Erection Manual For Cooler 10.6.16 PDF

4lant Client Contract Code Contract No.
Document ID
NPK PVFCCo PVFCCo-NPK PIN-EQS-7010-DZ-0003-039 66-0194
Main
Erection Manual Cooler Drum

Rev 00 Page 1 of 98
CLIENT :PETROVIETNAM FERTILIZERS AND CHEMICAL CORPORATION,VIETNAM (PVFCCo)

ROJECT :PHU MY NPK PLANT PROJECT,VIETNAM
EPC CONTRACT NO. :369 / 2015 / PVFCCo /DTXD-TKIS-PTSC / X-NPK
14.06.16. ATH / SVH
00 For Information 10-06-16 PSA 10-06-16 ASM 10-06-16 SRH 4

Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: -
Barcode
Copyright 2015 : All rights reserved
ThyssenKrupp Industrial Solutions (India) Private Limited
thyssenkrupp Industries India
Erection Manual
For
Cooler Drum 3.0 x 17M
Project: NPK Plant Project, Vietnam

Client: Thyssenkrupp Industrial Solutions (India) (TKIS)
TKIS PO NO: 38010823 DTD. 29-10-2015
TKII Work Order No.: 3M0049
Erection Manual For Cooler Page 1 of 79

Index
1. Introduction and Pre-Requisites before actual Mechanical Erection
a. General Information related to project/Equipment
b. Safety Recommendations related to work
c. Transportation, Unloading and Storage and preservation details
d. Foundations
2. Mechanical Erection Instructions for Cooler
a. Reference Documents
i. Drawings
ii. List and Details of Tools and Tackles - with scope
iii. Fabrication Drawings of Temporary Erection Structure with MTO
iv. Resource and Machinery Requirement
b. Erection activities and sequence
i. Checking and Hand-Over of Foundations
ii. Support Roller Assembly Erection and Alignment
iii. Erection of Shell
iv. Grouting of Base-frames
v. Girth Gear Erection and Alignment
vi. Drive Assembly Erection and Alignment
vii. Guards Erection and Assembly
viii. Inlet Hood and Seal
ix. Outlet Hoods and Seal
x. Electrical Installation
xi. Lubrication System Installation
3. Erection schedule for cooler
4. Quality Assurance :
a. Protocols & ITP
b. WPS
c. Consumables specification with estimated qty


a. General Information related to project/Equipment

Cooler 3.0x17m will be dispatched in 2 parts, the details of which are as follows:
Dispatchable unit1 Dispatchable unit2

Length - 7150 mm Length - 9850 mm
Weight - ~ 15000 kg Weight - ~ 25000 kg
Tyre Weight ~4200 kg Tyre Weight ~4200 kg
Tyre OD 3395 mm Tyre OD 3395 mm
Cooler Drum
Process Parameters
Material : NPK / DAP
Bulk density : 895 - 1070 kg/m3
Feed Size : >2mm - 17-23%
: 2-4 mm - 61-74%
: >4 mm - 9-15%
Feed Moisture (Normal/Maximum) : 1.3-1.5% / 1.5%
Capacity (Normal) : 36-52 TPH
Capacity (Design) : 60 TPH
Duty per day : 24 Hrs
Product Moisture : 1.3-1.5 % / 1.5%
Equipment details
Cooler Drum Size : 3000 mm Dia. x 17000 mm Long
Slope : 4%
Shell Plate Thk : 16 mm Min
Cooler Drum Speed : 4.2 rpm
Riding Rings
Diameter : 3113 ID mm - 3395 OD mm
Width : 370 mm
Trunnion Rollers
Diameter : 840 mm
Width : 420 mm
Thrust Rollers
Diameter : 450 mm
Width : 200 mm

Bearing Type : Roller bearing
Cooler Drum Inlet Chute

Type : Male 60 min. slope
Inlet chute thk : 6 mm
Feed end seal : Labyrinth Seal
Cooler Drum Outlet Chute

Type : Female 60 min. slope
Discharge Chute thk : 6 mm
Feed end seal : Labyrinth Seal
Ring Gear
Type : Spur teeth
No. of Teeth : 170
Module : 24
Face Width : 300 mm
Pinion
Type : Spur teeth
No. of Teeth : 23
Module : 24
Face Width : 330 mm
Girth Gear Lubrication System

Lubrication Type : Grease Spray
Air requirement for lubrication : 160 NLPM (Preliminary)
System
Drive System
Gearbox type : Helical
Main motor power : 132 kW,
Main motor speed : 1500 rpm
Drive arrangement : Girth gear & pinion
Speed control : Variable frequency drive


b. Safety Recommendations related to work

Safety Recommendations related to work:

1. While pulling the drums inside the building, proper locking should be done from both the sides.
2. While doing any welding work at site, proper earthing to be made sure.
3. While welding at height, proper scaffolding to be provided.
4. Ventilators to be provided inside the shell while welding to avoid suffocation.
5. Proper care to be taken while operating the hydraulic jacks.
6. Proper care to be taken while working under suspended load.


c. General Transportation, Unloading and Storage and preservation
detail

Please refer below sketches / drawings for transportation of ODC consignment.


Please refer below sketch for unloading of drum shells.

STORAGE AND PRESERVATION DETAILS
Open storage Heavy Fabricated Materials / Voluminous Cargo:-

All the fabricated items need to be stored properly with proper supports to avoid any damage to
part as well as water ingress. When material arrive at the site, all parts must be placed on wooden
beams with the provision of suitable protection against rain, contamination and damage. The
parts must not be stored directly on the ground.
Fabricated material such as drum shells, feed and discharge hoods, base frames etc preferably
be unloaded near the respective buildings and on levelled and compacted surface with proper
elevated support with adequate tarpaulin sheets.
Lack of adequate support in the centre of housings & base frames could lead to buckling of
equipments, hence required intermittent supports should be provided.
No material should be stacked on one above the other, except where crating of material is
possible however, care should be taken so that there is no deformation on stacking.
Covered Storage:-
All equipments / items like gear boxes, motors, couplings, lubrication system, crusher, roller
assembly, pinion drive assembly etc shall be stored in covered storage.
All machined components should be stored in covered storage area.
All machined surfaces should be protected against falling objects to avoid peel off of the tectyl
paint and well protected from water / moisture and dust ingress.
All Electrical & Instrumentation items and hydraulic systems and parts like and not limited to
measuring, sensing, weighing, analysers, power etc. shall be stored in covered areas.
In general the storage area must be dry, well aerated and ventilated, and shall be protected
against moisture, acids, and other chemical agents.
No material should be stacked on one above the other, except where crating of material is
possible however care should be taken so that there is no deformation on stacking.
No machined surface should be stacked on one above the other.
Since the materials are susceptible to mishandling, hence it is necessarily important that proper
care is adopted for handling and storage of equipments, preferably critical and sensitive parts be
stored in covered storage.
Note:
Any alterations, gas cutting, welding OEM must be consulted in writing.
While moving / transferring any material at site, proper lifting slings, ropes, tools and tackles
should be employed.
Items specifically mentioned above but not limited to shall be stored in proper manner to avoid
any damage, pilferages, etc.


d. Foundations

Please refer below sketch for the foundation details of cooler drum.
Handing over the foundation:

Civil department should give the following before handing over the foundation for mechanical
erection.
1. Insert plates on all the piers as shown in the protocol.
2. W/p marked on insert plate at inlet & outlet.
3. Reference elevation mark at inlet & outlet on insert plate.
4. Centre line of cooler at inlet side outlet side as well as on all piers.
5. Centre line of drive includes centre line of main gear box, main motor, auxiliary gear box &
auxiliary motor.
6. All foundation pockets should be clean till the depth.
7. After providing all the above details all the concern department should sign the protocol.


