Fagioli PSC (Asia) Pte Ltd

75, Joo Koon Circle,

Singapore 629094
Tel: (65) 6863 3316
Fax: (65) 6863 3315
Email: enquiry@fagioliasia.com.sg
Website: http://www.fagiolipsc.com

INDRAMAYU COAL FIRED POWER PROJECT

TRUBA JAYA ENGINEERING

BOILER DRUM LIFTING OPERATION

METHOD STATEMENT

Document Status Sheet

Document Title : Method Statement
Document No : P572/MS/01
Prepared by : C.P. FOO

Reason for Issue For Information For Bid For Installation

Legends: For Approval For Review

Rev. Reason for Issue DATE

00 FOR REVIEW 25/08/08

01 FOR SUBMISSION 10/09/08
02
03

Document No: P572/MS/01Rev01

10/09/08
 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

CONTENTS

A. Introduction

B. Description of Equipment

C. Description of Proposal
i) FPSC Equipment
ii) Erection of FPSC Equipment.
iii) Lifting Operations.

D. Contingency Procedures

E. Equipment Certification

F Appendix

Document No: P572/MS/01Rev01

10/09/08 Page 2
 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

A. INTRODUCTION

PT. Truba Jaya Engineering has been awarded the construction contract for the erection of
3 units of coal fired boilers by China National Electric Equipment Corporation (CNEEC)
for the PLTU 1 Jawa Barat 3x330 MW Power Plant, Indramayu, West Java - Indonesia.
The erection of the 3 units of Boilers includes the lifting of 3 units of steam drums. The
steam drum will be delivered at the ground level of the boiler structure and subsequently
lifted into place. This Technical Submission details the use of Fagioli PSC (FPSC) Centre
Hole Jacks to carry out the lifting operations.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

B. DESCRIPTION OF EQUIPMENT

i) Jacks & Anchors

The lifting operation will be carried out using FPSC Heavy Lift Centre Hole Jacks, details of
which are given in the Introductory Brochure enclosed in the appendix of this document.

FPSC Centre Hole Jacks move structures in a series of increments roughly equivalent to the
stroke of the hydraulic jack. For the purposes of lifting or pulling operations the jack piston is
simply extended and retracted in sequence. The wedge gripping mechanisms automatically
lock onto the strand cable and pull it through the jack as the piston extends, and then lock it in
its new position as the piston retracts to reset. Lowering is slightly more complicated,
requiring secondary hydraulic systems incorporated in the gripping mechanisms to override
their automatic operation. This allows the jacks to be opened without lifting during resetting
and also allows the cable to pass through the lower grips when actually lowering.

One particular feature common to all jack sizes is their fail-safe mechanism that ensures that
in the event of any hydraulic failure the load is automatically locked into the bottom anchor of
the jacks. This same feature also provides a facility for stopping the jacking operation at any
part of the jack stroke and transferring the load from the hydraulic system onto the
mechanical arrangement of the bottom anchor, making it unnecessary to hold the load for
extended periods on the hydraulic system.

As an added feature, both the jack piston and the main anchor beneath the jack may be
refurbished with the load hanging from the jack system, should this become necessary at any
point of the operation. It should be stressed however, that previous lifting operations requiring
lifting heights of over 100 meters and horizontal movements of 350 meters have been carried
out without requiring the use of this facility.

The far ends of the pulling strands are secured using an anchor block incorporating gripping
mechanisms identical to those in the anchor blocks in the pulling jacks.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

ii) Cables

The lifting cables are assembled from multiple lengths of 18mm diameter seven wire post-
tensioning strand. Each strand consists of six wires round a central core wire which, after
assembly, is drawn through a die to compact the pattern. The resulting strands have a
minimum specified breaking load of 38 tonnes.

The actual capacity of any jack is directly related to the number of strands which are used
with that particular jack, and is calculated based on a normal minimum load factor of 2.5 on
the breaking load of each strand.

