Boiler Erection 2

7/31/2019 Boiler Erection 2

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Erection of Steam GeneratorsErection of Steam Generators 11

WelcomeWe come toto

Power PlantPower Plant

ErectionErection

Presentation on Erection ofPresentation on Erection of

Steam GeneratorsSteam Generators


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TONNAGE SCHEDULE OF SG

10000

6000

4500

4000

1500

6500

Structures Pressure Parts Rotary Machines & Mills

Ducting Fuel Oil system& piping ESP


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1.0 Sequence of erection1.0 Sequence of erection

Erection of Main and AuxiliaryErection of Main and Auxiliarycolumnscolumns

Erection of MBLs (Main Brace Level)Erection of MBLs (Main Brace Level)

Erection ofErection ofCeiling GirdersCeiling Girders

Boiler Drum LiftingBoiler Drum Lifting
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Erection of PentErection of Pent House Headers and RoofHouse Headers and Roof

Erection ofErection ofWater Wall tubesWater Wall tubesand Ringand RingHeaderHeader

Erection ofErection ofSuper heater coils,Super heater coils,ReheaterReheatercoilscoils,, Economizer coilsEconomizer coilsand Eco inletand Eco inletheaderheader

Erection ofErection ofBack Pass RoofBack Pass Roof, steam cooled, steam cooledwalls and back pass lower headerswalls and back pass lower headers
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Erection of Eco link, MS Pipe and RHErection of Eco link, MS Pipe and RH

inlet & outlet pipes.inlet & outlet pipes.

Hydro test of BoilerHydro test of Boiler

Installation and Trial of FD fanInstallation and Trial of FD fan

Installation and Trial of SAPHInstallation and Trial of SAPH

Completion of Secondary Air pathCompletion of Secondary Air path


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Completion of Flue Gas path with FlapCompletion of Flue Gas path with Flap

DamperDamper

Installation and Trial of coal millsInstallation and Trial of coal mills

Boiler Light Up with LDO/ HFO/CoalBoiler Light Up with LDO/ HFO/Coal

Alkali Boil Out, Acid CleaningAlkali Boil Out, Acid Cleaning

Steam BlowingSteam Blowing


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Synchronization of unitSynchronization of unit

Trial operationTrial operation

PG TestPG Test

Handing Over to O&M GroupHanding Over to O&M Group


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2.0 Documents Required2.0 Documents Required

Erection DrawingsErection Drawings

Category 1 Drawing: Approved by NTPCCategory 1 Drawing: Approved by NTPC

Category 2 Drawing: Subject to commentsCategory 2 Drawing: Subject to comments

Category 3 Drawing: Not ApprovedCategory 3 Drawing: Not Approved

Category 2 Drawing: Taken for informationCategory 2 Drawing: Taken for information(Only conceptual drawing)(Only conceptual drawing)

ContdContd


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WPSWPS

FQPFQP (Field Quality Plan)(Field Quality Plan)

Welding ScheduleWelding Schedule

Contract DocumentsContract Documents (e.g. LOA, LOI, NOA Scope of(e.g. LOA, LOI, NOA Scope ofwork, General &Special condition of contract etc.)work, General &Special condition of contract etc.)

2.0 Documents Required2.0 Documents Required
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3.0 T&P Requirement3.0 T&P Requirement

FMC-LS-718 CraneFMC-LS-718 Crane : 1 No.:: 1 No.: 350 MT capacity350 MT capacitywith ringerwith ringer

FMC-LS-248FMC-LS-248 CraneCrane: 1 No.:: 1 No.: 150 MT capacity150 MT capacity KH-700KH-700 CraneCrane: 1 No.:: 1 No.: 150 MT capacity150 MT capacity

KF-500KF-500Crane: 1 No.:Crane: 1 No.: 100 MT capacity100 MT capacity TFC-280TFC-280 Crane: 6 No.:Crane: 6 No.: 75 MT capacity75 MT capacity TFC-75TFC-75 Crane: 1 No.:Crane: 1 No.: 25 MT capacity25 MT capacity WinchesWinches : 15 No. (of capacity: 15 No. (of capacity

2MT,5MT, 10MT, 20MT)2MT,5MT, 10MT, 20MT)

WinchesWinches : 2 No. (of capacity 30MT): 2 No. (of capacity 30MT) Chain Pulley Blocks, Hook chooks & Wire ropeChain Pulley Blocks, Hook chooks & Wire rope

slings as and when required.slings as and when required.


