DOCUMENT SUBMISSION STATUS: FOR APPROVAL

A 08.03.2016 FOR APPROVAL L.T.HA H.V.TUNG D.V.SON

REV DATE DESCRIPTION PREPARED CHECKED APPROVED

PROJECT TITLE

SONG HAU 1 THERMAL POWER PLANT (2x600MW)

OWNER OWNER’S CONSULTANT

VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING

EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT

VIETNAM MACHINERY TOKYO ELECTRIC POWER SERVICES COMPANY

INSTALLATION CORPORATION LIMITED - TEPSCO
(LILAMA)
SUB-CONTRACTOR

DATE NAME SIGN DOCUMENT TITLE

PREPARED 05.03.2016 L.T.HA

TURBINE BUILDING
CHECKED 08.03.2016 H.V.TUNG
Fabriction Procedure for Steel Structure
APPROVED 08.03.2016 D.V.SON

DOCUMENT NO. REV.

SH1-L45.1-P0UMA-M-M01-PRO-0001 A
 CONTENT

1. GENERAL ...........................................................................................................................
1.1 Scope .............................................................................................................................
1.2 Purpose ..........................................................................................................................
1.3 Applicable Specification, Standards and Codes ............................................................
1.4 Responsibility ................................................................................................................
1.5 Material..........................................................................................................................
1.6 Applicable Welding Processes ......................................................................................
1.7 Welding Consumables ...................................................................................................
1.8 Welding Procedure ........................................................................................................
1.9 Welder & Welding Operator Qualification ...................................................................
1.10 Working Area.............................................................................................................
1.11 . Flow Chart
2. PRE-FABRICATION ..........................................................................................................
2.1 Section and Plate Fabrication ........................................................................................
2.2 Miscellaneous fabrication..............................................................................................
3. ASSEMBLY.........................................................................................................................
3.1 General...........................................................................................................................
3.2 Assembly Sequence .......................................................................................................
3.3 Documentation ..............................................................................................................
[ATTACHMENT # 1] BUILT-UP BEAM PROCEDURE ..................................................
3. ASSEMBLY …………………………………………………………………………
3.1 General .........................................................................................................................
3.2 Assembly Sequence......................................................................................................
3.3 Documentation .............................................................................................................
4. Attachment
1. GENERAL
1.1 Scope
- This procedure includes the special demand of fabrication steel structure process
for the steel structure of Turbine Bunker building of Song Hau 1 Thermal
Power Plant Project.

1.2 Purpose
- This procedure covers the general plan for fabrication, assembly and Inspection
Test Plan (ITP) of the all project section for the Owner Project and shall be read
in conjunction with other Project Procedure and Specifications.
- This procedure covers the fabrication of all structure steel, platform, handrail,
stair, ladder, cage, grating and floor plate.

1.3 Applicable Specification, Standards and Codes

The following Specifications, codes and standards shall be used or referred to
during the duration of the project:
- Codes and Standards: S-400 Structure Steel
S-440 Painting
S-410 Gallery Work
S-422 Metal Decking & S-430 Welding
- AISC Manual of Steel Construction
- AWS D1.1 Structural Welding Code-Steel
- Quality Procedures to be submitted and approved before work commences

1.4 Responsibility
- Project manager: Control all the overall construction activities including
inspection and test
- Construction Discipline:
Execution of the site work as per this procedure
Preparation of the inspection and test for the site work as per this procedure
Execution of the inspection and test for site work as per this procedure
- Subcontractor:
Execution of the all activities in contract agreement
1.5 Material
- All materials shall conform to the international standards accepted by Vietnamese
Ministry of Construction (Vietnamese Standards, ISO, BS, DIN, US-, Japanese-,
France- and Australian Standards) and requirements of Tables S-400-1 and S-
400-2 (Song Hau 1 Thermal Power Plant requiremts).
- Steel for fabrication shall not be more heavily pitted or rusted than Grade C of the
Swedish Standard SIS 05.59.00.
- High strength bolts, nuts and washer shall conform to the chemical and
mechanical required of ASTM A490 (Bolt DIA.>16), A325 (Bolt DIA.< 16) or
equivalent. All A490, A325 (or equivalent) bolts shall be supplied with one
hardened washer and one load-indicating washer. High strength bolts, nut,

hardened washers and load indicating washers shall be galvanized. The use of a
direct tension indicator for tightening will not be permitted.
- Materials shall be controlled as per the Material receiving inspection procedure. -
Materials for each member to be used shall be shown on the Shop Drawings.
- Receipt of material upon receipt and concurrent with unloading, the structural
steel shall be inspected for conformance to bills of loading and determination of
damage in transport. All missing or damaged pieces shall be checked immediately
report and receiver has full responsibility.
- Structural steel shall be stored and handled in such a manner that members are not
subject to any damage. Also Structural steel shall be laid out and segregated to
facilitate identification.

