600 Mw Boiler Erection Manual

HTPC

HARYANA POWER GENERATION CORPORATION LIMITED PANCHKULA, HARYANA

DESEIN PRIVATE LIMITED CONSULTING ENGINEERS NEW DELHI

CENTRAL ELECTRICITY AUTHORITY SEWA BHAWAN, R K PURAM, NEW DELHI

2X600MW THERMAL POWER PLANT HISAR HARYANA-INDIA

Collection of Boiler Manual

DOCUMENT No: HISAR-GL

RELIANCE ENERGY LIMITED H-146/147, Sector-63 Noida (U.P) – 201301

DEVELOPMENT CONSULTANTS PRIVATE LIMITED CONSULTING ENGINEERS 24B PARK STREET, KOLKATA - 700 016, INDIA

SHANGHAI ELECTRIC CORPORATION No. 8, Xingyi Rd., Shanghai, 200336, China

SHANGHAI ELECTRIC IMP. AND EXP. CORP, No. 22, Lane 376, Yan’An Rd. (West), Shanghai, 200040, China

湖南省火电建设公司 HUNAN PROVINCIALTHERMALPOWER CONSTRUCTION CO.

99 Jianshe Zhonglu,Zhuzhou,China

CONTENTS

1. Boiler anchor bolts and base plate erection manual……………………1 2. The Erection and Lifting Manual of Girders……………………………7 3. Erection Manual of ESP………………………………………………………20 4. The Lifting and Erection Manual of Boiler Drum…………………………42 5. Air pressure testing manual of whole boiler………………………… 77 6.The Erection Manual of Wind Box…………………………………… 86 7. Erection Manual of Flue, Air, Coal Ducts……………………………… 93 8. The Erection Manual of pulverized coal burner……………………… 107 9. Erection Manual of water wall and buckstay……………………………116 10. Erection Manual of Boiler Heating Surface……………………………130 11. Erection Manual of the coal bowl mill……………………………… 146 12. The seal Erection Manual of boiler…………………………………… 164 13. The erection manual of air pre-heater……………………………… 172 14. Erection Manual of Fuel Oil Pipe and Device………………………… 184 15. The Scheme for boiler hydro test………………………………… 198 16. The Erection Manual of Axial Fan……………………………………… 215 17. Erection Manual of Coal Feeder………………………………………… 227 18. The Manual of overall plant insulation………………………………234 19. The Erection Manual of Steel Structure………………………………252

Boiler anchor bolts and base plate erection manual


DOCUMENT NO.: HISAR-GL-01 Page 1

DOCUMENT CONTROL SHEET

PROJECT : 2X600 MW THERMAL POWER PLANT HISAR HARYANA-INDIA

CLIENT : HARYANA POWER GENERATION CORPORATION LIMITED

DOCUMENT TITLE:


DOCUMENT NO.: HISAR-GL-01

REV. NO. :0

ENDORSEMENTS

0 2007-08-18 First Issue

Rev No Date Description Prepared by

Sign.( Initials) Reviewed by Sign. (Initials)

Approved by Sign.( Initials)




CONTENTS

1. Reference Document…………………………...……………………………………3

2. Introduction of Work…………………………………………………………………3

3. Erection Tools……………………………………………………………………3

4. Requisitions before Erection…………………………………………………….3

5. Procedure Sequence…………………………………………………………….4

6. Equipment Open Case Check …………………………………………………..4

7. Erection Procedure…………………………........... …………………. ……….4

8. Safety Cautions………... ……………………………………………………….5

9. Appendix FQP ( Boiler anchor bolt and base plate erection)……………..…….5




1 Reference Document Shanghai Boiler Works Ltd. Drawing No. 538918-E1-01 base plate

Shanghai Boiler Works Ltd. Drawing No. 555918-D1-02 anchor bolts fixed set

Shanghai Boiler Works Ltd. Drawing No. 555918-E1-0 anchor bolts

2 Introduction of Work

The Boiler of 2×600MW Hisar thermal power plant manufactured by Shanghai Boiler

Works Ltd. There are total 33 pieces of base plates, total weighs about 22373Kg and 33

foundation frames 4134.2Kg including 33 pieces of structure template, 104 pieces M36

bolts, 28 pieces M48 bolts, and every bolt with four nuts, two washer, one anchor plate.

3 Erection Tools

One mobile crane （50T）

One mobile crane （8 T）

One set of theodolite

One set of leveling instrument

Two sets of AC welding machine

Two line Plumb

One set of Tensiometer

One piece of Steel tape (100m)

One piece of Steel tape (50m)

Four pieces of Steel tape (3m)

Two pieces of Steel ruler (1m)

Two pieces of Angle ruler（300mm）

Two pieces of water level (300mm)

One crowbar（1200mm）

One crowbar（600mm）

4 Requisitions before Erection

4.1 Civil foundation has been checked and accepted.

4.2 Erection area has been cleaned.

4.3 There are road on the rear, right and left side of the boiler for 50t mobile crane to




move around. There is access for 8t truck to enter inside boiler steel structure foundation.

5 Procedure Sequence

Civil handover---foundation recheck---anchor bolts frame assembled and put to place

---pull steel wire on foundation---anchor bolt frame alignment---foundation acceptance

---foundation grouting---frame size recheck---erection, alignment of base plate

---checked and accepted---base plate grouting

6 Equipment Open Case Check

6.1 Count the quantities and measure the outer dimension as detailed in the supply sheet,

packing list and drawings.

6.2 Check if the equipment has crack, double skin, severely rust and damage, etc.

6.3 Welding joint check: if it has undercut, crack, etc.

6.4 Frication surface check: if it has fly edge, burr, scar or damage, etc

6.5 Using steel ruler to check bolt hole position and diameter.

6.6 Check planeness of base plate: using 1m steel ruler and feeler gauge with 90 degree

angle to verify.

7 Erection Procedures

7.1 After civil hand over, it is necessary to recheck the foundation data, such as size,

longitudinal and horizontal centerline and elevation, and then draw the line on the

foundation and compare with the civil mark to make sure it is right as drawing.

7.2 Draw the center line of upper foundation frame and mark it by red painting and punch.

The mark shall be made at the easily found place and be measured based on anchor

bolts hole.

7.3 Hoist the foundation frame to its place by 50t or 8t mobile crane, pay attention to its

erection direction sign and location when positioned.

7.4 Pull steel wire on foundation , after the foundation frame to its place, pull steel wire

with hexagon-headed bolts（L=200mm）by the civil centre line bench mark.

7.5 Leveling and alignment of frame, level the frame by putting some shim plate under it,

and move the frame to make the centre line of the upper part to match with the centre line




of civil foundation, check it by falling line plumb.

7.6 Adjust the elevation, perpendicularity and open size of anchor bolts according to

drawings. Secured the frame to the base and grouting. Recheck if all data keep same

after grouting.

7.7 Using woven or rag cloth to wrap on thread part and tie tight with iron wire to protect

the thread from damage during grouting.

7.8 When the grouted concrete strength meet design requirement, check all data on

frame, if data remained no change, the template can be removed and began to column

base plate erection

7.9 Before erection the base plate, number and mark shall be made on every plate as the

drawing. Slowly position the base plate and take care not to collide the thread of anchor

bolt, and when the two line match together, put the washer and nut.

7.10 After complete of all anchor base plate, check if it acceptable, then grouting in one

time.

8 Safety Cautions

8.1 The lifting capacity shall consider in terms of the weight of equipment and mobile

crane performance curve. It is prohibited to lifting without calculation.

8.2 The distance of oxygen and acetylene bottle shall over 5 meters and away from heat

resources not less than 10 meters. Measures shall be taken on gauges of these bottles to

keep from damage. 8.3 Check if the welding hose are complete well and iron wire tied at the joint to prevent the gas leakage and hurting. 9 Appendix FQP ( BOILER ANCHOR BOLT AND BASE PLATE ERECTION)（L-length of anchor bolt）

Des. Characteristics class unit Inspection standards Method and tools




Bolts fixed set Adequate intensity, rigidity

and stability Observation and hand

rock Size and quantities of bolt Meet design requirement Observation deviation between group bolt center line and foundation

mm ≤2 theodolite, ruler

relative deviation between each group center line

mm ≤1 Steel wire, ruler

top elevation mm +10~+5 Water level

Anchor bolts erection

Erection check

Perpendicularity deviation mm ≤L/450

（L-length of anchor bolt）

Plumb, ruler

Deviation between longitudinal and horizontal centerline and power

house benchmark main mm ±20

boiler center line select the frone axle line of

column by ruler

Distance ≤10m ±1 Distance deviation distance＞10m

main mm ±2

Level deviation main mm ≤0.5

Length ≤20m ≤3 Diagonal line Length ＞20m

main mm ≤4

Tension under force 5~15kg to measure

Elevation deviation of floor mm 0-20 Datum on one meter

high at one stand pillar

outer dimension deviation mm +20-0

preliminary anchor bolt center line deviation

mm ±2 Steel ruler

Base plate erection

Foundation surface pitting and shim plate

knock even Water level

Secondary grouting height mm ≥50 Steel ruler

pieces for every pile piece ≤3 location Under base plate

observation

Bearing force ％ ≥60%(foundation design

strength) calculation

Shim plate assem

bly Shim plate erection no loose, dot weld on adjacent shim and base

plate Hammer, observation

The Erection And Lifting Manual of Girders






DOCUMENT TITLE:

The Erection and Lifting Manual of Girders

DOCUMENT NO. : HISAR-GL-02

REV. NO. :0

ENDORSEMENTS








CONTENTS

1 The basis for compiling the manual …………………………….……….9

2 The range of erection and workload …………………………….……….9

3 Arrangement of construction personnel and their qualification…… ….9

4 The recommended list of machines, tools and safety article …..….. .10

5 Construction condition and requisitions before erection …………..…10

6 The construction procedure and method…………………………..……...11

7 Quality control and acceptance …………………………………………..…14

8 Requirement and measures for safety, civilization construction and

environment management…………………………………… ………… …17

9 Attached drawings …………….……………………………………………..19




1 The basis for compiling the manual

1.1Shanghai Boiler Works 90600 Plan Beam（537918-D1-08001）

1.2 Shanghai Boiler Works 90600 Plan Beam（537918-D1-08002）




1.6 LR1750 Crawler Lifting Instruction（REL supply）

2 The range of erection and workload

2.1 Project general situation

The boiler of the 2×600MW thermal power plant at Hisar India is subcritical unit produced

by Shanghai Boiler Works. The series of top girder from boiler front side to backside is

located among H-N axes main columns (except M axes main column), top girder shall be

lifted by LR1750 crawler; the crawler will get into boiler from backside and lift H-N line

columns in sequence from front to back.

2.2 construction scope

The space distance between each two columns is 27.8m, and H, N axes’ top girder is

divided to left and right side by reference of boiler symmetry centerline; J, K, L axes’ top

girder is stack girder, and detailed specification is shown as below: No Name No. of Drawings Weight(t) Dimension(L×H×W） Top elevation（Kg）

1 H axis top

girder 2 14.7 13.866×0.6×2.65 91.35

2 J axis top

girder 1 85 28.3×1.05×3 92.5

3 K axis top

girder 1 111 28.3×1.25×3.2 92.7

4 L axis top

girder 1 133 28.3×1.4×3.2 92.7

5 N axis top

girder 2 36.91 21.3×0.8×3.8 91.3

3 Arrangement of construction personnel and their qualification

It will be ascertained by Erection Company.




4 The recommended list of machines, tools and safety article

4.1 The recommended list of machines and tools

NO Name Type Quantity Remarks 1 Crawler LR-1750 1 2 Clamp ring 100t 4 Checked to be qualified 3 Steel rope 6×37+1 d=65 L=50m 2 4 Guy 2 5 Chain block 5t 12 Checked to be qualified

6 water level 1 Checked to be qualified

7 feeler 0.02-1mm 1

8 piano wire some

9 line plumb 0.5KG 1

10 steel ruler 1500mm 1 Checked to be qualified

11 steel ruler 500mm 1 Checked to be qualified

12 angle ruler 300mm 2 Checked to be qualified

13 steel tape 50m 1 Checked to be qualified

14 steel tape 100m 1 Checked to be qualified

15 spring balance 20KN 1 Checked to be qualified

4.2 outfit of safety article

4.2.1 Outfit of personal safety articles: safety helmet, safety belt, anti-fall devices and etc;

4.2.2 Outfit of safety articles on construction area: safety net, enclosure and etc.

5 Construction condition and requisitions before erection

5.1 Prepare construction power on site and guarantee sufficient illumination at night.

5.2 The working condition and performance of lifting machine should meet requirement,

the track for LR-1750 crawler passing should be smooth, tamped with earth. The height

should be min 0m and paved with roadbed, the intensity meet the requirement.

5.3 The anchor bolts fixup for residual steel structure columns should be protected. Steel

structure from line Ka to line N column, and line 4 to line 6 columns shall be installed after

the girder is lifted. The foundation between steel structures to ESP can’t come out of

ground.




W（H）

Record

Safety checking

5.4 Lineation of steel structure top column is finished and checked to be qualified.

5.5 Preparation on ground should be finished, such as lineation of girder, assemble on

ground, fabrication of necessary scaffold, preparation of safeguard devices.

5.6 The girder lifting manual is approved and makes all workers take part in the

construction familiar with technique content.

5.7 Except the remained steel structure, all the steel structures have been installed, and

the high strength bolts have been fixed tightly.

6 The construction procedure and method

6.1 construction process flow chart

Girder checking

The erection of J axes girder

The erection of junior beam between H、J axes

The erection of K axes girder

The erection of junior beam between J、K axes

Foundation lineation of top steel structure

The erection of remained steel structure between K、L

The erection of remained steel structure between L、N

The erection of L axes girder

The erection of H axes girder




6.2Construction method and requirement

6.2.1 Transportation, unloading and temporary storage of top girder

Place girder on hoisting position after it has been transported to site from port and

assembled on hoisting position. H axes girder is lifted between Ha and J. J、k、L are

placed on itsself axes line, formed 18°angle with horizontal axes, and suspend after

assembling. N axes are placed behind the furnace to lift. LR-1750 crane is used for

unload and cooperated to assemble on the ground.

6.2.2 Lifting process and lifting machine

Considering collocation of top girder and stability of the structure during lifting

process, the lifting sequence should be from boiler front side to backside, that is: H axes

top girder (left/ right) →J axes top girder →K axes top girder →L axes top girder

(upper)→N axes top girder (left/ right).

6.2.3 Selection of working condition and load distribution of lifting machine

LR-1750 crawler, main beam is 253ft (about77.11m) ,77°angle with level, the length of

fly jib is 115ft (about35.05m), 200t hook (weight 9t), with super balancer.

The load distribution chart of lifting machine is viewed as following during lifting process of

top girder:

Working condition of top lifting machine

Working condition of lifting machine Top girder

weight （t） range

（m） Rated load（t）

Lifting load（t）

Load ratio

Location of lifting machine

H axes top girder 14.7 24.38 156.59 17 12% A

J axes top girder 85 24.38 156.59 87 59% B

K axes top girder 111 24.38 156.59 113 77% C

The erection of N axes girder

The erection of junior beam between L、N axes




Working condition of lifting machine Top girder

weight （t） range

（m） Rated load（t）

Lifting load（t）

Load ratio

Location of lifting machine

L axes top girder 133 24.38 156.59 136 92% D

N axes top girder 36.91 24.38 156.59 39 26% E（take boiler center

as symmetry）

The above mentioned range can be adjusted according to site situation. The position of

lifting machine and girder see in attached drawing.

6.2.4 Lifting process and method

6.2.4.1Top girder will be lifted by single LR-1750 crawler.

6.2.4.2 Top girder will be unloaded by single LR-1750 crawler, J, K, L top girders should be

lifted before assembled on ground and accepted, during assembly the bottom of girder

should be flat, fix its both sides of its ends and middle by support so as to avoid overturn

of the girder.(The support is assembled by 2nos #16 channel, when connect it with girder,

fabricate and drill iron plate at site, and fix it on girder by bolt, at last weld channel with

iron plate)

6.2.4.3 During lifting, the lifting rope should be binded tightly to the correct position. The

right binding position is 2.5m from girder center to both sides with angle 30°.

6.2.4.4 Top girder will be unloaded by single LR-1750 crawler. The N line girders should

be stored between boiler backside which is between N line and ESP, H line girders placed

between Ha line and J line, and other top girders should be placed on corresponding axes

with angle more than 17° to boiler transversal axes (in the principle of not collide with line

4, 6 axes steel structure), the center should be in the same line of boiler center and make

temporary fixup.

6.2.4.5 The temporary fastness will take 4nos 2t chain blocks; make use of guy one side

is lifted to 87.1m cross beams between 3 axes and 4 axes column, the other side is fixed

on both sides reinforced plate of girder by steel rope and block loop (make temporary

opening and repair afterwards), and dismantle it after the crossbeams between two

girders are erected.




6.2.4.5 Check the specification, quantity, location of lifting lug and make sure welding

quality has met the requirement.

6.2.4.6 When the top girder is lifted to 100mm from ground by LR1750 crawler, do a brake

performance test and use electronic scale to check if the load situation of lifting machine

is conform with design, if there is no problem lift the top girder and adjust its location by

guy so as to avoid collision of steel structure of line 4, 6 axes. While the bottom height of

top girder is above top height of steel structure, adjust top girder to the right position by

pulling guy, then slowly loosen hook and lay it down, and regulate it to erection place by 5t

chain block, loose hook after 3-5 pieces fixed bolt are installed and temporary tightness

measures are prepared.

6.3 special technique measures

6.3.1 Selection of steel rope

6.3.1.1 A pair of steel ropes 6×37+1 d=65 and 4 heads will be used for binding the top

girder.

6.3.1.2 Calculation of stress carrying:

Because L axes top girder (upper) is the heaviest, check strength of steel rope according

to the weight of L axes top girder:

Carrying force of steel rope：F=136÷8÷cos15°=17.6（t）

The rupture force of 6×37+1 d=65 steel rope is 222.87t, so while the safety factor is K= 10,

it can lift 22.3t. So use a pair of 6×37+1 d=65 steel rope to lift top girder is safe.

7 Quality control and acceptance

7.1 quality control standard

7.1.1 Manufactory drawing, introduction manual and other technical documents will be

taken as standard preferentially.

7.1.2 Construction quality inspection and evaluation standard

7.1.2.1 Inspection of beam Quality inspection

procedure Inspection item nature unit qualified

Inspection method and measure tools




Equipment appearance

No crack, double

peel, rust and damage

observation

Workshop welding seam

Meet manufacture

requirement

Element material main No misuse Check against product technical

document

Deviation of beam length

mm -10~0

Measure the length & height of foursquare by steel tape and get max tolerance. (steel rule should be tested to be qualified, when

the rule works, it should be tensed by spring balance with

10kg force)

Deflection and side bending of beam

mm ≤1/1000 L， and ＞10mm

check in two directions which have 90°difference; line and steel tape

check

Inspection of beam

Diameter and position of beam lifting hole

Conform to drawings

Measure by steel rule (steel rule should be tested to be qualified, when the rule works, it should be

tensed by spring balance with 10kg force)

7.1.2.2 Installation of single beam Quality inspection



Elevation deviation ±5 Measure by reference of 1m elevation of each column

Level deviation ≤5 Check both sides position of girder

on the top by glass level pipe

Centerline deviation

mm

±5 measure the distance from girder centerline and column centerline

by steel rule

Installation of fish plate Flat, in correct

position, and close to component

Observe

welding Conform with manufacture’s requirements

Installation of each beam

High strength bolt

main

Conform with manufacture’s requirements




7.1.2.3 Boiler roof steel structure foundation lineation Quality inspection



Deviation between roof main column

and its center main

mm

≤10

Draw vertical and horizontal centerline of girder supports on

top column by reference of boiler 0m centerline. Use

theodolite or plumb, line and rule for checking. (steel rule should be tested to be qualified, when

the rule works, it should be tensed by spring balance with

10kg force) Elevation deviation

of roof column ±5

Elevation deviation between each

column

main mm

≤3

Check the center of roof column supports with reference of 1m

elevation of one column

distance≤10m

±1 Deviation between each top column center

distance＞10m

±2

Steel rule check(steel rule should be tested to be qualified, when the rule works, it should be


diagonal

≤20m ≤5

Installation and lineation

Deviation between diagonals

of top columns

diagonal

＞20m

main mm

≤4



7.2 Settings of control interspace witness point

Boiler roof steel structure foundation lineation: site witness (W), halt point (H).

7.3 Settings of interface handing over point: No

7.4 Technique discipline and quality control measures

7.4.1 Before equipment lifted, inspect dimension and location of sling point, and confirm if

it is welded tightly.

7.4.2 During the lifting process, always make sure the top girder is on level and keep the

steel rope of the lifting machine vertically.




7.4.3 After the first girder is positioned, fix it by chain block; after the second girder is

installed, install the hypo-girder immediately so as to form stable headframe structure.

7.4.5 After J, K, L line top girders (both upper and lower) positioned, make temporary

fastness by 5t chain block and 88m beam. It can be dismantled regarding site situation

after top girders and part hypo-girders are installed.

8 Requirement and measures for safety, civilization construction and environment

management

8.1 Wear properly and take helmet before going to site.

8.2 All construction workers should get details knowledge about safety technique and

work should be divided definitely.

8.3 Prevent electric shock when use special welding machine, other electric devices and

tools; the power panel should be equipped with creepage protector; during rainy day,

electric devices should be covered properly so as to avoid power leakage; it is forbidden

to connect power cable with knife switch directly or to socket.

8.4 The construction area should be kept clean, the rubbish and scraps should be cleared

away on time. Stick to civilization construction and keep the principle of “work finish,

materials used out, site cleaned”.

8.5 The railing and night caution light should be prepared so as to avoid falling into the pit.

8.6 Check the dimension and position of sling point, and whether the welding place is

fastened so as to guarantee load distribution of lifting machine and avoid unnecessary

accidents.

8.7 People are forbidden to linger under lifted equipment during lifting process and

caution line should be marked around.

8.8 Temporary scaffold should be fixed tightly and meet requirement.

8.9 The steel rope should be bind tightly and conform to requirement.

8.10 When lifting girder, the place between steel rope and girder pointedness should be

armored, and anti-deformation and anti-sliding measures should be taken.

8.11 After the first girder is positioned, fasten it; after the second girder is installed, install




the hypo-girder immediately so as to form stable headframe structure and avoid accident

due to long time.

8.12 When lifting single girder, guy should be fastened to both sides.

8.13 After the girder is positioned and fixed, loose hook slowly, then discharge ginpole,

later loose hook entirely as to keep stability of the lifting machine.

8.14 Arrange lifting time reasonably and guarantee against lifting at night, pay attention to

weather report, it is forbidden to lift when the wind power is above 2 degree.




9 Attached drawings

Locations drawing of crane

F E

76

54

87

6

32

1

ABC

32

1

DF E

SHANGHAI ELECTRIC (GROUP) CORPORATION (S E C)

SHANGHAI ELECTRIC GROUP CO.,LTD.

CENTRAL ELECTRICITY AUTHORITY

RELIANCE ENERGY LTD.

A-2, SECTOR 24

KOLKATA

NOIDA-201301 (U.P.)

CONSULTING ENGINEERS

RELIANCE ENERGY TOWER, EPC BUSINESS GROUP

OWNER CONSULTANT:-

OWNER:-

NEW DELHI

NEW DELHI

DESEIN PVT. LTD.

11650

11880

ER3810018750

9350

6350

BA

6950

3970

D

A

C

13900

N

8400

M

10950

L

9400

11400

10000

13900

654

H

J

K

Erection Manual of ESP 2X600MW THERMAL POWER PLANT HISARHARYANA-INDIA





DOCUMENT TITLE:

Erection Manual of ESP


REV. NO. :0

ENDORSEMENTS





Erection Manual of ESP 2X600MW THERMAL POWER PLANT HISARHARYANA-INDIA


CONTENTS

1. Reference Document……………………..…………..…….……22

2. Project Introduction and Working Scope…………………… 22

3. The list of Construction Personnel and Qualification….….23

4. The recommended list of machines, tools and safety

article…………………………………………………………………..23

5. Construction condition and requisitions before erection

………………………………………………………….………..…24

6. The construction procedure and method……………………24

7. Quality control and quality acceptance…………………..…30

8. Safety, civilization construction and requirement and

measures for environment management……….………………41

Erection Manual of ESP 2X600MW THERMAL POWER PLANT HISAR HARYANA-INDIA


1. Reference Document

1.1 Shanghai Metallurgical & Mining Machine Manufactory ESP Drawing

1.2 Shanghai Metallurgical & Mining Machine Manufactory ESP Erection Manual 2. Project Introduction and Working Scope

2.1 project introduction

ESP used on Hisar 2×600MW power station is electrostatic precipitator located in front of

IDF and backside of boiler. There are 4 parts foundations for each ESP, and each part

dimension is 45520mm×23352mm（depth×width）, it is mainly composed of steel support

structure, bottom beam, ash hopper, shell, emitting and collecting system, emitting and

collecting rapping, internal walkway, hood, platform and stair for maintenance, inner and

outer roof, top lifting, grease pipeline, electric heating device, inlet and outlet distribution

plate, rapping and electric system (including proper illumination).

2.2 working scope

ESP and related mechanical part: ESP foundation recheck and assist of handing over,

clean up ESP foundation and equipment assembly yard; install and revise anchor bolt

and its frame; install and dismantle of platform, collocate and assemble of special lifting

tools; equipment secondary transport; assemble and install of side wall, column, beam,

emitting and collecting system, top roof, ash hopper, hood, platform stair and heat

preservation oven; check and install of emitting and collecting rapping device; paint the

surface of metal; air leakage test; emitting and collecting rapping test; cooperate for

electric field voltage rising test and defection elimination; installation of air lock, guide

blade and ash collecting pipe under hopper; assemble and install of platform stair, rails

and bracket of hopper part; oil leakage test for welding seam of ESP shell, ash hopper

part; electric test for hopper heating device; cold air current distributing test; install of

other accessories. 3 The list of Construction Personnel and Qualification



Personnel arrangement

4 The recommended list of machines, tools and safety article

4.1 The recommended list of machines and tools

SL Name Specification Quat. Remarks

1 Tower crane 200t/m 1

2 Crawler 150t 1

3 Truck trailer 50t 1

4 Truck trailer 25t 1

5 Welding machine 30 Checked to be qualified

6 Electric welding tools 30set Checked to be qualified

7 Fire welding tools 10set Checked to be qualified

8 Steel tape 100m 1

9 Steel tape 50m 1

10 Chain block HS5 5 Checked to be qualified



13 Temporary stair 30 Self make

14 Theodolite 1 Checked to be qualified

15 Water level 1 Checked to be qualified

NO Type of worker Qualification Number Remarks

1 Class leader Senior rank 1 With management experience of same class unit construction

2 Engineer in charge engineer 1 With technical management experience of same class unit construction

3 Team leader Senior rank 2 With construction experience of same class unit

4 Team member Middle rank 50

5 rigger 6 With certificate



SL Name Specification Quat. Remarks

16 Steel rope 6×37+1 d=28 L=12m 1 pair Checked to be qualified

17 Steel rope 6×37+1 d=24 L=6m 2 pair Checked to be qualified

18 Steel rope 6×37+1 d=17.5 L=4m 4 pair Checked to be qualified

19 Steel rope 6×37+1 d=17.5

L=2.5m 10pair Checked to be qualified

20 Guy 2

4.2 outfit of safety article

4.2.1 Outfit of personal safety articles: safety helmet, safety shoes and etc.

4.2.2 Outfit of safety articles on construction area: safety net, enclosure and etc. 5 Construction condition and requisitions before erection

5.1 Prepare construction power, water, gas on construction site so as to meet

requirement.

5.2 Tower crane is installed, and its working condition and performance can meet lifting

requirement.

5.3 The assembly yard is big enough for lifting.

5.4 Hand over foundation and complete grouting.

5.5 Equipment arrival meets installation requirement. 6 The construction procedure and method

6.1 construction procedure

Refer to the installation manual of the second installation process.

6.2 construction method and requirement

6.2.1installation of steel support

6.2.1.1Count equipment as per drawings, rectify and change if it is required. Mark the

direction of steel column according to drawing, and cross centerline of each column and

punch it.

6.2.1.2 Transfer column, connecting beam and diagonal bracing to site according to

installation sequence, uphold column and hang climb stair (fabricated on site).



6.2.1.3 The separate column shall be fastened by guy after positioned and erect the

bracings between columns, and try to form stable frame as soon as possible by

reasonable lifting sequence. Connect it with bolt and nut.

6.2.1.4 After columns are lifted, align vertical, opening, diagonal, elevation, then tighten

bolt, and weld it. Then install maintenance platform.

6.2.2 Install support bearing.

6.2.2.1 Check equipment according to drawings, classify it and pile it up.

6.2.2.2 Conform to drawings mark cross centerline on related position of each column

and bearing plate.

6.2.2.3 Position guide bearing and flexible bearing respectively according to drawing,

adjust bearing level and weld it.

6.2.2.4 During erection process, fix the bearing top plate to the top plate of steel support,

and dismantle it after erection finished. Part of the support bearing splint and soleplate

shall be fixed by temporary bolts and remove them after installation.

6.2.3 Installation of ash hopper beam

6.2.3.1 Count equipment according to drawings, rectify and change if it is required.

6.2.3.2 Mark cross centerline on ash hopper soleplate and top plate, position abut

according to drawing. Align the top and lower cross centerline, then install transversal

beam.

6.2.3.3 Align the opening and diagonal between each adjacent column according to

drawing dimension. Weld according to requirement of drawing: first weld soleplate, then

transversal beam and vertical beam. Pay attention to welding sequence in order to avoid

deformation.

6.2.3.4 After hopper beam is installed, append side plate on hoper beam naturally

according to drawing’s position, but don’t assemble them. Check diagonal of hopper

bottom, install accessories of ash conveying system (such as aeration stone) if there is.

6.2.4 Installation of shell



6.2.4.1 Mark cross centerline on column soleplate, lift and position them to abut in turns,

make sure the centerlines are in superposition and fix them with bolts.

6.2.4.2 During installation process, measure perpendicularity, opening and diagonal, and

fix it by welding after checked to be qualified.

6.2.4.3 Revise the side plate before install it from bottom to up, and install frontispiece

plate simultaneously.

6.2.4.4 Check perpendicularity of vertical beam before installation, lift it to position after

checked to be qualified, later install roof plate of crossbeam, and align opening and

diagonal between emitting suspension points of roof plate.

6.2.4.5 After every dimension is checked to be qualified, weld side plate, column, roof

plate, and make sure there is no leakage in welding seam so as to avoid wind leakage

during operation.

6.2.4.6 Install and weld other parts, roof plate shall be welded after inner parts are

installed.

6.2.5 Emitting frame, emitting rapping

6.2.5.1 Before install emitting frame, check the levelness of top, middle and bottom frame,

and straightness of support beam.

6.2.5.2 Fit in and align support beam with top frame. Fasten 4 tightwires on suspension

position of emitting suspender; later position top frame by pulling the tightwire through

roof lifting hole. Align it before welding, then lift middle frame and weld it after aligned,

later assemble emitting rapping and bearing. Install emitting drive after installation of two

lines of rapping shaft. Install bottom frame after emitting frame is lifted to position, and cut

excrescent part on the furthest two bottom frames.

6.2.5.3 Finally check three directions and diagonal dimension of emitting frame, and weld

monorail tightly after alignment.

6.2.5.4 Temporarily suspend emitting frame after it is installed, and install suspender after

emitting suspension is installed. Fix emitting rapping by bolt, and weld it firmly after all



emitting system is adjusted.

6.2.6 Emitting wire

6.2.6.1 If emitting wire is spring wire, during installation process hang the hook on spring

wire end to suspension hook on emitting frame, and evenly drag the other side hook to

suspension hook which is on frame bottom by special tools.

6.2.6.2 Spring wire can be installed from one electric field to another one, from frame

sides to center, and line by line.

6.2.7 Installation of ash hopper

6.2.7.1 Lift and position the side plate after it is assembled on ground, then lift hopper

bottom and fix it with side plate to form ash hopper, and preposition it with bolt.

6.2.7.2 Check dimension of ash hopper as per requirement, and weld it after checked to

be qualified. Welding shall be tightly, and welding seam shall be continuously, flat without

leakage.

6.2.8 Collecting rapping

6.2.8.1 Mark centerline of the first and last collecting plate of each electric field, mark

installation position of rapping bar guide rail and centerline of rapping shaft on side plate.

6.2.8.2 Temporarily fix shock bar on the gap after installation of guide rail.

6.2.8.3 When install bracket, temporarily hang it on the casing, and position it after

collecting plate is connected with rapping shock bar.

6.2.9 Collecting suspension

6.2.9.1 Mark centerline of electric field on roof crossbeam and position of suspension

frame, confirm location of angle iron and fix it temporarily.

6.2.9.2 Lift and position suspension frame and fix it temporarily by bolt.

6.2.9.3 Lift I-beam, align suspension frame, connect them by welding, and then install

pedestal and the other I-beam. Finally check installation dimension of suspension frame

and weld it tightly after checked to be qualified.

6.2.10 collecting plate



6.2.10.1 All the collecting plates shall be checked before installation, and revise it if any

defections found.

6.2.10.2 Connect guide rail and collecting plate by bolt and nut before installation.

6.2.10.3 Clamp one group of electrode plate by special tools, and then lift it from

corresponding position on ESP electric field insert into ESP chamber. Sequence shall be

from middle to both sides.

6.2.10.4 Connect electrode plate with rapping shock bar by equipment bolt after

positioned. Revise it if it is deformed.

6.2.11 inlet trumpet and inlet distribution plate

6.2.11.1 Before installation, assemble it into 3 parts and check every dimension, and weld

it after checked to be qualified. Recheck it after welding; revise it if there is any

deformation.

6.2.11.2 Before installation of distribution plate, make sighs on trumpet, and install it as

per the marks.

6.2.11.3 Lift and position the assembled trumpet and distribution plate and weld it by

sequence.

6.2.12 outlet trumpet and distribution plate

6.2.12.1 Install distribution plate to suspension plate after suspension beam is positioned,

and fix with bolt. Install support bracket and then weld distribution plate.

6.2.12.2 Pre-assemble trumpet on ground and then lift it to position. It can also be lifted

separately. But make sure there is no welding deformation in spite of which method is

chosen. Revise it if any deformation found.

6.2.13 outer roof and oil route

6.2.13.1 First install inner roof, and then lift roof cover to roof. After roof cover is mostly

positioned install channel which one side is connected by bolts and the other side by

welding.

6.2.13.2 Install I-beam according to oil route drawing, and then weld oil tray and bracket



bottoms to I-beam, and measure the position. Lay oil pipeline according to drawings

simultaneity. Then lay roof steel plate and fit in oil pipeline. Hydraulic test shall be done to

oil pipelines as per required pressure so as to ensure no leakage during operation.

6.2.14 inspection door

6.2.14.1 Pay attention to the opening direction of the inspection door when install it.

6.2.14.2 Install the inspection door, the switch shall be flexible without jam and with good

sealness.

6.2.15 emitting driver

6.2.15.1 Install drivers on vertical beam of emitting frame, every part of driver shaft and

corresponding accessories can be pre-assembled, and weld driver shaft after it is

installed.

6.2.15.2 Install accessories of roof emitting drivers to the square cover, after aligned weld

heat preservation box and square cover to roof.

6.2.15.3 Install insulator, adjust driver shaft by inserting wedge, and take it out after fixed

by welding.

6.2.16 collecting driver

6.2.16.1 Before installation, install rock wool plate in the bracket of bottom side plate of

outer shell.

6.2.16.2 Install all parts as per drawings and planish the driver bottom by laminate.

6.2.16.3 Install coupling to shaft, and install cycloid pin wheel speed reducer to driver

bottom.

6.2.16.4 At last install rainproof cover and cover board.

6.2.17 after heat preservation box and other main equipments is installed; check every

part of ESP as per drawing, pay special attention to the following aspects:

6.2.17.1 Check if there is any non-welding of any part and dismantle temporary fixation.

6.2.17.2 Check sealness of the cover.

6.2.17.3 Check sealness of welding seam inside ash hopper, and dimension between ash



hopper side plates and block plate.

6.2.17.4 Check if there is paint on the inner wall of heat preservation box, and sealness of

the box; whether the insulator is clean or not in both inner and out sides and if there is any

defections; whether the bolt is tightened or not.

6.2.17.5 Check the dimension of the bottom of inlet distribution plate and bottomof side

plate of inlet trumpet.

6.2.17.6 Check whether the emitting frame support is firm or not, the center of dustproof

is excused or not, all bolts and nuts are spot welded or not.

6.2.17.7 Check strain of spring wire; whether the rapping shaft and pedestal is vertical;

rapping hammer can fall freely or not and its position is right or not; the tooth driver of pin

wheel is correct or not.

6.2.17.8 Check whether the collecting plate is hung into suspension hook, if the position

guide rail accords with drawings, whether there is enough elongation space in collecting

guide rail for shock bar, whether the distance between emitting and collecting meets

requirement.

6.2.17.9 Check the sealness of the inspection door and flexibility of its on-off. 7 Quality control and quality acceptance


7.1.1 Take manufacture drawing, instruction and other technical documents as

preferential standard, consult manufacture instruction for tolerance and refer to this

manual if manufacture instruction is not cleared.

