Project:

LEPCL 660MW CFPP, Karachi

COTRACTOR: SEPCOIII ELECTRIC OWNER: LUCKY ELECTRIC CONSULTANT: FICHTNER GMBH &
POWER CONSTRUCTION CO., LTD. POWER COMPANY LIMITED CO KG

Doc No. LEPCL-10-HTZ-MQB-200018-G01-A

Rev: A Total Pages 15

Title:

METHOD STATEMENT FOR FGD SYSTEM ERECTION

Compiled by Reviewed by(QA/QC, HSE, Engineering)

Name
Prepared by
SEPCOIII Signature

Date

Name Signature Date

Approved by
SEPCOIII

Approved by
Consultant
 Modification Record

Version Date Section Page Modification and basis

 Catalogue
1. References .....................................................................................................................................1
2. Purpose...........................................................................................................................................1
4. Scope ..............................................................................................................................................4
5. Responsibility .................................................................................................................................4
6. Manpower and Resource .............................................................................................................6
7. Methodology...................................................................................................................................7
8. Quality Control .............................................................................................................................13
9. Safety and Environment .............................................................................................................13
10. Attachment .................................................................................................................................15
METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A

1. References
1.1 American National Standard Institute (ANSI)
1.2 American Society of Mechanical Engineers（ASME）
1.3 American Society for Testing and Materials（ASTM）
1.4 Welded Steel Tanks for Oil Tanks （API 650）
1.5 Venting Atmospheric & Low Pressure Tanks （API STD 2000）
1.6 American Welding Society （AWS D1.1）
1.7 Approved construction documents, specifications and drawings
2. Purpose
The purpose of this method statement is to direct the future erection and control the construction process and
quality effectively of the equipment and pipeline erection of FGD system in order to ensure the project
completion on schedule with good quality.
This purpose shall be achieved by adhering to the following principles:
a. Always use approved specifications, drawings, documents, etc.
b. Always use qualified procedures and control processes.
c. Only trained, qualified & certified personnel can carry out work.
d. Always use equipment and instruments with valid calibration.
e. Never use damaged materials or tools; never use expired or spoiled consumables, and never use
malfunctioning equipment
f. Ensure performing all tests, measurements and inspections required.
g. Ensure that the type, capacity, and functionality of the tools and equipment are suitable for the work to be
performed.
h. Always use necessary personnel protective equipment, construction site barricade, and signage and safety
boards.
3. Project Profile
One FGD (Flue gas desulphurization) system is set to treat gases. One absorber is set up for boiler. Wet
limestone-gypsum flue gas desulphurization will be adopted including limestone slurry preparation system,
flue gas system, SO2 absorption system, venting system, gypsum dewatering system, process water system,
cooling water system, compressed air system and waste water system. There is no pressurized air fan for the
system and the air resistance will be overcome by ID fan only. The limestone will be purchased and
transported by truck. The waste water system is arranged inside the FGD island. The waste water from waste
water tank will be treated and discharged. Two sets of gypsum cyclone and two sets of vacuum belt
dewatering machine are designed for gypsum dewatering system. The gypsum will be transported and stored
in gypsum silo. The main equipment and pipeline shown as followed:
S/N Item Name Model and Specification Unit Quantity
一 Limestone slurry preparation system
Limestone unloading
1 Specification: 4.0m×4.0m×3m,Steel structure with steel Set 2
hopper grating
Limestone unloading Type: pulse ash cleaning, dust emission concentration:
2 Set 2
room dust remover ≤30mg/Nm³, Dust removal area: 168m2, Dust removal air

