CONTENTS:

1. Reference standards

2. Construction Introduction

3. Quantities of Main parts

4. Construction preparation

5. Sequence of process

6. HSE management

7. Safety Construction Risk Control Schedule

8. Attachment
1.REFFERENCE
STANDARDS

a) Erection drawings of MBPL.

b) Tolerance limits as per a p p r o v e d drawing & manual.

c) Quality indicators and acceptance criteria (FQP, WPS, Quality Policy)

d) IS12843-Tolerance for erection of steel structure.

e) IS7205-Safety code for erection of structural steel work

f) Contract Documents.

g) Standard field quality plan

2. CONSTRUCTION
INTRODUCTION

2.1
Scope:

The scope of work comprises executing works pertaining to Boiler Unit# 1 Steel structure

erection. All activities related to erection like shifting to work area, lifting, aligning,

leveling, fit up, bolting/welding (if required) and grouting.

2.2
Responsibility:
2.2.1 Project Manager I Construction
Manager:

a) Shall be responsible to implement this procedure

b) Shall impart directions to engineers/supervisors for successful implementation of

this procedure.

c) Shall arrange all required resources essential to implement this procedure.

2.2.2 Execution
Engineer:

a) He will report to 'Construction Manager/ Mechanical In-Charge.

b) He shall be responsible for overall activities and implementation of safety & quality.

c) He verifies and signs all the reports /formats as per FOP standards and

requirements.

2.2.3 QA/QC
Engineer:

a) To Report to QA/QC head and co-ordinate with HTG & APJL QA dept

b) To carryout inspection and ensure required quality control.

c) Documentation of relevant records as per FOP.

2.2.4 HSE
Officers:
a) Report to Site head/ Construction Manager

b) Shall be conversant with complete HSE plan and manage all safety requirements
during the execution.

f',,qe 1 of 29
3. QUANTITIES OF BOILER STEEL STRUCTURE:

Area Weight (MT) Remarks

Boiler Unit# 1 7954 I

4. ERECTION PREPARATIONS:

4.1 Material shifting methodology for Boiler supporting structure:

a) Availability of incoming materials in material yard is as per HTG packing Ii st.

Material is inspected physically as per approved drawings and deviations or

damages found, if any, informed to HTG before transportation of the same to erection

site.

b) Plan for material shifting to site (including scope of transportation,

vehicle mobilization) is received from concerned site engineer.

c) Based on the planned target for shifting material to erection area, requirement of

P&M assets and manpower are fixed and necessary material issue voucher

produced.

d) The lifting T & P and category wise manpower are finalized depending upon the

weight volume and configuration of the materials. it may vary as per the actual site

requirement and to be arranged immediately to meet the target without delay.

e) Skilled workmen having good previous experience are to be used for the lifting and

shifting process. They will be imparted training under Workmen Training Programs

at site.

f) Third Party certificate shall be made available for the lifting equipment before

deployment. The same shall also be checked for its working condition at site.

Through approved third party.

g) Proper approach for work area to confirm and lifting arrangements like Slings,

D-shackles, packing at sharp edges and PP ropes are to be made ready and kept at

work area.

h) Proper placement and centering for tying up of slings on the materials to be done

i) Safety measures for hook latching of the crane, features of slings and 0-shackles

etc.

j) Prior to unloading the material are to be well identified at site.

k) Lastly, taking into consideration of safety measures, material can be unloaded at

site within the reach for erection.

I) During shifting proper locking arrangements to be done for secure the materials
 Page 2 of 29
V
4.2 Schedule (Tentative)

4.2.1 Manpower

SI. Initial Peak time

Designation Remarks
No mobilization mobilization

a) Project Head 01 01 Tentative estimation for

b) Engineers 01 04 planning purpose only.

-
c) Safety Officer 01 02 The actual mobilization

d) Quality Engineer 01 01 will be commensurate

with actual requirement

e) Planning Engineer 01 01
based on front and
e) Supervisor 01 02
material avail ability.
f) Erection Foreman 01 02
Manpower to be
g) Fitter 01 12
enhanced immediately
h) Rigger 05 50
to meet the target.
i) Khalasi 02 40

j) Welder 01 05

k) Gas cutter 01 05

I) Helper 04 30

m) Grinder 04 08

4.2.2 Special Tools. I Instruments:

SI.No Tools/Instruments Qty. Remarks

a) Theodolite 02 nos Tentative estimation for planning

-
purpose only. The actual
Center punch marking
b) 02 nos mobilization will be done as per
tools
the job requirement based upon
c) Auto Meter 01 no
front& material availability.
d) Water level 02 nos
All lifting tools to be got certifed

e) Plumb level 02 nos from and agency approved by

Govt. of Jharkhand for this

f) Torque Wrench 02 nos
-·--�----- --------- proposed and certified issued shall
g) Spirit Level 02 nos
�-�---· ----- ---��-
r, __J
------
 I be posted to HTG before
h) Hammer and Spanner I 01 no each
I
deployment of the same.
i) Piano wire and plumb bob 01 no

j) 100 m steel tape 02 no

k) 50 m steel tape 02 no

I) Spring balance(250N) 02 no

4.2.3 Lifting Tackles:

SI. no Lifting tackles Size Qty Remarks

a) Steel Wire Rope Sling 12mmx 6mtrs 02 pair Tentative estimation for

I b) I Steel Wire Rope Sling I

28mmx 12mtrs 02 pair
planning purpose only.
I The actual mobilization
!
I c) Steel Wire Rope Sling 16" x 6mtrs 02 pair
will commensurate with
16" x 3mtrs 02 pair
I requirement at site
d) I Nylon belt type sling 1 5T,3T,2T 04 pair
based front upon
I
I
each
availability of fronts &
!
f) I Steel wire rope 12 mm&8 mm 800mtrs
material.
g) Steel wire rope 16 mm&19 mm 800mtrs

h) U Clamps 12mm&8mm 80 nos

each

i) 0-Shackles 3,5 , 10,20&30 40 pair

MT each.

