METHOD STATEMENT FOR HRSG WORKS

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SEC POWER PLANT PP-13 PROJECT

METHOD STATEMENT FOR ERECTION OF HSRG

WORK

DOCUMENT NO:NIS/626/MS/001_REV 00

SUBCONTRACTOR:NASS INDUSTRIAL
SERVICES

GAMA REVIEW
Discipline HSE Manager QA/QC Manager Site Manager
Superintendent
Name

Date

Sign
Remarks:
Any such review or consent by GAMA, shall not relieve the Subcontractor, in any case or for any reason whatsoever,
from any obligation, liability or responsibility arising out of or in connection with the Contract, including without being
limited thereto, to the responsibility for errors, omissions, discrepancies and non-compliances. Within this context, this
document shall not prevail over or amend the Contract, or relieve the Subcontractor from any of its duties, obligations,
responsibilities or liabilities under the Contract.
Anything presented herein by the Subcontractor shall in no event
i) excuse the Subcontractor’s non-performance under the Contract, or

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ii) entitle him to a variation under the Contract or an adjustment to the Contract Price.

SUBCONTRACTOR
Rev. Prepared HSE QA/QC Site Project
Date Description*
No. by Manager Manager Manager Manager

DOCUMENT HISTORY:

Rev. Remarks
Date
No. (Reason for Revision)

* Description:
Document issue purpose
- First Issue
- For Information
- For Review
- For Approval (or Issued for Construction)

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CONTENT

1.0  PURPOSE ..................................................................................................................................... 4 

2.0  SCOPE OF WORK ........................................................................................................................ 4 
3.0  RESPONSIBILITIES ...................................................................................................................... 4 
4.0  DEFINITIONS / ABBREVIATIONS ................................................................................................ 4 
5.0  PERSONNEL................................................................................................................................. 5 
6.0  MATERIALS .................................................................................................................................. 5 
7.0  EQUIPMENT.................................................................................................................................. 5 
8.0  SUBCONTRACTORS’ SUB-TIER CONTRACTORS .................................................................... 5 
9.0  EXECUTION .................................................................................................................................. 5 
10.0  TIME LINE OF ACTIVITIES ......................................................................................................... 29 
11.0  PROGRESS MEASUREMENT .................................................................................................... 29 
12.0  QUALITY REQUIREMENTS........................................................................................................ 29 
13.0  HEALTH, SAFETY and ENVIRONMENTAL REQUIREMENTS.................................................. 30 
14.0  RISK ASSESSMENTS ................................................................................................................ 32 
15.0  REFERENCES ............................................................................................................................ 32 
16.0  TECHNICAL APPENDICES ........................................................................................................ 32 
17.0  ATTACHMENTS .......................................................................................................................... 32 

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1.0 PURPOSE
This Method statement describes in detail of 3 Nos.Heat Recovery Steam Generator Erection
works for SEC Power Plant Project PP-13 being carried at KSA by M/s NIS , Bahrain. This
includes addressing programs for implementing commitments regarding the quality and Safety of
works.

2.0 SCOPE OF WORK

This document outlines the method for Receiving & Shifting of OWNER’S materials from
Warehouse to Site/Laydown Yard, Unloading and Storage of Equipments/Materials, Checking
the Quality & Quantity of Incoming Materials, Erection & Installation of All Equipments relevant
to the Plant,Assembly of the parts that make up the bearing Structures,relevant stairs and
walkways,Main & Intermediate connection pipelines,drains & Vents,Valves,İnlet & Outlet
ducts,Main Stacks etc.,Non destructive testing including PWHT,testing,Insulation & Touch-up
painting wherever applicable.

3.0 RESPONSIBILITIES
Operation Manager/Project Manager shall be responsible for overall coordination of the
activities and allocation of resources such that it meets the requirements of this MS.

4.0 DEFINITIONS / ABBREVIATIONS

OWNER: SEC (Saudi Electricity Company)
CONSULTANT: Worley Parson
SUPPLIER: S.T.F.S.p.A
MAIN CONTRACTOR: GAMA
ERECTION CONTRACTOR: Nass Industrial Service ,Bahrain (NIS)
ITP: Inspection Test Plan
QAP: Quality Assuranse Plan
WPS: Welding Procedure Specification
PQR: Procedure Qualification record
WQT: Welder Qualification Test
HSE: Health Safety Environment
TBN: To be nominated

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5.0 PERSONNEL

Planned Manpower Distribution Histogram attached.

6.0 MATERIALS

NASS shall mobilise required materials ,tools & consumables as per the Scope and project
schedule.

7.0 EQUIPMENT
Equipment Histogram Attached.

8.0 SUBCONTRACTORS’ SUB-TIER CONTRACTORS

Details of Sub-Contractor along with responsibilities shall be provided as a when freezed or
mobilised.

9.0 EXECUTION
9.1 Shifting,Storage & Handling of FIM:
a)Transportation of Materials
All relevant project materials shall be transported from Warehouse to NIS Laydown Area
/Erection Site on a Trailor after completion of required Formalities.

b) Unloading & Storage

Materials shall be unloaded with a help of Forklift/Crane and store with Utmost care either in
covered or Open area depending upon the requirement.

Materials in the open area shall be stored above ground (200mm) on a wood, on platforms or
pallets in a manner that will prevent any deterioration from debris, grease, paint spray or any
other foreign matter.

c) Inspection/Verification:
Incoming materials shall be offered for Inspection/Verification to ensure that the correct grade,
quality, condition, painting, identification and dimension have been supplied and are in
accordance with the Packing lists. Owner shall be informed immediately incase on any defects in
Incoming materials with reports & photograph.

Materials that cannot be identified by identification markings, new identification label have to be
provided on that particular item.

Damaged materials and Spare Materials shall be placed in a separate storage area from other
usable materials, with sufficient safeguard to prevent its use.

Daily Material Receipt (DMR)

Accepted FIM Materials shall be documented in the form of MRIR report for easy tracking.

