PROJECT

MUARA TAWAR ADD-ON PROJECT 650MW

OWNER
PT. PLN (PERSERO)

COUNSULTANT

EPC CONTRACTOR

PROJECT REV

CONTROL NO 0

Title:
METHOD STATEMENT FOR DIVERTER DAMPER
INSTALLATION OF BLOCK #2

DOCUMENT NO REV.
0

SCALE: NONE DATE:

PT. JURONG ENGINEERING LESTARI

 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

0 Issue for Approval

Rev Description Date Prepared Checked Approved
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

INDEX

1. General

2. Applicability

3. Responsibilities

4. Storage at Site

5. Erection & Installation

6. Tools & Equipment

7. Setting-Up Crane

8. Attachments

8.1 Risk Assessments for Erection of Diverter Damper

 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

1. GENERAL
This document describes the site erection procedure for “DIVERTER DAMPER”.

2. APPLICABILITY
This work instruction shall be applied to Muara Tawar Add On 650MW Combine Cycle Power
Plant Project for diverter damper erection.

3. RESPONSIBILITY

3.1. Construction Manager/ Area Manager

The Construction Manager/Area manager shall be responsible for coordination and
management of all erection activities at site and coordination with client and contractor.

3.2. Erection Engineer

3.2.1. Preparation & Implementation of this method statement.
3.2.2. Control of material handling and storage at site.
3.2.3. Establishment and execution of erection schedule and sequence.
3.2.4. Technical detailing of construction documents and drawing.
3.2.5. Ensures all erection task are carried out as per specification.
3.2.6. Check of permit to work.
3.2.7. Overall site safety management.

3.3. QA/QC Manager

QA/QC Manager shall be responsible for all QA/QC activities which are related to Job.
He shall be responsible for Non-Conformance report and Quality audits both internal &
external.

3.4. QA/QC Inspector

He shall be responsible for site QA/QC activities, coordination with site engineer,
Contractor for structural inspection.

3.5. HSE Manager/ Safety Officer

HSE Manager takes responsibility of all HSE activities at site. Safety Officer shall ensure
that work is carried out in safe manner and also toolbox talk. HSE meeting are conducted
by concerned supervisors and shall ensure proper mode of communication in case of
emergency. Ensure personnel adhere to Method Statement.

4. STORAGE AT SITE
For short storage on site the diverter damper and accessories, should be isolated from the
ground on leveled beams and with an appropriate rain protection. Any accumulation of
rainwater and / or dust should be avoided. Flange areas should be stored in a dry / air-
conditioned store. The damper parts should be stored away from normal access to prevent
damage by accidental collision. At delivery on site the items should be thoroughly inspected.
Missing parts and / or damages should be reported immediately.
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

5. ERECTION AND INSTALLATION

5.1 INTRODUCTION

The Diverter Damper is shipped in one assembly exclude the loose parts (the accessories
will be deliver in separate box). Make sure to carry out the work in accordance with
instructions in order to obtain a proper functioning of the damper and to guarantee the
gas tightness of the damper.

5.2 INSTALLATION
The Diverter Damper, arriving at site have to be prepared the temporary support for
temporary storage the diverter damper before start erection. All loose parts must be
checked and temporary stored not far away from the final location of the Diverter. Keep
the insulation dry during the installation procedure. Do not use wet insulation for field
insulation.

A. Install the elephant leg for temporary sitting the diverter damper by using concrete
blocks. Weld the skid rollers and temporary pulling lug on new diverter.

Skid Rollers

B. Lift the new diverter into the rail using at least 250-ton crane.

C. Install the electric winch or chain block at backside of diverter damper for pulling. Slowly
pull and roll-in the new diverter into position using 10-ton chain block or winch. Do
centering and alignment check of the final and correct position.
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

D. Jack up the diverter using four 50-ton hydraulic jack to remove the skid roller and to install
the down body. Do bolt tightening after fitting the down body structure. Remove the skid
rail. Do touch-up painting on weld areas where the skid rollers were removed.

