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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
PREPARED &
APPROVED BY BHEL:PS-SR:QUALITY
AUTHORISED
TO BE USED BY HEAD-QUALITY,PS-SR:CHENNAI
NO. OF
SL. NO. DESCRIPTION
SHEETS
30
03. PRE ASSEMBLY AND ERECTION OF COLUMNS
23
04. PRE ASSEMBLY AND ERECTION OF GIRDERS
3
05. PREPARATION FOR DRUM ERECTION
2
06 POST DRUM ERECTION CHECKS AND WORKS
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. The sequence of structural erection mainly depends on the
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.
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BOILER 01. SUPPORTING STRUCTURES
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 MBL’s, 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) 75 Tonne capacity crane can be deployed upto 2nd tier erection. The crane is
positioned inside the Boiler area. Sumitomo (150T) crane is used for further
erection. Bracings between columns, S1 and S2 (left) S7 and S8 (left) can be
deferred to bring in the Sumitomo crane and between column S7 and S8 ( Left) to
take out the same on erection completion of 5th tier.
2) 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.
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BOILER 01. SUPPORTING STRUCTURES
ERECTION
Note:
i) 6th & 7th tier cannot be erected separately since Heavy duty crane boom will be
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) Complete the structure erection by pre-assembly and assembly of ceiling girders A,
B, C, D, E.
Note :
The handling equipments manufacturer recommendations are to be strictly followed while
lifting the load, especially with respect to :
- Lifting load with respect to boom angle shall be monitored.
Positioning and the movement of crane shall be only on the consolidated and leveled
ground.
- Boom swing speed with load shall be monitored.
C 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 650 – 1000 ft Lbs
Bolt tension calibrator, torque wrench calibrator.
Temperature recorder (range 0 to 1000º C)
Theodolite – Minimum 2 Nos. ( One second accuracy. One number for
verification and other one for checking column verticality).
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. The calibration Certificate should have cross
reference of master calibrator and identify with the National Standards.
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02. FOUNDATION CHECKS
BOILER 02. FOUNDATION CHECKS
ERECTION
A. Civil Foundations:-
I) Refer Fig. 4A for typical arrangement of column foundation.
ii) Check the following.
- 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.
transverse axis)
- 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.
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BOILER 02. FOUNDATION CHECKS
ERECTION
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03. PRE ASSEMBLY AND ERECTION
OF COLUMNS
BOILER 03. PRE-ASSEMBLY AND
ERECTION ERECTION OF COLUMNS
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BOILER 03. PRE-ASSEMBLY AND
ERECTION ERECTION OF COLUMNS
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
- Shear lug location in case of first column base plate.
Refer to manufacturing unit for repair procedure / Comments wherever required.
v) 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) The details of centerline marking done at shop is indicated in Fig. 9.
viii) Align flange to flange match marks for both the flanges as per the erection joint details.
B PREPARATION FOR ERECTION OF COLUMNS
i) Check for punch mark to indicate the elevation at every 5 meter distance. ( Say 61. xx,
60, 55, 50 …..5,1 and 0) Refer Fig. 11.
ii) Accordingly punch mark the 1M elevation over the bottom piece.
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 (90º apart)
in two places (near MBL locations). Ref.Fig.12.
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BOILER 03. PRE-ASSEMBLY AND
ERECTION ERECTION OF COLUMNS
- 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) Erection of columns & Bracings:
i) Lift the First column bottom piece as shown in the Fig.13A.
ii) Place the Bottom column piece over the foundation with out damaging the bolt
threads, while lowering the piece through the bolts. Tighten the bolts, prior to
releasing the load from the crane.
iii) Erect all the first pieces of the columns in this manner.
iv) Align the individual pieces (verticality etc.) for the following (Refer Fig.14A, 14B &
14C).