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A

flow rate: 20000m³/h, Motor power:22kW

3 Limestone unloading
Q=101t/h, N=2×0.55kW, L=2.2m Set 2
vibration feeder
4 Metal separator N=5.5kW Set 2
5 Limestone crusher Q=101t/h Set 2
Limestone bucket
6 Q=101t/h, Length:57m Set 2
elevator
type: pulse ash cleaning; dust emission
7 Limestone storage silo
concentration:≤30mg/Nm³; dust removal area:36m2;Dust Set 1
dust remover
removal air flow rate:3000m³/h ;motor power:5.5kW
8 Limestone weight belt Q=60t/h, L=12m( distance between inlet centerline and
Set 2
conveyer outlet centerline), N=5.5kW
9 Wet ball mill horizontal, Output: 49t/h, Motor power: 1600kW, lubrication
Set 2
oil pump motor power:3kW, electrical heater power: 3×4kW
10 Mill slurry circulation Specification: Φ3.4m×3.2m
Set 2
tank Material: carbon steel lined with glass flake
11 Mill slurry circulation type: Top-mounted agitator, N=5.5kW
Set 2
tank agitator shaft and blade Material: carbon steel lined with rubber
12 Mill slurry circulation
Type: centrifugal, Q=400m3/h, H=40m, N=110kW Set 4
pump
13 Limestone slurry Flow rate: 333m3/h, Cyclone material: polyurethane,
Set 2
hydro-cyclone including one spare cyclone
14 Specification: Φ10.m×12.0m, material: carbon steel lined
Limestone slurry tank Set 2
with glass flake
type: side-entering, N=18.5kW
15 Limestone slurry tank
material: blade and shaft: Super duplex stainless steel or Set 6
agitator
equivalent
16 Limestone slurry pump centrifugal type, Q=189m3/h, P=35m, N=55kW Set 2
二 SO2 absorption system
Spray tower, Φ21.7m（the diameter of absorption area is
1 Absorber 18.5m）×50.7m(H), the volume of reaction slurry tank is Set 1
4949m3,the height of reaction slurry tank is 13.8m. material:
carbon steel & Rubber lining
Absorber spraying
2 material: FRP Set 5
layer pipelines
Absorber spraying
3 Hollow cone spray, material: SiC Set 1
nozzles
4 Mist Eliminator Two stage, ridge type, Φ18.5m. material: PP Set 1
Absorber circulation
5 material:2.4605, DN1500 Set 5
pump inlet filter
Horizontal centrifugal pump, Q=16800m3/h,
P=20.3 m /22.3 m H /24.3 m /26.3 m /28.3m,
Absorber circulation
6 N=1400kW/1600kW/1800kW/1800kW/2000kW, Set 5
pump
Impeller Material: Wear-resistant Ceramics,
Pump Shell Material: Lining Wear-resistant Ceramics
Absorber pulse
7 Centrifugal type Q=3750m3/h， P=25m，N=450kW Set 2
suspension pump
Absorber pulse
8 DN800, FRP Set 1
suspension pipelines
9 Oxidation air blower Centrifugal type, Q=20100Nm3/h, △P=103kPa, N＝800kW Set 4
Absorber oxidation
10 DN300(6 pcs), DN250(2pcs), material:2.4605 Set 1
distribution pipelines
11 Absorber bleed pump Centrifugal type, Q=400m3/h, P=52mH, N=132kW. Set 2
三 Emergency slurry discharge system
Specification: Φ19m ×19m(H),material: carbon steel &
1 Emergency slurry tank Set 1
Glass flake resin lining
Emergency slurry tank
2 Centrifugal type, Q=3000m3/h, P=24m, N=355kW Set 2
pulse suspension

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A

pump
Emergency slurry tank
3 pulse suspension DN700, material: FRP Set 1
pipelines
Emergency slurry
4 Centrifugal type, Q=500m3/h, P=25mH, N=75kW Set 1
pump
Absorber area drain pit Centrifugal type with self-priming tank, Q=80m3/h, P=35mH,
5 Set 2
pump N=22kW
Absorber area drain pit Top-mounted, N=4kW, material: carbon steel & Rubber
6 Set 1
agitator lining
Limestone slurry
Centrifugal type with self-priming tank, Q=40m3/h, P=30m,
7 preparation area drain Set 2
N=15kW
pit pump
Absorber area drain pit Top-mounted, N=4kW, material :carbon steel & Rubber
8 Set 1
agitator lining
Gypsum dewatering Centrifugal type with self-priming tank, Q=40m3/h, P=20m,
9 Set 2
area drain pit pump N=11kW
Gypsum dewatering Top-mounted, N=4kW, material: carbon steel & Rubber
10 Set 1
area drain pit agitator lining
Limestone unloading
11 type： Mobile sewage pump, Q=10m3/h, P=25m, N=5.5kW Set 1
area drain pit pump
四 Gypsum dewatering system
Gypsum
1 Q=370m3/h(inlet), one cyclone standby online Set 2
hydro-cyclone
2 Vacuum belt filter Q=79.8t/h(containing 10％ moisture) Set 2
3 Water ring vacuum pump, Q=25200m3/h,
Vacuum pump Set 2
-30~-60kPa,N=400kW
4 Filtrate receiving tank material: carbon steel & Rubber lining Set 2
5 Filter cloth flushing
Specification：Φ2m ×2.5m(H), material: carbon steel Set 1
water tank
6 Filter cloth flushing
Centrifugal type, Q=36m3/h, P=75m, N=22kW Set 2
water pump
7 Specification：Φ6m ×7.5m(H),material: carbon steel &
Filtrate water tank Set 1
Glass flake resin lining.
8 Filtrate water tank Top-mounted, N=7.5kW, material: carbon steel & Rubber
Set 1
agitator lining
9 Filtrate water pump Centrifugal type, Q=407m3/h, P=35mH, N=90kW Set 2
Waste water
10 Specification: Φ4.5m ×5m(H),material: carbon steel & Glass
hydro-cyclone feed Set 1
flake resin lining.
tank
Waste water
11 Top-mounted, N=4kW, material: carbon steel & Rubber
hydro-cyclone feed Set 1
lining
tank agitator
Waste water
12 hydro-cyclone feed
Centrifugal type, Q=160m3/h, P=40mH, N=45kW Set 2
pump

