Pt. Truba Jurong Engineering Labuan 2 Banten 2 X 300 MW CFSPP Project Assembly & Erection Boiler Pressure Parts Procedure
Pt. Truba Jurong Engineering Labuan 2 Banten 2 X 300 MW CFSPP Project Assembly & Erection Boiler Pressure Parts Procedure
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
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.
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
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.
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
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.
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
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
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
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
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
#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+
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
near grid F; is
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.
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
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
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
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%)$%'*( . ,i!t t&e( up to position *&ere it is to 'e insta))ed and te(porary &ang t&e( !ro( 'ea( and secure t&e( proper)y. -. Setting *or+ s&ou)d 'e per!or(ed a!ter a)igning pane)s. Pane)s )ocated in t&e p)ace *&ere 'ac+stays are to 'e insta))ed s&ou)d 'e sea) *e)ded.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
/. 1i. Bac+stays 'y inserting t&e guide pins to tie 'ar )ugs *&ic& are *e)ded to t&e pane)s. 4. #ecti!y t&e distortion occurring during insta))ation o! t&e 'uc+ stays to pane)s so t&at t&e tie 'ar )ugs *i)) (atc& correct)y. Do not insert t&e pin 'y (eans o! &a((ering. "./.". #oo! Tu'e Pane)s Preparation: T&e te(porary *or+ is to 'e )i!ted do*n !ro( t&e top 'ea( 'e!ore )i!ting co((ence. ,i!ting: ,i!ting t&e( up to position and &ang it !ro( t&e &angers rods. Upon co(p)etion o! t&e insta))ed pane)s3 a)ign t&e( and ad2ust t&eir )eve) 'e!ore !i.ing t&e( toget&er. A)ign(ent o! Beve)ed End L Tu'e 0e)ding. Prior to a)igning t&e( *it& rear pane)s3 t&ey are to 'e air purged to re(ove a)) !oreign (ateria)s. "./.H. 0ater 0a)) Pane)s Preparation: T&oroug&)y c)ean 'eve)ed ends L provide proper sca!!o)ding to per!or( t&e 'eve)ed end a)ign(ent.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
,i!ting: . Te(porary *or+s are to 'e )i!ted do*n !ro( t&e top 'ea(. -. Pane)s )i!ted up are t&en suspended 'y c&ain ')oc+ and a)igning &o)ding 2igs. /. A)ign tu'e end and t&en per!or( t&e *e)ding. 4. A)ign t&e pane)s. "./.A. Inter(ediate and ,o*er @eader Inter(ediate @eaders consist o!: #eK&eater 1ront 0a)) In)et @eader Econo(i?er Mediu( @eaders
,o*er @eader Consist o!: Bac+ pass ,o*er 1ront @eader Bac+ pass ,o*er #ear @eader Bac+ pass ,o*er Side @eader Econo(i?er In)et @eader
P !"# #$%&'( T&oroug&)y c)ean stu' 'eve)ed ends and inspect inside t&e &eader. L%)$%'*(
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
Te(porary *or+s are to 'e arranged !ro( t&e top 'ea(. C&ain B)oc+ s&ou)d 'e used to suspend t&e &eader )i!ted up to position. A!ter centering3 te(porary !i. it. "./.D. Super &eater L #e &eater E)e(ent Tu'es. P !"# #$%&'( 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%)$%'*( . ,i!t up eac& e)e(ent tu'e to t&e given position and insert it into t&e !ront *a)) pane) s)it to te(porary &ang it *it& *ire rope. -. A!ter co(p)eting )i!ted up a)) e)e(ents3 )i!t t&e( up one 'y one *it& c&ain ')oc+ to a)ign t&e support tu'e ends. /. A!ter a)ign(ent o! t&e !ront *a)) pane) and eac& &eader3 &eader stu' ends and #e &eater6Super &eater e)e(ent3 tu'e ends s&a)) 'e (atc&ed. 4. Co((ence *e)ding o! t&e a)igned tu'es ends. "./. %. Econo(i?er. Centering
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
In accordance *it& t&e insta))ation dra*ing3 (easure t&e center o! econo(i?er !ro( esta')is&ed 'oi)er standard )ines and (ar+ it on t&e stee) structure. Asse(')y 0or+ As t&e stee) structure are 'eing erected3 t&e econo(i?er support 'ea(s s&a)) a)so 'e asse(')ed3 and s5uare stee) 'ar s&ou)d 'e *e)ded to t&e (ain 'ea( according to t&e dra*ing !or t&e purpose o! preventing vi'ration o! t&e econo(i?er e)e(ent. Preparation 'e!ore ,i!ting C&ec+ and c)ean t&e 'eve)ed ends3 t&en cover t&e open ends 'y caps or p)astic s&e)) to prevent dust !ro( entering. Arrange )i!ting e5uip(ent !or )i!ting t&e(. L%)$%'* 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
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
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 !"# #$%&'( . Arrange t&e casing in t&e groups according to t&e p)ace o! insta))ation.
PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT ASSEMBLY & ERECTION BOILER PRESSURE PARTS PROCEDURE
Unit Issuing : Construction Approved By : Site Manager
DOC. NO
-. T&e de)ivery o! (ateria) to t&e p)ace o! insta))ation s&a)) 'e (ade depending on t&e condition o! t&e *or+ing !)oor and t&e progress o! t&e ot&er *or+s. /. Asse(')e t&e( in accordance to t&e dra*ing. I'.$#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.
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
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