EMAL Phase III

Erection of MP&EI systems

Aleksander Gornjak
Project Manager

EM Hidromontaa
P.O. BOX: 73739 Abu Dhabi
Tel. : +971-2-6724283
Email: emhidro@eim.ae

4/15/2015

Contents
1.
2.
3.
4.
5.
6.
7.
8.

Introducing EMH
Safety Policy
Environmental Policy
QC Policy
QA/QC Implementation
Organisation
Time Schedule
Mechanical activities

8.1 Gas Turbine

8.2 GT Generator
8.3 GT Air Intake
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8.4 GT Exhaust
8.5 GT Enclosures
8.6 GT Loose Parts
8.7 HRSG
8.8 Main Stack
8.9 Diverter damper
8.10 Steam piping
8.11 Other equipment
8.12 Fin fan system
8.13 Fuel gas system
8.14 Horizontal pumps
8.15 Vertical pumps
8.16 Static equipment
2

Contents
9. Electrical Activities
9.1 Main equipment
(transformers, IPB,
MV/LV panels,...)
9.2 Cables
9.3 Cable trays, conduits
9.4 Earthing
9.5 Lighting

10.3 Field Instruments

10.4 Instrument fittings
10.5 Control cable, conduits

11. Test equipment

12. References

10. I&C activities

10.1 Precalibration

10.2 GT Side

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Introducing EM Hidromontaa
Slovenian Engineering and Construction Contracting Company
Founded in 1948
Power generating and distribution plants, oil, gas and petrochemical
plants, pipelines, desalination plants..
Projects in: Algeria, Austria, Bahrain, Croatia, Czechoslovakia,
Germany, Libya, Nigeria, Netherlands, Norway, Pakistan, Syria,
Sri Lanka, Sweden, United Arab Emirates,
Venezuela, Yugoslavia
1983 established branch in Abu Dhabi
Prequalified as contractor in the UAE with:
TAKREER, ADGAS, ADCO, ADWEA, DEWA

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2.1 Safety Policy

Companys responsibility:
To provide safe and health working conditions
To provide training and instruction
To make available all necessary safety devices and protective
equipment and to supervise their use

Employees cooperate in the operation of this policy

Senior EMH Manager is fully responsible for maintaining
safety and healthy working conditions
The Company Safety Manager will ensure
that the policy will be kept up to date

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2.2 Safety Policy

EMAL EHS manual should be followed in all respect

All EMH employees should be aware of Site regulation and
procedures
EMH Management should ensure sufficient number of EHS staff
Daily Toolbox Talk should be
performed by Safety officers
Each EMH Supervisor should
advise his workers of potential
risk for specific work task

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3.1 Environmental Policy

Comitted to leading the industry in minimizing the impact of

its activities on the environment
Supporting pollution prevention and minimization programs
Using materials and energy efficiently to conserve natural
resources
Actively promote recycling
Training programs for employees to raise awareness of
environmental issues

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3.2 H.S.E Plan

No

Potencial Hazard

T.B.M

HOUSE KEEPING

MANAGING POINT
Daily TBT performed by Safety officers discussing different safety topics
Permanent house keeping team under control of designated Safety officer
Close coordination with waste disposal subcontractor (Dulsco)
Mandatory use of safety harness with double lanyard for each work above 2m height

ACCIDENT FROM A FALL

Strictly control of implementation at site

ELECTRICAL SHOCK

Only authorised and qualified electrical staff allowed to work on electrical components under PTW
Regular check of all electrical tools and distribution network

FINGER DAMAGE DURING

CABLEING

Use of proper tools while performing cable dressing and termination

Use of PPE wherever applicable

LIFTING OPERATION

Only certified staff allowed to work with lifting operation with cerified and inspected equipment
Regular inspection of lifting gears for evetual damage

OIL FLUSHING
OPERATION

Proper PPE and Oil Spilage Kits and Fire Fighting Equipment should be
available

A WOUNDED BY AN
EDGED MATERIALS

Protection of sharp edges with plastic material, mandatory use of protective equipment like helmets and hand gloves

