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JOB NO. DOC. NO.

N REV. NO.

C-10001 Procc – C1001 – CST


C - 012 0

DATE: FEB 28, 2012 S


SHEET: 1
ORG’D DORSAN
NGKAP DS
REV’D SHINDU
U SH
APP’D LAMBOK
K FIRDAUS LF

 
 
 
 
 
 

 
 
 
 
 
 
COA
AL BUNK
KER BA
AY ASSE
EMBY & ERECTION PRO
OCEDUR
RE

PLTU
U 2 x 25 MW
M
 
 
 
 
 
 
 
 
 
 
 
REV
R DATE DESCR
RIPTION ORG’D REV’D APP’D PT BARATA
B INA

1 28/02//12 ISSUED
D FOR APPROV
VAL DS SH LF
 
 
 
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Proc – C1001 – CST –
C
C-1001 0
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PROJE
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Feb 28, 2012 B
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2 x 25 MW

 

 

1. TABULAT
TION OF REV
VISED SHEET
TS

REVISIONS RE
EVISIONS
SHEET
S SH
HEET
1 1A 1B 1C 2 2A
A 2B 3 1 1A 1B 1C
1 2 2A
A 2B 3
1 X 31
2 X 32
3 X 33
4 X 34
5 X 35
6 X 36
7 X 37
8 X 38
9 39
10 40
11 41
12 42
13 43
14 44
15 45
16 46
17 47
18 48
19 49
20 50
21 51
22 52
23 53
24 54
25 55
26 56
27 57
28 58
29 59
30 60
 
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Proc – C1001 – CST –
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C-1001 0
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TABLE OF CONTENT

No. Descriptio
D ons Page

1 TITL
LE 3 of 17

2 SCOPE 3 of 17

3 OBJECTIVE 3 of 17

4 REFE
ERENCE 3 of 17

5 PRO
OCEDURES
S 3 of 17

5.1 Assembly
A of Weldin
ng Coal Bu
unker 3 of 17

5.2 Ground
G As
ssembly 4 of 17

5.3 Welding
W 6 of 17

6 SAFE
ETY MEAS
SSURES 13 of 17

7 ASSEMBLY CH
HART 14 of 17

8 TOLE
ERANCE AN
ND ACCEPT
TABLE CRIT
TERIA 15 of 17

9 Attac
chment
 
JOB NO
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Proc – C1001 – CST –
C
C-1001 0
0122
PROJE
ECT: DATE: S
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Feb 28, 2012 B
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2 x 25 MW

 

1.
1 TITLE.
Assemb
bly and erecction of coa
al bunker.
2.
2 SCOPE
This insstruction is to describe
e assembly method of coal bunke
er unit 1 & 2 for Lombok 2 x
25 MW Coal Fire Steam
S Powe
er Plant.
3.
3 OBJECT
TIVE
As a systematic gu
uidance for concern Su
upervisor or Engineer to assemblly and weld
ding of
al Bunker
the Coa
4.
4 REFERE
ENCES
4.1 . Gu or Establishiing Project Procedure
uidelines fo
4.2. Rig
gging Execution Plan
4.3. Ma nd Storage Proc.
aterial Rec., Moving an
4.4 . Ap
pproved Insspection Te
est Procedu
ure
4.5. Sh
hop drawing
g and Weld
ding Procedure Specificcation
5.
5 PROCED
DURES
5.1. A
Assembly of
o Steel Co
oal Bunker
5.1.1 General Requirements
- All assemblyy should u
use shop drawing
d w
with status for fabrica
ation or
onstruction..
co
- Th
he Manpow
wer for asse
embly should be qualifiied for this work
- All inspection
n and testin
ng shall follo
ow approve on Test Plan (ITP).
ed Inspectio
- To
olerance accceptance criteria
c for the fabrica
ation shall follows
f App
pendix 3
(F
Fabrication Tolerance)
T
- When
W fabrica
ating the chute and shell
s of coal bunker, the
t vertical position
we
elding of adjacent
a se
egments sh
hould be sttaggered, and the sttaggered
distance shou
uld be equa
al to or more than 300
0 mm (300
0mm).
 
