Pekerjaan pre-commissionin dan commissioning di area reforming mencakup:
Catalyst loading pada 101-B. Lihat Attachment-7 Catalyst loading 103-D
Radiant harp balancing (cold setting) Chemical cleaning 101-C dan 141-D
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement A. Preparation
A.1 Foundation hand over from civil, reconfirm dimensional and position of anchors Grease anchors bolts and nuts
Check and record foundation and anchor position
A.2 Liner plate installation Liner plate, non-shrink mortar.
Check and record for elevation A.3 Prepare work bench for pre assembly of radiant
panels and platform Steel beams, temporary platform
support and wooden plank. The bench should be sized enough for 2 panels
B. Radiant Box Pre Assembly & Installation
Panels of wall #2 & #4 require pre assembly on ground prior to erection/installation. At same time platform support can be installed to the extent feasible
Sequence of pre assembly and installation:
Wedges required for adjusting panel plumbness
Pre assembly on steel bench B.1 Wall panels (start from wall #4 & wall #3) and
floor walls, in sequential order: Pre assembled panels to be high strength bolted
B.2 Plumbness and diagonal dimensional check Bolts at splice to be manually tightened before plumbness check.
Gap at splice should be max. 3 mm.;
B.3 Bolt tightening and seal welding High strength bolting before seal welding
B.4 Liner plate tack welding and grouting Non-shrink mortar required
C. Combustion Air Duct & Arch Plate Installation
Ducts panels and arch platesarepre assembled on ground prior to installation. Each row is pre assembled into 2 pieces without seal plates
C.1 Install temporary support for ducts and 107-D Support are supplied by subcontractor based on designs furnished by TEC
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement
C.2 Install ducts: Cover openings with plank or
plywood for personnel protection C.3 Install seal plates for duct connection (sealing
compound & sealing gasket Weld duct end openings to wall structure
Align duct according to dwg., Maintain expansion clearance as per C.4 Arch grating
C.5 Install ends cover, After castable lining work
D. 107-D Pre-installation
D.1 Temporary support installation on top of ducts Dwg. NA Check alignment to inlet of 103-D and centerline to the reformer.
Plumb line from center of 107-D inlet stub is + 12 mm from center of drain opening on the floor D.2 Pre-installation of 107-D, at its designated
elevation and position 407-D series
E. Roof trusses
Requires pre assembly on ground to complete set of trusses before installation
E.1 Pre assembly of End-trusses & Sub-trusses Dimensional check against actual column position on radiant walls Column bevel ends are prepared on ground
E.2 Install:
Upper column
End trusses, Sub trusses, Vertical bracing Bracing & post
Tie bracing & effluent chamber support, roof bracing
E.4 Complete roof construction before H.3, including installation of exhaust fans
F. 107- D Setting and Adjustment
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement F.1 Install 107-D spring support, in locked condition
according to dwg.
Install hanger to spring support and weld the pin
Check spring no. and its location which is align with transfer line support points
Check that the 107-D is positioned center line to reformer for its entire length and align to 103-D inlet stub F.2 Roof trusses are completely installed, bolt tightened
and welded
Suspend 107-D by tightening spring turnbuckles, F.3 Remove 107-D temporary support after position
and level of the vessel is inspected.
F.4 Measure distance from 107-D end to 103-D inlet stub.
Cut 107-D field piece to the required length plus allowance for end preparation.
Bevel end according to WPS Fit-up and tack weld field piece
F.5 Welding pressure shell of 107-D field piece to start
from 103-D side Check vessel centerline to furnace
and adjust weld sequence if required F.6 Installation of water jacket
G. Duct Hanger & Manifold Installation G.1 Install duct hanger and set level of duct by
adjusting bolts
Adjust duct to center of 107-D inlet stub
Check level of duct, check expansion allowance on duct connection
Plumb line from center 107-D inlet stub, was within + 12 mm from midpoint of adjacent duct wall G.2 Install inlet manifold support & guide
Install inlet manifold and support hangers. Use turn buckles of intermediate support to maintain slope of manifolds
G.2 & G.3 can be done after radiant harps installation (H)
Maintain slope of (- 25 mm) + (3 mm) towards cross over pipe Check clearance as per drawing G.3 Weld Grinnell pipe covering protection saddle,
followed by guide roller and G.4 Remove duct temporary support
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement H. 101-B Radiant Harps installation
Each harp section will be erected using spreader beam. These harp sections was temporary seated on steel support below floor level.
