Documenti di Didattica
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MANUAL
(Supporting Structure)
Prepared by
1
INDEX
1. A) Introduction B1 – 01-0101G
B) Erection Sequence
B) Erection of Girders
9. Annexure
2
A) Introduction
a) Tower Crane
b) Crawler Crane
iii) All Columns in Air Pre heater area are also to be erected.
iv) Erect Ceiling girders G1L, G2L, G3, G2R and other Welded and
rolled beams.
3
C) Derrick with Crawler Crane
iii) Along with the sequence of erection of ceiling girders the middle row
columns (S14, S15) including the one which deferred (S13 orS18) are
to be erected with the help of derrick or crawler cranes.
i) Crawler Crane:
iii) Derrick
C. Measuring Instruments
Tape
5M 4 Nos
30M 2 Nos
Dumpy level
4
Theodolite
In addition to the above piano wire without knots and kink~ plumb bob
with oil dash pot and thermal chalks to be made available.
FOUNDATION CHECKS
vii) Clean the foundation top surface, bolt pockets and shear lug
opening.
ix) Check the freeness of nut over foundation bolt threads. Bolt
thread ends to be protected till final fit up.
5
- Elevation of top pf pedestal - “B” mm
thickness of packer required = (-B) – (-A) = - „t‟ mm
6
7
E) Position of Packers (Refer Fig. 2)
ii. Packers are to be located below the columns flange line and parallel to
the flanges. Wherever shear lugs are interfering, the packers are to be
cut suitably.
iii. Chip the pedestal surface at packer location for proper seating of
packer.
Or
The first packer can be aligned over the rough concrete (without
chipping for level) using high strength quick cement. Allow the mix to
cure as per the manufacturer‟s recommendation.
iv. Further packers/ shims are to be provided over the aligned forst
packers to achieve the calculated thickness of packers.
8
Fig. 2
9
a) Pre Assembly of Column:
Work order no
PGMA
DU
No.
Column designation
Note:
1)
10
2) Do not sling structural members without application of protective
materials like flexible thick non metallic piece.
iv) Check and measure the following in the individual pieces. Ensure they
are within the limits. Otherwise…………
Fig. 3
11
Fig. 4
12
Fig. 5
13
Fig. 6
14
….. refer to manufacturing unit for repair procedure / Comments.
Camber
Sweep
Twist
Ensure cleanliness of cover plate area 1n the flange and web in the
column joint area and HSFG
Bolt area.
v) Align all the pieces by pulling each piece to have proper contact at
milled end and tighten with service bolts in the rest plate provided on
the flanges of the column Pieces.
Camber and sweep for the full length of assembly (the permissible
limit is 1mm/ M Max 18 mm).
ix) Position the cover plate with shims (for change is sections) supplied
with web Supplied with web and flange. No interchanging of cover plate
is permitted. (Shop match marks are to be followed).
x) The service bolts (HSFG, Bolts shall not be used) for positioning the
cover plate.
Gas heating (neutral flame can be adopted for thinner sections (up
to 40 mm)
xii) Prior to welding ensure the contact area between flange and flange
cover plate to achieve the same “L” Clamp with wedges is to be used.
15
Fig. 7
16
xiii) On random samples carry out LPI/MPI on weld to ensure the
soundness of the weld. (Ref. Fig.5A & 5B).
xiv) Punch mark the elevation at every 5 meter from top. (Say 57.xxx, 55,
50 … 5, 1 and 0). See Fig: 6.
xv) Accordingly punch mark the 1 M and 0 M elevation over the bottom
piece.
xvi) Measure and record the distance from „O‟ Meter to bottom of the base
plate. Based on this the packer thickness for individual column is
decided.
xvii) Cleat angles to be welded at the appropriate level for the placement of
horizontal on flange and web side.
xviii) Fix the vertically stickers over individual column pieces on web and
flange in two places (near MBL Locations).
- For bottom piece at 1 „M‟ elevation and below the both joint area
at the convenient level.
