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PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 1 of 14 REVISION 0
1.
PREFACE This instruction is to describe erection method of Boiler proper carried out on erection works of Labuan 2x300 MW Coal Fired Steam Power Plant Project. In this connection, any modification to instruction shall be carried out after reviewing it with personnel concerned, if it happens.
2.
SCOPE OF APPLICATION This instruction shall be applied for erection works of Boiler proper identified as Boiler Unit 1 and Unit 2 of the above steam generating plant.
3.
CODE OF APPLICATION AND RELEVANCE DRAWING 3.1. 3.2. ASME SEC 1 : Rule of Construction of Power Plant. ASME B 31.1 : Power Piping.
4.
GENERAL NOTE 4.1. 4.2. 4.3. Before commencement of welding works, prepared instruction of the welding works and make know everyone concerned without exception. As per the works required inspection, carry out inspection under attendance of Superintendent / Engineer and as surreally record is result. Pay careful attention no to damage pressure parts of Boiler on Lifting Works.4.4. Rope of with safety rope around lifting area of Boiler Parts and put notice board entered “KEEP OFF EXEPT PERSONEL CONCERNED”.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 2 of 14 REVISION 0
4.4.
Prior to commencement of lifting works, assureadly carry out check of wire etc, use the lifting works and confirm that no any defective point exist.
5.
RESPONSIBILITY 5.1. 5.2. 5.3. Chief Engineer–Responsible for the overall planning, coordination and control of the erection job. Field Engineer–Responsible for field erection work implementation and maintaining acceptable quality standard. Field Superintendent and Supervisor–Responsible for the actual performance of the erection crew and actual checking of the work progress to make sure that it as per drawing specification and standard. 5.4. For these activity will support by Material Control, Quality Control, Welding Sec, and others section related with these activities.
6.
PROCEDURE 6.1. Basic Requirement 6.1.1. Schedule and Planning Master erection schedule is usually provided by the client. The detailed schedule is prepared by the contractor according to his planning which is based on the client’s master schedule. The millstone and the critical path can be identified which require proper planning. The sequence of erection activities and the resources required is included in the planning.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 3 of 14 REVISION 0
6.1.2. Erection Drawing and Erection Manual Erection drawing and manual usually provided by the clients. The Field Engineer, Superintendent shall check all drawings intended for Boiler Erection, and make sure that it is completed. All the information required is completed and all drawings shall be of current revision. 6.1.3. Packing List Packing List shall be made available by the client to the contractor. This included all the listing of materials, equipment and parts that are supplied. The Packing List should indicate the quantity of the material and equipment supplied and its specification as described in the erection drawing. This will also indicate the size and the total weight of the component and the method of storage. Also the packing number and material coding is very essential. 6.1.4. Storage Area and Warehouse Upon a thorough check on the drawing and the packing list, the quantity of materials and equipment is already known, including the method of storing, the size of the storage area and the warehouse can be identifies. 6.1.5. Resources
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 4 of 14 REVISION 0
Identification of resources is integral part of planning and scheduling is the most essential part of the basic requirement in undertaking boiler erection job in particular and in all jobs in general. Resources means, the materials, labor and equipment needed to perform boiler erection job. 6.2. Preparation Works 6.2.1. Checking of Boiler Erection Drawings This has to be done by the Chief Engineer, Field Engineer, Superintendent and Supervisor to determine the correct resources needed to perform the job. 6.2.2. Checking of Client Supplied Material and Equipment Checking and inspection of the materials and equipment including the spare parts is to be done by the material control. He will make sure that all materials, equipment and spare parts received from the supplier or the client conform with the quantity and the specifications started in the packing list or shipping. 6.2.3. Checking of Erection Materials, Equipment, Tools and Machinery In the early stage of planning, these resources had been already identified. The schedule of mobilization is as planed schedule made by the Chief Engineer and Field Engineer.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 5 of 14 REVISION 0
