pressure part method statement

TOTAL 49

[ Method Of Statement for Boiler Pressure Part and Steel Structure ]

PROJECT NAME

: Khabat Thermal Power Plant Units 1&2

DOCUMENT NO.

: [KP-00+++-CY712-B7501]

TITLE

: [Method Of Statement for Boiler Pressure Part and Steel Structure]

OWNER

: Ministry of Electricity (MOE) of Kurdistan Regional Government

PAGES

Purpose ☐ For Information ☐ For Review ☐ For Approval ☒ For Construction ☐ As-Built

1

03.02.2015

For Construction

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05.01.2015

For Construction

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DATE

DESCRIPTION

PREPARED CHECKED REVIEWED APPROVED GAMA POWER SYSTEMS ENG &CONTRACTING,INC.

Owner Ministry of Electricity (MOE) of Kurdistan Regional Government

Contractor POSCO ENGINEERING & CONSTRUCTION CO., LTD.

Main Subcontractor GAMA POWER SYSTEMS ENGINEERING & CONTRACTING,INC.

KHABAT TPP UNITS 1&2

[Method Of Statement for Boiler Pressure Part and Steel Structure]

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CONTENT

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PURPOSE....................................................................................................................... 3

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SCOPE OF WORK .......................................................................................................... 3

3.0

RESPONSIBILITIES ....................................................................................................... 3

4.0

DEFINITIONS / ABBREVIATIONS................................................................................... 8

5.0

MATERIALS .................................................................................................................... 8

6.0

EQUIPMENT ................................................................................................................... 9

7.0

SUBCONTRACTORS’ SUB-TIER CONTRACTORS ....................................................... 9

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MATERIAL HANDLING & STORAGE..........................................................................10

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ERECTION PLAN .................................................................................................…..…12

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EXECUTION ..................................................................................................................13

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PIPING TRANSPORTATION, PREPERATION AND RIGGING.....................................42

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QUALITY REQUIREMENTS ..........................................................................................47

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HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS .....................................48

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RISK ASSESSMENTS ...................................................................................................48

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REFERENCES ...............................................................................................................49

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ATTACHMENTS .............................................................................................................49



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PURPOSE The main objective of this document is to ensure that all activities are carried out: • In accordance with approved procedures, specifications and drawings etc. • Using special working and control processes which have been previously qualified, • Using qualified and when certified personnel for carrying out special processes, • Using materials which are kept under control from the receiving throughout the entire Working cycle, • By performing all tests, measurements and inspections required by the contract.

2.0

SCOPE OF WORK

This method statement is a clarification of the work of Boiler Steel Structure, and Pressure Parts including of all required accessories (Hanger rods, Steam Drum, downcomer pipes, Headers, Buckstays, Furnace and HRA walls, coil tubes, Riser pipes, Link pipes, casings, etc.) from the phase of preassembly until erection completion at Khabat Power Plant, Khabat, IRAQ. All is subject to our normal terms and conditions of assembly.

3.0

RESPONSIBILITIES 3.1 PROJECT MANAGER  Project Manager has the following responsibilities ; o o o o o o o o o o o o o

Plan, organize, direct, execute and coordinate the project. Supervise, direct and control all personnel assigned to the project. Be responsible for execution of the contract to obtain anticipated job quality, effective cost control, and compliance with job schedule. Be responsible to Management and the client for the project. Define project scope and services, and issue project instruction. Review and/or prepare the contract document. Prepare change orders as required. Be responsible for issuing the project budget and the project cost reports. Be responsible, for selecting vendors and approving bid evaluation documents for purchase order. Be responsible, through Site Manager, for construction. Be responsible, through HSE Manager, for HSE. Obtain Main-subcontractor's acceptance of the plant and arrange for close out of the project. Initiate project staff meetings.



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Be responsible to the Project Manager for performance of the project to meet the criteria of effective cost control and compliance with project schedule. Follow up with responsible parties to ensure that schedules are maintained or improved. Assure the scheduling and/or cost control report by planning, analyzing, and forecasting of project performance for management. Assess the effects of all deviations for project schedule, at the earliest possible time, for evaluation and remedial action by Project Manager. Preparation of all trend, status and progress reports. Assure communications between other engineering and construction disciplines. 3.2 SITE MANAGER

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Site Manager has the following responsibilities o

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Be responsible to the Project Manager for planning, coordinating and directing the engineering and design work to meet the criteria of anticipated job quality with economic design. Supervise and coordinate the work of the various engineering disciplines. Establish engineering and also define the delivertives and non-delivertives. Work with the lead engineers to formulate, evaluate and execute practical, economical and efficient design concepts suitable for the specific requirements of the project. Resolve the conflicts among the engineering disciplines during the engineering and design work. Monitor engineering and design progress and report problems to the Project Manager for resolution. Be responsible for coordinating overall execution at site. Set up and administer general operation of field office including camp facilities. Review constructability throughly prior to site opening. Coordinate with the construction members to prevent or solve possible problems. Supervise and control field staffs in site organization. Delegate and assign to each group of site organization all necessary functions to be performed during the phase of construction. Check construction-planning documents to see whether any problem may arise in future. Plan for preventive measure or set up a contingency plan. Establish a plan of construction execution considering actual site conditions. Direct field purchasing activities including material warehousing, and expedite site delivery. Preside weekly schedule meeting, weekly safety meeting, and monthly progress review meeting to assure that all activities are performed in accordance with original planning. Prepare construction status reports for the main-subcontractor and head office. Direct all construction activities under execution and evaluate the result of field test. Approve requests for field extra work order, change order, and memorandum work. Maintain cooperative contact with client's project manager.



