200-20-ME-DEC-00003

NFPS Offshore Compression Complexes Project COMP2

COMPANY Contract No.: LTC/C/NFP/5128/20

CONTRACTOR Project No.: 033734

Document Title

MATERIAL HANDLING PHILOSOPHY FOR CP6S AND CP7S COMPLEXES

COMPANY Document No.

: 200-20-ME-DEC-00003

Saipem Document No.

: 033734-B-D-17-SPM-ME-S-10002

Discipline

: MECHANICAL

Document Type

: DESIGN CRITERIA

Document Category/Class

: 1

Document Classification

: Internal

27-Jan-2023

Issued for Review

Ahmadzamani Yusop

Muhammad Sany Othman

Rosli Abu Bakar / Romano Marinoni

REV.

DATE

DESCRIPTION OF REVISION

PREPARED BY

CHECKED BY

APPROVED BY

Saipem S.p.A.

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REVISION HISTORY

Revision

Date of Revision

Revision Description

30-Dec-2022

Issued for Inter-Discipline Check

27-Jan-2023

Issued for Review

HOLDS LIST

Hold No

Hold Description

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TABLE OF CONTENTS

INTRODUCTION … 5

1.1 PROJECT OBJECTIVE … 5 1.2 PROJECT SCOPE … 5

DEFINITIONS AND ABBREVIATIONS … 7

2.1 DEFINITIONS … 7 2.2 ABBREVIATIONS … 8

REFERENCE, RULES, CODES AND STANDARDS … 10

3.1 COMPANY DOCUMENTS … 10 3.2 PROJECT DOCUMENTS … 11 3.3 CONTRACTOR DOCUMENTS … 11 INTERNATIONAL CODES AND STANDARDS … 12 3.4

PURPOSE OF DOCUMENT … 13

GENERAL DESIGN REQUIREMENT … 13

5.1 DESIGN LIFE … 13 5.2 EQUIPMENT LOCATION … 13 5.3 DESIGN ONE BUILD MANY (D1BM) … 13

GENERAL MATERIAL HANDLING PHILOSPHY … 14

MATERIAL HANDLING EQUIPMENT AND FACILITIES … 17

7.1 PEDESTAL CRANE … 17 7.2 MOBILE CRANE … 17 7.3 MONORAIL BEAM … 18 7.4 PAD EYE AND BEAM CLAMP … 18 7.5 PORTABLE A-FRAME … 19 7.6 MISCELLANEOUS HANDLING EQUIPMENT … 19

MATERIAL HANDLING EQUIPMENT REQUIREMENT … 20

8.1 GENERAL … 20 8.2 HSSE REQUIREMENTS … 20

MATERIAL HANDLING ROUTE, HATCHES AND LAYDOWN AREAS … 21

9.1 MATERIAL HANDLING ROUTE … 21 9.2 HATCHES … 21 9.3 LAYDOWN AREAS … 21

GENERAL MAINTENANCE APPROACH (OFFSHORE) … 22

10.1 HANDLING OF PRESSURE VESSELS… 22 10.2 HANDLING OF TANKS … 22 10.3 HANDLING OF EXCHANGERS AND HEATERS … 22 10.4 HANDLING OF FILTER AND COALESCERS … 22 10.5 HANDLING OF FLARE … 22 10.6 HANDLING OF GAS TURBINE GENERATOR … 23 10.7 HANDLING OF GAS TURBINE COMPRESSORS … 23 10.8 HANDLING OF PUMPS … 23 10.9 HANDLING OF EMERGENCY DIESEL GENERATOR … 23 10.10 HANDLING OF SEAWATER LIFT PUMPS … 24 10.11 HANDLING OF FIRE WATER PUMPS … 24 10.12 HANDLING OF AIR COMPRESSOR AND DRYER PACKAGE … 24 10.13 HANDLING OF HEAVY VALVES … 24 10.14 HANDLING OF CHEMICAL TOTE TANKS … 25 10.15 HANDLING OF TRANSFORMER … 25

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10.16 HANDLING WITHIN LIVING QUARTERS … 25 10.17 HANDLING OF EQUIPMENT EXCEEDING PEDESTAL CRANE CAPACITY … 25

MATERIAL HANDLING REPORT … 26

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INTRODUCTION

The North Field is the world’s largest natural gas field and accounts for nearly all of the state of Qatar’s gas production. The reservoir pressure in the North Field has been declining due to continuous production since the early 1990s. The principal objective of the NFPS Project is to sustain the plateau from existing QG South Operation (RL Dry Gas, RGE Wet gas) and existing QG North Operation (QG1 & QG2) production areas by implementing an integrated and optimum investment program consisting of subsurface development, pressure drop reduction steps and compression. Refer to the figure below for a schematic of the North Field.

