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Prepared by Power Sector – Technical Services (HQ) Noida
Corporate Quality Assurance Bharat Heavy Electricals Limited, New Delhi
SL. No. 1.1 1.2 1.3 2 3 4 6 7 Introduction Pressure Parts Erection Sequence Pressure Parts Components Boiler Drum Erection of Headers Erection of water walls, headers Down comer erection Erection of steam cooled walls and SH / RH/ EVAP. / ECO. COILS FBHE Header and Coil Erection B1 – 01 - 0208T B1 - 01 – 0212T B1 - 0I - 0202T B1 - 01 - 0203T B1 - 01 - 0205T B1 - 01 - 0206T B1 - 01 - 0207T TOPIC Instruction No. I - 01 - 0201G
8 9 10 10.1 10.2 10.3 10.4
Buckstay erection Air And Gas Tightness Test (Boiler) Annexures Manpower, Requirement. Bar Chart Erection Record of Formats Reference Documents
B1 – 01 - 0213T B1 – 01 - 0213L B1 – 01 - 213 G B1 – 01 - 214G
2 (back – Pass. Recommended hydraulic test procedure. the main function of erection group is to receive the components. At job site. welding & NDE also covered in this section.1: combustor area and Fig. Around 5600 MT of pressure parts components per unit are dispatched loose to the job site by road and rail. headers. store them.BOILER PRESSURE PARTS Introduction The general arrangement of pressure parts of a conventional design boiler of 250 MW unit is shown in Fig. so that commissioning activities can proceed without any difficulties. 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. preserve them during storage to sustain the original condition and assemble them which the permissible limit/tolerance specified in the Pub 2022 to achieve predetermined performance during operation. super – heater and reheater coils. 4 . water – walls and stream cooled walls. The locations of Pressure part components and assembled are also indicated in the figures. buck – stays. The major components in pressure parts to be erected are boiler drum. Hence. protect them from damage.
FQP on pressure parts is hyper linked with text here. Obtain statutory clearance as applicable. Third pass. Boiler Drum is inspected on ground prior to erection on receipt.3…… Pressure Parts Erection Sequence 3. Following members should be erected and welding completed. 63. Second pass. Minimum structure to be erected is referred in FQP on structure which is hyper linked.1 Boiler Drum Erection: Before starting Pressure erection study FQP on pressure part carefully and understand acceptance criteria.1.2 To carry out Dimension checks as per FQP.1.3 Final dimensions of combustor and second passes To be recorded 5 . It should be shifted under boiler structure carefully. Middle Walls FBHEs. Total number of column Height of the column maximum Number of column tiers Bracings vertical and horizontal. These structure arrangements are identified as – First pass – accommodating furnace. 3. air / flue ducts etc. steam cooled SH.heater with inter connecting duct – work. trusses etc. There is approximately 3850 MT to be erected prior to boiler drum erection.accommodating FBHE Air pre-heater (tubular type) and quad sector regenerative air pre. RH II. SH III.750M 05 nos. drum is dragged and placed at ground just below its permanent position in between combustor and back pass. 1.1 Preparatory works: Like in conventional boilers.1. SH IB. 38 nos.accommodating boiler drum. Economizer etc. 3850 MT structural weight is to be erected before drum lifting as enclosed in table. 1. Approx.
The main hoisting pulley blocks are attached to drum is safe manner with minimum 8 to 10 turns on each side. Mark and punch position of washer plates over the drum suspension welded beam and cross check the same with respect to boiler and drum axis. The axis of top and bottom pulley blocks should be in one line.1. Assemble rocker over washer plate wrt O Movement as given in the drawing. The anchor end of the wire ropes at pulley blocks at winch point and drum point should be checked for safety.3 Total operation from start of lift to release of load of electrical winch usually takes 06 to 07 hours. Avoid over lapping of wire ropes. Wire rope of 20 meter length for lashing multi sheave pulley block at cat head and 40 meter rope for lashing multi sheave pulley clock with drum is used.1. all arrangements for strand jack equipment emergency power. if required adjust It. the lifting equipment is placed and approach plat form is made at ceiling girder level. Mark and punch the center and angle over washer plate.2 Strand jack method is used for drum lifting. If decided for Stand jack system. Erect all washer plate along with rocker over welded beam where drum is to be suspended. o The co-ordinates of drum lifting structure is checked from boiler axis. sheaving etc are carried out. LPI/ DPT checks are carried out for welding of structure. 6 . 3. 3.1. Check axis measurement once again and fill up long sheet. quantity.4 Final dimensions of third pass (APH) To be recorded Temporary Cat Head lifting structure is locally fabricated (after vetting of engineering for the design) and erected. The axis mark on suspension rod with drum should be ensured. Take the diagonal of washer plate center to center. Mark and punch.1. Similar of conventional boilers. The wire ropes clamps should be checked for correct size capacity. tightness and positioning.
2.3.3 Upper panels 3.3.4 SCW SH lower panels 3.2.1 Roof pre.assembled and lifted to position with hanger tubes 3.3. furnace and second pass were erected from top to bottom. Pressure parts erection is undertaken in following sequence.3.5 Pent leg panels 3.2 Crane or electrical winches can lift the drum. rear. inter connecting links / pipes etc as and when availability of fronts and materials. ESP – erection can be preceded as a parallel activity.3 Final SH III 3. 3.6 Pent leg buck stays 3.3 Second pass Following sequence is followed 3.2.6 Evaporator 3.4 Inter panels + upper panels buck – stay 3.2. Refer section 05 for details. right and left side water wall 3. 3.7 Economizer 220.127.116.11.3. Furnace: Following sequence is followed.2 Building up front.5 RH II coils 3.8 Buck – stays / support matching to next stage of erection 7 .7 Down comer.3. 3. Similar to conventional boilers.2.assembled and lifted to position 3.2 SCW SH upper panels 3.2. riser.1 Roof pre.
fine fittings etc. with all supports.3. Erection Works completion for Hydraulic Test of Boiler Major pressure parts works for hydraulic tests are: Pressure parts HP joints – physical Refractory iron components Sea welding of furnace. chemical dozing lines. FBHE and second pass 5600 MT* 35000 Nos. 5.3. Insulation: refer section 07 for details Mineral wool insulation pins outside the first / second pass walls. gas ducts as per available of materials. Since combustion is pressurized. Seal pots and all attachments are fully welded. Approximate 12 kms of seal welded is done totally. After a through inspection of all completion of work and protocols completed. filling line. expanders.3. all attachments panel to panel are to be seal welded totally from outside and inside after back gouging.12 Erect FBHEs coils 3. Second pass is having negative pressure. Inside seal welding app 6 kms. LPI test is done for ensuring quality seal welding. which are not covered by refractory of combustor are flush ground to avoid erosion/ turbulence of hot flue gas / ash during operation.4 All balance pressure parts are erected as parallel activity. Refractory Dry out can be done at latter stage.* 16 MT* 20 Kms* 3. total system is tested with compressed air and leaks noticed are attended. comprising of the system from economizer inlet feed line isolation / NRV to main steam line isolation valve at boiler end consisting of all links. therefore it is seal welded typical to conventional boilers. FBHEs. sampling line. headers + loose tubes failing outside the second pass panels.9 All inter connection links / pipe.3.11 Then refractory work on FBHE Casing should be completed. drains. 3.5 4. all refractory holding down / anchoring parts inside combustor. vents.10 Complete FBHE Casing 3. 3.3. 8 .
Platforms Hydraulic test procedure is followed as enclosed in section 14.Note: * indicative quantity for exact quantity refer drawings as applicable. 9 .
