Professional Documents
Culture Documents
Boilr Structures
Boilr Structures
ERECTION GUIDELINES
FOR
500 MW
BOILER STRUCTURES
( COAL FIRED CONVENTIONAL TWO PASS DESIGN)
DOC.No: PS:QLY:050
REV.No:R00/09-2004
ERECTION GUIDELINES
FOR
BHEL:PS-SR:QUALITY
AUTHORISED
TO BE USED BY
DOCUMENT NO.
HEAD-QUALITY,PS-SR:CHENNAI
PS-QLY:050
ID No.
DATE OF ISSUE
CONTROLLED/
No.of
ISSUED BY
INFORMATION
SHEETS
COPY
74
R00/09-2004
COPY No.:
ISSUED TO :
HEAD QUALITY
INDEX
PSSR-QUALITY
SL. NO.
01.
Doc. No.
Rev. No.
: R00/ 09-2004
Sheet No.
: 01 / 01
DESCRIPTION
NO. OF
SHEETS
SUPPORTING STRUCTURE-INTRODUCTION
6
02.
FOUNDATION CHECKS
03.
04.
05.
06
07
Ref. Doc.No.2302-82
Released by BHEL-Tiruchy
30
23
BOILER
ERECTION
A)
Introduction
Boiler supporting structure forms 25% of the total weight of a steam generator. The entire
pressure parts are suspended from the structural steel work (Ref Fig.1) . In addition to the
above, air preheater load, partial load of ducting and piping are included. Also it forms
platforms at various levels for the movement of operator and space for maintenance of
various equipments (for Typical Key Plan Ref. Fig.2). Hence structural safety and stability
are the ultimate objectives of the design. The prime aim of an erector is to meet the design
requirements with optimum utilization of men, material and time. To achieve the above,
the erector shall adopt all technological improvements that have taken place in the area of
structural steel erection.
availability of major handling equipments like Tower crane, Crawler crane, etc.
The Supporting Structure arrangement is of welded plus (+) columns with bolted joint
design. The bolted joint design avoids heavy & critical welds between column pieces in
position, as required of tall columns & enables obtaining better alignment, also providing
ease of working. The joints are by using High Strength Friction Grip (HSFG) boltings,
which however, are able to be used carefully as per the specified procedure.
This section describes mainly boiler supporting structure erection upto drum lifting.
However erection activity of supporting structure for airheater, forming part of Boiler
supporting structure etc., continues, on similar lines, till completion. Refer the applicable
FQP for the logsheet formats to be filled and kept as record during structure erection.
B.
Erection sequence with high capacity crawler cranes ( FMC/& Heavy duty cranes like
Manitowac & Sumitomo Cranes)
Sumitomo Crane ( 150 T capacity) has capability to lift to position the columns, bracings
etc. whereas FMC/MANITOWAC Cranes ( 250 T capacity) can position all structural
components including ceiling girders.
The suggested location and movement of the cranes is shown in Fig.3.
Crawler crane of 75T capacity may be employed for pre-assembly area, erecting small
frames, ladders etc.
BOILER
ERECTION
ii) 3rd and 4th as well as 5th and 6th tier columns can be pre-assembled and erected, with
the help of high capacity cranes.
iii) To facilitate crane movement for column erection, defer the erection of a) rear side
Second MBLs, middle columns like S15,S16, S17,S18, S19,S20 & S21 also height
of foundation of these columns, should be temporarily restricted below the ground
level till the crane is moved out of respective locations.
iv) Between S8 and S9 (RHS) Ist tier columns the diagonal bracings can be deferred to
facilitate feeding of pressure parts.
Note: 1) Designers Clearance to be obtained before the above structural members
erection is deferred.
2) Any additional temporary bracings to be erected to take care of the structural
rigidity.
When the above cranes are not available, the following sequence can be followed using the
commonly available TATA 75 T crane.