The strands, although marked by the gripping mechanisms, do not suffer from any loss of
strength in use and frequently strands are re-used many times for lifting and pulling
operations on the same site. Physically damaged or severely corroded strands should not be
used.

New lifting cables for the jacks will be supplied for the contract.

iii) Power Packs & Control Systems

The jacking systems are operated by electro-hydraulic power packs. Individual units will be
used with a single or multiple outlets per unit. Synchronised speed of operation of jacks
connected to each outlet, irrespective of their relative loading, is automatically ensured by the
internal hydraulics of the power pack. In addition to the main hydraulic system all power
packs are equipped with additional systems for the operation of the secondary hydraulic
systems used to control the jack gripping mechanisms.

The power packs can be operated either directly (Manually) or by remote control.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

iv) Features of FPSC Equipment

The features of FPSC Centre Hole Jacks and Control Systems include:

• Comprehensive, completely automatic remote control and monitoring of the jacks from the
power pack locations.

• Mechanically fail safe gripping mechanisms.

• Pre-set overload protection.

• Automatic synchronized operation of lifting speeds, irrespective of individual jack loads.

• Load is held mechanically, not hydraulically, at any time movement is stopped.

• Movement can be stopped and held indefinitely at any point in the jack stroke.

• Extremely precise adjustment of the lift for setting of weld gaps or the fitting of steelwork
connecting bolts.

• Automatic lowering without personnel in attendance at the jacks.

• Ready re-distribution / adjustment of the jack loads.

• In the unlikely event of any component failure all items can be serviced or replaced with
the load suspended from a mechanically locked system.

• Full efficiency in all attitudes from vertical through to horizontal.

• Completely self-contained and very rugged units.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

C. DESCRIPTION OF PROPOSAL

i) FPSC Equipment

1. The weight of the drum is 202MT.

2. It is proposed to use 2 units of L180 Strand Jacks for lifting the drum.

3. Each L180 jack will be threaded with 9 cables each cable takes a capacity of 15MT with a
safe working load of 135MT. Total capacity of 2 unit of L180 is 270MT

4. A L4/15E power pack will be used to operate the 2 jacks at a speed of approximately
12m/hr.

ii) Erection of FPSC Equipment.

1. Temporary structure is to be installed as per drawing no P572-001(Pages1-8).

2. Once the temporary structure is erected, power pack and the Jacks can be lifted to
position.

3. Connect the power supply (3 phase, 380~410V, 100Amp) to the Power pack.

4. Connect the hydraulic hoses from the Power pack to the jacks.. The equipment will be
given a full function test prior to commencement of the lifting operation. On completion
of testing, the power pack relief valves should be set and locked off at 10% above
expected load.

5. Erect a temporary platform below the jacks to facilitate threading of strand cable.

6. Hoist strand cable 1 piece at a time by means of a winch. One end of the strand cable is
threaded through the jack and the other end terminated in fixed anchor block housed in
anchor housing. These anchor housings are pin-connected to the temporary link plates
which in turn are pin-connected to the drum lifting lug.

7. Once all the required numbers of strand cables are threaded, each strand is nominally
pre-tensioned to eliminate overloading any one single strand during initial lift-off.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

iii) Lifting Operations.

The following sequence will be used for the llifting of the Steam Drum:

i) The lifting pressures for each the jacks will be calculated according to the following
charts.

Increment Load / 2 Jacks Load / Jack Pressure / jack Remarks

Stage (Tonnes) (Tonnes) (Bars)
1 38 19 40
2 58 29 60
3 78 39 80
4 98 49 100
5 116 58 120
6 136 68 140
7 156 78 160
8 176 88 180
9 187 94 192 Expected load
10 194 97 200

Note: The above table is based on all components of the system including the lifting cables,
fixed anchor housing and link plates.

ii) Each of jacks will be pressurised to stage 1 of the chart and the jacks returned
(closed).

iii) Operate both jacks in synchronization, increasing pressure in steps of 20bars and in
coordination the ‘operation controller’ until the steam drum is lifted off the temporary
support.

iv) Stop the operation to facilitate safety checks, conditions of structural supports and
jacking equipment etc.

v) Continue thereof to operate the jacks, in full stroke. During lifting, marshals are
deployed to warn of fore-coming ‘interference/obstruction’ that may occurs when the
heavy equipment travels up-wards.

vi) Upon lifted to required height, the full load of the heavy equipment is transferred to
the mechanical gripping mechanism of the jacks (that is, NO LOAD should remain on
hydraulic/top anchor of the jacks).

