Method State for air preheater installation (rev d)

The purpose of this Method Statement is to explain the procedure of the Air Preheater (APH) installation work for VINH TAN 4 unit 1, 2. With this, we can perform safely and consistently.6.2.1 Beginning mark center line of base plate at grid line Q.. 6.2.2 After marking center line the level of base plate will be checked and ensure make same level by shim plate.

D 29.11.2016 H.J.BAE S.Y.KWAK S.J.PARK FOR APPROVAL

Owner’s Engineer

POWER ENGINEERING CONSULTING JOINT STOCK COMPANY 3

Dept MECH Dep’t

1 PURPOSE

The purpose of this Method Statement is to explain the procedure of the Air Preheater

(APH) installation work for VINH TAN 4 unit #1, #2 With this, we can perform safely andconsistently

This method statement is applied to the above mentioned works If there are any matters notmentioned in this statement then that will follow international standard such as AISC, AWSand ASTM

1) Verify the application of this procedure

2) With necessary tests and inspection

3) Verify the specification of supplied material to confirm if the delivered material is correct

4.1 Issued For Construction Drawings

4.2 Approved Contract Quality Plan

4.3 Project EHSS Management Plan

4.4 Painting Procedure (VT4-YR01-P0ZEN-070001)

4.5 American Institute of Steel Construction (AISC)

4.6 American Society for Testing and Materials (ASTM)

4.7 American Welding Society (AWS)

4.8 American National Standards Institute (ANSI)

5.1 Receiving and Storage of Material

5.1.1 Upon delivery of the material, construction engineer shall inspect if there is any discrepancy

with packing list and damage during the transportation The result shall be reported immediately to the supervisor

5.1.2 Materials should be segregated and stored at storage yard for easy handling as per erection

sequence

5.1.3 Generally, take appropriate measures such as the use of sheet covers and sleepers against

rust, strain, deformation and damage during storage of materials

5.1.4 Handling of materials and equipment shall be performed carefully so as not to damage or

loss them

5.1.5 All temporary materials, equipment, and jigs to be used for installation work shall be

carefully checked and adjusted before using them

Sealing Frame Top Bolting

Center Support Centering & Leveling

Center Support, Thrust Bearing Installation

Rotor-Lifting Device Installation to Center Support

Hydraulic Cylinder Installation to Rotor Lifting Device

Sliding Support (Cupshaped Support) Installation

Casing Bottom Main, Side Part Installation

Sealing Frame & Shoes, Bottom Installation

Thrust Bearing Temporary Support Installation

Rotor Core Installation

Casing Support middle part Installation

Casing Top Main Part Installation

Casing Top Side Part Installation

Guide Bearing Installation

Bearing Setting Fixing

Pin-Rack Segment & Support Installation

R.D.U (Rotor Drive Unit) Setting

Cold & Hot Heating Element Installation Rotor (Closed, Open) Segment Installation

5.2.2 Prevent friction of structural elements together

5.2.3 Preserve structural elements against shocks of any kind

5.2.4 Avoid trailing structural elements

The above recommendations must permit limiting accidental damaging of the paint film

If necessary, paint touching up shall be carried out according to general specification for

Painting

5.3 Stability of very high devices and of structural elements

5.3.1 Stability of very high devices shall be ensured at all times and, in particular, out of erection

hours (night, weekends)5.3.2 The erector shall ensure the stability of the Air Preheater whenever the progress of the

erection work does not permit getting stability from the structural elements bound together

6.1 Process Flow Chart

6.2 Setting up Center Line & Level of Base Plate

6.2.1 Beginning mark center line of base plate at grid line Q

6.2.2 After marking center line the level of base plate will be checked and ensure make same

level by shim plate

6.2.3 The tolerance of level will be confirmed as ITP

6.3 Assembly of Bearing Component

6.3.1 Assembly of Thrust Bearing

The thrust bearing will be installed on shim plate which it have just been adjusted samelevel Center line of base plate will coincident with center of thrust bearing

