Construction Method of Chimney Work: Cilacap 2x300MW CFSPP Project
Construction Method of Chimney Work: Cilacap 2x300MW CFSPP Project
Construction Method of Chimney Work: Cilacap 2x300MW CFSPP Project
CONSTRUCTION METHOD OF
CHIMNEYWORK
(Lifting System, Manpower, Quality &HSE Requirements)
CONSTRUCTION METHOD OF
1
Cilacap 2x300MW CFSPP Project
CHIMNEY WORK
1. GENERAL
As technical assistance, the procedure is compiled for the chimney construction of the 2×300MW
CFSPP project in middle Java of Indonesia. Due to the foundation will be laid by WIKA, so this
procedure will mainly describe the construction work of chimney shaft. But WIKA should consider
well the embedded iron-parts and openings for the succeeding activities those will be done by
Zhong’an after.
A new construction method, called the Electrical Liftform System Method (ELSM), will be
adopted for this concrete chimney construction. The ELSM include four parts, they are Workform
Units, Platform unites, Elevator System and operation frame system. The workform units adopt some
standard steel form and some special form, for ensuring strength and surface quality of concrete. The
Lifting system include of 16 sets Lift frame and operation frame. Every operation frame has an electric
motor connected the operation frame and lift frame by screw mandrel. Platform systems include
Operation Platform, upper Platform, and Lower Platform. The elevator system may use the straight
elevator or winch. The winch applies the special safety brake system.
As well as another new construction method, called Air Pressure Jack Method (APJM), will be
2. MAIN ACTIVITIES
The main activities of procedure for chimney construction as follows:
Step Main activities Work Contents Mark
1 Laying foundation Excavation, Concrete By Wika
2 Construction of concrete shaft Concrete, Scaffolding Cooperation
(from ±0.00m to +24m)
3 Assembly of ELSM (at +24M Level) Fabrication & Erection By Zhong’an
Step Main activities Work Contents Mark
4 Construction of concrete shaft Lifting, Concrete Cooperation
(from +24m to top)
5 Steel Stair and Platform Erection Lifting, Erection. Cooperation
2
Cilacap 2x300MW CFSPP Project
3. DESCRIPTION
3.1. Laying foundation
Construction by Wika, Spare the detail of description.
the influencing of the bigger openings for flue duct to the construction of ELSM, the level at
a height of 24m above the ground suits for assembly the ELSM.
special work form provided by ELSM. As you can see from the master assembly drawing of the
ELSM, attached drawing A, the special work form include Internal wok form & External Work
form, they get together as a work form unit. In this project, three work form units will be
the double-bank scaffolding will be applied around the external shaft. The purpose is not only
for the concrete construction but also for the assembly of ELSM.
3.2.3 Attention
a. To find the position of embedded iron-parts for the steel ladder against the work
3
Cilacap 2x300MW CFSPP Project
b. At the bottom of the concrete chimney, a height of +0.2m above the ground, 2 of
300×400 openings (holes) must pro-make for the steel rope through.
c. At a height of 0.2m above the ground, at the internal of the concrete shaft, 4 of 200×300
be conducted on the basis of the design drawings and construction specification strictly.
e. When the high-strength concrete is produced, prolong batching time in moderation, that
will delay the time of concrete into the work form, in order to emit the inner heat of
hydration beforehand.
f. Surface (rendering) of the openings, those will be filled at the succeeding activities,
must make rough and keep the rebar or iron-part exposed. For the quality, before the
next activity please to be sure it has been thoroughly swept and cleaned.
the size of ELSM, adjust and revised them in time if has errors.
According to the master assembly drawing, attached drawing A, and procedure as follow:
23#,24#,25#,27#,etc.
3. Part C(central tambour): combined by 12# ,in shape of “drum”
Check the scaffold internal & external scaffolds inspect the climb stairs used for
4
Cilacap 2x300MW CFSPP Project
Erect 96 sets of climb stand in 6 levels, and each level ha s 16 sets, which round the
concrete shaft in equal distance. Everyone set in each level is in same position with its
Prepare 25T crane for lifting the parts of ELSM, to be sure the area around the chimney
together.
4. Install upper-platform:1 include 4#,15#,13#,41#,42#
5. Install head frame: include 1#, 3#, 2#, 4#, 5#, 6#, 7#, 8#, 9#, 10#
6. Install lower platform: include 18#, 16#,17#,43#,39#,40#
7. Install hanging platform: include 19#, 20#
8. Install the workform units: include 32#, 33#, 34#, 35#, 36#, 31#,37#
9. Install elevator: 38#
10. Install winch: include steel cable of elevator and winch; steel cable of pull-up pole (for
When the ELSM on the position, inspect and adjust the axial line of chimney to
central line after assembly, check and adjusted in circler direction, diameter direction
After inspection, loading test, and it must be approved by the high level supervisor
before go to work..