13 Waste water
Q=134m3/h(inlet), one cyclone standby online Set 1
hydro-cyclone
14 Gypsum Rotating
Output：150t/h Set 2
Discharge Machine
15 Gypsum transfer belt
Output: 150t/h, P=22kW, L=50m Set 2
conveyor C1 A/B
Gypsum transfer belt
15 conveyor with two
Output: 120t/h, P=11kW, L=30m Set 2
plough- discharges
C2 A/B
五 Process water system

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A

Specification: Φ7m ×9m(H),material: carbon steel & Glass Set

1 Process water tank 1
flake resin lining.
Centrifugal type, Q=325m3/h, P=60m, Set
2 Process water pump 2
N=110kW,Overcurrent parts 316L
ME flushing water Centrifugal type, Q=150m3/h, P=75m, N=75kW, Overcurrent
3 Set 2
pump parts 316L
Emergency spraying Specification: Φ3.5m×5.5m(H), material: carbon steel &
4 Set 1
water tank Glass flake resin lining.

4. Scope
The scope of this method statement is applicable to the equipment and piping of FGD system erection.
5. Responsibility
5.1 Boiler manager
a. Establishment of construction organization, monitor job quality, schedule control and overall project
management.
b. Ensure that all of the work is done on time as per schedule and within the projected budget. Ensure that the
construction project is compliant with current building codes as well as any other legal or regulatory
requirements. Develop detailed project plans and are able to use these as a benchmark to track overall
progress.
c. As the first responsible person for the safety of the major, he shall be directly responsible for the HSE work
of the major. Responsible for organizing the identification and evaluation of safety and environmental factors
within the construction scope of the specialty, organizing the compilation and implementation of relevant
safety and environmental prevention measures and emergency response measures, and ensuring that
various safety measures meet the requirements of safe construction.
d. Organize or attend safety and production meetings, report the HSE management of the specialty, and
convey the requirements of the superior to the department. Guide the work of the unit's full-time & part-time
safety officer, support the HSE department and safety inspectors to perform their duties, and be responsible
for the rectification of safety problems; Don’t participate in any illegal activities; Participate in the preparation
of the program related to the professional safety hidden trouble management.
e. Responsible for all kinds of education and training of production safety. Report production safety accidents
timely & truthfully. To be responsible for the safety emergency rescue work of the specialty.
f. Lead the subcontractor mobilization meeting, arrange and request the subcontractor to carry out the
mobilization work.
g. Responsible and accountable for overall site management, dissemination or execution of quality
procedures that meets project specification and project requirements.
h. Establish and improve professional quality management network and ensure effective operation. Organize
and report professional quality management objectives, control plans and quality assurance measures.
i. Hold regular quality meetings, summarize experience and lessons, and formulate countermeasures.
Participate in the process quality inspection of project department.
5.2 Boiler engineer
a. Responsible for the identification and evaluation of risk factors and environmental factors within the
construction scope. Responsible for the preparation and implementation of various HSE risk control schemes
and technical measures.

