VA1 LSC 00100 QA M8 TPD 0006 (Steel Structure Fabrication Procedure) Rev.1

DOCUMENT SUBMISSION STATUS: FC
30/03/11
ISSUED FOR CONSTRUCTION
T.V.CUONG
D.V.HIEU
P.N.QUANG
11/03/11
ISSUED FOR CONSTRUCTION
T.V.CUONG
D.V.HIEU
N.H.QUAN
26/01/11
ISSUED FOR APPROVAL
T.V.CUONG
N.V.BIEN
P.N.QUANG
D
C
B
10/01/11
18/11/10
29/10/10
ISSUED FOR APPROVAL

ISSUED FOR APPROVAL
ISSUED FOR APPROVAL
REV
DATE
PREP.
CHKD
APPN
DESCRIPTION
OWNER
OWNERS CONSULTANT
POYRY ENERGY LTD

VIETNAM OIL AND GAS GROUP (PVN)
EPC CONTRACTOR
EPC CONTRACTORS CONSULTANT
VIETNAM MACHINERY
INSTALLATION CORPORATION (LILAMA)
PROJECT TITLE
VUNG ANG 1 THERMAL POWER PLANT 2 x 600MW

PACKAGE: M8
CONTRACT No.
222010/ LILAMA-LISEMCO
DRAWING TITLE:
steel structure FABRICATION PROCEDURE

SUB-CONTRACTOR
HAIPHONG EQUIPMENT MANUFACTURE AND

SHIPBUILDING CO.LTD, (LISEMCO)
DOCUMENT No.VA1-LSC-00100-QA-M8-TPD-0006
FUNCTION
NAME
SIGN
PREPARED
TO VIET CUONG
30/03/11
CHECKED
DAM VAN HIEU
30/03/11
APPROVED
PHAM NGOC QUANG
30/03/11
SCALE
DATE
REV. 1
Hai phong equipment manufacture and

shipbuilding company limited
Vung Ang 1 Thermal Power Plant
Ky Loi commune, Ky Anh district, Ha Tinh province
ITEM: COAL HANDLING SYSTEM M8
Mar. 30th, 2011

Rev: 1
Code: VA1-LSC-00100-QA-M8-TPD-0006
Page: 1/19
Steel structure Fabrication

Procedure
project
Vung Ang1 Thermal Power Plant
Item
COAL HANDLING SYSTEM M8
location
Ky Loi commune - Ky Anh District-Ha Tinh province
Steel structure Fabrication Procedure

Mar. 30th, 2011

Rev: 1
Page: 2/19
Index
No
Title
Page
Chapter 1: General Introduction.
Chapter 2: Fabrication procedure.
Chapter 3: Fabrication method.
Chapter 1: General Introduction

I. General Introduction
1. Executing Organization Chart (As shown in page 4).
Hai phong Equipment Manufacture and Shipbuilding CO., LTD
a. Responsibilities and rights
Hai Phong Equipment Manufacture and Shipbuilding CO., LTD is a member
company belonging to Vietnam Machinery Installation Corporation (LILAMA).
With its big site plan (8ha), modern equipment, and the teams of experienced
engineer and equipped with knowledge and new executing technologies, a large
number of workers as well as skillful workers, Hai phong Equipment
Manufacture and Shipbuilding CO., LTD is responsible for providing materials
and installation of equipment for Vung Ang 1 thermal power plant 2x600 MWCoal handling plant M-lot 2
All steel structure will be fabricated in factory of Lisemco in Hai Phong to
ensure quality, error and convenience for installation process of steel structure.
The whole process of structural steel fabrication, company will carry out by
itself equipment and staff member.

Mar. 30th, 2011

Rev: 1
Page: 3/19
b. The director of project

Full name: Nguyen Hong Quan
Position:
Project Director
Tel
: 031-3522496
Fax
: 031-3850120.
E-mail
: vungangpj@lisemco.com.vn
2. Inspection unit- quality control

Inspection unit quality control belonging to quality control Department which
is an independent organization with in manufacturing units operating under the
leaderships of the parent company, is responsible for quality control, checking to
ensure the steps of manufacturing technology and installation implemented
seriously for quality assurance of construction.