7.1.2 Construction quality inspection and assess standard.



Inspection

SL

Part name or

working

procedure

Inspection item Inspection

type

Inspection

time

Reference document and

standard format Site witness

E C O S

stati

on

Rem

arks

1 Foundation lineation Measure 1 installation manual record R R - R

2 Assembly and installation of ESP frame Measure 1 installation manual record R R - R

3 Secondary grouting of ESP foundation Measure 1 installation manual record Hidden work

R R - -

4 Installation of roof and side plate Measure 1 installation manual record R R - -

5 Installation of inlet & outlet trumpet Measure 1 installation manual record R R - -

6 Assembly and installation of ash hopper Measure 1 installation manual record R R - -

7 Installation of ESP stair and platform Measure 1 installation manual record R R - -

8 Assembly and erection of electrode Measure 1 installation manual record W R R - R

9 Installation of ESP distribution plate Measure 1 installation manual record R R - -

10 Installation of rapping and driving system Measure 1 installation manual record R R - R



11 Trial operation of rapping and driving devices Measure 1 installation manual record W R R R R R

12 Installation of ESP ash discharging system Measure 1 installation manual record R R - -

13 Installation of ash discharging pipeline Measure 1 installation manual record R R - -

C: REL E: Erection company O: Owner S: SEC H point: Halt point W point: Witness point R point: Record point

7.1.2.1 ESP foundation lineation

Item Inspection index unit Quality standard Inspection method and measuring tools

Distance deviation between foundation longitudinal & transversal

centerline to turbine house datum mark mm ±20

Steel tape measure, take axial of boiler front line column as boiler

centerline

space≤10m ±1 Space deviation

space＞10m mm

±2

Level deviation of soleplate mm ≤0.5

Diagonal≤20m ≤5 Center diagonal

Diagonal＞20m mm

≤8

Tense steel tape by spring balance, and measure under the same

force（5~15kg）

Elevation deviation of foundation every plane mm 0

-20

Measure with reference to boiler 1m elevation of one column, and

compare with design elevation

Dimension deviation of foundation mm +20

0

Foundation lineation

（installation of soleplate

） Centerline deviation of embedded bolt mm ±5

Measure by steel tape



Foundation surface

Heat blasted surface, and chisel the

position to be flat for laying shimplate Observe, measure by water level

7.1.2.2 Assembly and erection of ESP structure Quality standard

Item Inspection item unitqualified

Inspection method and measuring tools

Deviation of column elevation mm ±5 Take turbine house datum mark as reference, check 1m elevation of column by water level

Deviation between each column

elevation mm ≤3 Measure by reference of 1m elevation of each column

Space deviation between each

column mm ≤3

Measure top, middle and bottom of column by steel tape(steel rule should be tested to be qualified, when the rule

works, it should be tensed by spring balance with 10kg force)

Perpendicularity deviation

between each column ≤1/2500L of column check by theodolite in two directions which have 90°difference

Installation of column

Deviation of column diagonal

mm

≤5 Use steel rule check big diagonal of each column and its relevant small diagonal (steel rule should be tested to be

qualified, when the rule works, it should be tensed by spring balance with 10kg force)

Elevation deviation ±5 Measure by reference of 1m elevation of each column

Levelness deviation ≤5 Check both sides position of girder on the top by glass level pipe


mm

±5 measure the distance from girder centerline to column centerline by steel rule

Erection of fish plate Flat, correct position and tighten strictly with component

observe

Installation of beam

Welding Accord with manufacture rules



7.1.2.3 ESP foundation secondary grouting

Item Inspection item unit Quality standard Inspection method and measuring

tools

Foundation checking before grouting No sundries and filth Observe

Observe of anchor bolt (reinforcing steel bar)

No non-welding, oil dirty and welding slag Observe

Concrete grade of secondary grouting

Meet design requirement Check against design document

Secondary grouting Secondary grouting Compact, no hole, surface is flat without blasted, dimension accords with design requirement

Observe and check construction record

7.1.2.4 Erection of ESP roof and side plate

Item Inspection item unit Quality standard Inspection method and measuring tools

Appearance dimension Accord with drawings Device check Deviation of diagonal ≤10

Measure inlet and outlet end face by steel tape

Deviation of outlet and inlet centerline

mm

±10 Measure by steel tape with reference of

column centerline

Appearance checking Surface flat without obvious concave and protuberant, cut & polish temporary welding parts without sundries inside observe

Expansion joint Cold-drawn meet design requirement, welding direction of sealing plate is the same as medium flow direction

erection

Tightness test of welding seam No leakage Observe by kerosene leakage test and

check the record



welding Accord with manufacture requirement

7.1.2.5 Installation of inlet & outlet trumpet（Ditto）

7.1.2.6 Assembly and installation of ESP bottom beam and ash hopper

Item Inspection item unit Quality standard Inspection method and

measuring tools

Device check

Appearance dimension Accord with drawings Measure by steel tape

Deviation of interface length

0~-10 Outline dimension

deviation ash hopper Deviation of interface diagonal

≤10 Check by steel tape

Perpendicularity deviation of center axis of top and bottom hole of ash hopper

mm

≤10 Hang plumb-line, measure by

steel tape

Tightness test of welding seam No leakage Observe by kerosene leakage

test and check the record

Ash hopper outline Surface flat without obvious concave and protuberant, cut & polish temporary welding parts without sundries inside Observe

Installation

Welding Accord with manufacture requirement

7.1.2.7 Installation of ESP stair and platform (boiler 4-19)


Platform and stair erection

Deviation of platform elevation mm ±10 Check four corner position of platform



Levelness deviation of platform bracket

≤1/500L Check by water level

Height deviation between two platforms

≤5 Measure two points by steel tape

Deviation between platform and column centerline

±10 Draw line, measure by steel tape from longitudinal and transversal, check 2 points for ach direction

Perpendicularity

≤3 Check by water level Handrail column Space Space evenly, design accords with design Check by steel tape

Deviation of rail perpendicularity mm ≤10 check in two directions which have 90°difference;

check by line and steel tape

Handrail tie-in Flat without burr Observe

Boarding erection Straight without obvious concave and protuberant Observe

Welding Meet manufacture requirement Observe

Appearance of ash hopper Surface flat without obvious concave and protuberant, cut & polish temporary welding parts without sundries inside Observe

erection of handrail

Welding Meet manufacture requirement

7.1.2.8 Assembly and installation of ESP electrode


Installation of structure and shell Accord with manufacture documents erection

of electrode Collecting plate Curvature degree mm ≤10

Hang, line, check by steel tape on several points both from horizontal and vertical direction



Diagonal deviation ≤5 Check by steel tape

Deviation of frame levelness

≤10 Hang, line, check by steel tape on several points both from

horizontal and vertical direction Emitting frame Diagonal deviation ≤5 Check by steel tape

Distance deviation between collecting electrode plate to (emitting frame)

3 Check by special gauge on several points both from

horizontal and vertical direction

Perpendicularity deviation

≤L/1000 and≤10 Plumb-line on front and rear of electrode plate, check by

steel tape Collecting plate

Elevation deviation ±2 Take ESP roof crossbeam as reference, check by steel tape

and glass level pipe Perpendicularity

deviation ≤L/1000且≤10 Plumb-line on front and rear of frame, check by steel tape

Emitting frame Elevation deviation ±2

Take ESP roof crossbeam as reference, check by steel tape and glass level pipe

Space deviation of emitting and collecting system

10 Check distance from end point of tubular bared wire to

working face of collecting plate by special gauge on several points both on vertical and horizontal direction

Connection bolt tighten torque

Accord with manufacture documents Check by load wrench Collecting rapping device

Levelness deviation mm ≤3 Draw level line, check by steel tape

Emitting suspension device Suspender is straight, bracket is level; bolt

connected tightly and reliable; bushing bear stress evenly and without dust, oil filth on surface

Measure by tape, plumb-line, observe

Electrode cleaning Clear away burr, sharp, welding slag Observe



Electric field cleaning No sundries Observe

Bolt connection Bolt bear stress evenly, reveled length of thread is the same; tight with spot welding as per drawing Observe

Erection of heating device Accord with manufacture requirement

Welding Welding seam height accords with manufacture requirement, do kerosene test after welding

Notice：L is the height of collecting plate or collecting frame

7.1.2.9 Installation of ESP distribution plate

Item Inspection item unit Quality standard Inspection method and measuring

tools Deviation of plate perpendicularity

mm ≤5 Plumb-line, check by steel tape

Connection bolt Tighten by spot welding Observe

Installation Installation of block plate In right position, no influence on free expansion of emitting and collecting plate; weld

tightly Check by steel tape

7.1.2.10 installation of ESP rapping and driving device


Connection of suspension device

Accord with manufacture requirement Observe

Installation

Erection of coupling of driver shaft

Contact surface of round shimplate

Coated with blacklead powder and

lubricant Observe



Installation height of spring Accord with manufacture requirement Measure by steel tape

Stress bearing of suspender Load distribution reasonably Check by shaking suspender or hammering

manually

Installation of rapping hammer Fix tightly, run flexibly Run and observe

Collecting rapping

Emitting rapping Accord with manufacture requirement

Position deviation of rapping hammering point

Distribution plate rapping mm ±5

Run and check by steel tape

7.1.2.11 subsection trial operation of ESP rapping and driving device


General requirement Driving part runs stable without abnormal noise and vibration; no

leakage of speed reducer Run and observe

Sliding bearing ≤65 Bearing

temperature Rolling bearing

℃ ≤80

Check by thermometer

Working condition of rapping hammer Run flexibly, rap to the right position Run and observe

Hours for subsection trial operation ≥8 hours

Subsection trial operation

Gas tightness test Welding seam Tight without leakage Ventilate before heat preservation, and check



Rap at distribution plate at manhole

by soap water



8 Safety, civilization construction and requirement and measures for environment management

8.1 Carefully check lifting machine, electric tools before using.

8.2 try to avoid cross construction when lifting machine is working, if it is can not be

avoided, direct personnel of lifting machine shall discuss with related company and safety

supervisor shall monitor at site.

8.3 Erection of every platform shall keep up with installation progress so as to ensure

stability of the whole structure and safety of construction passage.

8.4 safety of construction temporary stair shall be accepted by group leader and safety

supervision engineer.

8.5 It is forbidden to move or dismantle safety device and signs randomly.

8.6 Prepare sufficient illumination for night construction and fire fighting devices on site.

8.7 When construct at rainy days, girders and support which workers have to walk shall

be underlayed with bedding.

8.8 The chain block, lifting rope, guy and other lifting tools can not be used if checked with

deflection, and can be used under overload.

8.9 Organize construction strictly according to safety construction process so as to avoid

hidden accident.

8.10 Equipment, safety device and every mark shall be managed in order.

8.11 Arrange fence and propaganda board around construction area.

8.12 Arrange all kinds of marks and notice on platform, such as “up and down from here”,

“no entry”, “pay attention to falling”, “forbidden to block the passage”, “forbidden to stack

heavy on passage”, “pay attention to safety”, “wear safety belt”, “pay attention to electric

shock”, “forbidden to throw materials on height”, “forbidden to move fire fighting devices”,

“no smoking”, “watch out fire”, “watch out falling” and etc.

8.13 During the process of ESP construction, keep up with preparation of all kinds of

safety devices, marks, sighs on construction so as to make a civilized construction

atmosphere.

The Lifting and Erection Manual of Boiler Drum






DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








Contents

1 Equipment and design instruction………………………………..……….44

2 Reference documents and standard……………………………..……….45

3 Construction condition and preparation…………………………..….…45

4 Organization and work distribution………………………………………..46

5 Construction content, outline and notice………………………….…..46

6 Quality requirement and acceptance……………………………..……..51

7 Requirement for safety civilization construction…………………….55

8 Related calculation and attached drawings ……………………..….…57




1 Equipment and design instruction 1.1 general situation of project

The boiler in India HISAR 2×600MW（BTG）Thermal Power Plant is manufactured by

Shanghai Boiler Works Ltd.

This boiler is single drum and made of SA299-A steel plate. Outer diameter of the drum is

φ2127mm, wall thickness is δ=192mm, whole length is about 28585mm and total weight

is 263143kg approximate. Above it, there are located nozzles of downcomer, saturated

steam, economizer, feed water, sampling, dosing and safety valve. The drum is

suspended onto lifting beam by two pieces of φ195mm SA-675Gr.70 suspenders, and

each suspender is about 7341kg in weight. Installation center elevation is 80000mm. The

weight of drum inside devices is 18363kg. Except suspender, it is about 281318kg.

Therefore, the drum is considered as 290t for lifting.

1.2 project character

The erection place of drum is: the distance from drum centerline to H axes is 2440mm，

its left and right shall be in symmetry with boiler centerline 5 axes and elevation is

80000mm. However, the space between boiler steel structure 4 axes to 6 axes is

27800mm, and net distance between crossbeams is 27500mm, it is 1085mm less than

drum’s whole length, that is drum exceeds 542.5mm comparing with net distance of 4

axes to 6 axes. Below 58000mm elevation under erection position of boiler is steel

structure platform.

Considering characteristic of boiler steel structure and actual situation of boiler erection,

the drum shall be lifted by 4 sets of 180t hydraulic lifting devices from the position where

is 4560mm departure from boiler rear, that is 7000mm distance from H axes and lifted

inclined with 19° tilt angle, place it in level after drum’s centerline reaches 76600mm and

move it towards boiler front about 4560mm by 4 sets 10t chain block, lift it to erection

height, then pull on suspender, at last align and check the drum.

1.3 construction scope

1.3.1 Fabricate, install and dismantle of lifting devices;

1.3.2 Check drum and inside devices;




1.3.3 Lineation of drum;

1.3.4 Lifting of drum;

1.3.5 Alignment, acceptance and fixation of drum.

2 Reference documents and standard 2.1 Boiler furnace and suspender（Shanghai Boiler Works Ltd.）

2.2 Boiler steel structure drawing（Shanghai Boiler Works Ltd.）

3 Construction condition and preparation 3.1 necessary conditions for construction

3.1.1 Drum lineation and checking is finished and checked to be qualified.

3.1.2 The steel structure shall be erected and checked to be qualified except those stated

in boiler lifting opening drawing and the girder, bracing and platform which will affect drum

lifting. The steel structure left for delayed erection is shown as following:

l All girders, platform and rails (drum transport passage) under 7.7m operation

floor among H～J columns on boiler right side;

l All girders, platform and rails (drum lifting passage) among 4～6 inner side

columns and Ha～J columns;

l All girders and bracing (drum lifting passage) under 17m among H-4(6)～J-4(6)

columns;

l All girders and bracing (drum lifting & leveling passage) under 76.6m among

H-4(6)～J-4(6) columns;

3.1.3 The transversal beam and its connecting beam on the second and third area from

boiler center to its both sides on the roof 90600mm shall not be erected for the moment.

3.1.4 The devices and temporary deposited parts between lifting passage (that is among

4~6 columns, and Ha ~J columns) shall not be erected for the moment; dismantle the

barriers in passage.

3.1.5 Fabrication and erection of special lifting device is finished and checked to be

qualified, trial operation of hydraulic lifting device is qualified.

3.1.6 The platform and stair which goes to boiler roof is safe and expedite.




3.1.7 Organize related personnel to check the lifting device, safety establishment and

lifting passage thoroughly before drum lifting.

3.2 Deployment of necessary machine & tools for construction

Name Nos. Name No.

180t hydraulic lifting device 4 sets LR1750/600T crawler 1

ZY60-P traveling jack（width

about 224mm） 16 10t manual chain block 8

5t manual chain block 12 interphone 6

12 pound hammer 2 Special wrench 2

Steel tape（30m） 1 Level tube 1

Steel tape（1m） 1 Vernier caliper 1

Steel wire φ60mm（6×37+1）

(26m) 4 punch 1

Special wrench can be made on site according to suspender bolt. If there is no long

enough steel rope, replace with short steel rope and connect the joint with 100t shackle.

4 Organization and work distribution REL shall take charge of arrangement of organization and work distribution.

5 Construction content, outline and notice 5.1 Before work starts, the technician shall give detailed explanation of security, technique

and quality to all constructors. Constructors shall understand drawings, and learn

technical criterion, regulations and related chapter. Constructors shall know construction

procedure, quality standard, and safety measures and start to work after approved by

every level managers.

5.2 drum checking and lineation

Check drum’s appearance, inner devices and suspender, and report to related company if

any deflection is found and try to eliminate it on ground.

Mark drum centerline by using centerline marked by manufacture and check it by level

tube, or take centerline of drum downcomer socket as reference to mark centerline of




pipe socket as drum’s longitudinal centerline, then according to drum’s perimeter to mark

quartering points on both sides on the basis of drum’s longitudinal centerline, punch and

make obvious sign, check if the lineation is correct by using level tube to check if the

deviation of front & rear punch and left & right punch on drum’s both sides is within

allowable tolerance or not.

5.3 storage of drum suspender

Clean and trial assembles the suspender and nut, and makes mark after dismantled and

put suspender on 76.6m platform;

5.4 erection of scaffold

Erect scaffold on drum for inserting suspender after drum lineation; erect a platform on

boiler left head on drum’s erection elevation so as to shorten lifting time.

5.5 installation of lifting device

Integral lifting devices are located on H, J girders.

5.5.1 According to drum lifting sketch map Ⅰ, Ⅱ: the gantry of special lifting girder will

locate on H girder. Put 12mm thick steel plate on the gap between lifting girder gantry and

H axes girder, and weld it with gantry (subsection welding to avoid stuck board). there are

two gantries with length 4000mm and same structure with lifting beamⅠ; stuck board is

used to fix H axes girder with gantry, when erect stuck board, first lock the girder tightly,

then weld the stuck board with gantry and the height of welding seam shall be bigger than

16mm. lifting girder Ⅰlocates on gantry and J axes girder as stated on drawing, fix lifting

girderⅠwith gantry by welding and welding seam shall be bigger than 16mm. Put 12mm

thick steel plate between J axes girder and lifting girderⅠ, fix steel plate on girder by

stuck board, weld lifting girderⅠ with steel plate (subsection welding to avoid stuck

board). Put［28b channel on lifting girder Ⅰ(concave is upturned and set limit baffle plate

on both sides), and put 2 sets traveling jack for each channel (traveling jack shall be

cleaned and coated with lubricate grease, the roller runs flexible, and connect the two

traveling jacks with channel ). Lift the special lifting girder Ⅱ to position and connect it

with traveling jack, connect the top of carrier with lifting girder Ⅱby welding a connection




plate and the height of welding seam shall be the same as thickness of connection plate.

Lifting girder Ⅱ can slip on girder Ⅰfore-and-aft.

5.5.2 Similarly erect lifting girder Ⅲ on lifting girder Ⅱ, connect by traveling jack, and

make sure lifting girder Ⅲ can slip on girder Ⅱfore-and-aft.

5.5.3 In order to make it convenient for level dragging, respectively install 2 sets of 10t

chain blocks on boiler front side of 2 groups lifting girder Ⅱ, and 2 sets of 10t chain blocks

on boiler backside to tow traveling jack (whose lug is welded to girder and lifting girder Ⅰ)

on girderⅡ; install 4 sets of 10t chain block on boiler inner side and 4 sets of 5t chain

block on boiler outer side to tow traveling jack (position of lug will be confirmed according

to site situation) on lifting girder Ⅲ.

5.5.4 Lay 12mm thick steel plate on the girder and fix its both sides with shimplate on

girder by welding(notice: it can’t be welded directly with girder). Fix steel tube for

reinforcing lifting girder gantry with the steel plate by welding.

5.5.5 Put checker plate above the area of lifting girder Ⅰ; and lay checker plate on the

middle of boiler roof 5 column and among H～J column to setup temporary platform as

operation platform for hydraulic lifting device;

5.5.6 Install LSD2000D hydraulic lifting device on both left and right side lifting

suspension frame, fasten and test it;

5.5.7 Install tightwire trolley frame above hydraulic lifting device.

5.6 lifting procedure

5.6.1 Pull on tightwire to connect top and bottom anchorage of hydraulic lifting device

(notice: consult to related use and maintenance instruction manual for operation of

hydraulic lifting device);

5.6.2 Check every connection of hydraulic pumping station, oil pipeline and operation

platform;

5.6.3 Test hydraulic system under no-load and check its operation;

5.6.4 Clean transport passage and check its condition;

5.6.5 check the direction of drum, transport it from boiler right side H～J column to boiler




house 4～6 column by hydraulic platform trailer, and unload it by hydraulic lifting device;

5.6.6 Adjust tension degree of tightwire;

5.6.7 Trial lifting before final lifting: l Lift drum to about 500mm;

l Slide down 300mm;

l Check tension degree of lifting tightwire;

l Check the equality of tightwire’s tension degree and security of the tightwire

clamps during trial lifting;

l Check levelness of drum after it is lifted. If there is obvious deviation, modulate by

adjusting the length of tightwire on both front and back side of drum.

5.6.8 Incline the drum during lifting: l Lift the drum to 500mm by running both sides hydraulic lifting devices

simultaneously;

l Stop operation of boiler right side hydraulic lifting device;

l Keep ascending of boiler left side hydraulic lifting device till there is 19° tilt angle

between drum and level(at that moment drag left side of drum by winch till right

side of drum gets across the 7000mm elevation girder platform on boiler right 4

l When the left side of drum is ascended, adjust left & right hydraulic lifting devices

to boiler center by 10t chain block so as to ensure the lifting devices and sling

points are on the same vertical line;

l When the left side hydraulic lifting device is ascended, correspondingly ascend

the right side hydraulic lifting device as per the distance between drum right side

to ground;

l During the whole lifting process, special person shall be assigned to supervise

lifting girder’s camber.

5.6.10 Ascend both sides simultaneously and keep 19° tilt angle, and pay special

attention to the space between both ends of drum to the beam so as to avoid collision;

5.6.11 modulates levelness of drum when it is lifted to 76600mm: l Stop operation of boiler left side hydraulic lifting device;

l Boiler right side hydraulic lifting device keeps on ascending;

l When the left side of drum is ascended, adjust left & right hydraulic lifting devices




to boiler left & right sides by chain block so as to ensure the lifting devices and

sling points are on the same vertical line;

l When the right side of drum reaches 76600mm, descend the right side when left

side is lifted until the drum is in level;

l After adjusted, the elevation of drum’s centerline is above 80000mm, otherwise,

continue lifting integrally.

5.6.12 Disentangle the 4nos 5t chain blocks which hauled traveling jack on boiler back

side and tense the 10t chain blocks on boiler front side so that the drum can be towed by

traveling jack towards boiler front side smoothly. The two operations shall harmonize with

each other very well until the drum is below its erection place; the hauling speed shall be

same and avoid collision between cross pin with limit plate. During hauling process, it is

required to dismantle reinforced connecting pipe between the two supporting girders Ⅰ.

5.6.13 Restart hydraulic lifting device, lift the boiler integrally and stop operation until

boiler center reaches 80000+200mm.

5.6.14 during the lifting course of drum after it is adjusted in level, install the two

suspenders which stored on 76.6m platform by LR1750 crawler and tighten the bolt; l After the drum is positioned, dismantle the steel rope which hung on crawler’s

auxiliary hook from drum suspender holes（including arc shimplate and nut which

pass through drum lifting girder）, and lift the lifting bolt of suspender which

pre-bind on drum, and dismantle temporary chain block and beam clamp and lift

suspender to the bottom of lifting girder.

l Hang suspender by 2nos 10t chain blocks which hang below lifting girder, insert

suspender through cylinder shimplate hole, then tighten nut; after the two

suspenders are installed, adjust the height which suspender exceeds over nut as

per drawing, align the position of nut on shimplate, and make the bottom of

suspender contact tightly with suspender batter board; lay down drum and make

suspender bear the stress.

5.6.15 alignment, level and reinforcement of drum: l Align drum as per sequence of elevation, level and position. The central elevation

of drum is assumed to +5mm (only suitable for this alignment).




l When the drum is required to level by rotating, lift the drum a little bit, and then

rotate it by pulling its front or back side lug by 10t chain block.

l After the drum is aligned, weld suspender nut, simultaneously make strong

temporary fixation on drum both sides and boiler front side so as to avoid swing

and rotation of the drum during the lifting process of other devices or erection of

connecting pipe.

l Complete quality acceptance on time.

5.6.16 Dismantle lifting devices and tools, including load bearing structure, hydraulic

lifting device, tightwire, hydraulic pump and etc, and maintain the devices on time. After

dismantling, resect the temporary welding parts on roof girder thoroughly (avoid damage

to girder) and polish it.

6 Quality requirement and acceptance 6.1 check drum and its internal devices

① Check carefully and confirm if there is crack, double peel, scar on its appearance, the

height of concave and pit can’t exceed 3～4mm, pay especial attention to check

manhole and manufacture welding seam of pre-welding parts.

② When check pipe socket, it is required to confirm if the height, outer diameter and wall

thickness of the pipe socket accord with manufacture design requirement and make sure

its inside is clean.

③Carefully check the manufacture welding seam of pre-welding parts, and remedy if any

seep-welding.

④The connecting plate of drum internal devices shall be sealness, and there is no

seep-welding and crack on all welding seam.

⑤Tighten bolt on steam separator component and make receding measures. The nut

shall be welded tightly so as to avoid bolt shedding during operation.

⑥The steam separator components shall be installed in same direction and height.

⑦When close manhole, lay sealing winding shimplate on sealing surface evenly, the

locking channels on manhole both sides shall be in same direction, same level, and the

bolts bear force evenly.




6.2 check suspender and lifting devices

①Before drum installed, recheck the manufacture dimension of lifting girder and

suspender.

②Check and trial assemble the thread of suspender and nut and make sure joint well.

③Arc cushion block under suspender’s nut shall contact well with drum and lay

shimplate when the gap is over 2mm.

④The suspender shall bear load evenly and in symmetry with boiler left & right sides.

⑤Installation of lifting devices shall conform to drawing requirement, and all tools and

machines shall be safety.

6.3 drum erection

6.3.1 Drum erection Quality standard

process Inspection item nature unit Qualified


Elevation deviation main ±5

Take frame 1m as reference, check center position of drum’s both

ends respectively Deviation of

longitudinal & transversal level

≤2 Check center position of drum’s both ends by glass level tube respectively

Deviation of axial center position

main ±5

Take boiler roof main girder’s center as

reference, hang plumb-line and check by steel tape

Drum

installation

Deviation of longitudinal centerline

main

mm

±5

Take boiler roof main girder longitudinal centerline as

reference, hang plumb-line and measure its distance to

the center of selected standard symmetry

socket, tense steel tape by spring balance and measure

under same force




Quality standard process Inspection item nature unit

Qualified Inspection method and

measuring tools Drum’s sling

contact with drum’s outer

surface

Inosculate with circular at 90°

contact angle，partial gap≤2mm

Measure by feeler

6.3.2 Erection of suspension device Quality standard

process Inspection item nature unit Qualified


Check appearance of fittings（lug, sling,

suspender, lifting traveler, pinned

shaft）

No damage, crack, and double peel on

surface; no damage on

suspender thread and joint well with

nut

Visual, trial install every suspender bolt and nut

Dimension of fittings Conform to drawings Check by steel tape and

etc.

Fitting’s material No misuse Check against production technical documents and do NDT to alloy element

Suspender camber

mm ≤1‰ L(suspender), and ≤4

line in two directions which have 90°difference and

check by steel tape Equipm

ent checking Manufacture welding seam

As per manufacture regulations

Connection of suspension device

main Conform to drawing

requirement Observe

Spherical pad joint surface

Coat with blacklead

lubricate Observe

Erection Installation height of spring balance

main Conform to technical

document Check by steel tape





Qualified Inspection method and

measuring tools

Stress carrying of suspender

main

Load distributed reasonably

Shake suspender by hand or hammer, and min. do 3 times： 1. after load added; 2. after hydraulic test and water filled;

3. when steam tightness test

6.3.3 Drum checking and lineation


Qualified

Inspection method and measuring

tools

appearance main

no crack, double peel and scar,

depth of concave and pit can’t

exceed 3～4mm

observe height of concave and pit, measure when

necessary

material

wall thickness mm

conform to manufacture

design requirement

drum furnace

welding seam conform to

manufacture requirement

position check as per manufacture

drawing

pipe joint height mm

pipe joint outer diameter

main

pipe joint wall thickness

main

pipe joint groove

Checking drum

pipe socket

pipe joint angle main

conform to manufacture

design requirement

check by steel tape, vernier caliper,

check randomly for same type pipe joint and nos. more than

2





Qualified

Inspection method and measuring

tools

welding seam of pipe socket

main conform to


internal cleaning no dust, rust, metal scraps and etc.

observe

when L＜5m mm ≤5

when L=5～7 m ≤7

when L=7～10 m ≤10

when L=10～15 m ≤15

tortuosity of drum whole length

when L≥15m ≤20

Line at 20mm of welding seam of

furnace both ends, and check by steel

tape in two directions which

have 90° difference, and

get the max. value

joint surface of manhole mm flat, no radial scar,

and partial scar≤0.5

observe and measure when

necessary

other welding seam main conform to


drum lineation main

there are center mark on drum both ends, and

mark drum centerline along

drum length

recheck by steel tape and glass level tube

7 Requirement for safety civilization construction 7.1 Technicians shall give the explanation on security and technique to all the

constructors before lifting.

7.2 Check the appearance of special lifting girder and other bearing devices; dismantle

and check traveling jack; do NDT for big pinned shaft, drum lug and welding seam, it is

forbidden to use if any crack and deformation is found. The lifting devices shall be

checked and accepted to be qualified after installed.




7.3 Arrange safety passage on boiler roof, and set up handrail for safety passage;

bespread safety net over other areas; hang reliable safety rope on girder.

7.4 Check lifting devices before lifting, and put into use after checked to be qualified and

installed correctly.

7.5 Special personnel shall be appointed to assemble and operate hydraulic lifting device,

and carry out strictly according to related instruction manual regulations.

7.6 The lifting shall be commanded unified; the command sign shall be clear, prepare

protection measures for unsuccessful communication, the construction teams

participated in lifting shall contact, cooperate with each other and avoid violent

construction.

7.7 Special personnel shall be appointed to supervise the lifting devices during the

process of trial lifting, lifting and alignment. Take strict precaution against crushing of

supports by tightwire and hurting of constructors. During lifting process, stop all the work

of electric welding, cut power of all welding machine so as to avoid unstable voltage and

damage to tightwire by electric arc.

7.8 During lifting process, first start the two lifting devices at the same time and lift the

drum 500mm away from temporary support, then ascend, descend and break several

times. Continue lifting when it is confirmed that the lifting devices run normally, brake runs

well and there is no deformation and overflow deflection of lifting device.

7.9 Pay great attention to the tilt angle during lifting process and make sure the angle

within 20°.

7.10 Watch the distance between drum both ends to the edge of beam in order to prevent

the drum ends and pipe sockets being obstructed by beam.

7.11 During trial lifting and level shifting process, check if any deformation of support

beams and stability of beam, the hauling shall be slowly, in same phase and smoothly.

7.12 When the drum is ascend or descend during alignment process, nobody is allowed

to stand under drum, in any circumstance all constructors are forbidden to put any part of

body inside suspender and drum wall.




7.13 It is forbidden to heat and weld on drum and suspender.

8 Related calculation and attached drawings Parameter：total weight of drum is 290t；total length of drum proper is L=28.585mm；drum

diameter is 2127mm；distance between drum lugs is 2B=13800mm；net space of lifting

passage left and right side is M=27500mm；distance between H, J column is 10000mm；

8.1calculation of drum tilt angle:

The total length of drum is 28585mm which is longer than net distance between 4 to 6

girders which is 27500mm, so it is required to lift the drum inclined and make sure there is

200mm distance from drum both ends to girders.

L=28585mm；M=27500-200×2=27100mm

COSα=27100/28585=0.948

so α≈19°

So the min. angle for lifting drum is 19°.

8.1.1calculation of lifting state

Because lifting lug is on the centerline of drum, so when the drum is lifted inclined,

the center of gravity of drum will not shift, but the distance between the two lifting lug will

lessen. The angle of tightwire of hydraulic lifting device shall ＜0.5°(this will be

considered as vertical), therefore, during lifting process the hydraulic lifting device shall

shift left & right so as to ensure the tilt angle of tightwire ＜0.5°. The lifting condition

drawing is shown as below:




α

BB

B1B1

O1

D

O2

46

boiler centerline

D O2O1

It is educed that the offset is:

B1=B2=B×Cosα=6.9×Cos19°=6.524m

It is obvious that after the drum reaches the tilt angle, center of the hydraulic lifting

devices shift 376mm to boiler center comparing with their original positions.

8.2design and stress calculation of lifting device

8.2.1special lifting support girderⅠ

This girder is box structure and assembled by 4 pieces steel plate, the whole length is

11000mm.




1110

500

20

500

115020

Mechanics property of girder section:

Piece 1：F=50×2=100cm2 ；Ix=50×23/12=33.33cm4；

Piece 2：F=2×111×2=444cm2；Ix=2×1113×2/12=455877cm4；

Distance between center of gravity：e=115/2＝57.5cm

Moment of inertia： Ix=（33.33+56.52×100）×2+455877

=1094393.7cm4=1×10-2 m4

Section modulus:

Wx=Ix÷e=1094393.7÷57.5=19032.9cm3=19032.9×10-6 m3

Load distribution calculation: the calculation length of this girder is 10000mm, the center

distance between the two girders on both sides is 2500mm. According to previous

calculation, after the drum reaches tilt angle, the two traveling jacks will shift 378mm

closer to center, when the drum is lifted the traveling jacks on both sides locate on the

center point between the two girders. Therefore, one of the girders will carry max. stress

after drum reaches tilt angle, it is shown as following drawing:




A

Fa

B

Fb

750 1000 1150

P/2 P/2

Considering dynamic load modulus during lifting process is:

K=1.1，P＝1.1×G/4=1.1×290×103/4=79.75×103 (kg)

It is known from drum lifting schematic drawingⅡ, when the drum is on the lifting position,

the lifting girder on the outer side will carry max. Load, which is a shown on top drawing.

Fa+Fb=P

Fa×2900=P/2×(2250+1150)

It can educed that Fa=46.75×103 (kg)；Fb=33×103 (kg)

Notice: P is tightwire load of single hydraulic lifting device on left & right sides; G is lifting

gross weight.

Calculation of lifting girder strength

Mechanics model is shown as following: (check according to simple supported beam,

bending allowable stress of material Q235 is【σ】=140MPa), there will be max. Bending

moment for girder when the two traveling jacks are shifted to the middle of girder.

700 46504650

10000

A

P P

B

For: P=46.75×103kg




Check bending strength:

Mmax=P×4.65×9.8=46750×4.65×9.8=2130397.5N.m

Max. Bending allowable stress carried by section is:

σ= Mmax/ Wx =2130397.5/19032.9×10-6=112MPa＜【σ】＝140 MPa

It is known that the strength of girder meet requirement. The max. Bending moment will

occur to girder only when the drum is levelly moved.

Checking strength of this girder: there is max. Bending moment on the middle of girder

when the drum is levelly shifted, so strength of the girder is required to check only under

that condition:

fmax = 2Pb（3l2-4b2）÷48EI

=2×46750×9.8×4.65 (3×102-4×4.652)/（48×200×109×1×10-2）

=9.5×10-3m＜[f]=L/750=10/750=13.3×10-3m

So strength of girder meet requirement.

8.2.2 Special lifting girder Ⅱ

It is known that when the traveling jack of girder Ⅲ shifts to special lifting girder Ⅱ,

there is max. Bending moment on girder Ⅱ. Mechanics model is shown as below: (check

according to simple supported beam, bending allowable stress of material Q235 is【σ】

=140MPa)

P P

950 950

2900

1000




For: P=79.75×103/2=39875kg f

Check of bending strength:

Mmax=P×9.8×0.9=39875×9.8×0.9=351697.5N.m

Consulted from the table, it is known that the double assembly of 2【45a

Wx＝2×1430＝2860×10-6m3 ,Ix＝2×32200＝64400cm4＝6.44×10-4 m4

Max. Allowable stress carried by section is:

σ= Mmax/ Wx =351697.5/2860×10-6=123MPa＜【σ】＝140MPa

Therefore：2Ⅰ45a meets strength requirement.

Check rigidity：

The max. Deflection value is on the middle of the girder:

fmax = 2Pb（3l2-4b2）÷48EI

=2×39875×9.8×0.9 (3×2.52-4×0.92)/（48×200×109×6.44×10-4）

=1.8×10-3m＜[f]=L/750=2.5/750=3.3×10-3m

Therefore: 2Ⅰ45a meets strength requirement.

8.2.3 Special lifting girder Ⅲ

mechanics model is shown as following: (check according to simple supported beam,

bending allowable stress of material Q235 is【σ】=140MPa)

For:P=79750kgf

Check bending strength:

Mmax=Pl/4=79750×9.8×0.7/4=136771.3N.m

350 700

350

P




Consulted from the table, it is known that the double assembly of 2【32

Wx＝2×692.2 ＝1384.4×10-6m3, Ix＝2×11100 ＝22200cm4=2.2×10-4 m4

Bending allowable stress of support beam is:

σ= Mmax/ Wx=547085/1384.4×10-6=98.8MPa＜【σ】＝140MPa


B．Check rigidity:

fmax = Pl3÷48EI

=79750×9.8×0.73/48×200×109×2.2×10-4

=0.12×10-3＜[f]=L/750=0.7/750=0.9×10-3m


8.2.4 Selection and checking of steel rope

The min. size of steel rope is φ60.5mm（6×37+1）, and its rupture force is 190t.

There are 4 heads for each lug, so safety factor of steel rope is n=8×190/2×79.75=9.5

8.2.5 Bottom special lifting frame

8.2.5.1 The shoulder girder of lifting frame is box type, and it is assembled by 4 pieces

steel plate with whole length 1100mm.

340

16

560

40

40

560

420

Mechanics property of girder section:

Piece 1, 3: F=56×4=224cm2 ；Ix=56×43/12=298.7cm4；

piece 2：F=1.6×34×2=108.8cm2；Ix=1.6x343 ×2/12=10481.1cm4；

distance between center of gravity: e=42/2＝21cm




moment of inertia： Ix=（298.7+192×224）×2+10481.1=172806.5cm4

Section modulus coefficient: Wx=Ix÷e=172806.5÷21=8229cm3=8229×10-6 m3

The calculation length of this girder is 1000mm, suppose the hydraulic lifting device works

under full load during lifting (or shifting), that is Fa＝Fb＝180T, so F=360T, stress carrying

of the girder at that moment is shown as bellow: (check according to simple supported

beam, bending allowable stress of material Q345 is【σ】=230MPa)

Fb

B

Fa

A

1000

F F

342

It is obvious that max. bending moment of girder is:

Mmax=Fa×0.329= 180×9.8×0.329=603.3KN.m

Max. stress of girder is:

σmax=Mmax/Wx=603.3×103/8229×10-6=73.3Mpa＜［σ］=230Mpa

8.2.5.2 Calculation of lug strength:

φ

thickness δ＝50mm




The lug is made of Q345B steel plate with thickness δ50mm, shearing section of each lug

connection plate is F1=17×5=85cm2, compressive section of each connection plate is

F2=22×5=110cm2, max. load capacity of each connection plate is Q=100t( actual is

79.75t).

Shearing strength carried by lug plate:

τ=Q÷F1=100000÷85÷10.2=115.3MPa＜[τ1]=140Mpa

Extrusion strength of lug plate:

σ=[Q(D2+d2)] ÷[F2(D2-d2)]

=[100000×(562+222)] ÷[110×(562-222)] ÷10.2

=122Mpa＜[σ1]=230Mpa

8.2.5.3 Recheck strength of lug welding seam:

For each lug, there are 4 welding seams with length Lf=370mm and height hf=16mm

So:

σhf=Q/（0.7×hf×∑Lf）=100000×9.8/（0.7×16×370×4）

=59.1Mpa＜［σ］=140Mpa

8.2.5.4 Recheck strength of pinned shaft:

shimplate

nutM48

pinned shaft

shoulder girder

lug

The material of pinned shaft is Q235, its section mechanics property and load is:

Section area: F=πd2/4=πx222÷4=380cm2




Section modulus: W=πd3/32=π×223÷32=1044.835cm3

Load carried by pinned shaft: P＝1.1×G/2=1.1×9.8×290×103/2=1563.1×103 (N)

Max. Bending moment carried by pinned shaft is:

Mmax=Pl/4=1563.1×103×0.292/4=114.1×103N.m

Bending strength: σ=Mmax/W=114.1×103÷(1044.835×10-6)=109.2Mpa＜[σ]=140Mpa

It is known from the calculation that the limit ring (washer) stated in assembling detailed

drawing is necessary; otherwise, stress carried by big pinned shaft will exceed its

allowable stress when the connection plate is shifted to the center of pinned shaft.

Shearing strength carried by both ends of pinned shaft is:

τ=P/F=1563.1×103/（380×2×10-4）=20.6Mpa＜[τ]=98Mpa




8.3 Attached drawings

Attached drawing 1 drum lifting devices installation drawingⅠ

A B C FE

SHANG

HAI

ELE

CTRIC (

GROU

P) C

ORPORAT

ION

(S E C)




A-2, S

ECTO

R 24

KOLKAT

A

NOIDA

-201

301 (U.

P.)

CONSULTIN

G ENG

INEERS

RELIA

NCE

ENERGY

TOWE

R,

EPC BU

SINESS GRO

UP

OWNE

R CONSU

LTAN

T:-

OWNER

:-

NEW D

ELHI

NEW D

ELHI

DESEIN PVT. LTD.

