FOR APPROVAL

PROJECT
NGHI SON 1 THERMAL POWER PLANT CONSTRUCTION
PROJECT
(CONTRACT NO. 010610/NS1-EVN-MC)
OWNER

VIETNAM ELECTRICITY
CONSULTANT

J-POWER / AF-CONSULT SWITZERLAND and

PECC3
CONTRACTOR

MARUBENI CORPORATION

REV. NO.
PROJECT CONTROL NO. NS1-18HA-M-JEE-1004
1
Title:
Work Plan Procedure for Erection of Top Girders of Boiler
Steel Structure
(On-Shore M&E Erection Portion)

Document No.: NS1-JEE-MCP-MS-004 Rev.: 1

0 First Issue aruna BJ 22 Dec 11 Scale: None Date: 22 Dec 2011

Rev. Description By App. Date JURONG ENGINEERING LIMITED

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

TABLE OF CONTENTS PAGE

1. INTRODUCTION 3 of 164

2. SCOPE OF WORK 5 of 164

3. ERECTION EQUIPMENT 9 of 164

4. SPECIAL TOOLS 11 of 164

5. TRANSPORTATION,UNLOADING,AND STORAGE 13 of 164

6. ERECTION SEQUENCE AND PROCEDURE 18 of 164

7. QUALITY CONTROL 43 of 164

8. DETAILED PROGRAMME (TIME BASED) 45 of 164

9. ORGANISATION AND MANPOWER 47 of 164

10. RISK ASSESSMENT 50 of 164

11. SCAFFOLDING REQUIREMENTS 57 of 164

12. LIGHTING REQUIREMENTS 65 of 164

13. ANNEXURE 70 of 164

a. ANNEXURE 1 DOCUMENTS
b. ANNEXURE 2 DRAWINGS
c. ANNEXURE 3 - WELDERS CERTIFICATES
d. ANNEXURE 4 - TEST CERTIFICATES
e. ANNEXURE 5 - CALIBRATION CERTIFICATES
f. ANNEXURE 6 STORAGE PROCEDURE / CHECK
g. ANNEXURE 7 TOOLS LIST

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

1.INTRODUCTION

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

1. INTRODUCTION

PROJECT : 2300MW NGHI SON-1 COAL FIRED THERMAL POWER

PLANT

OWNER : VIETNAM ELECTRICITY (EVN)

CONTRACTOR : MARUBENI CORPORATION

SPECIFICATION : THE CONTRACT SPECIFICATION WILL BE USED FOR THE

CONSTRUCTION WORK.

THIS ERECTION PROCEDURE IS SPECIFIC TO TOP MAIN

GIRDERS INSTALLATION ON THE BOILER STEEL STRUCTURE

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WORK PLAN PROCEDURE FOR ERECTION OF
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PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

2. SCOPE OF WORK

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

Scope of erection work

1. To ensure the stability of steel structure members to position the girders

2. The three main Girders weighing around 11 tons of

8 tons
85 of eachwill
(maximum
each willweight)
bebeinstalled
installed
of each
between column K6.3-K2.7, 5
L6.3-L2.7, M6.3-M2.7
between columns K6.3-K2.7,L6.3-L2.7,M6.3-M2.7.

3. Transportation of Girder from area tosite

port to site(Election location) - (By Heavy Cargo

. Transporter)
Transporter)

4. Peparation of Girder for positioning (to vertical position,install life line and
landing platform).

5. To confirm the correct orientation of Main girders.

6. Positioning of 600 ton crane.

7. Confirm all the sling wires and lifting methods are adapted as per enclosed
Drawing.

8. To ensure safety guidelines are in place before lifting.

9. Lifting and positioning of Girders.

columns
10. Alignment and bolt tightening of girder to clumns.
11.Details of Girders and Location:(Refer drawing NS1-11HFA-M-FWC-1309-R1 for Girder details)

a.Grids K6.3-K2.7,-(G4-1-NS)
b.Grids L6.3-L2.7,-(G4-2-NS)
c.Grids M6.7-M2.7,-(G4-3-NS)

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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
125127-46-1142 GENERAL NOTES

1. DO NOT SCALE THIS DRAWING. USE FIGURE

DIMENSIONS ONLY.
2. ABBREVIATIONS USED ON THIS DRAWING ARE IN
ACCORDANCE WITH ASME Y14.38
A "ABBREVIATIONS AND ACRONYMS". A
3. ALL WELD SYMBOLS USED ON THIS DRAWING IN
ACCORDANCE WITH AMERICAN WELDING SOCIETY
PUBLICATION ANSI/AWS 2.4, "STANDARD WELD
SYMBOLS FOR WELDING BRAZING AND
NONDESTRUCTIVE EXAMINATION".