1)
The crane is
Alternatively, if the full space is available around the boiler the Sumitomo crane can
be kept outside the Boiler when all bracings can be erected in normal sequence
(Generally the availability of space around the boiler is very less since other
agencies are also working). Up to the completion of 5th tier the Sumitomo crane is
used.
3)
Heavy duty crane is now located on the Furnace cavity of Boiler . 6th & 7th tier
columns are pre-assembled and erected.
BOILER
ERECTION
Note:
6th & 7th tier cannot be erected separately since Heavy duty crane boom will be
i)
touching 5th tier when 6th tier erection is being done. Outer columns are to be erected
first before taking up the erection of inner columns to avoid fouling with crane boom.
ii)
While erecting the first piece of all columns ensure correct orientation of its faces with
respect to boiler axis.
4)
Note :
The handling equipments manufacturer recommendations are to be strictly followed while
lifting the load, especially with respect to :
-
Positioning and the movement of crane shall be only on the consolidated and leveled
ground.
Boom swing speed with load shall be monitored.
Measuring Instruments:
The following measuring and test equipments calibration to be done and made
available prior to start of structural erection.
Tape
5 M ,30 M
Adequate Quantity
Torque Wrench
In addition to the above piano wire without knots and kinks plumb bob with oil dash pot and
thermal chalks to be made available.
Calibration:
All the instruments are to be calibrated.
BOILER
ERECTION
A. Civil Foundations:I)
ii)
Top level of each foundation with reference to bench mark, as obtained from
Civil group.
Check for the availability of Boiler axis as marked on the civil foundation.
Foundation bolt disposition with respect to pedestal axis and diagonals Ref.
Fig.4D.
iii) Chip off the pedestal top surface to remove loose layer.
iv) Clean the foundation top surface, bolt pockets and shear lug opening.
v)
Check foundation bolt for verticality and condition & correctness of threads and ensure
the freeness of nut movement.
vi)
Pre determine the packer thickness for each column, as required to get all the
column-top in same level.
BOILER
ERECTION
t mm
A mm
B mm
If
acceptance.
-
The thickness of packers shall be selected in such a way to use maximum of only 5
numbers. If shims are used the same shall be placed between the packers.
ii)
Chip the pedestal surface at packer location for proper seating of packer.
Or
The first packer can be aligned over the rough concrete (without chipping for level)
using high strength quick setting cement.
manufacturers recommendation.
Locate packers such that Grouting holes are not covered. If the shear lugs interfere,
the packers are to be cut & dressed suitably Ref.Fig. 5B.
iii)
Set the required thickness of packer assembly using minimum number of packers,
possible.
iv)
BOILER
ERECTION
A)
i)
Preparation of pre assembly bed is very much essential for pre-assembly of columns
keeping the piece in + position. The pre assembly bed shall be arranged in such a
manner that each column piece should have minimum three bottom supports (one at
the middle and other two one meter away inside from the column ends) to avoid excess
sagging or over hanging of pieces at ends.
consolidated and hard ground to avoid any possible sinking of bottom supports during
loading with column pieces. The span between the supports to be decided based on
the individual piece length. The width of the bed shall be minimum 6 metres so that
three or four individual column pieces can be pre-assembled at a time, with the help of
gantry crane. The bed preparation should suit the pre-assembly of ceiling girders and
pressure parts also and located as near as possible to the boiler area.
The suggested pre-assembly bed arrangement is indicated in Fig.No.6.
Note : Top level of all support beams shall be maintained with in 3mm using water
level. Minor adjustments to be made using shims to accommodate the section variation
of individual column pieces.
ii)
iii)
Position the column pieces on the pre-assembly bed as shown in Fig. 6. The preassembly bed shall be treated as firm/hard earth, prepared for the purpose.
BOILER
ERECTION
Note :
1)The match marks on the column pieces shall be strictly used for assembly to
avoid interchanging / rotation.
2) Fig.8 shows the typical erection joint (bolted) as prepared at the works.