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- Th
he segmentt dimension
n of coal bu
unker chute
e and shell should be decided
acccording to the dimension of recceived mate
erials, but the
t quantityy of coal
bu
unker chute
e and shell can not excceed the re
equirementss of drawings.
- Th
he lifting/sketch and dimension of every steel plate
e in each segment
s
sh
hould be pro
ovided whe
en assembliing/fabricatting coal bu
unker chute
e.
- Fo
or the conv
venience of lifting durin
ng assemblly, Coal bun
nker will be
e divided
into two partts (2): Uppe
er part & Lo
ower part.
- art 1 Upperr part is (C
Pa Coal Bunkerr Shell) & S g and 1st
Shell Lowerr part (Ring
co
onical part)
- Lo
ower part iss conical up
pper part an
nd lower pa
art.
- Th
he protection measurres for avo
oiding weld
ding deform
mations sh
hould be
ca
arried out when
w weldin
ng the chutte and shell of coal bunker.
5.1.2
2. Drawings
oved erecttion drawin
Appro ng shall be
e followed strictly in
n accordan
nce with
appro
oved reference drawing and applicable stand
dard.
5.1.3
3. Materrials
- All material to
t be used
d shall be ance with material
e treated iin accorda
eiving, movving and sto
rece orage material procedu
ure.
- Befo
ore start off assemblyy, all materrials shall b
be verified with the approved
a
draw
wing, material specificcations & sizze.
- Arra
angement, requisition and issue of
o material shall be as per proced
dure.
- The
e shop preassembly insspection re
eport of eacch part of steel
s materiials have
to be
b provided
d by the ssupplier/ven
ndor to en
nsure prope
er & accura
ate with
quality and avo
oid mixing w
with otherss.
5.1.4 Check Material
M to Be
B Used
Before exxecution, ch
heck materrials such ass:
- Che
eck dimensio
onal and m
material iden
ntification
 
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- Ensure the ma
aterial (wid
de, circumfe
erential len
ngth and th
hickness) according
to drawing
d req
quirement.
- Visu
ual Inspecttion, Visuall inspection
n covers p
physical da
amage of material,
m
checck of corro
osion, mate
erial bending/damage because off loading/unloading
and material packing.
- Che
eck Quantity, Check requireme
ent of ma
aterial aga
ainst the drawing
requ
uirement.
5.2. Grround Asse
embly

Ground assembly of coa


al bunker consists of three
t parts::
- port and up
Shell supp pper conical assembly..
- Shell and top cover assembly.
a
5.2
2.1. Assembly
A Lo
ower Shell a
and 1st con
nical part asssembly seq
quence
Provide temporaryy support fo
or the base
e of assembly  check
c leveliing base
support  put th
he Lower ring
r plate and assem
mbly on the
e base support 
install 30mm
3 Shelll support plate and Stiffener. A plete weld of Shell
After comp
support plate to be
b reverse up-side do
own to insttall upper conical pla
ate. 
Check dimension
d  welding chute  re
everse to fin
nal erection
n position.
 
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30 mm Shell 
Support 
Stiffeener  item n
no 4
plaate 
Lower ring 
plate item 
38

Tempp
Frame
e

Assemblyy Lower shell and 1st 
conical part.

5.2.2 Shell assemb


bly

Sh
hell assemb
bly sequencce;

Prrovide temp
porary supp
port for the base of assembly  checkk
lev
veling base
e support  nstall shell by shell on
in n the base plate 
In
nstall ring Cannel
C  ccheck dimen
nsion  welding
w shell.

Base support 
 
JOB NO
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Proc – C1001 – CST –
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5.3. WELDING

5.3.1 Weld
ding Processs and Consumable

Weldding processses, storag


ge, and handling of con
nsumables shall comp
ply with
site project
p procedure.