- For other pieces near ends (just near bolt area) at the convenient
level.
Note: The center line of stickers shall be matched with center line
marking of web and flange (shop punched) Refer Fig:7.
xix) Dismantle the column pieces from the pre assembly bed and stack it
near the erection area. To suit the sequence of erection, piece by
piece, from bottom to top.
i) All the column pieces are to be identified with work order no., PGMA,
DU no. and column – designation which are stenciled and punched on
each piece.
iii) Punch mark the „0‟ Meter and „1‟ meter elevation over the bottom
piece.
iv) Check the distance from „0‟ Meter elevation to bottom of the base plate
to calculate the packer thickness.
17
v) The variation, if any in shop punched overall length variation (O LV and
site measured O LV to be informed to manufacturing unit for
comments.
Fig. 8
18
Fig. 9
19
vi) Check individual column piece camber, sweep, twist and milled end
condition, Inform manufacturing unit on deviations for correction /
comments.
viii) Clean the HSFG bolt area in the column pieces and cover plate area.
The cover plates moved from column pieces are to be identified and
kept separately for re-fixing at the correct location during erection.
ix) Fix the cleat angle at the appropriate location on the flange and web
portion of the column pieces for placing the horizontal members.
ii) Place the column piece over the foundation with out damaging
the Bolt threads, while lowering the piece through bolts. Tighten
the bolts prior to releasing the load from crane.
iii) Erect all the first piece of the columns in this manner
iii) Align the individual pieces (verticality etc.) for the following (Ref. Fig.9)
vii) Check the length of the horizontal member and compare with the
measurement of space between columns (Any minor correction on
horizontal member to be some at ground level).
20
Fig. 10
21
Fig. 11
22
Box II S11 – S12 – S3 – S4 (Left & Right . Fig: 10B)
ix) Measure the distance between Box I to Box II and Box III on both sides
and tally with horizontal member length measured at site (necessary
correction on horizontal member to be carried at ground level (Figure
10 D).
xi) Complete the welding of cleat angle with horizontal member and
column (between boxes).
xiii) Position, align and weld the gusset plate at its location.
xiv) Position, align and weld/ bolt the vertical bracing with gesset plate
(Refer Fig: 12 – A to E)
xv) Erect the front middle and rear middle column pieces and align as
explained for other pieces.
xvi) Erect and align the horizontal members and vertical bracings and
complete the welding.
xvii) Complete the erection alignment and welding of Main brace level
(MBL) members in the boxes ups section.
xviii) Check the vertically of all columns and compare with previous
readings.
xix) Complete the grouting up to the bottom of the base plat and cure.
(Ref.Annexure - 4).
xx) Prepare the protocol for the completion of first piece erection and
obtain clearance for second piece erection.
xxi) The above mentioned steps are to be followed for subsequent piece
erection (Ref. Fig: 12)
- After the erection of second and subsequent piece the flange cleat
bolts (at 4 locations) are to be tightened uniformly.
- Provide web cover plate on either side following the shop match
marks.
23
- Fix the required length HSFC bolts with washer on nut side and snug
tighten the web cover plate (Refer Annexure 5).
Fig. 12
24
Fig. 13
25
Fig. 14
26
Fig. 15
27
Fig. 16
28
Fig. 17
29
Fig. 18
30
Fig. 19
31
Fix the required length HSFG bolts with washers on nut side and snug tighten
the flange cover plate.
If the bolt length at a particular joint is more (shank length) hardened washers
upto 3 Nos. (max 4 Nos) have to be used and placed suitably.
Note: Flange cover plate fixing for columns erected without Pre-assembly.
a) If the pre assembly of flange cover plate is not done follow the
sequence for fixing the flange cover plate for all column joint with
HSFG bolts and welding‟ as shown In Figure 14B.
c) Preheat and weld the flange cover plate to the column, after ensuring
proper contact. If mentioned in the drawing.
d) Fix the HSFG bolts with washer and snug tighten them.
xxii) HSFG bolts in flange and web areas are to be tightened only by TURN
OF NUT METHOD following the sequence explained for snug
tightening. Cross check the tightened bolts using calibrated Torque
wrench. (Set the torque wrench to required value using bolt tension
calibrator) (Ref.Annexure -5).
