HRSG Erection Manual Vendor SUR-V-99HA-1!91!003_RA

PROJECT NAME:

SUR INDEPENDENT POWER PROJECT

PO DESCRIPTION: HEAT RECOVERY STEAM GENERATOR

PO NO.: OPAB1-H1201

SUBJECT: ERECTION MANUAL (MECHANICAL, INCLUDING MAIN LIFTING AND INSULATION)

DOCUMENT NO.: SUR-V-99HA-1-91-003

OWNER

OWNER’S ENGINEER

CONTRACTOR

SUB. CONTRACTOR

A 11 Jul 2012 ISSUED FOR REVIEW ALS RDG

Rev. No

Date Description Prepared

by Checked

by Reviewed

by Approved

by

It may NOT be used, disclosed or reproduced for other purpose pertaining to this document or its contents without specific, written prior

permission of Daewoo E&C Co., Ltd.

For Review

NENOOTER/ERIKSEN

APPROVED BY: _PJH_______ X:\Procedures\Erection.Manual\Cover Sheet.R5

FIELD ERECTION MANUAL

HEAT RECOVERY STEAM GENERATOR

FOR

SUR IPP Project, Oman

NOOTER/ERIKSEN JOB NUMBER

113100

Rev. 0

APPROVED BY: PJH X:\Procedures\Erection Manual\INTRO.R3.doc

FIELD ERECTION MANUAL

GENERAL INFORMATION

1. DRAWINGS REFERENCED IN THIS MANUAL: Job specific drawings are referenced in this Manual. Drawings supplied by

Nooter/Eriksen Project staff directly through the drawing transmittal process shall be used for the erection of the HRSG. The drawing list in this manual is periodically updated and does not necessarily reflect the most recent revision level on this project.

2. SHIPPING/LIFTING WEIGHTS: Shipping weights obtained prior to the release of this manual shall be

regarded as “Preliminary” and used for estimating purposes only. Shipping weights, as shown on Bills of Lading, other shipment documents or stenciled on the equipment are not to be used for lifting or rigging purposes in the field. Refer to the field erection drawings to obtain this information.

3. SHIPPING SEQUENCE

A shipping sequence will be issued on a periodic basis to keep the Erector informed on the latest delivery status of the HRSG components. This will be a “working” document that will be updated with the latest information, including changes in anticipated delivery dates, shipping status, rail car numbers, etc. The delivery dates shown are not contractual dates, but a reflection of the current shipping information and are subject to change.

4. RELEASE FORMS Release forms accompanying the documentation for this manual shall be filed

with the manual. The release date on the Form shall be the effective date of the revised documentation.

It is the responsibility of the recipient to destroy all copies of the previously

released manuals and documentation when updated revisions are issued by Nooter/Eriksen.

Nooter/Eriksen will issue release forms and revised documentation only for

manuals listed in the “MANUAL DISTRIBUTION” portion of the Release Form. All manuals generated by others shall not be considered “Controlled Documents”.

INDEX SECTION PAGE 1.0 General ......................................................................................... 1

2.0 Definitions ..................................................................................... 1

3.0 Reference Documents .................................................................. 2

4.0 Nooter/Eriksen Contacts ............................................................... 2

5.0 Scope of Supply by Nooter/Eriksen .............................................. 3

6.0 General Scope of Field Work Required by Erector/Purchaser ..... 4

7.0 Non-Destructive Examination and Stress Relieving ..................... 6

8.0 Unloading, Handling and Storage ................................................. 7

9.0 Material and Equipment Furnished by the Erector ....................... 9

10.0 HRSG Erection ............................................................................. 9

11.0 Testing ........................................................................................ 11

12.0 Painting ...................................................................................... 14

13.0 Supporting Reference Documents.............................................. 14

14.0 Distribution Grid .......................................................................... 15

15.0 Shipping Sequence .................................................................... 15

16.0 Piping ......................................................................................... 15

17.0 Drain Valves ............................................................................... 15

SUR IPP PROJECT, OMAN N/E JOB NO. 113100

ERECTION PROCEDURE, REV. 0 PAGE 1

APPROVED BY RDG X:\Procedures\Erection.Manual\Erection_Procedure R16

FIELD ERECTION

RESPONSIBILITIES

1.0 GENERAL

1.1 THIS MANUAL SHALL BE PROVIDED TO ALL FIELD SUPERVISORY PERSONNEL INVOLVED IN THE HRSG ERECTION.

Read and review this entire manual and its contents before beginning field erection.

1.2 The minimum scope of work to be performed by the field erection

subcontractor (Erector) shall consist of all work required to provide a complete Heat Recovery Steam Generator (HRSG) with accessories. The field scope includes, but is not limited to: unloading, storage, hauling, erection, alignment, cleaning (inside and outside), and the commissioning required for start-up for satisfactory continuous commercial operation.

1.3 Each HRSG has been designed and is to be constructed in accordance with requirements of the American Society of Mechanical Engineers Power Boiler Code, ASME Section I and ASME Section VIII, Division 1.

1.4 The scope of major equipment furnished by Nooter/Eriksen, Inc. for

erection is shown on Nooter/Eriksen Drawing No. 113100-GA-001 (SUR-V-99HA-1-17-001).

2.0 DEFINITIONS

2.1 N/E: Nooter/Eriksen, Inc.

2.2 Purchaser: Daewoo E&C

2.3 Erector: Erection contractor responsible for the installation and assembly of the HRSG.

2.4 HRSG: Heat Recovery Steam Generator 2.5 Code: American Society of Mechanical

Engineers Power Boiler Code Section 1, Section VIII, Division 1, and ANSI B31.1.

2.6 K/D: Knocked Down Shop Fabrication



2.7 Modular: HRSG construction in which the coil bundles are shipped separate from the casing. Casing is shipped in panels for assembly at jobsite.

3.0 REFERENCE DOCUMENTS

These reference documents form an integral part of this manual and must be read carefully and understood before beginning any field erection. Reference documents are listed in Section 15.0 under the “General” tab location. Should you have any questions, please contact the individuals listed below:

Document Description Section No. Tab Location

3.1 N/E Standard Erection Procedures 13.1 thru 13.14 Procedures

3.2 Field Service Site Visits 13.15 Miscellaneous

3.3 N/E Backcharge/Extra Work Policy 13.16 Miscellaneous

3.4 Manway Covers 13.17 Miscellaneous

3.5 Descriptive Orientation 13.18 Miscellaneous

3.6 Lifting Device Drawings 13.19 Miscellaneous

3.7 Module Storage 13.20 Miscellaneous

4.0 N/E CONTACTS

4.1 Kevin Lacey Phone: (636) 651-1032 Project Engineer Fax: (636) 651-1507

E-mail: [email protected]

4.2 Alan Schulte Phone: (636) 651-1115 Project Manager Fax: (636) 651-1507


4.3 Andy Febus Phone: (636) 651-1040 Manager of Logistics Fax: (636) 651-1512




4.4 Keith Kennedy Phone: (636) 651-1000 Construction Supervisor Cellular: (314) 941-2165


4.5 Larry Greene Phone: (636) 651-1054 Director of Projects Fax: (636) 651-1507


5.0 GENERAL SCOPE OF SUPPLY BY NOOTER/ERIKSEN

Foundation Embedments Inlet Expansion Joint (K/D) Inlet Transition Duct Panels (K/D) Inlet Distribution Grid (K/D) Supplemental Duct Burner Runners Firing Duct Panels (K/D) Fuel Train Skid Scanner Cooling Air Skid Primary Casing Panels (K/D) Secondary Casing Panels (K/D) HRSG Coil Modules Recirculation Pumps Remote Steam Drums Deaerator Atmospheric Blowdown Tank Exhaust Stack (K/D) Expansion Joint at Stack (K/D) Exhaust Stack Silencer Baffles (K/D) HRSG Interconnecting Piping Pipe Supports Platforms, Stairs & Ladders (K/D) Boiler Trim & Valves (K/D) Field Seam Material (K/D) External Insulation for Interconnecting Piping, Valves and Drums. Temporary Use of Horizontal and Strong-Back Lifting Device for Erection of

Coil Modules. (Lifting Devices must be returned to N/E after use.)



6.0 GENERAL SCOPE OF FIELD WORK REQUIRED BY ERECTOR/PURCHASER Unload all Equipment Remove all Temporary Crating and Shipping Braces Heavy Haul Transport from Rail Siding to the Jobsite Install Anchor Bolts, Washers, Nuts, Slide Plates, Teflon Slide Packs, Shim

Packs, Shear Plates & Grout Erect Inlet Duct Transition Sections Erect Primary and Secondary Casing Panels Install Duct Burner Elements Install Inlet Expansion Joint Install Gas and Electric Lines, etc., between Burner Skids and Duct Burner Install HRSG Modules Install Gas Baffles Erect Firing Duct Install all Field Seams between Ducting, Modules, Burner, etc. Erect and Assemble Structural Steel for Remote Steam Drums Set Remote Steam Drums Install Recirculation Pumps Erect Exhaust Stack Install Pipe Supports Erect all Large Bore Piping Install and Weld in all Valves per Nooter/Eriksen’s Trim List for

Interconnecting Piping Install Safety Relief Valves, Drip Pan Elbows, Vent Stacks, Silencers with

Support Steel Assemble and Erect Structural Steel for Stair Tower Assemble and Erect Stairs and Platforms Assemble and Erect all Other Platforms and Handrails Install all Field Platform Support Clips Install Exhaust Stack Outlet Expansion Joint Install Stack Silencers Install Packing, Gaskets, Closures and Casing Penetration Sealing Devices

as Necessary per Detailed Drawings Supplied by Nooter/Eriksen Assemble and Erect EPA Platform on Exhaust Stack Install and Assemble all Instrumentation for Piping, Drums and Gas Side

Casing. Refer to Nooter/Eriksen’s HP and LP Trim Lists (Water Columns, Gauge Glasses, Pressure Gauges, Level Transmitters, Thermocouples, etc.)

Assemble and Install Drain Lines from all Safety Valves Assemble and Install Blow Offs from Water Columns Assemble and Install all other Drain Lines & Valves



Assemble and Install Drain Valves and Manifolds Along Side Each Heat Transfer Section including Collecting all Multiple Drains at each Bundle

Install Freeze Protection Tubeside Cleaning of HRSG Steam Blows Install Steam Drum Internals after Tubeside Cleaning Re-install non-return Valve Discs, Desuperheaters, Steam Sample Probes,

Measurement Devices or any other Equipment that was temporarily removed for Steam Blows

Install all Pneumatic Tubing or Pipe for Air Supplies and Signal Lines Install all Electrical Conduit, Wiring and Electrical Panels Install all External Personnel Protection (Not Required with Insulated Stack). Install all External Insulation on Remote Steam Drums, Drum Heads,

Interconnecting Piping, Drain Lines, etc. Install all External Insulation on Outlet Stack Install all External Insulation on Silencer Duct Touch-Up Primer and Finish Paint Commissioning, Check all Valves/Motor Operators Prior to Start-Up, etc.



7.0 NON-DESTRUCTIVE EXAMINATION AND STRESS RELIEVING

7.1 The Erector shall provide all necessary equipment and manpower to perform all required non-destructive testing as required by the Code or the Purchaser.

7.2 As a minimum requirement, the Erector shall 100% Magnetic Particle Test

(MT) all field welds at corner connections on major structural frames. If other more stringent non-destructive examination methods are required (as required in high seismic areas, and/or as specified on N/E drawings), the Erector shall perform them.

7.3 The Erector shall provide all stress relieving equipment and all necessary

materials and specialists as may be required to properly stress relieve the welds as required by the Code and the Purchaser.

7.4 The Erector shall perform the stress relieving as required by Code and

maintain charts of time versus temperature gradients, copies of which shall be submitted to the Purchaser. A copy of radiographic results and procedures will be forwarded to the Purchaser. Purchaser will forward all documentation to N/E that is to be included in the Master Document Package.

7.5 In addition to the Mandatory Code Requirements for non-destructive

examination of welds, it is recommended that the following additional radiography be applied:

1) At least 5% of all full penetration pressure part butt welds not

requiring radiography by the ASME Code, shall be 100% radiographed.

This should be implemented by radiographing 5% of this category of welds deposited by each welder.

In the event of a defect being identified in the prescribed 5%, a further 5% of welds deposited by that welder shall be radiographed. Should additional defects be identified, all welds deposited by that welder shall be radiographed.



This category of welds normally includes butt welds in the downcomer & riser piping, and butt welds in the boiler proper and boiler external piping.

2) Exhaust stack shall be erected, welded and inspected per the

requirements of ASME STS-1 and any local applicable codes. 8.0 UNLOADING, HANDLING AND STORAGE

8.1 Equipment to be installed shall be received, unloaded and stored by the Erector in areas designated by the Purchaser. The Erector’s work shall include moving the equipment from the storage area to the point of installation or as otherwise specified. The cost to unload and transport all items to the point of installation from the nearest railsiding shall be at no extra cost to N/E. It is the Erector’s responsibility to unpack or uncrate all equipment. This includes all protective materials/structures included with equipment furnished.

8.2 The Erector shall unload, erect or store the equipment without delay.

Detention and demurrage charges, associated with failure to off-load rail cars at the jobsite in the days allotted by the rail service, will be billed to the Purchaser. Erector must notify the railroad immediately of cleaned railcars to avoid unnecessary charges to the Purchaser. All deliveries, unloading and transporting of equipment shall be coordinated through the Purchaser to avoid interference with other operations. The Erector will ensure that end-to-end support of the modules is sufficient during transportation. If restraints are needed to ensure the integrity of the modules during travel on steep grades, the Erector will install them as required. If modules are stored, refer to the Module Storage Recommendations drawing located in the “Miscellaneous” section of this manual.

8.3 The Erector shall be responsible for the care and custody of the

equipment received. All N/E furnished equipment arriving at the railsiding or site shall be checked by a representative of the Purchaser and turned over to the Erector in good condition. The Erector shall be responsible thereafter for the equipment until it is installed and accepted by the Purchaser.