H.1 Remove shipping bracing from radiant harps except for erection purpose
H.2 Install the harp through opening on the roof structure, start with center harp. Temporary steel support was positioned so that the outlet manifold is rested 20 mm below its intended elevation
210-D103
H.3 Install spring hanger assembly and beam, tighten spring ass’y by turning threaded rod
Plumb hanger was within + 3 mm
212-D101 Check and record length of upper and lower attachment and over all spring assembly
J. 101-B Radiant Riser Transition Assembly welding J.1 Center and fit-up riser transition assembly to 107-D
inlet stub using support 210 - D105,
407 – D6 J.2 Perform welding in sequential order (together with
refractory work) as per drawing 407 – D6 Perform inspection as per dwg.
J.3 Re-check with plumb line from riser transition inlet stub as per F.2
J.4 Continue with water jacket installation
K. Radiant Harps Adjustment and Welding
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement K.1 Suspend harps on hand tightened springs and
remove temporary support
Install bottom header boxes to maximum extent, leave access for jigs and welding work
Drop plumb line from riser transition to floor opening. Centering riser tube was within + 12 mm from top of riser to connection point with outlet manifold,
Check if drain nozzle and thermowell connections are correctly centered over floor openings. Floor opening should be adjusted accordingly if conflicted.
See KBR’s balancing procedure
Do not weld cover plates at this stage.
Plumb hanger was within + 3 mm Measure and record distant of top flange from datum line before support is removed
K.2 Leveling center harp’s outlet manifold was within + 10 mm for 3 m length by using hanger’s threaded rod
Adjust elevation and level of end harps was aligning with center harp.
Fit up for welding.
210-D103 Level to within +10 mm per 2500 mm length.
Measure and record distant of top flange from datum line before welding
Measure and record elevation of manifold above floor at three points for each third
K.3 Weld manifold according to the approved
procedure Use jig to fix position of manifold
during welding
K.4 Record position of tube assemblies after welding Measure and record distant of top flange from datum line
Measure and record elevation of manifold above floor at three points for each third
K.5 Adjust the hanger based on final record of distant
of top flange from datum line Release or tightened the threaded
rod by the difference in record before and after welding
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement K.6 Raise riser to correct position for field welding by
adjusting spring turnbuckles.
107-D to remain as per F.6.
Before welding:
Check for correct weld gap Measure and record distant of top flange from datum line & elevation of manifold above floor at three points for each section
After welding finished:
Measure and record distant of top flange from datum line & elevation of manifold above floor at three points for each third
Adjust spring turn-buckles according to differences in record measurement
K.7 Install drain and thermowell connection and sleeves Welds as per approved procedure
210-D102
K.8 Riser insulating cans was installed after pneumatic
test of radiant coil (step P.) 210-D104
K.9 Install arch cover plates according to drawings Check bolt position/clearance for arch plate movement, adjust plates if required (ditto N.2)
K.1 Weld cover plate as per drawing Check expansion clearances
L. Refractory Lining & Burner tiles (Radiant Box) L.1 Install sidewall brick lining. Including tunnel burner
side bricks and burner tiles
Ensure that dimension of brick on burner wall side is correct to ensure straightness of tunnel wall
215-D series Supplier’s dwgs.
Test for anchor stud weld strength Maintain and check for expansion clearance on brick wall as per drawing
L.2 Install arch burner tiles Check for correct position for each
type of arch burners Check for tiles projection L.3 Install arch module lining except area around riser
transition assembly (if step P.1 is not yet perfrmed) Supplier dwgs.
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement L.4 Install tunnel wall bricks, floor brick and bull-nose
castable lining
L.5 Outlet manifold lining after catalyst loading. Step M.1, and system pneumatic test, step P.4
M. Catalyst Loading
M.1 Catalyst loading will start if radiant harps welding and upper structure is completed
Catalyst loading to proceed in accordance with procedure
Detailed procedure was developed using KBR’s loading procedure. Bed density of catalyst was confirmed prior to loading
M.2 Replace gasket with permanent material and bolt tightened as per instruction, after final inspection
of catalyst bed Bolt torque controlled
N. 107-D & Radiant Tubes Spring Adjustment (Cold Setting) N.1 Fill in water to 107-D jacket to operating level.
Remove spring locks and adjust spring to the operating load (cold)
N.2 Release radiant tubes spring locks Check for any obstruction, adjust arch plates if required
Check bolt position (on sloted holes) for duct movement N.3 Adjust spring to Final Cold Operating load settings Record final spring setting
Measure and record distance of top flange from datum line
N.4 Set 107-D spring limit stop 15 mm. upward and 3 mm downward.
