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M34

PROCEDURE FOR ASSEMBLY OF CONDENSER

FOR 3 X 330 MW STEAM POWER GENERATION
DOCUMENT NO: P-T3109-CONS-015
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 2 of 16 01

ORIGINATED APPROVED
REVIEWED BY DISTRIBUTION
BY BY
- CDCC : Original
- All Div. : Copy
- All Dept. : Copy

Effendy Joko Subrata Dey Iman Agus

Tonegien Purnomo Paryaman Subagyo

EFFECTIVE
REV. NO ISSUED DATE BRIEF OF REVISION
DATE
01 17-November-08 17-November-08

W-QC-A-001.E4

TABLE OF CONTENT

No. Descriptions Page

1. TITLE 3 of 15

2. SCOPE 3 of 15

3. OBJECTIVE 3 of 15

4. REFERENCES 3 of 15
5. DESCRIPTION OF WORK PROCEDURE 3 of 15
6. INSPECTION OF IMPORTANT EVENT 10 of 15

7. PRE-FABRICATION AND ERECTION FLOW DIAGRAM 13 of 15

8. ATTACHMENT
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 3 of 16 01

1. TITLE
Procedure for assembly of condenser for 3 x 330 MW steam power
generation.

2. SCOPE
This procedure describes the erection method of condenser in PLTU 1 Jawa
Barat (Indramayu) – Indonesia.
In this connection, if any modification to this instruction shall be carried out
after reviewing it with personnel concerned.

3. OBJECTIVE
This is to assure that the installation of condenser following the client
requirement, code and specification and to obtain good quality workmanship
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 4 of 16 01

during the installation works. And this is also as a systematic guidance for
concerned Supervisor or Engineer to assembly the condenser.

4. REFERENCES
4.1. P-T3109-SDCC-001, Guidelines for Establishing Project Procedure.
4.2. E03033-PR-3001 Construction Execution Plan.
4.3. Installation and Maintenance Manual.
4.4. Construction and Vendor Drawing.

5. DESCRIPTION
5.1. General Requirement.
 All assemblies should use shop drawing with status for
construction.
 Upper part of necks is made by left and right parts. Lower part
of neck is made up of left, middle and right parts. Upper part
of shell is made up of left and right parts. All of the parts will
be welded together after being carried to the field. All the
components of upper of shell will be carried to the field
scatteredly, then will be welded according to the drawing. All
of the parts will pre-assembly in the factory, then taken apart,
transported individually at last.
 It’s necessary for discharge chamber to be done water
pressure experiment after being welded (0.525 Mpa). Watering
sealing experiment needs to be done for the whole condenser.
Watering level is height mark +9000. All the parts must be
dried before being delivery.
 Cathodic protection is installed in water chamber.
 External drilling will be finished completely in the factory
(mounting holes of bypass sinker will be drilled in the field).
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 5 of 16 01

 Sealing experiment will be done in the plant for water

chamber. The experiment pressure should not be less than 0.4
MPa.
 The height of weld unmarked is a = 0.7 x the thickness of thin
wall.
 Parameters of name plate.
~ Type: N-17500.
~ Type of structure: dichotomizing single-pass surface.
~ Cooling area: 17500m
~ Cooling water pressure: 0.25 MPa(g).
~ Cooling water flow: 39730 t/h.
~ Cooling water temperature: 30 oC (backing pressure 0.0085
MPa.a)
5.2. Receiving and Storing Equipment.
All equipment shall be checked on received at field for any damage
and any missing part as per the packing list. If any discrepancies
found, it shall be reported as described in the material control
procedure. An OSD (Overage, Shortage, Damage) report shall be
prepared for any discrepancies.
Carefully handle shall be taken in transportation and storage of the
equipment to make sure that proper procedure adopted as per
manufacture recommendation.
5.3. Condenser Parts.
The main section list of condenser are shown in the following:
a. Upper half of neck (right and left).
b. Lower of neck (right, mid and left).
c. Unit assembly of diaphragms and shell side plate.
d. Inlet water box (right and left).
e. Outlet water box (right and left).
f. Lower half of hot well (right and left).
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 6 of 16 01

g. Condenser accessories (drain flash tank, support, etc).

