Industrial Orientation Report (9 Jul 2012)

REPORT ON INDUSTRIAL ORIENTATION

WITH

HSL CONSTRUCTOR PTE LTD

PREPARED BY : LIM KIAN NGEE

U1022332H

MAE


WITH HSL CONSTRUCTOR PTE LTD

2012

Table of Contents

Abstract .................................................................................................................................... i

Acknowledgement .................................................................................................................. ii

List of Tables ......................................................................................................................... iii

List of Figures ........................................................................................................................ iv

Chapter One

Introduction ................................................................................................................. 1

1.1 Background .................................................................................................... 1

1.2 Objective ........................................................................................................ 2

1.3 Main Job Scope .............................................................................................. 2

Chapter Two

GRP Pipe Lamination ................................................................................................ 5

2.1 Identification and Measurement .................................................................... 5

2.2 Pipe Cutting, Fitting and Angle Measurement ............................................ 10

2.3 Lamination Process ..................................................................................... 12

2.4 Hardness Test .............................................................................................. 15

Chapter Three

GRP Pipe Installation ............................................................................................... 17

3.1 Installation Method ..................................................................................... 17

3.2 Hydrostatic Test ......................................................................................... 19

Chapter Four

Onshore Activity ...................................................................................................... 21

4.1 Excavation ................................................................................................... 21

4.2 Box Culvert ................................................................................................. 22

Chapter Five

Offshore Activity ..................................................................................................... 25

5.1 Dredging Activity ....................................................................................... 25

5.2 Earth Retaining Stabilising Structure (ERSS) ............................................. 26

5.3 Installation of Intake Header ....................................................................... 28

5.4 Vibration Monitoring System ..................................................................... 30

Chapter Six

Conclusion ................................................................................................................ 31

Appendix ............................................................................................................................. A-1

Appendix A ............................................................................................................. A-1



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Abstract

Construction of a power plant consists of several different aspects and

phases. HSL Constructor Pte Ltd had been awarded the contract for

GMR Energy 2x400MW CCP – Offshore Civil Works Project at Jurong

Island by Samsung C&T Corporation. The project site is situated next to

Power Seraya Power Plant.

HSL Constructor Pte Ltd will undertake the following scope of work:

1. Circulating Water Intake Structure

2. Circulating Water Discharge Outfall Structure

3. Dredging

4. Onshore and Offshore Glass-Reinforced Plastic (GRP) Pipe

Installation

5. Intake Pipe Header Installation

6. Temporary Water Circulation (Underground) Piping System

Concrete Box Culvert

The GRP pipeline consists of straight and angled pipes. To form the

required angles, the GRP pipes need to be cut with high accuracy into

pieces first, followed by conducting pipe fitting checks before joining

them back through a process called “Lamination Process”.



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Acknowledgement

I would like to express my gratitude to Deputy Director of HSL

Constructor Pte Ltd, Mr Sing Tian, who has given me the opportunity to

be part of the GMR project team during my 10 weeks of Industrial

Orientation. During my stint with HSL Constructor Pte Ltd, I was given

learning opportunities such as practical on-site experience, situations

which warrant problem-solving and decision-making skills, experiencing

communication exchanges among team members and across disciplines

as well as handling and resolving conflict, which gave me insights on

how a project is executed.

Secondly, I would like to thank my two supervisors, Mr Ye Genjin

(Project Manager) and Mr Gavin Chan (Project Engineer) for their

guidance, teaching and support. From my initial induction 10 weeks ago

till today, I certainly have learnt much pertaining to operations and

safety from them. Their advice and coaching have helped me

considerably in carrying out my work duties.

Thirdly, I am grateful to the GMR project team colleagues for their

patience and guidance. The assistance and suggestions given have

proved helpful and aided me in the planning of my work scope.

Last but not least, I would like to thank my NTU tutor, Assoc Prof Ang

Hock Eng, for taking his time off for a site visit and getting back to me

whenever I have any enquiries.