i. Drawings

Reference Documents / Drawings for Mechanical Erection Instructions for Cooler

Sr.
Document Description TKIS Document ID TKII Drawing no.
No.
1 GA Drawing [70CL2001] PIN-EQS-7010-DZ-0003-001 FRT-RD-00111
FRT-RD-00044,
2 Foundation Load data [70CL2001] PIN-EQS-7010-DZ-0003-002
FRT-RD-00120
Support Roller Shaft Assembly
3 PIN-EQS-7010-DZ-0003-007 FRT-RD-00051
Drawing [70CL2001]
Thrust Roller Shaft Assembly Drawing
4 PIN-EQS-7010-DZ-0003-010 FRT-RD-00099
[70CL2001]
Pinion Shaft Assembly Drawing FRT-RD-00088,
5 PIN-EQS-7010-DZ-0003-014
[70CL2001] FRT-RD-00087
6 Tyre Fastening Drawing [70CL2001] PIN-EQS-7010-DZ-0003-015 FRT-RD-00035
Roller Station Assembly Drawing -
7 PIN-EQS-7010-DZ-0003-017 FRT-RD-00076
Feed End [70CL2001]
Roller Station Assembly Drawing -
8 PIN-EQS-7010-DZ-0003-018 FRT-RD-00116
Discharge End [70CL2001]
9 Drive Assembly Drawing [70CL2001] PIN-EQS-7010-DZ-0003-019 FRT-RD-00205
Roller base frame - Feed End
10 PIN-EQS-7010-DZ-0003-025 FRT-RD-00113
[70CL2001]
Roller base frame - Discharge End
11 PIN-EQS-7010-DZ-0003-026 FRT-RD-00122
[70CL2001]
12 Drive base frame [70CL2001] PIN-EQS-7010-DZ-0003-027 FRT-RD-00170
13 Girth Gear Fastening [70CL2001] PIN-EQS-7010-DZ-0003-030 FRT-RD-00057
14 Inlet Hood Seal Drawing [70CL2001] PIN-EQS-7010-DZ-0003-032 FRT-RD-00182
Discharge Hood Seal Drawing
15 PIN-EQS-7010-DZ-0003-033 FRT-RD-00187
[70CL2001]
Inlet Hood Assembly Drawing
16 PIN-EQS-7010-DZ-0003-035 FRT-RD-00183
[70CL2001]
17 Transportation Drawing [70CL2001] PIN-EQS-7010-DZ-0003-037 FRT-RD-00011
18 Shell Assembly Drawing [70CL2001] PIN-EQS-7010-DZ-0003-039 FRT-RD-00003
Foot print for support structure for
19 PIN-EQS-7010-DZ-0003-040 FRT-RD-00056
Cooler [70CL2001]
Transportation sketch for Cooler drum
20 FRT-RD-00296
lifting by single crane [70CL2001]
Tyre erection base frame for ground
21 FRT-RD-00303
assembly [70CL2001]
Erection saddle R=1516 for Cooler
22 FRT-RD-00306
drum [70CL2001]
Temporary roller support arrangement
23 FRT-RD-00301
for Cooler [70CL2001]


ii. List and details of tools and tackles - with scope

List and Details of Tools and Tackles - with scope

List below is considering erection of all four drums, the list is not exhaustive.
Sr.
Description Qty
No.
Tools & Tackles by Erection Contractor
1 Auto level / Total Station 1 No.
2 Master level 0.02 mm per meter 2 Nos.
3 Dial gauges 0-10 mm with magnetic stand 10 Nos.
4 Filler gauges 6, 12 length starting from strip thickness 0.03 4 Nos. each
5 Main heating oven (400 deg. Cent.) 1 No.
6 Portable oven (200 deg. Cent.) 6 Nos.
7 Heating torch 6 Nos.
8 Motorised winch (10 tons) 2 Nos.
9 2 sling for handling shell and tyre (16 meter) 4 Nos.
10 Piano wire 100 kg
11 Measuring tape 50 / 30 / 15 / 5 meters 2 Nos. each
12 Spring balance (20kg) 2 Nos.
13 Crawler mounted cranes (250 tons and 130 tons) 1 No. each
14 Pick and carry crane (25 tons) 1 No.
15 Water level (6mm x 50m) 4 Nos.
16 Vernier calliper 2 Nos.
17 Inside and outside micro-meter 1 No. each
18 Centre / Number and letter punch 1 No. Each
19 AG-4 / AG-7 / GQ-4 grinding machine 4 Nos. Each
20 Grinding and Cutting wheels 100 No. each
21 Concrete drilling machine (max. inches dia.) 2 Nos.
22 Hydraulic jack (100 tons) 2 Nos.
23 Hydraulic jack (50 tons) 4 Nos.
23 Button and bottle jack (25 tons) 2 Nos. Each
24 Torque wrench Mechanical (3900Nm) 2 Nos. Each
25 Torque wrench Hydraulic (10,000 Nm) 1 No.
26 Shim cutter 2 Nos.
1 No. Each for all
27 Ring and D type spanner / hammering spanner
sizes
28 Chisel and hammer 10 Nos.
1 No. Each of
HN 18-20
HN 21-22
29 Adapter sleeve lock nut spanner
TMFN 30-40
TMFN 40-52
TMFN 52-64
30 Chain block - Long lead (10 tons) 4 Nos.
31 Chain blocks 5 ton and 2 ton 4 Nos. Each
32 Oil stone 4 Nos.
33 D.P. set 30 Sets
34 Allen key 7/8 & 1 for girth gear fixing bolt 4 Nos. Each

Tool box consist of steel scale (6 & 12), mechanical plumb, hack saw
frame with blade, Ring and D type spanners up to 46 mm, Allen key set,
35 box spanners with ratchet up to 46 mm, spirit level, flat and smooth files, 5 Nos.
hammer, cutting flair, nose flair, circlip flair, screw driver, slide wrench,
Persian blue etc.
36 Emery wheel / paper, ribbon rough and smooth both As required
37 Scaffolding, pipes and clamps As required
38 Tarpaulin As required
39 Tube cutter / bender (die size as required) 2 Nos. Each
40 Chain wrench, pipe wrench 2 Nos.
41 Wire brush & Chipping hammer 10 Nos.
42 Pyrometer (200 degree centigrade max.) 2 Nos.
43 Diamond wheel with machine for concrete grinding 2 Nos.
Temporary fabricated support rollers with frame for drum erection and
44 10 Sets
rotation as per TKII drawing No. FRT-RD-00301-1/0
45 Welding Rectifier 650 Amperes 6 Nos. Min.
46 Brass and SS shims less than 1 mm As required
47 Buffing wheel 25 Nos.
48 All required lifting slings/ belts, D shackles, pulleys, bull dog grip etc. As required
Bunch of small slings for fixing pulleys, chain blocks and holding shell
49 As required
during dragging
Oil bath (site fabricated steel box) for coupling heating for assembly
50 1 No.
Size: 1100x1100x600mm
51 Burnt engine oil / used oil 600 Ltrs.
Special Tools & Tackles by TKII
1 Tensioning devices for Dryer and Cooler 1 Set
2 Shell erection wedges and clits for Dryer and Cooler 1 Set
3 Earthing clits for all drums 1 set
4 Slope measuring scale for each drum 1 No.
5 Hydraulic jack for drum lifting for maintenance for all drums 1 No per drum
6 Hydraulic button jacks for base frame adjustment for all drums 4 Nos per drum


iii. Fabrication Drawings of Temporary Erection Structure with MTO
- Shall be submitted separately.


