U Method Statement For Penstock Installation (20220918 - 0462)

MORAGOLLA HYDROPOWER PROJECT
Lot B – Mechanical and Electrical Facilities
Method Statement for Penstock Installation
Rev.2
September 2022
Method statement for penstock installation
Table of Contents
1. Engineering Overview.......................................................................................................... 1
2. Basis of Compilation ............................................................................................................ 1
3. Overall Construction Planning ........................................................................................... 1
3.1 Steel Pipe Installation Sequence................................................................................ 1
3.2 Installer Access ........................................................................................................... 8
3.3 Construction Water Planning.................................................................................... 8
3.4 Construction Ventilation Planning ........................................................................... 8
3.5 Construction Communication Planning................................................................... 9
3.6 Electricity Consumption Planning for Construction .............................................. 9
4. Installation Schedule ............................................................................................................ 9
5. Resource Input Plan ........................................................................................................... 10
5.1 People Configuration Plan....................................................................................... 10
5.2 Equipment Configuration Plan ............................................................................... 11
5.3 Self-Made Tooling Plan ............................................................................................ 13
6. Preparation before Installation ......................................................................................... 13
6.1 Site transportation of penstock ............................................................................ 13
6.2 Transportation Track Layout .................................................................................. 13
6.3 Preparation of Transport Trolley ............................................................................ 14
6.4 Preparation of In-Pipe Construction Platform...................................................... 15
7. Installation Process Measures ........................................................................................... 15
7.1 Installation Process Flow ......................................................................................... 15
7.2 Transportation Method of penstock ....................................................................... 15
7.3 Penstock Installation Adjustment ........................................................................... 16
8. Circumferential Seam Welding and Inspection ............................................................... 16
8.1 Preparation before Welding .................................................................................... 16
8.2 Welding Requirements ............................................................................................. 17
8.3 Welding Technology ................................................................................................. 18
8.4 Nondestructive Testing ............................................................................................. 19
8.5 Deficiency Treatment ............................................................................................... 20
9. Anticorrosive Coating Process .......................................................................................... 20
10. Quality Control Measures ............................................................................................... 21
11. Special Safety and Civilized Measures ........................................................................... 22
11.1 Special Safety Measures ......................................................................................... 22
11.2 Civilized Construction Measures .......................................................................... 23
1. Engineering Overview
Steel Penstock to pass the rated water 50.0 m3/s for two (2) water turbine units in each
15.55 MW shall consist of embedded type steel penstock starting from 7.2 m downstream of
the datum line of the surge tank gate up to the powerhouse.
The steel penstock starts from 7.2 m downstream of the datum line for the surge tank gate
to the Contract boundary at 7.5 m upstream side from the centerline of the water turbines. The
line profile consists of an upper horizontal portion, an inclined portion, a lower horizontal
portion, a bifurcation and two (2) branched pipe portions.
The steel penstock shall be of the embedded type and complete with straight pipes, bend
pipes, reducing pipes, bifurcation, branch pipes, seepage rings, stiffener rings, thrust rings,
grout holes and plugs and all other necessary components.
2. Basis of Compilation
According to the specification mentioned in the contract.
3. Overall Construction Planning

3.1 Steel Pipe Installation Sequence
(1) First phase
The first pipe section of IP6 should be installed as the position joint. The position joint
will be transported to IP6 through Adit No.3. Then, the pipe sections will be installed from IP6
to the joint section of Adit No. 2-2 downstream side and these pipe sections will be transported
through Adit No. 2-2. The 10T forklift will be used to transport in the upper horizontal portion.
Every time the length of the penstock transported by the forklift is 2m. For the inclined portion,
a motor hoist with wire rope will be applied to transport the pipes to the position. The layout of
the anchors is shown in Figure 2.
1
Figure 1 First phase installation diagram
Figure 2 Anchor and winch layout
2
1:The anchors are at the top of the cave and are used to fix the fixed pulley.
2:The anchors are on the floor and are used to fix the 1T winch.
3:The anchors are on the floor and are used to fix the fixed pulley.
4:The anchors are on the floor and are used to fix the 10T winch.
All the anchors should be installed by Lot A2 contractor.
Figure 3 Using the Motor hoist to transport the pipe section in the inclined shaft
(2) Second phase
The first pipe section of IP6 should be the position joint. The pipes will be installed from
the position joint to IP7. The joint section of IP7 will be reserved and not installed at this phase.
The pipe sections will be transported through Adit No.3. 10T forklift will be used to move the
pipes in the lower horizontal portion. Every time the length of the penstock transported by the
forklift is 2m.
Note：The installation of first phase and second phase will be carried out alternately.
Figure 4 Second phase installation diagram
3
Figure 5 Using the forklift to transport the pipe section