1.6 Applicable Welding Processes

- GMAW (Gas Metal Arc Welding)
- SMAW (Shielded Metal Arc Welding)
- FCAW (Flux Cored Arc Welding)

- SAW

1.7 Welding Consumables

- Consumables shall be selected as per Project requirements and approved by
LILAMA.
- Each Mill Certificate shall be submitted to LILAMA and then to Owner for
review if required. Storage and control for consumables shall be carried out in
accordance with the “Welding Consumable Control Procedure”.

1.8 Welding Procedure

WPS & WPQR shall be prepared by the LILAMA 45.1 and submitted by
LILAMA to OWNER for approval prior to starting of fabrication work.

1.9 Welder & Welding Operator Qualification

 Welder & Welding Operator qualification shall be carried out to AWS D1.1 and
the document “Qualification Procedure of Welder & Welding Operators”

1.10 Working Area

- Fabrication activities at LILAMA 45.1 factory – Nhon Trach I – IZ 0 Dong Nai
Province
- Blasting and painting application for structural steel materials shall be carried out
by LILAMA45.1 at LILAMA 45.1 Factory

1.11 Flow chart for Fabricatio

DRAWING SHOP-DRAWING

MATERIAL

BUILT UP SHAPE MEMBER OTHER PART

MARKING MARKING MARKING

CUTTING CUTTING CUTTING

FIT-UP DRILLING DRILLING

PRE-HEATING

WELDING

CORRECTION

MARKING

DRILLING

ASSEMBLING

WELDING
MILLING

DRILLING FINISHING

BLASTING

PAINTING

PACKING

Hold point for Checking

DELIVERY
2. PRE-FABRICATION
2.1 Section and Plate Fabrication
2.1.1 General
This section describes the fabrication sequence of all plates and sections, etc

2.1.2 Plate and Section Fabrication and Installation Works Flow

2.1.3 Fabrication Sequence
a) Receiving Approval for Construction (AFC) Drawing
The AFC Drawing is issued to LILAMA by
design contractor
. b) Preparation Shop drawing and Weld map.
All information need to Fabrication is shown in this drawing

The Shop drawing and Weld map shall be drawn by LILAMA 45.1 and then
submit to LILAMA to check and approval. Also submit Structure steel shop
drawing to Owner for reference.
c) Material Take Off (MTO)
MTO shall be prepared base on LILAMA approved shop drawing.
d) Receiving plate and sections
The plate and sections requested by the “Material Requisition Sheet” and the
“Material issue sheet” will be moved into the fabrication or cutting area from the
storage area. This procedure includes copies of the requisition and issue sheets.
e) Material Identification
The material traceability of all plates and sections shall be verified against delivery
documents received from LILAMA and checked against the material requirements
on the shop drawings prior to marking and cutting according to “Material
Identification Procedure”
f) Marking
Identified plates and sections to be fabricated shall be marked in accordance with
Shop Drawings and Cutting Plan. Marking shall be done in such a way that the
cutting is carried out in the most economical manner in order to minimize wastage.
g) Cutting
Marked plates and sections shall be cut to respective size by manual flame cutting
or other approved means.
h) Edge Preparation
All edges shall be 100% visually examined to ensure freedom of laminations, slag,
burrs, loose scale, rust, paint, grease and any other foreign material. Any beveled
edge that has been damaged, shall be repaired and NDT examination carried out
subject to approval by OWNER. Sharp or discontinuous edges shall be removed by
light grinding. Buttering of bevels and wide gaps which are subject to qualification
 shall be carried out subject to LILAMA and OWNER approval. NDT (if required)
on bevels shall be carried out prior to fit-up.
i) Fit up and Tack Welding
Marking shall be carried out in accordance with shop drawing and technical
specifications. Whenever practical, clamps, magnets, holding devices, welding
logs, shims, wedges or setting up fixtures shall be used in the assembly of parts of
the structure for tack welding.
j) Welding

