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44
ERECTION GUIDELINES
FOR
500 MW
1
ERECTION GUIDELINES
FOR
500 MW
PREPARED BY
& B H E L : P S S R : QUALITY
APPROVED BY
AUTHORISED TO BE
HEAD - QUALITY
USED BY
PS-SR : CHENNAI
1. INTRODUCTION 6
2. BOILER DRUM 48
3. ERECTION OF HEADERS 14
st
4. ERECTION OF 1 PASS RADIANT ROOF 5
8. ERECTION OF COILS 25
9. ERECTION OF BUCKSTAY 22
Introduction
The general arrangement of pressure parts of a conventional Two pass design boiler of
500 M W unit is shown in Fig.1 (First pass) and Fig.2 (second pass). The locations of
Pressure part components and assemblies are also indicated in the figures.
At job site, the main function of erection group is to receive the components, store them,
protect them from damage, preserve them during storage to sustain the original condition
and assemble them within the permissible limit/tolerance specified in the "Boiler pressure
parts Engineering Checks for Erection" (Pub.2022) to achieve pre-determined
performance during operation.
Around 4,480 tonnes of pressure parts components per unit are despatched loose to the
job site by road and rail. Hence, it becomes all the more important for the job site erection
group to take utmost care right from the receipt stage to completion of erection, so that
commissioning activities can proceed without any difficulties.
The major components in pressure parts to be erected are boiler drum, headers, water
walls and steam cooled walls, superheater, reheater coils, economiser coils and
buckstays.
Recommended hydraulic test procedure, welding & N D E are also covered in this section.
GENERAL NOTES:
1. Ensure that the component/parts are erected as per the latest applicable
contract drawings.
2. Read the drawing carefully and take care to note the specific erection points
given in the drawing.
01. DRUM
02. DOWN COMER
03.SUCTION MANIFOLD HEADER
04. CIRCULAR PUMP a.J2S3S
05. DISCHARGE LINES
06. LOWER RING HEADER
07. WW HOPPER
08. FRONT WW OUTLET HEADER
09.SIDE WW OUTLET HEADER
10. REAR 'WW HANGER OUTLET HEADER
11. REAR WW SCREEN OUTLET HEADER
12. VACANT
iJ.ECO. INLET HEADER
.ECO. COIL ASSY - LOWER
15. ECO. COIL ASSY - INTER
16. EC0. COIL ASSY - UPPER
17. EC0. OUTLET HEADER
18. EC0. LINKS TO DRUM
I9.SH. SATURATED CONNECTING TUBES
20.SH. RADIANT ROOF INLET HEADER
21.SH. RADIANT ROOF OUTLET HEADER
22. SH SIDE WALL INLET HEADER
2J.SH. SIDE WALL OUTLET HEADER
24.SH. FRONT WALL INLET HEADER
25. SH. REAR WALL INLET HEADER
26.5H/EC0 SUPPORT HEADERS
27. SH. REAR ROOF JUNCTION HEADER
28. LTSH INLET HEADER
29. LTSH COIL ASSY
30. LTSH OUTLET HEADER
31.SH. DESUPERHEATER
T
?.S«. DIVISION PANEL INLET HEADER
.3.SH. DIVISION PANELLETTES
34.SH. DIVISION PANEL OUTLET HEADER
35.SH. PLATEN INLET LINKS
36.SH. VERTICAL PLATEN INLET HEADER
37.SH. VERTICAL PLATEN ASSYS
38.SH. VERTICAL PLATEN OURET HEADER
39. RH. INLET HEADER
40. RH. FRONT ASSYS
41. RH. REAR ASSYS
42. RH. OUTLET HEAOER
43. WW TUBES
44. EXTV. SIDE WW TUBES
45.SH. RAOIANT ROOF TUBES
46. SCW TUBES
47.SH/EC0 SUPPORT TUBES
48.RISER TUBES
49.STEAM COOLED SPACER
3. All the components of pressure parts are given Mark Nos./ DU Nos. with P G M A
for the erector to identify with Mark No. indicated on erection drawings and erect
at the proper locations.
4. Take care to see from receipt at site till completion of erection the above
identification mark number /DU numbers painted on the components are
preserved properly. If necessary identification markings shall be repainted
carefully.
6. Comply with the field weld procedures while carrying out the welding.
7. Hydraulic test is to be conducted after all welding of pressure parts and non
pressure part attachments on to pressure parts are completed.
8. After site hydraulic test of the boiler no welding shall be performed in pressure
parts.
9. Prior to erection, all headers, lines, links, tubes, elements, panels etc. shall be
checked for clear internal passage.
10. Erected items should be protected from workmen climbing on them and water
falling on them. Caps shall be left on tubes and links until final fit up and
welding.
11. Erection attachment/lifting attachments that are welded to the components shall
be removed / cutoff after completing the erection without damaging the
component (Eg. Panels, coils, downcomer etc.)
12. Check the entire boiler to make certain that, all temporary ties to structural steel
are removed.
13. With the help of expansion movement diagrams (released under PGMA-00-030)
check to see that thermal movement of any pressure part is not restrained.
14. Check to see that the expansion indicators are properly installed.
15. Check particularly around furnace bottom for interference from movements of
boiler. If ash hopper is installed make sure that adequate clearance is provided
for downward/side ward movement of furnace walls headers.
16. Ensure that all voids in fusion/fin welded (Peg and flat fin) panels including
erection / lifting slots are closed in furnace/roof and back pass walls.
BOILER DRUM
1. TRANSPORTATION OF DRUM:
Before arrival of steam drum at site, the following preparation will be made
ready for unloading.
After lifting the rear end, the rear portion of wagon will be pulled out using 6MT
capacity pulling machines anchored else where. The wooden sleepers will be
stacked below the rear end as per Fig. No.4 so as to support the rear end.
Similarly the front end of the drum will be lifted with the help of cranes and this
end also will be packed with wooden sleepers so as to support the front end.
FIG. m
Using 2 Nos. 75 MT cranes, the drum kept over the wooden sleepers will be
slowly lowered over the drum skids, which are kept over the rails. (Details of
drum skid is shown in fig.5). It is possible by lifting alternate ends and removing
the sleepers sequentially. Wire rope will be tied over the drum along with skids.