8.3.1 Any material shortages which conflict with Nooter/Eriksen Shipping

List must be identified and reported to N/E by the Purchaser in writing within two (2) days of receipt of material. If inspection



requires opening of protective shipping containers, it is the Purchaser’s responsibility to repack and weather protect all items after inspection.

8.3.2 If damaged materials or equipment is received, N/E shall be notified in writing and with verifiable photographs or video provided within (2) days of receipt of material.

8.3.3 Materials or equipment received, with damage incurred in transit,

shall be indicated on the Bill of Lading (BOL) when the material or equipment receiving ticket is signed. Failure to indicate damages on BOL will result in the repairs being the Erector’s responsibility.

8.3.4 The following shipping information will be marked or permanently

attached on each major component or package received: a. Nooter/Eriksen Job Number/Unit Number (on N/E

General Arrangement Drawings). b. Component Name. c. Shipping Weight in Pounds. d. Package Dimensions (on boxes only).

8.4 The Erector shall keep a written record of all equipment and materials

received at the jobsite and perform regular inspections and maintenance during storage. These records shall be made available to the Purchaser and N/E at all times.

8.4.1 All materials and equipment shall be stored in weather protected

enclosures or buildings unless they are essentially unaffected by weather with prior Purchasers approval. All enclosures or buildings necessary for storage shall be provided by the Erector.

8.4.2 All ducting or casing, with internal insulation, should be stored in

a position that would allow drainage of any water from the insulation. Also, protective material, located at casing field seams, should be left in place to protect the insulation, until field seam installation begins.

8.4.3 Secondary casing panels are typically shipped with the internal

liner facing upward. The attachment points for tailing these panels are located on the casing (downward) side of the panel. It is the Erector’s responsibility to exercise caution in offloading



and rotating these panels for installation, so that there is no damage.

8.4.4 All piping must remain capped during storage and erection, in

order to preserve cleanliness.

8.4.5 Coils and drums are shipped with an internal vapor phase corrosion inhibitor added prior to sealing nozzles with plastic caps and tape. To maximize the protection against corrosion and contamination, coil and drum nozzle caps and tape should be maintained and remain intact as long as possible. It is acceptable, however, to remove caps on lower header nozzles temporarily to facilitate module draining during erection.

8.4.6 Valves and instrumentation are to be stored indoors.

9.0 MATERIAL AND EQUIPMENT FURNISHED BY THE ERECTOR

The Erector shall furnish all items required for the work not specifically being furnished by N/E. These items shall include, but not be limited to, labor saving devices; special equipment and technicians for stress relieving; temporary winterizing or freeze protection during erection for drainable and non-drainable parts of the HRSG; hydrotest equipment. The Erector shall furnish all necessary tools and construction equipment such as transporters, rigging equipment, welding equipment, consumables, trucks, cranes, etc., necessary to perform the work.

10.0 HRSG ERECTION

10.1 The Erector shall plan the erection of the HRSG taking into account N/E’s recommended field erection procedures and specific requirements from detailed project drawings, as listed in the Nooter/Eriksen Drawing List.

10.2 Erection Procedures are found with the reference documents at the back

of this manual in Section 15.0. Note: Erector must comply with any special erection and storage requirements

provided by manufacturers/designers of specialty equipment such as, but not limited to: A) Duct Burners B) Pumps



C) Expansion Joints D) Etc.

10.3 These procedures are provided as a guide for field erection based upon N/E’s design of the system. Deviation from these procedures is not recommended unless otherwise indicated on N/E’s Project Specific Erection Drawings. If the Erector chooses to follow other procedures and difficulty arises or damage occurs, the Erector will assume all responsibility and all associated additional costs. N/E reserves the right to review all changes to the procedure.

10.4 Caution: Certain components of this HRSG have been fabricated

using 91 Chrome materials (SA-213 T91, SA-335 P91, SA-387 Grade P91, SA-234 F91, etc). Check your project specific drawings for the exact location of this material.

This material has special welding, fabrication and heat treatment requirements. Compliance with these requirements is necessary to ensure the proper life of the component. Welding (including tack welding and welding of temporary attachments) must be controlled at all times. Experts should be consulted in developing the necessary welding procedures; all welders must be qualified per ASME Section IX using Alloy 91 materials.

Proper control of the heating of the material (preheat, heat input of

welding, post heating, cooling and post weld heat treatment) must be maintained at all times. It is recommended that testing after PWHT be performed to verify that the proper micro structure has been acquired by the appropriate welding/heat treat process. All weldments must be cooled to below 200F (93C) prior to the performance of post weld heat treatment.

Exposure of “as weld” (prior to the performance post weld heat treatment)

weldments to environmental elements is to be limited. Protection shall be provided to prevent direct exposure to moisture.

Special care is to be taken to reduce the amount of additional stress when

moving any “as weld” weldments. Use of the DC prod method of magnetic particle testing (MT) is prohibited. This material must not be exposed to an open flame (flame impingement).



Preheating to 400F (204C) of the material is to be done for all thermal operations, including welding, tack welding, thermal cutting, gouging, etc.

All arc strikes not in the welding preparation zone must be ground and

verified by non-destructive examination (NDE) as not being detrimental to the material.

When welding P91 to P22 material, N/E recommends that P91 welding

consumables are used. Failure to comply with these cautions may void the Nooter/Eriksen

Warranty. 10.5 Freeze Protection

Any piping or parts of the equipment that may collect water and freeze should be heat traced and insulated. This includes areas that could accumulate snow and ice, such as open top silencers, safety valve discharge stacks, etc.

11.0 TESTING

11.1 HYDROSTATIC TESTING After field assembly, each pressure level of the HRSG and any interconnecting piping within the ASME Code boundary must be hydrotested by the assembler and witnessed by their Authorized Inspector (AI).

Additional hydrotests may be necessary during the life of the HRSG if any alterations or repairs are performed within ASME Code boundaries.

The following information is provided to help protect the HRSG before and after hydrostatic tests. CAUTION: NOOTER/ERIKSEN DOES NOT RECOMMEND THE USE OF PNEUMATIC TESTS IN LIEU OF HYDROSTATIC TESTS. HYDROSTATIC TESTS, WHEN CONDUCTED PROPERLY, ARE A SAFE METHOD TO TEST FABRICATED EQUIPMENT BEFORE OPERATION. DUE TO THE INHERENT DANGER ASSOCIATED WITH A FAILURE UNDER PRESSURE FROM COMPRESSED GAS OR AIR, PRESSURIZING WITH AIR OR GAS CAN BE EXTREMELY DANGEROUS.



Verify that all instruments are isolated to prevent damage from over pressurization.

The HRSG components must not be exposed to pressures exceeding 1.5 times the MAWP. Review hydrotest procedures in the pressure safety valve manufacturer's manual. For hydrotest pressures that exceed design pressure, the valves must be isolated (pancaked or removed and replaced by blind flanges) from the test pressure. When safety valve design pressures will not be exceeded during hydrotest, some operators have successfully gagged the valves, but Nooter/Eriksen does not recommend this procedure.

CAUTION: USE OF SAFETY VALVE "GAGS” WHEN HYDROSTATIC TEST PRESSURES EXCEED DESIGN PRESSURES COULD RESULT IN DAMAGE TO THE VALVE. Severe corrosion can occur when inappropriate water is used for the hydrotest. N/E recommends the following: Demineralized, deaerated water or polished is recommended.

If demineralized water is not available, potable water may be used

provided all of the following are met: a. Water source must be flushed and proven clean prior to discharge into the boiler. b. Water is to be filtered prior to first fill for hydrotest. c. The water is to be sampled and tested prior to use. Testing shall be

conducted for pH, silica, iron, chloride, etc., for reference. d. Water samples are to be taken prior to filling the boiler and during

draining, and maintained for reference. e. Water must be drained immediately after hydrotest is complete.

The hydrotest water, whether demineralized and deaerated or acceptable potable water, must have the pH adjusted to 9.0 as a minimum

Diethylhydroxylamine (DEHA) oxygen scavenger should be added to

hydrotest water to reduce oxygen concentration to 2 to 7 ppb.

Chemicals should be added in a manner that provides thorough mixing.



If stainless steel parts are exposed to hydrotest media, chlorine content must not exceed 30 ppm or these parts should be removed for the hydrotest, if possible.

Providing a high capacity hydrotest pump to allow filling the HRSG as

quickly as possible will provide the best results in expelling air from the system. All vent valves should be open during filling to allow air to escape the system.

If a potential for freezing weather exists, the unit should be filled with the

warmest water available. (Note, however, that ASME Code defines metal and water temperatures in PG99. This should be consulted for proper temperatures.) Interior heating or other precautions may be necessary to prevent freeze damage.

After the test, the HRSG must be properly laid up to prevent damage from

corrosion or freezing. Unless water treated specifically for lay up was used during the hydrotest and will be chemically maintained over the lay up period, the HRSG must be drained and laid up dry within 24 hours. (See the Nooter/Eriksen Lay Up recommendations.)

If the HRSG will be drained, proper precautions must be taken to insure

that all water is removed from the unit. (See the Nooter/Eriksen draining recommendations.)

Stops on all spring cans should be removed after the field Hydrotest.

All valves have been tested by the manufacturer to ASME B16.34 or API

598 requirements for pressure boundary and seat leak tightness. N/E will warrant any leaking/seating issues on all N/E supplied valves through HRSG hydrotesting. Any drain valve leakage that occurs after HRSG hydrostatic testing has proved the valves were supplied as leak tight, is the responsibility of the purchaser/owner and will not be considered as a warranty issue by N/E.

CAUTION: HYDROTEST WATER LEFT IN THE HRSG CAN DO DAMAGE BY FREEZING OR CORROSION. Note: N/E will not accept any liability resulting from the particular chemistry of the hydrotest water.



12.0 PAINTING

The inner liner of the Nooter/Eriksen casing design system is exposed to turbulence and vibration forces from the gas turbine exhaust. The liner has to be securely attached to the cold casing. This is accomplished by the use of pins and/or other components. Since these parts must be attached directly to the outer casing, a certain amount of heat conduction is unavoidable and localized areas of the external casing may exceed the average casing temperature. In addition to the support system for the liner, there are liner/casing penetrations and bearing points for coils and other internals, where there may be localized hot spots on the outer casing. These hot spots may be noticed as small areas of paint discoloration. These areas of higher casing temperature do not indicate insulation breakdown and will not compromise the long term structural integrity of the unit. Paint discoloration and overall HRSG appearance is dramatically affected by the choice of paint. Paints should have a continuous temperature rating of at least 450F. Other paint concerns could be a high curing temperature, color matching, and VOC emissions. Nooter/Eriksen recommends using zinc rich primer. If a topcoat is required, an aluminum colored silicone acrylic or alkyd is recommended.

13.0 SUPPORTING REFERENCE DOCUMENTS

PROCEDURE NO. DESCRIPTION 13.1 EP-01 FOUNDATIONS, ANCHOR BOLTS & BASE PLATES 13.2 EP-02A SETTING OF MAJOR HRSG COMPONENTS (MODULAR) 13.3 EP-03A LIFTING AND RIGGING PROCEDURES (MODULAR) 13.4 EP-04A FIELD SEAM INSTALLATION (MODULAR) 13.5 EP-05A REMOVAL OF TEMPORARY STEEL/WOOD (MODULAR) 13.6 EP-06 STAIRTOWERS/PLATFORMS/LADDERS 13.7 EP-07 EXPANSION JOINT INSTALLATION 13.8 EP-08 GASKETS AND PACKING 13.9 EP-09 LARGE BORE PIPING 13.10 EP-10 SMALL BORE PIPING/TRIM 13.11 EP-11 FIELD WELDMENTS 13.12 EP-12 PSV’S, START-UP VENTS & STACKS 13.13 EP-13 RECOMMENDED TUBESIDE CLEANING 13.14 EP-14 NOT USED 13.15 FIELD SERVICE SITE VISITS



13.16 NOOTER/ERIKSEN BACKCHARGE / EXTRA WORK POLICY 13.17 MANWAY COVERS 13.18 DESCRIPTIVE ORIENTATION 13.19 LIFTING DEVICE DRAWINGS 13.20 MODULE STORAGE

14.0 DISTRIBUTION GRID

The inlet may require a field installed distribution grid, based on a flow model study. See Inlet Duct drawings for specific details.

15.0 SHIPPING SEQUENCE

A shipping sequence will be issued on a periodic basis to keep everyone informed on the latest delivery status of the HRSG components. This will be a “working” document that will be updated with the latest information, including changes in anticipated delivery dates, shipping status, rail car numbers, etc. The delivery dates shown are not contractual dates but a reflection of the current shipping information.

16.0 PIPING This contract requires that the 3” Nooter/Eriksen standard field trim be eliminated from the LB piping (except on all drum risers). Because of the elimination of the standard field trim, Nooter/Eriksen is not subject to field backcharges for mismatches on LB piping of less than 3” (i.e. if 3” field trim was left on, the field could have made the adjustment to the pipe).

17.0 DRAIN VALVES Block valves have been supplied on all drain lines. All valves have been hydro tested by the manufacturer to ASME B16.34 or API 598 requirements for pressure boundary and seat leak tightness. N/E will warrant any leaking/seating issues on all N/E supplied valves through hydrostatic testing. It is the purchaser’s responsibility to appropriately clean, flush and drain the HRSG during commissioning and/or normal operation. Opening of drain valves with the unit under pressure greater than 100 psig can be damaging to the valves. The exception to this rule is the opening of superheater and reheater drains under startup conditions to eliminate any condensate that may have accumulated. Any drain valve leakage that occurs after hydrostatic testing has proved the valves were supplied as leak tight, is the responsibility of the purchaser/operator and will not be considered as a warranty issue by N/E.

EP-01 PAGE 1 ERECTION PROCEDURE FOR

FOUNDATIONS ANCHOR BOLTS AND BASE PLATES

APPROVED BY: RDG X:\Procedures\Erection Manual\EP.01.R7

1.0 The contractor responsible for foundation installation shall meet the requirements of

N/E’s foundation drawing.

