Boiler Erection

BOILER ERECTION
• Column erection • Pressure part erection • Miscellaneous

COLUMN ERECTION
• The boiler presently in use are hanging type. • The column are broken up during manufacture into several pieces and transported to site • Where it is pre assembled in two or three pieces and erected. • Utmost care is taken in the pre-assembly stage to maintain the matching of the of the column end faces and to achieve vertically well within the tolerance limit

COLUMN ERECTION
• Verticality is single most important factor and is given top priority • The maximum column verticality is 20mm. • Once the column erection is over up to the full height cross beams are placed securely over the column which supports the main boiler

entire structure is adequately braced to achieve sufficient strength. • After cross beam erection. .COLUMN ERECTION • In order to carry out this job special erection tool like cranes with extra long boom to carry heavy loads at that height are used.

PRESSURE PART .

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3. Advantage and Weakness of Construction Method Description \Type ▣ Modulization / Concurrence Construction Methods ▣ Typical Construction Method Advantage ⊙ Competitive time for completion ⊙ Earlier completion through Modulization /Concurrence Construction ⊙ Many years of experience and Know-How To utilize standard data /Data base ⊙ Reduction design M/H Curtailment of S/S materials Reduction manufacturing/installation cost ⊙ Lay down Area need for pre-ass’y at site ⊙ Increasing Equipment / Construction Labor Cost S/S materials (about 50% ) ⊙ Long time for completion ⊙ High risk of safety accident due to lots of works at the high elevation Weakness ⊙ Increasing Module temporary material and ⊙ Long duration for S/S design and Complicated design .

. Comparison of Construction Methods ▣ Modulization / Concurrence Construction Methods ▣ Typical Construction Method ⊙ Concurrent construction of S/S and Boiler ⊙ S/S Modulization on the ground ⊙ Core Frame. Erection ⊙ Unit Lifting and installation ⊙ Using special Lifting device : Hydraulic jack .Assembly after installation : 30% ⊙ Planning and scheduling for concurrent construction sequence Planning ⊙ Using ordinary construction lifting device ⊙ Site assembly of Boiler equipment ▶ .Ground assembly : 70%.Assembly after installation : 80% .Ground assembly : 20%.2. Subsidiary S/S and Boiler installation at the same time ⊙ Boiler installation after completion of S/S installation with Bottom-Up method ⊙ Separate installation of S/S 1Tier ~ 5 Tier ⊙ Lifting after Moduliztion on the ground.500Tons] ⊙ Site assembly of Boiler equipment ▶ . .to be able to lift Module [2.

5 Momth 76m x 41m x 41m HxWxD 560MW x 2 Units Main Proper 5.643tons Boiler weight S/S 9.103tons Boiler weight S/S 5.191tons Duration (S/S at site~Firing) 15.08.14 Duration (S/S at site~Firing) (25 M) HxWxD 76m x 37m x 42m .07.16~1992.200tons 1990.Compare to Main Erection Process Modulization / ConcurrenceConstruction Methods Typical Construction Method 660MW x 2 Units Main Proper 5.

▷ Lifting S/S after pre-Ass’y Core Frame on the ground ▷ Pre-assembling Pressure Parts After Starting S/S ▷ Separately lifting STL/STR ▷ Pressure Parts unfurnished Core Frame Module Work Stand 1Tier Modulization/Concurrent Erection Method ? ? Typical Construction Method .

▷After installation of S/S Core Frame to install Pressure Panel and subsidiary-S/S at the same time ▷ Coil Modulization on the ground 2 month after starting S/S ▷Completion S/S 2 tier Sub-S/S Ass’y 2Tier 1Tier Modulization/Concurrent Erection Method Module Work Stand Typical Construction Method ? ? ? Panel Ass’y .

▷ In the process of Modulization of Boiler Furnace & Back Pass on the ground ▷ S/S Heavy Girder installation (Using Crane) ※ 2 month after Starting S/S Heavy Girder Lifting ▷ S/S Heavy Girder installation (Using Crane) ※ 6 month after starting S/S Heavy Girder Installation Heavy Girder Installation Module Ass’y on the Ground Modulization/Concurrent Erection Method Typical Construction Method ? ? .