3) Avoid slinging structural members without a protective material like flexible thick non
metallic piece.
iv)
Check and measure the individual column pieces & ensure that the following are within
the limits.
-
Camber
Sweep
Ensure cleanliness of cover plate area in the flange and web in the column joint area.
vi)
Align all the pieces by pulling each piece to have no gap at erection joints.
vii)
viii)
Align flange to flange match marks for both the flanges as per the erection joint details.
B
i)
ii)
iii)
Measure and record the distance from o Meter to bottom of the base plate. Based on
this the packer thickness for individual column is decided.
iv)
Cleat angles / seating plate to be welded at the appropriate level for the placement of
horizontal members on flange and web side. (Ref. Fig.10A & 10B).
v)
Fix the verticality stickers over individual column pieces on both the flanges (90 apart)
in two places (near MBL locations). Ref.Fig.12.
BOILER
ERECTION
-
For bottom piece at 1 M elevation and below the bolt joint area at the convenient
level.
For other pieces near ends (just near erection joint area) at the convenient level.
Note: The centerline of stickers shall be matched with centerline marking of web and
flanges (shop punched). Refer Fig.12.
vi)
Dismantle the column pieces from the pre assembly bed and stack it near the erection
area to suit the sequence of erection, from bottom to top.
C)
ii)
Place the Bottom column piece over the foundation with out damaging the bolt
threads, while lowering the piece through the bolts.
Tighten the foundation nut and recheck the alignment. In case of any disturbance noted,
alignment procedure to be repeated.
vi)
Erect the horizontal members between the aligned boxes (Fig 16) Length variation if
any may be corrected.
x)
Complete the welding of cleat angle with horizontal member and column (between
boxes).
10
BOILER
ERECTION
xi)
Erect and align the vertical bracings. Refer Fig. 17A, 17B, 17C, 17D, 17E. Position,
align and weld the gusset plate at its location.
xii)
xiii)
Erect and align the horizontal members and vertical bracings and complete the
welding
xiv)
Complete the erection alignment and welding of Main Brace level (MBL) members in
the boxed up section.
xv)
xvi)
xvii) Prepare the protocol for the completion of first piece erection and obtain clearance for
second piece erection.
Note:
Second tier erection is started after 7 days from the date of grouting. With quick set
Grout material second tier shall be started after 72 Hrs. Strength of grout should be
ensured by means of cube test.
xviii) The above steps in general are to be followed for subsequent tiers ( Fig. 18)
-
While erecting the second column piece align for erection joint matching, tighten
the hold down bolt with stopper / end plate.
- Provide the splice plate and hand tighten HSFG bolts as per shop match marks.
Note: The second piece is held in position with the crane till the completion of splice
plate and fixing of HSFG bolts.
- Erection, alignment and bolting sequence explained above shall be followed for the
subsequent pieces erection.
Note:
(a)
The vertical bracings at the top levels may be deferred till the erection and
alignment of ceiling girder for easy adjustment. For rest of the columns erect
the vertical bracings and do final welding.
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
BOILER
ERECTION
(b)
(c)
Prior to erection of top column piece, the girder pin connection matching and welding of
support plate with column top shall be completed as explained below:
-
The girder pin connection assembly is applicable for S8, S9, S10 & S11 Columns
(both right & left)
Align the axis of girder pin bottom part and column top.
Typical girder pin connection details are shown in the Fig. 20A & 20B.
Check the contact surface between bottom part of girder pin with flange web and
stiffener portion of column top using feeler gauge. (Blue matching not required).
Assemble the holding down plate with fasteners and align with column top and pin
assembly bottom part on either side of the flange.
Tack weld the holding down plate with column and bottom part of pin connection.
Provide stiffener to avoid welding distortion.