5.4. Condenser Section Pre-Assembly Work.
Due to limitation of space area for erection, condenser will be
assembled in two places i.e. on pre-assembly table and temporary
platform. The section of condenser such as upper half of neck, lower
of neck, shell side plate and hot well are possibly and partially
assembled at field pre-assembly table for purposing to speed-up the
work.
The table for pre-assembly should be made in according to the
dimension and weight of condenser parts. Also it should be in leveled
condition. On the pre-assembly work table, the parts which can be
possibly assembled are set by strong back plate and connected by
bolt and spot weld with required dimension.
5.5. Assembly work at original site position.
The temporary platform at original location required during assembly
and erection of condenser. This platform level should be set at the
5110 mm high and also purposed for temporary condenser support.
5.5.1. Condenser Foundation Preparation.
After handed over from civil group, the centerline and level are
marked on foundation. Temporary platform may fit-up and
embed to the condenser foundation with reference of
condenser level.
5.5.2. When the temporary platform was already prepared
completely, condenser neck can be started to assemble.
Installing and welding the three (left, middle and right) parts
of the lower necking port on the side plate, and then installing
and welding the upper necking port to lower necking port, and
lifting the necking under the steam cylinder. But, after
condenser neck completely assembled and before lifting
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 7 of 16 01

process, diagonal deviation check for condenser neck shall be

required and confirmed.
The condenser neck must be lifted up and hanged with
accordable hanging system to ensure of safety and accessible
for working below it.
5.5.3. After locating base plate to its foundation, installing spring
supporting plates and springs on base plate, and adjusting the
positions of springs to their elevations.
5.5.4. Lifting steam condenser hot well, and installing the spring
supporting plate under bottom of hot-well (see drawing
N17A.80.01.48-1(8)1) and its reinforcer, and installing and
welding the outlet port of steam condenser.
5.5.5. Installing side plates of shell and water box.
5.5.6. Installing water inlet side’s bulkhead (paying attention to the
tilting ratio of installation), then installing sagging plates, and
finally installing water outlet side’s bulkhead (paying attention
to the tilting ratio of installation).
5.5.7. Installing inside positioning rods, connecting plates and air
cooling section’s baffle plates, and adjusting the concentricity
of bulkhead plates with steel wire.
5.5.8. Lowering the necking part on the shell’s lining plate, and
welding it to the plate.
5.5.9. Placing protection layer on I-shape steel beams, then welding
the steam extracting pipeline and steam extracting pipes S1,
S2 and S3.
5.5.10. Installing cooling water pipes, and then doing water pressure
test of the shell.
5.5.11. Installing water boxes and then doing hydraulic pressure test
of them.
5.5.12. Installing water drain flash tank.
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 8 of 16 01

5.5.13. Connecting steam cylinder and steam condenser (including

connection of steam extracting out pipes).
5.5.14. Installing water level meters and its accessories.
5.6. Condenser Shell Assembly.
The 2 (two) of shell side plates can be fit up and welded to the lower
of neck as mention in drawing. Shell side plate is divided by 4 (four)
parts and dimension is in 12068 mm length and 4431.5 mm high.
After assembling hot well on spring pedestal, the condenser neck and
shell side plates can be lifted-down and assembled to the hot well.
And then, unit of diaphragms and water box also can be installed.
After the position of the condenser on spring pedestal be in the
desirable centerline with the turbine centerline, adjust and mark the
position of condenser end tube seat, tube seat support plate, rib and
side plate. Fit it up and weld them to each other. Its erection
sequences should be taken in consideration to ensure for working
continuity and quality. High intension must be given for the tube seat
(sagging plate) setting. Be sure that the sagging plate hole was
straight in line to each other to guarantee that Ti-tube can insert
properly. Piano wire or plumb bob method can be applied for
straightening the tube seat hole. To maintain the tube seat straight in
line and no affected by welding job, some stud bolt can be used as
temporary support during joint plate assembly. Some position should
be spot welded firmly and temporary deformation-proof support rib
should be set as soon when the assembly and alignment of the entire
condenser part are being finished.
Welding sequence should be implemented to prevent metal
deformation caused by weld activity of shell plate. Welding work
should be carried out according to related welding procedure.
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 9 of 16 01

