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

N6820-M04-2E-S2xxx

METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

Rev.: 00

Date: 18.01.2011
Page: 2

REVISION RECORDING

Date

Revision

Description of Revision

Prepared by

04.08.10

00

First Issue

UNNII
Mech.Eng.

Reviewed by

Approved by

MOHAMAD
HAMDY
M&E COORD.. Project Manager.

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: 18.01.2011
Page: 3

INDEX

1. SCOPE
2. PURPOSE
3. REFERENCE SPECIFICATION/ DRAWING
4. PARTIES INVOLVED
5. DESCRIPTION OF EQUIPMENT
6. RESPONSIBILITIES
7. MATERIAL RECEIVING
8. FOUNDATION SURFACE PREPARATION
9. EQUIPMENT INSTALLATION AND LEVELLING
10. SAFETY PROCEDURES
11. PLANT AND EQUIPMENTS
12. ATTACHMENTS

1. SCOPE
This procedure applies to air compressor station to be purchased and installed at

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N6820-M04-2E-S2xxx

METHOD STATEMENT

Rev.: 00

INSTALLATION OF AIR COMPRESSOR

Date: 18.01.2011
Page: 4

Al Ain receiving pump station as part of TRANSCO contract N6820

2. 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. It covers procedures, responsibilities, quality control
of resource input and task activities, acceptance criteria, verifying test and
inspection documents, and inspection points, which are planned and shown in
sequence on the prepared Inspection & Test Plan (ITP)

3. REFERENCE DOCUMENTS / DRAWING

3.1

Flow sheet Gas and Flow sheet Water from Atlas copco

3.2

N6820-M05-2E-D005
drawing

3.3

M6820-I01-4E-D005 P&ID Air compressor package surge system

3.4

ADWEA Standards Specification - W-M-SS-007 Rev0

Package

3.5

IOM manual compressor / assembly instruction canopy

Air

compressor

station

General

arrangement

for Air Compressor

4. 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. DESCRIPTION OF EQUIPMENT
As Part of Contract N6820, Air compressor systems will be installed at AARC
Pumping station. 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 . There will be 3 identical compressor station , out which
one compressor for surge vessel plant for GIC line , one for Um Al Gaffa line and
one will be common spare
The compressor to be installed are of multi stage, oil free , reciprocating type
manufactured by M/S Atlas copco . The compressor and other ancillaries will be

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N6820-M04-2E-S2xxx

METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

Rev.: 00

Date: 18.01.2011
Page: 5

installed inside noise and sound proof canopy except cooling tower
The main components in compressor system are

1. Reciprocating , multi stage water cooled , oil free air compressor Model 3HX2T
2. High Pressure Ancillary Equipment:

Dryer model HFD130W

Activated Carbon Filter model HQD16
Fine Filter model HDDP160
Water Pump Skid model WPS16HAT

3. Cooling Tower model CTE50

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 6

4. Canopy

6. RESPONSIBILITIES
6.1

Mechanical/ Civil Site Engineers

Reports directly to Project Engineer. They coordinate with Client/Consultant,

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. They coordinate with QC Inspectors for the necessary inspection during
each phase of job execution and completion.
They shall be also responsible for the Installation of vessel in accordance with the
issued AFC drawings, applicable ADWEA Standards and established procedures.
6.2 Mechanical / Civil Foremen
They report directly to the Concerned Discipline Supervisor for direct supervision
of his craftsmen involved in the job execution. He ensures that all activities are
being performed in compliance with this Method Statement.
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.
Manufacturers recommendation for the lift including the use of spreader bars,
slings, turnbuckles and so forth.
6.3 QC Inspectors
Discipline QC Inspectors shall conduct Quality Control Inspection for, Mechanical,
and other related activities covered under this job and raise Request for
Inspection (RFIs) for Witnessing and Hold Points as per approved ITP. He ensures
that all pertinent QC records are in order and finally handed-over to
Client/Consultant in organized manner.

7. MATERIAL RECEIVING

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 7

7.1

Discipline Supervisors, 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, and
other industry standards governing receiving, preservation and protection
of all machineries and their accessories at site.

7.2

Visually inspect all components for physical damage or contamination by

opening packages and crates

7.3

Verify that shipping protection has been applied and is still in effect

7.4

Verify that shop inspection has been completed and that the vendor had
supplied all necessary documentation and other disposition procedures.

7.5

Verify loose components with the package that they match the packing list
and is complete.

7.6

Verify proper identification of all components

7.7

Verify components against the provide delivery note

7.8

Verify that protective caps and plugs are in place. Machine/equipment is

lubricated as required

7.9

Report
defects/failures
to
the
manufacturer
regarding
the
machine/equipment supplied. Defect/failure shall be reported to OWNER
/ENGINEER for all client supplied items

8. FOUNDATION SURFACE PREPARATION

Compressor station required a plane industrial slab of minimum 300 mm
thickness without special preparation, Completion of this minimum requirement
shall be verified before the commencement of installation works

9. LIFTING
9.1

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.