9135

0

0.00

4

A side view

6

lifting girderⅠ

lifting girderⅡ

lifting girderⅢ

hydraulic lifting device

925

00

6900

19°

J line girder

bottom shoulder girder

lifting gantry

注

291

82.6

20

116

312

257

δ50

stuck plateⅠ

H axes girder

lifting gantry

special stuck plate

282

shimplate

66 104

421

343

265223

120

500

δ50

stuck plateⅡ

J axes girder

shimplate

lifting girderⅠ

stuck plateⅡ

NOTICE：Reinforce for lifting girderⅠ and

gantry by 2nos ¦µ10

8×4.

5 se

amle

ss s

teel

pip

e at

ea

ch s

ide.

The

re a

re 8

nos

stuc

k pl

ate

on e

ach

side

of

gant

ry, s

o to

tal 1

6nos

stu

ck p

late

. The

re a

re 2

nos

stuc

k pl

ateⅡ

for each lifting girderⅡ, so total

8nos stuck plateⅡ.stuck plateⅢ is used to

fixup J axes girder and the shimplate, there are

2nos stuck plateⅢ on each side of lifting

girder, so total 16nos stuck plateⅢ

.

stuck plateⅢ

stuck plateⅢ

δ50

500 265343

421

10478

282




Attached drawing 2 drum lifting devices installation drawingⅡ

A B C FE

87

65

4

87

6

32

1

A B C

32

1

D FE

SHANG

HAI

EL

ECTRI

C (

GROUP

) C

ORP

ORA

TION

(S

E C)




A-2

, SEC

TOR 2

4

KOLKA

TA

NOI

DA-

201

301 (

U.P

.)

CONSU

LTIN

G E

NGI

NEE

RS

REL

IAN

CE

ENERG

Y T

OWE

R,

EPC

BUSI

NESS

GRO

UP

OWN

ER

CONS

ULT

ANT

:-

OWNER

:-

NEW

DE

LHI

NEW

DE

LHI

DESEIN PVT. LTD.

B side view

JH

4

A side view

56

2440

7000

10000

hoist position

erection position

1390

013900

hydraulic lifting device

lifting girderⅢ

lifting girderⅡ

lifting girderⅠ

70052

50

2900

1250

lifting gir

der gantry

notice 4

1000

NOTICE：

1、

Chain block used for level hual is not

shown in this drawing;

2、The drum is lifted with the condition of

right side up and left side dowm;

3、Temporary platform is used to put other

establishment of hydraulic lifting device.

Detailed arrangement will be confirmed by

construction company.

4、

Reinforce lifting girderⅠ

and gantry with

2nos Φ

108×

4.5 steel pipe at each side.




Attached drawing 3 drum lifting devices installation drawing Ⅲ

A

B

C

F

E

87654

876

321

A

B

C

321

D

F

E

SH ANG HA I EL EC TRI C (G ROU P) C OR POR AT IO N (S E C)

S HAN GHA I E LEC TRI C G ROU P CO .,L TD.

C ENT RAL EL ECT RIC ITY AU THOR ITY

R ELI ANC E E NER GY LTD .

A -2 , SE CT OR 24

K OL KA TA

N OI DA- 20 13 01 (U .P .)

C ON SU L TI NG EN GIN EE RS

R EL IAN CE E NE RGY T OW ER , E PC B US IN ES S G ROU P

O WN ER C ON SU LTA NT :-

O WN ER: -

N EW DE LH I

N EW DE LH I

D ESE IN PVT . L TD.

7000

39700.00

B side view

2440

80000

76600

91350H JNOTICE

NOTICE：Reinforce each lifting girder by 2 groups Φ108×4.5 sealness steel pipe.




Attached drawing 4 fabrication of lifting girderⅠ

A B C FE

87

65

4

87

6

32

1

A B C

32

1

D FE

SHAN

GHA

I ELE

CTR

IC (G

ROUP)

CO

RPORA

TIO

N (S

E C

)




A-2,

SECTO

R 2

4

KOLK

ATA

NOIDA

-2013

01

(U.P.

)

CONS

ULTIN

G E

NGINE

ERS

RELIA

NCE E

NER

GY TO

WER

, EP

C B

USINE

SS

GROUP

OWN

ER

CONSU

LTA

NT:-

OWNE

R:-

NEW D

ELHI

NEW D

ELHI

DESEIN PVT. LTD.

1000

1000

110

00

A向

A向

A side view

C向

6000

5

1000

1000

1000

1000

1000

1000

1000

1000

1000

1500

100

01500

1000

200

02000

1150

2400

250

250

500

500

2020

C face view

1

23

4

5

6

SL

Name

Speci

fica

ion

Qua

ntity

Remark

s

1faceplate

1100

0*50

0*20

8

2web

plate

1100

0*11

10*2

08

3reinf

orc

ed rib

1110

*115

*20

80

45

channel

#28b

L=60

004

6

lug pl

ate

8

stee

l p

ipe

Φ89×

4.5

36

δ30

The ma

ter

ial list

is u

sed f

or 2 se

ts

sup

port

girde

r

Q23

5Q

235

Q23

5Q

235

Q23

520

#




Attached drawing 5 fabrication of lifting girderⅡ

A B C FE

87

65

4

87

6

32

1

A B C

32

1

D FE


SHANGHAI ELECTRIC GROUP

CO.,LTD.

CENTRAL ELECTRICITY AUT

HORITY


A-2, SECTOR 24

KOLKATA

NOIDA-201301 (U.P.)


RELIANCE ENERGY TOWER,

EPC BUSINESS GROUP

OWNER CONSULTANT:-

OWNER:-

NEW DELHI

NEW DELHI

DESEIN PVT. LTD.

SL

Name

Specific

aio

nQuantit

yRemar

ks

1I-bea

m2Ⅰ

45

L=36

00mm

2

2reinforce

d rib

430*70

*12

40

3st

eel tu

beΦ

108×

44

4channel

#28

b L=

3600

2

Q23

5Q

235

Q23

5Q

235

drum

lift

ing

gird

erⅡ

The

mater

ial

list

is used

for 1

set

2×200

2×

200

43

700

21

2224

800

2×

200

2×30

0

450

2×

300

300

3110

3

2900

3600




Attached drawing 6 fabrication of lifting girderⅢ

A B C FE

87

65

4

87

6

32

1

A B C

32

1

D FE


SHANGHAI ELECTRIC GROUP

CO.,LTD.

CENTRAL ELECTRICITY AUT

HORITY


A-2, SECTOR 24

KOLKATA

NOIDA-201301 (U.P.)



EPC BUSINESS GROUP

OWNER CONSULTANT:-

OWNER:-

NEW DELHI

NEW DELHI

DESEIN PVT. LTD.

SL

Name

Specific

aion

Quantity

Remar

ks

1I-be

anm

4

2reinforce

d rib

36

3sh

impl

ate

2

45

hydraulic lift

ing

devi

ce2

6

connection

pl

ate

4

end

conn

ect

ion

pl

ate

4

The m

ate

ria

l l

ist i

s u

sed

fo

r 1

se

t

Q23

5Q

235

Q23

5Q

235

Q23

5Q

235

dru

m li

ftin

g g

irder

Ⅲ

par

t3

fabr

icati

on

dra

wing

7ste

el

pip

e¦µ89×

4.5

8Q

235

500

500

7

630

513

0130

130

A

300

100

0

250

250

1A

3

1304

2

320

φ210

φ210

530

530

φ210

δ50

φ2107

1000

530

A-A

5 6

φ210

240*

300

*12

1000

*64

0*20

530*5

30*50

300

*60*

12

Ⅰ32

a；L=

200

0mm




Attached drawing 7 fabrication of guide frame

A B C FE

87

65

4

87

6

32

1

A B C

32

1

D FE



CENTRAL E

LECTRICITY AUTHORITY

RELIANCE

ENERGY LTD.

A-2, SECTOR 24

KOLKATA

NOIDA-201301 (U.P.)



EPC BUSINESS GROUP

OWNER CONSULTANT:-

OWNER:-

NEW DELHI

NEW DELHI

DESEIN PV

T. LTD.

20＃

I-be

am

lifting girderⅢ

position for erecting

X-bracing

lifting girderⅡ

1450

45°

400

990

200

1400

1400

1050 1500 1500

180

0




Attached drawing 8 deposit of drum suspender

A B C D FE

87

65

4

87

6

32

1

A B C

32

1

D FE

SHANG

HAI

ELEC

TRI

C (GR

OUP

) COR

POR

ATION

(S

E C)




A-2

, SEC

TOR 2

4

KOLKA

TA

NOI

DA-

20130

1 (

U.P.)

CONSU

LTIN

G E

NGIN

EERS

REL

IAN

CE EN

ERG

Y TOW

ER,

EPC

BUSI

NESS

GRO

UP

OWNER

CON

SULT

ANT:-

OWN

ER:

-

NEW

DE

LHI

NEW

DE

LHI

DESEIN PVT. LTD.

H4

HHa

JA

A

7660

0mm

5

AA

3600

6

6400

3500

I16a I-

beam

δ=16m

m st

eel

pla

te

φ16m

m r

ound

st

eel

beam clam

p in

ner

shi

mpla

te

3mm

rubber pl

ate

φ21

.5m

m

tigh

twi

re

Ha

1300

NOTICE：

1.

This

is

dru

m su

spen

der

depo

site

dra

wing

;

2

.Due

to

stee

l st

ruct

ure

gird

er, t

he s

uspe

nder

shall

be

depo

site

d 44

0mm

clos

er to

boi

ler

fron

t;

3

.Ins

tall

a s

uppo

rt a

t th

e up

per m

iddl

e of

eve

ry

gro

up o

f su

spen

der

, an

d in

stal

l man

ufac

ture

sup

plie

d

beam

clam

p at

the

top

, de

tail

s see

thi

s dr

awin

g;

4

.The

dep

osit

e pl

ace

is r

ight

belo

w er

ecti

on

posit

ion;

5

.In

orde

r to

mak

e co

nvin

ient

for

lift

ing,

suspe

nder

sha

ll b

e de

posi

ted

1300m

m hi

gher

tha

n

766

00mm

elev

atio

n so

it

is e

asy

to c

onne

ct l

ifti

ng

bolt;

6

.All

the

dep

osit

ed s

uspe

nder

shal

l be

hun

g on

the

for

mal

fird

er o

n 76

600m

m by

tig

htwir

e an

d ch

ian

bloc

k;

7

.Don

't e

rect

the

lon

gitu

dina

l bra

cing

in

the

area

whe

re s

uspe

nder

is

depo

site

d.

2000

＜10000




Attached drawing 9 drum suspender insert drawing

A B C FE

87

65

4

87

6

32

1

A B C

32

1

D FE

SHAN

GHA

I ELE

CTRIC

(GRO

UP)

CORP

ORATI

ON

(S E

C)




A-2,

SECTO

R 24

KOLK

ATA

NOIDA

-2013

01 (U

.P.)

CONS

ULTIN

G ENG

INEER

S

RELIA

NCE E

NERGY

TOWE

R,

EPC B

USINE

SS GR

OUP

OWNE

R C

ONSUL

TAN

T:-

OWN

ER:-

NEW D

ELHI

NEW D

ELHI

DESEIN PVT. LTD.

pinn

ed s

haft

5t b

loc

k ri

ng

lifti

ng b

olt

susp

end

er

detai

led d

rawing

A

crawl

er

detailed drawing see

connection type

susp

ende

r s

uppo

rt

sus

pen

der

tight

wire

se

e rig

ht d

raw

ing

tight

wire

see

rig

ht d

rawi

ng

shoul

der

gird

er s

ee

right

dra

wing

NOTICE：

1.Before tightwire pass through girder, put

supoort board and nut on the girder;

2.After rigging connected with lifting frame,

hoist crawler, and successively dismantle beam clamp

and support on 76600mm steel platform;

3.The length of block ring's pinned shaft

can't 200mm exceed suspender diameter.

drawing

craw

ler

NOTICE：1.This is design drawing of drum shoulder

girder;

2.When lifting, two tightwire are used to stride

over drum with shoulder girder, and at bottom the drum

lifting bolt is connected with 5t block ring.

Φ26

mm，

L=500

0mm

tigh

twi

re 1

no.

Φ89×

4.5s

teel

pi

pe L

=260

0mm

δ=16

mm s

teel

pla

te

2354

140

R70

Φ40

196

336

5T

bloc

k ri

ng

Φ24

mm，

L=1

6000

mm

tig

htwi

re drawing




Attached drawing 10 fabrication of bottom shoulder girder

A B C D FE

87

65

4

87

6

32

1

A B C

32

1

D FE

SHANG

HAI E

LECTR

IC (G

ROU

P) CO

RPORA

TION

(S

E C)




A-2

, SE

CTO

R 24

KOLKA

TA

NOI

DA-20

130

1 (U.

P.)

CONS

ULTIN

G EN

GIN

EER

S

REL

IANCE

EN

ERGY

TOWER

, EPC

BUS

INE

SS GR

OUP

OWN

ER C

ONS

ULTAN

T:-

OWNE

R:-

NEW

DELH

I

NEW

DELH

I

DESEIN PVT. LTD.

Remarks

Q345

1300*560*40

1300*360*16

Specification

1300*560*40

web plate

Name

sole palte

face plate

2 SL

13

Quantity

224

Weight

600*560*50

reinforced rib

lifting lug

5 46

32

44

reinforced rib

7reinforced rib

340*130*16

260*120*16

260*320*16

8

Q345

Q345

Q345

Q345

Q345

Q345

C

A-A

sectional view

AA

C fac

e d

etail

ed dr

awing

4

35

φ180

50

R280

280

600

320

φ220.5

φ240

φ180

B-B

sectional view

B2

40

16

400

40

2×

150

3

1B

6

130

0

342

1000

1300

342

560

（φ240）

Det

ailed

draw

ing1

of

Pinne

d sha

ft (2

pie

ces，

Q235）

Detai

led d

rawin

g o

f shi

mplat

e （

eac

h 2

piec

es）

50

φ220 475

φ250

20

395

M48

60

50

φ190

φ4910

shimplate

nut M

48

Lug

as

sembl

y d

rawin

g

shouder girder

pinned shaft

shoulder girder lug

7

530

Φ265

均布

3×Φ18

part

4 det

ailed

dr

awing

part

5 det

ail

ed dr

awing

340

130

40

30

120

260

40

40

370

260

150

320

600

φ220.5

par

t6 de

taile

d d

rawin

g

5、

Part position can be reinforced according to site

situation, which is not indicated in the drawing.

2、

Remedy reinforced rib at site, and its erection position

can be adjusted according to site situation.

1、When welding plates, 2～3mm clearance shall be left and

grooved，

and make full welding.

6、

Materila list is used for 2 sets.

4、

Height of all welding seams shall be bigger than min.

thickness of welded parts.

3、

Erect top limb plate after welding of lug and

inside reinforced rib.

Air pressure testing manual of whole boiler


DOCUMENT NO.: HISAR-GL-05 Page

77




DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








78

CONTENT

1 THE BASIS FOR COMPILING THE MANUAL………………………………79

2 PROJECT INTRODUCTION AND TEST RANGE…………………………...79

3 TEST PERSONNEL AND QUALIFICATION…………………………………79

4 NECESSARY MACHINE & TOOLS AND SAFETY PROTECTION

FACILITIES DURING TEST…………………………….……………..………...79

5 TEST CONDITION AND PREPARATION BEFORE TEST…………………80

6 TEST PROCEDURE, METHOD AND REQUIREMENT…………………….80

7 QUALITY CONTROL AND QUALITY ACCEPTANCE…………….…….…83

8 REQUIREMENT AND MEASURE FOR SAFETY AND CIVILIZED

CONSTRUCTION AND ENVIRONMENTAL MANAGEMENT………….……84





1.1 Directions and interrelated drawings for equipment erection from Shanghai Boiler

Works Ltd.

1.2 The drawings of flue, air and coal powder duct from SEPDI.

2 Project introduction and Test range

As per the features of boiler, arrange two delivering powder places: one is forced draft fan

on the right of boiler, the other is scavenging gate of air-inlet box of primary air fan.

2.1 Before test, inspect inner of flue, air and coal powder duct.

2.2 The erection of temporary point for delivering powder and temporary containment

2.3 Deliver powder and check as testing

2.4 Eliminate leakage point.

2.5 Remove temporary establishments

3 Test personnel and qualification

Prepared by REL at site.

4 Necessary machine & tools and safety protection facilities during Test

4.1 Necessary machines and tools during Test

No. Equipment name spec qty remark

1 truck 5T 1

2 welding machine 4 Checked to be qualified

3 electric torch 6

4 talc powder 2

4.2 Preparations of safety protection articles

4.2.1 Personal safety protection articles: safety helmet, safety belt, eye shield, gauze

mask etc.

4.2.2 Safety protection articles preparation in Test area: safety net, rail, caution tie and

etc.




5 Test Condition and Preparation before Test

5.1 Flue, air and coal duct and accessories have already been installed and moreover

they have been checked and accepted.

5.2 The seal of each kind door and hole of boiler proper are well, and they have been

installed and checked to be qualified.

5.3 Mill, coal feeder accompanying with its accessories, air preheater and electrostatic

precipitator have been installed and sealed well.

5.4 FDF, IDF and PAF have been installed, moreover their single testing have been

passed.

5.5 Burner and wind box have been installed, moreover joints on burner proper have

been temporarily closed by plates or sealing tape to keep them airproof.

5.6 The dampers of flue, air and coal powder can be flexibly operated, and indication is

correct. All pneumatic and electric actuators of pneumatic and electric dampers

(especially pneumatic and electric actuator of each kind damper at fan’s outlet and inlet)

can be used.

5.7 Pressure measuring device and hot air measuring device in furnace can be used.

5.8 Water sealed trough at top of bottom ash bin and water sealed flashboard have been

installed, and water have been passed to seal.

5.9 Outlet ash hopper of economizer and air preheater and ash sluicing device at the

bottom of electrostatic precipitator are sealed well.

5.10 Delivering powder device used in test has been installed. Talc powder is all ready.

The inner of flue, air and coal duct is cleanly.

5.11 Scaffolds, illuminance, communication and weather can cater to testing requirement.

5.12 Mechanical erection and welding etc workers should be organized to take part in,

and take self-checking notes.

6 Test procedure, method and requirement

6.1 Work procedure flow chart:




6.2 Test method and requirement

6.2.1 Testing method

6.2.1.1 Testing system flow:

(1).Flow one：FDF→ cold secondary air→ secondary air side of air preheater→ hot

secondary air→ wind box→ burner→ furnace→ flue duct of level and tail shaft→ bottom

flue duct of economizer→ top flue duct→ flue gas side of air preheater→ bottom flue

duct→ flue duct at inlet of ESP→ ESP → flue duct at inlet of ESP→ induced draft fan→

chimney.

(2).Flow two：PAF→ cold primary air（including hot primary air passed by adjusting

temperature air→ mill, blowing air for delivering powder→ pipes for delivering powder）

→at the side of primary air of air preheater→ hot primary air→ mill（including hot primary

bypass air of mixture box below coal feeder）→coal powder separator→ power delivery

pipe→ burner→ furnace→ flue duct of level and tail shaft→ flue duct at bottom of

economizer→ top flue duct→ flue gas side of air preheater→ bottom flue duct→ flue duct

at inlet of ESP→ ESP → flue duct at outlet of ESP→IDF→ chimney.

(3).The two flows start at the same time as testing.

6.2.2 Testing steps

6.2.2.1 Confirm to close damper as follow:

(1).Primary air fan on the right of boiler, pneumatic isolate damper at outlet of forced draft

Account for technical

The erection of temporary

Air pressure test of whole boiler

Clean duct inside

Qualified

Deal with defects、W point

Check and accept

Acceptance

Acceptance




fan, electric baffle door at outlet of induced draft fan.

(2).PAF, hot air recycle manual isolate damper of FDF

(3).PAF on the left of boiler, pneumatic isolate damper at outlet of FDF

(4).Electric coal gate at inlet of coal feeder

(5).Manual ball valve on coal powder sampling device, electric slide plate gate at outlet of

ash hopper at bottom of electrostatic precipitator, manual slide plate gate at outlet of ash

hopper at bottom of economizer, ash flushing globe valve at bottom of cold primary air

duct, ash flushing globe valve at bottom of cold secondary air duct, hydraulic shut-off

gate.

6.2.2.2 Confirm to open damper as follow:

(1).Electric baffle damper at outlet of IDF

(2).Electric contacting damper of cold primary air and cold secondary air.

(3).Adjusting temperature and delivering powder purge gate passed by cold primary air,

hot primary air damper passed by adjusting temperature air, mill and mixture box damper

passed by hot primary air, the damper of delivering powder pipe passed by blowing air,

pneumatic globe valve of coal powder at outlet of coal powder separator, adjustable

shrink core hole, adjustable baffle of secondary air outside burner(including the

secondary air and the side secondary air), electric coal gate at outlet of coal feeder, mill’s

damper passed by seal air, coal powder globe valve’s damper passed by seal air, coal

feeder’s damper passed by seal air.

(4).Electric baffle at outlet of wind box

(5).Electric baffle at outlet of air preheater, electric baffle of hot primary air and hot

secondary air at outlet of air preheater.

6.2.2.3 Start procedure

(1).After checking work as above without error, start according to fan starting and

operating procedure, slowly turn on motor-operated valve at inlet of IDF, pneumatic

isolate valve at outlet of forced draft fan on the right of boiler, pneumatic isolate valve at




outlet of PAF on the right of boiler. By monitoring hot air duct and furnace’s testing

pressure device, adjust fan output to make furnace pressure up to requirement of

equipment technical document. If there is no requirement, conform to 50mmH2O above

furnace working pressure, then deliver talc powder into delivering powder place, which is

lay.

(2).Carry out a overall inspection for joining test system, especially dampers, flange joint

surface, equipments of pulverized coal system, wind box and burner. If find any leakage

place, make a mark and take notes in time to deal with the defects. After finishing

checking, shut down FDF on the right of boiler, PAF and two IDF.

7 Quality control and quality acceptance

7.1 Quality control standard

7.1.1 Quality checking shall be on the basis of technical document such as drawing,

directions etc. For those manufactory technical requirement is not cleared, consult to

concerned provision.

7.1.2 Construction quality checking and assess standard

Air pressure test of whole boiler

Quality standard Checking item unit

qualified

Test pressure mmH2O carry out pressurized test as per provision of equipment technical document, if no provision, as per furnace working pressure, which is 50mmH2O

Gate. hole

Welding seam

Adjustable seal device

Air tight state

baffle

The measures of air pressure test according to ratification

Record and deal with defects Have whole defect notes, thoroughly deal with defects in time

7.2 Locate witness point for intermediate control




7.2.1 Make flue, air and coal duct and do leaking oil test for erection welding joint.

7.2.2 Clean and inspect the inner of flue, air and coal duct.

7.3 Technics discipline and quality assurance measure

7.3.1 Construct strictly according to drawings. After complete construction, clean inside in

time and transact visa.

7.3.2 When make and install all flue, air and coal ducts, need leaking oil witness list and

visa.

7.3.3 Carry out test as per working manual.

7.3.4 Detailedly and seriously record the leaking point during test.

7.3.5 Deal with defects in time and transact visa.

7.3.6 Carry out air pressure test on a fine day without wind.

8 Requirement and measure for safety and civilized construction and

environmental management

8.1 Before air pressure test, tell detailed technical to workers who take part in the test.

Make them understood test steps, checking time and respective work.

8.2 All the workers dress correctly and wear safety helmet, which take part in test. Wear

soft sole shoes and tie life belt when work at high. Obey command and wait for

arrangement during test.

8.3 Except workers, it is forbidden to enter air pressure test area, especially in pitching

powder area.

8.4 Set up a commanding team at air pressure test site, whose duty is contact,

organization and commanding. All inspectors should render the circs to commander in

time. Set up a special channel for communication tools which are used for air pressure

test, so that ensure information is transfered in time.

8.5 Build rail in fan delivering powder area, and build scaffold according to requirement.

Hang caution brand.

8.6 Draw safety tie and hang caution brand at test site.




8.7 Workers that deliver powder should wear gauze mask and eye shield. When pitch

powder, the person don’t close to entrance.

8.8 Before start fan, ensure every kind opening is opened and closed as per requirement.

8.9 Scaffolds at each checking position are perfect. Passages are clear. Illuminance is

enough.

8.10 During testing pressure, assign special persons to monitor furnace measuring

pressure device and measuring air rate device.

8.11 During testing pressure, don’t inspect without permission.







DOCUMENT TITLE:

The Erection Manual of Wind Box


REV. NO. :0

ENDORSEMENTS








CONTENTS

1 Basis of Preparation and Checking Criterions…………………………88

2 Project General and Construction Range…………….……………88

3 Allocation of Resources and Manpower Qualification………..……88

4 Necessary Machine & Tools and Safety Protection Articles for

Construction……………………………………………..…………88

5 Construction Condition and Preparation before Construction

………………………………………………...………………88

6 Construction Procedure, Method and Requirement……...………89

7 Quality Control and Quality Acceptance……………………..……89

8 Requirement and Measured for Safety and Civilized Construction and

Environmental management…………………………………………91




1 Basis of Preparation and Checking Criterions

1.1 Boiler Wind Box and Fixed Setting （drawings of Shanghai Boiler Works Ltd.）

2 Project General and Construction Range

2.1 General of project

The wind box system of 2×600MW thermal power plant on Hisar designed by Shanghai

Boiler Works Ltd. is installed at the two sides of the boiler.

2.2 Construction range

Mostly contain bellows joist frame、upside bellows、underside bellows。

3 Allocation of Resources and Manpower Qualification

It shall be prepared by REL Co.

4 Necessary Machine & Tools and Safety Protection Articles for Construction

4.1 Necessary machines and tools during word

NO Name Specs Qty remarks

1 Block pulley 10T 4

2 winch 5T 4 checked to be qualified

3 Chain block 1T 4 load test is qualified



6 welding machine 4 checked to be qualified

4.2 Preparation of safety protection articles

4.2.1 Personal safety protection articles: safety helmet, safety belt, eye shield, differential

speed self locking safety catches etc；

4.2.2 Safety protection articles preparation in construction area: safety net, safety rail and

etc.


5.1 Before construction, all the construction drawings shall be approved. For any problem,

it shall be managed according to normal procedure on time. The drawings which are not

approved shall not be consulted for construction.




5.2 Prepare the tools and machines before installation.

5.3 Disposal of construction power, gas source for construction shall be reasonable, and

ensure enough illumination at night on construction site.

5.4 Safety protection devices such as safety net, safety rope and etc on corresponding

construction floor of boiler steel structure shall be finished and be checked and accepted.

6 Construction Procedures, Method and Requirement

6.1 flow chart of construction procedure

6.2 Construction method and requirement

6.2.1 Equipment count and check

Equipments checking and numbering should accord to the equipment supplying list,

packing list and related drawings. According to the drawings, check the dimension and

appearance of the equipments so as to avoid unqualified equipments entering the

construction tache.

6.2.2 According to crane condition, truss-frame of wind box shall be assembled on ground

and then lifted and deposited. The components which connect wind box upside and wind

box underside with water wall shall be installed before boiler hydraulic test. Other

components are placed separately.

7 Quality Control and Quality Acceptance

7.1 Standard of quality control

7.1.1Quality checking should be on the basis of technical documents such as drawing,

Deposit of wind box truss-frame

Level of wind box truss-frame

Install of wind box upside

Install of wind box underside

Whole Check

Note and check




instruction and etc. Consult this erection manual if factory technical requirement is not

clear.

7.1.2 Construction quality checking and assessing standard

Wind box and truss-frame erection Quality check working

procedure Checking items units

qualified

column elevation deviation ±5

elevation deviation between each column

≤3

gap between each column ≤1‰ column gap, ≤10

column perpendicularity deviation ≤1‰ column length, ≤15

column erection

top column small/ big diagonal ≤1.5‰diagonal length, ≤15

elevation deviation ±5

level deviation ≤5

centerline deviation

mm

±5

joint plate installation flat, in correct position，tight components

beam erection

welding according to manufacture requirement

7.2 Technique discipline and quality guarantee measures

7.2.1 Make sure the damper flexible rotated without jam, scale divisions data of aperture

and scale plate is consistent.

7.2.2 Make sure no leakage during the installation of damper.

7.2.3 Make sure the wind chamber is on the same plane and the tolerance to furnace arc

part opening position of water wall shall be within ±3mm.

7.2.4 Strictly control geometrical dimension of ash hopper during assembling of wind box

truss-frame. The deviation of junction length couldn’t exceed ±5mm and deviation of

Junction diagonal couldn’t exceed ±10mm.

7.2.5 The center line of sight hole, oil-fire detector and oil gun shall be settled strictly

according to drawing. It shall be checked by line-plumb, if the opening position of the

cover plate of wind box is wrong, move the cover plate properly.




7.2.6 Strictly ensure levelness of truss-frame.

7.2.7 Inside and outside surface of wind box shall be flat without serious deformation.

Temporary welding pieces and dregs on surface shall be repaired and burnished to

ensure artistic.

7.2.8All the welding seams of assembled members shall be checked carefully. There are

should be no dummy and missing welding phenomenon. All welding seams connecting

with water wall shall be accomplished before hydraulic test.

7.2.9 All inspection holes of system shall be sealed without leakage, and inside cleaned

cleanlily to be no sundries and seeper before closed.


Environmental management

8.1 Wear safety helmet correctly before going to site. It is forbidden to wear slipper,

sandal, high-heel shoe and spiked shoes on site and go to site after drinking. Use life belt

correctly when working on height and hitch it firmly on top place.

8.2 All falsework needed for construction shall be firm and in correct position and can be

put into use after checked and accepted.

8.3 It is strictly forbidden to drop and throw things at high.

8.4 The machines, tools and etc used for hoisting shall be checked strictly before using. It

is forbidden to use unqualified machines and tools. Small tools shall be kept in

workbasket and electric tools shall be used correctly.

8.5 Correctly operate hoisting facilities such as chain block and etc, and forbid to use

under overload; hand chain together with hoisting chain shall be used when hang

temporary equipment and set up safety rope on heavies. Take the reinforcement

measures when long time hanging is required.

8.6 Obey professional hoisting personnel’s command during hoisting.

8.7 When using cutting tool, the position of joint shall be tied tightly to avoid fire and burn

accident caused by gas seeping. When drag belt, try to avoid joint loose and other small




pieces fallen down, the belt shall tend towards specified route; take isolation measures

during cutting and welding construction if there is combustible on height or below.

8.8 Correctly wear protection facilities such as eye shield and face mask during cutting,

welding and polishing. Constructors shall avoid getting electric shock and don’t operate

unfamiliar electriferous equipments at will.

8.9 Temporary deposited small installation piece shall be packed in wooden box on

platform. It is strictly forbidden to putting and throwing disorder so as to avoid materials

falling from height.

8.10 Cross construction is ineluctable during construction; first discuss the construction

scope and safety issues with every party. Cooperate with each other during every working

procedure. Try to stagger construction site, take safety isolation measures on the floor

where cross construction can’t be staggered.

8.11 Strictly forbid using the deposited truss-frame as the pivot to hang heavies.

Erection Manual of flue, air and coal ducts



93




DOCUMENT TITLE:

Erection Manual of Flue, Air, Coal Ducts


REV. NO. :0

ENDORSEMENTS








94

CONTENTS

1 BASIS OF PREPARATION………………….……………….…………… 95

2 SCOPE OF CONSTRUCTION……………………………….…………… 95

3 ALLOCATION OF CONSTRUCTION PERSONNEL AND QUALIFICATION

………………………………………………………………………..……96

4 EQUIPMENTS AND TOOLS FOR CONSTRUCTION AND SAFETY

PROTECTION ARTICLES…………………….………………………………..96

5 CONSTRUCTION CONDITION AND PREPARATION BEFORE

CONSTRUCTION ………………………………………..…………….……97

6 CONSTRUCTION PROCEDURE, METHOD AND REQUIREMENT … 98

7 QUALITY CONTROL AND QUALITY ACCEPTANCE ………….… 102

8 REQUIREMENT AND MEASURES FOR SAFETY CIVILIZATION

CONSTRUCTION AND ENVIRONMENT MANAGEMENT …………..… 105




95


1.1 The installation drawings of flue, air and coal ducts (Southwest Electric

Power Design Institute)

1.2 The installation drawings of flue, air and coal ducts（Shanghai Boiler Works

Ltd.）

1.3 The drawings of boiler steel structure（Shanghai Boiler Works Ltd.）

2 Project introduction and construction range

2.1 project construction

The flue, air and coal system of Hisar 2 × 600MW thermal power plants is

compose of primary air system, secondary air system, flue duct, pulverized

coal system, raw coal ducts and seal air system. primary cold air change into

primary hot air after entering air preheater and will be used as controlling

temperature air to dry by coal pulverized coal, and at the time carrying coal

powder; Secondary air system, used for combustion-supporting in boiler

furnace, is distributed from wind box after passing air inlet, silencer, FDF, and

heated from air preheater. Sealing air is educed from connection air duct of

cold primary air and used as sealing air for pulverized coal system after

passing sealing air fan. Each pulverizer educes four coal powder pipes which

respectively connected with burner on the boiler wall. There are two parts of

flue duct: ESP front flue duct and ESP rear flue duct. Flue, air ducts shall be

deposited at corresponding installation position according to erection progress

of steel structure, and installed when condition is ready.

This work composes of many single projects, and a mass of lifting,

depositing, assembling work during construction shall be completed at high,

which increases difficulty and fatalness for construction. There are many

scattered small pieces, a great deal of assembly work and cross construction

during installing.




96


Installation includes flue, air, coal, powder ducts, hanger & supporter and

accessory equipments.

3 Allocation of resources and manpower qualification

Prepared by REL at site.

4 Necessary machine & tools and safety protection facilities during

construction

4.1 Necessary machines and tools during construction

NO Name spec Qty Remarks

1 Autocrane 50t 1

2 Platform trailer 30 T 1

3 truck 8T 1

4 truck 18T 1

5 Block pulley 10t 2

6 winch 5T 4 With certificate and qualified

7 Electric welding

machine DC 4 With certificate and qualified

8 Electric welding

machine AC 8 With certificate and qualified

9 Steel tape 50M 2

10 Steel tape 5M 6

11 Chain block 10T 6 Load test is qualified





16 hammer 4pound 12

17 crowbar 4

18 water level 300mm、500mm Each 2 Verified qualified




97

NO Name spec Qty Remarks

19 Glass level pipe 100m

20 line-plumb 2

21 jack 5t 2 With certificate and qualified

22 jack 3t 2 With certificate and qualified

4.2 S preparations of safety protection articles

4.2.1 Personal safety protection articles: safety helmet, safety belt, eye shield,

differential speed self locking safety catches etc；

4.2.2 Safety protection articles preparation in construction area: safety net,

safety rail and etc.

5 Construction Condition and Preparation before construction

5.1 Disposal of construction power, gas source for construction shall be

reasonable, and ensure enough illumination at night on construction site.

5.2 Steel structure erection has the condition for depositing and erection

equipment. Impedimental pole pieces have been kept in advance above

deposited big pieces.

5.3 Passage for equipment transportation is clear.

5.4 Allocation of personnel is in position, familiar with the erection drawings

and has interrelated post qualification.

5.5 The construction tools are checked and prepared properly.

5.6 Equipments with complete accessory are delivered with certificate and

checked to be qualified; site assembly parts are already prepared with

handing-over notice of working procedure.

5.7 Safety establishment and caution board are completed; assembly yard is

neat without sundries; working platform at high, walkway and stairs are clear,

erection rails around platform.




98

6 Work procedure, method and requirement

6.1 Work procedure flow chart


6.2.1 Before project starts, the direct administrant and main constructors shall

read drawings, and make sure everybody realizes construction task,

construction method, and quality standard and safety precautions.

6.2.2 Equipment count, check and storage

On the basis of delivering list, packing list and drawings, count the equipments,

measure the dimension of equipment and check technics quality of aspect.

Particularly check the dimension of important parts like air damper,

compensator and etc. Refer the problems to interrelated company.

6.2.3 Flue, air, coal ducts assemble

6.2.3.1 Flue, air, coal ducts shall be partial assembled on ground in advance in

order to expedite installing progress, reduce workload at height, improve

Equipment counting

Flue, air, coal ducts assemble

Erection of flue, air, coal ducts and supporter& hanger

Clean inside of flue air, coal ducts

Air damper debug

Adjust constant spring hanger

Whole technique correct and check

Check by air pressure test

Leaking oil visa

Leaking oil visa

W, R point

W, R point

Checking visa




99

security during construction and ensure construction quality. The precondition

for assembling flue, air, coal ducts on ground is the dimension of steel

structure and load capacity of crane. But for single bigger figure parts, it is

considered to deposit during the period of lifting steel structure. Although the

compages of flue, air, coal ducts have proper rigidity, temporary reinforcement

is required when it is necessary; the temporary lug shall be welded tightly and

has enough carrying capacity.

6.2.3.2 According to assembling requirement, setup assembling platform, and

make sure platform earth well. As per drawings line out the longitudinal and

transversal centerline of assembled parts, mark the point by punch hole and

polish the groove up to the requirement. There is no paint in the welding area.

First check the dimension of assembling parts on ground so as to avoid big

error during installation. Make detailed record for preassemble. In the

assembling process, measuring hole, manhole and etc shall be confirmed as

per drawings. Check the dimension of assembled pieces and do leaking oil

test for it after assembled.

6.2.4 The installation of cold air duct is on basis of the joint of the cold air duct

of air preheater. According to the direction of cold air duct, install in turn as per

the location dimension of drawings.

6.2.5 Install hot air duct, deposit hot air duct during lifting of steel structure. Air

duct shall be deposited at its formal erection position as per drawing, and as

per actual condition make temporary reinforcement for the girder of supporter

&hanger and steel structure by spot welding.

6.2.5.1 The sequence of hot air duct installation respectively starts at the

center of header, as per the direction of hot air duct, install in turn in

accordance with the orientation dimension stated in drawings, and install




100

supporter & hanger at the same time. Temporary reinforcing pieces for air duct

shall be resected when supporter & hanger bear force equably.

6.2.6 Coal feeding pipe shall be installed as per the length of the arrived air

damper; compensator and anti-abrasion elbow, and accordingly adjust the

length of front & rear circular duct section.

6.2.7 Raw coal ducts shall be inserting when install the entrance of mill.

6.2.8 Installation of support & hanger

6.2.8.1 Supporter & hanger shall be installed flatly and tightly and contact with

pipes well; space between supporter & hanger shall accord with design

requirement, over loading is strictly forbidden for supporter & hanger during

installation so as to ensure safety of personnel and equipment. Tighten nuts so

as to avoid looseness after adjusting supporter & hanger.

6.2.8.2 When install fixed supporter & hanger, make sure supporter & hanger

bear forward force equably without deflexion and load is distributed reasonably.

The baseplate of fixed supporter shall be added with shimplate after alignment

at vertical and level plane (big size use profiled bar). Spot welding after filled

up tightly, the number of spot welding couldn’t be less than four under the

baseplate of supporter.

6.2.8.3 When install spring hanger, make hanger a little gradient to the

opposite direction of expansion & extended direction of duct section.

Displacement of hanger（stress bearing crossarm） is half of expansion

quantum of duct section at this position. The nameplate of spring hanger shall

be put at obvious position and the dial gauge is well and complete. It is

forbidden to cut adjustable pin by torch. Adjustable pin of constant spring shall

be put in invalidation hole after pulled out. Latch strip shall be reversely

buttoned at constant spring, and strictly forbid to throw away and hang




101

randomly. The fittings of spring hanger shall be complete, firm, no bend with

pull rod and the direction of lug is correct.