5.3.2 Weld
ding Procedure Specificcation

Weld
ding procedures shall be
b qualified in accorda
ance with th
he Code.

5.3.3 Weld
der Qualifica
ation

Weldeers shall be qualified in


n accordancce with the
e essential variables
v off Welder
Test Procedure and the supplemen ntal requireements of Code for Welder
technical qualifica
ation.

5.3.4 ding Work


Weld kmanship

5.3..4.1 Base
e Metal Prreparation
n

Suurfaces to be
b welded shall be vissually exam mined and mustm be cle
eaned to
brright metal for a distance of no ot less than n ½ in. (1 12.7 mm) from
f the
dge of the weld groovves. All su
ed urface finissh paints, including weld
w able
prrimers, shalll be removved from the weld groo ove when welding
w pre
e-painted
materials.

5.3
3.4.2 Cuttting Edge
e Preparattion and R
Repair

a.
a All cut edges
e shalll be visually
y examined
d for laminations, craccks, and
other defects.
d Sh harp edgess shall be removed byb grinding g. Edge
es to be painted shall be repaired. Prior to
defects on surface o making
repairs, the method to be used shall be submittted to CN NEEC for
approvaal.

b For fabriicated beam


b. ms, all web and flange
e, plates shall be cut such
s that
the principle rolling
g direction of the pla
ate lies alon
ng the long gitudinal
axis of th
he finished plate girde
er.
 
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c Thermally cut surrfaces shall be groun
c. nd to brig
ght metal prior to
subsequent welding
g.

5.3
3.4.3 Tac
ck Welds

All tack welds, origina


A ally perform
med to hold d memberss in alignm ment and
la
ater incorpporated into
o the completed welld tack we elds shall have
h the
s
same preheeat requirem
ments as th he root passs of the appropriate structural
w
welding proocedure. Prrior to contiinuation of welding, th
he "tack" weld
w shall
b ground to a featheredge to
be o permit acceptable
a weld meta al tie-in.
M
Minimum le
ength of tacck welds shall be 4 in n. (100 mmm) or the leength of
the attachmment whiche ever less is..

5.3.4.4 Ru
un-on and Run-off Tabs
T

Run-on and
R d run-off tabs shall be used for all
a welds at the plates,, tubular
e location
end ns, and at bbeam splice es and term
minations. These
T tabs shall be
p
produced from materia al of the sam
me grade aand type ass being weld
ded.

5.3.4.5 W
Welding Me
ethod

The ffollowing welding


w proccesses are :

SMAW
S SHIELDED
D METAL ARC
A WELD
DING

5.3.4.6 We
elding Matterial

Welding mate erial shall b


be confirme
ed before sstart to wo
ork, its is co
orrect in
acccording witth welding procedure.

Th
he treatmennt, storage,, handling of
o Welding consumable shall be followed
the
e procedure
e.

No on
Descriptio Welding Method
d W
Welding Mate
erial
.
Weldingg E70
016 (Ø 2.6)) mm
1 S
SMAW
Plate E7018
8 (Ø 3.2 & 4) mm
 
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10 
5.3.4.7 We
elding Seq
quence

Th
his method to guide welder for welding part to part and
d to avoid
de
eformation.

a. Weld seq
quence on p
plates.

3
1

4 1

3 2

b. Weld seq
quence on Profiles
P

Fillet Welld
 
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11 

9
9

5
4

3
2
1

Weld Intermitten
nt

5.3
3.4.8 We
elding Para
ameter

Weld
ding Filler Metal Ampe
ere Vo
oltage Travel
No Meth
hod Currentt
AWS No. Ø mm
m (A)) (V) (mm/ min)
6
E7016 2.6 DCRP 90 -- 120
1 18
8 - 28 40 - 150
1 SMA
AW E7018
8 3.2 DCRP 90 -- 140
1 20
0 - 30 40 - 200
E7018
8 4 DCRP 130 -- 170 20
0 - 30 60 - 250

5.3
3.4.9 Preheat
P an
nd Inter pa
ass Tempe
erature

a. Preheat shall be controlled by b infrared instrumen nt or temp


perature-
indicating
g crayons for accura ately monittoring the steel temperature
througho out all weld passes durring producction weldin
ng.

b. Minimum
m preheat for
f all steel shall be the
t greaterr of 100°F (38°C),
AWS D1.1 Table 3.2
2, or the ap
pproved WP
PS whicheveer is higher.

c. Maximum ature or prreheat for structural welding


m inter passs tempera
shall not exceed 500
0°F (232°C
C) unless oth
herwise qua
alified.
 