j) Chain pulley block 2T/3T/5T 30nos

each

k) Pulley Blocks 3T/5T/10T/20T 10 nos

-- - �
each
4.2.4 Machinery:
-

Initial Peak time I

SI.
Machinery mobilizatio mobilization I Remarks
no
n
- . -- --·-----
I a) 80 MT Flat arm crane 01 01 Tentative estimation for
,._.. -· - - -----·---
r! 01---- -----

::
40 MT Flat arm crane 01 planning purpose only;
l-- - --
50 MT crane 01 02 The actual mobilization
�
- - --
rage 4 of 29
 d) 75 MT crane 01 01 will commensurate with

e) 150 MT crane 01 01 requirement at site

f) 14 T Capacity 02 04 based front upon

hydra/Farana
availability of fronts &
g) 5t hoist 01 02
i material.
I h) 1 Ot hoist 01 01

i) 23 T TRX crane 01 01

j) 40 MT capacity trailer 02 03

k) 20 MT capacity trailer 01 02

I I) Welding Machines 05 10

m) Mother Oven 01 02
�
I n) Grinding Machines 03 05
I AG- 7 /GQ6/FF2
I
I

I
I o) Buffing Machine
I
I 03 10

4.2.5 Main safety facilities

SI. Name of safety

Size unit Qty Remarks
no facilities

- a) Safety net 3m*6m m2 7000

Tentative estimation
b) Safety rope cp12 m 1000
for planning purpose
Self-locking device only; The actual
c) I m 1200
matching rope mobilization will
Climb self-locking commensurate with
d) I I 30
device requirement at site
Retractable type fall based front upon
e) L=6m I 16
arrester availability of fronts &

f) Soft ladder L=14m I 50 material.

Safety harness with

g) 60
shock absorber
4.3 CONSUMABLE:

a) Welding Electrodes (as per vender approved).

b) Welder test piece

c) Grinding wheel

d) Oxygen & LPG

e) Lifting arrangement

f) Grouting Cement (Conbextra GP-2) (test certificate batch no and date

of manufacturer)

4.4 Other materials:

a) Wooden sleepers

b) Scaffolding Pipes

c) Scaffolding Clamps

d) Scaffolding Platform (Challis)

Page 6 or 29
 5.PROCESSSEQUENCE

5.1 Erection Process Flow Chart

Get an elevation reference point

Erection of steel members
from Adani/HTG and mark a
a) Lifting & positioning of columns
master elevation of meter from
as per drawings.
the 'O' level of the plant.
b) Column base plate (bottom

1 or top) elevation and verticality

of column to be checked as per
Check the longitudinal and approved drawings.
transverse centerline (axis) as c) Erection and fixing of
marked on each foundation and connecting beams and bracings.
make a record of deviations d) High HSFG bolts shall be stored
l in covered space and a register of
receipt and issue shall be
Checking and hand over of the maintained size wise.
Foundations as per approved e) Guy rope to be fixed wherever
drawinas required
1
Checking of materials as per Alignment of columns after box
drawing& packing list formation (Verticality checking) as
per drawing and Tolerances limits

Shifting materials to work area

l
Post erection process

a) Bolt tightening or (welding if

Preparation of columns beams, required) of columns, beams,
bracing & gussets bracings & splice connections by
a) Buffing& cleaning, if required using torque tightening m/c after
b) Center line marking & completion of alignment.
punching c) Selection of bolts b) Bolt tightening and welding to be
d) Fix the temporary ladder, done as per approved drawings of
platforms and fall arrestor. HTG. Going like this complete the
e)Micro chipping of foundation to be 1st tier structure
done. c) After completion of the above
f) Placement of packing plate and steps and checking by A D A N I &
leveling. proceed for grouting.

l d) Removal of hook ladders &

temporary platforms.
e) After grout setting time, start
Positioning of material within
erection of 2nd tier and proceed
crane reach for erection.
following the above steps.

h� (
Page 7 or 29 rj �7
5.2. ERECTION METHODOLOGY OF STEEL STRUCTURE

Note. All structural work to be completed as per a p p r o v e d drawings.

Steel structure before installation process should pay attention to combining the cleaning

work, must all joint surface de rusting, metallic luster, not cleaning it is strictly prohibited to

lifting, steel structure with a mop or cotton before assembly will surface cleaning to clean

equipment before lifting the stigma surface inspection, if there are any burrs cleaned with

a file and ensure column joint surface is more than 80% matched with counterpart.

First, unscrew the clamping nut of the anchor bolt and keep it properly. Then, according to

the elevation line given by civil engineering, adjust the leveling nut of the boiler anchor

bolt to the bottom surface of the column bottom plate and install the elevation, and make a

record/ or packers plate to be insert in position and leveled it.