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Submit monthly progress report to the client and expedite the approval on it. Submit monthly invoice for erection portion to the client and expedite the payment of it. Approve various field-originated reports to be submitted to the head office. Prepare Final Construction Report. Establish in accordance with contractual requirements an Inspection & Test Plan (ITP) indicating the extent of inspection based on item criticality. 3.3 SITE ENGINEER

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The site engineer carries full responsibility for the safe completion of the all works carried out during the operation as per the Method Statement. It is the responsibility of site engineer to ensure that the supervisor adequately briefing on the contents of this method statement. Except that supporting QA/QC Manager works. Plan, organize, direct, execute and coordinate the Boiler Erection. Supervise, direct and control all personnel assigned to the Boiler Erection. Be responsible, through Supervisor/foreman, for construction. Follow up with responsible parties to ensure that schedules are maintained or improved. Assess the effects of all deviations for project schedule, at the earliest possible time, for evaluation and remedial action by Site management. Preparation of all trend, status and progress reports. Preparation and following of the all required work permits, safe rules. Preparation of all lifting plan for all critical lifting operation (such as over the 20ton lifting operation, multi-lifting equipment used operation and complicated material lifting operations) Assure communications between other engineering and construction disciplines

3.4 SUPERVISOR/FOREMAN

Supervisor-foreman take responsibility for the provision of an efficient and effective work on site operation. Prior the commencement of works, the supervisor-foreman must ensure that all site personnel are adequately briefing on contents of this Method Statement and work. Also the control of the working area is under his responsibility either the engineer is there or not. o o

All Foremans/Supervisors be responsible of all construction activities on site as per the MS-ITP-HSE requirements. Be responsible of daily ‘toolbox talk’ as per the MS, QA/QC and HSE requirements.



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3.5 PERSONNEL

All personnel the priority is to finish the job without failure and mistake. For developing the experimantation the personnel trainings and certification will done. The trainings and certificates to be given are; HSE Induction, Height Works, Safe Rigging and Slinging, Barricading, Radiography test, Crane operations, Night Work, Emergency Response, Working at Wind and Rain, Safety Belt Usage, Permit to Work, Confined Space Work, Rigger and Signalman, Manbasket Training and Pressurised Tubes Training. The welders will certificated after welder quality test.

3.6 QC MANAGER/QC ENGINEER

QA/QC Manager is responsible for all quality matters related to the installation of all works including the administration of non-conformance management in close cooperation with various related departments. QC Manager/Engineer shall be responsible; o o o o o o

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for the following of required WPS as per project specification. requisition of correct consumables for the Project Monitoring the performance of the welders, Evaluation and Recording of the repair rate of the weldersand sharing with POSCO, Penalize the welders whose repair rate is high or not allow welding work. Assist and coordinate with Project Manager and all personnel assigned to the project in establishment of Project Quality Plan. Be responsible for ensuring that project quality management procedures are implemented effectively and are suitable for their purposes and use for which they are intended. Establish project quality audit program & schedule and perform the project quality audit within project organization and GAMA will submit Quality audit program to POSCO. Monitoring & Evaluation of quality management system activities based on the project quality plan. Coordination with Mainsubcontractors for project quality management system concerns. Be responsible to the Project Manager for controlling and handling all of project documents and keeping all studies, specifications, drawings, sketches, requisitions, calculation and data sheets, vendor prints etc. Documents of welding materials control. Plan and implement the quality training programs at site.



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Provide technical assistance to site management as necessary to initiate quality enhancement and resolve quality problems throughout the organization. Recording and control welding schedule and sharing with POSCO. Monitoring of, provide technical assistance and resolve all quality-related problems with the activities. Prove in accordance with the applicable quality and inspection requirements imposed by the contract the qualification and experience of all inspection personnel and monitor and audit on frequent basis to ensure technical compliance. Approve and issue all project documents. Ensure that adequate inspection personnel and test tool & equipment resources are available at all times, including peak load periods to meet the construction schedule. Raise non-conformance items, investigate their causes and make recommendations for corrective actions to prevent recurrence. Ensure all technical documentation is accurate and updated to current status. Conduct the education for quality consciousness to All responsible person (Engineer, Foreman, Supervisor, Labors) prior to the commencement of work. Give his staffs the instruction about duties and responsibilities on site. Supervise his staffs’ activities, functions and operations so that they are taken in accordance with the specified requirements and the approved procedures.

3.7 HSE MANAGER

Provide technical support in developing and implementing environmental programs on site. Assist in getting and maintaining required permits for work. To supply all personnel with standard PPE which consists of, Hard Hat, Safety Boots, Gloves and Safety Goggles. He must inform all Personnel of any specific requirements o

It shall be the joint responsibility of the Project Manager to initiate a health, environment and safety control-training program of Construction Safety Plan.

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All personnel who will be employed on the construction site shall attend this course as a matter of priority. Personnel who require additional training to meet specific Contract requirements shall be subject to the training stipulations of Construction Safety Plan. It shall be the responsibility of the Project Manager to appoint a Safety Manager. The HSE Manager shall prepare a safety control instruction to cover the construction site activities. It shall be responsibility to ensure that all site personnel and visitors adhere fully to these instructions by means of continual monitoring and regular auditing. To ensure all lifting equipment and accessories have valid certification To ensure all activities are being executed as per GAMA HSE plan and related procedures.

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DEFINITIONS / ABBREVIATIONS

The definitions used in this document are as follows :

Owner : Ministry of Electricity of Kurdistan Regional Government Contract : The main contract between the Owner and the Contractor Contractor: Posco E&C Main Subcontractor: GAMA Power Systems Inc. Subcontractor: MİTEK A.Ş. Project: Khabat thermal power plant unit 1&2 Work: All the system, equipment, material, provided by the contractor in connection with the design, engineering, construction and/or installation of the Project.

