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Pt. Truba Jurong Engineering Labuan 2 Banten 2 X 300 MW CFSPP Project Assembly & Erection Boiler Pressure Parts Procedure

This document provides procedures for the assembly and erection of boiler pressure parts for a 2 x 300 MW coal fired steam power plant project in Labuan Banten, Indonesia. It outlines the scope, applicable codes and standards, responsibilities, preparation works such as checking drawings and materials, and step-by-step erection procedures including lifting the boiler drum, final alignment, installing hangers and headers. Safety is emphasized throughout with requirements for inspection, rigging, and notices.

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0% found this document useful (0 votes)
83 views16 pages

Pt. Truba Jurong Engineering Labuan 2 Banten 2 X 300 MW CFSPP Project Assembly & Erection Boiler Pressure Parts Procedure

This document provides procedures for the assembly and erection of boiler pressure parts for a 2 x 300 MW coal fired steam power plant project in Labuan Banten, Indonesia. It outlines the scope, applicable codes and standards, responsibilities, preparation works such as checking drawings and materials, and step-by-step erection procedures including lifting the boiler drum, final alignment, installing hangers and headers. Safety is emphasized throughout with requirements for inspection, rigging, and notices.

Uploaded by

Imam
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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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

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1.

PREFACE T&is instruction is to descri'e erection (et&od o! Boi)er proper carried out on erection *or+s o! ,a'uan -./%% M0 Coa) 1ired Stea( Po*er P)ant Pro2ect. In t&is connection3 any (odi!ication to instruction s&a)) 'e carried out a!ter revie*ing it *it& personne) concerned3 i! it &appens.

2.

SCOPE OF APPLICATION T&is instruction s&a)) 'e app)ied !or erection *or+s o! Boi)er proper identi!ied as Boi)er Unit p)ant. and Unit - o! t&e a'ove stea( generating

3.

CODE OF APPLICATION AND RELEVANCE DRAWING /. . /.-. ASME SEC ASME B / . : #u)e o! Construction o! Po*er P)ant. : Po*er Piping.

4.

GENERAL NOTE 4. . Be!ore co((ence(ent o! *e)ding *or+s3 prepared instruction o! t&e *e)ding *or+s and (a+e +no* everyone concerned *it&out e.ception. 4.-. As per t&e *or+s re5uired inspection3 carry out inspection under attendance o! Superintendent 6 Engineer and as surrea))y record is resu)t.

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4./.

Pay care!u) attention no to da(age pressure parts o! Boi)er on ,i!ting 0or+s.4.4. #ope o! *it& sa!ety rope around )i!ting area o! Boi)er Parts and put notice 'oard entered 78EEP O11 E9EPT PE#SONE, CONCE#NED:.

4.4.

Prior to co((ence(ent o! )i!ting *or+s3 assuread)y carry out c&ec+ o! *ire etc3 use t&e )i!ting *or+s and con!ir( t&at no any de!ective point e.ist.

5.

RESPONSIBILITY ;. . ;.-. ;./. C&ie! Engineer<#esponsi')e !or t&e overa)) p)anning3 coordination and contro) o! t&e erection 2o'. 1ie)d Engineer<#esponsi')e !or !ie)d erection *or+ i(p)e(entation and (aintaining accepta')e 5ua)ity standard. 1ie)d Superintendent and Supervisor<#esponsi')e !or t&e actua) per!or(ance o! t&e erection cre* and actua) c&ec+ing o! t&e *or+ progress to (a+e sure t&at it as per dra*ing speci!ication and standard. ;.4. 1or t&ese activity *i)) support 'y Materia) Contro)3 =ua)ity Contro)3 0e)ding Sec3 and ot&ers section re)ated *it& t&ese activities.

6.