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

vii) Using two 5MT chain blocks at each jacks, pull the jack support beams together with
jack and steam drum towards the final drum centre line. During the pulling operation,
ensure that the jack support beams move in synchronisation.

viii) Once the jacks are over at the final center line, proceed to install the U-Bolts.

ix) Upon completion of installing the u-bolt, the steam drum can be lowered onto the U-
Bolts in slow pace.

x) Alignment of the steam drum may start and once the Alignment is inspected and
accepted by all parties, the lifting equipment can be dismantled.

D. CONTINGENCY PROCEDURES

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

Possible equipment failures will be dealt with as follows.

a) Main jack seal failure.

Remedy - replace the jack if the oil/pressure loss reaches an unacceptable level.
Time required – 12 hours (dependant on location and availability of craneage).

b) Hydraulic hose, valve or fitting failure inside power pack.

Remedy - detect the fault and replace part from the spares available.
Time required – 30 minutes.

c) Hydraulic hose, valve or fitting failure outside power pack.

Remedy - detect the fault and replace part from the spares available.
Time required - 30 minutes.

d) Hydraulic pump failure.

Remedy – replace with spare unit.
Time required - 10 hour.

g) Birdcage / broken strand.

Remedy - Expose problem strand and cut from cable.
Time required - 1 - 4 hours dependant on severity / location within cable.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

E. EQUIPMENT CERTIFICATION

The following certificates will be provided for the FPSC supplied items on this contract.

a) Lloyds Register of Industrial Services or Det Norske Veritas witness of 20% overload
test on lifting jacks and anchorages.

b) Manufacturers Certificate of Test (to destruction) for each coil of strand supplied.

c) Engineering Calculation of temporary structure.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

F. APPENDIX

i) Drawings:

The following drawings are attached:

• L180 Strand Jack - G.A. drawing.

• L180 Anchor housing - G.A. drawing.
• L4/15E power pack - G. A. drawing.
• DWG. P572-001 - General Arrangement of Lifting Proposal
• DWG. P572-002 - Loadings on permanent beam.

ii) Engineering Calculation:

iii) Jack Test Certificate

iv) Strand Cable Certificate.

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 Fagioli PSC (Asia) Pte Ltd
Indramayu Coal Fired Power Project
Lifting of Steam Drum

Method Statement

L180 MK 2 STRAND JACK

THEORETICAL LOAD / PRESSURE RELATIONSHIP
200

180

160

140

120
LOAD (TONNE

100

80

60

40

20

0
1 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
PRESSURE (BAR)

PRESSURE (BAR) 1 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
LOAD (Te) 0.474 9.5 19.0 28.4 37.9 47.4 56.9 66.3 75.8 85.3 94.8 104.3 113.7 123.2 132.7 142.2 151.6 161.1 170.6

MAXIMUM SAFE WORKING PRESSURE = 350 BAR

MAXIMUM SAFE WORKING LOAD = 180 TONNE

Document No: P572/MS/01Rev01

10/09/08 Page 13
L180 STRAND JACK

H
SAFE
ISSUED 26/01WORKING
180 Tonne
LOAD

MAXIMU STROKE
500 mm

MAXIMUM WORKING
350 Bar
PRESSURE

MAXIMUM TEST
420 Bar
PRESSURE
A

C
ASSEMBLY WEIGHT 1030 kg

LIFTING CABLE 12 No. ø18mm

SYSTEM Strands

B
LIFTING CABLE
165mm
DIAMETER
D

CABLE ULTIMATE
464 Tonne
TENSILE STRENGTH

DIMENSIONS G

A 1653mm Closed / 2153mm Open

B 531mm
C 581mm (Ports)
D 50mm
E 570mm Square E

F Ø27mm
F
G 470mm Square Centres
H 560mm
 Project Job Ref.