O. Installation of Arch and Tunnel Burners
O.1 Install burners as per drawing/instruction Check orientation and record burner tip projection
Check for easiness of operation of burner air damper
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement
P. Refractory and External insulation (Radiant Box)
Step P1, P2 & P5 was completed after system pneumatic test P.1 Install & welding riser cans with ceramic fiber
blanket 210-D104
P.2 Install ceramic cloth (Nextel BS-40) w/cardboard below riser cans
Install flexible boot on riser openings
Supplier’s dwgs.
P.3 Complete ceramic fiber lining on arch plates Supplier’s dwgs.
P.4 External insulation on air ducts
P.5 Complete refractory work on outlet manifold and header boxes, and castable on air ducts
Install tunnel slabs.
Provide protection on slabs by using plywood
Q. Inlet pigtail and external pipe welding and insulation To be performed before system pneumatic test, before or after catalyst loading, but after cross-over piping (step S1 to S5) Q.1 Fit up inlet pigtail by trimming excess length. Do
not “cold spring”.
Q.2 Insert 1.5t cardboard spacer to sockolet on inlet manifold and on radiant tubes before inserting pigtail into sockolet.
Perform visual check for the gasket before pigtail installation
Q.3 Socket weld inlet pigtails to radiant tubes and to
inlet manifold PT
Q.4 External insulation except at weld joints (was completed after pneumatic test)
Q.5 Adjust spring to Final Cold Operating load settings Record final spring setting
Measure and record distance of top flange from datum line
R. Convection & Transition Section Installation and Castable lining
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement Convection coil are supplied separately from its casing (convection
panels). Thus to complete the module, the convection panels, castable lining on the panels and installation of convection coils should be done in sequential order on steel bench before final installation.
Mechanical subcontractor to prepare lifting frame suitable for erection of heaviest module.
R.1 Install hot/cold leg’s convection box up to elev. + 6050. Dimensional check and bolt tightening and seal weld splices
Install transition floor and roof
Weld columns to cap plate before installation of upper module
Plumb and square check
Check for type and position / level of tubesheet supports and guides Strength bolted and seal welded
R.2 Castable lining work on convection box.
As alterntive, lining may be applied on horizontal posisiton before panel assembly
Check for anchor welds
Check for castable homogenity by hammer test
R.3 pre-assembly and install lowest convection modules, both legs
Install tie-beam between hot and cold leg, if any Full-weld column to pad plate before installation of next upper module
Ceramic fiber was place on top castable surface at module splice.
Install convection next modules in sequence between hot and cold leg. Follow step 2 to 4 for each module
Bolt and seal weld splices
install and weld distributor supports
Additional temporary tie-plate/rod may be necessary to hold firm the modules during erection
Position of tie-plate/rod are at column D & H, lower part. To be removed after column welding.
R.4 Install roof structure, including duct support Install platform on convection section Install end walls on transition section R.5 Install distribution plates
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement R.6 Ceramic fiber modules and castable lining.
Install burner tiles
R.7 Install superheater burners Check for position and projection
of burner tips
S. Cross Over Pipes And Convection Module Jump-Over Pipe Installation And Welding S.1 Plumb and install /weld strut hanger (FS01) as per
drawing, 610 mm from center line of inlet manifold 210-D401 Plumb was + 3 mm
Total length of strut = 2872 mm from inlet manifold center S.2 Install horizontal pieces (C001) with hangers and
-25 mm slope down to coil header
Weld to coil header after fit-up and elev. check
210-D401
S.3 From field weld end of (C001) measure actual elevation of field weld joints of cross over pipe S.3 Cut (C007) to actual length
Plumb and install /weld (C007) to “Barco” strut Weld to inlet manifold after fit-up,
S.4 Cut (C003) to actual length Fit-up and weld (C002)
S.5 Measure and cut (C006), (C005), (C004) to actual length. Same as S.3
S.6 Fit-up and weld steam superheater jump-over pipes Convection tubes are cold spring for fit-up, as per drawing. RT & PT S.7 External insulation except at field weld joint (was
completed after system pneumatic test)
T. Combustion Air Duct & Stack
T.1 Completely install ducts after the Fans and Air Preheater is ready
T.2 Install stack and connecting flue gas duct to ID Fan Stack is castable lined on the ground before erection.(step U.2)
ATTACHMENT-1.
PRIMARY REFORMER OVERALL MECHANICAL & REFRACTORY WORK SEQUENCE (TYPICAL)
No Activities Reference
drawing Remarks/ Inspection Requirement U. Castable lining / External Insulation on Convection Duct and Other Equipment
U.1 Castable and or ceramic fiber lining on transition duct, convection duct
U.2 Castable lining on stack (if required)
V. Accessories
V.1 Install dampers, actuator, flexible joint, manholes, peep doors, etc.
ATTACHMENT-2