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4.0 Erection Strategy4.0 Erection Strategy

PreassemblyPreassembly :: The main tool toThe main tool to

reduce the project cycle timereduce the project cycle time

Erection Sequence :Erection Sequence : TheThe

foresightednessforesightedness of the Executerof the Executer
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5.0 System of Nomenclature of5.0 System of Nomenclature of

contractor (e.g. BHEL)contractor (e.g. BHEL)

PG (Product Group)PG (Product Group)

MA (Main Assembly)MA (Main Assembly)

DU No. (Dispatch Unit number)DU No. (Dispatch Unit number)


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6.0 Project Cycle Time6.0 Project Cycle Time

36 months for Coal firing &36 months for Coal firing &

SynchronizationSynchronization

42 months for Completion of Trial42 months for Completion of Trial

operation & PG Test.operation & PG Test.


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SL NO MILESTONE MONTHS (FROMNOA)

REMARKS

1Establishment Of Site Office 6

1.1Mobilization Of Installation Staff At

Site

8

2Commencement of Boiler Erection 11

3Boiler Drum Lifting 15 Approx. Tonnage17%

4 Boiler Hydraulic Test (Drainable) 26 Approx. Tonnage61%

5Readiness of SG C&I for Boiler Lightup

30

6Readiness of ESP 31

7Boiler Light Up & Alkali Boil out 32 Approx. Tonnage81%Acid cleaning completion 33

9Steam Blowing completion. 34

10Safety valve Floating 35

11Steam to TG Set 36

12Coal Firing 36 Approx. Tonnage95%


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M O N T H L Y E R E C T I O N D E T

0

5 0 0

1 0 0 0

1 5 0 0

2 0 0 0

2 5 0 0

OCT'0

2

NOV'0

2

DEC'0

2

JAN'0

3

FEB'0

3

MAR'O

3

APR'0

3

MAY'0

3

JUN'0

3

JULY'03

AUG'03

SEP'0

3

OCT'0

3

NOV'0

3

DEC'0

3

JAN'0

4

FEB'0

4

MAR'O

4

APR'0

4

MAY'0

4

JUN'0

4

JULY'04

AUG'04

SEP'0

4

OCT'0

4

NOV'0

4

DEC'0

4

JAN'0

5

FEB'0

5

MAR'O

5

APR'0

5

MAY'0

5

JUN'0

5

JULY'05

AUG'05

SEP'0

5

M O N

QTY

(MT)

0

5 0 0 0

1 0 0 0 0

1 5 0 0 0

2 0 0 0 0

2 5 0 0 0

3 0 0 0 0

QTY(MT)

B L R # 3 M O N T H L YB L R # 4 M O N T H L YB L R # 3 C U M M .B L R # 4 C U


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H P E Q U I V A L E N T J O I N T C O M

0

1 0 0 0

2 0 0 0

3 0 0 0

4 0 0 0

5 0 0 0

6 0 0 0

7 0 0 0

JULY'03

AUG'03

SEP'0

3

OCT'0

3

NOV'0

3

DEC'0

3

JAN'0

4

FEB'0

4

MAR'O

4

APR'0

4

MAY'0

4

JUN'0

4

JULY'04

AUG'04

SEP'0

4

OCT'0

4

NOV'0

4

DEC'0

4

JAN'0

5

FEB'0

5

MAR'O

5

M O N

JOINTS

(NO.)

