Engineering, Construction and Installation of Hot

Gas Generator System

HOLCIM PHILIPPINES
Davao Plant

SUBJECT:
GENERAL Date: May 16 2017
CONSTRUCTIONMETHODOLOGY
PAGES: 13
CERTIFIED QUALITY SYSTEM – ISO 9001:2008
Table of Contents
0 INTRODUCTION ............................................................................................................................ 3
1 TECHNICAL ASSISTANCE............................................................................................................ 3
2 MANPOWER LOADING ................................................................................................................. 3
2.1 INDIRECT MANPOWER ............................................................................................... 3
2.2 DIRECT MANPOWER ................................................................................................... 4
3 TOOLS AND EQUIPMENT ............................................................................................................. 5
4 ENGINEERING..................................................................... ERROR! BOOKMARK NOT DEFINED.
4.1 ENGINEERING WORKS ............................................................................................... 5
5 MOBILIZATION .............................................................................................................................. 6
5.1 MANPOWER................................................................................................................... 6
5.2 TOOLS EQUIPMENT ..................................................................................................... 6
6 SITE PREPARATION ..................................................................................................................... 6
6.1 INSTALLATION OF PERIMETER FENCE.................................................................. 6
6.2 HAULING OF TEMPORARY OFFICE VAN AND TOOL VAN ................................ 7
6.3 INSTALLATION OF TEMPORARY POWER SUPPLY .............................................. 7
6.4 PERSONAL HYGIENCE................................................................................................ 7
6.5 TRAFFIC MANAGEMENT............................................................................................ 8
7 CIVIL AND STRUCTURAL WORKS............................................................................................... 8
7.1 CONSTRUCTION OF hot gas generator & tank FOUNDATION ................................. 9
7.1.1 LAYOUT AND SETTING....................................................................................... 9
7.1.2 EXCAVAT ON WORKS(FOR HOT GAS TANK) ................................................ 9
7.1.3 LEAN CONCRETING WORKS(NOT NTPI SCOPE) ......................................... 10
7.1.4 FORMWORKS (FOR HOTGAS EQUIPMENT FOUNDATION/PEDESTAL).. 10
7.1.5 REINFORCEMENT BARS (FOR HOTGAS EQUIPMENT
FOUNDAT ON/PEDESTAL) ................................................................................ 10
7.1.6 EMBEDDED STEEL PLATES……………………………………………….11
7.1.7 GROUNDING CABLES ........................................................................................ 11
7.1.8 CONCRETING WORKS (FOUNDATION/PEDESTAL/SLAB) ......................... 11
7.1.9 BACKFILLING AND COMPACTION................................................................. 12
7.2 ERECTION/installation of structural steel supports ...................................................... 12
7.2.1 INSTALLATION OF SUPPORT STRUCTURES ................................................ 12
8 MECHANICAL ERECTION / INSTALLATION AND ASSEMBLY WORKS ................................... 12
8.1 HOT GAS GENERATOR ............................................................................................. 12

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

 8.2 HOTGASduct ............................................................................................................... 13
8.3 dieselpiping ................................................................................................................... 13

INTRODUCTION
This methodology was done incompliance with the norms known as

SAFETYINCONSTRUCTION and in consideration with HOLCIM Plant Health

&Safety Standard Requirements.

TECHNICAL ASSISTANCE

• Consultant : Engr. Jerwel Zaldua

• Engineering Group
o Civil/Structural : Engr. Emerson Villanueva & Engr. James Doromal
o Mechanical: Engr. Gilbert Ramos
o Electrical: Engr. Joseph Domer
o Project Supervisor : Engr. John Renzel Rivera
o Safety Officer: Johnde Calida

MANPOWER LOADING

INDIRECT MANPOWER

ITEM NO. DESIGNATION NUMBER

1 PROJECT MANAGER 1
2 QUANTITY SURVEYOR 1
3 SAFETY OFFICER 1
4 PROJECT SEC./PURCHASER/TIMEKEEPER 1
5 PROJECT NURSE 1
6 SITE DRIVER 1
7 MATERIAL EXPIDITER 1
8 WAREHOUSEMAN/TOOLKEEPER 2
TOTAL INDIRECT MANPOWER 10

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

DIRECT MANPOWER
ITEM NO. DESIGNATION NUMBER DATE TO START
CIVIL / STRUCTURAL WORKS FOR HOT GAS EQUIPMENT
CIVIL
1 CIVIL ENGINEER/STRUCTURAL IN-CHARGE 1 June
2 SURVEYOR 1 June
3 FOREMAN 1 June
4 CARPENTER 1 June
5 MASON/STEELMAN 2 June
6 UTILITY / HELPERS 1 June
TOTAL CIVIL WORKS MANPOWER 7
STRUCTURAL
1 FOREMAN 1 July
2 LEADMAN 2 July
3 FITTER 3 July
4 WELDER 5 July
5 RIGGER/ERECTOR 5 July
6 PAINTER 2 July
7 UTILITY/HELPERS 5 July
TOTAL STRUCTURAL MANPOWER 23