iv. Resource and machinery requirement
- Please refer Annexure I

AnnexureI
Activityschedule,Resources&MachineryRequirmentforCooler
MaterialbyErection
Sr.No. Activities MaterialbyTKII Manpower Toolsrequired Duration
Contractor
TobeginwiththeCoolererectionwork,thefoundationoffirst&secondpiershouldbe
completedinallrespect.Ajointprotocolshouldbemaintained&signedbythecivil
departmentfromclientside,thesupplier&theerectioncontractor.Thecivil
departmentshouldgivethefollowingbeforehandingoverthefoundationfor
mechanicalerection.
Autolevel,
a Insertplatesonallthepiersasshownintheprotocol.
Totalstation,
b W/pmarkedoninsertplateatinlet&outlet. 1MillFitterand
1 Pianowire, 2days
c Referenceelevationmarkatinlet&outletoninsertplate 1Helper
Plumb,
d Centrelineofcooleratinletsideoutletsideaswellasonallpiers.
Fittertoolbox
Centrelineofdriveincludescentrelineofmaingearbox,mainmotor,auxiliarygear
e
box&auxiliarymotor.
f Allfoundationpocketsshouldbecleantillthedepth.
Afterprovidingalltheabovedetailsalltheconcerndepartmentshouldsignthe
g
protocol.
Themechanicalcontractorshouldnowstarttheerectionactivities.Thecontractor Totalstation,
shouldfirstmarkallthecentrelinesatinlet,outlet&onallthepiers.Theelevation 1MillFitter, Centrepunch,Hammer,
Angle50x50x6
2 markshouldbetransferredatallthedesiredlocations.Thecoolercenters,thesupport 1Helperand Markingthread, 2days
100meter
rollerbearingcentersthestraightdistance&thediagonalshouldbechecked& 1Welder Pianowire,
marked. 50mtape
Slopemeasuringblock,
Masterlevel(.02mm/
Groutingofpadplateof25mmthkonwhichpackingplatesandtaperwadgeswillrest
Padplates25mmthkas 1MillFitterand mtraccuracy),Chipping
3 shouldbedone.Thelevelofthepadplateshouldbecheckedinboththeaxis.Use 3days
required 2Helper chisel,Hammer,
masterlevel&taperblockof4%slopeforleveling.
Daimondcuttergrinding
wheel
AnnexureI
MaterialbyErection
Contractor
Aftercompletingthepadplategrouting,thefoundationisreadyforsupportrollerbase
frameerection.Withsuitablecrane,Winch,chainblockserectallthebaseframesat
theirdesiredposition.Ensuretheorientationofbaseframebeforeloweringonthe
packingplates.Alignallthebaseframes.Thealignmentchecksareasbelow(asper
approvedITP)
a Baseframecentrewithrespecttocoolercentre
Solidpackingplates Plumb,
b Straightdistanceofbaseframecentreofpier1frominletworkingpoint.
asrequired Pianowire,
c Inclineddistanceofbaseframefrompier1topier2.
(1mmto25mm), 50mtape,
d Inclineddistanceofbaseframefrompier2toworkingpointatoutlet.
stainlesssteelshims 1Millfitter, Springbalance20kg,
e Diagonalfrominletworkingpointtobaseframeatpier1. Machinetaper
ofthickness0.05mm, 1Fitter, Autolevelwith
f Diagonalsofbaseframeatpier1topier2. wedges8xperroller
4 0.1mm,0.25mm, 2Helper, measuringscale, 7days
g Diagonalofbaseframeatpier2toworkingpointatoutlet. stationbaseframe
0.5mmand1mm,Steel 2Rigger, Slopemeasuringblock,
h Elevationofallthebaseframes.
forlockingthebase 1Welder Masterlevel,
i Baseframeslopetobecheckedbymasterlevelbyusingtaperblock.
frame GrindingmachineAG4,
Aftercheckingalltheaboveaprotocolshouldbemaintained&shouldbesignedbyall
j (Channel,Beam,Pipe), Fillerguage,
theconcerndepartments.
GP2groutingmaterial Verniercalliper
k Afterallthechecksaredonethebaseframeshouldbetemporarylocked.
Ensurethefoundationboltsseating&theboltshouldremainverticalbeforereleasing
l forpocketgrouting.Theirshouldbeatleast4/5threadsabovethenutoffoundation
bolts.
Releasethefoundationforpocketgrouting.Propercuringshouldbedoneondaily
m
basis.Curingtimeshouldbe7days.
1Millfitter,
Torquetighteningofallthefoundationbolts.Anydifferenceobservedinelevation
1Fitter,
aftertoquetighteningmustbecorrected.Allthechecksmentionedinpointnumber4 Steelrod8mmthk, Suitablecapacitytorque
5 1Helper,
toberepeated&finalprotocoltobemade.Lockallthepackingplateswitheachother 100meters wrenchandsockets
1Rigger,
bysuitablesteelrod.
1Welder
Erectthesupportingrollerassemblyontothebaseframewithexactorientation& Crane,Winch,Chain
align.Duringalignmentcheckthefollowingpoints.(AsperapprovedITPandformats) block5tons,1''Sling,
Manilarope,Plumb,
a Rollercentrewithrespecttocoolercentre
Pianowire,50mtape,
b Floatingbearingcentretofixedbearingcentre
Autolevelwith
c Axialgapbetweenbearinghousingandbearingouterraceonfloatingside Molycot/Disel, 1Millfitter,
measuringscale,slope
d Dialreadingofbearings.[Axialalignment] Petrol, 1Fitter,
6 measuringblock,Master 6days
e Supportrollercentrewithbaseframecentre. Cleaningcolth, 2Rigger,
level,Grindingmachine
f Rollerslopetocheckedbymasterlevelbyusingtaperblock. Lubricant, 1Welder
AG4,Fillerguage,
g Torquetighteningofholdingdownbolts.
Vernier,Dialguage,
h Measurementofbearingclearances.
Torquewrench,Bearing
i Fillthebearingwithrequiredlubricant.
lockingspanner,Tool
j Makeaprotocolofalltheabovereadingsdulysignedbyalltheconcerndepartments. box
AnnexureI
MaterialbyErection
Contractor
Fabricationoftemporarystructureinside&outsidethebuildingforhandling,aligning
Plumb,50mtape,
&weldingofthecoolerdrum. Steelforstructure,
Grindingmachine
a Railtobefixedonthetopofstructureforslidingthecooler. Erectionsaddles, 1Fitter,6Rigger,2
7 AG4,Waterlevel,1''sling, 10days
Temperorysupport Welder,2Helper
ErectionsaddlesandTemporarysupportingrollerassemblyshouldbemadereadyfor chainblocks5,2tons,
b rollers,Rail150m
weldingofdryerdrum4nos. Manilarope100meters
Groundassemblyoftyreoncoolershell.Markthecentrelineoftyre&chairplateson
outletcoolerdrumfromtheedge.Placetheoutletcoolerdrumonatemporary Steelframe,Support
structurealongwithsaddle.Fixthechairplatesasperthepositionsmarked&tack roller,Scapfolding,
weldwithcoolerdrum.Insertthetyreontothedrum&slideittoitsrequiredposition. Gratings,Axialalignment Axialalignmentbrackets 6Rigger,2Helper, Crane,
8 2days
Fixthetyreretainingring&lockittemporarywithstoppers.Fixtheaxialalignment 1Millfitter,1Welder 1''sling
brackets,Wooden
bracketsalongwithjackbolt&weldittothedrum,Taketheairgapreadings&makea sleppers
protocol.
Keeptheoutletcoolerdrumalongwiththeassembledtyreonstructureoutsidethe Crane,10tonschain
8Rigger,1Welder,
9 building.Dragtheassemblyinsidethebuildingtillitreachestheworkingpoint.To block2nos,2''sling, 1day
1Millfitter
avoidsleepingoftheshelloppositesideholdingarrangementtobeprovided. Manilarope100mtr
Groundassemblyoftyreoncoolershell.Markthecentrelineoftyre&chairplateson
Steelframe,Support
inletcoolerdrumfromtheedge.Placetheinletcoolerdrumonatemporarystructure
roller,Scapfolding,
alongwithsaddle.Fixthechairplatesasperthepositionsmarked&tackweldwith 6Rigger,2Helper, Crane,
10 Gratings,Axialalignment Axialalignmentbrackets 2days
coolerdrum.Insertthetyreontothedrum&slideittoitsrequiredposition.Fixthe 1Millfitter,1Welder 1''sling
brackets,Wooden
tyreretainingring&lockittemporarystoppers.Fixtheaxialalignmentbracketsalong
sleppers
withjackbolt&weldittothedrum,Taketheairgapreadings&makeaprotocol.
Keeptheinletcoolerdrumalongwiththeassembledtyreonstructureoutsidethe Crane,10tonschain
8Rigger,1Welder,
11 building.Dragtheassemblyinsidethebuildingtillitreachestheoutletshell.Toavoid block2nos,2''sling, 1day
1Millfitter
sleepingoftheshelloppositesideholdingarrangementtobeprovided. Manilarope100mtr
Temperorysupport 8Rigger,1Welder,
12 Insertthetemperoroysupportrollers4setsbelowtheshell. 2days
rollerswithframe 1Millfitter,4Helper
1Fiter,1Helper,
13 Fix&weldtheerectonaidsinside&outsidethedrumoneveryjoint. Scaffolding,Gratings Shelljoiningbrackets 4days
2Welder
Alignthecompletecoolerwiththehelpoferectionaids&weldthelockplatesatevery 1MillFitter,2Welder,4 Pianowire,Steelscale,
14 Gratings Lockplates 7days
joint. Rigger,2Helper Fittertoolbox
Makethepointerarrangementfortakingthepolarreadings.Makeaalignment Steelforpointer 1Fitter,1Welder, Steelscale,
15 1day
protocol. alignment 1Helper Fittertoolbox
AnnexureI
MaterialbyErection
Contractor
Weldingofshelljoints.Followingproceduretobefollowedforwelding.
a Weldersshouldhavevalidcertificate.
b Weldersshouldgiveatestsample.
c Allweldingjointshouldstartatatime.
d Electrodesshouldbebakedinovenforatleastfor4hoursat300degreecentigrade.
Weldingelectrodes
Everyweldershouldcarryaportableovenhavingaheatingcapacityof100/120degree
e 7018,
centigrade. Agencyforweldtest
Weldingrectifier650
Dependingontheplatethicknessthejointshouldbepreheatedtorequired certify,
amps8nos.,
f temperaturebyheatingtorch.Preheatingshouldbedoneatleast3inchesonboth Testplates300X1502
Mainoven1no,
sidesofthejoint. no.foreachweld,
8Welders, portableoven8nos.,
16 g Stitchweldingshouldbedonebeforetheweldingstarts. 7018electrodes, 10days
6Helper thermochalkor
h Theoutsideweldingshouldbecarriedoutat3Gposition. Scapfolding,
pyrometer,
Tarpolineateveryjoint,
i Rootweldingshouldstartafterpreheatingtheshelltotherequiredtemperature. DPkit10nos.,
Ultrasonictesting
Heatingtorch8nos.,
j Aftercompletionofrootwelding,backgouging&grindingtobedone. agency
Grindingmachine
k CarryouttheDPtestofrootwelding.
AG7/58nos.
l AftercompletionofDPtestfillup&finalweldingtobedone.
m Duringfinalweldingcutalltheerectionaids&stiffeners&grindit.
n Backgougefrominside&grindit.
o CarryouttheDPtestfrominside.
p Completetheinsideweldingatflatposition.
q Carryouttheultrasonictest100%.
Makethepointerarrangementfortakingthepolarreadingsafterwelding.Makethe Steelforpointer 1Fitter,1Welder, Steelscale,
17 1day
protocol. alignment 1Helper Fittertoolbox
Afterultrasonictestlowerthecooleronmainsupportingrollers.Coolertobelowered 8Rigger,1MillFitter,
18 Fittertoolbox 2days
bydraggingthetemperorysupportrolleroutside. 1Welder,1Helper
1Millfitter,2Rigger,
19 Erectandpositionthethruster. Chainblocks5/2tons 2days
2Helper
Postioningoftyresshouldstartafterloweringthecooleronthemainsupportrollers. Weldingelectrodes
7018,Weldingrectifier
a Alignthetyreatpier1&2makeaprotocol.
650amps,Mainoven1
1Millfitter,1Fitter,4
b Checktheairgap&recordit. Scapfolding&gratings, no,Portableoven,
20 Axialalignmentbrackets Welder,2Helper, 7days
thermochalkor
2Rigger
pyrometer,Heating
Aligntheretainingringonbothsides[uphill&downhill]&weldthestoppers.Before torch10nos.,Dialguage,
c
weldingpreheatingofstoppersshouldbedone. Fillerguage
21 Fixandweldtheliftersatshellweldingjointandstiffenerpositions. 1Fitter,2Welder 3days