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12 
5.3
3.4.10 A strikes
Arc s

Arrc strikes outside


o the
e weld groo ove area a are not alloowed. Arcc strikes
ou
utside the weld
w groovee area shall be remove ed by grindding or remooval and
replacement of the secction affecte ed by the arc strike. All indicatiion(s) of
craacking shalll be subjecct to grinding and re--inspection to insure complete
c
removal.

5.3
3.4.11 Weld
W Identification

Th
he welders being tested shall pe ermanently mark with h paint stickk or low
strress metal stamp,
s each weld with
h his identiffying mark.

5.3
3.4.12 Inte
erruption o
of Welding
g

Whenever po ossible, welding of join nts shall be


e completedd in one continuous
op
peration. Where
W inte
erruption iss unavoidabble, at leasst one-third
d of the
we
eld joint th
hickness ovver the full weld lengtth shall be e completed d before
we
elding is disscontinued.

3.4.13 Correction o
5.3 of Unaccep
ptable Fits
s-Ups and Welds

a. Welding (buttering through member)


m in--situ to red
duce excesssive root
openingss is not acce
eptable with
hout specific approval by CNEEC..

b. Buttered layers on removed branch


b memmbers shall be ground d to the
desired profile
p and shall be subject
s to 100 percennt visual, magnetic
m
particle te
esting, and
d prior to re
efitting into the structu
ure.

5.3
3.4.14 Heat
H Straig
ghtening

Heeat Straighttening mayy be used. A heat sttraightening


g proposal shall be
su
ubmitted to o CNEEC forf approv o use in fabrication or any
val prior to
qu
uenched and tempered o-mechanical control processed
d or thermo p s
steel, the
maaximum tem mperature shall not exceed
e 1100
0°F (593°CC) or the te
empering
mperature, whicheverr is less.
tem

5.3
3.4.15 Temporary
T y Welds an
nd Repairs
s

a. Tempora
ary Weld
 
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13 
When teemporary welds
w are ne ecessary, th
hey shall be
e performed with
the sam
me care, ma eheat, and proceduress as
aterials, elecctrodes, pre
permanent weld in
nstallations.

Temporrary welding g shall not be removed d by arc-airr gouging, and


a
shall be
e removed w without anyy parent me etal damage e. Any dammage
(gougess, tears, etcc.) shall be repaired in
n accordancce with approved
proposaal.

b Weld Defect
b. D Rep
pair

Weld reepairs shall be perform


med in accorrdance with
h approved weld
repair procedures,
p which mayy be develo
oped for mu ultiple repair defect
types,

Work piiece temperrature shalll be a minim 0°F (56°C) higher


mum of 100
than the
e minimum preheat te emperature required foor the origin
nal
approveed welding procedure.

5.3
3.4.16 Qu
uality Con
ntrol

Weld insppection shaall include but not be


e limited tot Visual, PT, MT,
hic or UT inspection methods
radiograph m whiichever is re
equired..

In addition
n to other inspection n methods used, jointts shall be visually
inspected prior to welding, including checking fit-up for proper
alignment,, groove angle, root face, and root open ning to connform to
weld proceedure requiirements. All
A levels sh
hall visually
y inspect co
ompleted
welds, affter weld spatter has been removed, for the eir size,
ercut and surface flaw
configuratiion, appearrance, unde ws to ensuree that all
welds confform to appplicable cod
des.

