Method State for air preheater installation (rev d)

FOR APPROVAL

D
29.11.2016
C
11.11.2016
B
03.02.2016
A
10.11.2015
Rev
Date
Owner

H.J.BAE
H.J.BAE
H.J.BAE
Y.W.SHIN
Prepared

S.Y.KWAK S.J.PARK
S.Y.KWAK S.J.PARK
S.W.LEE G.B.KWACK
S.W.LEE G.B.KWACK
Checked
Approved

FOR APPROVAL
FOR APPROVAL
FOR APPROVAL
FOR APPROVAL

Details of Revision

VIETNAM ELECTRICITY
Owner’s Engineer

POWER ENGINEERING CONSULTING JOINT STOCK COMPANY 3

POWER ENGINEERING CONSULTING JOINT STOCK COMPANY 4
Contractor

Sub-Supplier

Project

Project Code

VINH TAN 4 THERMAL POWER PLANT

VT4
UAS Code
DD09

Date
(DD.MM.YYYY)

Name

Prepared

29.11.2016

J.H.Bae

Checked

29.11.2016

S.Y.Kwak

Approved

29.11.2016

S.J.Park

Dept.

Title

Unit Code
P0
KKS Code
ZEN

METHOD STATEMENT FOR
AIR PREHEATER INSTALLATION

Reg. No.
040332
Rev.

D

MECH. Dep’t

Document No.

Page-No.

VT4-DD09-P0ZEN-040332

41 Pages


EVNGENCO 3 / VTTPMB
DMPP Consortium

Vinh Tan 4 Thermal Power Plant

CONTENTS

1. PURPOSE
2. GENERAL
3. RESPOSIBILITY
4. REFERENCES
5. MATERIAL HANDLING
6. WORK PROCEDURE
7. JSA (JOB SAFETY ANALYSIS)
8. RISK ASSESSMENT
9. ATTACHMENTS

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DMPP Consortium

1.

Vinh Tan 4 Thermal Power Plant

PURPOSE
The purpose of this Method Statement is to explain the procedure of the Air Preheater
(APH) installation work for VINH TAN 4 unit #1, #2. With this, we can perform safely and
consistently.

2.

GENERAL
This method statement is applied to the above mentioned works. If there are any matters not
mentioned in this statement then that will follow international standard such as AISC, AWS
and ASTM.

3.

RESPONSIBILITY

3.1 Site Manager
Site Manager has the responsibilities for the application of this procedure and detail technical
aspects which is defined in this procedure.
3.2 Construction Manager
Construction Manager is responsible for the execution of construction activities.
3.3 QA/QC Manager
1) Verify the application of this procedure.
2) With necessary tests and inspection.
3) Verify the specification of supplied material to confirm if the delivered material is correct.

4.

REFERENCES
4.1 Issued For Construction Drawings
4.2 Approved Contract Quality Plan
4.3 Project EHSS Management Plan
4.4 Painting Procedure (VT4-YR01-P0ZEN-070001)
4.5 American Institute of Steel Construction (AISC)
4.6 American Society for Testing and Materials (ASTM)
4.7 American Welding Society (AWS)
4.8 American National Standards Institute (ANSI)

5.

MATERIAL HANDLING
5.1 Receiving and Storage of Material
5.1.1 Upon delivery of the material, construction engineer shall inspect if there is any discrepancy
with packing list and damage during the transportation. The result shall be reported
immediately to the supervisor.
5.1.2 Materials should be segregated and stored at storage yard for easy handling as per erection

sequence.
5.1.3 Generally, take appropriate measures such as the use of sheet covers and sleepers against
rust, strain, deformation and damage during storage of materials.
5.1.4 Handling of materials and equipment shall be performed carefully so as not to damage or
loss them.
5.1.5 All temporary materials, equipment, and jigs to be used for installation work shall be
carefully checked and adjusted before using them.
5.2 Handling of Sections
As the paint film is relatively fragile, it is absolutely necessary to check the points below when
sections are handled:

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DMPP Consortium

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5.2.1 Prevent lifting devices from friction against structural elements
5.2.2 Prevent friction of structural elements together
5.2.3 Preserve structural elements against shocks of any kind
5.2.4 Avoid trailing structural elements
The above recommendations must permit limiting accidental damaging of the paint film.
If necessary, paint touching up shall be carried out according to general specification for
Painting.