Qatargas Operating Company Limited is leading the development of the North Field Production Sustainability (NFPS) Project.

1.1 Project Objective

The objective of this Project includes:

• AchieNve standards of global excellence in Safety, Health, Environment, Security and Quality

performance.

• Sustain the Qatargas North Field Production Plateau by installing new Compression Complex facilities CP6S & CP7S in QG south with integration to the existing facilities under Investment #3 program.

• Facility development shall be safe, high quality, reliable, maintainable, accessible, operable, and

efficient throughout their required life.

1.2 Project Scope

The Project Scope includes detailed engineering, procurement, construction, transportation & installation, hook-up and commissioning, tie-in to EXISTING PROPERTY and provide support for start- up activities of the following facilities and provisions for future development. The WORK shall be following the specified regulations, codes, specifications and standards, achieves the specified performance, and is safe and fit‐for‐purpose in all respects.

Offshore

CP6S and CP7S Compression Complexes that are part of QG-S RGE facilities as follows:

• CP6S Compression Complex

• Compression Platform CP6S, Living Quarters LQ6S, Flare FL6S

• Bridges BR6S-2, BR6S-3, BR6S-4, BR6S-5

• Bridge linked Tie-in to RP6S

Production from existing wellheads (WHP6S & WHP10S) and new wellhead (WHP14S) are routed via riser platform RP6S to compression platform CP6S to boost pressure and export to onshore via two export lines through the existing WHP6S pipeline and a new 38” carbon steel looping trunkline from RP6S (installed by EPCOL). CP6S is bridge-linked to RP6S.

• CP7S Compression Complex

• Compression Platform CP7S, Living Quarters LQ7S, Flare FL7S

• Bridges BR7S-2, BR7S-3, BR7S-4, BR7S-5

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• Bridge linked Tie-in to RP7S

CP7S shall receive production from existing wellheads (WHP5S & WHP7S) and new wellhead (WHP13S). There is only one export line for CP7S through the existing export pipeline from WHP7S. CP7S is bridge-linked to RP7S.

RGA Complex Destressing

Migration of the Electrical power source, Telecoms, Instrumentation and Control systems from WHPs and RHPs hosted by RGA to the respective Compression Complexes listed below:

• WHP6S, WHP10S, WHP14S, RP6S and RP10S to CP6S Compression Complex

• WHP5S, WHP7S, WHP13S and RP7S to CP7S Compression Complex

Destressing of Telecoms, Instrumentation and Control system in RGA Complex Control Room, which would include decommissioning and removal of telecom system devices and equipment that would no longer be required post migration and destressing activity.

Onshore

An Onshore Collaborative Center (OCC) will be built under EPC-9, which will enable onshore based engineering teams to conduct full engineering surveillance of all the offshore facilities. The OCC Building will be located in Ras Laffan Industrial City (RLIC) within the Qatar Gas South Plot. MICC & Telecommunication, ELICS related scope will be performed in the OCC building.

Figure 1.2.1: NFPS Compression Project COMP2 Scope

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2 DEFINITIONS AND ABBREVIATIONS

2.1 Definitions

Definition

Description

COMPANY

Qatargas Operating Company Limited.

CONTRACTOR

Saipem S.p.A.

DELIVERABLES

FACILITIES

All products (drawings, equipment, services) which must be submitted by CONTRACTOR to COMPANY at times specified in the contract. All machinery, apparatus, materials, articles, components, systems and items of all kinds to be designed, engineered, procured, tested and manufactured, constructed, supplied, permanently installed by CONTRACTOR at SITE in connection with the NFPS Project as further described in Exhibit 6.

fabricated,

MILESTONE

A reference event splitting a PROJECT activity for progress measurement purpose.

PROJECT

NFPS Offshore Compression Complexes Project COMP2

SITE

(i) any area where Engineering, Procurement, Fabrication of the FACILITIES related the CPS6S and CP7S Compression Complexes are being carried out and (ii) the area offshore required for installation of the FACILITIES in the State of Qatar.

SUBCONTRACT

Contract signed by SUBCONTRACTOR and CONTRACTOR for the performance of a certain portion of the WORK within the Project.

SUBCONTRACTOR

Any organization selected and awarded by CONTRACTOR to supply a certain Project materials or equipment or whom a part of the WORK has been Subcontracted.

WORK

Scope of Work defined in the CONTRACT.

WORK PACKAGE

The lowest manageable and convenient level in each WBS subdivision.

VENDOR

The person, group, or organization responsible for the design, manufacture, testing, and load-out/shipping of the Equipment/ Material.