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9.2 Planning & Construction

A detailed Construcion Schedule shall be prepared using Primavera Project Planner/ Microsoft
Project/Spread Sheet highlighting:

a) Sequence of Erection of HRSG Components.

b) Critical Path

c) Manpower Histogram

The construction schedule shall be regularly updated every week in accordance to Contractor
and Consultant requirements in terms of progress of works and forecast to finish.

The sequence of activities indicated in the construction schedule may be modified or updated at
later stage of execution due to non availability of Erection Front,Owner’s requirement,Climatic
and Environmental Condition,Routes Operability etc.

Materials receipt status, Work front status along with quarantine list if any shall be published
weekly in excel format.

9.2 Erection of By-Pass Stack

a) By-Pass stack erection sequence shall be as follows:

1) Stack foundation preparation.

2) Erection of Steel Structure shall be done by the use of suitable crane.

3) Installation of Diverter box.

4) Installation of Upper steel structure.

5) Pre-Assembly of Stack Section-1 along with platform,ladder,gratings and other accessories if

applicable.

6) Installation of Stack Section-1.

7) Pre-Assembly of Stack Section-2 along with platform,ladder,gratings and other accessories if

applicable.

8) Installation of Stack Section-2.

9) Pre-Assembly of Stack Section-3 along with platform,ladder,gratings and other accessories if

applicable.

10) Installation of Stack Section-3.

11) Installation of CEMS Unit.

9.3 Erection of HRSG.

a) HRSG Casing erection Sequence:

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HRSG Casing Module shall be erected from Grid G to Grid N as follows:

1) Suitable Shimming shall be provided and Installed as required.

2) Suitable Main and Trail Crane located for lifting of Casing Modules 1,primary-self standing
type,casing (left or right) side panel.

3) Main crane Lifts Module 1 (Left or Right) side panel until become upright position.

4) Module 1 (Left or Right) side shall be place on foundation and bolts will be tightens.

5) Counterweight block Shall be placed on both side for fastening Module 1;

6) Modules 1 (Left or Right) side will be fatened to counterweight by steel ropes;

7) Crane is located for lifting of Module1,primary self standing type,horizontal bottom beams of
casing floor panel;

8) Crane lifts Module 1,primary-self standing type,horizontal bottom beams of casing floor panel;

9) Temporary supports are prepared to keep horizontal bottom beams of casing floor panel;

10) Main and Trailing crane shall be marched to other position for lifting the opposite casing side
panel of Mdule 1 to the one already put in position.

Above sequence is repeated for next self standing type Module but when erecting this module the
casing floor shall be lifted as a complete panel,since there is no matter of interference with the
susequent internal piping installation.

After completion of Casing for primary Module,the erection proceed with the installation of not self
standing modules.

Casing Erection shall proceed by the Installation of casing enclosures panels as follow:

1) Installation of bottom panels to be levelled,aligned to the HRSG main longitudinal and

tranversal axles,tack welded on the internal flanges of bottom beams.

(Note: Bottom panels of Module 1 shall be installed at a later stage when pressure part
modules are set to the installation of boiler internal piping header.)

2) Installation Vertical side panels of bolier alignment using fit-up bolts,verifying that the panels
are correctly oriented towards the flue gas path in accordance to the drawings.The installtion
of same panels on both side alternatively shall be done It is recommended to complete the
installtion of the same.Alighnment,Squaring,verticality of whole casing structure has to be
maintained within tolerance especially the value at the top level.Transversal beams shall be
progressively removed when vertical panels are fitted up and when squaring tolerance are
well within limit.

3) Installation of front and rear panel.

4) Execution of final alignment, levelling and verticality of the whole casing structure, relevant
control and control certification, to be carried out when all casing structures are erected,
bolted and tack welded. Final checks have to be completed and certified in accordance to
SUPPLIER design tolerances and Site Quality Control Plan before any final welding of the
casing structures is allowed to commence.Measured values of alignment, levelling and

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verticality of casing structures have to be recorded in a dedicated form to be arranged at site

by CONTRACTOR and delivered to SUPPLIER.Upon completion of casing alignment, and
before commencing final welding, it is important to verify the dimensions of casing opening
where pressure part modules shall be placed into theHRSG.The inside top flange - to- top
flange internal dimensions between the adjacent roof beams should be checked and
documented against the corresponding dimensions of the modules, to ensure that each
module can be set properly into casing structure.

5) Execution of final welding of all casing panels, in accordance to here above listed drawings of
the Project. All external welding have to be carried out in a continuous way, stitch welding
inside, in accordance to the details shown on the here above listed erection drawings of the
casing.

6) Installation of the field casing plates for sealing of the gap between the vertical panels and
the bottom panels, as per details shown on the here above listed erection drawings of the
casing.

7) Execution of final connections and welding of the truss guide beams.

8) Execution of paint touch up on all casing welds carried out at site, especially in the areas
where insulation mattresses have to be installed, in accordance to the painting cycle
applicable for the external casing sheets. It is compulsory that said activity is executed before
starting with the restoration of insulation and setting of liner plates.

9) Execution of the insulation in the naked strips left void between adjacent vertical side panels,
between vertical side panels and horizontal bottom panels, between adjacent horizontal
panels,laying and pinning suitable mattresses of ceramic fibre between the panels (double
layer,staggered when required) to be packed and covered by the loose lining filler plates.
Fixing pins have to be installed and welded at site, retaining studs are installed on the casing
sheets of the panels during prefabrication.