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QC Policy
Companys activities places emphasis on experience,
expertise, capability, reliability and quality
Ensure that the requirements of the International Standards
and/or customer specifications are met
ISO 9001:2008 Certification
All employees follow the organization
and controls set out within the
operation procedures

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QC Policy
Certificates ASME PP, A

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QC Policy
Certificates ASME A and National Board R

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5.1 QA/QC implementation

Checking of foundation
elevation & coordinates
Alignment check of gas
turbine
Following international
standards (ISO, ANSI, HSE
policy)

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5.1 QA/QC implementation

Loop checking of Pressure

Transmitter
HIPot test of MV cable
Following international
standards (ISO, ISA, HSE policy)

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5.2 QA/QC implementation

Material storage facilities
Air Passage, AC

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5.3 QA/QC Control Plan

No

Activities

1 Site construction

MANAGING POINT
All works should be performed in accordance with project specifications,
drawings and international standards
EMH Site Supervisors should ensure strict compliance with documentation

EMH QA/QC
2
inspection

Designated EMH QA/QC inspector should check together with supervisor

internally that the job is done in accordance with requirements
Internal inspection report should be prepared

3 R.F.I with Client

RFI with pre inspected data should be forwarded to Client for joint inspection
and final acceptance

4 Punch List control

Eventual punch list noted during inspection should be categorised and

cleared asap

QA/QC handover
document

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Final inspection reports according to ITPs should be handover to Client and

one copy should be kept in EMH records
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6.1 General Organisation Chart

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6.2 Mechanical Organisation Chart

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6.3 Electrical Organisation Chart

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6.4 Manpower mobilization schedule

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6.5 Construction equipment mobilization schedule

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Time Schedule

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Mechanical activities
8.1 Gas Turbine
Check foundation
Placement of Turbine
Assembly works
- Piping
- Mechanical
Insulation works
Final check

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Mechanical activities

8.2 GT Generator
Check foundation and
installation of supports
Placement of Generator
Assembly works
- rotor
- exciting compartment
Alignment against
gas turbine
Final check
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Mechanical activities
8.3 Turbine Air Inlet
Preparation of material and
equipment
Erection of Air Intake System
(Steel Structure, Ducts, Filter
System, Piping)

8.4 Turbine Exhaust

Preparation of material and
equipment
Erection of Gas Exhaust System
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Mechanical activities

8.5 Turbine Enclosures

Preparation of material and
equipment
Installation of enclosure &
sealing of penetrations

8.6 Loose Parts

Gas Turbine Grating/Turbine Enclosure Floor

Preparation of material and

equipment
Erection in accordance with
erection manual
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Mechanical activities
8.7 HRSG
Preparation of
foundations
Installation of
casing structure

Erection of HRSG
modules and drums
Installation and
welding of piping

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Mechanical activities

8.8 HRSG Main Stack

Prepare material
Installation of stack
segments
Welding

8.9 HRSG Diverter damper

Prepare material
Erection of diverter
Installation of diverter
stack
Finishing work
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Mechanical activities

8.10 Steam Piping

Prefabrication of piping
Process and utilities piping
Erection & welding
Testing & Flushing/Blowing

8.11 Other HRSG equipment

Check foundations
Placement and fixing
Interconnection with main
equipment
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Mechanical activities
8.12 Fin Fan Air Cooler System
Check foundation
Installation of supporting
steel structures
Placement of Fin Fan Coolers
and interconnection works

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Mechanical activities
8.13 Fuel Gas Compression & Fuel Gas Supply System
Phase I working area
Check & prepare
foundations
Placement of Gas
Compressors
Interconnection pipework
Alignment & grouting works
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Mechanical activities
8.14 Horizontal Pumps Installation
HRSG Feed Water Pumps
Closed cooling water
pumps
Make up water pumps
Back up Fuel Oil pumps
Service Water Pumps
Sump pumps

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Mechanical activities
8.15 Vertical Pumps

