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OWNER
OWNER’S ENGINEER
CONTRACTOR
SUB. CONTRACTOR
NE NOOTER/ERIKSEN
FOR
NOOTER/ERIKSEN
JOB NUMBER
113100
Rev. 0
GENERAL INFORMATION
2. SHIPPING/LIFTING WEIGHTS:
3. SHIPPING SEQUENCE
4. RELEASE FORMS
Release forms accompanying the documentation for this manual shall be filed
with the manual. The release date on the Form shall be the effective date of
the revised documentation.
Nooter/Eriksen will issue release forms and revised documentation only for
manuals listed in the “MANUAL DISTRIBUTION” portion of the Release
Form. All manuals generated by others shall not be considered “Controlled
Documents”.
SECTION PAGE
1.0 General......................................................................................... 1
11.0 Testing........................................................................................ 11
FIELD ERECTION
RESPONSIBILITIES
1.0 GENERAL
Read and review this entire manual and its contents before
beginning field erection.
2.0 DEFINITIONS
APPROVED BY RDG
X:\Procedures\Erection.Manual\Erection_Procedure R16
SUR IPP PROJECT, OMAN
N/E JOB NO. 113100
ERECTION PROCEDURE, REV. 0
PAGE 2
These reference documents form an integral part of this manual and must be
read carefully and understood before beginning any field erection. Reference
documents are listed in Section 15.0 under the “General” tab location. Should
you have any questions, please contact the individuals listed below:
Foundation Embedments
Inlet Expansion Joint (K/D)
Inlet Transition Duct Panels (K/D)
Inlet Distribution Grid (K/D)
Supplemental Duct Burner Runners
Firing Duct Panels (K/D)
Fuel Train Skid
Scanner Cooling Air Skid
Primary Casing Panels (K/D)
Secondary Casing Panels (K/D)
HRSG Coil Modules
Recirculation Pumps
Remote Steam Drums
Deaerator
Atmospheric Blowdown Tank
Exhaust Stack (K/D)
Expansion Joint at Stack (K/D)
Exhaust Stack Silencer Baffles (K/D)
HRSG Interconnecting Piping
Pipe Supports
Platforms, Stairs & Ladders (K/D)
Boiler Trim & Valves (K/D)
Field Seam Material (K/D)
External Insulation for Interconnecting Piping, Valves and Drums.
Temporary Use of Horizontal and Strong-Back Lifting Device for Erection of
Coil Modules. (Lifting Devices must be returned to N/E after use.)
SUR IPP PROJECT, OMAN
N/E JOB NO. 113100
ERECTION PROCEDURE, REV. 0
PAGE 4
Assemble and Install Drain Valves and Manifolds Along Side Each Heat
Transfer Section including Collecting all Multiple Drains at each Bundle
Install Freeze Protection
Tubeside Cleaning of HRSG
Steam Blows
Install Steam Drum Internals after Tubeside Cleaning
Re-install non-return Valve Discs, Desuperheaters, Steam Sample Probes,
Measurement Devices or any other Equipment that was temporarily removed
for Steam Blows
Install all Pneumatic Tubing or Pipe for Air Supplies and Signal Lines
Install all Electrical Conduit, Wiring and Electrical Panels
Install all External Personnel Protection (Not Required with Insulated Stack).
Install all External Insulation on Remote Steam Drums, Drum Heads,
Interconnecting Piping, Drain Lines, etc.
Install all External Insulation on Outlet Stack
Install all External Insulation on Silencer Duct
Touch-Up Primer and Finish Paint
Commissioning, Check all Valves/Motor Operators Prior to Start-Up, etc.
SUR IPP PROJECT, OMAN
N/E JOB NO. 113100
ERECTION PROCEDURE, REV. 0
PAGE 6
7.1 The Erector shall provide all necessary equipment and manpower to
perform all required non-destructive testing as required by the Code or the
Purchaser.
7.2 As a minimum requirement, the Erector shall 100% Magnetic Particle Test
(MT) all field welds at corner connections on major structural frames. If
other more stringent non-destructive examination methods are required
(as required in high seismic areas, and/or as specified on N/E drawings),
the Erector shall perform them.
7.3 The Erector shall provide all stress relieving equipment and all necessary
materials and specialists as may be required to properly stress relieve the
welds as required by the Code and the Purchaser.
7.4 The Erector shall perform the stress relieving as required by Code and
maintain charts of time versus temperature gradients, copies of which
shall be submitted to the Purchaser. A copy of radiographic results and
procedures will be forwarded to the Purchaser. Purchaser will forward all
documentation to N/E that is to be included in the Master Document
Package.
8.2 The Erector shall unload, erect or store the equipment without delay.
Detention and demurrage charges, associated with failure to off-load rail
cars at the jobsite in the days allotted by the rail service, will be billed to
the Purchaser. Erector must notify the railroad immediately of cleaned
railcars to avoid unnecessary charges to the Purchaser. All deliveries,
unloading and transporting of equipment shall be coordinated through the
Purchaser to avoid interference with other operations. The Erector will
ensure that end-to-end support of the modules is sufficient during
transportation. If restraints are needed to ensure the integrity of the
modules during travel on steep grades, the Erector will install them as
required. If modules are stored, refer to the Module Storage
Recommendations drawing located in the “Miscellaneous” section of this
manual.
8.3 The Erector shall be responsible for the care and custody of the
equipment received. All N/E furnished equipment arriving at the railsiding
or site shall be checked by a representative of the Purchaser and turned
over to the Erector in good condition. The Erector shall be responsible
thereafter for the equipment until it is installed and accepted by the
Purchaser.
8.4 The Erector shall keep a written record of all equipment and materials
received at the jobsite and perform regular inspections and maintenance
during storage. These records shall be made available to the Purchaser
and N/E at all times.
8.4.3 Secondary casing panels are typically shipped with the internal
liner facing upward. The attachment points for tailing these
panels are located on the casing (downward) side of the panel.
It is the Erector’s responsibility to exercise caution in offloading
SUR IPP PROJECT, OMAN
N/E JOB NO. 113100
ERECTION PROCEDURE, REV. 0
PAGE 9
8.4.4 All piping must remain capped during storage and erection, in
order to preserve cleanliness.
8.4.5 Coils and drums are shipped with an internal vapor phase
corrosion inhibitor added prior to sealing nozzles with plastic
caps and tape. To maximize the protection against corrosion
and contamination, coil and drum nozzle caps and tape should
be maintained and remain intact as long as possible. It is
acceptable, however, to remove caps on lower header nozzles
temporarily to facilitate module draining during erection.
The Erector shall furnish all items required for the work not specifically being
furnished by N/E. These items shall include, but not be limited to, labor saving
devices; special equipment and technicians for stress relieving; temporary
winterizing or freeze protection during erection for drainable and non-drainable
parts of the HRSG; hydrotest equipment. The Erector shall furnish all necessary
tools and construction equipment such as transporters, rigging equipment,
welding equipment, consumables, trucks, cranes, etc., necessary to perform the
work.
10.1 The Erector shall plan the erection of the HRSG taking into account N/E’s
recommended field erection procedures and specific requirements from
detailed project drawings, as listed in the Nooter/Eriksen Drawing List.
10.2 Erection Procedures are found with the reference documents at the back
of this manual in Section 15.0.
Note: Erector must comply with any special erection and storage requirements
provided by manufacturers/designers of specialty equipment such as, but
not limited to:
A) Duct Burners
B) Pumps
SUR IPP PROJECT, OMAN
N/E JOB NO. 113100
ERECTION PROCEDURE, REV. 0
PAGE 10
C) Expansion Joints
D) Etc.