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2.2 Abbreviations

Code

Definition

ANSI

API

ASME

ASTM

EER

ESD

HFE

IDC

LER

NFPS

NPS

OCC

OLB

P&ID

POB

American National Standard Institute

American Petroleum Institute

American Society of Mechanical Engineers

American Society of Testing and Materials

Nominal Diameter

Evacuation, Escape and Rescue

Emergency Shutdown

Flare Support Platform

Feet

Human Factor Engineering

Inter-Discipline Check

Inch

Local Equipment Room

North Field Production Sustainability

Nominal Pipe Size

millimetre

meter

Material Handling

Onshore Collaborative Centre

Onshore Logistic Base

Piping & Instrument Diagram

Pipeline

Person on Board

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RGE

SDV

WHP

Qatargas Company Limited

RasGas Wet Gas Asset

Shutdown Valve

International System of Units

Wellhead Platform

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3 REFERENCE, RULES, CODES AND STANDARDS

The following codes, standards and specification are referenced within the document shall be considered as part of this specification. Conflict among applicable specification and / or codes shall be brought to the attention of the COMPANY for resolution COMPANY decision shall be final and shall be implemented. The latest editions of codes and specification effective as on date of contract shall be followed.

In general, the order of precedence shall be followed:

a) Qatari Governmental and Regulatory Requirements

b) COMPANY Procedures, Policies and Standards (Exhibit 5 Appendix I)

c) Project Specifications.

d) Industry Codes and Standards

e) COMPANY and CONTRACTOR’s Lessons Learned

If CONTRACTOR/SUBCONTRACTOR deems any deviations from the specifications will result in significant project cost and schedule saving, proposal to such deviations shall be submitted to COMPANY for review and approval. CONTRACTOR/SUBCONTRACTOR shall not proceed with any deviation to the specifications without prior COMPANY approval. In general, all design activities shall conform to legal and statutory regulations, and recognized industry best practices.

3.1 Company Documents

S. No

Document Number

Title

LTC/C/NFP/5128/20

Contract Agreement

EXHIBIT 5

Project Instructions

EXHIBIT 6

Scope of Work

IML-ENG-GDL-001

Guidelines for Corridor and Corridor Crossings in RLC

N/A

Ras Laffan Environmental Data Summary

OMQ011 (181571_2_Part 2)

Updated Metocean Criteria Offshore Qatar

COMP-QG-RP-REP- 00008

NFPS Compression Project: EPC2 – Basis of Design – EPC2

COMP-TPF-PE-REP- 00031

D1BM Report

TCH-AIG-PRC-013

Code of Practice for Lifting Equipment

ONS-MNT-MS-001

Safe Scaffolds

P26-X03-028

Scaffolding Procedure

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3.2 Project Documents

S. No

Document Number

Title

200-20-AB-DEC-00001

200-20-EL-DEC-00001

200-42-HV-DEC-00002

200-51-IN-DEC-00003

200-20-ME-DEC-00002

200-20-PI-DEC-00004

200-20-SH-DEC-00004

200-20-SH-DEC-00005

200-20-SH-DEC-00007

200-20-SH-SPC-00011

200-52-TC-DEC-00002

Architectural Design Basis for CP6S and CP7S Complexes

Electrical Design Basis for CP6S and CP7S Complexes

HVAC Design Basis Offshore for CP6S and CP7S Complexes

Instrument and Control Systems Design Basis for CP6S and CP7S Complexes

Mechanical Design Basis for CP6S and CP7S Complexes

Piping & Layout Design Basis for CP6S and CP7S Complexes

Environmental Design Philosophy for CP6S and CP7S Complexes

Technical Safety & Loss Prevention Design Philosophy for CP6S and CP7S Complexes

Noise and Vibration Design Philosophy for CP6S and CP7S Complexes

HFE Workplace Design Specification for CP6S and CP7S Complexes

Telecommunication System Philosophy and Design Basis for CP6S and CP7S Complexes

3.3 Contractor Documents

S. No

Document Number

Title

Nil

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3.4

International Codes and Standards

S. No

Document Number

Title

API SPEC 2C

Specification for Offshore Cranes

API RP 2D

ASME B30.9

ASME B30.10

Recommended Practice Maintenance of Offshore Cranes

for Operation and

Slings

Hooks

ASME B30.11

Monorails and Underhung Crane

BS 2853

Design and Testing of Overhead Runway Beams

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4 PURPOSE OF DOCUMENT

The purpose of this document is to outline the considerations and philosophy pertaining to material handling and lifting procedures for the facilities installed as part of NFPS Offshore Compression Complexes Project COMP2.

This document is to provide guidelines for achieving robust technical design, allowing efficient and safe handling of all planned handling of goods and equipment for the PROJECT. This document shall be the basis of material handling study.