1.1 The Contractor shall establish the centerline of the unit and the longitudinal reference point and set anchor bolts per N/E’s foundation drawing.

1.2 All anchor bolts shall be located with the following tolerances. (Refer to

Drawing EP-01-01).

- From centerline of bolt group to HRSG centerline: ¼”. - Between adjacent anchor bolts with the group: 1/8”. - From centerline of bolt group to HRSG longitudinal reference point: ¼”. - Anchor bolt projection: ½”.

1.3 Anchor bolts shall be installed when possible using embedded sleeves (min

12” depth). This will assist in the installation of the equipment if either base plate holes or anchor bolts are located out of tolerance.

1.4 A benchmark for elevation reference shall be provided at a location close to

the HRSG. The reference elevation shall be the Purchaser’s reference elevation shown on N/E’s General Arrangement.

1.5 It is recommended not to grout (Note: Only non-shrink grout is to be used)

the foundation slide plates until after the HRSG columns have been set and properly aligned. Pre-grouting, before setting of these columns, eliminates the ability to adjust slide plates by shimming, which is normally required to allow adjustment due to manufacturing tolerances of the HRSG. The contractor has the flexibility to grout anytime after the HRSG columns have been set and properly aligned. However, in any case, foundation slide plates shall be sufficiently shimmed in the field to prevent damage to the HRSG equipment or foundations. Design, manufacture and installation of the foundations, shims and grout are not by Nooter/Eriksen.

1.6 Shear tabs, if shown at column base plate details, shall be installed after

column setting. Welding of the shear tabs shall be on three sides only. No welding on the side of the tab next to column base plate is permitted.

2.0 The Erector of the HRSG shall be responsible for the following items:

2.1 The Erector shall fit each HRSG foundation support point with a slide plate. Slide plates serve two functions. One, it allows the elevations of the top of the slide plate to be adjusted through shimming. Second, provides a flat surface on which the equipment can move due to temperature expansion.


FOUNDATIONS ANCHOR BOLTS AND BASE PLATES

2.2 The Erector shall check to insure that the anchor bolt threads are clean and

all damaged threads corrected using a thread chaser. 2.3 All anchor bolts, slide plates, grout and shims are furnished by someone

other than N/E. Nooter/Eriksen is not responsible for design and/or workmanship of any of the above referenced material located below the bottom of the HRSG base plates.

2.4 The Erector shall check the elevations of all foundations and the location of

all anchor bolts prior to equipment installation. Refer to the benchmark for elevation reference. Any deviation from allowable tolerances as listed on Drawing EP-01-01 should be brought to the attention of the Purchaser. All as built dimensions are to be documented and provided to N/E and the Purchaser upon request.

EP-02A PAGE 1 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS

APPROVED BY: WJP X:\Procedures\Erection.Manual\EP-02A.R15

1.1 Some components are provided to the field with lift lugs. These lugs are only designed to lift the components as supplied. These lugs are not designed to lift the components after any additional assembly by Field Erector. It is the Erector’s responsibility to design and install any lugs required for lifting of pre-assembled components. Each component shall be handled using N/E Erection Procedure drawings. All rigging, spreader beams, shackles, etc. shall be furnished and designed by the Erector to meet the expected loading and the requirements of the procedures.

1.2 MODULAR

1.2.1 The following items shall be checked to insure that critical attachment locations are maintained.

1.2.1.1 Set the top of the slide plates at the theoretical elevation.

1.2.1.2 Base plates shall be greased prior to installation. (Axle

quality grease is recommended). Check to make sure grease fittings are installed. There should be a minimum of two (2) per base plate, OR, if teflon slide packs are used, they must be installed, including welding of the upper pack to the bottom of the casing panel column base plate before setting of panels.

1.2.2 Set primary casing panels and roof beams as defined in EP-04A.

1.2.2.1 Each column shall be set so that the inside flange is at the theoretical distance from the centerline of the HRSG.

1.2.2.2 Erection tolerances are to be in accordance with EP-11. The

inside liner-to-liner dimensions should be checked and documented against the corresponding module dimensions to ensure that module can be set.

1.2.2.3 Unless otherwise stated on N/E’s Foundation Footprint

Drawing, anchor bolts shall be finger tight. All shall be double-nutted.

1.2.3 Install secondary casing panels

1.2.3.1 Erection tolerances to be in accordance with EP-11. (Also refer to EP-03 for rigging procedures.)


1.2.3.2 Upon completion of casing alignment, it is important to verify casing opening dimensions where modules will be placed in the HRSG. The inside liner-to-liner dimensions should be checked and documented against the corresponding module dimensions to ensure that module can be set. The pin row-to-pin row dimension shall also be checked at the field seam locations, to ensure that the field seam plates will fit.

1.2.3.3 Secondary casing panels are typically shipped with the

internal liner facing upward. The attachment points for tailing these panels are located on the casing (downward) side of the panel. It is the Erector’s responsibility to exercise caution in offloading and rotating these panels for installation, so that there is no damage.

1.2.4 After completion of all required welding, bolting and testing, it is

acceptable to set modules within the casing panel.

1.2.4.1 It is recommended not to grout the foundation slide plates until after the HRSG columns have been set and properly aligned. Pre-grouting, before setting of these columns, eliminates the ability to adjust slide plates by shimming, which is normally required to allow adjustment due to manufacturing tolerances of the HRSG. The contractor has the flexibility to grout anytime after the HRSG columns have been set and properly aligned. However, in any case, foundation slide plates shall be sufficiently shimmed in the field to prevent damage to the HRSG equipment or foundations. Design, manufacture and installation of the foundations, shims and grout are not by Nooter/Eriksen.

1.2.5 After each primary casing panel is set, shimmed, checked for correct

elevation, and plumbed, the anchor bolt washers and nuts can be installed. N/E provides enlarged holes in the base plates to facilitate module installation. Anchor bolt washers (as detailed on N/E drawings) are to be installed on the base plates as indicated on N/E foundation detail drawings.


1.2.6 When setting the modules, the nozzle connections shall be checked

against the Nooter/Eriksen drawings for correct station location and elevation to within (+) or (-) ¼”. Nozzle locations should be checked with a transit. Do not rely on shop stenciling for module location. Refer to Nooter/Eriksen field erection drawings for module configuration and unit location.

1.2.7 Removal of temporary shipping wood/steel must be completed before

startup. See Procedure EP-05A. 1.2.8 For each successive module set, particular attention shall be given to

make sure that the modules location and elevation are maintained. The nozzle orientation, as shown on Nooter/Eriksen drawings, shall be used as the primary guide for the setting and the alignment of modules.

1.3 DUCTING/BREECHING

1.3.1 All ducting is furnished in either completed sections or in knocked down panels. In each case the same check list of items required for module setting shall be followed, except that the top of each column shall be checked for correct station location and plumbness.

1.3.2 If the HRSG is provided with an SCR, the Erector is to verify that the

Catalyst Loading Opening is plumb and square so that the Catalyst Loading Doors will fit properly (trial fitting the Catalyst Loading Doors is recommended). This must be done prior to final welding of the SCR duct frame corner connections.

1.4 EXHAUST STACK

1.4.1 Exhaust stack shall be erected, welded and inspected per the requirements of ASME STS-1 and any local applicable codes.

1.4.2 All rigging, spreader beams, shackles, etc. shall be furnished by the

Erector to meet the requirements of the procedures. 1.4.3 Exhaust stacks are provided with either anchor chairs or an anchor bolt

ring. In either case, the stack is considered to be fixed against longitudinal movement.

1.4.4 Anchor bolts shall straddle natural centerlines.


1.4.5 Unless otherwise stated on N/E’s Foundation Footprint Drawing, all

stack anchor bolts shall be torqued tight per AISC, since the stack is considered fixed (See 1.6.2).

1.4.6 Prior to setting the stack, the Erector should prepare the concrete for

shim pack locations. Enough shim packs should be used to prevent damage to the foundations.

1.4.7 Exhaust stack can come in one piece, two pieces, or multiple sections

depending on the diameter of the stack. If supplied K/D, orientation of vertical seams will be found on fabricator’s drawings.

1.4.8 If the stack is provided with a damper, the damper shall be installed after

the bottom stack section is installed vertically on the stack foundation. The damper shall not be attached to any stack cylinders prior to lifting into final position, to prevent damage to the damper.

1.4.9 For thermal expansion between the last HRSG module and the fixed

exhaust stack, there will be an expansion joint. It is important to ensure the following items are checked.

- Elevations of module and stack are at the proper locations. - The centerline of the stack matches the centerline of the module. - Module and stack are plumb within ¼” - Distance between the module and stack maintained to within ¼” of

theoretical 1.4.10 It is recommended that the platforming required for EPA test ports be

installed just prior to lifting the stack sections. 1.4.11 Personnel protection at the elevated platforms can be installed prior to

erecting the stack if painting is not required. It is recommended that the personnel protection at the base be installed after the stack has been set and any painting requirements are completed.

1.5 REMOTE DRUMS

1.5.1 Normally the remote steam drums are supplied without lifting lugs attached in the shops.

1.5.1.1 See Drawing EP-03-5 for details of erection procedure.


1.5.1.2 Slings shall not break against any nozzle or nozzle reinforcement pad.

1.5.1.3 Softeners should be used with cable slings to prevent

damage to material.

1.5.2 Each drum will be fitted with at least two support saddles. Guides shall be installed around the saddle, after the drum is in its final position to limit any movement and for resisting lateral wind and earthquake loadings.

1.5.3 Both drum saddle base plates shall be greased prior to installation.

(Axle quality grease is recommended). If other slide mechanisms are used, greasing may be omitted. Check to make sure grease fittings are installed. There should be a minimum of one (1) grease fitting per saddle base plate.

1.5.4 When teflon slide packs are used at the drum saddle base plates, be

sure to attach the teflon slide packs to both the drum base plate and support steel, prior to setting the drum on the support structure.

1.5.5 It is very important that the steam drums be located properly. The

difference in elevation of the drum centerline, from one end to the other, shall be no greater than ½”.

Erector to check elevation and location of drum nozzles. Tolerance on location of these nozzles is:

Elevation: +/- ½” Location: +/- ¼”

1.6 ANCHOR BOLT TIGHTENING REQUIREMENTS

1.6.1 Anchor bolts that are to be snug tight shall be tightened per AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts.

1.6.2 Anchor bolts that are to be torqued tight shall be tightened per AISC

Specification for Structural Joints using ASTM A325 or A490 Bolts “Turn-of-Nut tightening”. It is not necessary to provide a representative sample, but follow the guidelines of the appropriate table.


1.7 Flow arrows are provided for convenience of the Erector. Nooter/Eriksen

accepts no liability for incorrectly marked flow arrows, as it is still the Erector’s responsibility to check components against drawings to assure proper installation orientation.

1.8 Field welding: As a minimum, all structural field welding is to be in accordance

with AWS D1.1. All pressure part field welding is to be in accordance with applicable codes.

EP-03ASB PAGE 1 LIFTING AND RIGGING

PROCEDURES REVISION 0

APPROVED BY: RDG X:\Procedures\Erection.Manual\EP-03ASB.R6

1.1 This procedure is presented to provide an understanding of how Nooter/Eriksen has designed the equipment to be handled during the setting or erection phase. It is the responsibility of the Erector to meet these requirements. Any deviation from these shall be brought to the attention of Nooter/Eriksen for review. Erector’s rigging plan shall be made available to Nooter/Eriksen, for information purposes only, prior to handling of heavy components.

1.2 All rigging and lifting equipment shall be designed and furnished by the Erector to

meet the expected loading and the requirements of all procedures and drawings. Design and use of this equipment shall comply with all applicable codes, industry standards and safety guidelines. One example of each type of lifting device (one Horizontal Lifting Device and one Strongback Device) shall be provided by Nooter/Eriksen, provided Erector executes Nooter/Eriksen’s standard Release & Indemnity Agreement. Before the Nooter/Eriksen supplied lifting devices are used, the Erector must verify that all device components are properly tagged to indicate that their capacity is consistent with the devices specified on Nooter/Eriksen’s job specific Lifting Drawings.

1.3 Lifting lugs are designed to handle shear, tension and bending. A small amount

of lateral load has been designed into the lug to account for any cable misalignment. Ideally the loads should act in line with the lug; however, a six degree (6°) maximum offset is acceptable. Lifting lugs are limited for use at –20°F and above. When lifting operation temperatures are below –20°F, contact Nooter/Eriksen for review.

1.4 In some cases, a freeze protection medium may be added to the modules prior

to shipment. In these cases, the freeze protection medium is Dow Chemical’s “Dow Frost”, or an N/E approved equal, which is propylene glycol. The MSDS is made available with the shipping documents. The removal and disposal of the freeze protection medium is the responsibility of the field erector.

1.5 MODULES

1.5.1 Each module is fitted with lifting lugs on the top headers or roof panel in the shop. There are usually three lifting operations performed on each module. The first is accomplished when the module first arrives at the jobsite and is lifted in the horizontal position from the railcar onto the transporter. Refer to the job specific N/E Module Lifting Drawings for the general procedure.



1.5.2 The horizontal off-loading lift is performed with the Horizontal Lifting Device. The device attaches as shown on the appropriate job specific N/E Module Lifting Drawing(s), utilizing all of the strap lugs that are provided with the shipping steel. The Horizontal Lifting Device must be adjusted (width of device, as well as lug position) to fit the geometry of the module. It may also be necessary to make adjustments between lifts of different modules.

1.5.3 It is necessary to support the module upper headers (this can be done through the roof beams), the lower headers, and all shipping beams during transportation on the heavy haul transporter and during storage. The supports should be installed in a manner to keep the upper and lower headers at the same plane as they were shipped from the module fabricator within +/-1”. See sketch “Module Storage (Staggered Pitch)”.

1.5.4 Refer to the actual job specific Nooter/Eriksen Module Lifting Drawings

for all details of the lifting devices.

1.5.5 The second lift is the lift from transporter to Strongback Device. This is performed using the same rigging that was used for the first lift.