End tube seat

Stud bolt

Piano wire
End tube seat
14 kg Sagging plate 14 kg

5.7. Condenser Shell and Neck Welding Assembly.

After condenser shell were completely assembled to the neck, at its
level, release the condenser neck from hanger, fit it up and then
weld. The expansion joint can be installed after the neck and shell of
condenser welded. Through the LP Turbine foundation hole, section
of expansion joint can be set down into its position.
5.8. Condenser Tube Installation.
Before the installation of tube, make sure that tube seat of the
condenser tube support plate (sagging plate) were clean and keen
less to ensure the Ti-tube safe, no damage on tube wall and smooth
during tube insertion. Before tube insertion, choose the only good
tube were inserted. Make sure that tube seat was clean from oil stain,
rust or welding spatter. Protect the tube end to prevent damage on
tube end while insertion.
Insert the tube smoothly with correct orientation of tube’s well line.
Set it carefully to the designed position from front side of condenser.
Cut the excessive length of the tube. After the tube was completely
inserted with acceptable length, expanding job can be started and
continued with Ti-tube seal weld.
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 10 of 16 01

5.9. Condenser Water Chamber Installation.

After condenser weld line were completely inspected and accepted,
water chamber installation can be started. Handle with care should be
taking during working inside water chamber. It should be no scratch
or damage on water chamber and end tube seat surface. Measure the
bolt tightened torque may be required.
5.10. Condenser Accessories Installation.
Some instrumentation are required for condenser operation. Nozzle
for instrument connection can be installed to its determined position.
Nozzle or pipe fitting for condenser completion also can be installed.
5.11. Grouting of Condenser Foundation.
After completion of the condenser erection and before water filling
test, grouting of condenser foundation can be proceeded. Non shrink
grouting material is required.

6. INSPECTION OF IMPORTANT EVENT.

6.1. Distance check of tube sheet.
During assembly of condenser, the distance of condenser tube sheet
and partition board centre check is required.
6.2. Kerosene - Penetrant Test of Condenser welding.
All condenser welding line should be kerosene penetrant check to
ensure of welding quality. The Ti–tube seal weld should be Dye
Penetrant Test to confirm its welding quality.
6.3. Ti-Tube Arrangement Check.
There were two different size of condenser Ti-tube. The arrangement
of tube should be confirmed as drawing.
6.4. Water Filling Test.
To ensure there is no leakage on tube end seating position, water
filing test method is acceptable. Fill the condenser about 300 mm
higher than the connection of LP Turbine and Condenser. Await it for
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 11 of 16 01

a day to check if any leakage by using flash light at the water

chamber side.
6.5. Final Inspection.
In purpose for completion of erection items, final inspection should be
proceeded. The items such as dimension confirmation, cleanliness,
nozzle orientation and elevation, and erection completion should be
confirmed.
6.6. Condenser Acceptance Criteria.
Inspection quality form of steam condenser assembly and erection is
as below.
6.6.1. Condenser Shell Assembly.
6.6.2. Condenser Ti-tube Assembly and Erection.