10.3 These procedures are provided as a guide for field erection based upon
N/E’s design of the system. Deviation from these procedures is not
recommended unless otherwise indicated on N/E’s Project Specific
Erection Drawings. If the Erector chooses to follow other procedures and
difficulty arises or damage occurs, the Erector will assume all
responsibility and all associated additional costs. N/E reserves the right to
review all changes to the procedure.
Exposure of “as weld” (prior to the performance post weld heat treatment)
weldments to environmental elements is to be limited. Protection shall be
provided to prevent direct exposure to moisture.
All arc strikes not in the welding preparation zone must be ground and
verified by non-destructive examination (NDE) as not being detrimental to
the material.
When welding P91 to P22 material, N/E recommends that P91 welding
consumables are used.
11.0 TESTING
After field assembly, each pressure level of the HRSG and any interconnecting
piping within the ASME Code boundary must be hydrotested by the assembler
and witnessed by their Authorized Inspector (AI).
Additional hydrotests may be necessary during the life of the HRSG if any
alterations or repairs are performed within ASME Code boundaries.
The following information is provided to help protect the HRSG before and after
hydrostatic tests.
Verify that all instruments are isolated to prevent damage from over
pressurization.
The HRSG components must not be exposed to pressures exceeding 1.5 times
the MAWP.
Severe corrosion can occur when inappropriate water is used for the hydrotest.
N/E recommends the following:
If a potential for freezing weather exists, the unit should be filled with the
warmest water available. (Note, however, that ASME Code defines metal
and water temperatures in PG99. This should be consulted for proper
temperatures.) Interior heating or other precautions may be necessary to
prevent freeze damage.
After the test, the HRSG must be properly laid up to prevent damage from
corrosion or freezing. Unless water treated specifically for lay up was
used during the hydrotest and will be chemically maintained over the lay
up period, the HRSG must be drained and laid up dry within 24 hours.
(See the Nooter/Eriksen Lay Up recommendations.)
Stops on all spring cans should be removed after the field Hydrotest.
All valves have been tested by the manufacturer to ASME B16.34 or API
598 requirements for pressure boundary and seat leak tightness. N/E will
warrant any leaking/seating issues on all N/E supplied valves through
HRSG hydrotesting. Any drain valve leakage that occurs after HRSG
hydrostatic testing has proved the valves were supplied as leak tight, is
the responsibility of the purchaser/owner and will not be considered as a
warranty issue by N/E.
Note: N/E will not accept any liability resulting from the particular chemistry of the
hydrotest water.
SUR IPP PROJECT, OMAN
N/E JOB NO. 113100
ERECTION PROCEDURE, REV. 0
PAGE 14
12.0 PAINTING
In addition to the support system for the liner, there are liner/casing penetrations
and bearing points for coils and other internals, where there may be localized hot
spots on the outer casing. These hot spots may be noticed as small areas of
paint discoloration. These areas of higher casing temperature do not indicate
insulation breakdown and will not compromise the long term structural integrity of
the unit.
The inlet may require a field installed distribution grid, based on a flow model
study. See Inlet Duct drawings for specific details.
16.0 PIPING
This contract requires that the 3” Nooter/Eriksen standard field trim be eliminated
from the LB piping (except on all drum risers). Because of the elimination of the
standard field trim, Nooter/Eriksen is not subject to field backcharges for
mismatches on LB piping of less than 3” (i.e. if 3” field trim was left on, the field
could have made the adjustment to the pipe).
Block valves have been supplied on all drain lines. All valves have been hydro
tested by the manufacturer to ASME B16.34 or API 598 requirements for
pressure boundary and seat leak tightness. N/E will warrant any leaking/seating
issues on all N/E supplied valves through hydrostatic testing. It is the purchaser’s
responsibility to appropriately clean, flush and drain the HRSG during
commissioning and/or normal operation. Opening of drain valves with the unit
under pressure greater than 100 psig can be damaging to the valves. The
exception to this rule is the opening of superheater and reheater drains under
startup conditions to eliminate any condensate that may have accumulated. Any
drain valve leakage that occurs after hydrostatic testing has proved the valves
were supplied as leak tight, is the responsibility of the purchaser/operator and will
not be considered as a warranty issue by N/E.
EP-01 PAGE 1
ERECTION PROCEDURE FOR
FOUNDATIONS
ANCHOR BOLTS AND BASE PLATES
1.0 The contractor responsible for foundation installation shall meet the requirements of
N/E’s foundation drawing.
1.1 The Contractor shall establish the centerline of the unit and the longitudinal
reference point and set anchor bolts per N/E’s foundation drawing.
1.2 All anchor bolts shall be located with the following tolerances. (Refer to
Drawing EP-01-01).
1.3 Anchor bolts shall be installed when possible using embedded sleeves (min
12” depth). This will assist in the installation of the equipment if either base
plate holes or anchor bolts are located out of tolerance.
1.6 Shear tabs, if shown at column base plate details, shall be installed after
column setting. Welding of the shear tabs shall be on three sides only. No
welding on the side of the tab next to column base plate is permitted.
2.0 The Erector of the HRSG shall be responsible for the following items:
2.1 The Erector shall fit each HRSG foundation support point with a slide plate.
Slide plates serve two functions. One, it allows the elevations of the top of
the slide plate to be adjusted through shimming. Second, provides a flat
surface on which the equipment can move due to temperature expansion.
2.2 The Erector shall check to insure that the anchor bolt threads are clean and
all damaged threads corrected using a thread chaser.
2.3 All anchor bolts, slide plates, grout and shims are furnished by someone
other than N/E. Nooter/Eriksen is not responsible for design and/or
workmanship of any of the above referenced material located below the
bottom of the HRSG base plates.
2.4 The Erector shall check the elevations of all foundations and the location of
all anchor bolts prior to equipment installation. Refer to the benchmark for
elevation reference. Any deviation from allowable tolerances as listed on
Drawing EP-01-01 should be brought to the attention of the Purchaser. All as
built dimensions are to be documented and provided to N/E and the
Purchaser upon request.
EP-02A PAGE 1
ERECTION PROCEDURE SETTING
OF MAJOR HRSG COMPONENTS
1.1 Some components are provided to the field with lift lugs. These lugs are only
designed to lift the components as supplied. These lugs are not designed to lift
the components after any additional assembly by Field Erector. It is the Erector’s
responsibility to design and install any lugs required for lifting of pre-assembled
components. Each component shall be handled using N/E Erection Procedure
drawings. All rigging, spreader beams, shackles, etc. shall be furnished and
designed by the Erector to meet the expected loading and the requirements of
the procedures.
1.2 MODULAR
1.2.1 The following items shall be checked to insure that critical attachment
locations are maintained.
1.2.1.1 Set the top of the slide plates at the theoretical elevation.
1.2.2 Set primary casing panels and roof beams as defined in EP-04A.
1.2.2.1 Each column shall be set so that the inside flange is at the
theoretical distance from the centerline of the HRSG.
1.2.5 After each primary casing panel is set, shimmed, checked for correct
elevation, and plumbed, the anchor bolt washers and nuts can be
installed. N/E provides enlarged holes in the base plates to facilitate
module installation. Anchor bolt washers (as detailed on N/E drawings)
are to be installed on the base plates as indicated on N/E foundation
detail drawings.
EP-02A PAGE 3
ERECTION PROCEDURE SETTING
OF MAJOR HRSG COMPONENTS
1.2.6 When setting the modules, the nozzle connections shall be checked
against the Nooter/Eriksen drawings for correct station location and
elevation to within (+) or (-) ¼”. Nozzle locations should be checked with
a transit. Do not rely on shop stenciling for module location. Refer
to Nooter/Eriksen field erection drawings for module configuration
and unit location.
1.2.8 For each successive module set, particular attention shall be given to
make sure that the modules location and elevation are maintained. The
nozzle orientation, as shown on Nooter/Eriksen drawings, shall be used
as the primary guide for the setting and the alignment of modules.
