method statement for fabrication and erection of demineralized water tanks

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PROJECT: CC-CHP Licherfelde Project Document Number: Document Title: Page: 1 of 12 Method Statement for Fabrication and Erection of Demineralized Water Tanks Rev.: 0 Date: 17.11.2014 Method Statement for Fabrication and Erection of Demineralized Water Tanks CC-CHP LICHTERFELDE COMBINED CYCLE POWER PLANT - BERLIN A1GHC DEMINERALIZED WATER TANKS 1&2 0 17.11.2014 Radakovic Z. Rev.: Description: Date: Prepared by: Aproved by: Verified by: Verified by client:

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Method statement for erection of tanks

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  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 1 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    Method Statement for Fabrication and Erection of Demineralized Water Tanks

    CC-CHP LICHTERFELDECOMBINED CYCLE POWER PLANT - BERLINA1GHC DEMINERALIZED WATER TANKS 1&2

    0 17.11.2014 Radakovic Z.Rev.: Description: Date: Prepared by: Aproved by: Verified by: Verified by

    client:

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 2 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    INDEX

    1. PURPOSE

    2. SCOPE

    3. REFERENCES

    4. DEFINITIONS / ABBREVIATIONS

    5. RESPONSIBILITIES

    6. PROCEDURE

    7. TESTING

    8. PAINTING

    9. DOCUMENTATION

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 3 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    1.0 PURPOSE

    The purpose of this Method Statement is to define the general sequence of events, interfaces and responsibilities relating to Fabrication and Erection works of De-mineralized water tank, in order to meet the project specification, reference codes and standards.

    2.0 SCOPE

    This Method Statement describes the methods of identifying and executing the total fabrication, erection, Inspection and Testing activities to enhance Safety, Quality, and compliance to Project Specification.

    3.0 REFERENCES

    Codes, Standards & Specifications Spec No.: Description 1A5Y-A1-GHC-DP-MET-0001 Demineralized Water Tank 1 Tank General Arrangement 1A5Y-A1-GHC-DP-MET-0002 Demineralized Water Tank 2 Tank General Arrangement 1A5Y-A1-GHC-DP-MET-0003 Bottom Plates 1A5Y-A1-GHC-DP-MET-0004 Tank Shell 1A5Y-A1-GHC-DP-MET-0005 Roof 1A5Y-A1-GHC-DP-MET-0006 Roof Walkway - Demineralized Water Tank 1 1A5Y-A1-GHC-DP-MET-0007 Roof Walkway - Demineralized Water Tank 2 1A5Y-A1-GHC-DP-MET-0008 Caged Ladder 1A5Y-A1-GHC-DP-MET-0009 Nozzle For Outlet To Mix Bed Exchanger N1 1A5Y-A1-GHC-DP-MET-0010 Manhole N2 1A5Y-A1-GHC-DP-MET-0011 Manhole N2 - Details 1A5Y-A1-GHC-DP-MET-0012 Nozzle For Outlet To Demi Water Pumps N3 1A5Y-A1-GHC-DP-MET-0013 Nozzle For Demi Water Return N4 1A5Y-A1-GHC-DP-MET-0014 Nozzle For Level Indicator N5 1A5Y-A1-GHC-DP-MET-0015 Manhole N6 1A5Y-A1-GHC-DP-MET-0016 Nozzle For Level Indicator N7 1A5Y-A1-GHC-DP-MET-0017 Nozzle For Level Indicator N8 1A5Y-A1-GHC-DP-MET-0018 Nozzles For CO2 Filter And Emergency Venting N9 1A5Y-A1-GHC-DP-MET-0019 Nozzle For Demi Water Inlet N10 1A5Y-A1-GHC-DP-MET-0020 Nozzle For Overflow N11 1A5Y-A1-GHC-DP-MET-0021 Nozzle For Drain N12 1A5Y-A1-GHC-DP-MET-0022 Reserve Nozzle N16 1A5Y-A1-GHC-DP-MET-0023 Reserve Nozzle N17 1A5Y-A1-GHC-DP-MET-0024 Earthing Lug 1A5Y-A1-GHC-DP-MET-0025 Nameplate

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 4 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    1A5Y-A1-GHC-DP-MET-0026 Design Documentation 1A5Y-A1-GHC-DP-MET-0027 Operation and Maintance Manual 1A5Y-A1-GHC-DP-MET-0028 Instruction for Inspection and Testing EN 14015:2004 Specification for the desige and manufacture of site built,

    vertical, cylindrical. Flat-bottomed, above ground, welded, steel tanks for the storage of liquidsat ambiente temperature and above.

