UG487/13.

7M

Boiler Erection Instruction

330BSM7

Written by Checked by Examined by Approved by Standards

WUXI HUAGUANG BOILER CO.LTD Peoples Republic of China

(WUXI BOILER WORKS)

August 2009

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Boiler Erection Instruction

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CONTENTS
UG487/13.7M.....................................................................................................................1 330BSM7................................................................................................................................1

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Boiler Erection Instruction

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I. Preface
1. This instruction is applied to provide some special instruction for some special structure of the boiler for reference during boiler erection. 2. For personnel taken part in boiler erection, relative regulations and standards shall be thoroughly understood, and this instruction and boiler installation drawings shall be carefully reviewed before start of boiler erection.

II. Key Characteristics of the Boiler

The boiler is a CFB boiler. The furnace of the boiler is made by fully suspended membrane water wall. Water wall panel, primary and secondary superheaters are installed inside the furnace, from which a cooling type connecting duct is lead to the steam cooled type high temperature cyclone separator. In HRA, the upper part is a two-pass steam cooled enclosure, the reheater bundles are installed inside the front pass, and the high temperature superheater bundles and high temperature economizer bundles are installed inside the rear pass. Flue gas dampers are suspended on the lower part of the enclosure, and the economizer and horizontal air preheater coils are installed on the bottom. The primary and secondary air tubes are installed with staggered arrangement, the air flows inside the tubes while the flue gas flows outside the tubes. There are large amount of circulating material inside the boiler, especially inside the dense phase of the lower furnace, therefore special attention shall be paid to the following aspects: 1. construction of the wear-proof layer: with higher temperature, which may shift abruptly, high risk of wearing due to high density of particles and many tubing, the structure is quite complex, the operating condition is hard in this part. 2. Wear-proof layer on the outlet of the furnace and on tubes nearby. 3. Construction on inlet and outlet of the cyclone separator; 4. Cyclone separator and material return device

III. Special structure and requirements for installation

1. Coal Feeding Device The coal chute shall be installed under the coal chute opening on the lower front wall, make sure the distance from both sides of the coal chute to the water wall tubes are the same; and the coal spreading air nozzle shall be aligned to the perpendicular bisector, otherwise the boiler wall may be exposed to the wearing of the particle. 2 combustion device 2.1 The air chamber as well as the grid is water cooled type, during the installation, guarantee the sealing of the air chamber, air leakage is not allowed. 2.2 Plastic band or tapes shall be applied to pack the holes on the nozzles to prevent them from being blocked. The plastic band of tapes shall be removed after harden f the casting material. And the surface of the concrete must be smooth. A space of 10mm shall be kept between the refractory concrete and boiler wall, in which aluminum silicate shall be filled.

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2.3 Carefully check the conditions of the air dampers, and make sure that the air damper, actuator and gauge indication identical. Before installation, it is necessary to mark the position of opening and closing on the end of the shaft. 2.4 Notes in the brickwork construction drawing shall be satisfied during the construction of the furnace wall. Reasonable selection and construction of the wear-proof Castable and high strength casting material is one of the key points that guarantee the safe and reliable operation of the CFB boiler. The materials for this boiler are selected in accordance with the characteristics of the CFB boiler, and the acceptance shall be made by the user in strict accordance with the relative physical and chemical index. It is recommended that the construction work shall be made by the material supplier, to make sure that the intended performance could be achieved. 2.5 Low alloy and high strength steel are applied as the material of drum and large bore downcomer, arc striking, electric connection and spot welding are strictly prohibit on any drum or large bore downcomer (on the large bore downcomer, welded plates are made for field electric connection). During the hydraulic test, the metal temperature on the outside of the drum wall shall not exceed 35. 3. Membrane water wall 3.1 The membrane water wall may be deformed due to lifting work during transportation; therefore the membrane water wall shall be corrected before filed installation. The fins may be cut before butt welding between different membrane water walls and the membrane water wall and the nozzles of the header and the fins shall be welded back after correction. All the butt welds inside the boiler shall be ground to smooth. 3.2 The reinforcement support for lifting work shall be installed outside of the membrane water wall, in case it has to be installed inside the membrane water wall, all the lifting lug shall be removed and the remaining part shall be ground to smooth. 4. The superheater panel and water cooled panel are relatively narrower, and ratio of length to width is relatively larger, therefore the reinforcement support shall be installed to prevent the panel from bending. All the superheater panels shall be fixed on the lower end, and the expansion is upward during operation. The panel shall not be blocked when is get through the boiler ceiling and sealing box, to prevent the pulling force of the constant spring hanger from being blocked (the hanger must be strain) , otherwise the panel may be deformed after the expansion is blocked. 5. Drawing requirements for the distance between lower front wall and water cooled air chamber shall be satisfied; otherwise the particles may not fluidizable in this area. 6. For the buck stays around the membrane water wall, when they are assembled with the bend plate, the nut shall be loosened by a half circle after tighten, and then be spot welded. By this way, a relative displacement is allowed between buck stay and bend plate, and loosen