6.4 Assembly of the Rotor Lifting Device

6.5 Assembly of APH-Casing at Bottom Part

6.5.1 Assembly of APH Support (sliding support)

Main & side support will lifting at level which are marked center line and it will be fixed

6.6 Lifting of Casing Bottom Main Part

Process lifting casing bottom main part after support had fixed they will fit up at position bytemporary support /or use chain block in order to tackle Ensure make level they will bechecked level and make same level by insert shim plate (Reference lifting plan)

6.7 Lifting of Casing Bottom Side Part

When casing bottom main part are fix casing bottom side part will lifting & fit up with main part, the mean while they must make same level with main part

After finished adjustment they will process fit up stiffener pipe & angle.

6.9 Installation Seal Frame

Seal frame will be erected at top face of casing bottom part they are connected to together see fig blow

6.10 Assembly and Mounting of APH Rotor.

6.10.1 Arrangement of the thrust bearing pivot: if case they are loose part, they will be

assembly at a ground with temporary support see blow Fig

6.10.2 Arrangement of the rotor core and pivots

Rotor core will put frame after thrust bearing will lifting assembly with it after they are fixed, the guide bearing will be erected

6.10.3 Assembly of the hydraulic cylinder for rotor lifting device.

6.10.4 Arrangement of the rotor core

The thrust bearing, rotor core, guide bearing pivot which assembly become 1 unit approximate 20ton they will make lifting plug in order to lifting up to casing bottom disc center fit up by temporary support.(Reference lifting plan )

6.11 Assembly of APH Casing Middle-part

6.11.1 Erection of APH casing support segment

Casing middle main & side part will fit first at position

6.11.2 Mounting of APH casing middle-part

The rest of segment will be erected fill space after main & part have already fixed

6.12 Assembly of Sealing Frame

Seal frame will be erected at top face of casing top part they are connected to together by bolt see fig blow

6.13 Assembly of Sealing Frame

6.13.1 Lifting of casing top main part (Reference lifting plan)

6.14 Adjustment of support bearing and guide bearing

6.14.1 Installation of guide bearing

6.14.2 Installation of shaft seal top

6.14.3 Adjustment of support bearing and guide bearing

6.15 Arrangement of the Rotor Segment.

6.15.1 Alignment of rotor closed segment

After the rotor had fixed, the rotor closed segment will be assembly with rotor core by bolt, Pin, screw, tack weld Total closed segment have 6pcs with weigh each of piece is 8.23ton They will be installed as per step (reference lifting plan)

6.15.2 Arrangement of the opened segment

The opened segment will be assembly after closed segment temporary fit up

6.15.3 Arrangement of the rotor completed

See fig after they had finished assembly

6.16 Lifting of casing top

6.16.1 Lifting of casing top side part( reference lifting plan)

6.16.2 Installation of casing top completed

6.17 Installation of the pin rack

6.18 Installation of the drive-unit

6.19 Installation of the seal gap adjusting devices, top and bottom

6.20 Installation of heating elements

6.22 Installation of water washing device

6.23 Installation of the fire extinguishing device

6.25 Installation of the expansion sleeve

6.26 Installation Lube oil Circulation, Lube oil Pipe & Oil Flushing

6.26.1 Lube Oil Circulation Installation

Install the Lube Oil Circulation System Horizontally, giving carefully consideration to proper installation position and the method of keeping the connection duct warm

Thoroughly clean the piping before installing it in the field

Apply Oil Flushing prior to trial run

6.26.2 Oil Pipe Assembly for Guide Bearing Circulation System

Assembly Oil Pipe follows Drawing of Guide Bearing Circulation After Welding done Cleaning inside pipe by Air cleaning

6.26.3 Oil Flushing for Guide Bearing Circulation System

Oil Flushing Procedure refer VT4-DD09-P0ZEN-040364 MS for U1 & U2 Air Preheater Oil