10) Installation of the loose lining enclosures plates, sent on site already pre fabricated, each of
them identified by marking, with holes drilled, cut at suitable dimensions such as to mach
shape and width/length of the specific area to be restored/coated. Loose lining filler plates are
kept in position by round washers to be fixed to the lining threaded studs using nuts. Nuts
have to be tack welded to the studs, no welding has to be carried out between adjacent loose
lining filler plates. The liner assembly of casing/inlet duct sections is designed to allow the
protective internal liner system to expand freely due to the temperature expansion of the
components. The liner system is composed of a series of overlapping plates, pinned to the
outside casing. It is important that the installation of the field seams be understood prior to
beginning work. Failure to install field seams correctly can lead to casing hot spots, loss of
insulation and general failure to the integrity of the liner system.

11. Restoration of insulation and lining at the junction area of panels of HRSG casing and
inlet ducthas to be carried out with the up most care and precision, to avoid any possible gas
leakage throughout lining plates and insulation. Said hot gas paths, that are not easily
detected and eliminated during boiler operation, will cause burning and damage of the
external casing and duct structures of the HRSG.

12. Installation of bumper pipes . Suitable scaffoldings have to be erected at each side of
boilercasing to allow positioning and welding of the guiding boxes. Said scaffolding shall
remain in place to allow the installation and shimming of the setting plates to be fixed to the
tube bundles of the pressure part modules.

13. Installation and bolting of buckstays to the main columns.

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14. Installation of Header Spacers, provided to counter the thrust of the headers towards the
casing panels in case of the occurrence of a disrupting earthquake. Backstays are shop
welded to the casing panels.

15. Installation and welding of the plates connecting the external stiffeners of the casing
panels to the HRSG main structures (columns, beams), in accordance to the applicable
drawings of the Project.

16. When casing panels are fully welded and all non destructive tests and controls foreseen
by the applicable site Quality Control Plan (QCP) are executed, witnessed and certified by
the OWNER it is requested that base plates of columns are grouted by the Civil Contractor,
using a suitable non shrinkable-self levelling mortar, leaving the shim packing in position.

17. Final tightening of the nuts of embedded anchor bolt to the base plates of the casing
columns shall be executed when grouting has sufficiently set.

18. Beginning of the erection of pressure part modules is bound to completion of the erection
and welding of all casing structures, execution and certification of required NDT and the
inspections listed in the Site Quality Control Plan.

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9.4 Inlet Duct

The inlet duct, possibly supplied in form of panels similar to casing panels,either insulated or
to be insulated at site condition.

Prefabrication and inner insulation before erection shall be evaluated keeping into account
availability of area, accessibility to the erection areas and availability of crane and truck.

The erection sequence is as follows:

1. Positioning and welding of floor panels;

2. Positioning of supporting lateral panels;

3. Positioning and welding of lateral panels;

4. Positioning and welding of roof panels;

5. Preparation of internal scaffolding for internal welding and insulation and external
welding.

6. Positioning, welding and insulation of the connection pieces between exhauster (round)
and duct (rectangular section).

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9.5 Outlet Duct

HRSG Outlet Duct connects the boiler casing to the stack breeching using a fabric expansion
joint.

The type and degree of prefabrication, sequence and methods of erection of the boiler outlet
duct main components are similar to the ones of the boiler inlet duct.

9.6 HRSG Casing & Ducts Access Doors.

Casing and inlet duct access doors shall be installed on the panels and sealed with a
designated bolting type gasket.

Care shall be taken to insure that the gasket is not damaged when doors are opened and/or
closed in the site. Casing access door gaskets should be replaced at the first sign of
becoming brittle. The bolting tape shall lay flat against the surface with no laps or gathering
on the material.

9.7 HRSG Stack

Each stack (5.5m of diameter, 60m high) shall be site pre-assembled in several segments of
variable length complete of all accessories and auxiliary components (access doors, ladders,
platforms, rain damper, silencer, personnel protection, mass damper and nozzles).

Each segment shall then be erected in sequential order by means of heavy lifting equipment
and jointed together by circumferential field welding.

The stack preassembly operations consist of prefabricating, at ground level in dedicated area
according to the general plant layout, the stack segments in which the whole stack is divided
into.

Stack segments are made of several shell courses. Maximum height and weight of segments
shall depend on the lifting equipment availability at site. The erection sequence is as follows

STACK SECTION 1: SHELL + BASE PLATE

STACK SECTION 2: SHELL + REINFORCEMENTS + HOOD
STACK SECTION 3: SHELL + REINFORCEMENTS + PLATFORMS
STACK SECTION 4: SHELL + REINFORCEMENTS + SILENCERS + PLATFORMS

Or there maybe 5th Section also, depending upon available materials, Weight, Available
Equipment etc.

Each shell course (OD=5520mm) is made of 3 curved and beveled shell plates welded with
internal angle of 120° (at the time of welding there is to be no paint within 50mm of the weld).

Alignment of vertical joints is obtained by strong packs tack welded across the seams (50mm
clear from weld as a minimum) and by means of shim plates and wedges. All seam welds are
to be in accordance with the applicable WPS.

The strong packs will be removed by cutting after the completion of the vertical seams. The
surface where they were attached will be ground smooth and inspected for cracks by DPT.

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Shell courses are to be completed with welding attachments according to the drawings.

Once the prefabrication operation of the segments are completed, all their surfaces shall be
spray / brush coated according to the corrosion protection specification prior to erection and
assembly of appurtenances with the only exception of the ends to be coupled.

Before starting with the erection of the segments making the stack, the installation of the
following stack components shall be completed:

- The silencer will be fixed on segment on which it is coming

- The rain damper on segment on which it is coming

- Platforms, ladders, landings, inspection doors, personnel protection on segments as per

drawings.

- The ladders across the joints will be fixed after the completion of the erection

Once the above mentioned stack accessories have been assembled, stack section no. 2
shall be assembled directly on the main stack section no. 1.

The base plate will sit on steel packs and wedges to ensure the level and the planarity of the
underside of the base plate not to deviate from the specified values. After segments 1 and 2
have passed the verticality check, manual torque will be applied to the nuts of holding down
bolts.