26
27
28
29
BOILER
ERECTION
i)
ii)
iii)
iv)
v)
vi)
vii)
d)
1.0
a)
b)
c)
d)
e)
f)
g)
2.0
Vertical bracing gives lateral stability to column offering resistance to horizontal forces
coming on the structure & transferring the forces to column base / foundation safely.
To maintain column stability in both X, Y direction against lateral buckling, lateral
supports are to be given.
Lateral support is given by the net work of horizontal bracings at about 8 to 10M
height interval.
Horizontal bracing gives resistance to lateral buckling of columns due to wind /
seismic / stability force.
The horizontal force through the horizontal bracing system is transferred to vertical
bracing nodal points, and from there to the ground without causing undue sway to
column.
Discontinuity in horizontal bracing will result in ineffectiveness & will not give
resistance to the sway of column effectively.
To transfer the lateral forces effectively to ground continuity of vertical / diagonal
bracing from ceiling to column base is very much essential.
Welding, Pre-heating and Non-Destructive Examination and post heat treatments
requirements.
Welding
Welders shall be qualified as per Welding Manual.
Welding consumables conforming to the design requirements shall be used.
Selection of welding consumable shall be out of the Approved list of welding
consumables issued by Welding Technology Centre, Trichy.
Manufacturers batch certificates are also to be verified.
Welding consumables used for this are to be stored properly and issued after
necessary baking. Electrodes issued for job should be kept in holding ovens and
maintain the temperature. The above are to be carried out as per Welding Manual.
Welding shall not be done when the surfaces are wet, oil traces are seen or
exposed to rain or high wind or when the welders are exposed to inclement
conditions.
The sizes and length of weld shall not be less or substantially in excess than that
specified in the drawing.
3.0
NDE Requirements
Refer NDE Manual
30
BOILER
ERECTION
A)
Position the girder pieces over the pre assembly bed inside the furnace cavity
keeping left, middle and right side pieces following shop punch mark details.
Typical details of girder pieces are given in Annexure I.
Web height at extended portion and compare with flange to flange inner distance
( For easy insersion 1 mm gap to be ensured on either side. If required grind web
ends to achieve the above).
i)
Repeat the dimensional check, carried out prior to welding, after Post Weld Heat
Treatment and compare the two.
ii)
iii)
Check the holes drilled in the web of ceiling girder (distance from the end and
Centreline distance of each group of holes, which is the Centreline distance of
Welded beams).
Check the size and location of pad plates welded on the web of ceiling girder.
These pad plates are to be welded only on sides and bottom face.
iv)
v)
vi)
vii)
Ensure pre-assembly bed is made on the leveled and consolidated area to avoid
sinking during placement of girders on the bed.
Ensure the pre assembly bed members are properly spaced to avoid sagging of
girder pieces when they are placed over it. ( Refer Fig . 22);
Match the pieces as per match marks provided in the pieces.
orientation of girder pieces as per drawing (Ref.Fig. 23 A & 23B)
Ensure the
BOILER
ERECTION
1.0
Fit Up :
a)
While leveling the pieces, the reference lines punched on the web at about 1 to 1.5M
level from bottom flange may be taken as reference.
b)
While adjusting the overall length of the girder, check the distance between girder pin
connection bolt hole centers which is marked in the bottom flange and as well as on
the top flange.
While adjusting the overall straightness of the girder piece the longitudinal centerline of
the girders and web line marked on the pieces may be taken as reference.
While matching the piece, flange root gap and web root gap shall be maintained
between 4 to 6mm and 6 to 8mm respectively in the field joint areas (Ref. Fig.23B).
c)
d)
e)
f)
Butting parts to be joined by butt welds shall be carefully aligned. An offset exceeding
10% of the thickness of the thinner part, but in no case more than 3.2mm may be
permitted.
Members to be welded shall be properly aligned and held in position by bolts, clamps,
wedges and other suitable devices until welding is completed.
g)
h)
i)
2.0
No tack weld to be made in the web for aligning. Instead L clamps and wedges shall
be used for web alignment to keep the joint free during the welding of flange joint.