5.3 Stability of very high devices and of structural elements
5.3.1 Stability of very high devices shall be ensured at all times and, in particular, out of erection
hours (night, weekends)
5.3.2 The erector shall ensure the stability of the Air Preheater whenever the progress of the
erection work does not permit getting stability from the structural elements bound
together.
6.

WORK PROCEDURE
6.1 Process Flow Chart

Center Support Centering & Leveling

Center Support, Thrust Bearing Installation

Rotor-Lifting Device Installation to Center Support

Sealing Frame Top Bolting

Casing Top Main Part Installation

Hydraulic Cylinder Installation to Rotor Lifting Device Guide Bearing Installation

Sliding Support (Cupshaped Support) Installation

Casing Bottom Main, Side Part Installation

Sealing Frame & Shoes, Bottom Installation

Thrust Bearing Temporary Support Installation

Rotor Core Installation

Rotor (Closed, Open) Segment Installation

Casing Top Side Part Installation

Pin-Rack Segment & Support Installation

R.D.U (Rotor Drive Unit) Setting

Casing Support middle part Installation

Cold & Hot Heating Element Installation

Soot Blower, LOU, Accessory
Installation

Sealing Frame Shoes, Top Installation
DOC.NO.VT4- DD09-P0ZEN-040332

Bearing Setting Fixing

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DMPP Consortium

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6.2 Setting up Center Line & Level of Base Plate
6.2.1 Beginning mark center line of base plate at grid line Q..
6.2.2 After marking center line the level of base plate will be checked and ensure make same
level by shim plate.

6.2.3

The tolerance of level will be confirmed as ITP

6.3 Assembly of Bearing Component
6.3.1 Assembly of Thrust Bearing
The thrust bearing will be installed on shim plate which it have just been adjusted same
level. Center line of base plate will coincident with center of thrust bearing.

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DMPP Consortium

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6.4 Assembly of the Rotor Lifting Device

6.5 Assembly of APH-Casing at Bottom Part
6.5.1 Assembly of APH Support (sliding support)
Main & side support will lifting at level which are marked center line and it will be
fixed.

Taper pin Ø 20 to
fix bearing
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DMPP Consortium

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6.6 Lifting of Casing Bottom Main Part
Process lifting casing bottom main part after support had fixed .they will fit up at position by
temporary support. /or use chain block in order to tackle. Ensure make level they will be
checked level and make same level by insert shim plate (Reference lifting plan)

6.7 Lifting of Casing Bottom Side Part
When casing bottom main part are fix .casing bottom side part will lifting & fit up with main
part, the mean while they must make same level with main part.

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6.8 Installation Casing Bottom Completed
After finished adjustment they will process fit up stiffener pipe & angle.

.

6.9 Installation Seal Frame
Seal frame will be erected at top face of casing bottom part they are connected to together see
fig blow.

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DMPP Consortium

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6.10 Assembly and Mounting of APH Rotor.
6.10.1 Arrangement of the thrust bearing pivot: if case they are loose part, they will be
assembly at a ground with temporary support see blow Fig.

6.10.2 Arrangement of the rotor core and pivots
Rotor core will put frame after thrust bearing will lifting assembly with it after they are
fixed, the guide bearing will be erected.

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6.10.3 Assembly of the hydraulic cylinder for rotor lifting device.

