Client: IL&FS Tamil Nadu Power Company Limited

Consultant: FICHTNER Consulting Engineers (INDIA) PVT. LTD

IL&FS Cuddalore
2600MW Thermal
Power Project

Contractor:
Shandong TIEJUN Electric Power Engineering Company Limited
Sub-Contractor: L& T Power-TPPC

Work procedure for Ducting Assembly & Erection

No.: 1AEB009

Total
Page:22

Work Procedure

compiled

verified

approved

LARSEN &
TOUBRO LTD.

date month

date

month

date month

year

year

year

CONTENTS
1. Reference standards
2. Construction introduction
3. Quantities of main parts
4. Construction preparation
5. Sequence of process
6. Quality requirement
7. HSE management
8. Safety construction risk control schedule

1. REFFERENCE STANDARDS

1.1) AWSD1.1/ASME SEC-IX -The welders shall be qualified in accordance with this standard.
1.2Dimensional checks At different stages of assembly and erection, dimensional inspection
shall be carried out for obtaining dimensions within the tolerance limits as specified in this
procedure and drawing.
1.3Quality Indicators and acceptance criteria FQP, WPS.

2. CONSTRUCTION INTRODUCTION
2.1) Scope:
The scope of work comprises executing works pertaining to ducting preassembly& erection.
Including receipt of fabricated material, loading, transporting & unloading at our works area for
preassembling, erecting, aligning, welding and testing required for ducting.

2.2) Responsibility:
2.2.1)Project Manager / Construction Manager:
Shall be responsible for providing resources to implement this procedure
Shall be responsible for control supervision and direction for implementation.
2.2.2)Execution Engineer:
Shall report to Construction Manager/ Mechanical In-Charge
Shall be responsible for overall activities & implementation.
Verifies and signs all the reports /formats as per FQP.
2.2.3)QA/QC Engineer:
Shall Report to QA/QC in-charge
Shall be responsible for necessary inspection to ensure proper quality control & maintain relevant
records as per FQP.
2.2.4) HSE Officers:
Shall report to Project Manager
Shall be aware of complete HSE plan and manage all safety requirements during the execution.

3. QUANTITES OF MAINPARTS:

Sl
No.
a)
b)
c)
d)
e)
f)
g)
h)
i)

Ducting description

Weight in MT

Flue gas Duct (before ID Fan)

Flue gas Duct (After ID Fan)
Hot primary Air Duct
Hot secondary Air Duct
Cold primary Air Duct
Cold secondary Air Duct
APH Inlet
APH Outlet
Economizer outlet
Total

642 MT
313 MT
197 MT
261 MT
156 MT
133 MT
122 MT
61 MT
107 MT
1992MT

4. CONSTRUCTION PREPARATION
4.1Material shifting
Material shifting includes transportation of materials from client stock yard to work site. Before
shifting the material it has to be checked properly with the reference of approved drawings. If any
deviations are found, it should be informed to HTG E&C. After completion of these formalities
material will be shifted to work site.
4.2Panel Assembly
Pre Assembly of loose Panels is done in the Fabrication Yard by the 20T gantry crane. The
dimension are checked and ensured with reference of drawing.
4.3Fit up & welding
Fit up is checked with client and after completing the inspection, welding will be started, and
inspection for welding has been done.
4.4Main Duct Assembly
Once assembling of individual loose panels are completed, the main duct assembly will be done by
using of 20T Gantry crane. As per dimension, Fit up is to be carried out.
4.5Welding
a) Welding shall be in accordance with relevant approved WPS.
b) Parts to be welded shall be carefully prepared as per relevant approved drawings.
c) Alignment and welding sequence shall be such as to minimize distortion and residual stress.