Ensure after dimensional check-up the girder assembly is properly locked in position by
using stoppers, L clamps, wedges, guy ropes and struts or by any suitable device to
avoid distortion during welding and Post Weld Heat Treatment operations. Ensure
proper locking, in such a way that the girder assembly can move longitudinally during
welding and Post Weld Heat Treatment operations to avoid accumulation of thermal
stress.
Dimensional check-up:
a) Section depth and flange width can be checked as cross reference since these
are already checked up in shop.
Tolerance : Section depth upto 1 M
- 3mm
Above 1 M upto 2 M
4.5mm
Above 2 M
+7.5mm
- 4.5mm
3mm
Flange width
BOILER
ERECTION
2.0
b) Check the following dimensions prior to clearing the assembly for welding and are to
be recorded in the log sheet.
1.
2.
3.
4.
5.
6.
Dimensional tolerance:
1. Individual piece camber and sweep
- Max. 5mm
2. Individual piece length
- 5 mm
3. Level of girder assembly
- Max. 5mm
4. Deviation in straightness on total length
- Max. 15mm
5. Flatness of Web
- Max. 10mm
6. Out-of squareness of assembly
- Max. 8mm
7. Overall length of assembly
- 15mm
(With the recommended gap for welding of web and flange at field joints, the overall
length of the girder shall be achieved within limits after allowing weld shrinkage).
8. Flatness of bottom flange at girder pin connection location . - Max.2mm
9. Longitudinal and cross diagonal of assembly(difference)
- Max.15mm
4.0
Pre-heating
a) Pre-heat temperature required for various range of plate material
thickness is as follows:
t
t
t
t
:
:
:
:
upto 19mm
over 19mm upto 38mm
over 38mm upto 63mm
over 63mm
Nil
65 C
100C
150 C
b) It is desirable to pre-heat using electric resistance coil heaters. Use of self pre-heat
is not permitted.
c) When electrode of 3mm and below are used the minimum pre-heat temperature
shall be increased by 50 C from the pre-heat temperature mentioned above.
5
BOILER
ERECTION
5.0
Welding
a)
b)
c)
d)
Welding consumables used for this are to be stored properly and issued after
necessary baking. Electrodes issued for job should be kept in holding ovens and
maintain the temperature. The above are to be carried out as per welding
manual.
e)
f)
g)
Complete the root plus three runs on inner side as per the sequence shown in
Fig. 24A.
h)
Back gouge/chip the weld from outer side and carryout LPI/MPI tests for ensuring
defect free root weld.
i)
Complete the outer side weld for three runs as per the sequence indicated in Fig.
No.24A.
Complete the flange joint weld, around 60% thickness of the joint on both sides of
flange alternately ( inner and outer) as per the sequence shown in Fig. 24B
After completion of 60% of flange welding check the web alignment (adjust with
wedges to achieve web alignment if required.)
j)
k)
l)
m) Preheat to 150 C and adopt the weld sequence for the web root welding plus
two runs as shown in Fig. 24A.
n)
Back gouge /chip the second side of the weld to achieve defect free root weld.
o)
p)
Complete the two runs of weld on the second side as per the sequence shown in
Fig.24B.
q)
Complete the balance flange joint and then the balance web joint as per the
sequence indicated respectively in Fig. 24A & 24B.
Note: The welding sequence of flange and web can be changed
on the number of welders engaged.
depending
6
BOILER
ERECTION
r)
Complete the fillet welding between flange and web on both sides.
s)
Carry out the post heating of weld joint for 1 hour at 250C
t)
Welding shall not be done when the surfaces are wet, oil traces are seen or exposed to
rain or high wind or when the welders are exposed to inclement conditions.
The sizes and length of weld shall not be less or substantially in excess than the
specified in the drawing.
u)
6.0
Butt welds in plates over 50mm thick shall be subjected to Post Weld Heat Treatment.