MECHANICAL WORKS
1 MECHANICAL ENGINEER 1 4th wk. of July
2 FOREMAN 1 4th wk. of July
3 LEADMAN 1 August
4 MILLWRIGHT 2 August
5 MECH. FITTER 3 August
6 WELDER 3 August
7 RIGGER 1 4th wk. of July
8 UTILITY/HELPERS 5 4th wk. of July
TOTAL MECHANICAL MANPOWER 17

ELECTRICAL WORKS
1 ELECTRICAL ENGINEER 1 3rd wk. of June
2 FOREMAN 1 3rd wk. of June
3 ELECTRICIAN 3 3 – will start 3rd
wk. of June rest
onwards
4 FITTER 2 3rd wk. of July
5 WELDER 4 3rd wk. of July

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

 6 HELPER 6 3rd wk. of July

TOTAL ELECTRICAL WORKS 17

TOTAL DIRECT MANPOWER 19 to 64 As per schedule

TOOLS AND EQUIPMENT

ITEM NO. DESCRIPTION QUANTITY
1 Boom Truck 1 - unit
2 Service Vehicle 1 - unit
3 Bar Cutter 1 - unit
4 Welding Machine 5 - units
5 Angle Grinder 6 - units
6 Electric Magnetic Drill 1 - unit
7 Cutting Outfit 5 - units
8 Electric Drill 2 - unit
9 Rotary Chipping Hammer 1 - unit
10 Chain Blocks2T&3TCapacity 8 - unit
11 Lever Blocks 1T&2TCapacity 8 - unit
12 Claw Bar 4 - pcs
13 Digging Bar 4 - pcs
14 Shovel 10 - pcs
15 Mechanical Hand Tools 1 - lot

ENGINEERING WORKS

Step 1. Reconnaissance and Preliminary Survey in order to get the as-

built data necessary for the design and engineering phase of the
project
Step 2. Complete engineering design of ducting
Step 3. Complete engineering design of piping
Step 4. Complete engineering design of inlet chute
Step 5. Design of civil foundations and structural supports
Step 6. Production of basic, construction and fabrication Drawings for
submission to Holcim
Step 7. Review and approval of drawings by Holcim
Step 8. Surveying and marking on site upon approval of engineering
drawings

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

MOBILIZATION
MANPOWER

Step 1. Attendance on the safety orientation conducted by HOLCIM

PHILS. DAVAO Plant Safety Department.
Step 2. Submission of manpower safety requirements
Step 3. Secure Safety badge from HOLCIM PHILS DAVAO plant issued
by Safety/Security Department.

TOOLS EQUIPMENT

Step 1. Inform safety department regarding the inspection of tools and

equipment to be utilized on site.
Step 2. Bring all tools and equipment on the site inspection area
prescribed by the safety inspector of HOLCIM and laydown on
the ground properly arrange.
Step 3. List down all the tools and equipment on the inspection form for
signing of safety inspector of HolcimPhils. Davao Plant.
Step 4. Secure Tag or Sticker approved to use and place on the
inspected tools and lifting equipment.

SITE PREPARATION

INSTALLATION OF PERIMETER FENCE

Step 1. Preparation of tools, materials and equipment needed

Step 2. Secure work permit from the area owner.
Step 3. Removal of scattered materials and obstruction within the
working area.
Step 4. Lay out
Step 5. Install Scaffolding pipe 3 meter length as a vertical post on the 16
mm diameter reinforcement bar.
Step 6. Install horizontal braces and secured with pipe clamp. Step
7. Install sway brace to avoid collapse due to wind pressure. Step 8.
Installation of blue sheets as covering secured with tie wire.

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

HAULING OF TEMPORARY OFFICE VAN AND TOOL VAN

Hauling of NTPI Office and Tool Van using crane/boom truck and hauling truck.

Step 1. Transport hauling truck loaded with office / tool van inside plant
premises up to designated area.
Step 2. Unload using crane / boom truck and position as per approved
location.
Step 3. Secured a cable sling with shackle and hooked up to the four
corner of the van prior to lifting
Step 4. The sequence will be repeated until all the necessary field office
and tool van were completely in position.