Note:
a) The vertical bracings at the top levels may be deferred till the erection
and alignment of first and last ceiling girder for easy adjustment. Rest
of the columns erect the vertical bracings and do final welding.
c) Prior to erection of top piece, the girder pin connection matching and
welding of support plate with column top shall be completed as
explained below:
32
The girder pin connection assembly is applicable for S11 & S13
columns (both right & left) and S18, S19 and on beams connecting
S11L – S18 – S11R and S13KL- S19-S13R. (Refer Drawing: Pin
connection key plan.
Align the axes girder pin bottom part and column top.
33
Fig. 20
34
Typical girder pin connection details are shown in the Fig: 15 A to be obtained
from Trichy.
Check the contact better bottom part pf girder pln with flange web and
stiffener portion of column top using feeler gauge. Full contact is to be
ensured.
Assemble the holding down plate with fasteners and align with column
top and pin assembly bottom part on either side of the flange.
Tack- weld the holding down plate with column and bottom part of pin
connection. Provide stiffener to avoid welding distortion.
35
Fig. 21
36
Fig. 22
37
d) Welding and NDE Requirements:
1.0 Welding
g) Welding shall not be done when the surfaces are wet, oil traces are
seen or exposed to rain or high wind or when the welders are exposed
to inclement conditions.
h) The sizes and length of weld shall not be less or substantially in excess
than the specified in the drawing.
i) Butt joints
38
t < 25 mm MPI / LPI on finished welds limited to 10% of weld
length at random.
PGMA
DU NO.
Girder designation.
Position the girder pieces over the pre-assembly bed (made for the
columns) keeping left, middle and right side pieces following shop
punch mark details.
Sweep
39
a) Preassembly keeping WEB Horizontal:
Numbers indicated in circle are the near side of the flange and
other numbers are for farther side of the flange.
Camber
Sweep
Weld fir up at the flange and web joint use „L‟ clamp (Ref.
Fig: 17B).
40
2.0 Preheating
3.0 Welding
b) Complete the root plus three runs on inner side as per the
sequence shown in Figure 17D.
c) Back gouge / chip the weld from outer side and carry out
LPI/MPI for ensuring defect free root weld.
d) Complete the outer side welds for three runs as per the
sequence indicated in Figure 17D.
h) Preheat to 150oC and adopt the weld sequence for the web
root. Welding plus two runs as shown in the Figure: 17D.
41
42
Fig. 23
43
Back gouge/ ship the second side of the weld to achieve defect free
root: weld.
Complete the two runs of weld on the second side as per the
sequence shown in Fig: 17E,
Complete the balance flange joint and then the balance web joint as
per the sequence indicated respectively in Fig: 17D & 17E.
Note: The welding sequence of flange and web can be changed depending on
the number of welders engaged.
Complete the fillet welding between flange and web on both sides.
Carry out the post heating of weld joint for 1 hour at 250Oc.
For effective weld thickness > 50 mm PWHT shall be carried out for
carbon steel material.
Note: For preheating, post heating and PWHT the temperature range given in
Erection weld sequence (EWS) to be referred.
5.0 NDE:
Carry out the following NDE checks (Also refer point no. 8.0 in page 16 of this
section)
Note: Fix and Weld the loose stiffener plates coming near the Girder pre-
assembly joints, before doing the post weld Heat treatment.
44
ii) Clean and paint the weld region.
iii) Check the holes drilled in the web of ceiling girder (distance from the
end and C/L distance of each group of holes which is the C/L distance
of W.B‟s ).