0

5 0 0 0

1 0 0 0 0

1 5 0 0 0

2 0 0 0 0

2 5 0 0 0

3 0 0 0 0

3 5 0 0 0

JOINTS

(NO.)

U # 3 M O N T H L YU # 4 M O N T H L YU # 3 C U M M U L A T I V EU # 4 C U M M U


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M O N T H L Y T O N N A G E D

0

1 0 0

2 0 0

3 0 04 0 0

5 0 0

6 0 0

7 0 0

8 0 09 0 0

1 0 0 0

OCT'0

2

NOV'0

2EC

'02

JAN'0

2

FEB'0

2

MAR'O

3

APR'0

3AY

'03

JUN'0

3

JULY'03

AUG'0

3

SEP'0

3

OCT'0

3

NOV'0

3

DEC'0

3

JAN'0

4

FEB'0

4

MAR'O

4

APR'0

4AY

'04

JUN'0

4

JULY'04

AUG'0

4

SEP'0

4

OCT'0

4

NOV'0

4EC

'04

JAN'0

5

FEB'0

5

AR'O5

APR'0

5

MAY'0

5

JUN'0

5

JULY'05

AUG'0

5

SEP'0

5

M O N

0

1 0 0 0

2 0 0 0

3 0 0 0

4 0 0 0

5 0 0 0

6 0 0 0

7 0 0 0

CUMMULAT

IVEMT

E S P # 3 M O N T H L YE S P # 4 M O N T H L YE S P # 3 C U M M .E S P # 4 C


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7.0 (A) Contract Value for Korba, Stage- III (1X500 MW)7.0 (A) Contract Value for Korba, Stage- III (1X500 MW)

under LOI No. 4669under LOI No. 4669

Description Prices (Rs)

1 0 Ex Works Price for main equipment 8,49,50,00,000

2 0 Ex Works Price for mandatoryspares 36,50,00,000

3 0 Type Test Charge 3,25,00,000

TOTAL 8,89,25,00,000

Total in words: Rupees Eight Billion Eight Hundred Ninety TwoMillion Five Hundred Thousand Only.

7.0 Budget


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7.0 (B) Contract Value for Korba, Stage- III (1X500 MW)7.0 (B) Contract Value for Korba, Stage- III (1X500 MW)

under LOI No. 4670under LOI No. 4670

Sl No Description Prices (Rs)

1 0 Unloading, receipt, handling, storage, completeinstallation, supervision, pre commissioning,commissioning, completion of facilities, conductingguarantee tests

86,00,00,000

2 0 Local transportation including port clearance & portcharges and inland insurance charges for mainequipment

19,35,00,000

3 0 Local transportation including port clearance & portcharges and inland insurance charges for mandatory

spares

1,40,00,000

TOTAL 1,06,75,00,000

Total in words: Rupees One Billion Sixty Seven Million Five HundredThousand Only.


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8.0 Scope of Work Under SG8.0 Scope of Work Under SG

PackagePackage

Furnace ,Water Wall Headers, Tubes,Furnace ,Water Wall Headers, Tubes,

RisersRisers

Drum with internals and fittingsDrum with internals and fittings

Super heaters, Re heaters &Super heaters, Re heaters &Economizer with its auxiliariesEconomizer with its auxiliaries


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Water circulation pumps with drivesWater circulation pumps with drives

and coolersand coolers

Spray type attemperators withSpray type attemperators with

valves and accessoriesvalves and accessories

Complete valves and fittings forComplete valves and fittings for

boiler & aux.boiler & aux.