INDRAMAYU 3X300 MW CFSPP PROJECT

Section Sheet no./rev.

UC 305X305X283 kg/m 1
Calc. by Date Chck’d by Date App'd by Date

Nor 9/3/2008

UC 305X305X283 kg/m SUPPORT BEAM DESIGN FOR 3.575 METER

LOADING AT THE CENTER
BS 5950-1:2000
PD+PL

LA LB

L
RA RB
INPUT DATA
; Service dead point load; PD = 0.000 kN;
; Service live point load; PL = 280.000 kN;
; Beam length; L = 3.575 m;
; LA = 1.788 m; (Loading at the center)
; LB = 1.788 m;
2
; Design strength; Py = 275.000 N/mm ;

OUTPUT RESULTS
Service load
Total service point load; P= PD+ PL=280.000kN
Support reaction ; RA= (P* LB)/L=140.000kN
RB= (P* LA)/L=140.000kN
Service maximum bending moment; Mmax= P* L/4=250.250kNm
Ultimate load
Total ultimate load; Pult=2.0* PD +2.0* PL=560.000kN
Ultimate support reaction; RA= Pult* LB/L=280.000kN
RB= Pult* LA/L=280.000kN
Ultimate maximum shear force; Fmax_ult= Pult/2=280.000kN
Ultimate maximum bending moment; Mmax_ult= Pult* L/4=500.500kNm

Design check for member classification

Use : 305x305x283kg/m
; Depth of section; D = 365.300 mm;
; Width of section; B = 322.200 mm;
; Flange thickness; T = 44.100 mm;
; Web thickness; t = 26.800 mm;
4
; Second Moment Area; IXX = 78870.000 cm ;
3
;Elastic modulus; ZXX = 4318.000 cm ;
3
; Plastic modulus; SXX = 5105.000 cm ;
2
; Area of section; A = 360.000 cm ;
ε = √(275N/mm /Py)=1.000
2

Moment capacity Clause 4.2.5

M = 1.2*Py* ZXX =1424.940kNm
Mc = Py* SXX =1403.875kNm
“Since Mc < M --- OK!”
“Since Mc > Mmax_ult --- OK!”
 Project Job Ref.

INDRAMAYU 3X300 MW CFSPP PROJECT

Section Sheet no./rev.

UC 305X305X283 kg/m 2
Calc. by Date Chck’d by Date App'd by Date

Nor 9/3/2008

Section shear capacity Clause 4.2.3

Shear area; Av = t × D = 9790.040 mm2
Shear capacity; Pv = 0.6*Py*Av =1615.357kN
”Since Pv > Fmax_ult --- OK!”

Check deflection
; Elastic modulus of steel;E = 205.000 kN/mm2;
Deflection δ= (P* L3)/(48*E* IXX )=1.648 mm
Limiting deflection δlimit= L/360=9.931mm
“Since δ < δlimit --- OK!”

Torsional buckling
Effective length; Le=1.0*L=3575.000mm
; Buckling parameter; u = 0.855 ;
; Torsional index; x = 7.700 ;
; Radius of gyration; ryy = 82.700 mm;
Slenderness; λ = Le/ ryy=43.229

From table 19: if λ / x=5.614

; Slenderness factor; v = 0.785 ;

From Cl: 4.3.6.9 ;ratio βw ; βw = 1.000 ;

From Cl: 4.3.6.7 equivalent slenderness; λLT= u * v * λ *βw0.5 = 29.014
From table 16; ;Bending strength; Pb = 275.000 N/mm2;
From Cl: 4.3.6.3 buckling resistant moment; Mb= Pb* SXX =1403.875kNm
From Cl: 4.3.6.6 ;Equivalent uniform moment factor; mLT = 0.74 ;
From Cl: 4.3.6.2 Mb/mLT=1897.128kNm
"Since Mmax_ult < Mb/mLT --- OK!”
“Since Mmax_ult < Mc --- OK!”
 Project Job Ref.