5.0

MATERIALS

Two type material to be use for installation. 1- Project based materials which are supplied by Main contractor (steel structure, steam drum, coils, walls, pipes, etc) 2- Consumable materials which are supplied by Mitek (as electrodes, argon/propan, grinding tools, scaffolding material, PPE’s and etc.). All electrodes, welding wires and flux will be as required by the WPS. All welding consumables will be stored in a dry location and will be kept in their original and undamaged packaging until used. Electrodes will be carried within heated oven to work area from warehouse. Electrodes will be dried in oven before send to work area. If there will be unused dried electrodes, they will carried back to warehouse. The required material during construction will be provided by Mitek A.Ş.



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immediately that construction will not delay. Welding consumables shall be followed in accordance with storage and handing of welding consumables procedure (KP-00++-CY712-B7503)

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EQUIPMENT

Site Lifting Equipment are;  400T Crawler crane,  220t mobile crane,  75T hi-up,  30T hi-up,  40T hi-up,  10T hi-up,  20t Trailer,  12T forklift,  20T capacity two vincy,  140T capacity 2each hydraulic jack,  40T capacity 24each hydraulic jack,  10T capacity 19each hydraulic jack will be used at site.  During construction if under need new equipment will be brought to site.  Manual lifting equipment chain blocks, trifores, hydraulic jacks etc.),  temporary hanging equipments (wires, clips etc.),

Other equipments  welding machine  Air compressor  PWHT machines  Power generator  Hydrotest pumps  Ventilation fans

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SUBCONTRACTORS’ SUB-TIER CONTRACTORS


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As far on Mitek A.Ş. will not have a subcontractor.

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MATERIAL HANDLING, STORAGE & PRESERVATION

Large materials will be stored in their closed wooden/steel boxes in lay-down area and stored. All material will given to site after signature the material request form and those forms were under control system taken until finishing the work. For availability and conservation; such as fittings, valves, bolts, nuts, washers,

gaskets, orifice, pumps, motors, sensetive

equipments and rest of small materials will be catagorized and kept in MİTEK project warehouse. In accordance of technical specifications preservations of the all material will be kept untill project finish date. MİTEK will manage the material receiving procedure. In case of any damage or dismatch between materials and material list then MİTEK will sent RFI and action of GAMA will be requested. Large bore (2''
be

delivered in wooden/steel cases. Large bore spools will be stocked at outdoor lay-down area with pipe's both ends are closed with plastic covers in order to keep foreign materials outside and preserve the prefabricated bevels. Spools will be kept in their steel cages untill erection, if spools are not in their steel cages, they will be kept on wooden timbers. All material outdoor lay down shall be set up signpost for identification. Small bore pipes will be categorized as material, diameter, thickness (Schedule). Pipes will be kept in their bundles on wooden timbers and pipes both ends will be closed with plastic covers. In order to prevent any mistake; pipe's material, diameter, schedule and heat number will be written onto pipe. During prefabrication and erection works, heat number of pipes will be transfered to every piece of pipe that has been cut from the bundle. Piping materials shall be identified by Vendor according to color coding system as described table above. Color code applications shall be done at factory, which will be supplied from Vendor.


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The color coding system ;

Table.1

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ERECTION PLAN 9.1 STEEL STRUCTURE Steel structure erection order will be followed according erection manual. Main steel

members bolting without any empty holes at boiler tier 1, second tier could be start without awaiting the completion of verticality and torqueing of boiler tier 1. During the erection of boiler tier 2 members, Tier 1 verticality and torqueing continue, and tier 1 verticality and torqueing must finalize before tier 2 erection completion time. Also grouting will be executed after completion of boiler tier 1 verticality and torqueing. In addition this method is applicable for the following tiers, like tier 3 erection start before the completion of tier 2 verticality and torqueing and tier 2 verticality and torqueing must finalize before tier 3 erection completion time and before erection of heavy girder. After the completion of Tier 3 main structure final bolt tightening; pressure part erection will begin which sequence is written down as;

9.2 PRESSURE PART LIFTING SEQUENCE LIST 1- Hanger Rod & Hanger Beam lifting and installation 2- Steam Drum lifting and installation 3- HRA Roof preassembly & Top header with tubes lifting and installation 4- Upper Stringer installation 5- Downcomer installation 6- Remain Header lifting 7- Buckstay lifting 8- Furnace upper section walls (right, left, front, rear) panel insallation 9- RH, FSH, STRINGER, PSH Coil lifting & installation 10- Economizer outlet header and ECO Coil lifting & installation 11- Furnace lower section walls panel installation 12- Boiler Internal Interconnection Piping Lifting and installation (Roof riser pipes, Transfer pipe, Feeder pipes, related supports) 13- Skin casing and Boiler attachments prior to hydrotest 14- Hydrotest and Reinstatement 15- Completion of Remaining Boiler accessories


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EXECUTION 10.1 STEEL STRUCTURE

For any type of work, erection, preassembly etc. all steps will be controlled by QA/QC department and also construction team. All assemblies and erections will be taken to checklist forms and archieved until finishing the job.