5 month earlier in comparison with Typical Method [Drum lifting point] ▷ S/S Core Frame design for Boiler load support ▷ Module work on the ground and concurrence installation of S/S and Boiler Lifting using Hydraulic Jack DRUM Lifting ▷ After completion of S/S 1~5 tiers starting pressure parts installation ※ 7.▷After S/S Core Frame / Heavy Girder completion starting sub-S/S installation and 20% of Pressure parts installation ※3 month after starting S/S ▣ 4.5 month after starting S/S Winch Drum Drum Pressure Parts Module assembly on the ground Modulization/Concurrent Erection Method ? ? Typical Construction Method .

▷ Back Pass module assembly on the ground ▷ Lifting after Boiler Coil Module work (Using Hydraulic Jack) ▷ Lifting after Sub-S/S module assembly Hydraulic Jack After Drum lifting ▷ Completion of S/S installation ▷ Separate installation of Boiler Pressure parts (Using Winch) Winch Back pass Module assembly on the ground Modulization/Concurrent Erection Method Typical Construction Method ? Coil Module Lifting ? .

5 month after starting S/S Hydraulic Jack Back Pass Lifting ▷ Completion of S/S installation ▷ Separate installation of Boiler Back Pass (Using Winch) ※ 16.5 month after starting S/S Winch Back pass Module Lifting 中 Modulization/Concurrent Erection Method Typical Construction Method ? ? .▷ 50 % completion of total S/S installation ▷ Concurrent Lifting Boiler Back Pass and S/S Support (Using Hydraulic Jack System) ※ 8.

60 % completion of total S/S installation 100% completion of Boiler pressure parts installation ※10 month after starting S/S Hydro Test ▷ Completion of S/S installation ▷ Completion of Boiler pressure parts installation ※ 19 month after starting S/S ▣ 9 month earlier in comparison with Samchunpo [Hydro test point] ▷ Installation S/S Aux. after Hydro test ▷ Ground Module assembly and S/S & Boiler concurrent construction ? Modulization/Concurrent Erection Method Typical Construction Method .

5 month after starting S/S ▣ 9 month earlier in comparison with Typical Method [First firing point] ▷ Ground Module assembly and S/S & Boiler concurrent construction First Firing Completion of S/S installation Completion of Boiler installation ※ 24.5 month after starting S/S Modulization/Concurrent Erection Method Typical Construction Method .Completion of S/S installation Completion of Boiler installation ※ 15.

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation Install Heavy Girder after Panel Erection .

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation Assemble RH Final & SH Final Tube Module .

Sequence of Modulization / Concurrent Installation Install Jack for Drum .

Sequence of Modulization / Concurrent Installation DRUM LIFTING .

Sequence of Modulization / Concurrent Installation Install Downcomer pipes (6ea) .

Sequence of Modulization / Concurrent Installation .

Module Assemble Back Pass Module (Hanger rods. roof panel. LTRH) .Sequence of Modulization / Concurrent Installation Prepare the Assembling of SH DIV.

Module .Sequence of Modulization / Concurrent Installation Lift the Subassembled SH DIV.

Sequence of Modulization / Concurrent Installation Install the Jack for SHP & RHP .

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation Install the Jack for Back Pass Module Lifting .

Sequence of Modulization / Concurrent Installation Install the Wire for Back Pass Module Lifting .

Sequence of Modulization / Concurrent Installation 1’st Lifting of Back Pass Module .

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation Assemble the Back Pass Wall Panel .

Sequence of Modulization / Concurrent Installation SH tube bundle lifting Lower panel lifting Assemble Back Pass LTRH Arch lifting .

Sequence of Modulization / Concurrent Installation .

Sequence of Modulization / Concurrent Installation Assemble Eco Tube. Eco Header .

Sequence of Modulization / Concurrent Installation Back Pass Module Final Lifting .

Suction inlet piping. . Water inlet header. Hopper panel.Sequence of Modulization / Concurrent Installation Install the Burner windbox. Low water panel.

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