Welding shall not be done if the surface of the member is wet (or) during the period of high wind
unless the welding operator and work are properly protected.
d) Members to be joined by fillet welding shall be brought and held as close together as possible
and in no event shall be separated not more than 3mm. Inspect the fit up & Diagonal Dimension
check by the client and get the clearance from them, after welding has been done.
4.6painting
The scope of painting is as follows:
a) Primary painting
Primary painting of the non-heating insulation duct is been done in workshop.
Primary painting of the site fabricated parts will be done at site.
b) Finishing painting
Finishing painting of the site fabrication, non-heating insulation parts will be done at site.
c) Detail requirements of painting work according to the painting procedure.
4.7Fabrication of Circular/ Square Duct
This Section (4.6) covers only for the items which are involving fabrication
4.7.1 Fabrication
a. Raw Material shifting includes transportation of materials from client stock yard to work site.
Before shifting the material it has to be checked properly with the reference of approved
drawings. If any deviations are found, it should be informed to HTG E&C. After completion of
these formalities material will be shifted to work site
b. Fabrication shall comply with the requirements of approved drawing.
c. Rolled section and plates shall be clean, free from kinks, bends (or) twists and straighten within
the tolerance allowed by relevant approved drawing.
d. Where straightening is necessary, it may be carried out by mechanical means application of
localized heat by using heating torch.
e. Rolled sections and plate which are not meeting the specification requirements shall be returned
for replacement.
f. Cutting plan shall be prepared and will be submitted to Contractor for review. Cut edges shall be
dressed to remove burrs and irregularities. Holes shall be dressed as required to remove burrs and
protruding edges.

g. Plates will be rolled to required dimensions as mentioned in approved drawings / approved

cutting plan.
4.7.2 Fit up & welding
a) Fit up is checked with client and after completing the inspection, welding will be started, and
inspection for welding has been done.
b) Fabricated parts shall be free from weld spatter, arc strikes, undercuts, misalignment, excess weld
metal deposition, under fill, slag, gas cut marks and other visual defects
4.7.3 Main Duct Assembly
Completed components shall be moved with a durable and distinguishing erection mark in such a
way as not to damage the material. Hard stamping / Painting of Mark No on the respective items
shall be used. Once fabrication of individual loose panels is completed, the main duct assembly will
be done. As per dimension, Fit up is to be carried out.
4.7.4 Welding
a) Welding shall be in accordance with relevant approved WPS.
b) Parts to be welded shall be carefully prepared as per relevant approved drawings.
c) Alignment and welding sequence shall be such as to minimize distortion and residual stress.
Welding shall not be done if the surface of the member is wet (or) during the period of high wind
unless the welding operator and work are properly protected.
d) Members to be joined by fillet welding shall be brought and held as close together as possible
and in no event shall be separated not more than 3mm. Inspect the fit up & Diagonal Dimension
check by the client and get the clearance from them, after welding has been done.
4.8Temporary arrangements for erection
After main duct assembly, Temporary supports and lifting hook arrangements to be done before
shifting of material to erection site.
4.9Inspection & Testing
After Finishing of Welding, Kerosene tests as per approved FQP have to be carried out. If any leaks
occur, the same shall be rectified and kerosene test to be done for final acceptance.
4.10Schedule
Start at Dec 20th2012 and finished at July 10th 2014.
4.10.1Manpower

Sl
no

Designation

Initial
mobilization

Peak time
mobilization

a)

Engineer In-charge

b)

Erection Foreman

c)

Fitter

20

d)

Rigger

40

e)

Khalasi

10

40

f)

Welder

40

g)

Gas cutter

h)

Helper

15

60

j)

grinder man

20

Total

62

231

Remarks
Tentative estimation for
planning purpose only; the
actual mobilization will be
done as per the front
availability.
The actual mobilization
should satisfy the work
progress.