7 JSA (Job Safety Analysis)

List of All Job

A Workers A.1 Not properly equipped with A.1 Instructing to wear proper PPE

B Crash/ traffic accident

C Crushing accident during assembly work

D Crushing may cause fatal injury

or permanent disability

E.1 Falling accident

E.2 Falling accident of material

B.1 Check the access road before passing the area

B.2 Designate a signalman who wear the red suit and safety helmet and control the work

C.1 Clearance of safety access roadC.2 Communication with the Signal manD.1 Preparation of a rigging lift list and plans for lifts of ten (10) tons or greater

D.2 Only a qualified and Certified operators Signalman should be in-place

D.3 Do not stand beneath the lifting areasD.4 Ensure loads are fixed with sling belt correctly

D.5 All lifting equipments must be in good conditions

D.6 Experienced lifting supervisor at all timesD.7 Only monthly checking color attached lifting tools allowed to use

D.8 All lifting tools must have identification tag (including serial number, certification number, SWL inspection date and due date)D.9 Provide safe entrance and exit access road for the labors passing

E.1 Proper equipping of PPEE.1 Proper uses the harness (2 lanyards) and life line over 2 meters

E.1 Checking the signal of signal man and checking the direction of the material lifting direction

E.1 All worker who work over 2 meters must

be trained the working at height training.E.2 Checking the joint status of lifting gearsE.2 Prohibiting man access under the lifting area

device to suit the crane capacity

F Equipment

and material

preparation

for Temp

F.1 Collision between machines

Overturning may cause death or permanent disability

F.1 Always keeps the site clear of any obstructions

F.1 Tool-box talks on a daily basisF.1 Adequate warning signboards

and damage to materials

F.3 Equipment oil leakage during operation

G.1 Working operation of the equipments may cause injury to personnel due to poor visibility of the area

H.1 Electric shock, fire, burn to body and injury to eye may cause death or permanent disability

F.2 Designate a signalman who wear the red suit and safety helmet and control the workF.2 Heavy machinery should have backward movement warning light and beacon

F.2 Equipment used to clear the site should be controlled and sorted by a banksman

F.2 Provide safe entrance and exit for the workers going to the area

F.2 All vehicles entering on the site must

turn-on their headlights day and night timeF.3 Daily check of the equipments prior to work

G.1 Must provide sufficient lightings on the entire working area

G.1 All equipments must ensure all lights are operational and not obscured by dirt or mudG.1 Supervisor must always be present for the entire working operation

G.1 All workers must be wearing proper PPEG.1 Ambulance and nurse must be available

in first aid station G.1 Must use industrial socket and plugG.1 Electric cabinet should not affect any water

H.1 Proper earthing and connection of weldingmachines and generators

H.1 Flashback arrestor and gauge should be installed prior to use cutting cylindersH.1 Proper PPE to be worn at all timesH.1 Must use and connect 3 core codes electricwire and separate distribution panel (must pass arrangement of ELCB) and avoid any water affect

H.1 Must use industrial socket and plugH.1 Electric cabinet should not affect any water

List of All Job

H Welding and

cutting works

H.2 Generator(diesel) equipment oil leakage during operation

H.2 Daily check of the equipments prior to start of work

H.2 Regular monitoring of the equipment in order to control and prevent oil leakage and other engine trouble

H.2 Provide secondary containment protection under the equipment to prevent contamination of the soil by oil spillageH.2 If oil leakage, must remove the oil and

H.3 Oil/chemical storage H.3 Diesel/chemical shall be stored in

secondary containment and MSDS requirements shall be communicated with all concerned

8 RISK ASSESSMENT

8.1 Layout Configuration

8.2 Crane Radius

8.3 Casing Bottom Installation

8.4 Rotor and Shaft Installation

8.5 Top Casing Installation

DOC.NO.VT4- DD09-P0ZEN-040332 Rev D 28 of 41

8.6 Heavy Equipment Load Test for Safety

All of the heavy equipments should be inspection and load test by Doosan EHS department according to the current regulation of Viet Nam (TCVN 4244; 2005)

