va1 lsc 00100 qa m8 tpd 0006 (steel structure fabrication procedure) rev.1

DOCUMENT SUBMISSION STATUS: FC

1 30/03/11 ISSUED FOR CONSTRUCTION T.V.CUONG D.V.HIEU P.N.QUANG 0 11/03/11 ISSUED FOR CONSTRUCTION T.V.CUONG D.V.HIEU N.H.QUAN E 26/01/11 ISSUED FOR APPROVAL T.V.CUONG N.V.BIEN P.N.QUANG D 10/01/11 ISSUED FOR APPROVAL C 18/11/10 ISSUED FOR APPROVAL B 29/10/10 ISSUED FOR APPROVAL

REV DATE DESCRIPTION PREP. CHKD APPN

OWNER

OWNERS CONSULTANT

EPC CONTRACTOR

EPC CONTRACTORS CONSULTANT

PROJECT TITLE

VUNG ANG 1 THERMAL POWER PLANT 2 x 600MW PACKAGE: M8

CONTRACT No. 222010/ LILAMA-LISEMCO

DRAWING TITLE:

steel structure FABRICATION PROCEDURE

SUB-CONTRACTOR

HAIPHONG EQUIPMENT MANUFACTURE AND SHIPBUILDING CO.LTD, (LISEMCO)

FUNCTION NAME SIGN DATE

PREPARED TO VIET CUONG 30/03/11

CHECKED DAM VAN HIEU 30/03/11

APPROVED PHAM NGOC QUANG 30/03/11

DOCUMENT No.VA1-LSC-00100-QA-M8-TPD-0006

SCALE REV. 1

POYRY ENERGY LTD VIETNAM OIL AND GAS GROUP (PVN)

VIETNAM MACHINERY INSTALLATION CORPORATION (LILAMA)

Hai phong equipment manufacture and shipbuilding company limited

Vung Ang 1 Thermal Power Plant

Ky Loi commune, Ky Anh district, Ha Tinh province

ITEM: COAL HANDLING SYSTEM M8

Mar. 30th, 2011

Rev: 1

Code: VA1-LSC-00100-QA-M8-TPD-0006

Page: 1/19

Steel structure Fabrication Procedure


project Vung Ang1 Thermal Power Plant Item COAL HANDLING SYSTEM M8 location Ky Loi commune - Ky Anh District-Ha Tinh province





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Index

No Title Page

1 Chapter 1: General Introduction. 2

2 Chapter 2: Fabrication procedure. 5

3 Chapter 3: Fabrication method. 6

Chapter 1: General Introduction I. General Introduction

1. Executing Organization Chart (As shown in page 4).

Hai phong Equipment Manufacture and Shipbuilding CO., LTD

a. Responsibilities and rights

Hai Phong Equipment Manufacture and Shipbuilding CO., LTD is a member

company belonging to Vietnam Machinery Installation Corporation (LILAMA).

With its big site plan (8ha), modern equipment, and the teams of experienced

engineer and equipped with knowledge and new executing technologies, a large

number of workers as well as skillful workers, Hai phong Equipment

Manufacture and Shipbuilding CO., LTD is responsible for providing materials

and installation of equipment for Vung Ang 1 thermal power plant 2x600 MW-

Coal handling plant M-lot 2

All steel structure will be fabricated in factory of Lisemco in Hai Phong to

ensure quality, error and convenience for installation process of steel structure.

The whole process of structural steel fabrication, company will carry out by

itself equipment and staff member.





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b. The director of project

Full name: Nguyen Hong Quan

Position: Project Director

Tel : 031-3522496

Fax : 031-3850120.

E-mail : [email protected]

2. Inspection unit- quality control

Inspection unit quality control belonging to quality control Department which

is an independent organization with in manufacturing units operating under the

leaderships of the parent company, is responsible for quality control, checking to

ensure the steps of manufacturing technology and installation implemented

seriously for quality assurance of construction.