4.10.2Mechanical
Sl
Machineries
Initial
Peak time
no
mobilization mobilization
a) 75MT Tower crane(unit 1)
1
1
b) 80MT Tower crane(unit 2)
1
1
c) 80T crawler crane
1
1
d) Winch-5T
1
2
e) Welding machine
10
30
f)
Trailor 40MT
1
2
g) Hydra 14MT
2
3
4.10.3Tools
Sl
Tools
Initial
Peak time
no
mobilization mobilization
a) Chain block 10MT
4
15
b) Chain block 5MT
6
25
c) Chain block 2MT
5
25
d) D-Shackle 10MT
4
25
e) D-Shackle 20MT
4
16
f)
Sling 25mm -15 mtr
4
20
g) Sling 25mm - 2 mtr
10
25
4.10.4Materials
a) Lifting arrangements Plates
b) Welding Electrodes
c) Cutting Wheel
d) Grinding Wheel

Remarks
Tentative estimation for
planning purpose only; the
actual mobilization will be
done as per the front
availability.

Remarks
Tentative estimation for
planning purpose only; the
actual mobilization will be
done as per the front
availability.

e) Oxygen & LPG

f) Wooden Slippers
g) Scaffolding
4.10.5Flowchart for pre-assembling process

Transportation of fabricated
materials to the place, where the
loose
panels
to
be
preassembled

Preassembly and fit up of loose

panels and inspection (fit up)

Welding of preassembled panels

and inspection for welding

Lifting
of
loose
panel
assemblies and formation of
main duct (fit up section).and
Inspection of fit up.(diagonal
dimensions etc.)

Welding of main duct, Final

inspection and clearance for
erection

5. SEQUENCE OF PROCESS
Shifting
This step includes the transportation of preassembled main duct to erection site. Main duct is
unloaded and positioned by crawler crane having capacity of 80 MT.
Erection and positioning
Before doing lifting of Main duct, it should be Inspect with HTG E&C and get permission. Then
main duct will be lifted by 75MT/80MT Tower crane.

Alignment, Fit up and welding

After lifting process, it is placed at required position by using chain blocks. The load is transferred
from Tower crane to chain block, and using proper steel wire rope locked it in proper position. After
all these steps are carried out, fit up process will be started. Once fit up process has been completed,
it is to be checked properly. After all checking has been done welding process is started and
required test as per FQP to be followed. Permanent supports are to be welded with main duct and
removal of temporary structure as well as platforms as follows. Required tests (kerosene test) and
inspections have been done after welding as per approved FQP. Fillet welding shall be checked by
Fillet gauge.

Construction Process Flow Chart:

Duct shifting to Boiler site.

Life line arrangement on

the Duct top flange &
temporary platform

Duct unloading
&Positioning.

Slings of required size along

with D-Shackles of required
capacity to be fixed

Lifting of Duct (as per

procedure).

Leak
test
after
completion of welding,
then inside cleaning and
close the man door

Positioning of the Duct.

Fit up & welding of Duct.

Erect permanent supporting of
Duct

6. QUALITY REQUIREMENT
a) Drawing control in working area shall be established and it will be monitored regularly
b) All inspections starts from material inspection to till work completion are carried out based
on the approved Field Quality Assurance Plan (FQP).
c) Ducting assembly length deviation within a tolerance of (2length, 10mm); Ducting
assembly bending deviation within a tolerance of (2length, 10mm)
d) Ducting erection elevation deviation within a tolerance of 20mm Ducting erection
horizontal location deviation within a tolerance of 30mm Ducting joint fit up deviation
within a tolerance of 1mm
e) Each stage inspection will be carried out by respective person. Also the report for the same
shall be documented.
f) Each report shall bear the identification no. for the items to be inspected.
g) Work completion status for Individual ducts shall be checked in line with FQP prior to
erection.
h) It is forbidden to welding temporary on the structure. Most of all temporary arrangements in the
form of clamping.
i) All welding shall be carried out as per approved Welding Procedure Specification/ Procedure
Qualification Records.

j) Welding shall be done in the event of heavy rain/ wind only if assembled duct is protected
from the environment.
k) Kerosene leak test shall be practiced by following the approved procedure with internally
qualified persons.
l) Final work completion inspection shall be done along with HTG E&C and FITCHNER /
ITPCL.

