FORCONSTRUCTION

Owner
UTTAR PRADESH RAJYA VIDYUT UTPADAN NIGAM LIMITED
(A UP Government Undertaking)
Owner’s Engineer

DEVELOPMENT CONSULTANTS PRIVATE LIMITED, KOLKATA

Contractor

DOOSAN POWER SYSTEMS INDIA PVT. LTD

Supplier

Project
OBRA “C” 2x660 MW THERMAL POWER EXTENSION PROJECT
Project Code
Date
(DD.MM.YYYY) Name Title
DP16004
UAS Code
Prepared Y. H. KIM QA00
METHODOLOGY
Unit Code
Checked O.S.KIM FOR P0

COOLING WATER PUMP KKS Code

Approved 1 B. C. KIM ZEN

Reg. No.
Department MECHANICAL DEPT.
070214
Owner’s Consultant Document No. Rev.
0
Contractor’s Document No.
Page-No.

Supplier’s Document No.

 METHOD STATEMENT
FOR WATER TANKAGE FABRICATION & ERECTION & ETC OF PUMPS, EOT CRANES

0 Y. H. KIM O.S.KIM B. C. KIM FOR APPROVAL

Rev Date Prepared Checked Approved Details of Revision

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 METHOD STATEMENT
FOR WATER TANKAGE FABRICATION & ERECTION & ETC OF PUMPS, EOT CRANES

CONTENTS:

1. PURPOSE

2. RESPONSIBILITY

3. REFERENCES

4. REQUIRED EQUIPMENTS FOR WORK

5. SHIFTING OF MATERIAL

6. FOUNDATION

7. ERECTION/ ASSEMBLING PROCEDURE

8.TEST

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 METHOD STATEMENT
FOR WATER TANKAGE FABRICATION & ERECTION & ETC OF PUMPS, EOT CRANES

1. PURPOSE:
The purpose of this method statement is to explain the procedure of the Cooling water pump
Erection for OBRA ‘C’ THERMAL POWER EXTENSION STATION. With this, we can perform safety
and consistently.

2. RESPONSIBILITY:
2.1 Site Manager

Site Manager has the responsibilities for the application of this procedure and detail technical
aspects which is defined in this procedure.

2.2 Construction Manager

Construction Manager is responsible for the execution of construction activities.

2.3 QA/QC Manager

Verify the application of this procedure with necessary tests and inspection.

Verify the specification of supplied material to confirm if the delivered material is correct.

3. REFERENCES
3.1 Issued For Construction Drawings

3.2 Approved Contract Quality Plan

3.3 Project EHS Management Plan

4. REQUIRED EQUIPMENTS FOR WORK:

4.1 Lifting Cranes: - Hydra/Crane with Capacity 20MT/40MT/80MT.

4.2 Transporting – By Trailer with Load Capacity 20MT/40MT.
4.3 Chain Pulley Block with Load Capacity 3 Ton / 5 Ton /10 Ton
4.4 Chain and lifting hooks, Shackles.
4.5 Jute ropes, Crow bars and small pipe for leverage.
4.6 Light but accurate straight edge.
4.7 Master level having accuracy of 0.02mm/m.
4.8 Kerosene and thinner for cleaning parts.
4.9 Threading compound to prevent rusting.
4.10 Feeler gauges and shims for adjusting level.

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 METHOD STATEMENT
FOR WATER TANKAGE FABRICATION & ERECTION & ETC OF PUMPS, EOT CRANES

5. SHIFTING OF MATERIAL:
5.1 The materials are to be shifted from lay down to erection area by trailers of suitable capacity
(40MTor20MT).

5.2 The materials are to be loading from lay down by suitable capacity of Crane & Hydras
(40MTor80MTand14MTor12MTrespectively)

5.3 The materials are to be loading & unloading from lay down to erection site by suitable of Crane
& Hydras with suitable capacity of Slings, D-Shackles.

5.4 Material identification mark number to be checked, same has to be followed for identifying the
material.

5.5 After unloading sleepers are to be provide den sure plates and equipments should not touch
ground.

5.6 Upon delivery of the material, construction engineer shall inspect if there is any discrepancy with
packing list and damage during the transportation.

6. FOUNDATION

The following item of the foundation shall be confirmed and accepted by DPSI and Client rep prior to
erection of the pump.
6.1 Level of the foundation.
6.2 Camber and flatness of foundation surface.
6.3 The foundation and grouting embedded components should be done by the experienced.
Foundation plate should not get loose or from pockets in the parent foundation.
6.4 The motor foundation opening should be as per approved general arrangement drawing to allow
maximum diameter component to pass easily.

7. ERECTION/ ASSEMBLING PROCEDURE

Follow the procedure given below in case of pumps to be erected for the first time or
the pumps to be assembled after dismantling for overhauling. Clean all the parts
thoroughly in Kerosene, petrol or benzene to remove dust, dirt, etc. Replace the parts
with a new one if found damaged. Use new gaskets and O-rings at the time of
reassembly of pump.