1.5.6 The third lift is the horizontal to vertical lift. This is accomplished by using

the Strongback Device. Refer to the actual job specific Nooter/Eriksen Module Lifting Drawings for details and procedure.

1.5.7 Once the module is in the vertical position, it can be placed between the

appropriate columns and set in its final position. Each module roof is equipped with support beams with a portion of the upper roof attached. When the module is placed between the support columns, the load is transferred from the module support beams to the upper frames.

1.5.8 After each lift, the lifting devices and all associated bolting/pins shall be

inspected by the Erector, to assure no damage has occurred and confirm that all bolting is tightened as required. Any bent, worn or damaged bolts/pins shall be replaced as necessary, with identical bolting/pins as stated on the pertinent Nooter/Eriksen Drawings from the following list: STRONGBACK01, STRONGBACK02, STRONGBACK03, STRONGBACK16, HORIZLIFTDEV 1, HORIZLIFTDEV 2, HORIZLIFTDEV 3, and HORIZLIFTDEV 7. Copies of these drawings are included in the “MISCELLANEOUS” section of this manual.



1.5.9 It is the Erector’s responsibility to assure that the lift devices provided by Nooter/Eriksen are being used properly and all lifting operations are in accordance with the requirements as noted on Nooter/Eriksen drawings and this Erection Manual to prevent damage to equipment and injury to personnel. Erector will be responsible for any damage caused due to failure to comply with these requirements.

1.5.10 After all use of the Nooter/Eriksen supplied lifting devices is completed, the Erector is to fully dismantle them for return to Nooter/Eriksen. If supplied containerized, Erector is to repack all components in containers for shipment.

1.6 DUCTING

1.6.1 Lifting lugs are provided on ducting supplied in panel sections. Refer to Erection Drawing EP-03A-09 through –12 for details of lifting procedure and lifting lugs.

1.6.2 Lifting lugs are designed to be used with spreader beams.

1.7 EXHAUST STACKS

1.7.1 Exhaust stacks are shipped to the sites in several different forms.

a. Multiple arc sections for field welding into cylindrical sections b. Shop fabricated cylindrical sections

1.7.2 The Erector has the option to build the stack by setting the cylinders

individually into the vertical position or to pre-assemble multiple cylinders into a sub-assembly on the ground before lifting. If the cylinders are sub-assembled on the ground, the Erector shall design and provide all bracing required to prevent damage to the stack.

1.7.3 It is the Erector’s responsibility to design and supply the required lifting

and rigging equipment based on their chosen method for erection of the stack.

1.7.4 If a stack is provided with a damper, the damper shall be installed after

the bottom stack section is installed vertically on the stack foundation. The damper shall not be attached to any stack cylinders prior to lifting into final position, to prevent damage to the damper.



1.8 REMOTE STEAM DRUMS

1.8.1 There are no lifting lugs provided on remote steam drums.

1.8.2 See Drawing EP-03-05A for details of erection procedure.

1.8.3 Slings shall not break against any nozzle or nozzle reinforcement pad. 1.8.4 Softeners should be used with cable slings to prevent damage to

materials. 1.8.5 The Remote Steam Drum lifting weights are 5% greater than the shipping

weights marked on the Steam Drums.

EP-04A PAGE 1 ERECTION PROCEDURE FOR FIELD

SEAM INSTALLATION (MODULAR)

APPROVED BY: RDG X:\Procedures\Erection.Manual\EP-04A.R9

1.0 GENERAL

1.1 This procedure will provide general details, design considerations and general installation procedures needed for installation. The Erector should refer to the erection drawings for actual job details.

1.2 The liner assembly on all breeching and modules is designed to allow the

protective internal liner system to expand freely due to temperature expansion of the components.

1.3 The liner system is composed of a series of overlapping plates, pinned to

the outside casing. 1.4 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 of the integrity of the liner system.

1.5 When casing and ducting are shipped with plastic weather protection on

the exposed insulation, it must be removed prior to installation of the field seam insulation.

2.0 ASSEMBLY SEQUENCE

2.1 Sidewall Casing Panels (Primary and Secondary)

2.1.1 The primary casing panels have the main structural columns attached to them. These panels are to be set on their foundations, bolted/welded and braced in their final positions. Combination bolted and welded connections are to remain bolted after welding. It is the Erector’s responsibility to perform structural welding in a manner that ensures that completed components are within the tolerances specified in EP-11.

2.1.2 The secondary casing panels are stiffened with flat bar. To install

these panels it will be necessary to insert one edge of the casing inside the column and rotate the other end in past the other column and slide the casing to the proper position for weld to the columns. See Drawing EP-04A-06.



2.1.3 The field seams between sidewall casing panels are seal welded

at the outer casing from the outside of the system. The insulation pins, insulation and inner liner are installed from the inside of the system. See Drawing EP-04A-07 and EP-04A-10.

2.2 Floor Beams and Floor Casing panels

2.2.1 For ease of installation, the floor beams are fit-up and held in position with bolted connections. Bolt the primary floor panel to columns on the sidewall casing. Attachment welding of floor beam to sidewall columns is shown on the Erection Drawings for the actual job details. Bolts are to be snug tight per AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts, unless otherwise specified on drawings.

2.2.2 Set the secondary floor casing in place and seal weld to the

adjoining primary floor casing from the liner side of the casing panel.

2.2.3 The field seam between the sidewall and the floor casing is

completed by installing the corner angle from the inside and installing the insulation and outer casing plate from the outside. See Drawing EP-04A-08.

2.3 Roof Beams

2.3.1 The roof beams are sent to the field with the casing, insulation and liners shop installed.

2.3.2 The roof beams are bolted to the sidewall columns as the primary

sidewall casings are erected. See the individual job details for bolt and weld requirements. This will provide stability for the structural frame. Bolts are to be snug tight per AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts, unless otherwise specified on drawings.

2.3.3 Attach the corner angles and insulation between the sidewall and

roof beam as the sidewall and the roof beams are erected (See Drawing EP-04A-09). Due to access issues, this must be completed before installing modules.



2.4 Roof Casing

2.4.1 The roof casings are shop installed onto the modules unless noted otherwise on drawings. Care should be taken to ensure that the liners are not damaged during the installation of the coils.

2.4.2 If tadpole gaskets are used, they shall be partially shop installed

on roof beams. Field attachment of tadpole gaskets on corner angles may be required after the corner angle is in place (see Drawing EP-04A-09), and before the modules are installed.

2.4.3 Field seams are required between the adjacent shop installed

module roofs and between the shop installed module roofs and the sidewall. See the individual module drawings for the field seam configurations supplied by the module fabricator.

3.0 FIELD SEAM LINER INSTALLATION

3.1 Field liner plates shall follow the lapping sequence of the shop liner plates.

The actual laps on shop assembled pieces may vary from what is shown in this standard. (See Drawing EP-04-10)

3.2 Before installing the field liner, the field seam cavity shall be completely packed with ceramic fiber insulation. Care shall be taken to ensure that all void areas are filled. If the field seam insulation is composed of multiple layers, insulation seams shall be staggered.

3.3 Insulation pins are installed in the shop on the inside of column flanges. Bend pins perpendicular to liner plate prior to installation of insulation.

4.0 VENDOR SUPPLIED EQUIPMENT

4.1 SCR and CO catalyst systems, as well as catalyst frames and burners,

could be field installed in Nooter/Eriksen’s casing. This equipment can be shipped to the site in either panels or in complete modules. The field assembly of this equipment, if required, will be provided under separate cover from the appropriate Vendor.

4.2 Field seams between the Vendor equipment and the Nooter/Eriksen

casing panels will be per Erection Procedure Drawings EP-04A-06 thru 09, and the individual job field seam drawings.

EP-05A PAGE 1 REMOVAL OF TEMPORARY

STEEL/WOOD REVISION 0

APPROVED BY: VPM X:\Procedures\Erection.Manual\EP-05A.R7

1.0 GENERAL

1.1 Temporary steel, wood and bolting may be used to secure the modules or other

components during shipment. Also, temporary support steel may be affixed to components to assure stability during shipment and/or installation.

1.2 Material to be removed will be painted YELLOW except as listed below.

Wood will not be painted yellow; all wood is to be removed. On large temporary steel, the bolting and approximately 12” from the bolted

connection on the steel will be painted yellow. 2.0 COIL MODULES

2.1 All steel that is used to secure the module to the rail car is to be removed

completely just prior to off loading. If the modules are to be stored on the rail car, they are to remain secured until just prior to off loading.

2.2 All material that is temporary by design shall be removed after the module is in

its full upright position. Any wood blocking should be removed before the module is installed into the casing.

2.3 In some instances, modules will be shipped to the site with metal strapping

wrapped around the tube field, centered between vibration supports, and below the lowest vibration support. This strapping must remain in place during the horizontal-to-vertical lift. After the horizontal-to-vertical lift is completed, the strapping is to be removed in the field. These straps are not painted yellow, since they must remain in place until the horizontal-to-vertical lift is completed

2.4 Some Evaporator modules are ultimately supported by their corresponding

Steam Drums via riser pipes. As such, the temporary bundle support steel must remain in place until all of the connecting riser pipes are 100% installed, welded, post weld heat treated (if required), and have received quality acceptance. Following completion of this work, the temporary bundle support steel can be removed and the casing field seams completed. This temporary bundle support steel is painted yellow for field removal. However, the Field Erector must verify that this steel is to be removed by a thorough review of N/E Field Erection Drawings (See Drawing EP-05A-1 and coil module drawings for details). If there is any lack of clarity regarding removal of temporary bundle support steel, N/E is to be contacted for assistance.

2.5 In some instances, Superheater and/or Reheater Module upper headers are

supported externally, either directly by spring can supports or by interconnecting piping. In these instances, temporary bundle support steel is provided to support the headers during shipping and erection. This temporary bundle support steel can be removed only after all external header supports and/or associated piping (including pipe supports) are 100% installed, welded, post weld heat treated (if required), and have received quality acceptance. Following completion of this work, the temporary bundle support steel can be



X:\Procedures\Erection.Manual\EP-05A.R7

removed and the casing field seams completed. This temporary bundle support steel is painted yellow for field removal. However, the Field Erector must verify that this steel is to be removed by a thorough review of N/E Field Erection Drawings (See coil module drawings for details). If there is any lack of clarity regarding removal of temporary bundle support steel, N/E is to be contacted for assistance.

2.6 For modules that are lifted using the Strongback Lifting Device, the following

must be considered: Shipping cradles at vibration supports and lower headers must remain intact

until module is installed on Strongback.

Shipping cradle at upper headers must be removed prior to installing

module on Strongback. All shipping cradle side plates and tie rods must be removed after module is

installed on Strongback, but prior to lifting from horizontal-to-vertical. Any retainer tabs installed on shipping cradle beams must be removed prior

to horizontal-to-vertical lift, to avoid interference with vibration supports. 3.0 STACK SHIPPING AND ERECTION STEEL

3.1 Stacks that are shipped in cylinders will have temporary steel, painted yellow, at the openings. This temporary steel should be removed after the stack is in the upright position.

3.2 Stacks that are shipped in 120 deg. segments shall have the temporary steel

remain in place until the stack has been assembled and welded into cylinders and in the upright position.

4.0 RAIL CAR “TIE DOWN” STEEL

4.1 All rail cars are to be cleared of tie down steel, by the Erector, prior to release back to the railroad. Charges will be applied to the Erector if not cleaned properly, or if rail cars are not turned back over to the railroad in the allotted free time.

5.0 CARE OF LIFTING DEVICES AND COIL MODULE SHIPPING SUPPORT STEEL

5.1 It is the Purchaser’s and Erector’s responsibility to load the Nooter/Eriksen coil module shipping support beams, shipping horses and lift devices on a truck for transport back to Nooter/Eriksen’s shop facility.



X:\Procedures\Erection.Manual\EP-05A.R7

5.2 It is the Erector’s responsibility to maintain the coil module shipping support and lift devices in the as received condition. No modifications to this equipment are to be performed without written consent by Nooter/Eriksen.

EP-06 PAGE 1 ERECTION PROCEDURE FOR STAIR

TOWERS/PLATFORMS/LADDERS

APPROVED BY: RDG X:\Procedures\Erection.Manual\EP-06.R5

1.0 GENERAL

1.1 The access steel is to be erected using the AISC Code, standard practice for steel building and bridges.

1.2 The tolerances as specified within AISC for connections shall be applicable. 1.3 Platform steel will be shop fabricated into sub-assemblies. 1.4 All pieces shall be marked with identifying numbers. The markings shall

correspond to markings shown on platform erection drawings. 1.5 The following grating installation procedures are to be performed by the

Erector.

a. Field cutting and reinforcement of all piping penetrations through grating.

b. Cutting of grating for piping supports.

2.0 STAIR TOWERS

2.1 It is recommended that the stair tower be erected as soon as possible. This will provide access to HRSG for performing other functions and will minimize the amount of temporary scaffolding.

2.2 The stair tower columns shall be set on piers provided by the concrete

Contractor. The structural steel columns and beams should be squared and plumbed prior to torquing the bolting. The anchor bolts and bolting shall be torqued per AISC.

2.3 The stair tower is attached to the HRSG at one or more levels. The

attachments should be field located and welded to the HRSG as indicated on the erection drawing. These should be installed as the stair tower goes up so that adequate bracing is provided. The stair tower shall not be used for access purposes until all bolting and attachment welding has been completed.

3.0 PLATFORMS AND LADDERS

3.1 It is recommended that the platforms be installed as soon as possible. This will provide access to many of the areas where functions necessary for the completion of the HRSG can be obtained without providing temporary scaffolding.

3.2 In order to insure proper platform elevations the attachment clips to the

HRSG are to be field installed.

EP-06 PAGE 2 ERECTION PROCEDURE FOR STAIR

TOWERS/PLATFORMS/LADDERS

3.3 The elevations of platforms shall be checked. It should be noted that the

elevations given for platforms, as well as all HRSG components, are from reference elevation. For N/E, this is always the bottom of the HRSG column base plates. (Reference: base plate elevation 0’-0”).

