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VERTICAL BENSON (VOTSG)


BENI SUEF│ BURULLUS│NEW CAPITAL - PROJECTS

EGYPT
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NEM INSTALLATION SEQUENCE

THE PROVIDED SEQUENSE AND PRE-ASSEMBLY STAGES IN THIS


PRESENTATION ARE NOT MANDATORY, BUT A RECOMMENDATION FROM
THE MANUFACTURER AND FOR REFERENCE ONLY.

ALL INFORMATION PROVIDED IN THESE SLIDES IS PRELIMINARY AND


SUBJECT TO FINAL ENGINEERING.
INSTALLATION MAIN STEEL

The boiler main steel columns 2 till 9 are


delivered to site with the side wall casing
attached

8x Pre-assembled main steel columns


with casing panels per boiler

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ARRIVAL AT SITE OF PANELIZED
MAIN STEEL

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PANELIZED MAIN STEEL
INSTALLATION

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PANELIZED MAIN STEEL
INSTALLATION

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PANELIZED MAIN STEEL
INSTALLATION

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INSTALLATION MAIN STEEL

Install the boiler top girders for main


steel columns 2 till 9

8x top girders

Note :
Bolted connections for the main steel
No welding required

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TOP GIRDER INSTALLATION

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INSTALLATION MAIN STEEL

Temporarily store the loose casing panels


by suspending these from the top girders

6 x loose casing panels

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INSTALLATION MAIN STEEL

Install the boiler main steel


columns for row 1 and 10

Install the horizontal bracings

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INSTALLATION OF THE
INTERMEDIATE CASING

Install the (temporarily suspended)


intermediate panels for the boiler
left and right side walls

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INSTALLATION UPPER SIDE
CASING PANELS

Install the upper side wall casing


panels

14 panels in total

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WELD DETAIL FOR SIDEWALL
CASING

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COMPLETION OF MAIN STEEL
STRUCTURE

Complete the main steel


structure by installing the
remaining bracing and stiffener
connections

Note :
Except for the:
-front and rear top space (gray area)
-rear side lower section (gray area)

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INSTALLATION FRONT AND REAR
WALL CASING

Install the casing


panels for the front
and rear wall

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INSTALLATION FRONT WALL
CASING
The front wall
consists of 5 panels

Panels can be bolted


together for quick
installation

Final welding can be


done in a later stage

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INSTALLATION REAR WALL CASING

Rear wall constist of


6 panels

Panels can be bolted


together for quick
installation
Welding can be done
later

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INSTALLATION REMAINING SIDE
WALL PANELS

Install the remaining 4


sidewall panels at
goalpost row 1 and 10,
connecting the sidewalls
with the front and rear
walls

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BOILER REMAINING TOP CASING

Install the 4 top panels


front and rear side

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TYPICAL INSULATION DETAILS
BOILER CASING
Apply internal insulation and liner sheeting to the boiler
casing

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INSULATION INTERMEDIATE
CASING

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INSTALLATION TOP PLATFORMS

During casing and


insulation works install
the:

 Remaining bracings
top side main steel
 Top platform

Note :
This ensures proper access
to the top of the boiler
during module loading

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GROUTING OF MAIN STEEL

Main steel needs to be


grouted prior to module
installation

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PREPARATIONS FOR MODULE


LOADING
TYPICAL MODULE LIFT DURING
TRANSPORT

During transportation
the modules are lifted
using a lifting frame
connected to the module
tube plates

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MODULE PREPARATION ON SITE

The module is
placed on a low
truck or SPMT for
transportation to
the boiler

Module tarpaulins
removed

Headers secured
to prevent sagging

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STRAND JACK SYSTEM ARRIVAL ON
SITE

A hydraulic strand
jack system is used
to lift the modules
into position

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STRAND JACK PLACEMENT ON TOP
GIRDERS

Module strand jack


system consists of :

- 8x module strand
jacks (150T)
- 2x header strand
jacks (20T)

Module connection beams:


- 8x

Module header connectors:


- 2x

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STRAND JACK PREPARATION

Strand jack system


placed on boiler top
girders

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STRAND JACKS ON TOP GIRDERS

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MODULE LOADING
DRIVING FIRST MODULE INTO
POSITION

Drive the module into lifting position and remove the temporary
steel

Temporarily store the field installed baffles and sealing plates on


top of the module prior to lifting (done for logistical advantage)

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MODULE LIFTING

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MODULE LIFTING SEQUENCE

The boiler modules


are lifted per string

First the center module


strings are lifted:

 String Nr. 2 and 3

1 2 3 4 After that the outer


module strings are
lifted:

 String Nr. 1 and 4

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MODULE LIFTING SEQUENCE

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MODULE LIFTING SEQUENCE

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MODULE HEADER ALIGNMENT AND
WELDING