The 75t crawler crane and 80t flat arm crane are used for the installation of the first steel

frame of the boiler as the main lifting machinery, among which the 75t crawler crane walks

between the axes of K2-K3 and 84-85, and is responsible for the hoisting of K2, K3, 84 and

85 shafts, and the 80t flat arm crane is responsible for the hoisting of the column and beam

installation of K4-K6 shafts. In the lifting process of the whole steel structure, the plan of

plate beam shall be considered. All columns between K4 and K6 rows, 83 and 84 and

their related connecting beams and supports shall be installed slowly. The second floor and

above adopts 80t flat arm crane and 40t flat arm crane as the main lifting equipment. The

80t flat arm crane is mainly responsible for the hoisting of the left steel frame of the

furnace, while the 40t flat arm crane is mainly responsible for the hoisting of the right steel

frame of the furnace.

The specific hoisting scheme is as follows: Boiler steel lifting order from furnace on the right

side of the furnace before the left direction, since K285A - 1 column, columns, the

installation order first hoisting K2B5A- 1. K2B5-1 column. and then lifting beam, between

the two columns with two columns stabilize after lifting column pillar and K2B4-1, K3B5-1

and then K3B4-1 connection between pillars beam. make K285-1, K3B5-1, K284-1,

K384-1 "mouth" glyph of four columns to form stable structure, and so on, gradually to the

furnace, furnace, right after the lifting job, After the lifting of the column and main beam of

the first layer of steel structure of the boiler, the alignment work shall be carried out. In the

process of alignment work, the secondary beams and horizontal supports between main

beams shall be hoisted For the need of lifting plate girder roof. according to the project
P<ige8of29
crane allocation situation, should be K7, K8 two columns of steel and K4 and K6 between

rows, 83 and 84 all columns and coupling beam and its related support, K2. K3 roof for

boiler plate girder hoisting and its two plate girder is seated connecting beam, and then

lifting K4 row of slow loading columns and beams, upon the K4 plate girder hoisting lifting

K5 axis slow loading columns and beams.

Wait until the first layer of steel frame installation, acceptance after the foundation of the

second grouting.

The main welding parts of the steel frame of this boiler are the small support of connection

on some truss beams, the pillow plate of column top plate beam, the joint of plate beam

stack beam, etc., and the others are connected and fixed by high-strength bolts.

The steel frame is hoisted from bottom to top by sections. After each layer of steel frame is

installed, corresponding stairs, platforms along with hand rails and balustrades a re installed

immediately. Large ash bucket, smoke duct, burner, big bellows and other components are

hoisted with steel frame, and water storage tank, low, low, economizer and other hoisting

channels are reserved. After the lower beam is installed, the upper beam is hoisted, and

the upper beam is aligned on the lower beam body. After the combination installation, the

welding is carried out. For the specific plan of the large plate beam, please refer to the

boiler roof beam installation instruction.

5.3 Planning and Preparation:

a) Ensure availability of space and firmed pathway for truck and crane operation. Truck

and crane capacity have been indicated in pervious pages.

b) Decide plan for unloading and material storage. Choose a firm and dry location.

Material stored in designated areas remains clearly identified for their location in that

area

c) Temporary approach to be prepare wherever required in boiler

5.4 Pre assembly requirement:

a) Civil foundation release protocol must be cleared before starting erection.

b) Erection member should be unloaded nearer to the foundation of erection. Ensure

sleeper arrangement

c) Check and service the foundation bolt/nuts.

d) Check the mark no, match line of splicing of the member as per drawing.

a'4{,i
e) Check the orientation of member to be erected as per drawing/,// � ,

Page 9 of 29 - j U
 f) Ensure the gusset plate, splice plate and bolts (quantity, type and size) are

available with the member as per drawing.

g) Prepare and check assembly bed for the member prepare and which need

pre-assembly before erection.

h) Prior to start erection straightness checking to be done on bed near to the boiler

foundation

5.5 Activity Description:

a) Erection work will be started on RHS column K2-B5A-1 (The first column was lifted
by 50t truck crane).K2-B5-1, K2-B4-1, K3-B5-1. K3-B4-1 (Box of 4 columns). As

per availability of material

b) The column shall be lifted with crane and made vertical so that the bottom of column
is above the top elevation of the embedded foundation bolts. Then lower the

column on the pedestal without damaging the bolt threads. while lowering the piece

through the bolts and make the column base plate sit over jack nuts. Tighten the

bolts. prior to releasing the load from the crane.

c) Erect all the first pieces of the columns in this manner.

d) Align the individual pieces (verticality etc.) for the following.

e) Elevation (1 meter punch mark shall be taken as reference for all column pieces)

f) Spacing between adjacent columns with respect to reference axis of boiler.

g) Tighten the foundation nut and recheck the alignment. In case of any
disturbance noted alignment procedure to be repeated.

h) Check the spacing between columns at horizontal beam level.

i) Two numbers of consecutive Columns and their base plates are to be erected one
by one and tie beams and bracings between them erected with help of crane and

same process to be followed for LHS grid.

j) Levelling and verticality of base plates & column have to be achieved by movement
of jack nuts of foundation bolts.

Page 10 of
29
k) After erection of four numbers of columns of 1st tier of two consecutive grids their
beam & bracings have to be completed.

I) Fix ladder and planks in column with the help of Scaffolding pipe and clamps and

fix piano wire and plumb bob for alignment checking of 1st tier.

m) Verticality alignment shall be checked with theodolite and spacing with a calibrated

measuring tape. (As shown in the Fig).