6.2.8.4 When install sliding support, make sure contact surface between the

sliding surface and duct bracket shall be flat, the contact area couldn’t be less

than 75% of designed area（in immovable seat shall advert as jointing）.Sliding

support could expand freely and the position accord with design requirement.

6.2.8.5 Ensure the direction of guide support in right position and the guide

block is flat during erection.

6.2.9 Auxiliary equipment and accessory install

6.2.9.1 Expansion joint is installed as the flowing direction of airflow. The

expansion joint connecting with equipment shall be connected after equipment

finally fixed. Expansion joint erection shall ensure enough expansion quantum.

When use temporary support & hanger, the joint shall be fastened and

wouldn’t conflict with the position of formal support & hanger, and remove them

after erection. Choose right welding rod as per corresponding material when

assemble expansion joint.

6.2.9.2 Mark on the full opening, closing position which the sign is correct and

clear on the outside of every kind of air dampers. Pay special attention to the

direction of air damper during installation especially the installation of isolation

air damper. Check baffle plate, flashboard before installation, and reserve heat

expansion spacing according to drawings, and gland seal is all right; the action

of opening & closing door of composite baffle plate shall keep the same step

with other baffle plates’, and the opening & closing angle shall be accordant. At

the same time, adjust the erection position and the direction of air damper with

other specialties so that air damper could be installed at the reasonable

position easy for operating maintenance by actuator.




102

6.2.9.3 Installation of remote operation device shall accord with the drawing

requirement and operate expediently, denote right, dispose trimly and would

not block channels; the base plate of base frame shall be fixed tightly and kept

in level.

6.2.9.4Operation device shall have opening & closing sign and stopper for full

opening & full closing whose opening scale is clear and accord with the actual

opening scale.

6.2.9.5 Flame-proof damper installation shall accord with design request, and

pay attention to the position and direction of the ducts eduction pipe of

flame-proof damper and considering flame-proof damper movement would not

hurt person and arouse fire during operation; flame-proof damper placed

outdoor shall have tilt angle more than 45° with the ground and put rust-proof

coating on the film of flame-proof damper.

6.2.9.6 Ejection direction of coal powder fire fighting devices extended to duct

and equipment shall be same with coal powder flowing direction.

6.2.9.7After install flue, air, coal ducts，clean out sundries in ducts and transact

close acceptance on time. Don’t break the parts during removing temporarily

reinforcing pieces.

7 Quality control and check


7.1.1 Quality checking shall be on the basis of technical document such as

drawing, directions etc. For those manufactory technical requirement is not

cleared, consult to this manual.


Flue, air, coal ducts assemble and installation Quality standard Working


qualified




103

Quality standard Working procedure

Checking items units qualified

length deviation of groupware ≤1/500 length ≤10

groupware camber ≤1/500 length ≤10

alignment of pipe joint Between ≤1，process groove jaws when thickness of duct wall≥5mm

deviation of erection elevation ±20

deviation of vertical and horizontal position of ducts installation

mm

±30

Clean ducts inside No sundries（including temporarily reinforcing iron parts incise neatly）

Undee expansion joint

Cold-drawn accord with design, welding direction of sealing plate shall be consistent with flowing

direction of medium

Socket expansion joint Enough expansion quantum，well

airproof

Explosion door

In right position and direction, thickness and facture of

explosion-proof film shall accord with design request

air locker In right position and direction,

operate flexibly

wood scrap separator Accord with design

Flashboard installation

Switch flexibly ,opening scale accords with design, close tightly, there is snick on shaft head at the

position of baffle

support & hanger Accord with design request

Flange connection Flange surface is flat, add mat right, bolt bar force equably, the protrudent

length of thread is same

tightness test for welding line Do oil leaking test for welding line，

and make sure not leakage

Compages and

erection

welding According to design request

7.2 Technique principle and quality guarantee measures




104

7.2.1 Erection dimension shall be strictly controlled as per manufacture

documents and drawings.

7.2.2 Flue, air, coal ducts and accessorial equipments shall be checked and

accepted, there is no crack, pore, serious rust and scathe on main

components and can be used after checking. All parts are installed according

to drawing requirement. Duct is erected levelly and vertically with artistic

technics.

7.2.3The height of welding seam shall strictly accord with the drawings request.

There are no flaws such as crack, air bubble, lack of fusion, welding slag etc

on the surface of welding seam and heat affected zone; there are no air hole,

dregs and seep-welding within welding line. Before welding, clear away the

rust, dirt, oil filth, ferric oxide and etc 30mm around two sides of welding seam

to reveal metal luster.

7.2.4 After finishing whole erection, the vertical and horizontal deviation of

center line for ducts erection shall be less than 30mm, elevation deviation is

within ±20mm which measured as reference of boiler steel structure. Duct

inside and outside is clean, scar shall be burnished to be slippery.

7.2.5 When ducts connect with machine equipments, it is strictly forbidden to

connect with strong force so as to avoid shift of machine equipment. There

shall be no cross welding line on installing and forced alignment so as to avoid

stress concentration. The welding line shall be artistic: welding joint is flat

without welding slag and drug peel and height of welding line shall accord with

design request.

7.2.6 During duct junction’s alignment, the stagger must be controlled less

than 1mm. For straight welding line of different duct section shall stagger

100mm at least. The distance between junction welding line and edge of its

nearest supporter & hanger couldn’t be less than 75mm.




105

7.2.7 Support & hanger shall be leveled not only in pipeline direction, but also

aligned in vertical direction by using water level. The above two points shall be

guaranteed and intermediate joint of sag rod can’t be bended. Duct equipment,

flange, bolt hole of hanger shall be processed by can’t be cut by torch at will.

All incised parts shall be burnished.

7.2.8 After adjustment of support & hanger, the protuberant length of lock nut’s

thread shall be the same so as to ensure technics artistic and convenient for

examining and repairing. The suspender is forbidden to misuse, mix using,

exchanged using. The parts of thread shall be fine without damnification and

coated with lead oil. The length of thread overtops screw cap is the same; Try

best to control it within 2-3 thread and tighten lock screw cap according to

rules.

7.2.9 Do oil leakage test for pipe assemble and erection welding joint as per

requirement.



8.1 Lifting tools & machines and electric tools shall be checked carefully before

using.

8.2 The scaffold shall be checked by interrelated safety department after

erected.

8.3 Make sure enough lighting at night and fire fighting establishment at

construction site.

8.4 Chain block, hoisting steel rope and etc could not be used overload

8.5 Keep construction area clean and the direction of electric, torch welding

strap is reasonable.

8.6 When work finished, clean the site in time and clear away rubbish and

scrap, construction material and small scattered parts shall be put at fixed




106

position.

8.7 It is strictly forbidden to remove and dismantle installing establishment and

signs at will.

The Erection Pulverized Coal Burner



107




DOCUMENT TITLE:

The Erection Manual of pulverized coal burner


REV. NO. :0

ENDORSEMENTS








108

CONTENTS

1 Basis of Preparation and Checking Criterions……………………..……109

2 Project General and Construction Range………………………….…….109

3 Allocation of Resources and Manpower Qualification…………………109


Construction…………………………………………………………………..…109

5 Construction Condition and Preparation before Construction ………110

6 Construction Procedure, Method and Requirement……………………110

7 Quality Control and Quality Acceptance……………………………….…112


Environmental management ………………………………………………..114





1.1 Construction organization Design Outline of 2×600MW Hisar Thermal Power Plant

1.2The manual of burner equipment（Shanghai Boiler Works Ltd.）

1.3 Erection drawings of burner equipment（Shanghai Boiler Works Ltd.）

2 Project General and Construction Range

2.1 General of project

The boiler of 2×600MW Hisar thermal power plant is drum boiler, whose parameter

is subcritical and type is“Π”, adopting controlling circle, primary intermediate RH, single

furnace, tangent circle burning at four corner, adjust temperature by swinging burner,

balance ventilation, eliminate dregs at solid state, whole steel suspended structure,

dispose coal-fired burner in the open air.

2.2 construction range

Including：Burner, the secondary air and the erection set of burner fixed set.

3 Allocations of Resources and Manpower Qualification




No. Name spec Qty Remarks

1 Caterpillar crane 150t 1

2 Truck crane 50t 1

3 Platform trailer 30 T 1

4 Truck 8T 1

5 Winch 3T 2 checked to be qualified

6 Electric welding

machine DC 1 checked to be qualified

7 Electric welding

machine AC 3 checked to be qualified

8 steel tape 5M 2 checked to be qualified

9 steel tape 50M 1 checked to be qualified




No. Name spec Qty Remarks




13 Jemmy 2

14 Level bar 500mm 2 checked to be qualified

15 Glass level pipe 30m 1

16 Line plumb 2



speed self locking safety catches etc；


etc.


5.1Construction drawings have been approved and the problems have been solved.

5.2 Prepare the tools & machines for erection.

5.3The alignment of water wall in burning area has been completed.

5.4 The erection of wind box truss has been checked and accepted.

5.5 The welding has been completed which is on burner, the jointing parts of water wall

on burning area and the embedded parts of water wall.

6 Construction Procedure, Method and Requirement

6.1 Flow chart of construction procedure




Technic note

Technic record


6.2.1Check before construction

6.2.1.1 After burner produced, some parts will be lost, deformed or damaged during traffic

and storage course. Before erection of burner, check, maintain and take record according

to drawing list and the instruction manual of burner and contact with manufacture if there

is any defect.

6.2.1.2 Check anti-abrasion porcelain on coal powder concentrator whether is damaged

or not. Watch out in erection and storage process to avoid damaging the anti-abrasion

porcelain.

6.2.1.3 Check whether the inner secondary air handle adjusting sleeve can pull flexibly,

whether the outer secondary air（tertiary air）universal joint, baffle running is flexible,

whether actual opening scale, direction are consistent with the outer’s.

6.2.2 Erection, position

Deposit the burner on relevant elevation steel structure platform by crawler or winch with

the help of chain block. After having construction condition, position it by chain block. Pay

Disqualify

check and accept, W point

Construction preparation

Burner storage

Lineation according to drawings

position, alignment, temporarily fix

Burner and accessory check

The whole check and accept

Disqualification

check and accept, W point

Deal with defects

Check & accept




attention not to damage the burner in erection and position course.

6.2.3Alignment

The burner shall be aligned after water wall is aligned. Find out the burning hole of

water wall and the cross center line of burner nozzle before alignment and make clear

marks. Adjust according to the cross line during positioning to ensure the center of

burner nozzle is concentric with the burning hole of water wall. Measure the distance by

pulling steel wire or steel tape, which is from the center line of water wall to the primary

air inlet pipe to the end surface of burner stabilizer fire equipment.

7 Quality Control and Quality Acceptance

7.1 Standard of quality control

7.1.1Quality checking should be on the basis of technical documents such as drawing,


clear.


The erection of pulverized coal burner Quality check working

procedure Items Units

qualified Equipment appearance

No flaw, distortion ,rust,

damage

t≤300mm ±3

300＜t≤500mm ±4

500＜t≤800mm ±5

The declination of center distance between nozzle

800mm＜t ±6

H≤2.5m ±4

2.5＜H≤5m ±8

The whole distance

declination of upside, downside

nozzle 5m＜H ±10

H≤5m ≤4 alloy

5m＜H ≤5

The erection

of pulverized

coal burner

The declination of nozzle center

cast H≤5m

mm

≤6




Quality check working procedure

Items Units qualified

5m＜H ≤7

Nozzle elevation declination

±5

Burner tangent circle and lineation There is correct tangent on

tangent circle platform, whose mark is clear

The declination of the center axis of nozzle and tangent

degree ≤0.5

Vertical degree declination of burner crust mm ≤5

Depth declination after entering furnace ±5

The angle declination of upside and downside nozzle

Accord with drawings, scale

denote correctly

Drive part（baffle, operating and adjusting mechanism）

Gland rigorous, run flexibly and freely. Scale indicator is correct

and is consistent with actual position

Leakproof joint surface Insert shimplate correctly, and

no leakage

Welding Accord with drawings

requirement

Sliding hanger

Accord with drawings, slide freely, hammer can’t collide the

equipments in its running range, steel wire clamp is tight

Fixed hanger Accord with suspension set requirement（refer to the

erection manual of water wall）


7.2.1 Measure the distance between the center line of water wall and burner nozzle by

hanging line plumb and angle tape.

7.2.2 Measure the distance between the end surface of burner stabilizer and the center

line of water wall by hanging line plumb and angle tape.

7.2.3 Measure the level degree of burner by level pipe.

7.2.4 Measure the layer distance and line distance of burner by steel wire and steel tape.




7.2.5 Burner erection position, dimension should accord with drawings requirement.

7.2.6 The way of guarantee of elevation of primary air inlet flange of burner is to ensure

the center elevation of burning hole and the erection level of burner as installing water

wall, which is easy to ensure the elevation of burner primary air inlet flange.

7.2.7 Burner nozzle is concentric with burning hole of water wall. Depth declination of

nozzle inset the furnace is ±5 mm. The distance between the end surface of burner

stabilizer and the center line of water wall front wall and rear wall is 198～200mm.

7.2.8 When install burner ensure the elevation and level degree of primary air inlet flange

is in the opposite position with coal powder duct; ensure levelness of burner and the

distance from the burner center line of water wall to the end of nozzle; ensure all welding

seam is sealed without leakage.

7.2.9 Spot welding should be firm for the angle iron of burner fixed devices and channel of

burner fixed frame. Weld firmly after checking and acceptance.

7.2.10 Burner couldn’t bear any load from coal powder duct designed by design institute.

7.2.11After installing burner ensures the drive part is rigorous, runs flexibly and freely.

Scale indicator is correct and is consistent with actual position.

7.2.12Before installing burner, check and clean burner inside and avoid trash leaving

inside so as not to jam when running.

7.2.13 Insert shimplate correctly on sealed joint surface without leakage.



8.1 Erection tools & machines and electric machines should be checked carefully before

using.

8.2 Whether falsework erection is checked and accepted by interrelated safety and

intendance department.

8.3 Arrange enough illumination at night and firefighting establishment at site.

8.4 Hoisting tools such as chain block, hoisting steel wire can’t be used overload.

8.5 Keep clean in construction area and arrangement of electric, torch welding cable




should be reasonable. Clean the site after work and clean up rubbish, trash in time.

Construction materials and small parts should be put at fixation place.

8.6 It is strictly forbidden to randomly removing and eliminating erection establishment

and sign.

8.7 Organize construction strictly according to safety construction procedure and

eliminate accident and hidden trouble initiatively.

Erection Manual of water wall and buckstay



116




DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








117

CONTENT

1 THE BASIS FOR COMPILING THE MANUAL…………………………….118

2 PROJECT INTRODUCTION AND CONSTRUCTION RANGE………….118

3 ALLOCATION OF CONSTRUCTION PERSONNEL AND QUALIFICATION

……………………………………………………………………………….. 118


PROTECTION ARTICLES …………………………………………… ……….118


CONSTRUCTION ………………………………………………..…………… 119

6 CONSTRUCTION PROCEDURE, METHOD AND REQUIREMENT….…120

7 QUALITY CONTROL AND QUALITY ACCEPTANCE…………………....123


CONSTRUCTION AND ENVIRONMENT MANAGEMENT ………….…… 128





This manual is compiled based on the drawings of the following equipments&materials:

1.1 Water wall（Shanghai Boiler Works Ltd.）

1.2 Water wall suspension device（Shanghai Boiler Works Ltd.）

1.3 Water wall area buckstay（Shanghai Boiler Works Ltd.）

1.4 Guide device（Shanghai Boiler Works Ltd.）

1.5 Level device（Shanghai Boiler Works Ltd.）

1.6 Steam water connecting pipe（Shanghai Boiler Works Ltd.）

1.7 Precipitation branch pipe（Shanghai Boiler Works Ltd.）


The all-welded finned water wall is composed of front wall, left & right side wall, rear

wall and left & right side extended wall. Front water wall is composed of 307ps of tubes

welded by fins; left & right side water wall is composed of 262ps of tubes welded by fins;

rear water wall is composed of 331ps of tubes welded by fins; left & right side extended

water wall is composed of 33ps of tubes welded by fins. Water wall upper header is

connected to drum by steam-water connecting pipe, lower header and downcomer

distribution header is connected by branch pipe for steam-water circulation.


It is prepared by REL at site.

4 Equipments and tools for construction and safety protection articles

4.1 equipments and tools for construction

SL Machine Specification/ Model Nos. Remarks

1 truck crane 50t 1

2 platform trailer 30t 1

3 pulley block 10t 5 checked to be qualified

4 winch 5t 5 checked to be qualified

5 chain block 10t 4 checked to be qualified

by load test




SL Machine Specification/ Model Nos. Remarks


by load test


by load test


by load test

9 cutting torch 8 checked to be qualified

10 line-plumb 6


12 grinding machine φ100 12 checked to be qualified

13 electric drill 10 checked to be qualified

14 steel tape 50m 2

15 steel tape 3m 10

16 lifting steel rope every specification some

4.2 safety protection articles

4.2.1 Personal safety protection articles: safety helmet, safety belt, protection goggles,

differential speed self locking safety catches, insulation glove, insulation shoes and etc.

4.2.2 Preparation of safety protection articles in construction area: safety net, safety rail,

safety caution board and etc.

5 Construction condition and preparation before construction

5.1 Power supply and gas arrangement should meet site requirement and make sure

sufficient illumination for night-time working.

5.2 The water wall horizontal buckstay, burner and wind box and etc shall be temporarily

positioned.

5.3 The material of alloy parts including welding joints shall be inspected by spectrum

analysis, and make striking mark on obvious position.

5.4 Check and clean the pipes, header and pipe sockets by compressed air-blowing.




Apply ball-passing test to the pipes and header to ensure clearance. Enclose the pipe and

header immediately after test, and sign the test records.

5.5 Ensure there is sufficient space for equipment stacking and assembly.

5.6 Ensure and keep the equipment transportation passage clear.

5.7 Ensure all the construction drawings are approved ,otherwise the construction should

not be started.

5.8 Ensure boiler suspension devices are erected.

5.9 All other headers above water wall upper header are lifted to position.

6 Construction procedure, method and requirement

6.1 Before water wall erection, temporarily put the horizontal buckstay of water wall on the

girder or platform nearby to its erection position.

6.2 Lift all headers to position and align. Fasten the aligned headers with channel steel

and turnbuckle (lock the header with hoop channel steel. It is strictly forbidden to directly

weld with header). After every dimension accepted, fasten the header tightly by channel

steel. For convenient erection of the radiant reheater located in front flue duct, don’t fix

for the moment the front and left&right water wall ,through which the mentioned radiant

reheater passes to connect with the header, and moreover, trail the down end of upper

parts of front and left&right water wall towards front by 1000mm and fix. Before install

nose of rear water wall, finish installing final-stage superheater and final-stage reheater at

first.

6.3 Before lifting, complete the preparation working including: assembly small pieces of

water wall panel on platform by welding, install the ear lugs and cut slot on the fins by

length of 350～400mm at both end of the panel.

6.4 Take the following steps to erect the water wall panels in turn from up to down:

a. Shift the water wall panel prepared to lift to the floor under furnace by platform truck,

erect and lift it to position by winch and truck crane jointly working with the chain block

hung on the ear lug welded at the end of the installed upside panel.The load imposed on




the two chain blocks should be even. The rated load of the two chain blocks should be

bigger than the weight of the water wall panel. Use another two chain blocks to hang the

panel evenly before releasing the winch.(remark: use two 10T and 5T chain blocks for

panel weighted between 5.1T～10T;and two 5T and 3T chain blocks for pane weighted

between 3.1T～5T ; and two 3T and 2T chain blocks for panel weighted below 3T).

b. Before matching and welding the two panels, recheck the position of the upside one to

ensure it is aligned and fixed.

c. Align the panel prepared to weld to match the upside one on both horizontal and

vertical direction.

d. The joint of pipe orifice should be flat and straight. Any shift, bending or misalignment is

strictly forbidden.

6.5After completing the whole erection of radiant reheater in front flue duct, align and

fasten the upper parts of front and left&right water wall. Take the same method to erect

the middle and down parts of water wall. (remark:the erection of different parts of front、

left&right water wall and radiant reheater should be alternated.）

6.6Align and fix the pipe panel of water wall one by one after lifting to position. Align the

panels before assembling. It is forbidden to weld before all of the panels located in the

same level are assembled. The clearance between each two panels should be strictly

controlled. Cut the fin or insert flat bar when necessary. Pay attention to ensure the

material of used flat bar matches that of the panel. Due to the shrinkage after welding,

broaden the assembly clearance properly to ensure ultimate dimension. Only spot

welding should be applied before completing the whole assembly except at the area

covered by the horizontal buckstay.

6.7 The erection of the horizontal buckstay

6.7.1Temporarily put and fastens the horizontal buckstays on nearby beams or platform at

the same elevation after installing the drum boiler.

6.7.2 Install the temporary shelf of horizontal buckstay on the installed water wall

according to drawing requirements (caution: plus deviation of elevation is not allowed).




Ensure the installation of temporary shelf is checked and accepted by quality assurance

department.

6.7.3 Lift the horizontal buckstay onto the temporary shelf by winch and chain block. Set

up channel steel at shelf outside to avoid the horizontal buckstay falling.

6.7.4 Weld the plate and channel steel tightly by angle steel at the two ends to be integral

with the horizontal buckstay so as to protect the end of channel steel from bending or

deformation during installing the horizontal buckstay.

6.7.5 Adjust the position and elevation of the horizontal buckstay, and then push it

towards and touch the water wall tightly by truss frame、jack and etc. Install comb clips by

welding.

6.7.6 Install the leveling device according to drawings. Pay attention to cater to the

expansion requirement.

6.8 Whole alignment and acceptance

6.8.1 Recheck and adjust the elevation and position of the water wall panels. Assembly

and weld the water wall panels side by side.

6.8.2 After the whole alignment and acceptance of water wall,install the connection

devices at the corner of the horizontal buckstays.

6.8.3 Cut and get rid of all temporarily installed reinforce and burnish the welding and

cutting trace.

6.9 The erection of steam-water connection pipes and downside connection pipes

All the connection pipes are erected separately. Apply ball passing test to each pipe

in vertical position and sign the test record by every parts. For vertical pipe line, assembly

and weld the pipes from two ends to the intermediate point to ensure vertical. Align before

welding, and any shift, deviation, bending or misalignment is strictly forbidden. The

erection of connection pipe and its suspension device should be alternated. Adjust the

suspenders to ensure the load imposed on each suspender is even (remark: check and

judge by shaking with hand or hammer at least three times: 1. after being loaded; 2. after

being filled with water during boiler hydraulic pressure test; 3. during steam sealing test)





7.1quality control standard

7.1.1 Quality inspection and acceptance shall be undertaken on the basis of technical

documents such as drawings, directions etc. For those not mentioned or not detailed in

manufactory technical instructions, please consult this manual.

7.1.2 Construction quality inspection and assess standard

7.1.2.1inspection of heating surface before erection

Quality standard working

procedure inspection items Unit

Qualified

check header and pipe

appearance

no crack, damage, chap, stave, sand hole, bed;

allowable pit depth: pipe ≤10% design wall

thickness, header ≤1mm

header orifice, pipe joint

position and dimension conform with drawing

inside cleaning of header and

pipe joint no dust, rust, seeper, metal scraps and etc

clean pipe inside

outer

diameter pipe（including

header pipe

joint） Wall

thickness

mm conform with drawing

length

width

diagonal

heating surface

tube outer

dimension

burner





procedure inspection items Unit

Qualified

gate hole

material specification of alloy

steel pipe no misuse

ball-passing test for single

heating surface tube

when testing, the ball can pass through the

tube smoothly (for different pipes, different

dimension balls are required)

Ball radius for ball-passing test

outer diameter of ball

bending radius

D1≥60mm 32mm〈D1〈60mm D1≤32mm

R≥3.5D1 0.85D0 0.8D0 0.7D0

2.5D1〈R〈3.5D1 0.85D0 0.8D0 0.7D0

1.8D1〈R〈2.5D1 0.75D0 0.75D0 0.7D0

1.4D1〈R〈1.8D1 0.7D0 0.7D0 0.7D0

R≤1.4D1 0.65D0 0.65D0 0.65D0

Notice:D0 is tube inner diameter；D1 is tube outer diameter；R tube bending diameter

7.1.2.2 Erection of suspension device

Quality standard working procedure

Inspection items unit Qualified

check appearance of parts（lug, suspender,

lifting board, pinned

shaft etc）

there is no damage, crack and double layer etc on

the surface; the surface of thread is complete and

joint well with nut dimension of parts according with drawing

equipment

checking

material of part no misuse





Inspection items unit Qualified

suspender flexure mm ≤1‰ L(suspender), and≤4

manufacture weld accord with drawing

connection of suspension device

accord with drawing

spherical joint face coated with blacklead lubricant

erection height of spring accord with equipment technical document installation

load of suspender load distributed properly

7.1.2.3 Match of heating surface tube


inspection items unit Qualified

groove type accord with drawing

deviation of groove angle degree ≤2.5

D≤60mm ≤0.5

D≤159mm ≤1

159mm＜D≤219mm ≤1.5

groove angle

D＞219mm ≤2

groove

preparation

groove cleaning there is no rust, oil fifth around 10～15mm of inner side and outer side

of pipe end

Misalignment ≤10% wall thickness, and ≤1mm tube

matching bending

mm ≤2/200

7.1.2.4 Erection of water wall Quality standard working

procedure Checking item unit

Qualified





Checking item unit Qualified

deviation of header elevation ±5

deviation of header longitudinal & transversal levelness

≤2

distance error between header longitudinal & transversal centerline

to furnace center ±5

distance error of header centerline ±5

Vertical declination of tube bundle

mm

≤1‰ L and ≤15

clean inside of header no dust, rust, seeper, metal scarps

and etc

connecting device conform to drawing and expand freely

sealing parts conform to drawing, flat, tighten and

no leakage of kerosene test

welding accord with drawing

deviation of burner nozzle

longitudinal & transversal centerline mm ±10

elevation error of horizontal buckstay mm ±5

distance error between horizontal

buckstay to heating surface pipe mm ±5

erection

connection of horizontal buckstay

and water wall

conform to drawing, no mis-welding,

lack of penetration and expand freely

7.1.2.4 Erection of steam water connecting pipe Quality standard working


Qualified

equipment

checking valve checking conform to manufacture






vertical deviation of vertical tube ≤2‰ ,≤15

Dg≤100mm ≤1‰, ≤20 horizontal

pipe flexure Dg＞100mm ≤1.5‰, ≤20

distance deviation between tube

centerline ±5

flatness deviation of tube panel

mm

≤10

suspension device conform to drawing, install tightly to

correct position

valve conform to manufacture requirement

erection

welding conform to manufacture requirement

7.2 Technique discipline and quality assurance measures

7.2.1Check equipment carefully.There are no defects on the appearance of header and

pipe panel such as damage、flaw、distortion、blister、layers; check and ensure the position

and dimension of the pipe orifice and pipe joint of header according with drawings;

recheck the appearance and dimension of pipe panel、screw angle. Check the position of

every opening and the steel parts of horizontal buckstay.

7.2.2 Before erection, clean equipment by air blowing and check the tubes by ball passing

test. Burnish the pipe groove and take enclosure measures. Sign the test and inspection

records.

7.2.3 “Aligning before connection” should be the procedure and principle for connecting

and welding at height. Before welding, align the water wall panels according to the center

line、elevation base line and punch hole marked when assembling on ground platform.

Align every piece of row pipe.

7.2.4 Before welding, align the cooling ash hopper and ensure every cooling ash hopper




is at the same elevation to cater to the erection requirements.

7.2.5 Check the temporary ears one by one after welding. The height of seam must

accord with drawings requirements. Avoid damaging the tubes when cutting away the

temporary ears.

7.2.6 Check and ensure no sundries、rust 、sand and etc exists in tubes. Temporarily cap

the tube orifice during erection process. It is strictly forbidden to leave the upward tube

orifice open.

7.2.7 Ensure the horizontal buckstay expand reasonably. Ensure the welding quality

according to drawings without error or lack of welding. Don’t damage the tubes as

welding the steel parts connected with the water wall.

7.2.8 Adjust and align the water wall panels according to interrelated technic

requirements of manufacturer.

7.2.9 Ensure the header elevation、the space between the water wall panel and steel

structure and the space between the water wall panels each other, adjust if failed to

conform to the requirements.

8 Requirements and measures for safety civilization construction and environment

management

8.2 Workers entering the site should correctly arm with safety protection articles.

8.5 No matter how long will it be stored, the materials, components, etc. should be laid in

order. Rebar、components、steel shuttering、scaffold、sheet、fastener and etc should be

stacked in sort, and underlaid with sleeper. Components should be placed steadily.

8.6 Equipments and trash shouldn’t be stacked too close to building’s wall、rail、trench,

and keep at least 50cm away.

8.7Clean up materials、scraps in time after finishing work. If they can’t be carried away at

the moment, collect and stack them in different sorts.

8.8 Lifting steel rope should be taken back in time after work and stacked in order.

Oxygen cylinders and acetylene cylinders should be placed according to safety

requirement criterions. Oxygen & acetylene pipeline and electric line should be placed in




order and coiled in time after work.

8.9 The welding cables and welding torch pipes on site should be placed reasonably as

per requirement. It should be collected and placed back in order after finishing work.

8.12 Constructor should have the idea of finished product protection and avoiding second

pollution. It is strictly forbidden to removing、scrawling and smearing in disorder.

8.14 Prepare enough illumination establishments in construction area to cater to the

requirements of construction and traffic safety. Keep them work well and adjust according

to project requirement.

8.18It is strictly forbidden to eliminating and removing the safety construction

establishment、civilization construction establishment and fire fighting establishment in

disorder.

8.26 Protect the finished product well. Keep the equipment surface clean from ash and oil.

It is forbidden to scrawl and smear on equipment surface or bases and avoid second

pollution.

8.27 Erect safety caution boards aside the road on extension side, which read :watch out

fire、watch out electric shock、be careful hand、stop、forbid tinder、forbid fire; etc.

8.28 The passage and scaffold can’t be overloaded with equipment or materials.

Construction materials shall be taken and lifted only when it is to be used. Waste material

and scraps ,and etc. shall be placed on firm place and bind tightly to avoid falling down.

8.29 Keep the passage clear at site; set up fence and hang cautious plate at dangerous

exit and entrance. When working at height or in cross working, do not throw tools、

materials or waste materials up and down, but lift by tool bags or hoist buckets. It is

forbidden to stay under materials being lifted.

8.30It is strictly forbidden to randomly removing the safety protection establishment such

as rail、safety net etc. When need to remove, apply to safety supervision department and

recover after work.

Erection Manual of Boiler Heating Surface



130




DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








131

CONTENTS

1 THE BASIS FOR COMPILING THE MANUAL………………………132

2 PROJECT INTRODUCTION AND CONSTRUCTION RANGE……… 132

3 ALLOCATION OF CONSTRUCTION PERSONNEL AND

QUALIFICATION………………………………………………………..……..132


PROTECTION ARTICLES……………………………………………..133


CONSTRUCTION…………………………………………………… .133

6 CONSTRUCTION PROCEDURE, METHOD AND REQUIREMENT….134

7 QUALITY CONTROL AND QUALITY ACCEPTANCE………………. 135


CONSTRUCTION AND ENVIRONMENT MANAGEMENT…………………144




132


1.1 Drawings of division platen SH, rear platen SH, final SH, LTSH, roof SH, rear HRA

wall SH, SH corrosive-proof devices, SH fixed devices, SH header, SH cross tube, SH

inlet & outlet conduit, rear HRA buckstay and level adjusting device. (Shanghai Boiler

Works Ltd)

1.2 Drawings of RH fixed device, RH corrosive-proof device, final RH, platen RH, radiant

RH, RH header, RH cross tube, RH inlet & outlet conduit. (Shanghai Boiler Works Ltd)

1.3 Drawings of economizer fixed device, economizer tube bundle, economizer header.

(Shanghai Boiler Works Ltd)



SH heating surface is composed of 4 parts: the first part is roof and four walls of rear HRA

flue duct; the second part is LTSH located in rear HRA flue duct; the third part is division

platen SH and platen SH located at furnace top; the fourth part is final SH located

between rear HRA extend side wall.

The RH system can be divided into 3 stages according to steam flow in turns: radiant RH,

Platen RH and final RH. Radiant RH is at the inner side of front water and both sides

water, and platen RH and final RH are at the top of nose.

Economizer is at the bottom of rear HRA and divided into 2 stages.

2.2 construction range

Heating surface of SH is: final SH, division platen SH and platen SH, rear HRA wall SH

and buckstay, LTSH, roof SH, crosstube, SH fixed device and SH corrosion-proof device.

Heating surface of RH is: platen RH, final RH, connection tube, RH fixed device and RH

corrosion-proof device.

Economizer: tube bundle, header, fixed device and corrosion-proof device of economizer.


It is prepared by REL at site.




133



S. No Designation Specification/Model Quantity Remarks

1 crawler 150t 1

2 truck crane 50t 1

3 platform trailer 30t 1

4 pulley block 10t 8 checked to be qualified

5 winch 5t 6 checked to be qualified

6 chain block 5t 20 checked by load test is

qualified


qualified


qualified

9 cutting torch 8 checked to be qualified

10 line-plumb 6


12 grinding machine φ100 10 checked to be qualified

13 electric drill 12 checked to be qualified

14 steel tape 50m 2

15 steel tape 3m 12

16 chain block 10T 1 checked by load test is

qualified



speed self locking safety catches, insulation glove, insulation shoes and etc.




5.1 Rigidity girder of inlet header & middle header of economizer, inlet header of radiant




134

RH and front HRA shall be completely deposited.

5.2 Carry out open-package inspection, counting, accepting and numbering as per

material supply list, packing list and drawing, if there is deflection transact Equipment

Deflection Notice and eliminate deflection as per disposal opinion.

5.3 The material of alloy component which includes manufacture welding joint shall be

tested by spectrum analysis, and mark on the distinct place.

5.4 Clean and check inside of pipe, header, and pipe socket and ensure lustration of

inside. Do ball-passing test for pipe, header pipe socket as per Erection Manual and

ensure its smoothness, close nozzle of pipe and header and transact ball-passing vise

after cleaning and ball-passing test.

5.5 Leave sufficient stack space at boiler back side for lifting heating surface of rear flue

duct.

5.6 Keep transportation passage expedite.

5.7 All construction drawings shall be approved; the drawings without approval can’t be

used at site.


6.1 Install the anti-rust device of every part to position on ground.

6.2 Install every suspension device to position.

6.3 Install SH, RH outlet conduit pipe. (First temporarily hang it, and align the pipe after

header is aligned.)

6.4 Install connecting tube from SH, RH, and economizer to drum. (First temporarily hang

it, and align the pipe after header is aligned.)

6.5 Install radiant RH outlet header, inlet & outlet header of rear SH, platen RH, final RH,

final SH, outlet header of LTSH and economizer.

6.6 Install division platen inlet & outlet header, roof SH outlet header, both sides wall SH

header, front wall SH header and roof SH inlet header.

6.7 Install tube bundle of radiant RH（carry out with water wall installation in turns, align

together, align and match inlet header after tube bundle is aligned.）Install RH inlet pipe




135

after alignment.

6.8 Install division platen SH, rear platen SH, platen RH, final RH and final SH tube

bundle, and install roof SH at the same time, finally align together.

6.9 Install tube bundle, rigidity girder and leveling device for extend wall and rear HRA

four side walls. (The right side wall shall be positioned after economizer is lifted)

6.10 Install monorail hoist and electric chain block, test it and check it to be qualified.

6.11 Install economizer suspension tube, LTSH vertical part tube bundle, and install rear

RHA roof at the same time, and align them together.

6.11 Install LTSH serpentine tube bundle by use of electric chain block, lift, align and

match step by step.

6.12 Install economizer middle header and SH inlet conduit pipe after LTSH installed.

6.13 After LTSH is installed, dismantle monorail hoist and chain block and polish the mark.

Install monorail hoist and chain block by use of middle header, and test it before use.

6.14 Lift economizer tube bundle after economizer header is erected.

7 Quality Control and checking

7.1quality control standard

7.1.1 Take manufacture drawing, erection manual and other technical documents as

preferential standard, consult manufacture instruction for tolerance and refer to this

manual if manufacture document is not cleared.


7.1.2.1check heating surface devices before erection



check appearance of header and tube

no crack, contusion, chap, stave, sand hole, delamination; allowable pit depth: tube≤10%

design wall thickness, header≤1mm

position and dimension of header orifice and tube joint

accord with drawing

clean inside of header and tube joint

no sundries such as dust, rust, seeper and

metal scraps




136



clean inside of tube

outer diameter tube（including

header tube joint）

wall thickness accord with drawing

length

width

diagonal

mm

burner

dimension of heating surface

tube gate hole

accord with drawing

material of alloy steel component

no misuse

ball-passing test for heating surface single tube (tube

bundle)

the ball can pass through tube smoothly (for different tubes, different steel ball or leathern

ball is required)

Radius of ball-passing test

outer diameter of ball

bending radius D1≥60mm 32mm〈D1〈60mm D1≤32mm

R≥3.5D1 0.85D0 0.8D0 0.7D0

2.5D1〈R〈3.5D1 0.85D0 0.8D0 0.7D0

1.8D1〈R〈2.5D1 0.75D0 0.75D0 0.7D0

1.4D1〈R〈1.8D1 0.7D0 0.7D0 0.7D0

R≤1.4D1 0.65D0 0.65D0 0.65D0

Notice:D0 is tube inner diameter；D1 is tube outer diameter；R tube bending diameter

7.1.2.2erection of suspension device




137



check appearance of parts（lug, suspender,

lifting board, pinned shaft etc）

there is no damage, crack and double layer etc on the surface; the surface of thread is complete and

joint well with nut

dimension of parts accord with drawing

material of part no misuse

suspender camber mm ≤1‰ L(suspender), and≤4

equipment checking

manufacture welding seam

accord with drawing

connection of suspension device

accord with drawing

spherical joint face coated with blacklead lubricant

erection height of spring

accord with equipment technical document installation

force bearing of suspender

load distributed reasonably

7.1.2.3 Match of pipe



groove type accord with drawing

deviation of groove angle degree ≤2.5

D≤60mm ≤0.5

D≤159mm ≤1

159mm＜D≤219mm ≤1.5

slope of

groove end face D＞219mm ≤2

groove fabrication

groove cleaning there is no rust, oil fifth around 10～15mm of inner side and outer side

of pipe end

pipe miss-match mm ≤10% wall thickness ≤1




138



matching deviation of matching ≤2/200

7.1.2.4 Erection of division platen SH, rear SH, final SH, platen RH, final RH





≤3

distance deviation between header longitudinal & transversal centerline


distance deviation of header centerline

±5

vertical deviation of tube bundle

mm

≤1‰ L，≤15

corrosion-proof device accord with drawing, welding shall be tight and flat and no influence to

heat expansion

erection

airproof parts accord with drawing, flat and fixed

7.1.2.5 Erection of vertical SH





≤3



perpendicularity & levelness deviation of header longitudinal

centerline ±5

erection

clearance between edge pipe and furnace wall

mm

≤1‰l, ≤15




139



downwards expansion clearance of

serpentine pipe bottom elbow

accord with drawing, welding shall be tight and flat and no influence to

heat expansion

7.1.2.6 Erection of horizontal SH





≤3



distance deviation between tube bundle

±5

levelness of tube bundle

mm

≤20

corrosion-proof device accord with drawing, welding shall be tight and flat and no influence to

heat expansion

erection

airproof parts accord with drawing, flat and fixed

7.1.2.7 Erection of roof SH





≤3


to furnace center

mm

±5

space between tubes even

erection

deviation of tube bundle elevation ±5




140



levelness of tube bundle ±5

clearance between edge tube and furnace wall

mm conform with drawing

sealing part conform with drawing, flat and

tighten

7.1.2.8 Erection of economizer header and suspension pipe





≤3

tube perpendicularity

mm

≤5 erection

space between tubes even

7.1.2.9 Erection of economizer Quality standard working


Qualified



≤3



vertical distance deviation between

longitudinal centerline of top & bottom header

horizontal ±5

erection

distance deviation between header centerline to serpentine pipe elbow

mm

±10




141



space deviation between tube bundle

±5

flatness of tube bundle

≤20

anti-corrosion device conform with drawing, welding is

tighten and flat without affection to heat expansion

sealing part mm conform with drawing, flat and

tighten

perpendicularity deviation of side

tube ≤10

clearance between side tube and

furnace wall conform with drawing

7.1.2.10 erection of HRA SH Quality standard working


Qualified



≤2



distance deviation between header centerline

±5

perpendicularity deviation between tube bundle

mm

≤1‰ L, ≤15

join device conform with drawing and expand

freely

sealing part conform with drawing, flat, tighten and no leakage for kerosene test

welding conform with drawing

deviation of rigid girder elevation mm ±5

erection

distance deviation between rigid girder to center of heating surface

tube mm ±5




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connection of rigid girder and HRA

wall

conform with drawing, no mis-welding, miss-welding and expand freely

7.1.2.11 erection of connection pipe for SH, RH and connection of economizer with drum Quality standard working


Qualified equipment checking

valve checking conform with manufacture

perpendicularity deviation of riser ≤2‰，且≤15

Dg≤100mm ≤1‰，且≤20 camber of level pipe Dg＞100mm ≤1.5‰，且≤20

distance deviation between lined tube parts

±5

flatness deviation of tube bundle

mm

≤10

valve conform with manufacture

requirement

erection

welding conform with manufacture requirement


7.2.1 Equipment checking: check quantity of equipment, dimension of every part, and

make good protection for anti-rust, check equipment appearance, if there is defection,

please transact “Equipment Defection Notice” and eliminate defection as per disposal

decision. Serpentine tube bundle and header joint shall be given serial number according

to sequence and marked clearly with paint.