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
b. To be responsible for the design and planning of safety and temporary facilities, and supervise the planning
and implementation of safety and temporary facilities.
c. Guide and support the safety inspection work of the unit from the technical aspect, and organize the
preparation of the safety hidden trouble treatment plan related to the specialty.
d. Responsible for all kinds of education and training of production safety. Responsible for the planning and
implementation of civilized construction and safety environment identification in the construction area.
e. To be responsible for the preparation of the emergency response plan of the specialty and participate in the
accident investigation of the specialty.
f. Prepare quality plan, and be responsible for checking, supervising and checking the implementation of
quality plan. Timely conduct secondary quality inspection and acceptance work.
g. Participate in professional design disclosure, construction drawing inspection, technical measures review
and construction technical disclosure activities.
h. Strictly implement quality management procedures, keep original records and implement corrective and
preventive measures.
5.3 Subcontractor construction manager
a. Attendance of pre-construction meeting and execution of sample work when required
b. Schedule control with progress plan
c. First stage test according to Inspection and Test Plan
d. Compliance of site quality system in accordance with site quality control plan
e. Quality control during work (comply with drawings and particular specifications)
f. Safety control during work (worker safety equipment wear, and installation and control responsibility of
temporary safety structure)
g. Proper material arrangement and cleaning up after work
h. Site supervisor/site engineer
i. Responsible to follow up all construction works including the HSE and QA/QC obligations and responsible
create a safe working site conditions. Implement all site qualifications and inspection processes.
5.4 Site engineer
a. Responsible for planning, coordinating and directing the engineering and design work to meet the criteria of
anticipated job quality with economic design.
b. Supervise and coordinate the work of the various engineering disciplines.
c. Work with the lead engineers to formulate, evaluate and execute practical, economical and efficient design
concepts suitable for the specific requirements of the project.
d. Resolve the conflicts among the engineering disciplines during the engineering and design work.
e. Monitor engineering and design progress and report problems to the turbine manager for resolution.
f. Be responsible for coordinating overall execution at site.
g. Review constructability throughly prior to site opening. Coordinate with the construction members to
prevent or solve possible problems.
h. Supervise and control field staffs in site organization. Delegate and assign to each group of site
organization all necessary functions to be performed during the phase of construction. Check
construction-planning documents to see whether any problem may arise in future. Plan for preventive
measure or set up a contingency plan.
i. Establish a plan of construction execution considering actual site conditions.
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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
g. Participate in weekly schedule meeting, weekly safety meeting, and monthly progress review meeting to
assure that all activities are performed in accordance with original planning.
k. Submit monthly progress report to the turbine department and expedite the approval on it.
5.5 QC Inspector
a. Shall be responsible for inspection on site work to ensure the procedures are being followed in order to
ensure that quality standards being achieved as per Project procedures, requirements and specifications.
b. Ensure that adequate inspection personnel and test tool & equipment resources are available at all times,
including peak load periods to meet the construction schedule.
c. Raise non-conformance items, investigate their causes and make recommendations for corrective actions
to prevent recurrence.
d. Conduct the education for quality consciousness to all construction person prior to the commencement of
work.
e. Give his staffs the instruction about duties and responsibilities on site.
f. Supervise his staffs’ activities, functions and operations so that they are taken in accordance with the
specified requirements and the approved procedures.
5.6 HSE supervisor
a. Shall be responsible for the implementation of the HSE procedures before and during the execution of
fabrication and erection.
b. Shall be responsible for check for any unsafe conditions on the working areas and liaise with field
Supervisor ensuring that the work is carried out as per approved Project safety plan and procedure.
c. To ensure all lifting equipment and accessories have valid certification.
d. Conduct the education for HSE consciousness to all construction person prior to the commencement of
work
5.7 Site foreman
a. Responsible to conduct material identification and collection, preassembly, lifting, fitting, welding and
erection works according to construction plan by following HSE and QA/QC obligations and reporting to site
engineers.
b. Responsible to the provision of an efficient and effective work on site operation. Prior the commencement
of works, the supervisor-foreman must ensure that all site personnel are adequately briefing on contents of
this Method Statement and work. Also the control of the working area is under his responsibility either the
engineer is there or not.
c. All Foremen are responsible of all construction activities on site as per the MS,ITP,HSE requirements.
6. Manpower and Resource
6.1 Manpower requirement
Personnel Qty.
Subcontractor construction manager 1
Site supervisor/ site engineer 2
Foreman 2
Crane operator 2
Fitter 6
Scaffolder 8

