Miscellaneous Metal Works for Biogas Scrubber System

CLIENT: TECHNOCHEM
Date of award : December 2018
Completion : November 2019

Overview

This project involved the supply, fabrication, and installation of miscellaneous metal works, pipe supports, pipe bridges, and access platforms for the Biogas Scrubber System. The scope of work ensured the structural integrity, durability, and accessibility of the system while adhering to all applicable codes, standards, and client requirements. Through careful planning and execution, the project successfully delivered robust and reliable infrastructure to support the operation and maintenance of the Biogas Scrubber System.

Scope of Work

1. Design Review and Approval

  • Review client-provided design documents, technical drawings, and site layouts.
  • Ensure compliance with applicable standards such as:
    • Structural Standards: BS EN 1993 (Eurocode 3) or AISC for structural steel.
    • Pipe Support Standards: ASME B31.3 for process piping.
    • Safety Standards: OSHA 1910 for access platforms and walkways.
  • Submit fabrication and shop drawings for client approval.
  • Coordinate with the client to finalize all tie-in points and site-specific adjustments.

2. Fabrication

  • Fabricate all components as per the approved shop drawings, ensuring:
    • Dimensional accuracy and adherence to design specifications.
    • Proper cutting, drilling, welding, and assembly using approved welding procedures (ASME Section IX).
    • Perform pre-assembly where feasible for efficient site installation.
  • Conduct surface preparation (e.g., sandblasting to SA 2.5) and apply appropriate coatings:
    • Pipe Supports and Miscellaneous Metal Works: Galvanization or epoxy primer as per project requirements.
    • Access Platforms and Pipe Bridge: Anti-corrosion coatings with non-slip surfaces.

3. Installation

  • Transport fabricated components to the site using proper handling techniques.
  • Install the following:
    1. Pipe Supports:
      • Align and secure pipe supports as per site layout and approved drawings.
      • Ensure proper load distribution and support for all biogas scrubber pipelines.
    2. Pipe Bridge:
      • Erect and secure the pipe bridge structure, ensuring stability and alignment.
      • Coordinate with piping teams to align with biogas pipelines.
    3. Access Platforms:
      • Install platforms, walkways, and ladders to provide safe access to the biogas scrubber system.
      • Ensure platforms are equipped with handrails, toe guards, and anti-slip gratings as per OSHA standards.
    4. Miscellaneous Metal Works:
      • Install auxiliary steelworks such as brackets, frames, and equipment support as required.
      • Perform site adjustments for final alignment and leveling of installed components.

4. Testing and Inspection

  • Conduct visual and dimensional inspections for all fabricated and installed components.
  • Perform non-destructive testing (NDT) for critical welds, including:
    • Magnetic Particle Testing (MPT) or Ultrasonic Testing (UT).
  • Verify the structural stability of pipe supports, bridges, and platforms through load testing, if required.
  • Submit inspection and testing reports for client approval.

5. Handover and Documentation

  • Provide the following documentation upon completion:
    • As-built drawings for all fabricated and installed components.
    • Material Test Certificates (MTC), WPS, and PQR.
    • Inspection and testing reports.
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