- Elevation (1 meter punch mark shall be taken as reference for all column pieces)
- Spacing between adjacent column with respect to reference axis of boiler.
v) Tighten the foundation nut and recheck the alignment. In case of any disturbance noted,
alignment procedure to be repeated.
vi) Check the spacing between columns at horizontal beam level.
vii) Box up the column as follows:
Box I S1-S2-S7-S8 (Left and Right) Refer Fig. 15A.
Connect with horizontal members and complete cleat welding ( Fig.16).
viii) BOX II S3-S4-S9-S10 (Left & Right). Refer Fig. 15B.
Connect with horizontal members and complete the cleat welding (Fig.16)
Align Columns S4-S10 (Left & Right). Refer Fig. 15C.
ix) 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).
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BOILER 03. PRE-ASSEMBLY AND
ERECTION ERECTION OF COLUMNS
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) Erect the remaining boxes of columns as explained for other pieces.
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) Recheck the verticality of all columns.
xvi) Grouting column base plates and cure with Portland cement.
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.
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BOILER 03. PRE-ASSEMBLY AND
ERECTION ERECTION OF COLUMNS
(b) Verticality of columns are to be checked before the erection of ceiling girder.
(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.
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BOILER 03. PRE-ASSEMBLY AND
ERECTION ERECTION OF COLUMNS
i) Vertical bracing gives lateral stability to column offering resistance to horizontal forces
coming on the structure & transferring the forces to column base / foundation safely.
ii) To maintain column stability in both X, Y direction against lateral buckling, lateral
supports are to be given.
iii) Lateral support is given by the net work of horizontal bracings at about 8 to 10M
height interval.
iv) Horizontal bracing gives resistance to lateral buckling of columns due to wind /
seismic / stability force.
v) 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.
vi) Discontinuity in horizontal bracing will result in ineffectiveness & will not give
resistance to the sway of column effectively.
vii) To transfer the lateral forces effectively to ground continuity of vertical / diagonal
bracing from ceiling to column base is very much essential.
d) Welding, Pre-heating and Non-Destructive Examination and post heat treatments
requirements.
1.0 Welding
a) Welders shall be qualified as per Welding Manual.
b) Welding consumables conforming to the design requirements shall be used.
c) Selection of welding consumable shall be out of the “Approved list of welding
consumables “ issued by Welding Technology Centre, Trichy.
d) Manufacturer’s batch certificates are also to be verified.
e) 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.
f) 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.
g) The sizes and length of weld shall not be less or substantially in excess than that
specified in the drawing.
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04. PRE ASSEMBLY AND ERECTION
OF GIRDERS
BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
A) Preassembly of Ceiling Girder:
- Identify the pieces for the following:
- Work order no.
- PGMA
- DU No.
- Girder designation.
- 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.
v) Ensure pre-assembly bed is made on the leveled and consolidated area to avoid
sinking during placement of girders on the bed.
vi) Ensure the pre –assembly bed members are properly spaced to avoid sagging of
girder pieces when they are placed over it. ( Refer Fig . 22);
vii) Match the pieces as per match marks provided in the pieces. Ensure the
orientation of girder pieces as per drawing (Ref.Fig. 23 A & 23B)
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
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.
c) 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.
d) 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).
h) 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.
i) 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.
2.0 b) Check the following dimensions prior to clearing the assembly for welding and are to
be recorded in the log sheet.
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 50º C from the pre-heat temperature mentioned above.
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
5.0 Welding
a) Welders shall be qualified as per Welding Manual.
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.
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.
j) 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
k) After completion of 60% of flange welding check the web alignment (adjust with
wedges to achieve web alignment if required.)
m) Preheat to 150º 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.
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 depending
on the number of welders engaged.
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
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 250ºC
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.
u) The sizes and length of weld shall not be less or substantially in excess than the
specified in the drawing.
a) 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.
b) The fillet welds for fixing attachments like pads etc. made on tension flanges over
50mm thick shall also be post weld-heat treated.
