Method statement of waterway tunnels concrete lining. PDF

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Method statement of waterway tunnels concrete lining. Owner’s Engineer Doc. No DLJV-CONS-MS-WT-02 Rev 03 Method Statement for Waterway tunnels lining concrete Project Name : Gulpur Hydropower Project Client : Mira power Limited Consultant : MWH NESPAK JV Contractor : Daelim-Lotte JV Site : Gulpur 03...

Description

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Owner’s Engineer 03

Rev

Method Statement for Waterway tunnels lining concrete

Project Name

:

Gulpur Hydropower Project

Client

:

Mira power Limited

Consultant

:

MWH NESPAK JV

Contractor

:

Daelim-Lotte JV

:

Gulpur

Site

03 07/06/2017 Issued for Approval

Naveed

Naseem

Tanzeel

Javed Afzal Lee Jae Chul Cho Sang wan

02 23/04/2017 Issued for Approval

Naveed

Naseem

Tanzeel

Javed Afzal Lee Jae Chul Cho Sang wan

01 26/03/2017 Issued for Approval

Naveed

Naseem

Tanzeel

Javed Afzal Lee Jae Chul Cho Sang wan

00 18/01/2017 Issued for Approval

Naveed

Naseem

Tanzeel

Javed Afzal Lee Jae Chul Cho Sang wan

Rev.

Date

Description

Prepared by QA/QC

EHS

Const.

Approved by

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

Owner’s Engineer 03

Contents 1. Purpose……………………………………………………………………………….3 2. Scope of work…………………………………………………………………………3

3 Organizatio and responsibilitie ……………………………………………………...9 4. Resources……………………………………………………………………………12 5. Execuation flow diagrame …………………………………………………………..14 6. Execution procedure………………………………………………………………….16 7. Quality assurance and Quality controll Plan………………………………………...26 8. Health, Safety and Environment management plan……………………………….....32 9. Attachments…………………………………………………………………………..44

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

Owner’s Engineer 03

1. Purpose This Method Statement covers the construction works of waterway tunnels concrete lining. The main purpose of this method Statement is:

•

To outline the works involved in this particular Structure.

•

To provide a document that managers must read and understand before starting the job.

•

To meet legal requirements, that is, hazard identification and control.

•

To program work, materials, time, staff, and to anticipate possible problems;

•

To use as a tool in quality assurance.

2. Scope of work. 2.1 Introduction of Headrace tunnel Headrace tunnels are water way pressure tunnels which composed Vertical pressure shaft, lower bend Horizontal pressure tunnel, penstock and outlet {Figure 1: waterway tunnels plan}

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

Each waterway tunnel contains: a) A vertical pressure shaft of 44.5 m height and 6.7m inner diameter (after lining concrete) b) A horizontal pressure tunnel of 122.5 m length with 6.7 inner diameter after lining.

{Figure 2: waterway tunnels 3D profile}

Vertical pressure tunnel H=44.5, D=6.7(inner)

2.1

Horizontal pressure tunnel L=122.5, D=6.7(inner)

Owner’s Engineer 03

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

2.2 Design and Specification Each vertical shaft contains: a) A vertical pressure shaft of 24.5 m height with 6.7m inner diameter(after lining concrete) b) A vertical transition part of 10.5 m height with 6.7m inner diameter(after lining concrete) Each horizontal tunnel contains: a) A lower bend of 19.635 m length with 6.7m inner diameter (after lining concrete). b) A horizontal pressure tunnel of 50.650 length with 6.7 inner diameter after lining concrete. c) A Steel penstock tunnel of 55 m length with 6.7 inner diameter after steel lining

{Figure 3: Waterway Tunnels profile}

Owner’s Engineer 03

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

Both Headrace tunnels has exactly the same length, diameter and design. {Figure 4: Vertical pressure Tunnel} Specification

Shape

circular

Diameter

7.6m (Inner Circular)

Height

24.5 m

Type of lining

Concrete lining

Thickness of lining

400 mm

Location

Typical cross section

Vertical Shaft tunnel 1 & 2

Items

{Figure 5: Vertical Tunnel transition part} Specification

shape

Square

Size

7.6×7.6m Inner After lining

height

10.5 m

Type of lining

Concrete lining

Thickness of lining concrete

1000 mm

Location

Horizontal Tunnel 1 & 2

Items

Typical cross section

Owner’s Engineer 03

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

{Figure 6: Lower bend} Specification

Shape

circular

Diameter

7.6m Inner (after lining)

length

19.635 m

Type of lining

Concrete lining

Thickness of lining concrete

1000 mm

Location

Typical cross section

Lower bend 1 & 2

Items

{Figure 7: Horizontal pressure Tunnel} Specification

Shape

Horse shoe

Diameter

7.6m (Inner Circular)