(3) Third phase
Figure 6 The anchors' installation diagram for bifurcation

Lot A2 shall install the anchors before the bifurcation install. All the anchors are at the top
of the cave, and they are used to hang the chain hoists. The layout of the anchors is shown in
Figure 6.
4
Figure 7 Third phase installation diagram

The bifurcation installation will be started from downstream to upstream. The water
pressure test will be conducted after the completion of the bifurcation installation. Three
bulkhead covers will be cut and removed after the water pressure test completion. The sections
of bifurcation will be transported through Adit No.3 by a 10T forklift.
Figure 8 Plan of support for bifurcation
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Figure 9 The support of bifurcation installation sectional view
We will use 16# I-beam and 10# channel steel as the bracket for bifurcation and conduct the
water pressure test with this bracket. The 16# I-beam is used as the column and beam of the
bracket, and the 10# channel steel is arranged around it to assist in fixing the bifurcation. The
specific arrangement is shown in Figure 8 and Figure 9.
(4) Forth phase
Two branch pipes installation will be started from the joint section with the bifurcation to
the downstream powerhouse. For the transportation of the branch pipes, the powerhouse OHT
crane will be used to unload the pipes to the platform at EL. 469.400. Trolley with the rail
system will be arranged in the two branch channels. The branch sections will be transported by
the trolley in the two branch pipes portion.
6
Figure 10 Forth phase installation diagram

(5) Fifth phase
From IP8 of bifurcation to IP7, the pipe sections will be installed. Finally, the reserved
joint section of IP7 will be installed.
Figure 11 Fifth phase installation diagram

(6) Sixth phase
From IP0 (BP of Penstock) to the section of Adit No. 2-2(Refer to DEC-MHP-HM-204),
balance pipes will be installed. Finally, the joint section will be completed at Adit No. 2-2.
Then, all of the penstock installations will be finished.
Note: Sixth phase can also be installed from downstream to upstream following with first
phase according to the construction progress of surge tank.
7
Figure 12 Sixth phase installation diagram

3.2 Installer Access
The installer will use the penstock transportation access. Inclined shaft section penstock
installation workers use inclined shaft stairs. The inclined shaft stair is arranged on one side of
the penstock hole, which is formed by the excavation of lot A2, and it is shown in Figure 13.
Anti-falling wire ropes are set on the side of inclined shaft stairs. Construction workers wear
safety belts when going up and down, and hang the safety belts on the anti-falling wire ropes.
Figure 13 Inclined shaft stairs diagram
3.3 Construction Water Planning