8Rigger,4Helper,
22 Removetheinsidetemporarysupportingstructure. 2days
2Welder
23 Shiftthegearbelowthecooler. 4Rigger,4Helper Chainblocks10tons 1day
AnnexureI
MaterialbyErection
Contractor
Assemblethebridgeplates,shims&prestressingshimswithgear.Torquetightened
theboltsofbridgeplates.
a Erectthebottomhalfofgirthgearalongwiththebridgeplateassembly.
b Arrangementforrotatingthecoolershouldbemade
Torquewrench,Winch
Rotatethecoolersuchthatthebottomhalfofgearshouldremainontop.Takecareof
c 10toncapacityfor
unbalancing.
1Millfitter,4Rigger, coolerrotating,Filler
24 d Erecttheotherhalfofgear Scaffolding,gratings Alignmentfixtures 10days
2Helper,4Welder guage,Dialguages3
e Checkthejointgap&ensureitiszerobycheckingwithfillergauge.
nos.,Main&potable
f Weldthealignmentfixturesoncooler[Axial&Radial]
oven,Heatingtorch
g AlignthegearAxial&radial&makeaprotocol.
h Weldtheuclampswiththecooler.Beforeweldingpreheattheshell.
i Afterweldingrecheckaxial&radialalignment&makeprotocol.
j Removetheprestressingshims&torquetightenedthebolts
Slopemeasuringblock,
Masterlevel(.02mm/
Groutingofpadplateof25mmthkonwhichpackingplatesandtaperwadgeswillrest
1MillFitterand mtraccuracy),Chipping
25 shouldbedoneondrivefoundation.Thelevelofthepadplateshouldbecheckedin Solidpackingplates 3days
2Helper chisel,Hammer,
boththeaxis.Usemasterlevel&taperblockof4%slopeforleveling.
Daimondcuttergrinding
wheel
Crane,Winch,Chain
26 Erectthedrivebaseframe. 2Rigger,2Helper block5tons, 1day
1''Sling,Manilarope
Assemblyofpinionbearingsonpinionshaft.
a Checktheshaft&bearingsurface.
b Fitadaptorsleevandbearingsontheshaft.
c Tightthelocknut. 1MillFitter,1Fitter, Fillerguage,Vernier,
27 Lubricant 2day
d Assemblethebearingonthepinionshaftmeasuretheclearances. 2Helper,1Welder Torquewrench
e Assembletheplummerblockanditssealingarrangement.
f Fixthecoupling.
g Fillthebearingwithrequiredlubricant.
AnnexureI
MaterialbyErection
Contractor
Erectthepinionshaftassemblyonthepinionbaseframe.
a Alignthepinionassemblywithgirthgear.Checkthefollowing.
b Checkthebacklash,rootclearance&contact
c Checkthepinioncentrewithrespecttocoolercentre
28
d Checkdistancebetweenfixedbearing&floatingbearing.
e Checkelevationofbaseframe.
f Checkslopeofbaseframe.
g Afterallthechecksaredonethebaseframeshouldbetemporarylocked.
Erectthemaingearbox Solidpackingplates Plumb,
a Fixtheinput&outputcouplings asrequired Pianowire,
b Alignthegearbox&checkthefollowing. (1mmto25mm), 50mtape,
c Maingearboxoutputshaftcentrewithrespecttopinionbearingcenters. stainlesssteelshims 1Millfitter, Springbalance20kg,
29
d Elevationofgearboxshouldbecheckedatall4corners. ofthickness0.05mm, 1Fitter, Autolevelwith
Machinetaper
e Couplingtocouplingstraight&diagonaldistance. 0.1mm,0.25mm, 2Helper, measuringscale, 15days
wedges12x
f Masterlevelofgearbox. 0.5mmand1mm,Steel 2Rigger, Slopemeasuringblock,
g Torquetighteningofgearboxholdingdownbolts. forlockingthebase 1Welder Masterlevel,
Erectthemainmotor frame GrindingmachineAG4,
a Radial&axialalignment. (Channel,Beam,Pipe), Fillerguage,
b Couplinggap. GP2groutingmaterial Verniercalliper
30
c Torquetighteningofmotorholdingdownbolts.
d Fixthecouplingonauxiliarygearbox&motor.
e Erect&aligntheauxiliarydrive&releaseitpocketgrouting.
Ensurethefoundationboltsseating&theboltshouldremainverticalbeforerealizing
31
forpocketgrouting.Theirshouldbeatleast4/5threadsabovethenut.
Releasethefoundationforpocketgrouting.Propercuringshouldbedoneondaily
32
bases.Curingtimeshouldbe7days.
AnnexureI
MaterialbyErection
Contractor
Aftercuringfulltightenedthefoundationbolts.Anydeviationobservedshouldbe
33
corrected.Alltheabovepointstoberechecked&readingsshouldberecorded.
34 Installthelubricationunit.Levelthelubricationunit&releaseitforgrouting. 1Fitter,2Helper Waterlevel 1day
35 Completethepipingbetweenlubricationunit&maingearbox. 1Fitter,2Helper Fittertoolbox 1day