3.4 The platforms are normally erected by first installing the support brackets and

clips to the HRSG and then lifting the pre-assembled sections into place and bolting or welding.

3.5 Ladder footings at grade shall be field erected. 3.6 Ladders shall be fully installed including cage connections, support clips,

footing bolts, and safety gates, prior to releasing them for access use.

EP-07 PAGE 1 EXPANSION JOINT INSTALLATION


1.0 GENERAL

1.1 Reference Section 10.0 of the “GENERAL” section of this Manual for storage and responsibility of the equipment that the purchaser receives on site.

1.2 The Erector shall use the lifting points and/or lugs provided with the

equipment. 1.3 For recommended lifting, handling and storage, refer to the vendor

procedures. 1.4 The Erector shall use extreme caution in the handling of the expansion joint.

The fabric shall be covered to protect from welding and puncturing. 1.5 The bolting that connects the expansion joint to HRSG equipment should be

provided by the expansion joint supplier. It is recommended that these bolts be inserted and tack welded in place prior to installing the expansion joint. Bolting for the attachment to other equipment will be by the Erector.

2.0 MODULAR EXPANSION JOINTS

2.1 All shipping ties are to be left in place until a minimum of one side of the joint is installed on the equipment. Use temporary cribbing, as required, to prevent excessive stretching of the fabric, or distortion of the internal liner system.

2.2 When installed, the expansion joint flanges, relative to each other, shall not

vary by more than ¾”, in compression, extension and lateral offset. Actual dimensions, if beyond this limit, shall be submitted to Nooter/Eriksen for review and approval.

2.3 Field joint material as shown on the field erection drawings, shall be provided

by the Erector unless otherwise noted.

3.0 KNOCKED DOWN EXPANSION JOINTS

3.1 The Manufacturers assembly procedures must be followed explicitly. Deviation from this procedure must be approved, in writing, by N/E or the performance and mechanical warranty will be to the account of the Erector.

3.2 When installed, the expansion joint flanges, relative to each other, shall be

within +/- ¼”, in compression, extension and lateral offset.

EP-08 PAGE 1 GASKETS & PACKING


1.0 GENERAL

1.1 All casing penetrations and access openings on the HRSG shall be gas tight. Sealing shall be at the outer casing.

1.2 Shop installed gaskets and packing joints may have loosened in shipping; a check

of all these areas should be done at the initial start up of the system, and any leaks found should be corrected as soon as possible, to prevent damage to the outer casing.

2.0 GASKETS 2.1 Code Pressure Part Gaskets

2.1.1 Three (3) manway gaskets are provided for every drum manway: One (1) gasket for field hydrotest and all field pressurization prior to start-up, including boil-out; one (1) gasket replaces the gasket used for boil-out on the system; and one (1) spare gasket is provided for initial operation.

2.1.2 Care should be taken with all gasket surfaces to insure that they are not

damaged. 2.1.3 All flanges and manway style gasket joints are to be assembled and

tightened, per industry standard. 2.1.4 The gasket surfaces shall be free of all dirt and grease (they are inspected

and approved prior to shipping). Damage incurred while stored, or in the Purchaser’s possession, shall be to the account of the Purchaser.

2.1.5 All valve and instrumentation packing shall remain in its original shipping

container (any cost resulting from mishandling of valve or instrumentation packing shall be to the account of the Purchaser).

2.1.6 Gage glass packing on the water column shall be replaced with new

packing after boil-out and prior to start-up. CAUTION: See the notes in EP-13, “Boiling-out Procedure”, about the temporary glass used for boil-out.

2.2 Casing Gaskets

2.2.1 All casing access doors are to be sealed with a flat bolting tape gasket (shop installed). Care should be taken to insure that the gasket is not damaged when the door is opened in the field.

2.2.1.1 All casing access door gaskets should be replaced at the

first sign of embrittlement. The bolting tape shall lay flat against the surfaces with no laps or gathering of the material.


2.2.2 Bolting casing connections are to be sealed with a flat bolting tape gasket

and tightened uniformly all around the perimeter.

2.2.2.2 The bolting tape shall lay flat against the surfaces with no laps or gathering of the material.

2.2.3 Sliding packing joints used on nozzle casing penetrations will have a

gasket between the bolt plate and the outer casing. This gasket should be checked for leakage at the initial start-up of the system (if leaks exist, tighten the bolting).

3.0 CASING PENETRATIONS

3.1 Shop Installed Packing Joints

3.1.1 Some pressure part nozzles, as noted on Nooter/Eriksen drawings, that project through the outer casing are packed with ceramic fiber rope insulation and have a gland installed to maintain a tight seal against the movement of the nozzle. The Erector is to apply anti-seize compound to all packing gland bolting.

3.1.2 All shop installed packing joints should be checked for leakage at the initial

start-up of the system. If a leak is found, the gland is to be tightened to achieve a seal. Additional rope packing is to be installed if the leak persists.

3.2 Shop Installed Bolt Plate Seals

3.2.1 Some pressure part nozzles, as noted on Nooter/Eriksen drawings, that project through the outer casing consist of a collar plate that is gasketed and bolted to the HRSG casing. These collar plates must be field welded to the nozzles.

3.3 Fabric Expansion Bellows (@ HRSG Roof)

3.3.1 The roof expansion bellows are shipped installed if the roof is attached in the shop.

3.3.2 Fabric bellows must be protected from weld splatter and puncture during

the erection phase. Wrapping with fire retardant blanket and fiberglass reinforced heat resistant tape will protect fabric bellows, if properly applied. Remove all temporary protection upon completion of erection. During operation, these joints should not be covered with insulation or lagging. If safety is an issue, surround the expansion joint area with expanded metal offset from the joint such that the heat will be dissipated and prevent personnel from coming in contact with the hot joint.

3.3.3 The fabric expansion bellows must be checked at the initial start-up of the system for leaks, and adjustments made, if necessary. It is the Erector’s or Startup/Commissioning Contractor’s responsibility to verify that


fabric seal retainer clamps are properly positioned and tightened before and after first fire.

3.4 Fabric Expansion Bellows (@ HRSG Floor)

3.4.1 The floor conical expansion bellows are shipped loose and must be field installed after the coil modules are set. These joints are pre-compressed and are supplied with shop installed straps. These straps are not to be removed until all welding and heat treating is completed on the pipeline that is routed through the bellows.

3.4.4 Floor conical expansion bellows must be protected from weld splatter and

puncture during the erection phase. Wrapping with fire retardant blanket and fiberglass reinforced heat resistant tape will protect fabric bellows, if properly applied. Remove all temporary protection upon completion of erection. During operation, these joints should not be covered with insulation or lagging. If safety is an issue, surround the expansion joint area with expanded metal offset from the joint such that the heat will be dissipated and prevent personnel from coming in contact with the hot joint.

3.5 Metal Expansion Bellows

3.5.1 Some penetrations utilize metal bellows expansion joints. These are typically small penetrations (2” NPS or less), and are field installed.

3.5.2 Metal expansion bellows must be protected from weld splatter and

puncture during the erection phase. Wrapping with fire retardant blanket and fiberglass reinforced heat resistant tape will protect metal bellows, if properly applied. Remove all temporary protection upon completion of erection. During operation, these joints should not be covered with insulation or lagging. If safety is an issue, surround the expansion joint area with expanded metal offset from the joint such that the heat will be dissipated and prevent personnel from coming in contact with the hot joint.


INSTALLATION OF LARGE BORE PIPING


1.0 GENERAL

1.1 All piping shall be installed to meet the requirements of ASME Section I, ANSI B31.1 and any local applicable codes as they pertain to welding, procedure qualification, post weld heat treatment, non-destructive examination, etc. It is the Erector’s responsibility to ensure that all Code requirements have been met as they pertain to assembly.

1.2 Large bore piping is defined as all piping over 2” NPS. 1.3 Piping is supplied in spool pieces to facilitate field assembly. Valves may

be shipped loose for field installation. Sufficient trim is provided in each of the spool pieces to allow for adjustment and tolerance accumulation.

1.4 It should be recognized that, due to the size of the components, shifting of

component parts during shipping, normal fabrication, and erection tolerances, a certain amount of mismatch is to be expected.

1.5 If the Erector feels that modifications in the design must be made due to

interferences, excessive misalignment, or for other reasons, N/E must be notified of the problem and given the opportunity to provide a solution (see N/E Backcharge policy). Any cutting or modifying of pipe spools without prior notification and approval by N/E will not be accepted for backcharge consideration. If field trim is removed from the project, Nooter/Eriksen will not be responsible for spool-to-spool alignment or termination points that differ less than 3” in any direction from theoretical locations.

1.6 Information needed for installation.

a. Nooter/Eriksen Piping Isometric Drawing b. Nooter/Eriksen P&ID Diagram c. Nooter/Eriksen Trim & Instrument List d. Fabricators Pipe Spool Drawings (if available) e. Nooter/Eriksen Pipe Support Detail Drawings f. Nooter/Eriksen HRSG Reference Drawings

1.7 Piping terminal locations are considered within tolerance if the pipe end is

within +/- 1” of theoretical in any direction. The Erector will check actual termination points to the theoretical termination points during field erection to maintain the +/- 1” tolerance.



1.8 Although applicable to all materials, the following is of particular importance for 9Cr 1Mo (P91) piping: 1.8.1 Field Erector should have a system in place that will assure that the

welding is properly performed. 1.8.2 Monitoring and maintaining heat control throughout the welding

process is vital for achieving acceptable field welding results.

2.0 NDE REQUIREMENTS

2.1 In addition to the Mandatory Code Requirements for non-destructive examination of welds, it is recommended that the following additional radiography be applied:

1) At least 5% of all full penetration pressure part butt welds, not

requiring radiography by the ASME or the local applicable codes, shall be 100% radiographed.

This should be implemented by radiographing 5% of this category of welds deposited by each welder.

In the event of a defect being identified in the prescribed 5%, a further 5% of welds deposited by that welder shall be radiographed. Should additional defects be identified, all welds deposited by that welder shall be radiographed.

This category of welds normally includes butt welds in the downcomer and riser piping, and butt welds in the boiler proper and boiler external piping.

2.2 All Chrome-Moly piping shall have NDE in accordance with ASME Section

I, ANSI B31.1, or the local applicable codes, whichever governs and is more stringent.

3.0 INSTALLATION

3.1 This section provides suggested installation steps to minimize the time required to install pipe spools. The Erector is free to modify or add to this procedure. The contents of this procedure should be considered as a guide.



3.2 Erector is to verify the tagging on each spool piece and valve and check dimensions using piping isometric drawings and the fabricators pipe spool drawings. Any major discrepancies shall be brought to the attention of Purchaser immediately.

3.3 Erector shall check the location of the connections where the pipe spools

are to be placed. The theoretical locations may vary from the actual depending upon how the modules have been set, how components have shifted during shipment, and normal fabrication and erection tolerance accumulation.

3.4 After the pipe spool pieces have been inspected dimensionally and the

connection locations verified, the Erector should pre-fabricate the completed pipe runs in sections as large as possible. Valves should be welded in and inspection, heat treatments, etc., made. Since the actual dimensions of the pipe run can now be verified, the Erector should trim pipe sections to fit actual dimensions.

3.5 Pipe sections should be lifted into place (tack welded only) and checked

for fit up before fully welding any section. It is usually possible to slightly rotate the pipe at the connections to achieve movement at the other end without affecting the weld gaps appreciably.

3.6 Piping expansion joints shall be installed per the expansion joint

manufacturer’s guidelines and accepted industry practices. It is not acceptable for piping expansion joints to be manipulated to make up for piping misalignment.

3.7 External insulation must be held back from all piping expansion joints and

casing seal devices for inspection, maintenance, and proper operation. .

4.0 PIPE SUPPORTS

4.1 All pipe runs will be provided with pipe supports, hangers, springs and/or guides, if needed, to meet design requirements.

4.2 Prior to installing any pipe run, the Erector should become familiar with the

supporting requirements. It is possible to create additional work if piping and supports are not installed in the proper sequence.



4.3 Pipe supports are to be field located and installed by either welding or bolting.

4.3.1 If pipe supports require attachment to platform steel, the Erector is

required to field trim or cut back the grating, as required, to allow pipe support to attach directly to platform support steel.

4.4 All field welds not specifically called out on pipe support drawings are to

be 3/16” fillet welds and shall be completely around the attachment so as to seal the connection.

4.5 Trim is provided in the length of the field welded pieces to allow for

adjustment and proper fit. The Erector should trial fit pipe supports, trim to fit and final install. Piping dimensions at supports should be considered as a reference and may vary +/- 2”.

4.6 To facilitate field installation, all pipe supports located on the straight

length of a pipeline can be moved +/- 0’-6” along the pipe centerline from their theoretical location. It is the contractor’s responsibility to verify that moving the pipe support to allow for field or shop tolerances, does not create an interference with any other pipeline branch, attachment or other structure on the HRSG. Contractor shall contact Nooter/Eriksen for guidance for any supports that need to be moved more than +/- 0’-6”.

5.0 HYDROTEST

5.1 All valves shall be checked during hydrotest for leakage. Any leaks shall be stopped by properly tightening the packing glands. If tightening is unsuccessful, the leaking valves shall be repacked. Nooter/Eriksen shall be notified of any valves where leakage cannot be stopped. Caution: The unit should not be operated with valves where leaks have been noticed unless approval from Purchaser is obtained. Failure to comply with this requirement may result in damage to valves.

5.2 All spring supports and constant supports must have travel stops in place prior to filling the HRSG.

5.3 All flanged pressure relief valves shall be removed, or a suitable pancake

shall be inserted at the inlet flange during hydrotest. 5.4 If welded safety valves are supplied, there must be verification that factory

installed hydrostatic test plugs are installed.