INDRAMAYU 3X300 MW CFSPP PROJECT

Section Sheet no./rev.

UC 305X305X283 kg/m 1
Calc. by Date Chck’d by Date App'd by Date

Nor 9/3/2008

UC 305X305X283 kg/m SUPPORT BEAM DESIGN FOR 3.575 METER

(LOADING AT THE END OF BEAM)
BS 5950-1:2000
PD+PL

LA LB

L
RA RB
INPUT DATA
; Service dead point load; PD = 0.000 kN;
; Service live point load; PL = 280.000 kN;
; Beam length; L = 3.575 m;
; LA = 0.500 m; (Loading at the end of beam)
; LB = 3.075 m;
2
; Design strength; Py = 275.000 N/mm ;

OUTPUT RESULTS
Service load
Total service point load; P= PD+ PL=280.000kN
Support reaction ; RA= (P* LB)/L=240.839kN
RB= (P* LA)/L=39.161kN
Service maximum bending moment; Mmax= P* LA*LB/L=120.420kNm
Ultimate load
Total ultimate load; Pult=2.0* PD +2.0* PL=560.000kN
Ultimate support reaction; RA= Pult* LB/L=481.678kN
RB= Pult* LA/L=78.322kN
Ultimate maximum shear force; Fmax_ult= Pult* LB/L=481.678kN
Ultimate maximum bending moment; Mmax_ult= Pult* LA*LB/L=240.839kNm

Design check for member classification

Use : 305x305x283kg/m
; Depth of section; D = 365.300 mm;
; Width of section; B = 322.200 mm;
; Flange thickness; T = 44.100 mm;
; Web thickness; t = 26.800 mm;
4
; Second Moment Area; IXX = 78870.000 cm ;
3
;Elastic modulus; ZXX = 4318.000 cm ;
3
; Plastic modulus; SXX = 5105.000 cm ;
2
; Area of section; A = 360.000 cm ;
ε = √(275N/mm /Py)=1.000
2

Moment capacity Clause 4.2.5

M = 1.2*Py* ZXX =1424.940kNm
Mc = Py* SXX =1403.875kNm
“Since Mc < M --- OK!”
“Since Mc > Mmax_ult --- OK!”
 Project Job Ref.

INDRAMAYU 3X300 MW CFSPP PROJECT

Section Sheet no./rev.

UC 305X305X283 kg/m 2
Calc. by Date Chck’d by Date App'd by Date

Nor 9/3/2008

Section shear capacity Clause 4.2.3

Shear area; Av = t × D = 9790.040 mm2
Shear capacity; Pv = 0.6*Py*Av =1615.357kN
”Since Pv > Fmax_ult --- OK!”

Check deflection
; Elastic modulus of steel;E = 205.000 kN/mm2;
Deflection δ= (Pult* LA 2* LB2)/(3*E* IXX *L)=0.763 mm
Limiting deflection δlimit= L/360=9.931mm
“Since δ < δlimit --- OK!”

Torsional buckling
Effective length; Le=1.0*L=3575.000mm
; Buckling parameter; u = 0.855 ;
; Torsional index; x = 7.700 ;
; Radius of gyration; ryy = 82.700 mm;
Slenderness; λ = Le/ ryy=43.229

From table 19: if λ / x=5.614

; Slenderness factor; v = 0.785 ;

From Cl: 4.3.6.9 ;ratio βw ; βw = 1.000 ;

From Cl: 4.3.6.7 equivalent slenderness; λLT= u * v * λ *βw0.5 = 29.014
From table 16; ;Bending strength; Pb = 275.000 N/mm2;
From Cl: 4.3.6.3 buckling resistant moment; Mb= Pb* SXX =1403.875kNm
From Cl: 4.3.6.6 ;Equivalent uniform moment factor; mLT = 1.000 ;
From Cl: 4.3.6.2 Mb/mLT=1403.875kNm
"Since Mmax_ult < Mb/mLT --- OK!”
“Since Mmax_ult < Mc --- OK!”
Link Plate Design 40thk ( A36 )