36 Filltherecommendedoilinmaingearbox. Lubricant 2Rigger,2Helper 1day
1Fitter,4Rigger,
37 Install&alignthetyerandgearguard&fixitssupport Scapfolding,gratings Chainblock,Sling1'' 2days
1Welder
38 Propergap&sealingtobedonenearpinionshaft. 1Fitter,2Helper 1day
39 Installthelubricationunit&spraypanels. 1Fitter,2Helper Fittertoolbox 1day
Benchvice,
40 Completethepipingfromlubricationunittospraypanel. 1Fitter,2Helper 4days
Pipebender
a Erectthebottomhalfoftheinlethood
Plumb,Waterlevel,
b Erectthetophalfofinlethood 4Rigger,1Fitter,
41 1''sling,chainblocks 5days
c Installthesealingarrangementatinlet. 1Welder
5/2/1tons,Manilarope
d Alignthecompleteinlethopper&fixthesupports.
a Erectthebottomhalfoftheoutlethood
Plumb,Waterlevel,
b Erectthetophalfofoutlethood 4Rigger,1Fitter,
42 1''sling,chainblocks 5days
c Installthesealingarrangementatoutlet. 1Welder
5/2/1tons,Manilarope
d Alignthecompleteoutlethopper&fixthesupports.
Note
Allrequiredtools,tacklesandconsumables(likeelectrodes,oxygen,acetylene,grinding
1
wheels,oiletc.)requiredforerectionworktobesuppliedbyerectioncontractor.
SpecialtoolsandtackleswillbesuppliedbyTKIIasperlistmentionaboveinpointno.
2
2.a.ii.

b. Erection activities and sequence

Erection activities and sequence:

1. To begin with the cooler erection work the foundation of first & second pier should be
completed in all respect. A joint protocol should be maintained & signed by the civil
department from client side, the supplier & the erection contractor. The civil department
should give the following before handing over the foundation for mechanical erection.
a) Insert plates on all the piers as shown in the protocol.
b) W/p marked on insert plate at inlet & outlet.
c) Reference elevation mark at inlet & outlet on insert plate.
d) Centre line of cooler at inlet side outlet side as well as on all piers.
e) Centre line of drive includes centre line of main gear box, main motor, auxiliary gear box &
auxiliary motor.
f) All foundation pockets should be clean till the depth.
After providing all the above details all the concern department should sign the protocol.
2. The mechanical contractor should now start the erection activities. The contractor should
first mark all the centre lines at inlet, outlet & on all the piers. The elevation mark should
be transferred at all the desired locations. The cooler centers, the support roller bearing
centers the straight distance & the diagonal should be checked & marked. [Refer sketch
no.1]

[Sketch no. 1]

3. Grouting of pad plate of 25 mm thk on which packing plates and taper wedges will rest
should be done. The level of the pad plate should be checked in both the axis. Use master
level & taper block of 4 % slope for leveling.
4. After completing the pad plate grouting, the foundation is ready for support roller base
frame erection. With suitable crane, Winch, chain blocks erect all the base frames at their
desired position & elevation by giving solid placing plates & machine taper wedges.
Ensure the orientation of base frame before lowering on the packing plates. Align all the
base frames. The alignment checks are as below (as per approved ITP)
a) Base frame centre with respect to cooler centre
b) Straight distance of base frame centre of pier 1 from inlet working point.
c) Inclined distance of base frame from pier 1 to pier 2.
d) Incline distance of base frame 2 to working point at outlet.
e) Diagonal from inlet working point to base frame at pier 1.
f) Diagonals of base frame at pier1 to pier 2.
g) Diagonal of base frame 2 to working point at outlet
h) Elevation of all the base frames.
i) Base frame slope to be checked by master level by using taper block.
j) After checking all the above a protocol should be maintained & should be signed
by all the concern departments.
k) After all the checks are done the base frame should be temporary locked.
l) Ensure the foundation bolts seating & the bolt should remain vertical before
realizing for pocket grouting. There should be at least 4/5 threads above the nut.
m) Release the foundation for pocket grouting. Proper curing should be done on daily
bases. Curing time should be 7 days.
5. Torque tightening of all the foundation bolts. Any difference observed in elevation after
toque tightening must be corrected. All the checks mentioned in point number 4 to be
repeated & final protocol to be made. Lock all the packing plates with each other by
suitable steel rod.
6. Erect the supporting roller assembly on to the base frame with exact orientation & align.
During alignment check the following points. (As per approved ITP and formats)
a) Roller centre with respect to cooler centre
b) Floating bearing centre to fixed bearing centre
c) Axial gap between bearing housing & bearing outer race on floating side only.
d) Dial reading of bearings. [Axial alignment]

e) Support roller centre with base frame centre.

f) Roller slope to be checked by master level by using taper block.
g) Torque tightening of holding down bolts.
h) Measurement of bearing clearances.
i) Fill the bearing with required lubricant.
j) Make a protocol of all the above readings duly signed by all the concern
departments.
7. Fabrication of temporary structure inside & outside the building for handling, aligning &
welding of the cooler drum.
a) Inclined support structure of suitable height to be provided.
b) At every 2/ 3 meter a vertical support should be provided from the ground.
c) At every 2/3 meters side locking for the structure to be done.
d) Rail to be fixed on the top of structure for sliding the cooler.
e) Erection saddles and temporary supporting roller assembly should be made ready
for welding of cooler drum 4 nos.
8. Ground assembly of tyre on cooler shell. Mark the centre line of tyre & chair plates on
outlet cooler drum from the edge. Place the outlet cooler drum on a temporary structure
(Tyre erection base frame for ground assembly TKII Drawing No. FRT-RD-00303-2/0)
along with saddle. Fix the chair plates as per the positions marked & tack weld with cooler
drum. Insert the tyre on to the drum & slide it to its required position. Fix the tyre retaining
ring & lock it temporary with stoppers. Fix the axial alignment brackets along with jack bolt
& weld it to the drum. Take the air gap readings & make a protocol.
9. Keep the outlet cooler drum along with the assembled tyre and erection saddles (TKII
Drawing No. FRT-RD-00306-3/0) on structure outside the building. Fix the two chain block
on both the sides of shell 180 degrees apart along the slope of the shell and one opposite
side. Release the shell with these two chain blocks and tight the other side chain block.
Slide the assembly inside the building till it reaches the working point. Temporary lock the
shell from both the sides by sling to avoid tilting of shell.
10. Ground assembly of tyre on cooler shell. Mark the centre line of tyre & chair plates on inlet
cooler drum from the edge. Place the inlet cooler drum on a temporary structure along
with saddle. Fix the chair plates as per the positions marked & tack weld with cooler drum.
Insert the tyre on to the drum & slide it to its required position. Fix the tyre retaining ring &
lock it temporary stoppers. Fix the axial alignment brackets along with jack bolt & weld it
to the drum, Take the air gap readings & make a protocol.