6.2.4. Checking of Labor Labor requirement for every stage of erection job is prepared by the Chief Engineer and his erection team, which is in accordance to their planning. 6.3. Boiler Erection It is assumed in this procedure that before starting the erection of the Boiler, the supporting structure were already erected and checked by others and clearance to proceed with the Boiler erection had been obtained. 6.3.1. Boiler Drum Raising The Boiler Drum 163 Tones with Hanger 10 Tones and also Rigging Tools 6,5 Tones is erected to its final location El.66.800 by using 2 units lifting jack type L300 with each capacity 180 Tones (safe Working Load) in the cases proposal 9 Parts 18mm Diameter Dyform Strand Cable @80m long. Prior to the lifting the Drum, the Boiler Strap Hanger are set to facilitate the setting of Drum in its final location. After marking the center line on roof girder, the strap hanger is set in position and goes along with the steam drum. The length of steam drum is 22150mm and the span between grid G3 and G5 is 21000mm. Hence the drum is required to be titled and
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 6 of 14 REVISION 0
lifted to avoid clashing with steel. On this case, the drum will be titled at an inclination 35 degrees. The jack will be mounted on jack support beams which will be mounted on roller type’s skates. The movement and restrain of beam will be by chain block. The jack will be operated from a single electric hydraulic power pack. The actual loads on jack as the drum is hoisted up at 35 degrees is considered (Lifting load of drum with internal 163 Tones + Hanger 10 Tones + Rigging Tools 6,5 Tones) at jack near grid G5 is 1343,49 KN and jack near grid G3 is 937,76 KN including safety factor 25%. 6.3.2. Boiler Drum Final Alignment After the drum is set in position, the below mentioned alignment is carried out to confirm the centering of drum along X and Y axis The levelness measuring and checking of steam drum can be carried out by selecting 2 points on each of the left and right end (totally 4 points). The elevation reference point of steam drum on the steel columns marked. (Detail Alignment sequence is attached)
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 7 of 14 REVISION 0
6.3.3. Installation of Furnace Supporting Hangers After the steam drum had completely aligned, the supporting shall be installed drawing. These shall be mounted to the furnace top supporting structure in the hanging position to make ready to support the furnace components. 6.3.4. Installation of Top Header and Riser Pipes Upper Header consists of: Back pass Roof Inlet Header Back pass Roof Outlet Header Back pass Upper Side Headers Furnace Upper Front wall Headers Furnace Upper Sidewall Headers Furnace Upper Rear Headers Re-heater Front wall Outlet Headers Re-heater Sidewall Outlet Headers Super-heater Division Inlet Headers Super-heater Division Outlet Headers Super-heater Vertical Platen Inlet Headers Super-heater Vertical Platen Outlet Header to its respective locations whereby the quantity corresponding to the number of hangers required in the erection
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 8 of 14 REVISION 0
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Re-heater Vertical Spacer Rear inlet Header Furnace Rear Hanger Outlet Header Economizer Outlet Header
Preparation: Thoroughly clean the beveled end of each header and the tube to check if there is any foreign matter inside the material before lifting. Placed back the caps on the beveled ends to protect them from damage. Lifting: Lift-up each header and tube in the correct position and hang it from header rod. Put marking on structure to identify the center of each header in relation to boiler standard line and level and temporary fix it. These measurements are to be recorded. 6.3.5. Buckstays Preparation: Provide marking on the structure to show setting level of the buck stay section. Lifting: 1. Lift them up to position where it is to be installed and temporary hang them from beam and secure them properly.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 9 of 14 REVISION 0
2. Setting work should be performed after aligning panels. Panels located in the place where backstays are to be installed should be seal welded. 3. Fix Backstays by inserting the guide pins to tie bar lugs which are welded to the panels. 4. Rectify the distortion occurring during installation of the buck stays to panels so that the tie bar lugs will match correctly. Do not insert the pin by means of hammering. 6.3.6. Roof Tube Panels Preparation: The temporary work is to be lifted down from the top beam before lifting commence. Lifting: Lifting them up to position and hang it from the hangers rods. Upon completion of the installed panels, align them and adjust their level before fixing them together. Alignment of Beveled End & Tube Welding. Prior to aligning them with rear panels, they are to be air purged to remove all foreign materials. 6.3.7. Water Wall Panels