PROCEDURE ". . Basic #e5uire(ent ". . . Sc&edu)e and P)anning

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Master erection sc&edu)e is usua))y provided 'y t&e c)ient. T&e detai)ed sc&edu)e is prepared 'y t&e contractor according to &is p)anning *&ic& is 'ased on t&e c)ient>s (aster sc&edu)e. T&e (i))stone and t&e critica) pat& can 'e identi!ied *&ic& re5uire proper p)anning. T&e se5uence o! erection activities and t&e resources re5uired is inc)uded in t&e p)anning. ". .-. Erection Dra*ing and Erection Manua) Erection dra*ing and (anua) usua))y provided 'y t&e c)ients. T&e 1ie)d Engineer3 Superintendent s&a)) c&ec+ a)) dra*ings intended !or Boi)er Erection3 and (a+e sure t&at it is co(p)eted. A)) t&e in!or(ation re5uired is co(p)eted and a)) dra*ings s&a)) 'e o! current revision. ". ./. Pac+ing ,ist Pac+ing ,ist s&a)) 'e (ade avai)a')e 'y t&e c)ient to t&e contractor. T&is inc)uded a)) t&e )isting o! (ateria)s3 e5uip(ent and parts t&at are supp)ied. T&e Pac+ing ,ist s&ou)d indicate t&e 5uantity o! t&e (ateria) and e5uip(ent supp)ied and its speci!ication as descri'ed in t&e erection dra*ing. T&is *i)) a)so indicate t&e si?e and t&e tota) *eig&t o! t&e co(ponent and t&e (et&od o! storage.

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A)so t&e pac+ing nu('er and (ateria) coding is very essentia). ". .4. Storage Area and 0are&ouse Upon a t&oroug& c&ec+ on t&e dra*ing and t&e pac+ing )ist3 t&e 5uantity o! (ateria)s and e5uip(ent is a)ready +no*n3 inc)uding t&e (et&od o! storing3 t&e si?e o! t&e storage area and t&e *are&ouse can 'e identi!ies. ". .;. #esources Identi!ication o! resources is integra) part o! p)anning and sc&edu)ing is t&e (ost essentia) part o! t&e 'asic re5uire(ent in underta+ing 'oi)er erection 2o' in particu)ar and in a)) 2o's in genera). #esources (eans3 t&e (ateria)s3 )a'or and e5uip(ent needed to per!or( 'oi)er erection 2o'. ".-. Preparation 0or+s ".-. . C&ec+ing o! Boi)er Erection Dra*ings T&is &as to 'e done 'y t&e C&ie! Engineer3 1ie)d Engineer3 Superintendent and Supervisor to deter(ine t&e correct resources needed to per!or( t&e 2o'. ".-.-. C&ec+ing o! C)ient Supp)ied Materia) and E5uip(ent

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C&ec+ing and inspection o! t&e (ateria)s and e5uip(ent inc)uding t&e spare parts is to 'e done 'y t&e (ateria) contro). @e *i)) (a+e sure t&at a)) (ateria)s3 e5uip(ent and spare parts received !ro( t&e supp)ier or t&e c)ient con!or( *it& t&e 5uantity and t&e speci!ications started in t&e pac+ing )ist or s&ipping. ".-./. C&ec+ing o! Erection Materia)s3 E5uip(ent3 Too)s and Mac&inery In t&e ear)y stage o! p)anning3 t&ese resources &ad 'een a)ready identi!ied. T&e sc&edu)e o! (o'i)i?ation is as p)aned sc&edu)e (ade 'y t&e C&ie! Engineer and 1ie)d Engineer. ".-.4. C&ec+ing o! ,a'or ,a'or re5uire(ent !or every stage o! erection 2o' is prepared 'y t&e C&ie! Engineer and &is erection tea(3 *&ic& is in accordance to t&eir p)anning. "./. Boi)er Erection It is assu(ed in t&is procedure t&at 'e!ore starting t&e erection o! t&e Boi)er3 t&e supporting structure *ere a)ready erected and c&ec+ed 'y ot&ers and c)earance to proceed *it& t&e Boi)er erection &ad 'een o'tained. "./. . Boi)er Dru( #aising

