PROJECT NAME: SUR INDEPENDENT POWER PROJECT PO DESCRIPTION: PO NO.: SUBJECT: HEAT RECOVERY STEAM GENERATOR OPAB1-H1201 ERECTION MANUAL (MECHANICAL, INCLUDING MAIN LIFTING AND INSULATION) DOCUMENT NO.: SUR-V-99HA-1-91-003 For Review OWNER OWNER’S ENGINEER CONTRACTOR SUB. CONTRACTOR N NOOTER/ERIKSEN E A 11 Jul 2012 ISSUED FOR REVIEW ALS RDG Rev. No Date Description Prepared by Checked by Reviewed by Approved by It may NOT be used, disclosed or reproduced for other purpose pertaining to this document or its contents without specific, written prior permission of Daewoo E&C Co., Ltd. FIELD ERECTION MANUAL HEAT RECOVERY STEAM GENERATOR FOR SUR IPP Project, Oman NOOTER/ERIKSEN JOB NUMBER 113100 Rev. 0 APPROVED BY: _PJH_______ X:\Procedures\Erection.Manual\Cover Sheet.R5 FIELD ERECTION MANUAL GENERAL INFORMATION 1. DRAWINGS REFERENCED IN THIS MANUAL: Job specific drawings are referenced in this Manual. Drawings supplied by Nooter/Eriksen Project staff directly through the drawing transmittal process shall be used for the erection of the HRSG. The drawing list in this manual is periodically updated and does not necessarily reflect the most recent revision level on this project. 2. SHIPPING/LIFTING WEIGHTS: Shipping weights obtained prior to the release of this manual shall be regarded as “Preliminary” and used for estimating purposes only. Shipping weights, as shown on Bills of Lading, other shipment documents or stenciled on the equipment are not to be used for lifting or rigging purposes in the field. Refer to the field erection drawings to obtain this information. 3. SHIPPING SEQUENCE A shipping sequence will be issued on a periodic basis to keep the Erector informed on the latest delivery status of the HRSG components. This will be a “working” document that will be updated with the latest information, including changes in anticipated delivery dates, shipping status, rail car numbers, etc. The delivery dates shown are not contractual dates, but a reflection of the current shipping information and are subject to change. 4. RELEASE FORMS Release forms accompanying the documentation for this manual shall be filed with the manual. The release date on the Form shall be the effective date of the revised documentation. It is the responsibility of the recipient to destroy all copies of the previously released manuals and documentation when updated revisions are issued by Nooter/Eriksen. Nooter/Eriksen will issue release forms and revised documentation only for manuals listed in the “MANUAL DISTRIBUTION” portion of the Release Form. All manuals generated by others shall not be considered “Controlled Documents”. APPROVED BY: PJH X:\Procedures\Erection Manual\INTRO.R3.doc ........ 7 Material and Equipment Furnished by the Erector ...........0 5.............................................0 15.......... 9 HRSG Erection ................... 15 Piping ........................................ 15 .......... 3 General Scope of Field Work Required by Erector/Purchaser ..0 9....... 1 Definitions .....0 7..........................................................0 17........................................................................................0 13.... 6 Unloading.... 4 Non-Destructive Examination and Stress Relieving ...........................0 16..................... 11 Painting ...................0 3.0 11.........................................0 8. 1 Reference Documents ................................................0 2................................. 9 Testing........................................................................................................................................ 2 Scope of Supply by Nooter/Eriksen .......0 14........................... 14 Distribution Grid ..............................................0 PAGE General...............................................0 6....................0 12...................... 15 Shipping Sequence .............................................................................................0 10................................0 4................................................................. 14 Supporting Reference Documents.........................INDEX SECTION 1....... Handling and Storage ...... 15 Drain Valves ................................. 2 Nooter/Eriksen Contacts..... 3 1. 1. 113100-GA-001 (SUR-V-99HA-1-17-001). The scope of major equipment furnished by Nooter/Eriksen.5 HRSG: Code: 2.0 GENERAL 1. Section VIII. hauling. and ANSI B31. and the commissioning required for start-up for satisfactory continuous commercial operation.Manual\Erection_Procedure R16 .0 DEFINITIONS 2.6 K/D: APPROVED BY RDG X:\Procedures\Erection. 113100 ERECTION PROCEDURE. Inc. Division 1. ASME Section I and ASME Section VIII.4 2. REV. cleaning (inside and outside). The field scope includes. for erection is shown on Nooter/Eriksen Drawing No. Read and review this entire manual and its contents before beginning field erection. OMAN N/E JOB NO. 1. Daewoo E&C Erection contractor responsible for the installation and assembly of the HRSG. but is not limited to: unloading. erection. Knocked Down Shop Fabrication 2. 0 PAGE 1 FIELD ERECTION RESPONSIBILITIES 1.1. Inc.2 2. Each HRSG has been designed and is to be constructed in accordance with requirements of the American Society of Mechanical Engineers Power Boiler Code.4 2. Division 1.2 The minimum scope of work to be performed by the field erection subcontractor (Erector) shall consist of all work required to provide a complete Heat Recovery Steam Generator (HRSG) with accessories. Heat Recovery Steam Generator American Society of Mechanical Engineers Power Boiler Code Section 1.1 2.SUR IPP PROJECT.3 N/E: Purchaser: Erector: Nooter/Eriksen. alignment.1 THIS MANUAL SHALL BE PROVIDED TO ALL FIELD SUPERVISORY PERSONNEL INVOLVED IN THE HRSG ERECTION. storage. please contact the individuals listed below: Document Description 3.com (636) 651-1040 (636) 651-1512
[email protected] thru 13.0 N/E CONTACTS 4.14 13.3 3.1 Kevin Lacey Project Engineer Phone: Fax: E-mail: Phone: Fax: E-mail: Phone: Fax: E-mail: (636) 651-1032 (636) 651-1507
[email protected] Tab Location Procedures Miscellaneous Miscellaneous Miscellaneous Miscellaneous Miscellaneous Miscellaneous 4.16 13.3 Andy Febus Manager of Logistics .SUR IPP PROJECT.1 3.2 3.7 N/E Standard Erection Procedures Field Service Site Visits N/E Backcharge/Extra Work Policy Manway Covers Descriptive Orientation Lifting Device Drawings Module Storage Section No.5 3.19 13.7 Modular: HRSG construction in which the coil bundles are shipped separate from the casing. 13.com (636) 651-1115 (636) 651-1507
[email protected] REFERENCE DOCUMENTS These reference documents form an integral part of this manual and must be read carefully and understood before beginning any field erection.com 4.17 13. Casing is shipped in panels for assembly at jobsite.6 3. 3. 113100 ERECTION PROCEDURE.0 under the “General” tab location. Reference documents are listed in Section 15.15 13.2 Alan Schulte Project Manager 4. OMAN N/E JOB NO.4 3. Should you have any questions.18 13. 0 PAGE 2 2. REV. 0 GENERAL SCOPE OF SUPPLY BY NOOTER/ERIKSEN Foundation Embedments Inlet Expansion Joint (K/D) Inlet Transition Duct Panels (K/D) Inlet Distribution Grid (K/D) Supplemental Duct Burner Runners Firing Duct Panels (K/D) Fuel Train Skid Scanner Cooling Air Skid Primary Casing Panels (K/D) Secondary Casing Panels (K/D) HRSG Coil Modules Recirculation Pumps Remote Steam Drums Deaerator Atmospheric Blowdown Tank Exhaust Stack (K/D) Expansion Joint at Stack (K/D) Exhaust Stack Silencer Baffles (K/D) HRSG Interconnecting Piping Pipe Supports Platforms. OMAN N/E JOB NO. 113100 ERECTION PROCEDURE.com 4.5 Larry Greene Director of Projects 5. Stairs & Ladders (K/D) Boiler Trim & Valves (K/D) Field Seam Material (K/D) External Insulation for Interconnecting Piping.com (636) 651-1054 (636) 651-1507 LGreene@ne. REV. (Lifting Devices must be returned to N/E after use.4 Keith Kennedy Construction Supervisor Phone: Cellular: E-mail: Phone: Fax: E-mail: (636) 651-1000 (314) 941-2165 KKennedy@ne.) . Valves and Drums.SUR IPP PROJECT. 0 PAGE 3 4. Temporary Use of Horizontal and Strong-Back Lifting Device for Erection of Coil Modules. Slide Plates. Gauge Glasses. etc. Level Transmitters. Pressure Gauges. Refer to Nooter/Eriksen’s HP and LP Trim Lists (Water Columns.) Assemble and Install Drain Lines from all Safety Valves Assemble and Install Blow Offs from Water Columns Assemble and Install all other Drain Lines & Valves .. OMAN N/E JOB NO. etc. Drip Pan Elbows. Shear Plates & Grout Erect Inlet Duct Transition Sections Erect Primary and Secondary Casing Panels Install Duct Burner Elements Install Inlet Expansion Joint Install Gas and Electric Lines. Closures and Casing Penetration Sealing Devices as Necessary per Detailed Drawings Supplied by Nooter/Eriksen Assemble and Erect EPA Platform on Exhaust Stack Install and Assemble all Instrumentation for Piping. Modules. Silencers with Support Steel Assemble and Erect Structural Steel for Stair Tower Assemble and Erect Stairs and Platforms Assemble and Erect all Other Platforms and Handrails Install all Field Platform Support Clips Install Exhaust Stack Outlet Expansion Joint Install Stack Silencers Install Packing. 0 PAGE 4 6. Gaskets. Nuts. 113100 ERECTION PROCEDURE. Thermocouples. Teflon Slide Packs. Washers. Vent Stacks.0 GENERAL SCOPE OF FIELD WORK REQUIRED BY ERECTOR/PURCHASER Unload all Equipment Remove all Temporary Crating and Shipping Braces Heavy Haul Transport from Rail Siding to the Jobsite Install Anchor Bolts.SUR IPP PROJECT. Drums and Gas Side Casing. REV. Erect and Assemble Structural Steel for Remote Steam Drums Set Remote Steam Drums Install Recirculation Pumps Erect Exhaust Stack Install Pipe Supports Erect all Large Bore Piping Install and Weld in all Valves per Nooter/Eriksen’s Trim List for Interconnecting Piping Install Safety Relief Valves. between Burner Skids and Duct Burner Install HRSG Modules Install Gas Baffles Erect Firing Duct Install all Field Seams between Ducting. Shim Packs. Burner. etc. Drain Lines. Desuperheaters. Measurement Devices or any other Equipment that was temporarily removed for Steam Blows Install all Pneumatic Tubing or Pipe for Air Supplies and Signal Lines Install all Electrical Conduit. . Wiring and Electrical Panels Install all External Personnel Protection (Not Required with Insulated Stack). etc. Interconnecting Piping.SUR IPP PROJECT. 113100 ERECTION PROCEDURE. OMAN N/E JOB NO. 0 PAGE 5 Assemble and Install Drain Valves and Manifolds Along Side Each Heat Transfer Section including Collecting all Multiple Drains at each Bundle Install Freeze Protection Tubeside Cleaning of HRSG Steam Blows Install Steam Drum Internals after Tubeside Cleaning Re-install non-return Valve Discs. Install all External Insulation on Outlet Stack Install all External Insulation on Silencer Duct Touch-Up Primer and Finish Paint Commissioning. REV. Install all External Insulation on Remote Steam Drums. Check all Valves/Motor Operators Prior to Start-Up. Steam Sample Probes. etc. Drum Heads. Purchaser will forward all documentation to N/E that is to be included in the Master Document Package.2 7. In addition to the Mandatory Code Requirements for non-destructive examination of welds.1 The Erector shall provide all necessary equipment and manpower to perform all required non-destructive testing as required by the Code or the Purchaser.3 7. In the event of a defect being identified in the prescribed 5%. As a minimum requirement. shall be 100% radiographed. The Erector shall provide all stress relieving equipment and all necessary materials and specialists as may be required to properly stress relieve the welds as required by the Code and the Purchaser. copies of which shall be submitted to the Purchaser. 0 PAGE 6 7.5 . REV. If other more stringent non-destructive examination methods are required (as required in high seismic areas. The Erector shall perform the stress relieving as required by Code and maintain charts of time versus temperature gradients. and/or as specified on N/E drawings).0 NON-DESTRUCTIVE EXAMINATION AND STRESS RELIEVING 7. Should additional defects be identified. 7. a further 5% of welds deposited by that welder shall be radiographed. the Erector shall perform them. This should be implemented by radiographing 5% of this category of welds deposited by each welder. A copy of radiographic results and procedures will be forwarded to the Purchaser.SUR IPP PROJECT. OMAN N/E JOB NO. the Erector shall 100% Magnetic Particle Test (MT) all field welds at corner connections on major structural frames. 113100 ERECTION PROCEDURE. it is recommended that the following additional radiography be applied: 1) At least 5% of all full penetration pressure part butt welds not requiring radiography by the ASME Code.4 7. all welds deposited by that welder shall be radiographed. All deliveries. 2) Exhaust stack shall be erected. If modules are stored.1 Any material shortages which conflict with Nooter/Eriksen Shipping List must be identified and reported to N/E by the Purchaser in writing within two (2) days of receipt of material. welded and inspected per the requirements of ASME STS-1 and any local applicable codes. OMAN N/E JOB NO. 113100 ERECTION PROCEDURE.0 UNLOADING. Erector must notify the railroad immediately of cleaned railcars to avoid unnecessary charges to the Purchaser. The Erector shall be responsible thereafter for the equipment until it is installed and accepted by the Purchaser. Detention and demurrage charges. associated with failure to off-load rail cars at the jobsite in the days allotted by the rail service.3 . The cost to unload and transport all items to the point of installation from the nearest railsiding shall be at no extra cost to N/E. 8. the Erector will install them as required. 0 PAGE 7 This category of welds normally includes butt welds in the downcomer & riser piping. REV. This includes all protective materials/structures included with equipment furnished. and butt welds in the boiler proper and boiler external piping.2 8.1 Equipment to be installed shall be received. will be billed to the Purchaser. It is the Erector’s responsibility to unpack or uncrate all equipment. refer to the Module Storage Recommendations drawing located in the “Miscellaneous” section of this manual. HANDLING AND STORAGE 8. unloading and transporting of equipment shall be coordinated through the Purchaser to avoid interference with other operations. unloaded and stored by the Erector in areas designated by the Purchaser. 8.SUR IPP PROJECT. If inspection 8. The Erector shall unload. erect or store the equipment without delay. If restraints are needed to ensure the integrity of the modules during travel on steep grades. All N/E furnished equipment arriving at the railsiding or site shall be checked by a representative of the Purchaser and turned over to the Erector in good condition. The Erector will ensure that end-to-end support of the modules is sufficient during transportation.3. The Erector’s work shall include moving the equipment from the storage area to the point of installation or as otherwise specified. The Erector shall be responsible for the care and custody of the equipment received. 8. 8. Package Dimensions (on boxes only). protective material.4 The following shipping information will be marked or permanently attached on each major component or package received: a. located at casing field seams. with damage incurred in transit. These records shall be made available to the Purchaser and N/E at all times. c. OMAN N/E JOB NO. should be left in place to protect the insulation.3 Materials or equipment received.2 If damaged materials or equipment is received. Secondary casing panels are typically shipped with the internal liner facing upward.3 . All ducting or casing. Also. should be stored in a position that would allow drainage of any water from the insulation. Shipping Weight in Pounds. 