Fig. 24
45
iv) Check the size and location of pad plates welded on the web of ceiling
girder. These pad plates are to be welded only on sides and bottom
face.
a) Identify the pieces as per work order No. PGMA, DU and Girder
No.
d) Check the web height (between flanges‟ Inner sides) at field joint.
e) Check the condition of edge preparation at the field joint and carry
out correction, if necessary.
2.0 Fit Up
b) While adjusting the over all length of girder, check the distance
between girder pin connection bolt hole centers which is marked
in the bottom flange as well as top flange.
c) While adjusting the over all straightness of the girder piece the
longitudinal centre line of the girders and web line marked on
the pieces may be taken as reference.
d) While matching the piece, flange root gap and web root gap
shall be maintained between 4 to 6 mm and 6 to 10 mm
respectively in the field joint areas. The reference lines punched
46
on the flange and web on the either side of the joint may be
taken as reference (Ref.Figure: 20).
Fig. 25
47
i) No tack weld to be made in the web for aligning.
Instead „L‟ clamps and wedges shall be used for web alignment
to keep the joint free during the welding of flange joint.
Section depth up to 1 M : +/ - 3 mm
Above 1M : +/ - 4.5 mm
Up – to 2 M : + 7.5 mm
Above 2 M : - 4.5 mm
48
9. Welded beam location distance on either side of the field joint.
(With the recommended gap for welding of web and flange at field
joints, the overall length of the girder shall be achieved within limits
after allowing weld shrinkage).
5.0 Pre-heating
i) Flame cutting
ii) Welding
T UP TO 19 mm : Nil
T Over 19 mm UP TO 38 mm : 65OC
T Over 38 MM UP TO 63 mm : 100oC
T Over 63 MM UP TO 19 mm : 150Oc
49
c) When electrode of 3 mm and below are used the minimum pre-heat
temperature shall be increased by 50Oc from the pre-heat
temperature mentioned above.
6.0 Welding
50
Fig. 26
51
Fig. 27
52
a) Butt welds in plates over 50 mm thick shall be PWHT for
unequal thickness of plates, the groove depth at the Weld shall
be considered for PWHT.
b) The fillet welds for fixing attachments like pads etc, made on
tension flanges over 50 mm thick shall also be post weld- heat
treated.
b) The fillet welds for fixing attachments like pads etc, made on
tension flanges 50 mm and above thickness shall also be post
weld heat treated.
For the fillet welds joining the tension flange to web need not
carry out post weld heat treatment.
All the post weld heat treatment Cycle shall be 600Oc to 650 Oc .
The above cycle shall be controlled within a tolerance of + / -
10Oc.
The heating rate above 400Oc and cooling rate after PWHT up to
400oC shall be as follows:
53
Fixing and location of thermocouple shall be made as per details In
Welding Manual Volume I (Chapter IV sheet 7/30).
8.0 N.D.E
Cut edges
a) Flame cut welding edges for thickness over 30 mm.# 100% MPI.
a) 100% LPI for back gouged / chipped area before second side
welding.
Fillet Welds
54
“No stray arc” shall be done on heat treated members.
2) The reference axes used for pin connection assembly with column top
to be matched with ceiling girder bottom bolt hole axis.
3) Check the contact between pin connection assembly top part with
ceiling girder bottom flange.
4) Fix the holding down plate on either side of p1.n assembly and fasten
the same with ceiling girder.
5) Check the alignment an tack weld the holding down plate with pin
connection top part. Provide stiffener to avoid welding distortion.
10) Dismantle the pin connection and carry out the following.
- Clean the pin surface and matching surface of top and bottom part.
- Inspect the pin rod for any visual defects and carryout LPI test.
- Tack weld the clip with top part of the pin assembly to avoid tilting
while erection. The tack weld to be removed only after the alignment of
ceiling girder to make the pin connection effective.
10. The lifting lug provided, over the individual ceiling girder piece are not
meant for lifting total assembly. The suggested lifting arrangement is
given in Fig. 23.
55
b) Centre line of ceiling girder is punched on either side of top flange.