5 GENERAL DESIGN REQUIREMENT

5.1 Design life

The new mechanical equipment shall be designed for an operational life of 30 years.

Government Regulations as listed in Environmental Design Philosophy for CP6S and CP7S Complexes (200-20-SH-DEC-00004) shall be consulted during the execution of works.

5.2 Equipment Location

Equipment shall be suitable for outdoor location on an offshore platform in a marine saline highly corrosive environment.

Fuel Gas Metering Station & Fuel Gas Beach Valve Station unit will be located onshore, hence equipment shall be suitable for coastal marine environment containing dust.

Equipment shall be designed for installation in respective hazardous / non-hazardous areas in accordance with the area classification drawings.

Equipment shall be located for offshore facility for regular operation and maintenance.

Permanent installed equipment located indoor shall follow respective classification the same.

5.3 Design One Build Many (D1BM)

It is intended to implement same design across all compression hubs to as much as reasonably possible. This will allow for optimised engineering cost, material and manufacturing cost and extend to ease of operation and equipment sparing.

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6 GENERAL MATERIAL HANDLING PHILOSPHY

The general material handling and lifting philosophy will consider the following;

a) As a general guideline, items (e.g. motors, pumps) weighing more than 23kg should be lifted or moved using a hoist or trolley. Items weighing less than 23kg could be manually handled. As far as practically possible, all components weighing more than 23kg, should be fitted with lifting point / method. All lifting point shall be third party certified and certificates shall be provided to Company

b) All load handling movements between supply vessels/ barges and platforms should be carried

out by the pedestal crane.

c) All material and equipment movement within the platform will be achieved by combining the use of pedestal crane and / or permanently or temporarily installed material handling equipment.

d) It is recommended that the pedestal crane lifting path during operations shall not go over the live equipment and the lifting activity shall also avoid dropped object risks onto seabed which may cause damage to pipelines/risers/cables that could lead to major catastrophic event or impact to Operation / Production. Pedestal crane path shall also avoid going over the gas turbines vent stacks. This is to avoid any risk of burning and striking crane components and lifted loads.

e) All permanent handling equipment for rated capacities shall be certified to lift and support the item/components from its current location to its adjacent laydown area, where it can be accessed directly by the pedestal crane or placed on suitable means of transport. The pedestal crane lifting path shall be incorporated into early phase where categorization of lifting operation is determined to allow appropriate mitigation & controls are put in place. The lifted object height shall be not more than 4 meters height above the deck as far as practical.

f) Deck hatches shall be provided in strategic locations to facilitate pedestal crane access to specific items of equipment at lower deck. Its shall be equipped with sufficient approved and certified lifting point for ease of removal.

g) Material handling equipment criteria tables (Table 6.1 & 6.2) defines the principle and the requirement for permanent or temporary material handling equipment, depending on the weight of loads and the frequency of handling operations. Preferred method of lifting is by crane for all items weighing more than 23 kg, however the table describes the acceptable alternate lifting method.

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Table 6.1 Material Handling Equipment Lifting Criteria

Daily

Weekly

Monthly

Bi-annually (2 time per year) Annually (1 time per year) Occasional (2 times per 5 years) Rare (Possibly once in 10 years)

Unplanned frequency

30mt to Maximum Capacity

LOADS

23kg

500kg

1mt

3mt

10mt

Category

Special purpose handling equipment – electrical powered

Tow trolley assisted by powered load pusher/puller

Manual four-wheels trolley

Powered transfer / lifting device / crane

Manual transfer

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7 MATERIAL HANDLING EQUIPMENT AND FACILITIES

7.1 Pedestal crane

The current Compression platform layout demonstrates that two pedestal cranes located in opposite direction to each other. This will provide the necessary coverage for all on-platform materials handling requirements, and offboard lifts between platform and vessels.

The LQ platform shall be accommodated with one pedestal crane with direct access to helideck for MEDIVAC purpose and will also provide the necessary coverage for all on-board materials handling requirements, and off-board lifts between platform and vessels.

The Riser platform will have one pedestal crane installed.

The cranes’ capacity shall be based on an identified credible lift/s by PROJECT, to transfer safely whether it maybe an on-board (Static) or off-board (Dynamic) lifting activity guided by the Cranes approved load chart. The off-board (Dynamic) lifting of the cranes shall be designed based on the significant wave height (SWH) of 2.0 m.

Pedestal Crane selected shall be electro-hydraulic driven for CP and LQ. While riser platform will be diesel driven.

Safe working load factor shall be considered for both on-board (static) lift and off board (dynamic) lift.