Soot blowing systemSoot blowing system


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Thermal insulation for the boiler andThermal insulation for the boiler and

pipingpiping

FD fans with silencers (2 no. per unit)FD fans with silencers (2 no. per unit)

Motors for the aboveMotors for the above

ID fans (2 no. per unit)ID fans (2 no. per unit)

Motors for the aboveMotors for the above


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Regenerative air pre heaters 4 No. perRegenerative air pre heaters 4 No. per

unit (2 no. PAPH &2 no. SAPH)unit (2 no. PAPH &2 no. SAPH)

Steam coil air pre heaters4 No. per unitSteam coil air pre heaters4 No. per unit

Coal preparation system which includesCoal preparation system which includesraw coal chutes, bunker shut off gates andraw coal chutes, bunker shut off gates and

raw coal feeders.raw coal feeders.

Coal pulverisers with motors (10 no. perCoal pulverisers with motors (10 no. per

unit) Bowl & Roller type XRP1003unit) Bowl & Roller type XRP1003


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Seal air fans (2 No. per unit)Seal air fans (2 No. per unit)

Coal burnersCoal burners

PF piping and ceramic bendsPF piping and ceramic bends

Complete ductingComplete ducting

DampersDampers


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Fuel oil systemFuel oil system

Galleries, stairways, walkways,Galleries, stairways, walkways,

roofing, handrails, platforms,roofing, handrails, platforms,

gratings etc.gratings etc.

Electrostatic precipitatorsElectrostatic precipitators

Cranes and hoistsCranes and hoists


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9.0 Constructional Details Of Boiler9.0 Constructional Details Of Boiler

Design Wt. of each unitDesign Wt. of each unit

(Boiler + ESP):32000 MT Approx.(Boiler + ESP):32000 MT Approx.

No of ceiling girdersNo of ceiling girders : 6: 6


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Elevation of T.O.S. of main columnsElevation of T.O.S. of main columns

84.945 m84.945 m

Type of Main columns: Star sectionType of Main columns: Star section

Type of aux columns: Box sectionType of aux columns: Box section

No. of HP joints: 27000 approx.No. of HP joints: 27000 approx.


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No of Coal elevationsNo of Coal elevations : 8 to 10: 8 to 10

No of Oil elevationsNo of Oil elevations : 4 to 5: 4 to 5

No of front & rear WW tubesNo of front & rear WW tubes : 269: 269

No of left & right side WW tubes: 212No of left & right side WW tubes: 212


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No of blocks in Eco systemNo of blocks in Eco system : 2 to 3: 2 to 3

No of rows of Eco system coils : 184No of rows of Eco system coils : 184

No. of tubes in one coil of EcoNo. of tubes in one coil of Eco : 6: 6

No of blocks in LTSH systemNo of blocks in LTSH system : 2: 2

No of rows of LTSH system coilsNo of rows of LTSH system coils : 124: 124

No. of tubes in one coil of LTSHNo. of tubes in one coil of LTSH : 6: 6


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No of rows of RH systemNo of rows of RH system : 74: 74

No. of tubes in one coilNo. of tubes in one coil : 12: 12

No of rows of Platen coilsNo of rows of Platen coils : 25: 25

No. of tubes in one coil of Platen : 16No. of tubes in one coil of Platen : 16


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No of rows of Divisional SH systemNo of rows of Divisional SH system

coilscoils : 6: 6

No. of coils in one row of Div. SHNo. of coils in one row of Div. SH: 8: 8

No of tubes in one coil of Div. SHNo of tubes in one coil of Div. SH

: 9: 9

No of LRSBNo of LRSB : 34: 34

No of Wall blowersNo of Wall blowers : 88: 88


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FD fanFD fan : 2 No, AXIAL AP1-26/16,: 2 No, AXIAL AP1-26/16,

Blade pitch control, 980 rpm, 1300Blade pitch control, 980 rpm, 1300kw motorkw motor

PA fanPA fan : 2 No, AXIAL AP2-20/12,: 2 No, AXIAL AP2-20/12,

Blade pitch control, 1480 rpm, 2950Blade pitch control, 1480 rpm, 2950kw motor.kw motor.