PRESSURE PARTS COMPONENTS 10 .
PRESSURE PARTS 13 .
Boiler Supporting Structure – Requirements 1. to avoid column to column elevation marking variation. (Refer checklist BR(STR) – 200 /210 -92 & Log sheet No FQA – O1-35-00. 2. next calibration due for calibration etc.L12. 17 . Joint inspection protocol for completion for structure prior to drum erection are to be filled and cleared for drum erection. Identify one main column (preferably S9 –or S10 – left or right) for all elevation measurement. Calibration Requirements 1. Boiler supporting required for drum lifting to be erected 1. Punch mark the elevation of drum (elevation shown in the Contract erection drawing) on the identified column for drum alignment. All the measuring instruments are to be identified and registered as per FQA System F. 2. with duly filled details like registration no. Calibration label (F -15 -02 are to be fixed on the instrument. II.15 and guidelines for calibration F – 15 /GL – O1.n all respects including alignment and full welding and cleared for drum erection.I. 3.
having sufficient capacity. Forged steel bull grips to suit the dia. 2 Nos. 25 mm dia. 2 Nos. 4 Nos. 8. 3. 2 Nos.III. 1. 4. Description Electric winch 10 ton capacity (for drum) Electric winch 3 or 5 ton capacity (for U rod) Wire Ropes 1400 M length. 2 Nos. 2 Nos. 8 Nos. 6 x 37 construction IWRC and right lay (for Drum) Wire rope 400M length. 4 Nos. 19 mm dia. 2. In no case the IR value should less than 1 mrga Ogm. 4 Nos. IWRC and right lay (for U rod) 10 sheeve 100 ton pulley block Single sheeve 10 ton pulley block 3 ton or 5 ton chain pulley block 3 ton pulling and lifting machine Or 9. Check up for proper relay setting. 6 x 37 construction and IWRC. 6 x 37 construction. Special Equipment – Requirement and Inspection S. 6. Inspection: 1. 5. 18 . 10. Electrical Winch Megger the winch motor for IR value. If necessary IR value can be improved by providing lamp for heating. 60 Nos. Wire rope 26 or 28 mm dia. No. 7. a) 40 mm length for lashing 10 sheeve pulley with cat band structure b) 80 M length for lashing 10 sheeve pulley with drum. Of rope Quantity 2 Nos. (Use SOOV Megger) Starter of the motor. 2.
19 . 2. Free rotation of pulley. if possible Excessive heating of motor. Fill up with correct grade grease wherever grease nipples are provided. Arrange for alternate AC/ DC source in case of failure of main AC source. Smooth switching over from AC to DC supply. Keep spare fuse 1. No groove wear out. Idle run the winch motor for 4 hours and check the following: a) b) c) d) e) Effectiveness of brake Phase voltage and current at no load. Check the effectiveness of braking system – if necessary. check the clearance) Properly lubricated. Arrange for AC power supply – 3 phase 415 volt 200 amps. Correct grove size. Pulleys During pulley servicing check the following: No wear out. No bearing wobbling (in case of bush. fir with new brake liners. and at load. times the maximum current capacity of the winch. chips and cracks on flange. Fill up gear box with correct grade of oil to specified level. Any abnormal sound in the gear box or any moving parts. Calibrate the ammeter and voltmeter for indicating correct rating (if provided for indication).
rope stretch. Trueness of the sheaves with shaft. Greasing holes are clean. flattened strands. 4. cuts and wear at bearing surfaces. Load Test for four Hours by loading with number of concrete blocks to its capacity. bird caging kinks. wear and abrasion. Chain Pulley Blocks Examine (if required with magnifying glass the links for: Elongation of stretch. 3. Wire Rope The total length of wire rope is to be inspected and record the damage details if any like: Broken wires. chips. Locking Mechanism. crushed strands. Deposits of hard grease or dirt which prevent the lubricant from flowing through the grooves. bulges in rope etc. Fill up with recommended grease. reduction in rope dia. All the clearances are within limits (recommended by the supplier). shall be removed. No shaft wear out. refer Notes. Clean the wire rope with wire brush. gouges. Examine the cleanliness of the grooves between the strands. jammed strands. 20 . high stranding and unlaying. Apply the lubricant to wire rope using a brush (cadmium compound. Check whether the lubrication is sufficient.) For rejection criteria. corrosion.
6.5. The wire rope will be rejected under the following conditions: a) Broken wires i) Six or more broken wires in one lay. Notes: 1) If the inspection reports are found satisfactory clear the equipment for use. Pulling and Lifting Machine Load test for 4 hours (by loading with number of concrete block to its capacity).½”) 21 . iii) More than one broken wire in the valley. 2) Criteria for rejection of wire ropes.. Check for any damage in threaded portion of I-Bolt. b) Wear and abrasions i) If the wear exceeds 1/3 of the diameter of the wire. etc. ii) Three or more broken wires in one strand in one lay. c) Reduction in rope diameter i) 1mm (3/64”) for rope diameter of up to and including 19 mm (3/4”) ii) 1. Check the saddle inner surface for nay damage. Check for any damage like cut mark.5 mm (1/16”) for rope diameter of 22 -28 mm (7/8” to 1”) iii) 2mm (3/32”) for rope diameters of 32 -38 mm (1/1/4” to 1. on the “u” Bolt. Bull Dog Grips Only forged steel bull dog grips to be used. Check that the „U‟ Bolt nuts are freely moving on the „u‟ Bolt threads.
and bolt two of them together. Bird caging.d) Rope Stretch i) An approximate elongation of 150 mm (6”) per 30 M (100 ft) of length for 6 strand of rope. Unloading and leading the boiler drum The wagon should be placed on the railway siding at such a location where it will be convenient to unload and lead to just underneath the boiler structure. 22 . e) Rejection of Rope The rope may be rejected if the following observed: i) ii) iii) iv) Corrosion Crushed. High. jarruned and flattened strand. Select rails. Lift on end of drum by crawler crane (75 MT Capacity) or by suitable jacks. insert the prepared rails bringing the entire width of wagon and stage. Anyone of the following methods may be adopted for unloading from the wagon: a) Method I ii) The place shall be well consolidated. An approximate elongation of 230 mm (9”) to 254 mm (10”) per 30 M (100 ft) of length for 8 strand of rope. should be properly anchored. Same arrangement should be made at the other end also. standing and unlaying. IV. Two and winches of 5 T capacity with 25 rom rope. kinks and bulges. Prepare stage by sleepers on either ends almost to the same height to that height of the wagon. which are capable of taking the weight of Drum.
F-11-01 of FQA System Manual). I is preferred out or a or b. VI Lifting Arrangement The total layout of drum lifting arrangement is to be decided at site depending on the site condition. dimensions are to be fixed to suit the site condition. A typical arrangement of cat head structure is shown in Fig: 3 Note: According to contract drawing. Winch anchorage c. Winch location. The design and drawing will be duly vetted by approved agency or by Unit. b. The dimensions are to be maintained as shown in the drawing. Fasten the winch rope on either end of the drum and skid the drum of the sleeper stage and release the wagon. The welding involved in fabrication and erection of cat head structure are to e subjected to 100% Liquid Penetrate Inspection for its soundness. Note: Cranes shall be placed on well consolidated ground and utmost care shall be taken in operating. 23 . a. d. b) Method II By using two crawler cranes (75 T capacity) the drum is unloaded The Method. signaling and correct slinging. Guide Pulley location. Now the drum is led towards the boiler either by skidding or by using two crawler cranes of 75 MT capacity with very careful signaling operations and brought to location in the correct orientation. Suggested Layout arrangement is given below. V CAT HEAD STRUCTURE (A FRAME) Fabricate the CAT Head Structure in fabrication Yard. (Record the LPI details in Exhibit No. Guide Pulley fixing arrangement.