The construction water will be used for mixing chemical paste during NDT, and the water
consumption is very few. Hence, it can be carried to the site with portable water tools according
to the dosage. Water intake facilities and pipelines are not set separately on the construction site.
The water for bifurcation's hydrostatic test is temporarily connected to the water supply pipe
for civil construction.
3.4 Construction Ventilation Planning
2 axial flow fans can be set at the upstream and downstream nozzles of the penstock which
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is installing. They can pump the construction smoke and dust to the outside of the working face.
When the whole excavation of the penstock has been completed, the entire pipeline system
has a stack effect, and the internal airflow is in a flowing state. The construction dust and
welding smoke on the downstream side will automatically flow out of the construction tunnel
of the upper horizontal section, and the construction smoke will be automatically pumped out.
3.5 Construction Communication Planning
10 walkie-talkies will be purchased for sending commands during transportation and
hoisting of the penstock. The PDT-268 walkie-talkie to be purchased has a power of 5W. The
measured effective transmission distance is about 5km, which can ensure the information
transmission during the installation of the penstock. The auxiliary communication or contact
with the outside can be made by hand-held telephone. Therefore, the information exchange and
transmission in the process of penstock transportation and hoisting are mainly based on walkie-
talkies and supplemented by hand-held telephones.
3.6 Electricity Consumption Planning for Construction
Connect the construction power supply from the built-in construction power bus in the
tunnel, and set up three-level cabinets in each construction operation place for the installation
of steel pipes. The power cables are laid along the tunnel wall to the vicinity of the working
place, which must be firmly fixed during laying.
The power supply for construction in the tunnel mainly uses the lamps and lanterns set
during civil construction. In the process of lifting and welding penstock, the light source is set
nearby according to the actual demand. The temporary mobile power supply in the tunnel uses
36V safe voltage LED lamps, and the common lighting uses LED energy-saving lamps. A LED
strip is arranged along both sides of the tunnel wall at the upper horizontal tunnel, inclined shaft,
lower horizontal tunnel, branch tunnel, etc. The light source of the lamp strip is white, the access
voltage is 220V, and each lamp strip is provided with independent transformer components.
4. Installation Schedule
Table 4-1 Installation Schedule of Penstock
Duration
No. Process Name Start Time Finish Time Remarks
(days)
9
Inclined shaft steel pipe IP6 toIP5 to

1 and upper flat pipe T1 T2 120 Adit 2#-2
installation T2=T1+120
Installation of the lower IP6 to IP7

2 T2 T3 120
flat section T3=T2+120
Bifurcation
3 Installation of bifurcation T3 T4 90
T4=T3+90
branch pipe
4 Installation of branch pipe T4 T5 60
T5=T4+60
Final joint
5 Installation of IP8 to IP7 T6 T7 30 T6=T4+1
T7=T6+30
Final joint
6 Installation of IP0 to 2#-2 T8 T9 30 T8=T7+1
T9=T8+30
Note: T1 is the time for the handover of the Inclined shaft steel pipe and upper flat pipe
working face from Lot A2 to Lot B.
5. Resource Input Plan

5.1 People Configuration Plan
See Table 5-1 for the configuration of penstock installation and construction personnel.
Table 5-1 Configuration Table of Penstock Installation and Construction Personnel
Number of
No. Type of Work Persons Remarks
(Persons)
1 General site in charge 1
2 Technician 1
3 Security guard 1
Qualified to use WFT,

4 Painting worker 2 DFT and Holiday
detectors
5 Measuring worker 1
10
Number of
No. Type of Work Persons Remarks
(Persons)
6 Crane man 2
7 Rigger 4
WPQ certificate will be

8 Welder 6
submitted 焊工证
9 Electrician 1
Qualified to conduct UT
10 Flaw detection 1
and RT tests
11 Auxiliary worker 4
Total 24
5.2 Equipment Configuration Plan

The configuration of the main construction equipment for penstock installation is shown
in Table 5-2:
Table 5-2 Configuration Table of Main Construction Equipment for Penstock
Installation
No. Device Name Model Specification Quantity Remarks
1 Truck crane 25t 1 vehicle Lease
2 Flat car 8t 1 vehicle Lease
3 Small truck 1 vehicle
1 set
4 Winch 1t, 10t
For each
5 Forklift 10t 1 set Lease
6 Temperature control box 2 sets
7 Tracked heating block 30 Piece
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8 Welding Electrode Oven ZYHC-60 2 sets
9 Mobile air compressor 3kW 3 sets
10 Welding machine ZX7-400 8 sets
11 Carbon arc gouging welder ZX7-630 4 sets
Oxygen and acetylene cutting

12 G01-30 4 sets
torch
10
13 Electrode Dryer TRB-10G
Pieces
14 Pneumatic shovel WM-3601 8 Pieces
15 Chain hoist 10t 4 Pieces
16 Chain hoist 5t 8 Pieces
17 Screw jack 25t 4 Pieces
18 Screw jack 16t 8 Pieces
19 Ultrasonic flaw detector CTS-22 1 set
1 set
20 RT flaw detection equipment
1台
21 Total station TS06 1 set
22 Polishing machine Φ100 4 Pieces
23 Polishing machine Φ180 2 Pieces
24 High-power axial fan 5.5kW 4 Pieces
25 DFT meters 1 set
26 WFT meters 1 set
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27 Temperature detector 1 set
28 Temperature and humidity meter 1 set
5.3 Self-Made Tooling Plan