11. Keep the inlet cooler drum along with the assembled tyre on structure outside the
building. Slide the assembly inside the building till it reaches the middle shell. Repeat the
above procedure.
12. Insert the temporary support rollers (TKII Drawing No. FRT-RD-00301-1/0) 4 sets below
the shell. ( 2nos.below each drum shell)
13. Fix & weld the erection aids inside & outside the drum on every joint.
14. Align the complete cooler with the help of erection aids & weld the lock plates at every
joint.
15. Make the pointer arrangement for taking the polar readings. Make an alignment protocol.
16. Welding of shell joints. Following procedure to be followed for welding.
a. Welders should have valid certificate.
b. Welders should give a test sample.
c. All welding joint should start at a time.
d. Electrodes should be baked in oven for at least for 4 hours at 300 degree
centigrade.
e. Every welder should carry a portable oven having a heating capacity of 100/120
degree centigrade.
f. Depending on the plate thickness the joint should be pre-heated to required
temperature by heating torch. Preheating should be done at least 3 inches on
both sides of the joint.
g. Stitch welding should be done before the welding starts.
h. The outside welding should be carried out at 3G position.
i. Root welding should start after preheating the shell to the required temperature.
j. After completion of root welding, back gouging & grinding to be done.
k. Carry out the DP test of root welding.
l. After completion of DP test fill up & final welding to be done.
m. During final welding cut all the erection aids & stiffeners & grind it.
n. Back gouge from inside & grind it.
o. Carry out the DP test from inside.
p. Complete the inside welding at flat position.
q. Carry out the ultrasonic test 100%.
17. Make the pointer arrangement for taking the polar readings after welding. Make the
protocol.

18. After ultrasonic test lower the cooler on main supporting rollers. Cooler to be lowered by
dragging the temporary support roller outside.
19. Erect & position the thruster.
20. Positioning of tyres should start after lowering the cooler on the main support rollers.
a. Align the tyre at pier 1 & 2 make a protocol.
b. Check the air gap & record it.
c. Align the retaining ring on both sides [uphill & downhill] & weld the stoppers.
Before welding, preheating of stoppers should be done.
21. Fix and weld the lifters at shell welding joint and spider positions.
22. Remove the inside temporary supporting structure.
23. Shift the gear below the cooler.
24. Assemble the bridge plates, shims & pre stressing shims with gear. Torque tightened the
bolts of bridge plates.
a. Erect the bottom half of girth gear along with the bridge plate assembly.
b. Arrangement for rotating the cooler should be made.
c. Rotate the cooler such that the bottom half of gear should remain on top. Take
care of unbalancing.
d. Erect the other half of gear.
e. Check the joint gap & ensure it is zero by checking with filler gauge.
f. Weld the alignment fixtures on cooler [Axial & Radial]
g. Align the gear Axial & radial & make a protocol.
h. Weld the u clamps with the cooler. Before welding pre heat the shell.
i. After welding recheck axial & radial alignment & make protocol.
j. Remove the pre stressing shims & torque tightened the bolts.
25. Grouting of pad plate of 25 mm thk on which packing plates and taper wedges will rest
should be done on drive foundation. The level of the pad plate should be checked in both
the axis. Use master level & taper block of 4 % slope for leveling.
26. Erect the drive base frame.
27. Assembly of pinion bearings on pinion shaft.
a. Check the shaft & bearing surface.
b. Fit adaptor sleeve and bearings on the shaft.
c. Tight the lock nut.
d. Assemble the bearing on the pinion shaft measure the clearances.
e. Assemble the plummer block and its sealing arrangement.

f. Fix the coupling.

g. Fill the bearing with required lubricant.
28. Erect the pinion shaft assembly on the pinion base frame.
a. Align the pinion assembly with girth gear. Check the following.
b. Check the backlash, root clearance & contact
c. Check the pinion centre with respect to cooler centre
d. Check distance between fixed bearing & floating bearing.
e. Check elevation of base frame.
f. Check slope of base frame.
g. After all the checks are done the base frame should be temporary locked.
29. Erect the main gear box.
a. Fix the input & output couplings.
b. Align the gear box & check the following.
c. Main gear box output shaft centre with respect to pinion bearing centers.
d. Elevation of gear box should be checked at all 4 corners.
e. Coupling to coupling straight & diagonal distance.
f. Master level of gear box.
g. Torque tightening of gear box holding down bolts.
30. Erect the main motor.
a. Radial & axial alignment.
b. Coupling gap.
c. Torque tightening of motor holding down bolts.
d. Fix the coupling on auxiliary gear box & motor.
e. Erect & align the auxiliary drive & release it pocket grouting.
31. Ensure the foundation bolts seating & the bolt should remain vertical before realizing for
pocket grouting. There should be at least 4/5 threads above the nut.
32. Release the foundation for pocket grouting. Proper curing should be done on daily bases.
Curing time should be 7 days.
33. After curing full tightened the foundation bolts. Any deviation observed should be
corrected. All the above points to be rechecked & readings should be recorded.
34. Install the lubrication unit. Level the lubrication unit & release it for grouting.
35. Complete the piping between lubrication unit & main gear box.
36. Fill the recommended oil in main gear box.
37. Install & align the gear guard & fix its support.

38. Proper gap & sealing to be done near pinion shaft.

39. Install the lubrication unit & spray panels.
40. Complete the piping from lubrication unit to spray panel.
41. Erect the feed hopper.
a. Erect the bottom half of the inlet hood.
b. Erect the top half of inlet hood.
c. Install the sealing arrangement at inlet.
d. Align the complete feed hopper & fix the supports.
42. Erect the discharge hopper.
a. Erect the bottom half of the discharge hood.
b. Erect the top half of discharge hood.
c. Install the sealing arrangement at discharge.
d. Align the complete discharge hopper & fix the supports.

3. Erection schedule for cooler


a. Protocols & ITP

Protocols & ITP:

1. List of Protocols:
a) KN.01en Vs02_Drum_Shell_Section_Lengths
b) KN.03en Vs02_Supporting_Rollers (Alignment)
c) KN.05en Vs01, Vs04_Axial_eccentricity_of_tyre
d) KN.06en Vs00_Contact_Situation_at_Rollers
e) KN.07en Vs02_Concentricity_drum_cylinder
f) KN.08en Vs03_Girth_Gear
g) KN.12en Vs01_Tyre_Shim_Plates
h) KN.20en Vs01 Measurement record for 2-support rotary drum
i) TM.03en Vs01_Meshing_-_Temperature
2. ITP:
For commented site ITP, please refer annexure II.

a) Protocol- KN.01en Vs02_Drum_Shell_Section_Lengths


b) Protocol- KN.03en Vs02_Supporting_Rollers (Alignment)


c) Protocol- KN.05en Vs01, Vs04_Axial_eccentricity_of_tyre



d) Protocol- KN.06en Vs00_Contact_Situation_at_Rollers


e) Protocol- KN.07en Vs02_Concentricity_drum_cylinder


f) Protocol- KN.08en Vs03_Girth_Gear







g) Protocol- KN.12en Vs01_Tyre_Shim_Plates



h) Protocol- KN.20en Vs01 Measurement record for 2-support rotary drum












i) Protocol- TM.03en Vs01_Meshing_-_Temperature


2. ITP
For Site ITP, refer annexure II
Erection Manual For Cooler

CLIENT LOGO CONTRACTOR LOGO
Annexure II
CONTRACT NO DOCUMENT NO
STANDARD ITP FOR ROTARY DRUM ERECTION
NNNN PIN LEP-CQA-002-A204
Responsibilities
Sl. no. Activity Description Check / Inspection Acceptance Criteria Verifying Records Remarks
Contractor TKIS-India TKII PMC / Client
1 PRE ERECTION ACTIVITIES
Review with drawings / Packing list /

As per approved drawings. No records P W NA R
Name plate
1.1 Equipment on receipt at site
Match / erection marks. As per approved drawings No records P W NA -
Verify the signed foundation handing