24 . b) Winch anchorage 1. Pour water to consolidate / compaction. using tower crane (if available) or derrick. The first guide pulley should be in line with the winch drum centre. Drum Lifting Winches Note: The design / method of anchoring are to be finalizes with Civil Engineering Section / approved agency.a) Winch Location (For all winches) The winch should be placed from the first guide pulley in such a way that the fleet angle of 1 to 1 – ¼ degree is maintained. Fill up the gaps better the holders with sand. Fill up the hole with boulders up to 6 feet height from the bottom. a shown in Fig: 4A Erect the cat head structure as per the drawing dimensions.” Fabricate a frame as shown in figure 4 B The same sequence is to b repeated to fill up to 6 feet. This will aid smooth booking of ropes over the winch drum. The fabricated frame to be positioned in the hole due in such a way that minimum 2 feet of the 18MB 400 is above ground level. Width # 3 feet and depth # 8 feet. Dig a hole in ground of size – “Length # 5 feet. leaving 4 feet of the 18 MB 400 at top as detailed below: First one layer of boulders.
Note: Winch can be anchored with arrangement using wire rope. right side) to suit the site condition. after checking with Civil Engineering Section. Take the wire rope directly from this guide pulley to the winch. Note: In case any other anchoring method is decided along with customer. This guide pulley should be located in such a way that it is in line. it may also be acceptable. c) “U” Rod lifting Winch These winches to be anchored with main column of the boiler (between S 12 and S 13 as shown in Fig: 4D. The projecting portion of ISMB 400 above ground level (approximately 2 feet) can be used as anchoring points for the drum lifting winch. Fill up the balance 2 feet depth with concrete mixture and cure it properly. The winch frame to be directly welded with anchoring arrangement through connecting members. This arrangement is to be made ready for both the drum lifting winches at the location decided by site. as shown in Fig: 4E Another set of pulley is to be fixed over the bottom of main column S11 R or S 11L (left and. with the pulley from winch the wire rope comes out of the block 1” pulley. 28 . d) Guide pulley location for drum One set of guide pulley is to be fixed over ISMB 600 Beam C or Beam D near the bottom Flange on left or right size near Column S 18. as show in Fig: 4C.
29 .Note: If required one more set of guide pulley may be fixed in S 13 left and right columns. A typical sketch for drum lifting arrangement is shown in Fig: 5 e) Guide pulley fixing arrangement Fabricate fixing plate as shown in Fig 6A. However it is always preferable to use less number of guide pulleys to minimize the frictional load on the total arrangement.
Use E 7018 electrode Pre heat to minimum 150Oc Ensure baking of electrode to recommended temperature (Welding Manual Vol.D . to avoid any possible damage to rope due to sparking.I). 100% LPI on fixing plate welding. In case any other fixing arrangement is decided at site. 34 . f) Fixing plate welding Only qualified welders are to be engaged. Ensure usage of holding oven to maintain electrode temperature above 100Oc. RECEIVING ARRANGEMENT Caution: No welding is permitted on boiler aside after bringing the drum lifting wire rope inside boiler area. While fixing over the column the fixing plate should be in line with web. Similar procedure to be followed for fixing the plate with main column. (Mainly to avoid sand accumulation in the wire rope groove). the procedure should be approved by site I/C before implementation. The guide pulleys to be fixed to the fixing plate using forged steel „D‟ shackles of correct grade and capacity as recommended by standards. g) Fixing arrangement at ceiling beam and column The fixing plate welding is to be carried out as show in Fig -6B.hole to be drilled to suit shackle dia: M.minimum available length from hole to the end of plate should be 1 -1/2 times the dia. of hole. VIII. Over the leveled ground spread thin sheets or tarpaulin to protect the wire rope touching the ground.
The reeving shall be done as shown in Fig: 7A Note: Any change in the reeving arrangement. Place the two 10 sheave pulleys at a convenient distance of say 5 to 7 meters for reeving. if decided at site. shall be informed to Head – Quarters Facility Engineering group and got approved before carrying out the changed method at site). 35 .
Fixing pulley block with cat head As shown in Fig 7B using 28 mm wire rope the top pulley shall be fixed with cat head arrangement. Minimum 10 layers are to be lashed. Correct size bull dog grip („U‟ clamp) to be used. When the rope is clamped by „U‟ clamps (Bull dog grip) „u‟ end should be on the dead end of the rope and there should be six „u‟ clamps at the interval of 6 inches for proper clamping. After fixing the top pulley block with cat head arrangement, the drum lifting wire rope shall be loosened and the bottom pulley to be brought down for fixing with drum.
b) Fixing pulley block with drum The lashing of pulley with drum shall be done as shown in Fig : 7C. Note: 1. Lashing generally will need adjustment because all the layers will nor get equal loading causing tilt in pulley block. It should be adjusted till pulley blocks are vertical when they are loaded. 2. Top and bottom pulleys are to be in one line, in such a way that the rope fall is perpendicular to both pulley shaft and drum axis. c) Guide pulley location for „U‟ Rod: Since the „U‟ Rod has to pass through the drum supporting beam, washer Plate rocker & nut, it is necessary to lift the „U‟ Rod up to the drum Supporting beam level through one lifting arrangement and then transfer the load to another lifting arrangement provided at the top. A three sheeve pulley of 10 T capacity is to be first fixed at the top, below the drum supporting beam. This pulley should be fixed so that it is at the centre of „U‟ Rod‟s arm distance. Refer: Fig 7D.
d) Fixing of bottom pulley with „u‟ Rod The bottom pulley to be fixed with „u‟ Rod as shown in Fig: 7E
Note: Retainer arrangement is given for keeping the arm distance as per drawing for easy insertion of the „u‟ Rod at the top. This is to be removed after inserting the „u‟ Rod in the washer plate, rocker and nut and after tightening the nut for minimum 10 threads. The location of guide pulley to be fixed at site according to site condition.
for transferring the load. Check the availability of all stubs / attachments. as per drawing. Close all the stub openings if end caps are missing. S18. 42 . Check the following dimension of „u‟ Rod with respect to drawing dimension. after removing the spacer rod. safety valve stub at the top and water riser stubs facing the furnace. Check the distance between the „u‟ Rod stopper plates. S11 R columns) and in front of back in front of back in front of column S12L & S12R The orientation of drum should be adjusted so as to keep the down – comer stubs at the bottom.Note: While fixing the location of guide pulley care to be taken that the “u” Rod lifting wire rope is not interfering with drum lifting wire rope. IX Checks on drum and “u” Rod Position the drum in the rear of combustor area pass (in rear area of S11 L. e) Arrangement for transferring the “U” Rod at Top: The lifting arrangement to be made at top as shown ion Fig 7F and the chain block pulley as shown. Check for the marking of drum axis and „U‟ Rod location on the drum. Note: It is essential to rotate and adjust the drum so as to keep down comer at the ground level it self to the correct orientation to avoid any major adjustment at the higher elevation. Keep the U Rod on horizontal plane Refer Fig: 7G Arm to arm distance Threaded length Out of plane of arm Free movement of nut. (According to shop match mark). After insertion in washer and rocker tighten with nut so that the required length of threads are above the nut.
