HRSG Erection Manual Vendor SUR V 99HA 1 91 003 RA

PROJECT NAME:
SUR INDEPENDENT POWER PROJECT

PO DESCRIPTION: PO NO.: SUBJECT:
HEAT RECOVERY STEAM GENERATOR OPAB1-H1201 ERECTION MANUAL (MECHANICAL, INCLUDING
MAIN LIFTING AND INSULATION)
DOCUMENT NO.:
SUR-V-99HA-1-91-003
For Review
OWNER
OWNERS ENGINEER
CONTRACTOR
SUB. CONTRACTOR
N NOOTER/ERIKSEN E
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.
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\Cover Sheet.R5
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 draw
ing 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. Sh
ipping weights, as shown on Bills of Lading, other shipment documents or stencil
ed on the equipment are not to be used for lifting or rigging purposes in the fi
eld. 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, incl
uding 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 d
ate of the revised documentation. It is the responsibility of the recipient to d
estroy all copies of the previously released manuals and documentation when upda
ted revisions are issued by Nooter/Eriksen. Nooter/Eriksen will issue release fo
rms and revised documentation only for manuals listed in the MANUAL DISTRIBUTION p
ortion of the Release Form. All manuals generated by others shall not be conside
red Controlled Documents.
APPROVED BY: PJH X:\Procedures\Erection Manual\INTRO.R3.doc
INDEX
SECTION 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 1
7.0 PAGE General................................................................
......................... 1 Definitions ........................................
............................................. 1 Reference Documents ............
...................................................... 2 Nooter/Eriksen Contacts
............................................................... 2 Scope of Suppl
y by Nooter/Eriksen .............................................. 3 General Sco
pe of Field Work Required by Erector/Purchaser ..... 4 Non-Destructive Examinati
on and Stress Relieving ..................... 6 Unloading, Handling and Storage
................................................. 7 Material and Equipment Furni
shed by the Erector ....................... 9 HRSG Erection ....................
......................................................... 9 Testing.............
........................................................................... 11 P
ainting ........................................................................
.............. 14 Supporting Reference Documents................................
.............. 14 Distribution Grid ............................................
.............................. 15 Shipping Sequence ............................
........................................ 15 Piping .............................
............................................................ 15 Drain Valves ...
............................................................................ 15
SUR IPP PROJECT, OMAN N/E JOB NO. 113100 ERECTION PROCEDURE, REV. 0 PAGE 1
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 min
imum 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 Ge
nerator (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 comme
rcial operation. Each HRSG has been designed and is to be constructed in accorda
nce with requirements of the American Society of Mechanical Engineers Power Boil
er Code, ASME Section I and ASME Section VIII, Division 1. The scope of major eq
uipment furnished by Nooter/Eriksen, Inc. for erection is shown on Nooter/Erikse
n Drawing No. 113100-GA-001 (SUR-V-99HA-1-17-001).
1.3
1.4
2.0
DEFINITIONS 2.1 2.2 2.3 N/E: Purchaser: Erector: Nooter/Eriksen, Inc. Daewoo E&C
Erection contractor responsible for the installation and assembly of the HRSG.
Heat Recovery Steam Generator American Society of Mechanical Engineers Power Boi
ler Code Section 1, Section VIII, Division 1, and ANSI B31.1. Knocked Down Shop
Fabrication
2.4 2.5
HRSG: Code:
2.6
K/D:
APPROVED BY RDG X:\Procedures\Erection.Manual\Erection_Procedure R16
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 manu
al 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. S
hould you have any questions, please contact the individuals listed below: Docum
ent Description 3.1 3.2 3.3 3.4 3.5 3.6 3.7 N/E Standard Erection Procedures Fie
ld Service Site Visits N/E Backcharge/Extra Work Policy Manway Covers Descriptiv
e Orientation Lifting Device Drawings Module Storage Section No. 13.1 thru 13.14
13.15 13.16 13.17 13.18 13.19 13.20 Tab Location Procedures Miscellaneous Misce
llaneous Miscellaneous Miscellaneous Miscellaneous Miscellaneous
4.0
N/E CONTACTS 4.1 Kevin Lacey Project Engineer Phone: Fax: E-mail: Phone: Fax: Email: Phone: Fax: E-mail: (636) 651-1032 (636) 651-1507 KLacey@ne.com (636) 6511115 (636) 651-1507 ASchulte@ne.com (636) 651-1040 (636) 651-1512 AFebus@ne.com
4.2
Alan Schulte Project Manager
4.3
Andy Febus Manager of Logistics
4.4
Keith Kennedy Construction Supervisor
Phone: Cellular: E-mail: Phone: Fax: E-mail:
(636) 651-1000 (314) 941-2165 KKennedy@ne.com (636) 651-1054 (636) 651-1507 LGre
ene@ne.com
4.5
Larry Greene Director of Projects
5.0
GENERAL SCOPE OF SUPPLY BY NOOTER/ERIKSEN
Joint (K/D) Inlet Transition Duct Panels (K/D) Inlet Distribution Grid (K/D) Sup
plemental Duct Burner Runners Firing Duct Panels (K/D) Fuel Train Skid Scanner C
ooling Air Skid Primary Casing Panels (K/D) Secondary Casing Panels (K/D) HRSG C
oil Modules Recirculation Pumps Remote Steam Drums Deaerator Atmospheric Blowdow
n Tank Exhaust Stack (K/D) Expansion Joint at Stack (K/D) Exhaust Stack Silencer
Baffles (K/D) HRSG Interconnecting Piping Pipe Supports Platforms, Stairs & Lad
ders (K/D) Boiler Trim & Valves (K/D) Field Seam Material (K/D) External Insulat
ion for Interconnecting Piping, Valves and Drums. Temporary Use of Horizontal an
d 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
emove all Temporary Crating and Shipping Braces Heavy Haul Transport from Rail S
iding to the Jobsite Install Anchor Bolts, Washers, Nuts, Slide Plates, Teflon S
lide Packs, Shim Packs, Shear Plates & Grout Erect Inlet Duct Transition Section
s Erect Primary and Secondary Casing Panels Install Duct Burner Elements Install
Inlet Expansion Joint Install Gas and Electric Lines, etc., between Burner Skid
s and Duct Burner Install HRSG Modules Install Gas Baffles Erect Firing Duct Ins
tall all Field Seams between Ducting, Modules, Burner, etc. Erect and Assemble S
tructural Steel for Remote Steam Drums Set Remote Steam Drums Install Recirculat
ion Pumps Erect Exhaust Stack Install Pipe Supports Erect all Large Bore Piping
Install and Weld in all Valves per Nooter/Eriksens Trim List for Interconnecting
Piping Install Safety Relief Valves, Drip Pan Elbows, Vent Stacks, Silencers wit
h 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 Pen
etration Sealing Devices as Necessary per Detailed Drawings Supplied by Nooter/E
riksen Assemble and Erect EPA Platform on Exhaust Stack Install and Assemble all
Instrumentation for Piping, Drums and Gas Side Casing. Refer to Nooter/Eriksens
HP and LP Trim Lists (Water Columns, Gauge Glasses, Pressure Gauges, Level Trans
mitters, Thermocouples, etc.) Assemble and Install Drain Lines from all Safety V
alves 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 Se
ction including Collecting all Multiple Drains at each Bundle Install Freeze Pro
tection Tubeside Cleaning of HRSG Steam Blows Install Steam Drum Internals after
Tubeside Cleaning Re-install non-return Valve Discs, Desuperheaters, Steam Samp
le Probes, Measurement Devices or any other Equipment that was temporarily remov
ed for Steam Blows Install all Pneumatic Tubing or Pipe for Air Supplies and Sig
nal Lines Install all Electrical Conduit, Wiring and Electrical Panels Install a
ll External Personnel Protection (Not Required with Insulated Stack). Install al
l External Insulation on Remote Steam Drums, Drum Heads, Interconnecting Piping,
Drain Lines, etc. Install all External Insulation on Outlet Stack Install all E
xternal Insulation on Silencer Duct Touch-Up Primer and Finish Paint Commissioni
ng, Check all Valves/Motor Operators Prior to Start-Up, etc.
7.0
NON-DESTRUCTIVE EXAMINATION AND STRESS RELIEVING 7.1 The Erector shall provide a
ll necessary equipment and manpower to perform all required non-destructive test
ing as required by the Code or the Purchaser. As a minimum requirement, the Erec
tor 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. The Erector shall provide all st
ress relieving equipment and all necessary materials and specialists as may be r
equired to properly stress relieve the welds as required by the Code and the Pur
chaser. The Erector shall perform the stress relieving as required by Code and m
aintain charts of time versus temperature gradients, copies of which shall be su
bmitted 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. In addition to the Mandatory
Code Requirements for non-destructive examination of welds, it is recommended th
at the following additional radiography be applied: 1) At least 5% of all full p
enetration pressure part butt welds not requiring radiography by the ASME Code,
shall be 100% radiographed. This should be implemented by radiographing 5% of th
is category of welds deposited by each welder. In the event of a defect being id
entified in the prescribed 5%, a further 5% of welds deposited by that welder sh
all be radiographed. Should additional defects be identified, all welds deposite
d by that welder shall be radiographed.
7.2
7.3
7.4
7.5
This category of welds normally includes butt welds in the downcomer & riser pip
ing, 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 Er
ectors 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 e
xtra cost to N/E. It is the Erectors responsibility to unpack or uncrate all equi
pment. This includes all protective materials/structures included with equipment
furnished. 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 a
void unnecessary charges to the Purchaser. All deliveries, unloading and transpo
rting of equipment shall be coordinated through the Purchaser to avoid interfere
nce with other operations. The Erector will ensure that end-to-end support of th
e modules is sufficient during transportation. If restraints are needed to ensur
e the integrity of the modules during travel on steep grades, the Erector will i
nstall them as required. If modules are stored, refer to the Module Storage Reco
mmendations drawing located in the Miscellaneous section of this manual. The Erect
or 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 conditio
n. The Erector shall be responsible thereafter for the equipment until it is ins
talled and accepted by the Purchaser. 8.3.1 Any material shortages which conflic
t with Nooter/Eriksen Shipping List must be identified and reported to N/E by th
e Purchaser in writing within two (2) days of receipt of material. If inspection
8.2
8.3
requires opening of protective shipping containers, it is the Purchasers responsi
bility to repack and weather protect all items after inspection. 8.3.2 If damage
d 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 b
e 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 Erectors 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 materia
ls received at the jobsite and perform regular inspections and maintenance durin
g 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 e
nclosures or buildings unless they are essentially unaffected by weather with pr
ior Purchasers approval. All enclosures or buildings necessary for storage shall
be provided by the Erector. All ducting or casing, with internal insulation, sh
ould be stored in a position that would allow drainage of any water from the ins
ulation. Also, protective material, located at casing field seams, should be lef
t in place to protect the insulation, until field seam installation begins. Seco
ndary casing panels are typically shipped with the internal liner facing upward.
The attachment points for tailing these panels are located on the casing (downw
ard) side of the panel. It is the Erectors responsibility to exercise caution in
offloading
8.4.2
8.4.3
and rotating these panels for installation, so that there is no damage. 8.4.4 Al
l piping must remain capped during storage and erection, in order to preserve cl
eanliness. Coils and drums are shipped with an internal vapor phase corrosion in
hibitor added prior to sealing nozzles with plastic caps and tape. To maximize t
he protection against corrosion and contamination, coil and drum nozzle caps and
tape should be maintained and remain intact as long as possible. It is acceptab
le, however, to remove caps on lower header nozzles temporarily to facilitate mo
dule draining during erection. Valves and instrumentation are to be stored indoo
rs.
8.4.5
8.4.6 9.0
MATERIAL AND EQUIPMENT FURNISHED BY THE ERECTOR The Erector shall furnish all it
ems required for the work not specifically being furnished by N/E. These items s
hall include, but not be limited to, labor saving devices; special equipment and
technicians for stress relieving; temporary winterizing or freeze protection du
ring erection for drainable and non-drainable parts of the HRSG; hydrotest equip
ment. The Erector shall furnish all necessary tools and construction equipment s
uch 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 a
ccount N/Es recommended field erection procedures and specific requirements from
detailed project drawings, as listed in the Nooter/Eriksen Drawing List. Erectio
n Procedures are found with the reference documents at the back of this manual i
n Section 15.0.
10.2
Note: Erector must comply with any special erection and storage requirements pro
vided by manufacturers/designers of specialty equipment such as, but not limited
to: A) B) Duct Burners Pumps
C) D) 10.3
Expansion Joints Etc.
These procedures are provided as a guide for field erection based upon N/Es desig
n of the system. Deviation from these procedures is not recommended unless other
wise indicated on N/Es 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. Caution: Certain components o
f this HRSG have been fabricated using 91 Chrome materials (SA-213 T91, SA-335 P
91, 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, fabrica
tion and heat treatment requirements. Compliance with these requirements is nece
ssary to ensure the proper life of the component. Welding (including tack weldin
g 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, co
oling and post weld heat treatment) must be maintained at all times. It is recom
mended that testing after PWHT be performed to verify that the proper micro stru
cture has been acquired by the appropriate welding/heat treat process. All weldm
ents must be cooled to below 200 F (93 C) 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 prov
ided to prevent direct exposure to moisture. Special care is to be taken to redu
ce the amount of additional stress when moving any as weld weldments. Use of the D
C prod method of magnetic particle testing (MT) is prohibited. This material mus
t not be exposed to an open flame (flame impingement).
10.4
Preheating to 400 F (204 C) of the material is to be done for all thermal operations
, including welding, tack welding, thermal cutting, gouging, etc. All arc strike
s not in the welding preparation zone must be ground and verified by non-destruc
tive examination (NDE) as not being detrimental to the material. When welding P9
1 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 free
ze should be heat traced and insulated. This includes areas that could accumulat
e 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 pi
ping within the ASME Code boundary must be hydrotested by the assembler and witn
essed 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 RECOMM
END THE USE OF PNEUMATIC TESTS IN LIEU OF HYDROSTATIC TESTS. HYDROSTATIC TESTS,
WHEN CONDUCTED PROPERLY, ARE A SAFE METHOD TO TEST FABRICATED EQUIPMENT BEFORE O
PERATION. DUE TO THE INHERENT DANGER ASSOCIATED WITH A FAILURE UNDER PRESSURE FR
OM COMPRESSED GAS OR AIR, PRESSURIZING WITH AIR OR GAS CAN BE EXTREMELY DANGEROU
S.
Verify that all instruments are isolated to prevent damage from over pressurizat
ion. The HRSG components must not be exposed to pressures exceeding 1.5 times th
e 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 press
ure. When safety valve design pressures will not be exceeded during hydrotest, s
ome operators have successfully gagged the valves, but Nooter/Eriksen does not r
ecommend this procedure. CAUTION: USE OF SAFETY VALVE "GAGS WHEN HYDROSTATIC TEST
PRESSURES EXCEED DESIGN PRESSURES COULD RESULT IN DAMAGE TO THE VALVE. Severe c
orrosion can occur when inappropriate water is used for the hydrotest. N/E recom
mends 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 fo
r hydrotest. c. The water is to be sampled and tested prior to use. Testing shal
l be conducted for pH, silica, iron, chloride, etc., for reference. d. Water sam
ples are to be taken prior to filling the boiler and during draining, and mainta
ined for reference. e. Water must be drained immediately after hydrotest is comp
lete. The hydrotest water, whether demineralized and deaerated or acceptable pot
able 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 conce
ntration to 2 to 7 ppb. Chemicals should be added in a manner that provides thor
ough mixing.
If stainless steel parts are exposed to hydrotest media, chlorine content must n
ot 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 warm
est water available. (Note, however, that ASME Code defines metal and water temp
eratures in PG99. This should be consulted for proper temperatures.) Interior he
ating 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 free
zing. 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 drai
ned and laid up dry within 24 hours. (See the Nooter/Eriksen Lay Up recommendati
ons.) If the HRSG will be drained, proper precautions must be taken to insure th
at all water is removed from the unit. (See the Nooter/Eriksen draining recommen
dations.) 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 requir
ements for pressure boundary and seat leak tightness. N/E will warrant any leaki
ng/seating issues on all N/E supplied valves through HRSG hydrotesting. Any drai
n 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 w
ill 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 chemistr
y of the hydrotest water.
12.0
PAINTING The inner liner of the Nooter/Eriksen casing design system is exposed t
o 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 pin
s and/or other components. Since these parts must be attached directly to the ou
ter casing, a certain amount of heat conduction is unavoidable and localized are
as 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 be
aring points for coils and other internals, where there may be localized hot spo
ts on the outer casing. These hot spots may be noticed as small areas of paint d
iscoloration. These areas of higher casing temperature do not indicate insulatio
n breakdown and will not compromise the long term structural integrity of the un
it. Paint discoloration and overall HRSG appearance is dramatically affected by
the choice of paint. Paints should have a continuous temperature rating of at le
ast 450 F. Other paint concerns could be a high curing temperature, color matching
, and VOC emissions. Nooter/Eriksen recommends using zinc rich primer. If a topc
oat is required, an aluminum colored silicone acrylic or alkyd is recommended.
13.0
SUPPORTING REFERENCE DOCUMENTS PROCEDURE NO. 13.1 13.2 13.3 13.4 13.5 13.6 13.7
13.8 13.9 13.10 13.11 13.12 13.13 13.14 13.15 EP-01 EP-02A EP-03A EP-04A EP-05A
EP-06 EP-07 EP-08 EP-09 EP-10 EP-11 EP-12 EP-13 EP-14 DESCRIPTION FOUNDATIONS, A
NCHOR BOLTS & BASE PLATES SETTING OF MAJOR HRSG COMPONENTS (MODULAR) LIFTING AND
RIGGING PROCEDURES (MODULAR) FIELD SEAM INSTALLATION (MODULAR) REMOVAL OF TEMPO
RARY STEEL/WOOD (MODULAR) STAIRTOWERS/PLATFORMS/LADDERS EXPANSION JOINT INSTALLA
TION GASKETS AND PACKING LARGE BORE PIPING SMALL BORE PIPING/TRIM FIELD WELDMENT
S PSVS, START-UP VENTS & STACKS RECOMMENDED TUBESIDE CLEANING NOT USED FIELD SERV
ICE SITE VISITS
13.16 13.17 13.18 13.19 13.20 14.0 DISTRIBUTION GRID
NOOTER/ERIKSEN BACKCHARGE / EXTRA WORK POLICY MANWAY COVERS DESCRIPTIVE ORIENTAT
ION LIFTING DEVICE DRAWINGS MODULE STORAGE
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 s
hipping 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 documen
t that will be updated with the latest information, including changes in anticip
ated delivery dates, shipping status, rail car numbers, etc. The delivery dates
shown are not contractual dates but a reflection of the current shipping informa
tion. 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 t
he elimination of the standard field trim, Nooter/Eriksen is not subject to fiel
d 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 VALV
ES Block valves have been supplied on all drain lines. All valves have been hydr
o 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 o
n all N/E supplied valves through hydrostatic testing. It is the purchasers respo
nsibility to appropriately clean, flush and drain the HRSG during commissioning
and/or normal operation. Opening of drain valves with the unit under pressure gr
eater 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 elim
inate any condensate that may have accumulated. Any drain valve leakage that occ
urs 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
1.0
The contractor responsible for foundation installation shall meet the requiremen
ts of N/Es foundation drawing. 1.1 The Contractor shall establish the centerline
of the unit and the longitudinal reference point and set anchor bolts per N/Es fo
undation drawing. All anchor bolts shall be located with the following tolerance
s. (Refer to Drawing EP-01-01). 1.3 From centerline of bolt group to HRSG center
line:
. Between adjacent anchor bolts with the group:
1/8. From centerline of bolt
group to HRSG longitudinal reference point: . Anchor bolt projection:
.
1.2
Anchor bolts shall be installed when possible using embedded sleeves (min 12 dept
h). This will assist in the installation of the equipment if either base plate h
oles or anchor bolts are located out of tolerance. A benchmark for elevation ref
erence shall be provided at a location close to the HRSG. The reference elevatio
n shall be the Purchasers reference elevation shown on N/Es General Arrangement. I
t is recommended not to grout (Note: Only non-shrink grout is to be used) the fo
undation slide plates until after the HRSG columns have been set and properly al
igned. 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. Howe
ver, in any case, foundation slide plates shall be sufficiently shimmed in the f
ield to prevent damage to the HRSG equipment or foundations. Design, manufacture
and installation of the foundations, shims and grout are not by Nooter/Eriksen.
Shear tabs, if shown at column base plate details, shall be installed after col
umn 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.
1.4
1.5
1.6
2.0
The Erector of the HRSG shall be responsible for the following items: 2.1 The Er
ector shall fit each HRSG foundation support point with a slide plate. Slide pla
tes serve two functions. One, it allows the elevations of the top of the slide p
late to be adjusted through shimming. Second, provides a flat surface on which t
he equipment can move due to temperature expansion.
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EP-01 PAGE 2 ERECTION PROCEDURE FOR 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. 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 materi
al located below the bottom of the HRSG base plates. The Erector shall check the
elevations of all foundations and the location of all anchor bolts prior to equ
ipment installation. Refer to the benchmark for elevation reference. Any deviati
on 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.
2.3
2.4
EP-02A PAGE 1 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS

1.1
Some components are provided to the field with lift lugs. These lugs are only de
signed to lift the components as supplied. These lugs are not designed to lift t
he components after any additional assembly by Field Erector. It is the Erectors
responsibility to design and install any lugs required for lifting of pre-assemb
led components. Each component shall be handled using N/E Erection Procedure dra
wings. All rigging, spreader beams, shackles, etc. shall be furnished and design
ed by the Erector to meet the expected loading and the requirements of the proce
dures. MODULAR 1.2.1 The following items shall be checked to insure that critica
l attachment locations are maintained. 1.2.1.1 1.2.1.2 Set the top of the slide
plates at the theoretical elevation. Base plates shall be greased prior to insta
llation. (Axle quality grease is recommended). Check to make sure grease fitting
s are installed. There should be a minimum of two (2) per base plate, OR, if tef
lon 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 pane
ls.
1.2
1.2.2
Set primary casing panels and roof beams as defined in EP-04A. 1.2.2.1 Each colu
mn shall be set so that the inside flange is at the theoretical distance from th
e centerline of the HRSG. 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. Unless oth
erwise stated on N/Es Foundation Footprint Drawing, anchor bolts shall be finger
tight. All shall be double-nutted.
1.2.2.2
1.2.2.3
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.)
APPROVED BY: WJP X:\Procedures\Erection.Manual\EP-02A.R15