5
Cilacap 2x300MW CFSPP Project
and part B, fix 29#, electromotor (23#) run in the other direction, the Internal Frame
(21#) and External Frame (22#) of part A and part B up. Fix 29# again. During the lifting, the
The operation instruction and technical training must be conducted to all working staff
before constructed.
Components assembly must check and inspect on the basis of the construction
specification.
After assembly, the ELSM must be checked up, inspected and tested, such as the
Inspecting and testing of the winch before use, the new steel rope must be sure rolled
ELSM Loading test to the ELSM must be done and approved by the high level
supervisor.
screw mandrel。Each screw powered by an electromotor. unfasten the 29#, let the electromotor
run to lift the Lifting Frame of part A and part B. Fix 29#, let electromotor (23#) run in the other
direction, the operation Frame (21#,22#) of part A and part B up. Fix 29# again. During the
lifting, the Work form units ascend along with lifting frame.
6
Cilacap 2x300MW CFSPP Project
preparation of rebar will be done on the ground, and vertical transportation can be done by the
lifting pole (number 4#) which suspended on the higher platform. The stop, weight and velocity
of lifting are controlled by a signal system. And the weight is not allowed more than 1000kg to
ensure safety.
the concrete work should be arranged at night. So the enough lighting system must be provided.
Concrete must be delivered to the working site, and then transported by elevator to the concrete
hopper (number 6#) on the higher platform, and then delivered into the work form. Before
pouring, the rendering (concrete surface) of the poured concrete must be sure that is rough
(>10mm) and clearly. Each pouring, the concrete curing must be last more than 7 days.
lower platform (number 16#, 17#, 20#) as the working platform to erect spin climbing stair
platform.
The platform will erect with the construction progress. The erection will use the lower platform
(number 16#, 20#) to vertical lifting. This procedure must be finished before the dismantling of
the lower platform. Components of the stair and platforms maybe lifted by a special winch its
steel cable pulley maybe hangs under the ELSM. Because stopping between every two cycle of
pouring concrete is allowed, so stop concrete working to erect the steel stair and platform is
7
Cilacap 2x300MW CFSPP Project
The lightning device can be erected and tested when the ELSM be partially dismantling.
used for the lifting for painting implementation. Before painting, the rendering must be cleared
by small shovels. Painting should be carried out vertically in colors with its ratio strictly
collars of shaft on the top of external operation frame. Direction should be leaded to the upper
place of each set of the frame by 5 tonnages open slider and then hooked on Radielizied Beam in,
8
Cilacap 2x300MW CFSPP Project
order to low the frame 16 sets of external operation frame can all be dismantled and lowered by
off cross bolts and lower to top concrete of the shaft, and then all the Radielizied Beam can be
tightly welded with embedded parts. 4 of 3-tons jack chains should hook on the “Ω” shape rings,
and the other sides can hook at the bottom of central tamhour with its center being pulled up
50mm to ensure the 4 jack chains be uniformly stressed. Finally, external should be set one by one.
One 5-ton open slider should be clamped at the end of conducting rope and bound at the both
sides of middle-upper operation by 2 jack ropes. Meanwhile, the long sliding rope should be
fastened at the middle-lower parts of operation. Then the steel rope can be strengthened to ensure
the disconnection of exterior and interior operation frame and slowly setting. When the top of
operation frame reach 1 meter, the both sides of operation frame seized by steel rope and fastened
on Radielizied Beam. 2 of 3-ton jack chains can be used to strengthen operation frame backward.
After the erection of tripod, platform, etc, jack chain can be loosened and lowered to ground.
Dismantling of Inclined Supporter and Steel Girder of Upper-Platform
When dismantling the Inclined Supporter, hemp rope should be used to tightly fasten the
Inclined Supporter on the shaft head frame to ensure no sliding during removing Steel Girder of
Upper-Platform, and it can be placed on the platform one by one, then lower all of them to ground.
Removal of steel rings can be processed in subsection. The suspended rod of small platform
can together be lowered with raking strut. The other small parts can be lowered by the lifting pole.
move up and down. While dismantling elevator, cable can be hanged at the bottom of elevator to
lower down together with elevator. During lowering, cable should be coiled up in groups.