Inner radius of U-Rod To find the expected thread length to be protruding above the nut (=P) Calculate the following. Arm length (straight length from the drum center to top of thread. TOS elevation of drum suspension beam Thickness of washer plate # A meters. # B Meters 43 .
Free path up to drum level for drum lifting (if any temporary members were welded for erection purpose they are to be removed between S11L. Free movement of all pulleys while lifting. This can be cross referred with drawing for minimum projection envisaged by designs. S11R combustor side and S12L to S12 R left and right side Back Pass area) 45 . Height of rocker Height of nut. During the above operation check the following points for correctness. No interference of wire rope. Anchorage of icle pulleys in the system. No vibration of boiler structure and the structure. A +B + C+ D = X metres (measured value) Drum elevation given in the drawing = Y metres Calculated distance from Top of nut to drum level Length of arm measured (X. Main hoist pulley blocks anchorage both at cat head structure and drum. the alignment of the drum will be easier with minimum adjustment. Also. Anchorage of winches. X) Trial Lifting of Drum: Lift the: drum to 1 to 2 meters height above the ground level and hold it for 10 minutes. S18.Y) meters = say Z meters = L meters Hence threaded portion above nut = (L-Z) = P meters This calculation will help to find out approximately how much threaded portion is above the nut after maintaining the drum level as per drawing.
if required.The drum may be lifted in tilted condition to clear the fouling. Similar trial lifting operation is to be carried out for „U‟ Rod also. the total system is ready for drum lifting. Readjust it. Then lower the drum to its location and recheck the above points once gain. Coupling for the motor with gear box. Soundness of “Winch – Break” (one at a time by transferring the loas on it to required). IX) Reference axis and angle marking Punch mark the reference line on the washer plate (to match the centre line of the rocker) to the specified angle shown in drawing for rocker alignment. S19 Also check the perpendicularity of the boiler axis with respect to drum longitudinal axis as shown in Fig: BC Note: All RBs are to be positioned with respect to “boiler longitudinal axis” and drum axis / Combustor and Back Pass. S 18. Typical marking detail is shown in Fig 8A Punch mark the boiler axis on the top flange of ceiling girder C3 and middle row of WBs over Columns S 17. After ensuring all the requirements. Position the square washer plate over the drum suspension beam and arrest it with cleat angle on four sides (the cleat angles are to be tack welded with structural members only) and check the correctness of position with respect to drawing.10 mm 46 . Winch current during lifting. Beam B and Ceiling Girder C # Maximum + /. Allowance tolerance from drawing dimension: A and B from center line of: # 3 + /-3 mm Beam D. as shown in the Fig: 8D.
Stop the „U‟ lifting winch when the gap between drum and „u‟ Rod is around 0. The drum should be maintained at same titled condition from horizontal throughout the lifting operation a sin initial position. Position the nut over the rocker. Release the sign attached to the „u‟ Rod and pulley block. The gap between drum bottom and „U‟ Rod should be maintained throughout the lifting operation. when the drum reaches 0. Stop the drum lifting winches. (Keep the nut slightly above). preferably morning i=under good natural light (for visibility).5 metre above the drum elevation shown in the drawing. Drum Lifting operation Start the drum lifting operation. Allow the nut to sir properly over the rocker. 49 . Make the drum in horizontal condition now. Allow the drum to travel at least 2 meters up and then start lifting the „U‟ Rod. recheck all given for trial lifting to ensure that arrangement is in normal condition. Tighten the nut so that the calculated value of threaded portion above the but is maintained. XII Position the rocker over the washer plate and align it with punched line on the washer plate. During drum lifting operation. Lift the „u‟ Rod using chain block. Then slowly lower the drum and allow it to sit over the „u‟ Rod. Insert the „u‟ Rod is the washer and rocker. Take the „u‟ Rod load on the other lifting arrangement provided at the top.5 meter. adequate enough to clear the fouling from structural members.
XIII Alignment of drum (Refer: Fig 9) Align the drum for horizontality. 50 . Tolerance allowed is – 5 mm from one corner to the other cornet (centre line marked on the drum). Keep the total lifting arrangement till the completion of drum alignment. Align the drum for its elevation – Tolerance ± 5 mm. Release the load on winch.
Check the contact between „u‟ Rod and drum (30o contact on either side from bottom most point). XIV DRUM INTERNALS Following procedure is to be followed. With the drum load on „U‟ Rod the nut should not be tightened or loosened to adjust drum level. Note: Check for the alignment of drum centre with reference to boiler axis – Tolerance ± 5 mm. The vertically of column (wherever possible) is to be checked and recorded) after drum lifting by the structural erection group. In case of any variation. Tolerance 10 mm. if the drum internals are dispatched separately or drum internals are removed and are to be fitted back: 53 . Any adjustment by nut should be done only after lifting the drum slightly up and „U‟ Rod in free condition. Record all the regarding in FQA log sheet number FQA01-Q400-L-O1. Check the vertically of each limb (arm) of „U‟ Rod (using plumb bob). report to designs at manufacturing unit for clarification.
Refer Fig: 10C. match marks are to be made so that same sub assembly component 1S fitted in the same place during reassembly. Check whether the primary separator is clamped to its supports rigidly with its axis vertical so that it does not tilt or fall during operation. Ensure that the weld joint of feed pipe are leak proof. All bolted connections are to be used with double washers. 11. 3. 12. Refer Fig: 10 B. to make certain they are open. A tolerance of ± 5. The concerned contract assembly drawing of drum internal is to be studied before start of the internal assembly. Seal welding is to be done only as per arrangement of drum internal drawing. But the supporting structures to be seal welded to the drier base angle as per arrangement shown in Fig : 10D. One washer is to be put at the back of nut and the other at the front of bolt and ensure that the washers cover the holes / slots fully. 2. Inspect all vent and drain holes in the internals. A typical cross sectional view of drum internal is shown in Fig: IOA. Ensure that all parts of separating chamber are fitted without any gap. Ensure that drum is free of all foreign particles. Ends (entry and exit) of secondary separators must be opened for steam passage. The welds at the joints should be complete and leak proof. Check. Check whether the screen drier boxes are fixed with each other such that the gap does not exceed 1 mm. 10. 10B. 7. 13. Refer Fig. 8. 9. especially tools and electrode bits which may remain inside after the erection of internals. The drier sections are not to be welded together nor to the drier supporting structure. 6.0 mrn is allowed in the vertically of turbo separator.BOILER DRUM 1. 5. 55 . 4. whether the passage are through in individual screen drier boxes and ensure that these are free from foreign material. While dismantling drum internals at site.
Check whether the down – comer cover assembly has been installed over the down – comer cover openings to avoid vortex formation during operation. The holes in the chemical doing pipe should be facing towards the Feed Distribution pipes. These holes are to be in the direction opposite to Chemical – Dosing.pipe. 15. 17. see that manhole door gasket is in perfect condition. 56 . Before closing the manhole door.14. Check for the orientation of holes in blow down pipe. 16.
ERECTION OF HEADERS 58 .
Flexible hose test * for long stubs of the header to ensure free passage. 1 Δ D X Presetting for that particular suspension depends on „O‟ Distance from origin of expansion Distance of the pressure part component that is suspended from reference structure. the drawings given in structural group are to be followed. 2. Axis marking at the ends in the II & IV quadrants. 59 . Note: For erection of supporting structure. a) b) c) d) e) Check the following on headers: Orientation of the headers. Distance of the suspension point on the structure from the reference structure. This difference is preset to accommodate thermal expansion a shown in the Fig. Checks on Supporting Structure Prior to Erection: Check the dimensional correctness of the pressure parts supporting structures (RBs) with respect to reference axis shown in the structural drawing. For the dimensions and the amount of presetting refer the contract drawing. Front / Rear marking for the headers perpendicular to drum axis. 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.ERECTION OF HEADERS 1. X+ Δ - For the dimensions and the amount of presetting refer the contract drawing. Left / Right marking for the headers parallel to drum axis.