E. Erect scaffold for the installation of counter flange (inlet, bypass and HRSG connection).
Fit-up and align the counter flanges, only (+/-) 6mm allowed for the misalignment unless
specify by design condition. Proceed for welding after the alignment inspection. Then,
do touch-up painting on weld areas.
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

F. Install the following loose items in parallel.

a. HPU unit, piping and supports
b. Steel platform, hand rail and ladders
c. Seal air fan and ducting
d. Vent valve and pipe spool
e. Tubing lines for transmitters

G. Installation of Hydraulic System

a. Install the support frame on the foundation.
b. Mark the holes for the chemical cartridges in the foundation.
c. Take the frame away.
d. Drill the holes.
e. Insert the chemical cartridges fully, and install anchor bolts according
manufacturer’s specification.
f. Lift the support frame on its place and mount the frame with the nuts and
washers.
g. Bring the hydraulic unit to the support frame by means of four lifting lugs.
h. Mount the nuts and washers on top of the mounting plate.

Mount the pipes and hoses according to thepiping drawing. The hydraulic circuit
connections are closed with plugs to avoid dust/dirt entrance. Do not remove these plugs
untill the connecting pipe work is fitted. Nevertheless for dirt protection, flushing of the
complete oil circuit after assembly is always required. Air bleeding nipples should be placed
at the highest locations in the system. During colddiverter commissioning, the stroke will be
adjusted and the cylinder base plates will be tightened.
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

HPU System

H. Installation of Seal Air System

a. Bring the Seal air fan frame to the location on the foundation, then :
b. Mark the holes for the reaction anchors cartridges of anchor bolts.
c. Take the frame away.
d. Drill the holes.
e. Insert the reaction anchors resin cartridges fully, and install anchor bolts
according manufacturer’s specification.
f. Bring the fan in position.

Install the seal air fans with buffers on the frame. Remove the blind plate, bolt the seal
air inlet adapter to the Diverter frame and fix the seal air inlet valves (keep the flange gasket
in place between the flanges). Mount the seal air actuator on the seal air valve.Then install
the seal air pipes, switch over valve and expansion joint.
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

Seal Air Fan

Piping

I. Lift and install the Guillotine Damper. Tighten the fasteners of the connecting parts.
Lower the guillotine blade into the insert by manually operating the electric actuator,
then close the cover.
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

Guillotine Blade
Cover

J. Erect scaffold inside the gas path (inlet, bypass stack, HRSG connection) for the
installation of insulation and liner plates.

K. Weld the insulation stud bolt pins, then install the insulation. Tight firmly the two nuts
with washer to secure the insulation. Install and fasten the expansion bellow fabric with
the back-up bar plates, then do the bolt tightening after installation.

L. Inside the gas path, install the insulation properly and compact to prevent air pockets.
Then install the liner plates, secure with nut and washer. Use GTAW for the tack
welding of nuts.

M. Remove the scaffold after the final inspection and acceptance is completed. Close and
tighten the manhole after housekeeping and final check.
 PT. JURONG ENGINEERING LESTARI
DIVERTER DAMPER INSTALLATION FOR BLOCK #2
PROJECT: MUARA TAWAR ADD-ON (650MW)
COMBINE CYCLE POWER PLANT

6. TOOLS AND EQUIPMENTS

— Mobile Cranes
— Sling wire and shackle
— Welding Machines
— Cutting Tools
— Confined Space Tools and Equipment
— Chain block
— Manlift
— Skid rollers
— Railing Structure
— Coring Machine
— Hydraulic Jack
— Pipe Bender

7. SETTING UP OF CRANES
The lifting supervisors shall check and ensure that the crane location for erection of
diverter damper. Horizontal base and the ground upon which the machine is standing is
solid and able to withstand the load

8. ATTACHMENT

8.1 Risk Assessments for Erection of Diverter Damper