7.1 Insert shaft sleeve on pump shaft with key in proper position .Mount impeller on the shaft with
gasket in position. Fit the helical screw lock nut in the impeller nut . Tighten the impeller nut with
gasket . In case of pumps impeller nut is inbuilt in impeller. Press the bearing bush in casing cover
and drill and tap bush and casing cover together at the junction of bush and casing cover . Fit a
grub screw in the tapped hole to avoid rotation of bush (This is necessary in case of replacement of
bush only). Press the bearing bush in bearing shell and drill and tap bush and bearing shell together
at the junction of bush and bearing shell. Fit a grub screw in the tapped hole to avoid rotation of
bush. Now fit the bearing shell along with bush in casing cover and fix the hex. socketed cap
screws.

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 METHOD STATEMENT
FOR WATER TANKAGE FABRICATION & ERECTION & ETC OF PUMPS, EOT CRANES

7.2 Insert casing cover on to the shaft with shaft sleeve. Insert the assembly so far completed into
pump casing with gasket in proper position. Tighten the hex. nuts on pump casing studs
diametrically opposite evenly.

7.3 Mount bottom column pipe on casing cover , tighten the nuts on casing cover studs diametrically
opposite evenly.

7.4 Connect bend to the pump casing with gasket in between the flanges. Also connect the first
rising pipe (if the rising pipe is in two or more pieces) to the bend with gasket in between the flanges
and tighten the bolts and nuts. In case of KPDS 20/13Q, 20/16Q, and 20/20Q pumps bend is both
end threaded. One end is to be fitted to pump casing and it other end flange to be fitted.

7.5 Apply thread compound liberally inside the screwed coupling . Fit the screwed coupling on
impeller shaft and then fit head shaft . While fitting screwed coupling, note that.

7.5.1 Use of thread compound is a must to prevent rust/seizing.

7.5.2 Half of the screwed coupling length should come on each shaft.

7.5.3 Ends of the shafts should rest on each other perfectly. Ensure this by taking colour seat.

7.6 Fit adapter to casing cover and tee joint to pump casing. Connect the bearing flushing pipe to
adapter and tee joint with the help of nuts.

7.7 Mount the taper column pipe on casing cover and tighten the nuts on pump casing studs/casing
cover studs diametrically opposite evenly. (for sizes 32 and 40 cm impeller diameters e.g. 40/32,
80/40 etc. taper column pipe will be mounted on casing cover flange). In case of KPDS 20/13Q,
2016Q and 20/20Q pumps taper column pipe is not applicable.

7.8 Fix the clamp to the bottom column pipe.

7.9 Lift the unit vertically with the help of slings and chain pulley block. While lifting take care that no
part of the pump is being dragged against the floor.

7.10 Put two girders or strong wooden logs across the opening of the tank in which pump is to be
fitted, to rest the clamp while erecting the pump. Lower the unit in the tank till the clamp rests on the
girder.

7.11 Press the intermediate bearing bush into the bearing spider then frill and tap (M6 x 10L) one
hole at the junction of bush and spider. Fit one grub screws in the tapped holes to avoid the rotation
of bush.(This is required in case of replacement of bush only)

7.12 Mount bearing spider on the bottom column pipe.

7.13 Apply thread compound liberally inside the screwed coupling fitted on the pump shaft and
threaded portion of intermediate shaft . Fit the successive screwed coupling in to intermediate shaft
and intermediate shaft in to the screwed coupling already fitted on pump shaft.

7.14 Lift the column pipe with the help of another clamp.

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 METHOD STATEMENT
FOR WATER TANKAGE FABRICATION & ERECTION & ETC OF PUMPS, EOT CRANES

7.15 Lower the standard column pipe and fix to the lower column pipe with the bearing spider (245)
in between. Tighten the diametrically opposite bolts one by one.

7.16 Fix a T joint on bearing spider and connect the end of first flushing pipe. Also connect the
successive bearing flushing pipe to the T joint with the help of nut.

7.17 Lift the complete unit slightly and remove the clamp of bottom column pipe lower the complete
unit till the clamp fixed to the standard column pipe rests on the girders.

7.18 Mount the bearing spider on the standard column pipe.

7.19 Repeat the procedure given in 8.13, 8.14, 8.15, 8.16 & 8.17 till head shaft , top column pipe
and bearing flushing pipes are fitted. Let the whole unit rests on the clamp fixed on the top column
pipe.

7.20 While fitting the column pipes, rising pipes are also to be fitted if rising pipe is in more than one
piece.

7.21 Mount the shaft sleeve (D.S.) with O-ring and key . Mount circlip to locate the shaft sleeve.

7.22 Fit the pipe nut for rising pipe along with gasket for pipe nut.

7.23 Fix the adapter plate to the stuffing box housing with gasket in between.

7.24 Lift the support plate with the help of eye bolts screwed on it and mount it on top column pipe.
Also mount stuffing box housing on the support plate with gasket at the joint and clamp the stuffing
box housing, support plate and top column pipe together with the help of bolts. Tighten diametrically
opposite bolts evenly.

7.25 Adjust the pipe nut till it touches the support plate. Tighten one more pipe nut from the upper
side of support plate.

7.26 Lift the unit slightly and remove the clamp fixed to the top column pipe . Remove the girders
used for erection and lower the whole unit till support plate rests on the top of tank.

8 TEST
After completion of the Pump, test shall be performed in accordance with WH FIELD INSPECTION
& TEST PROCEDURE SPECIFICATION.

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