10.1.1 PREASSEMBLY & ERECTION 10.1.2 FOUNDATION ACCEPTANCE CRITERIA AND PREPARATION

Anchors will hand overed by civil directly to Mitek A.Ş. when the inspection will be finished

10.1.3 FOUNDATION PREPARATION

The top of the foundation base shall be cleaned and free of laitance, loose particles, oil or grease. Laitance shall be removed by chipping. Anchor bolts shall be cleaned and padding shall be performed by using shim plates. The shim and grout plan shall be discussed with the Equipment erection supervisor prior to commencement of work. Adequate quantity of shim packs shall be provided. The shim packs shall be placed so that the load will be evenly distributed. It should be confirmed with the Equipment erection supervisor that the resultant load imposed at each location will not damage the foundation. The shim packs shall be leveled with the top of the shim being at the "Bottom of Base Plate Elevation". The column base plates are to be set on top of shim packs. After shimming works, all elevation dimensions are checked. non-tapered steel shims are required if sufficient contact area does not exist. Mild steel shims are acceptable regardless of the steel grade of the column or bearing material. If required, these shims must be contained, usually with a tack weld, so that they cannot be worked out of the joint. Full-contact bearing is always achieved when lighter sections are centered over heavier sections of the same nominal depth. After the alignment and bolting of the steel structure, but before grouting, all anchor bolts and nuts shall be tightened while the shims are checked with regard to their tight fit. After the



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hardening of the grouting compound, the anchorage shall again be checked and if required the nuts shall be tightened once again. All base plates shall be grouted and cured with the "nonshrink" grout as per the grout manufacturer's instructions.

10.1.4 ERECTION PREPARATION All structural steel shall be erected in accordance with the issued "For Construction" drawings. Before assembly of any structural steel element; position and level of anchor bolts will be checked. Where possible, preassembly of the steel structure elements will be done close to the foundations to minimize handling needs. The cranes which are used during pre-assembly may also be used to lift and erect the pre-assembled parts providing that the position of the crane(s) is/are correct and the lifting capacity/capacities is/are suitable for the purpose. Erection of the preassembly parts will be done with cranes. Adequate safe lifting capacity of the cranes is to be confirmed from the load charts of the cranes. The load charts will be issued for approval, before the start of the respective work. According to the order of assembly, all erection equipments and steel material to be ready in appropriate place on the site. Erection engineer will have all material control lists. Before start to erection, erection chief should verify the accuracy and ensure the conditions of the following topics for erection.

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Erection chief is be sure that chosen cranes or lifting equipments for erection are correct and safe.

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Crane lifting capacity charts shall be referred to and used during lifting studies.

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Crane, boom-truck and lifting equipments command and signalled by educated and certified riggers.

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All pre-assembly and erection areas including the full space for crane operation shall be clearly marked and barricaded to prevent to others (other than the erection team and authorized personel) from entering and/or walking through the work area.

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Safety equipments to be appropriate and ready to use.

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Tool-box trainings should be given before erection started and periodically after on.

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Erection can not be started if responsible foreman and/or erection engineer not available on site.

Erection area to be cleaned from scrap, waste and unused materials. Erection can not be continu without having required permissions and apply safety regulations. Install platforms and


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scaffolding for erection if necessary, and technical safety give approve for usage. Scaffolds and platforms shall be erected by competent persons. The methods of lifting and fixing shall be determined so that the members are not damaged during the handling process. During erection, all work shall be securely bolted, however no permanent bolting and welding shall be done unless the correct positioning and alignment of the member has been obtained. All completed work shall be within the required dimensional tolerances and all materials shall be free of twists or distortions that are likely to affect the structural integrity. It shall be checked to ensure that the correct bolt type as indicated by the manufacturer’s stamp is used and the bolt length is correct. Columns shall be positioned on the concrete foundations, with the nuts on the fixing bolts left loose. These nuts shall be tightened using air operated or manual torque wrenches and special care shall be taken to provide surfaces that are free from loose mill scale, dirt, oil, burrs or any other defect which would prevent tight sealing. After erection two columns, beams and vertical bracings between the columns, the connection bolts are installed but not tightened. Then all necessary dimensions like column verticality, space between connection plates etc. are adjusted in to correct dimensions. Finally, all bolts are tightened with calibrated torque wrench according bolt type. Tolerances for out of plumb and levels shall be as specified in the specifications and drawings. After the alignment and bolting of the steel structure, but before grouting, all anchor bolts and nuts shall be tightened while the shims are checked with regard to their tight fit. After the hardening of the grouting compound, the anchorage shall again be checked and, if required, the nuts shall be tightened once again. No flame or electrode cutting (carbone electrode method) shall be allowed for field made holes. Where field made holes are required for high strength bolts, they shall be drilled or sub-drilled and reamed to the specified size. Column panels will be mounted by crain in accordance to the project to anchor bolts. Manlift will help to erection team if necessary. If using manlift is impossible, safety belt will be used by using two extension rope with shock absorber. After obtaining the project conformity by take necessary measures, to ensure the safety by tightening anchor bolts.

10.1.5

PRE-ERECTION

Before pre-assembly/erection, bearing surfaces and other surfaces that will be in permanent contact with members shall be properly cleaned and dust free. All steel members shall be cleaned prior to start of erection. Any kind of pre-assembly will be done at site/yard must be on leveled ground surface.


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Pre-assembly size will be determined based on the limitations of the transportation means and width of the access roads as well as lifting capacity of the available cranes. All the preassembled structure will be securely tightened as per this Method Statement in such a way that no damage or unacceptable deflection on the structure are to be observed.