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of nuts is avoided. 7. 3 layers of the guiding devices are installed along the height of the furnace, 2 layers of guiding devices are installed inside the HRA. The guiding devices are applied to guide the thermal expansion of the boiler and to prevent vibration from happening. Clearances shall be left according to the drawings, and welding is not allowed. 8. During installation of the secondary air tube, position of each air tubes shall be corrected according to the drawing. The air tubes shall be seal welded to the water wall after they are installed into place. The opening and closing of the secondary air tubes shall be identical with the gauge indication. 9. The constant spring hanger on the interconnection tubes of the superheater and reheater may move both upwards and downwards, during the installation, the series number of the hanger must be carefully reviewed. In the series number, an X means the expansion is upward, and an S means the expansion is downward. Beside constant spring hangers, dampers, and changeable spring hangers are installed for hanging and compensate the thermal expansion. For the horizontal tubes which is relatively longer, the hanger shall be inclined for certain angle during assembly to prevent the inclination of the hanger form exceeding the allowable value during operation, the detail please refer to the drawing. When the load become steady, the constant hanger shall be fixed by fixing pin, the fixing pins shall not be removed during hydraulic test and tube cleaning, and the constant hanger shall be locked to be a rigid hanger to absorb the overload. After the hydraulic test and/ or the cleaning, the fixing pin could be removed, and the operation could be started after checking and adjusting the indicator for displacement to a cold state. 10. wear-proof material for tubes and headers Anchors are welded on the bends and headers exposed to the erosion of the flue gas, and high strength wear-proof casting material are applied to the anchors. Before applying the casting material, the surface shall be thoroughly cleaned, the refractory layer must be tight, any air hole is not allowed, the anchors must be covered, and the mixing, applying and maintenance of the refractory material shall be in accordance with the requirements of the manufacturer. When laying the wear-proof layer at the bottom of the heating surface, the joint part for the wear-proof layers at the both sides shall not be exposed to the erosion, the best way is to cast the whole panel as an integrated part. The refractory material at the interface of the dense phase and the dilute phase shall not exceed the center line of the water wall over the bends, otherwise, the particles flow along the wall may form a vortex, and the tube may be worn, the detailed please refer to brickwork drawing. 11. Construction of the Boiler Ceiling The wear-proof material shall be cast on the ground at first, and then be lifted to the ceiling. After assembly, the jointing parts shall be filled with casting material. Other heating surface

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and headers can also be assembled after they are cast on the ground. 12. Construction of the sealing device 12.1 Aluminum silicate wool with high temperature glue shall be filled in to all the fireside surface of sealing. 12.2 All expansion joints shall be seal welded to guarantee the air tightness. 12.3 The non-metallic flexible expansion joints at the lower furnace, inlet and outlet of the cyclone separator and under the flue gas damper shall be provided by professional manufacturer, and the construction work shall be made according to the instruction of the manufacturer and drawing requirements and technical specification 13. Construction of the cyclone separator and material return device 13.1 Due to the transportation condition, the cyclone separator shall be cut into several pieces and be assembled in the field. The correct geometry dimensions are very important to the performance and the safety operation of the cyclone separator, therefore the drawing requirements for assembly shall be followed. 13.2 The flue gas temperature within the cyclone separator is above 900C, and the flow rate is relatively high, therefore, large amount of pins are welded inside the cyclone separator to fix the refractory casting material as anti-erosion measures. The refractory material shall be of high wearproof quality and heat vibration stability. The surface of the lining material shall be as flat as possible, and the inlet and outlet transition shall be smooth. The refractory material suppliers requirements shall be strictly followed. 13.3 In side material return device, there are two kinds of different air nozzles, which are installed on the descend section (directly face the return leg of the separator) and rise section respectively, during the installation, the drawing requirements shall be carefully followed to avoid the confusion. Before casting of the refractory material, the holes of the nozzles shall be sealed by plastic band and/or taps, to prevent the holes form blocking. 14. The coil tubes of superheater, reheater and economizer shall be corrected before erection, the deformation during transportation shall be avoided. The wear-proof cover of superheater, reheater and economizer, must align the center line of the tube, to prevent the local erosion. The space between the tube banks and the front and rear wall shall be made according to the drawing, a larger space may form a flue gas aisle which may cause tube erosion. 15. Air leakage is not allowed in the welds of the expansion joints, the sealing plate shall be applied after installation of the lifting hole to prevent the high pressure air flows into the flue gas and result in local erosion. The space between the tube banks and the front and rear wall shall be made according to the drawing, a larger space may form a flue gas aisle which may