length

50.650 m

Type of lining

Concrete lining

Thickness of lining concrete

400

Location

Horizontal pressure Tunnel 1 & 2

Items

Typical cross section

Owner’s Engineer 03

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

Owner’s Engineer 03

{Figure 8: steel penstock Tunnel}

Type

Horse shoe

Diameter

7.6m (Inner Circular)

length

55 m

Type of lining

Steel lining

Thickness of lining concrete

700~1000 mm

Location

Typical cross section

Including out let part

Specification

Steel penstock Tunnel 1 & 2

Items

2.3 Work scope. The scope of works covers work procedures and technical requirements for cleaning, leveling concrete, steel fixing, fixing of formwork, pouring of concrete, curing of concrete, and to maintain quality and ensure structures are built in conformance with the design alignment.

2.4 Reference Documents. 2.4.1

Drawings(Revision-C)

1. GPDD-C-WT-001---------------------------------------------------------Water way General Plan 2. GPDD-C-WT-001------------------------------------------------Water way Profile (Tunnel No.1) 3. GPDD-C-WT-001------------------------------------------------Water way Profile (Tunnel No.2) 4. GPDD-C-IPTP-CLR-001------Inlet portal Transition part concrete lining reinforcement 1/3) 5. GPDD-C-IPTP-CLR-002------Inlet portal Transition part concrete lining reinforcement 2/3) 6. GPDD-C-IPTP-CLR-003------Inlet portal Transition part concrete lining reinforcement 3/3) 7. GPDD-C-VPT-CLR-001---------Vertical pressure tunnel concrete lining reinforcement 1/3)

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

Owner’s Engineer 03

8. GPDD-C-IPTP-CLR-002-------- Vertical pressure tunnel concrete lining reinforcement 2/3) 9. GPDD-C-IPTP-CLR-003-------- Vertical pressure tunnel concrete lining reinforcement 3/3) 9. GPDD-C-VPT-0001------------------Vertical pressure tunnel Excavation cross sections (1/2) 10. GPDD-C-LB--LBP-0001-----------------------Lower Bend Profile and typical sections (1/2) 11. GPDD-C-LB--LBP-0002------------------------Lower bend profile and typical sections (2/2) 12. GPDD-C-LB-CLR -0001--------------------Lower bend concrete lining reinforcement (1/2) 13. GPDD-C-LB-CLR-0002---------------------Lower bend concrete lining reinforcement (2/2) 14. GPDD-C-HPT-TS-0001--------------------------Horizontal pressure tunnel typical sections 15. GPDD-C-HPT-ESC-0002-------Horizontal pressure tunnel concrete lining reinforcement 16. GPDD-C-SPT-TS-0001---------------------------------Steel penstock tunnel typical sections 17. GPDD-C-OPT-ETS-0001----------------Outlet pressure tunnel typical excavation sections

2.4.2

Specifications(Revision-C)

1. Tunnels.

3. Organization and responsibilities Site Manager:

Cho Sung wan

• Summing up the result of management review of each discipline and reporting the results to project Manager.

• Planning and controlling project schedule. • Checking, analyzing and reporting the differences between schedule and actual progress. • Coordination to each section with respect to relevant technical matters. • Supervising the operation of document control system. • Controlling the project’s design documents and the change of the design documents at site. • Controlling for expediting the delivery of purchased material and handling materials at site.

Construction Manager: Mr. Lee Jae Chul • Ensuring identification and analysis of the technical requirements of the project. • Assuring that organization is equipped with adequate resources and information to achieve quality. • Assisting the Site manager in any aspect regarding engineering matter. • Practical responsibilities for implementation of work execution • Control of manpower and equipment • Coordination with QA/QC department regarding inspection and testing • Check and review of progress as per schedule

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Site engineer:

Rev

Mr. Naveed Akhtar

•

Preparation of work procedures

•

Document and drawing control.

•

Coordination with QA/QC department regarding inspection and testing

•

Check and review of progress schedule.

•

Control of manpower and equipment

•

Coordination with design and planning department

•

Assisting the Construction manager in any aspect regarding engineering matter.

QC Manager

Owner’s Engineer 03

Mr. Naseem

•

Initializing and establishing the quality management system through project QA/QC plan

•

Having responsibility to assure that all project activities affecting quality are in compliance with this plan.

•

Establishing objectives of continual improvement.

•

Ensuring surveillance, evaluation and inspection of materials.

•

Administering non conformity with respect to material and work execution.

•

Determining, collecting and analyzing appropriate data to demonstrate the suitability and effectiveness of the quality management system.

•

Coordination with the Owner’s Engineers on all QA/QC matters.

•

Production of concrete and laboratory testing record

QA Manager

Mr. Muhammad Aslam

•

Planning inspection activity and practicing inspection for work.

