pressure part method statement

[ Method Of Statement for Boiler Pressure

Part and Steel Structure ]

TOTAL 49

PAGES

PROJECT NAME

: Khabat Thermal Power Plant Units 1&2

Purpose

For Information

For Review

For Approval

For Construction

As-Built

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

1 03.02.2015 For Construction M.T T.S O.S O.S

0 05.01.2015 For Construction M.T T.S O.S O.S

Rev. No.

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

1.0 PURPOSE ....................................................................................................................... 3

2.0 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

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

9.0 ERECTION PLAN ...................................................................................................12

10.0 EXECUTION ..................................................................................................................13

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

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

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

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

15.0 REFERENCES ...............................................................................................................49

16.0 ATTACHMENTS .............................................................................................................49



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1.0 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 Plan, organize, direct, execute and coordinate the project.

o Supervise, direct and control all personnel assigned to the project.

o Be responsible for execution of the contract to obtain anticipated job quality, effective

cost control, and compliance with job schedule.

o Be responsible to Management and the client for the project.

o Define project scope and services, and issue project instruction.

o Review and/or prepare the contract document.

o Prepare change orders as required.

o Be responsible for issuing the project budget and the project cost reports.

o Be responsible, for selecting vendors and approving bid evaluation documents for

purchase order.

o Be responsible, through Site Manager, for construction.

o Be responsible, through HSE Manager, for HSE.

o Obtain Main-subcontractor's acceptance of the plant and arrange for close out of the

project.

o Initiate project staff meetings.



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o Be responsible to the Project Manager for performance of the project to meet the

criteria of effective cost control and compliance with project schedule.

o Follow up with responsible parties to ensure that schedules are maintained or

improved.

o Assure the scheduling and/or cost control report by planning, analyzing, and

forecasting of project performance for management.

o Assess the effects of all deviations for project schedule, at the earliest possible time,

for evaluation and remedial action by Project Manager.

o Preparation of all trend, status and progress reports.

o Assure communications between other engineering and construction disciplines.

3.2 SITE MANAGER

Site Manager has the following responsibilities

o 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.

o Supervise and coordinate the work of the various engineering disciplines.

o Establish engineering and also define the delivertives and non-delivertives.

o Work with the lead engineers to formulate, evaluate and execute practical, economical

and efficient design concepts suitable for the specific requirements of the project.

o Resolve the conflicts among the engineering disciplines during the engineering and

design work.

o Monitor engineering and design progress and report problems to the Project Manager

for resolution.

o Be responsible for coordinating overall execution at site.

o Set up and administer general operation of field office including camp facilities.

o Review constructability throughly prior to site opening. Coordinate with the construction

members to prevent or solve possible problems.

o 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.

o Establish a plan of construction execution considering actual site conditions.

o Direct field purchasing activities including material warehousing, and expedite site

delivery.

o Preside weekly schedule meeting, weekly safety meeting, and monthly progress review

meeting to assure that all activities are performed in accordance with original planning.

o Prepare construction status reports for the main-subcontractor and head office.

o Direct all construction activities under execution and evaluate the result of field test.

o Approve requests for field extra work order, change order, and memorandum work.

o Maintain cooperative contact with client's project manager.



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o Submit monthly progress report to the client and expedite the approval on it.

o Submit monthly invoice for erection portion to the client and expedite the payment of it.

o Approve various field-originated reports to be submitted to the head office.

o Prepare Final Construction Report.

o Establish in accordance with contractual requirements an Inspection & Test Plan (ITP)

indicating the extent of inspection based on item criticality.