1.2.3.2
Upon completion of casing alignment, it is important to verify casing opening di
mensions where modules will be placed in the HRSG. The inside liner-to-liner dim
ensions should be checked and documented against the corresponding module dimens
ions to ensure that module can be set. The pin rowto-pin row dimension shall als
o be checked at the field seam locations, to ensure that the field seam plates w
ill fit. Secondary casing panels are typically shipped with the internal liner f
acing upward. The attachment points for tailing these panels are located on the
casing (downward) side of the panel. It is the Erectors responsibility to exercis
e caution in offloading and rotating these panels for installation, so that ther
e is no damage.
1.2.3.3
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 t
he foundation slide plates until after the HRSG columns have been set and proper
ly aligned. Pre-grouting, before setting of these columns, eliminates the abilit
y to adjust slide plates by shimming, which is normally required to allow adjust
ment due to manufacturing tolerances of the HRSG. The contractor has the flexibi
lity 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, manufa
cture and installation of the foundations, shims and grout are not by Nooter/Eri
ksen.
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 enl
arged holes in the base plates to facilitate module installation. Anchor bolt wa
shers (as detailed on N/E drawings) are to be installed on the base plates as in
dicated on N/E foundation detail drawings.

1.2.6
When setting the modules, the nozzle connections shall be checked against the No
oter/Eriksen drawings for correct station location and elevation to within (+) o
r (-) . Nozzle locations should be checked with a transit. Do not rely on shop ste
nciling for module location. Refer to Nooter/Eriksen field erection drawings for
module configuration and unit location. Removal of temporary shipping wood/stee
l must be completed before startup. See Procedure EP-05A. For each successive mo
dule set, particular attention shall be given to make sure that the modules loca
tion and elevation are maintained. The nozzle orientation, as shown on Nooter/Er
iksen drawings, shall be used as the primary guide for the setting and the align
ment of modules.
1.2.7
1.2.8
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 ch
ecked for correct station location and plumbness. If the HRSG is provided with a
n SCR, the Erector is to verify that the Catalyst Loading Opening is plumb and s
quare so that the Catalyst Loading Doors will fit properly (trial fitting the Ca
talyst Loading Doors is recommended). This must be done prior to final welding o
f the SCR duct frame corner connections.
1.3.2
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. All rigging, spreade
r beams, shackles, etc. shall be furnished by the Erector to meet the requiremen
ts of the procedures. Exhaust stacks are provided with either anchor chairs or a
n anchor bolt ring. In either case, the stack is considered to be fixed against
longitudinal movement. Anchor bolts shall straddle natural centerlines.
1.4.2
1.4.3
1.4.4

1.4.5
Unless otherwise stated on N/Es Foundation Footprint Drawing, all stack anchor bo
lts shall be torqued tight per AISC, since the stack is considered fixed (See 1.
6.2). Prior to setting the stack, the Erector should prepare the concrete for sh
im pack locations. Enough shim packs should be used to prevent damage to the fou
ndations. 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 fabricators drawings. If the stack is provided with a dam
per, the damper shall be installed after the bottom stack section is installed v
ertically 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
. 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 item
s are checked. Elevations of module and stack are at the proper locations. The c
enterline of the stack matches the centerline of the module. Module and stack ar
e plumb within Distance between the module and stack maintained to within of theor
etical
1.4.6
1.4.7
1.4.8
1.4.9
1.4.10 It is recommended that the platforming required for EPA test ports be ins
talled 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 complet
ed. 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 e
rection procedure.

1.5.1.2
Slings shall not break against any nozzle or nozzle reinforcement pad. Softeners
should be used with cable slings to prevent damage to material.
1.5.1.3
1.5.2
Each drum will be fitted with at least two support saddles. Guides shall be inst
alled around the saddle, after the drum is in its final position to limit any mo
vement and for resisting lateral wind and earthquake loadings. Both drum saddle
base plates shall be greased prior to installation. (Axle quality grease is reco
mmended). 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) gr
ease fitting per saddle base plate. When teflon slide packs are used at the drum
saddle base plates, be sure to attach the teflon slide packs to both the drum b
ase plate and support steel, prior to setting the drum on the support structure.
It is very important that the steam drums be located properly. The difference i
n elevation of the drum centerline, from one end to the other, shall be no great
er than . Erector to check elevation and location of drum nozzles. Tolerance on lo
cation of these nozzles is: Elevation: Location: +/- +/-
1.5.3
1.5.4
1.5.5
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. Anchor bolts that are to be torqued tight shall be tightened per
AISC Specification for Structural Joints using ASTM A325 or A490 Bolts Turnof-Nu
t tightening. It is not necessary to provide a representative sample, but follow
the guidelines of the appropriate table.
1.6.2

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 Erectors resp
onsibility to check components against drawings to assure proper installation or
ientation. 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 accordanc
e with applicable codes.
1.8
EP-03ASB PAGE 1 LIFTING AND RIGGING PROCEDURES REVISION 0

1.1
This procedure is presented to provide an understanding of how Nooter/Eriksen ha
s 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 f
rom these shall be brought to the attention of Nooter/Eriksen for review. Erecto
rs rigging plan shall be made available to Nooter/Eriksen, for information purpos
es only, prior to handling of heavy components. All rigging and lifting equipmen
t shall be designed and furnished by the Erector to meet the expected loading an
d the requirements of all procedures and drawings. Design and use of this equipm
ent shall comply with all applicable codes, industry standards and safety guidel
ines. 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/Eriksens standard Release & Indemnity Agreement. Before the Noot
er/Eriksen supplied lifting devices are used, the Erector must verify that all d
evice components are properly tagged to indicate that their capacity is consiste
nt with the devices specified on Nooter/Eriksens job specific Lifting Drawings. L
ifting 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 misalignme
nt. 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 20F and above.
When lifting operation temperatures are below 20F, contact Nooter/Eriksen for revi
ew. 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 Chemicals Dow Fro
st, or an N/E approved equal, which is propylene glycol. The MSDS is made availab
le with the shipping documents. The removal and disposal of the freeze protectio
n medium is the responsibility of the field erector. MODULES 1.5.1 Each module i
s fitted with lifting lugs on the top headers or roof panel in the shop. There a
re usually three lifting operations performed on each module. The first is accom
plished when the module first arrives at the jobsite and is lifted in the horizo
ntal position from the railcar onto the transporter. Refer to the job specific N
/E Module Lifting Drawings for the general procedure.
1.2
1.3
1.4
1.5
APPROVED BY: RDG X:\Procedures\Erection.Manual\EP-03ASB.R6

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. It is necessary to support
the module upper headers (this can be done through the roof beams), the lower h
eaders, and all shipping beams during transportation on the heavy haul transport
er 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 f
abricator within +/-1. See sketch Module Storage (Staggered Pitch). Refer to the ac
tual job specific Nooter/Eriksen Module Lifting Drawings for all details of the
lifting devices. The second lift is the lift from transporter to Strongback Devi
ce. This is performed using the same rigging that was used for the first lift. T
he 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 Li
fting Drawings for details and procedure. Once the module is in the vertical pos
ition, it can be placed between the appropriate columns and set in its final pos
ition. Each module roof is equipped with support beams with a portion of the upp
er roof attached. When the module is placed between the support columns, the loa
d is transferred from the module support beams to the upper frames. After each l
ift, the lifting devices and all associated bolting/pins shall be inspected by t
he Erector, to assure no damage has occurred and confirm that all bolting is tig
htened as required. Any bent, worn or damaged bolts/pins shall be replaced as ne
cessary, with identical bolting/pins as stated on the pertinent Nooter/Eriksen D
rawings from the following list: STRONGBACK01, STRONGBACK02, STRONGBACK03, STRON
GBACK16, HORIZLIFTDEV 1, HORIZLIFTDEV 2, HORIZLIFTDEV 3, and HORIZLIFTDEV 7. Cop
ies of these drawings are included in the MISCELLANEOUS section of this manual.
1.5.3
1.5.4
1.5.5
1.5.6
1.5.7
1.5.8

1.5.9
It is the Erectors responsibility to assure that the lift devices provided by Noo
ter/Eriksen are being used properly and all lifting operations are in accordance
with the requirements as noted on Nooter/Eriksen drawings and this Erection Man
ual to prevent damage to equipment and injury to personnel. Erector will be resp
onsible 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 suppli
ed 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 secti
ons. Refer to Erection Drawing EP-03A-09 through 12 for details of lifting proced
ure and lifting lugs. Lifting lugs are designed to be used with spreader beams.
1.6.2 1.7
EXHAUST STACKS 1.7.1 Exhaust stacks are shipped to the sites in several differen
t forms. a. b. 1.7.2 Multiple arc sections for field welding into cylindrical se
ctions Shop fabricated cylindrical sections
The Erector has the option to build the stack by setting the cylinders individua
lly into the vertical position or to pre-assemble multiple cylinders into a subassembly on the ground before lifting. If the cylinders are subassembled on the
ground, the Erector shall design and provide all bracing required to prevent dam
age to the stack. It is the Erectors responsibility to design and supply the requ
ired lifting and rigging equipment based on their chosen method for erection of
the stack. If a stack is provided with a damper, the damper shall be installed a
fter the bottom stack section is installed vertically on the stack foundation. T
he damper shall not be attached to any stack cylinders prior to lifting into fin
al position, to prevent damage to the damper.
1.7.3
1.7.4

1.8
REMOTE STEAM DRUMS 1.8.1 1.8.2 1.8.3 1.8.4 There are no lifting lugs provided on
remote steam drums. See Drawing EP-03-05A for details of erection procedure. Sl
ings shall not break against any nozzle or nozzle reinforcement pad. Softeners s
hould be used with cable slings to prevent damage to materials. The Remote Steam
Drum lifting weights are 5% greater than the shipping weights marked on the Ste
am Drums.
1.8.5
EP-04A PAGE 1 ERECTION PROCEDURE FOR FIELD SEAM INSTALLATION (MODULAR)