(Refer log sheet No. FQA –OI – 05-00-L-03. 60 . 3.Refer FQA log sheet No. * . scarfing line and sub stub verticality. Insert the hanger rods / tie rods through bearing plate and tighten with nut. Position the baring plate over the support channels as per the structure drawing dimension and tack weld as shown in the Fig:2. FQA –O1-05-00-L-02 and Instruction No. g) The bow in both the planes.) Clean the weld edge preparation and apply weldable primer and fix all end caps. Erection of header supports.f) Sponge test * for open header stubs. BI.OI – 0204T/3 of 8 for the procedure.
Header lugs must be used for lifting as shown in the Fig: 5. The capacity. Provide the correct size cotter pin. is to be decided at site based on the weight of the header and position of the lifting winch. orientation.Note: Proper care is to be taken while lashing the ropes over the WBs. 63 . use a tag line to control the load (movement of header) Lift the header and place it over the temporary support and match the header axis with the centre line marked over the temporary support. lifting Wire rope diameter and guide pulley location etc. horizontality and distance from reference axis before arresting the header. Arrest the header as shown in the Fig 6: Other headers like bottom header which are connected with water – wall and like SHH 5 & 6 which are connected with steam cooled wall are to be positioned aligned and welded with water wall / SCW etc respectively. number of sheeve pulleys. Connect the hanger rod with the header lug using the pin. Check the elevation of the header. While lifting the header.
2. 65 . 3.Note: 1. Other important aspects of header suspension and header alignment are shown in Fig : 7A to 7E. The end caps should be removed only during final fit up. All temporary supports should be removed only prior to hydraulic test. The temporary supports should be erected in such a way that it should not be a hindrance to any permanent suspension / components.
00-LO2) After cleaning the tube. FQA – OI – OS.). This marking will help in erecting clean only cleaned tubes. This procedure is applicable for all loose tubes. (FQA log sheet No. During the sponge movement in the tubes.Procedure for sponge test A sponge piece of width & breath 1 ½ or 2 times dia of tube ID and length minimum 6:” (150 mm) to be pushed in the tube by compressing the sponge. If there is any choking. close the end openings with end caps. the accumulated dust if any or the VCO pellet powder etc. coils. Identify the cleaned tubes with paint marking (say X or Y etc. will be cleaned. the sponge will get stuck up. 71 . panels etc. Due to the air pressure sponge will be pushed ID the tube towards the other end. Pass compressed air in the tube where the sponge is inserted.
PRESSURE PARTS (Water Wall / SH Steam cooled wall) 72 .
Evaporator and let header (middle wall outlet header). pipes and headers close the openings with end caps after test. transition inlet Headers front and rear. Carry out sponge tests of all water wall panels. 73 . front and rear roof headers. Edge preparation Preassemble the following with panel seal box as shown in Fig : 1. Man hole doors. if any Any damage like sling mark. deep out. Preassemble the roof panel at ground as per site conditions and Lift combustor roof panels (front and rear) as per site convenience.I. Blower openings etc. (Front. Note End caps are to be removed just before final fir – up. Complete the erection including permanent supports and alignment of all headers as under. tool mark etc. to be rectified before lifting. Evaporator inlet headers (middle wall inlet header) etc. The surface of all tubes that are completely embedded in castable refractory should be painted with two coats of bituminous paints. Water Wall Proceed for erection form top to bottom refer chapter on erection sequence Carry out preassembly on ground depending upon site conditions. Location of opening as per drawing. right and rear side). instrument Openings. transition inlet Headers left and rear. Peep hole doors. left. Check the following Width of panel Length of panel Permanent Bow. riser tubes. o Combustor upper and lower WW headers.
4C) 74 . Weld item B bottom scalloped bar and seal box with pressure parts before the hydraulic test (refer the Fig: 1Y) 3. Lift all the top water wall panels and align the panels within permissible tolerance by adjusting panel to panel welding gap (Refer Fig: 4A to Fig . Water wall / SCW panels are to be handled with care to avoid permanent bow and damage. lifting arrangement is to be suitably decided at site based on the location of winch.Scalloped Bar Welding Detail 1. 2. Item A ahs to be welded to item B after pouring castable refractory inside the seal box (refer Fig 1Z). 4. 6. 7. The. 5.3 (for both lifting and alignment). The suggested panel handling method 1 is shown in Fig. Cut the scalloped bar (only top scalloped bar of seal box) as shown in (Fig: IX).
The tolerance on width & depth is to be maintained as per specified Tolerance (+ 10. In field align panel edge bars. level the individual header on temporary supports with water level. Pre assembly of Bottom header (Refer Fig 5A) Check the following during preferably. First. ensure that this pitch tolerance is not cumulated. 76 . Notes: Refer Figure : 4C 1. 2. Additional temporary supports are to be provided with main structural members to position them. Note: Care should be taken while erecting the bottom panel. erect the buck – stays coming in that panel and align (this will help us to maintain vertically of the water wall panels and furnace dimension within permissible limit) Erect all other panels and complete the welding following the above procedure. -15). After erecting all top water wall panels. While assembling the panels. Complete the welding after alignment. not tube centres in wall assembly.
rear. Align the bend tube (left / right side) with water wall panel and header stubs. 81 . Matching the centre points with respective axis. Measure A1. Arrest the bottom header over temporary support to avoid any possible movement. B3 and B4 – Tolerance ± 5 mm from centre point. Measure D1 & D2 – Tolerance D1. A2. (Minimum two supports are required fro each side). Carry out NDE checks. B2. A3 and A4. Align the bottom headers front. Then clear it for welding. Erect temporary supports for placing the bottom header after lifting.D2 = 15 mm max. Measure B1. Tolerance ± 3mm from centre point. Lift the bottom headers and place it on the temporary support. as shown in Fig: 5B. right side with boiler and combustor axis. Mark the centre points on four sides. Carry out post weld heat treatment. Select locations for fixing top pulley. left. Check the following Elevation of bottom header (each side at ends with water level).
SH STEAM COOLED WALL 1. Provide spacer blocks of necessary to avoid fouling. Complete the alignment of burner blocks and record the alignment and elevation with respect to combustor axis. seal pot return leg opening. Complete the welding and remove the temporary spacer block provided over coils. Erect all the SH steam cooled wall (erection method to be followed as explained for water – wall. rear and right side top headers of second pass (SH side wall inlet headers) and ensure that all permanent support are provided. 3. Make ground pre-assembly of all seal boxes of openings in back pass such as LRSB. Apply anti seizing compound on the studs. Of all openings. Complete the erection of all permanent supports. II.) Check the elev. Check the alignment of front. ash cooler opening. 5. HRSB and Instrument Openings. Complete erection of all bottom header supports. alignment and welding of all panels with openings such as combustor gas outlet opening. Complete the erection. 4. manholes PG Test openings as applicable. Complete the erection of all buck-stays. 2. Note: Fix the panels with burnet opening in their respective position as per drawing. Maintain gaps as per drawing. FBHE return leg opening. Complete the erection of all upper and lower buck stay beams. Complete the welding and remove temporary spacer blocks. Erect and align all furnace guides. FBHE return leg opening. Align the straight tube (first and rear) with water wall and header stub. and check the alignment. Erect all rear roof supports in back pass. left. Check the verticality of all SC walls 84 . Erect and align all riser tubes on temporary supports.