10.1.6

ERECTION

Wind velocities values shall be taken daily. When wind velocities ar above 25 knots (if it is less, limits determined by the manufactured shall be fallowed) all lifting operations to height will cease unless the rated load and boom lengths can be reduced according to manufacturer’s specifications. Measurements for the wind speed shall be done directly from the cranes aerometer and shall be crosscheckted by the handheld units. All lifts above ground level must account for wind force, i.e.side loads, down drafts etc. as applied to the load and the boom. Wind scale table is given in attached. According to attached lifting study and crane lifting capacity table, column, beam, bracing etc. components can be erected one by one or pre-erected on leveled ground partly and erect as panel. Adequate safe lifting capacity of the cranes is to be confirmed from the load charts of the cranes. For cranes not herein attached, load charts will be submitted for approval, before the start of the respective work. Before erection starts, the erection area shall be back-filled, leveled and compacted as necessary to perform easy, sound and safe operation including crane, truck, trailer etc. movements. Column panels will be erected by using crane(s) in accordance with IFC drawings. Manlift will help to erection team if necessary. After obtaining the project conformity by take necessary measures, to ensure the safety by tightening anchor bolts. If beams, vertical bracing etc can not be installed to ensure the safety by using chain block or using steel wire block. In necessary situation to ensure the column itself safety by using on two points with steel wire. When erection is done, all necessary survey controls to be done for control the erection as shown in drawings and tolerances. All parts connecting bolts to be checked as shown in the drawings and against the suitable torque value. Loosen bolts need to be tightened again.

10.1.7 STEEL STRUCTURE WELDING All steel structure welding shall comply with AWS D1.1. Coated surfaces to which welded attachments are to be made shall be cleaned to bare metal and all contaminants removed. The end of one hollow section shall be accurately shaped to fit the other. This shall be done by using


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properly prepared templates or equal approved methods. The correct fusion bevel shall then be cut. All weld spatter shall be removed and where steelwork is to be blast-cleaned all traces of spatter shall be removed before commencement of blasting. Welding procedure specifications and their records will be per AWS D1.1. Welder certification will be per AWS D1.1.

10.1.8

TOUCH-UP PAINTING AT SITE

After steelwork has been erected and the final procedures for connection completed, the exposed surfaces of any nuts, bolts, washers and untreated areas together with the surfaces of steelwork where the coating is damaged shall be prepared, primed and painted with a system equivalent to that applied at Works.

10.1.9

TORQUING METHOD 10.1.9.1 NON-PRELOADED BOLTS

The design of bolted connections loaded in shear should bearing type. No preloading and special provisions for contact surfaces are required. If shear plane passes through the threaded portion of the bolt, it should be taken into account for the bolt shear resistance calculation. The design of bolted connections loaded in tension should be connections with non-preloaded bolts. No preloading is required.

10.1.9.2 PRELOADED BOLTS

If oversized or slotted holes are used, it should be taken into account for the bolt slip resistance calculation. The class of friction surface of plates connected by preloaded bolts should be taken into account in the slip factor for the bolt slip resistance calculation. In oversized holes used to increase tolerances in erection, or where a joint loaded in shear is subject to impact, significant vibration or load reversal, slip-resistant bolted connections should be used. In beam-to-column bolted joints of the main frames, slip-resistant connections shall be used. Values of preloading force for tightening high strength preloaded bolts should be the following;


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Table2. Bolt tightening will be proceed as follows;  First, all loose bolts will be tightened by manual wrench.  Then, the bolts which are already manually tightened are tightened to 50-70% of the torque value by using manual torque wrench. After torquing, the bolts are marked with “I” with using permanent metal marker.  After that, the bolts which are already torqued to 50-70% of the torque value, are tightened to 100%. Then “I” marking is converted to “+” with using permanent metal marker.  Finally all torqued bolts are checked whether or not to reach requested torque values. Suitable tools (e.g. air or hydraulic operated torque wrench for great load ranges and manual torque wrenches for small load ranges) shall be used for tightening the nuts. Bolts shall be tightened always by turning nuts. Only where avoidable, the bolt head may be turned with the approval of GAMA. Bolts shall be tightened progressing systematically from the center to the free edges of joint. Tightening of bolts shall be controlled all the time. The work shall be done by competent and experienced bolting crews. Bolted connections shall be drifted to proper position and the holes inspected to ensure that bolt threads will not be damaged by forcing the bolts in place. Connections shall be tightly drawn together using not less than 25 percent of the total number of bolts in the completed joints, but never less than two bolts. Bolts for initial tightening shall be distributed uniformly about the joint. Visual inspection of bolt tightness shall be performed by checking whether the notched tail or bolt shears off or not. Bolt heads and nuts shall rest squarely on their mating surfaces. Where the surface of the bolt head or nut and the surface of the steel members form an inclination greater than the acceptance limits, larger, tapered or smooth beveled washers shall be used to make the contact tight and compensate for the lack of parallelism according to the standards. Any bolt assemblies which size when being tightened shall be replaced. All bolt heads shall


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be faced upward if applicable. Unless others specified, two carburized washers per bolt shall be used at all times. One washer under the bolt head and one under the nut shall be used. Drifts shall be used to correct hole alignments, if possible. Drifts of a larger diameter than the hole being drifted shall not be used. Offset holes may be corrected by reaming according to the standards. Missing holes shall be drilled but flame-cutting of the holes is not permitted. Erection bolts shall be replaced by the specified bolts as soon as possible. High strength bolts shall not be used as erection bolts. Tension control bolts use design features that indirectly indicate tension. The most common alternative design bolt is the twist-off bolt or tension control (TC) bolt. An assembly tool holds this bolt from the nut end while an inner spindle on the tool grips a spline section connected to the end of the bolt. An outer spindle on the tool turns the nut and tightens the fastener. When the designated torque has been reached, the spline snaps off. This type of torque control system allows for quick inspection, if the spline is gone then, in theory, the bolt has been properly tightened. Although each tension control bolt assembly (bolt, nut and washer) lot is tested by the manufacture to ensure it meets the minimum required clamp load, this system is based on torque control to snap the spline. Because of this torque based system, bolt assemblies must be used in their as-received (clean and lubricated by the manufacture), and strict adherence to the requirements of the appropriate standard, particularly those for storage, cleanliness, and verification is necessary. The A325 equivalent TC bolts are manufactured to the ASTM F1852 standard (Standard Specification for "Twist Off" Type Tension Control Structural Bolt/Nut/Washer Assemblies, Steel, Heat Treated, 120/105 Ksi Minimum Tensile Strength). The A490 equivalent TC bolts are to the ASTM F2280 standard (Standard Specification for "Twist Off" Type Tension Control Structural Bolt/Nut/Washer Assemblies, Steel, Heat Treated, 150 Ksi Minimum Tensile Strength). Each bolt is preassembled with an ASTM F436 flat washer and the appropriate heavy hex nut and sold as an assembly. The F1852 bolts are available plain finished or mechanically galvanized. The F2280 bolts are only available in plain finish. Almost the whole of TS bolts which BHI supplied are “S10T”, some assembled parts of top structural steel are required to use “F10T” (exp.for Tier.4: 160EA). S10T is torque shear type which does not need torque value(fin- tale will be dropped by itself when they reach to required shaft force) Alternative Design Bolts (Tension Control Bolts/ Bolt rivet)