1.0
GENERAL 1.1 This procedure will provide general details, design considerations a
nd general installation procedures needed for installation. The Erector should r
efer to the erection drawings for actual job details. 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. The liner syste
m is composed of a series of overlapping plates, pinned to the outside casing. I
t is important that the installation of the field seams be understood prior to b
eginning work. Failure to install field seams correctly can lead to casing hot s
pots, loss of insulation and general failure of the integrity of the liner syste
m. When casing and ducting are shipped with plastic weather protection on the ex
posed insulation, it must be removed prior to installation of the field seam ins
ulation.
1.2
1.3
1.4
1.5
2.0
ASSEMBLY SEQUENCE 2.1 Sidewall Casing Panels (Primary and Secondary) 2.1.1 The p
rimary casing panels have the main structural columns attached to them. These pa
nels 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 Erectors responsibility to perform structural welding in a ma
nner that ensures that completed components are within the tolerances specified
in EP-11. The secondary casing panels are stiffened with flat bar. To install th
ese panels it will be necessary to insert one edge of the casing inside the colu
mn 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.
2.1.2
APPROVED BY: RDG X:\Procedures\Erection.Manual\EP-04A.R9

2.1.3
The field seams between sidewall casing panels are seal welded at the outer casi
ng from the outside of the system. The insulation pins, insulation and inner lin
er 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 be
ams are fit-up and held in position with bolted connections. Bolt the primary fl
oor 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 AS
TM A325 or A490 Bolts, unless otherwise specified on drawings. Set the secondary
floor casing in place and seal weld to the adjoining primary floor casing from
the liner side of the casing panel. The field seam between the sidewall and the
floor casing is completed by installing the corner angle from the inside and ins
talling the insulation and outer casing plate from the outside. See Drawing EP-0
4A-08.
2.2.2
2.2.3
2.3
Roof Beams 2.3.1 The roof beams are sent to the field with the casing, insulatio
n and liners shop installed. The roof beams are bolted to the sidewall columns a
s the primary sidewall casings are erected. See the individual job details for b
olt and weld requirements. This will provide stability for the structural frame.
Bolts are to be snug tight per AISC Specification for Structural Joints Using A
STM A325 or A490 Bolts, unless otherwise specified on drawings. Attach the corne
r angles and insulation between the sidewall and roof beam as the sidewall and t
he roof beams are erected (See Drawing EP-04A-09). Due to access issues, this mu
st be completed before installing modules.
2.3.2
2.3.3

2.4
Roof Casing 2.4.1 The roof casings are shop installed onto the modules unless no
ted otherwise on drawings. Care should be taken to ensure that the liners are no
t damaged during the installation of the coils. If tadpole gaskets are used, the
y shall be partially shop installed on roof beams. Field attachment of tadpole g
askets on corner angles may be required after the corner angle is in place (see
Drawing EP-04A-09), and before the modules are installed. Field seams are requir
ed between the adjacent shop installed module roofs and between the shop install
ed module roofs and the sidewall. See the individual module drawings for the fie
ld seam configurations supplied by the module fabricator.
2.4.2
2.4.3
3.0
FIELD SEAM LINER INSTALLATION 3.1 Field liner plates shall follow the lapping se
quence of the shop liner plates. The actual laps on shop assembled pieces may va
ry from what is shown in this standard. (See Drawing EP-04-10) 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 sh
all be staggered. Insulation pins are installed in the shop on the inside of col
umn flanges. Bend pins perpendicular to liner plate prior to installation of ins
ulation.
3.2
3.3
4.0
VENDOR SUPPLIED EQUIPMENT 4.1 SCR and CO catalyst systems, as well as catalyst f
rames and burners, could be field installed in Nooter/Eriksens casing. This equip
ment can be shipped to the site in either panels or in complete modules. The fie
ld assembly of this equipment, if required, will be provided under separate cove
r from the appropriate Vendor. Field seams between the Vendor equipment and the
Nooter/Eriksen casing panels will be per Erection Procedure Drawings EP-04A-06 t
hru 09, and the individual job field seam drawings.
4.2
EP-05A PAGE 1 REMOVAL OF TEMPORARY STEEL/WOOD REVISION 0

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 affixe
d to components to assure stability during shipment and/or installation. Materia
l 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 yel
low.
1.2
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 sto
red on the rail car, they are to remain secured until just prior to off loading.
All material that is temporary by design shall be removed after the module is i
n its full upright position. Any wood blocking should be removed before the modu
le is installed into the casing. In some instances, modules will be shipped to t
he site with metal strapping wrapped around the tube field, centered between vib
ration supports, and below the lowest vibration support. This strapping must rem
ain in place during the horizontal-to-vertical lift. After the horizontal-to-ver
tical lift is completed, the strapping is to be removed in the field. These stra
ps are not painted yellow, since they must remain in place until the horizontalto-vertical lift is completed Some Evaporator modules are ultimately supported b
y 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 supp
ort steel can be removed and the casing field seams completed. This temporary bu
ndle support steel is painted yellow for field removal. However, the Field Erect
or must verify that this steel is to be removed by a thorough review of N/E Fiel
d 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 s
teel, N/E is to be contacted for assistance. In some instances, Superheater and/
or Reheater Module upper headers are supported externally, either directly by sp
ring can supports or by interconnecting piping. In these instances, temporary bu
ndle support steel is provided to support the headers during shipping and erecti
on. This temporary bundle support steel can be removed only after all external h
eader supports and/or associated piping (including pipe supports) are 100% insta
lled, welded, post weld heat treated (if required), and have received quality ac
ceptance. Following completion of this work, the temporary bundle support steel
can be
2.2
2.3
2.4
2.5
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removed and the casing field seams completed. This temporary bundle support stee
l is painted yellow for field removal. However, the Field Erector must verify th
at this steel is to be removed by a thorough review of N/E Field Erection Drawin
gs (See coil module drawings for details). If there is any lack of clarity regar
ding removal of temporary bundle support steel, N/E is to be contacted for assis
tance. 2.6 For modules that are lifted using the Strongback Lifting Device, the
following must be considered:
Shipping cradles at vibration supports and lower h
eaders must remain intact until module is installed on Strongback.
Shipping cradle at upper headers must be removed prior to installing module on S

trongback. All shipping cradle side plates and tie rods must be removed after mo
dule is installed on Strongback, but prior to lifting from horizontal-to-vertica
l. 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 shou
ld be removed after the stack is in the upright position. Stacks that are shippe
d 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.
3.2
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 t
he 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 Pur
chasers and Erectors responsibility to load the Nooter/Eriksen coil module shippin
g support beams, shipping horses and lift devices on a truck for transport back
to Nooter/Eriksens shop facility.
X:\Procedures\Erection.Manual\EP-05A.R7

5.2
It is the Erectors responsibility to maintain the coil module shipping support an
d lift devices in the as received condition. No modifications to this equipment
are to be performed without written consent by Nooter/Eriksen.
X:\Procedures\Erection.Manual\EP-05A.R7
EP-06 PAGE 1 ERECTION PROCEDURE FOR STAIR TOWERS/PLATFORMS/LADDERS

1.0
GENERAL 1.1 The access steel is to be erected using the AISC Code, standard prac
tice for steel building and bridges. The tolerances as specified within AISC for
connections shall be applicable. Platform steel will be shop fabricated into su
b-assemblies. All pieces shall be marked with identifying numbers. The markings
shall correspond to markings shown on platform erection drawings. The following
grating installation procedures are to be performed by the Erector. a. Field cut
ting and reinforcement of all piping penetrations through grating. Cutting of gr
ating for piping supports.
1.2 1.3 1.4
1.5
b. 2.0
STAIR TOWERS 2.1 It is recommended that the stair tower be erected as soon as po
ssible. This will provide access to HRSG for performing other functions and will
minimize the amount of temporary scaffolding. The stair tower columns shall be
set on piers provided by the concrete Contractor. The structural steel columns a
nd beams should be squared and plumbed prior to torquing the bolting. The anchor
bolts and bolting shall be torqued per AISC. 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 t
he stair tower goes up so that adequate bracing is provided. The stair tower sha
ll not be used for access purposes until all bolting and attachment welding has
been completed.
2.2
2.3
3.0
PLATFORMS AND LADDERS 3.1 It is recommended that the platforms be installed as s
oon as possible. This will provide access to many of the areas where functions n
ecessary for the completion of the HRSG can be obtained without providing tempor
ary scaffolding. In order to insure proper platform elevations the attachment cl
ips to the HRSG are to be field installed.
3.2
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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 elevat
ions given for platforms, as well as all HRSG components, are from reference ele
vation. For N/E, this is always the bottom of the HRSG column base plates. (Refe
rence: base plate elevation 0-0). The platforms are normally erected by first inst
alling the support brackets and clips to the HRSG and then lifting the pre-assem
bled sections into place and bolting or welding. Ladder footings at grade shall
be field erected. Ladders shall be fully installed including cage connections, s
upport clips, footing bolts, and safety gates, prior to releasing them for acces
s use.
3.4
3.5 3.6
EP-07 PAGE 1 EXPANSION JOINT INSTALLATION

1.0
GENERAL 1.1 Reference Section 10.0 of the GENERAL section of this Manual for stora
ge and responsibility of the equipment that the purchaser receives on site. The
Erector shall use the lifting points and/or lugs provided with the equipment. Fo
r recommended lifting, handling and storage, refer to the vendor procedures. The
Erector shall use extreme caution in the handling of the expansion joint. The f
abric shall be covered to protect from welding and puncturing. The bolting that
connects the expansion joint to HRSG equipment should be provided by the expansi
on joint supplier. It is recommended that these bolts be inserted and tack welde
d in place prior to installing the expansion joint. Bolting for the attachment t
o other equipment will be by the Erector.
1.2
1.3
1.4
1.5
2.0
MODULAR EXPANSION JOINTS 2.1 All shipping ties are to be left in place until a m
inimum of one side of the joint is installed on the equipment. Use temporary cri
bbing, as required, to prevent excessive stretching of the fabric, or distortion
of the internal liner system. When installed, the expansion joint flanges, rela
tive to each other, shall not vary by more than , in compression, extension and la
teral offset. Actual dimensions, if beyond this limit, shall be submitted to Noo
ter/Eriksen for review and approval. Field joint material as shown on the field
erection drawings, shall be provided by the Erector unless otherwise noted.
2.2
2.3
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. When installed, the expansion joint flanges, relative to each other, s
hall be within +/- , in compression, extension and lateral offset.
3.2
EP-08 PAGE 1 GASKETS & PACKING