8.SUR IPP PROJECT. REV. b. Component Name. Nooter/Eriksen Job Number/Unit Number (on N/E General Arrangement Drawings).2 8.4. with internal insulation. It is the Erector’s responsibility to exercise caution in offloading 8. shall be indicated on the Bill of Lading (BOL) when the material or equipment receiving ticket is signed. N/E shall be notified in writing and with verifiable photographs or video provided within (2) days of receipt of material.4. 8. The attachment points for tailing these panels are located on the casing (downward) side of the panel. until field seam installation begins. All enclosures or buildings necessary for storage shall be provided by the Erector.4 The Erector shall keep a written record of all equipment and materials received at the jobsite and perform regular inspections and maintenance during storage.1 All materials and equipment shall be stored in weather protected enclosures or buildings unless they are essentially unaffected by weather with prior Purchasers approval.4. Failure to indicate damages on BOL will result in the repairs being the Erector’s responsibility.3.3. d. 0 PAGE 8 requires opening of protective shipping containers. 8. 113100 ERECTION PROCEDURE.3. it is the Purchaser’s responsibility to repack and weather protect all items after inspection. 4.6 9. welding equipment. however.0 HRSG ERECTION 10.4.1 The Erector shall plan the erection of the HRSG taking into account N/E’s recommended field erection procedures and specific requirements from detailed project drawings. special equipment and technicians for stress relieving. The Erector shall furnish all necessary tools and construction equipment such as transporters. 113100 ERECTION PROCEDURE.0. as listed in the Nooter/Eriksen Drawing List. to remove caps on lower header nozzles temporarily to facilitate module draining during erection. necessary to perform the work. OMAN N/E JOB NO. It is acceptable. rigging equipment.SUR IPP PROJECT. REV.2 Note: Erector must comply with any special erection and storage requirements provided by manufacturers/designers of specialty equipment such as. etc. 8. To maximize the protection against corrosion and contamination..0 MATERIAL AND EQUIPMENT FURNISHED BY THE ERECTOR The Erector shall furnish all items required for the work not specifically being furnished by N/E. consumables. Coils and drums are shipped with an internal vapor phase corrosion inhibitor added prior to sealing nozzles with plastic caps and tape. Valves and instrumentation are to be stored indoors. temporary winterizing or freeze protection during erection for drainable and non-drainable parts of the HRSG. hydrotest equipment. but not limited to: A) B) Duct Burners Pumps . 10. These items shall include. cranes. in order to preserve cleanliness. Erection Procedures are found with the reference documents at the back of this manual in Section 15. coil and drum nozzle caps and tape should be maintained and remain intact as long as possible. so that there is no damage. labor saving devices.4 All piping must remain capped during storage and erection. 10.4. trucks. 0 PAGE 9 and rotating these panels for installation.5 8. but not be limited to. 8. the Erector will assume all responsibility and all associated additional costs. cooling and post weld heat treatment) must be maintained at all times. Exposure of “as weld” (prior to the performance post weld heat treatment) weldments to environmental elements is to be limited. Deviation from these procedures is not recommended unless otherwise indicated on N/E’s Project Specific Erection Drawings. Experts should be consulted in developing the necessary welding procedures.4 . Use of the DC prod method of magnetic particle testing (MT) is prohibited. OMAN N/E JOB NO. This material has special welding. Protection shall be provided to prevent direct exposure to moisture. N/E reserves the right to review all changes to the procedure. All weldments must be cooled to below 200F (93C) prior to the performance of post weld heat treatment. If the Erector chooses to follow other procedures and difficulty arises or damage occurs. Welding (including tack welding and welding of temporary attachments) must be controlled at all times. Proper control of the heating of the material (preheat. SA-234 F91. Compliance with these requirements is necessary to ensure the proper life of the component. all welders must be qualified per ASME Section IX using Alloy 91 materials. 113100 ERECTION PROCEDURE. post heating. Check your project specific drawings for the exact location of this material.3 Expansion Joints Etc. 0 PAGE 10 C) D) 10. fabrication and heat treatment requirements. SA-387 Grade P91. Caution: Certain components of this HRSG have been fabricated using 91 Chrome materials (SA-213 T91.SUR IPP PROJECT. This material must not be exposed to an open flame (flame impingement). These procedures are provided as a guide for field erection based upon N/E’s design of the system. It is recommended that testing after PWHT be performed to verify that the proper micro structure has been acquired by the appropriate welding/heat treat process. etc). heat input of welding. Special care is to be taken to reduce the amount of additional stress when moving any “as weld” weldments. 10. SA-335 P91. REV. 1 HYDROSTATIC TESTING After field assembly. 113100 ERECTION PROCEDURE. including welding. All arc strikes not in the welding preparation zone must be ground and verified by non-destructive examination (NDE) as not being detrimental to the material.SUR IPP PROJECT. DUE TO THE INHERENT DANGER ASSOCIATED WITH A FAILURE UNDER PRESSURE FROM COMPRESSED GAS OR AIR. etc. N/E recommends that P91 welding consumables are used. 10. 0 PAGE 11 Preheating to 400F (204C) of the material is to be done for all thermal operations. Additional hydrotests may be necessary during the life of the HRSG if any alterations or repairs are performed within ASME Code boundaries. ARE A SAFE METHOD TO TEST FABRICATED EQUIPMENT BEFORE OPERATION. safety valve discharge stacks. Failure to comply with these cautions may void the Nooter/Eriksen Warranty. tack welding. such as open top silencers. . gouging. etc. each pressure level of the HRSG and any interconnecting piping within the ASME Code boundary must be hydrotested by the assembler and witnessed by their Authorized Inspector (AI). HYDROSTATIC TESTS. This includes areas that could accumulate snow and ice. thermal cutting. When welding P91 to P22 material. OMAN N/E JOB NO. REV.0 TESTING 11.5 Freeze Protection Any piping or parts of the equipment that may collect water and freeze should be heat traced and insulated. WHEN CONDUCTED PROPERLY. The following information is provided to help protect the HRSG before and after hydrostatic tests. 11. PRESSURIZING WITH AIR OR GAS CAN BE EXTREMELY DANGEROUS. CAUTION: NOOTER/ERIKSEN DOES NOT RECOMMEND THE USE OF PNEUMATIC TESTS IN LIEU OF HYDROSTATIC TESTS. 113100 ERECTION PROCEDURE.0 as a minimum Diethylhydroxylamine (DEHA) oxygen scavenger should be added to hydrotest water to reduce oxygen concentration to 2 to 7 ppb. potable water may be used provided all of the following are met: a. When safety valve design pressures will not be exceeded during hydrotest. The hydrotest water. OMAN N/E JOB NO.5 times the MAWP. silica. e. If demineralized water is not available. and maintained for reference. .SUR IPP PROJECT. Testing shall be conducted for pH.. deaerated water or polished is recommended. etc. 0 PAGE 12 Verify that all instruments are isolated to prevent damage from over pressurization. CAUTION: USE OF SAFETY VALVE "GAGS” WHEN HYDROSTATIC TEST PRESSURES EXCEED DESIGN PRESSURES COULD RESULT IN DAMAGE TO THE VALVE. d. Water samples are to be taken prior to filling the boiler and during draining. Water is to be filtered prior to first fill for hydrotest. The water is to be sampled and tested prior to use. chloride. b. some operators have successfully gagged the valves. c. iron. the valves must be isolated (pancaked or removed and replaced by blind flanges) from the test pressure. Severe corrosion can occur when inappropriate water is used for the hydrotest. whether demineralized and deaerated or acceptable potable water. N/E recommends the following: Demineralized. but Nooter/Eriksen does not recommend this procedure. Water must be drained immediately after hydrotest is complete. Chemicals should be added in a manner that provides thorough mixing. must have the pH adjusted to 9. Review hydrotest procedures in the pressure safety valve manufacturer's manual. REV. Water source must be flushed and proven clean prior to discharge into the boiler. For hydrotest pressures that exceed design pressure. for reference. The HRSG components must not be exposed to pressures exceeding 1. if possible.) Interior heating or other precautions may be necessary to prevent freeze damage. After the test. is the responsibility of the purchaser/owner and will not be considered as a warranty issue by N/E. CAUTION: HYDROTEST WATER LEFT IN THE HRSG CAN DO DAMAGE BY FREEZING OR CORROSION. Unless water treated specifically for lay up was used during the hydrotest and will be chemically maintained over the lay up period. however. All valves have been tested by the manufacturer to ASME B16. REV. the HRSG must be drained and laid up dry within 24 hours.SUR IPP PROJECT. Note: N/E will not accept any liability resulting from the particular chemistry of the hydrotest water. N/E will warrant any leaking/seating issues on all N/E supplied valves through HRSG hydrotesting. Any drain valve leakage that occurs after HRSG hydrostatic testing has proved the valves were supplied as leak tight. All vent valves should be open during filling to allow air to escape the system. chlorine content must not exceed 30 ppm or these parts should be removed for the hydrotest. (See the Nooter/Eriksen draining recommendations. (Note. . 0 PAGE 13 If stainless steel parts are exposed to hydrotest media.) If the HRSG will be drained. 113100 ERECTION PROCEDURE. the HRSG must be properly laid up to prevent damage from corrosion or freezing. the unit should be filled with the warmest water available. If a potential for freezing weather exists. Providing a high capacity hydrotest pump to allow filling the HRSG as quickly as possible will provide the best results in expelling air from the system.) Stops on all spring cans should be removed after the field Hydrotest. OMAN N/E JOB NO. that ASME Code defines metal and water temperatures in PG99. proper precautions must be taken to insure that all water is removed from the unit. This should be consulted for proper temperatures.34 or API 598 requirements for pressure boundary and seat leak tightness. (See the Nooter/Eriksen Lay Up recommendations. there are liner/casing penetrations and bearing points for coils and other internals. These areas of higher casing temperature do not indicate insulation breakdown and will not compromise the long term structural integrity of the unit.0 SUPPORTING REFERENCE DOCUMENTS PROCEDURE NO. and VOC emissions. If a topcoat is required.6 13. an aluminum colored silicone acrylic or alkyd is recommended.12 13.5 13.11 13. Paints should have a continuous temperature rating of at least 450F.SUR IPP PROJECT. 0 PAGE 14 12.8 13.0 PAINTING The inner liner of the Nooter/Eriksen casing design system is exposed to turbulence and vibration forces from the gas turbine exhaust.15 EP-01 EP-02A EP-03A EP-04A EP-05A EP-06 EP-07 EP-08 EP-09 EP-10 EP-11 EP-12 EP-13 EP-14 DESCRIPTION FOUNDATIONS. color matching. This is accomplished by the use of pins and/or other components. Paint discoloration and overall HRSG appearance is dramatically affected by the choice of paint.4 13. 13.3 13.1 13.14 13. Since these parts must be attached directly to the outer casing. Nooter/Eriksen recommends using zinc rich primer. OMAN N/E JOB NO.2 13. 13. 113100 ERECTION PROCEDURE. The liner has to be securely attached to the cold casing. ANCHOR BOLTS & BASE PLATES SETTING OF MAJOR HRSG COMPONENTS (MODULAR) LIFTING AND RIGGING PROCEDURES (MODULAR) FIELD SEAM INSTALLATION (MODULAR) REMOVAL OF TEMPORARY STEEL/WOOD (MODULAR) STAIRTOWERS/PLATFORMS/LADDERS EXPANSION JOINT INSTALLATION GASKETS AND PACKING LARGE BORE PIPING SMALL BORE PIPING/TRIM FIELD WELDMENTS PSV’S.13 13.7 13. REV. In addition to the support system for the liner. These hot spots may be noticed as small areas of paint discoloration. Other paint concerns could be a high curing temperature. where there may be localized hot spots on the outer casing. START-UP VENTS & STACKS RECOMMENDED TUBESIDE CLEANING NOT USED FIELD SERVICE SITE VISITS .10 13. a certain amount of heat conduction is unavoidable and localized areas of the external casing may exceed the average casing temperature.9 13. the field could have made the adjustment to the pipe). 113100 ERECTION PROCEDURE. The delivery dates shown are not contractual dates but a reflection of the current shipping information. if 3” field trim was left on.16 13.SUR IPP PROJECT.e. flush and drain the HRSG during commissioning and/or normal operation. 17. 16. is the responsibility of the purchaser/operator and will not be considered as a warranty issue by N/E. 15.0 DRAIN VALVES Block valves have been supplied on all drain lines.34 or API 598 requirements for pressure boundary and seat leak tightness. Because of the elimination of the standard field trim. The exception to this rule is the opening of superheater and reheater drains under startup conditions to eliminate any condensate that may have accumulated. N/E will warrant any leaking/seating issues on all N/E supplied valves through hydrostatic testing. Any drain valve leakage that occurs after hydrostatic testing has proved the valves were supplied as leak tight. Nooter/Eriksen is not subject to field backcharges for mismatches on LB piping of less than 3” (i. . Opening of drain valves with the unit under pressure greater than 100 psig can be damaging to the valves.19 13. All valves have been hydro tested by the manufacturer to ASME B16. This will be a “working” document that will be updated with the latest information.18 13. including changes in anticipated delivery dates. See Inlet Duct drawings for specific details. shipping status. etc. based on a flow model study.0 SHIPPING SEQUENCE A shipping sequence will be issued on a periodic basis to keep everyone informed on the latest delivery status of the HRSG components.0 PIPING This contract requires that the 3” Nooter/Eriksen standard field trim be eliminated from the LB piping (except on all drum risers).17 13. REV. It is the purchaser’s responsibility to appropriately clean.20 14. OMAN N/E JOB NO. 0 PAGE 15 13.0 DISTRIBUTION GRID NOOTER/ERIKSEN BACKCHARGE / EXTRA WORK POLICY MANWAY COVERS DESCRIPTIVE ORIENTATION LIFTING DEVICE DRAWINGS MODULE STORAGE The inlet may require a field installed distribution grid. rail car numbers. It is recommended not to grout (Note: Only non-shrink grout is to be used) the foundation slide plates until after the HRSG columns have been set and properly aligned. shall be installed after column setting.0 The contractor responsible for foundation installation shall meet the requirements of N/E’s foundation drawing. Welding of the shear tabs shall be on three sides only. (Refer to Drawing EP-01-01).3 From centerline of bolt group to HRSG centerline: ¼”. it allows the elevations of the top of the slide plate to be adjusted through shimming.5 1.1 The Erector shall fit each HRSG foundation support point with a slide plate. before setting of these columns.4 1. shims and grout are not by Nooter/Eriksen. which is normally required to allow adjustment due to manufacturing tolerances of the HRSG. 1.2 Anchor bolts shall be installed when possible using embedded sleeves (min 12” depth). One. manufacture and installation of the foundations. provides a flat surface on which the equipment can move due to temperature expansion. 