DWG.1


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PRESSURE PART ERECTION

Prior to start erection activities:  Cheking of the material identification  Visual inspection for any damage, deformation etc.  Availablity of lifting and handling facilities suitable.  Checking of internal cleanness of panel and headers.

During the erection activities ensure as follows  Compliance of welding clearences.  Alignment, orientation, direction, elevation match with the drawing requirements.  Welding activities will be appreprate to standards.  Checking of center marking. If not found, center marking should marked on the ground.  Checking for damage on nipples, nozzles, support and panel.  It is not allowed to welds/arc strikes/grinding on the pressure part material (drum, panel, header, tubes, hanger rod, pipes)

Although all the application will do under boiler erection manual KP-90H++-VM600V0110.

10.2.1

HANGER ROD

The hanger rods will be preassembled at the ground level to PPSL framing structure before erection and will be erected to the correct position with steel structure. If required tailing will be made for protection of the hanger rods for any type of damage during lifting.


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DWG.2 10.2.2

STEAM DRUM

The proper erection will made with two HTE H-140 1400kn capacity hydraulic jacks. Steam Drum will lift until reaches 40m level. After that it will slide to project location (DWG.4). Hydraulic jacks/Chain blocks to be use for sliding horizontally to south side. Sliding operation occurs between steel structure and Jack base plate with teflon. (DWG.5) Teflon to be use for preventing any damage on steel structure. After sliding, drum lifting will continue until exact level. Basicly lifting sequence given below; (1) Hydraulic Jacks (strand) will be prepared before operation. (2) Steam Drum will take inside of boiler from west side. Undo the truck height and other conditions some steels may taken out from steel structure (such as vertical brace, beam, etc). (3) Strand jack hook to be tie to drum lifting lug directly. And than lifting will start. (4) Steam Drum will lift until reaches 40m level. After that it will slide to project location. (5) Drum U-bend support structure erection to be completed. (6) U-bend and Pin erection to be complete, steam drum put down precisely. (7) Drum Levelling to be adjust by Liner plate. (8) Finally, remove all temporary lifting system and attacments (jack, strand, plate, scaffolding, etc)


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DWG.4

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HRA ROOF PREASSEMBLY & TOP HEADER WITH TUBE INSTALLATION

HRA Roof wall will be lifted after ground assembly erection completion as one piece which are including of roof panel, roof inlet header, str.outlet header, furn.rear.outlet header, psh.outlet header and loose tubes (DWG.8). Headers will be transported from the lay-down area to site in their original transportation boxes. Headers will be placed right beneath the plan position onto HRA Roof panel and proper assembly will be made. Erection will be done with hydraulic jacks (DWG9). After erection the fixing will be done directly to hanger rods (DWG.7) or temporary hanging with wires will done. Detailed lifting method will be given at least two days before erection. The hanging method during lifting will be done as explained at 10.3 PREPERATION AND RIGGING section.

DWG.7


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DWG.10

10.2.4

UPPER STRINGER INSTALLATION

Upper stringer loose tubes to be installed after Roof Panel lifting. Stringers installation will be made there with hand lifting equipments as chain block, trifore etc.

10.2.5

DOWNCOMER PIPES

The downcomers spools will be ground assembled or erected one by one according the erection status. The erected spools will be temporarely fixed and welded on field on scaffold. The welding surface will be cleaned proper fit-up will be made and QA/QC will be allow the fit-up and then preheating operation will be done and weld will begin under WPS, PQR.


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DWG.11

10.2.6 REMAINING HEADERS LIFTING

Headers (DRW.12) will be lifted directly upwards and when header reaches to position, one team will install temporarely fixing will be done with the proper material. Hydraulic Jacks/Crane will be used for lifting operation. After completion of lifting, crane/jack will release the load onto fixing support. Slings will be removed from the header and lifting operation will be completed. During to lifting operation and stand by period

header tubes/nozzles will be protected to

preventing any damage. After installation alignment will be done as per seen at (DRW.13). Before hydrotest all supports shall be completed according to drawings.


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BUCKSTAY LIFTING

Buckstays will be lifted on panels by ground assembly which are possible. Buckstays that ground assembly is not possible will be erected directly upward and when buckstay reaches to position, one team will install temporarely fixing will be done with the proper material. Hydraulic Jacks/Crane will be used for lifting operation. After completion of lifting, crane/jack will release the load onto fixing support. Slings will be removed from the header and lifting operation will be completed. During to lifting operation and stand by period buckstay will be protected to preventing any damage.