1.0
GENERAL
tight.
joints
at the
as soon
1.1 All casing penetrations and access openings on the HRSG shall be gas
Sealing shall be at the outer casing. Shop installed gaskets and packing
may have loosened in shipping; a check of all these areas should be done
initial start up of the system, and any leaks found should be corrected
as possible, to prevent damage to the outer casing.
1.2
2.0
GASKETS 2.1 Code Pressure Part Gaskets 2.1.1 Three (3) manway gaskets are provid
ed for every drum manway: One (1) gasket for field hydrotest and all field press
urization prior to start-up, including boil-out; one (1) gasket replaces the gas
ket used for boil-out on the system; and one (1) spare gasket is provided for in
itial operation. Care should be taken with all gasket surfaces to insure that th
ey are not damaged. All flanges and manway style gasket joints are to be assembl
ed and tightened, per industry standard. The gasket surfaces shall be free of al
l dirt and grease (they are inspected and approved prior to shipping). Damage in
curred while stored, or in the Purchasers possession, shall be to the account of
the Purchaser. All valve and instrumentation packing shall remain in its origina
l shipping container (any cost resulting from mishandling of valve or instrument
ation packing shall be to the account of the Purchaser). Gage glass packing on t
he water column shall be replaced with new packing after boil-out and prior to s
tart-up. CAUTION: See the notes in EP-13, Boiling-out Procedure, about the tempora
ry glass used for boil-out.
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.2
Casing Gaskets 2.2.1 All casing access doors are to be sealed with a flat boltin
g tape gasket (shop installed). Care should be taken to insure that the gasket i
s not damaged when the door is opened in the field. 2.2.1.1 All casing access do
or gaskets should be replaced at the first sign of embrittlement. The bolting ta
pe 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 bet
ween the bolt plate and the outer casing. This gasket should be checked for leak
age 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 n
ozzles, as noted on Nooter/Eriksen drawings, that project through the outer casi
ng are packed with ceramic fiber rope insulation and have a gland installed to m
aintain a tight seal against the movement of the nozzle. The Erector is to apply
anti-seize compound to all packing gland bolting. All shop installed packing jo
ints should be checked for leakage at the initial start-up of the system. If a l
eak is found, the gland is to be tightened to achieve a seal. Additional rope pa
cking is to be installed if the leak persists.
3.1.2
3.2
Shop Installed Bolt Plate Seals 3.2.1 Some pressure part nozzles, as noted on No
oter/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 ship
ped installed if the roof is attached in the shop. Fabric bellows must be protec
ted from weld splatter and puncture during the erection phase. Wrapping with fir
e retardant blanket and fiberglass reinforced heat resistant tape will protect f
abric bellows, if properly applied. Remove all temporary protection upon complet
ion of erection. During operation, these joints should not be covered with insul
ation 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 p
revent personnel from coming in contact with the hot joint. The fabric expansion
bellows must be checked at the initial start-up of the system for leaks, and ad
justments made, if necessary. It is the Erectors or Startup/Commissioning Contrac
tors responsibility to verify that
3.3.2
3.3.3

fabric seal retainer clamps are properly positioned and tightened before and aft
er first fire.
3.4
Fabric Expansion Bellows (@ HRSG Floor) 3.4.1 The floor conical expansion bellow
s 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. The
se straps are not to be removed until all welding and heat treating is completed
on the pipeline that is routed through the bellows. Floor conical expansion bel
lows 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 prot
ection upon completion of erection. During operation, these joints should not be
covered with insulation or lagging. If safety is an issue, surround the expansi
on 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.
3.4.4
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 ins
talled. Metal expansion bellows must be protected from weld splatter and punctur
e 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 i
ssue, surround the expansion joint area with expanded metal offset from the join
t such that the heat will be dissipated and prevent personnel from coming in con
tact with the hot joint.
3.5.2
EP-09 PAGE 1 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING

1.0
GENERAL 1.1 All piping shall be installed to meet the requirements of ASME Secti
on I, ANSI B31.1 and any local applicable codes as they pertain to welding, proc
edure qualification, post weld heat treatment, non-destructive examination, etc.
It is the Erectors responsibility to ensure that all Code requirements have been
met as they pertain to assembly. Large bore piping is defined as all piping ove
r 2 NPS. 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. It shou
ld be recognized that, due to the size of the components, shifting of component
parts during shipping, normal fabrication, and erection tolerances, a certain am
ount of mismatch is to be expected. If the Erector feels that modifications in t
he design must be made due to interferences, excessive misalignment, or for othe
r reasons, N/E must be notified of the problem and given the opportunity to prov
ide a solution (see N/E Backcharge policy). Any cutting or modifying of pipe spo
ols without prior notification and approval by N/E will not be accepted for back
charge 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. Information neede
d for installation. a. b. c. d. e. f. 1.7 Nooter/Eriksen Piping Isometric Drawin
g Nooter/Eriksen P&ID Diagram Nooter/Eriksen Trim & Instrument List Fabricators
Pipe Spool Drawings (if available) Nooter/Eriksen Pipe Support Detail Drawings N
ooter/Eriksen HRSG Reference Drawings
1.2 1.3
1.4
1.5
1.6
Piping terminal locations are considered within tolerance if the pipe end is wit
hin +/- 1 of theoretical in any direction. The Erector will check actual terminat
ion points to the theoretical termination points during field erection to mainta
in 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 mainta
ining heat control throughout the welding process is vital for achieving accepta
ble field welding results.
2.0
NDE REQUIREMENTS 2.1 In addition to the Mandatory Code Requirements for non-dest
ructive examination of welds, it is recommended that the following additional ra
diography 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, shal
l be 100% radiographed. This should be implemented by radiographing 5% of this c
ategory of welds deposited by each welder. In the event of a defect being identi
fied 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 but
t welds in the downcomer and riser piping, and butt welds in the boiler proper a
nd boiler external piping. 2.2 All Chrome-Moly piping shall have NDE in accordan
ce with ASME Section I, ANSI B31.1, or the local applicable codes, whichever gov
erns 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 t
o 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 dimensi
ons using piping isometric drawings and the fabricators pipe spool drawings. Any
major discrepancies shall be brought to the attention of Purchaser immediately.
Erector shall check the location of the connections where the pipe spools are t
o be placed. The theoretical locations may vary from the actual depending upon h
ow the modules have been set, how components have shifted during shipment, and n
ormal fabrication and erection tolerance accumulation. After the pipe spool piec
es have been inspected dimensionally and the connection locations verified, the
Erector should pre-fabricate the completed pipe runs in sections as large as pos
sible. Valves should be welded in and inspection, heat treatments, etc., made. S
ince the actual dimensions of the pipe run can now be verified, the Erector shou
ld trim pipe sections to fit actual dimensions. Pipe sections should be lifted i
nto place (tack welded only) and checked for fit up before fully welding any sec
tion. It is usually possible to slightly rotate the pipe at the connections to a
chieve movement at the other end without affecting the weld gaps appreciably. Pi
ping expansion joints shall be installed per the expansion joint manufacturers gu
idelines and accepted industry practices. It is not acceptable for piping expans
ion joints to be manipulated to make up for piping misalignment. External insula
tion must be held back from all piping expansion joints and casing seal devices
for inspection, maintenance, and proper operation. .
3.3
3.4
3.5
3.6
3.7
4.0
PIPE SUPPORTS 4.1 All pipe runs will be provided with pipe supports, hangers, sp
rings and/or guides, if needed, to meet design requirements. Prior to installing
any pipe run, the Erector should become familiar with the supporting requiremen
ts. It is possible to create additional work if piping and supports are not inst
alled in the proper sequence.
4.2

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 re
quired 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. Trim is provided in the length of the field welded pieces to allow f
or adjustment and proper fit. The Erector should trial fit pipe supports, trim t
o fit and final install. Piping dimensions at supports should be considered as a
reference and may vary +/- 2. To facilitate field installation, all pipe support
s located on the straight length of a pipeline can be moved +/- 0-6 along the pipe
centerline from their theoretical location. It is the contractors responsibility
to verify that moving the pipe support to allow for field or shop tolerances, d
oes not create an interference with any other pipeline branch, attachment or oth
er structure on the HRSG. Contractor shall contact Nooter/Eriksen for guidance f
or any supports that need to be moved more than +/- 0-6.
4.5
4.6
5.0
HYDROTEST 5.1 All valves shall be checked during hydrotest for leakage. Any leak
s shall be stopped by properly tightening the packing glands. If tightening is u
nsuccessful, the leaking valves shall be repacked. Nooter/Eriksen shall be notif
ied 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 Purch
aser is obtained. Failure to comply with this requirement may result in damage t
o valves. All spring supports and constant supports must have travel stops in pl
ace prior to filling the HRSG. All flanged pressure relief valves shall be remov
ed, or a suitable pancake shall be inserted at the inlet flange during hydrotest
. If welded safety valves are supplied, there must be verification that factory
installed hydrostatic test plugs are installed.
5.2
5.3
5.4

6.0
VALVE POSITION DURING WELDING AND PWHT (BY MANUFACTURER) The following is a summ
ary of Valve manufacturers recommendations for positioning of valves during the w
elding/heat treating process. Nooter Eriksen is to be consulted for recommendati
ons on any valves that are not addressed below. Atwood-Morrill (Weir) Bonney For
ge Conval CCI Douglas Chero DSI (Welded Bonnet) CLOSED for welding and PWHT OPEN
1/16 TURN for welding and PWHT CLOSED TIGHTLY for welding and PWHT REMOVE TRIM
for welding and PWHT SEMI-OPENED for welding and PWHT REMOVE TRIM or FULLY CLOSE
D for welding and PWHT NO PREFERENCE for welding; SLIGHTLY OPENED for PWHT CLOSE
D TO 50% OF TORQUE VALUES for welding and PWHT CLOSED TIGHTLY for welding and PW
HT
DSI (all except Welded Bonnet) Edward (Univalve)
Edward (all except Univalve) Fisher Controls
NO PREFERENCE for welding; REMOVE TRIM for PWHT FULL CLOSED for welding and PWHT
FULL CLOSED for welding and PWHT NO PREFERENCE for welding and PWHT OPEN for we
lding and PWHT 15-25 % OPEN for welding and PWHT
Fluval Ituarte HP Valve Hora Intervalve Kitz

KVT (HP Valves)
OPEN TO PREVENT ARCING for welding and PWHT
Masoneilan
SLIGHTLY OPEN for welding; REMOVE TRIM for PWHT LIGHTLY CLOSED for welding and P
WHT OPEN VALVE IN THE HALF POSITION for welding and PWHT SLIGHTLY OPEN for weldi
ng and PWHT
Newco (Newmans) OMB
Pacific/Crane (Flex Gate or Globe) Pacific/Crane (all except Flex Gate or Globe)
P-K (Pan Korea) Powell Raimondi (>24 GATE) Raimondi (all others) Raisteam/Raimon
di (Pressure Seal Valves) Samshin Union Tech (Fisher)
SEATED LIGHTLY for welding and PWHT
FULLY OPEN for welding and PWHT OPEN for welding and PWHT CLOSED for welding and
PWHT OPEN for welding and PWHT OPEN for welding and PWHT
PARTIALLY OPEN for welding and PWHT BALL IN FULL OPEN POSITION for welding and P
WHT OPEN for welding and PWHT CLOSED for welding and PWHT CLOSED for welding and
PWHT
Valtek Velan Vogt
EP-10 PAGE 1 ERECTION PROCEDURE FOR SMALL BORE PIPING