6.0 VALVE POSITION DURING WELDING AND PWHT (BY MANUFACTURER)

The following is a summary of Valve manufacturer’s recommendations for positioning of valves during the welding/heat treating process. Nooter Eriksen is to be consulted for recommendations on any valves that are not addressed below. Atwood-Morrill (Weir) CLOSED for welding and PWHT Bonney Forge OPEN 1/16 TURN for welding and PWHT Conval CLOSED TIGHTLY for welding and PWHT CCI REMOVE TRIM for welding and PWHT Douglas Chero SEMI-OPENED for welding and PWHT DSI (Welded Bonnet) REMOVE TRIM or FULLY CLOSED for welding and

PWHT DSI (all except NO PREFERENCE for welding; SLIGHTLY OPENED Welded Bonnet) for PWHT Edward (Univalve) CLOSED TO 50% OF TORQUE VALUES for welding

and PWHT Edward (all except CLOSED TIGHTLY for welding and PWHT Univalve) Fisher Controls NO PREFERENCE for welding; REMOVE TRIM for PWHT Fluval Ituarte FULL CLOSED for welding and PWHT HP Valve FULL CLOSED for welding and PWHT Hora NO PREFERENCE for welding and PWHT Intervalve OPEN for welding and PWHT Kitz 15-25 % OPEN for welding and PWHT



KVT (HP Valves) OPEN TO PREVENT ARCING for welding and PWHT Masoneilan SLIGHTLY OPEN for welding; REMOVE TRIM for PWHT Newco (Newmans) LIGHTLY CLOSED for welding and PWHT OMB OPEN VALVE IN THE HALF POSITION for welding and PWHT Pacific/Crane SLIGHTLY OPEN for welding and PWHT (Flex Gate or Globe) Pacific/Crane (all except SEATED LIGHTLY for welding and PWHT Flex Gate or Globe) P-K (Pan Korea) FULLY OPEN for welding and PWHT Powell OPEN for welding and PWHT Raimondi (>24” GATE) CLOSED for welding and PWHT Raimondi (all others) OPEN for welding and PWHT Raisteam/Raimondi OPEN for welding and PWHT (Pressure Seal Valves) Samshin PARTIALLY OPEN for welding and PWHT Union –Tech (Fisher) BALL IN FULL OPEN POSITION for welding and PWHT Valtek OPEN for welding and PWHT Velan CLOSED for welding and PWHT Vogt CLOSED for welding and PWHT


SMALL BORE PIPING

APPROVED BY: _WJP_ X:\Procedures\Erection.Manual\EP-10.R10

1.0 GENERAL 1.1 All piping shall be installed to meet the requirements of ASME Section I,

ANSI B31.1 and any local applicable codes as they pertain to welding, procedure qualification, post weld heat treatment, non-destructive examination, etc. It is the Erector’s responsibility to ensure that all Code requirements have been met as they pertain to assembly.

1.2 Small bore piping is defined as all piping 2” NPS and smaller. 1.3 Small bore piping is normally supplied in random length pieces with

approximately 10% additional for field drop. The routing, installation and support of these lines is to comply with Nooter/Eriksen small bore piping isometric drawings, Notes 8A through 8D on small bore piping drawing GA-005, and standard support details on small bore piping drawing GA-007. If it is determined that rerouting is necessary, Nooter/Eriksen is to be notified prior to rerouting.

1.4 Although applicable to all materials, the following is of particular

importance for 9Cr 1Mo (P91) piping: 1.4.1 Field Erector should have a system in place that will assure that the

welding is properly performed. 1.4.2 Monitoring and maintaining heat control throughout the welding

process is vital for achieving acceptable field welding results.

2.0 INSTALLATION

2.1 INFORMATION NEEDED FOR INSTALLATION: a. Nooter/Eriksen Trim Piping Drawings b. Nooter/Eriksen P&ID Diagram c. Nooter/Eriksen Trim & Instrument List d. Fabricators Pipe Spool Drawings (if applicable) e. Nooter/Eriksen Pipe Support Drawings f. Nooter/Eriksen HRSG Reference Drawings

2.2 VALVES ARE SHIPPED LOOSE FOR FIELD INSTALLATION.

2.2.1 See Procedure EP-09, paragraph 6.0 for Manufacturer’s Recommendations for Valve Position during welding and PWHT.

2.3 Nooter/Eriksen drawings provide routing and supporting for small bore

piping within the Section I Code boundaries. The Erector/Owner should


SMALL BORE PIPING

X:\Procedures\Erection.Manual\EP-10.R10

notify N/E before changing routing or support locations. Minor changes to valve/instrument locations to provide accessibility do not require approval.

2.3.1 Portions of some small bore pipelines are supplied with specifically

engineered pipe supports. In such cases, these supports will be located on the piping isometric drawings. In all other cases, it is the Erector’s responsibility to locate and install pipe supports in accordance with Notes 8A through 8D on small bore drawing GA-005, and details on small bore piping drawing GA-007.

2.3.2 Tolerances for small bore pipe support locations are the same as

for large bore. (See Procedure EP-09, paragraph 4.6)

2.4 External insulation should be held back from all piping expansion joints and casing seal devices for inspection, maintenance, and proper operation.

2.5 As noted in EP-08, Paragraph 3.2.1, most sealing devices must be

installed before any piping assembly is started.

3.0 HYDROTEST

3.1 All valves shall be checked during hydrotest for leakage. Any leaks shall be stopped by properly tightening the packing glands. If this is unsuccessful, the leaking valves are to be repacked. Nooter/Eriksen shall be notified of any valves where leakage cannot be stopped.

Caution: The unit should not be operated with valves where leaks have been noticed, unless approval from Purchaser is obtained. Failure to comply with this requirement may result in damage to valves.


FIELD WELDMENTS


1.0 Structural sidewall panels, roof beams, structural roof panels, floor beams and structural floor panels shall be assembled with the following tolerances:

The letter items listed below correspond to the letter designation on Drawing EP-11-1. A. +/- 3/8” B. +/- 3/8” C. +/- ½” D. +/- ¼”

2.0 Tolerances for bolted or welded; stairtower, ladders, platforms and platform

supports, shall be in accordance with the latest edition of AISC. 3.0 Tolerances for piping structural supports, guides and hangers shall be

+/- ¼” unless otherwise noted on the individual job drawings. 4.0 All other tolerances not listed above shall be limited to “Industry Standards”, and

in no way affect the integrity and appearance of the HRSG. 5.0 If the HRSG is provided with an SCR, the Erector is to verify that the Catalyst

Loading Opening is plumb and square so that the Catalyst Loading Doors will fit properly. This must be done prior to final welding of the SCR duct frame corner connections.

Deviations from the above shall be brought to the attention of a Nooter/Eriksen representative, or the Nooter/Eriksen Project Engineer for verification that the deviation will in no way effect the integrity of the HRSG system.

R8

EP-12 PAGE 1 PSVs

START-UP VENT AND STACKS

APPROVED BY: PJH X:\Procedures\Erection.Manual\EP-12.R5

1.0 GENERAL

1.1 Pressure Safety Valves (PSVs) are to be stored in their original packing until installation.

1.2 Motor operated vent valves are to be stored in their original packing until

installed.

2.0 PRESSURE SAFETY VALVES AND STACKS

2.1 Lead adjustment seals shall remain intact on the valve during erection, start-up and operation of the HRSG. The seal shall not be removed for any reason; except spring replacement or calibration adjustment of the valve (Ref.: ASME Section 1, Para. PG-73.1.8).

2.2 Adjustments or setting changes of PSVs shall not be performed without

written authorization from Purchaser and the PSV manufacturer. 2.3 No valves shall be placed between the PSV discharge and the atmosphere. 2.4 PSV discharge piping and supports are to be installed complete at assembly.

Discharge piping shall not be left unsupported for any length of time. 2.5 The PSV discharge piping shall be square cut at the discharge end to

atmosphere (no modifications to discharge piping will be allowed). Discharge piping shall be directed away from platforms and/or areas used by personnel.

2.6 Body drains of all PSVs shall not be plugged during, or after, field installation.

Plugs supplied by the manufacturer for shipping, shall be removed when the PSV is removed from its original packing.

2.7 All gravity drains located in the PSV and the discharge piping shall be piped

to a safe area, away from platforms and operating stations, by the Erector. Material is to be furnished by the Erector, unless otherwise shown on trim drawings.

2.8 Weather shields installed on the PSV by the Erector, shall be properly vented

and arranged to permit servicing and normal operation. 2.9 Discharge piping that is routed to a collection pipe shall meet the

requirements of ASME Section I, Para. PG-71, or other applicable codes.

EP-12 PAGE 2 PSVs

START-UP VENT AND STACKS

APPROVED BY: PJH X:\Procedures\Erection.Manual\EP-12.R5

3.0 START-UP VENTS AND STACKS

3.1 Start-up vent discharge piping and supports are to be installed complete at assembly. Discharge piping shall not be left unsupported for any length of time.

3.2 The start-up vent discharge piping shall be square cut at the discharge end to

atmosphere (no modifications to discharge piping will be allowed). Discharge piping shall be directed away from platforms and/or areas used by personnel.

3.3 All gravity drains located in the start-up vent discharge piping shall be piped

to a safe area away from platforms and operating stations by the Erector. A reasonable amount of drain line material has been supplied by Nooter/Eriksen. Any additional materials must be furnished by the Erector. (See drawing EP-12-01)

EP-13 PAGE 1 RECOMMENDED

TUBESIDE CLEANING PROCEDURE

APPROVED BY: WJP X:\Procedures\Erection.Manual\EP-13.R9

Nooter/Eriksen recommends the use of an experienced cleaning contractor for this service. The cleaning contractor should inspect the HRSG and develop a cleaning procedure for the owner’s review. Nooter/Eriksen recommends that the cleaning procedure shall include steps for each area listed under Section 2: Hand cleaning, Organic material removal and Chemical scale removal.

This section contains general information and suggestions that may be used as an aid to evaluate a contractor's procedure or monitor the cleaning and should not be interpreted as an endorsement of any particular type of cleaning. Improper cleaning of the HRSG surfaces or the complete omission of cleaning can result in poor performance and potential damage to the boiler. The HRSG tube/pipe side surface must be thoroughly and properly cleaned prior to being placed in initial service. Periodic review of the cleanliness of the boiler is required as outlined in IV of the N/E O&M Manual.

1.0 General

The primary function of cleaning the tubeside is to provide a clean, uniform surface for passivation. Passivation is the buildup of a protective magnetite layer on wetted surfaces. This layer protects the inner surfaces from corrosion during operation.

Oil, grease and rust can prevent or cause uneven buildup and flaking of the protective magnetite layer during operation. These contaminants must be removed before operation.

The option to inspect the unit prior to chemically cleaning should be offered to all potential contractors. Lack of pre-inspection may result in an insufficient and/or inefficient cleaning solution being utilized. Improper solutions can significantly add to the circulation time required for cleaning.

Prior to commencement of a chemical clean for the HRSG, the following systems/controls must be in proper operation in order to insure boiler safeguards:

All HRSG alarms, trips, and interlocks All pressure parts have been installed and hydro-tested All insulation has been installed Suitable connections to all vents and drains have been installed

and are routed to avoid potential hazards Gas turbine has been readied for operation



2.0 Types of Cleaning

Depending on the HRSG condition, operating range, and site disposal facilities, a variety of cleaning procedures is available. The general categories of cleaning are listed below. N/E recommends that each step listed below be performed to insure that the system is properly prepared for operation.

2.1 Hand Cleaning: The first step should always be to clean

accessible areas by hand. Remove manhole covers on the steam, collector, and mud drums. Remove and clean out by hand as much grease, oil, and other foreign material as possible. Careful hand cleaning will reduce the time required for further cleaning.

2.2 Organic Material Removal: Following hand cleaning, any

remaining organics (such as oil, grease, or tube protective coatings) must be removed from the interior of the HRSG. Organics left on the tubes will impede heat transfer, prevent proper passivation of the metal, and inhibit cleaning. In addition, any loose foreign materials clinging to the inner tube surfaces should be flushed out.

Typically, this step will involve a preliminary flushing with warm water, followed by circulation of an appropriate cleaning solution. A heated alkaline solution is typically used, with the alkalinity and circulation temperature developed by the contractor for the specifics of the site. The cleaning solution should be periodically strained or blown down to remove foreign materials, and the chemistry readjusted as required. The cleaning should be finished with a warm water flush and blowdown using a good quality condensate that should continue until phosphate content is less than 2 ppm. An internal inspection should then be done, and the cleaning process repeated if oil or grease is still evident.

2.3 Chemical Scale Removal: This step is used to remove scale or other deposits. The solution is generally heated, and allowed to stand in the HRSG or circulated for a prescribed time or until testing shows the reaction rate has decreased. After the cleaning has been completed, the pH of the solution should be raised to promote passivation, or the solution should be drained and an alkaline solution circulated. Manholes should be opened, the seating surfaces flushed, and new gaskets installed. Proper procedures must be implemented for laying up the boiler after



the chemical cleaning to insure that damaging contaminants do not enter the system. CAUTION: THE CLEANING SOLUTION MUST BE COMPLETELY REMOVED FROM ALL THE INTERNAL SURFACES TO PREVENT DAMAGE. Scale removal will be inhibited if oil and grease are present. An alkaline cleaning should be performed prior to the scale/deposit removal phase of the cleaning. There are also mechanical means of deposit removal available for accessible tubes, such as in the evaporator. These include high pressure water lances and pull through scrapers.

2.4 General HRSG Steam Blow Procedures

Theory In order to insure a clean steam path after initial erection from the evaporator sections of the HRSG to the terminal points, it is necessary to instigate a thorough cleaning procedure. In general, this is accomplished through a steam blow, air blow, or a combination chemical clean/ steam (air) blow.

A steam blow procedure entails passing high velocity steam through the steam path in order to generate a sufficient cleaning ratio (CR). The cleaning ratio is defined as the ratio of the product of the density () and the square of the steam velocity (V) at the steam blow conditions to the same product at the design base load conditions.