The welding shall be carried out in accordance with Project approved “Welding
Procedure Specification”. The pre-heating temperature and welding inter-pass
temperatures shall be measured at regular intervals by the QC inspector during the
welding process; the correct temperature shall be maintained in the parent metal
within a distance from the weld zone of at least 75mm. Pre-heating will be carried
out by electrical heating method or specially shaped gas burners.
A copy of the approved welding procedure specification shall be displayed at
each respective welding station.
k) Visual Inspection and N.D.T
Upon completion of welding, 100% visual inspection will be carried out prior to
request for non-destructive testing. N.D.T shall be carried out in accordance with
the N.D.T Procedure for Structure, the approved N.D.T. Subcontractors procedures
and the applicable Codes and standards, ASTM Volume 03.03 Nondestructive
Testing. The N.D.T Procedure shall be according Welding Procedure-which one
was accepted by Owner and EPC Contractor LILAMA.
- Radiographic Testing (RT) or Ultrasonic Testing (UT) for butt weld joint
follows the standards of the project.

- Magnetic Testing (MT) for fillet weld follows the standards of the project.
Fabrication Final Inspection
Fab. Final Inspection shall be carried out in accordance with the requirements of
AWS D1.1. and the ASTM Dimensional Control Procedure, ASTM B610-08
Standard Test Method for Measuring Dimensional.
l) Painting and Painting inspection
Reference documents:
- SSP S-440 Painting Work
- SSPC Steel Structure Painting Council U.S.A
- ASTM Standards for Testing Material
The Painting of steel structure shall be carried out in conformity “with the approved
Painting Procedure”.

2.1.4 Final inspection

Reference documents:
- SSP S-440 Painting Work
- SSP S-400 Structure Steel
- SSP S-410 Gallery Work
- SSP S-422 Metal Decking
 - SSP S-430 Welding
- SSP S-440 Painting
- SSP S-451 Metal Siding

- ASTM & ASME Standards and Codes

Final Inspection shall be carrying out follow Inspection and Test Plan (ITP)-which
one was issued by EPC Contractor LILAMA prior to move to site for erection
work.

2.2 Miscellaneous fabrication

Miscellaneous items including pad-eyes, handrails, stairs, ladders, supports etc
shall be fabricated and installed in accordance with the approved shop drawings
and OWNER requirements. Plates used for fabrication of lifting eyes shall be 100%
NDT tested.

3. ASSEMBLY
3.1 General
This section describes the general plan for the assembly method of the structure.
Upon completion and acceptance of pre-fabrication, the items shall be released to
the assembly.
3.1.1 Fit-up
Work point or fixed points shall be established for monitoring of the fabrication
process. Supports shall be provided and level checks will be carried out prior to
assembly of the structure. All traceability numbers shall be verified against shop
drawings and documented on the applicable quality reports. Temporary
attachments will be removed by flame cutting or grinding without damage to the
parent material and final flushing of the attachment area will be done by grinding to
maintain the original plate surface, MPI shall be carried out after grinding.
All components shall be trial fitted before welding, where root gaps are out of
tolerance, the joint shall be dismantled to permit local grinding or buttering, to
achieve the required profile. NDT (if any) on bevels and lamination checks shall
be carried out prior to fit-up to adjacent members. The surface (foot-print area) of
chord members (plate or pipe) to be welded in TKY joint (including temporary or
permanent attachment) such as chords of tubular joints, pad-eyes, supports, etc
shall be ultrasonic tested before welding.
Circumferential fit-ups shall be such that the longitudinal weld seams of
o
adjoining sections are staggered by a minimum of 90 . Visual and dimensional
inspection shall be carried out prior to start of welding.
3.1.2 Tack Welding
Fit up and alignment for fabrication assembly shall checked by the Contract QC
inspector and notification given to LILAMA prior to welding as per approved
I.T.P. for structure.