For high tensile steels : ( DIN 17100 ST 52.3, IS 961 – HTW)
a) Butt welds in plates 50mm and above thick shall be Post Weld Heat Treated. For
unequal thickness of plates, the groove depth at the weld shall be considered for Post
Weld Heat Treatment.
b) The fillet welds for fixing attachments like pads etc. made on tension flanges 50mm
and above thickness shall also be post weld heat treated.
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 600ºC to 650ºC. The above cycle shall
be controlled within a tolerance of ± 10ºC. 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 400ºC and cooling rate after Post Weld Heat Treatment upto 400ºC
shall be as follows:
Thickness range Rate of Rate of Cooling ( Max)
Heating (Max)
Upto 25mm thick 220ºC /hr 110ºC/hr
Over 25 – 50mm thick 110ºC/hr 110ºC/hr
Over 50 – 75mm thick 75ºC/hr 110ºC/hr
Over 75mm thick 55ºC/hr 65ºC/hr
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
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).
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
5. Temporary platform shall be made around the column top so as to facilitate column
bolting with the ceiling girder.
6. Connected welded beams shall be kept ready for erection immediately after girder
erection.
7. 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.
1. Preassembled ceiling girder shall be shifted from preassembly bed to the nearest
columns.
2. The girder shall be assembled with pin connection assemblies at both ends.
3. The girder shall be kept over the wooden sleepers.
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.
5. Temporary Platform shall be made around girder for easy movement at top. The
typical arrangement is shown in Fig. 28.
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
1. 80mm wire rope 16 M long – 2no’s shall be tied to the girder at the center as
shown in Fig. 29.
2. Two Nos. D-Shackles shall be tied to each one of top portion of slings.
3. Two Nos arrestor channels shall be provided to keep both the slings at a
distance.
4. 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.
1. Erection check list shall be completed before erection of ceiling girder. Typical
check list is shown in Annexure – III.
2. Heavy duty crane shall be positioned at a predetermined distance in the
furnace cavity.
3. It is preferable to start girder erection early morning so as to avoid heavy wind.
4. 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.
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ANNEXURE – I
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16
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
ANNEXURE - I
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
ANNEXURE – II
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
ANNEXURE : III
SHEET : 01/04
CEILING GIRDER ERECTION
CHECKS FOR LIFTING
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
Annexure : III
Sheet : 02/04
9. Persons to be recognized for
Lifting directions.
10. Communication arrangement
11. Manpower availability
Remarks CONTRACTOR
Remarks BHEL/ERN.
Remarks BHEL/QAE
CUSTOMER
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
ANNEXURE : III
SHEET : 03/04
SL PARTICULARS CHECKS SIGNATURE REMARKS
NO
1. Girder supporting columns.
2. Verticality of columns
(All required).
3. Level of top of columns.
4. Marking of column top bolt holes center
5. Distance between two column centers at
top
6. Tightening of column bolts
7. All the necessary horizontal beams and
bracings to be aligned, welded & bolted
8. Main brace level structure at 9M, 21M,
31.2M, 43M, 56M & 68M on left, right and
front to be completed.
9. Cleaning of all mating surfaces like
column top, ceiling girder bottom, pin
connection surfaces.
10. Bolts to be tried thru holes for no
obstruction.
11. Lubrication of pin surfaces.
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BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS
Annexure : III
Sheet : 04/04
12. Bolting of pin connection on top of column & checking
of gaps prior to ceiling girder erection
13. Inspection of locking plate for pin connection.
14. Inspection of welding of bolt hole lugs to pin
connection
15. Pre-assembly clearance of ceiling Girder
( Dimensional & welding, NDT and stress relieving)
16. Fixing (Clamping) of temporary rails on top of the
flange of ceiling Girder for safety use. Welding of
temporary ladders on sides of girder.
17. Clamping of temporary angles on bottom flange of
ceiling girders for facilitating the scaffolding making
after erection.
18. Cross beams required to-connect should be kept
ready.