1.3 DUCTING/BREECHING
1.3.2 If the HRSG is provided with an SCR, the Erector is to verify that the
Catalyst Loading Opening is plumb and square so that the Catalyst
Loading Doors will fit properly (trial fitting the Catalyst Loading Doors is
recommended). This must be done prior to final welding of the SCR duct
frame corner connections.
1.4.1 Exhaust stack shall be erected, welded and inspected per the
requirements of ASME STS-1 and any local applicable codes.
1.4.2 All rigging, spreader beams, shackles, etc. shall be furnished by the
Erector to meet the requirements of the procedures.
1.4.3 Exhaust stacks are provided with either anchor chairs or an anchor bolt
ring. In either case, the stack is considered to be fixed against
longitudinal movement.
1.4.6 Prior to setting the stack, the Erector should prepare the concrete for
shim pack locations. Enough shim packs should be used to prevent
damage to the foundations.
1.4.7 Exhaust stack can come in one piece, two pieces, or multiple sections
depending on the diameter of the stack. If supplied K/D, orientation of
vertical seams will be found on fabricator’s drawings.
1.4.8 If the stack is provided with a damper, the damper shall be installed after
the bottom stack section is installed vertically on the stack foundation.
The damper shall not be attached to any stack cylinders prior to lifting
into final position, to prevent damage to the damper.
1.4.9 For thermal expansion between the last HRSG module and the fixed
exhaust stack, there will be an expansion joint. It is important to ensure
the following items are checked.
1.4.10 It is recommended that the platforming required for EPA test ports be
installed just prior to lifting the stack sections.
1.5.1 Normally the remote steam drums are supplied without lifting lugs
attached in the shops.
1.5.2 Each drum will be fitted with at least two support saddles. Guides shall
be installed around the saddle, after the drum is in its final position to
limit any movement and for resisting lateral wind and earthquake
loadings.
1.5.3 Both drum saddle base plates shall be greased prior to installation.
(Axle quality grease is recommended). If other slide mechanisms are
used, greasing may be omitted. Check to make sure grease fittings are
installed. There should be a minimum of one (1) grease fitting per
saddle base plate.
1.5.4 When teflon slide packs are used at the drum saddle base plates, be
sure to attach the teflon slide packs to both the drum base plate and
support steel, prior to setting the drum on the support structure.
1.5.5 It is very important that the steam drums be located properly. The
difference in elevation of the drum centerline, from one end to the other,
shall be no greater than ½”.
Elevation: +/- ½”
Location: +/- ¼”
1.6.1 Anchor bolts that are to be snug tight shall be tightened per AISC
Specification for Structural Joints Using ASTM A325 or A490 Bolts.
1.6.2 Anchor bolts that are to be torqued tight shall be tightened per AISC
Specification for Structural Joints using ASTM A325 or A490 Bolts “Turn-
of-Nut tightening”. It is not necessary to provide a representative
sample, but follow the guidelines of the appropriate table.
EP-02A PAGE 6
ERECTION PROCEDURE SETTING
OF MAJOR HRSG COMPONENTS
1.7 Flow arrows are provided for convenience of the Erector. Nooter/Eriksen
accepts no liability for incorrectly marked flow arrows, as it is still the Erector’s
responsibility to check components against drawings to assure proper installation
orientation.
1.2 All rigging and lifting equipment shall be designed and furnished by the Erector to
meet the expected loading and the requirements of all procedures and drawings.
Design and use of this equipment shall comply with all applicable codes, industry
standards and safety guidelines. One example of each type of lifting device
(one Horizontal Lifting Device and one Strongback Device) shall be
provided by Nooter/Eriksen, provided Erector executes Nooter/Eriksen’s
standard Release & Indemnity Agreement. Before the Nooter/Eriksen
supplied lifting devices are used, the Erector must verify that all device
components are properly tagged to indicate that their capacity is consistent with
the devices specified on Nooter/Eriksen’s job specific Lifting Drawings.
1.3 Lifting lugs are designed to handle shear, tension and bending. A small amount
of lateral load has been designed into the lug to account for any cable
misalignment. Ideally the loads should act in line with the lug; however, a six
degree (6°) maximum offset is acceptable. Lifting lugs are limited for use at –
20°F and above. When lifting operation temperatures are below –20°F, contact
Nooter/Eriksen for review.
1.4 In some cases, a freeze protection medium may be added to the modules prior
to shipment. In these cases, the freeze protection medium is Dow Chemical’s
“Dow Frost”, or an N/E approved equal, which is propylene glycol. The MSDS is
made available with the shipping documents. The removal and disposal of the
freeze protection medium is the responsibility of the field erector.
1.5 MODULES
1.5.1 Each module is fitted with lifting lugs on the top headers or roof panel in
the shop. There are usually three lifting operations performed on each
module. The first is accomplished when the module first arrives at the
jobsite and is lifted in the horizontal position from the railcar onto the
transporter. Refer to the job specific N/E Module Lifting Drawings for the
general procedure.
1.5.2 The horizontal off-loading lift is performed with the Horizontal Lifting
Device. The device attaches as shown on the appropriate job specific
N/E Module Lifting Drawing(s), utilizing all of the strap lugs that are
provided with the shipping steel. The Horizontal Lifting Device must be
adjusted (width of device, as well as lug position) to fit the geometry of
the module. It may also be necessary to make adjustments between lifts
of different modules.
1.5.3 It is necessary to support the module upper headers (this can be done
through the roof beams), the lower headers, and all shipping beams
during transportation on the heavy haul transporter and during storage.
The supports should be installed in a manner to keep the upper and
lower headers at the same plane as they were shipped from the module
fabricator within +/-1”. See sketch “Module Storage (Staggered Pitch)”.
1.5.4 Refer to the actual job specific Nooter/Eriksen Module Lifting Drawings
for all details of the lifting devices.
1.5.5 The second lift is the lift from transporter to Strongback Device. This is
performed using the same rigging that was used for the first lift.
1.5.6 The third lift is the horizontal to vertical lift. This is accomplished by using
the Strongback Device. Refer to the actual job specific Nooter/Eriksen
Module Lifting Drawings for details and procedure.
1.5.7 Once the module is in the vertical position, it can be placed between the
appropriate columns and set in its final position. Each module roof is
equipped with support beams with a portion of the upper roof attached.
When the module is placed between the support columns, the load is
transferred from the module support beams to the upper frames.
1.5.8 After each lift, the lifting devices and all associated bolting/pins shall be
inspected by the Erector, to assure no damage has occurred and confirm
that all bolting is tightened as required. Any bent, worn or damaged
bolts/pins shall be replaced as necessary, with identical bolting/pins as
stated on the pertinent Nooter/Eriksen Drawings from the following list:
STRONGBACK01, STRONGBACK02, STRONGBACK03,
STRONGBACK16, HORIZLIFTDEV 1, HORIZLIFTDEV 2,
HORIZLIFTDEV 3, and HORIZLIFTDEV 7. Copies of these drawings are
included in the “MISCELLANEOUS” section of this manual.
EP-03ASB PAGE 3
LIFTING AND RIGGING
PROCEDURES
REVISION 0
1.5.9 It is the Erector’s responsibility to assure that the lift devices provided by
Nooter/Eriksen are being used properly and all lifting operations are in
accordance with the requirements as noted on Nooter/Eriksen drawings
and this Erection Manual to prevent damage to equipment and injury to
personnel. Erector will be responsible for any damage caused due to
failure to comply with these requirements.
1.5.10 After all use of the Nooter/Eriksen supplied lifting devices is completed,
the Erector is to fully dismantle them for return to Nooter/Eriksen. If
supplied containerized, Erector is to repack all components in containers
for shipment.
1.6 DUCTING
1.6.1 Lifting lugs are provided on ducting supplied in panel sections. Refer to
Erection Drawing EP-03A-09 through –12 for details of lifting procedure
and lifting lugs.