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cause tube erosion. Expansion plates is installed between the lowest layer of the tube plate and the support beam, the contacting surface of each expansion tubes shall be clean, and the connection bend plate of lower outlet and flue gas outlet must be firm and air-proof. 16. Insulation shall be applied to the air pipes and steam-water connecting tubes. However the insulation may not be applied to the coal feeding pipe and ash discharge pipe of the separator or only one layer of asbestos rope of 10 mm may be applied. 17. Special attention shall be paid during installation of the convection enclosure tubes of the HRA, make sure the tubes match the HRA. 18. Upper and lower insert tubes are installed into the metal expansion joint of the material return device, during the assembly, the space between the insert tubes shall be evenly. The space shall be covered by the cover of the upper insert tube. During assembly of the flange on both sides of the expansion joint, the gasket made by the silicon aluminum fiber plates shall be carefully disposed. This location is exposed to positive pressure, any leakage would be hard to be controlled, include the flange cover for fly ash recirculation nozzle over the expansion joint. 19. The location and depth of the thermocouple installation shall be made in accordance with the drawing requirements. 20. The metal temperature of the heating surface tubes superheater and reheater system please refer to the arrangement drawing of the measuring points. 21. For all the holes and doors, the inside shall be filled by the pre-fabricated refractory bricks, and then close the cover to prevent the casting material from destroyed by erosion of the circulation material. The refractory material shall be filled in case the distance from the covers at the both sides of the material return device to the grid nozzle is too large, to prevent the formation of the non-fluidized zone and agglomeration. 22. Holes of8 shall be made with a space of 500500 on connecting ducts between the outlet of the separator and convection enclosure, material return device under the separator and the connecting chute between the material return device and furnace during boiler refractory curing, to dry up the moisture in the refractory lining, after the refractory curing and boiling out, the holes can be seal welded. 25. During the site hydraulic test, the water must be clean and of low corrosive to the tube system. 26. The heaviest lifting part of this boiler is drum, which is about 96t (including the drum interior), the diameter is 1.820m, and the length is 17.73m. the main girder is the largest lifting part, with HeightWidthLength=2.60.512.5m and the weight is about 12.5t.

IV. Refractory curing and boiler dry-out (according to the operation instruction of the

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51Y-SM8 boiler) Attention: after the first operation, its very important to check the material return device after first time of operation, during the inspection, the circulation material inside the loop seal shall be discharger, and the foreign material (chippings fall off form the refractory lining during boiler dry-out and curing, the size and weight of these chippings are larger than the circulating material, the material return may be effected if they are not cleaned out ), this is a very important step to make sure the future operation of the material return device.

V: attentions shall be taken for assembly of the tor-shear high strength bolts
Fully steel structure is applied for the boiler structure, the main load bearing member applied high strength bolt connection, the width of the structure id 31 meter ((B0 B31), the depth is 3638meter BEBH), the upper elevation of the main girder is 61meter. The whole structure can be divided by 6 layers, with truss system. 8 vertical supports, i.e. B0B5.5B15.5B25.5B31BEBGBH, are installed to transfer the horizontal force to the boiler foundation, to guarantee the stability of the column and the transfer of the wind and seismic load. 21 columns are installed on 0 meter level; the weight of the main steel structure is 1254 tons. The steel structure is hoisted and installed floor by floor. The construction shall not be continued before the acceptance of the high strength bolts. During installation, all the members shall be installed into place, and special attentions shall be paid during making the construction plan, the weight of different members are as follows: Name 1st floor 2nd floor 3rd floor 4th floor 5th floor 6th floor Top plate Dwg. No. 330B302 330B303 330B304 330B305 330B306 330B307 330B34 Weight 304ton 166.3 ton 209.5 ton 134.3 ton 138 ton 96.6 ton 207.6 ton