One of the 6 shieve pulley block will be connected to the front end drum skid
with one inch sling and other 6 shieve pulley block will be kept near boiler
column which are either connected with build up I beam or 4" wire rope. 10 T
electrical winch will be positioned near Boiler column in Boiler area. One-inch
wire rope on winch will be connected to both the 6 shieve pulleys through guide
pulleys. Grease will be applied over the rails (three rows) for smooth skidding of
drum.
Skidding operation will be started initially by lifting the front end of drum slightly
with crane & operating the winch.
7. All four drum-lifting wire ropes shall be physically checked for any damages.
10. Approach for all pulley blocks and rocker plates shall be ensured.
11. Persons shall be identified for proper signaling, winch operation and
inspection during erection.
IMPORTANT NOTE
D R U M INTERNALS.
Adopt the procedure given below to assemble the drum internals at site.
1. Study the concerned contract assembly drawing before start of the internal
assembly.
4. All bolted connections are to be used with double washers. One at the back
of nut and the other at the front of bolt and ensure that the washers cover
the holes/ slots fully.
5. Inspect all vent and drain holes in the internals to make certain they are
open.
6. Ensure that the weld joint of feed pipe are leak proof.
7. The drier sections are not to be welded together nor to the drier supporting
structure. But the supporting structures to be seal welded to the drier base
angle as per arrangement shown in Fig. 12D.
8. Ends (entry and exit) of secondary separators must be opened for steam
passage. Refer Fig. 12B.
9. Ensure that all parts of separating chamber are fitted without any gap. The
welds at the joints should be complete and leak proof.
FIS.J2A.QRUM INTERNALS
(FOR CONTROLLED CIRCULATION)
10. Check whether the primary separator is damped to its supports rigidly with
its axis vertical so that it does not tilt or fall during operation. Refer Fig : 12B.
A tolerance of ± 5mm is allowed in the vertically of turbo separator.
11. Check whether the passage through individual screen drier boxes are free
from foreign material. Refer Fig:12C.
12. Check whether the screen driver boxes are fixed with each other such that
the gap does not exceed 1 mm.
13. Ensure that drum is free of all foreign particles especially tools and electrode
bits may remain inside after the erection of internals.
14. Before closing the manhole door, see that manhole door gasket is in perfect
condition.
15. Check whether the downcomer cover assembly has been installed over the
downcomer openings to avoid vortex formation during operation.
16. Check for the orientation of holes in blow down pipe. These holes are to be
in the direction opposite to chemical dosing pipe.
17. The holes in the chemical dosing pipe should be facing towards the feed
distribution pipes.
Note : For erection of supporting structure, the drawings given in structural group
are to be followed. For the header location with respect to reference axis the
pressure parts drawings are to be followed. There will be a difference in dimension
of the centre line of supports at the top and centre line of header with respect to
reference axis. This difference is preset to accommodate thermal expansion as
shown in the Fig.1.
X+A Distance of the suspension point on the structure from the reference
structure.
For the dimensions and the amount of presetting refer the contract
drawing.
ORIGIN OF
EXPANSION
FIG. 1- H E A D E R S U P P O R T WITH O F F S E T ( T Y P )
e. Flexible hose test for long stubs of the header to ensure free passage.
g. The bow in both the planes, scarfing line and stub verticality. Clean the
weld edge preparation and apply weldable primer and fix all end caps.
- Position the bearing plate over the support channels as per the structure
drawing dimension and tack weld as shown in the fig :2.
- Insert the hanger rods/tie rods through bearing plate and tighten with nut.
F i G . 3. T E M P O R A R Y SUPPORT
Erect all the hanger rods (for all headers) and tighten the nut in such a way to
maintain the hanger rod holes in one line to fix header easily and align.
4. Erection of header
1
- G = Elevation of header - /4 the diameter of header
Center line (as per drawing) (as per drawing)
Note: Use soft materials like gunny bag while lashing the ropes over the W B s to avoid
dents, rubbing marks on the same.
The capacity, number of shieve pulleys, lifting wire rope diameter and guide
pulley location are to be decided at site based on the weight of the header and
position of the lifting winch.
While lifting the header, use a tag line to control the load (movement of header).
Note: For headers which have an offset with the supporting structure axis - lift the
header and place it over the temporary support and match the header axis with the
centerline marked over the temporary support.
Connect the hanger rod with the header lug using the pin.
Check the elevation of the header, orientation, horizontality and distance from
reference axis before arresting the header.
Other headers like ring header which are connected with waterwall and like
SHH9 which are connected with steam cooled wall (SCW) are to be positioned,
aligned and welded with water wall / S C W etc. respectively.
Note: 1. The end caps should be removed only during final fit up.
2. The temporary supports should be removed prior to hydraulic test only. The
temporary supports should be erected in such a way that it should not be a
hindrance to any permanent suspension/components.
Other important aspects of header suspension and header alignment are shown in
Fig. 7 A t o 7 E .
SUPPORT CHANNELS AT
pRessose PARTS SUPPORH
L E V E L (PPSL)
HANGER ROD
LENGTH OF W E L D I N G SHALL BE AS
CALLED FOR IN THE CONTRACT DRAWINGS.
COLLECTOR CHANNEL
S U P P O R T S TO CEILING THE COLLECTOR CHANNELS SHOULD
Sff M A I N T A I N E D H O R I Z O N T A L .
I TH£ W O T S A T THE C f f l L I N G T O P .
:
I G. 7 C ._ H A N G ER ROD QF.TAI1- 3
B O T T O M RING H E A D E R :
Furnace water wall system has been provided with bottom ring header of 914.4 mm
OD and 95 mm thickness. Bottom ring header supplies water to various water wall
tubes.
These headers are transported to site in four pieces and each header weighs around
40 to 45 MT. Header is provided with orifice adopters which are welded at shop.
Orifices are fixed to the adopters by means of marman couplings. Orifices and
couplings are erected after steam blowing of Boiler system.