COLUMN VERTICALITY ,\LlGNMENT

(!3Y fH!':OOOLITE)

!
H,·�1R
I
LINE - --L -I CQt,.�

><EAulNGr � J
I
!
-
v ::.. vT.3:TTON /1
I
I

I
J
/ :J

:: \
/
.
�
s9> -
-
-
+ .. -
I �
1l::i£QQQ.L.1 l E.
I -l _ /
L::5?Lt;,. <N
\...::..NTRE
,,,., LINE
./ MATCH
( '-A..-\.RK

I
--x:,::-- - i..:'_1 .
\ ,l :- = !
y--Jjll
: .:=. =:=1 �
... �I
11

�
5· '""
Pl.A TES
·_.:.-----

n) The elevation/meter marking of the column shall be checked taking top elevation of
column as per drawing and one meter elevation shall be rechecked & marked before

erection.

o) Fix guy rope (2nos) on the top of 1st tier column by using U clamps.

p) Ensure proper lifting and rigging plan of the crane before lifting of structure member.

Page 11 of
29
 11
q) Appropriate capacity crane will be used to lift the s 4
truc ture.

brtuA1u.)d

Page 12 of
29
 r) Erection of the structure members will be done gradually by the crane as

per experienced signal man's signal.

s) When column gets lifted & positioned skilled riggers should go to rest the column
on foundation bolt and after alignment of column fix nuts and check nuts in the

foundation bolt.

t) After checking the level and verticality of column base plate foundation bolt
nut should be tightened using proper size spanner.

u) Guy rope will be fixed by using U clamp with nearby rigid

structure member/foundation.

v) After fixing nuts of foundation bolt and tightening guy rope, the load will be

released from the crane. and then one rigger will go through ladder using rope and

fall arrester for unhooking and removing of 0-shackle and sling.

w) Rigging to be done as per proper lifting plan by competent rigger. fitter and Foreman.

x) Following the above procedure. entire 1st tier structure erection will be completed.

y) As per girder erection plan some columns erection to be hold for crawler

crane movement and same shall be erected after completion of girder erection

simultaneously.

z) After the alignment completion of the first floor, the column foot will be delivered to

the civil dept. for secondary grouting, Install above the first floor according to the

above procedure

5.6 1st TIER STEEL STRUCTUREALIGNMENT:

a) Level of column Base plate should be maintained by moving the jack nuts as per

drawing/or lay aligning packers plates before column erection as applicable.

b) Verticality will be maintained by the use of plumb bob and piano wire after box up

and cross checked in the presence of Client then protocol signed.

c) Foundation bolt are then properly tightened.

d) The level and theodolite measure the elevation and verticality of the column.

5.7 BOLT TIGHTENING METHODOLOGY:

a) Boxed up columns after alignment. Tie rope has to be kept in load with chain blocks

Page12of29 �IA--t{�
 till bolt tightening has been done.

b) Tie the PP rope along the ladder with fall arrestor at columns.

c) Arrange torque bolt tightening m/c and torque bolt shear rn/c. from Mis HTG E&C

and shift to the erection site.

d) Ensure proper running condition of machine, workmen should take safety measures

by wearing hand gloves while running the machine to prevent from electric shock.

and necessary ppe

e) Tight the bolts for Column and base plate joints, next tight the bolts for main

beams with columns and next tight for beams with bracings.

f) After tightening process apply shear cutting m/c in the same above process, then
release the load from guy rope and remove the ladder & platform.

5.8 Checks required during bolting

a) Contact surfaces shall be free from oil, grease, dust. loose rust & other

defe cts which hamper the development of friction between the mating

members.

b) Alignment of the mating members shall be such that the bolts fit into the hol

es easily and there shall not be any kind of forcing for insertion of the bolts.

c) The calibration of the torque wrench shall be checked according to the torqu

e value to be used. The tolerance of torque value is up to - 5%.

d) During high humidity condition the bolt tightening process shall not be done

5.9 Tightening of Bolts

High strength bolts can be firmed when steel frame alignment meets the requirements of

standard inspection. In order to make all bolts in the bolt group evenly stressed, the

general joint should be tightened from the middle sequence outward. H - type steel joints,

high - strength bolts should be tightened first web after flange.

After the initial tightening of the bolts, further review the spacing between the columns,

the diagonal Angle and the elevation of the top of the columns After qualified, perform final

tightening. When it is finally tight, the electric wrench switch can only be pressed after all

the club heads are inserted into the inner sleeve, otherwise the bolt cannot reach the

axial force and will affect the service life of the sleeve. The final tight plum head beat

off is eligible.

All bolts must be inspected after tightening, and the joints at the joints of high-strength

bolts after passing the inspection should be corroded according to the design
Page 13 of 29 Lj U -ti�t,.,u't;J
requirements in time.

Before tightening the bolts, the parts to be assembled are adjusted and held in place by

means of temporary pins in sufficient numbers and filling the holes so as to prevent any

deformation of the assembly. The bolts that must enter the remaining holes are then

tightened. After this, the pins are withdrawn and replaced one by one by bolts which are

in turn tightened in the same conditions as the first ones.

The tightening torque value to be applied are determined on the basis of bolt

manufacturer's instruction or to the values provided in the procedure.

As a rule, tightening must be carried out starting from the more rigid part of the assembly

and progressing toward its free part. Also the tightening may be carried out from the

center of the assembly gradually proceeding towards the outer part.