CRV

Vsteamblow

design

( )

( )

2

2

The shear force generated on the tube walls is proportional to the velocity head of the flowing fluid through the pipe network. Therefore, the larger the cleaning ratio the larger the shear force (i.e. the better the cleaning of the tube walls). A cleaning ratio greater than 1.1 is normally required in power boilers to insure adequate cleaning of all steam path surfaces. Occasionally a lower value may be acceptable for low pressure systems but 1.0 should be considered the absolute minimum.

It is apparent that a low pressure (high specific volume) fluid will result in the minimization of the actual amounts of water



required while helping to generate the largest velocity head. Therefore, it is desirable to utilize a low pressure fluid when performing a steam path cleaning.

One should note the importance that all legs of the steam path need to be subjected to proper cleaning ratios. The variable geometry throughout the steam path will require the calculation of several cleaning ratios. Steam Blow When the combustion turbine is available, a steam blow is typically performed. The combustion turbine is generally utilized as the heat source for the boiler to generate the required capacity of steam.

There are two general categories of steam blows - intermittent and continuous. Intermittent Blows - Intermittent steam blows involve the building up of pressure in the appropriate steam drum to a predetermined upper value and then opening a quick acting steam blow valve at the end of the piping network to generate a high velocity steam by flashing water in the drum. When the drum pressure returns to the lower calculated pressure level (minimum for cleaning ratio required), the steam blow valve is closed to repressurize the drum and the sequence repeated. An intermittent blow is generally favored over a continuous blow when insufficient make up water capacity is available for a continuous blow. The required purging sequence of an intermittent blow, which may require as many as 100 cycles, generally makes the intermittent blow a more costly procedure in means of time and man-hours.

Continuous Blows - Continuous blows involve operating the boiler at a reduced pressure for a continuous period of time. The reduced pressure generates a large specific volume (high velocity) flow that passes through the steam path on a continual basis. A sacrificial valve is generally utilized at the terminal point of the temporary steam blow piping for maintaining required pressure. By eliminating the cyclic sequencing of an intermittent blow, the required time and subsequent man-hours may be significantly reduced for a continuous blow. However, a continuous blow requires that large amounts of treated water be available for usage. It is not uncommon to empty a large storage tank during the course of a four-hour continuous blow.



Note: Steam blows may still be performed even though the combustion turbine is unavailable. In this event, a sufficient auxiliary boiler must be utilized to generate the required steam (flow, temperature and pressure).

2.5 HRSG Operation for Steam Blowing

The intent of this section is to present general information pertaining to operation of the Heat Recovery Steam Generator (HRSG) during the steam blow process. The guidelines and advice provided are for information purposes only and the party responsible for the HRSG cleaning is advised to seek the services/advice of a qualified cleaning professional.

The HRSG and the plant design will have an impact on the decisions to be made concerning the steam line cleaning. Many of these issues are operational in nature and several are highlighted below for consideration when developing a site specific steam blow procedure.

Combustion Turbine (CT) Loads -

Most steam blows can be accomplished at gas turbine loads below 30%. The turbine should be operated with the guide vanes wide open. This maximizes the exhaust flow and steam flow and minimizes the exhaust temperature and fuel usage. If multiple pressure systems are to be blown at once, significantly higher CT loads are generally required.

Sometimes the steam from one HRSG will be used to blow common steam line piping in cases where the steam from two HRSG's that go to one steam turbine. The ideal scenario would be to identically operate each HRSG. For units with duct burners, a higher CT load is generally required.

Steam Drum Water Levels -

Water level must be maintained in all steam drums during a steam blow to prevent damage. These systems are not designed to run dry.



The extent of drum level fluctuation during a steam blow is a function of the cleaning method applied. When a continuous blow is utilized, the boiler is able to reach an equilibrium condition and subsequently, the drum level should remain fairly constant. However, the flashing nature of an intermittent steam blow will generate very large swings in drum level. The water level must be maintained between the LLWL and the HHWL.

During an intermittent type of steam blow where the drum pressure varies, the water level fluctuations will be significant. The operator should start with a small drum pressure change and work up to larger pressure changes to assure that the water level can be controlled.

Start-Up-

When heating up the boiler for the steam blow process, temporary steam blow valves should be utilized to control the HRSG ramp rates. Refer to the startup requirements in the N/E O&M Manual.

Steam blow steam must not be discharged through the HRSG main start-up valves. The valve seats would be subjected to damage.

Water Quality / Water Chemistry -

The quality of water used for steam blows should be the same quality as the water intended for normal operation. HRSG's will carryover water from the steam drums during the steam blow. This water should be as clean as possible to avoid chemical deposition in piping and coil sections. The feedwater pH should be increased to 9 by injecting ammonia. This is equivalent to an ammonia concentration of about 0.3 ppm.

The boiler must be drained after steam blows unless deaerated water was used. In this case a wet lay-up may be used. Consult the N/E O&M manual for lay-up.

Freezing water can result in tremendous damage to an HRSG. Consult the N/E O&M Manual on freeze protection.



Operating Pressures- HRSG operating conditions can be varied to augment the steam blow process. For example, the HP drum operating pressure should be maximized when blowing an IP system. This will allow more heat to approach the IP evaporator maximizing the IP steam flow.

Reheaters- When blowing the HP system of an HRSG with a reheater, the reheater may have to be operated without the benefit of cold reheat steam. Under these conditions, the IP steam flow must still flow though the reheater. Vents on the hot reheat line should be open to maximize the IP steam flow and minimize the reheater operating pressure. The CT operating mode should be selected to minimize the exhaust temperature.

Desuperheater Operation – N/E advises that the water flow to the desuperheaters be isolated during steam blows. Water sprayed under the wrong conditions can lead to damage. If desuperheaters are utilized, there must be adequate steam flow and steam superheat to vaporize the water. The steam must have a minimum of 25°F of superheat after the desuperheater. In no case must the desuperheater block valve be opened with insufficient steam flow past the desuperheater.

Erection- Care has been taken to supply all HRSG components in a good condition. The erector must also strive to maintain this condition during all phases of the erection process.

Measurement Devices - The steam blow process may affect steam flow meters. The accuracy of these devices is dependent upon the finish of the interior surface. These devices should be removed if practical.

Non-Return Valves - The main steam valve must be 100% open during steam blows so as not to cause undue wear on the valve seats. Non-return valve vendors require that the non-return valve disc (cage) be removed during a steam blow. N/E will not be responsible for damage to the non-return valve in the event that the erector chooses to leave the non-return valve internals in line during the steam blows.



In many cases, the steam blow may represent the first time that large quantities of heat have been passed through the HRSG. Therefore, during the heat up process, items typically associated with first fire of the boiler (i.e. thermal expansion of pipelines) must be addressed and inspected to insure proper working order.

Further questions or support regarding blows should be directed to the N/E Project Manager. Air Blow When sufficient water is not available, an air blow may be performed to generate the same end result of a steam blow. External air tanks are pressurized to predetermined levels and connected to the steam path piping. The air is released through the steam piping at levels sufficient to generate the required cleaning ratios. The external air tanks are then repressurized and the sequence repeated similar to the intermittent steam blow. This will generally require larger velocities than a steam blow due to the reduced density of the air. Combination Chemical Clean/ Steam (Air) Blow A thorough chemical clean of the steam path piping prior to performing a steam (air) blow may significantly reduce the time required to meet the clean acceptance criteria. The reduction in steam blow time is most noticeable when utilizing the intermittent steam blow method. The chemical clean may be performed simultaneously with the water path cleaning which may help to reduce the additional cost of the chemical cleaning of the steam path.

Acceptance Once it has been demonstrated that the required cleaning ratios have been met, steam targets are inserted in the temporary steam piping for testing at the steam blow conditions. The targets are subsequently removed and inspected for marks and impressions. The cleaning requirements (i.e. number and depth of marks on target) for final acceptance are typically defined by the end user, steam turbine manufacturer, and the BOP contractor.



Issues to Note:

For best results, the steam blow valve should be a sacrificial butterfly valve or gate valve. The excessive flow obstruction in a globe valve can lead to rapid wear on the valve seats and is more subject to locking up due to impregnated obstructions.

In general, the plant demineralization make-up water train does not

have sufficient capacity to generate the required amounts of water utilized during a steam blow without subsequently imposing large time delays. It may be advisable to hire an auxiliary demineralization plant for steam blows.

Steam blow piping is not generally rated for base load steam

temperatures. Care must be taken to insure that the superheated steam is maintained within boiler design values as well as temporary piping design values.

Power plants are generally flexible so that one can optimize the

conditions for a given steam blow. However, flow must be maintained in all pressure systems during a steam blow to provide sufficient cooling of tubes.

A temporary desuperheater in the steam blow piping may help to

eliminate exceeding design temperatures of temporary piping. Furthermore, by desuperheating the boiler effluent the subsequent reduction in steam velocity helps to minimize the noise generated by the sonic steam flowing through the temporary piping.

Boiler operation during steam blows is a very transient operation that

requires complete attention of the boiler operator. Large fluctuations in drum level will be encountered during intermittent steam blows and during valve opening modifications of a continuous blow.

When two units are manifolded together, both boilers must be in

operation to generate the required cleaning ratios of the common piping. Care must be taken when bringing both units up simultaneously so as not to develop excessive pressure fluctuations between the boilers.

If not required for temperature control during the steam blow,

permanent desuperheating stations are to be removed from the steam path during steam blows.



Pneumatically inserted target plates eliminate the requirement of having to bring the boiler down after reaching the cleaning ratios, inserting the targets, and then starting the boiler up again and reaching the acceptable cleaning ratios.

Steam blow steam must not be discharged through the HRSG main

start-up valves. These valves are generally globe-type control valves and are subject to damage when passing dirty steam (steam blow steam). When heating up the boiler for the steam blow process, the temporary sacrificial steam blow valves should be utilized to control the ramp rate of the pressure systems.

HRSG Insulation must be installed prior to heat-up of the boiler. While

providing personnel protection, the insulation also prevents the formation of surface micro-fissures in the event of boiler operation during extreme weather conditions.

The saturation temperature differential generated between the initial

drum pressure and final drum pressure during an intermittent steam blow must be limited to 75°F (41.6°C)

3.0 Considerations

This section highlights considerations on when to clean the HRSG, protection of the HRSG, and other planning/work that may not be provided by the contractor. 3.1 The unit should always be inspected and cleaned after initial

erection. Future cleanings should be scheduled as required based on inspections and monitoring of performance.

3.2 The decision on whether cleaning for mill scale removal will be

necessary should be made by the owner in conjunction with those who will be doing the water treatment of the plant during operation.

3.3 A P&ID should be supplied to the cleaning contractor to lay out

the circulation path.



3.4 All pre-boiler piping, including feedwater storage/treatment facilities, should be cleaned when the HRSG is cleaned. If this will not be possible, it may be best to delay cleaning for scale removal until after operation has removed loose deposits from the feedwater system.

3.5 Control valves, orifices, and other instrumentation that could be

damaged during the cleaning should be removed or bypassed.

3.6 A temporary gauge glass is provided for use during the cleaning procedure, if deemed necessary by the cleaning contractor. Inform the contractor of the maximum working pressure and temperature on this temporary glass.

WARNING: THE DISPOSABLE TUBE TYPE GAUGE GLASS TYPICALLY USED DURING THE CLEANING PROCESS IS NOT SUITABLE FOR STEAM SERVICE. THIS GLASS COULD SHATTER UNDER SERVICE PRESSURE AND RESULT IN DAMAGE OR PERSONAL INJURY. A LOCKOUT PROCEDURE SHOULD BE EMPLOYED TO INSURE THE REMOVAL OF THIS TEMPORARY GAUGE GLASS AFTER THE CHEMICAL CLEAN HAS BEEN COMPLETED AND PRIOR TO PERMANENT OPERATION.

3.7 As it circulates through the HRSG, the cleaning solution will cool. Solution temperature should be monitored at the inlet and outlet points of the HRSG to ensure an effective temperature is maintained. Restricting air flow through the duct (by covering the stack or closing access doors) will reduce the amount of heat lost in the HRSG. Heating of the cleaning and rinsing fluid is normally accomplished in an external heat exchanger supplied by the cleaning contractor.

3.8 The contractor should take steps to ensure circulation of the

cleaning solution through all sections of the HRSG. In particular, the path of least resistance in the evaporators may be through the downcomer(s) and not through the tubes. This may require blocking the downcomer(s) during chemical cleaning.

3.9 Steam drum internals can remain installed during the chemical

cleaning. Note, however, that the mesh pads are made of stainless steel, and must be removed if the cleaning solution will attack this material. Re-install the mesh pads before steam blow or operation. If the chevron separators are removed for inspection or additional cleaning, they must be reinstalled with the same orientation.



CAUTION: FOREIGN MATTER ON THE INTERNALS COULD RESULT IN STEAM PURITY PROBLEMS. THEY SHOULD BE INSPECTED AND CLEANED AS REQUIRED.

3.10 Depending on the cleanliness of the pre-boiler water facilities,

the deaerator spray nozzles and trays may filter some material during initial operation. The deaerating function should be monitored for proper operation after startup.

3.11 Sample lines should be closed during steam blow and chemical

cleaning to avoid plugging.

3.12 The customer should retain records of the entire cleaning procedure including the chemicals used in the process.

3.13 Safety procedures should be reviewed or developed as

necessary prior to any chemical cleaning.

3.14 When the cleaning is completed, the customer and contractor should verify that the unit is clean and all the coils have been completely drained.

3.15 Disposal of the cleaning solutions may contribute substantially

to the cost of the process. The cost associated with longer circulation times of weaker cleaning fluids may be offset by the disposal cost of more caustic/acidic fluids.

3.16 If the combustion turbine is to be used as the source for heating

the cleaning solution, care must be taken to insure that the provided cleaning solution pumps are sufficient to maintain drum level. Incorrect pump size will increase the time required to clean the boiler.

3.17 Noise attenuation of the temporary steam blow piping may be

required. Generally, a steam blow silencer is provided due to noise constraints. However, the steam flowing through the piping may reach sonic speeds and as such, generate a considerable amount of noise. It does no good to have a silencer rated for 85 dBA when the noise emitting from the upstream pipe is 115 dBA. A temporary desuperheater station at the outlet of the HRSG piping will help to limit the velocities and therefore the noise generation.