Check the width and depth of back pass. which are to be maintained as per drawing. 7.6.. SH-3 inlet header and complete the welding with SC wall. 85 . Check the end gaps/ clearance available. Align the SH-3 outlet header and complete the welding with SC wall.
09. RH – 2 Inlet. Adequate Gap Should be maintained between ReHeater – 2 & Evaporator Coils and between evaporator outlet header & superheated – 3 outlet header as shown in the drawing. 87 . Check the alignment of EVAP inlet / outlet header. Economizer. Complete the welding of link pipes with headers. Outlet Headers. 08. During Erection. Inlet and Outlet Headers with SCW wall and complete welding.
PRESSURE PARTS (Down Comers) 88 .
Check the respective inlet header stub (for down comer connection) distance from reference axis. Complete the erection of all permanent supports and seismic guides. Lifting arrangement is to be decided at site. the erection attachments to be removed and used for subsequent level.) centre lien with respect to reference axis. Check the individual piece length and orientation of supply pipe stubs (86 nos. After completion of one joint. Further pipes are to be erected as explained above. Clean the joint for welding after achieving all dimensions within permissible limit. Check the drum down – comer stubs (six nos. Check the weld fir up. washer and nuts for erection and alignment. Check the vertically. Check the drum down comer stub to stun distance Note: These checks can be done before drum erection also. (Refer Fig : 1) Erect all top pieces and align with the drum stub. 89 . Use the erection lugs and associated rod.). Check the down – comer pipe to pipe distance. Check the distance of down – comer pipe from reference axis.
Buck Stay) 91 . Coils.PRESSURE PARTS (Down Comers.
92 . Further pipes are to be erected as explained above. the erection attachments to be removed and used for subsequent level. After completion of one joint. Complete the erection of all permanent supports and seismic guides.
such as Economizer. Check for any permanent bow (if bow is observed. deep cut and dent etc. 5. and also fabricate a lifting device as shown in Fig IB. Evaporator coils which are supplied as two paris are 10 be ground assembled before lifting to position. 93 . Ensure flexible connections availability and welding as per drawing.deformation frame as shown in Fig 1A (Temporary binder if ant is to be removed). 2. Check the weld end connections such as edge preparation and ID and compare with header stub weld end connections. Evaporator. Clean the edge preparation and apply weldable primer..ERECTION OF COILS I. The coil penetration location at the steam cooled walls are to be provided with suitable level tubes. B0 half sleeves shall also be provided over the coils exposed to the operating range of individual soci blower. Remove the end caps and carry out sponge test and then fix all th end caps. Precision shields are to be provided for hanger tubes and sorefn tubes are the fuef gas in et to back pass. 1. 3. Check for damages like sling marks. Complete following jobs at ground. inform manufacturing unit for corrective action before taking it up for erection). Fabricate and anti. and hanger tubes. Erection weld of hanger tubes at EL 57. Sponge test is to be carried out for the SH. RH. SH – 3. RH coils.050M should be done at ground itself. a) half sleeves of fuel length with suitable material shall be provided at the top most rows of all co ranks to protect against erosion. EVAP. 4. The suspension arrangement to be pre assembled and positioned as explained in the first pass roof erection. Pre erection checks Check the width and length of the coils. 1. Economizer coil assy. The end caps are to be removed only at the time of final fir up.
Erect all the hanger tubes with permanent support and complete the welding with header. RH. The coils are to be lifted as shown in Fig 2 in the sequence from top to bottom. 3. This arrangement should be in such a way that it can be shifted at top to lift each coil. RH-2. EVAP. 2. 94 . Evap. II. 1. Erection of coils (SH-3. SH – 3. and Economizer coils) Check alignment of all headers. Economizer.6. Fix the lifting and guide pulleys according to site condition.
and above RH coil assy in ear SCW. The baffle plate arresting arrangement is to be completed above Evaporator coil assy. 6. Erect the Eco upper 2. Ensure that this dimension is as per drawing. Link pipes to drum including permanent support.1 Evap.2 in front and rear walls. 10.Note: Provide baffle plates as per drawing of back pass at front and rear walls as recommended by manufacturing Unit. Eco.2 connecting suspension arrangements. Weld the SH – 3. Check alignment the Eco inlet header with its supports and align. upper Eco coils 2. 9. The baffle plate arresting arrangements is to be completed as per drawing in above economizer 1. Complete the erection and welding of Eco outlet header to eco.1 and lower bank 1. RH. Measure the total height of all economizer banks including the support plate. Weld the terminal tube connection between upper and lower coils. 1. 4. Weld the hanger tubes after checking the header alignment. using the floating pulley system. Upper Eco coil terminal tube connection with the outlet header – stubs. with upper coil. 7. Evap. RH inlet header SH inlet header 2. Lift the Evap.2. Complete the welding of inlet header stub with the terminal tubes. 8. Lift the lower Eco coils and suspend with the supporting plate already erected. 97 . and above SH – 3 coil assy. Inlet header. Weld the bottom terminal tube with the header stubs (Header is already welded with rear steam cooled wall) through the connecting tubes. 5. RH. in front wall. 3.
Lift the buck 0 stay and place it over the temporary support provided on the main column at the appropriate level (where the buck – stay is to be fixed with wall panels) as shown in Fig 3. to avoid the buck – stay beam slipping from its location. including permanent supports (orientation of Stubs to be checked). Align the buck – stay beam with stirrups (Ensure that the stirrup is in full contact with the buck – stay beam flange). Complete welding of Link pipes from Evap. Out let header at combustor bottom. Out let header at combustor bottom. Complete the erection. 1A to Fig 1D. alignment and welding of Eco outlet header to eco. Complete line pipes from Middle wall out let header to Evap. alignment and welding of DESH links between FBHE out let header to SHH – 5 (SH inlet) header. Lock the assembly of the ends and in between. the stirrup bolt location in the bucks stay slots should be checked for the relative expansion of ~all with respect to the buck – stay indicated in the drawing. Complete welding of link pipes from Evap. 5. 98 . Important aspects of coil erection and alignment are shown in the back pass fig. The location of the bolt in the slot. (Ensure the bottom stirrup angle is in full bearing with the toe of the buck – stay beam flange). Weld the top and bottom angle with the stirrup. Complete the erection. (Refer: Fig 2C). 4. during erection. Bolted type design (Refer Fig 2B) While preassembly. Link pipes to drum including permanent support. should be such that the relative movement of the wall with respect to buck-stay is fully permitted and should fully conform to the contract drawing. Out let header to drum along with permanent support. Preassembly of Buckstay (Refer: Fig 2A) Assemble the key channel with stirrups (the number of stirrups and its locations to be maintained as pee contract drawing). for cold – Junction.
Check and ensure the completion of panel to panel welding and closing of all voids in the buck stay region. Complete the erection of furnace guide. Complete the corner link connection (the corner link should be inclined outwards with respect to wall. 99 . Fix the buck. Ensure that the key channel is in full contact with all tubes of the wall panels. The buck stay does not expand). Fix the top scalloped plate / pas on wall panel. Weld the bottom side scalloped plates/ pas on wall panels after leveling them. (Refer Fig: 4). This is to accommodate the expansion of wall. (There shall be no rigid connection between vertical and horizontal buck – stays). The important aspects of buck – stay erection details are given in the Figs: SA to 5W.stay assembly (already preassembled) over the scalloped plate / pad. the welding. Mark the centre line of the buck – stay on the wall panels. and complete. Keep 3 mm clearance for the guides to move down without any obstruction for boiler expansion. (the leveler channel shall be rigidly connected at one end and guided at the other end). Weld the scalloped plate / pas with key channel both at top and bottom. Complete the erection of leveler channels with guide. Complete the erection of buck – stay including support hangers and links.