Electrode care and storage


s procedures sh
hall include storage co
onditions
prior to op
pening conttainers, holding tempe
erature afteer opening and any
recondition
ning proce edures forr electrodees exposed d to atmospheric
g the manuffacturer's recommendations.
conditions for periodss exceeding

Each qualified welde


er shall be e establishin
ng with a unique ide
entifying
number, used to iden
ntify all weld
ds performeed by him.

nd weld are
Welders an eas shall be
e provided with
w protecction during
g periods
of incleme
ent weatheer and / or excessive e wind con
nditions, prrotection
nclude electrode, wire, and fluxess etc
methods in
 
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14 

6. SAFETY
Y MEASSU
URES.

Tools lik
ke big hammmer, hand d hammer, jack, wren nch, etc. shall
s be equipped witth safety
rope. Th
he tools sha
all be stored
d in the too n be placed in disord
ol bag and not der.

porary platfform for erection provvision should be on rigid conditio


All temp on, all plan
nks must
e, hand railing surrounding the wo
be tight up by wire ork must bee provided..

The safeety belt sha


all be tighte
ened to uppper firm placce before o
overhead woork
If necesssary, safetty aisle sha able. No sttay or entryy in danger area. Wa
all be availa alking on
beam without any safety measure is stricctly prohibitted.

For overrhead workk at night or


o in the place with poor sunshin ne, adequa
ate lighting shall be
ensured, and it sha
all be preve
ented to gett an electricc shock.

Welding and gas cutting


c spattter should be protected by fire proof sheeet to avoid
d fire
drop dow
wn. The Firre extinguissher should be provide
ed in surrou
unding the welding
w are
ea.
 
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15 
7. ASSE
EMBLY CHA
ART

Recceived Materials 
             Of   
     Coal Bunker

Vissual 
Over shortagge and  NO 
Check Dimensions 
damage rep ports  Mark / Part No. 
Quantity 
YES

Report to 
Client  Assembling

Rou
undness
NO Dimensions 
Check Root gap, root face. 
Degree of bevel 
D
Client should  confirrm to 
C
Subcont with writting 
YES

Welding 

- Repair 
R
- M
Modification 
- R
Replace Material 
NO Final D
Dimensional 
Weld Visual 
Check  N
NDT ( If Required 
  In C
Client Specification ) 
 
YES

 
Touch up
Painting 

Check Pain
nting inspection 
 
YES

Mobilize to site
 
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16 
8. TOLE
ERANCE AN
ND ACCEPT
TABLE CRIT
TERIA  

Item To
olerance (m
mm) Rem
marks

1. Mark line (base


( plate + 2.0
hole)

2. Marking (others) + 2.0


  line
For th
he
3. Gas cuttting line + 2.0

4. Gas cu
utting 1.0 and belllow

5. Roughness of
R o gas cutting
g mary : 50s & bellow
Prim
surfface Secon
ndary : 100ss & bellow  

6. Grove Angle + 5.0 & bellow

7. Gap of roo
ot opening -2 < a < = +2 a : drrawing
dimeension

8. Gap of but
b joint 2 + 1.0

9. Gap of T joint 1 & bellow


w

10. Gap of Leg g length of 0 ~ +2 Throat th


hickness 0
fillet weld ~ +2

11. Reinforcem
ment of fillet 0.2S & bello
ow S = leg
g length
weeld

12. Reinforcem
ment of butt 0 ~ +3
we
eld.

13. High Low  t/10 t = Plate thickness

14. Deviation of
o upper & ± D/500 D = Outside
O
Low ends diam
meter.

15. T eccentriccity of upperr


The  10
& low end
e tale

16. Height Deviation


D ± 10
 
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17 
17. T circum deviation of
The 0  + 18
8
t internal joint of ring
the
beam at Ch
hute section

18. T location deviation off


The ±5
reinforcing ring

19. The vertica


al deviation  1.5 D
between thhe two end
1000
face an
nd axis

9.
9 Attach
hment
   
 
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18 

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