7.2.2 Spectrum analysis: the material of alloy steel part shall be checked with spectrum

analysis and marked on the conspicuous position.

7.2.3 Ball-passing flushing: pipe, header and pipe socket shall be flushed and checked in

order to keep inside cleaning, make ball-passing test for pipe and header pipe socket and

make sure inside is expedite. Close nozzle of pipe and header and transact test vise after

the test.




143

7.2.4 Installation of serpentine tube bundle: erect level LTSH after rear flue duct

subassembly is aligned and accepted and chain block is tested to be qualified. When

install, firstly align and match the above welding seam and then align and match the next

welding seam; after alignment, check and adjust distance between tube bundle and

distance from tube bundle end side to rear wall and front wall.

7.2.5 Pipe joint welding: generally it is aligned by wrapping bandage so as to keep

smooth of pipe inside. After welding start, check stagger and leaning of pipe joint by ruler,

if the stagger goes beyond, timely rework is required.

7.2.6 Alignment of subassembly: align subassembly timely after it is positioned. Take

whole steel structure aligned mark as reference to align subassembly pipe platen, and

adjust elevation and levelness of header. When the first time aligns subassembly, take

+5mm as header center elevation. Temporary fixation of subassembly shall be carried

when the subassembly is aligned, generally [12.6 or upward specification I beam is used

as temporary connection part. In order to ensure stability of subassembly, wrap bandage

at proper place on header and frame column, and temporary connection part is only

welded with bandage. It is forbidden to weld on header and column.

7.2.7 The welding seam on lifting devices shall be checked one by one, the length and

height of welding seam shall conform to design.

7.2.8 The chain blocks shall be checked to be qualified before use, actual load of single

chain block shall be less than 75％ of allowable hoisting capacity, tighten the chain block

when it is not working.

7.2.9 The electric tools and power supply devices shall be checked to be qualified before

use, constructors shall wear safety glasses when they use grinding machine, and wear

safety mask when it is scoop out, it is not allowed to stand within 3m of grinding machine

circumrotated area. The electric grinding head shall be tightly clamped so as to avoid

falling into the pipe.

7.2.10 Make sure there is no sundries, rust slag and sand in the pipe, the pipe nozzle

shall be closed during erection process, and the upturned pipe nozzle is forbidden to




144

open.

7.2.11 the steel rope shall have 10 times safety factor.

7.2.12 the chain block shall be operated by special person, and it is forbidden to lift

inclined. Weld limit channel so as to avoid falling off the chain block and cut off the power

when work is finished.

8 Requirement and measures for safety and civilized construction and


8.1 Wear safety protection devices correctly before going to site.

8.2 All the materials and components shall be stacked according to variety and

specification. They should be stacked in axial parallel and make disorder end face inside

and arrange obvious caution board.

8.3 Every kind of equipment and scrap can’t be stacked close to wall, rail and drain of

buildings, at least 50cm distance shall be left, and both ends of wall and rail shall be

closed.

8.4 Every kind of material and component shall be cleared away when work is finished.

Those can’t be carried away immediately shall be stacked focus with classification.

8.5 The lifting rope shall be taken back after lifting finished, and can’t be left about. The

oxygen cylinder and ethyne cylinder shall be placed as per requirement, the oxygen and

ethyne cable and power cable shall be disposed as per criterion, and coil it on time after

work finished.

8.6 The electric & torch welding cable shall be arranged in order. Collect it with order

before duty off and hang it in order so as to keep site civilization and clean.

8.7 Constructors shall have the consciousness of protecting finished product and

avoiding secondary pollution. It is forbidden to dismantle, take, scrabble and smear

randomly.

8.8 Arrange sufficient illumination devices on construction area to meet requirement for

night construction and safety requirement of passage. Keep illumination devices in good

condition and modulate it on time according to construction requirement.




145

8.9 The safety symbol, civilized construction sign, caution board on construction area

shall be complete and striking.

8.10 It is forbidden to dismantle and move the safety devices, civilized construction

devices and fire-fighting devices randomly on construction site.

8.11 It is forbidden to discard the deletery solid castoff, liquid castoff randomly; it shall be

stored in designated place with classification.

8.12 The passage and scaffold can’t be carried with over its allowable hoisting capacity

things, construction materials shall be lifted when it is required to use. The spot welded

components can not be moved when working at height; the cut parts and corner wasted

material and etc shall be placed on firm place or bind tightly by galvanized iron wire in

order to avoid falling down.

8.13 Keep the passage on construction site expedite; set up fence and suspension

caution board on the entrance and exit of danger area. It is forbidden to throw tools,

materials and corner wasted material up & down, it shall be lifted by tools bag or hoist

bucket. It is forbidden to catch material and stay under lifted material.

Erection Manual of the coal bowl mill



146




DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








147

Contents

1、The basis for compiling the manual……………………………………148 2、Compiling purpose……………………………………………………… 148 3、The general situation and work quantity……………………………. 148 4、The resource allocation………………………………………………… 149 5、Construction procedure and method………………………………… 151 6、Construction record……………………………………………………… 151 7、Quality standard and control………………………………………..… 162 8、The protection measure of safety and environment……………… 163




148

1、The basis for compiling the manual

1.1 The erection drawings and directions of HP1103 bowl mill (shanghai heavy machinery

factory)

1.2 The erection of boiler accessory (southwest electric power design institute)

2、compile purpose

The purpose of this manual is to improve the erection technics and quality of the coal mill

and to enhance control of working procedure. This manual, only used for the erection of

bowl mill of boiler unit 1# and 2# in hisar 2×600MW thermal power plant ,mainly aims

at describing the erection technics and quality requirements, and the required resource

allocation、necessary tools &machines and observing safety items and etc. for completing

the construction. This manual is compiled based on the documents on hand, and if

drawings、documents are updated later, follow the updated technical requirements to

perform the installation and commissioning.

3、The general situation and work quantity

3.1 The general situation of equipment

PAF forced air blowing type pulverized coal system is adopted in hisar 2×600MW

thermal power plant. Each boiler is equipped with 8 HP1103 medium speed mills made in

shanghai heavy machinery factory. All mills are layed at the floor of bunker bay located at

both sides of boiler.

The erection range should include 16 mills for 2 boiler units,and division of work should

be as follow: motor baseplate、reducing gear baseplate、alignment and leveling of mill’s

side body baseplate; speed reducer、side body device 、milling bowl’s apron case device、

milling bowl shell、impeller、grinding roller 、air seal、spring device、inverted cone、

separator body、Venturi device、head cover device、discharge valve device、the erection

of lube station、pipeline and accessory; Whole set adjustment.

3.2 Main parameters

Mill type HP1103




149

Maximum output 75.3t/h

Maximum air rate 130.8t/h

Maximum resistance 4.5 Kpa

Rotary speed of the grinding bowl 30.18r/min

Reduction box KMP300

Driving mode of the reduction box wo-stage drive of spiral bevel gear and epicyclic gear

Drive ratio 29.748

Motor YHP560-6

Rated power 750kw

Rated rotary speed 978rpm

Power voltage 3300V

Power frequency 50HZ

Rotary direction counter clockwise while facing the

shaft extension end of the motor

4、Resource allocation

4.1Allocation of man resources and qualification requirement

No. Post Skill

Requirement Qty Remarks

1 Team leader Senior 1

With erection and management

experience of the same type

machine

2 engineer engineer 1

With erection technic and

management experience of the

same type machine

3 member secondary 10 With erection experience of the

same type machine

4 rigger 1 With interrelated certificate




150

No. Post Skill

Requirement Qty Remarks

5 welder 4 With interrelated certificate

4．2 Machines、tools for construction

No. Equipment name spec Qty Remark

1 Truck crane 25t 1

2 winch 5t 1

3 Hoisting device for mill

maintenance 1

4 Platform truck 25t 1

5 Oil-jack 10t 1～2 checked to be

qualified

6 Hand chain block 3 t、5 t Each 2

7 Steel ruler 1m 1～2

8 precise manometer Y150 0～

1.6MPa 2

With Precision rank

0.4 （ each step

0.005MPa）

9 micrometer 0～10mm 6

With Precision

0.01mm ， require 2

small size instrument

10 Frame leveller precision

0.02mm 1

checked to be

qualified

11 Frame level gauge Precision

0.01mm 1

checked to be

qualified

12 Vernier caliper 1 checked to be

qualified




151

No. Equipment name spec Qty Remark

13 Common fitter tool 2 checked to be

qualified

14 Levelling instrument 1 checked to be

qualified

15 Level pipe 1

16 Feeler gauge Each kind 2

17 Line plumb 2

18 Magnetic instrument set 6

19 Steel tape 5m 1

20 Steel tape 50m 1

21 Steel leveller 1

5、Construction condition and preparation before construction

5.1 Approved construction drawings and technical documents are all ready, and the

workers have been acquainted.

5.2 Tools&machines and materials used for construction are all ready.

5.3 The received order and time of equipment cater to the continuous construction

requirement.

5.4 Mill civil foundation have been checked and accepted.

5.5 construction passages are clear and cater to the equipment erection and transport

requirement.

5.6 water、electric power and gas for construction are all ready.

5.7 Platform、walkway and stairs are clear. Safety rail and caution boards are all ready.

5.8 hoisting equipments for mill maintenance have been checked and accepted.

6、The construction procedure、method and requirement

6.1Work flow:

Count and number equipment components、check appearance→ foundation recheck and




152

acceptance→ foundation lineation→ shimplate allocation→ leveling and alignment of

baseplate→ reduction box erection→ erection of side body and lining board→ erection of

grinding bowl、grinding bowl shell and impeller→ erection of apron shell and clearance

adjustment of inner air seal→ erection of air seal → erection of separator、inner cone

and the head cover of separator→ erection of grinding roller （remark:it is also feasible to

lift the grinding roller into the side body and install it inside before performing the previous

step）→ erection of motor→ erection of lube system and cooling water system.

6.2 The construction procedure and method

6.2.1Equipment count and checking

6.2.1.1 Ensure there are no any surface defects causing strength influence on equipment

such as air hole、flaw and looseness and etc.

6.2.1.2 The position of fixing hole and expansion hole of baseplate should conform to the

provision of equipment technical document.

6.2.1.3 Ensure the worm wheel and worm in reduction box mesh well. Any crack、dirt and

rust on the machined surface is not allowed. Check and ensure butter protection for worm

wheel assemblies is in normal condition.

6.2.1.4 Check and ensure that the outer diameter and aperture, etc. of the equipment

components conform to the deviation tolerance requirements as shown on the drawings

and make records.

6.2.1.5 connecting bolts of each connecting parts of grinding bowl、each lining board of

side body and other connecting parts should be tighten

6.2.1.6 The separator baffleplate should run smoothly, and all of the baffleplate opening

angle should be the same and consistent with the opening angle indicator.

6.2.1.7 The center coal falling pipe shall be vertical to the surface of the flange connected

with separator.

6.2.1.8 No any sundries in the oil tank of the hydraulic power station are allowed.

6.2.2 The foundation acceptance and lineation




153

Check and accept foundation according to the drawings from design institute. The

acceptance of civil foundation should accord with the requirements of drawings and

equipment technical document. Any civil foundation failed to meet the requirements

should be mended. After accept foundation, perform foundation lineation.

6.2.3 Lifting and transportation of the coal mill

The mill equipments should be mainly transported to bunker bay by truck. Use the

hoisting establishment for mill maintenance to position and erect. Before lifting each part

of the coal mill, get familiar with its actual weight shown in the mill erection directions. The

mill erection should be from bottom to top, firstly install the side body and its downside

parts, including gear box、side body device and etc, secondly install separator and

grinding roller, finally install the top cover and outlet of separator、discharge valve and etc.

6.2.4 The installation of the anchor bolt

The anchor bolts of mill have been embedded in foundation. When check and accept

foundation, ensure the anchor bolts are vertical and concentric with the bushing. Keep the

bushing clean from any sundries so as to ensure mill expand freely. Keep the bushing

away from water、sundries to avoid concrete cracking caused by freezing.

6.2.5 The installation and adjustment of the baseplate of reduction box and baseplate of

side body

6.2.5.1 Before positioning the baseplate of reduction box and side body, roughen the

foundation by depth of about 25mm, and the roughened area should be 5-10mm wider

than shimplate on each side. Dispose formal shimplates following the principle as below:

1、on load concentrative position

2、on both sides of anchor bolt of baseplate

3、the distance of each two nearby shimplate groups should be 300-700mm

6.2.5.2 According to the mill general assembly drawings, lay the baseplate on foundation.

Pay attention to ensure the position and orientation of the sliding baseplate and fixed

baseplate.




154

6.2.5.3 Dispose temporary shimplates at proper position under baseplate. Pay attention

to keep away form the formal shimplate position. Use bevel shim plate to align all of the

baseplates and adjust the elevation to meet the requirements of mill general assembly

drawings.

6.2.5.4 After adjustment, spot weld the two parts of pair bevel shim plate to avoid sliding.

Pretighten the anchor bolt of the gear box and side body by hand.

6.2.6 The installation of gear box

6.2.6.1 Clean the bottom surface of gear box and the top surface of baseplate.

6.2.6.2 Coat slightly the bottom surface of gear box and guiding rail with light oil. Before

installing gear box, check and ensure the two pins have been installed in the connection

flange, and the extension length of the pins should be 15.24±0.38 mm.

6.2.6.3 After lifting the gear box in position, install the eight adjusting plate on baseplate.

6.2.7 The installation of side body and its lining board

6.2.7.1 Clean the bottom surface of side body and the top surface of baseplate, and

slightly coat the two surfaces with light oil.

6.2.7.2 Istall the side body and its lining board on baseplate ensures that the air inlet is in

correct position as shown on mill general assembly drawings. Install the pin stop of

baseplate.

6.2.7.3Align and centralize the gear box and side body by adjusting plate (refer to the

special tool drawings). At the time, don’t fix or pin the gear box.

6.2.7.4 According to the manufacturer torquemoment requirement, fix tightly the side

body on bearing plate.

6.2.8 The installation of the grinding bowl, grinding bowl shell and impeller

6.2.8.1 Clean the touch surface of apron shell of grinding bowl hub. Dispose the

quartered apron shell surrounding the inner wall of lining of the side body.

6.2.8.2 Remove the wearable cover from grinding bowl hub.

6.2.8.3 Use grinding bowl hoisting device to lift the grinding bowl in position. Clean the




155

bottom surface of grinding bowl. Slightly coat the surface touching the gear box with light

oil.

6.2.8.4 Lower the grinding bowl device into side body and lay it on the gear box. Dowel

pins should be correctly positioned and aligned (remark: one dowel pin deflects from

center line). Caution: if the oil box of gear box is empty, don’t turn the input shaft of gear

box as aligning the dowel pin. Before turning the gear by hand, pour gear oil into oil box of

gear box to the level as required so as to avoid damaging the thrust bearing or other

bearings in gear box.

6.2.8.5 Coat the thread of the eight bolts, which are used to fix the grinding bowl shell on

gear box, with thread binding agent. The thread length screwed into the connecting flange

of gear box should be 76mm.

6.2.8.6 Fix hexagon nut and washer (coated with anti-lock glue) and use socket key to

tighten the bolt nuts.

6.2.8.7 Use the special hydraulic pretightening device from factory to pretighten the bolt

by three steps following the sequence as shown in the right sketch.

1 tighten the bolts one by one by pretightening force

11.2Mpa(10,500Kgf）following the sequence.

2 Repeat steps 1, tighten bolts by 26.2Mpa (24,500Kgf)

3 Repeated step1, tighten bolts by 37.37Mpa (35,000Kgf)

6.2.8.10 Coat the grinding bowl cover and the grinding bowl

with sealing glue and fix the wearable cover. Tighten the

tighteners as per factory torquemoment requirement.

6.2.9 The apron shell device and inner air seal clearance

Remark：Before installation, supply lube into the oil box of the gear box to the working oil

level.

6.2.9.1 Align the quartered parts of the apron shell and joint them firmly along the

perimeter of the grinding bowl hub. Ensure the quartered parts are installed and aligned




156

at radial symmetry position by tightener and dowel pin supplied together with apron shell.

Flange with bolt hole should be installed with the bolt hole opening downward.

6.2.9.2 Erect one adjusting bolt on each quartered part, and use these adjusting bolts to

support and lift the apron shell device of grinding bowl hub. Measure the clearance

between apron shell device of grinding bowl hub and air seal ring of side body. Use sheet

pack to adjust the clearance to be 0.5-1.6mm.

6.2.9.3 Install the sheet pack and fix the apron shell on grinding bowl hub. Tighten the

bolts as per factory torquemoment requirement.

6.2.9.4 Remove and mark all of the lifting bolts and one quartered apron shell.

6.2.9.5 Check the clearance between apron shell and inner air seal ring to meet the

requirement as shown in mill general assembly drawing. During the erection procedure,

assembling and disassembling of the apron shell may be repeated for several times to

ensure the above mentioned clearance.

6.2.9.6 Turn the grinding bowl by 120° by turning the input shaft of gear box by

hand .Recheck the clearance between apron shells and air seal ring at the same point. If

the clearance reading is consistent with the latest measured value, tighten the fastener of

air seal ring as per factory torquemoment requirement. Caution: before turning the gear

box by hand, pour gear oil into the oil box of gear box to the level as required so as to

avoid damaging thrust bearing and other bearings in gear box.

6.2.9.7 Reerect all the parts of apron shell and tighten the fastener according to the

drawing B-GP-2175.

6.2.9.8 Adjust and fasten the scraper device and its shield on apron shell device by

hexagonal screw. Check and ensure the distance between scraper and the bottom cover

of side body is 8±1.5mm. Weld the scraper device on apron shell.

6.2.10 Fix the gear box

6.2.10.1 Fix the gear box on the baseplate by tightening the bolts as per torquemoment

required by the manufacturer. Don’t forget to coat the thread with anti-lock lube before




157

tightening the bolts.

6.2.10.2 Ream the original pin eye to enlarge the diameter from 1.33 inch to φ38±0.012

mm. Coat the dowel pins with MoS2 grease before pressing them into pin eyes.

6.2.11 Install the air seal

Perform air seal erection only after the lube system is ready to be used.

6.2.11.1 Clean the surface of all the parts planned to erect, and then assemble them

according to factory assembly drawing.

6.2.11.2 Insert one piece of 0.5mm sheet copper into the space surrounding the

pulverizing bowl hub.

6.2.11.3 Insert the sealing elements steadily, and tighten the bolts.

6.2.11.4 Remove the sheet copper. Check and ensure the clearance is 0.5mm.

6.2.11.5 Start the lube system, and recheck the clearance while turning the grinding bowl

shell. End the adjusting job only if the clearance at any point surrounding the grinding

bowl hub is about 0.5mm.

6.2.11.6 After completing the clearance adjusting, tighten the bolts according to

torquemoment required by the manufacturer. Don’t forget to coat the thread with

LeiTai271 binding agent before tightening the bolts.

6.2.12 the installation of the separator body

Because the weight of separator is quite heavy, take measures to ensure safety during

erection.

6.2.12.1 Lay the separator body on sleeper with the bottom flange downward. Clean the

bottom flange of the separator and the top flange of the mill side body.

6.2.12.2 After cleaning, coat the flanges with anchor brand 609 sealing glue. Lift the

separator body onto the mill side body. Align the separator body to ensure its center line

matchs that of the mill side body so as to ensure the air inlet、grinding roller through hole

and coal powder pipe in right position.

6.2.12.3 Fix the separator body onto the mill side body by tightening the bolts as per the




158

torquemonent value required by the manufacturer. Don’t forget to coat the thread with

LeiTai277 thread binding agent before tightening the bolts.

6.2.12.4 Adjust the lining board of the separator to ensure that the clearance between its

bottom edge and the adjustable shell of impeller of grinding bowl is 13±1.5mm. After

adjustment, spot weld the nuts with bolts.

6.2.13 the installation of the inner cone and the upper cover of separator

The Inner cone and the upper cover of separator are preassembled and marked in factory.

When installing at site, please pay attention to the marks.

6.2.13.1 Clean the flange joint face of separator upper cover and that of the separator

body, and then coat the joint faces with anchor brand609 sealing glue.

6.2.13.2 Place the inner cone into the separator body with the sharp end downward and

support it vertically and firmly. Align the cone to ensure its access door coaxial with that of

the separator body.

6.2.13.3 Lifting the upper covers onto the separator body, and align it by the guiding mark

(one M20 thread hole). Fix by tightening the bolts as per factory required torquemoment

value. Coat the thread with LeiTai277 thread binding a

6.2.14 The installation of the Venturi device and the multi-outlet device of the discharge

valve.

6.2.14.1 Clean all of the joint faces of the components planned to erect, including all

flange surface and inner wall of holes. Coat all of the joint faces with anchor brand609

sealing glue.

6.2.14.2 Ring the coal feeding pipe of the Venturi device with the inverted cone to the

point as high as possible and fix it by screws.

6.2.14.3 Mount the venturi device on multi-outlet of the discharge valve. Align it by the

guiding marks (two reticles) to ensure the erection position correct, and then fasten with

bolts according to factory required torquemoment value. Coat the thread with LeTai271

thread binding agent before tightening the bolts.




159

6.2.14.4 Mount the multi-outlet device of discharge valve on the separator’s upper cover

and align it by the guiding mark. Fasten with bolts according to factory required

torquemoment value. Coat the thread with LeTai271 thread binding agent before

tightening the bolts.

6.2.14.5 Open the access of the inner cone, and check and ensure that the distance

between the top of the inner cone and the bottom of the coal feeding pipe is 115mm.

6.2.14.6 Loose and let the inverted cone slide down to the position 76mm away from the

top of the inner cone. And then weld the inverted cone on the coal feeding pipe.

6.2.14.7 Connect the center coal feeding pipe to the multiple outlet discharge valve.

6.2.15 the installation of grinding roller

6.2.15.1 Remove the end covers and the thrust plates and withdraw the trunnion.

6.2.15.2 According to factory general assembly drawings, assemble the grinding roller

head device. Insert the trunnion of the grinding roll into the trunnion bearing. Pay attention

to the orientation and position of the both trunnion bearings. Replace the trunnion end

cover and thrust plate.

6.2.15.3 When the assembly of all components has been finished, carefully turn the

grinding roller back to the grinding bowl. Pay attention to prevent it from impacting on the

grinding bowl’s lining plate and adjust the space between them to 3～5mm(in working

status).

6.2.16 the installation of the side covers of grinding roller and spring

6.2.16.1 Preload the spring with preloading force 27.5MPa (18,144kgf) by the spring

preloading device supplied by manufacturer, and then locks it firmly. The spring’s

compression length should be 26.9mm. Due to the travel limit of the hydraulic cylinder of

the spring preloading device, the preloading procedure should be performed by several

steps. And due to the pressure loss, the reading of the pressure gauge should be 28Mpa

to get 27.5MPa preloading force on the spring device.

6.2.16.2 Clean the joint face of the grinding roller side cover and the side flange of the




160

separator, and coat them with anchor brand 609 sealing glue.

6.2.16.3 Assemble the limit draw rod of grinding roller and lock the locknut.

6.2.16.4 Vertically lift the grinding roller side cover to the position that the height of the

limit draw rod of grinding roller is 50mm higher than that of the grinding roller end. And

then travel close to the side flange of the separator slowly. Ensure the limit draw rod of

grinding roller is guided into the slot in the grinding roller end.

6.2.16.5 Fix the side cover by tightening the bolts according to factory required

torquemoment value. Coat the thread with LeTai271 thread binding agent before

tightening the bolts

6.2.16.6 The space between the spring device and the roller should be 1-1.5mm.

6.2.17 the installation of motor

6.2.17.1 Install half coupling separately on the input shaft of gear box and the output shaft

of motor. Heat the coupling in heated oil before connect it to the shaft to get tight joint.

6.2.17.2 Clean the anchor bolt hole, and then position the generator and its baseplate on

foundation. Apply 1mm stainless steel sheet between generator and baseplate. Perform

preliminary alignment by temporary shimplate.

6.2.17.3 After connecting the extension shaft, align the coupling. The disalignment error

and end surface declination of coupling of generator and gear box should not exceed the

specified value of the manufacturer.

6.2.17.4 First grouting the anchor bolt.

6.2.17.5 Install coupling shield (fix with expansion bolt).

6.2.18 the allocation of formal shimplat and final grouting of base

After completing the erection of mill proper and generator, go on formal shimplate

allocation and the final grouting.

6.2.18.1 Dispose and seat permanent shimplate with grouting. Check the clearance

between shimplates each other or between the shimplate and baseplate with feeler and

ensure the normal result reading not exceed 0.05mm while partial reading not exceed




161

0.10mm.

6.2.18.2 Each group of shimplate is generally made up of three shimplates (one is flat

shimplate, while the other two are beveled shimplates pair), while partially not exceed 5

pieces. The specification of shimplate should be as follow: width 100mm, length

180mm, the gradient of beveled shimplate 1:10 with featheredge thickness 5mm.

6.2.18.3 After the acceptance of shimplate allocation, spot weld at its side to avoid sliding,

and then go on the final grouting.

6.2.19 Tighten the anchor bolts

After the final grouting base fully solidified, tighten the anchor bolts by special hydraulic

bolt tightening device.

6.2.19.1 Tighten the anchor bolt of reducing gear box: tighten the anchor bolts of reducing

gear box diagonally by two steps by tightening device provided by factory. Take first step

with tightening force 16.36Mpa, while the second step with tightening force 37.12Mpa

(681KN).

6.2.19.2 Tighten the anchor bolts of the side body: tighten anchor bolts of the side body

diagonally by two steps by tightening device provided by factory. Take first step with

tightening force 16.36Mpa, while the second step with tightening force 37.12Mpa(681KN).

6.2.19.3 Recheck the coupling center of the motor and the reducing gear box to ensure it

is accepted, and then tighten anchor bolts of motor and install dowel pin on diagonal

position of baseplate.

6.2.20 the installation of the lube syetem of gear box

6.2.20.1 Place the lube set of gear box on erection base. After leveling and aligning, fix it

by expansion bolts.

6.2.20.2 Install the pipeline connecting the lube set to the gear box. The installed pipeline

should be tidy and in beautiful appearance. The slope angle of the sloping return oil pipes

should conform to factory requirement. Take measures to ensure the oil pipes clean.

6.2.20.3 Erect the cooling water pipes according to drawings. Apply hydraulic test to the




162

oil cooler of lube set by 1.25 times of working pressure or 1.25 times of rated pressure

shown on the data plate.

7、Quality control and acceptance

7.1 Quality control standards

Technical documents such as drawings, instructions and etc from manufacturers should

have the first priority for quality control and inspection.

7.2 Inspection point

7.2.1 Witness points: oil tank cleaning、oil cooler hydraulic test 、oil flushing

7.2.2 Halt points:

7.2.2.1 closure of the manhole of oil station(hidden work)

7.2.2.2 clearance adjusting during the bowl mill proper installation

7.2.2.3 closure of the manhole of the bowl mill(hidden work )

7.2.2.4 Coupling and bearing alignment

7.2.2.5 Shimplate allocation (hidden work)

7.3 Technic discipline and quality assurance measures

7.3.1Properly dressed before entering site. Protect the installed equipment to avoid

damage.

7.3.2 The arrangement of oil pipe should be reasonable and artistic, conforming to

technics requirement. Cap the pipe orifice in time to ensure the system clean.

7.3.3 Respectively lay the disassembled parts in special box. Carefully pack and protect

the precise part and don’t press or lose.

7.3.4 Don’t use flat spade、file etc. to get rid of rust on precisely processed surface and

don’t get rid of oil by fire

7.3.5 It is forbidden to randomly ignite arc or spot weld on equipment.

7.3.6 Get signed agreement before close any access door.

8 、 Requirement and Measures for Safety and Civilized Construction and





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8.1 Workers entering site should dress properly and wear safety helmet. Wear soft sole

shoes and put on life belt when working at height.

8.2 Persons not concerned should not be allowed to enter the construction site.

8.3 When lifting equipment, it is strictly forbidden to stay under the boom or the lifting

equipment. Take care to avoid impacting other equipments or materials.

8.4 When using grinding machine or electric welding torch or cutting torch etc., wear

goggles to protect eyes. Tie the hose of cutting torch tightly.

8.5 Avoid electric shock when using electric tools.

8.6 Don’t wear glove when using hammer. Avoid falling due to losing balance when using

crowbar.

8.7 Keep the construction site clean and clean away trash and waste materials in time.

The seal Erection Manual of boiler



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DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








165

CONTENTS

1 The basis for compiling the manual………………………………………166

2 Project introduction and construction range………………………….. 166

3 Construction personnel and qualification……………………………….166


construction…………………………………………………………………….. 166

5 Construction condition and preparation before construction ………167

6 Construction procedure, method and requirement………………….… 167

7 Quality control and quality acceptance ………………………………..…169

8 Requirement and measures for safety civilization construction and

environment management ……………………………………………..…170




166


1.1 seal device (drawings from Shanghai Boiler Works Ltd.)


2.1 General construction

The boiler in hisar 2×600MW thermal power plant is designed and produced by shanghai

Shanghai Boiler Works Ltd., whose seal include top seal, tail seal, furnace nose seal,

radiant reheater through water wall seal, furnace arch area seal and etc.


Boiler seal construction rang of hisar 2×600MW thermal power mainly contain top seal,

tail seal, furnace nose seal, radiant reheater through water wall seal, furnace arch area

seal. Except top seal, other parts are called bottom seal.

3 Construction personnel and qualification

Prepared by REL at site


construction


No. Machine spec qty remark

1 Chain block 2t 10 load test is qualified

2 Chain block 1t 10 load test is qualified

3 Cutting torch 8 checked to be qualified

4 Electric welding machine 10 checked to be qualified

5 Grinding machine φ100 8 checked to be qualified

6 Electric grinding machine 8 checked to be qualified

7 Steel tape 50m 2



speed self locking safety catches etc.




167


etc.


5.1 All the drawings have been proved before construction. Deal with the discoverable

problems by normal rules in time. Don’t use unproved drawings in construction.

5.2 The erection of water wall, superheater and reheater have been completed and

accepted.


6.1 Work procedure flow chart:

Count equipment R→number equipment、pipe correction→alloy steel parts optical

checking R → the primary seal of roof pipe, weld seal parts with heating face parts →

furnace seal→ H →perfect roof primary seal→ W（hidden surface work visa） →

hydraulic test of boiler monolithic→seal the place where top suspension device through

roof→the second seal of roof and water wall→seal in furnace arch area→ H →take

concerted construction with boiler wall to perform roof seal→ quality acceptance W


6.2.1 Equipment count

All the equipment should be counted, numbered, checked and sorted. Alloy parts perform

spectral analysis. Due to the big amount and multiformity, count fenders carefully to make

the later work convenient.

6.2.2 Erection

6.2.2.1 Roof primary seal

Primary seal is hidden surface work. In construction process, don’t miss and burn-off

bearing parts. Complete the checking and acceptance of roof pipe cross joint. Perform

primary seal after erecting roof fixing device.

6.2.2.2 Furnace seal

After completing the joint and alignment of water wall, perform splicing work. Weld on




168

both sides as splicing slot, whose thickness can’t less than fim’s. Due to splice many

place of water wall, do checking carefully to avoid neglect. Because nose fender’s

configuration is complex that is difficult to be installed, seriously collate the drawings in

construction.

6.2.2.3 The second seal of roof

The second seal of roof and the embedded work of high pressure pipe welding should be

completed after the erection of roof pipe and roof fixing device and before the hydraulic

test of boiler. After finishing the embedded work of roof primary seal and the second seal,

passing the hydraulic test of boiler, finishing heat insulation and filling work, perform the

second seal of roof.

6.2.3 Central construction points

6.2.3.1 Sealing erection should construct according to drawings, which is between roof

and water wall, at the places through water wall. Ensure the sealing quality, especially at

the border place.

6.2.3.2 Seal in tail shaft HRA tubes area, pay attention to its erection order. When some

parts need to assemble on the ground, perform seal or assemble the seal component.

6.2.3.3 Seal in furnace nose area and at the place of radiant reheater through water wall,

pay attention not to exist the place that block seal and leak smoke

6.2.3.4 Seal in furnace arch area, due to much work, should be patient and careful in

construction. Due to the high temperature in this area, choose the proper welding rod to

weld alloy plate. Perform sealing work before erecting wind box. Close both ends and

don’t weld the plate covered with small expansion joint.

6.2.3.5 After finishing the construction of seal device and before insulation, seriously

inspect the construction quality of hidden surface work. After the acceptance, do the

hydraulic test and insulation construction.

6.2.3.6 Insulation material at expansion joint position can’t influence the free expansion of

expansion joint.




169

6.2.3.7 After finishing the erection of seal device, exist the handing over problems of

working procedure with insulation construction team, fill in handing over form of working

procedure after acceptance according to procedure.



7.1.1 Quality checking should be on the basis of technical documents such as drawing,


clear.


The erection of boiler seal parts


procedure Checking items unit

qualified

Parts (framework, seal

plate etc)erection position

and dimension

Conform to design

Seal parts surface flexure ≤5

The level degree deviation

of local seal part joint

mm ≤5

Seal plate open pipe hole Opening position and dimension is proper,

enough space for pipe expansion

Bolt connection

Connection is firmly, the revealable thread

length is uniform. Full welding at bottom of

component inside, the amount and position of

bolts and nuts accord with design requirement

The connection of self

tapping bolt

Bolts are not loose and fallen, amount and

position accord with design requirement




170


procedure Checking items unit

qualified

Thermal expansion

checking

Enough space for expansion. No error and

leaking welding


7.2.1 The parts’ erection position and dimension conform to the requirement of drawings.

Welding curve is uniform without dregs and air hole.

7.2.2 Don’t force to joint seal plate. Position and dimension of opened hole is proper.

Enough space for expansion.

7.2.3 Hanger rod connection is firm, and bearing force is moderate.

7.2.4 Enough space for thermal expansion, no error and missing welding phenomenon.

7.2.5 Technics and appearance is tidy and artistic.

7.2.6 All the seal should meet the requirement of expansion and seal.

7.2.7 All confined ducts connected with seal welding parts, should be welded by qualified

high pressure welder. When weld seal, don’t damage confined ducts.

7.2.8 Quality checking and working procedure on each construction stage of boiler top

seal should be qualified, and take corresponding checking notes and transact visa

procedure.

7.2.9 Self-checking and acceptance should be practical and realistic.



8.1 All the tools should be in good condition, which can be normally operated and used.

8.2 Optimize construction environment at high. Scaffold should be fixed and has rail.

Worker should tie the safety belt tightly. Properly keep the tools and materials to avoid

falling down.

8.3 Temporary illumination line at site should be frequently checked and maintained.

Exposed electric welding line and power line should be repaired or replaced.




171

8.4 Check chain block and wire rope before using. Chain block don’t overload and

hoisting chain don’t flex.

8.5 When erect equipment, protect it from collision, extrusion and fall.

8.6 Set up protection and isolation establishment in cross construction to avoid fallen

thing injuring person.

8.7 When carry equipment, pay attention not to be injured.

8.9 Insist on civilization construction. Live up to work finish, material out and site clean.

8.11 Stack each kind material and component according to its variety and spec. stack

them in line with clear label, laying untidy side towards inside.

8.13 It is forbidden to randomly remove safety protection establishment such rail, safety

net and etc. when they have to be removed, get application to interrelated department,

but resume after completing work.

The erection manual of air preheater



172




DOCUMENT TITLE:

The erection manual of air pre-heater


REV. NO. :0

ENDORSEMENTS





The erection manual of air preheater



173

CONTENTS

1 The basis for compiling the manual………………………….174

2 Project introduction and construction scope………………174

3 Construction personnel and qualification………….…….…174

4 Necessary machine & tools and safety protection facilities

during construction……………………………………………… 175

5 Construction condition and preparation before

construction………………………………………………………..176

6 Construction procedure, method and requirement….……176

7 Quality control and quality acceptance………..……………182

8 Requirement and measures for safety civilization

construction and environment management…….….……….183




174


Factory drawings, technical document of air preheater and general layout drawing of

boiler

2 Project introduction and construction scope


2-29VIT (65)-2185(2438) SMRC trisector air preheater made in Shanghai Boiler works

limited is applied in hisar 2×600MW thermal power plant. It is made up of cold end

connecting plate, hot end connecting plate, center section of cold end connecting plate,

center section of hot end connecting plate, pocket ring assembly and sealing spool of cold

end, pocket ring assembly and sealing spool of cold end, rotor post, rotor(module),

support bearing, guide bearing, casing, pin rack and driving device, main pedestal

assembly and expansion assembly, primary air section pedestal, side pedestal and

expansion assembly, heat transfer element, sealing assembly and etc.

Pin rack circle driving device furnished with one main motor, one auxiliary motor and one

pneumatic motor is applied to the air pre-heater. To keep long-term, safe and steady

operation, the air pre-heater is furnished with fire fighting water system, water flushing

system, support bearing and guide bearing lube oil system, hot end clearance follow-up

device, soot blower, fire alarm system and system halt alarm device and etc.