Photo.1

DWG.14


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FURNACE UPPER SECTION WALLS (RIGHT, LEFT, FRONT, REAR) PANEL INSTALLATION

The preassembly and lifting operation of the wall panels could not done as one set depending of the allowance the steel structure boiler zone. Because of the high lenghts preassembly will not done at wall panels. As seen at following drawings the coloured parts (DWG.16, DWG.17, DWG.18) will be erected directly and assembled according Quality requirement. During to assembly dimensional check to be verified as per ITP requirement. When assembling of furnace panel, in order to avoid mismatching of buckstay hole with welding shrinkage, allowable tolerance will be considered not only as full length of panel but also each panel of panel. Transportation details are explained at 11.0 TRANSPORTATION, PREPERATION AND RIGGING section.

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RH, FSH, STRINGER, PSH COIL LIFTING & INSTALLATION

Coils are to be ground assembled as reheater 1st bank to reheater 2nd bank joint number FW-RH-02, final superheater 1st bank to final superheater 2nd bank joint number FW-FSH-02, primary superheater 1st bank to primary superheater 2nd bank and to primary superheater 3rd bank joint numbers are FW-PSH-03 and FW-PSH-04. Stringer will be in single pieces. The erection will be done as same as the lifting method explained at section 11.1. Crane, vincy or hydraulic jacks will be used during lifting. After lifting temporary wires or hanging mechanism will be prepared for hanging the coils before welding. After the welding activities all quality requirements will be done.

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Photo 2. Such a lifting device (photo.2) will be designed and produced at site for lifting the preassembled coils. During lifting operation and stand by period coils will be protected to preventing any damage. The coils will be fixed to device with bolt and nuts and tailed from horizantal position to vertical position as defined at lifting part. The certification of the lifting device will be made by a third party.

10.2.9.1 ECONOMIZER OUTLET HEADER, ECO COILS LIFTING & INSTALLATION Economizer outlet header will be erected After erection of PSH Coils. and than economizer coils will lift and erected. After finish the weld the economizer inlet header will be lifted and welded.

10.2.10

FURNACE LOWER SECTIONS WALLS PANEL INSTALLATIONS

The preassembly and lifting operation of the lower section wall panels could be done as one set depending of the allowance the steel structure boiler zone (DWG.20). Because of the high lengths (apr.17m) preassembly will not done too much. During to preassembly dimensional check to be verified as per ITP requirement. measuring dimensions and crossdimension check, usage of propan before welding, making all NDT tests before erection, use of

proper

preassembly

desck

etc.

Transportation

details

are

explained

at

11.0


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TRANSPORTATION, PREPERATION AND RIGGING section.

DWG.20 10.2.12 BOILER INTERNAL & INTERCONNECTION PIPING LIFTING AND INSTALLATION Piping will be discussed under 3 group which are riser pipes, link (transfer) pipes and feeder pipes. General sequence for piping is as follows: 

Cutting: just used approprate methods



Beveling: just used approprate methods



Cleaning: cleaning inside of the pipe with air if required



Fit-Up: will begin after fixing all the headers.



Fit-Up Checks:



QC welding release



preheating before weld (If required)



welding



PWHT (If required)



NDT:

This applications will be done for all the piping groups.


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10.2.12.1 RISER PIPES Riser pipes will erected after erection of the HRA roof panel and riser pipes will be erected together with link pipes in taking care of sequence. After that first hanging with temporary wires/chain blocks. Then adjust the position for proper fit-up. Within QA/QC department control and procedures the weld and NDT tests will be done.

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10.2.12.2 LINK (TRANSFER) PIPES

Link pipe will be erected together with riser pipes in taking care of sequence at roof location. After that first hanging with temporary wires/chain blocks. Then adjust the position for proper fit-up. Within QA/QC department control and procedures the weld and NDT tests will be done.

DWG.24


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10.2.12.3 FEEDER PIPE

When the pipes reaches to side the spools will be begin to ground assembly across the site conditions and hanging will be begin as same riser pipes and link ducts first temporary and then the weld will be done with QA/QC department control and procedures and NDT test will be done. After this hanger will be put on and connection to the pipe will be made.

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SUPPORT

According to sequence of piping, the related supports will be positioned on proper locations during fit-up or after completion of welding. The positioning, adjustment as per drawings shall be complete.

10.2.13

SKIN CASING AND BOILER ATTACHMENTS PRIOR TO HYDROTEST

The casing attachments on pressure part tubes will be welded before the hydrotest. However, corner part of skin casing should be erected before installation of link plate for buckstay because of limited area for casing installation (DWG.27,DWG.28). All weldings will be controlled by QA/QC team and required NDT test will be made before hydrotest.

DWG.27


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DWG.28

10.2.14

HYDROTEST AND REINSTATEMENT

Hydrotest method statement and test package will be prepared seperately.

10.2.15

COMPLETION OF REMAINING BOILER ACCESSORIES

Remaining parts of boiler accessories will be installed after hydrotest such as enclosure, expansion joints, burner, camera etc.


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TRANSPORTATION, PREPERATION AND RIGGING 11.1 WALL PANEL PREPARATION 1- To support the wall panel during lifting, if need 200 NPI steels will be welded temporarily to buckstays with 90° to be removed after erection. No unconfirmed action will be taken on a project material which is not allowed in erection manuel or contractor will not allow. Please see the detail drawing below.

DWG.29 2- To take the complete weight of the wall, special lifting eye pads will be pre-fabricated at site.


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DWG.31 3- In order to place eye pads, membrane plates will be cut to be welded after completion of erection, lifting points as sample shown on the drawing below.

DWG.31

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Photo 2.