Initial tightening will be done up to around 50% of required torque value. Then the

position of the nut will be marked with respect to bolt and washer.

After initial tightening all the bolts, final tightening will be done up to the required torque

value by means of calibrated torque wrench. After initial tightening the bolts plum

blossom head shall be marked with white paint to make required identification.

2.10 Installation precautions for high strength bolts:

a) The high-strength bolt should enter the hole freely during installation and should not

be forced to hit. The washer of the high-strength twisted shear bolt is installed on one

side of the nut, and the side with chamfered corner of the washer hole shall contact

with the nut. and shall not be installed in reverse (the washer of the high-strength bolt

with large hexagon head shall be installed on one side of the bolt head and the nut

side, and the side with chamfered corner of the washer hole shall contact with the bolt

head, and

shall not be installed in reverse). Temporary bolts shall be used for steel frame beams

temporarily in place. High-strength bolts shall not be used instead of temporary

bolts.

b) When bolts cannot be freely pierced, do not use gas cutting and reaming, and use

reamer to wring holes When repairing holes, make the plate layer close to prevent iron

scraps from entering the slot. After wring holes, use grinder to remove burrs at the edge

of holes and remove iron scraps.

c) Bolt penetration direction should be the same. In order to maintain a beautiful

appearance, the high-strength bolt penetration direction on the main channel should be

determined to take the direction radiating outward from the axis of row and row as the
regc14ol29 Jrtt--tr�oLj
 penetration direction of high-strength bolt, and the high-strength bolt at the vertical

support should be installed in the direction of circular rotation.

d) Fastening of high-strength bolt: it must be carried out in two times. The first time is the

initial screw, pre screw it with an electric wrench, and mark it with paint immediately

after the end of the initial screw to avoid repeated pre screw or omission; The second

tightening is the final twist, the final twist shear type high strength bolt should be off

the plum card head. In order to make all bolts in the bolt group evenly stressed, the

initial and final screw should be carried out in a certain order.

e) if the number of bolts is small, the tightening sequence shall be crossed; The joints

of large number of bolts must be tightened from the middle to the outside of the bolt

group.All bolts must be checked after tightening, and the connection plate at the

high-strength bolt connection after passing the inspection shall be painted anti-

rust according to the design requirements.

f) It is carried out from the free end which is not restricted in the ground direction with high

joint stiffness.

g) Spread from the center of the bolt group to the periphery.

h) Special electric wrench should be used for final twisting. Manual torque wrench can

also be used if some operation is difficult. Final twisting torque should be carried out

according to the design requirements. When using an electric wrench, the end of the

screw ends when the bolt ends, check the exposed wire buckle shall not be less than 2

buckle, broken plum head should be put into the tool bag to collect together. to prevent

falling from high height and causing safety accidents.

i) In the final tightening process of bolts, all plum blossom heads must be recovered and

stored centrally. After the completion of the installation of each steel structure, the plum

blossom heads shall be counted and compared with the release records of

high-strength bolts and the design quantity of high-strength bolts. The inspection

shall be conducted according to every 100 of the difference quantity.

j) all high-strength bolts must be packed in plastic bags and boxes during installation.

and it is strictly forbidden to throw them anywhere.

k) the friction surface of bolts shall be flat and dry, and there shall be no oxide skin,

paint. welding scar, etc. on the friction surface.

I) check torque wrenches used for fastening high-strength bolts regularly, and re-calibrate
Page 15 of 29 �£, --q'"�4-v<'u-
y
 and replace torque wrenches with an error of more than 5%.The method is as follows:

tighten three high-strength bolt connection pairs of each nominal diameter with the

initial wrench and the final wrench respectively, and check the tightening torque with the

manual torque wrench. When the tightening torque is inconsistent with the actual

torque, the electric torque wrench must be adjusted.

m) the finalizing of high-strength bolts of the first floor (segment) steel frame should be

completed within the same day. After the completion of the final screw joint site should

be timely anti-corrosion, joint site local gaps should be filled with mud.

n) Torque inspection should be carried out within lh - 48h after the completion of the final

twist of the connection pair of large-strength hexagon bolt. The inspection quantity

should be randomly checked by 10% according to the number of nodes, and should not

be less than 1 O;Each node selected for inspection shall be selected for 10% according

to the number of bolts, and shall not be less than 2. If the upper and lower beam joint

surface of large laminated plate beam adopts high strength large hexagon head bolt

connection pair for fastening, it shall be regarded as a group of nodes, and the number

of random inspection of each plate.beam bolt shall not be less than 20.

o) After the end screw of the shear type high-strength bolt connection, the number of bolts

that fail to end the end screw of the club head shall not be more than 5% of the number

of bolts of the node, except for those that cannot use a special wrench to end the end

screw of the club head due to structural reasons. For all torsional shear type

high-strength bolt connection pairs with untwisted plum heads, the torque method or

rotation method should be used for final twisting and marking to check the quantity.

Check 10% according to the number of nodes. but not less than 10 nodes Check

the final torque of the torsional shear type high-strength bolt connection pairs with

unscrewed plum head in the selected nodes.

