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METHOD OF SATEMENT FOR TUBE
1.0 Purpose:
The purpose of this method of statement is to provide a preliminary reference
guideline and describes in detail for removal and installation for baffle tubes from
front wall for Stage-III Steam Units #6 at Rabigh Power Plant. ADDAR bears no
responsibility in case of any changes, alteration and /or modification of the procedure
as required during actual execution for more details and confirmation of the
specification, site inspection shall be carried out by the prime bidder and the agency
for the modification work.
2.0 Scope and Purpose of Method Statement
-This document outlines the method for replacement front wall baffle tubes (139
tubes –SA213T12) including Skin casing ,skin casing and refractory from level
FL+28800 to FL+34155.
-The procedure provides guidance for assessing the activities for replacement of
tubes. This guidance is based on the requirements set forth in the project requirement,
safety requirement and Quality assurance program.
-There will be a requirement of installation and dismantling of temporary material
/support, permanent material and support during the modification process.
-Perform Step by step installation of new panels according to the assembly drawings.
2.1 Objectives
This document provides guidance in implementing an effective program for
replacement of Titanium tubes for the Heat Exchanger. This includes addressing
programs for the following:
(1) Implementing commitments regarding the quality of the work.
(2) Managing and providing oversight to ensure installation and related quality
control has been adequately addressed by specifications, drawings, and
procedures.
(3) Managing and providing supervision and control to assure quality of work and
closely implement/monitor schedule.
(4) Recording installation and test activities.
(5) HSE at the time of work.
This procedure is one component of a complete replacement of tube work program.
This and other procedures will be used, as needed, to provide assurance that
replacement of tubes activities are being conducted as required by the specification
and manufacturer procedures. It is not expected that completion of the entire
procedure will be accomplished during any one inspection and /or every time the
inspection procedure is used. It is a continuing activity until all tubes are replaced.
2.2 Inspection and Recording Requirements
The engineer should verify that the supervisor/foreman with construction
responsibilities for the replacement of tubes works is familiar with the method
statement and is issued with copies of the inspection checklists and test plans. The
engineer should satisfy procedures provided by QA/QC inspections to ensure the
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replacement of tubes works meet specified engineering requirements and drawings.
As part of the assessment, the QC inspection procedures must ensure a quantitative
or qualitative acceptance criteria for determining the prescribed activities have been
accomplished satisfactorily.
The QC inspection personnel, in coordination with site supervisor, should verify that
the quality of the works and related testing activities are within the project design
specifications requirements.
The supervisor should verify that the replacement of tubes works is accomplished in
accordance with the specifications and the manufacturer’s procedures. The
supervisor should verify any testing and confirm that the information meets the
project requirements.
2.3 Training and Qualification of Personnel
The supervisor should verify that the personnel have sufficient knowledge of the
procedure requirement. The supervisor should review any training and qualification
records for those individuals who shall do the task to determine whether they are
skilled enough to follow the procedure before the actual work is carried out.
3.0 Responsibilities and resources
3.1 Responsibilities:
The project manager (ADDAR), has overall responsibility for the co-
ordination and implementations of the cutting and welding activity, including
manpower and plant utilization, engineering support, material scheduling and
cost control.
Project Manager (ADDAR), Project Engineer (ADDAR) / will be responsible
for the replacement of baffle tubes
3.2 Resources:
ADDAR Equipment
Compressor
Welding machine
Grander machine
Beveling machine
Electrical Tools.
Hand Tools
Lifting and Rigging Equipment:
Scaffolding:
Other small hand tools and tackles
ADDAR Manpower
Site manger
Engineers
QC/QA Engineer
Supervisor / Foreman
Fabricators
Welders
Insulator
Fitters
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I&C Technician
Helpers
Other miscellaneous.
4.0 Material :
Description Material Qty
SLITTED FIN (t9x w30.5) SA387-22-1 136
SLITTED FIN (t9x w10) SA387-22-1 72
SLITTED FIN (t6x w30.5) SA387-12-1 136
SLITTED FIN (t6x w30.5) SA387-12-1 136
SLITTED FIN (t6x w30.5) SA387-12-1 136
SLITTED FIN (t6x w30.5) SA387-12-1 136
SLITTED FIN (t6x w10) SA387-12-1 70
SLITTED FIN (t6x w10) SA387-12-1 2
SLITTED FIN (t6) SA387-12-1 132
SLITTED FIN (t6) SA387-12-1 136
SLITTED FIN (t6) SA387-12-1 4
TUBE (Ø 38.1xt4.6) SA213M-T12 139
5.0 Welding procedure :
No Weld Parts Material DIMENSIONS NO.OF PREHEAT(MI FILLER
No. JOINTS N.°C) METAL
DIA THICK TIG/Rod
(mm) (mm)
Front Wall Baffle Tube (Rifle) SA213-T12 38.1 4.6 139 150
(Existing)
1 D6 ER80S-G
Front Wall Baffle Tube (SMOOTH) SA213M-T12 38.1 4.6 139 150
Front Wall Baffle Tube (SMOOTH) SA213M-T12 38.1 4.6 139 150
2 D7 Front Wall Baffle Tube (SMOOTH) SA213M-T12 38.1 4.6 139 150 ER80S-G
3 ----- Slitted Fin /Skin Casing SA387-12-1 -------- ---------- ---------- --------------- E9018B3
6.0 Preparation:
1. Keep all necessary drawings (assembly drawing, sectional drawing, part details.)
and
document (procedures, execution plan etc..) with latest revision ready, prior to start of
work.
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2. Prepare the necessary handling facilities (lifting equipment, hoist, forklift, crane
and support, etc. to removed and store the various spare parts of equipment).
3. Coordinate with the electrical, mechanical and I&C department if necessary to
remove any component (switch pressure, pressure transmitter, soot blower’s burners,
thermocouple, etc..) before starting disassembly work.
4. Tool list and consumable list shall be made and be arranged to avoid any delay.
5. Make the works’ procedure and the schedule based on the estimate beforehand.
6. Arrange the workmen in required groups for rehabilitation work. Make a group
structure for mobilization.
7. The scaffolding in the around lower panels and super heater 3RY-SH shall be
planned and necessary step shall be calculated and arranged.
For the use of electrical equipment for heating and welding illumination, calculate
temporary electrical capacity and decide a temporary electrical source of supply. In
case shortfall, diesel generator shall be arranged.
8. Opening the manholes /Access door opening in different side of the furnace and
super heater.
Precaution:
Obtain necessary work permits before start of any work. Ensure electrical
supply to the actuators is disconnected. The circuit breaker is locked and
tagged.
The FD fan should be electrical isolated. the breaker must be racked out
locked and Tagged
Note: -All data is too recorded during headers and tubes inspection and
removal.
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