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ORGANIZATION CHART FOR LOT-M8VUNG ANG 1.THERMALPOWER PLANT PROJECT

LILAMA PMB

PROJECT MANAGERMr.NGUYEN HONG QUAN

E-mail: [email protected]@vnn.vn

DEPUTY PROJECT MANAGER& SITE MANAGERMr. PHAM NGOC QUANG

E-mail: [email protected]

PROJECT COORDINATORMr. TO VIET CUONGMobi: 01696815187

E-mail: [email protected]

QC/QA PRJ. MANAGEMENTMr. NGUYEN QUANG VINH

SAFETY&SE MANAGEMENTMr. PHAM VAN TUYEN

Mobi: 0934692591E-mail: [email protected]

MANUFACTURING MANAGERMr. NGUYEN VAN BIEN

Mobi: 0989126635E-mail: [email protected]

LISEMCO ltd,.GENERAL DIRECTOR

Mr. TRAN VIET KHANHEmail: [email protected]

Date of isuue: Otc 12th, 2010

MECHANIC AND WELDER TEAM - 25

WORK-SHOP No1Mr NGUYEN VAN DOANH

WORK-SHOP No2Mr. NGUYEN VAN HUNG

MECHANIC AND WELDER TEAM - 25

PAINTING PACKING & SHIPPMENT

Mr.DOANVAN HA

PAINTINGTEAM-01

PEOPLE 12

WORK SHOP SUPERVISORENGINEERS

OFFICE MANAGERMs.TRUONG THI HUONGMs.HO THI KHANH HOA

QC/QA PRJ. MANAGERMr. VU VAN QUANGMr MAI HUY CUONGMr.VU DUC THANH

RECEIVING EQUIPMENTAND HAND MANAGER

Mr. NGUYEN DINH QUYNH

TECHNICAL MANAGEMENTMr. DO XUAN DUNGMobi: 0982592029

MATERIALS MANAGEMENTMr. BUI DUC THIETMobi: 0904828298

SAFETY&SECURITY MANAGERMr. PHAN VAN HUNGMs: NGUYEN THI LAM

STEEL STRUCTURETEAM 02PEOPLE 35

STEEL STRUCTURETEAM 02PEOPLE 35

PACKING & SHIPPMENTTEAM -01

PEOPLE 06

STEEL STRUCTURE+MECHANIC

TEAM-02PEPLE 30

ELECTRICIAN+INSULATING+

COMMISSONINGTEAM 01PEPLE 19

PAINTERTEAM - 01PEPLE 8

WELDERTEAM - 01PEPLE 15

Inspection unit- quality control has rights of suspending activities which not

comply with procedures , and has risk of bad influence on quality manufactured

products as well as installation leading bad effects on construction quality.

Inspection shall followed he details in lines with the approved ITP which are

completed by LILAMA.

AdminPolygon





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3. Reference:

- Specification of the project.

- FLS General Workshop instructions.

- Document No. VA1-LI-00100-M-G1-ITP-0002 INSPECTION AND TEST

PLAN FOR STEEL STRUCTURE SHOP FABRICATION

- Document No. VA1-LI-00100-QA-G1-ITP-0001 INSPECTION AND TEST

PLAN FOR PAINTING

- Standard: DIN.

4. Shop, fabrication teams

Fabrication teams are responsible for executing construction in accordance with

design, quality assurance and work progress and directly carry out at shop in

lisemco.

In case of unexpected problems in construction process exceeds the capacity of

fabrication units. They can request related parts supporting technology,

eqiupment, manpower. All the requirements of fabrication groups must be

presented in writen form system of Lisemco (in case the customers do not have

special requiremetns). These requirements are given Economy-Technology

Department, Lisemco. Economy-Technology Department must have answer in

writen form within 24 hours.

II. Objects, scopes and references.

1. Objects The process of structural steel fabrication is to give a manufacturing scientific

plan, strict inspection system, ensuring quality to meet the quality control system

ISO 9001 : 2000 which company Lisemco is applying, also satifies the

customers requirements about product quality and construction progress.