3.18 Following cleaning, proper lay up procedures should be followed. Reference the Nooter/Eriksen lay up recommendations.

3.19 N/E does not endorse or recommend any particular type of

chemical clean / steam blow (including thermal shock steam blows). The above information is provided for information only.

3.20 It is advisable to remove the steam drum mesh pads prior to

commencing with a chemical cleaning which will circulate through the steam path. The mesh pad will act as a sieve in such a situation and would require an extensive cleaning after the chemical cleaning is accomplished. The mesh pads should be reinstalled prior to commencing with steam blows.

3.21 Boil out with caustic soda (NaOH) or soda ash (Na2CO3) is not recommended. IF these chemicals are to be utilized, the superheaters must be filled with properly treated condensate during the cleaning.

NOOTER/ERIKSEN PAGE 1 RECOMMENDED JOBSITE VISITS

REVISION 2 ERECTION PROCEDURE DOCUMENT

APPROVED BY: TSP X:\PROCEDURES/ERECTION.MANUAL\FIELDSERV.R2

FIELD SERVICE SITE VISITS 1.0 Pre-Construction Meeting

1.1 Meeting to be held at Nooter/Eriksen’s office in St. Louis.

1.2 Must be attended by: Purchaser Erector N/E Personnel

1.3 Erection Procedure Manual Documentation reviewed. The Erection Procedure Manual will be furnished to the Purchaser and the Erector prior to this meeting.

1.4 Erection presentation made on project HRSG.

2.0 Recommended First Site Visit

2.1 Estimated time of visit: 5-10 days.

2.2 Visit is to coincide with the arrival and setting of the major components or modules.

2.3 During the first visit, the following items will be reviewed.

2.3.1 Verify that the Erector has checked the foundation per EP-01

and has records to document the inspection.

2.3.2 Review of loads before off-loading if available. Check for rail damage, check packing lists, check for missing equipment, etc….

2.4 Observe off-loading operations. Confirm that the proper handling and

erection procedure is being used and provide comments.

2.5 Observe transporting and setting operations.

2.6 Review the material handling/storage procedures of the Erector as defined in the Erection Procedures.

3.0 Recommended Second Site Visit

NOOTER/ERIKSEN PAGE 2 RECOMMENDED JOBSITE VISITS

REVISION 2

X:\PROCEDURES/ERECTION.MANUAL\FIELDSERV.R2

3.1 Estimated time of visit: 3-5 days

3.2 Visit is to coincide with the installation of the field seams and piping.

3.3 During this visit the following items should be reviewed.

3.3.1 Module setting. Check the documentation of the Erector to

make sure that the modules are in the correct location.

3.3.2 Verify by visual examination the washer and anchor bolt installation.

3.3.3 Check material storage.

3.3.4 Review the field seam and piping installation with the people

who will supervise this work in the field.

3.3.5 Observe the installation of the field seams and piping. 4.0 Recommended Third Site Visit:

4.1 Estimated time of visit: 3-5 days.

4.2 Walk through after substantial completion of the system.

4.3 During this visit, the following items shall be reviewed.

4.3.1 Review the field seam installation both internal and external to the system.

4.3.2 Review piping installation and hangers/supports.

4.3.3 Review installation of trim piping, instrumentation and small

bore piping and supports.

4.3.4 Review the installation of the Duct Burner, SCR System, etc., if applicable.

NOOTER/ERIKSEN PAGE 1 EXTRA WORK BACKCHARGE

POLICY REVISION 0

ERECTION PROCEDURE DOCUMENT

APPROVED BY: PJH X:\Procedures\Erection.Manual\BC.POLICY.R3

1. For any field concerns or problems, Nooter/Eriksen should be initially notified

using the attached Field Issue Report. If the issue causes extra costs, that the Erector claims are Nooter/Eriksen’s responsibility, a Field Change Order will also be required.

2. All backcharges or extra work claims against Nooter/Eriksen must be made

on the attached Field Change Order (FCO) form with accompanying appropriate documentation (Photographs, Sketches, etc.) establishing that a deviation from Nooter/Eriksen’s design exists.

3. Nooter/Eriksen, Inc. will not authorize work without having a completed, and

agreed upon, reasonable estimate of manhours and cost filled in. 4. Nooter/Eriksen, Inc. reserves the right to have any and all corrective work

supervised by a Nooter/Eriksen representative and/or performed by a Nooter/Eriksen designated contractor.

5. If Nooter/Eriksen, Inc. agrees to have the Erector perform any work, an

approved FCO will be returned to the Erector. No claims will be honored for work done without this approval from Nooter/Eriksen.

6. If Nooter/Eriksen agrees to have corrective work done on a time and material

basis, all claims for payment must be documented with receipts and vouchers for equipment, materials, and labor time tickets. All labor rates will be quoted in advance and specified in the Purchase Order.

7. Construction Manager, Erector, and/or Purchaser mark-ups on backcharges

will not be accepted by Nooter/Eriksen unless clearly established by the original job Purchase Contract.

8. If field trim has been removed from piping on this project, Nooter/Eriksen will

not be responsible for pipe spool-to-spool alignment or termination points that differ less than 3” in any direction from theoretical locations.

FIELD ISSUE REPORT

PROJECT NAME: N/E FIELD ISSUE REPORT NO. N/E JOB #: CUSTOMER REF. NO.

FROM: DATE OF ISSUE: TO: UNIT NO. CC: REF. DWG. NO. ISSUE CODE: (N/E use only) JOB SITE FILE COMPONENT TYPE: (N/E use only)

PROBLEM CATEGORY:

(N/E use only)

DESCRIPTION OF PROBLEM:

ORIGINATOR: DATE: REQUESTED RESPONSE DATE: RESOLUTION OF PROBLEM: (ORIGINATOR SHOULD PROVIDE SUGGESTED RESOLUTION)

ACTION CATEGORY:

ACCEPT AS IS REWORK IN FIELD SUPPLY MATERIAL RETURN FOR REPAIR RESOLVED DATE: RESOLVED BY: APPROVED BY: PJH

X:\Procedures\Erection Manual\Field Issue Report.R3doc

FORM PROJ.008 REV. 2 9/3/02 (APPROVED BY: RKG )

FIELD CHANGE ORDER

CONTRACT # JOB # FIR # FCO # SUBMITTAL DATE: VERBAL WRITTEN VENDOR: PROJ. NAME/LOC: UNIT # DESCRIPTION OF PROBLEM: REFERENCE DRAWING NO.(S): POSSIBLE PROBLEM CAUSE: DESCRIPTION OF SOLUTION (ATTACH ADDITIONAL PAGES IF REQUIRED) CRAFT EST. HRS. FINAL HRS. SKETCH ATTACHED (YES/NO) CIRCLE ONE SUBTOTAL MANHOURS HRS HRS ESTIMATED FINAL TOTAL LABOR COST $ $ MAT'L REQ'D: TOTAL MATERIAL $ $ EQUIP. REQ'D: TOTAL EQUIPMENT $ $ SUBC. REQ'D: TOTAL SUBCONTRACT $ $ $ $ CLAIM SUBMITTED BY: TITLE: N/E AUTHORIZATION TO PROCEED: DATE:

FINAL COST: REJECTED BY:

APPROVED BY: DATE:

DATE: N/E CONTRACT PRICE: WARRANTY CATEGORY:

REASON:

APPROVED BY: WJP X:\Procedures\Erection Manual\Excerpt from O&M Manual.R5 .doc

EXCERPT TAKEN FROM O&M MANUAL

3.0 Drum Manway Cover Usage and Gasketing

All elliptical manway covers follow the same general requirements with 12" (305 mm) x 16" (406 mm), 14" (356 mm) x 18" (457 mm), and 18" (457 mm) x 24" (610 mm) being the most common sizes.

3.1 Open the manway and clean the old gasket from the cover and

manway ring. Both of the surfaces must be cleaned thoroughly with caution. A method must be used that does not flatten out the required machined roughness. Gasket surfaces are to be finished to 125-250 RMS.

All covers and rings must be inspected for pits or grooves on the sealing surfaces. If pits greater than 1/32” (0.8mm) deep exist, it will be necessary to repair the gasket surface by weld repair and remachining under the direction of your ASME National Board Inspector. If the manway covers, rings and plates cannot be repaired, then they must be replaced. New covers must be inspected for surface imperfections.

3.2 Proper gasketing, as defined in Table 3.2 and 3.3, is required to install

the cover. Do not flex, twist, bend or deform the gasket in any way before installation. This could damage the gasket and compromise its structural integrity.

Center the gasket on the manway cover. Bring the cover and gasket in contact with the manway ring. Install the studs in the plates or yokes and finger tighten to allow the manway cover and gasket to stay in place. Make sure the studs, nuts and washers are clean and well lubricated with nickel anti-seize compound to achieve the proper bolt load. Davits should be adjusted as necessary, to allow the proper alignment when bringing the cover and gasket in contact with the ring. To provide an effective seal, even compressive forces must be exerted on the gasket. To accomplish this, tighten the nuts (1) flat at a time going back and forth diagonally from nut to nut, following the pattern as shown below for (6) stud manways, or alternating back and forth for stud and yoke type manways, until all of the bolting is tightened to 10% of the final torque value Continue tightening the bolting following the recommended sequence (1) flat at a time until all bolting is tightened to 25% of the final torque value. Following the same method tighten the


bolting to 50% of the final torque value and then 75% of the final torque value. Finally tighten all bolting to 100% of the final torque value following the same method. Torque wrenches should be calibrated and in good working order.

DR-27V DR-26V CAUTION: HEAVY DUTY IMPACT WRENCHES WITH DRIVES GREATER THAN 1/2" (12.7mm) SHOULD NOT BE USED. IT IS IMPERATIVE THAT THE NUTS BE TIGHTENED ONE (1) FLAT AT A TIME PER NUT ON A ROTATIONAL BASIS WHEREBY NUTS ARE TIGHTENED SEQUENTIALLY ACROSS DIAGONALS. NEVER TIGHTEN ADJACENT NUTS IN SEQUENCE.

3.3 You may start to pressurize the boiler at this point. If the gaskets leak,

tighten each nut one (1) flat at a time alternating between the nuts (i.e., use the tightening procedure described above) until the leaking stops. As the boiler is heated, the internal pressure will force the cover against the gasket and, if properly installed, the seal will be effective; however, additional tightening may be required due to the heating/pressurization. It is to be noted that a "leak", as referenced here, is running water. A slow drip is acceptable on a cold boiler for this sequence. When the unit is up to pressure and temperature, if necessary, retighten the bolts to the values noted in Table 3.1.

CAUTION: TIGHTENING OF MANWAY BOLTS WHILE THE UNIT IS UNDER PRESSURE SHOULD BE DONE FROM THE SIDE OF THE MANWAY AS A SAFETY PRECAUTION.

If the boiler is shut down and allowed to cool, it is important to again check the torque on the nuts before repressurizing, to assure that the required torque values have been maintained.

1 2


Table 3.1 Required Torque Values for Manway Bolts

Type of Cover TorqueDR-26V 260 ft-lb (353 N-m)DR-27V 170 fl-lb (230 N-m)

Lenape Type "H" 150 ft-lb (203 N-m)Lenape Type "N" 100 ft-lb (136 N-m)

12" x 16" (305mm x 406mm)

Type of Cover TorqueDR-26V 260 ft-lb (353 N-m)DR-27V 170 fl-lb (230 N-m)

Lenape Type "S" 150 ft-lb (203 N-m)

Type of Cover TorqueDR-26V 260 ft-lb (353 N-m)DR-27V 260 ft-lb (353 N-m)

Lenape Type "S" 150 ft-lb (203 N-m)

14" x 18" (356mm x 457mm)

18" x 24" (457mm x 610mm)

Table 3.2 Gaskets for 12" x 16" (305 mm x 406 mm) Manways (unless otherwise specified)

PRESSURE - PSIG

PRESSURE (BARG)

TYPE OF COVER

GASKET TYPE

1200 + (83 +)

DR-26V OR

DR-27V

1” WIDE CHESTERTON/SELCO “STEEL TRAP” 304SS/GRAPHITE MANWAY GASKET WITH PRESSURE SENSITIVE ADHESIVE ON ONE SIDE.

1001 TO 1199 (69 - 82)

DR-27V 1/8” (3mm) THICK X 1” (25mm) WIDE REINFORCED FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRESSURE SENSITIVE ADHESIVE ON ONE SIDE 100 TO 1000

(7 - 68)

Lenape Type “H” OR

DR-27V

LESS THAN 100 (< 7)

Lenape Type “N” OR

DR-27V

THERMO-SURE TACKY CLOTH No. 6250. 3/16” (5mm) NOMINAL THICK X 1” (25mm) WIDE




PRESSURE (PSI)

PRESSURE (BARG)

TYPE OF COVER

GASKET TYPE

1200 + (83 +)

DR-26V OR

DR-27V


301 TO 1199 (21 - 82)

DR-27V 1/8” (3mm) THICK X 1” (25mm) WIDE REINFORCED FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRESSURE SENSITIVE ADHESIVE ON ONE SIDE

100 TO 300 (7 - 20)

Lenape Type “S” OR

DR-27V LESS THAN 100

(< 7) Lenape Type “S” Not Machined OR DR-27V

THERMO-SURE TACKY CLOTH No. 6250. 3/16” (5mm) NOMINAL THICK X 1” (25mm) WIDE

PRESSURE (PSI)

PRESSURE (BARG)

TYPE OF COVER

GASKET TYPE

1200 + (83 +)

DR-26V OR

DR-27V


201 TO 1199 (15 - 82)

DR-27V 1/8” (3mm) THICK X 1” (25mm) WIDE REINFORCED FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRESSURE SENSITIVE ADHESIVE ON ONE SIDE

LESS THAN 200 (14)

Lenape Type “S” Not Machined

OR DR-27V

HRSG Erection Manual Vendor SUR-V-99HA-1!91!003_RA

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