Mar. 30th, 2011

Rev: 1
Page: 4/19
ORGANIZATION CHART FOR LOT-M8

VUNG ANG 1.THERMALPOWER PLANT PROJECT
LILAMA PMB
LISEMCO ltd,.
GENERAL DIRECTOR
Mr. TRAN VIET KHANH
Email: lisemco@hn.vnn.vn
PROJECT MANAGER
Mr.NGUYEN HONG QUAN
E-mail: quanhn.nd37@gmail.com
psb.lisemco@vnn.vn
PROJECT COORDINATOR
Mr. TO VIET CUONG
Mobi: 01696815187
E-mail: vietcuong.lisemco@gmail.com
DEPUTY PROJECT MANAGER

& SITE MANAGER
MANUFACTURING MANAGER
Mr. NGUYEN VAN BIEN
Mobi: 0989126635
E-mail: Bienlisemco@yahoo.com.vn
Mr. PHAM NGOC QUANG

E-mail: ngocquang32id@gmail.com
RECEIVING EQUIPMENT
AND HAND MANAGER
OFFICE MANAGER
Mr. NGUYEN DINH QUYNH
Ms.TRUONG THI HUONG

Ms.HO THI KHANH HOA
SAFETY&SECURITY MANAGER
QC/QA PRJ. MANAGER
Mr.PHAN VAN HUNG

Ms: NGUYEN THI LAM
Mr. VU VAN QUANG

Mr MAI HUY CUONG
Mr.VU DUC THANH
TECHNICAL MANAGEMENT
MATERIALS MANAGEMENT
Mr. DO XUAN DUNG

Mobi: 0982592029
Mr. BUI DUC THIET

Mobi: 0904828298
SAFETY&SE MANAGEMENT
QC/QA PRJ. MANAGEMENT
Mr. PHAM VAN TUYEN

Mobi: 0934692591
E-mail: tuyen.lisemco@gmail.com
Mr. NGUYEN QUANG VINH
WORK SHOP SUPERVISOR

ENGINEERS
ELECTRICIAN+
INSULATING+
COMMISSONING
TEAM 01
PEPLE 19
STEEL STRUCTURE
+MECHANIC
TEAM-02
PEPLE 30
PAINTER
TEAM - 01
PEPLE 8
WELDER
TEAM - 01
PEPLE 15
WORK-SHOP No1
WORK-SHOP No2
Mr NGUYEN VAN DOANH
Mr. NGUYEN VAN HUNG
MECHANIC AND WELDER

TEAM - 25
MECHANIC AND WELDER

TEAM - 25
STEEL STRUCTURE
TEAM 02
PEOPLE 35
STEEL STRUCTURE
TEAM 02
PEOPLE 35
PAINTING
PACKING & SHIPPMENT
Mr.DOANVAN HA
PAINTING
TEAM-01
PEOPLE 12
PACKING & SHIPPMENT

TEAM -01
PEOPLE 06
Date of isuue: Otc 12th, 2010
Inspection unit- quality control has rights of suspending activities which not
comply with procedures , and has risk of bad influence on quality manufactured
products as well as installation leading bad effects on construction quality.
Inspection shall followed he details in lines with the approved ITP which are
completed by LILAMA.

Mar. 30th, 2011

Rev: 1
Page: 5/19
3. Reference:
- Specification of the project.
- FLS General Workshop instructions.
- Document No. VA1-LI-00100-M-G1-ITP-0002 INSPECTION AND TEST
PLAN FOR STEEL STRUCTURE SHOP FABRICATION
- Document No. VA1-LI-00100-QA-G1-ITP-0001 INSPECTION AND TEST
PLAN FOR PAINTING
- Standard: DIN.
4. Shop, fabrication teams
Fabrication teams are responsible for executing construction in accordance with
design, quality assurance and work progress and directly carry out at shop in
lisemco.
In case of unexpected problems in construction process exceeds the capacity of
fabrication units. They can request related parts supporting technology,
eqiupment, manpower. All the requirements of fabrication groups must be
presented in writen form system of Lisemco (in case the customers do not have
special
requiremetns). These requirements are given Economy-Technology
Department, Lisemco. Economy-Technology Department must have answer in

writen form within 24 hours.
II. Objects, scopes and references.
1. Objects
The process of structural steel fabrication is to give a manufacturing scientific
plan, strict inspection system, ensuring quality to meet the quality control system
ISO 9001 : 2000 which company Lisemco is applying, also satifies the
customers requirements about product quality and construction progress.
2. Application scope