7 4 axis. Carry out ground assy. The end caps are to be removed only at the time of final fit up. and support arrangement. Refer Fig 2 for details enclosed. 10. The suspension arrangement to be pre assembles and positioned. Pre erection checks Check the width and length of the coil assy. 3.2 a & b.. SH 2. 2. Erection of coils (SH – 1. (Temporary binder if any is to be removed).2 a & b. In FBHE 1. 100 . 11. II. Fix the lifting and guide pulleys according to site condition. SH – 1.1 a & b SH 2. 1 2. 2. Check the any permanent bow (if bow is observed. RH -1 a and 1b) 1) Position inlet and out let headers on permanent supports for coil assy. Clean the edge preparation and apply weldable primer. Check for damages like sling marks. deep cut and dent etc. Complete following jobs at ground 9. 7. Fabricate an – deformation frame as shown in Fig 1A. Remove the end caps and carry out sponge test and then fix all the end caps. coil assy.2 a & b. and also fabricate a lifting device as shown in Fig 1B. This arrangement should be in such a way that it can be shifted at top to lift each coil. RH. 8. 3. Sponge test is to be carried out for the SH. Ensure that PBHE enclosure is made before erecting coils and refractory is completed in approachable areas. Transfer the reference line from boiler axis for PBHE 1. SH 2. Check the weld end connections such as edge preparation and ID and compare with header stub weld end connections. 5.2 a & b . 3 and 4. 4.ERECTIN OF FBHE COILS I) 1. inform manufacturing unit for corrective action before taking it up for erection).1 a & b SH 2. RH – 1 a and 1b Check alignment of all headers for respective coil 6.
Weld the terminal tube connection w. Make sure that weld accessibility is maintained for easy welding. with headers.as above with respect to FBHE axis. Align with respect to coil terminal points. 101 . The coils are to be lifted as shown in Fig 2 in the sequence and lowered in enclosure using the floating pulley system. Maintain correct elevation. 10) Carry out welding. 12) Complete the balance refractory. Mark Erection weld locations in FBHE area Make connections with link pipes at inlet and outlet of coil assy. header stubs.t. Ensure correct location of DESH. 2) 3) 4) 5) 6) 7) 8) 9) Check the orientation of header stubs. 11) Carry out test before refractory completion. Ensure correct position and alignment for SH and CRH path. Maesure the end gaps in coil assy.r.
) Closing of all corner openings etc. wind box for burners. Closing of instrument tappings and LPSB. 106 . Prior to start of the test ensure work completion on the following fronts: Completion of welding – area wise. Closing of openings in burner block. and attend the same. Tightness test by pressurization with air. This work is done by an identified supervisory audit team and Protocol made accordingly. I) Visual Inspection Visual inspection of the entire system is carried out first and noted defects. Air and gas tightness test of boiler is conducted. to detect air ingress / leakage points through the fin. from cyclone to back pass and entire fluidized ash path up to economizer outlet damper. The critical areas checked are for Completion of fin to fin welding. rope etc. Refractory areas/ Pour able. prior to taking up insulation work. respective wing boxes. cast able insulation works. Visual inspection. flange joints etc. erection omissions are attended. Proper closing of all doors Access Doors and Inspection doors with asbestos. II. FBHEs Duck work from combustor to cyclones. attachment welds. HRB soot blower openings etc. The test is carried out in two stages I. Completion of fin to fin welding. The total area covered is boiler combustor – pass. Completion of hydraulic test.
is pressurized 10 150 mmwc + 25. The boiler is checked is stages (as mentioned below) and the leakage points. physically and later on with soap solution. Duct from Cyclone to back pass Duct from Back pass Economizer hoppers. 107 .ii) Air Tightness Test The entire system. sealing tape etc. Repeat the test. for pressurizing the Boiler. iv) INPUT REQUIRED Temporary duct work from blower / ejector to the boiler wind box connecting duct. ii) Stages of Air Tightness Test: Combustor Area FBHE Area Cyclone area Seal Pot Area Speise Valves flanges Duct from combustor to Cyclones four nos. for the same. after executing necessary blanking arrangements. economizer outlet damper. Blanking of boiler first pass at the ring header level (Refer Fig:2) Tight close all the peepholes. elevation wise. gaskets. In case blower / ejector. Use asbestos rope. putty. duct up to APH Path AHP Pass Damper at Boiler outlet Forced draft fan or auxiliary air blower along with associated starter or ejector with compressed air. are noted. till all the points are attended to the satisfaction of the supervisory audit team A protocol is made and boiler is normalized and released for insulation work. test / instrument pockets. -0 mmwc (or as per contract terms) and checked for air leakage points. Depressurize and attend to all the identified lrake of defects. to be made ready. manholes. till all the all the points are attended to the satisfaction of the supervisory audit team.
Closing of openings in burner block. prior to taking up insulation work. Tightness test by pressurization with air at 2000 mmWC in entire fluidization path using pa Fan. erection omissions are attended. HRB soot blower openings etc. 127 . I) Visual Inspection Visual inspection of the entire system is carried out first and noted defects. Prior to start of the test ensure work completion on the following fronts. to detect air ingress / leakage points through the fin. The total area covered is boiler combustor – pass. Closing of instrument tappings and LRSB. rope etc. Refractory areas/ Pour able. respective wind boxes. Completion of hydraulic test. from cyclone to back pass and entire fluidized ash path up to economizer outlet damper. flange joints etc. and attend the same. FBHEs Duct work from combustor to cyclones. The critical areas checked are to Completion of fin to fin welding . I) II) Visual inspection. wind box for burners. Completion of fin to fin welding.Air and Gas Tightness Test Air and gas tightness test of boiler is conducted. Proper closing of all doors Access Doors and Inspection doors with asbestos. attachment welds. cast able insulation stages. This work is done an identified supervisory audit team and Protocol made accordingly. Blank design is to be approved by manufacturing unit. Completion of welding – area wise.) Closing of all corner openings etc.
Blanking of boiler first pass at the ring header level (Refer Fig: 2) Tight close all the peepholes. Repeat the test. physically and later on with soap solution. Duct from Cyclone to back pass Economizer hoppers. elevation wise. putty. for the same. duct up to APH Path AHP Pass Damper at Boiler outlet IV) INPUT REQUIRED Forced draft fan or auxiliary air blower along with associated starter or ejector with compressed air. Depressurize and attend to all the identified leaks or defects.II) AIR – Tightness Test The entire system. The boiler is checked in stages (as mentioned below) and the leakage points. after executing necessary blanking arrangements. manholes. to be made ready. is pressurized to 2000 mmwc and checked for air leakage points. sealing tape etc. are noted. economizer outlet damper. 128 . gaskets. Back pass is checked at design pressure using ID fan suction effect. blocking Back pass area. A protocol is made and boiler is normalized and released for insulation work. Temporary duct work from blower / ejector to the boiler wind box connecting duct. till all the points are attended to the satisfaction of the supervisory audit team. Use asbestos rope. for pressurizing the Boiler. In case of blower / ejector. test/ instrument pockets. III) Stage of Air Tightness Test Combustor Area FBHE Area Cyclone area Seal Pot Area Speise Valves flanges Duct from combustor to Cycolnes four nos.