1.0
GENERAL 1.1 All piping shall be installed to meet the requirements of ASME Secti
on I, ANSI B31.1 and any local applicable codes as they pertain to welding, proc
edure qualification, post weld heat treatment, non-destructive examination, etc.
It is the Erectors responsibility to ensure that all Code requirements have been
met as they pertain to assembly. Small bore piping is defined as all piping 2 NP
S and smaller. Small bore piping is normally supplied in random length pieces wi
th approximately 10% additional for field drop. The routing, installation and su
pport of these lines is to comply with Nooter/Eriksen small bore piping isometri
c drawings, Notes 8A through 8D on small bore piping drawing GA-005, and standar
d support details on small bore piping drawing GA007. If it is determined that r
erouting is necessary, Nooter/Eriksen is to be notified prior to rerouting. Alth
ough 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 wil
l assure that the welding is properly performed. 1.4.2 Monitoring and maintainin
g heat control throughout the welding process is vital for achieving acceptable
field welding results.
1.2 1.3
1.4
2.0
INSTALLATION 2.1 INFORMATION NEEDED FOR INSTALLATION: a. b. c. d. e. f. 2.2 Noot
er/Eriksen Trim Piping Drawings Nooter/Eriksen P&ID Diagram Nooter/Eriksen Trim
& Instrument List Fabricators Pipe Spool Drawings (if applicable) Nooter/Eriksen
Pipe Support Drawings Nooter/Eriksen HRSG Reference Drawings
VALVES ARE SHIPPED LOOSE FOR FIELD INSTALLATION. 2.2.1 See Procedure EP-09, para
graph 6.0 for Manufacturers Recommendations for Valve Position during welding and
PWHT.
2.3
Nooter/Eriksen drawings provide routing and supporting for small bore piping wit
hin the Section I Code boundaries. The Erector/Owner should
APPROVED BY: _WJP_ X:\Procedures\Erection.Manual\EP-10.R10
EP-10 PAGE 2 ERECTION PROCEDURE FOR SMALL BORE PIPING

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 Por
tions of some small bore pipelines are supplied with specifically engineered pip
e supports. In such cases, these supports will be located on the piping isometri
c drawings. In all other cases, it is the Erectors responsibility to locate and i
nstall pipe supports in accordance with Notes 8A through 8D on small bore drawin
g GA005, and details on small bore piping drawing GA-007. Tolerances for small b
ore pipe support locations are the same as for large bore. (See Procedure EP-09,
paragraph 4.6)
2.3.2
2.4
External insulation should be held back from all piping expansion joints and cas
ing seal devices for inspection, maintenance, and proper operation. As noted in
EP-08, Paragraph 3.2.1, most sealing devices must be installed before any piping
assembly is started.
2.5
3.0
HYDROTEST 3.1 All valves shall be checked during hydrotest for leakage. Any leak
s shall be stopped by properly tightening the packing glands. If this is unsucce
ssful, the leaking valves are to be repacked. Nooter/Eriksen shall be notified o
f any valves where leakage cannot be stopped. Caution: The unit should not be op
erated with valves where leaks have been noticed, unless approval from Purchaser
is obtained. Failure to comply with this requirement may result in damage to va
lves.
X:\Procedures\Erection.Manual\EP-10.R10
EP-11 PAGE 1 ERECTION PROCEDURE FOR 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 le
tter items listed below correspond to the letter designation on Drawing EP11-1.
A. B. C. D. +/- 3/8 +/- 3/8 +/- +/-
R8 2.0
Tolerances for bolted or welded; stairtower, ladders, platforms and platform sup
ports, shall be in accordance with the latest edition of AISC. Tolerances for pi
ping structural supports, guides and hangers shall be +/- unless otherwise noted
on the individual job drawings. All other tolerances not listed above shall be l
imited to Industry Standards, and in no way affect the integrity and appearance of
the HRSG. If the HRSG is provided with an SCR, the Erector is to verify that th
e Catalyst Loading Opening is plumb and square so that the Catalyst Loading Door
s will fit properly. This must be done prior to final welding of the SCR duct fr
ame corner connections.
3.0
4.0
5.0
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.
PAGE 1 PSVs START-UP VENT AND STACKS

EP-12
1.0
GENERAL 1.1 Pressure Safety Valves (PSVs) are to be stored in their original pac
king until installation. Motor operated vent valves are to be stored in their or
iginal packing until installed.
1.2
2.0
PRESSURE SAFETY VALVES AND STACKS 2.1 Lead adjustment seals shall remain intact
on the valve during erection, startup and operation of the HRSG. The seal shall
not be removed for any reason; except spring replacement or calibration adjustme
nt of the valve (Ref.: ASME Section 1, Para. PG-73.1.8). Adjustments or setting
changes of PSVs shall not be performed without written authorization from Purcha
ser and the PSV manufacturer. No valves shall be placed between the PSV discharg
e and the atmosphere. PSV discharge piping and supports are to be installed comp
lete at assembly. Discharge piping shall not be left unsupported for any length
of time. The PSV discharge piping shall be square cut at the discharge end to at
mosphere (no modifications to discharge piping will be allowed). Discharge pipin
g shall be directed away from platforms and/or areas used by personnel. Body dra
ins 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 rem
oved from its original packing. All gravity drains located in the PSV and the di
scharge 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 oth
erwise shown on trim drawings. Weather shields installed on the PSV by the Erect
or, shall be properly vented and arranged to permit servicing and normal operati
on. Discharge piping that is routed to a collection pipe shall meet the requirem
ents of ASME Section I, Para. PG-71, or other applicable codes.
2.2
2.3 2.4
2.5
2.6
2.7
2.8
2.9
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PAGE 2 PSVs START-UP VENT AND STACKS

EP-12
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 unsupport
ed for any length of time. The start-up vent discharge piping shall be square cu
t 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. All gravity drains located in the start-up vent discharge pi
ping 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 No
oter/Eriksen. Any additional materials must be furnished by the Erector. (See dr
awing EP-12-01)
3.2
3.3
APPROVED BY: PJH X:\Procedures\Erection.Manual\EP-12.R5
EP-13 PAGE 1 RECOMMENDED TUBESIDE CLEANING PROCEDURE

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 owners review. Nooter/Eriksen recommends that the cleaning pro
cedure shall include steps for each area listed under Section 2: Hand cleaning,
Organic material removal and Chemical scale removal. This section contains gener
al information and suggestions that may be used as an aid to evaluate a contract
or s procedure or monitor the cleaning and should not be interpreted as an endor
sement of any particular type of cleaning. Improper cleaning of the HRSG surface
s or the complete omission of cleaning can result in poor performance and potent
ial 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 t
he 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 clea
n, uniform surface for passivation. Passivation is the buildup of a protective m
agnetite layer on wetted surfaces. This layer protects the inner surfaces from c
orrosion during operation. Oil, grease and rust can prevent or cause uneven buil
dup and flaking of the protective magnetite layer during operation. These contam
inants 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 b
eing utilized. Improper solutions can significantly add to the circulation time
required for cleaning. Prior to commencement of a chemical clean for the HRSG, t
he following systems/controls must be in proper operation in order to insure boi
ler safeguards:
All HRSG alarms, trips, and interlocks All pressure parts have b
een installed and hydro-tested All insulation has been installed Suitable connec
tions to all vents and drains have been installed and are routed to avoid potent
ial hazards Gas turbine has been readied for operation
APPROVED BY: WJP X:\Procedures\Erection.Manual\EP-13.R9

2.0
Types of Cleaning Depending on the HRSG condition, operating range, and site dis
posal facilities, a variety of cleaning procedures is available. The general cat
egories 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. Carefu
l hand cleaning will reduce the time required for further cleaning. Organic Mate
rial Removal: Following hand cleaning, any remaining organics (such as oil, grea
se, 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 cl
inging to the inner tube surfaces should be flushed out. Typically, this step wi
ll involve a preliminary flushing with warm water, followed by circulation of an
appropriate cleaning solution. A heated alkaline solution is typically used, wi
th the alkalinity and circulation temperature developed by the contractor for th
e specifics of the site. The cleaning solution should be periodically strained o
r blown down to remove foreign materials, and the chemistry readjusted as requir
ed. 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 th
an 2 ppm. An internal inspection should then be done, and the cleaning process r
epeated 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, an
d allowed to stand in the HRSG or circulated for a prescribed time or until test
ing 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 solutio
n should be drained and an alkaline solution circulated. Manholes should be open
ed, the seating surfaces flushed, and new gaskets installed. Proper procedures m
ust be implemented for laying up the boiler after
2.2

the chemical cleaning to insure that damaging contaminants do not enter the syst
em. CAUTION: THE CLEANING SOLUTION MUST BE COMPLETELY REMOVED FROM ALL THE INTER
NAL SURFACES TO PREVENT DAMAGE. Scale removal will be inhibited if oil and greas
e are present. An alkaline cleaning should be performed prior to the scale/depos
it removal phase of the cleaning. There are also mechanical means of deposit rem
oval available for accessible tubes, such as in the evaporator. These include hi
gh 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 f
rom the evaporator sections of the HRSG to the terminal points, it is necessary
to instigate a thorough cleaning procedure. In general, this is accomplished thr
ough 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 pat
h in order to generate a sufficient cleaning ratio (CR). The cleaning ratio is d
efined 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.
CR
(
V 2 ) steam blow (
V 2 ) design
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 cleani
ng ratio the larger the shear force (i.e. the better the cleaning of the tube wa
lls). 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 abs
olute minimum. It is apparent that a low pressure (high specific volume) fluid w
ill result in the minimization of the actual amounts of water

required while helping to generate the largest velocity head. Therefore, it is d
esirable 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 subjec
ted to proper cleaning ratios. The variable geometry throughout the steam path w
ill require the calculation of several cleaning ratios. Steam Blow When the comb
ustion 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 - i
ntermittent and continuous. Intermittent Blows Intermittent steam blows involve
the building up of pressure in the appropriate steam drum to a predetermined upp
er value and then opening a quick acting steam blow valve at the end of the pipi
ng 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 c
leaning ratio required), the steam blow valve is closed to repressurize the drum
and the sequence repeated. An intermittent blow is generally favored over a con
tinuous blow when insufficient make up water capacity is available for a continu
ous blow. The required purging sequence of an intermittent blow, which may requi
re as many as 100 cycles, generally makes the intermittent blow a more costly pr
ocedure in means of time and man-hours. Continuous Blows Continuous blows involv
e operating the boiler at a reduced pressure for a continuous period of time. Th
e reduced pressure generates a large specific volume (high velocity) flow that p
asses through the steam path on a continual basis. A sacrificial valve is genera
lly utilized at the terminal point of the temporary steam blow piping for mainta
ining required pressure. By eliminating the cyclic sequencing of an intermittent
blow, the required time and subsequent man-hours may be significantly reduced f
or 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 storag
e tank during the course of a four-hour continuous blow.