    4.0 DEFINITIONS / ABBREVIATIONS

    Client - VATTENFALL EUROPE WRMEContractor - IBERDROLA INGENIERIA Y CONSTRUCCIONManufacturer - MONTAVAR METALNA LOLA Belgrade, SerbiaAFC - Approved for ConstructionHSE - Health, Safety and EnvironmentPPE - Personal Protective EquipmentNDE - Non-Destructive ExaminationRT - Radiographic TestUT - Ultrasonic TestingMT - Magnetic particle TestingPT - Penetrating TestingPWHT - Post Weld Heat TreatmentWPS - Welding Procedure SpecificationRF Pad - Reinforcement Pad

    5.0 RESPONSIBILITIES

    5.1 Construction Supervisor shall be responsible for the implementation of this procedure who shall pass on instructions down the line to maintain the required quality level at each stage of construction.

    5.2 Mechanical Foremen shall be responsible for the execution of correct working techniques with strict adherence to this method statement and reference documents.

    5.3 Site Superintendents / Foremen shall be directly responsible for the Quality produced by the workers under them. They shall confirm that latest drawings, specifications, grades of

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 5 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    materials, correct tools etc are used. They shall also guide the workers in the interpretation of drawings/documents so that the work is carried out in correct sequential manner, meeting the various in process inspection activities.

    5.4 The Foremen shall be responsible for deploying qualified welders. They shall also be responsible for ensuring that the welders withdraw electrodes as per WPS and that they work within the welding parameters of approved WPS.

    5.5 QC Inspectors / Welding Inspectors shall be responsible for carrying out the in process Inspection of fabrication, arrangement for NDT and relevant tests as per ITPs. They shall also be responsible for maintaining the documentation & records of inspection.

    6.0 PROCEDURE

    6.1 Quality Control

    The QC Inspector shall:

    Confirm that the approved procedure is being followed. Confirm that documents / drawings (latest revisions) are used for fabrication. Confirm the use of correct materials as per specifications, construction drawing & WPS. Confirm Baking / Holding ovens And Welding machines have valid calibrations certificates. Confirm that the welding is carried out using windshield cover during dusty and windy

    periods, which would affect the quality of welds. Confirm that the welders are qualified to relevant WPS. Confirm that all NDT and Inspection points are carried out.

    6.2 Safety

    6.2.1 All equipments and accessories shall be verified and of adequate capacity according to HSE requirements.

    6.2.2 All personnel involved in fabrication / erection works shall be informed of hazards and will adopt preventive measure while using said substances.

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 6 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    6.2.3 All electrical equipments shall be properly earthed.

    6.2.4 All the welders must use their safety equipments such as welder helmets, hand gloves and personal protective equipments.

    6.2.5 All necessary safety precautions to be followed while carrying out NDTs such as RT, PT, MT, and UT as mentioned in the relevant procedures.

    6.3 Sequence of Operation

    6.3.1 Receipt of Material and Storage

    All related materials, which are received, shall be stored in the lay down area. They shall be stacked properly without touching the ground, placed on wooden rafters. Care shall be taken to stack materials properly segregated.Special precautions must be taken to minimize the risk of damage to the corrosion resistance properties of stainless steel. Stainless steel shall be handled so as to minimize contact with iron or other types of steel during all phases of fabrication and construction.

    6.3.2 Receipt Inspection of Materials

    On receipt of materials, Mechanical Supervisor / Foremen shall check the material class, size schedule and heat nos. discrepancies shall be reported to QA/QC department. Due to Instructions shall be given to workers to transfer all necessary information before using for construction.

