COAL FIRE POWER PLAN STEAM DRUM LIFTING METHODS
some people maybe confuse how to lift Steam Drum on Coal Fire Power Plan
the cheapest and easier way to erect steam drum is by use hydraulic Jack and make temporary support on Boiler steel structure
1 SCOPE OF WORK
This method statement is to lifting boiler steam drum on 1x 600 MW Suralaya Power Plan Project, Banten, Indonesia.
2 PURPOSE
This procedure is to describe all activities to be performed in the lifting of Steam Drum to ensure that all works are properly planned and executed in accordance with all the requirements of the contract document, carried out on erection works of Suralaya 1x600 MW Coal Fired Steam Power Plan Project
3 SCOPE APPLICATION
This procedure covers the methods, equipment, tool and materials for the lifting of Boiler Steam Drum prior to pressure part.
4 RESPONSIBILITY
4.1 Site Manager – Responsible for ensuring that all works are performed in accordance with this procedure.
4.2 Chief Engineer – Responsible for the overall planning, coordination and control of the erection job.
4.3 Field Engineer – Responsible for field erection work implementation and maintaining acceptable quality standard.
4.4 Field Superintendent and supervisor – Responsible for the actual performance of the erection crew and actual checking of the work Progress to make sure that it is drawing specification and standard.
4.5 Safety Engineer – Responsible for ensuring that all activities are carried out in a safety manner and compliance with the established safety procedure.
4.6 Quality Control Engineer – Responsible to monitor and inspect the cyclone erection ensuring it is being done in compliance with this procedure, ITP (Inspection and Test Plant), Drawing, Project specification and other reference standard document and procedure.
4.7 For these activities will support by material control, welding section, and other section related these activities.
5 REFERENCE
5.1 Basic Requirement
5.1.1 Reference drawing & Vendor Document
5.1.1.1 To check all drawings intended for steam drum lifting, and make sure that is complete. All the information required is completed and drawings shall be current revision.
5.1.1.2 Check Equipment and Materials
5.1.1.3 The Steam Drum and its accessories such as hanger rods, drum internals, etc. Has to be check before lifting. The temporary materials such as steels, anchor housing, eye bolt and others that will be used for lifting need to be check also.
5.1.1.4 Drum Support
5.1.1.5 The drum support structure erection completion has to be check including the leave out steels which should be erected only after the drum is lifted. Hence all steels members other than leave out steel has to be installed, aligned, bolted and inspected before drum lifting commences
5.1.1.6 Lifting Plan, Method statement and procedure of lifting Boiler steam drum shown at attachment –
6 LIFTING EQUIPMENT, TOOLS, AND MATERIAL LIST.
6.1 Hydraulic Jack 150 ton capacities : 4 Pcs
6.2 Wire Strand 50 ton capacities : 10 Pcs
6.3 Skid Roller 100 ton capacities : 8 Pcs
6.4 Skid Roller 50 ton capacities : 16 Pcs
7 STEAM DRUM LIFTING (see attachment )
7.1 Preparation
7.1.1 Ensure the direction of steam drum is correct since loading on the port
7.1.2 Before Installation of steam drum ensure all of the bolt have been tightening
7.1.3 Install barricade on the exclusion zone to prevent workers inside to lifting zone area
7.1.4 Safety tool box meeting must be done to explain dangerous condition that may be occurred and how to prevent.
7.1.5 Install temporary jack support on the top of boiler steel structure
7.1.6 Install 4 Pcs Hydraulic jack and it’s accessories such us frame to support jack, skid roller etc.
7.1.7 Prepare all of rigging tools to be used
7.1.8 Clear area from first tire until top tire, ensure there are no obstruction that may obstruct during steam drum lifting
7.1.9 Confirm to CNTIC site in charge and all sub-contractor in suralaya power plan project inform lifting area preparation and explain dangerous condition that may be occurred
7.1.10 Ensure that ground condition stability is enough to support transporter to transport steam drum to lifting area.
7.1.11 Prepare concrete block and soft wood as temporary saddle in order as temporary placement of steam drum for cleaning and repair of steam drum if there are any damages.
7.1.12 Drum and hangers
7.1.12.1 The Drum is hung from the main structure by two ‘U’ type strap hangers. To easier of lifting operations and facilities the erection of hangers, the ‘U’ rod hangers shall be assembled at ground level or the drum in order to be lifted simultaneously.
7.1.12.2 Before assembling the ‘U’ rods the following should be taken inconsideration are :
7.1.12.2.1 The spacing of the ‘U’ rods corresponds to the Drum diameter
7.1.12.2.2 The bolt circle diameters of the bearing boxes correspond to the diameter of the ‘U’ rods, its mean that:
7.1.12.2.2.1 The hangers threads are clean
7.1.12.2.2.2 To check the nuts onto the rods
7.1.12.2.2.3 Joints of ‘U’ rods – attention on the threads
7.1.12.2.3 The threads are protected to avoid all damage during lifting of the Drum and are also well protected where the steam pass through the structure and bearings
7.1.12.2.4 Then the ‘U’ rods are fixed as per the dimensions and the drawing
7.2 Lifting Sequences
7.2.1 Transporter come to erection area, initially the Drum is positioned in the ground floor 2 meters away from its required Original position to avoid touching with boiler steel structure during inclination process of steam drum .
7.2.2 Install lifting tools to the steam drum.
7.2.3 Lift up steam drum around 3 meter height then hung “U” hanger on the steam drum from side of steam drum by using 45 ton Rough crane and tie in with wire sling
7.2.4 Lock jack 3&4 and Lift up jack 1&2 to decline steam drum position until 30 degree until steam drum free from any obstruction
7.2.1 Lift up both of jack watch out if any obstructions during lift by radio (HT) and communicate to the jack operator.
7.2.2 After steam drum lifted until final elevation approximately El.77.80 lock jack 1&2 and lift up jack 3&4 to straight steam drum in horizontal position.
7.2.3 The Drum lift and positioned at the elevation approximately El.77.80 meters, and operation of hydraulic shall be locked.
7.2.4 The trucks are moved towards to front boiler direction (to line E1) by slide steam drum in temporary rail until final position.
7.2.5 After completion of lateral movement of drum and the trucks, the trucks shall be locked.
7.2.6 Each ‘U’ rod to be lifted by crane 600 T guided by spreader bar to install easier through the hole and lock them by nuts
7.2.1 Adjust the drum at its final elevation by means of lifting device
7.2.2 Confirm that the ‘U’ rods are in contact with the bottom generating line of steam drum
7.2.3 Adjust the bearing orientation and plates as per drawing
7.2.4 Tighten the nuts of hangers in order to reach perfect contact of all parts
7.2.5 Simultaneously release the hydraulic jack systems and dismantle the lifting equipment
7.2.6 Do the weld operation after completion of inspection
7.2.7 On completion of positioning the drum, the confirmation of tension on the ‘U’ rods is necessary. The tension on the each strap must be equal to the down load
1 INSPECTION
1.1 It is necessary to record all inspection during various phases of erection progress an to verify inspection sheets are in compliance with drawings
30 degree 200 ton steam drum lifting