11.2 TRANSPORTATION

During loading and unloading, certified lifting equipments/device (crane, trailer, shackles, slings, ropes etc.) will be used by trained riggers. Rigging method will be chosen according to material's mass and volume. The maximum deflection tolerated on a panel during handling will be less then 1/20 (one-twentieth) of its length which given in erection manual. During transportation wooden shimming will be done for protection of the panel. If several panels will be transferred at one time symmetric wooden shimming will be done between the panels. Appropriate lifting equipments will be used with all precautions taken as described in risk assessment. Pipe spools and other materials will be transported from lay-down area to erection site in accordance with time schedule (prior to erection work)

in order to prevent crowd of

material in work site. Vehicles and cranes; such as trucks, trailers, pick-ups and mobile/crawler cranes, hi-ups will be inspected periodically and used by certified operators.


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LIFTING

After arrival of the pressure part material under the boiler, they will be placed under Furnace Hall. Crane, hydraulic jacks or any other lifting equipment will be used for lifting activities. If need Lifting beam will be obtained. Certified lifting equipments/device (crane, trailer, shackles, slings, ropes etc.) will be used by trained riggers. In the lifting operations the erector will indicate the safety measures to be taken. The detailed lifting plan for the each lifted material which is over 20ton or material that will be lifted with more then one lifting equipment will be submit to GAMA for approval 1 week before the lifting of the material. Water wall lifting example: 123456-

Transportation of the wall panel to the boiler, The wall will be placed under Furnace Hall. Necessary lifting lugs and equipments will be connect to the wall panel. Crane, hydraulic jacks or any other lifting equipment will be used for lifting activity. Until the material goes to vertical position, second crane will take the load by tailing. After the vertical position lifting will continue until exact elevation. Please see the drawing below.

DWG.33 This rigging type will be used for lifting.


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DWG.34

11.3 WELDING Welding procedure specifications which are in attachement and their records will be ASME Section IX. Welder certification will be per ASME Section I. The boiler will have A Stamp which the responsibility area is boiler proper-The ASME Boiler and Pressure Vessel Code (ASME BPVC) and Boiler external piping and joints ASME Section Committe B31.1. All pressure part weldings will be performed according to the details on drawings and ASME Section IX, ASME 31.1. The design resistance of fillet welds in calculations of welded connections should be taken considering the real throat thickness to be used in the welding. Length of fillet welds shall not be less than four times the nominal size of the weld or 40 mm whichever is more. As a minimum, the size of a weld to be used on stressed connections is 6 mm fillet.


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DWG.35

12.0

QUALITY REQUIREMENTS

QA/QC Manager is responsible for all quality matters related to the installation of pipe works including the administration of non-conformance management in close co-operation with various related departments. QA/QC Engineer shall be responsible for the development of PQR/WPS, Qualification and approval of PQR/WPS, requisition of correct consumables for the Project Monitoring the performance of the welders, Evaluation and Recording of the repair rate of the welders, Penalize and no welding the welders whose repair rate is high. QC Inspector shall be responsible to verify the correct implementation of the project



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specifications in the execution of fabrication, erection and welding of pipe, Witnessing of Inspections and tests, and preparation of records according to ITP, shall also be the responsibility of QC Inspector. QC Inspector shall check the correct implementation of consumable control procedure.Inspection and Test Plans shall be prepared based on Subcontractor’s Inspection Plan Guide for Site (Doc. No: KP-00+++-MQ732-G0015) by Subcontractors.Equipment shall be assigned and labeled with a unique identification number on the equipment or on the container, when equipment is too small and listed on Calibration Follow-up List (Doc. No:PR-013-F01) by the QC Supervisor and Commissioning Supervisor. The QC Supervisor and Commissioning Supervisor shall determine calibration period for equipments and recall them periodically for calibration. Pressure test package prepared according to Test Pack Preparation Procedure (Doc. No: KP-00+++-MQ732-G0012) Post Weld Heat Treatment prepared according to Post Weld Heat Treatment Procedure (Doc.No:KP-00+++-MQ732-G0017) Pressure Test prepared according to Pressure Test Procedure (Doc. No: KP-00+++-MQ732-G0023)

13.0

HEALTH, SAFETY and ENVIRONMENTAL REQUIREMENTS

The proper scaffolding, lift and lifting equipments will be used which all will be certicated. At proper areas safety net will be used. All workers will have proper PPE’s. The detailed HSE plan is attached. MİTEK A.Ş. will obey GAMA’s HSE plan with international standards and local laws.

14.0

RISK ASSESSMENTS The Risk Assessment is attached.

15.0

REFERENCES

Followed parts and clauses of the contract documents are referred: 

DRAWINGS



STANDARD SPECIFICATIONS FOR CONSTRUCTION



ACTUAL JOB SPECIFIC MANUFACTURER MODULE LIFTING DRAWINGS FOR ALL DETAILS OF THE LIFTING DEVICES.



ERECTION MANUAL FOR BOILER



TECHNICAL SPECIFICATIONS



LIFTING PROCEDURES BY MANUFACTURER


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 

SITE JOB/WORK SPECIFIC SAFETY AND HEALTH PLAN SITE JOB/WORK SPECIFIC LIFTING PLAN



ASME Sec. I



ASME 31.1



ASME IX



ISO-E-GSS-B-16



AWS-ASTM-E-7018



AWS-ASTM-E-9018 DI

16.0

[KP-00+++-CY712-B7501]

ATTACHMENTS Attachment-1 Attachment-2 Attachment-3 Attachment-4

HSE Plan Job Safety Analyses and Risk Assessment (for Steel Structure) Job Safety Analyses and Risk Assessment (for Pressure Part) WPS List

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pressure part method statement

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