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FOR APPROVAL

PROJECT
NGHI SON 1 THERMAL POWER PLANT
CONSTRUCTION PROJECT
(CONTRACT NO. 010610/NS1-EVN-MC)
OWNER

VIETNAM ELECTRICITY
CONSULTANT

J-POWER / AF-COLENCO and PECC3


CONTRACTOR

MARUBENI CORPORATION

REV. NO.
PROJECT CONTROL NO. NS1-11LA-M-JEE-1020
0
Title:
WORK PLAN PROCEDURE FOR ERECTION OF
BOILER FEED WATER PUMP
(On-Shore M&E Erection Portion)

Document No.: NS1-JEE-MCP-MS-020 Rev.: 0

0 First Issue Sayan Aruna B J SS 28 Dec 11 Scale: None Date: 28 Dec 11

Rev. Description By Chk. App. Date


JURONG ENGINEERING LIMITED

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CONTENTS

1. INTRODUCTION 3/75

2. DOCUMENTS/DRAWINGS REFERENCES 5/75

3. SCOPE OF WORKS 7/75

4. ERECTION EQUIPMENTS, MATERIALS & TOOLS 10/75

5. SPECIAL TOOLS, TACKLE & EQUIPMENT 12/75

6. TRANSPORTATION, UNLOADING & PRESERVATION AT SITE 14/75

7. ERECTION SEQUENCE & PROCEDURE 17/75

8. ERECTION SCHEDULE (TENTATIVE) 33/75

9. ORGANIZATION & MANPOWER 35/75

10. RISK ASSESSMENT 37/75

11. SPECIFIC SAFETY REQUIREMENTS 49/75

ANNEX 1 DRAWING LIST (Drawings Attached)

ANNEX 2 DOCUMENTS (Document Attached)

ANNEX 3 TOOL LIST

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1. INTRODUCTION

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1. INTRODUCTION

This work plan procedure describes the field assembly and Installation for
Boiler Feed Water Pump and ancillaries of Nghi Son 1 Thermal Power Plant
Project.

PROJECT: NGHI SON 1 2X300MW COAL FIRED THERMAL POWER


PLANT, HAI HA COMMUNE, TINH GIA DISTRICT,
THANH HOA PROVINCE, VIETNAM

OWNER: VIETNAM ELECTRICITY (EVN)

CONTRACTOR: MARUBENI CORPORATION (MC)

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2. DOCUMENTS /DRAWINGS
REFERENCES

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2. DOCUMENTS/DRAWINGS REFERENCES

Contract No: 010610/NS1-EVN-MC


Document Reference:
a. Vendors Erection Manual
b. Contract ITB clause 4.2.6
c. Construction drawings Refer to Annexure 2.

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3. SCOPE OF WORKS

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3. SCOPE OF WORKS

Included in this Work Plan Procedure

Material Unloading & Storage at Site


Transportation from Site Storage Area to Erection Area
Installation of Boiler Feed Water Pump and Ancillaries

Note: Detail Scope of Works refer to Works Flow Chart (Refer page 19 of 75)

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9/75

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4. ERECTION EQUIPMENT, MATERIALS &


TOOLS

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4. ERECTION EQUIPMENTS, MATERIALS & TOOLS

4.1 Mobile Crane 50Ton Capacity 1 Nos. ( For Unloading @ Lay down/
storage)

4.2 Roller Skate 50Ton 4 Nos. ( For Sliding Activity @ Erection Area & Rail
Beam 300x300mm)

4.3 Chain Block 15Ton 2 Nos. (For Adjust Equipment for installation)

4.4 Turbine Hall Overhead Crane 80/20 Ton Unloading and shifting of materials
from maintenance Bay.
4.5 Equipment weight:

1). BFP weight= 6.0 Ton


2). Pedestal +Sole plate for BFP weight= 4.0 Ton
3). Fluid coupling weight= 6.0 Ton
4). Motor weight= 15.0 Ton
5). Motor Base weight= 0.46 Ton
6). Oil cooler weight= 2.0 T
7). Booster pump with Base= 2.39 Ton

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5. SPECIAL TOOLS, TACKLE AND


EQUIPMENT

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5 SPECIAL TOOLS, TACKLE & EQUIPMENT

The field installation doesnt cover any special tools, tackle or equipments.
If any special tools, tackle or equipments which specifically required, advanced
information shall be given by vendor, and specific erection/installation
procedure shall be provided for the installer in advanced, for necessary
preparation and familiarization.