1. Between adjacent anchor bolts with the group: 1/8”. From centerline of bolt group to HRSG longitudinal reference point: ¼”.1 The Contractor shall establish the centerline of the unit and the longitudinal reference point and set anchor bolts per N/E’s foundation drawing. A benchmark for elevation reference shall be provided at a location close to the HRSG. The reference elevation shall be the Purchaser’s reference elevation shown on N/E’s General Arrangement.01. APPROVED BY: RDG X:\Procedures\Erection Manual\EP.0 The Erector of the HRSG shall be responsible for the following items: 2. eliminates the ability to adjust slide plates by shimming.6 2. if shown at column base plate details. 1.EP-01 PAGE 1 ERECTION PROCEDURE FOR FOUNDATIONS ANCHOR BOLTS AND BASE PLATES 1. The contractor has the flexibility to grout anytime after the HRSG columns have been set and properly aligned. However. Design. 1.R7 . No welding on the side of the tab next to column base plate is permitted. Pre-grouting. Anchor bolt projection: ½”. All anchor bolts shall be located with the following tolerances. foundation slide plates shall be sufficiently shimmed in the field to prevent damage to the HRSG equipment or foundations. This will assist in the installation of the equipment if either base plate holes or anchor bolts are located out of tolerance. Shear tabs. Slide plates serve two functions. Second. in any case. Refer to the benchmark for elevation reference. All anchor bolts.3 2. 2.EP-01 PAGE 2 ERECTION PROCEDURE FOR FOUNDATIONS ANCHOR BOLTS AND BASE PLATES 2. Any deviation from allowable tolerances as listed on Drawing EP-01-01 should be brought to the attention of the Purchaser. All as built dimensions are to be documented and provided to N/E and the Purchaser upon request. slide plates.2 The Erector shall check to insure that the anchor bolt threads are clean and all damaged threads corrected using a thread chaser. Nooter/Eriksen is not responsible for design and/or workmanship of any of the above referenced material located below the bottom of the HRSG base plates. The Erector shall check the elevations of all foundations and the location of all anchor bolts prior to equipment installation. grout and shims are furnished by someone other than N/E.4 . . spreader beams. OR.1 1.1. shall be furnished and designed by the Erector to meet the expected loading and the requirements of the procedures.2 1. These lugs are only designed to lift the components as supplied.2 Set the top of the slide plates at the theoretical elevation. Base plates shall be greased prior to installation. etc.3. Unless otherwise stated on N/E’s Foundation Footprint Drawing. (Axle quality grease is recommended).2 1. 1. All rigging.2.2. These lugs are not designed to lift the components after any additional assembly by Field Erector. 1. 1. All shall be double-nutted. (Also refer to EP-03 for rigging procedures.1 Each column shall be set so that the inside flange is at the theoretical distance from the centerline of the HRSG.2. including welding of the upper pack to the bottom of the casing panel column base plate before setting of panels.Manual\EP-02A. Each component shall be handled using N/E Erection Procedure drawings. shackles.2. they must be installed. The inside liner-to-liner dimensions should be checked and documented against the corresponding module dimensions to ensure that module can be set.1 The following items shall be checked to insure that critical attachment locations are maintained.3 Install secondary casing panels 1.2.2.) APPROVED BY: WJP X:\Procedures\Erection. MODULAR 1.2.2.R15 .2. Erection tolerances are to be in accordance with EP-11.2 Set primary casing panels and roof beams as defined in EP-04A.1 Erection tolerances to be in accordance with EP-11.1.2. 1.1 Some components are provided to the field with lift lugs. It is the Erector’s responsibility to design and install any lugs required for lifting of pre-assembled components.2. if teflon slide packs are used. Check to make sure grease fittings are installed. anchor bolts shall be finger tight. There should be a minimum of two (2) per base plate.2.EP-02A PAGE 1 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS 1.3 1. and plumbed.3. It is the Erector’s responsibility to exercise caution in offloading and rotating these panels for installation. before setting of these columns. manufacture and installation of the foundations. it is acceptable to set modules within the casing panel.4 After completion of all required welding. it is important to verify casing opening dimensions where modules will be placed in the HRSG. 1. shimmed. 1. Design.5 After each primary casing panel is set. so that there is no damage. N/E provides enlarged holes in the base plates to facilitate module installation. bolting and testing. The pin rowto-pin row dimension shall also be checked at the field seam locations.2.4. shims and grout are not by Nooter/Eriksen. . However.2.1 It is recommended not to grout the foundation slide plates until after the HRSG columns have been set and properly aligned. which is normally required to allow adjustment due to manufacturing tolerances of the HRSG. eliminates the ability to adjust slide plates by shimming.2.3. in any case.2 Upon completion of casing alignment. The attachment points for tailing these panels are located on the casing (downward) side of the panel. 1. to ensure that the field seam plates will fit. Anchor bolt washers (as detailed on N/E drawings) are to be installed on the base plates as indicated on N/E foundation detail drawings. The contractor has the flexibility to grout anytime after the HRSG columns have been set and properly aligned.3 1. checked for correct elevation. the anchor bolt washers and nuts can be installed. The inside liner-to-liner dimensions should be checked and documented against the corresponding module dimensions to ensure that module can be set. Pre-grouting.2. Secondary casing panels are typically shipped with the internal liner facing upward. foundation slide plates shall be sufficiently shimmed in the field to prevent damage to the HRSG equipment or foundations.EP-02A PAGE 2 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS 1.2. 2 1. Refer to Nooter/Eriksen field erection drawings for module configuration and unit location. as shown on Nooter/Eriksen drawings. welded and inspected per the requirements of ASME STS-1 and any local applicable codes.1 Exhaust stack shall be erected.4.4 EXHAUST STACK 1. shackles. shall be used as the primary guide for the setting and the alignment of modules. except that the top of each column shall be checked for correct station location and plumbness. the nozzle connections shall be checked against the Nooter/Eriksen drawings for correct station location and elevation to within (+) or (-) ¼”.3 1. Nozzle locations should be checked with a transit. 1. If the HRSG is provided with an SCR. Exhaust stacks are provided with either anchor chairs or an anchor bolt ring.2.2.EP-02A PAGE 3 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS 1. In each case the same check list of items required for module setting shall be followed. See Procedure EP-05A.4. shall be furnished by the Erector to meet the requirements of the procedures.4. In either case. Removal of temporary shipping wood/steel must be completed before startup.3 DUCTING/BREECHING 1. 1. the stack is considered to be fixed against longitudinal movement. Do not rely on shop stenciling for module location.1 All ducting is furnished in either completed sections or in knocked down panels. This must be done prior to final welding of the SCR duct frame corner connections. The nozzle orientation.4.8 1.3.2. the Erector is to verify that the Catalyst Loading Opening is plumb and square so that the Catalyst Loading Doors will fit properly (trial fitting the Catalyst Loading Doors is recommended). particular attention shall be given to make sure that the modules location and elevation are maintained.4 . spreader beams. Anchor bolts shall straddle natural centerlines. All rigging.7 1.3. etc. 1.2 1. For each successive module set.6 When setting the modules. the damper shall be installed after the bottom stack section is installed vertically on the stack foundation.7 1. there will be an expansion joint.4.5. The centerline of the stack matches the centerline of the module. Elevations of module and stack are at the proper locations.4.1. The damper shall not be attached to any stack cylinders prior to lifting into final position. or multiple sections depending on the diameter of the stack.4. Exhaust stack can come in one piece.5 Unless otherwise stated on N/E’s Foundation Footprint Drawing. It is recommended that the personnel protection at the base be installed after the stack has been set and any painting requirements are completed. It is important to ensure the following items are checked.8 1. 1.2).EP-02A PAGE 4 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS 1. since the stack is considered fixed (See 1.9 1. two pieces.5. 1. For thermal expansion between the last HRSG module and the fixed exhaust stack.10 It is recommended that the platforming required for EPA test ports be installed just prior to lifting the stack sections.4. to prevent damage to the damper.4. Enough shim packs should be used to prevent damage to the foundations. Module and stack are plumb within ¼” Distance between the module and stack maintained to within ¼” of theoretical 1. If supplied K/D. orientation of vertical seams will be found on fabricator’s drawings.6 1. 1. the Erector should prepare the concrete for shim pack locations. If the stack is provided with a damper.4.1 See Drawing EP-03-5 for details of erection procedure.11 Personnel protection at the elevated platforms can be installed prior to erecting the stack if painting is not required. all stack anchor bolts shall be torqued tight per AISC. . Prior to setting the stack.6.1 Normally the remote steam drums are supplied without lifting lugs attached in the shops.4.5 REMOTE DRUMS 1. 1. There should be a minimum of one (1) grease fitting per saddle base plate. The difference in elevation of the drum centerline.EP-02A PAGE 5 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS 1. It is very important that the steam drums be located properly. Tolerance on location of these nozzles is: Elevation: Location: +/. Anchor bolts that are to be torqued tight shall be tightened per AISC Specification for Structural Joints using ASTM A325 or A490 Bolts “Turnof-Nut tightening”.1. Erector to check elevation and location of drum nozzles.2 . If other slide mechanisms are used.2 Each drum will be fitted with at least two support saddles. but follow the guidelines of the appropriate table. after the drum is in its final position to limit any movement and for resisting lateral wind and earthquake loadings.3 1.5 1.5.½” +/.5.1 Anchor bolts that are to be snug tight shall be tightened per AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts. from one end to the other.6.3 1.5.5. When teflon slide packs are used at the drum saddle base plates.5.¼” 1.5. greasing may be omitted. prior to setting the drum on the support structure.6. It is not necessary to provide a representative sample.4 1. Guides shall be installed around the saddle. shall be no greater than ½”.1. (Axle quality grease is recommended). 1. be sure to attach the teflon slide packs to both the drum base plate and support steel. Softeners should be used with cable slings to prevent damage to material.6 ANCHOR BOLT TIGHTENING REQUIREMENTS 1. Both drum saddle base plates shall be greased prior to installation. Check to make sure grease fittings are installed.2 Slings shall not break against any nozzle or nozzle reinforcement pad. 1. as it is still the Erector’s responsibility to check components against drawings to assure proper installation orientation.EP-02A PAGE 6 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS 1.1. all structural field welding is to be in accordance with AWS D1.7 Flow arrows are provided for convenience of the Erector.8 . All pressure part field welding is to be in accordance with applicable codes. Field welding: As a minimum. Nooter/Eriksen accepts no liability for incorrectly marked flow arrows. The removal and disposal of the freeze protection medium is the responsibility of the field erector. Any deviation from these shall be brought to the attention of Nooter/Eriksen for review. MODULES 1. 1. for information purposes only.5. prior to handling of heavy components. a freeze protection medium may be added to the modules prior to shipment.Manual\EP-03ASB. the freeze protection medium is Dow Chemical’s “Dow Frost”. which is propylene glycol. It is the responsibility of the Erector to meet these requirements. When lifting operation temperatures are below –20°F. One example of each type of lifting device (one Horizontal Lifting Device and one Strongback Device) shall be provided by Nooter/Eriksen.1 This procedure is presented to provide an understanding of how Nooter/Eriksen has designed the equipment to be handled during the setting or erection phase. the Erector must verify that all device components are properly tagged to indicate that their capacity is consistent with the devices specified on Nooter/Eriksen’s job specific Lifting Drawings. All rigging and lifting equipment shall be designed and furnished by the Erector to meet the expected loading and the requirements of all procedures and drawings.R6 . tension and bending. provided Erector executes Nooter/Eriksen’s standard Release & Indemnity Agreement. There are usually three lifting operations performed on each module. however. contact Nooter/Eriksen for review. Lifting lugs are limited for use at – 20°F and above. In some cases. In these cases. Design and use of this equipment shall comply with all applicable codes. The first is accomplished when the module first arrives at the jobsite and is lifted in the horizontal position from the railcar onto the transporter.5 APPROVED BY: RDG X:\Procedures\Erection. a six degree (6°) maximum offset is acceptable. Ideally the loads should act in line with the lug. industry standards and safety guidelines.EP-03ASB PAGE 1 LIFTING AND RIGGING PROCEDURES REVISION 0 1. Lifting lugs are designed to handle shear.3 1. Before the Nooter/Eriksen supplied lifting devices are used.4 1. or an N/E approved equal.1 Each module is fitted with lifting lugs on the top headers or roof panel in the shop.2 1. A small amount of lateral load has been designed into the lug to account for any cable misalignment. The MSDS is made available with the shipping documents. Erector’s rigging plan shall be made available to Nooter/Eriksen. Refer to the job specific N/E Module Lifting Drawings for the general procedure. 6 1. This is performed using the same rigging that was used for the first lift. worn or damaged bolts/pins shall be replaced as necessary. The Horizontal Lifting Device must be adjusted (width of device. The supports should be installed in a manner to keep the upper and lower headers at the same plane as they were shipped from the module fabricator within +/-1”.4 1. and HORIZLIFTDEV 7.5. See sketch “Module Storage (Staggered Pitch)”. When the module is placed between the support columns. Once the module is in the vertical position.5. as well as lug position) to fit the geometry of the module. 