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T&e Boi)er Dru(

"/ Tones *it& @anger

% Tones and a)so

#igging Too)s "3; Tones is erected to its !ina) )ocation E)."".A%% 'y using - units )i!ting 2ac+ type ,/%% *it& eac& capacity A% Tones Bsa!e 0or+ing ,oadC in t&e cases A(( Dia(eter Dy!or( Strand Ca')e proposa) D Parts EA%( )ong. Prior to t&e )i!ting t&e Dru(3 t&e Boi)er Strap @anger are set to !aci)itate t&e setting o! Dru( in its !ina) )ocation. A!ter (ar+ing t&e center )ine on roo! girder3 t&e strap &anger is set in position and goes a)ong *it& t&e stea( dru(. T&e )engt& o! stea( dru( is -- ;%(( and t&e span 'et*een grid F/ and F; is - %%%((. @ence t&e dru( is re5uired to 'e tit)ed and )i!ted to avoid c)as&ing *it& stee). On t&is case3 t&e dru( *i)) 'e tit)ed at an inc)ination /; degrees. T&e 2ac+ *i)) 'e (ounted on 2ac+ support 'ea(s *&ic& *i)) 'e (ounted on ro))er type>s s+ates. T&e (ove(ent and restrain o! 'ea( *i)) 'e 'y c&ain ')oc+. T&e 2ac+ *i)) 'e operated !ro( a sing)e e)ectric &ydrau)ic po*er pac+. T&e actua) )oads on 2ac+ as t&e dru( is &oisted up at /; degrees is considered B,i!ting )oad o! dru( *it& interna) "/ Tones G @anger % Tones G #igging Too)s "3; TonesC at 2ac+

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near grid F; is

/4/34D 8N and 2ac+ near grid F/ is D/H3H"

8N inc)uding sa!ety !actor -;I. "./.-. Boi)er Dru( 1ina) A)ign(ent A!ter t&e dru( is set in position3 t&e 'e)o* (entioned a)ign(ent is carried out to con!ir( t&e centering o! dru( a)ong 9 and J a.is T&e )eve)ness (easuring and c&ec+ing o! stea( dru( can 'e carried out 'y se)ecting - points on eac& o! t&e )e!t and rig&t end Btota))y 4 pointsC. T&e e)evation re!erence point o! stea( dru( on t&e stee) co)u(ns (ar+ed. BDetai) A)ign(ent se5uence is attac&edC

"././. Insta))ation o! 1urnace Supporting @angers A!ter t&e stea( dru( &ad co(p)ete)y a)igned3 t&e

supporting s&a)) 'e insta))ed to its respective )ocations *&ere'y t&e 5uantity corresponding to t&e nu('er o! &angers re5uired in t&e erection dra*ing.

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T&ese s&a)) 'e (ounted to t&e !urnace top supporting structure in t&e &anging position to (a+e ready to support t&e !urnace co(ponents. "./.4. Insta))ation o! Top @eader and #iser Pipes Upper @eader consists o!: Bac+ pass #oo! In)et @eader Bac+ pass #oo! Out)et @eader Bac+ pass Upper Side @eaders 1urnace Upper 1ront *a)) @eaders 1urnace Upper Side*a)) @eaders 1urnace Upper #ear @eaders #eK&eater 1ront *a)) Out)et @eaders #eK&eater Side*a)) Out)et @eaders SuperK&eater Division In)et @eaders SuperK&eater Division Out)et @eaders SuperK&eater $ertica) P)aten In)et @eaders SuperK&eater $ertica) P)aten Out)et @eader #eK&eater $ertica) Spacer #ear in)et @eader 1urnace #ear @anger Out)et @eader Econo(i?er Out)et @eader