3 Construction personnel and qualification No Post Skill requirement Qty Remarks

1 Team leader senior 1 With interrelated management experience

2 Team engineer engineer 1 With erection technical and

management experience

3 member senior/middling 8 With erection experience of air preheater

4 rigger 2 With interrelated qualification and With lifting experience of air preheater

5 welder 4 With interrelated qualification




175


construction


No Equipment name spec Qty Remarks

1 Crawler crane 150t 1

2 Special tools provided by

air preheater factory 1

3 Truck crane 50t 1


5 Oil-jack 10t 1~2 checked to be qualified

6 Electric spanner 1 Match with each spec

sleeve

7 Steel ruler 1m 1~2

8 scraper 6

9 Precision pressure gauge Y150

0~1.6MPa 2

Precision is 0.4 grade(each

scale is 0.005MPa)

10 leveler 0~10mm 4 Precision is 0.01mm，require

2 small size instrument

11 Frame leveler 1 checked to be qualified

12 Common fitter tool 2 checked to be qualified

13 Level pipe 1

14 feeler Each kind spec 2

15 Line plumb 2

16 Steel tape 5m 1

17 Steel tape 50m 1

18 Steel level 2




176

4.2 Preparation of safety protection articles.

4.2.1 Personal safety protection articles: safety helmet, safety belt, goggles etc;


etc.


5.1 Approved construction drawings and technical documents are all ready and workers

engaged are trained.

5.2 Tools & machines and materials used for installation are all ready.

5.3 Equipment received order and date caters to the continuous installation requirement.

5.4 Platform, columns, beams and vertical braces located at furnace rear vertical flue

pass and at the same elevation as that of air preheater, which will interfere with the lifting

of air pre-heater components, should not be installed at the time.

5.5 Passageway is clean and caters to the equipment erection and transport requirement.

5.6 Platform, walkway and stairs are clean. Safety rail and caution board are all ready.

6 The construction procedure, method and requirement

6.1 Foundation lineation: determine the position centerline of air preheater according to

boiler general layout drawing and air preheater general layout drawing. Check elevation

and level of beams which support air preheater.

6.2 Install expansion device, cold end center section, support bearing, cold end pocket

ring、main pedestal assembly and primary air section pedestal.

6.2.1 According to the general drawing of air preheater and centerline determining

procedure, determine and mark all centerlines for equipment required to be centered.

Locate expansion device on support beam.

6.2.2 Adjust expansion devices up to required elevation using spacer plates. Ensure each

expansion device at the same level with level deviation within ±2mm.

6.2.3 Weld the bedplate of expansion device on boiler steel structure.

6.2.4 Install cold end center section on expansion device (lugs on center section should




177

be used only to lift center section and any other use is strictly forbidden) and tighten the

binding bolts.

6.2.5 According to manufacturer drawings, install support bearing onto bearing pedestal

of cold end center section. Adjust the bearing pedestal to ensure the elevation of support

bearing conform to requirements. Adjust spacers under support bearing and check the

level of support bearing at four points with direction angle 90°apart from each other to

ensure support bearing slope within 0.4mm/m.

6.2.6 According to the requirements of manufacturer drawings, install main pedestal

assembly and primary air pedestal assembly on corresponding center section pocket ring

with center deviation not exceeding ±2mm. Use temporary brace to fix pedestal

assemblies mentioned above with cold end center section (It is forbidden to weld

temporary brace on sector plate or pedestal circular plate). Weld pedestal assemblies

mentioned above on cold end center section.

6.2.7 According to the interrelated manufacturer drawings, install support bearing lube oil

system.

6.3 Install rotor post, hot end center section, guide bearing subassembly, air seal

subassembly and seal spool.

6.3.1 According general assembly drawing of air preheater and centerline determining

procedure, position the related components.

6.3.2 According to the requirement of related manufacturer drawings, assemble the guide

end axes and rotor post to be an integrated part.

6.3.3 Before locating rotor post on support bearing, remove the protection cover on

supporting flange and clean the contact surface to get rid of impurity, blur, burr, oil, dirt

and etc.

6.3.4 According to the requirement of related manufacturer drawings, locate rotor post on

support bearing without damaging any other parts.

6.3.5 Protect the bearing with plastic cloth to keep away from foreign materials such as




178

dust and etc. until the rotor post is completely installed.

6.3.6 Adjust the rotor post to basically vertical position. Then fasten it with temporary

support.

6.3.7 According to the requirement of manufacturer drawings, install hot end center

section with the guide end axes passing through its center hole. Vertically locate the hot

end center section on corresponding hot end pocket ring of main pedestal and primary air

pedestal. After alignment, weld it according to the requirement of drawing.

6.3.8 According to the drawing requirement, install the guide bearing, and position the air

seal subassembly.

6.3.9 Remove all temporary support from the rotor post.

6.3.10 Getting rid of sundries such as grease on the end surface of rotor post and clean

specified area prior to leveling the rotor post. Put frame leveler at proper place of rotor

post (point at rotating centerline). Turn the rotor post assembly and measure the slope

after each 90°turn. Ensure the slope not exceed 0.40mm/m by adjusting the guide

bearing pedestal.

6.3.11 According to the requirement of drawings, install hot end static seal assembly.

Adjust concentricity of the static seal assembly and rotor post and ensure the deviation

conform to the requirement of factory drawings.

6.3.12 According to the requirement of drawings, install cold end static seal assembly.

Adjust the coaxiality, height and clearance of cold end static seal assembly and rotor post

to conform to requirement. Then temporarily connect with cold end center section by spot

welding.

6.3.13 Erect the guide bearing lubricating device.

6.4 Erect side pedestal and its expansion device.

6.4.1 According to the requirement of drawings, determine the installation position.

6.4.2 Position the expansion device of side pedestal, and adjust it up to the required

elevation specified in manufacturer drawing using spacer plate. And then weld the




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bedplate of expansion device on steel structure.

6.4.3 According to the requirement of drawings, install the side pedestal and fasten it with

temporary support. The top flange of side pedestal should not be welded until the

installation of rotor modules is completed.

6.5 Install the cold end pocket ring and its brace pipes.

6.5.1 According the general drawing of air preheater and the centerline determining

procedure, determine the erection position of cold end pocket ring.

6.5.2 According to the requirement of drawings, erect the cold end pocket ring. After

positioning and aligning, fasten it by bolts and weld it according to drawing requirements.

6.5.3 According to the drawings, erect brace pipes. Don’t weld it with static seal assembly

now (perform welding after the adjustment and fixation of static seal assembly). Prior to

installing the brace pipes, check and ensure the cold end pocket ring is temporarily

assembled using temporary brace bars and the radius error conform to the factory

requirement.

6.6 Installation of driving device side shell assembly, proper housing shell segments, side

pedestal and hot end rigidity ring and brace pipes.

6.6.1 According to the requirements of drawings, determine the erection position and

locating center line of the driving device side shell assembly, proper housing shell

segments and side pedestal.

6.6.2 According to drawings requirements, locate the driving device side shell assembly,

proper housing shell segments and side pedestal, which make up of the middle shell of air

pre-heater together with main pedestal assembly and primary air pedestal assembly.

Fasten them with temporary support if necessary.

6.6.3 Align and adjust side shell of drive device, the assembly of side shell and auxiliary

bracket plate, make the elevation, level, roundness and leveling degree of whole middle

shell conformed to the requirement of drawings.( erect shell’s access door after finishing

the erection of heat transfer element).




180

6.6.4 Erect the side support of driving device, and ensure its center line conform to the

requirement of drawings. Weld it with cold end pocket ring. Fasten the pocket ring with

temporary support.

6.6.5 According to the interrelated manufacturer drawings, install hot end pocket ring.

After aligning and accepted, fasten it with bolts and weld it according to the requirement

(caution: don’t weld side pedestal assembly and area for lifting module on shell). Until

now, hot end pocket ring located at the place of main pedestal and primary air pedestal

has been installed.

6.6.6 Install brace pipes between the hot end pocket ring and the hot end seal spool.

Don’t weld brace pipes with hot end seal spool at this time (weld after adjustment and

fixation of static seal assembly is completed). Prior to installing the brace pipes, check

and ensure the hot end pocket ring is temporarily assembled using temporary brace bars

and the radius error conform to the factory requirement.

6.7 Erect flue angle, connection plate, flange and tension ring.

6.7.1 According to the requirement of drawings, determine the erection position of cold

end flue angle and connection plate.

6.7.2 Erect the tension ring of cold end connecting plate taking advantage of brace pipes,

and ensure the outer diameter of cold end connecting plate equal to that of transition ring.

6.7.3 According the requirement of drawings, erect the cold end corner on shell plate.

Before welding, ensure the opening dimension and elevation conforms to the requirement

of drawings. Then erect flanges. If necessary, perform proper cutting.

6.7.4 Erect the tension ring of hot end connecting plate taking advantage of brace pipes,

and ensure the outer diameter of hot end connecting plate equal to that of transition ring..

6.7.5 According the requirement of drawings, erect the hot end corner on shell plate.

Before welding, ensure the opening dimension and elevation conforms to the requirement

of drawings. Then erect flanges. If necessary, perform proper cutting.

6.8 Erect rotor modules, semi modules, heat transfer elements, pin rack circle and driving




181

device, water flushing pipes, fire fighting pipes, soot blower and fire alarm device etc.

6.8.1 Remove shell and hot end pocket ring segments located between side pedestals. At

the same time, perform final welding to all other parts.

6.8.2 Remove temporary brace bars that interfere with the erection of rotor modules.

6.8.3 According to the requirement of drawings, erect rotor modules and semi modules

according to specified order. Adjust the rotor’s level, roundness and elevation up to the

requirement of drawing. If rotor modules are planned to be installed from one side, just

reserve access place for module installation at one side.

6.8.4 According to the requirement of drawings, erect heat transfer elements

6.8.5 Prior to erecting pin rack circle according to related assembly drawings, recheck the

rotor’s level, roundness and elevation and complete the final location of guide bearing.

6.8.6 Erect driving device (caution: prior to positioning and installing reducing gear, check

and ensure its rotating direction is consistent with that of the rotor).

6.8.7 Prior to seal welding, adjust the height and coaxiality of the cold end static seal

assembly up to the requirement of drawings according to the assembly drawing of end

axis.

6.8.8 Re-erect the shell and pocket ring segments temporarily removed for convenience

of modules erection.

6.8.9 Erect water flushing pipes, fire fighting pipes, soot blower and fire alarm device.

6.9 Erect the angle steel of rotor, sealing angle steel, sealing sector plate, radial seal plate

and by-pass seal plate.

6.9.1 According to the requirement of radial seal subassembly drawing, erect angle steel

of rotor, sealing angle steel, sealing sector plate and radial seal plate.

6.9.2 According to the requirement of axial seal subassembly drawing, erect axial seal

plate.

6.9.3 According to the requirement of by-pass seal plate subassembly drawing, erect

by-pass seal plate.




182

6.10 Adjust sector plate, radial seal plate, axial sector plate, axial seal plate and by-pass

seal plate. Erect static seal assembly.

6.10.1 According to seal erection and adjusting drawings, erect radial seal straight edge

assembly and axial seal straight edge assembly.

6.10.2 According to seal clearance drawing (in the manual of erection, operation and

maintenance), adjust each seal plate.

6.10.3 After finishing adjusting and positioning of sector plate and seal spool, install static

seal assembly both on cold and hot end according to static seal assembly drawing.

6.11 Erect accessories, air seal pipe, rotor halt alarm device, manhole door, access door,

platform, ladder etc.



The above erection procedure maybe has some difference with the manufacturer

manual of erection, operation and maintenance. At that time, the manufacturer manual

should have priority.

7.2 inspection points

7.2.1 Witness points: base lineation, erection and alignment of support bearing and guide

bearing, leveling rotor post, check of rotor level and roundness,

7.2.2 Halt points:

7.2.2.1 Close manhole door (hidden work)

7.2.2.2 The adjustment of sealing clearance (H point).


7.3.1 Technics discipline

7.3.1.1. Protect the installed equipment from being damaged.

7.3.1.2 The arrangement of oil (water) pipe should be reasonable and artistic and

conform to technics requirement. Cap the pipe orifice in time to ensure the system clean.

7.3.1.3 Respectively put the disassembled parts in special box. Carefully pack and




183

protect the precise part and don’t press or lose.

7.3.1.4 Don’t use flat spade, file etc. to get rid of rust on precisely processed surface and

don’t get rid of oil by fire.

7.3.1.5 It is forbidden to randomly ignite or spot weld on equipment.

7.3.1.6 Get signed agreement before close any access door.






equipment. Take care to avoid impacting other equipments or materials. Using specified

lifting ear supplied along with the equipment to lift big components such as cold center

section、rotor post and end axes subassembly, hot center section, rotor modules and

driving device, etc.





crowbar.

8.6 When install or check seal assembly inside air pre-heater, use power not exceeding

36V for illumination and don’t turn the rotor by motor but by hand. It is strictly forbidden to

use 250V power for illumination.

8.7 After finishing the erection of cold end connecting plate, laid safety net under the

connection plate in time. After finishing the erection of heat transfer elements, pave thin

plate or sheet iron above it to avoid being blocked by sundries

8.8 Use pneumatic motor to drive the rotor of air preheater. Don’t operate without

adequate lubrication.

Erection Manual of Fuel Oil Pipe



184




DOCUMENT TITLE:

Erection Manual of Fuel Oil Pipe and Device


REV. NO. :0

ENDORSEMENTS





Erection Manual of Fuel Oil Pipe



185

CONTENTS

1 THE BASIS FOR COMPILING THE MANUAL…………………………….186

2 Project introduction and construction range …..…………………… 186


QUALIFICATION ………………………………………………………………...186


PROTECTION ARTICLES……………………..……………………………… 186


CONSTRUCTION……………………………………………………………….. 187

6 CONSTRUCTION PROCEDURE, METHOD AND REQUIREMENT…… 187

7 QUALITY CONTROL AND QUALITY ACCEPTANCE…………………… 190


CONSTRUCTION AND ENVIRONMENT MANAGEMENT ……………… 196

Erection Manual of Fuel Oil Pipe And Device



186


1.1The pipe laying of plant（Southwest Electric Power Design Institute）

1.2 The fuel oil pipe of boiler（Shanghai Boiler Works Ltd.）

2 Construction Range

Answer for the erection of the pipe laying of plant, the fuel oil pipe of boiler and the

equipment and pipeline in front of boiler.

3 Allocations of Resources and Manpower Qualification




No. machines Spec qty remarks

1 Autocrane 25t 1

2 Chain block 1t 4 Load test is qualified

3 cutting torch 4 With certificate and

qualified

4 Line-plumb 2

5 DC electric welding

machine 2

With certificate and

qualified

6 AC electric welding

machine 2

With certificate and

qualified

7 grinding machine φ100 4 With certificate and

qualified

8 electric drill 4 With certificate and

qualified

9 Steel tape 50m 1

10 Steel tape 3m 2





187

4.2.1 Personal safety protection articles: safety helmet, safety belt, eye shield etc；


etc.


5.1 Related construction drawings should be approved, it is strictly forbidden to use

drawings without approved.

5.2 Pipe trench and rack for common piping can be erected after civil work is accepted.

5.3 Hydraulic test should be taken after system erection work is checked and accepted,

and go along system blowing after hydraulic test is up to the standard, and then start oil

circulation.

5.4 Worker should be familiar with drawings and interrelated technical requirement.

5.5 Workers should prepare the tools before working.

5.6 Valve used for pipe system shall be checked to be qualified after reparation and

pressure test.

5.7 Construction water and power supply shall meet project requirement.

6 Construction Procedures, Method and Requirement

6.1 flow chart of construction procedure

Hanger & supporter erection

Tubing

Receive & count of equipment and material

Explain technic

Pressure test of system (W point)

System blowing out (W point)

Check and accept (W point)




188


6.2.1 Check the equipment and material after received, examine and check whether pipe

material is rusty and deformed, valve & pipe piece and other equipment are well. Report

to the leadership on time when find any problem.

6.2.2 Tubing and erection

6.2.2.1 Do sandblasting of the inner wall of tube to get rid of rust before erection. Clean

out the sand and other sundres inside tube before pipe matching, especially the ground

assembled tubes, and opening jaws should be closed in time.

6.2.2.2 Try best to assemble small caliber pipe, pipe pieces and valve of the operating

platform in the front of boiler at site, after that close the nozzle and transport to boiler.

Install supporter & hanger before install pipes to be convenient for pipe matching.

6.2.2.3 Oil pipe is required to use pure argon, therefore, the rust around 15mm of pipe

nozzle has to be cleared away and reveal metal polish.

6.2.2.4 Before joint two big caliber pipes make sure spot welding around is tighten. Start

weld when it is confirmed there is no stagger.

6.2.2.5 First fix the main pipe as installing oil pipe, and then install other branch pipes;

please consult to drawings when connect pipe joints of every area so as to avoid error.

6.2.2.6There shall be 3‰ gradient of the pipe and gradient direction is to drain and fuel

outlet point. Drain and fuel outlet point shall be at the lowest position of pipe.

6.2.2.7 In principle, there is one drain point of steam main pipe in every 50mm and one oil

delivery & return pipe purge in every 50m. 15 drain point and 4 oil discharge point in all is

considered.

6.2.2.8 Open the pipe and make sure there are no sundries inside, then match the pipe

nozzle; besides, try best to finish opening hole work before close pipe.

6.2.2.9 Layout of tubes such as drain pipe, blowdown pipe can’t affect passage, and the

routing shall be concise and beauty.




189

6.2.2.10 Length of the tubing short pipe shall be longer than pipe outer diameter and

longer than 150mm, and the distance from welding joint to hanger’s edge shall be more

than 50mm.

6.2.3 Erection of valve, pipe pieces and other equipments

6.2.3.1 All the valves should be cleaned up and tested pressure. The testing pressure is

1.25 times of nominal pressure, the valves shall be closed after pressure test.

6.2.3.2 Dn50 and small valves shall be jointed with tube after added with shimplate on

ground; when add flange shimplate, please tighten bolt after it has been pulled in right

position, and bolt tighten shall ensure cross line is in symmetrical; after bolt tighten, the

exposed thread is 2～3, for the hexad bolt, their facing direction shall be the same.

6.2.3.3 Pay attention to the flowing direction when install valve, valve disposal at platform

should be correct and lined to be easy for operation and repairing.

6.2.3.4 Make good coverage protection measures for the easily damaged equipments

such as imported valve and etc.

6.2.3.5 Make sure construction position meets drawing requirement when install ignition

oil gun and the oil gun can move flexibly and freely.

6.2.3.6 Consider the expansion quantity when install oil gun metal tube so as to make

sure the tube is level during commission; the tube can’t be bended overage during

erection.

6.2.3.7 Disposal of flange joint part couldn’t block passage and shall be easy to remove.

In principle, it shall be levelly collocated.

6.2.3.8 Pay attention to the flowing direction of medium when install compensator.

6.2.4 Supporter & hanger erection

6.2.4.1 Erection of supporter &hanger should be strictly distinguished to be three kinds:

fastness, slippage, and guiding so as to avoid wrong erection.




190

6.2.4.2 Make sure supporter &hanger is erected horizontally and vertically, and bear

equal force. Make sure fixed supporter is fixed tightly, gliding supporter glide freely and

guiding supporter move flexibly.

6.2.4.3 The spring locating stud of spring supporter &hanger can be removed after pipe is

installed and supporter &hanger beared force.

6.2.4.4 When install hangers where expansion displacement tubes are fixed, the hangers’

base should be shifted about expansion quantum to the reverse position of expansion

direction.

6.2.4.5 The self-made hangers can’t be opened by torch welding. It should be drilled by

machine and the end of cut profiled bar shall be polished.



7.1.1 Quality checking shall priority take technical document such as drawing, directions

etc. For those manufactory technical requirement is not cleared, consult to this manual.


7.1.2.1 Erection of flue heater and filter

Quality standard Working


qualified

heater appearance

flat, clean, without flaw and rust,

flange combined surface without

run-through nick

padding and dope as per drawings

gas tightness test hydraulic test is qualified under 1.25

working pressure , keep 5 minutes

heater

erection

deviation of centerline mm Accord with design requirement




191



qualified

expansion clearance with

pedestal hole

anchor

bolt expansion direction with

pedestal hole

Accord with design requirement

Equipment checking

Without flaw, inside clean, density of

filtrating net accord with drawing

requirement, and flat without

damage

sealing padding and dope

Sealing surface is clean, no rust, pit

scar; padding and dope accord with

requirement

Filter

erection

Air valve, oil stain valve installation No leakage, operate flexibly

7.1.2.2flue duct installation in boiler room



Qualified

factory process component According to the design request

Surface quality According to the design request Construction

preparation Inside quality According to the design request

Add air ＜±15 mm

channel ＜±15 mm

deviation of

tube

elevation Cover under ground ＜±25 mm

Coordinate

and

elevation

checking Vertical pipe

mm

≤2/1000mm

≤15 mm

Pipe matched pipe inside checking clean without sundries




192



Qualified

Dn＜100 ＜1mm flatness of

joints Dn≥100 ＜3mm

matching

and welding

seam

checking

Space between welding seam to its

bending point ＞pipe outer dia,＞100mm

Space between welding seam and

the hole ＞50mm

Space between the two welding

seams ＞pipe outer dia，＞150mm

Space between the welding seam

to edges of supporter &hanger

mm

＞50mm

Pipe

matching

and welding

seam

checking

Welding seam checking According to the design request

check inside of connecting pipe clean without sundries

screw

thread

connection Connecting matching

screw thread without snaggletooth,

burr, length according to

requirement, joint well, use correct

coating material, and remain 2～3

thread

Inner connecting pipe checking According to the design request

The gradient of flange end surface ≤1mm

Flange

connection

flange shimplate mm

According to the design request,

cannot use double layer shimplate,

and coat the non-oil tube with black

lead, inner diameter of shimplate

shall be 2～3mm bigger than pipe

inner diameter




193



Qualified

bolt, nut

material and specification meet

design requirement, the direction

shall be same, stress equally, and

expose 2-3 thread, coat the thread

with black lead or supramoly

Valve inner checking

clean before install, connect

naturally without punchy

connection, the valves which will

dismantle and check and do gas

tightness test shall meet design

requirement

Erection position and direction

correct direction, position conform

to design and commission

requirement

Valve connection

connect tightly, shimplate is in right

position and tightly, and upright

with pipe centerline

Valve

erection

operator

operation system works flexibly

and correctly, angle between

driven rod and valve rod shall be

bigger than 30°

speed reducer no jam and operate freely

operation switch device no jam and switch freely

Electric

valve

adjustment journey control device operate freely, switch creditable




194



Qualified

torque restriction device Protecting action exact and

credible

opening scale indicator device Indication position correct

The position of Cold-drawn jaws According to the design request duct

Cold-drawn Cold-drawn numerical value According to the design request

pipe pedestal Accord with design provision

Duct installation

Duct dispose reasonably, gradient

is not less than 2/1000,with good

heat compensation measures

Valve installation Installation is firm, the position is

easy to operate and repair

drain pipe

erection

hangers & support; base distance According to the design request，

artistic technics.，welding is firm

Earthing set fastness，artistic technics，accord

with design request Fuel oil pipe

earthing Earthing resistance According to the design request

tightness

test tightness test

checked to be qualified under 1.25

times working pressure hydraulic

test




195



Qualified

hydraulic

test hydraulic test

As per design drawing, work at

1.25 times of working pressure

when there is no requirement and

keep for 5mins. For those can’t do

hydraulic test or difficult to do, if it is

double welded or arc welding and

the welding seam is qualified to

NDT, it is allowed to escape

hydraulic test.

7.1.2.3 Oil, gas pipe installation in plant area（ditto）

7.1.2.4The erection of fuel oil pipe and steam pipe（ditto）

7.2 technics discipline and quality pledge measure

7.2.1 Check the material’s disfigurement and report the problem in time.

7.2.2 Clean out pipe inner sundries before installation. In principle, don’t open hole on the pipe which

has been erected on equipment. Transact visa procedure under the special circumstances. Duct

blowing must transact visa.

7.2.3 All the valves except adjusting valve, fast valve, and magnet valve must be repaired

with disassembly and tested pressure.

7.2.4 All the shimplate used on fuel oil pipe shall be metal wrapped shimplate.

7.2.5 The bending diameter and stretch length of auto-bended same diameter bender

shall be the same, and the angle shall as per design drawing.

7.2.6 Oil discharge port couldn’t connect with the whole plant water drainage system; oil

discharge and water drainage port couldn’t face to buildings and equipment; the types of l

water drainage operation platform should keep in consistent.

7.2.7 Supporter & hanger should be erected firmly, be level and vertical and bear force

averagely.




196

7.2.8 There shall be no side bend after pipeline installed, and the pipeline shall be in one

line and no stagger.

7.2.9 Valve and oil gun shall operate freely without getting jammed after erection.

7.2.10 Metallic tube and other import equipment should be properly maintained and kept to avoid to be

mangled by electric welding.



8.1 Tools, components, materials should be placed at the stated position at construction

site according to the layout.

8.2 Lifting steel rope should be taken back in time after work and stacked in order.

Oxygen cylinder acetylene cylinder should be placed according to safety requirement

criterion. Oxygen & acetylene pipeline and electric line should be placed in order and

coiled in time after work.

8.3 The electric, welding cable on site should be placed reasonably as per requirement. It

should be collected and placed back in order after finishing the work.

8.4 Constructor should have the idea of finished product protection and avoiding the

second pollution. it is strictly forbidden to removing、taking scrawling and smearing in

disorder.

8.5 there should be no rubbish on the construction site; every construction ground shall

be clean and tidy without oil dirt, seeper, yarn, clout, welding rod, useless steel and etc.

Clean site everyday before duty off and keep construction site “work finish, material out

and site clean”.

8.6 there should be enough illumination in working area to ensure safety requirement for

night construction and traffic at night. Keep lighting establishment well and adjust

according to project requirement.

8.7 Construction area should definitely plot out non-smoking area and set up

non-smoking area and no dog-end on the ground.

8.8 Safety sign, civilization construction sign, warning and caution board should be




197

complete and clear in every construction area.

8.9 Plot out clearly of civilization construction area without dead angle and carry out

responsibility. Every kind of machine, equipment and material should be uniformly

managed by hanging brand.

8.10 It is strictly forbidden to randomly removing safety construction establishment,

civilization construction establishment and fire fighting establishment in construction site.

8.11The passage and scaffold can’t be carried with over its allowable hoisting capacity

things, construction materials shall be lifted when it is required to use. The spot welded

components can not be moved when working at height; the cut parts and corner wasted

material and etc shall be placed on firm place or bind tightly by galvanized iron wire in

order to avoid falling down.

8.12 Keep the passage on construction site expedites; set up fence and suspension

caution board on the entrance and exit of danger area. It is forbidden to throw tools,

materials and corner wasted material up & down, it shall be lifted by tools bag or hoist

bucket. It is forbidden to catch material and stay under lifted material.

The Scheme for boiler hydro test



198




DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








199

CONTENTS

1 Basis for preparation and quoted standard……..………… 200

2 Project general situation and scope of hydro test…………200

3 Controls of Water Source, Temperature, Quality &

Consumption……………………………………………………… 201

4 Equipments and tools for construction and safety protection

articles………………………………………………………………201

5 Test condition and preparation before test …………….… 203

6 Construction procedure, method and requirement………206

7 Quality control and acceptance…………………………..… 210

8 Requirement and measures for safety civilization

construction and environment management……..…………212

9 Attached drawings………..……………………………………214




200

1 Basis for preparation and quoted standard

Technical documents and drawings provided by Shanghai Boiler Works Ltd.

2 Project general situation and scope of hydro test

2.1 Project general situation

The boiler of the 2×600MW thermal power plant at Hisar India is sub-critical Π type with

primary intermediate reheat, tangential firing, control circulating drum. Hanging structure

of boiler is adopted in arrangement. The total water capacity of boiler heating surface is

800m3，in which 1005m3 for economizer and water cooling system, 425m3 for superheat

system and 235m3 for reheat system.

2.2 Scope of Hydro Test

The scope of boiler hydro test is including all the pressure parts and assistant piping and

valves at the front of primary valves. The test shall be carried out on two systems:

Primary system：from blank of feed water pipe at economizer inlet to hydro test blind

valve of main steam piping (including economizer, drum, water wall, superheater and

assistant piping & valve system at the front of primary (such as valves air, drainage,

sampling, chemical dosing and sewage valves system) and instrument tubes.

Secondary system：from hydro test blank at inlet of wall reheater to hydro test blind

valve at outlet of reheater finish ( including wall reheater, reheater platen, final reheater

and assistant piping & valve system (such as water drainage & vent, air valves &

instrument tubes at the front of primary valves).

As per the regulation of Shanghai Boiler Works and requirements of Owner, the hydro test

pressure for primary system shall be 1.5 times of drum’s working pressure, and for

secondary system shall be 1.5 times of the pressure at wall reheater inlet, that is:

Primary system：Drum’s working pressure × 1.5=19.79×1.5=29.69Mpa

Secondary system：Pressure at wall reheater inlet × 1.5=4.35×1.5=6.53Mpa




201

3 Controls of Water Source, Temperature, Quality & Consumption

3.1 Water for hydro test shall be DM water taken from water treatment plant. Feed

chemicals into temporary water tank and then heat, and feed the mixing water from

temporary water tank into boiler when the water quality and temperature are qualified.

3.2 Water temperature：As regulation of Shanghai Boiler Works, water temperature for

boiler hydro test shall be not less than 20℃。However, for the material of drum is SA 299,

the water temperature for hydro test shall be not more than 50℃ according to the

requirements of Shanghai Boiler Works. Considering that it will take long time (approx.

4hours) to boost and lower down the pressure, the water temperature inside of drum shall

be kept at 20℃~50℃ before starting boost pump to boost the pressure of primary

system.

3.3 Water quality: Add 10ppm ammonia and 200ppm of hydrazine into DM water. PH≥

9~10，the concentration of chlorine ion shall be not more than 0.2mg/L.

3.4 Water consumption: 770m3 water is for primary system,

235m3 water is for secondary system.

At least 1300 M3 of DM water shall be provided during the period of boosting pressure.




1 Welding machine 5 pieces Checked to be qualified

2 F type wrench 10 pieces Checked to be qualified

3 grinding machine φ100 3 pieces Checked to be qualified

4 Electric grinder 3 piece Checked to be qualified

5 Pressure gauge Y100 0~2.5MPa 1 piece Local pressure of compressed air

6 Pressure gauge Y250 0~40MPa 2 piece Outlet of drum and

superheater

7 Pressure gauge Y250 0~40MPa 0.4grade 1piece Outlet of pressure testing pump




202


8 Pressure gauge Y150 0~10MPa 1 piece Outer of reheater

9 Pressure gauge Y150 0~10MPa 0.4grade 1 piece Outlet of pressure testing pump

10 Pressure gauge 300ｍ3 2 pieces

11 Feed water pump Head: 150～200m One piece Checked to be qualified

12 electric pressure

tester 0～50MPa 2 pieces

Checked to be qualified

13 air compressor 8㎏/cm2，9ｍ3/min 1 piece

14 adjustable wrench 12” 10 pieces Checked to be qualified

15 adjustable wrench 15” 4 pieces Checked to be qualified

16 Valve wrench 10 pieces Made in site

17 flashlight 30 pieces

18 interphone 20 pieces

19 temperature

indicator 0~100℃ 2 pieces

20 Infrared

thermometer 1 piece

4.2 List of materials to be used in hydro test

S. No Designation Specification quantity remark

1 Gate valve

PN4.0，DN150 2pieces Match flange and connecting parts

2 stop valve PN4.0，DN150 1 piece 3 Check valve PN4.0，DN100 1 piece 4 stop valve PN4.0，DN100 3pieces

5 stop valve

PN10，DN100 1 piece Behind check valve

6 Gate valve PN4.0，DN200 2pieces Match flange and connecting parts

7 stop valve PN32， DN20 2pieces 8 stop valve PN32， DN32 4pieces 9 Needle type valve PN32 ，DN10 3pieces 10 Needle type valve PN4.0，DN10 1 piece 11 stop valve PN4.0，DN50 5 pieces




203

S. No Designation Specification quantity remark 12 Reducing tee DN32×10×32，PN32 3 pieces 13 Reducing tee DN100×32×100，PN10 2 pieces 14 Reducing tee DN32 ×32 × 32，PN32 1 piece 15 Heat pressing angle fittings PN4.0，DN200 6 pieces 16 Heat pressing angle fittings PN4.0，DN100 25 pieces 17 Heat pressing angle fittings PN4.0，DN150 30 pieces 18 Heat pressing angle fittings PN4.0，DN50 12 pieces 19 Heat pressing angle fittings PN10，DN100 6 pieces 20 Seamless steel pipe φ219×6 50m 21 Seamless steel pipe φ159×4.5 50m 22 Seamless steel pipe φ108×4 15m 23 Seamless steel pipe φ57×3.5 60m 24 Seamless steel pipe φ42×5.5 200m 25 Seamless steel pipe φ16×3 6m

#20

26 ammonia N2H4.H20 Kg 40% 27 hydrazine NH3.H2O Kg 25%

Remark: this material form is made by estimate. Add or reduce as per actual circs at site;



speed self locking safety catches, insulation glove, insulation shoes and etc.



5 Test condition and preparation before test

5.1 In boiler proper range, complete the erection of steel structure for bearing weight,

steel structure erection is all ready. Complete final fastening of all high strength bolts.

Cutting, burnishing and patching paint work of temporary welding parts on steel structure

have been completed.

5.2 Stairs, platforms and rails are already perfected; all passages can be passed, plates

are all ready. Leave enough expansion space for expansion part. Expansion indicators

have already been installed. Welding parts are up to the requirement.




204

5.3 The main pipe line of boiler steam & water system can be connected: Primary system:

from blank of feeding water pipe at economizer inlet to hydro test blind valve of last-stage

superheater outlet extension; Secondary system: from hydro test blank at inlet of wall

reheater to hydro test blind valve at outlet of reheater finish.

5.4 Complete all the joint welding and NDT of heating surface equipments, which are

qualified.

5.5 Accessories of boiler pressed parts have already been installed (including soot blower

hole, inspection-hole, manhole, thermal measurement point, expansion indicator,

heat-insulating hook and etc).

5.6 Complete adjustment of suspending device on the boiler top, and ensure hanger bar

bear force uniformly. Before feeding water, use bolts or locating plates to temporarily fix

constant spring hanger, variable spring hanger, butterfly spring hanger, which are

temporarily used to be rigidity hanger.

5.7 All the fixed device and anticorrosion device of boiler proper have been installed.

5.8 Primary seal parts of boiler seal device have been installed and welded. Finish filling

seal bar in boiler wall. The welding of sealing seam has been completed. Complete

welding on anticorrosion device, heat-insulating hook, opening seat, thermal

measurement point and etc, whose appearance are up to requirement. Complete incision

of all the temporary parts of bearing pressure parts and polish them, whose surface is not

under base material and base materials haven’t been damaged.

5.9 Complete spectrum rechecking of all boiler alloy parts, which take part in hydro test,

and they been verified without error. Boiler sundry pipes have been installed (including

complete the erection of drainage, air, sewage, sampling at primary and secondary

valve).

5.10 Complete hydro gauge of water tank at primary and secondary valve.

5.11 Thermal sampling instrument pipes must be installed at primary valve. Complete

erection of temperature component.




205

5.12 Feeding water, boost pump’s maintenance, erection and tentative operation have

been completed. Complete the erection of hydro temporary system and check to be

qualified.

5.13 Complete the erection of main steam extending pipe, extending pipe of reheater cold

reheating section, extending pipe of reheater hot reheating section and respective

supporter & hanger in block valve of hydro test.

5.14 Don’t insulate and paint for bearing pressure welding seam on equipments,

components and pipes in hydro test range and other inspected parts.

5.15 Build firm safety protection establishment in boiler range and ensure enough

illuminance for boiler platform on each floor and furnace.

5.16 Quantum of DM water can be insured and its quality is qualified with eligible report,

whose water quality shall be up to requirement as follow: chloride ion content is less than

0.2mg/L; hydrazine content is 250-300mg/L; PH value is 10-10.5(adjust by ammonia),

water temperature is controlled between 20~50℃. When carry out hydro test, wall

temperature of drum must not less than 21℃.

5.17 Condensate make-up water tank’s inner is cleaned, and the pipes connected with it

have been installed.

5.18 Deal with defects in construction and transact visa.

5.19 Air compressor can be normally used at site. Complete erection of temporary pipes,

which are used for hydro test of boiler proper.

5.20 Scaffolds have been built and checked to be qualified, which are convenient for

hydro test inspection.

5.21 Tools for hydro test are all ready (including temporarily fabricated pieces).

5.22 Local pressure gauges have been installed. Pressure gauges for hydro test are

checked to be qualified.

5.23 Drainage pipe can be connected after hydro test.

5.24 Editing, proofing, approving procedures for technical scheme of the whole hydro test




206

have been completed.

5.25 Passages at site are flat and unobstructed; covers are prepared, safety pretection

establishments are all ready.

5.26 Temporary valves for hydro test have been maintained and suppressed; tag

attachments of all systems and valves for hydro test have been completed.


6.1Air Pressure Test

Design of primary and secondary steam & air pressure test system: put an air compressor

at site. Outlet pipe of air compressor is connected with outlet pipe of drain header, using

drain pipe to fill air for primary and secondary steam system inner. When pressure rise to

0.3Mpa, stop to fill air. Assign workers to inspect steam pope and heating surface in the

whole boiler hydro test range. If there is any leakage, bubble will be found or a sharp. The

leakage must be handled in time。

6.2 The cleaning and blowing of temporary system

The cleaning of feeding water tank and its connective pipe: use DM water to clean feeding

water tank and pipes of hydro system. Make system inner clean.

Before connecting boiler’s feeding water pipes and boosting pressure pipes with formal

system, use DM water to clean. After that, connect with formal pipes after acceptance and

record.

6.3 Hydro test

6.3.1Mode of feeding and draining water for hydro test

Ammonia and hydrazine shall be mixed in the DM water inside of temporary water tank

and then the mixture shall feed directly into boiler by temporary feed water pump after the

water temperature and quality qualified. Water inlets for primary system are on the

discharging pipe of down comer distributor and discharging pipe of economizer inlet; that

for secondary system is on the discharging pipe of wall reheater inlet header. Feed

primary system and secondary system simultaneously.




207

Boosting point for primary system is on the discharging pipe of economizer inlet header;

that for secondary system is on the discharging pipe of wall reheater inlet header.

Pressure releasing for primary and secondary systems shall be carried out through

operating headers’ discharging pipe. Drainage can be completed through each draining

and relief pipes.

6.3.2 Boosting procedure for hydro test

Hydro test shall be carried out separately for primary steam system and secondary steam

system, the detailed steps as follows:

6.3.2.1 Close the valves which are relevant to boiler proper (such as emergency

discharging valve and etc.). Open vent valve and economizer re-circulating valve.

6.3.2.2 Start feed water pump to fill DM water mixed with ammonia and hydrazine. Store

water and feed chemicals in temporary water tank. Water quality and temperature shall

be inspected and up to requirements before filling the water into boiler.

6.3.2.3 When air exhausts, and water flows without air bubbles, close vent valves. When

the valves are closed completely, stop feeding water, and close the main feeding valve.