Stack erection will proceed in accordance with the following phases:

- Remove lifting lugs from stack section no. 2;

- Lift stack section no. 3, fitted with appurtenances and temporary platforms near the top end,
if required;

- Align stack section no. 3 with strong packs tack welded across the seams (50mm clear from
weld as a minimum) and by means of shim plates and wedges;

- Release slings from temporary platforms fitted near the top of stack section no. 3 when
provisional connection to stack section no. 2 allows a safe release;

- Complete weld of circumferential butt joint, inclusive of back gauge, if foreseen

- Internal scaffolding is required to execute the back gauge weld of the two stack segments
joint. The access to the scaffold will be through a manhole 600x600 mm located some 800
mm lower than the joint. The scaffold shall be removed after weld acceptance GAMA/Owner.

- Remove lifting lugs from stack section no. 3:

- All temporary attachment shall be removed without damaging the base material.
Any portion of the weld on the internal surface of the stack subjected to flue gas
shall be made flush and ground smooth

- Coating shall be applied to circumferential joint, touch up and remove

temporary platforms from stack section no. 2 to be re-used for next stack section
coupling operation;
- Lift stack sections no. 4 according to the same sequence and procedure;

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- Remove any temporary work and temporary aviation warnings;

- Install ladders across the joints.

Vertically check will be performed at completion of each stack section assembly.

Stack base plate will be grouted after the positioning of the last highest stack section and in
any case after stack verticality check acceptance.

The grout shall be non-shrink type. Immediately before grouting, the space under the base
plate will be cleaned. Steel packs will be left in place and totally enclosed by the grout. After
curing time, when grout has developed its nominal strength, holding down bolts will be snug
tight. Anchor bolts shall be re-tightened 30 days after grouting application.

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Note: The erection of the HRSG main stack has to be limited to the top height of the
boiler casing at elevation ~ 30.00 to 35.00 meter, for safety reasons, due to the rotation
of the main crane loaded with pressure part modules.

9.8 HRSG Pressure Part Modules:

Pressure Parts Modules for 1 HRSG consist of 8 (eight) modules probably shipped at site
completed with roof casing plate, hangers and interconnecting pipes between.

Unloading, Storage & Lifting of Modules shall be done with the help of 600 MT main crane
and 300 MT trailing crane and as per the special instruction of Supplier if any.

Pressure part modules shall be arranged inside the casing in 2 Nos./Row and from casing
module 1 to 4 or vice versa.

Preconditions for pressure modules installation shall be as follows:

The boiler casing structure is fully installed, tightened, welded and NDEs tested.

Restoration of insulation and liner between adjacent modules shall be completed.

Bumpers have been installed.

All NDT activities has been performed and certified as quality plan.

Grouting and mortar has sufficiently matured as per specification

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While settling the modules into casing structure the nozzle connections shall be checked
against SUPPLIER specific erection drawings of the Project for correct displacement in
location and elevation. Nozzle location shall be checked with an inspection.

No other crane shall work in areas adjacent to the lifting area, including Civil Contractor tower
cranes if any, while pressure part modules lifting operation are in progress.

Tube skin thermocouple shall be welded on pressure part module on site wherever
applicable.

Lifting of pressure part modules shall be carried out in full accordance to specific drawings
and instructions issued by SUPPLIER to avoid any damaging of the modules.

All lifting equipment’s and devices at completion of each lift shall be checked to assure that
no damage has occurred during lifting. Any bent, worn or damaged component shall be
replaced.

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9.9 Internal Piping & Structure

When all pressure parts modules are installed into the boiler casing, it is possible to
commence the erection of boiler internal piping, headers and auxiliary structures, like:

1 Trusses for stiffening the tube bundles, guiding the down-comers, horizontal gas baffle
plates to confine the gas flow to the tube bundles of the pressure part modules.

2 Vertical Gas Baffle Plates for sealing the hot gas passes through the adjacent modules and
through casing structures (floor, walls, roof) and modules.

3 Connection Piping and Internal Headers.

Internal details and piping shall be introduced into the boiler casing through the access doors
and the opening left by the bottom panels not installed during casing erection.
When all risers have been welded to steam drums, temporary boiler internal supporting
plates of evaporator pressure modules shall be removed.

9.10 Trusses, Horizontal & Vertical Gas Baffles Plates

Trusses can be classified as follows:
a. Upper trusses, the ones installed between adjacent rows of modules, and between the
first/last row of modules and the casing front/rear panels, at the elevation of the upper
headers
b. Intermediate trusses (only for Module 1)
c. Lower trusses, the ones installed between adjacent rows of modules, at the elevation of
the lower headers

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Suitable scaffoldings have to be erected in the row between two adjacent modules, starting
from casing floor up to the top of the tube bundles of the modules, to allow the installation of
aforesaid components.
The horizontal gas baffles, fixed to the upper and lower trusses by bolting because trusses
act as supporting frames for the gas baffles, are installed as a barrier to the hot gas flue
creating a dead chamber at the boiler floor (lower dead chamber) and the boiler roof (upper
dead chamber).

Upper and lower trusses and the horizontal gas baffles are delivered at site prefabricated,
singularly marked for an easy identification and installation.
Intermediate trusses at two different elevations (+10195 e +19995) for reinforcement
porpoises have to be installed only on MODULE 1.
Access doors to pressure part module connecting piping and tube bundles are provided at
suitable positions on the lower baffle plates.
Prefabricated Vertical Baffle plates duly marked for easy identification shall be installed at
both gas inlet and outlet side of each module.

9.11 Connection piping & Internal headers:

During the installation of internal headers and fitting of piping it’s recommended that the liner
of floor panels is suitably protected with wooden boards and fire proof blankets, to avoid
contamination and scratching of liner sheets with grinding slag and welding spatters.

Extra lengths are left on header nozzles and piping spool, to be trimmed at site, to facilitate
the erection and fitting up of the lines.

Piping bevels shall be carried out in accordance to SUPPLIER design and applicable WPS.