7. HSE MANAGEMENT
a) Good soil condition to be maintained for the easy approach of man and machinery to the work
area.
b) Proper luminous intensity or area lightning are to be kept when work to be carried out at night.
c) Proper insulations & laying of electrical cables and good earth at every points to be done to
avoid electrical hazards.
d) Tested tools and tackles having valid test certificates should be used for the lifting & shifting of
the materials.
e) Lifting machineries including crawler cranes, winches and rope pulleys should also have duly
tested clearance.
f) Load test certificate for Tower crane should be available.
g) Ropes used for load lifting purpose, though being certified should be visually checked again to
ensure the physical disturbances like birdcage, broken strands etc. in the rope.
h) Tag lines should be used at both the ends to ensure safe shifting of the load.
i) Proper barrier around the work area to be provided to avoid unauthorized trespass of people
inside.
j) Good approach like ladders, lifelines and working platform should be provided and clearance
from the safety engineer should be taken to facilitate smooth work.
k) Housekeeping to be done at regular intervals and the materials should be kept in its proper place
at site as well as in sub-contractors store. The scrap should not be thrown to zero meters freely,
it should be collected in boxes separately and the boxes should be removed with the help of
cranes.
l) In case of heavy rain all the equipment on site should be covered, all the electric appliances,

illumination and panels should be covered. And there should be proper grounding of equipment
on site so as to avoid any chance of electric shock, before start of work after heavy rain
electricians should check the equipment and structure to avoid any chances of electric shock.
And if water has accumulated on structure it should be removed and cleaned off before start of
work.
m) Lifting operation permit must be prepared for carrying out the lifting work in these situation (if
weight reached 95% of the rated load of the lifting machinery;(if have two or more than two
cranes together lift the same object; if doing lift work below or near the High-voltage wire.
n) Use of open flame around flammable, explosive area should not be allowed, must have hot work
permit and appropriate measures be taken prior to start of any hot work.
o) The ladder should be connected with the structure at an angle of 60, in a manner that the base
of ladder is fixed and rigid and the top of the ladder is connected with the platform or structure
rigidly. When the person climbs the ladder he should face the ladder. And it is not allowed to
carry material while climbing the ladder. Material is to be lifted separately by means of rope.
Only one person is allowed to climb or work on the ladder at a time.
p) The temporary platform should be fixed and rigid, platform should not have any holes, all the
plates joints should have an overlap of 20 cm. Platform should have a handrail of at least 1.05 m
and platform should have toe guard with at least height of 18 cm.
q) In the time of hot weather, high elevation work should be avoided. There should be adequate
water facility on site, medicines should be made available on site to avoid any casualty caused
due to hot weather.
r) Before using chain blocks, the safety check of chain blocks should be done. Chain blocks hook
& chain should be checked prior to its use and safety load test should also be done. It is not
allowed to lift weight more than the rated capacity of chain block. If the capacity of chain block
is less than 5 ton, only one person is allowed to operate it and if it is more than 5 tons, then 2
persons are allowed to operate it. The chain of chain block should not be in twisted state, if it is
it should be rectified.
s) The power supply panels should be properly earthed, joints inside the panels should be insulated
and there should be no loose or open joints The panel should be protected from rain water by
providing cover on it; the cable should not be laid in or near hot work areas; if the cable is

supported on wooden platform it should be earthed and if it is supported on steel it should have
wood in between. The illumination should also be protected from rain water by providing
covers.
t) If any duct is shifted on site for erection, it should be erected within 3 days after shifting.
u) PPEs like safety shoe, safety helmet, hand gloves, safety belt, fall arrestor, welding shield for
welders, safety goggles for grinders etc. are to be provided to the workmen to assure their safety
and good health at work.
v) Weather report shall be given to erection department regularly. As per that report, execution
engineer should be made the schedule and sequence of erection process.
w) Safety training at regular intervals and safety pledge on daily basis should be worked out at site
premises to increase the safety consciousness and skill of the workmen.
x) GRA (Group Risk Assessment) and STA (Safety Task Assignment) to be prepared.

