PERGAU H.E.P. - KELANTAN, MALAYSIA
STEEL TUNNEL LINING (STL) OF 60 degree INCLINED SHAFT


WORKSCOPE
Detail engineering, supply, fabrication, installation, and painting of approximately 350m of 5.0m dia. steel tunnel lining (Quenched and Tempered), including 2 transition sections and a rolling lobsterback bend.

Project Data
Location Kelantan, Malaysia
Client Kerjaya Balfour Beatty Cementation Sdn. Bhd.
Owner Tenaga Nasional Berhad
Contract Period 1993-1996
Contract Value £5.5 million
Contract Tonnage 1320 te
Design Code CECT, BS5500
Material Specification Quenched and Tempered with min.
UTS of 780 N/mm2
Diameter Range 4.2m to 6.0m
Thickness Range 16mm to 35 mm
Post Weld Heat Treatment None



DESIGN / DRAWINGS

The basic design was verified by our own engineers and detailed design undertaken.

Permanent works drawings, including the development and cutting arrangement drawings required for fabrication were produced on Autocad.

Due to complexity of the access for installation work, a disproportionate amount of design and drafting work was necessary for the temporary works facilities.

METHODOLOGY

The basic methodology devised at the tender stage was developed further utilising computer graphics to simulate the key areas of the installation works. This enabled the project team to evaluate a number of options quickly and accurately.

Temporary works equipment was designed and configured to overcome the unique problems associated with the project.

SITE ESTABLISHMENT

As it was not feasible to transport pre-fabricated sections to the site location it was decided that a purpose built facility would be established on site.

An area of land was recovered from the rain forest local to the Surge Shaft to accommodate our site overall facilities.

It was determined that craneage cost savings could be made if the fabrication facility was sited adjacent to the access point (Surge Shaft) to allow the same crane to be utilised for both purposes.

FABRICATION

Foundations were laid and an 18m high open ended fabrication shop was erected and fitted out with a vertical plate rolling m/c, cutting tables, rotators, automatic welding m/c's, preheat facilities, assembly jigs, and access platforms. The Portal Crane rail system ran through the workshop and over the Surge Shaft.

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