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Cooling Tower Pumps

Condensate System Pumps
Prepare foundations
Set pad liner and sole plate
Installation as per pump
manufacturer instructions

32

Mechanical activities
8.16 Static Equipment

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Compressed air system

Heat exchangers
Tanks and vessels
Tube Cleaning System
Silencer
Miscellaneous Bottles

33

Electrical activities

9.1 Main equipment

Transformers
Check foundation
Placement of transformer
Assembly works (electrical
& mechanical)
Oil filling and filtration
Final check
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Electrical activities

9.1 Main equipment

Insulated Phase Busduct

Preparation of material and
equipment
Erection and welding of IPB
into final location
Generator circuit breaker
installation
Connection to main and
auxiliary transformer
Connection to generator
HIPot test

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Electrical activities

9.1 Main equipment

MV/LV Panels
Check foundation
Bulk installation in
accordance to drawing
Busbars connection
Testing of busbars (HIPot,
Joint resistance)
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Electrical activities
9.2 Cables

MV/LV, Control
Preparation of pulling
cards
Cable drums
Route preparation
Setting of roller and
pulling
Dressing
Testing

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Electrical activities
9.3 Cable trays and Conduits
Preparation of supports
Installation of trays in
accordance to drawing
Earthing & Touch-up
paint
Covering

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Electrical activities
9.4 Earthing
Installation of earthing system
in accordance to drawing
CAD welding
Earth resistance test

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Electrical activities
9.5 Lighting
Preparation of material
Installation of lighting panels, lighting
fixtures in accordance to the drawings
Cable pulling
Termination
Testing

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10

I&C activities

10.1 Precalibration
Follow Data Sheets
Compare Setpoint of the
Instrument
Calibration
Calibration certificates

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10

I&C activities

10.2 GT Side
Skid mounted instruments
(Lube oil, fuel gas, fuel oil, skids..)
Install the skid as per the drawings
Check the alignment & accessibility of
skid & instruments

Equipment mounted instruments

(Turbine vibrations, TEs, filter house
DPTs..)
Check the related P&ID and install the
instruments
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10

I&C activities

10.3 Field instruments

Check the related P&ID and
location drawings
Installation of instruments
(Racks, LCPs or direct mounted
instuments)
Consider parallax, alignments,
accessibility and rigidity factors
of installation
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10

I&C activities

10.4 Instrument fittings

Impulse line tubing
Trace the tapping points
with the relevant P&IDs
Connect impulse line to
instrument folowing
Hook-up drawing
Hydro test or pressure
test
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10

I&C activities

10.5 Control cable & conduit

Trace the cable trays with
relevant drawings
Folow the Cable pulling
cards
Dressing
Glanding, Termination,
Continuity test, Loop test
Conduits shall be installed
and the secondary cables
shall be pulled
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11

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11.1 Test Equipment

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11.2 Test Equipment

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11

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11.3 Test Equipment

48

11

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11.4 Test Equipment

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12

References

EMAL Phase II CCPP 1023MW

2012 - 2014
Complete MEI Works
Client: Samsung C&T / EMAL
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12

References
TNBE 1034MW/70 MIGD IWPP
2007-2008
Complete MEI Works - P&WI
Client: ADWEA/TAPCO
FUJAIRAH F2 IWPP
102 MIGD/Day MED Plant
2008-2010
Complete MEI Works WI
Client: ADWEA/FAPCO

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12

References

SHUWEIHAT S1 IWPP
1500MW Power Plant
2002 - 2004
Erection of TBN & BOP
Client: ADWEA / SCIPCO/ Siemens
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12

References

SHUWEIHAT S2 1550MW IWPP

2009-2011
Complete MEI Works PI
Client: ADWEA / RPC / Samsung C&T
4/15/2015

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EMAL Phase III

Erection of MP&EI systems

EM Hidromontaa
P.O. BOX: 73739 Abu Dhabi
Tel. : +971-2-6724283
Email: emhidro@eim.ae

4/15/2015

54