2. Application scope





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This process is applied to fabrication equipment and manufacturing of steel

structure.

3. References

Shop drawings, related technical documents and standards.

The technical standards are given by Owner.

4. Fabrication chart and inspection

o Content of Work

Implementation unit Inspection criteria Evaluation criteria

Inspection tools Report form

-Check inputmaterials.

-Executing technology

-Material officer. -Quality control - Supervisor party A

- Original - Number - Dimension - Visual inspection

- Certificate oManufacturer. - Accroding toorder

- Tape-measure, caliper

- No wrapping,rust, blistery.

- By visual.

- Certificates - Comparing orders

- Marking andcutting

- Workers

-Inspections - Executing technology - Quality control

- Dimension, beveledangel.

- Design drawing.

- External insepction.

- Tape-measure.

-Straightening -Detailed assembly -Inspection

- Workers -Executing technology. - Quality control.

- Dimension,straightness, welding

joint prepared. - External inspection.

- Design drawingand error.

- Welding joint checking tape-measure, control wire,

- Assembly. - Assemblyinspection

- Executing technogy - Workers

- Quality control - Supervisor party A

- Straightness, square,dimension...

-Design drawingand error

- Meter, tape for inspection of square angle.

- Welding beam,pillar, accessory.

- Welder with validcertificates.

- According to weldingprocedure system.

- Externalinspection.

-Executing technology.

-Nondestructive testing.

- Quality control. - Supervisor party A. - Subcontractor.

- Welding jointsurrounding.

- According towelding procedure.

-External inspection. - Cheking welding jointinside.

- Tecnicalrequirement o

f

construction.

- By visual, welding joint tape inspection. - Checking by ultrasonic.

- Repairingdefects. -Checking and fixing.

- Welders. - Subcontractor.

- According toinspection results.

- Accroding toquality requirement o-External inspection.

- Cheking welding jointinside.

f - By visual, checking by ultrasonic. construction.

- Grinder, welding machine.

- Sanding blast,paint.

- Manufacturing unit.

- Paintinginspection.

- Supervisor party A.

- Executing technology - Quality control.

- Surfaces preparation and paint. - Painting inspection.

- According totechnical requirement (seepainting procedure).

- Checking by visual.

- Checking by gauge for measuring thickness of paint.

III. Construction organization design.

1 -Bases on the construction design.

- Basing on technical standards of designer.

- Basing on tecnical design document of construction.





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- Basing on real condition of construction plan and construction work

quantity.

- Basing on rate canculating document for construction and construction

organization.

- Basing on material capacity, machinery, and manpower.

2 - Construction organization design.

Construction organization is very important task ensuring fast construction

process and achieved the best effect. The contractor will be responsible for this

task. They carry out the supported work like working platform, storage, yards of

materials gathered as well as products, water allocation system for construction.

The construction work quantity is mainly organized as follows:

In the shop of company

+ Fabrication of steel structure.

+ Cleaning, painting steel structure.

In the construction process, contractor is in full compliance with technical

procedures, rules and regulations of acceptance in accordance with designers

standard and owners requirement.

Basing on construction plan, the contractor carries out to clean ground, prepare

assembling platform, machinery for construction work.





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Chapter 2: Fabrication procedure

False

False

False

Assembly

False

False

Delivery for units

Inspectio Returni

Material receiving

Cutting

Repairin

Tack welding

Finish welding

blast cleaning

Inspectio Repairing

finish painting

Packing Complete payment

document

acceptance report

acceptance report

acceptance report

Inspectio Repairing

Inspectio Repairing

Inspectio Repairing

Inspectio Repairing

False

Inspectio g

False





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Chapter 3: Fabricating methods I. Check input materials of Work.

According to designers requirements, Contractor supply types of material

having clear origin, attaching material certificate.