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List of Tables

Table 1 Onshore Pipe Identification Number (10PAB) .......................... 5

Table 2 Onshore Pipe Identification Number (20PAB) .......................... 5

Table 3 Offshore Pipe Identification Number (SH1/2) ........................... 6

Table 4 Offshore Pipe Identification Number (SH2/2) ........................... 6

Table 5 General Guideline of Lamination Specification ....................... 14

Table 6 Specification of Type of Layers ................................................ 14

Table 7 Specifications of 1 Pass ............................................................ 14



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List of Figures

Figure 1.1.1 GRP Pipe General Layout Plan ........................................... 2

Figure 1.3.1 Onshore Pipe Installation Drawing (10PAB) ..................... 3

Figure 1.3.2 Onshore Pipe Installation Drawing (20PAB) ..................... 3

Figure 1.3.3 Offshore Pipe Installation Drawing (SH1/2) ...................... 4

Figure 1.3.4 Offshore Pipe Installation Drawing (SH2/2) ...................... 4

Figure 2.1.1 Cutting Plan (10PAB and 20PAB) ..................................... 7

Figure 2.1.2 Cutting Plan (Manhole 10PAB) ......................................... 7

Figure 2.1.3 Cutting Plan (Manhole 20PAB) ......................................... 8

Figure 2.1.4 Cutting Plan (SH1/2) .......................................................... 8

Figure 2.1.5 Cutting Plan (SH2/2) .......................................................... 9

Figure 2.1.6 Measurement of GRP Pipe Length ...................................... 9

Figure 2.2.1 GRP Pipe Before Cutting .................................................. 10

Figure 2.2.2 GRP Pipe After Cutting ..................................................... 10

Figure 2.2.3 Tapered GRP Pipe ............................................................. 11

Figure 2.2.4 GRP Pipe Fitting ................................................................ 11

Figure 2.2.5 Measurement of GRP Pipe Angle ..................................... 12

Figure 2.3.1 Voids Filled with Putty (Before Grinding) ........................ 13

Figure 2.3.2 Voids Filled with Putty (After Grinding) .......................... 13

Figure 2.3.3 Lamination Process ............................................................ 15



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Figure 2.4.1 Hardness Test Equipment .................................................. 15

Figure 2.4.2 Hardness Test ..................................................................... 16

Figure 3.1.1 Section View of Bell and Spigot Joint .............................. 17

Figure 3.1.2 “Come-along” Jack and Chain Method ............................. 18

Figure 3.1.3 Complete Installation of GRP Pipe ................................... 19

Figure 3.2.1 Hydrostatic Test Set-up ..................................................... 19

Figure 3.2.2 Hydrostatic Test ................................................................. 20

Figure 4.1.1 Sheet Pole Before and After Excavation ........................... 21

Figure 4.2.1 Layout of Box Culvert ....................................................... 22

Figure 4.2.2 Rebar Being Tied ............................................................... 23

Figure 4.2.3 Formwork Activity ............................................................ 23

Figure 4.2.4 Concreting Activity ........................................................... 24

Figure 5.1.1 Dredging Crane Barge ....................................................... 25

Figure 5.1.2 Dredging Plan .................................................................... 26

Figure 5.2.1 Earth Retaining Stabilizing Structure ................................ 26

Figure 5.2.2 Seabed without ERSS ......................................................... 27

Figure 5.2.3 Seabed with ERSS .............................................................. 27

Figure 5.2.4 Crane with Vibro-hammer ................................................. 28

Figure 5.2.5 Vibro-excavator on Barge ................................................. 28



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Figure 5.3.1 Plan View of Intake Header ............................................... 28

Figure 5.3.2 Leveling Structure System Model ..................................... 29

Figure 5.4.1 Location of PUB Lines from GRP Pipe Installation ......... 30

Figure 5.4.2 Installation of Vibration Monitoring System .................... 30



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Chapter One

Introduction

1.1 Background

GMR Energy 2x400MW CCP Project is the construction of a power

plant that uses seawater to generate electricity. HSL Constructor Pte Ltd

is the Main Contractor for the supply and installation of both the onshore

and offshore GRP pipes.