P !"# #$%&'(

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
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T&oroug&)y c)ean t&e 'eve)ed end o! eac& &eader and t&e tu'e to c&ec+ i! t&ere is any !oreign (atter inside t&e (ateria) 'e!ore )i!ting. P)aced 'ac+ t&e caps on t&e 'eve)ed ends to protect t&e( !ro( da(age. L%)$%'*( ,i!tKup eac& &eader and tu'e in t&e correct position and &ang it !ro( &eader rod. Put (ar+ing on structure to identi!y t&e center o! eac& &eader in re)ation to 'oi)er standard )ine and )eve) and te(porary !i. it. T&ese (easure(ents are to 'e recorded. "./.;. Buc+stays P !"# #$%&'( Provide (ar+ing on t&e structure to s&o* setting )eve) o! t&e 'uc+ stay section. L%)$%'*( . ,i!t t&e( up to position *&ere it is to 'e insta))ed and te(porary &ang t&e( !ro( 'ea( and secure t&e( proper)y. -. Setting *or+ s&ou)d 'e per!or(ed a!ter a)igning pane)s. Pane)s )ocated in t&e p)ace *&ere 'ac+stays are to 'e insta))ed s&ou)d 'e sea) *e)ded.

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
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/. 1i. Bac+stays 'y inserting t&e guide pins to tie 'ar )ugs *&ic& are *e)ded to t&e pane)s. 4. #ecti!y t&e distortion occurring during insta))ation o! t&e 'uc+ stays to pane)s so t&at t&e tie 'ar )ugs *i)) (atc& correct)y. Do not insert t&e pin 'y (eans o! &a((ering. "./.". #oo! Tu'e Pane)s Preparation: T&e te(porary *or+ is to 'e )i!ted do*n !ro( t&e top 'ea( 'e!ore )i!ting co((ence. ,i!ting: ,i!ting t&e( up to position and &ang it !ro( t&e &angers rods. Upon co(p)etion o! t&e insta))ed pane)s3 a)ign t&e( and ad2ust t&eir )eve) 'e!ore !i.ing t&e( toget&er. A)ign(ent o! Beve)ed End L Tu'e 0e)ding. Prior to a)igning t&e( *it& rear pane)s3 t&ey are to 'e air purged to re(ove a)) !oreign (ateria)s. "./.H. 0ater 0a)) Pane)s Preparation: T&oroug&)y c)ean 'eve)ed ends L provide proper sca!!o)ding to per!or( t&e 'eve)ed end a)ign(ent.

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
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,i!ting: . Te(porary *or+s are to 'e )i!ted do*n !ro( t&e top 'ea(. -. Pane)s )i!ted up are t&en suspended 'y c&ain ')oc+ and a)igning &o)ding 2igs. /. A)ign tu'e end and t&en per!or( t&e *e)ding. 4. A)ign t&e pane)s. "./.A. Inter(ediate and ,o*er @eader Inter(ediate @eaders consist o!: #eK&eater 1ront 0a)) In)et @eader Econo(i?er Mediu( @eaders

,o*er @eader Consist o!: Bac+ pass ,o*er 1ront @eader Bac+ pass ,o*er #ear @eader Bac+ pass ,o*er Side @eader Econo(i?er In)et @eader

P !"# #$%&'( T&oroug&)y c)ean stu' 'eve)ed ends and inspect inside t&e &eader. L%)$%'*(

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
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Te(porary *or+s are to 'e arranged !ro( t&e top 'ea(. C&ain B)oc+ s&ou)d 'e used to suspend t&e &eader )i!ted up to position. A!ter centering3 te(porary !i. it. "./.D. Super &eater L #e &eater E)e(ent Tu'es. P !"# #$%&'( T&oroug&)y c)ean t&e 'eve)ed ends3 inspect e)e(ent tu'es to ensure t&at t&ey are not da(age. L%)$%'*( . ,i!t up eac& e)e(ent tu'e to t&e given position and insert it into t&e !ront *a)) pane) s)it to te(porary &ang it *it& *ire rope. -. A!ter co(p)eting )i!ted up a)) e)e(ents3 )i!t t&e( up one 'y one *it& c&ain ')oc+ to a)ign t&e support tu'e ends. /. A!ter a)ign(ent o! t&e !ront *a)) pane) and eac& &eader3 &eader stu' ends and #e &eater6Super &eater e)e(ent3 tu'e ends s&a)) 'e (atc&ed. 4. Co((ence *e)ding o! t&e a)igned tu'es ends. "./. %. Econo(i?er. Centering