B B

C C

D D

C600 C600 C600

E E

C600 C600 C600

F F

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G G

H H

1 05-19-11 HT ISSUE FOR DETAILING

0 05-12-11 HT FOR FIRST ISSUE
I DR. I
REV. DATE INIT. REVISIONS DESCRIPTION

CONSTRUCTION
FABRICATION
1 05/19/2011 HT DETAILING
COMPLETE MATERIAL ORDER
PARTIAL MATERIAL ORDER

BID/QUOTATION

REV. DATE APPR. ISSUED FOR

PROJECT

NGHI SON 1 THERMAL POWER PLANT CONSTRUCTION PROJECT

J (CONTRACT NO. 010610/NS1-EVN-MC) J
OWNER

VIETNAM ELECTRICITY

CONSULTANT
J-POWER / AF-COLENCO and PECC3

CONTRACTOR

MARUBENI CORPORATION
TYP. REV. NO.
PROJECT CONTROL NO. NS1-11HFA-M-FWC-1142 1

STEEL FRAMING PLAN(LEV R)

K TOS EL.60330 K
TYP.
TYP.

C600
2 x 300 MW STEAM GENERATORS
FWNAC CONTRACT 65-125127-01
DRAWING NUMBER SCALE:
1:80
REVISION

125127-46-1142 1
DRAWN BY HT 12/02/2010 65-125127-01
CHECKED BY RV 05/19/2011
L PRODUCT CODE 79 SIZE A0 L
THIS DRAWING IS THE PROPERTY OF THE

FOSTER WHEELER NORTH AMERICA CORP.

CLINTON, N.J.

AND IS LENT WITHOUT CONSIDERATION OTHER THAN THE BORROWER'S

AGREEMENT THAT IT SHALL NOT BE REPRODUCED, COPIED, LENT, OR
DISPOSED OF DIRECTLY OR INDIRECTLY NOR USED FOR ANY PURPOSE
OTHER THAN THAT FOR WHICH IT IS SPECIFICALLY FURNISHED. THE
APPARATUS SHOWN IN THE DRAWING IS COVERED BY PATENTS.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Tekla Structures
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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

3. ERECTION EQUIPMENT

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WORK PLAN PROCEDURE FOR ERECTION OF
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PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

3. ERECTION EQUIPMENT

3.1. Crawler crane 250 ton Capacity 2 Numbers

3.2 Crawler crane 600 ton Capacity- 1 Number
3.3 Crawler crane 70 ton Capacity - 1 Number
3.4 Mobile Hydraulic Crane - 50 ton Capacity - 2 numbers
3.5 Wire sling 65mm x 15m
3.6 Wire sling 56mm x 12m = 2 nos
3.7 Wire sling 56mm x 6m = 2 nos
3.8 Sharkles - 80 ton = 4 nos
3.9 Sharkles - 55 ton = 2 nos
3.10 Sharkles - 35 ton = 2 nos
3.11 Steel plate 32mm x 1.5 x 6m
3.12 Wood block 200 x 200 x 2m - 32 nos
3.13 Scaffolding BS 6m pipe and 100mm
3.14 Chanel 200 x 200 x 6 - 12 nos
3.15 Pipe 80 SCD 4" 6m 1 nos

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

4.SPECIAL TOOLS

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

4.SPECIAL TOOLS

The steel structure erection doesnt cover any special equipment.However, shear
wrench will be used to shear the bolts. The product catalogue ( Instruction Manual)
of shear wrench was enclosed in the Annexure - 1.

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

5.TRANSPORTATION,UNLOADING
AND STORAGE

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

5.TRANSPORTATION,UNLOADING,AND EQUIPMENT

5.1Transportation

In principle, suitable transport such as trailers, low bed trailers, shall be selected
and used for transportation. Road survey for transportation access shall be conducted.

5.2 Material Receiving

Girders shall be inspected visually for any damages.If materials are rejected after checking,
non-conformance report shall be
submitted to EVN, and the rejected steel structures shall be repaired on the advise of
EVN/MC.

5.3 Material Handling

Care shall be taken to prevent the surfaces of from contamination and damage
during materials handling and transportation.
The primer coated Girders shall be handled with sling wires with pads in order to prevent
damage to the primer coated of the Girders.The Girder will be handled in the
correct manner to evenly distribute the load preventing distortion of lifts.