In what follows, focus will be placed primarily on the GRP pipes (which

I had the opportunity to be more heavily involved in), from preparing the

pipe material for lamination to installation and testing on-site. The report

will also touch on the other onshore and offshore activities required to

facilitate the installation of the GRP pipes, namely excavation to the

required depth and concreting works for onshore installation and

construction of an earth retaining stabilising structure (ERSS) and

dredging for offshore installation.



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1.2 Objective

The GRP pipeline consists of straight and inclined pipes. To create the

bend curves, cutting of the pipes needs to be carried out in accordance

with the cutting plan before they are joined through a lamination process.

1.3 Main Job Scope

The main scope I was assigned to work on is to ensure that the right GRP

pipes are marked accurately before cutting, pipe fitting of the cut pieces

are in accordance with the approved design drawings before proceeding

with lamination. In addition, the occasion arose for me to be involved in

arranging and preparing for lifting operations using an 90 tonne crane

required for shifting and pipe fitting of the GRP pipes.

Onshore GRP Pipe Installation

Offshore GRP Pipe Installation

Figure 1.1.1 : GRP Pipe General Layout Plan



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Figure 1.3.2 : Onshore Pipe Installation Drawing (20PAB)

90° Elbow Joint Lamination



with Flange


Manhole Lamination


Manhole Lamination



with Flange

Figure 1.3.1 : Onshore Pipe Installation Drawing (10PAB)



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Figure 1.3.3 : Offshore Pipe Installation Drawing (SH1/2)

Figure 1.3.4 : Offshore Pipe Installation Drawing (SH2/2)

7.26° Elbow Joint Lamination

Manhole Lamination



45° Lateral “Y” Joint Lamination



21° Elbow Joint and Manhole Lamination



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Chapter Two

GRP Pipe Lamination

2.1 Identification and Measurement

The GRP pipes come in different shipments and based on the drawings

of 10PAB, 20PAB, SH1/2 and SH2/2, each piece comes with an

identification number.

S/N Drawing

Number Position Identification Number

Require

Lamination GRP Pipe

1 10PAB 1, 10, 10, 9 220-01, 150-01, 150-02, 130-01 Yes 90° Elbow Joint

2 10PAB 6 20-01 No Straight




6 10PAB 5, 12, 7 100-01, 250-02, 110-01 Yes 45° Elbow Joint


8 10PAB 6, 11, 2 20-06 Yes Manhole


10 10PAB 4, 12, 10A, 19 90-01, 250-04, 140-01, 230-01 Yes 45° Elbow Joint with

Flange

Table 1 : Onshore Pipe Identification Number (10PAB)

S/N Drawing


Require

Lamination GRP Pipe

1 20PAB 1, 8, 8, 6 220-02, 210-01, 210-02, 180-01 Yes 90° Elbow Joint

2 20PAB 5, 9, 2 25-03, 240-01 560-01 Yes Manhole


4 20PAB 3, 10, 8A, 16 160-01, 250-05, 200-01, 230-02 Yes 45° Elbow Joint with

Flange

Table 2 : Onshore Pipe Identification Number (20PAB)



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S/N Drawing


Require

Lamination GRP Pipe

1 SH1/2 11, 15A, 15B, 6 310-01, 325-01, 325-02, 260-01 Yes 80° Elbow Joint

2 SH1/2 1 10-01 No Straight




6 SH1/2 12, 8, 9, 13 320-01, 280-01, 290-01, 580-01 Yes 21° Elbow Joint and

Manhole

7 SH1/2 10, 7 300-01, 270-01 Yes 6.16° Elbow Joint





Table 3 : Offshore Pipe Identification Number (SH1/2)