1. It may also be necessary to make adjustments between lifts of different modules.2 The horizontal off-loading lift is performed with the Horizontal Lifting Device. This is accomplished by using the Strongback Device. STRONGBACK16. HORIZLIFTDEV 2. Each module roof is equipped with support beams with a portion of the upper roof attached.7 1. Any bent.5. it can be placed between the appropriate columns and set in its final position. It is necessary to support the module upper headers (this can be done through the roof beams). STRONGBACK02. The third lift is the horizontal to vertical lift.5. Refer to the actual job specific Nooter/Eriksen Module Lifting Drawings for all details of the lifting devices.3 1. the lower headers. After each lift. Copies of these drawings are included in the “MISCELLANEOUS” section of this manual. The device attaches as shown on the appropriate job specific N/E Module Lifting Drawing(s).5 1. to assure no damage has occurred and confirm that all bolting is tightened as required.8 . STRONGBACK03.EP-03ASB PAGE 2 LIFTING AND RIGGING PROCEDURES REVISION 0 1.5. The second lift is the lift from transporter to Strongback Device. HORIZLIFTDEV 1. HORIZLIFTDEV 3. the lifting devices and all associated bolting/pins shall be inspected by the Erector.5. and all shipping beams during transportation on the heavy haul transporter and during storage. with identical bolting/pins as stated on the pertinent Nooter/Eriksen Drawings from the following list: STRONGBACK01.5. the load is transferred from the module support beams to the upper frames. utilizing all of the strap lugs that are provided with the shipping steel. Refer to the actual job specific Nooter/Eriksen Module Lifting Drawings for details and procedure. 7 EXHAUST STACKS 1. 1. Erector will be responsible for any damage caused due to failure to comply with these requirements. to prevent damage to the damper. 1. b. the Erector shall design and provide all bracing required to prevent damage to the stack. The damper shall not be attached to any stack cylinders prior to lifting into final position.4 . 1.1 Exhaust stacks are shipped to the sites in several different forms. 1.1 Lifting lugs are provided on ducting supplied in panel sections. If the cylinders are subassembled on the ground.3 1.5. Lifting lugs are designed to be used with spreader beams.6.6.7.EP-03ASB PAGE 3 LIFTING AND RIGGING PROCEDURES REVISION 0 1.2 1.6 DUCTING 1.9 It is the Erector’s responsibility to assure that the lift devices provided by Nooter/Eriksen are being used properly and all lifting operations are in accordance with the requirements as noted on Nooter/Eriksen drawings and this Erection Manual to prevent damage to equipment and injury to personnel.7.5. 1. If a stack is provided with a damper. the damper shall be installed after the bottom stack section is installed vertically on the stack foundation. a. Erector is to repack all components in containers for shipment.7.2 Multiple arc sections for field welding into cylindrical sections Shop fabricated cylindrical sections The Erector has the option to build the stack by setting the cylinders individually into the vertical position or to pre-assemble multiple cylinders into a sub-assembly on the ground before lifting. If supplied containerized.7.10 After all use of the Nooter/Eriksen supplied lifting devices is completed. Refer to Erection Drawing EP-03A-09 through –12 for details of lifting procedure and lifting lugs. It is the Erector’s responsibility to design and supply the required lifting and rigging equipment based on their chosen method for erection of the stack. the Erector is to fully dismantle them for return to Nooter/Eriksen. 3 1. 1. The Remote Steam Drum lifting weights are 5% greater than the shipping weights marked on the Steam Drums.4 There are no lifting lugs provided on remote steam drums.EP-03ASB PAGE 4 LIFTING AND RIGGING PROCEDURES REVISION 0 1.8.8.8.1 1.8 REMOTE STEAM DRUMS 1.5 . Slings shall not break against any nozzle or nozzle reinforcement pad.8.2 1. See Drawing EP-03-05A for details of erection procedure. Softeners should be used with cable slings to prevent damage to materials.8. . . . . . To install these panels it will be necessary to insert one edge of the casing inside the column and rotate the other end in past the other column and slide the casing to the proper position for weld to the columns. It is the Erector’s responsibility to perform structural welding in a manner that ensures that completed components are within the tolerances specified in EP-11. See Drawing EP-04A-06.4 1. Combination bolted and welded connections are to remain bolted after welding. loss of insulation and general failure of the integrity of the liner system. design considerations and general installation procedures needed for installation.R9 . The liner system is composed of a series of overlapping plates.2 1. It is important that the installation of the field seams be understood prior to beginning work.1.1 This procedure will provide general details.3 1.Manual\EP-04A. When casing and ducting are shipped with plastic weather protection on the exposed insulation.0 ASSEMBLY SEQUENCE 2. 2. These panels are to be set on their foundations. Failure to install field seams correctly can lead to casing hot spots.1 Sidewall Casing Panels (Primary and Secondary) 2. pinned to the outside casing.0 GENERAL 1.1 The primary casing panels have the main structural columns attached to them. The liner assembly on all breeching and modules is designed to allow the protective internal liner system to expand freely due to temperature expansion of the components. 1. The secondary casing panels are stiffened with flat bar.EP-04A PAGE 1 ERECTION PROCEDURE FOR FIELD SEAM INSTALLATION (MODULAR) 1.1.2 APPROVED BY: RDG X:\Procedures\Erection. The Erector should refer to the erection drawings for actual job details.5 2. it must be removed prior to installation of the field seam insulation. bolted/welded and braced in their final positions. The roof beams are bolted to the sidewall columns as the primary sidewall casings are erected. this must be completed before installing modules. This will provide stability for the structural frame.2 Floor Beams and Floor Casing panels 2. 2.2. See Drawing EP-04A-08. the floor beams are fit-up and held in position with bolted connections.EP-04A PAGE 2 ERECTION PROCEDURE FOR FIELD SEAM INSTALLATION (MODULAR) 2. Bolts are to be snug tight per AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts. Set the secondary floor casing in place and seal weld to the adjoining primary floor casing from the liner side of the casing panel. Bolt the primary floor panel to columns on the sidewall casing. Attachment welding of floor beam to sidewall columns is shown on the Erection Drawings for the actual job details.1 The roof beams are sent to the field with the casing. unless otherwise specified on drawings. See the individual job details for bolt and weld requirements.3 The field seams between sidewall casing panels are seal welded at the outer casing from the outside of the system. Attach the corner angles and insulation between the sidewall and roof beam as the sidewall and the roof beams are erected (See Drawing EP-04A-09).1. Due to access issues.2 2.3. unless otherwise specified on drawings. 2. The field seam between the sidewall and the floor casing is completed by installing the corner angle from the inside and installing the insulation and outer casing plate from the outside. The insulation pins. insulation and inner liner are installed from the inside of the system. insulation and liners shop installed.3 Roof Beams 2.2.3 2.3.1 For ease of installation.3 . 2. Bolts are to be snug tight per AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts.2. See Drawing EP-04A-07 and EP-04A-10.3.2 2. 1 SCR and CO catalyst systems. This equipment can be shipped to the site in either panels or in complete modules. could be field installed in Nooter/Eriksen’s casing. If tadpole gaskets are used. Bend pins perpendicular to liner plate prior to installation of insulation.3 3.1 The roof casings are shop installed onto the modules unless noted otherwise on drawings. Care should be taken to ensure that the liners are not damaged during the installation of the coils. if required.1 Field liner plates shall follow the lapping sequence of the shop liner plates. Insulation pins are installed in the shop on the inside of column flanges. Care shall be taken to ensure that all void areas are filled. 4.4. insulation seams shall be staggered.2 .2 2.EP-04A PAGE 3 ERECTION PROCEDURE FOR FIELD SEAM INSTALLATION (MODULAR) 2.4 Roof Casing 2. If the field seam insulation is composed of multiple layers. See the individual module drawings for the field seam configurations supplied by the module fabricator.4. Field attachment of tadpole gaskets on corner angles may be required after the corner angle is in place (see Drawing EP-04A-09). 2.0 FIELD SEAM LINER INSTALLATION 3. (See Drawing EP-04-10) Before installing the field liner. The actual laps on shop assembled pieces may vary from what is shown in this standard. the field seam cavity shall be completely packed with ceramic fiber insulation. and the individual job field seam drawings. Field seams are required between the adjacent shop installed module roofs and between the shop installed module roofs and the sidewall. will be provided under separate cover from the appropriate Vendor. The field assembly of this equipment.4.0 VENDOR SUPPLIED EQUIPMENT 4.2 3. 3.3 4. and before the modules are installed. Field seams between the Vendor equipment and the Nooter/Eriksen casing panels will be per Erection Procedure Drawings EP-04A-06 thru 09. they shall be partially shop installed on roof beams. as well as catalyst frames and burners. . . . . . . . After the horizontal-to-vertical lift is completed. post weld heat treated (if required). the Field Erector must verify that this steel is to be removed by a thorough review of N/E Field Erection Drawings (See Drawing EP-05A-1 and coil module drawings for details).5 APPROVED BY: VPM X:\Procedures\Erection. However. Wood will not be painted yellow.2 2. the temporary bundle support steel must remain in place until all of the connecting riser pipes are 100% installed. N/E is to be contacted for assistance. Material to be removed will be painted YELLOW except as listed below. the bolting and approximately 12” from the bolted connection on the steel will be painted yellow. all wood is to be removed.EP-05A PAGE 1 REMOVAL OF TEMPORARY STEEL/WOOD REVISION 0 1. If the modules are to be stored on the rail car. temporary bundle support steel is provided to support the headers during shipping and erection. In some instances.2 2. In these instances. and have received quality acceptance. All material that is temporary by design shall be removed after the module is in its full upright position. since they must remain in place until the horizontal-to-vertical lift is completed Some Evaporator modules are ultimately supported by their corresponding Steam Drums via riser pipes. post weld heat treated (if required). modules will be shipped to the site with metal strapping wrapped around the tube field. either directly by spring can supports or by interconnecting piping. the temporary bundle support steel can be removed and the casing field seams completed. This strapping must remain in place during the horizontal-to-vertical lift. As such. and have received quality acceptance. temporary support steel may be affixed to components to assure stability during shipment and/or installation. welded. If there is any lack of clarity regarding removal of temporary bundle support steel.R7 . wood and bolting may be used to secure the modules or other components during shipment. centered between vibration supports.Manual\EP-05A.4 2. 1. the temporary bundle support steel can be 2. Superheater and/or Reheater Module upper headers are supported externally. and below the lowest vibration support. they are to remain secured until just prior to off loading. These straps are not painted yellow. welded.3 2.1 All steel that is used to secure the module to the rail car is to be removed completely just prior to off loading. Following completion of this work. In some instances.0 GENERAL 1. This temporary bundle support steel is painted yellow for field removal. This temporary bundle support steel can be removed only after all external header supports and/or associated piping (including pipe supports) are 100% installed. the strapping is to be removed in the field. Also. On large temporary steel. Any wood blocking should be removed before the module is installed into the casing.0 COIL MODULES 2. Following completion of this work.1 Temporary steel. R7 .Manual\EP-05A. shipping horses and lift devices on a truck for transport back to Nooter/Eriksen’s shop facility. prior to release back to the railroad. X:\Procedures\Erection. 3.1 It is the Purchaser’s and Erector’s responsibility to load the Nooter/Eriksen coil module shipping support beams.0 RAIL CAR “TIE DOWN” STEEL 4. painted yellow. However. If there is any lack of clarity regarding removal of temporary bundle support steel. the following must be considered: Shipping cradles at vibration supports and lower headers must remain intact until module is installed on Strongback. to avoid interference with vibration supports. at the openings. This temporary steel should be removed after the stack is in the upright position. by the Erector. 5. This temporary bundle support steel is painted yellow for field removal.0 CARE OF LIFTING DEVICES AND COIL MODULE SHIPPING SUPPORT STEEL 5. Shipping cradle at upper headers must be removed prior to installing module on Strongback. 2.1 All rail cars are to be cleared of tie down steel.1 Stacks that are shipped in cylinders will have temporary steel.6 For modules that are lifted using the Strongback Lifting Device. the Field Erector must verify that this steel is to be removed by a thorough review of N/E Field Erection Drawings (See coil module drawings for details). 3. All shipping cradle side plates and tie rods must be removed after module is installed on Strongback. Charges will be applied to the Erector if not cleaned properly.EP-05A PAGE 2 REMOVAL OF TEMPORARY STEEL/WOOD REVISION 0 removed and the casing field seams completed. or if rail cars are not turned back over to the railroad in the allotted free time. but prior to lifting from horizontal-to-vertical.0 STACK SHIPPING AND ERECTION STEEL 3. segments shall have the temporary steel remain in place until the stack has been assembled and welded into cylinders and in the upright position. Any retainer tabs installed on shipping cradle beams must be removed prior to horizontal-to-vertical lift.2 4. Stacks that are shipped in 120 deg. N/E is to be contacted for assistance. Manual\EP-05A. No modifications to this equipment are to be performed without written consent by Nooter/Eriksen.EP-05A PAGE 3 REMOVAL OF TEMPORARY STEEL/WOOD REVISION 0 5.R7 .2 It is the Erector’s responsibility to maintain the coil module shipping support and lift devices in the as received condition. X:\Procedures\Erection. . a.5 b. This will provide access to many of the areas where functions necessary for the completion of the HRSG can be obtained without providing temporary scaffolding. The tolerances as specified within AISC for connections shall be applicable. Cutting of grating for piping supports. This will provide access to HRSG for performing other functions and will minimize the amount of temporary scaffolding. 3.4 1.1 It is recommended that the stair tower be erected as soon as possible.1 It is recommended that the platforms be installed as soon as possible.3 3. The stair tower columns shall be set on piers provided by the concrete Contractor. The stair tower is attached to the HRSG at one or more levels.2 2.2 APPROVED BY: RDG X:\Procedures\Erection. The markings shall correspond to markings shown on platform erection drawings. In order to insure proper platform elevations the attachment clips to the HRSG are to be field installed.0 GENERAL 1. standard practice for steel building and bridges. 1.R5 . All pieces shall be marked with identifying numbers. The following grating installation procedures are to be performed by the Erector. These should be installed as the stair tower goes up so that adequate bracing is provided.3 1. The attachments should be field located and welded to the HRSG as indicated on the erection drawing.Manual\EP-06.1 The access steel is to be erected using the AISC Code. 2. The stair tower shall not be used for access purposes until all bolting and attachment welding has been completed. The anchor bolts and bolting shall be torqued per AISC. The structural steel columns and beams should be squared and plumbed prior to torquing the bolting.0 PLATFORMS AND LADDERS 3. Platform steel will be shop fabricated into sub-assemblies.2 1.0 STAIR TOWERS 2.EP-06 PAGE 1 ERECTION PROCEDURE FOR STAIR TOWERS/PLATFORMS/LADDERS 1. 