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 10 of 14 REVISION 0
Preparation: Thoroughly clean beveled ends & provide proper scaffolding to perform the beveled end alignment. Lifting: 1. Temporary works are to be lifted down from the top beam. 2. Panels lifted up are then suspended by chain block and aligning holding jigs. 3. Align tube end and then perform the welding. 4. Align the panels. 6.3.8. Intermediate and Lower Header Intermediate Headers consist of: Re-heater Front Wall Inlet Header Economizer Medium Headers
Lower Header Consist of: Back pass Lower Front Header Back pass Lower Rear Header Back pass Lower Side Header Economizer Inlet Header
Preparation:
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 11 of 14 REVISION 0
Thoroughly clean stub beveled ends and inspect inside the header. Lifting: Temporary works are to be arranged from the top beam. Chain Block should be used to suspend the header lifted up to position. After centering, temporary fix it. 6.3.9. Super heater & Re heater Element Tubes. Preparation: Thoroughly clean the beveled ends, inspect element tubes to ensure that they are not damage. Lifting: 1. Lift up each element tube to the given position and insert it into the front wall panel slit to temporary hang it with wire rope. 2. After completing lifted up all elements, lift them up one by one with chain block to align the support tube ends. 3. After alignment of the front wall panel and each header, header stub ends and Re heater/Super heater element, tube ends shall be matched. 4. Commence welding of the aligned tubes ends. 6.3.10. Economizer. Centering
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 12 of 14 REVISION 0
In accordance with the installation drawing, measure the center of economizer from established boiler standard lines and mark it on the steel structure. Assembly Work As the steel structure are being erected, the economizer support beams shall also be assembled, and square steel bar should be welded to the main beam according to the drawing for the purpose of preventing vibration of the economizer element. Preparation before Lifting Check and clean the beveled ends, then cover the open ends by caps or plastic shell to prevent dust from entering. Arrange lifting equipment for lifting them. Lifting Elements will be lifted up by block, after assembly of the element, fix the support bars and weld. Economizer Casing The casing will be assembly on the ground in several divided block (including insulation and inner casing). After all blocks are being lifted, they will be matched at the connecting points. Backstay
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 13 of 14 REVISION 0
After temporary assembly of the economizer casing, welding on the part where the backstay would be fixed shall be finished, then the backstay will be hauled in. 6.3.11. Accessories Of Pressure Parts Installation 1. Accessories directly attached to pressure parts, including seal plate, seal bars, fins tie bars, seal boxes, thermocouple etc, should be places in the respective position and then welded. 2. The installation should be completed before hydrostatic test. 6.3.12. Inner & Outer Casing Preparation: 1. Arrange the casing in the groups according to the place of installation. 2. The delivery of material to the place of installation shall be made depending on the condition of the working floor and the progress of the other works. 3. Assemble them in accordance to the drawing. Installation 1. Installation of the casing should be coordinated with the refractory and insulation works.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 14 of 14 REVISION 0
2. During installation, care should be taken not to damage the refractory and the pressure parts. 3. Supporting places to support manholes, seal boxes etc. should be installed with consideration given to boiler thermal expansion. 4. Selection of welding rods and manner of preheating should be in accordance with the vendor’s WPS. 5. After welding completion, should be perform visual inspection. 6.3.13. Inspection Holes Inspection 1. Upon completion of pressure part work, check if there is any foreign material remaining inside each header. 2. Use an inspection mirror to check the above. 3. If there is any foreign material, remove it by air purge. 4. After inspection, seal weld inspection holes. 7. FLOW CHART Flow Chart for the boiler erection (Boiler Parts). 8. ATTACHMENT Assembly Process of Upper Header and panel Detail Sequence of Assembly Water Wall Panel Rigging Plan for Wall Installation ( Detail Procedure Will Purpose)
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 1 of 14 REVISION 0
1.