Mar. 30th, 2011

Rev: 1
Page: 6/19
This process is applied to fabrication equipment and manufacturing of steel

structure.
3. References
Shop drawings, related technical documents and standards.
The technical standards are given by Owner.
4. Fabrication chart and inspection
o
Content of
Work
Implementation unit Inspection criteria Evaluation

criteria
-Check
input -Executing technology
materials.
-Material officer.
-Quality control
- Supervisor party A
- Original
- Number
- Dimension
- Visual inspection
Inspection tools Report form
Certificate
o- Certificates
Manufacturer.
- Comparing orders
- Accroding to Tape-measure,
order
caliper
- No wrapping, - By visual.
rust, blistery.
- Marking and - Workers

- Dimension, beveled - Design drawing. - Tape-measure.
cutting
- Executing technology angel.
-Inspections
- Quality control
- External insepction.
-Straightening - Workers
Dimension, - Design drawing Welding
joint
-Detailed
-Executing technology. straightness,
welding and error.
checking
tapeassembly
- Quality control.
joint prepared.
measure,
control
- External inspection.
-Inspection
wire,
- Assembly.
- Workers
- Straightness, square, -Design drawing - Meter, tape for
Assembly - Executing technogy
dimension...
and error
inspection of square
inspection
- Quality control
angle.
- Supervisor party A
- Welding beam, - Welder with valid - According to welding
pillar, accessory. certificates.
procedure system.
External -Executing technology. Welding
joint - According to - By visual, welding
inspection.
- Quality control.
surrounding.
welding procedure. joint tape inspection.
Checking
by
-Nondestructive - Supervisor party A.
-External inspection.
Tecnical testing.
- Subcontractor.
- Cheking welding joint requirement
of ultrasonic.
construction.
inside.
- Welders.
According
to - Accroding to - Grinder, welding
Repairingdefects - Subcontractor.
inspection results.
quality
machine.
.
-External inspection.
requirement
of - By visual, checking
-Checking and
- Cheking welding joint construction.
by ultrasonic.
fixing.
inside.
- Sanding blast, - Manufacturing unit.
paint.
- Executing technology
- Quality control.
Painting - Supervisor party A.
inspection.
- Surfaces preparation - According to - Checking by visual.

and paint.
technical
- Checking by gauge
- Painting inspection. requirement (see for
measuring
painting
thickness of paint.
procedure).
III. Construction organization design.

1 -Bases on the construction design.
- Basing on technical standards of designer.
- Basing on tecnical design document of construction.

Mar. 30th, 2011

Rev: 1
Page: 7/19
- Basing on real condition of construction plan and construction work

quantity.
- Basing on rate canculating document for construction and construction
organization.
- Basing on material capacity, machinery, and manpower.
2 - Construction organization design.
Construction organization is very important task ensuring fast construction
process and achieved the best effect. The contractor will be responsible for this
task. They carry out the supported work like working platform, storage, yards of
materials gathered as well as products, water allocation system for construction.
The construction work quantity is mainly organized as follows:
In the shop of company
+ Fabrication of steel structure.
+ Cleaning, painting steel structure.
In the construction process, contractor is in full compliance with technical
procedures, rules and regulations of acceptance in accordance with designers
standard and owners requirement.
Basing on construction plan, the contractor carries out to clean ground, prepare
assembling platform, machinery for construction work.