2. Field cutting and reinforcement of all piping penetrations through grating. For N/E. as well as all HRSG components.3 The elevations of platforms shall be checked. It should be noted that the elevations given for platforms. and safety gates. this is always the bottom of the HRSG column base plates. support clips. Ladder footings at grade shall be field erected. 3.EP-06 PAGE 2 ERECTION PROCEDURE FOR STAIR TOWERS/PLATFORMS/LADDERS 3. footing bolts. prior to releasing them for access use. are from reference elevation. (Reference: base plate elevation 0’-0”).6 .5 3. Ladders shall be fully installed including cage connections. The platforms are normally erected by first installing the support brackets and clips to the HRSG and then lifting the pre-assembled sections into place and bolting or welding.4 3. 2 2.0 GENERAL 1.5 2. the expansion joint flanges.R7 . relative to each other. The fabric shall be covered to protect from welding and puncturing.2 1. extension and lateral offset. relative to each other. Actual dimensions. by N/E or the performance and mechanical warranty will be to the account of the Erector.Manual\EP-07. in writing.1 All shipping ties are to be left in place until a minimum of one side of the joint is installed on the equipment. 2. in compression.EP-07 PAGE 1 EXPANSION JOINT INSTALLATION 1.0 of the “GENERAL” section of this Manual for storage and responsibility of the equipment that the purchaser receives on site. handling and storage. Field joint material as shown on the field erection drawings. When installed.4 1. Bolting for the attachment to other equipment will be by the Erector.¼”. as required. the expansion joint flanges. to prevent excessive stretching of the fabric. refer to the vendor procedures. shall be within +/. When installed. 3. Use temporary cribbing.3 3. For recommended lifting. The Erector shall use extreme caution in the handling of the expansion joint. shall not vary by more than ¾”. shall be submitted to Nooter/Eriksen for review and approval.0 MODULAR EXPANSION JOINTS 2.2 APPROVED BY: RDG X:\Procedures\Erection. extension and lateral offset. in compression.0 KNOCKED DOWN EXPANSION JOINTS 3. Deviation from this procedure must be approved. It is recommended that these bolts be inserted and tack welded in place prior to installing the expansion joint. shall be provided by the Erector unless otherwise noted. The Erector shall use the lifting points and/or lugs provided with the equipment. or distortion of the internal liner system.1 The Manufacturers assembly procedures must be followed explicitly. The bolting that connects the expansion joint to HRSG equipment should be provided by the expansion joint supplier. if beyond this limit.3 1. 1.1 Reference Section 10. CAUTION: See the notes in EP-13. Care should be taken with all gasket surfaces to insure that they are not damaged.0 GASKETS 2.4 2. or in the Purchaser’s possession. and any leaks found should be corrected as soon as possible.1 Code Pressure Part Gaskets 2.1. The bolting tape shall lay flat against the surfaces with no laps or gathering of the material.2 Casing Gaskets 2. about the temporary glass used for boil-out.1.1 Three (3) manway gaskets are provided for every drum manway: One (1) gasket for field hydrotest and all field pressurization prior to start-up. APPROVED BY: RDG X:\Procedures\Erection.Manual\EP-08. shall be to the account of the Purchaser.2 2.6 2. Care should be taken to insure that the gasket is not damaged when the door is opened in the field. one (1) gasket replaces the gasket used for boil-out on the system. 1.1 All casing penetrations and access openings on the HRSG shall be gas tight. 2. All flanges and manway style gasket joints are to be assembled and tightened.1 All casing access door gaskets should be replaced at the first sign of embrittlement.2 2. The gasket surfaces shall be free of all dirt and grease (they are inspected and approved prior to shipping). to prevent damage to the outer casing.EP-08 PAGE 1 GASKETS & PACKING 1. Sealing shall be at the outer casing.5 2. including boil-out. Damage incurred while stored. Shop installed gaskets and packing joints may have loosened in shipping. Gage glass packing on the water column shall be replaced with new packing after boil-out and prior to start-up. per industry standard.3 2. All valve and instrumentation packing shall remain in its original shipping container (any cost resulting from mishandling of valve or instrumentation packing shall be to the account of the Purchaser).1 All casing access doors are to be sealed with a flat bolting tape gasket (shop installed). “Boiling-out Procedure”. a check of all these areas should be done at the initial start up of the system. and one (1) spare gasket is provided for initial operation.1.R9 .1.1.1. 2.2.1.2.0 GENERAL 1. If safety is an issue.3 Fabric Expansion Bellows (@ HRSG Roof) 3.2. tighten the bolting).1 The roof expansion bellows are shipped installed if the roof is attached in the shop. During operation.2 The bolting tape shall lay flat against the surfaces with no laps or gathering of the material.1 Some pressure part nozzles.3.3 Sliding packing joints used on nozzle casing penetrations will have a gasket between the bolt plate and the outer casing. these joints should not be covered with insulation or lagging.2 Shop Installed Bolt Plate Seals 3.1.3 .1. This gasket should be checked for leakage at the initial start-up of the system (if leaks exist.1 Some pressure part nozzles. All shop installed packing joints should be checked for leakage at the initial start-up of the system.2. Remove all temporary protection upon completion of erection.EP-08 PAGE 2 GASKETS & PACKING 2. The fabric expansion bellows must be checked at the initial start-up of the system for leaks. Additional rope packing is to be installed if the leak persists. The Erector is to apply anti-seize compound to all packing gland bolting.2. as noted on Nooter/Eriksen drawings. as noted on Nooter/Eriksen drawings.2 3. 2.2 3.3.1 Shop Installed Packing Joints 3. that project through the outer casing consist of a collar plate that is gasketed and bolted to the HRSG casing. 3. that project through the outer casing are packed with ceramic fiber rope insulation and have a gland installed to maintain a tight seal against the movement of the nozzle. It is the Erector’s or Startup/Commissioning Contractor’s responsibility to verify that 3. the gland is to be tightened to achieve a seal. 3. Wrapping with fire retardant blanket and fiberglass reinforced heat resistant tape will protect fabric bellows. If a leak is found.2. These collar plates must be field welded to the nozzles. 2. surround the expansion joint area with expanded metal offset from the joint such that the heat will be dissipated and prevent personnel from coming in contact with the hot joint. if properly applied.2 Bolting casing connections are to be sealed with a flat bolting tape gasket and tightened uniformly all around the perimeter.0 CASING PENETRATIONS 3.3. 3. and adjustments made.2. if necessary. Fabric bellows must be protected from weld splatter and puncture during the erection phase. 4. Remove all temporary protection upon completion of erection. surround the expansion joint area with expanded metal offset from the joint such that the heat will be dissipated and prevent personnel from coming in contact with the hot joint.4 3. if properly applied.EP-08 PAGE 3 GASKETS & PACKING fabric seal retainer clamps are properly positioned and tightened before and after first fire.4. These joints are pre-compressed and are supplied with shop installed straps.1 Some penetrations utilize metal bellows expansion joints. If safety is an issue. surround the expansion joint area with expanded metal offset from the joint such that the heat will be dissipated and prevent personnel from coming in contact with the hot joint. These are typically small penetrations (2” NPS or less). if properly applied. During operation. If safety is an issue.5 Metal Expansion Bellows 3.5. these joints should not be covered with insulation or lagging.5. 3. These straps are not to be removed until all welding and heat treating is completed on the pipeline that is routed through the bellows. Remove all temporary protection upon completion of erection. During operation. Wrapping with fire retardant blanket and fiberglass reinforced heat resistant tape will protect metal bellows. Wrapping with fire retardant blanket and fiberglass reinforced heat resistant tape will protect fabric bellows. 3. Floor conical expansion bellows must be protected from weld splatter and puncture during the erection phase.1 The floor conical expansion bellows are shipped loose and must be field installed after the coil modules are set. 3.4 Fabric Expansion Bellows (@ HRSG Floor) 3. and are field installed. these joints should not be covered with insulation or lagging. Metal expansion bellows must be protected from weld splatter and puncture during the erection phase.2 . d.7 Nooter/Eriksen Piping Isometric Drawing Nooter/Eriksen P&ID Diagram Nooter/Eriksen Trim & Instrument List Fabricators Pipe Spool Drawings (if available) Nooter/Eriksen Pipe Support Detail Drawings Nooter/Eriksen HRSG Reference Drawings 1. e. The Erector will check actual termination points to the theoretical termination points during field erection to maintain the +/. etc.0 GENERAL 1.R11 . If field trim is removed from the project. It should be recognized that. post weld heat treatment. 1. and erection tolerances. procedure qualification. excessive misalignment.1 and any local applicable codes as they pertain to welding. b. N/E must be notified of the problem and given the opportunity to provide a solution (see N/E Backcharge policy). Nooter/Eriksen will not be responsible for spool-to-spool alignment or termination points that differ less than 3” in any direction from theoretical locations.5 1.1” tolerance. c. Piping is supplied in spool pieces to facilitate field assembly. ANSI B31. Sufficient trim is provided in each of the spool pieces to allow for adjustment and tolerance accumulation. It is the Erector’s responsibility to ensure that all Code requirements have been met as they pertain to assembly. APPROVED BY: RDG X:\Procedures\Erection. Information needed for installation. non-destructive examination.2 1.3 1. Valves may be shipped loose for field installation. Large bore piping is defined as all piping over 2” NPS.6 Piping terminal locations are considered within tolerance if the pipe end is within +/. a certain amount of mismatch is to be expected. If the Erector feels that modifications in the design must be made due to interferences. f. due to the size of the components. or for other reasons.4 1. normal fabrication. shifting of component parts during shipping. Any cutting or modifying of pipe spools without prior notification and approval by N/E will not be accepted for backcharge consideration.Manual\EP-09. a.EP-09 PAGE 1 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING 1.1 All piping shall be installed to meet the requirements of ASME Section I.1” of theoretical in any direction. 2 All Chrome-Moly piping shall have NDE in accordance with ASME Section I.1.2 Monitoring and maintaining heat control throughout the welding process is vital for achieving acceptable field welding results. shall be 100% radiographed.8.8. 2.0 INSTALLATION 3. ANSI B31. whichever governs and is more stringent.0 NDE REQUIREMENTS 2.1 Field Erector should have a system in place that will assure that the welding is properly performed. a further 5% of welds deposited by that welder shall be radiographed. or the local applicable codes. Should additional defects be identified. 1. and butt welds in the boiler proper and boiler external piping. The Erector is free to modify or add to this procedure.8 Although applicable to all materials. . not requiring radiography by the ASME or the local applicable codes. all welds deposited by that welder shall be radiographed. it is recommended that the following additional radiography be applied: 1) At least 5% of all full penetration pressure part butt welds.1 This section provides suggested installation steps to minimize the time required to install pipe spools.EP-09 PAGE 2 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING 1. In the event of a defect being identified in the prescribed 5%. 3.1 In addition to the Mandatory Code Requirements for non-destructive examination of welds. This category of welds normally includes butt welds in the downcomer and riser piping. the following is of particular importance for 9Cr 1Mo (P91) piping: 1. 2. The contents of this procedure should be considered as a guide. This should be implemented by radiographing 5% of this category of welds deposited by each welder. hangers. if needed.1 All pipe runs will be provided with pipe supports. maintenance. the Erector should become familiar with the supporting requirements. the Erector should trim pipe sections to fit actual dimensions. It is usually possible to slightly rotate the pipe at the connections to achieve movement at the other end without affecting the weld gaps appreciably. Prior to installing any pipe run. After the pipe spool pieces have been inspected dimensionally and the connection locations verified. the Erector should pre-fabricate the completed pipe runs in sections as large as possible.7 4.3 3. Pipe sections should be lifted into place (tack welded only) and checked for fit up before fully welding any section. Valves should be welded in and inspection. springs and/or guides.2 Erector is to verify the tagging on each spool piece and valve and check dimensions using piping isometric drawings and the fabricators pipe spool drawings.0 PIPE SUPPORTS 4. and proper operation. and normal fabrication and erection tolerance accumulation.6 3.EP-09 PAGE 3 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING 3.. The theoretical locations may vary from the actual depending upon how the modules have been set. how components have shifted during shipment. heat treatments. to meet design requirements. etc. It is possible to create additional work if piping and supports are not installed in the proper sequence. 4.5 3.2 . It is not acceptable for piping expansion joints to be manipulated to make up for piping misalignment. 3. Since the actual dimensions of the pipe run can now be verified.4 3. . External insulation must be held back from all piping expansion joints and casing seal devices for inspection. Piping expansion joints shall be installed per the expansion joint manufacturer’s guidelines and accepted industry practices. made. Erector shall check the location of the connections where the pipe spools are to be placed. Any major discrepancies shall be brought to the attention of Purchaser immediately. To facilitate field installation. 4. 4. If welded safety valves are supplied. All spring supports and constant supports must have travel stops in place prior to filling the HRSG. the Erector is required to field trim or cut back the grating. trim to fit and final install. The Erector should trial fit pipe supports.5 4. Failure to comply with this requirement may result in damage to valves. the leaking valves shall be repacked. It is the contractor’s responsibility to verify that moving the pipe support to allow for field or shop tolerances. 