PREFACE This instruction is to describe erection method of Boiler proper carried out on erection works of Labuan 2x300 MW Coal Fired Steam Power Plant Project. In this connection, any modification to instruction shall be carried out after reviewing it with personnel concerned, if it happens.
2.
SCOPE OF APPLICATION This instruction shall be applied for erection works of Boiler proper identified as Boiler Unit 1 and Unit 2 of the above steam generating plant.
3.
CODE OF APPLICATION AND RELEVANCE DRAWING 3.1. 3.2. ASME SEC 1 : Rule of Construction of Power Plant. ASME B 31.1 : Power Piping.
4.
GENERAL NOTE 4.1. 4.2. 4.3. Before commencement of welding works, prepared instruction of the welding works and make know everyone concerned without exception. As per the works required inspection, carry out inspection under attendance of Superintendent / Engineer and as surreally record is result. Pay careful attention no to damage pressure parts of Boiler on Lifting Works.4.4. Rope of with safety rope around lifting area of Boiler Parts and put notice board entered “KEEP OFF EXEPT PERSONEL CONCERNED”.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 2 of 14 REVISION 0
4.4.
Prior to commencement of lifting works, assureadly carry out check of wire etc, use the lifting works and confirm that no any defective point exist.
5.
RESPONSIBILITY 5.1. 5.2. 5.3. Chief Engineer–Responsible for the overall planning, coordination and control of the erection job. Field Engineer–Responsible for field erection work implementation and maintaining acceptable quality standard. Field Superintendent and Supervisor–Responsible for the actual performance of the erection crew and actual checking of the work progress to make sure that it as per drawing specification and standard. 5.4. For these activity will support by Material Control, Quality Control, Welding Sec, and others section related with these activities.
6.
PROCEDURE 6.1. Basic Requirement 6.1.1. Schedule and Planning Master erection schedule is usually provided by the client. The detailed schedule is prepared by the contractor according to his planning which is based on the client’s master schedule. The millstone and the critical path can be identified which require proper planning. The sequence of erection activities and the resources required is included in the planning.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 3 of 14 REVISION 0
6.1.2. Erection Drawing and Erection Manual Erection drawing and manual usually provided by the clients. The Field Engineer, Superintendent shall check all drawings intended for Boiler Erection, and make sure that it is completed. All the information required is completed and all drawings shall be of current revision. 6.1.3. Packing List Packing List shall be made available by the client to the contractor. This included all the listing of materials, equipment and parts that are supplied. The Packing List should indicate the quantity of the material and equipment supplied and its specification as described in the erection drawing. This will also indicate the size and the total weight of the component and the method of storage. Also the packing number and material coding is very essential. 6.1.4. Storage Area and Warehouse Upon a thorough check on the drawing and the packing list, the quantity of materials and equipment is already known, including the method of storing, the size of the storage area and the warehouse can be identifies. 6.1.5. Resources
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 4 of 14 REVISION 0
Identification of resources is integral part of planning and scheduling is the most essential part of the basic requirement in undertaking boiler erection job in particular and in all jobs in general. Resources means, the materials, labor and equipment needed to perform boiler erection job. 6.2. Preparation Works 6.2.1. Checking of Boiler Erection Drawings This has to be done by the Chief Engineer, Field Engineer, Superintendent and Supervisor to determine the correct resources needed to perform the job. 6.2.2. Checking of Client Supplied Material and Equipment Checking and inspection of the materials and equipment including the spare parts is to be done by the material control. He will make sure that all materials, equipment and spare parts received from the supplier or the client conform with the quantity and the specifications started in the packing list or shipping. 6.2.3. Checking of Erection Materials, Equipment, Tools and Machinery In the early stage of planning, these resources had been already identified. The schedule of mobilization is as planed schedule made by the Chief Engineer and Field Engineer.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 5 of 14 REVISION 0