Table 5-3 Self-Made Tooling Configuration Table
Transport trolley for the penstock

1 1.130t 2 Sets
inclined pipes and branch pipes
2 In-pipe construction platform 1.587t 1 Rack
Sealing tool for the lower nozzle

3 / 1 Piece
of the inclined shaft
6. Preparation before Installation

According to the Work Program of Lot B (Rev.8), the civil contractor should hand over
the penstock tunnel on May 30, 2022. After handing over of the working face, all the
preparatory work before the installation of penstock will be carried out. The relevant
preparatory work is as follows:
6.1 Site transportation of penstock
10T forklift will be used to transport the penstock to the installation position. However,
Inclined pipes and branch pipes will use track and trolley to transport. Every time the length of
the penstock transported by the forklift is 2m. During transportation, it shall be reinforced firmly,
and square wood shall be added to the contact part to prevent deformation during transportation.
6.2 Transportation Track Layout
Install the trolley track in the inclined section, the transport track span is 1.9m, and the
specification is 18kg/m light rail. The length of each track is 8m. The track is arranged on the
pier, the plane size of the pier is 400*400mm, and the height is determined according to the
installation of the track. Ф20mm steel rebar is used as steel dowel, 10# channel steel is used
as backing plate, and the track is fixed by welding, as shown in Figure 14. All piers pouring
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work is completed by lot A2.
Figure 14 Schematic diagram of inclined shaft track

6.3 Preparation of Transport Trolley
There is 1 transport trolley for inclined section penstock transportation, with a trolley width
of 1,950 mm, length of 2000mm, height of 385mm, and transport span of 2000mm. The trolley
structure is welded with 14# and 16# I-steel, which is made of Q235. The middle of the trolley
is of a circular arc structure, and the bottom of the trolley is connected with 4 traveling wheels
by welding. The diameter of the traveling wheels is Ф150mm. The schematic diagram of the
steel pipe transport trolley is as follows:
Figure 15 Steel Pipe Transport Trolley
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6.4 Preparation of In-Pipe Construction Platform
14# and 10# I-beams are used for welding the steel structure skeleton, Φ48×3.5mm steel
pipes are used for welding, and the top surface is paved with 3mm thick patterned steel plates.
4 groups of lifting lugs are set on the top surface of the construction platform. The lifting lugs
are 65mm in diameter and 30mm in thickness and welded on both sides. The lifting lugs are
connected with 4 cable hinges, of which 2 are short hinges and the other 2 are long hinges,
which can be switched when the platform needs to shift and change hooks. Each cable hinge
bears 3t, and the other end of the cable hinge is connected with a one-way inclined opening
hook.
After the construction platform is in place, hang the free end of the short hinge at the
penstock nozzle and slowly slip out the steel wire rope until the two iron cable hinges are
fully stressed. After the short hinge is stressed, hang the free end of the long hinge at the
penstock nozzle as a backup. After the comprehensive inspection, the short hinge can be
released from slipping out. When the construction platform needs to be displaced, connect the
slip wire rope shackle with the long hinge hook and slowly lift it upwards. After meeting the
short hinge release condition, release the short hinge. After the construction platform is
displaced to the required position, hang the short hinge according to the above steps.
7. Installation Process Measures

7.1 Installation Process Flow
The installation process of penstock: Preparatory Work → Steel pipe transportation in
place → Steel pipe installation adjustment → Installation dimension inspection → Girth
welding → Weld non-destructive testing →Apply respective coats at welding seam locations
both internally and externally→ Quality acceptance.
Preparatory Work includes the fabrication of the trolley and platform outside of the
penstock tunnel and the installation of guide rails after taking over the tunnel from Lot A2.
7.2 Transportation Method of penstock
With a 10T forklift, transport the penstock to the installation position. Inclined section and
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branch pipes will use the trolley with rail to transport.