It is of paramount importance that the execution of welding, Post Weld Heat Treatment
(PWHTs), Nondestructive Tests (NDTs) are strictly executed and monitored in accordance to
the approved WPSs/WPQRs, PWHTs and NDTs specifications, prepared by the Erection
Contractor(s) and approved by NoBo.

Internal scaffolding previously installed before the installation of the pressure part modules
shall be modified accordingly.

9.12 Piping through Boiler Casing.

Suitable metallic and textile expansion bellows shall be provided to allow the expansion of
piping linked to the pressure part modules throughout the casing lateral walls, roof and floor.

Some of the roof expansion joints which are not shop installed on pressure part modules
shall be installed at site, as per the applicable drawings and supplier Instruction.
Expansion bellows shall be protected from weld spatters and puncture during the erection
phase.

Internal insulation if any shall be properly installed and secured.

9.13 Steel Structure

While mounting main and auxiliary frameworks, including ladders, gangways, service
platforms and gratings, it cannot be completely sequenced. It all depends on the availability

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of material, lifting equipment, personnel, drawings and access availability and accordingly
Erection sequence shall be scheduled. However, sequencing shall be done in such a way in
order to avoid clashes with other equipment or installation of our own or those already
erected and/or installed by other sub-contractors on site.

Auxiliary structures, to allow accessibility to all components of the boilers include:

- Prefabricated columns, beams and bracers

- Bolts
- Handrails
- Ladders
- Gratings
- Stair-steps

Secondary structures assembly shall consist of following activities:

Assembly and installation of the main boiler stairway, complete with gratings, handrails and
foot guards including the final tightening of the bolts after checking the verticality and
dimensions of the structure;

On-site assembly of all the secondary structures, beams, stairs, walkways, handrails, foot
guards, gratings etc., with arrangement and welding of cantilever attachments / connection
brackets with reinforcement to the bearing structures;

On-site assembly of the frame for the top support structures of the silencers;

Assembly of hoist tower structures.

A general sequence for steel structures erection shall be as follows:

1. Transportation of prefabricated sections to the erection area;

2. Installation of stairs-towers sections;

Note: After each section of Installation, it shall be checked for verticality and
tightening of bolts.

2. Final check for verticality and, after shimming, if necessary, pouring of concrete;

3. Installation of steam drums supporting structures;

4. Installation of auxiliary structures, including gratings handrails and details at elevation

above steam drums

6. Completion of auxiliary structures at all elevations

The structural erection shall be sequenced in such a way that they do not interfere with
major installation and as per reference documents. Consequently, stairs and gangways shall
be erected as the progress of the main activities allows it, for easier accessibility to the
working areas. Main stairs shall be erected first provided that they do not interfere with major
plant erection.

During the assembly, following operation order shall be taken care:

 Perpendicular check and transversal survey;

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 Bolts tightening;

 The grouting of the base plates of columns;

 The coupling bolts of the secondary structures shall be protected, right after their
tightening, with a coat of organic or inorganic zinc plating;

 The assembly of stairs and gratings will start right after the execution of the final
perpendicular check of the single structure and shall be completed swiftly.
Regulation railings shall be immediately installed on the boiler floors and also in
spots which may be temporarily exposed (for example in correspondence of the
boiler itself); those not compatible with access needs will be dismantled at the
end of the assembly;

 Column-column couplings:
Couplings between column sections, the surfaces of the tips in contact are
worked. The coupling covers shall be mounted with the relative fillings and the
complete contact between surfaces to be tightened as well as coaxially of the
holes shall be obtained.

 Varnishing and coupling protection;

 Final verifications of perpendicularity, squaring and frame and/or case leveling

after the execution of the entire assembly;

 Touch up painting on the welded surfaces;

9.14 Grating Assembly:

Gratings supplied in shaped-on-design panels with toe-guard already welded shall be directly
installed on the structure as per the drawings with the help of crane. Loose toe-guard shall be
welded after erection of gratings panel wherever applicable.

For the small bore piping and/or process pipes the passing hole shall be provided if applicable or
existing cut-out shall be adjusted.

The assembly of stairs and handrails, including gratings, shall be performed parallel to allow the
immediate access to erected components or to the ones still to be erected

9.15 Bolts Tightening

The tightening of bolts shall be carried out by using a suitable mean to achieve desired result.

The contact surfaces between washer, nut and thread shall be greased. The riveted part surfaces
in contact with the head of the bolt and with the nuts shall be parallel. As an exception, the
surfaces can present inclinations as long as they are not compared to a surface perpendicular to
the bolt axis. For inclinations, inclined washers shall be used in order to guarantee a correct asset
of the nut head.

Coupling tightening shall be performed tightening first the central bolts and then alternating those
adjacent to them.

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As soon as the bolts have been tightened it shall be clearly marked. Before beginning the
assembly of the parts under pressure, high resistance bolt tightening shall be completed.
Exceptions to this rule may be allowed only in special cases.

9.16 HP, IP & LP Drum

Steam drums shall be positioned on supporting structures, previously installed and welded to the
main roof beams of HRSG casing, just after completion of the erection of pressure part modules.

Lifting of HP drum shall be carried out using the 600 MT crane used for lifting the pressure part
modules, provided with cable slings of correct length and diameter, to be rigged not breaking
against any nozzle or nozzle reinforcement pad of the drum.

Proper Packing shall be used with cable slings to prevent scratching and/or damage to the
material.

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Dedicated lifting plan shall be prepared for handling and lifting of the drum well in advance before
erection.

Drums shall be positioned in accordance to specific project erection drawings, taking into
consideration that the support saddles of drum shall be provided with Teflon pads, sliding on steel
plates lined with Teflon too.

Check shall be done to make sure to attach the Teflon sliding packs to both the drum base plates
and support steel prior to setting the drum on the support structure.

Guides shall be installed around each saddle after the drum is set in its final position
Anchor bolts for saddles should be warm tight. All anchor bolts shall be equipped with double
nuts.

