.
Wood donning under the lifting anchor should be properly.
5.1.5 The area around the column pockets shall be backfilled compacted
After the precast erection operation is not be done unless all the activity should
be completed.

5.1.6 The proper column is identified (Tag identify) and horizontally placed as per
IFC drawing.
The head must be near to the corresponding foundation.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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5.1.2 ERECTION OF COLUMNS

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It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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5.2.1 Prior to final lifting of the columns the following must be prepared on the
Ground.
a) Placing of main rebar stirrups ( loose) for cast in-situ moment beams.
b) Fitting of erection gears like props foot fixation, guiding r o p e s f o r rigging
c o m e along. Props f oot bracket will be mounted & bolted to the column
at 32mm dia. holes provided during pre-cast.
c) Fitting of prism on the last top most corbels for levelling purposes.
5.2.2 Definitive positioning of t h e H e a d a n d Tail Cranes.
Under corbel levels and the tail of the column wit h heavy duty PVC round
Sling.
5.2.3 Both crane lifting a n d rotating, the tailing crane will maintain t h e column
b o t t o m just above the ground and
Head crane lift until the verticality of the c o l u m n is reached its
position.
5.2.4 The tail crane is released, and the head crane rotates t o place the column
ver t ica l o ve r the pedestal pockets.
5.2.5 The column is lowered until it just touched the shim plates (the pedestal
being completely cleaned a n d p r e p a r e d f o r g r o u t i n g .

5.2.6 Centre lines are implemented by the surveyor. Edges lines


are drawn by the superintendent,

Both side on top of the pedestal. Location w i l l be controlled b y ruler


matching marked l i n e s of e a c h s i d e s of

The column a n d ped e st a l t o p s o f i t s corresponding foundations as


shown below:
5.2.7 Tops of push/pull props are fixed on the column and nearby foundations. After
lowering of the column, a rough
Column vertical adjustment is made with a long spirit ruler and Theodolite
or Total Station in two directions.
5.2.8 Bracing with 8 hardwood triangular wedges as shown in above sketch.
5.2.9 Prior to release of the head crane by removal of heavy duty wire ling,
column shall be supported by the propose

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It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
Rev. Page
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As shown in the attached sketch bottom portion and top portion of props
shall be fixed by Hilti anchors and clamps respectively. After making sure
stability of the column man lift shall be utilized for removal of head crane's
sling.
5.2.10 Final levelling of the column is made by the surveyor measuring the position
of the previous fixed prism on.
computed position of corbel (total station system) and final adjustment with
the use of the push pull props.
5.2.11 Push/pull props will be removed after the grouting has been set and cured.
5.2.12 Pouring of the grout the same day.

5.2 Erection of the moment & Transverse Beams

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It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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5.2.4.1 Scaffolding platform with hand rail, temporarily steel bracket shall be fixed
up to the bottom of the beam.
5.2.4.2 Prepare the moment beam at ground level by fining slings as required,
final cleaning of bearings for support structure etc. A f t e r t hen using a
crane, hoist the moment beam to fixed and level properly.
5.2.4.3 Move the boom of the crane so as to make the steel reinforcement of
the moment beam slide into the steel reinforcement of the columns
ensuring that the boom of the crane does not touch either support structure.
5.2.4.4 As soon as the matching of the steel bars with coupler of the beam and
the columns has been completed, fix two couplers in place at each end
of the beam at the end of the upper level of the central upper level central
bars of 32 mm diameter.
5.2.4.5 Place the moment beams on the support structures.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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5.2.4.6 Verify that the ends of the formwork on the support structures are in
correct position, rectifying where necessary using screw thread jacks
placed on the support structures (the crane can assist by taking partial
beam weight).
5.2.4.7 When all are in correctly positioned the crane may be removed.
5.2.4.8 Scaffold inspector must replace the handrail to make the service.
5.2.4.9 Complete formwork as necessary on the entry end of the beam.
5.2.4.10 Complete the steel fixing and the formwork at each end of the beam.
5.2.4.11 Concrete both ends of the beam in accordance with concreting
procedures.

5.3 Erection of Pin Connection Beams

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It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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The erection of this type of beams differs from above beam by the following:

5.3.1 Prior to the installation of a pin connection beam, two workers shall go
to the top using scaffolding or Man lift/Cherry Picker of the Corbel will
be levelled as needed by a grout and a neoprene pad (thickness & size
as per IFC drawings).
5.3.2 Just before lowering d o w n the beam, the pin bar is inserted i n the
cleaned hole of the corbel.
5.3.3 Lift and install the Pin Connected Beam on top of the corbel by using
the Crane.
5.3.4 Crane lifting the beam.
5.3.5 Man lifts positioned a t the edge of each beam.
5.3.6 Grouting

6 INSPECTION: -

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It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
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 Arrangements for erection shall be as per Rigging plan document No.


 After erection the verticality will be checked and for beams level and alignment will
checked as per IS 12843- within tolerance limit for Erection.
 The clearance for further activities shall be recorded as per approved ITP (Protocol)

7 SAFTEY PRECAUTION: -

 Ensure the personnel are provided with appropriate PPE (Safety shoe, Helmet with chin
Strap, Hand gloves, Goggles etc.)
 Barricading surrounding area should be ensured.
 During erection elements lifting appliances and its relevant document should be checked
by any competent person.
 During erection and alignment, the person who will be working at height must be use all
the PPE’s.
 The erection shall be carried out in day light only under qualified supervisory staff.

8 DOCUMENTATION: -

 All documents shall be prepared and maintained in approved formats as per ITP Doc.
No. TPF/BUTENE-1/60923W/ITP-06

SECTION: 5.0 HEALTH SAFETY AND RISK ASSESSMENT


The site engineer shall follow all safety rules as defined by the safety personnel as
analysed for job safety for different civil works depending upon the nature and type of
job. The site engineer shall ensure that all lifting tools & tackles are having valid
certificates. All necessary safety measures as per approved Site HSE PLAN
requirement or product manufacturer’s recommendation or Engineering Specification
shall be followed. A risk assessment shall be followed as per approved JHA.

SECTION: 6.0 QUALITY ASSURANCE & QUALITY CONTROL

Quality Assurance shall be ensuring the systematic implementation of this procedure


to achieve/derive the required/determined product. Quality control shall ensure all
·necessary checks and tests are done as per the specific requirements of project job
specification /ITP. Also necessary quality records shall be maintained as objective
evidence.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization
Rev. Page
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SECTION: 7.0 FORMATS

As per Technip Project Quality Plan and approved ITP

Note: In case, there is any conflict between this Job procedure and contract then contract
shall prevail.

This document is developed by TechnipFMC and the information it contains are property of TechnipFMC.
It shall not be used for any purpose other than those for which it was supplied.
CONFIDENTIAL – Not to disclose without authorization

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