Individual piece of ring header is erected over the temporary brackets welded in the
columns with the help of 2 Nos. 75 MT cranes positioned inside the furnace cavity,
Refer Fig. No.7G.
Ring headers are erected before erection of water wall bottom hopper panels. After
erection of all four headers, headers are aligned with respect to drawing. After
alignment, headers are arrested properly before welding.
Both the front headers joints are welded simultaneously. Similarly rear header joints
are completed. This sequence is adopted to avoid any misalignment during welding.
Refer fig No.7F.
B O T T O M RING H E A D E R ORIFICE A S S E M B L Y .
Bottom ring header supplies water to various water wall^rbes. Each water wall tube is
provided with an ORIFICE A S S E M B L Y , at the Inlet, installed in the bottom ring Header
as indicated in Fig. No. 7H.
REAR
RiGHl
G_ OF MATCH WITH
FURNACE AXIS
FRONT
Orifice assembly consists of orifice plate, marman coupling and orifice adopter. Orifice
adopter is welded inside the header and these adopters are welded at shop itself.
Orifice assembly is installed in the ring header after completion of steam blowing
activity. Orifice size and number are checked with reference to the drawing Orifice bore
sizes are checked with " G O - N O - G O " gauge before installation. Orifice plate installed
over the orifice adopter and fixed to the adopter with marman coupling which is
tightened with stainless steel bolt and nut. After installation of orifice assembly in one
Header, Cover plate is provided around section of orifice assembly. The same
procedure is followed for all the headers, after complete installation of orifice
assemblies and cover plates, header is cleaned thoroughly and manhole doors are
closed with new gaskets.
MARMAN COUPLING
3 INDEXING PINS ON
ORIFICE ADAPTER MUST
ENGAGE THE 3 MATCHING
H O L E S IN T H E ORIFICE TO
P R O P E R L Y IDENTIFY T H E
REQUIRED ORIFICE.
EIO:-7H ORIFICE IN L O W E R WW
Radiant roof consists of 150 nos. of front fin welded loose tubes and 150 nos. of rear
fin welded loose tubes.
These loose tubes with mark nos. punched on it are transported to site as loose tubes.
Method -1.
Inlet and outlet headers of radiant roof are erected on permanent suspensions as per
drawing.
Front loose tubes 8 to 10 nos. are assembled as a panel in the furnace cavity.
Temporary angle stiffners are fixed at two places as shown in the fig. 1B.
These panels are suspended approximately at roof elevation with the help of
temporary wire ropes which are tied to the ceiling structure.
All front panels are erected and aligned with respect to Boiler axis. Support channel is
fixed over the plate lugs already welded to the tubes. Support channel is connected to
the support rod through pin connection. Support rods are adjusted to get the proper
alignment of tubes. After alignment of temporary panels, front tubes are welded with
inlet header stubs.
Radiant roof rear tubes also erected following the same procedure mentioned above.
All rear tubes are welded with the rear outlet header supports. Middle joints of roof
tubes are welded after completion of final alignment of both front and rear tubes.
Temporary binders are removed and support lugs on tubes are welded with the end
bars at the location shown in the drawing Radiant roof tubes are erected after the
erection of all top headers, suspensions, S H links and end bar assemblies.
Method : II
Front tube is welded with corresponding rear tube in pre-assembly area. Refer fig.
No.1C.
Preassembled front and rear tubes are assembled in furnace cavity as a panel consist
of 5 to 6 tubes with temporary binder. Inlet and Outlet headers are erected on
permanent suspensions.
Preassembled panels are erected with the help of winches. Panels are suspended
from ceiling structure with the help of temporary wire ropes. After complete erection of
roof tubes, suspension channels are fixed to the tube lugs which are already welded to
the suspension rods through pin connection.
Suspension rods are adjusted so as to align the roof tubes. After final alignment, roof
tubes are welded with Inlet and outlet header stubs.
Temporary tie channels are removed and permanent support lugs are welded with end
bars.
Method - III
Both inlet and outlet header suspension and roof tube suspensions are suspended
from ceiling structure. Front roof tubs are preassembled with front inlet header and rear
roof tubes with outlet header in furnace cavity, Ref. Fig. 1D.
Permanent support channels along with two rows of temporary stiffner channels are
fixed on both front and rear assemblies.
Front tubes are welded with inlet headers and rear tubes are welded with rear header
stubs.
Two winches are used to erect the tubes with header. One of the winch wire rope is
connected to the temporary channel through the pulley blocks connected at ceiling
structure and other winch wire rope is connected to the header. Slings are connected
through the suspension lugs of headers.
Front tubes with inlet header are connected at an inclined fashion by operating both
the winches simultaneously.
After hoisting to its final elevation support channels are fixed to permanent support
rods and headers suspension lugs to the permanent tie rods.
After completion of front tubes with inlet header erection, rigging arrangement is shifted
to rear side-ceiling structure. Preassembled rear tubes with header are erected in the
same way as indicated above.
Front and rear tubes are aligned by adjusting the suspension rods. After final
alignment, middle joints are welded and tube support lugs are welded with end bars.
In all the above methods, precautions are taken to check the mark numbers with
reference to radiant roof assembly drawing.
ERECTION OF
WATER WALL AND SH STEAM
COOLED WALL
I. Waterwall
- Waterwall tubes are made out of riffled tubes in furnace region-typical riffled
tube is shown in Fig. 1
- Carry out sponge test of all water wall panels, water hanger tubes, waterwall
arch/screen tubes and close the openings with end caps.
- Any damages like sling mark, deep cut, tool mark etc. (to be rectified before
lifting).
- Edge preparation
- Preassemble the following with panel seal box as shown in Fig.2 (Optional).
- Manhole doors, peephole doors, Instrument Openings, Scot blower openings etc.
Note:- The surface of all tubes that are completely embedded in castable refractory
should be painted with two coats of bituminous paint.
1. Cut the scalloped bar (only top scalloped bar of seal box) as shown in Fig.2X
2. Weld item B bottom scalloped bar and seal box with pressure parts before the
hydraulic test (refer the Fig.2Y)
3. Item A has to be welded to item B after pouring castable refractory inside the
seal box (refer Fig.2 Z).