For unequal thickness of plates, the groove depth at the weld shall be considered for
Post Weld Heat Treatment.
The fillet welds for fixing attachments like pads etc. made on tension flanges over
b)
50mm thick shall also be post weld-heat treated.
For high tensile steels : ( DIN 17100 ST 52.3, IS 961 HTW)
Butt welds in plates 50mm and above thick shall be Post Weld Heat Treated. For
a)
unequal thickness of plates, the groove depth at the weld shall be considered for Post
Weld Heat Treatment.
The fillet welds for fixing attachments like pads etc. made on tension flanges 50mm
b)
and above thickness shall also be post weld heat treated.
a)
For the fillet welds joining the tension flange to web need not be out post weld heat treated.
All the post weld heat treatment cycle range shall be 600C to 650C. The above cycle shall
be controlled within a tolerance of 10C. The recommended temperature for Post Weld
Heat Treatment must be selected as the mid point of the recommended range.
Soaking time for Post Weld Heat Treatment shall be 1 hr. /25mm thick upto 50mm and 2 hr
+15 minutes for each additional 25mm thickness over 50mm.
The heating rate above 400C and cooling rate after Post Weld Heat Treatment upto 400C
shall be as follows:
Thickness range
Rate of
Rate of Cooling ( Max)
Heating (Max)
Upto 25mm thick
220C /hr
110C/hr
110C/hr
110C/hr
75C/hr
110C/hr
55C/hr
65C/hr
10
BOILER
ERECTION
Autographic calibrated recorder shall be used to record rate of heating, soaking and rate of
cooling. Fixing and location of thermocouple shall be made as per details in Welding Manual.
(Typical case Refer to Fig. 25 & 26).
7.0 Non Destructive Examination ( N.D.E.)
Ceiling girder assembled keeping web vertical.
Cut edges
a) Flame cut welding edges for thickness over 38mm 100% MPI
b) Random MPI for all edges of thickness above 20mm
Weld build up areas
Weld build up areas in flanges and web 100% MPI/LPI.
Flange butt joint
100% MPI for thickness 25mm and above.
100% RT for thickness 32mm and above.
Web butt joint
a) 100% LPI for back gouged/chipped area before second side welding.
b) SPOT RT 10% The defective areas shall be further repaired and re-radiographed.
Fillet welds
a) Fillet weld between ( tension) bottom flange and web 100 % MPI
b) When both flange and web are above 25mm 100% MPI
c) Other fillet welds random MPI.
8.0 Final check up and finishing:
After Post Weld Heat Treatment, surface to be cleaned properly and painted with two
coats of red oxide primer.
Cement washed surfaces are to be cleaned properly in the HSFG bolt area including
cleat angles.
Dimensional check-up of girder shall be carried out and to be recorded in the log sheets.
No stray arc shall be done on heat treated members.
B.
All the main columns except middle columns shall be erected, welded and bolt
tightened.
All main horizontal members, diagonal bracing shall be erected in that particular span
where the girder is lifted.
Verticality of columns shall be checked and logged.
One side of staircase shall be completed upto 75 metres so as to facilitate easy
movement of persons during erection.
11
BOILER
ERECTION
5.
6.
7.
Temporary platform shall be made around the column top so as to facilitate column
bolting with the ceiling girder.
Connected welded beams shall be kept ready for erection immediately after girder
erection.
Guy ropes with pulling machines shall be tied to the columns and anchored at both
sides of columns so as to have adjustment at the top during erection.
(B) Preparation of Heavy duty crane ( FMC crane) for girder lifting
After completion of preassembly of girders all the four ceiling girders are erected with
the help of FMC crane/ Heavy duty crane with ringer attachment.
The FMC crane LS 718 HL 250 T cap. /heavy duty crane shall be assembled with 310
ft boom with ringer attachment. The crane shall be assembled near Electrostatic
Precipitator area and moved inside the furnace cavity.