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A

Electrician 1
Welder 30
Helper 15
HSE supervisor 2
QC inspector 2
Total 71
The actual quantities would be adjusted depending on the site workload.
6.2 Equipment requirement
S/N Name of tools and equipment Specification and models Qty. remark
1 Mobile crane 50t 1
2 Welding machine / 30
3 Grinding machine / 10
4 Theodolite / 1
5 Level instrument / 1
6 Steel tape 0-100m 1
7 Steel tape 0-5m 1
8 Chain blocks 1 – 20t Lot
9 Slings Several Lot
10 Hand tools / Lot
11 Hydraulic jacking 35t 30
Safety facilities(safety
12 harness, safety rope, safety / Lot
net, warning tape and so on)
The actual quantities and categories would be adjusted depending on the site workload.
7. Methodology
7.1 Preparation:
a. Review the erection drawings to identify required materials, tools, equipment and sequence of assembly
and erection.
b. Inspect materials for damages or nonconformities.
c. Prepare a flat working place.
d. Ensure that erection drawings are completed and in the latest revision.
7.2 Equipment receiving
a. All equipment received at site shall be inspected in accordance with vendor’s instruction for site storage,
installation and preservation.
b. Equipment shall be off loaded from trailer using the recommended lifting point and approved techniques.
c. All loose items that are not required for immediate installation shall be suitably identified and retained in the
stores.
d. Protective covers on all equipment shall be removed if they appear damage and equipment inspected
before replacing the cover, if any damage has occurred, Discrepancy report shall be issued with photograph
showing damages as necessary and recorded.
7.3 Erection of absorber and other thanks
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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
7.3.1 Foundation review
Before tanks erection started, foundation shall be checked with civil department, and make sure that the
foundation is according to specification requirement. If there were some obstacles on foundation to erecting of
the tank, such foundation should be repaired by civil sub-contractor. The foundation shall be marked on four
position (0 º, 90 º, 180 º and 270 º) and will be done by civil department. The item to be inspection of
foundation are Dimension, Flatness, Levelness and sump location.
7.3.2 Erection of bottom frame and annual plate （absorber and emergency slurry tank only）
a. The positions and dimension of holes for absorber and emergency slurry tank anchor bolts shall be
checked as per drawing.
b. Chipping of the foundation will be carried out for setting of pad plates and after setting to correct elevation it
will be grouted.
c. Assembly and erect the bottom frame as per drawing.
d. Released for secondary grouting.
7.3.3 Erection of bottom plates
a. The bottom plate shall be arranged in accordance with Bottom Plate Drawing and Orientation Drawing.
b. First Lay down the sketches plate, start from center through to the four direction angle (0 º, 90 º, 180 º and
270 º).
c. The bottom center plate shall be laid on the center point which had been marked by stretching piano wires
crosswise above the foundation. Center bottom plates which will be basis for laying other plates.
d. The arrangement of bottom plates shall be laid out from center to outward and tack-welded in surface to be
straight.
e. Bottom plates shall be assembled and tack-welded using special jigs for anti-distortion if necessary.
f. Weld sketches plates which shell plate will be laid long of weld from out to inward.
g. Care shall be exercised during welding of bottom plates to assure minimum distortion and uniform lapping
with as possible, plates shall be held in close construction at all lap joint.
h. After completion of welding works of bottom, tested using Vacuum Box and Soap suds to all welding line
with a vacuum of 5 to 7 psi.
7.3.4 Fabrication and erection of shell plates
a. The tanks will be erected with the method upside down. Temporary structural members 200 mm width
preferably fabricated from 350 or 400 mm beam are erected at proper distance. The shell plates are erected
on these structural members. These structural members provide passage for the manpower, equipment
inside the tank. This also helps in air circulation.
b. The shells are placed or erected first on the support members.
c. The shell circle line for erection shall be drawn on the bottom plates and punched equally by number of
shell plates.
d. When the assembling of the first ring have completed, the vertical joints shall be tack-welded from inside to
outside.
e. After completion of the tack-welded on the vertical joints, the level of top edge and plumbness shall be
inspected with an instrument theodolite.
f. The first continuous welding shall be made from the outside for vertical joints and back weld from inside.
The Welding from down to up. The strong back or key plates shall be installed at right angle with the weld line
to prevent plate distortion during welding.
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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
g. Prior to application of the first bead to the inside welding, the strong back or key plates shall be removed
and welded joints shall be cleaned thoroughly in a manner that will leave the exposed surface satisfactory for
fusion the weld metal to be added. This cleaning shall be made from inside by arc-air gouging and / or
grinding to evenly and smoothly.
h. Installation of cone roof and rafter lug: Mark the position of rafter lug on internal surface of top course shell
plate and then welded there to.
i. Roof plates shall be installed in accordance with drawing after all roof structure bolted and welded
completely.
j. Roof plates shall be laid out and tack-welded using special jigs for anti-distortion if necessary.
k. At the continuous welding, transverse joints shall be welded first. The welding shall be started at the center
of plate width and proceeded outwards symmetrically. When all transverse joints are welded, welding of the
longitudinal joints shall be made from center to outward in a same manner as the transverse joints,
circumferential joints between roof plates and top angle shall be welded finally.
l. Assembly the jacking units and the hydraulic circuit commissioning with hydraulic pump.
m. During the assembly of the next uppermost shell ring the previously finished part of the tank has loaded the
tank trestles. This part is now lowered until it rests on the shoring trestles.
n. The climbing jacks and sliding chairs are lowered one at a time using the rope with chain and holder.
During this operation both the grip jaw sets of the jack must be in disengaged position.
o. The lifting and fend-off lugs are now welded to the next uppermost shell ring.
p. The same procedure as above now repeated for following shell rings. As the load on the lifting trestles now
has increased, the oil pressure must be increased, but not mot than necessary for liftings.
q. Before the assembly of the last (bottom) shell ring, all shoring trestles are removed. If necessary, the pump
can be placed outside the tank. When the last shell ring is welded to the tank wall, the whole tank is lowered
and welded to the bottom plates.
r. Dismantled the lifting equipment.
s. Each tank accessories and appurtenances shall be assembled and installed in accordance with the
applicable construction drawings.
7.4 Erection of wet ball mill
a. Review the foundation and check the location, centers, diagonals and dimensions as per drawing and
ensure the holes for anchor bolts are correctly.
b. Locate elevation reference points and scribe centerlines on the foundations.
c. Install trunnion bearing sole plates on shims and crown to specification.
d. Grout trunnion bearing sole plates.
e. Install pinion bearing sole plate, do not grout.
f. Install trunnion bearing bases with swivel and bushing.
g. Assemble shell and heads, torque all bolts.
h. Install shell and head assembly in trunnion bearings. Coat trunnion journal and bushing with heavy oil
before lowering into position.
i. Check trunnion bearing clearances.
j. Complete both trunnion bearing assemblies.
k. Install lubrication systems to facilitate jacking of mill.
l. Install gear and check the radial runout and rim face runout.
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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
m. Install lower pinion section of gear guard to foundation.
n. Install pinion bearing assembly.
o. Check for gear backlash and tooth contact; also check for uniform contact pattern. Dowel pinion pillow
blocks.
p. Install drive assembly (reducer, motor, etc.).
q. Grout pinion bearing sole plate.
r. Install trunnion liners, head liners and shell liners.
s. Complete lube system installation
t. Install gear guard assembly and gear lube system.
u. Install discharge trommel screen.
v. Install feeder assembly.
w. Complete field piping.
x. Inspect inside mill and around area for left or forgotten items such as wrenches, bolts etc.
y. All points requiring lubrication should be checked to ensure that the proper type and amount of lubricant
has been used.
7.5 Erection of pumps and other rotary equipment
7.5.1 Preparation
a. Foundation shall be completed and checked for correctness and levelness as per drawings and
specifications. Prior to installation, foundation shall be clean with correct anchor bolt holes’ location,
centerlines marked, elevations and levels established for correctness. Shimming and wedging shall be carried
out as per drawings and specification. As required, perform on site installation of the various equipment as per
approved construction drawings and specification and instruction by a manufacturer/vendor representative.
b. Prior to installation, inspection for equipment acceptance to be carried out. Equipment installation includes
loading, hauling, unloading, inspection, lifting, shimming, aligning, placing and securing in its final position.
c. Remove all temporary supports, bracing or other foreign objects that were installed in the equipment or
machinery to prevent damage during shipment, storage and erection, and repair any damage sustained. This
may need vendor assistance.
d. Before positioning the equipment, it shall be checked against the drawings to verify the pipe installation of
flanges, nozzles, junction boxes, coupling and other items that require external connection.
e. Prepare foundation surface, install equipment, and level the equipment as per approved drawings and
specification.
7.5.2 Erection
a. For pump installation, alignment of axle centers between driving machine (motor) and pump is of essential
importance. When connecting driving machine to pump, axial line of pump shall be taken as reference for
alignment; when there is intermediate equipment installed between driving machine and pump, axial line of
intermediate equipment shall be taken as reference for alignment.
b. In general, liner and shims will be used for installation. And according to the type of base plate, flat liner and
shims, wedge or small jacks will be used to facilitate the adjustment.
c. Non-shrinkage cement mortar will be used for grouting work. Foundation of pump and machine will be
grouted in two lines. After initial alignment, primary grouting will be done for anchor bolt holes. When the
mortar reaches certain strength, precise alignment will be performed, then secondary grouting work may be
carried out.
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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
d. The parallelism and concentricity between flanges of piping to be connected with pump and inlet/outlet
flanges of pump shall meet requirements stated in relevant specification. And during connection, no undue
stress will be imposed on pump body. After final alignment, dial indicator will be applied when connecting
piping flange to pump flange.
e. Rotate pumps by hand to ascertain that they turn freely. Align pump with driver after coupling installation;
ensure that the axial and radial deviations, and axial clearance are within the approved tolerance.
f. Disconnect the coupling, check motor for rotation, run-in uncoupled and check bearing. After motor no load
test, re-couple pump to motor.
g. Installed proper lubricants (fuel, coolant) prior to commissioning after review.
h. For installation of agitator, technical specification and codes shall be strictly followed, especially the agitator
of reactor, perpendicularity requirement of its center axle is very strict, so after positioning of reactor, not only
the perpendicularity of housing shall be carefully measured, but also level of top flange (connected with
agitator flange) shall be precisely adjusted, to assure the perpendicularity of center axle of agitator.
i. Activities relevant to tolerances for agitator horizontal/vertical alignment shall be performed according to the
technical specification. Any misalignment of relevant vessels must by adjusted accordingly.
7.6 Fabrication and erection of pipeline
For the pipeline there are several kinds of material in FGD system such as carbon steel pipe, stainless pipe,
porcelain lining pipe etc. The porcelain lining pipe is designed connected by flanges and bolts. And the pipe
will be fabricated in proper length as per drawings in workshop before transported to site. So in this document
only carbon steel pipe and stainless pipe erection will be mentioned.
7.6.1 Cutting and beveling
a. All pipes and fittings shall be cleaned before prefabrication by air blowing. In addition, for large diameters
pipe rag cleaning should be conducted if found practical.
b. Proper Safety procedure shall follow before starting the job.
c. Pre-fabrication of Stainless Steel and Carbon Steel piping shall be done in separate fabrication bays.
d. Marking should be done as per Isometric spool number measurement.
e. Cutting of pipes, fittings and edge preparation as per the drawing and WPS.
f. Based on spool breakdown of piping isometrics, pipe length shall be cut. Extra length for pipe shall be
provided in spools for field adjustment.
g. Pipes shall cut using Oxy-acetylene cutting or plasma as per project requirement. Flame cutting of
Stainless Steel is not allowed. Stainless steel shall be cut with cutting disc. The edge cleaning and beveling
shall be done using abrasive grinding disc.
h. The edges to be welded shall be prepared to meet the joint design requirements by any of the following
method recommended:
• Carbon Steel (C.S)
Gas cutting, Machining or grinding methods shall be used. After gas cutting, oxides shall be smoothened /
removed by chipping and grinding.
• Stainless Steels (S.S), Nickel Alloys
Machining or grinding methods shall be used. After cutting, cut surface shall be machined or ground smooth.
i. Electrical power source should be used for hand machine during fabrication.
7.6.2 Fit-up and track welding

