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TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT BOILER DRUM ERECTION PROCEDURE
Unit Issuing : Construction Approved By : Site Manager

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1.

General The Boiler Drum (166 Tones ) with Hanger (10 Tones) and also rigging tools (6.5 Tones) is erected to its final location (EL 66800) by using 2 unit PSC heavy lift jack type L 300 lifting jack with Capacity each unit are ( 110 tones SWL ) in the cases proposed 7 parts 18 mm diameter Dyform strand cables @ 70 meter long. The detailed preparation work, erection and final alignment are as follow. 2. Equipment Specification L 300 Lifting (2 Numbers) Capacity : each @ SWL 110 MT based upon 7 parts (from total of 19 strands) Dyform Strand @ safety factor 2.5. Stroke Cble Skate Roller : 450 mm. : 7 Nos .18 mm Strand @ 70 meter long. : 8 Nos each @ 100 ton mechanical skate rollers.

Hydraulic Control hoses : 2 units of hydraulic control hoses, sufficient for carrying out above work. Power Pack Capacity Supply System : L4/12 E : 2 Nos liner at 15 liter : 415 V 3 phase 50 Hz

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT BOILER DRUM ERECTION PROCEDURE
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Capacity Lifting rate Chain Blocks. Capacity

: 220 tones : 12 M / hours.

: 5 ton : 10 ton

2 units 2 units

All necessary spare parts and specialist hand tool to support of lifting.

4.

Installation of Equipment. The actual equipment installation method at site is by 450 tonnes crane available at site. The following is proposed:

a) b) c)

The lifting strands will be delivered to site in coils (approximately 2 tones each) The jack base will be tack welded to the jack supports beams together with the The jacks and fixed anchor will now be threaded with their strands comprising The complete assemblies of jacks, beams, cables, anchors and fabrications will The power pack now be positioned at high level and the hydraulic connections The system is now ready for testing and connection to the drums.

and will be cut to length using disc cutter .The end of strands will be prepared for threading. moving skates and the fixed anchor blocks installed inside their fabrications. the lifting cables. d) e) made. f) now be lifted in to place and secured.

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT BOILER DRUM ERECTION PROCEDURE
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5.

Strap Hanger setting of Boiler Drum Prior to the lifting the Drum, the Boiler Drum strap hangers are set to facilitate the setting of Drum in its final location. After marking the center line on roof girder, the strap hanger is set in position and goes along with the steam drum. The detail is as per Drawing RED-004-CM2-SD-2004.

6.

Drum Lifting Details The length of steam drum is 22150 mm and the span between grid G3 and G5 is 21000 mm. Hence the drum is required to be tilted and lifted to avoid clashing with steel. On this case, the drum will be tilted at an inclination of 35 degrees. The jacks will be mounted on jack support beams which will be mounted on roller types skates. The movement and restrain of beam will be by chain block. The jacks will be operated from a single electric hydraulic power pack. The actual loads on jacks as the drum is hoisted up at 35o is considered (Lifting load of drum with internals 166t + hangers 10t + rigging tools 6.5t) at jack near grid G5 is 1343.49 KN and jack near grid G3 is 937.76 KN including safety factor 25%. The following sequence is proposed to clear the steel work on gridlines.

a)

Preparatory works such as temporary scaffold access platforms at top deck steel

for jack operators and erectors and other levels access for watchmen at various elevations must be prepared in advance. b) The lifting equipment will be tensioned up to 25 % increment unit 1 the drum lifts clear its supports.

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT BOILER DRUM ERECTION PROCEDURE
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c)

Drum is lifted up by approximately 100 mm from the present position and held for

approximately 15 minutes while all direct load bearing temporary and permanent girders and beams, jacking system are checked for any undue deflections or connections (steel/hoses) non conformities. d) Once the system has been cleared for safe lifting, the wood/steel/concrete block that were supporting the drum at ground floor are removed using mobile crane, forklift, and chain blocks. e) The lifting equipment will be tensioned up to 25 % increment unit 1 the drum lifts clear its supports as details attached (3). After removal of Drums support, the drums permanent U rod hangers are positioned on either side of the drum near actual locations secured by temporary clamping and slings in such a way as to remain vertical even when the drum is lifted in an inclined position. f) Continue lifting until there is 1.5 meter clearance beneath the drum. The Drum shall be raised up in a gradually speed to minimize the jack effect of the load. It shall be lifted in a horizontal position if possible and If not it shall be in the position where both hooks of the lifting device is carrying the load. The angle of inclination shall be on position where the lifting cable is not its vertical position. g) Lifting one end (the end with the jack nearest the drum final position center line) unit 1 the drum reaches an inclination of 35 degrees to the horizontal. At this inclination, the drum should clear the steel on both sides. A continuous monitoring on the condition of the lifting system shall be done. The spotter will continuously following the drum while on its way up to check for any obstruction along the way of the drum. If there any obstruction, the spotter should be inform the lifting engineer to hold the lifting until the obstruction is cleared, then resume the lifting. h) steel. Lift both ends together until 1 the highest end is clear above the + 60. M level

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i)

Lift on the lowest end only until the drum is returned to horizontal. At the same

time pull the movable jack support beam away from the center line to maintain the plumb of the lifting cables. j) Once drum is horizontal is horizontal continue lifting both end together until the U After U Bolt installation is complete, transfer the load from the lifting cables to The lifting device shall dismantled together with the temporary support to clear Bolt connection can be made. k) the bolts by gently bleeding the system down. l) the way for the erection work to progress, Note during the lifting the power pack operator will monitor the individual jack loads .In addition; the operator will need to be in contact with the lift co-coordinators and spotters watching the drum clearance as it passes each level.

7.

Final Alignment of Steam Drum After the drum is set in position, the below mentioned alignment is carried out to confirm the centering of drum along X and Y axis .Details in attachment (4).

a. b. c. d.

Rolling. Elevation of Drum. Level of Drum. Drum Centering. The steam Drum shall finally alignment first before the connection of any pipe on to it. Alignment shall be checked and confirmed in the following manner.

1.

Check the X and Y axis of the drum centre line if it coincides with the line

previously established. If not adjustment shall be made to the position of the drum by pulling

PT. TRUBA JURONG ENGINEERING LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT BOILER DRUM ERECTION PROCEDURE
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to the direction where there is a negative variance, until be come zero variance. This shall be done on all direction where there is a difference with the lay out 2. 3. Check the final elevation of the drum horizontal axis. Check the leveling of the drum .This shall be done by checking the left and right

end of the drum along the horizontal axis of the drum and also on both end, front and rear side of the drum respectively. Make sure that the position of the drum is as per lay out and accrue level. 8. 1. General Notes: Manning scheme for lifting of Drum shall prepared after reviewing thoroughly by

personnel relevant to the works, and the procedure shall be carried out under careful verification in safety at every step. 2. Area within the lifting works shall be roped off with safety marks rope and notice Lifting tools such as wire rope /strand, chain block etc shall be checked firmly in Sign to Jack operator shall be given only nominated person shall be handling winch board denoted KEEP OFF EXCEPT PERSONEL CONCERNED shall be putt there. 3. advance and confirmed thoroughly that no any defective point exist. 4. only by sign his sign.