Heavy duty crane with ring horse attachment involves following assembles.
a) Crawler and cabin
b) Ringer attachement
c) Mast assembly
d) Boom assembly
e) Arrangement of jacks
f) Reeving of boom wire rope.
g) Loading of counter weights.
h) Fixing of jib.
After complete assembly, the crane shall be moved to the furnace cavity.
Girders shall be erected from the predetermined positions in furnace cavity as per
Fig.27 welded beams on front side, Girder B & Girder C shall be lifted from
position I. The girder D & E shall be lifted from position II.
(C)
1.
2.
Preassembled ceiling girder shall be shifted from preassembly bed to the nearest
columns.
The girder shall be assembled with pin connection assemblies at both ends.
3.
4.
The girder shall be kept at angle of 20 degree to the horizontal plane as the length
of the girders is more compared to the span of the column.
Temporary Platform shall be made around girder for easy movement at top. The
typical arrangement is shown in Fig. 28.
5.
12
BOILER
ERECTION
4.
80mm wire rope 16 M long 2nos shall be tied to the girder at the center as
shown in Fig. 29.
Two Nos. D-Shackles shall be tied to each one of top portion of slings.
Two Nos arrestor channels shall be provided to keep both the slings at a
distance.
The details of slinging is shown in Fig.29
5.
Small tools like spanners, pulling machine etc. shall be kept ready.
6.
The list of Tools and Tackles for ceiling girder lifting is given in Annexure II.
2.
3.
(E)
1.
2.
3.
4.
Erection check list shall be completed before erection of ceiling girder. Typical
check list is shown in Annexure III.
Heavy duty crane shall be positioned at a predetermined distance in the
furnace cavity.
It is preferable to start girder erection early morning so as to avoid heavy wind.
The girder shall be lifted slowly at an inclined direction with respect to
horizontal plane.
5.
Manila rope tied at the both ends shall be controlled to avoid sway during
erection.
6.
After reaching top of column, the girder shall be made parallel to column and
kept over the columns.
7.
8.
9.
13
ANNEXURE I
14
15
16
17
BOILER
ERECTION
ANNEXURE - I
Sl
CEILING
LENGTH
WIDTH
THICKNESS
THICKNESS
THICKNESS
DEPTH
WEIGHT
No
GIRDER
IN MM
IN MM
OF MIDDLE
OF END
OF WEB MM
IN MM
MT
FLANGE MM
FLANCE MM
63
50
MID : 25
3788
50
3780
54
3788
60
3800
103
DESIG.
01.
25710
1000
END : 32
02
25710
1300
50
40
MID : 25
END : 36
03
25700
1400
56
50
MID : 25
END : 36
04.
29510
1500
100
75
MID : 32
END : 50
18
BOILER
ERECTION
1 No
2 Nos
4 Nos
4 Nos
2 Nos
2 SETS
2 NOS
19
BOILER
ERECTION
CONTRACTOR NO.
__________________________
__________________________
REFERENCE DRG.NO.
__________________________
SL.No. PARTICULARS
1.
CHECKS
SIGNATURE
REMARKS
2.
3.
4.
5.
Trial lift
6.
7.
8.
BOILER
ERECTION
9.
10.
Communication arrangement
11.
Manpower availability
12.
Remarks
CONTRACTOR
Remarks
BHEL/ERN.
Remarks
BHEL/QAE
CUSTOMER
21
BOILER
ERECTION
SL
PARTICULARS
CHECKS
SIGNATURE
REMARKS
NO
1.
2.
Verticality of columns
(All required).
3.
4.
5.
6.
7.
8.
9.
10.
11.
22
BOILER
ERECTION
12.
13.
14.
15.
16.
17.
18.
19.
23
BOILER
ERECTION
1.
Mark the drum axis from A girder centerline and arrive at furnace axis.
2.
The drum, furnace and boiler axis shall be punch marked over WBs and ceiling girder.