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
a. Fit-up assembly and joint alignment shall be carried out, by using couplers or clamps. All the required pipe
holding work benches, assembling brackets, ‘U’ bolts etc. would be made to suit the pipe sizes.
b. For butt welds a uniform root gap shall be maintained as per WPS
c. For all socket weld joints the pipe end shall be free from cutting burrs, the axial gap between male and
female component shall be maximum of 3 mm and minimum of 1.5 mm.
d. All welding ends shall be beveled with and angle of 35 degree, ±5 degrees, and a root face of 1.6 mm.
e. Welding end plane shall be normal to pipe axis as defined in the piping drawing, within 0.25 degree.
f. The inside misalignment shall not exceed 1.5 mm (1/16”)
g. The maximum tolerance for axial dimensions, face-to-face, center-to-face and locations of attachment shall
be ±3mm.
h. Lateral transition of branches and connections from centerline of the run shall not exceed ±1.6mm
i. Internal misalignment shall be limited to 1.6mm for pipe up to 24”, 3.2 mm for pipe diameter 26” and above.
j. Seam orientation of welded straight pipe and pipe to fittings shall be in such a way that, circumferential
angle between seam is at an angle of 30°.
k. Branches joint, connecting to the header line including reinforcement pad shall be pre-fabricated in the
shop to avoid difficulties in site.
l. The pipes shall be tack-welded in equidistant positions to avoid cracking and bending or joint during welding.
Tack weld shall be done by a qualified welder as per approved WPS.
m. In case of pipes with different thickness, the larger thickness shall be tapered in compliance with standard
to match smaller thickness.
n. Line numbers, Sheet numbers, Spool numbers, material code and Joint numbers are to be clearly marked
on the spools with the welder identification for each joint.
7.6.3 Piping erection
a. All lifting tools, equipment and ropes used for erection shall be inspected and certified by HSE regulations.
Activities shall be done according to the proper method statement for lifting and handling.
b. Pre-fabricated spools shall be shifted to site carefully; care shall be taken while handling and stacking of
spools to prevent any possible damage.
c. The Pre-Fabricated spools shall be identified by spool and line numbers before erection.
d. The pre-fabricated supports shall be installed as per drawings, the pipe supports details shall be followed in
the piping layout drawings and Isometric drawing for location and supports detail drawing.
e. Erection of spools shall be carried out area by area as per piping layout drawings and Isometric drawings.
f. Erect the spools in position using crane or other lifting devices as per the drawings.
g. Joints shall be aligned and complete the fit-up / welding as per applicable WPS, Isometric drawing and
Project specifications.
h. All flanged connections shall be made using fully threaded stud bolts and nuts. A minimum of one complete
thread shall protrude from the nut after completion of tightening.
i. The final correction and modifications made to fabricate spool in order to allow for stress free installation,
which should include; adjustment to pipe support, adjustment of flanges where free spaces are available in
bolt holes, cutting and re- welding or introduction of additional field joints or fit-up pieces.