4.3. Contractor shall contact Nooter/Eriksen for guidance for any supports that need to be moved more than +/. Piping dimensions at supports should be considered as a reference and may vary +/.0 HYDROTEST 5.0’-6” along the pipe centerline from their theoretical location. there must be verification that factory installed hydrostatic test plugs are installed. attachment or other structure on the HRSG. as required. All flanged pressure relief valves shall be removed. Nooter/Eriksen shall be notified of any valves where leakage cannot be stopped. does not create an interference with any other pipeline branch.0’-6”. to allow pipe support to attach directly to platform support steel. Caution: The unit should not be operated with valves where leaks have been noticed unless approval from Purchaser is obtained.1 All valves shall be checked during hydrotest for leakage. Trim is provided in the length of the field welded pieces to allow for adjustment and proper fit. or a suitable pancake shall be inserted at the inlet flange during hydrotest.EP-09 PAGE 4 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING 4.4 . 5.2 5.6 5.3 Pipe supports are to be field located and installed by either welding or bolting.4 All field welds not specifically called out on pipe support drawings are to be 3/16” fillet welds and shall be completely around the attachment so as to seal the connection. all pipe supports located on the straight length of a pipeline can be moved +/. Any leaks shall be stopped by properly tightening the packing glands.3 5.2”.1 If pipe supports require attachment to platform steel. If tightening is unsuccessful. SLIGHTLY OPENED for PWHT CLOSED TO 50% OF TORQUE VALUES for welding and PWHT CLOSED TIGHTLY for welding and PWHT DSI (all except Welded Bonnet) Edward (Univalve) Edward (all except Univalve) Fisher Controls NO PREFERENCE for welding. Nooter Eriksen is to be consulted for recommendations on any valves that are not addressed below.0 VALVE POSITION DURING WELDING AND PWHT (BY MANUFACTURER) The following is a summary of Valve manufacturer’s recommendations for positioning of valves during the welding/heat treating process.EP-09 PAGE 5 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING 6. REMOVE TRIM for PWHT FULL CLOSED for welding and PWHT FULL CLOSED for welding and PWHT NO PREFERENCE for welding and PWHT OPEN for welding and PWHT 15-25 % OPEN for welding and PWHT Fluval Ituarte HP Valve Hora Intervalve Kitz . Atwood-Morrill (Weir) Bonney Forge Conval CCI Douglas Chero DSI (Welded Bonnet) CLOSED for welding and PWHT OPEN 1/16 TURN for welding and PWHT CLOSED TIGHTLY for welding and PWHT REMOVE TRIM for welding and PWHT SEMI-OPENED for welding and PWHT REMOVE TRIM or FULLY CLOSED for welding and PWHT NO PREFERENCE for welding. REMOVE TRIM for PWHT LIGHTLY CLOSED for welding and PWHT OPEN VALVE IN THE HALF POSITION for welding and PWHT SLIGHTLY OPEN for welding and PWHT Newco (Newmans) OMB Pacific/Crane (Flex Gate or Globe) Pacific/Crane (all except Flex Gate or Globe) P-K (Pan Korea) Powell Raimondi (>24” GATE) Raimondi (all others) Raisteam/Raimondi (Pressure Seal Valves) Samshin Union –Tech (Fisher) SEATED LIGHTLY for welding and PWHT FULLY OPEN for welding and PWHT OPEN for welding and PWHT CLOSED for welding and PWHT OPEN for welding and PWHT OPEN for welding and PWHT PARTIALLY OPEN for welding and PWHT BALL IN FULL OPEN POSITION for welding and PWHT OPEN for welding and PWHT CLOSED for welding and PWHT CLOSED for welding and PWHT Valtek Velan Vogt .EP-09 PAGE 6 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING KVT (HP Valves) OPEN TO PREVENT ARCING for welding and PWHT Masoneilan SLIGHTLY OPEN for welding. Small bore piping is defined as all piping 2” NPS and smaller. 1.2 Nooter/Eriksen Trim Piping Drawings Nooter/Eriksen P&ID Diagram Nooter/Eriksen Trim & Instrument List Fabricators Pipe Spool Drawings (if applicable) Nooter/Eriksen Pipe Support Drawings Nooter/Eriksen HRSG Reference Drawings VALVES ARE SHIPPED LOOSE FOR FIELD INSTALLATION. 1. 2.1 See Procedure EP-09. and standard support details on small bore piping drawing GA007.4. 2. The routing.0 for Manufacturer’s Recommendations for Valve Position during welding and PWHT. ANSI B31. Notes 8A through 8D on small bore piping drawing GA-005.1 and any local applicable codes as they pertain to welding.2. procedure qualification. f. b.2 Monitoring and maintaining heat control throughout the welding process is vital for achieving acceptable field welding results. Small bore piping is normally supplied in random length pieces with approximately 10% additional for field drop.3 1. the following is of particular importance for 9Cr 1Mo (P91) piping: 1.0 GENERAL 1.EP-10 PAGE 1 ERECTION PROCEDURE FOR SMALL BORE PIPING 1. installation and support of these lines is to comply with Nooter/Eriksen small bore piping isometric drawings.4. c.3 Nooter/Eriksen drawings provide routing and supporting for small bore piping within the Section I Code boundaries. d. The Erector/Owner should APPROVED BY: _WJP_ X:\Procedures\Erection.1 All piping shall be installed to meet the requirements of ASME Section I. If it is determined that rerouting is necessary. 2. paragraph 6.0 INSTALLATION 2. non-destructive examination. Although applicable to all materials. etc. Nooter/Eriksen is to be notified prior to rerouting.R10 .2 1.1 INFORMATION NEEDED FOR INSTALLATION: a.4 2.1 Field Erector should have a system in place that will assure that the welding is properly performed. It is the Erector’s responsibility to ensure that all Code requirements have been met as they pertain to assembly. post weld heat treatment.Manual\EP-10. e. EP-10 PAGE 2 ERECTION PROCEDURE FOR SMALL BORE PIPING notify N/E before changing routing or support locations. 2. most sealing devices must be installed before any piping assembly is started. unless approval from Purchaser is obtained. In all other cases. Caution: The unit should not be operated with valves where leaks have been noticed.1.2. Failure to comply with this requirement may result in damage to valves. As noted in EP-08.3. maintenance.R10 . and details on small bore piping drawing GA-007.1 All valves shall be checked during hydrotest for leakage.0 HYDROTEST 3. Minor changes to valve/instrument locations to provide accessibility do not require approval. these supports will be located on the piping isometric drawings.3. and proper operation.5 3. X:\Procedures\Erection.4 External insulation should be held back from all piping expansion joints and casing seal devices for inspection.Manual\EP-10. Any leaks shall be stopped by properly tightening the packing glands. 2. Nooter/Eriksen shall be notified of any valves where leakage cannot be stopped. it is the Erector’s responsibility to locate and install pipe supports in accordance with Notes 8A through 8D on small bore drawing GA005.1 Portions of some small bore pipelines are supplied with specifically engineered pipe supports. (See Procedure EP-09.2 2. If this is unsuccessful. Paragraph 3. paragraph 4.6) 2. Tolerances for small bore pipe support locations are the same as for large bore. In such cases. the leaking valves are to be repacked. ½” +/.Manual\EP-11. 3. C. A. stairtower. Tolerances for piping structural supports. All other tolerances not listed above shall be limited to “Industry Standards”. D.¼” unless otherwise noted on the individual job drawings.3/8” +/. or the Nooter/Eriksen Project Engineer for verification that the deviation will in no way effect the integrity of the HRSG system. roof beams. ladders.EP-11 PAGE 1 ERECTION PROCEDURE FOR FIELD WELDMENTS 1. APPROVED BY: RDG X:\Procedures\Erection.0 Tolerances for bolted or welded. floor beams and structural floor panels shall be assembled with the following tolerances: The letter items listed below correspond to the letter designation on Drawing EP11-1.0 5.0 4.3/8” +/.0 Deviations from the above shall be brought to the attention of a Nooter/Eriksen representative.R8 . B. the Erector is to verify that the Catalyst Loading Opening is plumb and square so that the Catalyst Loading Doors will fit properly. shall be in accordance with the latest edition of AISC.¼” R8 2. platforms and platform supports.0 Structural sidewall panels. If the HRSG is provided with an SCR. +/. This must be done prior to final welding of the SCR duct frame corner connections. structural roof panels. guides and hangers shall be +/. and in no way affect the integrity and appearance of the HRSG. . except spring replacement or calibration adjustment of the valve (Ref.Manual\EP-12. unless otherwise shown on trim drawings.0 GENERAL 1.5 2.R5 .2 2.6 2.7 2. Para. Discharge piping shall not be left unsupported for any length of time. or other applicable codes. or after. startup and operation of the HRSG.0 PRESSURE SAFETY VALVES AND STACKS 2. shall be properly vented and arranged to permit servicing and normal operation. Body drains of all PSVs shall not be plugged during.2 2.4 2. Material is to be furnished by the Erector. Plugs supplied by the manufacturer for shipping. 1. PG-73.1. Weather shields installed on the PSV by the Erector. Motor operated vent valves are to be stored in their original packing until installed. Discharge piping that is routed to a collection pipe shall meet the requirements of ASME Section I. No valves shall be placed between the PSV discharge and the atmosphere. by the Erector.8 2. 2.8).PAGE 1 PSVs START-UP VENT AND STACKS EP-12 1. All gravity drains located in the PSV and the discharge piping shall be piped to a safe area. shall be removed when the PSV is removed from its original packing. Discharge piping shall be directed away from platforms and/or areas used by personnel. The seal shall not be removed for any reason.3 2. Adjustments or setting changes of PSVs shall not be performed without written authorization from Purchaser and the PSV manufacturer.9 APPROVED BY: PJH X:\Procedures\Erection. away from platforms and operating stations.1 Pressure Safety Valves (PSVs) are to be stored in their original packing until installation. PG-71. The PSV discharge piping shall be square cut at the discharge end to atmosphere (no modifications to discharge piping will be allowed). Para.: ASME Section 1. field installation. PSV discharge piping and supports are to be installed complete at assembly.1 Lead adjustment seals shall remain intact on the valve during erection. PAGE 2 PSVs START-UP VENT AND STACKS EP-12 3.0 START-UP VENTS AND STACKS 3.1 Start-up vent discharge piping and supports are to be installed complete at assembly. Discharge piping shall not be left unsupported for any length of time. The start-up vent discharge piping shall be square cut at the discharge end to atmosphere (no modifications to discharge piping will be allowed). Discharge piping shall be directed away from platforms and/or areas used by personnel. All gravity drains located in the start-up vent discharge piping shall be piped to a safe area away from platforms and operating stations by the Erector. A reasonable amount of drain line material has been supplied by Nooter/Eriksen. Any additional materials must be furnished by the Erector. (See drawing EP-12-01) 3.2 3.3 APPROVED BY: PJH X:\Procedures\Erection.Manual\EP-12.R5 EP-13 PAGE 1 RECOMMENDED TUBESIDE CLEANING PROCEDURE Nooter/Eriksen recommends the use of an experienced cleaning contractor for this service. The cleaning contractor should inspect the HRSG and develop a cleaning procedure for the owner’s review. Nooter/Eriksen recommends that the cleaning procedure shall include steps for each area listed under Section 2: Hand cleaning, Organic material removal and Chemical scale removal. This section contains general information and suggestions that may be used as an aid to evaluate a contractor's procedure or monitor the cleaning and should not be interpreted as an endorsement of any particular type of cleaning. Improper cleaning of the HRSG surfaces or the complete omission of cleaning can result in poor performance and potential damage to the boiler. The HRSG tube/pipe side surface must be thoroughly and properly cleaned prior to being placed in initial service. Periodic review of the cleanliness of the boiler is required as outlined in IV of the N/E O&M Manual. 1.0 General The primary function of cleaning the tubeside is to provide a clean, uniform surface for passivation. Passivation is the buildup of a protective magnetite layer on wetted surfaces. This layer protects the inner surfaces from corrosion during operation. Oil, grease and rust can prevent or cause uneven buildup and flaking of the protective magnetite layer during operation. These contaminants must be removed before operation. The option to inspect the unit prior to chemically cleaning should be offered to all potential contractors. Lack of pre-inspection may result in an insufficient and/or inefficient cleaning solution being utilized. Improper solutions can significantly add to the circulation time required for cleaning. Prior to commencement of a chemical clean for the HRSG, the following systems/controls must be in proper operation in order to insure boiler safeguards: All HRSG alarms, trips, and interlocks All pressure parts have been installed and hydro-tested All insulation has been installed Suitable connections to all vents and drains have been installed and are routed to avoid potential hazards Gas turbine has been readied for operation APPROVED BY: WJP X:\Procedures\Erection.Manual\EP-13.R9 0 Types of Cleaning Depending on the HRSG condition. After the cleaning has been completed. and allowed to stand in the HRSG or circulated for a prescribed time or until testing shows the reaction rate has decreased. 2. operating range. or tube protective coatings) must be removed from the interior of the HRSG. Remove manhole covers on the steam. and site disposal facilities. this step will involve a preliminary flushing with warm water. Proper procedures must be implemented for laying up the boiler after 2. followed by circulation of an appropriate cleaning solution. Careful hand cleaning will reduce the time required for further cleaning. and the chemistry readjusted as required.EP-13 PAGE 2 RECOMMENDED TUBESIDE CLEANING PROCEDURE 2. and mud drums. oil. An internal inspection should then be done. any loose foreign materials clinging to the inner tube surfaces should be flushed out. and other foreign material as possible. the seating surfaces flushed. The solution is generally heated. The cleaning should be finished with a warm water flush and blowdown using a good quality condensate that should continue until phosphate content is less than 2 ppm. In addition.3 Chemical Scale Removal: This step is used to remove scale or other deposits. and the cleaning process repeated if oil or grease is still evident. 2. The cleaning solution should be periodically strained or blown down to remove foreign materials. Organics left on the tubes will impede heat transfer. grease. a variety of cleaning procedures is available.1 Hand Cleaning: The first step should always be to clean accessible areas by hand. collector. The general categories of cleaning are listed below. Remove and clean out by hand as much grease. any remaining organics (such as oil.2 . with the alkalinity and circulation temperature developed by the contractor for the specifics of the site. Manholes should be opened. and inhibit cleaning. and new gaskets installed. Organic Material Removal: Following hand cleaning. N/E recommends that each step listed below be performed to insure that the system is properly prepared for operation. Typically. prevent proper passivation of the metal. A heated alkaline solution is typically used. or the solution should be drained and an alkaline solution circulated. the pH of the solution should be raised to promote passivation. EP-13 PAGE 3 RECOMMENDED TUBESIDE CLEANING PROCEDURE the chemical cleaning to insure that damaging contaminants do not enter the system. CAUTION: THE CLEANING SOLUTION MUST BE COMPLETELY REMOVED FROM ALL THE INTERNAL SURFACES TO PREVENT DAMAGE. Scale removal will be inhibited if oil and grease are present. An alkaline cleaning should be performed prior to the scale/deposit removal phase of the cleaning. There are also mechanical means of deposit removal available for accessible tubes, such as in the evaporator. These include high pressure water lances and pull through scrapers. 