Among the members the largest and heaviest member is the main girder DL-5, the HeightWidthLength= 260050012500, and the weight is 12.5 tons Five anti-slip test plates and the temporary bolts (ordinary bolts) for testing the anti-slipping coefficient are to be supplied to site, and the list number is 330B302MX. The special tools for installation, and the quantity of the wenches shall be in accordance with the technical contract, the supplement of these tools please refer to the 330B302MX. 1. Steel structure arrangement area and their serial numbers The steel columns of the boiler are evenly distributed within the plane determined by the axe B0B31 and BEBH.

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1.1 abbreviations Bbeam Hhorizontal support 1.2 examples of the serial numbers 1.2.1 Serial numbers of the beams BE B5.5

Boiler ordinate B5.5 axis Boiler abscissa BE axis 1.2.2 Serial numbers of beam 11 B E 1 Serial No. of beam The beam is within the area of E Means the member is a beam Indicated that the beam is in the 11 meter elevation 1.2.3 Serial numbers of horizontal stay 11 H E 101 Serial No. of the stay The stay is within the area of E Means that the member is a horizontal stay Indicated that the beam is in the 11 meter elevation 1.2.4

1.2.4 Serial numbers of vertical stay

BE ---2

Serial No. of the stay BE axes vertical plane 1.3 examples for the size of specification of the structural members H 4206602030 Hserial No. of column 420 the height of the column height; 660alar plate width 30alar plate thickness; 20web thickness W 3004001020 Wvertical bracing code 300section height; 400alar plate width

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20-- Alar plate thickness; 10web thickness I 500300812 I serial numbers of the beam 500-- Section height; 300 alar plate width 12-- Alar plate thickness; 8 web thickness 2. Attention points for installation of the steel structure 2.1 The measuring tools applied shall pass the examination, and the environments influence to the measuring results shall be taken into consideration. 2.2 Secondary grouting shall be made after the alignment of the column base plate, the grouting shall be filled at least 85% between the foundation and the base plate of the column. And the column plate shall not bear any weight before the finish of the grout curing. 2.3 Color codes of all the structural members are: No. 1 2 3 4 5 6 7 Name 1st floor 2nd floor 3rd floor 4th floor 5th floor 6th floor Top plate Dwg. No. 330B302 330B303 330B304 330B305 330B306 330B307 330B34 Color code Red Orange Yellow Green cyan Blue White

2.4 All the members shall be checked before installation, and the installation shall not be started until all the unqualified members are repaired. 2.5 before installation, the sizes of the beams shall be checked, and the all the vertical columns shall be inspected for the vertical deviation, for the columns of the same floor, the deviation shall be controlled within 1/1000, and deviation for on signal column shall not exceed 25mm. 2.6 Measures shall be taken to eliminate the accumulative deviation before installation 2.7 The load bearing members of the steel structure are made by welding of the plate; the material of the plate is Q345-B. When the thickness of the plate exceed 32mm, the plates are required to be pre-warmed on the field, and the pre-warm temperature is 100150. 2.8 The beam, column and vertical support shall be made by I bars, the horizontal bracing is made by channel steel, and the elevation of the base plate lower surface is -500mm, for each column base plate, 4 adjusting bolts on anchor bolts are provided to adjust the flatness of the base plate. The column joint shall be high than the horizontal supporting plane for 1200mm, and the elevation of the upper surface of the beam is the elevation of each horizontal supporting