S/N Drawing


Require

Lamination GRP Pipe








8 SH2/2 1, 7, 14 15-06, 380-01, 590-01 Yes Manhole










18 SH2/2 8. 3 390-01, 340-01 Yes 45° Lateral "Y" Joint


20 SH2/2 15A, 15B 450-01, 450-02 No Straight

21 SH2/2 2A, 2B 330-01, 330-02 No Straight

22 SH2/2 9A, 9B 400-01, 400-02 No Straight

Table 4 : Offshore Pipe Identification Number (SH2/2)



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After identifying the GRP pipes that require lamination, pipe marking

needs to be carried out according to the cutting plan. In the instance pipe

marking is not according to the cutting plan, offset marking would be

required, which entails more time and effort. The pipe length is

measured based on the centre line of the GRP pipe.

Figure 2.1.1 : Cutting Plan (10PAB and 20PAB)

Figure 2.1.2 : Cutting Plan (Manhole of 10PAB)

Plan View Side View

Markings on GRP Pipe



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Figure 2.1.3 : Cutting Plan (Manhole of 20PAB)

Figure 2.1.4 : Cutting Plan (SH1/2)

Plan View Side View

Markings on GRP Pipe



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Figure 2.1.5 : Cutting Plan (SH2/2)

Figure 2.1.6 : Measurement of GRP Pipe Length

Centre Line of

GRP Pipe



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2.2 Pipe Cutting, Fitting and Angle Measurement

The GRP pipe will be cut upon confirmation of the constituent pipe

lengths with the cutting plan. After cutting, the GRP pipe will be split

into several parts with reference to the cutting plan. After the fitted end

of the GRP pipe is tapered using bevel method with 45° angle (refer to

Figure 2.2.3), various parts will be fitted according to the required angle.

Figure 2.2.1 : GRP Pipe Before Cutting

Figure 2.2.2 : GRP Pipe After Cutting



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Figure 2.2.3 : Tapered GRP Pipe

Figure 2.2.4 : GRP Pipe Fitting

After fitting, the pipe angle needs to be checked and measured before

proceeding to the lamination process (refer to Figure 2.2.5). This is done

by finding the centre point of the GRP pipe fitted parts through

extending the centre line. If the angle is not in accordance to the cutting

plan, then parts of the GRP pipe will have to be re-adjusted.



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Figure 2.2.5 : Measurement of GRP Pipe Angle

2.3 Lamination Process

After the GRP pipes are fitted according to the drawings (10PAB,

20PAB, SH1/2 and SH2/2), the surface areas to be laminated need to be

grinded to remove hardened resin so as to achieve stronger bonding for

the 1st layer of lamination. Upon completion of grinding, the lamination

process will take place in the following steps:

1. Voids (3-10mm) in between the tapers will be filled with putty.



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Figure 2.3.1 : Voids Filled with Putty (Before Grinding)

2. The putty will polymerize until hardened.

3. Subsequently, excess putty will be removed by grinding.

Figure 2.3.2 : Voids Filled with Putty (After Grinding)

4. Different pipe diameters have different specifications for the

lamination process. Refer to Appendix A for more details of each

specification.

Putty



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S/N Diameter Type of Lamination Total Number of Pass

1 2000 Elbow Joints 8

2 2000 Manhole 19

3 3000 Elbow Joints 16

4 3000 Manhole 3

Table 5 : General Guideline of Lamination Specification

S/N Type of Layer Thickness for 1 Layer

1 CSM 0.5mm

2 Combi 0.8mm

Table 6 : Specification of Type of Layers

5. Each pass of the lamination consists of 7 layers. Apply resin (70%

of unsaturated polyester isophthalic and 30% of styrene monomer)

before lamination and eliminate the air bubbles before the

insertion of each layer. Allow curing of each pass before

proceeding to the next pass. Grind the laminated surface area after

curing.