It is important in having drums correctly installed and leveled with a difference in elevation of the
drum center line from one end to the other not greater than 10 mm. The elevation and the
location of drum nozzles shall be within the following tolerances:
Elevation: +/- 10 mm.
Location: +/- 6 mm.

After that final positioning of the HP drum has been completed, following activities shall be carried
out:

a) Erection and welding of all lines connected to the nozzles of the drum, including vents and
drains.

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b) Erection of drum safety valves, silencers of safety valves and supporting structures (to be
carried out after completion of the hydraulic tests), valves, vents and drains.

c) Execution of pressure tests of the drum in accordance with contractual standards and codes
and SUPPLIER DESIGN.

d) Installation of internal filter pads (to be carried out after completion of HRSG chemical
cleaning).

e) Execution of final inspection, and general cleaning of the drum after completion of chemical
cleaning.

f) Replacement of manhole gaskets at completion of HRSG chemical cleanings.

The filters shall be removed before carrying out drum pressure test for being reinstalled inside the
drum after completion of the boiler chemical cleaning.

The installation of all internals parts like cyclones and demisters commences after the completion
of all Mechanical Activities and when the Boiler has completed its chemical cleaning and/or
blowing.

9.17 Blow Down tank:

The atmospheric blow down tank shall be installed on ground designed and specified within the
erection drawings. Placement and assembly will follow the site requirements after a proper check
of the foundation provided. Installation shall be as per relevant approved drawings
issued for such a purpose.

Hereby listed activities shall be carried out at site:

1. Control of elevation and dimension of civil foundations and tank embedment;

2. Cleaning and brushing of tank embedment;

3. Positioning of tank on foundations, leveling the tank with suitable shim packing;

4. Installation of piping, vents, silencer, valves, drains, supports;

5. Connection of piping, vents, drains, details and accessories to the tanks;

6. Execution of hydraulic pressure tests, including preparatory operations for the execution of
pressure tests, supplying of base materials for laying of temporary lines, blinding and/or capping
of flanges and nozzles, eventual removal of instrumentation, execution of pressure tests, final
restoring of lines and instrumentation after completion of the tests;

7. Replacement of manhole gaskets and closing of manholes;

9.18 Pressure Part Piping:

Piping shall be installed to meet the requirements of drawings, Codes & Standards as they
pertain to welding, procedure, qualification, post weld heat treatment, nondestructive
examination.

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Piping erection being major and the most critical activity of the whole construction schedule of the
HRSG, therefore best resource shall be deployed for erecting the piping in accordance to
contractual schedule.

Prior to any operations, a check shall be made to ensure that the supplied spools and
components are in accordance with the relevant documents (specifications, drawings,
certifications). If anything found deviating from (specification, drawings, certification), same shall
be reported to Owner.

A correct marking is the necessary prerequisite for proper checking operations:

- Identification of materials shall remain possible, either by retaining or by transferring the mark
stipulated by the product standard or by a unique code (Stamping by round edges is
recommended).

- Piping ≤ 2” spools, further cutting and adjustments on site, shall report on each part spared from
the identification number a new marking (equal from the original mark) to ensure material
traceability.

- Appropriate measures shall be taken to avoid corrosion-inducing contamination of stainless

steel and non-ferrous materials. If contamination occurs, it shall be removed as soon as
practicable.

-Drain line, which are likely to cause condensation shall be installed with adequate slopes and
traps.

- Internal and external surfaces to be welded shall be clean and free from paint, oil, rust, scale
and other material that would be detrimental to either the weld or the base metal when heat is
applied.

- Coated parts shall be free of coating products for a sufficient length of both sides of the weld.

- To protect the ends of piping (e.g. bevels, screwed ends, flange faces) suitable measures shall
be taken e.g. covering, coating, etc. The applied protection shall be removed only before the
parts are joined.

- Prefabrication of Spools (Cutting, Beveling, Welding) shall be done as per WPS, Drawings,
Codes & Standards.

- Pre-assembly of spools at ground shall be done as much as permitted for handling and
accessibility for erection.

- Before starting pipelines erection, pipe routing and accessibility of spools shall be checked, to
anticipate and correct any interference with structures or parts already installed. Particularly,
pipes connecting harp lower headers to headers external to the HRSG, shall be positioned, if
available, before installation of the overhanging harps, to avoid possible interference during
erection.

- While Installation proper dummies shall be installed in place of Non available valves.

Large Bore Piping & Supports.

- All lines > 2” shall be considered to be supplied as prefabricated, with primer coating applied.

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- All modification works shall be indicated on Erection drawings that have been carried out
because of route changes of lines (mark-up drawings at site), to allow the easiest execution of
the “as built” drawings,

- Excess length available in pipe spools shall be trimmed to fit site condition.

- Pipes supports shall be trial fit, trim to fit and shall be finally installed.

- All piping spools shall be air blown using Compressor before erection in order to remove any
foreign materials trapped inside spools.

Small bore Piping & Support

- All piping equal or lower than 2” shall be fabricated and erected in suit to site condition.

- All modification works shall be indicated on Erection drawings that have been carried out
because of route changes of lines (mark-up drawings at site), to allow the easiest execution of
the “as built” drawings,

- Vents and drains of all HRSG equipment, piping, valves and safety valves, primary tubing, tanks,
pumps and any other boiler components, shall be routed to the nearer collecting /discharging pit
or equipment, even if the location of the discharging point and detailed routing of lines is not
precisely shown on drawings and isometric drawings.

