Method Statement for Erection of Boiler First Pass

MERSİN SODA SANAYİİ 320T/H CFB BOILER

METHOD STATEMENT FOR ERECTION OF BOILER

FIRST PASS

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Method Statement for Erection of Boiler First Pass

1 30.07.2015 C. B. A. A. İ. G.
0 28.07.2015 C. B. A. A. İ. G. First Issue Review
REV DATE PREPARED CHECKED APPROVED MODIFICATIONS STATUS
CLIENT

SODA SANAYİİ A.Ş.

PROJECT

Şişecam Mersin Soda Sanayii – 320t/h Fluidized Bed Boiler

CONTRACTOR, CONSORTIUM LEADER

EFOR ENDÜSTRİYEL TESİSLER MONTAJ İMALAT VE İNŞAAT A.Ş.

CONTRACTOR, CONSORTIUM MEMBER

RAFAKO S.A.

Project: KKS DOC TYPE Format:

YE N/A EP A4

EFOR Document No: Method Statement for

VPE Document No: Erection of Boiler First Pass Language:
E

ADULARYA Document No:

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Method Statement for Erection of Boiler First Pass

1. Index
1 General Information .............................................................................................................................. 4
1.1 Equipment Specification................................................................................................................ 4
1.1.1 Delivery Items ........................................................................................................................ 4
1.2 Description of Works ..................................................................................................................... 5
1.2.1 Right/Left, Front and Rear Walls of First Pass ....................................................................... 5
1.2.2 Roof of first pass .................................................................................................................... 8
1.2.3 Middle wall ............................................................................................................................ 8
1.2.4 Wing walls ............................................................................................................................. 8
1.2.5 Fluidization Bottom ............................................................................................................... 9
1.3 Work Sequence ............................................................................................................................. 9
2 Measuring instruments and measuring equipment for erection check ........................................ 10
2.1 TESTING ....................................................................................................................................... 10

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Method Statement for Erection of Boiler First Pass

1 General Information
1.1 Equipment Specification
1.1.1 Delivery Items

First pass consists of several parts as follows:

- Right/Left walls of first pass
- Front wall of first pass
- Rear wall of first pass
- Roof of first pass
- Middle wall of first pass
- Fluidization bottom (fluidized nozzle bed)
- Wing walls
- Hangers of first pass
- Buckstays of first pass

Right/Left walls of first pass:

Right and left walls of first pass will be delivered to site from abroad as 6 pieces. Right and left walls of
first pass are approximately 31 tons each, without buckstays. Reference document: 171394-243200R_1;
171394-244200R_1

Front wall of first pass:

Front wall of first pass will be delivered to site from abroad as 18 pieces. Front wall of first pass is
approximately 58 tons, without buckstays. Reference document: 171394-242201R_3; 171394-
242205R_1

Rear wall of first pass:

Rear walls of first pass will be delivered to site from abroad as 20 pieces. Rear wall is approximately 59
tons, without buckstays. Reference document: 171394-245200R_1; 171394-245201R_0

Roof of first pass:

Roof of first pass will be delivered to site from abroad as 10 pieces. Roof of first pass is approximately 4,1
tons, without buckstays. Reference document: 171394-242200R_0

Middle wall of first pass:

Middle wall of first pass will be delivered to site from abroad as 6 pieces. Middle wall of first pass is
approximately 17,4 tons. Reference document: 171394-239200R_1

Fluidization bottom:
Fluidization bottom will be delivered to site from abroad as 1 piece. Fluidization bottom is approximately
18,4 tons. Reference document: 171394-239600R_1

Wing walls:
Wing walls will be delivered to site from abroad as 2 pieces, each. There are 8 wing walls in total. Wing
walls are approximately 4,5 tons, each. Reference document: 171394-241200R_2

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Method Statement for Erection of Boiler First Pass

Hangers of first pass:

Hangers of first pass will be manufactured in EFOR workshop as several parts. There are 68 pieces of
hangers in total for first pass. Reference document: 171394-181000R

Buckstays of first pass:

Buckstays of first pass will be manufactured in EFOR workshop and delivered to site as several parts.
There are 14 buckstay lines on first pass. Total weight of buckstays is 91 tons. Reference document: EF-
2014-062-E2-60-008-rev2

1.2 Description of Works

The erection activities will be considered in two phase, pre-assembly and assembly works.
Generally, first pass erection must be considered separately for side walls, roof, middle wall, wing walls
and fluidization bottom.