ID fanID fan :2 No, NDZV 47 SIDOR, Inlet:2 No, NDZV 47 SIDOR, Inlet

damper + VFD control, 580 rpmdamper + VFD control, 580 rpm4050 kw motor4050 kw motor


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10.0 Constructional Details of ESP10.0 Constructional Details of ESP

ESP efficiency: 99.914 %ESP efficiency: 99.914 %

No of ESP passes: 4 pass per unitNo of ESP passes: 4 pass per unit

No of fields : 8 fields/passNo of fields : 8 fields/pass


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Total no. of collecting electrodes perTotal no. of collecting electrodes perboilerboiler : 11712: 11712

Nominal length of collecting elNominal length of collecting el ::13 m13 mNominal length of collecting el :750Nominal length of collecting el :750

mmmm Type of emitting el: Spiral withType of emitting el: Spiral with

hookshooksSize of emitting electrode: 2.7 mmSize of emitting electrode: 2.7 mm

dia.dia. Total no of emitting electrodes perTotal no of emitting electrodes per

boilerboiler : 1,03,680: 1,03,680


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Rappers for collecting electrodesRappers for collecting electrodes

No. of rappers: one drop hammer perNo. of rappers: one drop hammer per

rowrow

Rapper size: 4.9 kgRapper size: 4.9 kg

Frequency of rap: varying from 20 rapsFrequency of rap: varying from 20 raps

per hour at inlet field to 1 rap per hourper hour at inlet field to 1 rap per hour

at the exit field.at the exit field.


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Rappers for emitting electrodesRappers for emitting electrodes

No. of rappersNo. of rappers : Approx. one drop: Approx. one drophammer for two rows of electrodes.hammer for two rows of electrodes.

Rapper sizeRapper size : 3.0 kgs: 3.0 kgs

Frequency of rapping: 10 raps per hourFrequency of rapping: 10 raps per hour No. of hoppers per unit: 32No. of hoppers per unit: 32


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11.0 Insulation Details11.0 Insulation Details

Mineral Wool

Pourable RefractoryCastable Refractory


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12.0 Stress Relieving of Ceiling12.0 Stress Relieving of Ceiling

GirdersGirders HeatingHeating up to 620 degree:up to 620 degree:

Web- @ 65 deg/hrWeb- @ 65 deg/hrFlangeFlange - @75 deg/hr- @75 deg/hr

Soaking:Soaking: At 620 degrees for a timeAt 620 degrees for a timeperiod ofperiod of

WebWeb - 96 Min.- 96 Min.

FlangeFlange - 135 Min- 135 Min

Cooling:Cooling: @ 65 deg/hr for both flange &@ 65 deg/hr for both flange &web up to 300 degrees and then left forweb up to 300 degrees and then left fornatural cooling.natural cooling.


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13.0 Boiler Mountings13.0 Boiler Mountings

Location No Set Pr.(Kg/cm2)

SafetyValves

Drum 2 207.0,209.0

4 211.1,211.1,213.2,213.2

SHoutlet

SV 2 188.5,188.5

ERV 5 185.5,185.5,186.6,186.6,186.6RH Inlet 4 52.4,52.4,54.0,54.0

Outlet(1) 4 49.4,49.4,50.9,50.9

Outlet(2) 4 48.4,48.4,48.9,48.9

Soot Blower 1 40

Waterlevelindicator

Drum DWLG 2

EWLI 4 -----------------------


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14.0 Materials used in Pressure Parts14.0 Materials used in Pressure Parts

Material Area of Application

SA 335 P91 (MS line)

SA 213 T91 (Re heater stage-II, SH Platen & Divisional)

SA 213 TP 347H (Platen& Div. SH, RH, SC spacers)

SA 213 T22 (Platen& Div. SH, RH tubes)

SA 213 T11 (Radiant Roof, LTSH )

SA210Gr C (WW panels, UCT, LCT,WW hanger tubes, WW screen tubes, WW bottomHdr nipples, BP SC wall tubes, BP hanger tubes)