9.1 Arrangement Drawing

9.4 Organization Chart

9.5 Manpower Mobilization Plan

9.6 Erection Schedule for Air Preheater

9.7 WPS for Air Preheater (WPS No WT – G1Y – 1010 – 015)

9.8 Certificate of Lifting Equipments using for APH erection

9.1 Arrangement Drawing

No Description Specification Unit Quantity Remark

9.3 Scaffolding work plan

Mr Pham Van ChienTel: 0916.709.786

Lilama Construction Manager

Mr Hoang Van HuynhTel: 0968618218

Lilama QA/QC Manager

Mr Nguyen Tri ThucTel: 0939398217

QC StaffMr: La Manh TuanTel: 01666839879

Doosan MechanicalGeneral Manager

Mr S.W Lee Tel: 094.343.3871

Doosan MechanicalManager

Mr J H Bae Tel: 0949.763.154

Doosan QA/QC Manager

Mr J.C LeeTel: 0943.220.475

DS Non-press Part Engineer

Mr Nguyen Van NinhTel: 0120 572 6581

Doosan Site Director

Mr G B GwakTel: 0943.174 649

Supervisor Mr.: Nguyen Dang LocTel: 0963 167 012

9.5 Manpower Mobilization Plan

DOC.NO.VT4- DD09-P0ZEN-040332 Rev D 36 of 41

Actual 2016-01-04 -42372 - Current 2016-01-18 2016-03-01 44 29.2 14.6 50.0% 15 15 Actual 1 29.2 - 0.0%

-Current 2016-01-21 2016-03-11 51 29.8 14.9 50.0% 15 15 Actual 1 29.8 - 0.0%

Current 2016-01-16 2016-03-15 60 22.0 11.0 50.0% 11 11 Actual 1 22.0 - 0.0%

Current 2016-02-06 2016-02-13 8 - Actual 1 - - Current 2016-02-15 2016-03-17 32 24.2 - 0.0% 12 12 Actual 1 24.2 - 0.0%

-Current 2016-02-18 2016-03-23 35 8.1 - 0.0% 4 4 Actual 1 8.1 - 0.0%

Top sleeve angle install

Machining of the rotor

Booster pump & chemical injection system install

Radial seal plate welding

Fire extinguishing device install

Sensor & panel install

Radial seal plate install & welding

Grating & platform install

Assembly of retrectable sootblower

Water washing devices install

TET HOLIDAY

Top casing main erection on the structure

Bottom & middle casing welding

Seal gap adjusting devices,top and bottom

Roller conveyer install

Installation of heating elements

Support & Guied bearing final aligment

Machining devices install

Pinrack install & tack weld

Pinrack adjusting & welding

Driver units install

Rotor casing middle part install & welding ( remain open)

Crane hoist setting

Guied bearing install & centering disc removal

Support & Guied bearing adjusting work

Shaft sealing to install

Rotor segment lifting & setting

1CF1515W42A05A

% Dur.

Finish Weight(ton)

INSTALLATION AIR-PRE HEATER A&B

Activity ID Activity Name '16.01.29 Start

1CF1515W42A04

Aligment of rotor core/rotor parts

Welding (regarding the sequence) of rotor

Rotor core install

Casing middle install

Lifting & bolting top seal frame on the rotor

Marking of position of the supports

Leveling steel struture (Grinding)

Thrust bearing into the steel structure

Top main and middle casing welding (incl guide BRG platform)

Top casing erection on structure steel

Top & middle casing welding

1CF1515W42A04A.01

1CF1515W42A04A.02

Work scaffold installation

Dismantling STR'L & handrail interference

1CF1515W42A04B.01

1CF1515W42A04B.02

1CF1515W42A04B.03

Bottom casing erection on steel structure (incl stiff Pipe)

Sleeve angle install

Seal frame on bottom casing install

Rotor core pre-assembly