Dismantling of, Radielizied Beam head form and central tambour:
Firstly, the upper parts of head frame should be dismantled. All dismantled parts of head
9
Cilacap 2x300MW CFSPP Project
frame can be lowered to ground by lifting pole with last sections (5 meters in height) being left
with the aim of dismantling Radielizied Beam. When dismantling of Radielizied Beam, they
must be strengthened by jack chains near to head frame. After the small platform being safely
hooked, the Radielizied Beam can be cut apart by welders from shaft, and the connection bolt
pins and take-up can be removed, and deliver them to ground. After the completion all of this,
the left head frame can be dismantled. The tambour can be cut into 4 pieces to individually
lower. When cutting and de-erecting tambour, small platform can be used to hook them up. The
1/4 of the tambour being cut down by welders can be lowered to ground after it receiving stress.
working site.
(2) Fabrication equipment: steel plate roller, sandblast and planer shall be prepared well at working
site.
(3) Transporting equipments: gantry crane, single beam crane, wagon and others equipment
transportation.
(4) Fabrication and erection of the support for the lifting system, the cap of the system and top
girder beam.
1. Set up the equipments and test, inspect, by approved
2. Fabrication steel planks, move by gantry crane
3. Rolling planks, move by gantry crane
4. Move into chimney by wagon
5. Lift planks to the foundation frame by the single ring-beam crane
6. Jointing, inspection, welding
7. Insulation construction
10
Cilacap 2x300MW CFSPP Project
drawing.
(2) The Air Pressure Jack Method (APJM) is not allowed to work without test, inspection, and
5. PLAN OF MANPOWER
Classification, Qualification, Quantity and Sourcing of Manpower:
worker
11
Cilacap 2x300MW CFSPP Project
7 Bar worker 10 10
Concrete
8 2 2
Worker
9 Mech. Eng. 1 1
10 Machinist 8 4 4 Middle rank
11 Electrician 2 1 1 Grade 5
12 Welder 2 2
13 Lifting worker 1 1 Grade 5
Unskilled
14 8 8
worker
15 Interpreter 1 1 Above CET 6
Total: 68 persons
6. QUALITY
1) All onsite steel materials, concrete, firebrick, refractory mortar, asphalt, etc have factory
certification and also have been re-inspected with the results of meeting standards, and then
it can be used. All coating and aircraft painting materials are all being provided with factory
lab with accurate computation and satisfied strength requirements. Masonry bonding
and splashed slurry must be washed away by high pressure water to increase its visual
quality. All concrete used must be the same brand to assure the consistent color and luster,
and all formworks must be mended with plastic or wooden plates if there are holes existing
achieve traceability of all steel material usage, all material, specs, quantity, variety and
12
Cilacap 2x300MW CFSPP Project
location meeting the requirements of design drawing, quality checking and inspection
criteria. Sample test should be implemented before reinforcing steel bar welding. The
sample test can be done under the same onsite conditions with one test of each 300.
6) Strictly implement inspection system with self-inspection, re-inspection at each operation.
If the upstream operation does not qualified or inspected, the next operation can not be
proceeded to increase onsite checking and inspection rate. All crews and management
personnel must earnestly record and fill relating technical data and file them in time.
7) Operators must strictly follow producing instructions of antiseptic material and producing
close inspection should be given to the reinforcement, upholding and fastness of bolts to
assembly all parts with strictly following lifting system drawing. If there are ameliorations
torsion and partiality stress of lifting system. Each concrete pouring should be lower than
formwork 50mm to 80mm to achieve flat connection. Special person should be assigned to
take charge of vibration. Layered pouring, vibration should be uniformly carried on with
vibrating spears with 500mm vibrating gap to ensure complete vibration and compactness.
Alveolate hole, reinforcement exposure and big holes are prohibited. The bearing
formworks of manhole and fueduct cannot be dismantled until concrete intensity reaching
70%.
9) When chimney shaft being constructed 15m to 20m in height, settlement observation is
lifting form, pressure test of test blocks should be implemented and the operation frame can
be lifted when the strength of stress-bearing section of concrete at the bottom of operation
13
Cilacap 2x300MW CFSPP Project
frame reaches 7Mpa. Strict control should be implemented on this during construction. The
concrete mixing ratio application form (signed by technicians, quality controller) must be
methods follow Quality Checking, inspection and assessment of Thermal Power Plant
project.