SA106Gr C (Suction manifold & Disch. Line of CC pump, WW O/L Hdrs, Saturation

tubes

SA335 P 12 (DESH link LTSH to Div. I/L header & Div. O/L header to platen )

SA515Gr70 (DC pipes, Lower ring Hdrs)

SA387Gr12CL2 (Collector plate, Crown plate)


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15.0 Major steps taken to reduce15.0 Major steps taken to reduce

cycle timecycle timePre assembly:Pre assembly:

If we reduce the no of lifts, the cycle time of anyIf we reduce the no of lifts, the cycle time of anyactivity reduces itself. Therefore, two auxiliaryactivity reduces itself. Therefore, two auxiliary

columns of boiler are welded at ground and thencolumns of boiler are welded at ground and thenthey were erected in single lift. For examplethey were erected in single lift. For example

Aux column + Aux ColumnAux column + Aux Column

MBLMBL Bracing + Gusset PlateBracing + Gusset Plate


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During mill erection, union head andDuring mill erection, union head and

journal may be preassembled in yard,journal may be preassembled in yard,

transported to site and then erected. Thistransported to site and then erected. This

has reduced the number of lifts from 60has reduced the number of lifts from 60

to 30.to 30.

Coal pipes may be welded at groundCoal pipes may be welded at groundwhere ever it was possible.where ever it was possible.


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Foresightedness:Foresightedness:

If MBL members are not available inIf MBL members are not available insequence then ?sequence then ?

Planning for Space for movement ofPlanning for Space for movement of

crane for erecting ceiling girderscrane for erecting ceiling girdersMiddle columns &Middle columns &

Rear equipmentsRear equipments


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Planning for loose soilsPlanning for loose soils

CAT HAED structures developed atCAT HAED structures developed atground.ground.

Drum dragging saddles (2 no.)Drum dragging saddles (2 no.)fabricationfabrication

To use the psychological slack timeTo use the psychological slack time

After Drum Lifting: Erection of SilencersAfter Drum Lifting: Erection of Silencers& BP Roof P/A etc& BP Roof P/A etc

After Hydro TestAfter Hydro Test


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use of sliding pulley arrangement touse of sliding pulley arrangement to

erect the Economizer coils and LTSHerect the Economizer coils and LTSH

coils, which reduces the change overcoils, which reduces the change overtime from one coil to another.time from one coil to another.

Use of same resource for maximumUse of same resource for maximumtime e gtime e g

ScaffoldingsScaffoldings

Sky climbersSky climberscranescranes


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Supply of electricity supply fromSupply of electricity supply from

two sourcestwo sources

Installation of welding equipmentsInstallation of welding equipments

at different locationsat different locations

Arrangement for alternateArrangement for alternate

resources in critical areas likeresources in critical areas like

welding of P91 Materialwelding of P91 Material


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17.0 QUALITY ASSURANCE17.0 QUALITY ASSURANCE

* A- class check :* A- class check : criticalcritical

* B- class check:* B- class check: majormajor

* C- class check:* C- class check: minorminor


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How to ensure qualityHow to ensure quality ??

Use of good quality manpower andUse of good quality manpower and

material like argon gas, weldingmaterial like argon gas, welding

consumables etcconsumables etc

Deployment of qualified, experiencedDeployment of qualified, experienced

and sincere supervisorsand sincere supervisors

Higher frequency of inspectionHigher frequency of inspection

O S18 0 DEVIATIONS AND THEIR


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18.0 DEVIATIONS AND THEIR18.0 DEVIATIONS AND THEIR

DISPOSITIONING STRATEGIES:DISPOSITIONING STRATEGIES:

MDRMDR

SARSAR

NCRNCR


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19.0 SAFETY ASSURANCE19.0 SAFETY ASSURANCE

PEP talkPEP talk

DemonstrationsDemonstrations

Use of PPEsUse of PPEs

RewardReward

Warning & PenaltyWarning & Penalty


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ThankThank

YouYou

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