(For drum and pressure parts erection reference).
3.
Erect, align and weld the drum suspension support beam on either side of boiler axis.
4.
5.
Erect, align, and weld cat head structure (A frame) for the purpose of drum lifting
arrangement as per contract drawing.
6.
Erect, align and weld staircase on both sides up to drum level (Ref. Section on Stairways
& Galleries).
7.
Provide temporary approach ladder (From drum level to ceiling girder level) and platform
for drum lifting operation.
8.
The minimum structural requirements are to be completed in all respect and the structure
shall be cleared for drum erection.
9.
The following are the minimum requirement of structure for drum erection.
BOILER
ERECTION
MA
Description
01.
35
010
Foundation Materials
02.
35
111
Ist Pass
03.
35
112
2nd Pass
04.
35
121
1st Pass
05.
35
122
2nd Pass
06.
35
130
07.
35
140
08.
35
150
09.
35
190
10.
35
211
1st Pass
11.
35
212
2nd Pass
12.
35
213
Cross Girder
1st Pass
13.
35
214
Cross Girder
2nd Pass
14.
35
221
1st Pass @
15.
35
222
2nd Pass @
16.
35
231
Ceiling Bracing
1st Pass
17.
35
232
Ceiling Bracing
2nd Pass
18.
35
311
1st Pass
19.
35
312
2nd Pass
20.
35
321
1st Pass
21.
35
322
2nd Pass
22.
35
331
1st Pass
23.
35
332
2nd Pass
24.
35
341
1st Pass
25.
35
342
2nd Pass
26.
35
351
1st Pass
27.
35
352
2nd Pass
28.
35
361
1st Pass
29.
35
362
2nd Pass
2
BOILER
ERECTION
36
381
Landing Platforms
1st tier *
31.
36
382
Landing Platforms
2nd tier*
32.
36
383
Landing Platforms
3rd tier*
33.
36
390
Drum Floor *
34.
36
441
1st Pass
35.
36
442
1st Pass
36.
36
443
1st Pass
37.
36
451
2nd Pass
38.
36
452
2nd Pass
39.
36
453
2nd Pass
40
36
511
41.
36
512
42.
36
513
43.
36
521
44.
36
522
45.
36
523
46.
36
531
47.
36
532
48.
36
533
50
36
700
Fasteners
51.
36
811
52.
36
821
53.
36
822
54.
36
823
55.
36
851
@ -
Rolled shapes which are required for drum lifting are to be erected and
others as and when requirements arises.
* These items are not mandatory for drum lift, but may be important from
regulation, operation / erection and health/safety point of views.
NOTE: For details refer applicable PGMA list.
statutory
BOILER
ERECTION
1.0 After completion of drum erection the following activities are to be carried out
immediately.
1.1 Check the verticality of column and cross refer to verticality readings taken after ceiling
girder alignment.
1.2 The left out member in MBL for drum erection in the furnace region are to be erected.
1.3 Remove the temporary structure erected, if any after the erection of permanent
members.
1.4 Erect the support structure for silencer.
1.5 Position the silencer on support structure and arrest temporarily for safety reason.
1.6 Erect align and weld all Rolled Beams for starting of pressure part work.
Note: Erection sequence for Sl.No. 1.4 to 1.6 is depending upon the availability of Tools
and Plant.
2.0 Heavy duty crane shall be deployed for completing the erection alignment and welding of
monitor roof assembly ( Ref Fig.31A & 31B)
3.0 The balance members of PG-35 and PG-36 are to be erected aligned and welded in a
phased manner for ease of pressure parts erection and approach to various locations.
4.0 Complete the erection, alignment and welding of PG 39 members (Fans and duct
structure) in a phased manner as per site progress.
5.0 Complete the erection, alignment and welding of structure between units, boiler and D
row columns, boiler and bunker bay.
6.0 Do not cut structural members in case there is interference with boiler components.
Consult the designer for comments/correction work.