6.2.4. Checking of Labor Labor requirement for every stage of erection job is prepared by the Chief Engineer and his erection team, which is in accordance to their planning. 6.3. Boiler Erection It is assumed in this procedure that before starting the erection of the Boiler, the supporting structure were already erected and checked by others and clearance to proceed with the Boiler erection had been obtained. 6.3.1. Boiler Drum Raising The Boiler Drum 163 Tones with Hanger 10 Tones and also Rigging Tools 6,5 Tones is erected to its final location El.66.800 by using 2 units lifting jack type L300 with each capacity 180 Tones (safe Working Load) in the cases proposal 9 Parts 18mm Diameter Dyform Strand Cable @80m long. Prior to the lifting the Drum, the Boiler Strap Hanger are set to facilitate the setting of Drum in its final location. After marking the center line on roof girder, the strap hanger is set in position and goes along with the steam drum. The length of steam drum is 22150mm and the span between grid G3 and G5 is 21000mm. Hence the drum is required to be titled and
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 6 of 14 REVISION 0
lifted to avoid clashing with steel. On this case, the drum will be titled at an inclination 35 degrees. The jack will be mounted on jack support beams which will be mounted on roller type’s skates. The movement and restrain of beam will be by chain block. The jack will be operated from a single electric hydraulic power pack. The actual loads on jack as the drum is hoisted up at 35 degrees is considered (Lifting load of drum with internal 163 Tones + Hanger 10 Tones + Rigging Tools 6,5 Tones) at jack near grid G5 is 1343,49 KN and jack near grid G3 is 937,76 KN including safety factor 25%. 6.3.2. Boiler Drum Final Alignment After the drum is set in position, the below mentioned alignment is carried out to confirm the centering of drum along X and Y axis The levelness measuring and checking of steam drum can be carried out by selecting 2 points on each of the left and right end (totally 4 points). The elevation reference point of steam drum on the steel columns marked. (Detail Alignment sequence is attached)
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 7 of 14 REVISION 0
6.3.3. Installation of Furnace Supporting Hangers After the steam drum had completely aligned, the supporting shall be installed drawing. These shall be mounted to the furnace top supporting structure in the hanging position to make ready to support the furnace components. 6.3.4. Installation of Top Header and Riser Pipes Upper Header consists of: Back pass Roof Inlet Header Back pass Roof Outlet Header Back pass Upper Side Headers Furnace Upper Front wall Headers Furnace Upper Sidewall Headers Furnace Upper Rear Headers Re-heater Front wall Outlet Headers Re-heater Sidewall Outlet Headers Super-heater Division Inlet Headers Super-heater Division Outlet Headers Super-heater Vertical Platen Inlet Headers Super-heater Vertical Platen Outlet Header to its respective locations whereby the quantity corresponding to the number of hangers required in the erection
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 8 of 14 REVISION 0
-
Re-heater Vertical Spacer Rear inlet Header Furnace Rear Hanger Outlet Header Economizer Outlet Header
Preparation: Thoroughly clean the beveled end of each header and the tube to check if there is any foreign matter inside the material before lifting. Placed back the caps on the beveled ends to protect them from damage. Lifting: Lift-up each header and tube in the correct position and hang it from header rod. Put marking on structure to identify the center of each header in relation to boiler standard line and level and temporary fix it. These measurements are to be recorded. 6.3.5. Buckstays Preparation: Provide marking on the structure to show setting level of the buck stay section. Lifting: 1. Lift them up to position where it is to be installed and temporary hang them from beam and secure them properly.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 9 of 14 REVISION 0
2. Setting work should be performed after aligning panels. Panels located in the place where backstays are to be installed should be seal welded. 3. Fix Backstays by inserting the guide pins to tie bar lugs which are welded to the panels. 4. Rectify the distortion occurring during installation of the buck stays to panels so that the tie bar lugs will match correctly. Do not insert the pin by means of hammering. 6.3.6. Roof Tube Panels Preparation: The temporary work is to be lifted down from the top beam before lifting commence. Lifting: Lifting them up to position and hang it from the hangers rods. Upon completion of the installed panels, align them and adjust their level before fixing them together. Alignment of Beveled End & Tube Welding. Prior to aligning them with rear panels, they are to be air purged to remove all foreign materials. 6.3.7. Water Wall Panels