Erect and weld waterwall hanger tube with waterwall rear hanger header
after alignment (check the verticality before welding).
Note: The lifting arrangement for waterwall hanger tube, arch/screen tubes can be
prepared as explained for LTSH and Economiser coils. (Floating pulley arrangement).
- Erect and weld waterwall screen tubes with waterwall rear screen outlet
header.
- All the burner blocks shall be preassembled with burner panel and kept in
four corners respectively and temporarily arrested with main structure. The
lifting arrangement shall be made as shown in Fig.3.
- The suggested panel handling method is shown in Fig. 4 (for both lifting and
alignment).
- Lift all the top waterwall panels and align the panels within permissible
tolerance by adjusting panel to panel welding gap. (Refer Fig. 5A to 5C)
Notts : Figure : 5C
1. Field to align panel edge bars, not tube centers in wall assembly.
2. While assembling the panels, ensure that this pitch tolerance is not
cumulated. The tolerance on width & depth is to be maintained as per
specified Tolerance.
- After erecting all top water wall panels, erect the buckstays coming in that panel
and align (this will help in maintaining verticality of the waterwall panels and furnace
dimension within permissible limit).
- After erecting the first row of rear waterwall panel (welding with waterwall hanger
tubes) the arch tubes can be erected and welded with waterwall panel and
waterwall screen tube. Care should be taken in erection and alignment of the rear
arch tubes so that the gap required between them and R H rear coils can be
achieved. The formation of rear arch tubes is shown in Fig. No.5D.
Note: Before the erection of Rear waterwall all Reheater coils are to be erected.
- Erect all other panels and complete the welding following the
above procedure.
Note : Care should be taken while erecting the "Z" panel. Additional temporary
supports are to be provided with main structural members to position them.
- All the buckstays are to be erected before taking up the next level
water wall erection.
a) The drum to header connecting riser tubes are to be routed first and matching with
drum and header stub shall be carried out.
b) Weld the middle joint after routing the riser tubes between drum stub and water wall
header stub.
c) Now simultaneously weld the riser tubes joints with drum and header stub.
d) Wooden blocks can be used for avoiding touching of riser tubes with coils, on both
sides as shown in Fig. 6A, This would help to get a final fit up after welding of riser
tubes as shown in Fig. 6B.
- Complete the erection of all permanent supports. Release the boiler and furnace
from all temporary supports.
- Recheck the furnace alignment fireball checking and full welding of all Burner
panels,
- Complete the erection, alignment and welding of all upper and lower corner
transition tubes (UCT and LCT).
- Erect and align the S H rear roof junction header on permanent support.
- Lift all the rear roof panels and fix them on the permanent support.
- Erect and align the left and right side top headers of second pass (SH
side wall inlet headers) on permanent support.
Method - 2
- Second pass roof panels are pre-assembled with rear junction header on the pre-
assembly bed located at second pass furnace cavity.
- All the joints with the header end for welding completion in pre-assembly itself.
- Three Nos. temporary stiffener channels are fixed to the panels to avoid buckling of
panels during erection.
- After completion of pre-assembly, the entire panel with header is lifted with the help
of two winches rigged through the ceiling structures.
While lifting, the panel is tilted by about 30 degree to avoid fouling with the
middle columns structures.
After crossing top of middle column structure, panel is made horizontal and
raised to the final elevation.
After reaching final position, panel load is taken in permanent supports and
temporary supports are removed.
Align the LTSH inlet header and complete the welding with rear S C wall and
connections to LTSH coils.
After erection completion of all steam cooled walls align the following headers.
Complete the erection, alignment and welding of extended side waterwall inlet
header with the extended waterwall panels.
Complete the erection and welding of waterwall supply tubes with rear
waterwall and extended side inlet header.
Complete the erection alignment and welding of links between S H front wall
inlet header and S H extended S C W inlet header.
F I G : 2. SEAL B O X DETAILS
FIG. 2Y FIG 2Z
b) OPENING FOR POURING
/ REFRACTORY ^
1. CUT THE SCALLOPED BAR (ONLY TOP SCALLOPED BAR OF SEAL BOX)
AS SHOWN IN FIG. IX.
2. WELD I T E M ® . BOTTOM SCALLOPED BAR AND SEAL BOX WITH
PRESSURE PARTS BEFORE THE HYDRAULIC TEST (REFER THE FIG. tY)
3. ITEM 0 WAS TO BE WELDED TO ITEM (g) AFTER POURING CASTABLE
REFRACTORY INSIOE THE SEAL BOX (REFER FIG. 1 2 )
PANEL
BOILER / F U R N A C E AXIS
TUBE SPACING *
TUBE DIA + 18 MAX.
1.5 M1N
EW ( H D R )
G A P
® - ® = © = ® = RET WEEN
BOTTOM OF RH
( R E A R ) «. R E A R
ARCH TUBES
L'iL .£"> A R R A N G E M E N T O F Ji E A R _ A R C H _ T I J D B A NO
R E M ••'Al E R COIL'.;
TOTAL N O S . O F P A N E L S 164 N O S
SIZE O F T U B E S : DIA 5 1 X 5 . 6 M M
PITCH O F T H E A D J A C E N T T U B E S 63.5 M M
MATERIAL O F T H E T U B E S : SA210GR.A&GR. C
MAX. NO O F T U B E S IN E A C H P A N E L : 28 N O S
F U R N A C E WIDTH : 19177 M M
- There are six downcomer pipes connecting boiler drum at top and bottom ring
header at bottom.
- Down comer pipe straight pipe pieces are preassembled on pre-assembly bed
on the ground.
- After pre-assembly these pieces are transported to furnace cavity and erected
below the drum with the help of winches.
- Preassembled top pieces are welded with drum stubs and second pieces are
fixed to the top piece with the help of erection attachment as shown in the Fig.
No.1
- After welding the second piece, further straight pieces are erected and welded
up to suction manifold following the same procedure.
- Suction manifold is received in three pieces. All three pieces are erected
individually and assembled with temporary supports at elevation approximately
27 metres.