Material inspection made as below requirement:

- Check material certificate of origin.

- Standard geometrical size: check by tape-measure, caliper

- Surface: convex, concave, void, crack, warping

- Technical characteristics of material:

- Physical-mechanical properties of steel: sampling, testing and certificating.

- Welding material properties according approved WPS & PQR.

- Components, properties of other materials.

- Control, inspection process of input materials for works following to designers

standard and the below diagram:

HaiPhong equipment Manufacture and

Shipbuilding CO., LTD

Materials

Delivering to company

material department inspection, correlation,storage

certificate of quality, quantity, weight

Gim st cng ty (QC)

check size, type of materials...

A partys supervisor inspect steel tag, typ... e of materials

Type of steel for fabrication works consist of:

1. Steel plate according to project standard, or appropriate 2. Steel shape according to project standard, or appropriate 3. Materials service for fabrication: welding material, painting material, the

other auxiliary materials





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Entire above materials strictly controlled and monitored according to materials

summary tables including detailed data. After be imported to Company, the

materials delivered to executing units for fabrication

II. Construction ground preparing. In order to service for fabrication as well as asembly all parts in Company, Company perform arrangement the construction ground at units. Assemblying platform for fabrication and inspection carefully prepared achieving standard surface. III. Products fabricating

Common fabricating steps:

Step 1: The parts shall be marked and cut according to marking and cutting dwgs

and design dwgs.

Marking and cutting according to the diagram shall be performed by assembly

group, parts marked and cut on the platform under the control, monitoring of

shop, group engineering staff, and QC of Company. The parts must be checked

the size, cleaness, beveled angle, hole welding, ... according to the Project

standard by Companys QC during marking and cutting process, when QC find

out that the parts achieving requirement, they shall be moved to the next stage.

Step 2: Assembly parts

After cutting, the parts shall be moved to assembling areas where assembling

work made by assembling group. Companys QC inspects the size, joint

clearance, tack welding, reinforced measure against deformationwhen these

achieve the Projects standard, the parts moved to the welding stage.

Before welding, structure should be inspected according to FIT-UP

INSPECTION FOR WELDING No: VA1-QCF-M-15 in document No: VA1-LI-

00100-M-GI-ITP-0002 (INSPECTION AND TEST PLAN FOR STEEL

STRUCTURE SHOP FABRICATION).





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Step 3: Welding

Welded connection executed according to welding procedure (WPS) which

Lisemco submitted to the Owner and supervisors, consultants. This procedure

performed by welders having valid certificates. Overall welding process strictly

inspected by welding QC about welding materials, the welders, quality of

welding jointsso as to restrict welding defects and avoid failures at the

beginning of the stage. All welding joints checked 100% external form

according to technical requirement of the project. The defected welding joints

shall be carried out to prepare following to repairing welding joint procedure

during inspection. .

Size of the parts inspected after finish welding ensuring to be in allowable

tolerance of the Project.

The weld should be inspection according to WELDING VISUAL RECORDS

No: VA1-QCF-M-14 in document No: VA1-LI-00100-M-GI-ITP-0002

(INSPECTION AND TEST PLAN FOR STEEL STRUCTURE SHOP

FABRICATION).

After welding, the struture should be inspection according to STEEL

STRUCTURE FABRICATION FINAL INSPECTION REPORT No: VA1-

QCF-M-013 in the document No: VA1-LI-00100-M-G1-ITP-0002

(INSPECTION AND TEST PLAN FOR STEEL STRUCTURE SHOP

FABRICATION) before painting.

All of taking-over form made according to Projects requirements and after the

parties ( the Owner, TVGS, LISEMCO contractor) have finished signing the

acceptance certificate, then move to painting stage

*) Welding procedure specification, process welding, and NDT for welding

work of reclaimers, stackers, unloaders, and towers shall be completely followed

FLS General Workshop Instructions which was issued.

AdminPolygon





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Step 4: Painting.