7.3 Penstock Installation Adjustment
After the steel pipe is transported to the installation position, use 4 screw jacks to jack up
the steel pipe to the installation elevation. Adjusting the butt joint of the bottom of the steel pipe
to meet the specification requirements, weld 2~3 positioning plates of the same material at the
bottom of the steel pipe. Tie the steel pipe section and the previous section with a chain block
at the top and side. After confirming that the steel pipe has been reliably fixed at the installation
position, move the trolley out of the bottom of the steel pipe. Pull the trolley to the starting point
of transportation with the inclined slip rope to prepare for the next section of the steel pipe.
The riveter can press and adjust the circumferential seam of the steel pipe. The butt joint
device (Including the screw jack) is arranged on the pipe construction platform to adjust the
circumferential joint and adjust the roundness, misalignment, gap and other dimensions of the
pipe mouth to meet the specification requirements before positioning welding.
8. Circumferential Seam Welding and Inspection

8.1 Preparation before Welding
(1) Welders engaged in welding of penstock shall pass the examination as required and
with the welder certificate issued by the corresponding competent department and submit the
certificate.
(2) Check the quality certificate and certificate of welding materials, and confirm that
qualified welding materials can be put into use;
(3) Welding seam preheating and post-heating equipment mainly includes temperature
control cabinet, heating block and its auxiliary power cord, welding material heating equipment
mainly includes the oven and its auxiliary power cord, and welding material storage equipment
mainly includes welding material heat preservation box, heat preservation barrel, etc.
(4) Take measures to prevent the wind and rain;
(5) In case of the following situations happen in the welding environment, protective
measures should be adopted. Otherwise, the welding operation should be stopped:
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① Wind Speed: Gas shielded welding is more than 2m/s, and other welding methods are
more than 8m/s;
② The relative humidity is greater than 90%;
③ The ambient temperature is lower than: Low alloy steel below -10℃;
④ Welding in rainy days.
(8) Before welding, remove rust, slag, grease and water marks within 50mm of the groove
and both sides. Check the installation size, groove size and positioning welding quality.
8.2 Welding Requirements
(1) Welding Process
The penstock is made of Q345R, and the circumferential seam of the penstock is welded
by SMAW.
(2) Welding Material and Heating Method
The welding material used for girth welding is 507, and the diameter of the electrode is
Ф3.2mm and Ф4.0mm, the diameter of carbon is Ф8mm and Ф10mm. Electrode and carbon
rods for carbon arc gouging shall meet the requirements of relevant standards. Welding
materials shall be sealed and moisture-proof during storage and transportation. The warehouse
shall be well ventilated, with room temperature not lower than 5℃ and relative humidity not
higher than 60%, and the room temperature and relative humidity shall be recorded regularly.
Electrodes shall be stored on shelves with a height distance of not less than 300mm from the
ground and not less than 300mm from the wall.
Heating temperature and time during the use of welding materials shall be implemented
according to the specifications of welding materials manufacturers. After drying, the electrode
should be kept in a constant temperature box at 100~150℃, and the coating of the electrode
should be free from falling off and obvious cracks. When in use, the welding rod is loaded into
the heat preservation cylinder. The number of thermal insulation cylinders filled each time shall
not exceed 80 electrodes.
(3) Welding Parameter
In the welding process, the welding heat input is strictly controlled to reduce the weld line
17
energy, thus reducing the welding stress. Parameters of Q345R steel electrode arc welding: The
current type is DC reverse connection, the welding current is 110~170 A, the arc voltage is
24~28 V, the welding speed is 4.5cm~12cm/min, and multi-layer and multi-channel welding is
performed.
8.3 Welding Technology
(1) Groove Form
The penstock has a diameter of 2.3m~3.8m, a plate thickness of 12mm~20mm, a single V-
grooved with an angle of 60°, a blunt edge of 2mm and an assembly clearance of 2mm.
The wall thickness of the bifurcation is 20mm, and the circumferential joint of the tile butt
joint is a single V-grooved with an angle of 60°, a blunt edge of 2mm and an assembly
clearance of 2mm. The thickness of the crescent rib is 40mm, and the combined weld at the
junction of the crescent rib and pipe wall is a K-grooved.
The welding seam of the lifting lug is a T-shaped fillet weld, and the groove form is the
unilateral V-shaped groove, the groove angle is 45°, and the blunt edge is 2mm.
(2) Tack Welding
The welding materials and welding requirements for fixed welds are the same as those for
formal welds. Spot welding shall be firm, reliable and free from defects; The locating weld shall
have a thickness of not less than 15mm, a length of not less than 100mm and an interval of not
less than 600mm. The locating weld shall be welded on the root cleaning side, and the locating
weld shall be removed during root cleaning.
(3) Girth Welding
In order to ensure the welding quality and deformation control, the parts above the center
line of the steel pipe should be welded on the outer side first, and the root should be cleaned on
the inner side. The parts below the center line shall be welded on the inner side first, and the
root shall be cleaned on the outer side.
Multi-layer, multi-channel and symmetrical welding method is adopted for circumferential
welding of the penstock, and multi-layer, multi-channel, symmetrical, segmented and backward
welding method is adopted for welding of bifurcation. The indirect joints of each weld layer
18
should be staggered. After each weld is welded, it should be cleaned by the wire brush or slag
remover, and the next welding can be carried out after the cleaning inspection.
8.4 Nondestructive Testing
(1) Classification of Welds
Class-I Weld: Main stress welds, such as all the welds in the bifurcation, longitudinal seam
of the pipe wall and closed circumferential seam of the make-up joint.
Class-II Welds: Secondary stress welds, such as circumferential seam of pipe wall, butt
weld of stiffening ring and sealing weld of grouting hole.
Class-III Welds: Other welds that do not belong to Class-I and Class-II welds.
(2) Appearance check