    6.3.3 Edge Preparation

    Weld edge preparation shall be made as per joint design given in drawing / WPS. All paint, rust, grease etc. shall be cleaned for a distance of 25mm from the weld edge from inside and outside of the welding components.

    6.4.4 Brief Description of Detailed Work

    The tanks are made of flat bottom, cylindrical shell, cone roof, nozzles and accessories.

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 7 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    The tank has been supplied in rolled plates to be assembly and welded on site as following descriptions:

    a) For the erection set up please refer to the attached drawings.

    b) The bottom will be supplied in plates to be position and fit upped on the tank foundation using a suitable crane . Lifting holder will be welded on each plate to be use for the lifting in to final positioning of the same. After the position the fit up will start and as soon completed welding has to be perform.

    c) The plates will be positioned on a leveled concrete foundation where the circumference of the shell plates (fabricated shell plates) has been identified by guide plates tack welded on the bottom. As soon all the plates composing the shell plates are on position a plate fit up will be execute. In order to avoid the bending of the plates along the welding area, steel devices will be fixed and the bending will be controlled and adjusted during the welding with pins. Completed the welding the devices will be removed and the used tack welding will be cleaned with grinder. Time by time the shell plates will be supported by profiles in order to avoid any collapsing and any misalignment. To erect the tank shell scaffolding will be erected. The above operation will be repeated three times in order to complete the tank shell.

    d) The welding of the shell to the bottom shall be practically completed before the welding of bottom joints that may have been left open to compensate for shrinkage of any welds previously made is completed.

    Shell plates may be aligned by metal clips attached to the bottom plates, and the shell may be tack welded to the bottom before continuous welding is started between the bottom edge of the plate and the bottom plates.

    e) Secondly, Tank roof shall be assembled as follow:

    Tracing, positioning and welding of the roof plate on the shell; Erection of roof supports scaffolding on the tank middle; Dismounting of the support scaffolding.

    Erection of the service platforms and ladder will be performed using a suitable crane.The platform and ladder anchor plates will be welded on the tank shell. After this operation the erection activities will start.

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 8 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    f) The three shell including tank roof should be lifted with suitable capacity crane.Second shell is now aligned and welded (all welds) to the bottom side of third shell according to drawing. Similarly, all the shell plates are erected (second, first) accordance with the drawing.

    g) Welding shall be done between bottom shell and bottom annular plates (fillet welded) from both sides.

    The initial weld pass inside the shell shall have all slag and non-metals removed from the surface of the weld and then examined for its entire circumference prior to welding the first pass outside the shell. (temporary weld fit up tacks excepted), both visually and by any one of the following methods to be agreed to by purchaser and manufacturer;a. Magnetic particle.b. Applying a solvent liquid penetrant to the weld and then applying a developer to the

    gap between the shell and the bottom and examining for leaks after s minimum dwell time of one hour.

    c. Applying a water-soluble liquid penetrant to either side of the joint and then applying a developer to the other side of the joint and examining for leaks after a minimum dwell time of one hour

    6.3.5 Fit up of Assembly

    Before fit up, the components and fittings shall be visually checked for inside cleanliness.The fit up shall be carried out as per the requirements of WPS & drawing. Fit up shall be carried out by using bridge tacking within the grooves using a qualified welder. Arc shall be stuck inside the groove and not on the inside or outside surfaces of shell plates.

    6.3.6 Inspection of Assembly

    Inspection of fit up assemblies including dimensional check shall be carried out prior to release for welding.

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 9 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    6.3.7 Welding Joints

    All welding procedures and welder qualifications shall be according with EN 15614-1

    Requirements of the WPS, specification of piping and HSE practices shall be followed. Weld joint number shall be written near the joint by solid paint marker. Only qualified welders shall be used for Tacking & Welding. All temporary Tacks/ bridge shall be removed one by one (by grinding) as the welding progresses. Continuous welds shall be used for all horizontal top side joints and for vertical joints. Horizontal bottom-side joints shall be seal-welded if specified by the purchaser. Seal welding should be considered to minimize the potential for entrapped moisture, which may cause corrosion.