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surface 10850 19280 30880 39280 49080,61000 . The structure of the top plate, all the main beams DL-1 DL-2 DL-3 DL-4 DL-5 DL-17 DL-44 shall be connected by high strength bolts on both sides. 3. The boiler is of full steel structure, the connections are made by high strength bolts. Advanced technology is applied and the requirement for installation is strict. The technical specification of the high strength bolts shall be followed during installation and inspection to ensure the installation quality and the stability of the boiler. (The details please refer to the specification for design, construction and acceptance for high strength bolts JGJ82-91). 3.1 During the manufacture of the steel structure connecting piece, the interface is finished by sand blasting, the anti-slip coefficient shall not lower than 0.4, during assembly, all the oxide, burr, oil, paintings and other foreign matter on contacting surfaces, including the contacting surface to the head of the bolts, to nuts, to washers, etc. shall be removed. During the assembly of the high strength bolts, the friction surface shall be kept to be dry. It is prohibited to deliver the assembly work in the rain to avoid any decrease of the anti-slip coefficient and thereby influence the bearing capacity of the steel structure. 3.2 The assembly of the high strength bolts shall be in accordance with the general list of the construction drawing, and the quantity of the bolts provided each day shall be in accordance with the quantity needed for the days assembly, the sealing package of the bolts can only be removed before the bolt assembly, and the bolts shall be randomly disposed. The bolts shall be clean, and maintained in good condition, the length of the bolts must be selected according to the drawing requirement, and the bolts are not allowed to be mixed together. 3.3 The assembly of the tor-shear high strength bolts: friction surface preparation member assembly temporary tightening calibration the installation deviation check and inspection installation of the high strength bolts first time 50% torque structure quality re-check and record final tightening check the tightening quality the rust prevent paint shall be applied locally. 3.4 The assembly bolts (temporary bolts) could be applied for positioning of the members, the high strength bolts shall be applied as temporary bolts, the irrational forced positioning is not allowed. During positioning, the assembly, the quantity of assembly bolts for temporary positioning shall not less than 1/3 of the bolt hole in that area or 2, and the quantity of the positioning pins shall not exceed 30% of the assembly bolts quantity. 3.5 During the assembly, in case any hole for the bolt is not concentric, operations like hamming are not allowed to be applied to make the bolt get through the hole. Reamer is allowed to enlarge the hole while flame cutting is prohibited. 3.6 The surface inclination of the section contact to the head of the bolt shall not exceed 1/20 of the bolt axes, in case the inclination exceed 1/20, an inclined washer shall be applied as an offset method.

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3.7 During first tightening and final tighten of the high strength bolts, the tightening shall be started from the free end, i.e. the bolts shall be tightened from the center and then symmetrical to both sides. The torque for the first tightening (M22) is 300N.M. special wrench shall be applied for final tightening, which shall be finished after the wobbles are wrenched out, for the large joints, the bolt shall be tightened for 3 times: first tighten, second tighten and final tighten. The torque of the secondary tighten is the same with that of the final tighten. 3.8 Bolt joints, contact area and requirements for clearance: 3.8.1 During the assembly of the column, if the end surface contact area exceeds 70%, washer is not required. 3.8.2 When the contact area less than 70% and the clearance not exceed 1.6mm, washer is not required. 3.8.3 when the contacting area less than 70%, and the clearance is between 1.6mm and 6.2mm, washer shall be added, and the washer shall be of low carbon material, the joint shall not be unsupported. 3.9 Clearance between connecting plate and alar plate, and the clearance between connecting plate and the web: 3.9.1 When the clearance less than 1mm, washer is not required. 3.9.2 When the clearance is between 1mm and 3mm: the thicker side shall be cut, and the transition shall be 1:10. 3.9.3 When the clearance is larger than 3mm, the washer shall be placed, and the washer shall be finished with the same requirement to the friction surface. 3.10 When install the horizontal bracing, in case the negative deviation happens to beam and horizontal member, and the requirements for assembly dimension can not be satisfied, comb washer is allowed to be installed. Maximum 2 washers shall be place on each side, and the contacting surface of the comb washer shall be cleaned as the contacting surface. If the clearance is too big, a thick washer shall be applied, both sides of the washer shall be submitted to sand blasting. Anti-rust and anti corrosion painting shall be applied to the joints at each level after the bolt tightening; putty shall be applied to all the clearance. The anti-corrosion painting shall be applied for at least twice to protect the joints. Tor-shear high strength bolt connection Name Performance Material Standard number class Bolt 10.9S 20MnTiB GB/T3632-2008 Nut 10S 35 GB/T3632-2008 Gasket Hardness 45 GB/T3632-2008 For the whole boiler steel structure, the quantity of the high strength bolt connection required is about 40,000 sets. The main structure applies M22 screw holes, the diameter of the holes are 24mm. 4. Opening made for water wall lifting Opening for water wall lifting is allowed for installation of the water wall. The plane of the opening could be made by the installation company, and the precondition is to ensure the stability

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of the whole steel structure.