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6. TRANSPORTATION, UNLOADING &


PRESERVATION AT SIDE

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6 TRANSPORTATION, UNLOADING & PRESERVATION AT SITE


6.1. Material Receiving
To make sure Boiler Feed Bumps, booster pumps & motors, hydraulic
coupling and accessories has to be checked for its physical damage.
Inspection and checking should be done according to receiving inspection
and material control procedure.
6.1.1 Any over, shortage or damage from the delivered pump accessories
should be noted on the detailed packing list. Inspection Report and OS&D
(Over, Shortage and Damage) report. Damaged materials should be separately
unloaded in an area designated for deficient delivery. Inspection will be
conducted for necessary action.
6.1.2 Pump units delivered in wooden Cases will be inspected before
unloading and package inspection Report will be made with photographs
signed by EVN/MC & JEL.
6.1.3 Receiving inspection report will clarify the actual quantity and the
Condition of materials received in comparison with the detail packing
list.
6.2 . Unloading & Transportation
The Boiler Feed Water Pumps & motors are delivered in large sizes in
wooden cases, it should be handled carefully if situation necessitate make a
trial lift or operation test of the lifting equipment and devices to ensure
these are all safe to use prior to lifting works:
- Check the stability of crane.
- Wire slings, shackle are properly selected.
- Work load chart verified.

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6.3 Material Storage


The Motors and Pumps are stored outside (with cover) in lay down area
whereas Electrical panels & Instruments which will be stored as indoor.
Regular inspections and maintenance shall be carried out as per Vendors
Recommendations.
Check points (outdoor)
- Appearance of wooden cases / equipment
- Ground condition & stability
- Lighting
- Drainage
- Fencing & Locks
- Surrounding Road Condition
- Canopy (sheet, canvas etc) condition
- No moisture deposited inside sheet.
Check points (indoor)
- Check appearance
- Cleanliness of Building
- Ventilation, Roof, Humidity
- Fire protection.
To avoid error in Pump Units for site installation, identification and
marking outside wooden cases will be done.

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7. ERECTION SEQUENCE &


PROCEDURE

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7 ERECTION SEQUENCE & PROCEDURE


7.1 Work Flow Chart
(Field Installation of Boiler Feed Water Pump)

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Material Receiving an Inspection

Transportation

Foundation surface, datum lines,


chipping & anchor bolt orientation check

External connections (pipe,nozzles,


junction boxes)

Lifting & positioning of Boiler Feed


Pump, Motor, Booster Pump &
Hydraulic Coupling

Alignment of motor to Hydraulic Coupling &


Booster Pump (to ensure axial and radial Inspection
clearances)

Alignment of Hydraulic Coupling to Boiler


Feed Pump (to ensure axial and radial Inspection
clearances)

Piping works-lubrication system

Piping water system connections

Final alignment & securing Inspection

Grouting

Flushing of Oil System

Instrument connections

Ready for Operation

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7.2 Preparation Foundation

7.2.1. Confirm the position and size of box-out hole prior to chipping work.
Make sure the hole size is sufficiently large to pour soft grout after
installation of equipments base plate, refer figure (1) page 21 of 75
of 56.

7.2.2. Punch bench marks for pump center line and reference lines as shown
in Figure-1 Set the X & Y axes to fix, Set the reference level.