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 10 of 14 REVISION 0
Preparation: Thoroughly clean beveled ends & provide proper scaffolding to perform the beveled end alignment. Lifting: 1. Temporary works are to be lifted down from the top beam. 2. Panels lifted up are then suspended by chain block and aligning holding jigs. 3. Align tube end and then perform the welding. 4. Align the panels. 6.3.8. Intermediate and Lower Header Intermediate Headers consist of: Re-heater Front Wall Inlet Header Economizer Medium Headers
Lower Header Consist of: Back pass Lower Front Header Back pass Lower Rear Header Back pass Lower Side Header Economizer Inlet Header
Preparation:
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 11 of 14 REVISION 0
Thoroughly clean stub beveled ends and inspect inside the header. Lifting: Temporary works are to be arranged from the top beam. Chain Block should be used to suspend the header lifted up to position. After centering, temporary fix it. 6.3.9. Super heater & Re heater Element Tubes. Preparation: Thoroughly clean the beveled ends, inspect element tubes to ensure that they are not damage. Lifting: 1. Lift up each element tube to the given position and insert it into the front wall panel slit to temporary hang it with wire rope. 2. After completing lifted up all elements, lift them up one by one with chain block to align the support tube ends. 3. After alignment of the front wall panel and each header, header stub ends and Re heater/Super heater element, tube ends shall be matched. 4. Commence welding of the aligned tubes ends. 6.3.10. Economizer. Centering
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 12 of 14 REVISION 0
In accordance with the installation drawing, measure the center of economizer from established boiler standard lines and mark it on the steel structure. Assembly Work As the steel structure are being erected, the economizer support beams shall also be assembled, and square steel bar should be welded to the main beam according to the drawing for the purpose of preventing vibration of the economizer element. Preparation before Lifting Check and clean the beveled ends, then cover the open ends by caps or plastic shell to prevent dust from entering. Arrange lifting equipment for lifting them. Lifting Elements will be lifted up by block, after assembly of the element, fix the support bars and weld. Economizer Casing The casing will be assembly on the ground in several divided block (including insulation and inner casing). After all blocks are being lifted, they will be matched at the connecting points. Backstay
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
ISSUANCE DATE: Page 13 of 14 REVISION 0
After temporary assembly of the economizer casing, welding on the part where the backstay would be fixed shall be finished, then the backstay will be hauled in. 6.3.11. Accessories Of Pressure Parts Installation 1. Accessories directly attached to pressure parts, including seal plate, seal bars, fins tie bars, seal boxes, thermocouple etc, should be places in the respective position and then welded. 2. The installation should be completed before hydrostatic test. 6.3.12. Inner & Outer Casing Preparation: 1. Arrange the casing in the groups according to the place of installation. 2. The delivery of material to the place of installation shall be made depending on the condition of the working floor and the progress of the other works. 3. Assemble them in accordance to the drawing. Installation 1. Installation of the casing should be coordinated with the refractory and insulation works.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
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ISSUANCE DATE: Page 14 of 14 REVISION 0
2. During installation, care should be taken not to damage the refractory and the pressure parts. 3. Supporting places to support manholes, seal boxes etc. should be installed with consideration given to boiler thermal expansion. 4. Selection of welding rods and manner of preheating should be in accordance with the vendor’s WPS. 5. After welding completion, should be perform visual inspection. 6.3.13. Inspection Holes Inspection 1. Upon completion of pressure part work, check if there is any foreign material remaining inside each header. 2. Use an inspection mirror to check the above. 3. If there is any foreign material, remove it by air purge. 4. After inspection, seal weld inspection holes. 7. FLOW CHART Flow Chart for the boiler erection (Boiler Parts). 8. ATTACHMENT Assembly Process of Upper Header and panel Detail Sequence of Assembly Water Wall Panel Rigging Plan for Wall Installation ( Detail Procedure Will Purpose)
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