Note: Steam blows may still be performed even though the combustion turbine is u
navailable. In this event, a sufficient auxiliary boiler must be utilized to gen
erate the required steam (flow, temperature and pressure). 2.5 HRSG Operation fo
r Steam Blowing The intent of this section is to present general information per
taining to operation of the Heat Recovery Steam Generator (HRSG) during the stea
m 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 serv
ices/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 cleani
ng. Many of these issues are operational in nature and several are highlighted b
elow for consideration when developing a site specific steam blow procedure. Com
bustion Turbine (CT) Loads Most steam blows can be accomplished at gas turbine l
oads below 30%. The turbine should be operated with the guide vanes wide open. T
his maximizes the exhaust flow and steam flow and minimizes the exhaust temperat
ure and fuel usage. If multiple pressure systems are to be blown at once, signif
icantly higher CT loads are generally required. Sometimes the steam from one HRS
G will be used to blow common steam line piping in cases where the steam from tw
o HRSG s that go to one steam turbine. The ideal scenario would be to identicall
y 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 dr
ums 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 cl
eaning method applied. When a continuous blow is utilized, the boiler is able to
reach an equilibrium condition and subsequently, the drum level should remain f
airly constant. However, the flashing nature of an intermittent steam blow will
generate very large swings in drum level. The water level must be maintained bet
ween 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 oper
ator should start with a small drum pressure change and work up to larger pressu
re changes to assure that the water level can be controlled. Start-UpWhen heatin
g up the boiler for the steam blow process, temporary steam blow valves should b
e 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 mai
n 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 qu
ality as the water intended for normal operation. HRSG s will carryover water fr
om the steam drums during the steam blow. This water should be as clean as possi
ble to avoid chemical deposition in piping and coil sections. The feedwater pH s
hould be increased to 9 by injecting ammonia. This is equivalent to an ammonia c
oncentration of about 0.3 ppm. The boiler must be drained after steam blows unle
ss 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 PressuresHRSG operating conditions can be varied to augment the steam
blow process. For example, the HP drum operating pressure should be maximized wh
en blowing an IP system. This will allow more heat to approach the IP evaporator
maximizing the IP steam flow. ReheatersWhen blowing the HP system of an HRSG wi
th 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 t
he reheater. Vents on the hot reheat line should be open to maximize the IP stea
m flow and minimize the reheater operating pressure. The CT operating mode shoul
d be selected to minimize the exhaust temperature. Desuperheater Operation N/E a
dvises 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 25F of superheat after the desuperhea
ter. In no case must the desuperheater block valve be opened with insufficient s
team flow past the desuperheater. ErectionCare has been taken to supply all HRSG
components in a good condition. The erector must also strive to maintain this c
ondition during all phases of the erection process. Measurement Devices The stea
m blow process may affect steam flow meters. The accuracy of these devices is de
pendent 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 s
team blows so as not to cause undue wear on the valve seats. Non-return valve ve
ndors require that the non-return valve disc (cage) be removed during a steam bl
ow. 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 proces
s, items typically associated with first fire of the boiler (i.e. thermal expans
ion 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 Pro
ject Manager. Air Blow When sufficient water is not available, an air blow may b
e 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 th
e required cleaning ratios. The external air tanks are then repressurized and th
e 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 ai
r. Combination Chemical Clean/ Steam (Air) Blow A thorough chemical clean of the
steam path piping prior to performing a steam (air) blow may significantly redu
ce the time required to meet the clean acceptance criteria. The reduction in ste
am blow time is most noticeable when utilizing the intermittent steam blow metho
d. The chemical clean may be performed simultaneously with the water path cleani
ng 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 f
or testing at the steam blow conditions. The targets are subsequently removed an
d inspected for marks and impressions. The cleaning requirements (i.e. number an
d depth of marks on target) for final acceptance are typically defined by the en
d user, steam turbine manufacturer, and the BOP contractor.

Issues to Note:
For best results, the steam blow valve should be a sacrificial butterfly valve o
r 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 obs
tructions. In general, the plant demineralization make-up water train does not h
ave sufficient capacity to generate the required amounts of water utilized durin
g a steam blow without subsequently imposing large time delays. It may be advisa
ble to hire an auxiliary demineralization plant for steam blows. Steam blow pipi
ng is not generally rated for base load steam temperatures. Care must be taken t
o 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 de
superheating the boiler effluent the subsequent reduction in steam velocity help
s to minimize the noise generated by the sonic steam flowing through the tempora
ry piping. Boiler operation during steam blows is a very transient operation tha
t requires complete attention of the boiler operator. Large fluctuations in drum
level will be encountered during intermittent steam blows and during valve open
ing modifications of a continuous blow. When two units are manifolded together,
both boilers must be in operation to generate the required cleaning ratios of th
e common piping. Care must be taken when bringing both units up simultaneously s
o 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 brin

g 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. T
hese valves are generally globe-type control valves and are subject to damage wh
en passing dirty steam (steam blow steam). When heating up the boiler for the st
eam blow process, the temporary sacrificial steam blow valves should be utilized
to control the ramp rate of the pressure systems. HRSG Insulation must be insta
lled prior to heat-up of the boiler. While providing personnel protection, the i
nsulation also prevents the formation of surface micro-fissures in the event of
boiler operation during extreme weather conditions. The saturation temperature d
ifferential generated between the initial drum pressure and final drum pressure
during an intermittent steam blow must be limited to 75F (41.6C) Considerations Th
is section highlights considerations on when to clean the HRSG, protection of th
e 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 c
leanings should be scheduled as required based on inspections and monitoring of
performance. The decision on whether cleaning for mill scale removal will be nec
essary should be made by the owner in conjunction with those who will be doing t
he water treatment of the plant during operation. A P&ID should be supplied to t
he cleaning contractor to lay out the circulation path.
3.0
3.2
3.3

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 bes
t to delay cleaning for scale removal until after operation has removed loose de
posits from the feedwater system. Control valves, orifices, and other instrument
ation that could be damaged during the cleaning should be removed or bypassed. A
temporary gauge glass is provided for use during the cleaning procedure, if dee
med necessary by the cleaning contractor. Inform the contractor of the maximum w
orking pressure and temperature on this temporary glass. WARNING: THE DISPOSABLE
TUBE TYPE GAUGE GLASS TYPICALLY USED DURING THE CLEANING PROCESS IS NOT SUITABL
E 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 T
HE REMOVAL OF THIS TEMPORARY GAUGE GLASS AFTER THE CHEMICAL CLEAN HAS BEEN COMPL
ETED AND PRIOR TO PERMANENT OPERATION.
3.5
3.6
3.7
As it circulates through the HRSG, the cleaning solution will cool. Solution tem
perature should be monitored at the inlet and outlet points of the HRSG to ensur
e 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 l
ost in the HRSG. Heating of the cleaning and rinsing fluid is normally accomplis
hed in an external heat exchanger supplied by the cleaning contractor. The contr
actor should take steps to ensure circulation of the cleaning solution through a
ll sections of the HRSG. In particular, the path of least resistance in the evap
orators may be through the downcomer(s) and not through the tubes. This may requ
ire blocking the downcomer(s) during chemical cleaning. Steam drum internals can
remain installed during the chemical cleaning. Note, however, that the mesh pad
s 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, the
y must be reinstalled with the same orientation.
3.8
3.9

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 cleanlin
ess of the pre-boiler water facilities, the deaerator spray nozzles and trays ma
y filter some material during initial operation. The deaerating function should
be monitored for proper operation after startup. Sample lines should be closed d
uring steam blow and chemical cleaning to avoid plugging. The customer should re
tain records of the entire cleaning procedure including the chemicals used in th
e process. Safety procedures should be reviewed or developed as necessary prior
to any chemical cleaning. When the cleaning is completed, the customer and contr
actor should verify that the unit is clean and all the coils have been completel
y drained. Disposal of the cleaning solutions may contribute substantially to th
e cost of the process. The cost associated with longer circulation times of weak
er cleaning fluids may be offset by the disposal cost of more caustic/acidic flu
ids. If the combustion turbine is to be used as the source for heating the clean
ing solution, care must be taken to insure that the provided cleaning solution p
umps are sufficient to maintain drum level. Incorrect pump size will increase th
e time required to clean the boiler. Noise attenuation of the temporary steam bl
ow piping may be required. Generally, a steam blow silencer is provided due to n
oise 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 w
ill help to limit the velocities and therefore the noise generation.
3.11
3.12
3.13
3.14
3.15
3.16
3.17

3.18
Following cleaning, proper lay up procedures should be followed. Reference the N
ooter/Eriksen lay up recommendations. N/E does not endorse or recommend any part
icular type of chemical clean / steam blow (including thermal shock steam blows)
. The above information is provided for information only. It is advisable to rem
ove 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 st
eam blows. Boil out with caustic soda (NaOH) or soda ash (Na2CO3) is not recomme
nded. IF these chemicals are to be utilized, the superheaters must be filled wit
h properly treated condensate during the cleaning.
3.19
3.20
3.21
NOOTER/ERIKSEN PAGE 1 RECOMMENDED JOBSITE VISITS REVISION 2 ERECTION PROCEDURE D

OCUMENT
FIELD SERVICE SITE VISITS 1.0 Pre-Construction Meeting 1.1 1.2 Meeting to be hel
d at Nooter/Eriksens office in St. Louis. 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. Erecti
on presentation made on project HRSG.
1.4 2.0
Recommended First Site Visit 2.1 2.2 Estimated time of visit: 5-10 days. Visit i
s to coincide with the arrival and setting of the major components or modules. D
uring the first visit, the following items will be reviewed. 2.3.1 Verify that t
he 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 rai
l damage, check packing lists, check for missing equipment, etc. 2.4 Observe offloading operations. Confirm that the proper handling and erection procedure is b
eing used and provide comments. Observe transporting and setting operations. Rev
iew the material handling/storage procedures of the Erector as defined in the Er
ection Procedures.
2.3
2.5 2.6
3.0
Recommended Second Site Visit
APPROVED BY: TSP X:\PROCEDURES/ERECTION.MANUAL\FIELDSERV.R2
NOOTER/ERIKSEN PAGE 2 RECOMMENDED JOBSITE VISITS REVISION 2

3.1 3.2 3.3
Estimated time of visit: 3-5 days Visit is to coincide with the installation of
the field seams and piping. During this visit the following items should be revi
ewed. 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 Re
view the field seam and piping installation with the people who will supervise t
his work in the field. 3.3.5 Observe the installation of the field seams and pip
ing.
4.0
Recommended Third Site Visit: 4.1 4.2 4.3 Estimated time of visit: 3-5 days. Wal
k through after substantial completion of the system. During this visit, the fol
lowing items shall be reviewed. 4.3.1 Review the field seam installation both in
ternal 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 bo
re piping and supports. 4.3.4 Review the installation of the Duct Burner, SCR Sy
stem, etc., if applicable.
X:\PROCEDURES/ERECTION.MANUAL\FIELDSERV.R2
NOOTER/ERIKSEN PAGE 1 EXTRA WORK BACKCHARGE POLICY REVISION 0 ERECTION PROCEDURE

DOCUMENT
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/Eriksens responsibility, a Field Change Order will als
o be required. All backcharges or extra work claims against Nooter/Eriksen must
be made on the attached Field Change Order (FCO) form with accompanying appropri
ate documentation (Photographs, Sketches, etc.) establishing that a deviation fr
om Nooter/Eriksens design exists. Nooter/Eriksen, Inc. will not authorize work wi
thout having a completed, and agreed upon, reasonable estimate of manhours and c
ost filled in. Nooter/Eriksen, Inc. reserves the right to have any and all corre
ctive work supervised by a Nooter/Eriksen representative and/or performed by a N
ooter/Eriksen designated contractor. If Nooter/Eriksen, Inc. agrees to have the
Erector perform any work, an approved FCO will be returned to the Erector. No cl
aims will be honored for work done without this approval from Nooter/Eriksen. 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 equip
ment, materials, and labor time tickets. All labor rates will be quoted in advan
ce and specified in the Purchase Order. Construction Manager, Erector, and/or Pu
rchaser mark-ups on backcharges will not be accepted by Nooter/Eriksen unless cl
early established by the original job Purchase Contract. 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 an
y direction from theoretical locations.
2.
3.
4.
5.
6.
7.
8.
APPROVED BY: PJH X:\Procedures\Erection.Manual\BC.POLICY.R3
FIELD ISSUE REPORT

