MAC : Projects : Mechanical Projects

CIVIL WORKS - Hand excavation in rock was performed in areas where underground existing services were encountered. Foundations for new equipment, tanks, pumps and structures totalled 1 4,000 mÂ³ and involved construction of 2 new 7.50 m deep underground sulfur storage pits, major concrete foundations for stacks, miscellaneous foundations and plinths on paving for pipe supports, fire proofing to existing steel structures, concrete cable trenches, ducts for underground cables, pit for underground drum and concrete paving for all new plant area
STRUCTURAL STEEL - Erection totalling 1600 ton that included pipe racks, support structures for equipment and Fin Fan Coolers including stairs and platforms, extensions and reinforcements to existing pipe bridges, and steel trestle towers
UNDERGROUND PIPING WORKS:
- Oily water sewer drainage and surface storm water collection of the new Sulfur Recovery Units, as well as firewater run-off from paved areas. The system comprised an underground piped gravity sewer with manholes, catch basins, equipment hub drains and a lift station with lift-pumps that were tied to the existing network
- An amine drain to carry amine drainage, of hard piped closed gravity drain to a below ground holding tank in a concrete pit Underground fire water network tied to the existing network including installation of hydrants, monitors and hose-reels, external underground networks for buildings including storm water drainage, from network up to tie in with existing drainage network, installation of drinking water for the buildings and the plant
MECHANICAL WORKS - Static and rotary equipment installation and pre-commissioning, including columns, exchangers, vessels, converters, pumps and blowers; assembly and erection of derrick structure and thermal oxidizer stack 93.0 m high; installation of new and replacement of existing trays, assembly of Air Cooled Exchangers and structure
ABOVEGROUND PIPING - Installation of new inter-connecting lines to carry feed gas (acid gas and SWS gas) from tie-ins within existing SWS-2 & ATU-2 units to the new SRU's via upgraded existing structural racks within the refinery and new pipe bridges and racks connecting common and train racks
An existing 18â€ jacketed line converted to a sour flare header, terminating in an existing sour flare pipe at existing flare
Electrically traced Molten Sulfur Transfer lines from the new SRU's to the new Sulfur Holding Tanks running across existing process area:
- Installation of electrically traced Loading and Drainage lines from Sulfur Holding Tanks & Pumps to new Sulfur Loading Arms on new elevated pipe supports & bridges
- Interconnecting Process & Utility Piping to and from the new equipment
More than 1,100 ton of large bore piping was fabricated and installed including steam jacketed piping as well as 80 ton of small bore piping for steam tracing supply and condensate return across the systems
ELECTRICAL Works - I nstallation of equipment, power, lighting, grounding systems for the new plant units including all works related to modifications inside the existing plant area:
Supply of 13.8kV power from existing substation via feeder cables to the new substation through new circuit breakers; distribution to 4.16 kV & 480 V double ended SRU switchgear via step down transformers and installation of neutral g rounding r esistors, bus ducts, switchgear, distribution boards, UPS system, control panels and transformers to 480 V for skin effect heat tracing system
4.16 Adjustable Frequency Drives (AFD) panels for blowers and 125 V DC system comprising 2 battery chargers, DC panel board, batteries, racks and monitoring panels
Installation of 4,600 m of cable trays, 13,500 m of conduits and 155,000 m of cables
INSTRUMENTATION Works - Procurement of bulk materials for the control, instrumentation and telecommunication systems including loop checking, testing, calibration, pre-commissioning, inspection in operating units with control room and
Technical room energized, work involved revamping works as well The scope of work included installation, inspection & testing of:
- Detection, monitoring, control and sampling systems
- Analyser instrumentation, communications systems for the two new sulfur plants and amine treating units with a sour water stripper and valves including stroking of all control and emergency isolation valves
Cable ladders, cable tray supports, installation of marshalling cabinets, auxiliary cabinets and system cabinets within Central Control Room (CCR) and existing PIB.
Installation of wiring between existing facilities; new Uninterrupted Power Supply (UPS).
Installation of fibre optic cables, PAGA speakers, telephone and telecom wiring.
Hook up, air tubing, junction boxes, wiring, connection & grounding to marshalling and system cabinets.
Installation involved 9,065 m of cable trays and 145,000 m of cables.
INSULATION works - Turnkey supply, fabrication and installation for HRSG and Steam Cycle Piping.
PAINTING works - for all uninsulated equipment and piping.
MANPOWER / QUALITY / SAFETY

The project involved over 3.3 million man-hours of Direct labor and over 0.8 million man-hours of Indirect labor with a sustained peak load of direct manpower of 950 plus 150 indirect labor & supervision totaling 1100 men. All personnel were accommodated & catered for in MAC’s camp adjacent to the job site where full life support facilities were provided.

The achieved Quality Control Index was 97.8%.

The Safety Record involved 4 million work man-hours without any Lost Time Accident.