All welds of penstock shall be visually inspected according to the specifications to ensure
that the surface quality, weld foot, splash, flash and other indicators meet the specification
requirements.
(3) Testing requirements
Non-destructive testing personnel shall receive professional training and hold technical
qualification certificates issued by relevant departments and suitable for their work. Internal
quality inspection can be carried out after the appearance quality inspection is qualified.
Ultrasonic flaw detection or RT flaw detection method can be selected for internal flaw
detection of welds. When one of the flaw detection methods is in doubt, another flaw detection
method should be adopted for reexamination. The proportion of NDT for weld interior shall be
carried out according to the following table.

Table 8-2 Non-Destructive Testing Proportion
Ultrasonic Flaw Detection RT Inspection
(%) (%)
Type of Steel
Class-I Class-II Class-I Class-II
Q345R 100 50 25 10
Remarks: 1. After ultrasonic flaw detection is adopted for Class-I welds, ray or RT flaw detection shall
19
be used for re-inspection. The re-inspection length shall not be less than 5% of the total weld length, and
each weld shall not be less than one film.2. In case of the suspicious waveform of Class-II weld after
ultrasonic inspection, which cannot be accurately judged, RT inspection shall be applied for re-inspection.
3. According to the contract, 100% UT and 20% RT shall be carried out for welded joints of pressure steel
pipes.
8.5 Deficiency Treatment
(1) The protrusions on the pipe wall surface should be polished and removed. When cracks
and other dangerous defects are found inside or on the surface of the weld, the contractor shall
analyze them, put forward the defective repair parts and repair measures, and repair them by
the contractor with the approval of the supervisor.
(2) The internal defects of welds shall be removed by carbon arc gouging or grinding
wheel and shall be ground into grooves convenient for welding by grinding wheel, which shall
be checked before welding repair. If the defect is a crack, it shall be tested according to relevant
specifications, and the welding repair can only be carried out after confirming that the crack
has been eliminated.
(3) The reworked welds shall be rechecked by ultrasonic testing or RT testing.
9. Anticorrosive Coating Process

(1) Surface De-rusting
Both sides of the installation weld of penstock and bifurcation and the surface of the weld
shall be de-rusted manually by using a grinder wire wheel (Grinder with wire wheel).
(2) Coating Material
Coatings used for penstock shall be produced by manufacturers with production licenses
issued by relevant departments, and the product specifications and quality shall conform to
relevant national standards, contract documents and technical requirements. Coating of
penstock shall be implemented according to relevant contract requirements or technical design
documents.
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10. Quality Control Measures