INSTALLATION OF TEMPORARY POWER SUPPLY

Step 1. NTPI Electrician shall coordinate to HOLCIM Electrical In-charge

regarding the location of the temporary power supply.
Step 2. Secure work permit from the area owner.
Step 3. Preparation of tools, materials and equipment needed.
Step 4. Installation of temporary post using scaffolding pipe anchor to the
existing ground slab using reinforcement bars or welded on fixed
rigid structure.
Step 5. Prepare the location of transformer shed.
Step 6. Place the transformer on the shed.
Step 7. Cable pulling of wire cable.
Step 8. Install cable from the main source to NTPI supplied step down
transformer.

(Note: Tapping from main source shall be done by HOLCIM

Electrician)
Step 9. Install cable from transformer to electrical main panel.

PERSONAL HYGIENE

Comfort room and washing facilities near the area of the Hot Gas generator
project will be provided by NTPI and will maintain the cleanliness.

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

TRAFFIC MANAGEMENT

NTPI shall be comply on the traffic scheme and procedure implemented by the
plant.

Step 1. Follow the designated traffic route

Step 2. Obey the traffic signage posted
Step 3. Follow the speed limit
Step 4. Provision of traffic aide on the trailer or big truck to be position
on the front / back of the truck to guide the driver while driving
inside the plant premises. (if required)
Step 5. Secure permit on the Plant Manager / Maintenance Manager /
PPE Manager when closing the road in advance for proper

dissemination to all department head of HOLCIM. If necessary

to close a road.

CIVIL AND STRUCTURAL WORKS

These consist of civil foundation support of Hot Gas Generator, Tank Structural
Supports of fuel piping and hot gas ducting. This will be detailed during the

Engineering phase (Concrete Breaking Excavation, Leveling & Trimming,

Hauling/Disposal of extracted soil & Backfilling Works), Concreting Works (include

forms & rebar installation, setting of anchor & Concrete Casting); Structural

Erection Works and Tinsmith Works. Fabrication of Structu al Materials in most

cases will be done off-site and will be delivered to site during erection.

Demolition works will be done by Holcim.

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

 A. CIVIL WORKS

9 STEPS FOR CONSTRUCTION AND FOUNDATION FOR HOT GAS GENERATOR MAIN
EQUIPMENT

STEP 1. LAYOUT AND SETTING

1. Secure work permit from the area owner

2. Clearing and grubbing (removal of scattered materials and obstruction)
3. Preparation of tools and equipment needed for the survey work
4. Start setting the survey instrument
5. Establish and transfer all line & grid references using theodolite transit or
total station.
6. Establish and transfer the reference elevation using levelling instrument.
7. Install permanent benchmark prior to start drilling/chipping works by marking
on undisturbed location on existing concrete slab.

STEP 2. EXCAVATION WORKS FOR HOT GAS EQUIPMENT

1. Secure Excavation permit and work permit to safety and area owner.
2. Preparation of tools, materials and equipment needed.
3. Barricade the working area.
4. Installation of Safety signage on the working area.
5. Lay out marking the area to be excavated.
6. Start cutting the concrete pavement using concrete cutter.
7. Excavate the proposed support foundation up to desired depth
8. Installation of temporary ladder with handrail for the access of workers in
case of deep excavation is required.
9. In case water was encountered during excavation, a sump pit with
submersible pump will be provided for easy dewatering and assisted
manually.
10. If necessary a temporary drainage or canal along the edge of the
excavation will be provided with flow going to sump pit.
11. Dewatering will be done daily if necessary.
12. Cleaning the area of debris.

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

STEP 3. LEAN CONCRETING WORKS (FOR HOT GAS EQUIPMENT)

1. Preparation of tools and equipment needed

2. Mobilize Tamper rammer / Plate compactor on the area.
3. Start compacting the area.
4. Conduct Field Density Test if necessary.

STEP 4. FORMWORKS (FOR HOTGAS EQUIPMENT FOUNDATION/PEDESTAL)

1. Preparation of tools, materials and equipment needed

2. Fabricate Forms as specified on the approved drawing
3. Lay out marking where the forms to be installed.
4. Hauling of fabricated Forms
6. Installation of fabricated forms as specified on the approved drawing.
7. Check the alignment.
8. Installation of shoring/Bracing to the prevent movement of forms during
concreting work.
9. Check the final alignment (plumbness and squareness)
10. Request for inspection

STEP 5. REINFORCEMENT BARS (FOR HOTGAS EQUIPMENT

FOUNDATION/PEDESTAL)

1. Preparation of tools, materials and equipment needed

2. Fabricate reinforcement bars as specify on the approved drawing
3. Lay out where the reinforcement bars to be installed.
4. Hauling of fabricated reinforcement bars
5. Installation of fabricated reinforcement as specified on the approved drawing
and fix with tie wire.
6. Check the alignment of the installed reinforcement bars
7. Installation of spacer block between reinforcement and forms to maintain the
concrete covering.
8. Request for inspection.