This will enable to know the difference between boiler axis and
C/L of ceiling girder after erection.
12. Assemble the girder pin connection with respective ceiling girder
bottom.
13. Lift the girder and position over column either from front end of from
rear and to suit the site condition and major T & P used for erection.
Ref: Fig. 24 A for combustor ceiling structure key plan & fig. 24 B for
back pass ceiling structure key plan
Align the axis WB, bolt hole, with left, right and middle column S11R
– S18 – S11L bolt holes. Align pin bottom part and column top.
Align holding down bolts holes with column top and fasten the
same. Long stud bolts shall fasten with ceiling girder and column
top or furnace side.
Note: Provide stay rope till the ceiling girders are boxed up with
WBs for safety reasons.
56
16. When two adjacent ceiling end RB‟s are positioned, tack weld the cleat
angle.
Note: In welded beams, pad plates are welded for facilitating the
erection of rolled beams over it. Hence before lifting the WB‟s ground
with respect to WB drawings.
18. Align all ceiling girder and check for the following: (Refer Fig: 24 B).
- The left out stiffener plates are to be welded with ceiling girder.
20. Erect, align and weld all ceiling bracing members and compression
members between ceiling girder top.
Note: The members in the drum lifting region may be deferred till the
completion of drum lifting and the same shall be erected immediately
after the drum lifting operation.
21. Check the vertically of all columns after the alignment fo ceiling girders.
22. Transfer the boiler axis from the ground to ceiling girders top.
23. Record the difference between the transferred boiler axis to center line
of individual ceiling girder.
57
Fig. 28
58
PREPARATION FOR DRUM ERECTION
1. Mark the drum axis from F3 – F F4, F1- G2, B1- B2, Beam D, Beam G,
Beam B1 – B2 center line and arrive at combustor axis.
2. The drum, Combustor And Back Pass boiler axes shall be punch
marked over WB‟s and ceiling girders G1 (L & R, G2 (L & R), G3 (For
boiler drum and pressure parts Erection reference).
3. Erect, align and weld the drum suspension support beam on either side
of boiler axis as per approved drawing.
5. Erect. Align and weld cat head structure (“A” frame) for the purpose of
drum lifting arrangement as per contract drawing.
6. Erect, align and weld staircase on both sides up to ceiling girder level
an drum level (Ref. Section on Stairways & Galleries).
Ceiling girders
Ceiling bracings
59
PGMA Description Weight (Tons)
G. Total 3849.7
Required floor and stairs along with Floor grills for Drum lifting is planned to
be released under PGMA 35-390.
Horizontal bracings on all main brace levels (MBLs) between columns and
Out side columns.
60
Inside combustor expecting rear pass and Inside back pass excepting
front side up to drum path.
Horizontal bracings left out in the drum path are to be erected immediately
after drum erection.
61
POST DRUM ERECTION CHECKS AND WORKS
The left out member in MBL for drum erection in the combustor and
back pass region are to be erected.
Erect align and weld all rolled beams for starting of pressure part
work.
2.0 Complete the erection alignment and welding of monitor roof assembly
(Ref Fig No. 25A & 25B)
62
Fig. 29
63
PLATFORM, STAIRWAYS & GALLERIES
Structures for stairways shall be erected such that the proper slope, as
envisaged in the design – documentation are maintained.
Stairway structural shall be checked up for proper fit up of Toe plates and end
connections of step / treads. If due to some reason the connections are loose
and the toe plates are not available they shall be re-fixed/ tightened again
before commissioning.
Stairs shall be guided by two sets of hand rails and posts and special bends.
They shall be fitted parallel on each side of the stair stringer beams either
through bolted connection or welded connection as per dimensions given in
the design documentation. The spacing of the posts shall not be greater than
1800 mm or as specified in the design documentation.
Hand railing between two levels shall be connected smoothly by using special
bends or 90 elbows.