6.10.4 Arrangement of the rotor core
The thrust bearing, rotor core, guide bearing pivot which assembly become 1 unit
approximate 20ton they will make lifting plug in order to lifting up to casing bottom
disc center fit up by temporary support.(Reference lifting plan )

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DMPP Consortium

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6.11 Assembly of APH Casing Middle-part
6.11.1 Erection of APH casing support segment
Casing middle main & side part will fit first at position

6.11.2 Mounting of APH casing middle-part
The rest of segment will be erected fill space after main & part have already fixed.

6.12 Assembly of Sealing Frame
Seal frame will be erected at top face of casing top part they are connected to together by bolt
see fig blow.

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DMPP Consortium

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6.13 Assembly of Sealing Frame
6.13.1 Lifting of casing top main part. (Reference lifting plan).

6.14 Adjustment of support bearing and guide bearing
6.14.1 Installation of guide bearing

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DMPP Consortium

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6.14.2 Installation of shaft seal top

6.14.3 Adjustment of support bearing and guide bearing

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6.15 Arrangement of the Rotor Segment.
6.15.1 Alignment of rotor closed segment
After the rotor had fixed, the rotor closed segment will be assembly with rotor core by
bolt, Pin, screw, tack weld. Total closed segment have 6pcs with weigh each of piece is
8.23ton. They will be installed as per step (reference lifting plan).

6.15.2 Arrangement of the opened segment
The opened segment will be assembly after closed segment temporary fit up.

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DMPP Consortium

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6.15.3 Arrangement of the rotor completed

See fig after they had finished assembly.

6.16 Lifting of casing top
6.16.1 Lifting of casing top side part( reference lifting plan)

6.16.2 Installation of casing top completed.

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6.17 Installation of the pin rack

6.18 Installation of the drive-unit

6.19 Installation of the seal gap adjusting devices, top and bottom

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DMPP Consortium

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6.20 Installation of heating elements

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DMPP Consortium

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6.21 Installation of the soot blower bottom

6.22 Installation of water washing device

6.23 Installation of the fire extinguishing device

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6.24 Installation of the machining device and rotor machining

6.25 Installation of the expansion sleeve
-. Top Side

-. Bottom Side

6.26 Installation Lube oil Circulation, Lube oil Pipe & Oil Flushing
6.26.1 Lube Oil Circulation Installation
Install the Lube Oil Circulation System Horizontally, giving carefully consideration to proper
installation position and the method of keeping the connection duct warm.
Thoroughly clean the piping before installing it in the field.
Apply Oil Flushing prior to trial run.

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DMPP Consortium

Vinh Tan 4 Thermal Power Plant

6.26.2 Oil Pipe Assembly for Guide Bearing Circulation System
Assembly Oil Pipe follows Drawing of Guide Bearing Circulation. After Welding done
Cleaning inside pipe by Air cleaning.
6.26.3 Oil Flushing for Guide Bearing Circulation System
Oil Flushing Procedure refer VT4-DD09-P0ZEN-040364 MS for U1 & U2 Air Preheater Oil
Flushing (Rev. A)
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DMPP Consortium

7.

Vinh Tan 4 Thermal Power Plant

JSA (Job Safety Analysis)

List of All Job
Steps

List of All Known Hazards

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DMPP Consortium

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A. Workers

A.1 Not properly equipped with
PPE operly equipped with PPE
"A.2 Worker abnormal physical
condition (drunken&fatigue)"

A.1 Instructing to wear proper PPE
A.2 Make the worker to take enough rest

B.
Transportation
of equipment
& delivery of

materials

B. Crash/ traffic accident

B.1 Check the access road before passing the
area
B.2 Designate a signalman who wear the red
suit and safety helmet and control the work

C. Ground
Assembly

C. Crushing accident during
assembly work

C.1 Clearance of safety access road
C.2 Communication with the Signal man

D. Heavy
Lifting Works

D. Crushing may cause fatal injury
or permanent disability

D.1 Preparation of a rigging lift list and plans
for lifts of ten (10) tons or greater.
D.2 Only a qualified and Certified operators.
Signalman should be in-place
D.3 Do not stand beneath the lifting areas
D.4 Ensure loads are fixed with sling belt

correctly
D.5 All lifting equipments must be in good
conditions
D.6 Experienced lifting supervisor at all times
D.7 Only monthly checking color attached
lifting tools allowed to use
D.8 All lifting tools must have identification
tag (including serial number, certification
number, SWL inspection date and due date)
D.9 Provide safe entrance and exit access road
for the labors passing