Load Applied = 1100 kN

Factor of safety = 2
Design force = 2200 kN
Number of Link Plate, N 2
Tension force to lug, F = P/N
F= 1100 kN
D1 = 124 mm
D2 = 124 mm
D3 = 360 mm
D4 = 124 mm
Lug thickness, t = 40 mm Ok 0.25 x D4= 31 mm
Lug hole, Dia. = 112 mm
Design strength; Py = 250 N/mm2
Bearing strength; Pbs = 460 N/mm2

Shear capacity
P1 and 2 = 0.6 x(2 x 0.9 x Py x D 1/2 x t)
P1 = 1339.2 kN > F OK !
P2 = 1339.2 kN > F OK !

Tension capacity
P3 = Py x D3 x t
P4 = Py x (D4 x t / 0.67)
P3 = 3600.0 kN > F OK !
P4 = 1850.7 kN > F OK !

Type of coefficient; kbs= 0.8

End distance; e = 180.0 mm

Bearing capacity
Pbs1 = kbs x dpin x t x pbs
Pbs2 = 0.5 x k bs x e x t x p bs
Pbs1 = 1648.6 kN > F OK !
Pbs2 = 1324.8 kN > F OK !
SYSTEM CHECKLIST

Strand Yes No

i) Strand diameter 18mm [ ] [ ]

ii) Excessive rusting [ ] [ ]
iii) All strands tight [ ] [ ]
iv) 'Kinks' [ ] [ ]
v) 'Bird Caging' [ ] [ ]
vi) Excessive oil [ ] [ ]
vii) Strand pattern throughout the length OK [ ] [ ]
viii) Correct no. of strands used [ ] [ ]
ix) Correct length of strand used [ ] [ ]

Underlined answers are the correct condition.

Jacks Yes No

i) Jacks in correct position [ ] [ ]

ii) All fixing tight [ ] [ ]
iii) Leakage (main ram) [ ] [ ]
iv) Leakage (mini-jacks) [ ] [ ]
v) Couplings undamaged [ ] [ ]
vi) All jacks run smoothly up and down [ ] [ ]
vii) Mini-jacks run smoothly up and down [ ] [ ]
viii) Synchronisation of jacks [ ] [ ]
ix) Grips are new/inspected [ ] [ ]

Underlined answers are the correct condition.

Power Pack Yes No

i) Hydraulic tank level OK [ ] [ ]

ii) Diesel tank level OK (if applicable) [ ] [ ]
iii) Motor runs smoothly [ ] [ ]
iv) Leak free [ ] [ ]
v) Over centre valves installed correctly [ ] [ ]

vi) Couplings undamaged [ ] [ ]

vii) Hydraulic system functioning [ ] [ ]
viii) All relief valves set [ ] [ ]
ix) All gauges undamaged [ ] [ ]
x) All hoses connected to correct outlets [ ] [ ]

Underlined answers are the correct condition.

SYSTEM CHECKLIST

Hoses Yes No

i) Undamaged and leak free [ ] [ ]

ii) Couplings undamaged [ ] [ ]
iii) Couplings are fully connected [ ] [ ]
iv) Hoses fully uncoiled [ ] [ ]
v) Correct size and class of hoses are used [ ] [ ]
(high pressure/ low pressure)

Underlined answers are the correct condition.

Anchor Blocks Yes No

i) Anchor blocks seated correctly [ ] [ ]

ii) Fixed anchor retaining plates tight [ ] [ ]
iii) Pins fully in and retainers installed [ ] [ ]
(if anchor fabrications are used)
iv) Sufficient strand length (min. 25mm) [ ] [ ]
protrudes from the fixed anchor block
v) Same strand pattern with the jack [ ] [ ]
(same orientation)
vi) Sufficient bearing area [ ] [ ]

Underlined answers are the correct condition.