1.7.1 Exhaust stacks are shipped to the sites in several different forms.
1.7.2 The Erector has the option to build the stack by setting the cylinders
individually into the vertical position or to pre-assemble multiple cylinders
into a sub-assembly on the ground before lifting. If the cylinders are sub-
assembled on the ground, the Erector shall design and provide all
bracing required to prevent damage to the stack.
1.7.3 It is the Erector’s responsibility to design and supply the required lifting
and rigging equipment based on their chosen method for erection of the
stack.
1.7.4 If a stack is provided with a damper, the damper shall be installed after
the bottom stack section is installed vertically on the stack foundation.
The damper shall not be attached to any stack cylinders prior to lifting
into final position, to prevent damage to the damper.
EP-03ASB PAGE 4
LIFTING AND RIGGING
PROCEDURES
REVISION 0
1.8.3 Slings shall not break against any nozzle or nozzle reinforcement pad.
1.8.5 The Remote Steam Drum lifting weights are 5% greater than the shipping
weights marked on the Steam Drums.
EP-04A PAGE 1
ERECTION PROCEDURE FOR FIELD
SEAM INSTALLATION (MODULAR)
1.0 GENERAL
1.1 This procedure will provide general details, design considerations and
general installation procedures needed for installation. The Erector should
refer to the erection drawings for actual job details.
1.2 The liner assembly on all breeching and modules is designed to allow the
protective internal liner system to expand freely due to temperature
expansion of the components.
1.4 It is important that the installation of the field seams be understood prior to
beginning work. Failure to install field seams correctly can lead to casing
hot spots, loss of insulation and general failure of the integrity of the liner
system.
1.5 When casing and ducting are shipped with plastic weather protection on
the exposed insulation, it must be removed prior to installation of the field
seam insulation.
2.1.1 The primary casing panels have the main structural columns
attached to them. These panels are to be set on their
foundations, bolted/welded and braced in their final positions.
Combination bolted and welded connections are to remain bolted
after welding. It is the Erector’s responsibility to perform structural
welding in a manner that ensures that completed components are
within the tolerances specified in EP-11.
2.1.2 The secondary casing panels are stiffened with flat bar. To install
these panels it will be necessary to insert one edge of the casing
inside the column and rotate the other end in past the other
column and slide the casing to the proper position for weld to the
columns. See Drawing EP-04A-06.
2.1.3 The field seams between sidewall casing panels are seal welded
at the outer casing from the outside of the system. The insulation
pins, insulation and inner liner are installed from the inside of the
system. See Drawing EP-04A-07 and EP-04A-10.
2.2.1 For ease of installation, the floor beams are fit-up and held in
position with bolted connections. Bolt the primary floor panel to
columns on the sidewall casing. Attachment welding of floor
beam to sidewall columns is shown on the Erection Drawings for
the actual job details. Bolts are to be snug tight per AISC
Specification for Structural Joints Using ASTM A325 or A490
Bolts, unless otherwise specified on drawings.
2.2.2 Set the secondary floor casing in place and seal weld to the
adjoining primary floor casing from the liner side of the casing
panel.
2.2.3 The field seam between the sidewall and the floor casing is
completed by installing the corner angle from the inside and
installing the insulation and outer casing plate from the outside.
See Drawing EP-04A-08.
2.3.1 The roof beams are sent to the field with the casing, insulation
and liners shop installed.
2.3.2 The roof beams are bolted to the sidewall columns as the primary
sidewall casings are erected. See the individual job details for
bolt and weld requirements. This will provide stability for the
structural frame. Bolts are to be snug tight per AISC Specification
for Structural Joints Using ASTM A325 or A490 Bolts, unless
otherwise specified on drawings.
2.3.3 Attach the corner angles and insulation between the sidewall and
roof beam as the sidewall and the roof beams are erected (See
Drawing EP-04A-09). Due to access issues, this must be
completed before installing modules.
EP-04A PAGE 3
ERECTION PROCEDURE FOR FIELD
SEAM INSTALLATION (MODULAR)
2.4.1 The roof casings are shop installed onto the modules unless
noted otherwise on drawings. Care should be taken to ensure
that the liners are not damaged during the installation of the coils.
2.4.2 If tadpole gaskets are used, they shall be partially shop installed
on roof beams. Field attachment of tadpole gaskets on corner
angles may be required after the corner angle is in place (see
Drawing EP-04A-09), and before the modules are installed.
2.4.3 Field seams are required between the adjacent shop installed
module roofs and between the shop installed module roofs and
the sidewall. See the individual module drawings for the field
seam configurations supplied by the module fabricator.
3.1 Field liner plates shall follow the lapping sequence of the shop liner plates.
The actual laps on shop assembled pieces may vary from what is shown
in this standard. (See Drawing EP-04-10)
3.2 Before installing the field liner, the field seam cavity shall be completely
packed with ceramic fiber insulation. Care shall be taken to ensure that all
void areas are filled. If the field seam insulation is composed of multiple
layers, insulation seams shall be staggered.
3.3 Insulation pins are installed in the shop on the inside of column flanges.
Bend pins perpendicular to liner plate prior to installation of insulation.
4.1 SCR and CO catalyst systems, as well as catalyst frames and burners,
could be field installed in Nooter/Eriksen’s casing. This equipment can be
shipped to the site in either panels or in complete modules. The field
assembly of this equipment, if required, will be provided under separate
cover from the appropriate Vendor.
4.2 Field seams between the Vendor equipment and the Nooter/Eriksen
casing panels will be per Erection Procedure Drawings EP-04A-06 thru
09, and the individual job field seam drawings.
EP-05A PAGE 1
REMOVAL OF TEMPORARY
STEEL/WOOD
REVISION 0
1.0 GENERAL
1.1 Temporary steel, wood and bolting may be used to secure the modules or other
components during shipment. Also, temporary support steel may be affixed to
components to assure stability during shipment and/or installation.
2.1 All steel that is used to secure the module to the rail car is to be removed
completely just prior to off loading. If the modules are to be stored on the rail
car, they are to remain secured until just prior to off loading.
2.2 All material that is temporary by design shall be removed after the module is in
its full upright position. Any wood blocking should be removed before the
module is installed into the casing.
2.3 In some instances, modules will be shipped to the site with metal strapping
wrapped around the tube field, centered between vibration supports, and below
the lowest vibration support. This strapping must remain in place during the
horizontal-to-vertical lift. After the horizontal-to-vertical lift is completed, the
strapping is to be removed in the field. These straps are not painted yellow,
since they must remain in place until the horizontal-to-vertical lift is completed
2.5 In some instances, Superheater and/or Reheater Module upper headers are
supported externally, either directly by spring can supports or by
interconnecting piping. In these instances, temporary bundle support steel is
provided to support the headers during shipping and erection. This temporary
bundle support steel can be removed only after all external header supports
and/or associated piping (including pipe supports) are 100% installed, welded,
post weld heat treated (if required), and have received quality acceptance.
Following completion of this work, the temporary bundle support steel can be
APPROVED BY: VPM
X:\Procedures\Erection.Manual\EP-05A.R7
EP-05A PAGE 2
REMOVAL OF TEMPORARY
STEEL/WOOD
REVISION 0
removed and the casing field seams completed. This temporary bundle support
steel is painted yellow for field removal. However, the Field Erector must
verify that this steel is to be removed by a thorough review of N/E Field
Erection Drawings (See coil module drawings for details). If there is any lack
of clarity regarding removal of temporary bundle support steel, N/E is to be
contacted for assistance.
2.6 For modules that are lifted using the Strongback Lifting Device, the following
must be considered:
Shipping cradles at vibration supports and lower headers must remain intact
until module is installed on Strongback.