A walkway along the Crane Boom and boom tip access platform shall be provided for inspection of boom structures and wire ropes, pulleys and blocks, and flash flood lights. Grease points shall be located so that they are accessible from the sheave service platform, which shall be located on the same location as the boom rest. A jib crane or monorail shall be provided for crane maintenance activity (e.g. repair of diesel engine components) on machinery platform.

All safety features and requirements shall follow the PROJECT Specification for Offshore Pedestal Cranes (200-20-ME-SPC-000XX).

The proposed on-board (Static) and off-board (Dynamic) lifting path of the Pedestal Crane shall be so that it has a limited number of restrictions (i.e. subsea structures, process equipment, exhaust stack) to avoid additional risk or limitations when handling materials.

Lifting operation shall be in accordance with TCH-AIG-PRC-013; Code of Practice for Lifting Equipment. The positioning and height of pedestal plus the boom length shall be incorporated into platform design & layout to avoid introducing unwanted constraints and restrictions in operating the crane.

7.2 Mobile crane

Generally, for onshore, mobile crane shall be utilized. Dedicated parking location shall be identified within equipment layout with sufficient lifting radius and capacity to be design off.

For cranes that are being set up in unpaved areas, ground bearing pressure calculation exerted by the crane along with steel mats used below the out riggers and crane setup location shall be reviewed and approved by COMPANY.

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7.3 Monorail Beam

A monorail beam shall be used for material handling where pedestal crane cannot be used due to lack of accessibility. Monorail beams shall be installed adjacent to the equipment to enable equipment and maintenance parts are easily transferred to the respective laydown areas. Wherever possible, monorail beam shall be extended to laydown area for ease of loads transfer.

Trolley hoist (either permanent or removable) that planned to be used shall not exceed the SWL of the monorail beam. Monorail beams shall be clearly marked with its SWL and designed to suit intended equipment to be lifted. Monorail inspection ie: load test, shall be in accordance with TCH-AIG-PRC-013; Code of Practice for Lifting Equipment.

If a removable trolley hoist is planned to be used, provision shall be provided for installation and removal (i.e. pad eye / beam clamp with chain hoist).

PROJECT preference is to utilise removable trolley / hoists on monorail beams. In so it can be removed for preservation as per relevant maintenance program to avoid being impacted by environmental conditions.

The lifting requirements for equipment shall be incorporated into the respective Operating & Maintenance procedures/strategies to determine which shall be permanent or temporary.

Platform will have other locations/areas that should have provision with monorail beam protruding out to nearest drop / laydown area.

7.4 Pad Eye and Beam Clamp

Lifting pad eyes shall be provided in locations where;

a) It is not reachable by monorail and trolley hoist

b) Provision of the monorail and trolley hoist is not practical or economical

c) Lugs for frequent maintenance

d) Areas where equipment / component is exceeding the capacity of portable material handling

equipment

A pad eye shall be used in preference to beam clamp in passive fire protection areas to prevent the indiscriminate used of beam clamp on the steelwork and damage the painted surface.

Pad eyes shall not be used for transferring except if detail in approved plan. However, load rigging from one pad eye to another pad eye is allowed if the pad eye is designed to cater the angled load bearing and detail in approved lifting plan.

A pad eye shall have clear identification of load rating capacity and test date which would be captured under a maintenance program. Pad-eye inspection ie: load test, shall be in accordance with TCH-AIG- PRC-013; Code of Practice for Lifting Equipment.

A beam clamp with manual chain hoist can be used for lifting of isolation pipe spools and bulk valves as require for maintenance. It is also recommended to be used for other frequently maintenance equipment, valves, removable spools, spectacle blinds, etc. that weighing 3 MT and below. This is to minimize the number of permanent lifting pad eyes, which requires periodic inspection, load test and maintenance. Coating shall be checked prior and post beam clamp usage.

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7.5 Portable A-Frame

A portable A-Frame may be used for handling loads up to 3 MT and for equipment that accessed infrequently. The A-Frame will be portable type or engineered load bearing scaffolding to facilitate the installation at congested area and have the provision for height and span adjustment. Swivel type wheels shall be provided for better manoeuvring operation. Light weight material shall be used to ease of manoeuvring.

Where Load Bearing Scaffoldings are to be used for lifting purposes, approval shall be obtained from COMPANY Scaffolding Supervisor. The lifting activity involving the use of load bearing scaffolding for lifting shall be considered as non-routine lifting operation and necessary approval shall be obtained.

It shall meet the requirements of COMPANY procedure ONS-MNT-MS-001-Safe Scaffolds & P26-X03- 028 Scaffolding Procedure.