Tolerance for foundation items as follows;

a) Tolerance for specified distance from datum center line 3


mm
b) Right angle between axial and transverse center line 1
mm
c) Location of foundation bolt 3
mm
d) Elevation of foundation bolt
+ 12 mm / - 0 mm

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Figure-1: Foundation Details of Boiler Feed Pump Associated Equipments

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7.3. Setting of Packer Plates(Padding)


7.3.1 Chipping

Setting of packer plate shall be done in correct level and position. Prepare
the foundation surface by chipping the location for base plate setting. The
foundation surface shall be chipped at around 10 mm ~ 20 mm from top of
concrete but total depth shall be follow design drawing about 30 50 mm.
as show in Figure-2.

Figure - 2

7.3.2 Position of Packer Plates


Place the packer plates as close as possible on sides of the foundation
bolts provided these will not interfere with the bolt holes. Make sure that
the surface of foundation is clean.

7.3.3 Setting of Packer Plates


Set and secure the packer plates on adequate places on the foundation
using Non shrink mortar padding. Mixed mortar and place the hard
mortar in its correction position with padding box. Measure the level in
both longitudinal and lateral directions, after these have been properly
leveled by transit or water level (see Figure-3) Record the reading for
reference of the succeeding installation.

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Leveling acceptance criteria given below.


Tolerance:

Base Height: 0 ~ 5 mm.


Slant : 10/100 mm.

Figure 3

Check the packer plate adhesion by lightly tapping the plates as show in Figure-4.
Re-work at once any loose packers.

Figure 4

7.3.4 Curing of Grout

After setting of packer plate, packer plate and mortar shall be covered
with mats or rags and to spray with water to prevent quick dry-up. A
minimum of 48 hours or depend on type of grout used shall be kept
untouched. Confirmed the setting condition internally beforehand
witness check and keep records of height of packer plate.

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7.4 Installation of Base Plate (if necessary)

7.4.1 Adjusting the Height of Packer Plates

Based on the record of the packer plates setting, place a shim on the
packer plates up to the predetermined reference height. As much as
possible, minimum number of liners shall be used.
7.4.2 Leveling the Base Plate

Tighten lightly the foundation bolts and carry out leveling using the
machined surface of the base plate. If leveling of base plate cannot be
achieved easily, use the flange surface of the discharge nozzle and / or
suction nozzle or the machine surface of the bearing box.
Acceptance Criteria
Level: 10/100 mm or less (per 1 meter length)
Apply a straight edge to measure the level in both longitudinal and
lateral directions. Place a liner between the packer and the base plate to
adjust. As for motor base plate is same above method.
7.5 Installation of Pump and Motor
7.5.1 Anchor Bolt Setting
The anchor bolts shall be installed together with the pump unit, after
confirming that the packer plates have set correctly and curing period
is completed.

a) Make clean the inner surface of box-out hole by air blowing.


b) Put the anchor bolts in box-out holes.
c) After setting of pump on the foundation. Install the anchor bolt into the
base plate holes.
d) Align and adjust the pump to the correct alignment and pour the soft
mortar (non-shrink grout) into box-out holes.

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7.5.2 Setting of Unit (Pump and Motor)


a) Tighten all anchor bolts (after curing minimum 48 hours)
b) Check the sitting position of the unit and adjust if necessary.
c) Adjust the alignment between the pump and motor.
d) Check and adjust the level and center height of the pump with
auto-level.
e) Inspection of level and center line.
f) Pre coupling alignment shall be carried out as per section 7.7 page

28 of 75.
7.5.3 Measurement of jointing Point

Determine the distances from the center of the base to the center of the
pump and the jointing points of the discharge and suction nozzles
respectively. (See Figure-5)

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Figure 5: Outline Arrangement of Boiler Feed Pump Equipments