3.1 Stacks that are shipped in cylinders will have temporary steel, painted yellow, at
the openings. This temporary steel should be removed after the stack is in the
upright position.
3.2 Stacks that are shipped in 120 deg. segments shall have the temporary steel
remain in place until the stack has been assembled and welded into cylinders
and in the upright position.
4.1 All rail cars are to be cleared of tie down steel, by the Erector, prior to release
back to the railroad. Charges will be applied to the Erector if not cleaned
properly, or if rail cars are not turned back over to the railroad in the allotted
free time.
5.0 CARE OF LIFTING DEVICES AND COIL MODULE SHIPPING SUPPORT STEEL
5.1 It is the Purchaser’s and Erector’s responsibility to load the Nooter/Eriksen coil
module shipping support beams, shipping horses and lift devices on a truck for
transport back to Nooter/Eriksen’s shop facility.
X:\Procedures\Erection.Manual\EP-05A.R7
EP-05A PAGE 3
REMOVAL OF TEMPORARY
STEEL/WOOD
REVISION 0
5.2 It is the Erector’s responsibility to maintain the coil module shipping support and
lift devices in the as received condition. No modifications to this equipment are
to be performed without written consent by Nooter/Eriksen.
X:\Procedures\Erection.Manual\EP-05A.R7
EP-06 PAGE 1
ERECTION PROCEDURE FOR STAIR
TOWERS/PLATFORMS/LADDERS
1.0 GENERAL
1.1 The access steel is to be erected using the AISC Code, standard practice for
steel building and bridges.
1.2 The tolerances as specified within AISC for connections shall be applicable.
1.4 All pieces shall be marked with identifying numbers. The markings shall
correspond to markings shown on platform erection drawings.
2.1 It is recommended that the stair tower be erected as soon as possible. This
will provide access to HRSG for performing other functions and will minimize
the amount of temporary scaffolding.
2.2 The stair tower columns shall be set on piers provided by the concrete
Contractor. The structural steel columns and beams should be squared and
plumbed prior to torquing the bolting. The anchor bolts and bolting shall be
torqued per AISC.
2.3 The stair tower is attached to the HRSG at one or more levels. The
attachments should be field located and welded to the HRSG as indicated on
the erection drawing. These should be installed as the stair tower goes up so
that adequate bracing is provided. The stair tower shall not be used for
access purposes until all bolting and attachment welding has been
completed.
3.2 In order to insure proper platform elevations the attachment clips to the
HRSG are to be field installed.
3.3 The elevations of platforms shall be checked. It should be noted that the
elevations given for platforms, as well as all HRSG components, are from
reference elevation. For N/E, this is always the bottom of the HRSG column
base plates. (Reference: base plate elevation 0’-0”).
3.4 The platforms are normally erected by first installing the support brackets and
clips to the HRSG and then lifting the pre-assembled sections into place and
bolting or welding.
3.6 Ladders shall be fully installed including cage connections, support clips,
footing bolts, and safety gates, prior to releasing them for access use.
EP-07 PAGE 1
EXPANSION JOINT INSTALLATION
1.0 GENERAL
1.1 Reference Section 10.0 of the “GENERAL” section of this Manual for storage
and responsibility of the equipment that the purchaser receives on site.
1.2 The Erector shall use the lifting points and/or lugs provided with the
equipment.
1.3 For recommended lifting, handling and storage, refer to the vendor
procedures.
1.4 The Erector shall use extreme caution in the handling of the expansion joint.
The fabric shall be covered to protect from welding and puncturing.
1.5 The bolting that connects the expansion joint to HRSG equipment should be
provided by the expansion joint supplier. It is recommended that these bolts
be inserted and tack welded in place prior to installing the expansion joint.
Bolting for the attachment to other equipment will be by the Erector.
2.1 All shipping ties are to be left in place until a minimum of one side of the joint
is installed on the equipment. Use temporary cribbing, as required, to prevent
excessive stretching of the fabric, or distortion of the internal liner system.
2.2 When installed, the expansion joint flanges, relative to each other, shall not
vary by more than ¾”, in compression, extension and lateral offset. Actual
dimensions, if beyond this limit, shall be submitted to Nooter/Eriksen for
review and approval.
2.3 Field joint material as shown on the field erection drawings, shall be provided
by the Erector unless otherwise noted.
3.2 When installed, the expansion joint flanges, relative to each other, shall be
within +/- ¼”, in compression, extension and lateral offset.
1.0 GENERAL
1.1 All casing penetrations and access openings on the HRSG shall be gas tight.
Sealing shall be at the outer casing.
1.2 Shop installed gaskets and packing joints may have loosened in shipping; a check
of all these areas should be done at the initial start up of the system, and any
leaks found should be corrected as soon as possible, to prevent damage to the
outer casing.
2.0 GASKETS
2.1.1 Three (3) manway gaskets are provided for every drum manway: One (1)
gasket for field hydrotest and all field pressurization prior to start-up,
including boil-out; one (1) gasket replaces the gasket used for boil-out on
the system; and one (1) spare gasket is provided for initial operation.
2.1.2 Care should be taken with all gasket surfaces to insure that they are not
damaged.
2.1.3 All flanges and manway style gasket joints are to be assembled and
tightened, per industry standard.
2.1.4 The gasket surfaces shall be free of all dirt and grease (they are inspected
and approved prior to shipping). Damage incurred while stored, or in the
Purchaser’s possession, shall be to the account of the Purchaser.
2.1.5 All valve and instrumentation packing shall remain in its original shipping
container (any cost resulting from mishandling of valve or instrumentation
packing shall be to the account of the Purchaser).
2.1.6 Gage glass packing on the water column shall be replaced with new
packing after boil-out and prior to start-up.
CAUTION: See the notes in EP-13, “Boiling-out Procedure”, about the
temporary glass used for boil-out.
2.2.1 All casing access doors are to be sealed with a flat bolting tape gasket
(shop installed). Care should be taken to insure that the gasket is not
damaged when the door is opened in the field.
2.2.2 Bolting casing connections are to be sealed with a flat bolting tape gasket
and tightened uniformly all around the perimeter.
2.2.2.2 The bolting tape shall lay flat against the surfaces with no
laps or gathering of the material.
2.2.3 Sliding packing joints used on nozzle casing penetrations will have a
gasket between the bolt plate and the outer casing. This gasket should be
checked for leakage at the initial start-up of the system (if leaks exist,
tighten the bolting).
3.1.2 All shop installed packing joints should be checked for leakage at the initial
start-up of the system. If a leak is found, the gland is to be tightened to
achieve a seal. Additional rope packing is to be installed if the leak
persists.
3.3.1 The roof expansion bellows are shipped installed if the roof is attached in
the shop.
3.3.2 Fabric bellows must be protected from weld splatter and puncture during
the erection phase. Wrapping with fire retardant blanket and fiberglass
reinforced heat resistant tape will protect fabric bellows, if properly applied.
Remove all temporary protection upon completion of erection. During
operation, these joints should not be covered with insulation or lagging. If
safety is an issue, surround the expansion joint area with expanded metal
offset from the joint such that the heat will be dissipated and prevent
personnel from coming in contact with the hot joint.
3.3.3 The fabric expansion bellows must be checked at the initial start-up of the
system for leaks, and adjustments made, if necessary. It is the Erector’s
or Startup/Commissioning Contractor’s responsibility to verify that
EP-08 PAGE 3
GASKETS & PACKING
fabric seal
retainer clamps are properly positioned and tightened before and
after first fire.
3.4.1 The floor conical expansion bellows are shipped loose and must be field
installed after the coil modules are set. These joints are pre-compressed
and are supplied with shop installed straps. These straps are not to be
removed until all welding and heat treating is completed on the pipeline
that is routed through the bellows.