KN.20en Vs01 Measurement
over protocol for dimensions / level / As per approved drawings / equipment
1.2 Take over of foundation record for 2-support rotary P W W RAN
centre line co-ordinates / number and layout / orientation drawing / template.
drum
size of pockets / foundation bolts.
Chipping & grouting of packing plate on

foundation for erection of equipment.
As per approved drawings / equipment
1.3 Preparation of foundation Marking of centre line on foundation, No records P W W RAN
layout / orientation drawing / template.
No./dia/length of anchor bolts,depth of
pocket,verticality of pockets.
Manufacturer's test certificate / Calibration

Calibration of testing & measuring
1.4 Range/ suitability/validity certificates from TKIS, India recognised Test certificates P H NA R
instruments.
laboratories
Preparation of erection scheme,

adequacy of erection space for Feasibility/safety considering plot plan,
1.5 receiving / erection of equipment, equipment layout, erection data sheet Feasible and safe erection scheme Approved erection scheme P H NA R
placement of main / trailing cranes and load chart. Physically check the area.
etc.
Fitness certificate & load chart and

Scrutiny of crane documents including
Adequacy of crane capacity, lifting validity. appropriate derating commensurate with Crane documents P W NA R
1.6 beam / slings / shakles / wire rpoes the age of the crane / safety factor.
etc,
General appearance No external damage. No records
P R NA R
Trial load test, if required. Passing the load test Test Certificate
Improvements made, if required, as per

As per soil investigation report. Soil reports P R NA R
Soil investigation report
Strengthening of soil at erection front,
1.7
if required Trial loading using moving loads, if No soil settlement noticed with visual
Approved Erection scheme P RAN NA RAN
required. inspection.
Page 1 of 10
Annexure II
Responsibilities
2 INSTALLATION
Base Frame of Supporting rollers

2.1
(Before Pocket Grouting)

100% dimensional checking. Measurement
2.11 Elevation record for 2-support rotary P W W R
within + / -1 mm
drum
100% dimensional checking. (Measured by KN.20en Vs01 Measurement

2.12 Centre Distance applying spring balance tension) record for 2-support rotary P W W R
Measurement within +/-2 mm drum

2.13 Diagonal Distance applying spring balance tension) record for 2-support rotary P W W R

100% checking by taper block / auto level.
2.14 Baseframe Slope record for 2-support rotary P W W R
Levelling accuracy of 0.1 mm/ mtr.
drum
Levelling of base frames across the drum 100% checking by auto level. Levelling
2.15 PIN LI-CQA-204-F-02 P W W R
centreline. accuracy of 0.1 mm/ mtr.
As above from sr. no. 2.11 to

Completed initial alignment (as above
As above from sr. no. 2.11 to 2.15 2.16 and pocket grouting P H W R
from sr. no. 2.11 to 2.15)
clearance in writing
Pocket Grouting of Foundation
2.2
Bolts
Cleanliness of the pockets and type of
As per drawing and specification PIN LI-CQA-100-F-13 P W W RAN
grout material
Base Frame of Supporting rollers

2.3
(After Pocket Grouting)

2.31 Elevation record for 2-support rotary P W W W
within + / -1 mm
drum

2.32 Centre Distance applying spring balance tension) record for 2-support rotary P W W W
Page 2 of 10
Annexure II
Responsibilities

2.33 Diagonal Distance applying spring balance tension) record for 2-support rotary P W W W

2.34 Baseframe Slope record for 2-support rotary P W W W
drum
Levelling of base frames across the drum 100% checking by auto level. Levelling
2.35 PIN LI-CQA-204-F-02 P W W W
2.36 Tightnesss of Foundation Bolts 100% Hammer tight No records P W W W
2.37 Tightness of Packing Plate 100% Hammer tight No records P W W W
2.4 Support Rollers
KN.03en
2.41 Elevation Vs02_Supporting_Rollers P W W W
within +/-1 mm
(Alignment)
KN.03en
Centre to centre distance between rollers 100% dimensional checking. Measurement
2.42 Vs02_Supporting_Rollers P W W W
at same pier (Both uphill and downhill) within +/-0.5 mm
(Alignment)
2.43 Diagonal between rollers at same pier PIN LI-CQA-204-F-03 P W NA W
within +/-1 mm

2.44 Roller slope PIN LI-CQA-204-F-04 P W W W
2.5 Thrust Roller Assly.
Centre to centre distance from nearest 100% dimensional checking. Measurement

support rollers frame within +/- 1 mm.
2.52 Slope PIN LI-CQA-204-F-04 P W W R
Levelling of thrust roller across the drum 100% checking by auto level. Levelling
Lowering of drum on support
2.6 As above As above Clearance in writing P H W R
rollers
2.7 Drum Erection
2.71 Shell Checking (Before positioning) Orientation As per approved drawing P W W RAN
Page 3 of 10
Annexure II
Responsibilities
Dimensional check (Diameter) at 8 - 12
places at shell ends. Measurement within +/-
KN.07en
3.7 mm for dryer
Concentricity Vs02_Concentricity_drum_cy P W W RAN
+/- 3.0 mm for cooler
linder
+/- 3.3 mm for granulator
+/- 2.2 mm for coater
Weld Joint checking / Preparation As per approved drawing PIN LI-CQA-202-F-04 P W W RAN
Page 4 of 10
Annexure II
Responsibilities
KN.01en
Longitudinal measurement. Acceptable
Overall Dimension Vs02_drum_Shell_Section_L P W W RAN
tolerance +/- 5 mm.
engths
2.72 Shell Fit up Joint Gap Asper drawing PIN LI-CQA-202-F-04 P W W RAN
Filler gauge measurement. Tolerance 1.5

Joint mismatch PIN LI-CQA-202-F-04 P W W RAN
mm.
+/- 3.7 mm for dryer
KN.07en
Radial run out at 8-12 positions at each +/- 3.0 mm for cooler
Vs02_Concentricity_drum_cy P W W RAN
joint +/- 3.3 mm for granulator
linder
PIN LI-CQA-202-F-05
Shell Flange runout (Radial & axial) +/- 2.5 mm P W W RAN
PIN LI-CQA-202-F-06
2.73 Shell Welding Clearance As above As above PIN LI-CQA-202-F-04 P H W R
2.74 Shell Welding
PIN LI-CQA-213-F-01
Establishment of WPS/PQR Approval of WPS/PQR ASME Sec IX - latest edition. P H NA R
PIN LI-CQA-213-F-02
Check welders certification and witness ASME Sec IX - latest edition. / approved
Welder Qualification PIN LI-CQA-213-F-03 P H NA R
tests WPS/PQR
ASME Sec IIC - latest edition. Approved

Consumables. Conformity to specification & validity. PIN LI-CMM-01-F-01 P R NA R
WPS and manufacturer's test certificates.
Shell Joint NDT 100% DPT after back chipping ASME section VIII PIN LI-CQA-214-F-01 P R NA R
Radiography of 100% T-Joint and 20% of

No defects PIN LI-CQA-216-F-01 P R NA R
circumferential seam.
2.8 Tyre
Measured at 8 - 12 axial positions (equally

distant) on each tyre. Runout within
KN.05en Vs01,
2.81 Axial Runout Vs04_Axial_eccentricity_of_t P W W R
yre
100% dimensional checking as per

2.82 Retainer Block Fixing Inspection Format P W W R
approved drawing. Tolerance +/- 1 mm.
Page 5 of 10
Annexure II
Responsibilities
2.83 Retainer Block Welding Visual inspection as per ASME section VIII Inspection Report P W NA R
Page 6 of 10
Annexure II
Responsibilities
KN.06en
Tyre / Roller Contact 80 % Contact by visual inspection Vs00_Contact_Situation_at_ P W W RAN
Rollers
2.9 Drive Assembly
2.91 Girth Gear erection (Spring Mounted)
2.911 Spring plate
a Orientation 100% visual inspection as per drawing. No records P W W RAN
b Torque tightening of bolts Torque value as per drawing Torque Tighteneing Record P RAN W R
2.912 Girth Gear
a Gear Fit up As per assembly drawing No records P W W R
b Gear Joint Gap Within 0.05 mm No records P W W R
Axial run out -