- Suction manifold is aligned parallel to front water wall and it is in line with drum
longitudinal axis, Refer Fig. 2.
- After completion of welding of suction manifold, all six downcomer pipes are
fitted to the suction manifold top stubs and welded.
- Three Nos. suction spools are fitted and welded to the bottom stubs of
suction manifold.
- Three Nos. motor operated suction valves are fitted to the bottom of suction
spool with stem horizontal and temporarily supported.
- After locating the hand wheel properly, valves are welded with the suction
spool.
- C C pump volute without Impeller is fitted to the bottom of suction spool and
supported temporarily.
- Bottom flange of the volute is carefully aligned and leveled before welding
with the suction spool.
- Precautions are taken to avoid any distortion during welding of volute with
suction spool.
- Two Nos. manual operated discharge valves are erected on discharge side
of the volute and welded.
- After completion of erection and welding, the following jobs are required to
be completed.
- Radiography of joints
Stress relieving
- After completion of Hydro test, C C pump volute blanks are removed and C C
pumps are erected. (Refer C C pump erection procedure).
VIEW-A
2
Design pressure 208.5 K g s / c m
2
Hydro Test pressure 312.8 kgf/cm
2
Suction pressure 195.6 Kgf/cm
Motor
2
Motor case design pressure 208.5 Kgf/cm
2. Glandless
4. Bearings and motor windings are directly cooled by same boiler water.
Controlled circulation 500 M W Boiler is provided with three Nos. circulating pumps
of each of 50% capacity. The Boiler water-circulating pump comprises a single
stage centrifugal pump driven by a wet stator induction motor as shown in Fig. No.1
The motor suspended beneath the pump casing is filled with water at full system
pressure, Whilst no seal exists between the pump and motor, a baffle plus base
clearance between the stator and motor casing neck, restrict solids and hot water
entering the motor. The rotor shaft is supported by water lubricated, tilting pad
radial and thrust bearing mounted on the end of the stator shell.
Each pump has a center inlet and two tangential discharges. Each discharges of
the pump is provided with the elbow down stop check valve in the discharge lines.
The discharge lines are connected to the front bottom ring header.
- Suction manifold and suction valves three Nos. with spool pieces are
perfectly leveled.
- All three volutes are transported to furnace cavity and slings are attached
to erection eyebolts provided on the casing.
PUMP C A S E .
DISCHARGE
...DISCHARGE
• MAIN STUD
EXCHANGER CONNECTION
DTE : HEAT EXCHANGER OMITTED
FOR CLARITY
•STATOR WINDINGS
ROTOR
MOTOR CASE - . A
• STATOR !.AM">!AItO 'S
COVERENO
BEARING HOUSING I COVER-END JOURNAL BEARING
i (TILTING PAOI
THRUST DISC
AND AUXILIARY IMPELLER
FILTER
GASKET
MOTOR COVER
FIGTr1;C.mn'UTINfl H'Mf
SYSTEM PIPEWORK
PUMP CASE
"'4
INSULATION
SYSTEM PIPEWORK
E Q U A L A L L ROUND f L A N G E
T H R O U G H O U T LIFT
SHACKLE
R E M O V A B L E LIFTING LUGS
(Ref. Oniyl
HEAT E X C H A N G E R
KEEP C O O L E R
OPERATIONAL
WHEN INSTALL-NO '."OTOR ASSEMBLY
THE MOTOR
ON A HOT BOILER
LOW PRESSURE
SYSTEM
F L E X I B L E HOSE
T E R M I N A L BOX
T E R M I N A L BOX C A B L E
ENTRY G L A N O .
(CUSTOMER SUPPLY
LOOP SUPPLY C A B L E S AT
L E A S T 600mm TO A L L O W
ALLOW AT LEAST 600mm F R O M ANY FOR CIRCULATOR EXPANSION
O B S T A C L E FOR THE MOTOR TO SINK A N D C O N T R A C T I O N WITH
WHEN THE BOILER SYSTEM IS H E A T E C BOILER PIPEWORK
AND THE SYSTEM EXPANDS.
KEEP A R i A BENEATH MOTOR C L E A R
OF A N C I L L A R Y EQUIPMENT TO PERMIT
SUBSEQUENT MOTOR R E M O V A L .
MINIMUM DISTANCE REQUIRED
IS9V4.4mm. -L
NOTE:
ENSURE THAT INTER CONNECTING
PIPEWORK ASSEMBLY IS M A R K E D
WITH. AND MATCHES THE UNIT
SERIAL NUMBER
Fl r—*f
r y A T
EXCHANGER INSTALLATION
- Dummy and covers are fixed to the bottom flange and nuts are tightened
to the required torque value indicated by the pump manufacturer.
- After completion of Hydro test, dummy covers are removed and volute is
thoroughly cleaned.
- Inspection cover at the top of the transit canister is removed and drain
plug is removed to drain off the inhibitor.
- Using long lift power hoists, motor is lifted to the position until the motor
impeller is about to enter the pump case. In this condition motor load is
transferred to chain type hoist.
- Distance between the pump case and motor flanges are measured at
four 90 degree points on the flange periphery. If necessary motor is
adjusted to make the distances equal all around.
- Care is to be taken to see that the studs are centered in the motor flange
holes.
- The stud threads are coated with high temperature anti-seize compound
and nuts are installed by hand.
- Nuts are tightened with hydraulic stud tensioning unit following the
procedure given by the manufacturers.
- Heat exchanger is aligned parallel to the motor as shown in the Fig. No. 4
by adjusting the screws on the bracket, on completion of adjustment,
adjusting screws are locked with locknuts and lifting tackles is removed.
Check the width and length of the coils, flexible connections availability and
welding as per drawing.
Check for damages like sling marks, deep cut and dent etc.
Check the weld end connections such as edge preparation and ID and
compare with header/stub weld end connections
Check for any permanent bow (if bow is observed, inform manufacturing unit
for corrective action before taking it up for erection).
Remove the end caps and carry out sponge test and then fix all the end caps.
The end caps are to be removed only at the time of final fit up.