3.4.4 Floor conical expansion bellows must be protected from weld splatter and
puncture during the erection phase. Wrapping with fire retardant blanket
and fiberglass reinforced heat resistant tape will protect fabric bellows, if
properly applied. Remove all temporary protection upon completion of
erection. During operation, these joints should not be covered with
insulation or lagging. If safety is an issue, surround the expansion joint
area with expanded metal offset from the joint such that the heat will be
dissipated and prevent personnel from coming in contact with the hot joint.
3.5.1 Some penetrations utilize metal bellows expansion joints. These are
typically small penetrations (2” NPS or less), and are field installed.
3.5.2 Metal expansion bellows must be protected from weld splatter and
puncture during the erection phase. Wrapping with fire retardant blanket
and fiberglass reinforced heat resistant tape will protect metal bellows, if
properly applied. Remove all temporary protection upon completion of
erection. During operation, these joints should not be covered with
insulation or lagging. If safety is an issue, surround the expansion joint
area with expanded metal offset from the joint such that the heat will be
dissipated and prevent personnel from coming in contact with the hot joint.
EP-09 PAGE 1
ERECTION PROCEDURE FOR
INSTALLATION OF LARGE
BORE PIPING
1.0 GENERAL
1.1 All piping shall be installed to meet the requirements of ASME Section I,
ANSI B31.1 and any local applicable codes as they pertain to welding,
procedure qualification, post weld heat treatment, non-destructive
examination, etc. It is the Erector’s responsibility to ensure that all Code
requirements have been met as they pertain to assembly.
1.3 Piping is supplied in spool pieces to facilitate field assembly. Valves may
be shipped loose for field installation. Sufficient trim is provided in each of
the spool pieces to allow for adjustment and tolerance accumulation.
1.4 It should be recognized that, due to the size of the components, shifting of
component parts during shipping, normal fabrication, and erection
tolerances, a certain amount of mismatch is to be expected.
1.5 If the Erector feels that modifications in the design must be made due to
interferences, excessive misalignment, or for other reasons, N/E must be
notified of the problem and given the opportunity to provide a solution (see
N/E Backcharge policy). Any cutting or modifying of pipe spools without
prior notification and approval by N/E will not be accepted for backcharge
consideration. If field trim is removed from the project, Nooter/Eriksen will
not be responsible for spool-to-spool alignment or termination points that
differ less than 3” in any direction from theoretical locations.
1.7 Piping terminal locations are considered within tolerance if the pipe end is
within +/- 1” of theoretical in any direction. The Erector will check actual
termination points to the theoretical termination points during field erection
to maintain the +/- 1” tolerance.
2.2 All Chrome-Moly piping shall have NDE in accordance with ASME Section
I, ANSI B31.1, or the local applicable codes, whichever governs and is
more stringent.
3.0 INSTALLATION
3.1 This section provides suggested installation steps to minimize the time
required to install pipe spools. The Erector is free to modify or add to this
procedure. The contents of this procedure should be considered as a
guide.
EP-09 PAGE 3
ERECTION PROCEDURE FOR
INSTALLATION OF LARGE
BORE PIPING
3.2 Erector is to verify the tagging on each spool piece and valve and check
dimensions using piping isometric drawings and the fabricators pipe spool
drawings. Any major discrepancies shall be brought to the attention of
Purchaser immediately.
3.3 Erector shall check the location of the connections where the pipe spools
are to be placed. The theoretical locations may vary from the actual
depending upon how the modules have been set, how components have
shifted during shipment, and normal fabrication and erection tolerance
accumulation.
3.4 After the pipe spool pieces have been inspected dimensionally and the
connection locations verified, the Erector should pre-fabricate the
completed pipe runs in sections as large as possible. Valves should be
welded in and inspection, heat treatments, etc., made. Since the actual
dimensions of the pipe run can now be verified, the Erector should trim
pipe sections to fit actual dimensions.
3.5 Pipe sections should be lifted into place (tack welded only) and checked
for fit up before fully welding any section. It is usually possible to slightly
rotate the pipe at the connections to achieve movement at the other end
without affecting the weld gaps appreciably.
3.6 Piping expansion joints shall be installed per the expansion joint
manufacturer’s guidelines and accepted industry practices. It is not
acceptable for piping expansion joints to be manipulated to make up for
piping misalignment.
3.7 External insulation must be held back from all piping expansion joints and
casing seal devices for inspection, maintenance, and proper operation. .
4.1 All pipe runs will be provided with pipe supports, hangers, springs and/or
guides, if needed, to meet design requirements.
4.2 Prior to installing any pipe run, the Erector should become familiar with the
supporting requirements. It is possible to create additional work if piping
and supports are not installed in the proper sequence.
EP-09 PAGE 4
ERECTION PROCEDURE FOR
INSTALLATION OF LARGE
BORE PIPING
4.3 Pipe supports are to be field located and installed by either welding or
bolting.
4.4 All field welds not specifically called out on pipe support drawings are to
be 3/16” fillet welds and shall be completely around the attachment so as
to seal the connection.
4.5 Trim is provided in the length of the field welded pieces to allow for
adjustment and proper fit. The Erector should trial fit pipe supports, trim to
fit and final install. Piping dimensions at supports should be considered as
a reference and may vary +/- 2”.
4.6 To facilitate field installation, all pipe supports located on the straight
length of a pipeline can be moved +/- 0’-6” along the pipe centerline from
their theoretical location. It is the contractor’s responsibility to verify that
moving the pipe support to allow for field or shop tolerances, does not
create an interference with any other pipeline branch, attachment or other
structure on the HRSG. Contractor shall contact Nooter/Eriksen for
guidance for any supports that need to be moved more than +/- 0’-6”.
5.0 HYDROTEST
5.1 All valves shall be checked during hydrotest for leakage. Any leaks shall
be stopped by properly tightening the packing glands. If tightening is
unsuccessful, the leaking valves shall be repacked. Nooter/Eriksen shall
be notified of any valves where leakage cannot be stopped.
Caution: The unit should not be operated with valves where leaks have
been noticed unless approval from Purchaser is obtained. Failure to
comply with this requirement may result in damage to valves.
5.2 All spring supports and constant supports must have travel stops in place
prior to filling the HRSG.
5.3 All flanged pressure relief valves shall be removed, or a suitable pancake
shall be inserted at the inlet flange during hydrotest.
5.4 If welded safety valves are supplied, there must be verification that factory
installed hydrostatic test plugs are installed.
EP-09 PAGE 5
ERECTION PROCEDURE FOR
INSTALLATION OF LARGE
BORE PIPING
DSI (Welded Bonnet) REMOVE TRIM or FULLY CLOSED for welding and
PWHT
KVT (HP Valves) OPEN TO PREVENT ARCING for welding and PWHT
Union –Tech (Fisher) BALL IN FULL OPEN POSITION for welding and
PWHT
1.0 GENERAL
1.1 All piping shall be installed to meet the requirements of ASME Section I,
ANSI B31.1 and any local applicable codes as they pertain to welding,
procedure qualification, post weld heat treatment, non-destructive
examination, etc. It is the Erector’s responsibility to ensure that all Code
requirements have been met as they pertain to assembly.
1.2 Small bore piping is defined as all piping 2” NPS and smaller.
1.3 Small bore piping is normally supplied in random length pieces with
approximately 10% additional for field drop. The routing, installation and
support of these lines is to comply with Nooter/Eriksen small bore piping
isometric drawings, Notes 8A through 8D on small bore piping drawing
GA-005, and standard support details on small bore piping drawing GA-
007. If it is determined that rerouting is necessary, Nooter/Eriksen is to be
notified prior to rerouting.