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
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In accordance *it& t&e insta))ation dra*ing3 (easure t&e center o! econo(i?er !ro( esta')is&ed 'oi)er standard )ines and (ar+ it on t&e stee) structure. Asse(')y 0or+ As t&e stee) structure are 'eing erected3 t&e econo(i?er support 'ea(s s&a)) a)so 'e asse(')ed3 and s5uare stee) 'ar s&ou)d 'e *e)ded to t&e (ain 'ea( according to t&e dra*ing !or t&e purpose o! preventing vi'ration o! t&e econo(i?er e)e(ent. Preparation 'e!ore ,i!ting C&ec+ and c)ean t&e 'eve)ed ends3 t&en cover t&e open ends 'y caps or p)astic s&e)) to prevent dust !ro( entering. Arrange )i!ting e5uip(ent !or )i!ting t&e(. L%)$%'* E)e(ents *i)) 'e )i!ted up 'y ')oc+3 a!ter asse(')y o! t&e e)e(ent3 !i. t&e support 'ars and *e)d. E+&'&,%-! C#.%'* T&e casing *i)) 'e asse(')y on t&e ground in severa) divided ')oc+ Binc)uding insu)ation and inner casingC. A!ter

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
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a)) ')oc+s are 'eing )i!ted3 t&ey *i)) 'e (atc&ed at t&e connecting points. B#+/.$#0 A!ter te(porary asse(')y o! t&e econo(i?er casing3 *e)ding on t&e part *&ere t&e 'ac+stay *ou)d 'e !i.ed s&a)) 'e !inis&ed3 t&en t&e 'ac+stay *i)) 'e &au)ed in. 6.3.11. A++!..& %!. O) P !..1 ! P# $. I'.$#22#$%&' . Accessories direct)y attac&ed to pressure parts3 inc)uding sea) p)ate3 sea) 'ars3 !ins tie 'ars3 sea) 'o.es3 t&er(ocoup)e etc3 s&ou)d 'e p)aces in t&e respective position and t&en *e)ded. -. T&e insta))ation s&ou)d 'e co(p)eted 'e!ore &ydrostatic test. 6.3.12. I''! 3 O1$! C#.%'* P !"# #$%&'( . Arrange t&e casing in t&e groups according to t&e p)ace o! insta))ation.

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-. T&e de)ivery o! (ateria) to t&e p)ace o! insta))ation s&a)) 'e (ade depending on t&e condition o! t&e *or+ing !)oor and t&e progress o! t&e ot&er *or+s. /. Asse(')e t&e( in accordance to t&e dra*ing. I'.$#22#$%&' . Insta))ation o! t&e casing s&ou)d 'e coordinated *it& t&e re!ractory and insu)ation *or+s. -. During insta))ation3 care s&ou)d 'e ta+en not to da(age t&e re!ractory and t&e pressure parts. /. Supporting p)aces to support (an&o)es3 sea) 'o.es etc. s&ou)d 'e insta))ed *it& consideration given to 'oi)er t&er(a) e.pansion. 4. Se)ection o! *e)ding rods and (anner o! pre&eating s&ou)d 'e in accordance *it& t&e vendor>s 0PS. ;. A!ter *e)ding co(p)etion3 s&ou)d 'e per!or( visua) inspection. 6.3.13. I'."!+$%&' 4&2!. I'."!+$%&' . Upon co(p)etion o! pressure part *or+3 c&ec+ i! t&ere is any !oreign (ateria) re(aining inside eac& &eader. -. Use an inspection (irror to c&ec+ t&e a'ove. /. I! t&ere is any !oreign (ateria)3 re(ove it 'y air purge.

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4. A!ter inspection3 sea) *e)d inspection &o)es. 5. FLOW C4ART 1)o* C&art !or t&e 'oi)er erection BBoi)er PartsC. 6. 0i)) PurposeC ATTAC4MENT Asse(')y Process o! Upper @eader and pane) Detai) Se5uence o! Asse(')y 0ater 0a)) Pane) #igging P)an !or 0a)) Insta))ation B Detai) Procedure

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