1.2.1 Right/Left, Front and Rear Walls of First Pass

Pre-assembly works will cover preparation of a welding table on a prescribed pre-assembly area, lifting
of delivered panels and other manufactured parts, fit-up and welding works. For this work, there will be
miscellaneous elements and equipment. Approximately 60t of steel profiles, plates and several steel
parts will be used for pre-assembly works. These profiles will be mainly used for manufacturing of a
welding table and temporary reinforcements. The welding table shall be rigid, and well-leveled by
surveying machines. There will be two adjoining welding tables for allowing two concurrent pre-
assembly works. A 100t capacity mobile crane, a smaller crane and a truck will be continuously working
for vertical and horizontal manipulation of related parts during pre-assembly works. Approximately 30
workers including welders will be working continuously during pre-assembly works. East side of the
boiler-coal building area will be used for this work. KD-1 is selected as pressure part pre-assembly area,
see Figure-1.

Assembly of first pass will take place after readiness of first part on the ground. To lift heavy and large
boiler wall parts, some temporary steel profiles will be installed as reinforcements. These reinforcements
are temporary and will be dismantled after hanging the boiler first pass walls to the steel structure.
These big parts will be lifted by using multiple cranes. One big crawler crane (with capacity of 450-600
tons) will be the main lifting element. Two 100t or 75t capacity mobile cranes will be assisting for taking
the wall parts from horizontal position to vertical position. One small crane will be used as manlift to
take out the lifting lugs from the wall parts.

Boiler right and left wall will be lifted as one-piece, each. 6 pieces will be welded to each other on the
welding table. Buckstays will be installed to the walls. If necessary, the buckstays will be installed
vertically, instead of horizontally. This method will ease taking the wall parts from horizontal position to
vertical position. But this method will be reassessed on site if possible or not. If not, buckstays will be
installed normally and temporary steel beams will be used as reinforcements. Main lifting points for
front wall are shown in Figure-2. Lifting operation of side boiler first pass wall with temporary
installations and by the help of 3 cranes is illustrated in Picture-1.

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Method Statement for Erection of Boiler First Pass

After taking the wall to vertical position, main crane shall haul the wall over the boiler structure and lift
down through boiler opening on +55m level, see Figure-3 for openings on +55m level. Before lifting the
walls, hangers (suspensions) of boiler first pass shall be installed already. The walls will be attached to
these already installed hangers, see Picture-2 for illustration of this work.

Figure-1: Site area distribution

Figure-2: Main lifting points for front wall

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Method Statement for Erection of Boiler First Pass

Picture-1: Lifting of side wall of first pass

Figure-3: Boiler openings on +55m level to be left for installation of First pass walls (EF-2014-062-E2-10-
011-R3)

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Method Statement for Erection of Boiler First Pass

Picture-2: Attaching the first pass walls to already installed hangers

1.2.2 Roof of first pass

Roof parts will be lifted one by one to their positions. Roof parts are divided to two main part, front wall
side and rear wall side. Rear wall side panels will be lifted first since they are delivered with roof header.
After lifting of these parts, hanging points on the header will be immediately attached to the hangers
which are already installed onto the main steel structure. After installation of rear side roof parts, front
side roof parts will be lifted and mounted between the front wall and rear side roof parts.

1.2.3 Middle wall

Middle wall will be installed as one pre-assembled piece, after all connection welding is finished on the
welding table on the ground. Some temporary reinforcement will be installed for a proper lifting. After
lifting, middle wall will be hovered over the boiler structure and lifted down from the opening which is
indicated in Figure-3. The middle wall will be attached to the hangers which are already installed onto
the steel structure. Temporaries which are attached onto the wall surface will be removed after hanging
the wall.