Fabricate an anti deformation frame as shown in Fig. 1A, (Temporary binder if any
are to be removed)
3 FLOATING PULLEY
ERW PIPE
500
© a
SO
100
12 TO 16 MM THICK
300 THICKNESS OF PLATE JUST I ESS THAN 9
®- 7 © S
20 100
2HJ
6P \
PLATE THICKNESS * OR > 8 MM
TH - 20 MM 0-
32 MM d
©
_LP_
Crown plates and End bars can be pre assembled over the pre-assembly bed on
the ground crown plates are placed between two end bars and welded with end
bars maintaining the gap and dimensions as per the drawing For facilitating coil
erection, gap between crown plates may be kept 3 to 5 mm more than the
dimension given in the drawing Typical end bar and crown plate assembly is shown
in the fig, 1. These are around 25 such assemblies supporting superheater and
Reheater coils. These assemblies erected from the furnace cavity with the help of
electrical winches. After reaching its elevation, these assemblies can be
suspended, on the permanent supports. All these assemblies are erected before
the erection of roof panels.
This arrangement should be in such a way that it can be shifted at top to lift each
coil.
The coil load is to be transferred to crown plate by providing a temporary rest bar
as shown in Fig : 3A & 3B.
DIP TROLY
The coil load is to be transferred to Hi-crown/end bar by welding Hi-crown with coil
seal band after checking verticality and spacing.
Check and record the bottom clearance after erection completion of arch portion.
LTSH Lower and upper bank shall be pre-assembled on the preassembly bed and
check overall dimensions.
Prepare a floating pulley system for the erection of L T S H and Eco coils as shown in
Fig. 4.
Lift the pre-assembled L T S H coils after sponge test and weld with S H hanger
tubes.
Note. : The cassette baffle plates for LTSH and Eco can be pre
assembled and then the coils can be erected.
ROPE PULLER TO L O C A T E
PULLEY
32 MM ROPE
; TIED TO STRUCTURE
! OM BOTH END
THROUGH SIDE
WALLS
DETAIL - A
Weld the LTSH bottom terminal tube with the header stubs (Header is already
welded with rear steam cooled wall) through the connecting tubes.
Erect the Economiser outlet header and support with hanger tubes after checking
the header alignment.
Lift the upper Eco coils using the floating pulley system.
Weld the upper Eco coil terminal tube connection with the header stubs.
Erect the Eco upper and lower bank connecting suspension arrangement.
Lift the lower Eco coils and suspend with the support plate already erected, with
upper coil.
Weld the terminal tube connection between upper and lower coils.
Erect the Eco inlet header with its supports and align.
Complete the welding of inlet header stub with the Eco lower terminal tubes.
Complete the erection and welding of Eco outlet header to drum links including
permanent support.
Important aspects of coil erection and alignment are shown in the Fig. 5A to 5L &
5N, 5R.
Divisional panels are transported to furnace cavity and lifted to the position using
erection lugs and rigging arrangement from ceiling structures. After lifting to its final
elevation, panels are temporarily supported with wire rope from ceiling structure.
These temporary supports can be removed only after the welding completion of
loose tubes with divisional panel header. Temporary rope supports are removed
and loaded on permanent supports. A typical panel arrangement is shown in Fig.
5Q & 5 R.
FIG. 5 N
DETAIL-A
FIG: 5Q
Units with wrap around buckstay system require that the Buckstays are
preassembled and raised to their respective elevations hung prior to erection of
furnace walls. Stirrup plates are pre-assembled with top and bottom angle as
shown in Fig No. 1.
Pre-assembled stirrup and angle assemblies are inserted over the furnace
side flange of the buckstays beam.
Method: I
Wire rope of one inch diameter three nos. are hung as close to waterwall
location from ceiling structure.
Three holes are drilled on the main buckstay beam as shown in the Fig.
No.2A.
Top level buckstay is first erected with the help of separate rigging
arrangement.
Before lifting, the wire ropes which are hung from ceiling structure are inserted
through the holes in the buckstay beam.
These buckstays are raised to the location through these wire ropes.
- Buckstay is temporarily fixed to the wire rope at the elevation shown in the
drawing. With the help of T-rod and clamps as shown in the Fig No.2 B.
- With horizontal leg of the Tee under the buckstay and the vertical leg above, all
the clamps are installed using the buckstay as platform.
- The clamp nuts are tightened properly with the help of mechanical wrench.
- Following the above procedure, buckstays at different elevations are hung from
the same wire rope at the locations shown in the drawing.
Method: II
- Preassembled buckstays are rigged through ceiling structure and erected over
the brackets as shown in the Fig no. 2 C .
- After erection of waterwall panels and alignment, these buckstays are supported
with chain blocks and moved towards waterwall panels.
- After positioning the buckstay at correct location, scalloped plates are welded
with waterwall and key buckstays on both top and bottom side of key buckstay
flanges.
CHANNEL
t OF BUCKSTAY BEAM
AND CHANNEL
SPACER PLATE
I—RA (TYP )
80LTLESS STIRRUP
SECTION-AA
WELD STOP
THIS A L L O W S A L L W O R K TO B E
DONE FROM ON T O P O F T H E B U C K S T A Y
S K E T C H N O . B.
FINAL ELEVATION
SKETCH. C.
- Align the buckstay beam with stirrups. (Ensure that the stirrup is in full contact
with the buckstay beam flange).
- Weld the top and bottom angle with the stirrup. (Ensure the bottom stirrup angle
is in full bearing with the toe of the buckstay beam flange).
- Lock the assembly at the ends and in between, to avoid the buckstay beam
slipping from its location.
- Lift the buckstay and place it over the temporary support provided on the main
column at the appropriate level (where the buckstay is to be fixed with wall
panels) as shown in Fig : 2 C .
- Mark the centerline of the buckstay on the wall panels. (Refer Fig. 4).
CL-CENTRE LINE O F
BUCK STAY
S-SCALLOPED PLATES
FIG.4.BUCKSTAY C / l MARKING
- Check and ensure the completion of panel to panel welding and closing of all
voids in the buckstay region.