Mar. 30th, 2011

Rev: 1
Page: 8/19
Chapter 2: Fabrication procedure

Material receiving
Returni
Inspectio
False
Delivery for units
Cutting
Repairing
Inspectio
False
Tack welding
Repairing
Inspectio
False
Finish welding
Repairing
Inspectio
False
Assembly
Repairing
Inspectio
False
acceptance report
blast cleaning
Repairing
Inspectio
False
acceptance report
finish painting
Repairing
Inspectio
False
acceptance report
Packing
Complete payment
document

Mar. 30th, 2011

Rev: 1
Page: 9/19
Chapter 3: Fabricating methods

I. Check input materials of Work.
According to designers requirements, Contractor supply types of material
having clear origin, attaching material certificate.
Material inspection made as below requirement:
- Check material certificate of origin.
- Standard geometrical size: check by tape-measure, caliper
- Surface: convex, concave, void, crack, warping
- Technical characteristics of material:
- Physical-mechanical properties of steel: sampling, testing and certificating.
- Welding material properties according approved WPS & PQR.
- Components, properties of other materials.
- Control, inspection process of input materials for works following to designers
standard and the below diagram:
Materials
Delivering to company
HaiPhong equipment
Manufacture and
Shipbuilding CO., LTD
material department
inspection, correlation,storage
certificate of quality, quantity,
weight
Gim st cng ty (QC)

check size, type of materials...
A partys supervisor
inspect steel tag,
...
type of materials
Type of steel for fabrication works consist of:

1. Steel plate according to project standard, or appropriate
2. Steel shape according to project standard, or appropriate
3. Materials service for fabrication: welding material, painting material, the
other auxiliary materials

Mar. 30th, 2011

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Page: 10/19
Entire above materials strictly controlled and monitored according to materials

summary tables including detailed data. After be imported to Company, the
materials delivered to executing units for fabrication
II. Construction ground preparing.
In order to service for fabrication as well as asembly all parts in Company,
Company perform arrangement the construction ground at units. Assemblying
platform for fabrication and inspection carefully prepared achieving standard
surface.
III. Products fabricating
Common fabricating steps:
Step 1: The parts shall be marked and cut according to marking and cutting dwgs
and design dwgs.
Marking and cutting according to the diagram shall be performed by assembly
group, parts marked and cut on the platform under the control, monitoring of
shop, group engineering staff, and QC of Company. The parts must be checked
the size, cleaness, beveled angle, hole welding, ... according to the Project
standard by Companys QC during marking and cutting process, when QC find
out that the parts achieving requirement, they shall be moved to the next stage.
Step 2: Assembly parts
After cutting, the parts shall be moved to assembling areas where assembling
work made by assembling group. Companys QC inspects the size, joint
clearance, tack welding, reinforced measure against deformationwhen these
achieve the Projects standard, the parts moved to the welding stage.
Before welding, structure should be inspected according to FIT-UP
INSPECTION FOR WELDING No: VA1-QCF-M-15 in document No: VA1-LI00100-M-GI-ITP-0002 (INSPECTION AND TEST PLAN FOR STEEL
STRUCTURE SHOP FABRICATION).

Mar. 30th, 2011

Rev: 1
Page: 11/19
Step 3: Welding
Welded connection executed according to welding procedure (WPS) which
Lisemco submitted to the Owner and supervisors, consultants. This procedure
performed by welders having valid certificates. Overall welding process strictly
inspected by welding QC about welding materials, the welders, quality of
welding jointsso as to restrict welding defects and avoid failures at the
beginning of the stage. All welding joints checked 100% external form
according to technical requirement of the project. The defected welding joints
shall be carried out to prepare following to repairing welding joint procedure
during inspection. .
Size of the parts inspected after finish welding ensuring to be in allowable
tolerance of the Project.
The weld should be inspection according to WELDING VISUAL RECORDS
No:
VA1-QCF-M-14
in
document
No:
VA1-LI-00100-M-GI-ITP-0002
(INSPECTION AND TEST PLAN FOR STEEL STRUCTURE SHOP

FABRICATION).
After welding, the struture should be inspection according to STEEL
STRUCTURE FABRICATION FINAL INSPECTION REPORT No: VA1QCF-M-013
in
the
document
No:
VA1-LI-00100-M-G1-ITP-0002
(INSPECTION AND TEST PLAN FOR STEEL STRUCTURE SHOP

FABRICATION) before painting.
All of taking-over form made according to Projects requirements and after the
parties ( the Owner, TVGS, LISEMCO contractor) have finished signing the
acceptance certificate, then move to painting stage
*) Welding procedure specification, process welding, and NDT for welding
work of reclaimers, stackers, unloaders, and towers shall be completely followed
FLS General Workshop Instructions which was issued.