Annexure .1 MANPOWER REQUIREMENT S. 1 2 3 4 5 6 7 8 9 10 11 12 13 Fitters CATEGORY MANDAYS 3000 9000 1500 2400 1800 900 600 5000 300 300 500 600 6 Riggers / Khalasi Welders Tack – Welders Grinders Gas Cutters Electricians Helpers Radiographer Evaluator – II Winch Operator Crane Operator/ Assistants Strand Jack Lifting Equipment Vendor Man Power (Increase drum is lifted by Strand Jack Method) 129 . NO.
FQA – 01 10 Clarence and pitches between Coils and FBHE Walls RH -1 SH – 1.S. SH – 2 11 12 13 14 15 16 17 Vertically and loading of Suspension rods Field welding Log Oil Burnet alignment Dimensions Check of oil burners Elevation Check of openings Hanger loading check Hydraulic test rectification Leakage noticed and Note: quality to add nos. No. 1 2 3 4 5 6 7 8 9 Description Drum alignment Internal clearance of headers Banana Bow of header & vertically of stub Locations of headers Check for panels Verticality of WW/ SC Wall Panels Combustor alignment Back pass alignment Clearance between coils and Steam Cooled walls and pitches SH – 3 Coils Eavp Coils RH – 2 Coils Economizer coils 1.2 Annexure -3 Record No.1. 2. 2. 131 .2. in line with FQP. 1.1.
Annexure . 1 Description Boiler Pressure Parts Engineering checks for erection Boiler Pressure Parts Recommended Hydraulic Test Procedure Product check list of pressure parts Welding Manual Vol-1 Welding Manual Vol-2 Field Heat Treatment schedule Handling and erection procedure for Boiler Drum – By strand Jack method NDE Manual Erection Welding Schedule Field Quality Plans Heat Treatment Manual T & P Deployment Plan Issuing Authority Trichy Reference No. 2 3 4 5 6 7 8 Trichy Trichy Trichy PSSR – QUALITY PSSR – QUALITY Trichy PSSR QUALITY PSSR – QUALITY Trichy PSSR – QUALITY PSSR – QUALITY PSSR – FEX A standard T & P List is attached 9 10 11 12 13 132 . No.4 S.
S.5 Crane 1.Shackle 3t 2t 3 2.5 Pull Lift Pull Lift 3t 5t 3 3t 5t 3T 5t 25 t 20 t 10 t 5t 26 7 2 3 5 62 158 39 21 133 . 18 MT cap 8 MT cap QTY 1 1 1 4 1 03 03 1 17 8 2 21. 1 Description of T & P / Duration (Tentative : periodically to be reviewed) Carne 1.Shackle D.Shackle D. No.5 Telescope Crane 1. 1.1 Strand Jack Lifting arrangement Electrical Winch Electrical Winch 3T 5T cap 31 2. 75 MT cap 40 MT cap.1 Crane 1.Shackle D.Shackle D.2 Crane 1.4 TFC 280 1.6 Hydra 1. 2.4 D-Shackle D.1 Chain Blocks Chain Blocks 2.7 Portal Gantry Crane 150MT cap.3 Hook Chook Hook Chook 2. 100 MT cap.1 Heavy Duty Crane 325 t Cap.
13 Turn Buckles 3 t .10 Wire Rope sling 1 inch Wire Rope sling 1.15 Electrical winch 3T 5T 60 m 300 m 11 6 6 5.5 inch Wire Rope sling ¾ inch Wire rope sling ½ inch 1500 m 2.122 2.4.6 Wire Rope Pulley Wire Rope Pulley Wire Rope Pulley Wire Rope Pulley 5t s/s 20t 3/s 10t 3/s 10t 2/s 20 Chain Pulley Blocks 2.14 Hand Winch 2.9 Slings assorted Wire Rope Wire Rope Wire Rope Wire Rope ¾ inch ½ inch 5/8 inch 7/8 inch 6 2.12 Power Cable 185 sq mm Power Cable 70 sq mm Power Cable 100 sq mm 16 2.2 T cap 35 1500 M a.3.8 2.5 t 1 2 2. M 2130 M 2130 M 10 9 10 134 .
Power Panel.6 Tractor Trolley Trailer Trailer TATA Truck Truck Hippo Trailer 10T cap 40T 20T 10T 24 T 25 T 400 cUM 100 Cum CUM 1 1 1 1 1 4 4.1 4.2 3. Pumps.1 5.4 3.1 8. Alternatively EDTA Chemical Cleaning Equipment 1 LOT 8 8.3 Electrical Air Compressor (For refractory works) Electrical Air Compressor Air blower 1 1 1 1 5 5.2 Sky Climber. (for six person load) Pin.5 3.Rack Lift (-Do-) 6 Hydraulic Test Pump One for Boiler HT One for piping MP / LP HT 2 7 Acid Cleaning Equipment 5 Nos. Piping.3 3.3 3.1 3.3 Welding Generator Welding Transformer Welding Rectifier 28 5 35 135 . Mixing Tank 1 no.2 4. Instruments.2 8.
1 9.9 For Drum Lifting Activity 9.1 Drilling M/C 11.3 9.2 Screw Jack 14 15 16 20 t 3T Temperature Recorder for stress relieving Bench vice Torque Wrench 110 kgm 10 inc 136 .4 Electrical reversible capacity winch 10 T 2 Nos.2 Magnetic drilling m/c 11. 25 mm dia.1 Hydraulic Jack 13.2 Portable Oven for electrodes 13 13. new lifting rope of about 1200 meters 100 MT 10 sheave pulleys 10 T idle single pulleys 3 Sets 4 Nos. 9 10 Huck Boiling M/C 10. 10 Nos.3 FF2 Machine 12 12.1 Grinding M/C Grinding M/C Grinding M/C Grinding M/C 10.1 Stationary electrodes 12.2 Bench Grinder AG7 GQ 4 AG 4 GQ 4 8 inch 10 6 2 3 1 3 1 3 Baking Oven for 4 18 4 7 4 01 4 11 11.2 9.
3 Mortar Mixing m/c 19. blanket Ceramic blanket Hand tools Illumination for construction lighting 15 sets 50-Nos.32 amps Theodolite optical 1 sec. 150 Nos. booth for storage of filled and empty cylinders 18 19 Dewatering Pump 19. kerosene tank.2 Gas Cutting equipment 1. Equipment for Grouting 02 4 19. oil pump burners.1 Pan Type Mixing m/c needed during grouting 19.7.17 1.halogen lamps fittings lighting posts 350 Nos. Acetylene with 2 12 100 VIZ.1 Pug Cutting m/c 1.7.7. Accuracy Brick cutting m/c Equipment for dry out a set of blowers. spark arrestor and gages.3 Cylinders 02. cylinder caps. 350 Nos.2 Electrical Vibrator 19. standard fittings. 2000 Nos. 4 01 01 4 1 01 22 23 24 25 26 27 137 .4 Weighing balance 20 21 Concrete sleepers Scaffolding Pipes 20 meter long Scaffolding Pipes 15 meter long Scaffolding Pipes assorted Scaffolding clamps Main Switch Boards 63 amps.
138 . Shaper. Milling Hacksaw M/C. each 29 30 Power Supply Booth earthing rubber matts. pit etc. GI Pipes. 4 Nos.28 Radiography equipments. Survey meters. Power 1 Nos. sets earthing wire. 1 set Pit for camera storage Lathe.