8. SAFETY CONSRTUCTION RISK CONTROL SCHEDULE

Sl

JOB STEPS

HAZARD/REACTION

CONTROL&CHECK

TO FAILURE

REQUIRED

Transportation

-Fabricated ducts loaded on

-All lifting tools & tackles

of fabricated

trailer or transported by

and crane or hydra should

ducts from

crane or hydra may hit to

be in good condition &

fabrication yard

person on road or at the

certified by competent

to erection site.

time of loading.

person.

-Failure of crane or tool &

-Regular checking of

tackles.

moving vehicle

-Fall of materials

-A transportation

no.
01

ACTION BY

- Erection Engineer

- Rigging Foreman

- Rigging Foreman
supervisor to be made
responsible to guide the
trailer & alert people
during transportation.
-Rigging Foreman
- Hit injury.

- Proper sling or belt

should be used to lifting
load.

-Tag line to be tied to

- Rigging Foreman

fabricated member & load

guided by two people with
the help of guide rope.

-Dont try to lift the bunch

of fabricated member.

- Area should be

- Rigging Foreman

barricaded.

- Rigging Foreman

-Always use all the

required PPEs.

-Safety Engineer

- Proper stacking of
material
Should be done.

02

Erection of

- Fall of person from man

- Height Work permits as

-Erection engineer/

ducts /

basket or fixed ladder

well as lifting permits

safety engineer.

dampers /

(check lists) have to be

Expansion

issued after checking of

bellows /

site condition. Safety

Supports /

engineer will be checked

platform /by the

the entire site conditions

use of crane &

as well as safety

man basket

precautions, whether they

(jula).

are properly taken or not.

- Erection Engineer

- Erection Engineer

After ensuring these things

site permit has been
approved for doing job.

-Safety Engineer

- Fixed ladder should be

checked daily by rigger
foreman before starting of
work.
- Person working on the

- Rigging Foreman
-Safety Engineer

man basket should anchor

- Fall of material.

his safety belt on rigid

material or lifeline.
Engineer
- No person allowed to
work without safety
belt/lifeline.

Engineer

- Signal man should give

the signal to the operator.
- Always use your required
PPEs.
03

Other activity

-Hazards due to the

-Hot work permits and

(bolt

ignorance of safety

height work permits have

tightening /

precaution while working

to be taken before starting

welding / gas

at height and hot work

work. Both HSE and

cutting /

activities (welding and gas

execution people jointly

grinding during

cutting)

check and ensure that the

preassembly and

precautions are properly

erection)

taken. Clearance for work

- Erection Engineer

will be given only after

this.
- Fall of person or material
due to displacement of
members or loose bolt or
tack weld.

- Erection Engineer/
- Erection of scaffold

safety Engineer

require before doing any

operation at height.
-identification tag will be
provided for each member
of scaffolding materials
(green for good condition
and red for damaged

- Erection Engineer

- Fire & explosion hazard

items).
- If working at height,

- Erection Engineer

always ensure others

working below are aware
of the work above and
collecting tray (GI sheet)

- Erection Engineer/
-safety Engineer

and fire extinguisher will

be provided for ensuring
Hazards due to ignorance

protection.

of

Before starting the work in

precaution

while

working in confined space

-safety Engineer

confined space, inside

oxygen level has to be
checked and confined
space permit has to be
taken.

04

Guide rope

- Fall of ducts without

-Rope or wire rope to be

tying for ducts.

proper tying with uniform

tied with column anchor

load distribution.

properly before releasing

- Rigging Foreman

of crane after erection.

05

Area lighting at

- Improper area lighting

- Proper & adequate area

-Safety

erection site.

- Fall hazard

lighting to be provided

Engineer./Electrical

before start any night

Engineer

activity. and no job to be

carried out at the height at
the time of rain.
06

Grinding at

- Breakage of wheels

- Wheel guard is to be

height

- Contact with wheel

ensured

- Start the

- Grinding wheel RPM to

machine

be checked & condition of

Engineer

grinding wheel is to be
Engineer

checked
- flying particles.