6.3.2.4 Start boosting pump to boost the pressure of system. Boost primary system at

the speed not more than 0.294Mpa/min, and suspend boosting when the pressure is up

to 2.96Mpa (the pressure of secondary system is 0.65MPa). Then check the system at all

aspects. If no abnormal condition is found, go on boosting.

6.3.2.5 When it goes up to 19.79Mpa working pressure (secondary system is 4.35MPa),

suspend boosting. Then have a second thorough inspection to the system. Check if there

is leakage on pressure parts, if the pressure parts can expand freely and if the stress on

hanger is average. If no abnormal condition is found, go on boosting and have system

super pressure test.

6.3.2.6In the process of working pressure rising to test pressure, strictly control the speed,

the speed not more than 0.098Mpa/min and report pressure values at each 0.2Mpa.

When pressure rises up to 29.69Mpa (secondary system is 6.53MPa)，stop boosting, and




208

close main boosting valve and maintain the pressure for 20 minutes (or maintain the

pressure for a certain period according to the IBR), monitor pressure gauge carefully and

record pressure variation values within the 20 minutes.

6.3.2.7 Open headers’ releasing valve of water pressure control station, lower down the

pressure slowly and the speed not more than 0.098Mpa/min. When pressure lower down

to 19.79Mpa (secondary system is 4.35MPa) and then stop releasing. Check the system

thoroughly and take down the record. After acceptance inspectors confirm that hydro test

is reached to the qualification standard, the pressure can be released and the speed not

more than 0.294MPa/min.

6.3.2.8The method of boosting the pressure of secondary system is as same as lowing

down the pressure of primary system. During the concrete operation, make the pressure

of primary system below 12.0Mpa and then slowly start the boosting valve of secondary

system.

6.3.2.9 When pressure test is carried out on primary system, the secondary system must

be reliably isolated from primary system.

6.3.2.10 According to the secondary network planning, the hydro test date temperature is

low, so advise to heating.

6.4 Anti-corrosion measures after boiler hydro test

6.4.1 After hydro test is qualified, low the pressure to 1.0Mp and preserve the water in the

boiler which is called wet maintain method.

6.4.2 Sampling the water in the boiler every 30 days, assay the PH value of the water and

the content of hydrazine of boiler water, if the concentration of hydrazine is less than

200mg/L and PH value is less than 9, dosing the chemicals to the boiler circularly until

those value is up to standard. (For circular chemical dosing is needed so that the system

of feed water pumps shall be kept after hydro test.)

6.5 special technique measures

6.5.16.5.1 Interrelated calculation of tested pipe:




209

Use Φ42*5.5，20 seamless steel pipe to be boosting pressure pipe, test pressure

P=29.69Mpa, working temperature t=50℃.

Allowable maximal pressure calculation:

[P]=2Ψn[σ]Sy/（Dw-Sy）

In expressions:

Ψn——welding seam lowering coefficient, seamless steel pipe Ψn =1.0

[σ]——allowable pressure

Condition as above and using seamless steel pipe condition as follow:

[σ]= [σ]J，[σ]J =125MPa

Dw——pipe outer diameter, Dw =42mm

Sy——virtual wall thickness of pipe, Sy =5.5mm

Substitution calculation expression:

[P]=2×1×125×5.5/（42-5.5）=37.67MPa>P=29.69MPa

Adopting Φ42*5.5，20 seamless steel pipe to be boosting pressure pipe is allowed.

6.3.2 Testing pressure pipe for feeding water

UseΦ108×4，20# seamless steel pipe to be Testing pressure pipe for feeding water, the

testing pressure P=6.53Mpa, working temperature t=50℃, allowable maximal pressure

calculation:

[P]=2Ψn[σ]Sy/（Dw-Sy）

In expressions:

Ψn——welding seam lowering coefficient, seamless steel pipe Ψn =1.0

[σ]——allowable pressure

Condition as above and using seamless steel pipe condition as follow:

[σ]= [σ]J，[σ]J =125MPa

Dw——pipe outer diameter ,Dw =108mm

Sy——virtual wall thickness of pipe, Sy =4mm

Substitution calculation expression:




210

[P]=2×1×125×4/（108-4）=9.62MPa>P=6.53MPa

AdoptingΦ108×4，20# seamless steel pipe to be feeding water and testing pressure

pipe is allowed.



7.1.1 Manufactory drawing, introduction manual and other technical documents will be

taken as standard preferentially.

7.1.2 Construction quality inspection and evaluation standard

7.1.2.1 The whole hydro test of boiler

Quality inspection procedureInspection item

qualified

Test pressure comply with the requirements of manufactory

technical documents

quality of water comply with the requirements of manufactory

technical documents

temperature of water comply with the requirements of manufactory

technical documents

temperature of environment Not less than 5℃

Test procedure comply with the requirements of erection manual

Inspection of stringency

Compression parts and all welding seam, man hole,

hand hole, flange, valves have no leakage and

deformation

Hydro

test

Recovery after test Agree with factory technical requirement, treat

defects discovered in test

7.2 Settings of control witness point

7.2.1 Temporary pipe inner cleaning and pipe stringency: witness point at site (W point)




211

7.2.2 Environment temperature, temperature of feeding water in boiler and wall

temperature of storage tank: witness point at site (W point)

7.2.3 Monitoring of water quality of DM water and feeding chemical control: key working

procedure, witness point at site (W point).

7.2.4 Boosting & lowing down pressure speed and pressure control in hydro test: key

working procedure, witness point at site (W point).

7.2.5 Inspection of welding seam of boiler seal and welding position of primary sealing

parts: key working procedure, witness point at site (W point)

7.2.6 Inspection of all pressed welding joint, pressed valve and pressed parts: key

working procedure, witness point at site (W point)

7.2.7 Deformation circs of supporter and hanger in feeding water process: key working

procedure, witness point at site (W point).

7.2.8 Measure girder flexibility before and after feeding water: key working procedure,

witness point at site (W point).

7.2.9 Observation record for settlement: key working procedure, witness point at site (W

point).

7.2.10 Expansion record before and after feeding water: witness point at site (W point)

7.3 Settings of interface handing over point: No

7.4 Technique discipline and quality control measures

7.4.1 The pressure gauge reading of primary steam and secondary steam separately is

on base of drum and high temperature reheater.

7.4.2 Keep pressure for 20 minutes on coming to the test pressure in hydro test, and then

lower down the pressure to working pressure. If no crack, deformation and leaking water

phenomenon after checking, the hydro test is qualified. When do hydro test, at the same

time inspect thermal specialty components used in test.

7.4.3 Carry out hydro test according to test procedure. Strictly control boosting and

lowering pressure speed.




212

7.4.4 When do boosting pressure test for primary steam system, open the air exhaust

valve of reheater to avoid valve leakage, and protect reheater.

7.4.5 Come to the requirement of stringency inspection as follow: compression parts, all

welding seam, hand hole, access door, flange, valve and etc have no leakage,

deformation and crack.

7.4.6 Drain water completely after test to treat defects.

8 Requirement and measures for safety, civilization construction and environment

management

8.1 All the workers dress correctly and wear safety helmet, which take part in hydro test.

Wear soft sole shoes and tie life belt when work at high. Obey command and wait for

arrangement during hydro test. Don’t move at will.

8.2 It is forbidden to enter hydro test site except workers.

8.3 Set up a commanding team at hydro test site, whose duty is contact, organization and

direct. All inspectors should render the circs to commander in time. Set up a special

channel for communication tools which are used for hydro test, so that ensure information

be transfered in time.

8.4 All the workers that join the hydro test have already been told the technical and been

familiar with the arrangement of work, test steps and inspecting time.

8.5 Stop all the welding and cutting work on boiler proper in testing pressure process.

8.6 Build rail, hang identification brand and put up safety precautions in testing pressure

pump’s range

8.7 In the process of hydro test, any person couldn’t stand at the opposite side of welding

blind or flange side. Don’t knock at bearing parts.

8.8 Assign special persons to operate testing pressure pump.

8.9 In boosting pressure process, frequently proof up and down pressure gauge to avoid

over pressurization.

8.10 Scaffolds at each checking position are perfect. Passage is clear. Illuminance is




213

enough.

8.11 During over pressurization test, don't inspect without permission.

8.12 Dosage workers should wear gauze mask and eye shield.

8.13 Assign electric maintenance and monitoring work for testing pressure pump.

8.14 Assign special workers to supervise chemical water in hydro test

8.15 After the acceptance of hydro test, transact visa in time.

8.16 If the water temperature isn’t up to test requirement hence need heating, then

heating steam pipe need to temporary heat preservation to avoid scald.




214

9 Attached drawings

System diagram of boiler hydro test

正式系统

临时系统

DR

UM

前水冷壁上集箱

前水冷壁下集箱

侧水冷壁上集箱

侧水冷壁上集箱

侧水冷壁下集箱

侧水冷壁下集箱后水冷壁下集箱

后墻悬吊管出口集箱

后墻排管出口集箱

省煤器出

口集箱

省煤器悬吊出口集箱省煤器悬吊出口集箱

省煤器悬吊出口集箱

省煤

器进

口集箱

未过处延伸侧墻上集箱

未过处延伸侧墻上集箱

未级

过热器出

口集

箱

未级过热

器进

口

集箱

二级减温器

后屏

过热器出

口集

箱

后屏过热

器进口

集

箱

分隔屏

过热

器出口箱

分隔屏过热器进口集箱

分隔屏过热器进口集箱

一级减温器

低温过热器出口集箱

低温过热器进口集箱

前顶棚过热器进口集箱

前顶棚过热器出口集箱

后烟井侧墻上集箱

后烟井侧墻上集箱

后烟井过热器前墻下集箱

后烟井过热器后墻下集箱

后烟井过热器前墻上集箱

后烟井侧墻下集箱

后烟井侧墻下集箱

未过处延伸侧墻下集箱

前墻再热器进口集箱

前墻再热器进口集箱

侧墻再热器进口集箱

侧墻再热器进口集箱

前墻再热器出口集箱

前墻再热器出口集箱

侧墻再热器出口集箱

侧墻再热器出口集箱

屏式再热器进口集箱

屏式再热器出口集箱

屏式再热器出口集箱

未级再热器进口集箱

未级再热器出口集箱

放气

压力表

压力表

压力表

放气

放气

接进水管

压力表

加热蒸汽

接省煤器再循环管座

紧急放水

接省煤器再循环管

φ57×3.5

φ108×4

φ42×5.5

φ16×3

试压泵

A

φ159×4

φ28×4

试压泵

B

φ108×4

上水泵φ

219×

6

φ57×3.5

φ57×

3.5

φ159×4.5

φ219×

6

φ159×4.5

除盐水进水管

压缩空气

φ42×5.5

φ57×3.5

水冷壁下集箱疏水管

上水箱

上水箱

接前墻再热器进口集箱

蒸汽加热管道

包墙下集箱

标审

审核

批准

日期

制图

设计

工程

名称

图名

比例

图号

湖南省火电建设公司

印度海萨

2×

600MW（

BTG）

燃煤电站工程

水压试验系统图

The Erection Manual of Axial Fan



215




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ENDORSEMENTS








216

CONTENTS

1 Basis of Preparation and Checking Criterions………………………..217

2 Project General and Construction Range………………………………217

3 Allocation of Resources and Manpower Qualification…………….218


Construction…………………………………………………………218

5 Construction Condition and Preparation before Construction…….220

6 Construction Procedure, Method and Requirement………………220

7 Quality Control and Quality Acceptance…………………………..224


Environmental management………………………………………..225




217


1.1 The drawings and technical document from fan factory.

1.2 The erection drawing J0302 from SEPDI.



The forced draft fans and induced draft fans used in hisar 2×600MW thermal plant are

axial fans designed and produced by shanghai blower fan factory. Each unit is equipped

with two forced draft fans, two primary air fans and two induced draft fans, laid at the front

and behind floor of electrostatic precipitator. Their type and parameters are as follows:

FDF driving motor

type：FAF25-13.3-1 type：YKK630-6

total wind pressure： 4284Pa voltage：3.3KV

flow rate： 261.695m3/s power：1400KW

rotating speed：985r/min rotating speed：985r/min

total weight of fan：~18000Kg weight of driving motor：9200Kg

PAF driving motor

type：PAF20.2-12.5-2 type：YKK800-4

total wind pressure： 15401Pa voltage：11KV



total weight of fan：~16000Kg weight of driving motor ：24000Kg

IDF driving motor

type：SAF38.5-22.4-1 type：YKK900-8

total wind pressure： 5514Pa voltage：11KV



total weight of fan：~80000Kg weight of driving motor：31500Kg




218


Construction range include: four induced draft fans, four forced draft fans and four

primary air fans together with interrelated motors & lube oil system and accessories.


No. Post Skill Requirement Qty Remarks

1 Team leader senior 1 With erection and

management experience

2 member middling 8

3 rigger 3 With interrelated qualification

4 welder 4 With interrelated qualification


construction


No. Equipment name spec Qty Remarks

1 Special tools provided by fan

factory 1

2 Truck crane 50t 1


4 Oil-jack 10t 1~2 checked to be qualified

5 Electric spanner 1 all specification




219


6 Steel ruler 1m 1~2

7 Measure temperature

instrument 1 checked to be qualified

8 Precise pressure gauge Y150

0~1.6MPa 2

With precision grade

0.4(each scale is

0.005MPa)

9 micrometer 0~10mm 6

With precision grade

0.01mm，require 2

small size instrument

10 Frame leveler 1 checked to be qualified

11 Inside caliper gauge 1 checked to be qualified

12 Outside micrometer calipers 0~600mm 1 checked to be qualified

13 Depth vernier caliper 1 checked to be qualified

14 vernier caliper 1 checked to be qualified

15 internal micrometer 1 checked to be qualified

16 Common fitter tool 2 checked to be qualified

17 Leveling instrument 1 checked to be qualified

18 Level pipe 1




220


19 feeler Each spec 2

20 Line plumb 2

21 Magnetic instrument seat 6 checked to be qualified

22 Steel tape 5m 1

23 Steel tape 50m 1

24 Steel level 1


4.2.1 Personal safety protection articles: safety helmet, safety belt, goggle and etc.

4.2.2 Safety protection articles preparation in construction area: safety net, rail and etc.


5.1 approved construction drawings and technical documents are all ready and workers

engaged are trained.

5.2 Tools & machines and materials used for installation are all ready.

5.3 Equipment received order and date caters to the continuous installation requirement.

5.4 Fan civil foundation have been checked and accepted.

5.5 Passageway is clean and caters to the equipment erection and transport requirement.

5.6 water, electric power and gas for construction are all ready.

5.7 Platform, walkway and stairs are clean. Safety rail and caution board are all ready.

6 The construction procedure, method and requirement

6.1 Work flow chart




221

Erection of rotor shell

Final grouting

Erection of oil station Erection of accessories

General check and accept

Disqualifi

Erection of rotor blade and

Erection of motor and

Grout anchor bolt hole

Disqualifi

cation

Check and accepted

Preparation for construction

Foundation lineation

Shimplate allocation

Position and alignment

Disqualifi

cation

Check and accept

Technical instruction

Inlet Erection

Maintenance of fan body

Check and accepted Jackshaft Erection

Second alignment Witness point




222

6.2 Construction method and requirements

6.2.1Foundation lineation and shimplate allocation

6.2.1.1Check foundation appearance to be flat without crack, holes, honeycomb shaped

area or exposed steel bar. Clean away sundries from foundation surface. Check and

clean away sundries from anchor bolt hole.

6.2.1.2Recheck foundation dimensions per requirements shown in the drawings. The

deviation of the main longitudinal and latitudinal center line should not exceed 10mm，and

the distance deviation of parallel center line should not exceed±3mm. Check and ensure

dimension of anchor bolt conform to drawing by steel tape. The dimension error of anchor

bolt hole should not exceed 10mm. The allowed foundation elevation tolerance is±5mm.

6.2.2 Shimplate should be applied in load concentrated place, under bedplate main steel

ribs and on both sides of anchor bolt. Shimplates should be seated with grout and contact

the bedplate tightly.

6.2.3 Open-package inspection of received equipment for received quantity, damage or

shortage

6.2.3.1According to supply list、package list and drawings, check the received quantity.

Check the equipment dimension and appearance to be satisfactory.

6.2.3.2 Assemble equipment components per manufacturer serial No. and instructions.

6.2.4 The erection of bearing bracket and main axes

6.2.4.1Set and align bearing bracket and main axes with foundation longitudinal and

latitudinal center line. Correct the elevation of bearing bracket using adjusting screw as

designed and specified in civil drawings, and the elevation tolerance is ( ).

6.2.4.2After alignment of bearing bracket, level the rotor and make sure its longitudinal

and latitudinal slope is less than 0.1/1000.

6.2.4.3 Install vane assembly. Carefully check the factory code marked on vane and hub

to avoid mismatch. Torque the vane bolts per manufacturer instructions using torque

spanner.




223

6.2.4.4 Install the top cover. Tighten the binding bolts. Check clearance between the top

of vane and top cover to be 1.8mm (+0.5).

6.2.4.5Align main axes and make sure longitudinal slope not exceed 0.1/1000. Aligning

method of main axes: weld four adjusting bolt on the side of center hole of inlet chamber

to adjust the level of main axes

6.2.5 Assembly and erection of air inlet chamber and diffuser

6.2.5.1Assemble air inlet chamber and diffuser according to manufacturer location mark

without displacement. Every weld joint should be grooved and fully penetrated.

6.2.5.2 Both distance from installed inlet chamber to side flange face of impeller shell and

that from diffuser to the opposite side flange face of impeller shell should be 20mm.

6.2.5.3 Dispose air inlet chamber and diffuser at opposite side of oil station.

6.2.5.4 Pay attention to flow direction during connecting inlet expansion joint and exhaust

expansion joint.

6.2.6 Alignment and erection of motor coupling

6.2.6.1Generally alignment the driving motor and ensure the distance between two

coupling discs per manufacturer requirements. For primary air fan and forced draft fan, no

jackshaft heat expansion should be considered and flexible diaphragm should be in

nature status. For induced draft fan, jackshaft heat expansion should be considered and

expansion space should be reserved.

6.2.6.2After grouting anchor bolt, perform final alignment to ensure distance deviation of

the end faces of coupling discs not exceed 0.10mm with anchor bolts tightened.

6.2.6.3After final alignment, deviation of two pairs of coupling should be within 0.06mm

(4).Install the sheath of jackshaft and coupling.

6.2.7 Erection of oil station and oil pipe.

6.2.7.1 Clean away sundries and dust in oil box.

6.2.7.2 Check pipeline connecting bearing bracket and oil station to be firm and reliable.

Perform oil cooler hydraulic test (test with the pressure shown on nameplate).




224

6.2.7.3 Lay oil pipeline from oil station to fan. Before installation, blow the pipes inside by

compressed air to make it clean. After filling oil tank, perform oil flushing.

6.2.8 Final grouting

6.2.8.1Spot welded shimplates according with requirements.

6.2.8.2Clean foundation and make sure there are no sundries and dust.

6.2.8.3Anchor bolts should be vertical and not inclined.

6.2.8.4Thickness of grouting and concrete grade conformed to requirement.



Technical documents such as drawings, instructions and etc from manufacturers should

have the first priority for quality control and inspection.

7.2 inspection points

7.2.1 Witness points: Oil tank cleaning, oil cooler hydraulic test, oil flushing

7.2.2 Halt points:

7.2.2.1 Closure of manhole of oil station (hidden work)

7.2. 2.2 Bearing Erection (hidden work)

7.2.2.3 Closure of fan’s manhole (hidden work)

7.2.2.4 Coupling alignment, bearing alignment


7.3.1 Technics discipline

7.3.1.1Properly dressed before entering site. Protect the installed equipment to avoid

damage.

7.3.1.2 The arrangement of oil (water) pipe should be reasonable and artistic, conforming

to technics requirement. Cap the pipe orifice in time to ensure the system clean.

7.3.1.3 Respectively lay the disassembled parts in special box. Carefully pack and protect

the precise part and don’t press or lose.

7.3.1.4 Don’t use flat spade, file etc. to get rid of rust on precisely processed surface and




225

don’t get rid of oil by fire.

7.3.1.5 It is forbidden to randomly ignite or spot weld on equipment.

7.3.1.6 Get signed agreement before close any access door.

7.3.2 Quality assurance measure

7.3.2.1 Perform the alignment and connection of coupling according to factory

requirement. The angular deviation of coupling discs shouldn’t exceed 0.05mm, and the

shaking degree shouldn’t exceed 0.05mm. The reserved value of coupling center should

strictly conform to factory requirements.

7.3.2.2 Make sure that the bearing box is leak-proof by hydraulic test with pressure 1.25

times of cooling water pressure.

7.3.2.3 Prior to shifting to next working procedure, every working procedure should be

checked and accepted by related departments.

7.3.2.4 Ensure elevation, level, alignment and direction of each part should be

satisfactory.

7.3.2.5 Oil, water, lube and cooling system are leak-proof.





8.2 Who is not worker couldn’t enter the construction site.


equipment. Take care to avoid impacting other equipments or materials.





crowbar.




226

8.7 Keep the construction site clean and clean away trash and waste materials in time.

Erection Manual of Coal Feeder



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228

CONTENTS

1 THE BASIS FOR COMPILING THE MANUAL……………………………229

2 PROJECT INTRODUCTION AND CONSTRUCTION RANGE…………...229


QUALIFICATION…………………………………………………………………229


PROTECTION ARTICLES………………………………………………………230


CONSTRUCTION………………………………………………………………...230

6 CONSTRUCTION PROCEDURE, METHOD AND REQUIREMENT…….231

7 QUALITY CONTROL AND QUALITY ACCEPTANCE…………………….232


CONSTRUCTION AND ENVIRONMENT MANAGEMENT………………….232




229


1.1 Drawing and erection manual (Coal Feeder Manufacture)

1.2 Coal feeder erection manual (Southwest Electric Power Design Institute)

1.3 Installation construction design outline of this project



The coal feeder of Hisar 2×600MW thermal power plant is the product of Shanghai

Generation Complete Equipments Design Institute. Its model is: CS2036HP electronic

weight coal feeder. There is 8nos coal feeder for each unit, therefore total 16nos for this

project. They are located at 17m floor in bunker bay. Its parameters are shown as below:

Coal feeder Main motor

Model: CS2036HP Model: GT1650907

Capacity: 9~90t Power: 5.5KW

Coal feeding distance: 2500mm Chain cleaning motor

Flame-proof pressure: 0.35MPa Model: GT1661507

Measure precision: ±0.5% Power: 0.37KW

2.3construction range

2.3.1 Position, level, alignment and fix of equipments.

2.3.2 Erection of coal feeder inlet & outlet coal chute, coal gate and connection pipe.


SL Position Technique degree

requirement Quantity Remarks

1 Group leader High degree 1 Technique managing experience on

same unit

2 Main worker Middle degree 10 Technique managing experience on

same unit

3 Scaffold worker 2 Has related certificate




230

SL Position Technique degree

requirement Quantity Remarks

4 Rigger 2 Has related certificate

5 Welder 1 Has related certificate

4 Equipments and tools for construction and safety protection articles 4.1 equipments and tools for construction

SL Name Specification Quantity Remarks

1 chain block 3t 2

2 hexad wrench 1set

3 adjustable spanner 2set

4 plane file 1

5 jack 5t 2

6 level tape 1 precision 0.1mm/m

7 steel tape 5m 2


4.2.1 Personal safety protection articles: safety hamlet, safety belt and etc.

4.2.2 Safety protection devices on construction area: safety net, fence and etc.


5.1 Equipment foundation is checked and accepted, the longitudinal & transversal

centerline and elevation of equipment foundation are rechecked to accord with drawing

and equipment.

5.2 Construction water, electricity and gas shall be supplied on time, oxygen and ethyne

shall be packaged by cylinder.

5.3 The construction passage is unobstructed with sufficient illumination and safety

protection devices.


6.1 construction process flow chart




231

6.2 installation of equipment

6.2.1 As per erection drawing of design institute, recheck center, elevation and geometry

dimension of equipment foundation. Deviation of every dimension shall be within ±10mm.

6.2.2 Clear away sundries and oil filth on the foundation surface, recheck the position of

embedded steel as per drawing requirement.

6.2.3 Lift coal feeder to 17m floor by crane, transport it levelly and then position it by chain

block.

6.2.4 Align as per position, longitudinal & transversal centerline and elevation of erection

drawing, adjust by using shimplate when elevation is not enough, and fix it by welding

after alignment according to drawing.

6.2.5 Install coal chute which is between coal scuttle outlet to coal feeder inlet and coal

feeder outlet to mill inlet, coal gate and connector as per drawing.

6.2.6 Install pipe and accessories such as coal flow monitor, motor protector, seal air, fire

fighting as per drawing requirement.

6.2.7 After coal feeder is with power, adjust tightness degree and off-center of belt till up

to the standard under guidance of manufacture representative.

Lineation and cleaning of foundation

Position, level and alignment of equipment

Fix equipment and foundation embedded steel by welding

Installation of inlet & outlet coal chute, coal gate and connector

Installation of accessories

Equipment trial operation, adjustment tightness degree and off-center of belt




232



Quality checking shall be on the basis of technical document such as drawing, directions

etc. For those is not cleared in manufactory technical requirement, consult to related

regulation of criterion and acceptance standard.

7.2 setup middle procedure witness point: no

7.3 setup handling over point of middle procedure: no

7.4 technique principles and quality guarantee measures

7.4.1 Equipment vibration shall meet manufacture or criterion requirement.

7.4.2 Equipment shall be installed with technique beauty.

7.4.3 Every working procedure shall be self-checked and accepted, it is forbidden to do

the next procedure when the previous one is not qualified.

7.4.5 It is forbidden to scrabble, mark and do spot welding on the equipment surface. The

mechanical mark shall be cleared completely.

7.4.6 During installation process, check and record every working procedure according to

the principle combining self-check, mutual check and specialty check; hidden subsurface

work shall be checked qualified and recorded before its hidden.

8 Requirement and measures for safety civilization construction and

environment management

8.1 Before go to site, wear properly with helmet, wear safety belt when work on height. It

is forbidden to smoke on construction site.

8.2 Construction scaffolds shall be erected on site completed with specified regulations

8.3 Protection glasses is required to take when use grinding machine and cutting

machine.

8.4 When use electric tools, make sure the cover of the cable isn’t damaged and use

power panel with leakage protection device.

8.5 It is forbidden to stand under the lifting beam and lifted equipment when equipment is




233

lifted. Special person shall be assigned to pull the lifted equipment. It is forbidden to take

nozzle as lifting point when lift rubber lined equipment so as to avoid personal injury and

damage to the surface of rubber lined.

8.6 When hand chain block and electric chain block is used, it is forbidden to pull and lift

inclined and work under overload.

8.7 When the cylinder is used to fill oxygen and ethyne, the distance between each

cylinder shall meet safety regulations, and layed in order.

8.8 Avoid electric shock when use welding machine, grinding machine and other electric

devices and tools; cover the electric devices well in rainy days to avoid electric shock; it is

forbidden to connect power cable with knife switch or put into socket directly.

8.9 It is forbidden to use electric welding for rubber lined and plastic lined device and pipe.

8.10 When work inside vessel, ensure good ventilation and prepare ventilator so as to

avoid sunstroke due to high temperature, special person shall supervise at the manhole.

8.11 The construction devices and materials shall be piled up in order and can’t block the

passage. Clean up the remaining materials and keep site neat.

The Manual of overall plant insulation



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235

CONTENTS

1 Preparation………………………………………………………240

2 The general situation………………………………………… 240

3 Resource allocation …………………………………………240

4 The arrangement of the construction progress………… 243

5 The construction procedure and method………………… 243

6 The quality standard and control …………………………254

7 The safety precautions …………………………………… 255




236

1 Preparation

1) Designing for whole plant insulation and painting.

2) Insulation structure

3) The erection manual for FAA series of electrostatic precipitators.

The drawings of the electrostatic precipitator’s insulation layer, the serial number:

W78060A、B、C.

2 The general situation

The HISAR 2×600MW coal burning power plant in India,the whole plant insulation work

including fume, air and coal system, fuel oil system, vapor and water pipeline section,

public facility, auxiliary equipment of the boiler and steam turbine, overhaul platform and

ladder which are between the two units. The insulation installation of for the boiler body

and steam turbine is not in the scope of this manual; please refer in the relative drawings

and instructions from producers.

3 Resource allocation

3.1 The division of the construction workers

A. engineering technical staff:

Be responsible to make construction manual and make safety and technical briefing to

the construction workers.

Instruct the construction workers for performing their job, check the implementing of the

construction manual, monitor the construction quality at site and supply technical

consulting service.

Check the quality of each finished job; amend it if there is any defect in time.

B. construction administrator:

Instruct the construction workers to grasp the work sequence and technical requirements.

Supervise and urge them to perform the construction as per the manual.

Check to see if the installation on the equipment position has been finished, report to the

engineering technical personnel and make construction records.




237

Be in charge of the transportation and storage of the materials at site. Monitor and inspect

the construction quality at site. Arrange the work progress as per the requirements.

Be aware of construction security items. Supervise and urge the cleaning at site.

C. the person who are responsible to construction:

Has certain professional proficiency. Be familiar with the construction technics and quality

requirements. Obey the arrangement of the engineering technical personnel’s and

construction administrators. Guarantee the construction quality and progress.

Ensure the construction workers know well about the engineering specialty and perform

jobs as per the manual and drawing’s requirements strictly.

Make sure the construction workers can coordinate well with other types of work to carry

out crossing work.

Ensure the construction security and be in charge of the cleaning job at site.

3.2 The requirements for the construction workers.

Serial

No.

Types of

work Quantity Qualification Requirement

1

Thermal

insulation

worker

40 Skilled

worker

Can read normal construction drawings and

instruction books, work independently and have

strong safe consciousness

2 Lifting

worker 2

Skilled

worker

Be familiar with lifting work, have work experience

and strong safe consciousness

3 Welder 10 Skilled

worker Welder for common structure

4

sheet

metal

worker

6 Skilled

worker Be familiar with lofting technics，work independently

5 Common

worker 10

Semi-skilled

worker Have work experience and safe training

3.3 The necessary tools, machines and the equipments




238

Serial No. Name Specification Quantity

1 Hammer 3 pounds 40 pieces

2 Steel tape 5m 40 pieces

3 Steel tape 10m 5 pieces

4 Steel ruler 1m, 300mm Respectively

40 pieces

5 Straight screwdriver 200mm 40 pieces

6 Cross screwdriver 200mm 40 pieces

7 Electric hand drill J1Z-4A 20 sets

8 Electric hand riveter P1M-5 20 sets

3.4 The main insulation materials

Aluminium Silicate thorn blanket density 150kg/m3

Usage temperature≤1000℃

Aluminium Silicate tube shell density 170kg/m3


Rock wool Stitched blanket density 120kg/m3


Rock wool tube shell density 150kg/m3


Combined Silicate slurry (dry condition) density 200kg/m3


The applied scope of the insulation materials:

a. pipelines and equipments with medium temperature≥350℃ use Aluminium

silicate products.

b. pipelines and equipments with medium temperature＜350℃ use rock wool

products.

c. Use combined Aluminium Silicate slurry material for valve insulation.




239

4 The arrangement of the construction progress

The planned starting time for the project: year: 200 month: Date:

the planned finishing time: year: 200 month: Date:

5The construction procedure and method

5.1 The conditions before construction

5.1.1 for the equipments and pipelines need to take water and air pressure tests, must

perform the tests first then perform the construction.

5.1.2 The three cylinders of the steam turbine have been capped; the junctions for each

drainage and instrument’s plug seat have been fixed as per the requirements of

drawings; the chock plugs have been installed for each orifice and hole.

5.1.3 The insulation materials have past the inspection.

（1） The materials shall have factory pass certificate, each index meets the designed

requirements.

（2） The recheck must be carried out before the insulation materials get into the

storage. Carry out sampling inspection on their main physicochemical

performance and outline dimension, besides to check their factory pass

certificates and each test record. For the materials that don’t conform to the

requirements of ‘The Technical Condition and Method of Thermal Equipment

and Pipeline in Thermal Power Plant’, the construction unit can reject to use

them until the institute of design agrees to modify the designing.

（3） Store the insulation materials in the storage which is well ventilated and

damp-proofing as per their material and specification and keep them dry.

5.1.4 The cleaning and mitigate corrosion work on the ektexines of pipelines and

equipments has been finished.

5.1.5 The sampling points of pipelines and heat engineering have been fixed.

5.2 The general requirements.

5.2.1 Normally the temperature of fluid liquid is taken as the insulation temperature of the




240

pipelines.

5.2.2 The equipment assemblies and each assembly’s insulation shall be the same with

the connected equipments.

5.2.3 The pipelines and equipments need insulation:

a. the steam, water and oil pipelines, accessory and thermal equipments with

medium temperature that are more than 50℃ .

b. the fume, air, coal and powder system’s pipelines and equipments with medium

temperature that are more than 50℃ .

c. for all the steam release pipelines, only take insulation in the scope of 2.1 meters

above the building floor or the area that operating staffs can touch.

5.2.4 The items that are need to take insulation (the scald-proofing insulation).

a. all the pipelines and equipments that need radiating;

b. pipelines and equipments that have transient heat releasing: security valves,

security systems, exhausting to air and pollution discharge;

c. tension apparatus and filer;

d. hot well;

e. the section under the expansion junction, tension junction;

f. container’s name plate, exchanger and mechanism device;

g. pipeline’s or equipment’s support frame;

h. flange interface, except those steam devices, heating for temperature

keeping,or tube shells, the insulation device shall be capable to be dismounted,

the bolts are screwed up, materials are qualified in insulation.

5.2.5 All the valves including the control valves on the pipelines that their work

temperature are over 150℃ shall have insulation that are as thick as the

pipelines’s.

5.2.6 The thermal insulated pipes shall be supported on the steel seats and the height of

the seats shall be over the height of the insulation’s bottom.




241

5.2.7 Install the same type of the insulation support with the container for the insulated

tank. The other methods that owner agreed can be also used.

5.2.8 Take consideration for the compressor engine, pump and other machines

individually as per the similar technics.

5.2.9 The insulation shall withstand the leaked out water, mechanical abrasion or other

things that can damage the insulation.

5.2.10 the vertical pipelines and containers shall use supporting rings. The ring interval

shall be at the same position with the insulation expansion hatch. Each vertical

container shall have two support rings at leas: one is above the bottom, anther

one is under the top of the container.

5.2.11 the insulated expansion interface provides the expansion coefficient between the

insulation materials and the pipelines or equipments. The expansion interface

shall use fluffy fibre insulation materials. For the container, set 25 mm

expansion clearance for all the interfaces, mouths, entering orifices or other

accessories. The maximum span of the expansion clearance on the containers

and pipelines are:

0℃～120℃ 9 m 121℃～200℃ 4.5 m

201℃～315℃ 3.5 m 316℃～ 480℃ 3 m

481℃~～ 650℃ 2 m

5.2.12 When the insulation layer is thicker than 80mm, lay it by layers; similar thickness

for each layer; stagger the joints of inner and outer layers; no cavity between

the layers or joints.

5.2.13 For all the 38㎜≤caliber≤57㎜ and T＜350℃ pipelines, use Rock wool Stitched

blanket as the insulation material; for other caliber≤57 ㎜ pipelines, use Aluminium

Silicate fibre cord as the insulation material and the cord diameter is 25mm.

5.2.14 The tube shell uses aluminium alloy. When the outer diameter after insulation is

less than 330㎜, use 0.5mm; when the outer diameter after insulation is no less than 330




242

㎜, use 0.6mm. The equipments and duck of fume and air use pressed aluminium thin

plate, 0.7㎜ for the equipments and round duck of fume and air; 0.7㎜ for rectangular

duck of fume and air.

5.3 The construction flow chart

Preparation

Sort and count equipments and sampling inspection

Qualified or not

Install insulation hook nail and support frame

Lay the insulation materials

Install float coat and external cover sheet

Qualified or not

Quality check and acceptance

Replace equipments again

No

No

Yes




243

5.4 The insulation layer and technical requirements

5.4.1 The straight insulation layer construction.

（1） For the horizontal pipelines that use circle or semi-circle tube shell and single

layer insulation, the longitudinal joint seams shall be placed at the right or left

side of the pipeline axis. For the roofing tile shaped insulation products, the

longitudinal joint seams shall be avoid to be placed on the top of the pipeline if

possible.

（2） When the pipelines use stratified insulation, the joints between the layers shall

be staggered. 15° is for longitudinal staggered joints; the circumferential

staggered joints are more than 100mm; the longitudinal insulation joint seams

on outer layer of the horizontal pipelines shall be avoid to be placed on the top

of the pipelines.

（3） There shall be bifilar galvanized iron wires to annularly bind each layer of

insulation products; the iron wires are 100mm far from the end side of the

insulation materials and the tightly twisted iron wires ends need to be inbuilt in

the longitudinal joint seams.

（4） Install weight bearing rings every 2.5～3 meters for the vertical pipelines; the

width of the rings is 10～20mm less than the thickness of the insulation layers,

or is the 2/3 of the thickness of the insulation layers.

（5） Set expansion seams every 3～5 meters on H.P. pipelines. Place them under

the weight bearing rings or the hanging frames for the vertical pipelines; place

them at the 2 sides of the support frames for the lateral pipelines. Normally the

widths of the expansion seams are 30～40mm, no more than 50mm. Fill them

End

Yes




244

with mineral fiber materials.

5.4.2Bending tubes

Starting from the bending point, divide each insulation tube shell into several pieces as

per the bending degree and radius and cut it into sectors. The cutting surfaces shall be

smooth and flat, the dimension shall be precise. The H.P. pipelines 1～3 expansion

seams; the width is 10～15mm; fill them with mineral fiber materials. Use galvanized iron

wires to bind them into sector blocks; cut off the joint seams and make them round after

installation.

5.4.3Flange

（1） Reserve the position for dismounting bolts at the ends of the flanges and pipeline

insulation; normally the length is the length of flange bolts plus 25mm. The

overlapping length of the equipment ‘s flange insulation and equipment insulation

is equal to the thickness of the equipment insulation, but it is no less than 75mm;

the overlapping length of the pipeline‘s flange insulation and pipeline insulation is

equal to the thickness of the pipeline insulation, but it is no less than 50mm;

（2） Cut the insulation products as per the flange insulation dimension; bind them on

the equipment’s or pipeline’s insulation cover shells by iron wires or beltings and

then install the metal cover shells out of them.

5.4.4 Valve welding

The valve body’s insulation uses the same insulation materials and has the same

thickness with the pipeline welded with it. The shape after insulation is similar with valve

body. Bind with iron wires and plaster with float coat in thickness of 10～15mm.

5.4.5 Flange valves

The position and the overlapping length of the insulation of the flange’s dismounting bolt

is required to be the same with the flange insulation. When uses soft materials, the

mineral fiber felts can be cut into strips or squares; colligate the valves and then covered

by the metal cover shells.

5.4.6 Equipments




245

Use iron wires or beltings to hoop the insulation materials on the equipments. If there is

no pre-welded hook nail on the equipments then the hook nails shall be welded on the

wall of the equipments. The hook nails and pin nails shall be laid out in a quincunx figure.

Quantity: 4 ones/M2 is for the upper part;8 ones/M2 is for the side part; 16 ones/M2 is

for the lower part. For the equipments that are not allowed to perform welding on them,

can weld the hook nails and pin nails on the anchor ears; fix the anchor ears by bolts on

the equipments or bind them on the equipments by hoop rings made of galvanized iron

wires by twisting. Fix, and then lead out Φ1.2mm iron wires from hoop rings to fix the

insulation materials.