CONDENSER SHELL ASSEMBLY

Quality
Inspection Item Unit Method & Tool
Criteria
Tube seat Interval Dev. mm -20~0 Measure by using steel
Between Actual and Designed rope at a number of
Value points at several sections
Verticality Dev. Of Tube seat mm/m ≤1 Measure by using
and Partition Board to Base suspending-wire weight
plate plumb
Centerline of 2 Dev. Value mm ±1
partition board Relative mal- mm Centerline
Orifices position deviation of 2
direction adjacent tube
orifices should
be ≤1

Local Bending of Condenser mm ≤3 Measure by using steel

Shell wire
Overall Bending of Condenser mm ≤20 Measure by using steel
Shell in its full Length wire
Flatness Dev. of Condenser mm ≤10 Measure by using steel
Neck Top Plate wire
Diagonal Dev. Of Condenser mm ≤20 Measure by using steel
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 12 of 16 01

Neck Top End wire

Internal Bracing, Baffle Plate & Welded & Fixed Inspectby following
Accessories without missing drawing requirements
Condenser Shell Perforating Follow
requirements on
drawings
Welding Seam Tightness No penetration Oil impregnation test

CONDENSER TI-TUBE ASSEMBLY AND ERECTION

Method &
Inspection Item Unit Quality Criteria
Tool
Visual Inspection of Ti-tube No crack, air pocket, Observe by
corrosion pit, dent, using, magnifier
cross breaks, cold lap of 5-10 times
and burrs
Clearance between mm 0.20~0.50 Measure by
Tube Sheet
tube orifice and Ti- vernier caliper
Inspection
tube
Tube Orifice of No rust, no burr while Observe
Partition Board having 1×45° chamfer
angle
Tube Sheet and No lengthwise Observe
87 of
of10
11
Orifice Cleaning marking-in, oil stain,
rust and burr while
having metallic luster
Ti-tube Ti-tube end Bright & Clean without
surface greasy stain,
Assembly oxidation, dust,
corrosion pit,
lengthwise marking-in
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 13 of 16 01

while achieving
metallic luster
Expanding % 4~6 Measure by
coefficient of Ti- vernier caliper
tube
Expanded- mm 33~36 Measure by
connecting depth depth gauge
Ti-tube length mm 0~0.5 Measure by
extended out depth gauge
partition board
Argon arc welding No air cavity and crack Inspect by
of Ti-tube end penetrating
fluid
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 14 of 16 01

PRE-FABRICATION AND ERECTION FLOW DIAGRAM

Material Receiving

Pre-assembly (at work Field assembly and

table) erection

Part of main body of condenser Foundation chipping and

Shell side plates, fit-up and weld. marking for level and
Marking the position of inner tube centerline
seat.

Sliding temporary platform

marking and leveling.
Part of Condenser Neck.
Lower of neck, fit-up
and weld.
Upper half of neck, fit-up
and weld. Temporary platform setting
to condenser level
Hot well, fit-up and weld.
arrangement.

Condenser spring pedestal

setting.

Condenser Accessories position

marking Condenser neck assembly

Y
B
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 15 of 16 01

B
Hanger rod assembly

Condenser neck, lifting and

hanging

Condenser shell side plates

assembly. End tube seat
positioning, sagging plate
setting.

Side plate setting and welding, joint

plate, support plate setting

Condenser neck –
condenser shell
welding.

Turbine exhaust pipe,

C hood spry pipe setting
and welding
 DOCUMENT NO. :
PROCEDURE FOR ASSEMBLY OF CONDENSER P-T 3109-CONS-015
FOR 3 X 330 MW STEAM POWER GENERATION ISSUED DATE :
November 17th, 08

UNIT ISSUING : APPROVED BY : SITE MANAGER PAGE REVISION

CONSTRUCTION 16 of 16 01

C Condenser
expansion joint
setting

Y
Condenser
accessories fit-up
and weld

Kerosene penetrant test of weld line.

Condenser dimensional check
Ti-Tube insertion

Ti-tube cutting
and expanding

Ti-tube seal arc weld

Dye penetrant test of
seal weld line
Water chamber
installation

Condenser inside
cleaning

Condenser water
filling test, balancing
and spring support
adjustment
Final Completion
inspection

Condenser handing
over