7.6 Miscellaneous Handling Equipment

Transportation of equipment from one location to another within the platform at each deck level shall be performed by using wheeled handling equipment. Equipment shall be transferred along material handling routes to designated laydown area that can be accessed by pedestal cranes.

The lifting angle shall not exceed 60° otherwise a spreader bar shall be used. In normal condition, the lifting angle will be limited to 30°.

Below is typical equipment used but not limited to the following:

a) Manual deck trolley

b) Roller dollies

c) Cylinder truck

d) Powered deck trolley

e) Pallet truck

Slings, spreader beams and shackles shall be kept in the maintenance store (rigging loft) or any other designated area.

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8 MATERIAL HANDLING EQUIPMENT REQUIREMENT

8.1 General

The specification of typical lifting equipment should include, but not be limited to the following:

a) Practical and environmental suitability of the equipment and accessories for use in hazardous

areas rated Zone 1 & zone 2.

b) All handling equipment / accessories shall be non-sparking type.

c) The materials used in the construction of the handling and lifting equipment shall be suitable for the use in an offshore (hydrocarbon production) platform in a saliferous marine environment.

d) All lifting equipment shall be inspected and tested by a competent authority and supplied with “type of test and test certifications”. These also shall form part of a relevant maintenance program. Sufficient design calculation should be made available.

e) All lifting points and equipment such as pad eyes, monorails, trollies, hoists, davits, hatch lifting

points etc shall be tagged as per Company procedure and listed in approved registered.

f) Lifting devices shall be designed / selected for a safe working load factor of 125% of the item to

be lifted.

8.2 HSSE Requirements

The material handling equipment and their locations must take into consideration the HSSE requirements such as;

a) Hazardous area Zone Classification

b) Exhaust gas from gas turbines, fire water pump and diesel engine

c) Handling of consumables and corrosive items such as chemicals, absorbent, lubricants,

hydraulic oils, etc.

d) Installation of lightning / flame arrestor, wind socks and aviation light at high points e.g. pedestal

crane

e) Hazards associated with the use of the proposed material handling system, particularly a dropped object onto platform decks and into the seabed which could cause damage to major process hydrocarbon, utility equipment and pipeline.

f) Escape routes i.e. the installation of permanent fixed material handling equipment /lifitng shall

not impair the primary escape route that requires obstacles free routes

g) Approved Lifting Plans shall be able to eliminate and mitigate identified hazards to ALARP

h) Wherever possible during lifting and transfer operations, the centre of gravity shall be always on

vertical position below the hook as much as possible to avoid any transversal loads

i) Obstruction of crane driver’s view at the laydown areas and during lifting / transfer operations

shall be minimized.

j) Sufficient buffer zone / protection for mobile equipment travel (ie: mobile crane / truck)

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9 MATERIAL HANDLING ROUTE, HATCHES AND LAYDOWN AREAS

9.1 Material Handling Route

Material handling routes shall be designed with suitable width and load capacity to withstand the loads transportation such as maintenance items, consumables, as well as material handling equipment during maintenance activities.

The width of handling routes shall consider the suitable transporter and the size of maintenance items to be carried along the handling routes.

Handling route may utilized heavy duty grating up to 3MT load capacity where-ever practical. Usage of temporary plated shall be avoided.

Handling routes design / area shall maintain the stability of the item being transported (ie: while on bunding/coaming area).

9.2 Hatches

Hatches (with lifting aids) shall be provided at suitable locations to enable monorail trolley hoists or pedestal cranes to reach laydown areas or equipment at lower deck.

If the hatches area is also planned for material handling routes, the hatch cover shall be designed to cater the handling loads capacity. Hatch provision at the specific decks shall be based on outcome from material handling study.

9.3 Laydown Areas

The dimensions of each laydown area will be sized based on the dimensions of the largest possible part and Cargo Handling Equipment that need to be lifted by the pedestal cranes. The dimensions of temporary laydown area nearby equipment will be based on the dimensions of the largest maintenance item to be placed at this area by permanent or temporary lifting equipment.

Laydown areas shall be plated and designed for the maximum live loads based on the heaviest equipment and Cargo Handling Equipment on the deck that they serve with clear identification/marking on deck of rated load capacity per square meter.

As minimum each deck shall be provided with laydown area accessible by pedestal crane. The laydown area shall be able to facilitate maintenance activities on board and for transfer of equipment from or to supply boat and platform.

The lay-down areas and supply boat moored positions should be within the reach of the pedestal crane radius and within the good visibility of crane operator.

One intersection laydown accessible by both cranes shall be provided on Compression platform.

Buffer zone / protection shall be design accordingly ensuring swing risk is eliminated.