19. Arrangements for lifting and fixing of cross beams.
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05. PREPARATION FOR
DRUM ERECTION
BOILER 05. PREPARATION FOR
ERECTION DRUM 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 WB’s 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.
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.
1
BOILER 05. PREPARATION FOR
ERECTION DRUM ERECTION.
MINIMUM STRUCTURES REQUIREMENT FOR DRUMERECTION
(LIST OF REVAMPED PG –MA)
Sl.No. PG MA Description
01. 35 010 Foundation Materials
02. 35 111 Main Columns Left - Ist Pass
03. 35 112 Main Column s Left - 2nd Pass
04. 35 121 Main Columns Right - 1st Pass
05. 35 122 Main Columns Right - 2nd Pass
06. 35 130 Main Columns Middle, except S14 L ,S14 R and S17
07. 35 140 Auxiliary Columns Left
08. 35 150 Auxiliary columns Right
09. 35 190 Girder Pin Connection
10. 35 211 Ceiling Girder (fabricated) - 1st Pass
11. 35 212 Ceiling Girder (fabricated) - 2nd Pass
12. 35 213 Cross Girder - 1st Pass
13. 35 214 Cross Girder - 2nd Pass
14. 35 221 Ceiling – Rolled Shapes - 1st Pass @
15. 35 222 Ceiling – Rolled shapes - 2nd Pass @
16. 35 231 Ceiling Bracing - 1st Pass
17. 35 232 Ceiling Bracing - 2nd Pass
18. 35 311 Floor Bracing 1 MBL - 1st Pass
19. 35 312 Floor Bracing 1 MBL - 2nd Pass
20. 35 321 Floor Bracing II MBL - 1st Pass
21. 35 322 Floor Bracing II MBL - 2nd Pass
22. 35 331 Floor Bracing III MBL - 1st Pass
23. 35 332 Floor Bracing III MBL - 2nd Pass
24. 35 341 Floor Bracing IV MBL - 1st Pass
25. 35 342 Floor Bracing IV MBL - 2nd Pass
26. 35 351 Floor Bracing V MBL - 1st Pass
27. 35 352 Floor Bracing V MBL - 2nd Pass
28. 35 361 Floor Bracing VI MBL - 1st Pass
29. 35 362 Floor Bracing VI MBL - 2nd Pass
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BOILER 05. PREPARATION FOR
ERECTION DRUM ERECTION.
MINIMUM STRUCTURES REQUIREMENT FOR DRUMERECTION
(LIST OF REVAMPED PG –MA)
30. 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 Main Beams – Lower - 1st Pass
35. 36 442 Main Beams – Middle - 1st Pass
36. 36 443 Main Beams – Upper - 1st Pass
37. 36 451 Main Beams – Lower - 2nd Pass
38. 36 452 Main Beams – Middle - 2nd Pass
39. 36 453 Main Beam – Upper - 2nd Pass
40 36 511 Front Bracing – Lower
41. 36 512 Front Bracing – Middle
42. 36 513 Front Bracing – Upper
43. 36 521 Side Bracing – Lower
44. 36 522 Side Bracing – Middle
45. 36 523 Side Bracing – Upper
46. 36 531 Rear Bracing – Lower
47. 36 532 Rear Bracing – Middle
48. 36 533 Rear Bracing – Upper
50 36 700 Fasteners
51. 36 811 Floor grills & Guard Plate *
52. 36 821 Main Stairs – Lower
53. 36 822 Main Stairs – Middle
54. 36 823 Main Stairs – Upper
55. 36 851 Handrails & Posts*
@ - 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 statutory
regulation, operation / erection and health/safety point of views.
NOTE: For details refer applicable PGMA list.
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06. POST DRUM ERECTION
CHECKS AND WORKS
BOILER 06. POST DRUM ERECTION CHECKS
ERECTION AND WORKS
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.
1.5 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.
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HSFG BOLT TIGHTENING