After checking according to STEEL STRUCTURE INSPECTION RECORD

BEFORE PAINTING No: VA1-QCF-M-012 in the document No: VA1-LI-

00100-M-G1-ITP-0002 (INSPECTION AND TEST PLAN FOR STEEL

STRUCTURE SHOP FABRICATION), products will be cleaned by abrasive

grain for blasting, boring machine for hard-to-handle, ensuring technical

requirements of this project. The quality control is ensured to move painting

stage and final acceptance for packing.

All the acceptance forms are made according to project requirements and after

the parties signed acceptance report to move the working stage, its time for

packing.

Due to design of parts with its own features, the construction part of work like

scraper, piler, unloader, tower of project have some different features.

III.1.The fabrication of Reclaimer: the fabrication of each unit

The cutting stage must carry out on CNC machine. After cutting, the plates are

connected together according to working drawing and finish welding for

connecting plates; check Nondectructive testing (NDT). If these results are

achived, conduct the assembly beam. The platform is used for assembly beam,

for example:





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During beam assembling in three-sided process, each unit is connected

completely according to design set, bracing to avoid welding deformation; and

then weld the whole beam inside. After checking by visual about welding of

beam inside, cap the plate to control the dimension of the beam and conduct to

welding finish. Checking by visual the overall dimensions of welding seam; the

flatness of beam sides according to the length design of beam. If these results

achieved, conduct Nondestructive testing and acceptance to move for cleaning

and painting.





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Roller support is made with the same way.

Dump bailer supports in fabricating procedure and inspection are skidded on the

platform.

Dump bailer will be fabricated and accepted in accordance with gauge.

All units connecting together which are difficult to clean and paint, after

finishing, they are cleaned and painted with anticorrosive paint before

assembling.

The remains of scraper will be completely fabricated, accepted and finish

painting at the LISEMCO Contractors shop, and then conduct to assembly and

install.

III.2. The fabrication of Stacker: the fabrication of each unit

The cutting stage must carry out on CNC machine. After cutting, the plates are

connected together according to working drawing and finish welding for





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connecting plates; check Nondestructive testing (NDT). If these results are

achieved, conduct the assembly beam. The platform is used for assembly beam.








and painting.

Roller support is made with the same way.

Band conveyor support in fabricating process and inspection is performed on

gauge support.





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All units connecting together which are difficult to clean and paint, after

finishing, they are cleaned and painted with anticorrosive paint before

assembling.

The remains of Stacker will be completely fabricated, accepted and finish

painting at the LISEMCO Contractors shop, and then conduct to assembly and

install.

III.3. Unloader machine fabrication : execution with each unit.

Cutting stage performed by CNC machine. After pleteting , the plates connected

according to fabrication drawing and finishing welded, if NDT checking is

achieved, beam assembling will be implemented. Platform used for this work








and painting.





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The remains of unloader will be made with the same way and cleaned and

painted at the LISEMCO Contractors shop, and then conduct to pack and

install.

III.4. Fabrication for direction turning tower: Because tower structure

coupling bolt, so fabrication process is process which fabricate loose parts , after

that testing assembly each unit.

+ The pillar, beam are cut by steel shape (I,V...) with right dimension, marked by

arrows directing position of gusset plate, attaching gusset plate after drilling

hole.

+ Bracing is performed with cutting dimension, attached gusset plate, welding,

dimension inspection after welding and flatness, then move to clean and paint.





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+ Platform and ladder are fabricated with the same way.

+ After loose materials are checked, cleaned and painted.

+ Packing and installing in construction site.

IV. Inspection of dimensional tolerance

+ Measurement testing, tolerance in dimension acceptance inspection according

to project standards (Document no:VA1-FLS-00100-M-M2-DST-6040)

0.7/100 mm0.6/100 mm1.8/100 mm

2.6/100 mm5.2/100 mm

32

501000

12864

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va1 lsc 00100 qa m8 tpd 0006 (steel structure fabrication procedure) rev.1

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