2.4 General HRSG Steam Blow Procedures Theory In order to insure a clean steam path after initial erection from the evaporator sections of the HRSG to the terminal points, it is necessary to instigate a thorough cleaning procedure. In general, this is accomplished through a steam blow, air blow, or a combination chemical clean/ steam (air) blow. A steam blow procedure entails passing high velocity steam through the steam path in order to generate a sufficient cleaning ratio (CR). The cleaning ratio is defined as the ratio of the product of the density () and the square of the steam velocity (V) at the steam blow conditions to the same product at the design base load conditions. CR ( V 2 ) steam blow ( V 2 ) design The shear force generated on the tube walls is proportional to the velocity head of the flowing fluid through the pipe network. Therefore, the larger the cleaning ratio the larger the shear force (i.e. the better the cleaning of the tube walls). A cleaning ratio greater than 1.1 is normally required in power boilers to insure adequate cleaning of all steam path surfaces. Occasionally a lower value may be acceptable for low pressure systems but 1.0 should be considered the absolute minimum. It is apparent that a low pressure (high specific volume) fluid will result in the minimization of the actual amounts of water EP-13 PAGE 4 RECOMMENDED TUBESIDE CLEANING PROCEDURE required while helping to generate the largest velocity head. Therefore, it is desirable to utilize a low pressure fluid when performing a steam path cleaning. One should note the importance that all legs of the steam path need to be subjected to proper cleaning ratios. The variable geometry throughout the steam path will require the calculation of several cleaning ratios. Steam Blow When the combustion turbine is available, a steam blow is typically performed. The combustion turbine is generally utilized as the heat source for the boiler to generate the required capacity of steam. There are two general categories of steam blows - intermittent and continuous. Intermittent Blows Intermittent steam blows involve the building up of pressure in the appropriate steam drum to a predetermined upper value and then opening a quick acting steam blow valve at the end of the piping network to generate a high velocity steam by flashing water in the drum. When the drum pressure returns to the lower calculated pressure level (minimum for cleaning ratio required), the steam blow valve is closed to repressurize the drum and the sequence repeated. An intermittent blow is generally favored over a continuous blow when insufficient make up water capacity is available for a continuous blow. The required purging sequence of an intermittent blow, which may require as many as 100 cycles, generally makes the intermittent blow a more costly procedure in means of time and man-hours. Continuous Blows Continuous blows involve operating the boiler at a reduced pressure for a continuous period of time. The reduced pressure generates a large specific volume (high velocity) flow that passes through the steam path on a continual basis. A sacrificial valve is generally utilized at the terminal point of the temporary steam blow piping for maintaining required pressure. By eliminating the cyclic sequencing of an intermittent blow, the required time and subsequent man-hours may be significantly reduced for a continuous blow. However, a continuous blow requires that large amounts of treated water be available for usage. It is not uncommon to empty a large storage tank during the course of a four-hour continuous blow. EP-13 PAGE 5 RECOMMENDED TUBESIDE CLEANING PROCEDURE Note: Steam blows may still be performed even though the combustion turbine is unavailable. In this event, a sufficient auxiliary boiler must be utilized to generate the required steam (flow, temperature and pressure). 2.5 HRSG Operation for Steam Blowing The intent of this section is to present general information pertaining to operation of the Heat Recovery Steam Generator (HRSG) during the steam blow process. The guidelines and advice provided are for information purposes only and the party responsible for the HRSG cleaning is advised to seek the services/advice of a qualified cleaning professional. The HRSG and the plant design will have an impact on the decisions to be made concerning the steam line cleaning. Many of these issues are operational in nature and several are highlighted below for consideration when developing a site specific steam blow procedure. Combustion Turbine (CT) Loads Most steam blows can be accomplished at gas turbine loads below 30%. The turbine should be operated with the guide vanes wide open. This maximizes the exhaust flow and steam flow and minimizes the exhaust temperature and fuel usage. If multiple pressure systems are to be blown at once, significantly higher CT loads are generally required. Sometimes the steam from one HRSG will be used to blow common steam line piping in cases where the steam from two HRSG's that go to one steam turbine. The ideal scenario would be to identically operate each HRSG. For units with duct burners, a higher CT load is generally required. Steam Drum Water Levels Water level must be maintained in all steam drums during a steam blow to prevent damage. These systems are not designed to run dry. During an intermittent type of steam blow where the drum pressure varies. the flashing nature of an intermittent steam blow will generate very large swings in drum level. However. . The boiler must be drained after steam blows unless deaerated water was used. Start-UpWhen heating up the boiler for the steam blow process. the boiler is able to reach an equilibrium condition and subsequently.EP-13 PAGE 6 RECOMMENDED TUBESIDE CLEANING PROCEDURE The extent of drum level fluctuation during a steam blow is a function of the cleaning method applied. This is equivalent to an ammonia concentration of about 0. Steam blow steam must not be discharged through the HRSG main start-up valves. Consult the N/E O&M Manual on freeze protection. The operator should start with a small drum pressure change and work up to larger pressure changes to assure that the water level can be controlled. The water level must be maintained between the LLWL and the HHWL. Freezing water can result in tremendous damage to an HRSG. HRSG's will carryover water from the steam drums during the steam blow. Water Quality / Water Chemistry The quality of water used for steam blows should be the same quality as the water intended for normal operation. Refer to the startup requirements in the N/E O&M Manual. The valve seats would be subjected to damage. The feedwater pH should be increased to 9 by injecting ammonia. the drum level should remain fairly constant. temporary steam blow valves should be utilized to control the HRSG ramp rates. In this case a wet lay-up may be used. This water should be as clean as possible to avoid chemical deposition in piping and coil sections. the water level fluctuations will be significant. When a continuous blow is utilized. Consult the N/E O&M manual for lay-up.3 ppm. Non-return valve vendors require that the non-return valve disc (cage) be removed during a steam blow. These devices should be removed if practical. Water sprayed under the wrong conditions can lead to damage. In no case must the desuperheater block valve be opened with insufficient steam flow past the desuperheater. there must be adequate steam flow and steam superheat to vaporize the water. Desuperheater Operation – N/E advises that the water flow to the desuperheaters be isolated during steam blows. The CT operating mode should be selected to minimize the exhaust temperature. . ReheatersWhen blowing the HP system of an HRSG with a reheater. Under these conditions. The steam must have a minimum of 25°F of superheat after the desuperheater. Non-Return Valves The main steam valve must be 100% open during steam blows so as not to cause undue wear on the valve seats. Measurement Devices The steam blow process may affect steam flow meters. the reheater may have to be operated without the benefit of cold reheat steam. The accuracy of these devices is dependent upon the finish of the interior surface. N/E will not be responsible for damage to the non-return valve in the event that the erector chooses to leave the non-return valve internals in line during the steam blows.EP-13 PAGE 7 RECOMMENDED TUBESIDE CLEANING PROCEDURE Operating PressuresHRSG operating conditions can be varied to augment the steam blow process. the HP drum operating pressure should be maximized when blowing an IP system. ErectionCare has been taken to supply all HRSG components in a good condition. The erector must also strive to maintain this condition during all phases of the erection process. Vents on the hot reheat line should be open to maximize the IP steam flow and minimize the reheater operating pressure. This will allow more heat to approach the IP evaporator maximizing the IP steam flow. the IP steam flow must still flow though the reheater. If desuperheaters are utilized. For example. thermal expansion of pipelines) must be addressed and inspected to insure proper working order.EP-13 PAGE 8 RECOMMENDED TUBESIDE CLEANING PROCEDURE In many cases. The reduction in steam blow time is most noticeable when utilizing the intermittent steam blow method. The air is released through the steam piping at levels sufficient to generate the required cleaning ratios. Therefore. items typically associated with first fire of the boiler (i. The external air tanks are then repressurized and the sequence repeated similar to the intermittent steam blow. number and depth of marks on target) for final acceptance are typically defined by the end user. .e. Acceptance Once it has been demonstrated that the required cleaning ratios have been met. Combination Chemical Clean/ Steam (Air) Blow A thorough chemical clean of the steam path piping prior to performing a steam (air) blow may significantly reduce the time required to meet the clean acceptance criteria. steam turbine manufacturer. External air tanks are pressurized to predetermined levels and connected to the steam path piping. during the heat up process. and the BOP contractor. The chemical clean may be performed simultaneously with the water path cleaning which may help to reduce the additional cost of the chemical cleaning of the steam path. The cleaning requirements (i. The targets are subsequently removed and inspected for marks and impressions. an air blow may be performed to generate the same end result of a steam blow. the steam blow may represent the first time that large quantities of heat have been passed through the HRSG.e. This will generally require larger velocities than a steam blow due to the reduced density of the air. Air Blow When sufficient water is not available. steam targets are inserted in the temporary steam piping for testing at the steam blow conditions. Further questions or support regarding blows should be directed to the N/E Project Manager. However. Power plants are generally flexible so that one can optimize the conditions for a given steam blow. A temporary desuperheater in the steam blow piping may help to eliminate exceeding design temperatures of temporary piping. both boilers must be in operation to generate the required cleaning ratios of the common piping. In general. by desuperheating the boiler effluent the subsequent reduction in steam velocity helps to minimize the noise generated by the sonic steam flowing through the temporary piping. the plant demineralization make-up water train does not have sufficient capacity to generate the required amounts of water utilized during a steam blow without subsequently imposing large time delays.EP-13 PAGE 9 RECOMMENDED TUBESIDE CLEANING PROCEDURE Issues to Note: For best results. permanent desuperheating stations are to be removed from the steam path during steam blows. If not required for temperature control during the steam blow. The excessive flow obstruction in a globe valve can lead to rapid wear on the valve seats and is more subject to locking up due to impregnated obstructions. . Furthermore. When two units are manifolded together. It may be advisable to hire an auxiliary demineralization plant for steam blows. the steam blow valve should be a sacrificial butterfly valve or gate valve. Care must be taken when bringing both units up simultaneously so as not to develop excessive pressure fluctuations between the boilers. Steam blow piping is not generally rated for base load steam temperatures. Care must be taken to insure that the superheated steam is maintained within boiler design values as well as temporary piping design values. Large fluctuations in drum level will be encountered during intermittent steam blows and during valve opening modifications of a continuous blow. Boiler operation during steam blows is a very transient operation that requires complete attention of the boiler operator. flow must be maintained in all pressure systems during a steam blow to provide sufficient cooling of tubes. protection of the HRSG. These valves are generally globe-type control valves and are subject to damage when passing dirty steam (steam blow steam). 3. and then starting the boiler up again and reaching the acceptable cleaning ratios. and other planning/work that may not be provided by the contractor. The decision on whether cleaning for mill scale removal will be necessary should be made by the owner in conjunction with those who will be doing the water treatment of the plant during operation.EP-13 PAGE 10 RECOMMENDED TUBESIDE CLEANING PROCEDURE Pneumatically inserted target plates eliminate the requirement of having to bring the boiler down after reaching the cleaning ratios.6°C) Considerations This section highlights considerations on when to clean the HRSG. The saturation temperature differential generated between the initial drum pressure and final drum pressure during an intermittent steam blow must be limited to 75°F (41.2 3. the insulation also prevents the formation of surface micro-fissures in the event of boiler operation during extreme weather conditions. While providing personnel protection. Future cleanings should be scheduled as required based on inspections and monitoring of performance.1 The unit should always be inspected and cleaned after initial erection.0 3. inserting the targets. 3. Steam blow steam must not be discharged through the HRSG main start-up valves.3 . the temporary sacrificial steam blow valves should be utilized to control the ramp rate of the pressure systems. When heating up the boiler for the steam blow process. A P&ID should be supplied to the cleaning contractor to lay out the circulation path. HRSG Insulation must be installed prior to heat-up of the boiler. they must be reinstalled with the same orientation. THIS GLASS COULD SHATTER UNDER SERVICE PRESSURE AND RESULT IN DAMAGE OR PERSONAL INJURY.7 As it circulates through the HRSG. Inform the contractor of the maximum working pressure and temperature on this temporary glass. If this will not be possible. Steam drum internals can remain installed during the chemical cleaning. should be cleaned when the HRSG is cleaned. The contractor should take steps to ensure circulation of the cleaning solution through all sections of the HRSG. Note. Heating of the cleaning and rinsing fluid is normally accomplished in an external heat exchanger supplied by the cleaning contractor. 3. if deemed necessary by the cleaning contractor. A LOCKOUT PROCEDURE SHOULD BE EMPLOYED TO INSURE THE REMOVAL OF THIS TEMPORARY GAUGE GLASS AFTER THE CHEMICAL CLEAN HAS BEEN COMPLETED AND PRIOR TO PERMANENT OPERATION. In particular. If the chevron separators are removed for inspection or additional cleaning. Restricting air flow through the duct (by covering the stack or closing access doors) will reduce the amount of heat lost in the HRSG. and other instrumentation that could be damaged during the cleaning should be removed or bypassed. 