2.0 INSTALLATION
2.3 Nooter/Eriksen drawings provide routing and supporting for small bore
piping within the Section I Code boundaries. The Erector/Owner should
2.3.1 Portions of some small bore pipelines are supplied with specifically
engineered pipe supports. In such cases, these supports will be
located on the piping isometric drawings. In all other cases, it is
the Erector’s responsibility to locate and install pipe supports in
accordance with Notes 8A through 8D on small bore drawing GA-
005, and details on small bore piping drawing GA-007.
2.3.2 Tolerances for small bore pipe support locations are the same as
for large bore. (See Procedure EP-09, paragraph 4.6)
2.4 External insulation should be held back from all piping expansion joints
and casing seal devices for inspection, maintenance, and proper
operation.
3.0 HYDROTEST
3.1 All valves shall be checked during hydrotest for leakage. Any leaks shall
be stopped by properly tightening the packing glands. If this is
unsuccessful, the leaking valves are to be repacked. Nooter/Eriksen shall
be notified of any valves where leakage cannot be stopped.
Caution: The unit should not be operated with valves where leaks have
been noticed, unless approval from Purchaser is obtained. Failure to
comply with this requirement may result in damage to valves.
X:\Procedures\Erection.Manual\EP-10.R10
EP-11 PAGE 1
ERECTION PROCEDURE FOR
FIELD WELDMENTS
1.0 Structural sidewall panels, roof beams, structural roof panels, floor beams and
structural floor panels shall be assembled with the following tolerances:
The letter items listed below correspond to the letter designation on Drawing EP-
11-1.
A. +/- 3/8”
B. +/- 3/8”
C. +/- ½”
R8
D. +/- ¼”
2.0 Tolerances for bolted or welded; stairtower, ladders, platforms and platform
supports, shall be in accordance with the latest edition of AISC.
3.0 Tolerances for piping structural supports, guides and hangers shall be
+/- ¼” unless otherwise noted on the individual job drawings.
4.0 All other tolerances not listed above shall be limited to “Industry Standards”, and
in no way affect the integrity and appearance of the HRSG.
5.0 If the HRSG is provided with an SCR, the Erector is to verify that the Catalyst
Loading Opening is plumb and square so that the Catalyst Loading Doors will fit
properly. This must be done prior to final welding of the SCR duct frame corner
connections.
1.0 GENERAL
1.1 Pressure Safety Valves (PSVs) are to be stored in their original packing until
installation.
1.2 Motor operated vent valves are to be stored in their original packing until
installed.
2.1 Lead adjustment seals shall remain intact on the valve during erection, start-
up and operation of the HRSG. The seal shall not be removed for any
reason; except spring replacement or calibration adjustment of the valve
(Ref.: ASME Section 1, Para. PG-73.1.8).
2.3 No valves shall be placed between the PSV discharge and the atmosphere.
2.4 PSV discharge piping and supports are to be installed complete at assembly.
Discharge piping shall not be left unsupported for any length of time.
2.5 The PSV discharge piping shall be square cut at the discharge end to
atmosphere (no modifications to discharge piping will be allowed). Discharge
piping shall be directed away from platforms and/or areas used by personnel.
2.6 Body drains of all PSVs shall not be plugged during, or after, field installation.
Plugs supplied by the manufacturer for shipping, shall be removed when the
PSV is removed from its original packing.
2.7 All gravity drains located in the PSV and the discharge piping shall be piped
to a safe area, away from platforms and operating stations, by the Erector.
Material is to be furnished by the Erector, unless otherwise shown on trim
drawings.
2.8 Weather shields installed on the PSV by the Erector, shall be properly vented
and arranged to permit servicing and normal operation.
2.9 Discharge piping that is routed to a collection pipe shall meet the
requirements of ASME Section I, Para. PG-71, or other applicable codes.
3.1 Start-up vent discharge piping and supports are to be installed complete at
assembly. Discharge piping shall not be left unsupported for any length of
time.
3.2 The start-up vent discharge piping shall be square cut at the discharge end to
atmosphere (no modifications to discharge piping will be allowed). Discharge
piping shall be directed away from platforms and/or areas used by personnel.
3.3 All gravity drains located in the start-up vent discharge piping shall be piped
to a safe area away from platforms and operating stations by the Erector. A
reasonable amount of drain line material has been supplied by
Nooter/Eriksen. Any additional materials must be furnished by the Erector.
(See drawing EP-12-01)
Oil, grease and rust can prevent or cause uneven buildup and flaking
of the protective magnetite layer during operation. These contaminants
must be removed before operation.
Theory
In order to insure a clean steam path after initial erection from
the evaporator sections of the HRSG to the terminal points, it is
necessary to instigate a thorough cleaning procedure. In
general, this is accomplished through a steam blow, air blow, or
a combination chemical clean/ steam (air) blow.
( V 2 ) steam blow
CR
( V 2 ) design
One should note the importance that all legs of the steam path
need to be subjected to proper cleaning ratios. The variable
geometry throughout the steam path will require the calculation
of several cleaning ratios.
Steam Blow
When the combustion turbine is available, a steam blow is
typically performed. The combustion turbine is generally utilized
as the heat source for the boiler to generate the required
capacity of steam.
Intermittent Blows -
Intermittent steam blows involve the building up of pressure in
the appropriate steam drum to a predetermined upper value and
then opening a quick acting steam blow valve at the end of the
piping network to generate a high velocity steam by flashing
water in the drum. When the drum pressure returns to the lower
calculated pressure level (minimum for cleaning ratio required),
the steam blow valve is closed to repressurize the drum and the
sequence repeated. An intermittent blow is generally favored
over a continuous blow when insufficient make up water
capacity is available for a continuous blow. The required purging
sequence of an intermittent blow, which may require as many as
100 cycles, generally makes the intermittent blow a more costly
procedure in means of time and man-hours.
Continuous Blows -
Continuous blows involve operating the boiler at a reduced
pressure for a continuous period of time. The reduced pressure
generates a large specific volume (high velocity) flow that
passes through the steam path on a continual basis. A sacrificial
valve is generally utilized at the terminal point of the temporary
steam blow piping for maintaining required pressure. By
eliminating the cyclic sequencing of an intermittent blow, the
required time and subsequent man-hours may be significantly
reduced for a continuous blow. However, a continuous blow
requires that large amounts of treated water be available for
usage. It is not uncommon to empty a large storage tank during
the course of a four-hour continuous blow.
EP-13 PAGE 5
RECOMMENDED
TUBESIDE CLEANING
PROCEDURE
The HRSG and the plant design will have an impact on the
decisions to be made concerning the steam line cleaning. Many
of these issues are operational in nature and several are
highlighted below for consideration when developing a site
specific steam blow procedure.
Start-Up-
When heating up the boiler for the steam blow process,
temporary steam blow valves should be utilized to control the
HRSG ramp rates. Refer to the startup requirements in the N/E
O&M Manual.
Operating Pressures-
HRSG operating conditions can be varied to augment the steam
blow process. For example, the HP drum operating pressure
should be maximized when blowing an IP system. This will
allow more heat to approach the IP evaporator maximizing the
IP steam flow.
Reheaters-
When blowing the HP system of an HRSG with a reheater, the
reheater may have to be operated without the benefit of cold
reheat steam. Under these conditions, the IP steam flow must
still flow though the reheater. Vents on the hot reheat line
should be open to maximize the IP steam flow and minimize the
reheater operating pressure. The CT operating mode should be
selected to minimize the exhaust temperature.
Desuperheater Operation –
N/E advises that the water flow to the desuperheaters be
isolated during steam blows. Water sprayed under the wrong
conditions can lead to damage. If desuperheaters are utilized,
there must be adequate steam flow and steam superheat to
vaporize the water. The steam must have a minimum of 25°F of
superheat after the desuperheater. In no case must the
desuperheater block valve be opened with insufficient steam
flow past the desuperheater.
Erection-
Care has been taken to supply all HRSG components in a good
condition. The erector must also strive to maintain this condition
during all phases of the erection process.