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 8

9.3

Do not let slings bear on the equipment, and especially not on compressor
components which are not sufficiently resistant to take them (coolants,
water pipes, electrical cabinet).

9.4

Do not allow the slings to come into contact with and damage paintwork.

9.5

Avoid using steel slings with bare cables .In such cases, allow for local
protection over contact points, or, even better, a spreader (stiffened
spreader)

9.6

The sling diameter must be appropriate to the load to be lifted (For

guidance, steel sling diameter for a compressor must be a minimum of 14
mm).

9.7

Comply with safety instructions applicable to handling and lifting.

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 9

10. EQUIPMENT INSTALLATION AND LEVELLING

10.1

10.2

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.

10.3

Position the drilling jig (delivered with the compressor) to the ground and
mark fixing points.

10.4

Drill fixing holes into the foundation slab by following the erection
instructions below.

10.5

Erection instructions and Operation

Drill hole. (Diameter = 25 mm / depth = 170 mm).

10.6

Clean drill hole. The chemical bolt may be laid in wet supports. In such case
just make sure to evacuate all water collected in the drill hole.

10.7

The resin must flow into the capsule (warm to the touch).

10.8

Place the capsule in the drill hole.

10.9

Position threaded studs (rotation -percussion).(speed 750 tr/min).

10.10 Visual inspection while filling up.

10.11 Comply with the delay before tightening the lock-nuts.

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 10

10.12 Place the torques. (15 daNm).

After the chemical bolts positioning
10.13 Bring the compressor to its position.
10.14 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. Tolerance is 0.5
millimetres / metre. Once the compressor is level, insert the shims of
varying thickness provided over the 20 millimetre shims (Item 3) previously
inserted.

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 11

10.16 Allow the compressor frame to rest on the shims by releasing the levelling
screws (item 4). Clamp the compressor to the foundation slab. Fit and
tighten lock-nuts (item 2).
10.17 Pour finishing concrete between the slab (item 5) and the base plate (item
1). A high fluidity, shrink-proof concrete must be used.

Cooling tower
10.18 Cooling tower to be fixed as per the approved GA drawing ( Fixing details
shown below)

10.19

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 12

10.20 Cooling tower will installed on the top of I ( 75X75) section as show on
the above drawing

Other Auxiliaries
10.21 Cooling water skid also to be fixed using chemical anchor bolt and levelled
10.22 Air drier is to be placed on the foundation as per the approved GA drawing (
No anchor bolt is required )
10.23 All compressed air piping to be installer as per the GA dawning according to
GA drawing and Manufacturers process diagram
10.24 The piping system should be tight & leak proof.
10.25 Once completion of installation of All components inside the canopy ,
Canopy installation to Carrie out according to the Canopy assembly
instruction from manufacturer ( Attached for information)
10.26 Cooling water piping ( uPVC ) to completed according to GA drawing and
Manufacturers process diagram
10.27 Darin piping to be completed according to GA drawing and Manufacturers
process diagram
10.28 All the installation to be cross checked again and Air compressor installation
QCR to be filled properly

11. SAFETY PROCEDURE

11.1

Observe all Safety Notices and Site Rules

11.2

Follow the method statement

11.3

Wear appropriate Personnel Protective Equipment (PPE)

11.4

Be aware of crushing hazards and pinch points when handling and joining
pipes

11.5

Avoid walking and working under suspended loads

11.6

Be aware of loose material excavation /opening drop of , uneven ground

and other obstructions

11.7

Allow ample space for each employee to work safety

11.8

Use tools for the proper purpose.

11.9

Check all tools /equipments for damage before use with daily equipment
checklist

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N6820-M04-2E-S2xxx

METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

Rev.: 00

Date: 18.01.2011
Page: 13

11.10 Remove the damage tools /equipments immediately and affix the visible
label
11.11 Do not use any tools /equipments that is unsafe
11.12 Check all lifting gear for capacity and condition before use.
11.13 Earth all electrical generator for lighting
11.14 Keep the working area clean at all time.
11.15 Be available always adequate first aid supply in the site
11.16 Be available all safe certificate and documents at work area
11.17 Risk assessment : Refer to attachments

12. PLANT AND EQUIPMENTS

12.1

Crane

12.2

Rigging gears

12.3

Hand tools

12.4

Industrial spirit level

12.5

Shims

13. ATTACHMENTS
13.1

Inspection test Plan Air compressor installation N6820-000-ITP-0055-00

13.2

Inspection QCRs
N6820 M-C-QCR 006 Air compressor Levelling Record
N6820-M-QCR 005 Air compressor installation completion check list

13.3

Drawings
N6820-M05-2E-D005 Air compressor station General arrangement
M6820-I01-4E-D005 P&ID Air compressor package surge system

13.4

Process sheet Gas / Process sheet Water

13.5

IOM Manual compressor

13.6

Assembly instruction -Canopy

13.7

Compressor Bottling down instructions

13.8

Risk Assessment

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METHOD STATEMENT
INSTALLATION OF AIR COMPRESSOR

N6820-M04-2E-S2xxx
Rev.: 00

Date: 18.01.2011
Page: 14

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