12) As to the common faults against chimney construction quality, refer to Project Quality
7. SAFETY
1) Armed must be put on when entering job site. Safety belt must be fastened firmly when
operating at the area without safety net or at the edge of platform. Safety net pothooks with
1m gap should be set under operation frame or operation platforms. The waste on safty net
must be cleaned; pothooks must be checked to ensure hooks in good condition after each
shift. The outside operation platform should be installed with 1.25m high railing , and one
cross rail should be set 180mm above the platform to suspend safety nets.
2) When chimney construction is implemented, dangerous area should be set with fence and
warning board.30m around shaft are dangerous area while chimney is constructed more
area. Any construction should stop and personnel can not be allowed to work on the
personnel of next shift the hidden troubles or questioned problems. Before machinists go to
work, they should earnestly check machines, brakes, the condition of operation slings and
other safety factors. Any problems found should be settled, and then the elevator can be
started. Woodworkers should check all system condition to see whether they are under good
14
Cilacap 2x300MW CFSPP Project
condition or not, then they can be lifted. Any problems found should be settled in time.
assigned person should monitor the lifting of operation frame to avoid streakily lifting and
applied to running parts every each 3 days, complete checking once after lubricating oil
filling of each week together with thorough checking of all parts, electrics, elevators,
brakes, top pulleys, conducting ropes to solve problems existing. Records should be kept by
specially-assigned person.
5) Strictly implement technical overhanding and safety overhanding. Each complex operation
procedures must have technical over-handing books strictly followed by all crews and
shifts.
6) All machines and electrics must be operated and maintained by specially qualified workers.
Others can not operate or maintain them. Safety operation board should be hung at the
operation sites. Before working, electricians should check the grounding and creepage of
equipments. If creepage occurs, operation only can start after problem being solved.
Flashing measures should be taken to all electric equipments and operators should turn off
overall-control switch before leaving. Lighting should be ensured at operation site and
construction during night. The elevator operator should concentrate on his work to ensure
Excessive stack is prohibited. Each lift of reinforcing steel bar cannot exceed 1 ton. The
materials will not being used should be delivered to ground in time. Material stack on
operation platform cannot exceed 150kg/m2, and the platform should be immediately
cleaned after the completion of pouring. The forgotten tools and left bricks are prohibited.
8) The fire door on suspension cage should be closed when using. Personnel in the suspension
15
Cilacap 2x300MW CFSPP Project
cage are prohibited from stretch their heads or hands out of the cage. The lifting of
personnel and materials in same time are prohibited. The distance should be more than 5
meters between acetylene tank and oxygen tank with reliable sunshading and fixation
suspension rings should be assured to reach 70% of design requirement, then suspension
ring can bear stress, which avoids drawout of suspension ring under stress
8. ENVIRONMENT
1) Precaution boards, quality and safety sign posts should be placed onsite to remind
nicely with neat and clear marks under charge of specially-assigned persons. Cross or
prohibited. Raffles and concrete in Elevator pits should be immediately cleaned. Bypass
and inside working site of shaft should be cleaned each shift. Operators should dress in
uniform. Slippers and high-heel shoes are prohibited inside of working sites.
4) Water accumulation should not occur on bypasses and working site to ensure neatness and
smoothness of bypasses. Electric protection equipments and measures are all ready to
avoid long-time lighting and to assure the offices and toolhouse neat and ordered.
5) After the finishing of each shift, the garbage should be cleaned before leaving to achieve
materials, machines and equipments to increase the site utilization and environment-oriented
16
Cilacap 2x300MW CFSPP Project
const
9. ATTACHMENT
Attachment A, Master Drawing of ELSM (1), ELSM (2)
Attachment B, Lift form System Parts
Attached C, APJM Sketch
Attached D, Chimney Work Flow Chart
Attached E, Equipment List and Winch Parameter
1. General...........................................................................................................................................................2
2. The main activities........................................................................................................................................2
3. Description of the main activities..................................................................................................................3
3.1. Laying foundation...............................................................................................................................3
3.2. Construction of concrete shaft (from ±0.00m to +24m)....................................................................3
3.3 Assembly of ELSM (at +24M Level)..................................................................................................4
3.4 Construction step of the ELSM...........................................................................................................6
3.5 Description of main procedure:...........................................................................................................7
3.6 Dismantling of ELSM at the top of chimney......................................................................................8
4. Steel liner construction................................................................................................................................10
5. Plan of manpower........................................................................................................................................11
6. Quality:........................................................................................................................................................12
7. Safety...........................................................................................................................................................14
8. Environment.................................................................................................................................................16
9. Attachment...................................................................................................................................................17
drawing A, master drawing of ELSM (1)................................................................................................17
17
Cilacap 2x300MW CFSPP Project
18