PROJECT NAME: N/E JOB #: FROM: TO: CC: N/E FIELD ISSUE REPORT NO. CUSTOMER REF.
NO. DATE OF ISSUE: UNIT NO. 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: REQUESTED RESPONSE DATE: RESOLUTION OF PROBLEM:
DATE:
(ORIGINATOR SHOULD PROVIDE SUGGESTED RESOLUTION)
ACTION CATEGORY: ACCEPT AS IS RESOLVED DATE:
APPROVED BY: PJH X:\Procedures\Erection Manual\Field Issue Report.R3doc
REWORK IN FIELD
SUPPLY MATERIAL RESOLVED BY:
RETURN FOR REPAIR
FIELD CHANGE ORDER

CONTRACT # JOB # SUBMITTAL DATE: VERBAL VENDOR: DESCRIPTION OF PROBLEM: PROJ. NA
ME/LOC: FIR # FCO # WRITTEN UNIT #
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 MAT L REQ D: EQUIP. REQ D:
SUBC. REQ D:
HRS ESTIMATED TOTAL LABOR COST $ TOTAL MATERIAL $ TOTAL EQUIPMENT $ TOTAL SUBCON
TRACT $ $
HRS FINAL $ $ $ $ $ TITLE: DATE:
CLAIM SUBMITTED BY: N/E AUTHORIZATION TO PROCEED: FINAL COST: APPROVED BY: DATE:
N/E CONTRACT PRICE: WARRANTY CATEGORY:
FORM PROJ.008 REV. 2 9/3/02 (APPROVED BY: RKG )
REJECTED BY: DATE: REASON:
EXCERPT TAKEN FROM O&M MANUAL

3.0
Drum Manway Cover Usage and Gasketing All elliptical manway covers follow the sa
me general requirements with 12" (305 mm) x 16" (406 mm), 14" (356 mm) x 18" (45
7 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 sur
faces must be cleaned thoroughly with caution. A method must be used that does n
ot flatten out the required machined roughness. Gasket surfaces are to be finish
ed 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 n
ecessary to repair the gasket surface by weld repair and remachining under the d
irection 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 inspec
ted 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 g
asket in any way before installation. This could damage the gasket and compromis
e its structural integrity. Center the gasket on the manway cover. Bring the cov
er and gasket in contact with the manway ring. Install the studs in the plates o
r 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 nicke
l 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 yo
ke type manways, until all of the bolting is tightened to 10% of the final torqu
e value Continue tightening the bolting following the recommended sequence (1) f
lat at a time until all bolting is tightened to 25% of the final torque value. F
ollowing the same method tighten the
APPROVED BY: WJP X:\Procedures\Erection Manual\Excerpt from O&M Manual.R5 .doc
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 sam
e method. Torque wrenches should be calibrated and in good working order.
1
2
DR-27V
DR-26V
CAUTION: HEAVY DUTY IMPACT WRENCHES WITH DRIVES GREATER THAN 1/2" (12.7mm) SHOUL
D NOT BE USED. IT IS IMPERATIVE THAT THE NUTS BE TIGHTENED ONE (1) FLAT AT A TIM
E PER NUT ON A ROTATIONAL BASIS WHEREBY NUTS ARE TIGHTENED SEQUENTIALLY ACROSS D
IAGONALS. NEVER TIGHTEN ADJACENT NUTS IN SEQUENCE. 3.3 You may start to pressuri
ze 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 descr
ibed above) until the leaking stops. As the boiler is heated, the internal press
ure 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 he
ating/pressurization. It is to be noted that a "leak", as referenced here, is ru
nning 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 UN
IT IS UNDER PRESSURE SHOULD BE DONE FROM THE SIDE OF THE MANWAY AS A SAFETY PREC
AUTION. 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.
Table 3.1
Required Torque Values for Manway Bolts
12" x 16" (305mm x 406mm) Type of Cover Torque DR-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 ftlb (136 N-m)
14" x 18" (356mm x 457mm) Type of Cover Torque DR-26V 260 ft-lb (353 N-m) DR-27V
170 fl-lb (230 N-m) Lenape Type "S" 150 ft-lb (203 N-m) 18" x 24" (457mm x 610m
m) Type of Cover Torque DR-26V 260 ft-lb (353 N-m) DR-27V 260 ft-lb (353 N-m) Le
nape Type "S" 150 ft-lb (203 N-m)
Table 3.2 Gaskets for 12" x 16" (305 mm x 406 mm) Manways (unless otherwise spec
ified)
TYPE OF COVER DR-26V OR DR-27V DR-27V Lenape Type H OR DR-27V Lenape Type N OR DR-27
V GASKET TYPE 1 WIDE CHESTERTON/SELCO STEEL TRAP 304SS/GRAPHITE MANWAY GASKET WITH
PRESSURE SENSITIVE ADHESIVE ON ONE SIDE. 1/8 (3mm) THICK X 1 (25mm) WIDE REINFORCE
D FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRE
SSURE SENSITIVE ADHESIVE ON ONE SIDE THERMO-SURE TACKY CLOTH No. 6250. 3/16 (5mm)
NOMINAL THICK X 1 (25mm) WIDE
PRESSURE - PSIG PRESSURE (BARG) 1200 + (83 +) 1001 TO 1199 (69 - 82) 100 TO 1000
(7 - 68) LESS THAN 100 (< 7)
ified)
TYPE OF COVER DR-26V OR DR-27V DR-27V Lenape Type S OR DR-27V Lenape Type S Not Mach
ined OR DR-27V GASKET TYPE 1 WIDE CHESTERTON/SELCO STEEL TRAP 304SS/GRAPHITE MANWAY
GASKET WITH PRESSURE SENSITIVE ADHESIVE ON ONE SIDE. 1/8 (3mm) THICK X 1 (25mm) W
IDE REINFORCED FLEXIBLE GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION
INHIBITED PRESSURE SENSITIVE ADHESIVE ON ONE SIDE THERMO-SURE TACKY CLOTH No. 62
50. 3/16 (5mm) NOMINAL THICK X 1 (25mm) WIDE
PRESSURE (PSI) PRESSURE (BARG) 1200 + (83 +) 301 TO 1199 (21 - 82) 100 TO 300 (7
- 20) LESS THAN 100 (< 7)
ified)
TYPE OF COVER DR-26V OR DR-27V DR-27V Lenape Type S Not Machined OR DR-27V GASKET
TYPE 1 WIDE CHESTERTON/SELCO STEEL TRAP 304SS/GRAPHITE MANWAY GASKET WITH PRESSURE
SENSITIVE ADHESIVE ON ONE SIDE. 1/8 (3mm) THICK X 1 (25mm) WIDE REINFORCED FLEXIBL
E GRAPHITE WITH STAINLESS STEEL FOIL INSERT AND CORROSION INHIBITED PRESSURE SEN
SITIVE ADHESIVE ON ONE SIDE
PRESSURE (PSI) PRESSURE (BARG) 1200 + (83 +) 201 TO 1199 (15 - 82) LESS THAN 200
(14)

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PROJECT NAME:

SUR INDEPENDENT POWER PROJECT

FIELD ERECTION MANUAL

FIELD ERECTION MANUAL

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

EP-02A PAGE 2 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS

EP-02A PAGE 3 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS

EP-02A PAGE 4 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS

EP-02A PAGE 5 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS

EP-02A PAGE 6 ERECTION PROCEDURE SETTING OF MAJOR HRSG COMPONENTS

EP-03ASB PAGE 1 LIFTING AND RIGGING PROCEDURES REVISION 0

EP-03ASB PAGE 2 LIFTING AND RIGGING PROCEDURES REVISION 0

EP-03ASB PAGE 3 LIFTING AND RIGGING PROCEDURES REVISION 0

EP-03ASB PAGE 4 LIFTING AND RIGGING PROCEDURES REVISION 0

EP-04A PAGE 1 ERECTION PROCEDURE FOR FIELD SEAM INSTALLATION (MODULAR)

EP-04A PAGE 2 ERECTION PROCEDURE FOR FIELD SEAM INSTALLATION (MODULAR)

EP-04A PAGE 3 ERECTION PROCEDURE FOR FIELD SEAM INSTALLATION (MODULAR)

EP-05A PAGE 1 REMOVAL OF TEMPORARY STEEL/WOOD REVISION 0

EP-05A PAGE 2 REMOVAL OF TEMPORARY STEEL/WOOD REVISION 0

Shipping cradle at upper headers must be removed prior to installing module on S

EP-05A PAGE 3 REMOVAL OF TEMPORARY STEEL/WOOD REVISION 0

EP-06 PAGE 1 ERECTION PROCEDURE FOR STAIR TOWERS/PLATFORMS/LADDERS

EP-06 PAGE 2 ERECTION PROCEDURE FOR STAIR TOWERS/PLATFORMS/LADDERS

EP-07 PAGE 1 EXPANSION JOINT INSTALLATION

EP-08 PAGE 1 GASKETS & PACKING

EP-08 PAGE 2 GASKETS & PACKING

EP-08 PAGE 3 GASKETS & PACKING

EP-09 PAGE 1 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING

EP-09 PAGE 2 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING

EP-09 PAGE 3 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING

EP-09 PAGE 4 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING

EP-09 PAGE 5 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING

EP-09 PAGE 6 ERECTION PROCEDURE FOR INSTALLATION OF LARGE BORE PIPING

EP-10 PAGE 1 ERECTION PROCEDURE FOR SMALL BORE PIPING

EP-10 PAGE 2 ERECTION PROCEDURE FOR SMALL BORE PIPING

EP-11 PAGE 1 ERECTION PROCEDURE FOR FIELD WELDMENTS

PAGE 1 PSVs START-UP VENT AND STACKS

PAGE 2 PSVs START-UP VENT AND STACKS

EP-13 PAGE 1 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 2 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 3 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 4 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 5 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 6 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 7 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 8 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 9 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 10 RECOMMENDED TUBESIDE CLEANING PROCEDURE

Pneumatically inserted target plates eliminate the requirement of having to brin

EP-13 PAGE 11 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 12 RECOMMENDED TUBESIDE CLEANING PROCEDURE

EP-13 PAGE 13 RECOMMENDED TUBESIDE CLEANING PROCEDURE

NOOTER/ERIKSEN PAGE 1 RECOMMENDED JOBSITE VISITS REVISION 2 ERECTION PROCEDURE D

NOOTER/ERIKSEN PAGE 2 RECOMMENDED JOBSITE VISITS REVISION 2

NOOTER/ERIKSEN PAGE 1 EXTRA WORK BACKCHARGE POLICY REVISION 0 ERECTION PROCEDURE

FIELD ISSUE REPORT

FIELD CHANGE ORDER

EXCERPT TAKEN FROM O&M MANUAL

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