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
8. Quality Control
The contractor will perform in accordance with the project technical standards, instructions for steel structure
erection and use of construction products and the technical regulation requirements for steelworks. The
contractor will establish and maintain quality of different items of work.
8.1 Control of preparation work
a. Inspection and Testing Plan (ITP) and Method Statement (MS) should be approved.
b. Inspection of material: the size and quantities should meet the requirements as per drawings.
c. Approval of WPS covering all the material specifications.
d. Spool drawings marking field and shop weld joints shall be prepared, numbered and reviewed.
8.2 Control of fabrication and erection work
a. Pre-fabrication of Stainless Steel and Carbon Steel piping shall be done in separate fabrication bays.
b. Pipes shall cut using Oxy-acetylene cutting or plasma as per project requirement. Flame cutting of
Stainless Steel is not allowed. Stainless steel shall be cut with cutting disc. The edge cleaning and beveling
shall be done using abrasive grinding disc.
c. For butt welds a uniform root gap shall be maintained as per WPS.
d. All welding ends shall be beveled with and angle of 35 degree, ±5 degrees, and a root face of 1.6 mm.
e. All pipes shall be internally cleaned by air blowing. In addition, for large diameters pipes rag cleaning
should be conducted if found practical.
f. The piping ends shall be covered after inspection to prevent unauthorized removal of the end cover prior to
making the joint to the succeeding section of piping.
g. After assembly and installation, the piping shall be cleaned inside to remove all loose material. The
cleanliness shall be verified visually and/or by video inspection techniques.
h. All pipe openings shall be sealed before, during and after erection to prevent the ingress of moisture and
foreign matter. Threaded ends shall be plugged and sealed by waterproof grease tape or purpose made
plastic caps or plugs. End cap or cover shall be placed on the open valve ends.
i. The ends to be welded shall be properly cleaned to remove paint, oil, grease, rust, oxides, sand, earth and
other foreign matter. The ends shall be completely dry before the welding.
j. The welding work piece shall be shielded against high winds and rain.
k. Any defect and cracks shall be repaired by gauging out and or grinding such defect from the side of the
joints as required and re-welding.
9. Safety and Environment
Subcontractor shall arrange safety engineer for the site management and supervise. The following measures
about the construction risk assessment in the attachment shall be followed by every person working in site.