5.4 Material Storage

Please refer Job storage procedure in the ANNEXURE-6. Based on site condition
the contractor will decide the suitable storage area to facilitate field installation.
The Steel Structures shall be stored on Temporary supports confirming to the
manufacturers requirements. The contractor will request the release of material
from the storage area as per procedure.

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 CRANE 600T/ 250T LOCATION

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 PACKING STYLE OF
MAIN GIRDER

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18/139

MAIN GIRDER ROUTE - TRANSPORT

STRANPORTPLAN
PLAN
MAIN GIRDER ROUTE - STRANPORT
TRANSPORT PLAN

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

6.ERECTION SEQUENCE AND

PROCEDURE

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WORK PLAN PROCEDURE FOR ERECTION OF
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PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

6.ERECTION SEQUENCE AND PROCEDURE

6.1 BEFORE ERECTION

The following checks are to be carried out:

a) To check elevation of supporting steel and record for any difference, if steel structure
beyond the tolerance, the rectification of structures to be carried out.
b) The co-ordinates of K, L & M columns on the rows 1.4 & 7.3 have to be checked
before Girders are erected.
c) Checking of connection points on the column and confirmation before lift Main
Girders.
d) Calculation of lifting devices (cranes,sling wires,d-shackles etc.,)

e) Ensure the readiness and operation of 600 Ton crane

Note: The three Main girders are transported as a single piece each weighing around 85
Tons .

6.2 FLOW DIAGRAM

DIAGRAM
A flow diagram is attached herewith for the actual flow of work to be followed at
site

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

FLOW DIAGRAM FOR MAIN GIRDER ERFETION

PREPARATION WORK
(Marking, Chipping & Packer setting)
ALIGNMENT &INSPECTION

MATERIAL TRANSPORT
BOLT TIGHTENING WORK

STEEL STRUCTURE ERECTION WORK

TIER 1 TO TIER 4

MAIN GIRDER ERECTION

STAIR CASE & HANDRALL

HANDRAILIL
ERECTION WORK

6.3.3INSTALLATION
INSTALLATION:

a. Erect Structure, the main member column, beam or girders and bracing until fourth
tier to the Elevation +61,350mm.
b. K column Girder will be lifted first to its position thereafter remaining two girders
at rows 1.4 to 7.3 (L, M) shall be lifted

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WORK PLAN PROCEDURE FOR ERECTION OF
TOP GIRDERS OF BOILER STEEL STRUCTURE

PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

6.3 INSTALLATION
6.3 INSTALLATION
a. Erect Structure, the main member column, beam or girders and bracing until fourth tier to
the Elevation +61,350mm.
b K column Girder will be lifted first to its position thereafer remaining two girders at rows 1.4
to 7.3 (L, M) shall be lifted.
c. The Girders will be unloaded at site South Side of Boiler refer page 23 of 164.
d. By using 250 ton, 70 ton, 50ton cranes, the Girders are tilted to vertical position refer page
24-30 of 164.
e. All the preparation work and confirmation of lift lugs will be performed before lift.
f. The Lifting method sketch showing the details are attached .
g. Note that before erection joint surfaces are cleaned and assured no foreign materials
such as oil, soil, sand, etc are present.
h. Necessary scaffolding will be installed before Girders lift refer page 32 of 164.
i. The Girders are lifted to position by 600 ton crane refer page 36 & 37 of 164.

6.4 BOLTING WORKS

Bolting works will be done in accordance with the specification 125127-46-46A9B

(refer annexure-1). Assembly of structure will be done with the use of shear type bolts as per
drawing or RCSC specification.

Step 1: Confirm steel structure alignment completion.

Step 2: Clean thoroughly the area to be bolted

Step 3: Use tapered wedge to adjust bolt holes.

Step 4: Install HT/TC bolts of correct size progressively as stipulated in RCSC

specifications.

Step 5: First tighten the bolts using manual wrench.

Step 6: Using electric shear wrench systematically progress tightening from the most
rigid part of the joint to its free edges until the end part of the bolt is sheared off.

Step 7: Bolt verification will be done by tensioning device (skid more or equal),thin
feeler gauge and small tape measure with thin hook.

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WORK PLAN PROCEDURE FOR ERECTION OF
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PROJECT: 2300MW NGHI SON-1 COAL FIRED

POWER PLANT

BOLTING SEQUENCE

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