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7.6 Grouting
Grouting plays the most important in the installation work of rotating
equipment, especially pumps. In general accepted practice, grouting will be
carried out with the base plate fully loaded.
7.6.1 Preparation
Clean by air blow and moisten the bottom of the base plate and the
foundation surfaces effectively so that there will be full adhesion between
the grout and the foundation.
7.6.2 Grout Material
An approved non-shrink grout material shall be used in filling the hollow
base of the equipment. The amount of water required for mixing shall be
as recommended by the manufacturer.
7.6.3 Pouring of Grout
Pour the grout mixture into the grout holes from one side so that flow is
reached to the other end of the grouting area, if necessary agitate with an
iron rod. Air vent holes shall be provided on the corner of the base plate
to release air. Make sure the grout mixture is completely spread into all
surfaces under the base plate leaving no voids that would create pump
problems during operation. Grout shall be poured completely into the bolt
holes and across the nearest travel of the foundation surface continuously
to ensure air is trapped between the surfaces.
7.6.4 Curing
Grouting part shall be covered with mats or rags on to which water is
sprayed to prevent rapid drying. Keep the unit untouched for minimum of
48 hours after pouring of mortar. Remove the grout forms 2 days later
and check adherence between the base plate and mortar by means by
means of light hammering.

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7.7 Alignment
7.7.1 Pipe Strain Check
To check for piping strain, fix dial indicators on pump casing as show in
figure-6 to monitor its movement both vertically and horizontally. Piping
flanges should be
monitored separately
by continuously
observing the
indicator reading.

If the movement
exceeds 5/100
mm, piping strain is
considered excessive
and it should be
corrected. Loosen
the pipe until
alignment is
complete, then re-
tighten and re-test
for strain.

Figure 6: Dimensional Arrangement of Boiler Feed Pump Equipments

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7.7.2 . Pump, Fluid coupling, Motor and Booster Pump Alignment


To run the pump safely in low vibration level Alignment shall be
adjusted so that the pump shaft, coincide with the shaft of Fluid Coupling
and Motor, (figure (7), refer page of
3056).
of 75)
Step of alignment:
1). Pump coupling + Fluid coupling
2). Fluid coupling + Motor
3). Motor + Booster
a) Mark a reference point to the pump and fluid coupling shaft at
90 intervals ( top, right, bottom and left )
b) Attach dial indicators to the pump and prime mover (fluid
coupling) shaft respectively. Set to zero the indicators at top
(vertical) reading.
c) Rotate both pump and fluid coupling shafts together all the way
to 360 noting the readings at 90 intervals (top, right, bottom, left
and top). If the zero setting is not accomplished after 360 rotation, a
complete new set of readings is necessary by check radial dial gauge
bracket sag
d) Check the Radial dial gauge bracket sag by rotate pipe 180 then
check sag measurement on dial gauge. Sag will be a minus reading,
record reading and set dial gauge to the sag measurement.
Note:
(1) Before commence coupling alignment loosen each motor holding
down bolt and check "SOFT FOOT" If soft foot is detected add
shim until eliminated. Soft foot should not exceed 0.05 mm

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(2) All readings shall be from the pump shaft 0 mark. Rotate the
shaft and record the reading on 0,90, 180, 270.
(3) Rotate the shaft in one (1) direction only (operating direction
only )

* All reading shall be viewed from motor.

Figure 7

1) Radial Measurement

For example:

TIR X direction = +0.05 + (-0.03) = +0.02 / 2 = +0.01


TIR Y direction = +0.08 + ( 0.0) = +0.08 / 2 = +0.04

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Typical Tolerance of TIR (X and Y direction)


General Acceptance of TIR Tolerance: 0.05 mm

TIR Tolerance for Special couplings are as follows:

1. Rigid Type Coupling : max 0.05 mm


2. Gear Type Coupling : max 0.20 mm
3. Flexible Type Coupling : max 0.14 mm
4. Chain Type Coupling : max 0.50 mm

Note: These values are for reference only. Details should be checked in
the manufacturers standard
This TIR (Total Indicator Record) has 2 values for X direction and Y
direction. Based on these values, shafts and coupling should be aligned to
required clearance.

2) Axial Measurement

General Tolerance of TIR for Angular

: 0.05 mm >1500rpm
: 0.10 mm 1500rpm

General Tolerance of for Axial


: 0.05 mm
Note:
If the value of manufacturer recommendation is
Available it shall be follow.