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

 STEP 6. EMBEDDED STEEL PLATES ( FOR HOT GAS EQUIPMENT)

1. Fabricate a plywood template for the location anchor with embedded plates
as specified on the drawing.
2. Install the fabricated template on the top of pedestal/foundation to serve as
a guide for the anchor/plate setting.
3. Install the anchor/plate and fixing by welding.

STEP 7. GROUNDING CABLES

1. Lay out of grounding cables.
2. Welding of grounding cables.
3. Cleaning and checking of welds.

STEP 8. CONCRETING WORKS (NOT NTPI SCOPE FOUNDATION/PEDESTAL/SLAB)

After completing the necessary requirement prior to concrete pouring i.e.
formworks, rebar works, anchor bolts and grounding cables concrete casting

will follow up to the required elevation by chute assisted manually.

1. Preparation of tools and equipment needed

2. Mobilize or bring concrete vibrator on site.
3. Mobilize or bring slump test and concrete cylinder sampling on site
4. Coordinate to all as required the concrete pouring activity including gate
guard regarding the concrete pouring schedule.
5. Assign concrete coordinator at main gate to assist the transit mixer in going
to site.
6. Get concrete samples and slump test on the delivered concrete
7. Proceed with concrete pouring after all the necessaries was taken on the
approved structure.
8. Concrete curing by means of water sprinkling shall be done minimum of
seven consecutive days.

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

 STEP 9. BACKF ILL ING AND COMPACT ION FOR HOT GAS G ENERATOR
EQU IPMENT
Backfilling works will be done as per standard engineering procedure and
tested by layer, after formworks were stripped- off from the foundation and
pedestal.

1. Preparation of tools, materials and equipment needed.

2. Removal of temporary barricade
3. Filling materials will be transfer back to the area temporarily stockpiled to a
distance capable on equipment reach. Spread filling materials to required
thickness and compacted with mechanical compactor.
4. The procedure will be repeated to the next and every layer until the required
ground elevation is attained.

B. STRUCTURAL WORKS

ERECTION/installation of structural steel supports

INSTALLATION OF SUPPORT STRUCTURES

Step 1. Layout the Hot gas duct/piping as per approved location.

Step 2. Install the brackets as per erection detail
Step 3. All lifting works will be done by HOLCIM.
Step 4. Full welding after alignment (if required)
Step 5. Note: Scaffolding will be done by others/Holcim as required
Step 6. Remove excess materials.
Step 7. Touch-up painting.
Step 8. Housekeeping

MECHANICAL ERECTION / INSTALLATION AND ASSEMBLY WORKS

HOT GAS GENERATOR

Step 1. Preparation of tools, materials and equipmen needed.

Step 2. Fill up completely the task analysis and secure permit

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

 Step 3. All lifting will be by Holcim
Step 4. Hauling of Hot Gas Generator with all access ories
Step 5. Install diesel tank
Step 6. Final alignment & tightening of belt.
Step 7. Testing and Commissioning

HOT GAS duct

Step 1. Fabricate Hot gas duct in accordance with the approved drawings
Step 2. Site Delivery
Step 3. Preparation of tools and equipment needed.
Step 4. Fill up completely the task analysis and secure permit
Step 5. All lifting will be by Holcim
Step 6. Install the duct including expansion joint (provided by HPI)
Step 7. Final alignment & tightening of bolt
Step 8. Leak Testing

diesel piping
Step 1. Fabricate piping in accordance with the approved drawings
Step 2. Site Delivery
Step 3. Preparation of tools and equipment needed.
Step 4. Fill up completely the task analysis and secure permit
Step 5. All lifting and scaffolding works will be by Holcim/Others.
Step 6. Install the piping including all fittings
Step 7. Final connection
Step 8. Leak Testing

MODIFICATION OF INLET CHUTE

Step 1. Fabricate chute in accordance with the approved drawings and
site measurements
Step 2. Site Delivery
Step 3. Preparation of tools and equipment needed.
Step 4. Fill up completely the task analysis and secure permit. Request
for shutdown as per Holcim requirements.
Step 5. All lifting and scaffolding works will be by Holcim/Others.
Step 6. Install the chute
Step 7. Final connection

CERTIFIED QUALITY SYSTEM – ISO 9001:2008

Very truly yours,
NTPI INTERNAT IONAL , INC.

IAN T. ZAFRA
Sales Manager

CERTIFIED QUALITY SYSTEM – ISO 9001:2008