- Weld the bottom side scalloped plates/ pad on wall panels after leveling
them.
- Ensure that the key channel is in full contact with all tubes of the wall panels.
- Fix the top scalloped plate/pad on wall panel, and complete the welding.
- Weld the scalloped plate/pad with key channel both at top and bottom.
- Complete the corner link connection (the corner link should be inclined
outwards with respect to wall. This is to accommodate the expansion of wall.
The buckstay does not expand).
The important aspects of buckstay erection details are given in the Fig's : 5A
to 5T.
POURABLE
INSULATION
BUCKSTAY BEAM
FILLER PADS
FIG . 5A
BUCKSTAY BEAM
FIG. 5B
LOAD T R A N S F E R E D TO T H E PERPENDICULAR
WALL THRO' CORNER CONNECTION
FIG. 5E
FIG. 5 K
BUCKSTAY BEAM
SECTION - XX
VIEW . Y
FIG. 5L
FIG. 5S
1. Around penetration for pendant surfaces and the radiant roof/SH screen
tubes/second pass roof tubes.
2. Between loose front waterwall tubes above front upper panel and below radiant
roof.
4. Extreme rear arch tubes and side waterwalls/ extended side waterwalls.
6. Gaps between tubes / nipples in the steam cooled rear, side and front wall and
the respective headers.
7. Extreme tubes of front rear hopper panel and side waterwall lower panel.
- Side waterwall / extended side waterwall and the extreme tubes of radiant roof.
- Extended side steam cooled wall and the extreme tubes of S H screen tubes.
Steam cooled sidewall and the extreme tubes of second pass roof.
Gap between tubes/ nipples of side waterwall lower header at the ash
hopper throat region.
Fusion / fin welded panel fin splits at the panel tube-to-tube butt joint
location.
This is general procedure given as a guide line. Approved procedure for the contract to
be followed for each boiler.
General
After installation of all pressure parts, the Unit is subjected to required Hydrostatic
Pressure test.
The Unit shall be hydro tested for confirmation to IBR code requirements in two areas:
A) Main Boiler with water circulation system (from feed check valve inlet to
Economiser, Drum, Waterwalls) and super Heater system from Drum to M S stop
valve (Ref. Fig. 1)
Test Pressure
4) All radiographs and stress reliving charts of Pr. Parts system accepted
and signed by Boiler Inspector.
5) All necessary valves including drain and vent valves are installed.
6) All safety valves with shop installed hydrostatic plug are installed.
7) All manhole doors like drum and bottom ring headers are closed with the
Bolting arrangement.
8) Isolating valves are provided to all the other branching system like Soot
Blowers system tapping, Aux. steam tapping, spray connections,
Pressure Gauges etc.
9) All buckstays on waterwalls and second pass are completed along with
corners connections.
10) All fin welding of waterwalls, roof tubes and second pass panels are
completed.
13) Radiographic plugs are welded and Instrument tapping are closed.
14) C C pump impeller and motor assembly is not installed as this assembly
is not to be subjected to hydro test pressure. C C pump volute is blanked
with suitable blanks. These blanks are bolted to the volute with the
suitable gasket. Tightening of the bolts are done as per the procedure
given by pump supplier.
15) Fine fittings including drains, vents and instrument tapping are
completed.
It is preferable to do the hydro test at the one stroke at the stipulated hydro test
pressure indicated in the pressure part arrangement drawing. If it is not possible
to accomplish this, the hydro test may be conducted twice, once for drainable
portion and another full hydro test including non-drainable portion.
2) All debris are removed manually from all pressure parts including Headers and
Drum .
3) All vents necessary to prevent air entrapment during filling operation such as
superheater link vents, eco, link vents, Drum vents etc, are kept open.
4) Filling pump of 40-50 Ips flow rate with 100 metre head is connected to
permanent filling line through bottom waterwall drain header.
5) Pressuring pumps preferably 3 pumps with the following details are connected
to the bottom drain header. Through one inch tapping point.
All three pumps outlets are connected to common pressuring line with independent
isolation valves. In case only two pumps are available 0 - 250 Kg/Sq.cm and 0 - 600
Kg/sq. cm may be used.
6) At least three calibrated pressure gauges are fixed at the following locations.
Drum Level
Operating floor level
Near pressurizing pumps
The indicator of the pressure gauges selected should have at least 6" dial
graduated for a range of double the intended maximum test pressure, but in no
case the range be less than 1!4 times that pressure. The pressure gauges are
to be calibrated as per Q A manual.
8) Joint inspection protocol prior to hydro test of Boiler for the completion of the
works is to be made and duly filled up (Ref. F Q P ) .
TABLE -1
2
500 M W - Recommended Air pressure - 2 k g / C m (G) Pr., after regulator
2
Range of Pressure Gauge 0 - 4 Kg/ C m
Water Quality
Note
The temperature limitation for hydrostatic testing is 20 deg. C. The important point is
that the hydrostatic pressure should not be applied when the water temperature is less
than this limit.
The easiest way to achieve and maintain proper hydrostatic temperature in cold
weather is with an external steam supply. The full water is heated with a direct contact
heater and the temperature is maintained by using the steam coil air heater. For a new
project where no steam is available, it is advised to consider electric heaters or fuel
fired space heaters.
The treated Demineralised (DM) water shall include 10-ppm ammonia and 200-ppm
hydrazine. This treated water will have a pH value of approximately 10.
In case only water walls economiser are to be hydro tested, filtered water clear, free
from suspended and colloidal impurities with a restriction of the total dissolved solid
contents to 100 ppm can be used. It should be free from chlorine, free from colour and
pH valves varies between 8.8 to 9.
Note
After chemical cleaning, steam blowing and lay up of the units, if situation warrants to
do hydraulic testing of the pressure parts usage of treated D M water or treated
condensate is only recommended. For quality of treated DM water Refer Table -2.
Table-2
Quality of Water
1. pH at 25 deg. C 7*0.2
5. Si0 PPM
2
Less than 0.02 is
preferable
6. Chloride P P M as N a d Nil
The DM water or Condensate treated with 10-ppm ammonia and 200-ppm hydrazine
to have a pH value of approximately 10.