(1) In order to ensure the installation and welding quality of penstock, it is the premise to
ensure the construction progress by organizing technical disclosure, clarifying the process and
quality requirements and fully understanding the construction quality.
(2) Adhere to the system of pre-shift meetings and strengthen the skills training of
employees. Before the daily construction, a pre-shift meeting shall be held, and the operation
team leader and on-site technical person in charge shall specify the construction tasks and
construction quality control points of the day and make technical disclosure to avoid quality
accidents and hidden dangers caused by unclear technical and quality requirements of
construction personnel.
(3) The construction procedures, methods and techniques shall be strictly implemented
according to the requirements, and the construction technicians and quality management
departments shall strictly inspect and control the construction process. If it is found that the
construction fails to comply with the plan, the barbaric construction and the operation fails to
comply with the specifications, it must be resolutely stopped, and the relevant responsible
persons shall be punished.
(4) After the construction of a single process is completed, the quality management
department will conduct a comprehensive inspection of the construction quality and resolutely
rectify the unqualified parts.
(5) In the construction process, the quality control inspection plan shall be carefully
implemented. Strengthen the stand-by system for the whole construction process, and correct
the potential quality and safety hazards if found on the spot to eliminate the potential quality
risks in the bud.
(6) The construction process is strictly based on construction measures, design drawings,
technical clauses and quality standards of relevant specifications, and construction personnel
are strictly required to comply with them. After each working procedure is up to standard, the
construction of the next working procedure can be carried out to ensure that the construction of
each working procedure meets the requirements of specifications and design quality standards
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and ensure the working procedure quality.
(7) Regularly check the running status of machines and tools and handle abnormal sounds
and other abnormal phenomena in time to avoid quality and safety accidents.
(8) Strengthen the inspection of weld appearance quality. The welding appearance quality
shall conform to the welding appearance quality standard. The weld shall be full and the
surface shall be free of flash, residual coating, splash and sundries.
(9) In order to ensure the welding quality, the welding materials shall be managed by
designated personnel, and the heating temperature, holding time, distribution and recycling of
welding rods shall be recorded.
(10) When welding, the heated electrode should be placed in the heat preservation
cylinder and covered in time after taking the electrode to prevent it from being affected by
dampness.
(11) The locating solder joints, spacing, length and thickness should be appropriate to
avoid tearing during welding, and the locating electrode should be the same as the formal
welding electrode.
(12) Each working procedure shall be carried out in strict accordance with the three-
inspection system, and the original records shall be made, and the acceptance form shall be
filled in time. The three-inspection system refers to the system of initial inspection by the team,
re-inspection by the operation team, and final inspection by the quality management department.
11. Special Safety and Civilized Measures

11.1 Special Safety Measures
(1) Before all construction personnel enters the site, they shall carry out safety production
education to improve the safety production awareness of all construction personnel.
(2) Enter the construction site, wear safety helmets and other labor protection articles,
and fasten the hat belt.
(3) Instruments, materials, etc. shall be placed reasonably and standardly.
(4) The lighting is sufficient, and the mobile lighting shall use safe traveling lights with
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a voltage below 36 V.
(5) Scaffolding is safe and stable with reasonable structure, which is convenient for
construction and inspection.
(6) When working at height, the construction personnel shall fasten their safety belts and
prohibit throwing anything.
(7) Pedestrians are forbidden to walk or stay in the lifting area when lifting the split
segment or pipe joint.
(8) Lifting command and operation shall be carried out by certified and skilled lifting
personnel.
(9) Keep the distance between the oxygen cylinder and acetylene cylinder > 5m, keep the
cylinder stable, check whether the pressure gauge is in good condition at any time, and close
the valve in time when not in use， and flashback arrestors shall be installed at cylinder end
and torch end.
(10) With the remaining electrode, the abandoned electrode head back in time for
safekeeping.
(11) Keep the site clean, and make everything clear.
(12) Construction personnel should count tools and instruments to avoid loss.
(13) Personnel irrelevant to operation are prohibited from entering the construction site.
(14) Safety protection and construction measures must be taken to coordinate and arrange
all the work in time, and crossover operations should be avoided as far as possible.
(15) Fire extinguishers.
(16) Pneumatic tools for erection work.
（17）Necessary safety clothes shall be provided to the welders. Distinguishable colours
of the helmets shall be used to identify the employees.
11.2 Civilized Construction Measures
(1) Educate the construction personnel to abide by the rules and regulations of the
construction site, take good care of the environment, put into construction production with a
good mental outlook, and conduct friendly coordination and communication with other
23
participating units.
(2) All construction personnel on site must wear labor uniforms and identification cards
to prove their identity.
(3) Strictly control the safe and civilized construction on the construction site and ensure
that the materials are sorted and placed in order. When the work is finished, the materials are
exhausted, and the site is cleared. The team leader shall check the clean-up of the working area
before leaving work.
(4) Maintain the environmental sanitation of the construction site. After the completion
of the work, arrange for the personnel on duty to clean the construction surface and keep the
construction area clean.
(5) The wastes and waste residues of various operations shall be removed at any time,
and the wastes, waste residues and other wastes shall be transported to the designated waste
disposal area to ensure the cleanness and neatness of the working area and do a good job in
civilized construction management.
24