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NFPS Offshore Compression Complexes Project COMP2 MATERIAL HANDLING PHILOSOPHY FOR CP6S AND CP7S COMPLEXES

10 GENERAL MAINTENANCE APPROACH (OFFSHORE)

10.1 Handling of Pressure Vessels

A davit arm shall be installed at the manhole flange cover (as part of vessel supply) for supporting heavy manhole flanges. Adequate temporary laydown area shall be allocated in front of the manholes for transferring internal components to/from the vessels. Davit arm shall be provided on top of column should pedestal crane access is not available. The Davit shall form part of a maintenance program to avoid assembly degradation.

10.2 Handling of Tanks

No specific material handling is foreseen for tank.

10.3 Handling of Exchangers and Heaters

For removable STHE, removal of tube bundle shall use a combination of jacking bolt system, pulling mechanism, and temporary pulling posts. An approved temporary support design or monorail trolley hoist may be used to support the load, depending on the location. Space area for tube bundles removal shall be kept clear from any obstruction and space requirements for the tube bundles removal area shall be indicated in equipment layout drawing. The same space shall be used for bundle cleaning activity. The tube bundle once removed can be relocated to laydown area or directly lifted by Pedestal Crane.

The same method applied for electric heaters.

Fixed Shell & Tube Heat Exchanger (STHE) is not anticipated, however for design consideration tube bundle and/or whole equipment removal will not be considered except the space provision for cleaning activity.

For air cooled exchangers, fans and motors handling shall be done by using pad eye / beam clamp and chain block arrangement. Alternatively, manual stacker may be used.

For plate heat exchangers, the frame shall be removed using pad eyes with chain hoist arrangement. The maintenance items such as plates shall be manually handled by one or two persons.

10.4 Handling of Filter and Coalescers

Sufficient material handling equipment shall be provided to support a vessel cover removal and filter elements replacement, prior to transferring to laydown area. It is envisaged that most of filter elements can be manually handled by one or two persons. Davits or hinges shall be provided for the heavy covers, and it shall be formed part of a maintenance program to avoid assembly degradation.

10.5 Handling of Flare

A flare tip material handling system (by Specialist Contractor) will be provided for flare tip removal and replacement. The flare tip handling specification, which will be developed during Detailed Design, will specify the functional requirement of flare tip change-out. Structural elements of the removal systems such as rails and mountings will be permanently installed where mechanical items such as winches, and wire ropes will be installed as and when required. This equipment shall be on lease / purchased.

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NFPS Offshore Compression Complexes Project COMP2 MATERIAL HANDLING PHILOSOPHY FOR CP6S AND CP7S COMPLEXES

10.6 Handling of Gas Turbine Generator

Gas turbine assembly (located inside the enclosure) shall be removed by using VENDOR supplied lifting device. Provision of handling mechanism for all maintainable items inside the enclosure shall be provided by VENDOR.

Provision of handling mechanism inside of enclosure maybe permanently fixed or added during maintenance activities with all integrated to those outside of enclosure.

Alternator rotors removal shall be considered for maintenance instead of removing the complete set of alternators / generator. Special tool provided by VENDOR shall be used for the alternator rotors removal.

The maintenance items such as alternator rotor and turbine assembly shall be placed on a transport cradle (VENDOR supplied) and further transferred to laydown area for further handling by the pedestal crane. Stator shall be transferred to laydown via deck powered trolley.

GTG air intake filters require filter element change out which is to be done via manual handling. Lifting provision shall be provided from/to filter housing to ease the handling of filter cartridges / boxes.

Monorail is be provided for gear box removal.

10.7 Handling of Gas Turbine Compressors

Compressor bundle removal space area shall be kept clear from any obstruction and space requirements for the bundles removal area shall be indicated in layout drawing. The maintenance items such as compressor bundle and gas turbine shall be placed on transport cradle and further transferred to laydown area for further handling by the pedestal crane.

Monorail beam with trolley hoist together with the special tool provided by VENDOR shall be used for compressor bundle removal.

Monorail is provided for gear box removal.

10.8 Handling of Pumps

Main items would be the pump and motor. Depending on weight, monorail beam or mobile handling equipment may be utilized. Eye bolt configuration on equipment is not preferred.

10.9 Handling of Emergency Diesel Generator

For engine maintenance, cylinder heads and radiator assembly shall be lifted to the removal area. For major maintenance, alternator and radiator will be removed from skid. Monorail trolley hoist will be used to lift and transfer the alternator and radiator assembly to the alternator removal area. Roller dollies will be used to transfer the equipment to laydown area.

For major maintenance of engine, an engine block assembly is the heaviest component that will be removed from the skid. Normally for the minor maintenance, engine component such as head and piston will be removed for maintenance. Monorail trolley hoist will be used to lift and transfer the equipment from skid to Engine Maintenance Area. Roller dollies may be used to transfer the equipment to laydown area.