5.11 Minimum Bolt Tension in KN for HSFG Bolts

I Bolt Class
I
I M22

110.9 ! 190

5.12 QUALITY REQUIREMENT:

a) Drawing control in working area shall be established and it will be monitored

regularly. )Alt ��/t-uf

Page 16 of 29 � j (} ---J
 b) Column elevation tolerance shall be +or- 5 mm.

c) Spacing and diagonal tolerance shall be +or- mm/meter subject to a maximum of

15 mm or as specified in M/s HTG erection drawing/ manual.

d) Verticality tolerance limit shall be 1 mm meter subject to a maximum of +or- 15

mm or as specified in erection drawings of M/s HTG.

e) All inspections starting from material inspection to work completion are carried out

based on the approved Field Quality Procedure (FOP).

f) Each stage inspection will be carried out by respective person. Also the report

for the same shall be documented.

g) Each report shall bear the identification no. for the items to be inspected.

h) Bolting should be done as per the procedure, which has been mentioned

above. i) Quality control requirement for stair and handrail should be followed as

per the

drawings.

j) Structural members shall be sequentially stocked nearby site by providing

suitable blocks and the area should be barricaded to restrict unauthorized access.

k) Final work completion inspection shall be done along with Mis HTG and Mis

ADANI.

I) All consumables (like grouting material) shall be procured from approved source

only. Along with test certificate.

.
m) During transp ortation and installation of steel structure to take protective

measures to prevent destruction of the Steel Structures Painting.

5.13 Anti-Corrosion:

Proper packing shall be used under the slings to avoid damage/rubbing on the

steel structure. The paint at which the paint is damage shall be cleaned with sand

paper and primer coal of specified standard applied to check carrion.

Steel structure shall be placed upon wooden/ logs to avoid carrion due to soil

touching.

5.14 NEXT TIER ERECTION:

Protocols to be prepared and submitted simultaneously as per the erection. After

alignment. bolt tightening/welding and checking by M/s HTG and M/s ADAN! of 1st tier

structure, erection of 2nd tier & subsequent tiers of boiler steel structure shall be

taken up as per steps and sequence detailed above

Page 17 of 29
6. HSE MANAGEMENT:
Followings are the safety measures to be taken during the erection of Boiler steel structure.

a) Good soil condition to be maintained for the easy approach of men and machinery to

the work area.

b) Erections are to be kept well lit when work is to be carried out during night.

c) Proper insulations &lying of electrical cables connected through RCCB and good

earthing at every point to be done to avoid electrical hazards.

d) Tested tools and tackles having valid test certificates shall be used for the lifting &

shifting of the materials.

e) Lifting machinery like cranes. winches and rope pulleys well have valid test

certificate.

f) Ropes used for load lifting purpose. though being certified should be visually

checked again to ensure the physical disturbances like birdcage, broken strands etc.

in the rope.

g) Tag lines should be used at both the ends to ensure safe shifting of the load

h) Proper barricading around the work area to be provided to avoid unauthorized

trespassing of people inside.

i) Good approach like ladders. lifelines and working platform should be provided

and clearance from the safety engineer should be taken to facilitate smooth work.

j) Housekeeping to be done at regular intervals and the materials should be kept in

its proper place at site as well as in sub-contractors store.

k) PPEs like safety shoe, safety helmet. hand gloves, safety belt. fall arrestor. welding

shield for welders, face guard for grinders, safety goggles etc. are to be provided to

the workmen to assure their safety and good health at work.

I) Safety training at regular intervals and safety pledge on daily basis should be

worked out at site premises to increase the safety consciousness and skill of the

workmen.

m) GRA (Group Risk Assessment) and STA (Safety Task Assignment) to be prepared

n) Safety net to be fixed before erection of second tier

o) Arrangements of hand tools bag to prevent falls of tools from height.

p) Necessary work permits to be taken prior to start work.

q) Workers engaged in height work to be tested/examined prior to start work.

f•agc18of29 �--b(W!.�'J
 7.Safety Construction Risk Control Schedule

Person
Sequence of Hazards and
Control Respon:
Job Steps Consequence Measures
s ble

1. Make sure the sling rs tied/bound/tighten cor

rectly.

j 2. Physically check the lifting devices (slings, S

! hackles etc ... ) are in good conditions and s
I afe for use. '

3. Ensure compactness of ground where heavy ,

I
i equipment crane has to position.
! I
14. Analyze the load (Weight. shape. lifting poin
1. Struck down by t ,
ts, etc.) and the lifting device.
hing and material
i 5.
I
Use hand gloves when tighten the slings.
S I

Loading-Tran
16 . Ensure proper locking of material to avoid f
2. Squeezed by the all during transportation. Erection
sportation
sling/Material 7. Only skilled and experienced rigging crew al
and Engineer.
3. Crane fall accide ong with rigging foreman should be engage
Unloading of
ntly d during loading and unloading of material.
Structure and Safety
8. Ensure all heavy machinery equipments, era
other 4. Trailer may hit w

nes should have reverse horn. back ward m Officer

Materials ith other objects/
ovement light are working properly.
toppled
9. Ensure the transportation path is clear from ;

traffic.

10. Follow all traffic rules during transportation o

f material to site.

11. Ensure use of guideline ropes tied with mat

erial during unloading of material.

I

I 12. Don't move or stand under the material duri

ng unloading

13 After unloading, arrange proper locking arra

ngement to avoid topple of material.
----� -------·· L_ --
--------
J',1�,· JY ,1 29
,t,lf 4-q���
 114. Area barricading to be done.

i 15. Only authorized driver/operator to be e nga

ged.