    Full penetration butt-welds shall be used for joining ring section. Tanks and their structural attachments shall be welded by the shielded metal arc, gas metal-arc, gas tungsten-arc or flux-cored arc Process using suitable equipment. All tank welding shall be performed in accordance with the requirements of related drawings and welding procedure specifications. Welding shall be performed in a manner that ensures complete fusion with the base metal. Each layer of weld metal or multi layer welding shall be cleaned of slag and other deposits before the next level is applied.

    The edges of all welds shall merge with the surface of the plate without a sharp angle. For vertical butt joints, the maximum acceptable under cutting is 0.4mm of the base metal. For horizontal butt joints, undercutting not exceeding 0.8mm in depth is acceptable.During the operation, plates shall be held in close contact at all lap joints.

    Note:o Break all sharp edges, remove all burrs, and spatterso Base plate fillet welds shall be continuouso All Nozzle above 2 NB shall be provided with reinforcement pads and all RF pads shall be

    provided with M6 Tap hole.o All structural attachments to Tank or roof shall be continuous seal weldedo Nozzle pipe shall be seamless.

    6.3.8 Visual Inspection of Joints Before, During and after Welding

    QC / Welding Inspectors shall perform in-process visual inspection before, during and after completion of welding of the joints.

    The identification tag will be tied up or marked on each welded joints.

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 10 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    A weld shall be acceptable by visual inspection if the inspection shows the following:

    a) There are no other cracks, other surface cracks or arc strikes in or adjacent to the welded Joints.

    b) Under cutting does not exceed the limits given for vertical and horizontal butt joints. For welds that attach nozzles, manholes, cleanout openings, and permanent attachments, under cutting shall not exceed 0.4mm.

    c) The frequency of surface porosity in the weld does not exceed one cluster (one or more pores) in any 100mm of length, and the diameter of each cluster does not exceed 2.5mm.

    6.3.9 Identification of Joints and execution of NDE

    The QC / Welding Inspector shall identify the joints to be offered fort NDE as per requirement & the applicable piping specifications.As welding progresses, control shall be taken as soon as it is practicable. The contractors inspector may determine the location where the control are to be taken.

    o QC Inspector shall organize for NDE as per the requirements . HE shall also organize for NDTs repairs. The QC inspector shall be responsible for interpretation and reporting of NDEs and also for coordination of NDE with Contractors representatives.

    o The initial weld pass inside the shell shall have all slag and non-metals removed from the surface of the weld and then examined for its entire circumference prior to welding the first weld pass outside the shell (temporary weld fit-up tacks excepted), both visually and by the following method to be agreed to by purchaser and manufacturer.

    a. Liquid Dye penetrant

    All defects found in welds shall be called to the attention of the contractors inspector, and the inspectors approval shall be obtained before the defects are repaired. All completed repairs shall e subject to the approval of the contractors inspector.

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 11 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    7.0 TESTING

    Following checks to be carried out agter completion of all Fabrication and Erection works.

    Out of roundness Peaking Check Verticality / Plum Check Radius of the Bottom Orientation of the Nozzles with Tank

    Examination and Testing of the Tank Bottom

    Upon completion of welding of the tank bottom, the bottom welds and plates shall be examined visually for any potential defects and leaks. Particular attention shall apply to areas such as sumps, dents, gouges, three-plate laps, bottom plate breakdowns. Arc strikes, temporary attachments removal areas, and welding lead arc burns. Visual examination acceptance and repair criteria are specified in 6.5. In addition, all welds shall be tested by the penetrant test. (Or MT)