1.2.4 Wing walls

Wing walls will be lifted in three parts, each. See sketch-4 for distribution of parts for installation of wing
walls. Part 1 will be lifted down from top of boiler structure through the openings on roof parts. Then
part 1 will be attached to the hangers which will be already installed onto the steel structure. A winch

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Method Statement for Erection of Boiler First Pass

and two elevators will be installed on the roof of first pass to lift part 2. Alternatively, a 100t crane and a
smaller crane can be used to lift part 2. Part 2 will be slipped through front wall of first pass. After
finishing alignment, welding between wing walls, roof and front wall will be done. Then part 3, wing wall
header will be lifted and welded to the shown position.

Figure-4: Wing walls parts distribution

1.2.5 Fluidization Bottom

Fluidization bottom will be lifted from the bottom of the first pass, from the ground. The bed bottom will
be delivered by a truck to the bottom of the first pass. Temporary lifting lugs will be installed onto the
wall in order to attach lifting eyes. Winches will be installed onto the top of first pass roof. These winches
will be used to lift the fluidization bottom. After lifting is completed, Connection welding to the side walls
will be carried out.

1.3 Work Sequence

1. First of all, right side wall will be pre-assembled on the ground.

2. In the meantime, on a second welding table left side wall will be also pre-assembled.

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Method Statement for Erection of Boiler First Pass

3. First pass hangers (suspensions) will be lifted and fixed to the steel structure on +55m level.
4. After finishing right side wall welding, buckstays and temporary reinforcements will be installed.
5. Right side wall will be lifted by 3 cranes operation, lifted down from the boiler opening on +55m
level and fixed to the hangers.
6. After right side lifting, middle wall parts will start being pre-assembled on welding table.
7. Left side wall will be lifted in same method.
8. One of front wall parts will start being pre-assembled on welding table.
9. Middle wall will be lifted and fixed to the hangers.
10. Other part of front wall will start being pre-assembled on welding table.
11. Finished part of front wall will be lifted and fixed to the hangers.
12. One of rear wall parts will start being pre-assembled on welding table.
13. Other part of front wall will be lifted and fixed to the hangers.
14. Other part of rear wall will start being pre-assembled on welding table.
15. Finished part of rear wall will be lifted and fixed to the hangers.
16. Finally, last part of rear wall will be lifted and fixed to the hangers.
17. Welding of installed wall parts to each other will start after all side walls are installed.
18. In the meantime, temporary reinforcements will be removed from wall surfaces.
19. After finishing all welding between side walls, roof parts will be lifted and fixed to the hangers
one by one.
20. After finishing roof parts installation, roof welding will start.
21. Wing walls part 1 will be lifted and fixed to hangers one by one.
22. Wing walls part 2 will be lifted from bottom of boiler one by one and fixed to part 1.
23. In the meantime, buckstays of front and rear walls will be lifted and assembly will start from top
to bottom.
24. After lifting part 2 of all wing walls, fluidization bottom will be lifted from bottom of boiler and
fixed to the side walls.
25. Wing wall part 3 will be lifted to their position and welding will start.
26. All welding between first pass walls, roof, wing walls and fluidization bottom will be completed
as well as buckstays.
27. Final alignment (according to drawing) of hangers (suspensions) of first pass will be done after
welding completed.

2 Measuring instruments and measuring equipment for erection check

Dimensional checks will be done by sensitive surveying machines (total station) as well as traditional
measuring devices. Some special devices will also be used for unreachable areas.

2.1 TESTING
Scope of testing will be according to Inspection and Testing Plan (ITP) and Welding Plan. The Scope of the
Testing shall follow Detail Design Documentation, ITP and Welding Plan. If there are any discrepancies,
higher level of scope is valid.

Reference document: 171394-038101A Guidelines for preserve manufacturing and erection tolerances

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