16 Flag man to be deployed.

17. Wheel chock block to be used.

1. Ensure safe distance during assembling of ti

e members with main girder.
Erection
Assembling of 1. Struck by material
Engineer
tie members s 13 .
with main 2.Property Damage i with girder.
Safety
!
Girder I 4. Use proper PPE's during executing the job.

Is Use proper and safe working platform to ex Officer

ecute the job.

6. Use safety harness and fall arrester.

1. Use of full body harness with double lanyar I

d.
I
2. Ensure TBT prior to commencement of wor

k. I

3. Unauthorized persons should not be allowed

Erection
to work at height.

4. Ensure physical inspection of the area prior Enqineer.

Work at
1.Fall of person to deploy workers at height.
height
5. Ensure proper fixing of ladder with the colu Safety

mn.
Officer
6. Ensure safe and free ladder access to the
working platform

7. Ensure use of rope grab fall arrestor along

1

I with polyamide rope to the ladder access.

I I
i
I I 8. Area should be barricading
I
'-·----- _l_ - - -- - - -----

Page 20 of 29
 9. Ensure arrangement of proper working p latf

orm.

10. Ensure that all openings at height are hard

barricaded and additional protection with saf

ety net.

11. Maintain good housekeeping near of the wo

rking area.

12. Ensure installation of lifeline rope (8 to 10

mm) for safe access working at height.

1. Check all tools and tackles before starting th

I

I e work.
2. Ensure TPI of and colour coding of all lifting
Erection
Tools and Tackles.

3. Ensure that the working platform arranged w1 Engineer

i2
Fall of material th toe guard, handrail and mid rail.
Safety
4. Proper housekeeping to be ensured before a

I
I
nd after completion of work.
Officer
I 5. Ensure use of lifting bag and securing of all

loose hand tools to avoid fall from height.

I
I 1 . Compaction of earth for positioning theCrane

/Hydra/ Frara.
Erection
2. EnsureTPI of loose lifting gears prior to use. I
3. Operator of Crane should have valid driving Enqineer.
I

1. Toppling of Crane license.

1 I
Safety
Lifting Work
I /Hydra 4. Ensure of wind speed during carry on unloa

ding and lifting activities.

I 5. Before starting the work check the condition
Officer
Lifting of
of Crane.
Structure I
1. Prior to commencement of the work TBM m
Erection
2. ust be conducted and all possible hazards a

a) Failure of lifting T nd its control measures to be briefed among

Page 21 of
29
l ools & tackle -�--_e_w_o_r n_g e_w_ _
Engineer/

Page 21 of
29
 b) Fall of material 2. PTW to be obtained prior to start work. Safety
c) Material may hitt 3. Ensure job supervisor is enough experience
Officer
he worker d and qualified for the executed job.

working at height , 4. Sling & D-Shackles should be tested by TPI

competent person.

5. Physically check the condition of all lifting T

ools & Tackles and ensure that they are saf

e for use.

6. Ensure 3.3.3 regulation is complied with.

I
7. Ensure deployment of competent & experien /

ced person. I
8. Ensure wind speed rs safe for material liftin '

g.

!9. Ensure weather is in good condition.

I

i 10. Allow maximum 30 Kg per person for manu

\ . al handling of materials.

111. Ensure of safe rigging arrangement.

'12. Double tag line should be used.

13. Ensure fixing of packing at the side of sling

s or belts to avoid damage to them.

14. Ensure fixing of life line rope prior to erect

of the structural members where ever neces

, sary.

15. Use P.A system to aware people working ne

arby.

16. Ensure Proper communication among the er

ection crew during lifting of material.

17. Workers at height must ensure their safe &

proper position during fit up of members wi.l

I
J h columns.
------

Paqo 22 of
29
 1. Work area should be restricted with un-a uth

orized entry.

2. Experienced Signal man will be present duri

ng operation of the I Erection
3. Crane may get i
Crane. I Engineer
hit with person
3. Person should not be allowed to stand u nde
or other nearby !
i Rigging
materials during swi r the suspended load of the Crane or mater
ial. Forman
ng
4. Double tag line should be used. I
I
Safety
5. Work area should be maintained good

hous ekeeping.
I officer
6. After erection of the members ensure fasteni

ng of the same to avoid falling.

1. Flash back arrestor should be used.

2. Area should be free from combustible and fl

ammable material. PTW to be obtained.

3. Fire extinguisher should be kept at job are

a.

4. Proper housekeeping to be ensured at work

Erection
area.
Hot work
5. Cylinder should be kept rn trolley vertical p Engineer,
1. Fire hazard
1. Gas cutti osition and secured.
2. Person injury
Safety
ng 6. Physically check the dual guage regulator

condition.
Officer
7. Ensure of Fire blankets at job area.

8. Ensure of PPEs required as per job.

9. Ensure compressed gas cylinder having valv

e protection cap

10. Damaged accessories not be used

Paqe 23 uf 29
 1. Ensure healthiness of the wheel and expiry

date.

2. Should be use helmet with face shield.

3. Ensure wheel guard of the Mic.

4. Area free from combustible and flammable ,
Erection
2.Grinding material.
1
1. Eye injury and 5. Fire extinguisher should be kept at job Enginee,
are I
Body injury. a.

6. Use of all PPE as per as required. I

Safety
!
I

i 7. Use Fire blanket to arrest fire spatters.

i Officer
8. Ensure the power supply is routed through

ELCB/RCCB.

9. Inspection sticker to be provided and to be 1

I
maintained.
I
1. Area should be free from combustible a I
nd flammable material.