Pre-Construction
Risk Assessment and Impact Evalu.docx

9.1 Lifting work

a. All the work of lifting must be following the requirement of the HSE.
b. Lifting during the night shift will not be permitted unless there are enough lights for working.
c. Well experienced and professional workers shall be at working site for each activity after safety training and
passing the examination.

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
d. Job shall be carried in the presence of safety supervisor.
e. Ensure the mobile crane is in good condition and all lifting will be within 90% of crane capacity.
f. Lifting in the heavy rain, frog and strong wind (force six or above) is forbidden.
g. Prior to lifting heavy objects, lifting training shall be carried out by the rigger and operator.
h. It is forbidden to cross the lifting area or stay under the lifting objects.
i. Before lifting, the load will be checked to ensure that it is secure
j. Avoid contacting slings with sharp edges.
k. SWL of lifting gears & tackles shall be ensured for the lifting by operator and riggers.
l. All cranes shall be subjected to the statutory inspections in accordance with local regulation.
m. Warning signals of “No Entry” and safe ropes shall be provided as required.
9.2 Assembly and erection work
a. Regular training should be conduct for all workmen about the safe work practice & procedures by full time
safety officers and maintain the training records.
b. All work related Personnel protective equipment’s must be worn as per work nature such as safety goggles
for eye protection, Safety helmet for head protection from the falling material hazards, Hand gloves while
handling materials, and safety shoes for foot protection, etc.
c. The safety harness or falling arrest device must be used properly when working at height.
d. All access/exit point shall be maintained free from obstacles, materials, equipment etc.
e. All scaffolding shall be inspected, approved and tagged before using.
f. While assembling the vertical panel, the temporary supports must be welded to stop the panel from falling.
g. Ensure appropriate working platform with proper access if the job is at difficult location.
h. Never require workers work at height if they are afraid to do so, if they are subject to acrophobia, or if they
are nervous or sick.
i. Be sure that all safety guards are in place in workers’ tools/Equipment. Do not remove, displace, damage, or
destroy any safety device or safeguard furnished or provided for use on the job, not interfere with the use
thereof.
j. Do not enter the area where barricaded.
k. Prior to the maintenance /Servicing of powered tools reenergize, lock out and tag out from the source of
power supply.
l. Barricade danger areas. Guard rails or perimeter cables may be required. (Barricade the dangerous area
with proper barricading and caution sign board which can able to understand by the workmen.)
m. The workers must master the basic knowledge and skills of his own job. The welders，operators and
riggers must be employed with certification. All the workers must pass the security examination and training.
n. Hot work area must be equipped with the qualified firefighting equipment.
o. Only the electrician can be allowed to connect the power supply. All the panel must be installed leakage
protection and grounding device. The switch board，welding machine，diesel generator，winding engine，
working platform for welders，containers，bottom plate of tanks，crawler crane and etc. must be unloaded on
hard grounding. On the distribution box should be marked the electricians’ name and contact number as
required.
p. Reinforcement measure must be carried out while the assembly is suspended on the boiler steel structure
for temporary storage. Regular inspection is required.

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METHOD STATEMENT FOR FGD SYSTEM ERECTION LEPCL-10-HTZ-MQB-200018-G01-A
9.3 Radiography
a. Posters showing the rated power output, that radiation is taking place, no entry allowed, and danger shall
be displayed where radiation work is being carried out. Before starting the radiological work, the restricted
area shall be checked to confirm by blowing a whistle or other audio device that no unauthorized persons are
in the area and reconfirmed during the radiation work.
b. Radiation apparatus shall be operated by a technician authorized by the local authority.
c. During radiation work, doses of radiation at the boundary of the restricted area shall be measured and
recorded.
d. When radiation work is scheduled at night above ground level, a watchman shall be stationed on the
ground.
e. Storage of Radioactive Material: Radioactive materials shall be packed in a container, which shall be
placed in a storage pit. Both container & storage pit shall be
9.4 Environment and housekeeping
a. The recoverable waste, such as steel waste produced during erection should be delivered to the
designated place and reclaimed for use.
b. The package of the raw material and other solid waste should be sorted deposit and concentrate dispose.
c. Solid waste, such as slag, scale and electrode head produced in the welding operation should be collected
specially and concentrate dispose.
d. Materials should be stored in such a manner as to prevent deterioration or instruction of foreign matter and
to ensure the prevention of their quality and fitness for work.
e. Stored materials should be protected from atmospheric effects due to rain, wind or moisture to avoid
deterioration.
f. Always store Oxygen, acetylene and other fuel gas cylinders in top-right position.
g. Sufficient free space must be provided between each section to allow easy access for firefighting.
h. Nobody are allowed smoking at site unless at the designated smoking points.
i. Sufficient and suitable fire extinguishers and fire buckets should be provided wherever necessary for fire
safety.
j. Whenever the leakage of dangerous gases is seen/felt all the persons working in that area should be
withdrawn and electricity should be cut off.
k. When stacking the cylinders vertically, it should be ensured that they are properly secured by suitable
brackets or stands so that they do not fall.

10. Attachment
10.1 Pre-Construction Risk Assessment and Impact Evaluation

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