Qualified welders in accordance with approved WPS will carry out tack welding.
 Pre-dimensional survey shall be carried out as per “Dimension Control Procedure”.
LILAMA shall be notified in advance if required.
3.1.3 Welding
a) Generally the welding sequence shall be carried out to minimize distortion but in
all cases shall be in accordance with the approved welding procedures.
b) The welding shall be carried out in accordance with Project approved “Welding
Procedure Specification”. The pre-heating temperature and welding inter-pass
temperatures shall be measured at regular intervals by the QC inspector during the
welding process; the correct temperature shall be maintained in the parent metal
within a distance from the weld zone of at least 75mm. Pre-heating will be carried
out by electrical heating method or specially shaped gas burners.
c) Contractor QC will perform 100% visual inspection, as per approved ITP for
structure and shall notify LILAMA in advance of any inspection that requires
witnessing. NDT of through members shall be carried out before the fit up and
welding of an overlapping member.
3.1.4 Circumferential Welding
Splicing of tubular member should be in accordance with API Spec 2B. Orientation
of longitudinal seam joints shall be as per project specification requirements.
Tubular sections shall be spliced so that the longitudinal weld seams of adjoining
o
sections shall be staggered by a minimum of 90 .
3.1.5 Inspection
Inspection shall be carried out in accordance with AWS D1.1, the relevant section
of the Quality Plan and the ITP for Structural Steel, reference shall be made to
section 2.0 items (h) of this Procedure

3.2 Assembly Sequence

Refer to the attachment of the assembly sequence drawing. Each step of the
assembly sequence shown on the attached drawings is a general representation
only.

3.3 Documentation
The quality department is responsible for filing and maintaining all documents
related to the quality records. The records are to be furnished to OWNER upon
completion of fabrication and will form part of the final QA/QC dossier.
4. Attachment:

[ATTACHMENT # 1] BUILT-UP BEAM PROCEDURE

Fabrication stages of Assemble

beam
I. General Requirements of Assemble Beam:
- Section area of replaced fabrication beam shall be equal or bigger than typical beam.
- Assemble beam after completion shall be ensured straightness compared with typical
beam.
- Ensure perpendicular between web and flange.
- Welding seam shall be smooth and roundness. Height of welding seam shall be ensured
specification.
II. Required Equipments to Assemble Beam Fabrication
1. Build up on machine.
2. Semi-automatic cutting machine.(Portable cutting machine) and CNC cutting machine.
3. Beam automatic welding machine.
4. Bending machine.
5. FCAW machine.
III. Fabrication Stages of Assemble Beam
1. Marking
Base on material specification and cutting surface dimension of assemble beam, choose
suitable plate to thickness of web and flange of beam. Marking and cutting according to
dimension of web and flange on plate depended on assembled beam.
After complete cutting, grind sides smoothly, especially sharp sides.
Cutting direction

Figure 1: Marking and cutting by portable cutting machine

 2. Fit-up
- Place a flange first, locate stably on the buildup machine.
- Marking fit-up position of web on flange
- Fit-up web to marked position on flange. Tack weld web and flange with 50 mm, the
distance between tack weld joints is 400-500mm.

Figure 2: Fit-up web and flange on the build up machine

3. Weld of fabrication beam
The welding work shall be performed on 02 torches Beam automatic welding machine

Figure 3: Weld fabrication beam by doubles welding machine

4. Fabrication beam bending
After complete welding, beam shall be transferred to bending stage. The bending work
shall be performing on automatic bending machine. During bending process, regularly check
straightness of beam by ruler. Resulting of straightness change is required, comparing between
straightness change and straightness limitation by company provided is important step to
demonstrate that mechanical properties will not be adversely affected. The bending work shall
be done until acceptable straightness of beam.
 Figure 4: Bend fabrication beam by bending machine.

5. Quality of Welding
QC will perform 100% visual inspection, as per approved ITP for structure and shall
notify LILAMA in advance of any inspection that requires witnessing. NDT of through
members shall be carried out before the fit up and welding of an overlapping member.
- UT for Completed Penetration weld joint follow the standards of the project.
- MT for Completed Penetration weld joint follow the standards of the project.
6. Safety
All staff must be following safety standard. In Vietnam, we have TCVN 5308-91
“Technical procedure in working safety” and regulation No. 10/QD-TCHC safety for
human:
- Safety for machines
- Electricity safety
- Safety for fire protection and blow up…
- Set up signboard with slogan “NO AUTHORITY NO ENTRY” “SAFETY
FIRST”…
- Provide all of labour safety, on job protection clothing, hat, shoes, glasses,
safety-belt…

- Organize safety training course for all staff and provide safety certificate as
permission access into site.
- Provide fire proofing equipment