Mar. 30th, 2011

Rev: 1
Page: 12/19
Step 4: Painting.
After checking according to STEEL STRUCTURE INSPECTION RECORD
BEFORE PAINTING No: VA1-QCF-M-012 in the document No: VA1-LI00100-M-G1-ITP-0002 (INSPECTION AND TEST PLAN FOR STEEL
STRUCTURE SHOP FABRICATION), products will be cleaned by abrasive
grain for blasting, boring machine for hard-to-handle, ensuring technical
requirements of this project. The quality control is ensured to move painting
stage and final acceptance for packing.
All the acceptance forms are made according to project requirements and after
the parties signed acceptance report to move the working stage, its time for
packing.
Due to design of parts with its own features, the construction part of work like
scraper, piler, unloader, tower of project have some different features.
III.1.The fabrication of Reclaimer: the fabrication of each unit
The cutting stage must carry out on CNC machine. After cutting, the plates are
connected together according to working drawing and finish welding for
connecting plates; check Nondectructive testing (NDT). If these results are
achived, conduct the assembly beam. The platform is used for assembly beam,
for example:

Mar. 30th, 2011

Rev: 1
Page: 13/19

Mar. 30th, 2011

Rev: 1
Page: 14/19
During beam assembling in three-sided process, each unit is connected

completely according to design set, bracing to avoid welding deformation; and
then weld the whole beam inside. After checking by visual about welding of
beam inside, cap the plate to control the dimension of the beam and conduct to
welding finish. Checking by visual the overall dimensions of welding seam; the
flatness of beam sides according to the length design of beam. If these results
achieved, conduct Nondestructive testing and acceptance to move for cleaning
and painting.

Mar. 30th, 2011

Rev: 1
Page: 15/19
Roller support is made with the same way.

Dump bailer supports in fabricating procedure and inspection are skidded on the
platform.
Dump bailer will be fabricated and accepted in accordance with gauge.

All units connecting together which are difficult to clean and paint, after
finishing, they are cleaned and painted with anticorrosive paint before
assembling.
The remains of scraper will be completely fabricated, accepted and finish
painting at the LISEMCO Contractors shop, and then conduct to assembly and
install.
III.2. The fabrication of Stacker: the fabrication of each unit
The cutting stage must carry out on CNC machine. After cutting, the plates are
connected together according to working drawing and finish welding for

Mar. 30th, 2011

Rev: 1
Page: 16/19
connecting plates; check Nondestructive testing (NDT). If these results are

achieved, conduct the assembly beam. The platform is used for assembly beam.
and painting.
Roller support is made with the same way.
Band conveyor support in fabricating process and inspection is performed on

gauge support.

Mar. 30th, 2011

Rev: 1
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All units connecting together which are difficult to clean and paint, after
finishing, they are cleaned and painted with anticorrosive paint before
assembling.
The remains of Stacker will be completely fabricated, accepted and finish
painting at the LISEMCO Contractors shop, and then conduct to assembly and
install.
III.3. Unloader machine fabrication : execution with each unit.

Cutting stage performed by CNC machine. After pleteting , the plates connected
according to fabrication drawing and finishing welded, if NDT checking is
achieved, beam assembling will be implemented. Platform used for this work
and painting.

Mar. 30th, 2011

Rev: 1
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The remains of unloader will be made with the same way and cleaned and
painted at the LISEMCO Contractors shop, and then conduct to pack and
install.
III.4. Fabrication for direction turning tower: Because tower structure

coupling bolt, so fabrication process is process which fabricate loose parts , after
that testing assembly each unit.
+ The pillar, beam are cut by steel shape (I,V...) with right dimension, marked by
arrows directing position of gusset plate, attaching gusset plate after drilling
hole.
+ Bracing is performed with cutting dimension, attached gusset plate, welding,

dimension inspection after welding and flatness, then move to clean and paint.