•

Administering non conformity with respect to material and work execution.

•

Checking inspection results and preparing official reports

•

Review quality of all materials at site and ensure compliance to all project specifications and quality and collaborate with department for all material procurement and maintain quality of materials.

•

Analyze all products and nonconformance processes and evaluate all documents to ensure maintenance of optimal quality

•

Coordination with the Owner’s Engineers on all QA matters.1

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

EHS manager

Rev

Owner’s Engineer 03

: Mr. Tanzeel

•

Avoid all personal injuries during the execution of the Project by targeting to Zero LTI.

•

Ensure that all personnel employed on the Project are competent to carry out their designated tasks safely by supporting continuous HSE training, adequate HSE measures, instruction and supervision.

•

Create positive health, safety and environment attitudes and perceptions at all levels of the Site organization, and to raise health, safety and environmental awareness in general.

•

Implement a training program that supports the achievement of personnel competency in relation to Health, Safety, and the Environment.

•

Carry out all operations related to construction and commissioning with the health and safety of personnel and the impact on the environment as the prime consideration.

•

Complete the site work without incurring any significant property damage to permanent or temporary facilities.

•

Continually monitor and improve HSE performance.

Chief Surveyor

: Fawad Ahmed

•

Create the miniature of the construction plans that would serve as the source of the site plans

•

Keep in touch with the engineering and design personnel’s.

•

The Survey Engineer is considered part of field management and is responsible for various aspects of field engineering and surveying for the project. The Survey Engineer is in responsible/ in charge for all construction layout and survey documentation, and as such (structure alignment, before ,during and after the concrete placement)

•

Works directly with the Field Engineer Manager regarding initial project layout requirements, means and methods of establishing project survey control, and field reporting.

•

Works with Field Engineers in the following tasks: o engage in site layout, construction planning, scheduling, quality control, and job site safety.

•

Provides and maintains horizontal and vertical survey control by use of a level, total station, etc., including organized documentation of survey notes.

•

Assists in the preparation of final records for the project, including as-built.

•

Works with site engineer/foreman to ensure structures are built in conformance with the design alignment and contractual requirements.

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Owner’s Engineer 03

Rev

4. Resources 4.1. Manpower {Table 1 Manpower detail for Horizontal tunnels excavation and support)

Vertical Tunnels S/N

Designation

Day

Night

Horizontal Tunnels Day

Night

1

Shift Engineer

1

1

1

1

2

Surveyor

1

1

1

1

3

Surveyor helper

2

1

2

1

4

Foreman

2

2

1

1

10

10

5

5

05

05

4

4

05

05

4

4

5

5

4

4

12

10

5

5

5

6

7

Steel fixer

Carpenter

Welder

8

Mason

9

Unskilled labor

10

Operators

Total

4

4

2

2

47

44

29

28

Note: Manpower can be changed according to site conditions.

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Rev

Owner’s Engineer 03

4.2. Major Equipment and Tools [Table4: Major equipment for waterway tunnels concrete lining]

S/N

Site

Equipment

Capacity

Work

Excavator (jack hammer)

0.6 CUM

Scaling, trimming

Charging car

2 man basket

Steel plate form

6 M (High)

Rebar fixing

1

Concrete pump

120 m3/hour

Concrete pouring

1

Water pumps

3”

Dewatering, curing

1

Gas cutter

Cutting works

1

Welding machine

Welding works

2

8

vibrators

Concrete pouring

3

9

compressor

750 CFM

Cleaning work

1

10

Generator

500 KW

Power supply

1

Mobile Crane

50 tons

Stationary pump

120 m3/hour

1 2 3

5 6 7

Horizontal tunnels

4

1

3 4 5 6

Vertical tunnels

2

Qty. 1

Cleaning, dismantling, rebar fixing

shifting of steel liner, rebar’s etc.

1

1

Concrete supply

1

Welding machine

Welding works

1

vibrators

Concrete pouring

2

Gas cutter

Steel cutting works

1

chain blocks

shifting of vertical steel

Note: Quantity of above major equipment and tool can be changed due to site conditions

liner

4

Method statement of waterway tunnels concrete lining. Doc. No

DLJV-CONS-MS-WT-02

Owner’s Engineer 03

Rev

5. Flow diagram 5.1 Vertical tunnels lining concrete flow diagram [Figure 2: Sequence of work for waterway vertical shafts excavation & support]

Removal of Existing Temporary facilities

Steel fixing Assembling of liner Erection of steel ribs lining form lifting structure at the top of shaft tunnel

Fixing of Shifting of squeezed liner form at the bottom of vertical shaft

Fixing of steel liner

Pouring of concrete

Survey of alignment and verticality

Survey monitoring

Wait for concrete setting Shifting of liner for next stage

Continuous concrete curing

Method statement of waterway tunnels co...