General

Checking of spools, fittings, valves, supports, any component of the line, before commencing
the erection of each specific pipe line. In case that any piping spool, support, valve and/or
accessory has no identification tag shall be immediately notified to SUPPLIER.

a) All site welding and associated Non Destructive Tests and controls shall be carried out in
accordance to specifications, Code & ITP.

b) Basic coated electrodes must be exclusively used for site welding.

c) It is compulsory that welding on pressure parts commences only when the execution of
associated Non Destructive Tests is assured.

d) Welded joints have to be carried out by electric arc welding. Electric arc manual welding
process shall be in accordance with Standards and Codes

e) All site welders shall be qualified according to all Standards and Codes.

f) Before starting any site welding, updated list of all welders shall be submitted for an approval
, showing for each welder his welding qualification for different welding categories, positions and
materials. Said list shall be kept updated during execution of work and shall be handed over to
concern person if required.

g) Each site welding shall be stamped with the number and/or initials of the qualified welder who
carried out the welding.

h) Welding record master book shall be maintained, indicating the names and punch numbers of
all welders, the list of performed welding with date of execution, reference of any repairs that has
been carried out. Such register shall be made available to concern person upon request.

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i) Preparation of the pipe edges to be welded (beveling) shall be in accordance to applicable

WPS, Standards and Codes. The edges themselves shall be finished by means of tools and/or
grinding. Surfaces cut with oxyacetylene torch shall be ground to remove the de-carbureted base
material. Surfaces shall be cleaned with accuracy so as to appear perfectly free from oxides,
greases, paints, scales, etc.

j) Spools to be welded, especially for high alloy steel, shall be linked and aligned to each other by
means of suitable coupling devices before the execution of the first welding layer foreseen by
WPS. Temporary tack-welding has to be carried out by qualified welders and shall be eliminated
by grinding. Temporary tack welding is forbidden for materials to be heat treated.

k) Welding rods to be used shall ensure a deposit having the same chemical and physical
characteristics of the base material to be welded.

l) Packages of welding rods shall be preserved in a suitable oven in the store.

Each welder shall be equipped on site with a portable oven for the preservation/protection of the
welding rods during working hours. All welding rods shall be preserved in the oven in the store
during the whole night, suitably labelled to allow an easy identification, for being redistributed
the next morning.

m) All welding defects shall be attended as per applicable procedure and standard.

n) Butt weld joints of carbon steel piping and low alloy steel piping shall be carried out with a
root pass made by TIG process (in Argon atmosphere).

o) In case that the thickness of spools and/or valves to be welded is different, the spool with
bigger thickness has to be internally/externally beveled and ground to get same diameters in
correspondence of the welding.

p) All primary lines starting from piping and/or equipment shall be completed up to the second
root valve (included).

q) All threaded junctions shall be in accordance with all applicable Standards and Codes.

r) Tack welding between flanges and bolts shall not be done.

s) Vertical runs of piping shall be supported by suitable blocks which shall be welded to piping
using approved welding procedures and welding rods

t) During the execution of works, care shall be taken to avoid any possible corrosion,
damage or presence of any foreign matter into piping, tanks or any other components of the
HRSG, by means of sealing caps installed at the piping and/or nozzle ends. Caps shall be
removed only just before lifting the pipe spool and, when possible, just before carrying out the
welding. It is compulsory that all piping spool have to be carefully blown before being fitted up.

u) All valves, particularly the motorized ones, have to be welded keeping the actuator in closed
(valve flap or plug in contact with relevant seat but not in a forced position) or open in
accordance to the instruction of the Valve Manufacturer and up to the completion of pressure
test of the line.

v) Fixing pins of spring supports shall be removed after completion of pressure tests and final
setting of the supports.

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w) Primer coating shall be immediately applied to each welded joint for protection after
completion of welding, heat treatment and NDT, in accordance to contractual painting
specification.

x) Calibrated diaphragms of flanged flow meters shall be immediately removed after the erection
and installed only after completion of boiler steam blowing. Welded flow meters have to be
installed after completion of steam blowing at least for the main steam ad hot reheated steam
lines, using a temporary spool during HRSG steam blowing, to be erected, welded, removed.

y) Temporary spools shall be welded for welded flow meters before carrying out boiler pressure
tests, including the execution of required NDT and PWHT

Piping Supports & Hangers

Supports and hangers shall be erected according to erection drawing. Prior to erection, hangers
shall be inspected for damage, proper assembly and greasing.

- Structural attachment shall be accurately located with relation to columns and frame center line,
equipment location and required offset. Attachments for sliding supports, anchor bases and floor
stands shall be accurately leveled. Sliding supports and guide bearings shall be arranged in the
cold position such that the sliding pad is located on its supporting parts for all movements
predicted by the design.

- Variable spring hangers and constant hangers delivered by manufacturers as locked, shall be
kept locked during the installation and assembly of the piping, unless otherwise specified by
SUPPLIER.

- Supports shall be installed to ensure that the identification, load and travel scales are readily
visible. All threaded parts shall be fully engaged and locking nuts tightened.

- The fixing of the support to the structure shall be adjusted to ensure that the angles of support
rods are in accordance with the specified limits.

LP Economizer Recirculating Pumps:

Pump assembly with all auxiliaries and accessories shall be stored indoor strictly in accordance
with Manufacturer’s instruction and on the basis of what indicated in the paragraph dedicated to
preservation of aforesaid machinery.

During storing into warehouses, installation, alignment and pre commissioning operations
preceding the first start up, the pumps shall be adequately protected with temporary sheds and/or
polythene sheets.

Pump rotors shall be weekly rotated to avoid damaging of the pump seals.

Pumps are supplied on skids, therefore following assembly activities shall be carried out:
a) Control of foundations and relevant embedment, cleaning included, before positioning
the pump skid.

b) Control and execution, by means of suitable plates and/or shims, of pump elevation
and preliminary alignment. Shims shall be made of rustproof material, possibly of unitary
thickness and any packing of shims shall anyway not include more than three shims.

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c) Execution of the final alignment before and after connecting suction and discharge
piping, in accordance with tolerances required by the Supplier of machinery, inclusive of
the coupling/uncoupling operations of the pump/motor union joint.