Figure 8

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Piping
Exercise care in piping work without affecting the pump alignment. Piping
arrangement shall be so designed so as not to induce excessive force to the
pump especially during the hot condition of the line by using expansion
joint, bending, loop, hanger, etc.
It must be noted that any excessive force exerted during the piping work
will cause misalignment that will lead to increased bearing temperature,
interference of internal sliding parts and high vibration. These situations
will cause serious damage to the equipment, such as shaft breakage, casing
cracks, etc.
Allowable Tolerances

Allowable tolerance are defined in respective subsection of this procedure,


Tolerance not mentioned herein shall be referred to Specification
manufacturers installation manual.
7.8 Quality Inspection

Inspection and testing shall be performed in accordance with reference


document Field Inspection and Test Plan (ITP) (11MAA-T-JEE-0015.
Rev.0) Also quality inspections shall be performed to the items listed
below in addition to manufacturers recommended inspection items :
(1) Erection Completion ( Rotating Equipment )
(2) Foundation surface preparation
(3) Packer plate and base plate setting
(4) Pump alignment
(5) Grouting work preparation and completion
(6) Check that documentation conforms to specification requirements.

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8. ERECTION SCHEDULE (TENTATIVE)

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8 ERECTION SCHEDULE (TENTATIVE)

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ID Task Name Duration Start Finish May June July August September October November December January February March
4/15 4/22 4/29 5/6 5/13 5/20 5/27 6/3 6/10 6/17 6/24 7/1 7/8 7/15 7/22 7/29 8/5 8/12 8/19 8/26 9/2 9/9 9/16 9/23 9/30 10/7 0/1 0/2 0/2 11/4 1/1 1/1 1/2 12/2 12/9 2/1 2/2 2/3 1/6 1/13 1/20 1/27 2/3 2/10 2/17 2/24 3/3 3/10 3/17 3/24
1 BOILER FEED PUMPS-unit-1 138 days Wed 5/2/12 Fri 11/9/12

2 Foundation preparation & padding works 11 days Wed 5/2/12 Wed 5/16/12

3 Installation of hauling structures 12 days Thu 5/17/12 Fri 6/1/12

4 On base of equipmenst (Booster pump,hydraulic coupling,motor,Feed pump) 35 days Mon 6/4/12 Fri 7/20/12

5 Set and align base pedestals 45 days Mon 6/25/12 Fri 8/24/12

6 Coupling alignment & base grout 45 days Mon 7/16/12 Fri 9/14/12

7 Release for pipe connections & weld 21 days Mon 8/6/12 Mon 9/3/12

8 Final alignment & grout 55 days Mon 8/27/12 Fri 11/9/12

9 BOILER FEED PUMPS-unit-2 133 days Mon 9/3/12 Wed 3/6/13

10 Foundation preparation & padding works 11 days Mon 9/3/12 Mon 9/17/12

11 Installation of hauling structures 12 days Tue 9/18/12 Wed 10/3/12

12 On base of equipmenst (Booster pump,hydraulic coupling,motor,Feed pump) 35 days Thu 10/4/12 Wed 11/21/12

13 Set and align base pedestals 46 days Thu 10/25/12 Thu 12/27/12

14 Coupling alignment & base grout 45 days Thu 11/15/12 Wed 1/16/13

15 Release for pipe connections & weld 21 days Thu 12/6/12 Thu 1/3/13

16 Final alignment & grout 50 days Thu 12/27/12 Wed 3/6/13

Project: BOILER FEED PUMPS Task Split Progress Milestone Summary Project Summary External Tasks External Milestone Deadline
Date: Wed 12/28/11

Page 1

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9. ORGANIZATION & MANPOWER

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9 ORGANIZATION & MANPOWER


See Organization & Manpower below:
SITE ORIGANIZATION

MARUBENI CORPORATION
RAJU KRISHNA MOORTHY(RKM)