    Hydro testing

    After the entire tank is completed but before any permanent external piping is connected to the tank, the shell (except for the shell of tanks designed in accordance with accordance Appendix F) shall be tested by one of the following methods

    a. If water is available for testing, the tank shall be filled with water as follows:(1) To the maximum design liquid level, H;(2) For a tank with a tight roof , to 50mm (2in.) above the weld connecting the roof plate or compression bar to the top angle or shell; or(3) To a level lower than that specific in sub item one or two when restricted by over flows, an internal floating roof, or other freeboard by agreement between the purchaser and manufacturer. The tank shall be inspected frequently during the filling operation, and any welded joints above the test-water level shall be examined in accordance with item b.b. If sufficient water to fill the tank is not available, the tank may be tested by (1) painting all of the joints on the inside with highly penetrating oil, such as auto mobile spring oil, and carefully examining the outside of the joints for leakage;

  • PROJECT:CC-CHP Licherfelde Project

    Document Number: Document Title: Page: 12 of 12Method Statement for

    Fabrication and Erection of Demineralized Water Tanks

    Rev.: 0Date: 17.11.2014

    (2)Applying vacuum to either side of the joints or applying internal air pressure as specified for the roof test in 5.3.6 and carefully examining the joints for leakage; or (3) using any combination of the methods stipulated in 5.3.5.b sub items 1 and 2.

    8.0 Painting

    Painting specification 1A5Y-A1-GHC-IP-MET-0026 Internal Painting system : Painting system S-3 External Painting system : Painting system S-S Stairs and Railing should be galvanized or used Painting system S-S

    If blast cleaning is necessary, it shall be done with sharp acicular grains of sand or grit containing not more than 2% by weight iron as free iron or iron oxide. Steel shot or sand used previously to clean non-stainless steel is not permitted

    Control of Non-conforming Product

    During construction activities, care shall be taken to produce any non-conforming product.

    9.0 DOCUMENTATION

    Following documents should be prepared as minimum

    o Daily Weld Inspection Reporto Painting Inspection Reporto Alignment and Verticality Check Reporto Non-Destructive Examination Report

    10.0 Attachments

    1. Inspection Test Plan2. Risk Assessment

  • DETAJL BDetail B

    ( 1 : 10 )

    PREREZ C-CSection C-C

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    B

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    C

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    Dimenzije: KD t.:

    t. sestavne risbe:

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    Koliina: Rev.:

    kommm

    WATER TANKS

    100m3

    Phase I

    IBERDROLA

    0

    12

    50100

    50

    20

    5

    n5000n5012

    50

    7

    5

    1. Check measure protocol of concrete fundament.2. Alignment of bottom plates.3. Welding of bottom plates. Use temporary connection plates to prevent distortion.4. Control of welding.5. Mark on flat bottom plate position of first cylindrical shell. 6. Put around marking line plates for temporary fixing first cylindrical shell.

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    Phase II

    IBERDROLA

    1. Put first plate of first cylindrical shell on bottom plate.2. Temporary fix plate with L profiles.

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    100m3

    Phase III

    IBERDROLA

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    Phase 4

    IBERDROLA

    1. Weld vertical welds between first and second plate.2. Weld vertical weld between second and third plate.3. Control dimension and straightness.4. Measure perimeter, and cut over length.5. Weld last vertical weld on first layer.6. Put temporary plates for connection first layer and plates of next layer.

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    Phase V

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    WATER TANK

    100m3

    Phase VI

    IBERDROLA

    A

    1. Put all plates in second layer.2. Weld vertical weld between first and second and third plates in second layer.3. Make control and final measurement of perimeter.4. Cut over length on third plate.5. Weld last vertical weld. on second layer.

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    Phase VII

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    100m3

    Phase VIII

    IBERDROLA

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    Phase 9

    IBERDROLA

    After welding both radial welds between layers, weld radial weld between first layer and bottom plate.

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    Material:

    Signacija/Poz.:

    Koliina: Rev.:

    kommm

    WATER TANK

    100m3

    Phase X

    IBERDROLA

  • DETAJL ADetail A

    ( 1 : 5 )

    Rev.

    Polizdelek:

    Dimenzije: KD t.:

    t. sestavne risbe:

    Material:

    Signacija/Poz.:

    Koliina: Rev.:

    kommm

    WATER TANK

    100m3

    Phase 11

    IBERDROLA

    A