Measurement Devices -
The steam blow process may affect steam flow meters. The
accuracy of these devices is dependent upon the finish of the
interior surface. These devices should be removed if practical.
Non-Return Valves -
The main steam valve must be 100% open during steam blows
so as not to cause undue wear on the valve seats. Non-return
valve vendors require that the non-return valve disc (cage) be
removed during a steam blow. N/E will not be responsible for
damage to the non-return valve in the event that the erector
chooses to leave the non-return valve internals in line during the
steam blows.
EP-13 PAGE 8
RECOMMENDED
TUBESIDE CLEANING
PROCEDURE
In many cases, the steam blow may represent the first time that
large quantities of heat have been passed through the HRSG.
Therefore, during the heat up process, items typically
associated with first fire of the boiler (i.e. thermal expansion of
pipelines) must be addressed and inspected to insure proper
working order.
Air Blow
When sufficient water is not available, an air blow may be
performed to generate the same end result of a steam blow.
External air tanks are pressurized to predetermined levels and
connected to the steam path piping. The air is released through
the steam piping at levels sufficient to generate the required
cleaning ratios. The external air tanks are then repressurized
and the sequence repeated similar to the intermittent steam
blow. This will generally require larger velocities than a steam
blow due to the reduced density of the air.
Acceptance
Once it has been demonstrated that the required cleaning ratios
have been met, steam targets are inserted in the temporary
steam piping for testing at the steam blow conditions. The
targets are subsequently removed and inspected for marks and
impressions. The cleaning requirements (i.e. number and depth
of marks on target) for final acceptance are typically defined by
the end user, steam turbine manufacturer, and the BOP
contractor.
EP-13 PAGE 9
RECOMMENDED
TUBESIDE CLEANING
PROCEDURE
Issues to Note:
For best results, the steam blow valve should be a sacrificial butterfly
valve or gate valve. The excessive flow obstruction in a globe valve
can lead to rapid wear on the valve seats and is more subject to
locking up due to impregnated obstructions.
Steam blow piping is not generally rated for base load steam
temperatures. Care must be taken to insure that the superheated
steam is maintained within boiler design values as well as temporary
piping design values.
Power plants are generally flexible so that one can optimize the
conditions for a given steam blow. However, flow must be maintained
in all pressure systems during a steam blow to provide sufficient
cooling of tubes.
Steam blow steam must not be discharged through the HRSG main
start-up valves. These valves are generally globe-type control valves
and are subject to damage when passing dirty steam (steam blow
steam). When heating up the boiler for the steam blow process, the
temporary sacrificial steam blow valves should be utilized to control the
ramp rate of the pressure systems.
3.0 Considerations
3.1 The unit should always be inspected and cleaned after initial
erection. Future cleanings should be scheduled as required
based on inspections and monitoring of performance.
3.2 The decision on whether cleaning for mill scale removal will be
necessary should be made by the owner in conjunction with
those who will be doing the water treatment of the plant during
operation.
3.6 A temporary gauge glass is provided for use during the cleaning
procedure, if deemed necessary by the cleaning contractor.
Inform the contractor of the maximum working pressure and
temperature on this temporary glass.
3.9 Steam drum internals can remain installed during the chemical
cleaning. Note, however, that the mesh pads are made of
stainless steel, and must be removed if the cleaning solution will
attack this material. Re-install the mesh pads before steam
blow or operation. If the chevron separators are removed for
inspection or additional cleaning, they must be reinstalled with
the same orientation.
EP-13 PAGE 12
RECOMMENDED
TUBESIDE CLEANING
PROCEDURE
3.11 Sample lines should be closed during steam blow and chemical
cleaning to avoid plugging.
2.2 Visit is to coincide with the arrival and setting of the major components
or modules.
2.3 During the first visit, the following items will be reviewed.
2.3.1 Verify that the Erector has checked the foundation per EP-01
and has records to document the inspection.
2.4 Observe off-loading operations. Confirm that the proper handling and
erection procedure is being used and provide comments.
3.2 Visit is to coincide with the installation of the field seams and piping.
3.3.4 Review the field seam and piping installation with the people
who will supervise this work in the field.
4.3.1 Review the field seam installation both internal and external to
the system.
4.3.4 Review the installation of the Duct Burner, SCR System, etc., if
applicable.
X:\PROCEDURES/ERECTION.MANUAL\FIELDSERV.R2
NOOTER/ERIKSEN PAGE 1
EXTRA WORK BACKCHARGE
POLICY
REVISION 0
ERECTION PROCEDURE DOCUMENT
3. Nooter/Eriksen, Inc. will not authorize work without having a completed, and
agreed upon, reasonable estimate of manhours and cost filled in.
4. Nooter/Eriksen, Inc. reserves the right to have any and all corrective work
supervised by a Nooter/Eriksen representative and/or performed by a
Nooter/Eriksen designated contractor.
8. If field trim has been removed from piping on this project, Nooter/Eriksen will
not be responsible for pipe spool-to-spool alignment or termination points that
differ less than 3” in any direction from theoretical locations.
ISSUE CODE:
(N/E use only)
JOB SITE FILE COMPONENT TYPE:
(N/E use only)
PROBLEM CATEGORY:
(N/E use only)
DESCRIPTION OF PROBLEM:
ORIGINATOR: DATE:
ACTION CATEGORY:
DESCRIPTION OF PROBLEM:
DESCRIPTION OF SOLUTION
(ATTACH ADDITIONAL PAGES IF REQUIRED) CRAFT EST. HRS. FINAL HRS.
$ $
WARRANTY CATEGORY:
All elliptical manway covers follow the same general requirements with 12"
(305 mm) x 16" (406 mm), 14" (356 mm) x 18" (457 mm), and 18" (457 mm) x
24" (610 mm) being the most common sizes.
3.1 Open the manway and clean the old gasket from the cover and
manway ring. Both of the surfaces must be cleaned thoroughly with
caution. A method must be used that does not flatten out the required
machined roughness. Gasket surfaces are to be finished to 125-250
RMS.
All covers and rings must be inspected for pits or grooves on the
sealing surfaces. If pits greater than 1/32” (0.8mm) deep exist, it will
be necessary to repair the gasket surface by weld repair and
remachining under the direction of your ASME National Board
Inspector. If the manway covers, rings and plates cannot be repaired,
then they must be replaced. New covers must be inspected for
surface imperfections.
3.2 Proper gasketing, as defined in Table 3.2 and 3.3, is required to install
the cover. Do not flex, twist, bend or deform the gasket in any way
before installation. This could damage the gasket and compromise its
structural integrity.
Center the gasket on the manway cover. Bring the cover and gasket in
contact with the manway ring. Install the studs in the plates or yokes
and finger tighten to allow the manway cover and gasket to stay in
place. Make sure the studs, nuts and washers are clean and well
lubricated with nickel anti-seize compound to achieve the proper bolt
load. Davits should be adjusted as necessary, to allow the proper
alignment when bringing the cover and gasket in contact with the ring.
1 2
DR-27V DR-26V
3.3 You may start to pressurize the boiler at this point. If the gaskets leak,
tighten each nut one (1) flat at a time alternating between the nuts (i.e.,
use the tightening procedure described above) until the leaking stops.
As the boiler is heated, the internal pressure will force the cover
against the gasket and, if properly installed, the seal will be effective;
however, additional tightening may be required due to the
heating/pressurization. It is to be noted that a "leak", as referenced
here, is running water. A slow drip is acceptable on a cold boiler for
this sequence. When the unit is up to pressure and temperature, if
necessary, retighten the bolts to the values noted in Table 3.1.
Table 3.2 Gaskets for 12" x 16" (305 mm x 406 mm) Manways (unless
otherwise specified)
Table 3.4 Gaskets for 18" x 24" (457 mm x 610 mm) Manways (unless
otherwise specified)