9.19 Touch Up Painting

All equipment and accessories will be supplied with surface preparation and at least with primer
coating. Where necessary, touch up painting shall be done after erection in full compliance with
the applicable paint specification.

All burrs and edges shall be removed before touch up painting.

Inspections and, if required, touch up of the painted surfaces of the equipment will be carried out
prior to the final erection and completion.

At touch up painting completion, an inspection will be undertaken of all activities and witnessed
by parties as per ITP.

The acceptance of work and comments if any, shall be recorded on a general approved format

Note:

Any damages of painting during Transportation shall be reported to Owner in the MRIR and
supported by photo records.

10.0 TIME LINE OF ACTIVITIES

Detailed Schedule attached.

11.0 PROGRESS MEASUREMENT

Detailed progress measurement Sheet shall be submitted after taking off complete BOQ for
GAMA approval.

12.0 QUALITY REQUIREMENTS

Inspection and Recording Requirements
The engineer shall verify that the Engineer/Supervisor/Foreman with construction responsibilities
for the execution of works is familiar with this method statement and is issued with copies of the
inspection checklists and test plans. The engineer should satisfy procedures provided by QA/QC
inspections to ensure the pipe welding works meet specified engineering requirements and
drawings. As part of the assessment, the QC Inspection Procedures must ensure a quantitative
or qualitative acceptance criteria for determining the prescribed activities have been
accomplished satisfactorily.

The QC inspection personnel, in coordination with Site Engineer/Supervisor, shall verify that the
quality of the works and related testing activities are within the project specifications
requirements.

The Engineer/Supervisor shall verify that the works is accomplished in accordance with the
specifications and the Supplier’s procedures. The Supervisor should verify any as-built record of
works and testing, and confirm that the information meets the project requirements.

All inspection shall be done as per approved QAP & ITP.

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Training and Qualification of Personnel

The Supervisor shall verify that the personnel have sufficient knowledge of the procedure
requirements. The Supervisor shall review any training and qualification records for those
individuals who shall do the task to determine whether they are skilled enough to follow the
procedure before the actual work is carried out.

Non Destructive Testing (NDT)

All NDE shall be performed in accordance with applicable Codes /Project Specification. Minimum
NDE percentage shall be done as per applicable Project Specification. A separate written
relevant NDE procedure shall be submitted to GAMA for approval.

NDE shall be performed and interpreted by qualified personnel only.

Quality Assurance plan & Inspection Test Plan attached.

Details & Responsibilities of the Sub-Contractor for NDT work shall be submitted at a later
stage.

CV of the QA/QC manager attached.

Non-Conformities procedure attached.

List of the Control and Test Equipment & Tools attached. Calibration certificate shall be submitted
progressively after mobilizing to site.

QA/QC Team:
1) QA/QC Manager
Mr. Yahiya Mahdi Hilal Abdualla Madan
Diploma in Mechanical & Plant Engineering with 20 years of Experience.

Additional Certifcation:
NDT-ASNT LEVEL II in RT, UT, PT,MT& VT
CSWIP 3.1 - Certified Welding Inspector, TWI 2008
CSWIP BGAS 3.2– Certified Painting Inspector, TWI 2010
IOSH Safety Management
Electrical wire man license

2) QA/QC Supervisor
3) Mr. A. Shajahan
Higher Secondary school Certificate with 17+ years of Experience.

Additional Certifcation:

Certified Associated welding Inspector (CAWI –AWS).

Certified ASNT Level II in RT, UT, MT ,PT &VBT

13.0 HEALTH, SAFETY and ENVIRONMENTAL REQUIREMENTS

Contact Details of HSE Site Team:

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1) HSE Manager
Mr.Edwin Suganob
Qualification:
Diploma in Safety Engineering with 14+ years of Experience
Additional Certifcation:

Certificate of Attendance for incident/injury free

Certificate of Attendance for chemical spill control

Certificate of participation for Oxy-Acetylene training

Certificate of completion for Fire safety training

Certificate of Training for Excavation and training safety

Certificate of attendance for Site incident prevention program

Certificate of Training for Scaffolds and ladder safety

Certificate of attendance for tools and equipment maintenance

Certificate of completion for Control of hazardous energies (COHE/LOTO)

Certificate of Training for fall protection and Ladder safety

Certificate of completion for Basic and advance electrical safety

Certificate of training for Safe Rigging and Slinging

Certificate of Training for Tower crane Rescue (High Angle training Centre)

Certificate for Instructional Training course for Assisted Rescue Kit (ARK)

Certificate of completion for First Aid and Adult CPR/AED

Certificate of completion for Basic Occupational Safety and Health

Certificate of completion in supervisor skills workshop

2) HSE Supervisor
TBN
General PPE’S like Helmet, Safety Shoes, safety Glass, coverall, Safety Harness etc. shall
be provided to all workforce. Special PPE’S like Breathing Devices shall be arranged if
required.
HSE PLAN ATTACHED.

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14.0 RISK ASSESSMENTS

Hazard Identification & Risk Assessment Procedure attached.

15.0 REFERENCES
PP1314-00-Y-UP-WP-003 Project Quality Plan
GEMSS-G-05 Quality Control & Quality Assurance Plan.

16.0 TECHNICAL APPENDICES

NIS/GAMA/ITP/626-01 Quality Plan & Inspection & Test Program.

QCP-34 Non Conformance Procedure.

17.0 ATTACHMENTS
Attachment-1 Planned Manpower Distribution Histogram.
Attachment-2 Equipment Histogram (Subcontractor & GAMA)
Attachment-3 Detailed Schedule
Attachment-4 Quality Assurance Plan & Inspection Test Plan
Attachment-5 CV of the QA/QC Manager
Attachment-6 Non-Conformities Procedure
Attachment-7 List of the Control and Test Equipment & Tools attached. Calibration
Certificate shall be submitted progressively after mobilizing to site.
Attachment-8 HSE Plan
Attachment-9 Hazard Identification & Risk Assessment Procedure.

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