1st Layer CSM ("E" glass mat and "C" glass veils)

2nd Layer Combi ("E" glass mat and woven roving)

3rd Layer Combi ("E" glass mat and woven roving)

4th Layer Combi ("E" glass mat and woven roving)



7th Layer CSM ("E" glass mat and "C" glass veils)

Table 7 : Specifications of One Pass



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Figure 2.3.3 : Lamination Process

6. Repeat Step 5 until the required thickness of lamination is

achieved.

2.4 Hardness Test

To ensure the quality of the laminated joints, hardness test must show a

value of 37 and above after the curing of each pass.

Figure 2.4.1 : Hardness Test Equipment



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Figure 2.4.2 : Hardness Test

Hardness Test Value = 50



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Chapter Three

GRP Pipe Installation

3.1 Installation Method

The straight and laminated GRP pipes will be installed according to the

drawings (10PAB, 20PAB, SH1/2 and SH2/2). The installation method

for bell and spigot joints sealing is by double toroidal elastomeric gasket

(O-ring).

The O-ring has a precise compression set to develop the sealing action.

In addition, the bell and spigot joints are equipped with a locking key

and a pressure tap on the outer surface of the bell to allow hydrostatic

testing.

Figure 3.1.1 : Section View of Bell and Spigot Joint

2 O-ring Gasket

Pressure Tap for

Hydro Testing

Bell

Spigot



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The procedure of GRP pipe installation is as follows:

1. Clean the bell, spigot and O-ring thoroughly.

2. Stretch the O-ring over the spigot and position it in the groove.

3. Equalize the tension on the O-ring by pulling it out of the groove

simultaneously on opposite sides of the spigot.

4. Lubricate the surface of the O-ring that is already positioned into

the grooves, as well as the internal surface of the bell.

5. The spigot end of pipe will be guided into the bell end. If the pipe

is fitted, rotate the pipe section in order to have the test nipple on

the bell on the top, and the slots for the lock joint accessible.

6. Tie 2 nylon slings, or ropes, around both the installed bell section

and the spigot. Leave the slings somewhat loose.

7. Connect the appropriate slings on either side of the pipe with a

“come-along” jack and chain running outside of the planks to

avoid damage to the pipe.

Figure 3.1.2 : “Come-along” Jack and Chain Method



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8. Take up the slack on both sides. At the same time, continue to jack

the spigot end into the bell until the end of the bell edge reaches

the insertion limit marked on the spigot end.

Figure 3.1.3 : Complete Installation of GRP Pipe

3.2 Hydrostatic Test

To check if the bell and spigot is sealed up completely, hydrostatic test is

carried out. The pressuring system shall be fitted to the nipple on the

assembled pipe.

Figure 3.2.1 : Hydrostatic Test Set-up

Sling

“Come-along” Jack and Chain

Locking Key

Locking Key Hole



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Hydrostatic test is executed as follows:

1. Unscrew the plug on the nipple.

2. If using compressed air, the maximum test pressure is 5 bar.

3. If using water, the maximum test pressure is 10 bar.

4. Pump in the compressed air or water into the nipple.

5. The pressure will be maintained for 5 minutes.

6. Check for any pressure loss or visible leakage of the joint and

piping system connected to the nipple.

7. Absence of any drop in pressure means a perfect sealing.

8. In the case of failure during the test, the bell and spigot joint must

be dismantled to clean the joint and replace the O-ring.

Figure 3.2.1 : Hydrostatic Test

Pressure Tap Connected to Nipple

Hand Pump



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Chapter Four

Onshore Activity

4.1 Excavation

Excavation needs to be carried out before the GRP pipes can be installed.

The depth of the excavation and ground conditions determine the type of

method to be employed for excavation. Driving sheet piles into the

ground using the vibro-excavator prevents soil from collapsing after

excavation.

Figure 4.1.1 : Sheet Pile Before and After Excavation

Vibro-excavator

Sheet Pile

Sheet Pile



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4.2 Box Culvert

Seawater needs to be discharged back to the sea; the box culvert serves

the function of carrying the seawater.

