Boiler Erection of Pressure Parts PDF

Boiler Erection
Date: 13/01/2017 By
https://boilersinfo.com/
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
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.
• After cross beam erection, entire structure
is adequately braced to achieve sufficient
strength.
PRESSURE PART
3. Advantage and Weakness of Construction Method
Description ▣ Modulization / Concurrence

\Type
▣ Typical Construction Method
Construction Methods
⊙ Earlier completion through Modulization ⊙ Many years of experience and Know-How

/Concurrence Construction To utilize standard data /Data base
Advantage
⊙ Competitive time for completion ⊙ 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 ⊙ Long time for completion

Cost
⊙ High risk of safety accident due to lots of
Weakness ⊙ Increasing Module temporary material and works
S/S materials (about 50% ) at the high elevation
⊙ Long duration for S/S design

and Complicated design
2. Comparison of Construction Methods
▣ Modulization / Concurrence ▣ Typical Construction Method

Construction Methods
⊙ Concurrent construction of S/S and Boiler ⊙ Boiler installation after completion of S/S
installation
⊙ S/S Modulization on the ground
⊙ Core Frame, Subsidiary S/S and Boiler ⊙ Separate installation of S/S 1Tier ~ 5 Tier
installation at the same time with Bottom-Up method
⊙ Lifting after Moduliztion on the ground, Erection ⊙ Unit Lifting and installation
⊙ Using special Lifting device : ⊙ Using ordinary construction lifting device
Hydraulic jack - to be able to lift Module
[2,500Tons] ⊙ Site assembly of Boiler equipment
⊙ Site assembly of Boiler equipment ▶ - Ground assembly : 20%,
▶ - Ground assembly : 70%, - Assembly after installation : 80%
- Assembly after installation : 30%
⊙ Planning and scheduling for concurrent
construction sequence Planning
Compare to Main Erection Process
Modulization / ConcurrenceConstruction Methods Typical Construction Method
660MW x 2 Units 560MW x 2 Units

Main Proper 5,643tons Main Proper 5,103tons
Boiler weight Boiler weight
S/S 9,191tons S/S 5,200tons
Duration Duration 1990.07.16~1992.08.14
15.5 Momth
(S/S at site~Firing) (S/S at site~Firing) (25 M)
HxWxD 76m x 41m x 41m HxWxD 76m x 37m x 42m
▷ Lifting S/S after pre-Ass’y Core Frame After Starting
▷ Separately lifting STL/STR
on the ground S/S
▷ Pressure Parts unfurnished
▷ Pre-assembling Pressure Parts
Core
Frame
Module
Work Stand 1Tier
Modulization/Concurrent Erection Method Typical Construction Method

▷After installation of S/S Core Frame to install
2 month after
Pressure Panel and subsidiary-S/S at the same time ▷Completion S/S 2 tier
▷ Coil Modulization on the ground starting S/S
?
Panel
Ass’y
?
?
Sub-S/S
Ass’y
2Tier
1Tier
Module
Work
Modulization/Concurrent Erection Method Stand
Typical Construction Method
▷ In the process of Modulization of Heavy Girder ▷ S/S Heavy Girder installation
Boiler Furnace & Back Pass on the ground (Using Crane)
▷ S/S Heavy Girder installation (Using Crane)
Lifting
※ 6 month after starting S/S
※ 2 month after Starting S/S
? Heavy Girder
Heavy Girder Installation
?
Installation
Module Ass’y
on the Ground

▷After S/S Core Frame / Heavy Girder completion ▷ After completion of S/S 1~5 tiers
starting sub-S/S installation and DRUM starting pressure parts installation
20% of Pressure parts installation
※3 month after starting S/S Lifting ※ 7.5 month after starting S/S
▣ 4.5 month earlier in comparison with Typical Method
[Drum lifting point]
▷ S/S Core Frame design for Boiler load support
Winch
▷ Module work on the ground and concurrence installation
of S/S and Boiler
Lifting using
Hydraulic Jack
?
Drum
Drum
Pressure Parts
Module
assembly on the
ground

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

assembly on the
ground

▷ 50 % completion of total S/S installation ▷ Completion of S/S installation
▷ Concurrent Lifting Boiler Back Pass and Back Pass ▷ Separate installation of Boiler Back Pass
S/S Support (Using Hydraulic Jack System) Lifting (Using Winch)
※ 8.5 month after starting S/S ※ 16.5 month after starting S/S
Hydraulic Jack
Winch
Back pass
Module
Lifting 中
? ?

60 % completion of total S/S installation ▷ Completion of S/S installation
100% completion of Boiler pressure parts Hydro Test ▷ Completion of Boiler pressure parts
installation installation
※10 month after starting S/S ※ 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

Completion of S/S installation Completion of S/S installation
Completion of Boiler installation First Firing Completion of Boiler installation
※ 15.5 month after starting S/S ※ 24.5 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

Sequence of Modulization / Concurrent Installation
Install Heavy
Girder after
Panel Erection
Assemble RH Final &

SH Final Tube Module
Install
Jack for
Drum
DRUM
LIFTING
Install
Downcomer
pipes (6ea)
Assemble Back Pass Module

Prepare the (Hanger rods, roof panel, LTRH)
Assembling of
SH DIV. Module
Lift the Sub-

assembled SH
DIV. Module
Install the Jack

for SHP & RHP
Install the Jack

for Back Pass
Module Lifting
Install the Wire

for Back Pass
Module Lifting
1’st Lifting
of
Back Pass
Module
Assemble the
Back Pass
Wall Panel
SH tube
bundle
lifting
Lower panel lifting
Assemble Back
Pass LTRH
Arch lifting
Assemble Eco
Tube, Eco Header
Back Pass
Module
Final Lifting
Install the
Burner windbox,
Low water panel,
Hopper panel,
Water inlet header,
Suction inlet piping.

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Boiler Erection

• The boiler presently in use are hanging type.

• Verticality is single most important factor

• In order to carry out this job special

Description ▣ Modulization / Concurrence

⊙ Earlier completion through Modulization ⊙ Many years of experience and Know-How

⊙ Lay down Area need for pre-ass’y at site

⊙ Increasing Equipment / Construction Labor ⊙ Long time for completion

⊙ Long duration for S/S design

▣ Modulization / Concurrence ▣ Typical Construction Method

Modulization / ConcurrenceConstruction Methods Typical Construction Method

660MW x 2 Units 560MW x 2 Units

Modulization/Concurrent Erection Method Typical Construction Method

Modulization/Concurrent Erection Method Typical Construction Method

Modulization/Concurrent Erection Method Typical Construction Method

Hydraulic Jack Winch

Back pass Module

Modulization/Concurrent Erection Method Typical Construction Method

Modulization/Concurrent Erection Method Typical Construction Method

Modulization/Concurrent Erection Method Typical Construction Method

Modulization/Concurrent Erection Method Typical Construction Method

Assemble RH Final &

Assemble Back Pass Module

Lift the Sub-

Install the Jack

Install the Jack

Install the Wire

Lower panel lifting

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