E. Unloading
Equipment
and
Materials

E.1 Falling accident

E.1. Proper equipping of PPE
E.1. Proper uses the harness (2 lanyards) and
life line over 2 meters.
E.1. Checking the signal of signal man and
checking the direction of the material lifting
direction
E.1. All worker who work over 2 meters must
be trained the working at height training.
E.2. Checking the joint status of lifting gears
E.2. Prohibiting man access under the lifting
area

E.2 Falling accident of material

E. Unloading
Equipment
and Materials

E.3 Squeezed by the materials

DOC.NO.VT4- DD09-P0ZEN-040332

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E.3. Keeping the left over material on the
ground
E.3. Analyzing the loads (weight, shape, lifting
points, etc…) and lifting
device to suit the crane capacity

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F. Equipment
and material
preparation
for Temp.
facilities

Vinh Tan 4 Thermal Power Plant

F.1 Collision between machines.
Overturning may cause death or
permanent disability

F.1. Always keeps the site clear of any
obstructions.
F.1. Tool-box talks on a daily basis
F.1. Adequate warning signboards
F.1. Checklist on all vehicles must be provided
every day.

F.2 Unnecessary movements of
equipments towards a person that
causes injury
and damage to materials

F.2. Designate a signalman who wear the red
suit and safety helmet and control the work
F.2. Heavy machinery should have backward
movement warning light and beacon
F.2. Equipment used to clear the site should be
controlled and sorted by a banksman
F.2. Provide safe entrance and exit for the
workers going to the area
F.2. All vehicles entering on the site must turnon their headlights day and night time

F.3 Equipment oil leakage during

operation

F.3. Daily check of the equipments prior to
work

G. Working
Operation
During
Night Time.

G.1 Working operation of the
equipments may cause injury to
personnel due to poor visibility of
the area.

G.1. Must provide sufficient lightings on the
entire working area
G.1. All equipments must ensure all lights are
operational and not obscured by dirt or mud
G.1. Supervisor must always be present for the
entire working operation
G.1. All workers must be wearing proper PPE
G.1. Ambulance and nurse must be available in
first aid station
G.1. Must use industrial socket and plug
G.1. Electric cabinet should not affect any
water

H. Welding
and cutting

works

H.1 Electric shock, fire, burn to
body and injury to eye may cause
death or permanent disability

H.1. Proper earthing and connection of welding
machines and generators
H.1. Flashback arrestor and gauge should be
installed prior to use cutting cylinders
H.1. Proper PPE to be worn at all times
H.1. Must use and connect 3 core codes electric
wire and separate distribution panel (must pass
arrangement of ELCB) and avoid any water
affect
H.1. Must use industrial socket and plug
H.1. Electric cabinet should not affect any
water

List of All Job
Steps

List of All Known Hazards

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How to Eliminate Hazards

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H. Welding and
cutting works

8.

Vinh Tan 4 Thermal Power Plant

H.2 Generator(diesel)
equipment oil leakage during
operation

H.2. Daily check of the equipments prior to
start of work
H.2. Regular monitoring of the equipment in
order to control and prevent oil leakage and
other engine trouble
H.2. Provide secondary containment
protection under the equipment to prevent
contamination of the soil by oil spillage
H.2. If oil leakage, must remove the oil and
contaminated soil immediately

H.3 Oil/chemical storage

H.3. Diesel/chemical shall be stored in
secondary containment and MSDS
requirements shall be communicated with all
concerned

RISK ASSESSMENT

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8.1 Layout Configuration

8.2 Crane Radius

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