3. it may be best to delay cleaning for scale removal until after operation has removed loose deposits from the feedwater system.8 3.5 3. A temporary gauge glass is provided for use during the cleaning procedure. Solution temperature should be monitored at the inlet and outlet points of the HRSG to ensure an effective temperature is maintained. Control valves. including feedwater storage/treatment facilities.6 3. orifices. that the mesh pads are made of stainless steel. however. the path of least resistance in the evaporators may be through the downcomer(s) and not through the tubes. Re-install the mesh pads before steam blow or operation.4 All pre-boiler piping.9 . and must be removed if the cleaning solution will attack this material.EP-13 PAGE 11 RECOMMENDED TUBESIDE CLEANING PROCEDURE 3. This may require blocking the downcomer(s) during chemical cleaning. WARNING: THE DISPOSABLE TUBE TYPE GAUGE GLASS TYPICALLY USED DURING THE CLEANING PROCESS IS NOT SUITABLE FOR STEAM SERVICE. the cleaning solution will cool. It does no good to have a silencer rated for 85 dBA when the noise emitting from the upstream pipe is 115 dBA. the deaerator spray nozzles and trays may filter some material during initial operation. Disposal of the cleaning solutions may contribute substantially to the cost of the process.17 . The cost associated with longer circulation times of weaker cleaning fluids may be offset by the disposal cost of more caustic/acidic fluids. the customer and contractor should verify that the unit is clean and all the coils have been completely drained.13 3.11 3.15 3. The deaerating function should be monitored for proper operation after startup. the steam flowing through the piping may reach sonic speeds and as such. If the combustion turbine is to be used as the source for heating the cleaning solution. Generally. Sample lines should be closed during steam blow and chemical cleaning to avoid plugging. However. 3. The customer should retain records of the entire cleaning procedure including the chemicals used in the process. Incorrect pump size will increase the time required to clean the boiler.EP-13 PAGE 12 RECOMMENDED TUBESIDE CLEANING PROCEDURE CAUTION: FOREIGN MATTER ON THE INTERNALS COULD RESULT IN STEAM PURITY PROBLEMS. generate a considerable amount of noise.10 Depending on the cleanliness of the pre-boiler water facilities. A temporary desuperheater station at the outlet of the HRSG piping will help to limit the velocities and therefore the noise generation.16 3. Safety procedures should be reviewed or developed as necessary prior to any chemical cleaning.12 3. care must be taken to insure that the provided cleaning solution pumps are sufficient to maintain drum level. THEY SHOULD BE INSPECTED AND CLEANED AS REQUIRED. 3. When the cleaning is completed. a steam blow silencer is provided due to noise constraints. Noise attenuation of the temporary steam blow piping may be required.14 3. proper lay up procedures should be followed. It is advisable to remove the steam drum mesh pads prior to commencing with a chemical cleaning which will circulate through the steam path. N/E does not endorse or recommend any particular type of chemical clean / steam blow (including thermal shock steam blows). The above information is provided for information only. The mesh pads should be reinstalled prior to commencing with steam blows.19 3. The mesh pad will act as a sieve in such a situation and would require an extensive cleaning after the chemical cleaning is accomplished. the superheaters must be filled with properly treated condensate during the cleaning. Boil out with caustic soda (NaOH) or soda ash (Na2CO3) is not recommended.21 .20 3. 3. Reference the Nooter/Eriksen lay up recommendations.18 Following cleaning.EP-13 PAGE 13 RECOMMENDED TUBESIDE CLEANING PROCEDURE 3. IF these chemicals are to be utilized. 2 Review of loads before off-loading if available. Louis.0 Pre-Construction Meeting 1. During the first visit. The Erection Procedure Manual will be furnished to the Purchaser and the Erector prior to this meeting. Observe transporting and setting operations.4 Observe off-loading operations.NOOTER/ERIKSEN PAGE 1 RECOMMENDED JOBSITE VISITS REVISION 2 ERECTION PROCEDURE DOCUMENT FIELD SERVICE SITE VISITS 1.5 2. 2.0 Recommended First Site Visit 2. check packing lists.3.4 2. 2. Must be attended by: Purchaser Erector N/E Personnel 1. the following items will be reviewed. Visit is to coincide with the arrival and setting of the major components or modules. Check for rail damage.3 Erection Procedure Manual Documentation reviewed.1 1. check for missing equipment.3 2. Erection presentation made on project HRSG.0 Recommended Second Site Visit APPROVED BY: TSP X:\PROCEDURES/ERECTION.R2 . 2.2 Meeting to be held at Nooter/Eriksen’s office in St. 2. etc….6 3.1 Verify that the Erector has checked the foundation per EP-01 and has records to document the inspection. Review the material handling/storage procedures of the Erector as defined in the Erection Procedures.3.2 Estimated time of visit: 5-10 days.MANUAL\FIELDSERV. Confirm that the proper handling and erection procedure is being used and provide comments.1 2. 1. 4.3. 3. X:\PROCEDURES/ERECTION.5 Observe the installation of the field seams and piping.2 Verify by visual examination the washer and anchor bolt installation.0 Recommended Third Site Visit: 4. 4.1 3. 3.3.NOOTER/ERIKSEN PAGE 2 RECOMMENDED JOBSITE VISITS REVISION 2 3.3.1 Module setting. 3. SCR System.3 Check material storage.2 Review piping installation and hangers/supports.3. etc. During this visit.MANUAL\FIELDSERV.3. Walk through after substantial completion of the system. instrumentation and small bore piping and supports.1 Review the field seam installation both internal and external to the system.3 Review installation of trim piping.3.R2 .3. if applicable. 4.1 4. 3.4 Review the field seam and piping installation with the people who will supervise this work in the field.2 4. 4.3..2 3.4 Review the installation of the Duct Burner. the following items shall be reviewed. Check the documentation of the Erector to make sure that the modules are in the correct location. During this visit the following items should be reviewed. 3.3 Estimated time of visit: 3-5 days.3. 4.3 Estimated time of visit: 3-5 days Visit is to coincide with the installation of the field seams and piping. reserves the right to have any and all corrective work supervised by a Nooter/Eriksen representative and/or performed by a Nooter/Eriksen designated contractor. Construction Manager. 6. If field trim has been removed from piping on this project. 5. 7.) establishing that a deviation from Nooter/Eriksen’s design exists. 8. All backcharges or extra work claims against Nooter/Eriksen must be made on the attached Field Change Order (FCO) form with accompanying appropriate documentation (Photographs. Nooter/Eriksen. Inc. 4. Sketches. Nooter/Eriksen will not be responsible for pipe spool-to-spool alignment or termination points that differ less than 3” in any direction from theoretical locations. an approved FCO will be returned to the Erector. If Nooter/Eriksen agrees to have corrective work done on a time and material basis. If the issue causes extra costs. a Field Change Order will also be required. Inc. 3. and labor time tickets. materials. If Nooter/Eriksen. will not authorize work without having a completed. 2. etc. and agreed upon.POLICY. For any field concerns or problems. Nooter/Eriksen. agrees to have the Erector perform any work. all claims for payment must be documented with receipts and vouchers for equipment. that the Erector claims are Nooter/Eriksen’s responsibility. reasonable estimate of manhours and cost filled in. APPROVED BY: PJH X:\Procedures\Erection. Nooter/Eriksen should be initially notified using the attached Field Issue Report.NOOTER/ERIKSEN PAGE 1 EXTRA WORK BACKCHARGE POLICY REVISION 0 ERECTION PROCEDURE DOCUMENT 1. Erector. All labor rates will be quoted in advance and specified in the Purchase Order. No claims will be honored for work done without this approval from Nooter/Eriksen. Inc.Manual\BC. and/or Purchaser mark-ups on backcharges will not be accepted by Nooter/Eriksen unless clearly established by the original job Purchase Contract.R3 . CUSTOMER REF.FIELD ISSUE REPORT PROJECT NAME: N/E JOB #: FROM: TO: CC: N/E FIELD ISSUE REPORT NO. REF. NO. ISSUE CODE: (N/E use only) JOB SITE FILE COMPONENT TYPE: (N/E use only) PROBLEM CATEGORY: (N/E use only) DESCRIPTION OF PROBLEM: ORIGINATOR: REQUESTED RESPONSE DATE: RESOLUTION OF PROBLEM: DATE: (ORIGINATOR SHOULD PROVIDE SUGGESTED RESOLUTION) ACTION CATEGORY: ACCEPT AS IS RESOLVED DATE: APPROVED BY: PJH X:\Procedures\Erection Manual\Field Issue Report. DWG. NO. DATE OF ISSUE: UNIT NO.R3doc REWORK IN FIELD SUPPLY MATERIAL RESOLVED BY: RETURN FOR REPAIR . HRS. NAME/LOC: FIR # FCO # WRITTEN UNIT # REFERENCE DRAWING NO.FIELD CHANGE ORDER CONTRACT # JOB # SUBMITTAL DATE: VERBAL VENDOR: DESCRIPTION OF PROBLEM: PROJ. SKETCH ATTACHED (YES/NO) CIRCLE ONE SUBTOTAL MANHOURS MAT'L REQ'D: EQUIP. REQ'D: SUBC. FINAL HRS.(S): POSSIBLE PROBLEM CAUSE: DESCRIPTION OF SOLUTION (ATTACH ADDITIONAL PAGES IF REQUIRED) CRAFT EST. REQ'D: HRS ESTIMATED TOTAL LABOR COST $ TOTAL MATERIAL $ TOTAL EQUIPMENT $ TOTAL SUBCONTRACT $ $ HRS FINAL $ $ $ $ $ TITLE: DATE: CLAIM SUBMITTED BY: N/E AUTHORIZATION TO PROCEED: FINAL COST: APPROVED BY: DATE: N/E CONTRACT PRICE: WARRANTY CATEGORY: FORM PROJ. 2 9/3/02 (APPROVED BY: RKG ) REJECTED BY: DATE: REASON: .008 REV. 3. it will be necessary to repair the gasket surface by weld repair and remachining under the direction of your ASME National Board Inspector.2 Proper gasketing. tighten the nuts (1) flat at a time going back and forth diagonally from nut to nut. To accomplish this. Bring the cover and gasket in contact with the manway ring. Do not flex.R5 . All covers and rings must be inspected for pits or grooves on the sealing surfaces. Both of the surfaces must be cleaned thoroughly with caution. A method must be used that does not flatten out the required machined roughness. following the pattern as shown below for (6) stud manways. Center the gasket on the manway cover. Install the studs in the plates or yokes and finger tighten to allow the manway cover and gasket to stay in place.1 Open the manway and clean the old gasket from the cover and manway ring.3. bend or deform the gasket in any way before installation. until all of the bolting is tightened to 10% of the final torque value Continue tightening the bolting following the recommended sequence (1) flat at a time until all bolting is tightened to 25% of the final torque value. This could damage the gasket and compromise its structural integrity. and 18" (457 mm) x 24" (610 mm) being the most common sizes.doc . 14" (356 mm) x 18" (457 mm). is required to install the cover. Following the same method tighten the APPROVED BY: WJP X:\Procedures\Erection Manual\Excerpt from O&M Manual. If the manway covers.0 Drum Manway Cover Usage and Gasketing All elliptical manway covers follow the same general requirements with 12" (305 mm) x 16" (406 mm). New covers must be inspected for surface imperfections. then they must be replaced. nuts and washers are clean and well lubricated with nickel anti-seize compound to achieve the proper bolt load. to allow the proper alignment when bringing the cover and gasket in contact with the ring. even compressive forces must be exerted on the gasket. as defined in Table 3. or alternating back and forth for stud and yoke type manways.EXCERPT TAKEN FROM O&M MANUAL 3. Gasket surfaces are to be finished to 125-250 RMS. rings and plates cannot be repaired. To provide an effective seal. Make sure the studs. 3. If pits greater than 1/32” (0. twist. Davits should be adjusted as necessary.2 and 3.8mm) deep exist. the seal will be effective. It is to be noted that a "leak".R5 . Finally tighten all bolting to 100% of the final torque value following the same method. A slow drip is acceptable on a cold boiler for this sequence.7mm) SHOULD NOT BE USED. additional tightening may be required due to the heating/pressurization. to assure that the required torque values have been maintained.. if necessary. CAUTION: TIGHTENING OF MANWAY BOLTS WHILE THE UNIT IS UNDER PRESSURE SHOULD BE DONE FROM THE SIDE OF THE MANWAY AS A SAFETY PRECAUTION. 1 2 DR-27V DR-26V CAUTION: HEAVY DUTY IMPACT WRENCHES WITH DRIVES GREATER THAN 1/2" (12. as referenced here. however. APPROVED BY: WJP X:\Procedures\Erection Manual\Excerpt from O&M Manual. is running water. retighten the bolts to the values noted in Table 3. the internal pressure will force the cover against the gasket and. If the boiler is shut down and allowed to cool.3 You may start to pressurize the boiler at this point. if properly installed. use the tightening procedure described above) until the leaking stops. When the unit is up to pressure and temperature.doc . If the gaskets leak. Torque wrenches should be calibrated and in good working order. 3.1.e. NEVER TIGHTEN ADJACENT NUTS IN SEQUENCE. IT IS IMPERATIVE THAT THE NUTS BE TIGHTENED ONE (1) FLAT AT A TIME PER NUT ON A ROTATIONAL BASIS WHEREBY NUTS ARE TIGHTENED SEQUENTIALLY ACROSS DIAGONALS. As the boiler is heated. tighten each nut one (1) flat at a time alternating between the nuts (i.bolting to 50% of the final torque value and then 75% of the final torque value. it is important to again check the torque on the nuts before repressurizing. 6250.68) LESS THAN 100 (< 7) APPROVED BY: WJP X:\Procedures\Erection Manual\Excerpt from O&M Manual. 1/8” (3mm) THICK X 1” (25mm) WIDE REINFORCED FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRESSURE SENSITIVE ADHESIVE ON ONE SIDE THERMO-SURE TACKY CLOTH No.82) 100 TO 1000 (7 .1 Required Torque Values for Manway Bolts 12" x 16" (305mm x 406mm) Type of Cover Torque DR-26V 260 ft-lb (353 N-m) DR-27V 170 fl-lb (230 N-m) Lenape Type "H" 150 ft-lb (203 N-m) Lenape Type "N" 100 ft-lb (136 N-m) 14" x 18" (356mm x 457mm) Type of Cover Torque DR-26V 260 ft-lb (353 N-m) DR-27V 170 fl-lb (230 N-m) Lenape Type "S" 150 ft-lb (203 N-m) 18" x 24" (457mm x 610mm) Type of Cover Torque DR-26V 260 ft-lb (353 N-m) DR-27V 260 ft-lb (353 N-m) Lenape Type "S" 150 ft-lb (203 N-m) Table 3.2 Gaskets for 12" x 16" (305 mm x 406 mm) Manways (unless otherwise specified) TYPE OF COVER DR-26V OR DR-27V DR-27V Lenape Type “H” OR DR-27V Lenape Type “N” OR DR-27V GASKET TYPE 1” WIDE CHESTERTON/SELCO “STEEL TRAP” 304SS/GRAPHITE MANWAY GASKET WITH PRESSURE SENSITIVE ADHESIVE ON ONE SIDE.PSIG PRESSURE (BARG) 1200 + (83 +) 1001 TO 1199 (69 .doc .Table 3. 3/16” (5mm) NOMINAL THICK X 1” (25mm) WIDE PRESSURE .R5 . R5 .4 Gaskets for 18" x 24" (457 mm x 610 mm) Manways (unless otherwise specified) TYPE OF COVER DR-26V OR DR-27V DR-27V Lenape Type “S” Not Machined OR DR-27V GASKET TYPE 1” WIDE CHESTERTON/SELCO “STEEL TRAP” 304SS/GRAPHITE MANWAY GASKET WITH PRESSURE SENSITIVE ADHESIVE ON ONE SIDE.20) LESS THAN 100 (< 7) Table 3. 6250.doc . 1/8” (3mm) THICK X 1” (25mm) WIDE REINFORCED FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRESSURE SENSITIVE ADHESIVE ON ONE SIDE THERMO-SURE TACKY CLOTH No.Table 3.3 Gaskets for 14" x 18" (356 mm x 457 mm) Manways (unless otherwise specified) TYPE OF COVER DR-26V OR DR-27V DR-27V Lenape Type “S” OR DR-27V Lenape Type “S” Not Machined OR DR-27V GASKET TYPE 1” WIDE CHESTERTON/SELCO “STEEL TRAP” 304SS/GRAPHITE MANWAY GASKET WITH PRESSURE SENSITIVE ADHESIVE ON ONE SIDE.82) 100 TO 300 (7 . 1/8” (3mm) THICK X 1” (25mm) WIDE REINFORCED FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRESSURE SENSITIVE ADHESIVE ON ONE SIDE PRESSURE (PSI) PRESSURE (BARG) 1200 + (83 +) 201 TO 1199 (15 .82) LESS THAN 200 (14) APPROVED BY: WJP X:\Procedures\Erection Manual\Excerpt from O&M Manual. 3/16” (5mm) NOMINAL THICK X 1” (25mm) WIDE PRESSURE (PSI) PRESSURE (BARG) 1200 + (83 +) 301 TO 1199 (21 .