Mar. 30th, 2011

Rev: 1
Page: 19/19
+ Platform and ladder are fabricated with the same way.
+ After loose materials are checked, cleaned and painted.

+ Packing and installing in construction site.
IV. Inspection of dimensional tolerance
+ Measurement testing, tolerance in dimension acceptance inspection according
to project standards (Document no:VA1-FLS-00100-M-M2-DST-6040)
TOLERANCES
>0.5
30
120
315
1000
2000
4000
8000
12000 16000 20000
12000 16000 20000
30
120
315
1000
2000
4000
8000
0.1
0.1
0.2
0.3
0.5
0.8
1.2
0.2
0.5
0.2
0.5
10
12
14
=3
0.8
1.2
3 < S = 50
1.5
1.5
2.5
3.5
50 < S = 100
2.5
2.5
3.5
4.5
L=10
10<L=50
50<L=120
120<L=315
1.8/100 mm
0.9/100 mm
0.6/100 mm
0.3/100 mm
2.6/100 mm
1.5/100 mm
0.7/100 mm
0.4/100 mm
5.2/100 mm
3.5/100 mm
1.8/100 mm
1.3/100 mm
315<L=1000
L>1000
0.9/100 mm
0.6/100 mm
16

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DOCUMENT SUBMISSION STATUS: FC

ISSUED FOR CONSTRUCTION

ISSUED FOR CONSTRUCTION

ISSUED FOR APPROVAL

ISSUED FOR APPROVAL

POYRY ENERGY LTD

EPC CONTRACTORS CONSULTANT

VUNG ANG 1 THERMAL POWER PLANT 2 x 600MW

steel structure FABRICATION PROCEDURE

HAIPHONG EQUIPMENT MANUFACTURE AND

DAM VAN HIEU

PHAM NGOC QUANG

Hai phong equipment manufacture and

Mar. 30th, 2011

Steel structure Fabrication

Vung Ang1 Thermal Power Plant

COAL HANDLING SYSTEM M8

Ky Loi commune - Ky Anh District-Ha Tinh province

Steel structure Fabrication Procedure

Hai phong equipment manufacture and

Mar. 30th, 2011

Chapter 1: General Introduction.

Chapter 2: Fabrication procedure.

Chapter 3: Fabrication method.

Chapter 1: General Introduction

Steel structure Fabrication Procedure

Hai phong equipment manufacture and

Mar. 30th, 2011

b. The director of project

2. Inspection unit- quality control

Steel structure Fabrication Procedure

Hai phong equipment manufacture and

Mar. 30th, 2011

Vung Ang 1 Thermal Power Plant

Ky Loi commune, Ky Anh district, Ha Tinh province

ITEM: COAL HANDLING SYSTEM M8

ORGANIZATION CHART FOR LOT-M8

DEPUTY PROJECT MANAGER

Mr. PHAM NGOC QUANG

Mr. NGUYEN DINH QUYNH

Ms.TRUONG THI HUONG

QC/QA PRJ. MANAGER

Mr.PHAN VAN HUNG

Mr. VU VAN QUANG

Mr. DO XUAN DUNG

Mr. BUI DUC THIET

QC/QA PRJ. MANAGEMENT

Mr. PHAM VAN TUYEN

Mr. NGUYEN QUANG VINH

WORK SHOP SUPERVISOR

Mr NGUYEN VAN DOANH

Mr. NGUYEN VAN HUNG

MECHANIC AND WELDER

MECHANIC AND WELDER

PACKING & SHIPPMENT

Date of isuue: Otc 12th, 2010

Hai phong equipment manufacture and

Mar. 30th, 2011

requiremetns). These requirements are given Economy-Technology

Department, Lisemco. Economy-Technology Department must have answer in

Steel structure Fabrication Procedure

Hai phong equipment manufacture and

Mar. 30th, 2011