- Before filling the boiler with water an air tightness test is to be performed to
detect leakages due to valve left in open position, X-ray plug forgotten, any cuts
or gouges etc. not observed by visual inspection. This will reduce the DM water
consumption, as well as time.
- The air should be filtered and free from oil and dust prior to entering the unit.
- The boiler is to be pressurized not more than 2 kg/sq.cm (G), taking safety
aspects into consideration.
- Before admitting air, close the drum manhole, handhole stubs, isolating valves
in drain lines, branching lines and vent lines including the vent valves in S H link,
eco link and drum link, Drain and Test Valves in official pressure gauge etc.
- After completing the air tightness testing keep the vents open.
Filling pumps is used to fill the system. Details of Typical filling pump is given below.
PUMP DETAILS
Speed 2960 R P M
Rating 90 KW
MOTOR DETAILS
Motor Rating 90 KW
Speed 2960 R P M
Amps 160 A
Voltage 415 V
Filling pump suction line is connected to the DM water tank and delivery line is
connected to the Boiler filling line. Filling line is connected to the Boiler drain Header,
Recirculation line is connected from the delivery line to the tank.
- Suction valve is kept open and delivery valve is closed. Pump is started and correct
direction of rotation is checked. Air vent valve is kept open during start up.
- Delivery valve is gradually opened and recirculation valve is closed for filling the
boiler.
- Filling line pressure is monitored through the pressure gauge on the delivery line.
- The boiler water circulation system is filled through filling lines connected to the
boiler drain headers and Economiser Filling Line.
- A s the water raises up to drum manholes, the later shall be tightly closed and filling
shall be completed once the water flows fully in air vents, which are closed
subsequently.
- In no case water entry into superheater should be permitted through the drum. This
is to prevent carry over of suspended impurities into the superheater.
- Superheater is filled through the S H drain header with treated DM water of quality
as indicated in Table-2, until all the elements are filled and the water overflows
through the vent valves.
- Vent valves are closed and opened several times to allow the entrapped air to be
vented out.
- Filling pump is stopped and delivery valve is closed pressurizing the system.
Accessories with pump - Spring loaded safety valve, non return valve, Isolating valve
and pressure gauge.
- Hydro Test Pump suction is connected to the mini DM water tank which received
water from main D M water tank.
- Hydro Test pump delivery is connected to the drain header with 25 to 38mm
seamless pipe.
- Suction valve is kept open. Pressurising pump is started and delivery valve is
opened immediately.
2
- Pressure is increased at the rate of not more than 10 K G / C M per minute up to
2
approximately 80% of the test pressure and by 1-2 K g / C m (g) per minute beyond
that value.
Bharat Heavy Electricals Limited
BOILER
Erection RECOMMENDED HYDROSTATIC TEST PROCEDURE
- At this stage, all the safety valves with hydro test plugs installed are gagged.
2
- Pressure is recorded at every 10 K g / C m rise with time. Time V s Pressure graph
can be plotted.
- Raise the pressure to the hydrostatic test pressure. The pressure shall be under
proper control at all times. The pump operator and the responsible person watching
the official test gauge must have radio-telephonic contact. Once the test pressure is
reached the responsible person watching the test gauge shall give orders to stop
the test pumps immediately and to cut off the electric connections.
- The test pressure is held for about half an hour. During the holding time the test
gauge pressure reading shall not drop noticeably.
Hydrostatic Testing
- After the hydraulic test pressure has been noted and agreed to by the Inspector,
the hydraulic test pressure is then reduced to not less than the maximum allowable
working pr. And the whole pressure parts check will be carried out.
- If leaks are found, it will be necessary to release the pressure and drain these
portions. Make the repairs and refill the unit as mentioned above and repeat
hydrostatic test.
- Details of the leaks noticed during Hydraulic Tests are to be furnished as given
below for better understanding :
b) Description of leak(s) such as straight tube elbow, shop or field weld, torchcut,
where a lug was removed, and attachment weld etc.
While releasing the pressure, the vents should be opened when the system
pressure reaches 1 kg/sq,cm to prevent creation of vacuum in the system.
Note : Remove the gags at less than 80% design set pressure.
After completion of the Hydraulic test, the inspector shall carefully examine the
boiler inside and outside and satisfy himself that it has satisfactorily withstood
the test.
To enable the inside inspection of the boiler, the interior has to be equipped
with suitable scaffolding for inspecting the elements, walls, tubes and welds.
Due to the fact that during the pressure test the boiler and boiler house area
are under an increased risk of danger, special safety precautions have to be
taken to prevent accidents. These arrangements are made by the erection and
commissioning services according to the instructions of the site
managements.
During the period of raising, holding and releasing the test pressure, the entry
to the boiler house is prohibited for all persons not participating in the pressure
test. Works at the pressure parts or in the direct neighborhood^ are not
permitted.
After completion of the hydrostatic test a written report as per the IBR format
shall be issued and signed by the Inspection Authority.
- There is generally some time delay between hydrostatic test and further initial
boiling out and chemical cleaning of the unit. Hence, the unit should be kept
under preservation for protecting the internal surface from oxidation.
- Fill the unit with hydrazine and Ammonia treated DM water containing 300-
ppm hydrazine and 10ppm Ammonia with a pH value of 10.0 to 10.5 till it
overflows at vents.
- The unit should be kept under nitrogen cover with a pressure of 0.5 kg/sq.cm.
In the absence of nitrogen capping facility the unit should be pressurized with
the aid of a fill pump to 5 kg/sq.cm. pressure.
- In case the sample water does not meet the criteria for lay up water, the
conditioning system shall be operated as to restore the required composition.
- No welding shall be carried out on pressure parts when the system is under
preservation or the system is filled with water.
- The reheater should be laid up under nitrogen pressure with the reheater
isolating devices closed or with the blank flanges.
TABLE - 3
1. CIRCULATION S Y S T E M 170
2. D R U M (FULL) 60
3. FP.nNnMI.9FR 150
4. SUPERHEATER 130
5. REHEATER 105
TOTAL 615 C U M