This equipment is located within enclosure.

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10.10 Handling of Seawater Lift Pumps

These pumps comprise of the submersible pumps, motors, discharge head and sectional pipes. During maintenance activities, the pumps assembly shall be directly lifted using a pedestal crane.

Pumps installation and retrieval tools and required handling equipment shall be provided by pump’s VENDOR.

Sufficient laydown / staging area shall be made available on platform for pump column placement.

Service water lift pump shall be handled via monorail beam.

10.11 Handling of Fire water pumps

The Firewater Pump comprises of submersible pump, columns, line shafts, discharge head, right angle gearbox and diesel engine. The pumps and sectional columns shall be directly lifted using a monorail beam on LQ platform while on CP platform is via pedestal crane.

The heaviest component that needs to be removed from the diesel engine is a piston head. The repair or replacement of whole engine components is considered rare case. Thus, beam clamp and chain hoist should be used for lifting and transferring the components onto manual deck trolley. Lifting provision shall be made available for the gear box removal.

Engine removal shall be via monorail beam.

10.12 Handling of Air compressor and dryer package

Main items would be the compressor and motor for air compressor unit. Monorail beam shall be utilized.

Internal filling for dryer can be manually by one or two persons. Depending on its amount monorail may be provided.

10.13 Handling of Heavy Valves

Consideration for the lifting and handling of heavy valves and in-line instrument for maintenance - this may include.

a) Accessibility by pedestal cranes

b) Accessibility by monorail trolley hoists

c) Accessibility by beam clamp, padeyes and chain hoists

d) Accessibility by manual deck trolley

e) Accessibility to handling routes and laydown areas.

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10.14 Handling of Chemical Tote Tanks

Chemicals tote tanks shall be directly handled by pedestal crane, from supply vessel to the dedicated storage area. Coaming area shall be provided where chemical is anticipated to be stored to prevent loss of containment. This may include chemical injection points related area. A cylinder or drum trolley shall be used for transferring cylinder bottles and drums from laydown area to the dedicated use location.

Decanting of tote tanks to permanent tanks shall be by gravity. Tote tank shall be designed in so it will avoid potential spillage during its material handling activities.

10.15 Handling of transformer

Regular maintenance of transformers will be done in-situ. For the major maintenance, transformer will be removed and transferred to laydown area. Transformer will come with rollers/wheels that can be reattached to the transformer in order to pull them out of the Transformer Room.

Handling route (ie: on false floor) shall be designed in accordance to material handling load impose.

10.16 Handling within Living Quarters

Pedestal crane shall have direct access to galley laydown area and helifuel tote tank

Sufficient space shall be provided for galley food and garbage container. 10 foot container size shall be considered for laydown.

For the laundry area, equipment such as washing machines and tumble dryers which weigh less than 1mt shall be removed and transferred by deck trolley to the laydown for replacement. Adequate LQ doors/ramps to aid the transferring of equipment to designated laydown areas shall be provided.

Some of the galley equipment such as refrigerator, griddle, range, bread prover etc. shall be equipped with castor wheels for easy transferring of the equipment for replacement otherwise a deck trolley may be used.

All these heavy equipment shall be located in area adjacent to laydown area.

The Computers, LED Screens, Projectors in the LQ buildings are standard office items which are estimated to be within manual handling limit. Deck trolley may be used as assistance for transferring the equipment to laydown area.

LQ design shall consider sufficient space for deck trolley movement. Ramps may be provided at the door area for trolley movement.

10.17 Handling of Equipment Exceeding Pedestal Crane Capacity

Barge Crane / Jack-up Barge Crane / Dynamic Positioning Vessel Crane shall be considered for any lift beyond pedestal crane capacity.

Items / equipment to be explicated within material handling report.

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NFPS Offshore Compression Complexes Project COMP2 MATERIAL HANDLING PHILOSOPHY FOR CP6S AND CP7S COMPLEXES

11 MATERIAL HANDLING REPORT

A material handling report will be prepared based upon estimated weights and sizes of materials/equipment to be handled. The report will address specific handling requirements and typically include:

• A narrative of the facility and equipment, addressing the materials handling provisions;

• Materials handling table showing the maintainable items, location, load, frequency of change- out, lay-down areas and provision of permanent and/or temporary handling equipment; and

• Materials handling layout sketch typically identifying the location of the pedestal crane, crane lift radius, permanent handling equipment (ie: monorails.),lay-down areas, and material handling route with anticipated floor loadings.

The materials handling report shall be reviewed and further developed during the Detailed Design phase.

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Project: Q-21699 - Saipem COMP2 Folder: Material Handling

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