3.3 SITE ENGINEER

o 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.

o Plan, organize, direct, execute and coordinate the Boiler Erection.

o Supervise, direct and control all personnel assigned to the Boiler Erection.

o Be responsible, through Supervisor/foreman, for construction.

o Follow up with responsible parties to ensure that schedules are maintained or

improved.

o Assess the effects of all deviations for project schedule, at the earliest possible time,

for evaluation and remedial action by Site management.

o Preparation of all trend, status and progress reports.

o Preparation and following of the all required work permits, safe rules.

o 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 All Foremans/Supervisors be responsible of all construction activities on site as per the

MS-ITP-HSE requirements.

o 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 for the following of required WPS as per project specification.

o requisition of correct consumables for the Project Monitoring the performance of the

welders,

o Evaluation and Recording of the repair rate of the weldersand sharing with POSCO,

o Penalize the welders whose repair rate is high or not allow welding work.

o Assist and coordinate with Project Manager and all personnel assigned to the project in

establishment of Project Quality Plan.

o 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.

o Establish project quality audit program & schedule and perform the project quality audit

within project organization and GAMA will submit Quality audit program to POSCO.

o Monitoring & Evaluation of quality management system activities based on the project

quality plan.

o Coordination with Mainsubcontractors for project quality management system

concerns.

o 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.

o Documents of welding materials control.

o Plan and implement the quality training programs at site.



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o Provide technical assistance to site management as necessary to initiate quality

enhancement and resolve quality problems throughout the organization.

o Recording and control welding schedule and sharing with POSCO.

o Monitoring of, provide technical assistance and resolve all quality-related problems with

the activities.

o 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.

o Approve and issue all project documents.

o Ensure that adequate inspection personnel and test tool & equipment resources are

available at all times, including peak load periods to meet the construction schedule.

o Raise non-conformance items, investigate their causes and make recommendations

for corrective actions to prevent recurrence.

o Ensure all technical documentation is accurate and updated to current status.

o Conduct the education for quality consciousness to All responsible person (Engineer,

Foreman, Supervisor, Labors) prior to the commencement of work.

o Give his staffs the instruction about duties and responsibilities on site.

o 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.

o 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.

o The HSE Manager shall prepare a safety control instruction to cover the construction

site activities.

o 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.

o To ensure all lifting equipment and accessories have valid certification

o To ensure all activities are being executed as per GAMA HSE plan and related

procedures.

2



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4.0 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: MTEK A..

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, PPEs 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..



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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)

6.0 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

7.0 SUBCONTRACTORS SUB-TIER CONTRACTORS



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

8.0 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 MTEK project

warehouse. In accordance of technical specifications preservations of the all material will be

kept untill project finish date. MTEK will manage the material receiving procedure. In case of

any damage or dismatch between materials and material list then MTEK will sent RFI and

action of GAMA will be requested.

Large bore (2''



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The color coding system ;

Table.1



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9.0 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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10.0 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.. 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 "non-

shrink" 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.

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

and safe.

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

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

certified riggers.

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.

Safety equipments to be appropriate and ready to use.

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

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 pre-

assembled 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 manufacturers

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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10.2 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++-VM600-

V0110.

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.3

DWG.4



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DWG.5

DWG.6



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10.2.3 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.8

DWG.8

DWG.9



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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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DWG.12

DWG.13



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10.2.7 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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10.2.8 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.

DWG.15



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DWG.16



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DWG.17



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DWG.18



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10.2.9 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.

DWG.19



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Photo 2.

Such a lifting device (photo.2) will be designed and produced at site for lifting the pre-

assembled 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 cross-

dimension 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.

DWG.23



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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.

DWG.26



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10.2.12.4 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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11.0 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

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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

DWG.32



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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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11.3 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:

1- Transportation of the wall panel to the boiler, 2- The wall will be placed under Furnace Hall. 3- Necessary lifting lugs and equipments will be connect to the wall panel. 4- Crane, hydraulic jacks or any other lifting equipment will be used for lifting activity. 5- Until the material goes to vertical position, second crane will take the load by tailing. 6- 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

Subcontractors 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 PPEs. The

detailed HSE plan is attached. MTEK A.. will obey GAMAs 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 ATTACHMENTS

Attachment-1 HSE Plan

Attachment-2 Job Safety Analyses and Risk Assessment (for Steel Structure)

Attachment-3 Job Safety Analyses and Risk Assessment (for Pressure Part)

Attachment-4 WPS List