Professional Documents
Culture Documents
N REV. NO.
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
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
B1
2 x 25 MW
2
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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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
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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).
JOB NO
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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
7
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.
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
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5.3. WELDING
5.3.1 Weld
ding Processs and Consumable
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
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.
9
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
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
SMAW
S SHIELDED
D METAL ARC
A WELD
DING
5.3.4.6 We
elding Matterial
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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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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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
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.
12
5.3
3.4.10 A strikes
Arc s
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
3.4.13 Correction o
5.3 of Unaccep
ptable Fits
s-Ups and Welds
5.3
3.4.14 Heat
H Straig
ghtening
5.3
3.4.15 Temporary
T y Welds an
nd Repairs
s
a. Tempora
ary Weld
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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.
b Weld Defect
b. D Rep
pair
5.3
3.4.16 Qu
uality Con
ntrol
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.
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
JOB NO
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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.
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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8. TOLE
ERANCE AN
ND ACCEPT
TABLE CRIT
TERIA
Item To
olerance (m
mm) Rem
marks
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
7. Gap of roo
ot opening -2 < a < = +2 a : drrawing
dimeension
8. Gap of but
b joint 2 + 1.0
11. Reinforcem
ment of fillet 0.2S & bello
ow S = leg
g length
weeld
12. Reinforcem
ment of butt 0 ~ +3
we
eld.
14. Deviation of
o upper & ± D/500 D = Outside
O
Low ends diam
meter.
17
17. T circum deviation of
The 0 + 18
8
t internal joint of ring
the
beam at Ch
hute section
9.
9 Attach
hment
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