SITE MANAGER
SS CHAN

QA/AC IN-CHARGE MATERIAL CONTROL ENGINEER SAFTY IN-CHARGE RIGGER IN-CHARGE


IN-CHARGE
SRIKUMAR THEVA NIRUT KRISKUMAR JOHN

QA/QC ENGINEER MECH. ENGINEER


RIGGER TEAM

THOMAS SAYAN

MECH.SUPERVISOR

FOO

ERECTION &
INSTALLATION
TEAM

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10. RISK ASSESSMENT

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10 RISK ASSESSMENT
See the Table below:
Risk Assessments

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NGHI SON 1 2 x 300MW THERMAL POWER PROJECT, VIETNAM

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RISK MATRIX

Likelihood
Consequence

Almost
Unlikely Possible Likely
Certain
Catastrophic
Eg. Kill or Permanent MEDIUM HIGH EXTREME EXTREME
Disability
Major
Eg. Long term Injury MEDIUM MEDIUM HIGH EXTREME
or Illness
Moderate
Eg. Medical Attention
with several days off
LOW MEDIUM MEDIUM HIGH
work
Minor
Eg. First Aid Needed
LOW LOW MEDIUM MEDIUM

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10.1 General Hazards

1. Site Safety
There are various risks associated with working on any site and site
regulation as laid down by the site owner

2. PPE Personal Protective equipment


- Safety Helmet
- Full Body Safety Harness
- Earplugs
- Safety Shoe
- Eye Protection / Goggles
- Leather Gloves
- Other equipments that required by the site operator.

3. Safety Precautions
- Barricade the working area by hard barriers/tap barriers.
- Safety precaution signboards must be posted.
- Authorized personnel only allowed.
- Daily toolbox meeting.

4. Working in Erection.
- Check lifting devices such as wire ropes, shackles, chain blocks etc. are
free from defected.
- Check lifting equipment position is stable.
- Scaffolding, when used as work platform, is confirmed Tag for Use by
authorized person.
- Material safety data sheets are check for proper implementation of the
required safety measures during handling and application of the material.
- Personal protective equipment required for the safe performance of the
work is available for the personnel use.
- Application of the barricade for the working area before start erection
work
10.2 Emergency Action Plan
Fire watch man shall be assigned during the execution of hot work activity and
all of its employees have given a basis induction courses on fire fighting and
aware of the existing safety standards set forth by Client Fire Department.

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1. Fire and Security Protection / Prevention


- Ensure that necessary fire preventive measures are being religiously
performed by different level of organizations.
- Fire Fighting equipment such as Fire extinguisher, Hose reel and Fire
blanket are subject to evaluation and approval by Client Fire
Department.
- Fire Extinguishers are to be inspected prior to the work period.
- Fire Watchers will be identified.

2. Action In The Event of Plant Emergency


- To follow the client emergency procedure during the period of work.
- All work must stop and switch off all the power source and machines.
- All personnel must proceed to the assembly point.
- The personnel who detected a fire, toxic, flammable or asphyxiating gas
leak must initially ensure their own safety and.
- Direction person to person or by messenger by proving pertinent
information to the Fire Station.

3. First Aid
- Provide certified/competent first aid personnel to be deployed within the
vicinity of the worksite. These personnel must be satisfactorily possess
and completed any training course as required by Client.
- Provide first aid clinic and necessary first aid medicines at the worksite.
- An entry permit system is in place at work area to ensure that all
confined space entries are managed safely.

4. Emergency Flow Chart

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Accident
occurs

Employee notices
the injured

Primary Contact Emergency Response


calls 01656.323.047 Team contacts First-Aid
Trained personnel

Ambulance
First-Aid trained
personnel provide
First-Aid Trained people
medical services
transfer the injured
Person ambulance

Severe Injury (Sending to


Nearest Hospital)

3 days Reportable Accident

Site incident report

Accident investigation

Corrective action

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11. QUALITY CONTROL

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11 QUALITY CONTROL

The work execution shall be carried out as per ITP 11MAA-T-JEE-0015.


Rev.0

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