KN.08en Vs03_Girth_Gear -
c Gear Axial and Radial Run Out for dryer and cooler P W W R
Radial run out -
d Torque Tightening of Gear Joining Bolts Torque value as per drawing Torque Tighteneing Record P RAN W R
2.92 Girth Gear Erection (Flange Mounted)
Axial run out -

Gear Joining Flange Axial & Radial Run +/- 0.2 mm for coater
a As per drawing P W R
Out Radial run out -
b Gear Fit up As per assembly drawing No records P W W R
Page 7 of 10
Annexure II
Responsibilities
c Gear Joint Gap Within 0.05 mm No records P W W R
Axial run out -

+/- 0.13 mm for coater TM.10en Vs04_Girth gear -
d Gear Axial and Radial Run Out P W W R
Radial run out - for granulator and coater
e Torque Tightening of Gear Joining Bolts Torque Value as per drawing Torque Tighteneing Record P RAN W R
2.93 Pinion Erection
Pinion Base Frame (Before Pocket

2.931
Grouting)
100% dimensional checking. Measurement PIN LI-CQA-204-F-10

a Elevation P W W R
within +/-4 mm
100% dimensional checking. (Measured by

PIN LI-CQA-204-F-10
b Centre Distance applying spring balance P W W R
tension)Measurement within +/-2 mm
100% checking by taper block / auto level. PIN LI-CQA-204-F-10
c Baseframe Slope P W W R
Levelling of base frames across the drum 100% checking by auto level. Levelling PIN LI-CQA-204-F-10
d P W W R
As above from sr. no. 2.931

Completed initial alignment (as above
As above from sr. no. 2.931 a,b,c,d a,b,c,d and pocket grouting P H NA R
from sr. no. 2.931 a,b,c and d.)
Pocket Grouting of Foundation clearance in writing
2.932
Bolts
Cleanliness of the pockets and type of
As per drawing and specification PIN LI-CQA-100-F-13 P W NA RAN
grout material
Pinion Base Frame (After Pocket

2.933
Grouting)
100% dimensional checking. Measurement PIN LI-CQA-204-F-10

a Elevation P W W W
within +/-2 mm
100% dimensional checking. (Measured by

PIN LI-CQA-204-F-10
b Centre Distance applying spring balance P W W W
tension)Measurement within +/-1 mm
100% checking by taper block / auto level. PIN LI-CQA-204-F-10
c Baseframe Slope P W W W
Page 8 of 10
Annexure II
Responsibilities
Levelling of base frames across the drum 100% checking by auto level. Levelling PIN LI-CQA-204-F-10
d P W W W
e Tightnesss of Foundation Bolts 100% Hammer tight No records P W W W
f Tightness of Packing Plate 100% Hammer tight No records P W W W
2.934 Pinion Alignment
As per drawing. Measured at 8 - 12 for dryer and cooler
a Root Clearance and Backlash P W W R
locations TM.10en Vs04_Girth gear -
for granulator and coater
for dryer and cooler
b Contact with Gear Blue matching with 70-80% contact. P W W R
TM.10en Vs04_Girth gear -
for granulator and coater
c Free End Bearing Float 6 mm or as per drawing P W W R

PIN LI-CQA-204-F-11
As per drawing / recommended by bearing

Bearing - Radial Clearance P W W R
manufacturer PIN LI-CQA-204-F-11
Pinion Teeth Temperature (During pre +/- 2 degrees celsius across entire tooth TM.03en Vs01_Meshing_-
P W W R
commissioning trial run) flank. _Temperature
Main Gear box, Auxiliary Gear Box

2.94
and Motor
PIN LI-CQA-204-F-10
a Base Frame As per pinion base frame P W W R
As per supplier manual or 0.1 mm for axial PIN LI-CQA-204-F-14

b Coupling Alignment Axial and Radial Alignment P W W R
0.15 mm for radial. PIN LI-CQA-204-F-15
2.95 Gear Hood As per Drawing No records P RAN W R
Completed final alignment (as above sr. As above. Sr. no. 2 and final
As above (sr. no. 2) P H NA R
no. 2) grouting clearance in writing
Full Grouting of base plates and
3
foundation bolts
Cleanliness of foundations and type of
As per drawing and specification PIN LI-CQA-100-F-13 P W NA RAN
grout material
Page 9 of 10
Annexure II
Responsibilities
4 QC documents Check completeness & correctness As per drawing and specification QC dossier P H NA R
Legend:
P - Perform
H - Hold point ( further sequential work shall commence only after clearance from TKIS-India/TPI/PMC/Client - as applicable)
R - Review & approve
RAN - Random witness
W - Witness & approve
Page 10 of 10
b. WPS









c. Consumables specification with estimated qty
- Electrode : E7018
- Approx. qty: 300 Kgs

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4lant Client Contract Code Contract No.

Erection Manual Cooler Drum

CLIENT :PETROVIETNAM FERTILIZERS AND CHEMICAL CORPORATION,VIETNAM (PVFCCo)

14.06.16. ATH / SVH

00 For Information 10-06-16 PSA 10-06-16 ASM 10-06-16 SRH 4

Project: NPK Plant Project, Vietnam

TKIS PO NO: 38010823 DTD. 29-10-2015

TKII Work Order No.: 3M0049

Erection Manual For Cooler Page 1 of 79

Erection Manual For Cooler Page 2 of 79

1. Introduction and Pre-Requisites before actual Mechanical Erection

Erection Manual For Cooler Page 3 of 79

Dispatchable unit1 Dispatchable unit2

Erection Manual For Cooler Page 4 of 79

Bearing Type : Roller bearing

Cooler Drum Inlet Chute

Cooler Drum Outlet Chute

Girth Gear Lubrication System

Erection Manual For Cooler Page 5 of 79

1. Introduction and Pre-Requisites before actual Mechanical Erection

Erection Manual For Cooler Page 6 of 79

Safety Recommendations related to work:

Erection Manual For Cooler Page 7 of 79

1. Introduction and Pre-Requisites before actual Mechanical Erection

Erection Manual For Cooler Page 8 of 79

Please refer below sketches / drawings for transportation of ODC consignment.

Erection Manual For Cooler Page 9 of 79

Erection Manual For Cooler Page 10 of 79

Please refer below sketch for unloading of drum shells.

Erection Manual For Cooler Page 11 of 79

STORAGE AND PRESERVATION DETAILS

Open storage Heavy Fabricated Materials / Voluminous Cargo:-

Erection Manual For Cooler Page 12 of 79

1. Introduction and Pre-Requisites before actual Mechanical Erection

Erection Manual For Cooler Page 13 of 79

Handing over the foundation:

Erection Manual For Cooler Page 14 of 79

2. Mechanical Erection Instructions for Cooler

Erection Manual For Cooler Page 15 of 79

Reference Documents / Drawings for Mechanical Erection Instructions for Cooler

Erection Manual For Cooler Page 16 of 79

2. Mechanical Erection Instructions for Cooler

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List and Details of Tools and Tackles - with scope

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Erection Manual For Cooler Page 19 of 79

2. Mechanical Erection Instructions for Cooler

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2. Mechanical Erection Instructions for Cooler

Erection Manual For Cooler Page 21 of 79

21 Fixandweldtheliftersatshellweldingjointandstiffenerpositions. 1Fitter,2Welder 3days

34 Installthelubricationunit.Levelthelubricationunit&releaseitforgrouting. 1Fitter,2Helper Waterlevel 1day

35 Completethepipingbetweenlubricationunit&maingearbox. 1Fitter,2Helper Fittertoolbox 1day

2. Mechanical Erection Instructions for Cooler

Erection Manual For Cooler Page 22 of 79

Erection activities and sequence:

Erection Manual For Cooler Page 23 of 79

Erection Manual For Cooler Page 24 of 79

Erection Manual For Cooler Page 25 of 79

e) Support roller centre with base frame centre.

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Erection Manual For Cooler Page 27 of 79

Erection Manual For Cooler Page 28 of 79