2. Fire extinguisher and fire blanket to be

1. Fire hazard on the job.
available

3. Proper housekeeping to be ensured at

work area.
Erection
4. Power supply through 30ma ELCB I RC
3.welding
CB. Engineer.

5. There should not be any cuts or joints i

n the power supply cables.

I Safety

2. Electrical shock.
6 Use of all PPEs as per as required. Officer
3. Burning injury.
7. Ensure of double body earthen to the
4 Physical injury.
Welding Mic.
5. Dust and smoke
8. M/c to be protected from rain water.

9 Proper lugs to be used for m/c

10. Tagging and periodic inspection of rn/c. j

Page 24 of 29
 1. Ensure water sprinkling m and around the d

usty area.
2. If necessary provide nose mask to the work
1. Oust-Breathing
men.
Pr
I
I oblem
3. Ensure speed limit control of moving
Environmenta I 2. Hot Weather- vehicle Safety
!
I Issues
I Sun stroke s. officer

j 3. Noise-Hearing 4. Drink sufficient water during working hour.

5. Take rest on rest shelter only.

lose
I 6. Use ear plug at noisy area.

7. Ensure noise control devices are working pr

operly.
I

Page 25 of 29
8.Attachment

8.1 Layout of crane on the first floor

/ / - / - / -- / / / - -/

-\.-

=
80T
( ->s--

'

75t C:,/

Route -·
of

- - ,-

'
75tRoute of crane

'

'

'
/ / /

/ / / / / /

Pc1�Je 26 of 29
8.2 Crane layout plan above the second floor

/- - / . ·-/ ·/ -/ / .. ::. : /

SOT
·---a '. --

40T

/ r /
/ / / /
/ / /
8.3 40T flat arm crane working condition

�I§!'. m 3-20 23 2.5

I 28 30 33 35
I . rn .J3 �s ..t..� 50

I
I
U]t�t -tO.O 34.2 311 25.2 22.5 21.0 l 7.8 16.3 l 5.-t l-t. l 13. -t
I 27.3
l
�If!_ m
53
I
55 5.�
i
(i{)
I
g]t�t l2A l l.8 11.0 I 10.5
I
I
8.4 75T crane

I � l'<:(:n}I
19 2
I

37

H = ·�--�
-�l--
�LC/.(m )

.
L· .
! • --�
70 I

=R
# ... ..
) .)

I 55.0 -,
5-t 5
55.5
5.:�5 ' 45.7

6 4 LS -4i.S I .s: .2 40.3 39.S )9.5 j9.0 i

7 .JJ.5
!
i )3.J .>2.6 J2.6 )2.0 J:!.C 315 >0.5 30.5

s 27.6 27.6 I :!.7.0 27.0 26.6 26.6 26.0 26.0 lG.O 2.5.3
9 23.5 2JA I 2).4 _3_,) zz.s 22.5 !L 22.0 '.?2.0 22.0
� ::.o .... I 20.4 20.-l 20.2 19.S L9.8 19 5 19.l :9.2
!O )9.2

I 12
I�
:6.2 i
'
16. l

LU
16.0

D.I
15.9

I J.O i
15.7

z.s
15.6
12.7
:s..;
:2.6
15.:

l.:.)
1-l.9

12.2 �0

16 ILO 11.0 1.0.S 10.7 :o.6 LO. .! :0.2 I 10.2

13 I 9.� 9, 9.2 9.0 s.s 8.� 3.6

20 6 1 7. <) 'i.& 7.6 7.5 7.5

21 6.9 r..� 6.6 6.6 66

6. l '-.0 5.8 5.7 �-;
24
5.9 5 j 5.2 5.1 5.0
26
4-; 4.7 ,l.5 ,t,.l
28 I
I �.o 4.0 •1.0

-I
30
3.6 3.:
32
J. l
34
36 ----·----· -- ------
I i
---- ----
33
4-0

� t� -
42
- ·
-- � - :-----+-- --�
''

I =: -1--i
L-- :� ·-r---+�-
-=-----
�--.._--
+----.---

:---�-�:

·��---:!
lr: °;'t,' I :-o
l:!
�'.)
7?.. f s
10
L_2-_
L 70
1
!
6
70
s
JO
s
!Q
.Lz.,'.
30
4_
_;1)

Page 28 of 29
8.5 SOT flat arm crane working condition
l .4 70m 1 · ;5l{� r::)' 1111 H� «
1.4 Load curve of 70 m operating condition
r;:r ·!; Load
r • (2:'i. 80. ())

Load curve of first gear

(JO. 66. 7 l
�·)
... _. •,; ..

( io. lH. ())

Ill· (.'iO. :a;_ ,-; )
:u (60. ��- :IJ
(70.�I.O)
. :o
Ill Radius

10 t.=i :.!O ::o Ill ,() tiO 70<1111

."fl_t}l.
�_I_!_
- . �-'!! .i , : l .:ti :-i
'" -- !l
-h ----tu
1 ----
�
�ll. 0 ,::. 0 titi. 7 o .'J7. 'J . , I. '.! .,o. q ,. - 7 .tx. � ::ti.
� 10.
--�-
ti�. I.S.
-
() 1·· ',
1.:

-�-;_ l :t��- .:i

--------
J:..'.. 0 JO. 0 �9. :1 �t<- l �7. 0
··• �-�- q -�LY ': l. 0

Page 29 of 29