- Face shield / Safety

goggles to be used

- Dust hazard

- Leather hand gloves to

be ensured

- Fire hazard
- Scaffold collapse

- Plug top is to be ensured

- Erection Engineer

- Connection to be taken
through ELCB

07

Welding

-Electrical shock

Power connection to
be

taken

- Erection Engineer

through

ELCB
- Proper main
earthling & body
earthling are to be
ensured

-Safety

Engineer

- Shed/cover is to be

Electrical engineer

provided for welding

- Fire hazard

machine
- Welding job to be
done on dry surface
- Cable condition is
to be checked

- Safety Engineer

&Leather hand
gloves to be used
- Arc eye

-Portable fire
extinguisher (CO2 /
DCP)

- Unauthorized entry

-Proper
housekeeping is to

- Safety Engineer

be maintained
-welding shield is to
be used
-Area

is

to

be

cordoned of
-Proper warning
board is to be
displayed.
08

Gas cutting

- Leakage in the hose

- Hose joints to be
checked

by

- Erection Engineer

using

soap solution & hose

clamps are

to

be

used
-Flash back

-Flash back arrestor

Erection Engineer

is to be ensured at
both
-Back fire

torch

end

&

cylinder end
-Correct size nozzle

Erection Engineer

is to be ensured
-Proper clearance is
to

be

maintained

between job & nozzle

-Condition
regulator,

of
hose

&

torch to be checked
-Falling of cylinders
-Proper
-Fire hazard

housekeeping

-Unauthorized entry

be maintained

is

to

- Safety Engineer

-Stone lighter is to be
used
-Fire extinguisher is
to be kept ready
-

Area

to

be

cordoned of
09

Unbarricated

-Dont walk through

Execution

excavation pit

flooded

engineer/safety

water

without knowing the

engineer

conditions of ground.

-During
Rain
storm

and

Unprotected tower.eg.

stay

under

hilltops

boom,

the

crane
unstable

towers

lightning,
away

from

and

other

Execution
engineer/safety
engineer

high points of land

like electrical poles,
high

structures

fences, metal pipes

Execution

etc.,

engineer/safety
Electrical shock

-Keep

electrical

appliances

away

from water (including

rain, wet ground)

-Observe

engineer

If

Execution
engineer/safety

any

power line has fallen

on ground, vehicle,
dont touch anything

engineer

metallic
vehicle

in

the

and

stay

inside

until

professional

help
Execution

arrives.
-All
10

electrical

appliances should be
Rain

and

wind

during

connected

through

engineer/safety
engineer
Execution
engineer/safety

RCCB
-Try to get inside a

heavy lifting

Erection Engineer

shed, protected area.

Flying

debris

can

engineer
Execution
engineer/safety
engineer

cause injury.
-Weather report will
Fall

of

objects-

be

given

to

the

Dangerous

erection department

occurrence

daily.

happen

may

Heavy weight lifting

plan

should

be

Execution
engineer/safety
engineer

ensured.
11

Erection

check

list

should be followed
Heavy wind

-Shall

be

activity

Execution

stopped
in

worst

engineer/safety
engineer

condition.
-Fly/fall of objects

Execution
-Stop work at places

engineer/safety

with risk of falling

engineer

objects

or

fall

of

persons

Execution
engineer/safety
engineer
Execution

-Remove
loose

or

secure

material

at

engineer/safety
engineer

elevation and avoid

handling

of

sheet

material especially

Execution
engineer/safety

-Secure
-Heavy
while

wind

comes

doing

lifting

operation

scafolds

rigidly

-Dont perform lifting

work and height
work.

-If wind speed cross

the limit of 9.5
m/s(34.2 km/hr) the
activity will be
stopped.

-The erected material

should

not

be

hanged with PP rope,

chain pulley block or
sling.

engineer

Need to be taken the

duct closer to the
boiler steel structure
and tied up with
them