Align the modules and


the headers

Example of a Install the headers


header suspensions where
suspension applicable

Remove the
temporary header
lifting provisions

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MODULE HEADER ALIGNMENT AND
WELDING

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MODULE HEADER ALIGNMENT AND
WELDING

Weld all module


header connections

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BOILER INTERNAL PIPING

Install all boiler


internal piping, till
first circumferential
weld outside the
casing

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INTERNAL BAFFLING AND SEALING
PLATES

Install all HRSG internal:

 Side wall gas baffles


 Side wall sealing plates
 Sealing plates between modules
 Tube plate shoulders

Note:
All baffling and sealing plates were stored on top of the
module during lifting for easy handling

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INTERNAL BAFFLING AND SEALING
PLATES

Tube plate shoulder


(brown)

Side wall sealing plate


(light blue)

Sealing plate between


modules (purple)

Side wall gas baffle

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INTERNAL BAFFLING AND SEALING
PLATES

Install all HRSG internal:

 Hot box gas baffles


 Hot box sealing angles

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STAIR CASE

Install the HRSG staircase

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DRUMS AND HP SEPARATOR INSTALLATION


DRUMS AND HP SEPERATOR
BOTTLE

Install the LP LP Drum


drum IP Drum

Install the IP
drum
HP separator
bottle
Install the HP
separator bottle

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DRUMS AND HP SEPERATOR
BOTTLE

IP and LP steam drum HP separator bottle

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EXTERNAL PIPING INSTALLATION


REMAINING SECONDARY STEEL

Install the remaining


secondary steel, like
platforms, ladders and
supporting, except for the
blow down tank platform

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EXTERNAL PIPING

Start installation of the


boiler external piping

Note:
Piping installation is
executed in parallel with
the secondary steel
installation

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EXTERNAL PIPING

Installation of the boiler external piping

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INLET DUCT AND BOILER REMAINING CASING


BOILER REMAINING CASING –
FRONT AND REAR SIDE

Remaining casing
front :
 2 panels

Remaining casing
rear :
 4 panels

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BOILER BOTTOM INLET DUCT

Install the inlet duct


bottom panels :

 7 panels

inlet duct bottom side

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INSTALLATION OF THE INLET DUCT
BOTTOM PANELS

Install the inlet duct


bottom panels

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BLOW DOWN SYSTEM AND BLOW OFF PIPING


BLOW DOWN TANK

Install the blow down tank including platform


underneath the inlet duct

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BLOW OFF PIPING

Install the blow off piping and steam silencers

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OUTLET DUCT AND TRANSITION DUCT INSTALLATION


PRE-ASSEMBLY OF THE OUTLET
DUCT

Pre-assemble the
vertical panels of the
outlet duct - right and
left side

Total nr. of panels 14x

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PRE-ASSEMBLY OF THE OUTLET
DUCT

• Pre-assemble
the outlet duct -
front and rear
side

• Total nr. of loose panels 8x

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PRE-ASSEMBLY OF THE OUTLET
DUCT

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PRE-ASSEMBLY OF THE
TRANSITION DUCT

The transition duct consists out of 4x 90° shells, which


are pre-assembled into one piece at ground level

The duct is rectangular on the bottom and round on the


top

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OUTLET & TRANSITION DUCT
ASSEMBLY

Install the pre-assembled transition duct onto the pre-


assembled outlet duct

Complete all external insulation and secondary steel for


the assembly at ground level

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FLUE GAS SILENCERS

Install the flue gas silencers on top of the main


steel girders

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OUTLET DUCT

Install the pre-assembled


outlet duct (including
transition duct) onto the
HRSG main steel
structure

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LIFTING OF THE OUTLET DUCT

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STACK DAMPER

The stack damper is


delivered to site in two
pieces

Pre-assemble the stack


damper on the ground

After pre-assembly it
can be lifted on top of
the transition duct

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STACK INSTALLATION
TYPICAL DELIVERY OF STACK
SHELLS TO SITE

The stack sections


come delivered to
site in transport
frames

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PRE-ASSEMBLY OF THE STACK

The stack sections


are delivered in 90
degree shells

8 stack shells per


boiler stack

Pre-assemble the stack


into one or two liftable
parts

Complete all external


insulation and
secondary steel for the
assembly at ground
level

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INSTALLATION STACK

After pre-assembly
completion the stack
parts can be lifted
into position

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LIFTING OF STACK PART

Stack elevation
reached 60m

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INLET DUCT FRONT WALL


THE INLET DUCT – FRONT WALL

Install the Inlet duct front wall


panels

 7 panels

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FABRIC EXPANSION BELLOW

Install the fabric


expansion bellow
between the inlet
duct and the by-pass
stack

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PIPING PENETRATION BELLOWS

Install the fabric


expansion bellows for
all piping penetrations

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CONSTRUCTION COMPLETED

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