5.4.7 Round equipment capped end.

（1） At the intersection places of the capped end curved faces and the equipment

cylinders, set bearing rings for hooping or welding. Weld Φ8mm round steels

on the bearing rings and make them into circles or joint them into radial figure.

（2） Set a movable ring made of Φ6mm galvanized iron wires at the center of the

capped end so to make a radial figure by connecting the galvanized iron

wires or steel belts with the circles made of Φ8mm round steel on the bearing

rings.

（3） Make the insulation materials that have the same material and thickness with

round equipments’ insulation into sector blocks by machining, and arrange

them on the capped ends in a regular and neat way then fix them by the radial

iron wires or steel belts. For the insulation in layers, the sector blocks shall be

staggered and seam covered.

（4） While making the lower capped ends, can weld on hook nails, fix and lead out

iron wires to bind the hard insulation products; or weld on pin nails and use

self-lock presser bits to press the soft materials and then bind them tightly by

the radial iron wires or steel belts. If the equipments are not allowed to perform

welding on them, can weld galvanized round steel rings on the bearing rings to

fix the insulation materials.




246

5.5 The construction and technical requirements of the metal cover shells

5.5.1 While install the straight pipes at site, make them to be tightly appressed to the

outer layer of the pipeline insulation layer, and overlap the two joint seams, then hit the

bite jointing. For the soft insulation materials, use overlapping and wedging joint, drill by

hand driller, fix by tapping screws; the span of the tapping screws is about 200mm. For

the metal shells that have large insulation outer diameter, shall make round raised

bracing by machining for the axial overlapping. The drill head diameter is 0.8 times the

tapping screw diameter. The joint seams shall be tight, smooth and at the hidden place;

normally circumferential bell socket is 50mm; 75～100mm is for the big diameter and H.P.

pipelines. The circumferential overlapping is good to follow the slope direction of the

pipelines, the overlapping mouth shall be downwards, i.e.

Use rosette spanner pilers to make rosette pattens on the metal shells at the end of the

straight tubes and near the flanges to protect the insulation materials.

5.5.2 Weld bolts on fume and air ducks, fans or other equipments and pipeline walls to fix

the metal shells.

（1） As per the shape of the insulated target, the dimension of the metal shell and

the size of the insertion seam, perform arrangement and lineation, confirm the

positions of the welded bolt’s centers and mark them.

（2） Temporarily weld the bolts on the marked positions, check to make sure is

normal to the outside and then perform the formal welding. While welding the

hex bolts, perform welding every other side (weld 3 sides totally) on the sides of

the hexagon. While welding screw rods, perform welding on the half circle of

every circle.

（3） Use bolt nuts to press the insulation layer tightly; trial install the metal shells;

use hollow drill to punch out holes on the shells; take out the nuts; use washers

and nuts to press the shells on the insulation layer and screw up the nuts.

5.5.3 The fume and air duck made of pressed sheets:

（1） Because of the fixing method is complicated, so the arrangement and lofting




247

procedures must be performed according to the size of the pressed sheets

and the cross-section of the fume and air duck.

（2） Weld steel angle legs on the outer wall of the fume and air duck. The leg’s

height is 20mm higher than the insulation layer.

（3） After laying the insulation layer, use 30×30×3 angle steel to connect the legs

firmly at the lateral direction, then weld bolts on the connected angle steel; the

axial span is tallied with the center of the pressed sheet’s wide wave.

(4 ) Use electric saw for the blanking of the pressed sheets, do not cut by gas

welding. Before installation, mount the angle protecting iron sheet on the lower

angles of the rectangle then install the bottom pressed sheets. Fix the pressed

sheets on the M10 bolt; overlay the groove shaped bands, which have been

drilled out holes, on the pressed sheets, then place the washers, screw up the

bolts and perform leveling. The one side of upper corner armor is appressed on

the pressed sheet, another side is appressed on the insulation layer, and then

install the top pressed sheets. The top of level fume and air duck has 1～2% of

inclination, and water can go down through one side or two sides. The direction

of the water goes down can be chosen as per the arrangement of the duck.

a) For the ducks that use soft insulation board, install the pressed sheet’s

narrow wave outward. Place the orifice at the center of the wide wave.

5.5.4 The round equipments and capped ends

As per the differences of the cylinder diameter and the insulation material, the metal

shells can be fixed by scuffing, bolts and frame of the cover case. The frame of the cover

case is used for the heaters and water feeding tanks, etc. that use soft insulation boards.

Weld the legs (the length is 10mm more than the thickness of the insulation) made of

30×3 flat steel on the walls of the equipments in the cross spans of 500mm. After the

overlaying of the insulation boards, use clinch bolts to fix the 50×25×1 groove shaped

bands that are parallel with the axes of the equipments; the connection and fixation

between the groove shaped bands and the metal shells uses tapping screw.




248

5.5.5 The precautions for the machining of the metal shells:

（1）Do not use the metal cover sheets that have defects like wrinkling, cracks, deep

slash-cut and corrosion. When the insulation layer construction is finished, install

the metal shells immediately lest the scaffold need to be reset up.

（2）The baiting of the metal shells shall be accurate on dimension, rational on cutting,

reduce the scrap producing.

（3）The machined metal shells shall be piled up in a orderly way and number them to

facilitate move and usage of them.

（4）Any part that can use hoisting, the machined metal shell products can not use

steel wire ropes to bide and lift them directly. The parts that can not apply

hoisting, use soft cotton cord to bind them firmly and pull or lift them lightly lest

the deformation of the finished products.

（5） Step on or pile goods on the metal shells is forbidden.

5.6 The insulation for electrostatic precipitator

5.6.1 The insulation materials for electrostatic precipitator

The performances of the insulation materials in the following table are excerpted from the

main performances table of theinsulation paint design instruction book. As the 5th clause

in technical requirements from the insulation layer general drawing of the producer, rock

wool technique is chosen by the consumer. The quantity of the rock wool stitched blanket

is filled in as per the quantity in the attached insulation paint table 1. Please pay attention

on the following notes: this quantity if for one boiler, the wastage and construction

overmeasure have been considered in it, and all kinds of hardwares(like pressed

sheets,etc.) are supplied by the work s.




249

5.6.2 The insulation construction for the electrostatic precipitator

a. Overlay and fix the rock wool stitched blankets with thickness of 50mm on the side wall

sheets of the electrostatic precipitator by 3 layers;

b. Use round steels and nails（￠3）to fix the insulation materials on the wall sheets. The

span of 2 round steels is 600㎜; weld 1 nail at the center of the 2 round steels, and the

span of 2 nails is also 600㎜; alternately weld the round steels and nails so the span

between the round steel and nail is 300㎜;

c. When the rock wool stitched blankets with thickness of 50mm for 3 layers of insulation

have been fixed, use nails with washers and round steels with pad sheet welded on them

to press the rock wool stitched blankets tightly; weld 40×40×4 angle steels on the round

steels, then be ready to install the pressed steel insulation sheets on the angle steels;

d. Stagger the seams 3 layers of rock wool stitched blankets to reduce heat dissipation;

e. The rock wool stitched blankets with thickness of 80mm is for the insulation around the

inspection door;

5.6.3 The construction for the pressed steel sheets for the electrostatic precipitator

insulation

1) While installing the pressed steel sheets of the electrostatic precipitator insulation, be

aware of keeping a good external appearance; upper part covers the lower part for

the longitudinal overlapping part and there shall be a wavelength of overlaying for the

Serial No.

Material name

thickness㎜

Volume weight ㎏/ｍ3

Usage temperature

Conductivity factor formula W/ｍ·ｋ

Quantity ｍ3

1

Rock wool

stitched blanket 50 120 ≤350 0.036+0.00015Tｍ

2

Rock wool

stitched blanket 80 120 ≤350 0.036+0.00015Tｍ




250

horizontal overlapping part; the whole insulation layer shall be sealed for water-proof

protection; there is only rock wool, no pressed steel sheets in the roof and there is

folded plate transition for the angular parts.

2) There are 17 sorts of pressed steel insulation sheets totally with 820㎜ in width and

are different in length.

3) The fixation is simple. Weld angle steel with round steel, then use hitter to rivet

connect the pressed steel sheets on the angle steels in turn and then connect 2

pressed steel sheets by rivet connection too. The rivet connection with angle steels

uses ￠5×11K self-plugging aluminium rivets; the rivet connection between the 2

sheets uses ￠4×6K self-plugging aluminium rivets.

4) Any of the triangular pressed steel insulation sheets cut down from bugle and ash

bucket shall be split jointed on the relative position with anther piece that has the

same serial No. as per the diagrammatic presentation.

5) Pay attention to the insulation turning parts and take the typical examples of the

drawing as reference, use bent plate of the corresponding part to transit and connect

with the pressed steel insulation plate. Use aluminum rivets to firmly fix the

connection. No need to say, the insulation layer at the corner shall be filled with

insulation materials and reach the insulation depth.

6) The construction, which is for the overlaying of the insulation materials and the

installation of the pressed steel insulation sheets, at some dead angles like the places

for the bracing of ladder and platform, vibration transmission and access door, etc.

shell be performed carefully to make the outer walls looks good.

6 The quality standard and control

6.1 The check reports of the insulation materials shall meet the requirements.

6.2 The span of the hook nails conforms to the designed requirements.

6.3 The welding of the hook nails conforms to the welding chapter.

6.4 The 1st layer’s seams are staggered and the 2nd layer’s seams are covered in the




251

main insulation layer; the thickness meets the designed requirements.

6.5 For the woven wire of the main insulation layer, the butt jointing of the woven wireis

firm and appressed on the main insulation. There is no broken end between thejoint

of the woven wires and hook nails and no empty layer on the surface. The woven

wires at the place of expansion seam shall be broken.

6.6 when the circumstance temperature is lower than 25℃, the outer shell temperature of

the metal can not be higher than 50℃ and be no more 60℃ for scald-proof

insulation; when the circumstance temperature is higher than 25℃, the outer shell

temperature of the metal can not be higher than 25℃+ T(the circumstance

temperature).

7 The safety precautions

7.1The staff who enters the construction site must stand to the relative disciplines of the

construction site, work overhead must wear safety belts;

7.2 Set up fence, temporary scaffold and security net in the overhead construction area.

The temporary security facilities shall be set up checked by special personnels and can

not be dismounted by irrelative people.

7.3 Try to avoid upper and lower construction at the same area and time; if has to, then

separate measures must be carried out.

7.4 Prepare tool bags for the overhead job, strictly prevent from the stuffs falling from high

places. Bind the stuffs that could fall down.

7.5 Check the scaffold before get on duty and solidify it if there is something wrong.

7.6 The binding for the platforms or self-made gangplank platforms shall be firm. The

piling up of the materials shall be decentralized and can not be over elevated, over widen

and over loaded used.

7.7 The mechanical lifting tower or wind lash for vertical transportation shall be installed

firmly and passed the inspection. Follow the operation code strictly. The bottom of the

lifting case shall be safety cushioned during goods unloading. The contact signals




252

between upper and lower places shall conform to each other. Nobody can seat in the

case. Set up fence for the entering and exiting gates.

7.8 Wear insulation glove while using the electric tools. The illumination meets the

requirements. Shut off the power, check the tools after work. Work has done, materials

have used out and the site is clear. Perform civilized construction.

The Erection Manual of Steel Structure



253




DOCUMENT TITLE:



REV. NO. :0

ENDORSEMENTS








254

CONTENTS

1.The basis for compiling the manual ……………………………………259

2.The range of erection and workload……………………………………259

3.The recommended list of T&P…………………………………………259

4.Recheck, marking and secondary grouting of the base plates…………261

5.The construction procedure and method………………………………261

6. The erection techniques of steel structure ………………………………266

7.The erection items which should be noticed………………………….267

8.The using standards and requirements of high strength bolts………...268

9. The measures and notice items of safety……………………………..271

10．Appendix……………………………….. …………………………….. …..275




255

1 The basis for compiling the manual 1.1 The general drawing of boiler unit

1.2 The drawing of foundation load of steel structure, Shanghai Boiler Works Ltd

1.3 The arrangement drawing of steel structure

1.4 The instruction of steel structure, Shanghai Boiler Works Ltd

2 The range of erection and workload

The boiler framework of the thermal power plant at Hisar India will be a whole-steel

structure. Its main parts will be jointed with high strength bolts. Its main body shall be

comprised of column, beam, vertical supporting, horizontal supporting, girder, platform

and stairs etc. The width (the distance between the left and right outside row of columns)

of steel structure is 42.6m; the depth (the distance between the front and back row of

columns) is 49.75m. There are 33 columns in the framework. The top elevation of the

framework is 92.5m. On the other hand, the minor parts in the framework, such as

platforms and stairs will be jointed by welding. The boiler steel structure will bear many

types of load besides the self-weight of the boiler, such as various steam & water

pipelines, oil/air/gas ducts, ash-blowing equipments, the sealing parts of the boiler,

platforms in various tiers and construction tools etc.

3 The recommended list of T&P

The T&P to be provided shall meet the construction requirements at site, this is a

proposed list of T&P.

The recommended list of T&P

Serial No. Name Numbers Type Note

Crawler crane 1 No. 600t

Crawler crane 1 No. 150t

spanner 15 No.s 22”

punch 15 No.s According to the bolt

chain hoist 16 No.s 2T Load test eligibility





256



jack 10 No.s 10T

jack 8 No.s 5T

iron hammer 10 No.s 4P

iron hammer 5 No.s 8P

crooked chisel 22 No.s #20

ø22

theodolite 1 No.s

gradienter 1 No.s

rope ladder 30sets 20m

pipe cutter 8 No.s

welding machine 2 No.s Direct current

welding machine 4 No.s alternating current

steel tape 1 No. 100m

steel tape 1 No. 50m

steel ropes 3 No.s φ11×6000

steel ropes 15 No.s φ15.5×

6000

steel ropes 4 No.s φ21.5×

6000




level bar 6 No.s 300mm

bare L-sqaure 5 No.s

windlass 6 No.s 5T




257

windlass 8 No.s 10T

Note: the general tools such as jack and steel wire shall be arranged as per actual

requirements.

The special tool for assembling high strength bolt:

Motorized spanner for preliminary screwing 4 sets

Motorized spanner for final screwing 4 sets

Manual spanner for preliminary and final screwing 6 sets

4 Requisitions before Erection 4.1 Checking and marking of the completed base plates

The installation of the base plates shall be completed. Recheck the elevation of the base

plates and column pedestals. The cross center line of the base plates shall be lined and

marked by painting, and extended to the side of the base plate. Match the cross center

line at the longitudinal and latitudinal center line of foundation, 1m elevation of column

shall be taken as the benchmark of the base plate. The base plate shall be fixed with

foundation bolt and in a horizontal position. The geometrical center line of the base plate

shall match with the corresponding axis of foundations

4.2 The secondary grouting of base plate

After foundation centerline marking and installation of base plate, check and qualify them,

sign acceptance. Start secondary grouting after completing erection of the first tier

structure. Take proper measures to ensure at least 85% contact between bottom of base

plate and grout top, for example, using non-shrinkable quick-setting concrete. No erection

activity to be taken up till the grout reaches its 85% strength

5 The construction procedure and method

5.1 The preparation before construction

5.1.1 All the drawings shall be acquainted and checked by related personnel before

erection of steel structures.

5.1.2 There shall be technical explanation from technical person to labor as per the

requirements of construction drawings and related technical documents.




258

5.1.3 Various measuring tools like steel tape, ruler, bare L-square and level bar shall be

calibrated before using to ensure measuring accuracy.

5.1.4 Count, check and number the equipments

l Match the number of parts like columns, girders and batter braces etc, with the

drawings and package list.

l Check the dimension of the parts according to the drawings. Any deviation shall be

within the tolerance.

l Visual examination is needed. Any cracks, sand holes, overlap or pits on the parts’

surface are not permitted.

Check the figure dimension. Check and note the length of columns and beams, the

dimension of end face, the camber and sweep value etc. to see if it meets the

requirements. Make sure the length, the dimension of end surface, side degree of

curvature、vertical deflection etc. of the girder are in conformity with the requirements.

Rectify the components which are beyond acceptable limits.

l Mark 1m elevation on columns. Measure from bolt holes center that on the top of the

first tier column, decide where 1m elevation is and punch on it as a line. Record the

distance between the punch and the column foot. It is required to match the column 1m

elevation with the civil benchmark elevation.

l Mark the front and rear direction of every columns.

l Find the centerline of columns’ wing plate and fin plate, and punch them then stick the

centerline tag on it. The friction grip surface shall be cleaned. Rust, oil stain and burr shall

be cleaned to ensure a healthy jointing.

l Number the equipments. Number it according to the drawings of Shanghai boiler

plant.

l Recheck and mark all high strength bolts at site by spectrum analysis prior to putting

them into use.

5.2The installation of equipments l The brief instruction of equipment’s installation process




259

l Install, align and accept the framework one by one in the process of boiler framework

erection. Erect the platforms and stairs, lift the flue and wind ducts to their position at the

same time if condition permitted. Each tier of steel structures shall be hoisted according to

the procedure, i.e., alignment, preliminary screw of the bolt, alignment and preliminary

screw of the bolt again, final screw of the bolt. After the acceptance, next step shall be

done.

l The basic procedure of erection: the first tiers installation—the first tiers

acceptance—erection from one tiers to another—acceptance one by one—the erection of

girder—the acceptance of girder—the overall acceptance of the steel structure

l The basic procedure of hoisting: in order to keep stability, it is required to erect from

the bottom to the top, from the front to the rear. columns shall be lifted to form stable

frame at the beginning, then erect and connect pieces together one by one till completing

steel structure’s assembly of the first tier, thereafter start the next procedure.

l The sequence of each tier installation: column—beam—vertical

supporting—horizontal supporting—check and accept

l The installation of high strength bolt: fix the punch—fit temporary bolt—adjust

geometrical dimension—replace temporary bolt with high strength bolt and preliminary

screw—final screw after acceptance—painting the completed joint.

l In the lifting process of steel structure, other components like flue ducts, down comers

etc, shall be located temporarily in time for future work if condition permitted.

l Prior to the installation of steel structure, the technician shall explain to all the workers

the requirements of safety and technology. In the process of installation, there shall have

professional measurers and calibrated measuring instruments to monitor the quality of

installation.

l To facilitate the transportation and lifting of drum and HP parts, some steel structure

components shall be installed afterwards. It is emphasized that any delayed parts should

not affect the strength and stability in general. The scheme of steel structure assembly

and girder hoisting will be improved after getting the relevant drawings at site, please take

attention to the new version at any time.

5.2.1 The installation of equipments

The steel structure assembly of the first tier.




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The columns shall be laid as per the sequence of construction. Put the column on the iron

assembly frame. The temporary platform (it shall bear the weight of the persons who

stand on it and construction tools laid on it) shall be built firmly at 800mm below the

connecting part between column and beam to facilitate the installation of beam between

columns. The column shall have rope ladders and guy rope with it. Determine the 1m

elevation and punch on it as a line.

According to the hoisting capability of crane at site, tie up column of steel structure with

steel wire, lift it with crane. When the column foot is lifted 100mm above the foundation,

keep it still and clean up clay at column foot. Then drop the components slowly to the

position and bolt it on the base plates. Adjust the horizontality and verticality of

components with the guy rope.

After the position and adjustment of column (H-3) hoisting, lift the column (J-3) to the

position in the same way. Then install the connecting beam between those two columns.

The installation sequence as follows: column（H－4）, beam (from H-3 to H-4), column

（J－4）, beam（from J-3 to J-4）, beam（from H-4 to J-4） and so on.

After the completion of lifting, the four columns form a stable frame like a door. The frame

shall be checked by theodolite with other auxiliary tools like guy cables.

After the process shown above, the next lifting shall be started according to the frame, the

sequence of lifting and installation: column（H－6）- column（J－6）- beam - column（H

－7）- beam - column（J－7）- beam - beam - column（H－5） - beam - (from the front

to the back)-columns and beams of the K row - columns and beams of the L row -

columns and beams of the M row- columns and beams of the N row.

The corresponding horizontal bracings, inclined bracings and sub-beams shall be

installed along with column of installation.

In order to facilitate person’s movement, the installation of platforms and stairs of the first

tier shall be kept pace with the main framework installation and completed with the

accomplishment of the alignment of main framework.

The boiler frameworks shall be aligned one by one in the sequence of their erection. It is




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forbidden to proceed with mounting of the next frame before alignment of the already

mounted frame to avoid uncorrectable mistake that might be found after the completion of

erection.

The alignment of the first tier steel structure:

The gradienter and theodolite shall be used for measurement and adjustment of

horizontality of frames and the height mark of the top column.

Adjust the space between the top of columns and diagonals by 50m steel tape, and then

record the measurement.

After the alignment of frame, temporary bolt shall be replaced by high strength bolt and

tightened to a preliminary torque value.

Tighten the bolts of the first tier framework finally

The second grouting of foundations:

Before the secondary grouting of boiler foundation, make sure that the oil stain, welding

slag and debris etc have been removed.

After the alignment and installation of main parts of the first tier framework and tightening

of the high strength bolts, the second tier installation shall be started and the installation

method shall be the same as that of the first tier.

The high strength bolt shall pass through the hole smoothly without being hammered. The

direction of fixation shall be kept consistent for proper tightening. The metal chip shall be

avoided to drop on the friction surface while the components are reamed. The reamed

holes shall be cleaned and removed.

When temporary bolts being replaced by high strength bolts, Unscrew the temporary bolts

after pretightening high strength bolts, tighten high strength bolts finally after completing

all replacement.

The installation method of the third, fourth, fifth, sixth tier etc. shall be the same as that of

the first tier.

The lifting method of girders will be specified in the girder erection manual. The hanger

beam which is related to hangers of HP parts shall be lifted with the hangers pre-installed.




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For some HP parts facility erection, there have some top beams remained, which

normally are not erected in advance. The erection for these should not be done until the

relative HP parts have been installed.

5.2.2 The overall alignment of frameworks

Align the verticality of frames by theodolite and record shall be done.

Measure the diagonals of space between top columns and keep record.

Control the height mark by gradienter and measure the height mark of the column’s top

and keep record.

5.2.3 The erection of top beam

In the process of lifting and erection of girder, the primary and secondary lifting shall be

instructed by supervision engineer and the location of hanger rods of HP parts shall be

kept in mind. The space for the lifting of HP parts shall be preserved.

6 The erection techniques of steel structure 6.1The preparation

The measurement and recheck of main dimension of steel structure shall be by virtue of

eligible measuring instruments. The outdoor measurement shall be carried out in the

condition as in natural situation. Measurement shall be made by tension-meter at the

same tightening strength (the range of tightening strength is between 5-15kg.)

6.2 The requirements for erection

A. After every tier steel structure erection has been completed, the panting for mark to the

high strength bolts should be available after the same has been final tightened.

B. The final tighten for high strength bolts used to next columns and main beams should

be completed along with the detail erection at present. And before the passing column

releasing hook, the quantity of temporary bolts at the connected plate for upper and below

columns should no less than 50%.

C. Measure the verticality of column along the center-line marking of column in X, Y plane

by theodolite, the measurement should be done by trained personnel and the record

should be kept.

D. The installation of beam and vertical bracings shall be done with safety and stability.

The number of temporary bolt on the beams shall be not less than 20%, and there are 2




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bolts at least. The lifting and installation of each tier platforms must be completed before

the lifting of next tier frameworks.

E．Since there will be a deviation of vertical and horizontal center line at the top of boiler

and on the ground, it shall be necessary to recheck the two vertical and horizontal center

lines by plumb-line and steel tape. Mark the center line with obvious sign with

centre-punch and red paint on the top plate beam. Mark the sign on each tier as reference

for the installation of other equipments and pipes.

F. The angle iron shall be wrapped well for the protection of steel frame and steel wire

while tying steel wires on the steel structure.

7 The erection items which should be noticed

l In order to avoid uncorrectable mistake which might be found after the completion of

erection, the steel structures shall be erected and aligned one by one after beginning first

tier. It is forbidden to proceed for mounting the next frame before the previous having not

been aligned.

l While the component is going to be put into position it shall be temporarily connected

by ordinary bolts, the number of which shall be not less than 20% of the holes on the

junction with minimum two bolts. The high strength bolts are then used for final

connection after the alignment of frames.

l After finishing the lifting and erection of the first floor frames, align the verticality of

columns, and then replace the bolts with high strength bolts. Recheck and accept the

verticality after replacing the temporary bolts. Tighten the high strength bolt finally.

l All high strength bolts of the lower columns and bracings shall be screwed finally

before lifting upper column.

l Before the hook is released, the upper column and lower column shall be well jointed

by jointing plates and temporary bolts.

l The measurement of verticality shall be completed by trained person using a

theodolite and maintain the record.

l The erection of beam and vertical bracings structure shall be carried with absolutely




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safety and stability, The erection of platforms and stairs shall be done simultaneously to

facilitate the movement of construction equipment and workman.

l During the process of erection of steel structure, it shall be forbidden to strike and

wedge to adjust it. The entire frame after the erection shall be without distortion and loose

connection.

l The platform of each tier shall be arranged in order. Ensure the erection angle of

stairs. The platform and stairs shall be erected simultaneously and welds shall be ground

to make surfaces smooth

8 The using standards and requirements of high strength bolts

8.1The deposit, storage and check of high strength bolts:

l The high strength bolt connecting shall be in conformity with the national standard

and supplied by the factory as a complete set with certificate card.

l In the course of storage, shipment and execution, the high strength bolt shall be

prevented from getting damaged.

l The dimension and technical conditions of high strength bolt connection shall conform

to the relevant technical regulation.

l The high strength bolt shall be tightened as per the torque limits given by boiler

supplier for respective sizes.

l Coefficient of anti-sliding of the friction surface shall be checked as per the

requirements. The minimum value shall be not less than the design regulation.

l If the package of high strength bolts have been damaged or have some quality

problems, the bolts shall be checked and qualified according to the boiler supplier

standards before using them.

l The high strength bolt shall be stored in classification by the specification noted on

the package box and deposited in the storehouse, the floor of which should be dried to

prevent rust and debris. Do not open the package and pile up the bolt before the time of

use.

l The specification and numbers of high strength bolt shall be as per the need of




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erection, and taken and receipt of these bolts shall keep record for checking. The surplus

bolts shall be stored properly and in order.

8.2 The erection requirements of high strength bolt connection:

l Make use of the high strength bolts according to its length and dimension as per

drawings without mixing them and it is forbidden to replace them with other bolts.

l Check the corresponding jointing surface before fitting the high strength bolts, the

joint plates and the installed area of components shall be clean and without oil stain, sand,

burr or welding slag. No painting before installation and completion of joints.

l While the high strength bolts are put into the hole, no hammering is to be done. The

components shall be revised if the bolts are not suitable. The used high strength bolts are

not to be reused for any permanent installation.

l The direction of bolts shall be kept consistent at the process of installation of every

set of high strength bolts

l The motorized spanner shall be calibrated by the standard instruments of checking

the torque before using it everyday and used for tightening the high strength bolt after

being qualified.

l While erecting the high strength bolt, the side of nut with strength mark and washer

with chamfering shall be toward outside (i.e. not toward the jointed surface of

components).

l Preliminary and final tightening of the high strength bolts shall be completed in the

same day in principle.

l When it rains and there is no shield for working, the tightening work of high strength

bolts shall not be done.

l Mark a sign on the high strength bolt after tightening it and anti-rust paint shall be

painted on it immediately.

l Do not damage and pollute the screw of high strength bolts to avoid changing the

torque coefficient.




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l For fitting the high strength bolts, the friction surface of component shall be kept dry

and fitting work shall not be done in rain.

l The connecting parts of high strength bolts shall be flat and cleaned without welding

splash and burr.

l The high strength bolts shall be put into the holes without hammering and can not be

used as temporary bolts. The direction of installation shall be consistent for facilitating the

work. When there is some mismatch between the holes of the jointing parts of

components, adjust it with punch pin.

l The hole which cannot be drilled through shall be expanded and rewelded based

upon the approval by chief construction manager (who is responsible for

design/manufacturing). The diameter of the re-drilled hole shall be not more than 2mm of

design diameter. The re-welding work shall be done with welding rod whose dynamics

capability corresponding to the welded parts and forbidden to plug the hole with steel

pieces. The number of re-welded hole shall be not more than 20%. Record the diameters

of all such holes

l If the hole on components to be reamed, it shall be taken care to prevent the metal

scrapes from falling between the friction surfaces and the burrs in holes shall be removed

after reaming. The maximum diameter shall be no more than 1.2d (“d” represents the

diameter of bolts) after reaming.

l In tightening the high strength bolts, it shall be done with two steps (i.e., the

preliminary and final tightening). For the preliminary tightening, it is to be 60%-80% of

designed pre-tension value and the torque of final tightening shall meet the requirements

of design. Generally the bolt ends shall protrude 2-3 thread pitches above the nuts after

final tightening.

l The sequence of tightening the high strength bolts shall begin with from the central

one of the junction and then extend sidewise in two directions.

l For a few of high strength bolts which are difficult to be tightened with motorized

spanner, it is allowable to be tightened by manual spanner, the mark should be given on




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screw bolt for finalized checking;

l During the erection, the motorized spanner should be check periodically.

8.3 The tightening of high strength bolt connection

l The sequence of tightening the high strength bolt connection and the torque for

preliminary and final tightening shall meet the design/manufactures requirements.

l After the final tightening has been completed, final torque check for hexagonal bolts

should be carried out after one (1) hour, there shall be a check of torque of final screw

within 48 hours. And the result of same check should meet the design/manufactures

requirements.

l The final tightening of the high strength bolts which are installed during a day shall be

completed the same day.

l In tightening the high strength bolts, it shall be done in two steps, the first step is

preliminary tightening, i.e., tighten the bolts with spanner to 60%-80% of designed

pre-tension value; the second step is final tightening, the torque of final tightening shall

meet the requirements of design and drawings.

l In order to have all the bolts subjected to the same strength, the preliminary and final

tightening shall be carried out by certain sequence. Generally the sequence of tightening

shall begin with from the central one of the junction and then extend sidewise in two

directions. The sequence for “H” type of steel junction shall be from the middle part then

to both sides edge.

9 The measures and notice items of safety

l There shall be a professional person responsible for the safety in the erection of steel

structure. The person shall be responsible for the safety management, check, and

supervision, and also the setting of warning marks of dangerous areas with the fulfillment

of safety measures in the related range.

l All the personnel who take part in the construction work shall be qualified with

certification and wear the identification.

l The inspection of safety work




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A. The state of personnel

B. The state of safety measures for lifting, such as steel wire, safety net, safety helmet,

safety belt and emergency staircase etc.

l The personnel shown below shall be not allowed to work at high level.

A. The personnel who is below 18 years old or 55 years old and above.

B. The persons who are not familiar with the usage of safety belt(The one who can use it

correctly after being taught can also be allowed to work at high elevation).

C. The person who got acrophobia, heart disease, epilepsy and so on.

D. The one who have mental problems or heavy physiological defects for their activity

capability.

E. The one whose high blood pressure is above 180p or the low blood pressure is higher

than 110p.

F. The rectify eyesight of two eyes is below 0.8.

G．the person who is hard of hearing, color blindness or asthma.

l The personnel who feel ill or in abnormal state shall be not allowed to work at high

level.

l When there is lightning storm, hail or the average wind speed is above 10m/s, the

work should be stopped. There shall have measures to prevent sliding and enough

lighting for work at night. The erection of heavy equipments shall be not allowed to carry

out at night.

l The one who drink before working shall be forbidden work at high level and stop work

temporarily with self-examination.

l The suspension cages、 big baskets、 suspension plates and ropes or other

equipments like that shall be forbidden to use as the suspension frame for construction at

high level.

l It is forbidden to use suspension cages which load goods to carry people up and

down.

l The material of temporary false work shall be checked for suitability. To build the




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temporary platform it is necessary to conform to the related regulation and check the such

platform firmly.

l The site shall be cleaned frequently and avoid debris dropped from the high level.

l The special person shall be assigned for the supervision of crane and inspect it

before working everyday.

l The operator shall be qualified for his work. The signal for command shall be clarified

for understanding.

l While starting the assembly work, the tools should be kept safely, the necessary

system should be confirmed to against drop and fall; all the tools and screws and other

hard material should be not tossed between the workmen engaged to do assembly

l If it is necessary that the workers shall work for a certain time and then replaced by

others. There shall have necessary segregating measures between upper and lower tier.

l The identification for work shall be carried out at the erection of heavy equipments.

l The special regulation of the motorized spanner for installing the high strength bolts:

A. The operator should wear glasses and ear guard as protective measures.

B. Regarding the operation for motorized spanner, the handle should be firmly griped by

the operating person.




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The preparation of construction

Clean up the equipment

Assemble joints

The erection of steel structure of the first tier

The alignment of steel structure of the first tier Inform to rectify

qualified for next step NO

Erect the second tier

The alignment of steel structure of the second tier

Tertius grouting of

foundation

Inform to rectify


The final tightening of high strength bolt of

Continue erection and alignment of the

third to seventh tier as per the same

The overall alignment of the steel structure Inform to rectify


The erection of the top girders

Completion

Centre-line the

girders

The erection flow of steel structure




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10．Appendix

10.1 Quality Inspection Standard of Column

Quality inspection process

Check items Class unit Good Excellent

Checking method and measure tools

Equipment appearance Without crack, double -skin、serious rust、

damage Observe

Workshop weld seam Conform with manufacture’s requirement

Material character

main

Without misuse Check against material technique

documents

Height deviation of girder

Conform with manufacture’s requirement

Width deviation of girder

≤1/1000(girder length)，full length≤10


check

torsion value of girder ≤1/1000(girder length)，full length≤10

Lay girder on level, weld same height round steel to the four

square of the girder. Put two steel wires for diagonal lines on the top, measure the distance of the center

point of the two lines, half of the distance is torsion value.

L≤4m ±2

Height deviation

of bracket L＞4m ＋2 －4

According to the same datum plane(end face of each pillar),

measure the height of bracket’s two ends and get the average

value.(steel rule should be tested to be qualified, when the rule works, it should be tensed by spring balance

with 10kg force)

Girder check

Bracket gradient

mm

≤2

According to the same datum plane, measure the height of bracket’s two

ends and the height deviation is level gradient (steel rule should be tested to be qualified, when the rule works, it should be tensed by spring

balance with 10kg force)); as the cylinder for reference, measure hade by angle rule and feeler.




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10.2 Quality Inspection Standard of Beam Quality inspection

process

Check items Class unit Good


Equipment appearance

Without crack, double -skin、serious rust、

damage Observe

Workshop weld seam

Conform with manufacture’s requirement

Material character main Without misuse Check against material technique

documents

Beam length deviation

mm 0~-10

Measure length and heights of foursquares, and get the max

tolerance. (steel rule should be tested to be qualified, when the rule works, it should be tensed by spring

balance with 10kg force)

deflection and twist value of beam

mm ≤1/1000(girder length)，

full length≤10


check

Beam check

Diameter and position of beam lift

hole Conform with drawings

Measure by steel rule (steel rule should be tested to be qualified, when the rule works, it should be


10.3 Quality Inspection Standard of Single Column Quality inspection

Check items class unit Good


Column elevation deviation mm ±5

check 1m elevation of column by water level by

reference of turbine house benchmark

process

Respective elevation deviation of each column

mm ≤3 Measure by reference of

1m elevation of each column




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Space deviation between each column

mm ≤1/1000(column distance),

and≤10

Measure the distance on top, middle and bottom of

column (steel rule should be tested to be qualified, when the rule works, it should be tensed by spring balance

with 10kg force)

Perpendicularity deviation of column

≤1/1000(column distance)，and≤15

check by theodolite in two directions which have

90°difference

Column top big/ small diagonal

Column diagonal deviatio

n big/ small diagonal

on 1m elevation

main mm

≤1.5/1000(diagonal length ), and≤15

Use steel rule check big diagonal of each column and

its relevant small diagonal (steel rule should be tested

to be qualified, when the rule works, it should be tensed by

spring balance with 10kg force)

10.4 Quality Inspection Standard of Single Beam

Quality inspection process Check items class unit

Qualified


Elevation deviation ±5 Measure by reference of 1m

elevation of each column

Horizontal deviation ≤5 Check both sides position of girder on the top by glass level

pipe


mm

±5 measure the distance from

girder centerline and column centerline by steel rule

Installation of fish plate Flat, in correct position, and close to component Observe

welding Conform with manufacture’s requirements

Installation of each beam

High strength bolt

main





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10.5 Quality Inspection Standard of Boiler Roof Steel Structure Installation Scoring

Quality inspection

process

Check items class unit

Qualified


Deviation between roof column girder

and its center main mm ≤10

Draw vertical and horizontal centerline of girder supports

on top column by reference of boiler 0m centerline. Use

theodolite or plumb, line and rule for checking. (steel rule

should be tested to be qualified, when the rule works, it should be tensed by spring

balance with 10kg force) Elevation deviation

of roof column ±5

Elevation deviation between each

column

main mm

≤3

Check the center of roof column supports with

reference of 1m elevation of one column

space ≤10m

±1 Deviation between each top column support

space ＞10m

±2

Steel rule check(steel rule should be tested to be

qualified, when the rule works, it should be tensed by spring

balance with 10kg force) diagon

al ≤20m

≤5

Installation and scoring

Deviation between supports diagonals

of top olumns

diagonal

＞20m

main mm

≤4

Steel rule check(steel rule should be tested to be

qualified, when the rule works, it should be tensed by spring

balance with 10kg force)

10.6 Quality Inspection Standard of Boiler Roof Steel Structure Installation

Quality inspection

process

Check items class unit

Qualified


steel structur

Deviation of girder support and top column plane

support centerline main mm ≤3 Steel rule




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Elevation deviation of girder

±5 Measure with reference of 1m

elevation of one column

Horizontal deviation of girder

main mm

≤5 Check both sides position of

girder on the top by glass level pipe

Space deviation of girder main mm ±5

On the position of f girder’s both ends, measure the distance of longitudinal centerline between girders’ top and bottom cover

board. Steel rule check(steel rule should be tested to be qualified, when the rule works, it should be


Horizontal deviation of girder

≤5 Calculate according to space

deviation of girder

Diagonal deviation of girder

main mm ≤1/1000(diagonal length ),

and≤10



Position deviation of beam lift hole

mm ±3

According to drawings and take girder vertical and horizontal

centerline as benchmark, measure by steel rule (steel rule should be tested to be qualified, when the rule works, it should be


Diagonal deviation of beam lift hole

mm ≤1/1000(diagonal length ), and≤10



Installation of fish plate Flat, in correct position, and close to component Observe

Weld main Conform with manufacture’s requirements




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High strength bolt installation


10.7 Quality Inspection Standard of High Strength Bolts

Quality inspection

process

Check items class unit Qualified


φ≤17mm ＋1.0 0.0

Tolerance of bolt

aperture φ＞17mm

mm ＋1.5 0.0

φ≤17mm ≤1.0 Ellipse of bolt hole

φ＞17mm mm

≤1.5

Bolt, nut appearance No crack, damage, thread is in good condition,, no oil

filth, rust and etc.

Equipment check

Check of bolt, nut and washer Conform with equipment

technical documents

Node attrition joint face

Appearance treatment meets the requirement of

equipment technical documents; no rust peel,

oil filth, dust; no disfigurement like

deformation, warped, bend, burr

Bolts connection

Bolt, tighten torque main Conform with equipment

technical documents

600 Mw Boiler Erection Manual

Documents

Transcript of 600 Mw Boiler Erection Manual