Figure 4.2.1 : Layout Plan of Box Culvert

The construction of the box culvert is executed as folows:

1. Tie rebar according to approved design.

20PAB

10PAB

Box Culvert



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Figure 4.2.2 : Rebar Being Tied

2. Construct formwork (using plywood to form the shape of box

culvert).

Figure 4.2.3 : Formwork Activity

Rebar

Plywood



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3. Pour concrete into the formwork.

Figure 4.2.4 : Concreting Activity



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Chapter Five

Offshore Activity

5.1 Dredging Activity

Before the installation of offshore GRP pipes, the seabed needs to be

dredged to the required depth.

Figure 5.1.1 : Dredging Crane Barge

The dredging crane barge has a global position system (GPS) and depth

monitoring system to indicate the position and the depth of the seabed.

The dredging activity can be carried out according to the dredging plan

using the above system.



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Figure 5.1.2 : Dredging Plan

Upon completion of dredging, bucket and sounding test will be

conducted to verify the actual depth of the sea bed.

5.2 Earth Retaining Stabilising Structure (ERSS)

To protect Public Utilities Board (PUB) lines and prevent offshore soil

erosion, installation of a earth retaining stabilising structure is required.

Figure 5.2.1 : Earth Retaining Stabilizing Structure



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Figure 5.2.2 : Seabed without ERSS

Figure 5.2.3 : Seabed with ERSS

ERSS

GRP Pipe

PUB Line

GRP Pipe

PUB Line

Soil Erosion Exposed PUB Line



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Two methods are used to install ERSS. The first method uses the crane

with vibro-hammer to drive the sheet piles whereas the second uses

vibro-excavator.

Figure 5.2.4 : Crane with Vibro-hammer Figure 5.2.5 : Vibro-excavator on Barge

5.3 Installation of Intake Header

The purpose of the intake header is to take in seawater from the sea to

generate electricity.



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To install the intake header, the seabed needs to be flattened with a

leveling system. The system consists of a platform, which is guided by 4

poles to move in a direction perpendicular to the seabed whereas the

leveling beam will be guided by the platform to move horizontally so as

to flatten the sea bed (refer to Figure 5.3.2 below for the prototype model

I built to illustrate how the leveling system works).

Figure 5.3.1 : Plan View of Intake Header

Vertical Direction

Horizontal Direction

Leveling Beam

Platform



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Figure 5.3.2 : Leveling Structure System Model

5.4 Vibration Monitoring System

The offshore activities might affect and damage the PUB pipes (Refer to

Figure 5.4.1), therefore it is essential to install a vibration monitoring

system to serve as early detection for prompt remedial action.

Figure 5.4.1 : Location of PUB Lines from GRP Pipe Installation

P U

B

L I

N E

Trench of 6m length

Offshore GRP Pipe

Trench of PUB Line

18m



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Figure 5.4.2 : Installation of Vibration Monitoring System



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Chapter Six

Conclusion

Safety is of utmost importance. It protects people, minimises injury,

provides a safe working environment and controls construction costs.

Implementing a safety program entails proper and early planning for

work activities which ensures the quality of work and that work progress

is according to plan.

Before the execution of a project, it is important to pre-plan the timeline

into different phases. Some phases need to be completed before

proceeding to the next. For instance, installation of GRP pipes requires

the completion excavation and lamination of the pipes first. Hence, it is

important to meet the given datelines of various phases so as to prevent

delay to the project.

High quality of work needs to be guaranteed so as to prevent and reduce

time loss and costs of re-works. Therefore, it is important to go through

and check the work details thoroughly before actual execution.



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Effective communication is vital during project execution. It greatly

helps to prevent people from doing extra “double” work and keeps team

members informed of work activities that need to be carried out.



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Industrial Orientation Report (9 Jul 2012)

Documents

Transcript of Industrial Orientation Report (9 Jul 2012)