U Method Statement For Penstock Installation (20220918 - 0462)

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U Method Statement For Penstock Installation (20220918 - 0462)

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MORAGOLLA HYDROPOWER PROJECT

Lot B – Mechanical and Electrical Facilities

Method Statement for Penstock Installation

3. Overall Construction Planning

Figure 1 First phase installation diagram

Figure 2 Anchor and winch layout

Figure 4 Second phase installation diagram

Figure 5 Using the forklift to transport the pipe section

Figure 6 The anchors' installation diagram for bifurcation

Figure 7 Third phase installation diagram

Figure 8 Plan of support for bifurcation

Figure 9 The support of bifurcation installation sectional view

Figure 10 Forth phase installation diagram

Figure 11 Fifth phase installation diagram

Figure 12 Sixth phase installation diagram

Figure 13 Inclined shaft stairs diagram

3.3 Construction Water Planning

Inclined shaft steel pipe IP6 toIP5 to

Installation of the lower IP6 to IP7

5. Resource Input Plan

Qualified to use WFT,

WPQ certificate will be

5.2 Equipment Configuration Plan

No. Device Name Model Specification Quantity Remarks

1 Truck crane 25t 1 vehicle Lease

2 Flat car 8t 1 vehicle Lease

3 Small truck 1 vehicle

6 Temperature control box 2 sets

7 Tracked heating block 30 Piece

No. Device Name Model Specification Quantity Remarks

8 Welding Electrode Oven ZYHC-60 2 sets

9 Mobile air compressor 3kW 3 sets

10 Welding machine ZX7-400 8 sets

11 Carbon arc gouging welder ZX7-630 4 sets

Oxygen and acetylene cutting

15 Chain hoist 10t 4 Pieces

16 Chain hoist 5t 8 Pieces

17 Screw jack 25t 4 Pieces

18 Screw jack 16t 8 Pieces

19 Ultrasonic flaw detector CTS-22 1 set

21 Total station TS06 1 set

22 Polishing machine Φ100 4 Pieces

23 Polishing machine Φ180 2 Pieces

24 High-power axial fan 5.5kW 4 Pieces

25 DFT meters 1 set

26 WFT meters 1 set

No. Device Name Model Specification Quantity Remarks

27 Temperature detector 1 set

28 Temperature and humidity meter 1 set

5.3 Self-Made Tooling Plan

No. Device Name Model Specification Quantity Remarks

Transport trolley for the penstock

2 In-pipe construction platform 1.587t 1 Rack

Sealing tool for the lower nozzle

6. Preparation before Installation

Figure 14 Schematic diagram of inclined shaft track

Figure 15 Steel Pipe Transport Trolley

7. Installation Process Measures

The installation process of penstock: Preparatory Work → Steel pipe transportation in

place → Steel pipe installation adjustment → Installation dimension inspection → Girth

both internally and externally→ Quality acceptance.

7.2 Transportation Method of penstock

branch pipes will use the trolley with rail to transport.