Hand railing and posts having well- finished and not got bent or twist during
transporation, stacking and handling shall be used. They shall be fixed to the
structural beams such that they are truly parallel or perpendicular to the
member concerned.
Platform, beams around the main structures connected and stiffened to the
main structure as per the design documentation.
Wherever floor gratings are fixed using clips and studs, they shall be done
using minimum of four clips per grill.
Clips shall be fixed that they shall not project above the grating so as to cause
hindrance to walkway. Load bearing bars of the grills shall always be kept
such that they are perpendicular in its own plane to the main load bearing
member of the platform beam.
Platforms around the furnace shall be fitted with two sets of parallel hand
railings and vertical handrail posts such that they are always available to give
the safety requirements for walkway around the steam generator. They shall
be fixed as per design documentation. All square corners shall be connected
smoothly using 90 elbows. Any undue projection around the floor shall be
offset by providing necessary hand railings.
64
Guard plates shall be fixed as per contract drawing so s to give the necessary
safety facility during erection and usage.
Note:
Ensure that undue excessive loadings are avoided on the platform than for
which they are designed. Concentrated loads caused due to piling of welding
gas cylinders shall be avoided.
65
Fig. 30
66
Fig. 31
67
Fig. 32
68
Fig. 33
69
Fig. 34
70
Fig. 35
71
Fig. 36
72
Fig. 37
73
Fig. 38
74
Fig. 39
75
STRUCTURAL STEEL ERECTION NOTES
ii) Surface preparation holes is 12.5 Microns and edge preparations for
welds is 25 Microns unless otherwise specified.
iv) Holes for bolts shall not be formed by gas cutting process.
viii) Every bolt shall be provided with a steel washer under the nut so that
no part of the threaded portion of the bolt is within the thickness of the
parts bolted together.
x) Ends of members are to be cut at site to suit opposite profiles (if not
already done).
xi) Ends of the members are to be welded all round to opposite profiles
are as follows, where ever not indicated otherwise.
Sl. Size of
Section
No. Weld
I 600, L130 X 130 X 12
1. 10
L150 X 150 X 12
I 500 L 450 X 1400 X (1400)
2. 8
L 100 X 100 X 10
I 350, I 300, (300, [250, 1250])
3. 6
L 80 X 80 X 8
I 200, ([200],150, L75 X 75 X 61)
4. 4
L 65 X 65 X 6, L50 X 50 X6
5. I 150, I 125 4
76
xii) The symbol shown the floor drawings indicate the symbol shown
direction of load bearing bars of the grill.
xiv) Place one hardened steel washer under element turned (nut or bolt
head) during tightening.
xv) HSFG Bolts once tightened are not to be slackened, removed and
Reused.
xvi) Hand railing shall not cantilever more than 900 mm beyond the last
handrail post.
xviii) Flame cutting shall be permitted for coping, trimming, cutouts or other
minor rework of members required to be performed with the approval
of, or as directed by the Erection Engineer. Flame cutting is not
permitted for relocating or enlarging of bolt holes.
77
MANPOWER REQUIREMENT FOR STRUCTURE ERECTION (UPTO
DRUM ERECTION)
1. Fitters 1200
2. Rigger/Khalasi 3600
3. Welders 1350
5. Grinders 300
7. Electrician 300
8. Helpers 3000
Total 12,150
78
Fig. 40
79
BOILER SUPPORTING STRUCTURE ERECTION TOLERANCES
I. Foundations:
15 mm
Grouting gap:
30 mm (Min.)
70mm (Max.)
1 mm per Metre
Max. ± 5 mm
Max. ± 15 mm
1 mm / Metre
1 mm / Metre
II. Column
80
III. Ceiling Girders
girder piece
well as Camber
Mating surface of the bottom flange of the ceiling girder where it comes and
sirs over the column top pieces shall not have twist or warpage more than 2
mm.
IV. GENERAL
Straight flat bars of floor grills (load bearing members shall span in
between two supporting beams of platforms).
81
GROUTING
The grouting of annular space the column bass shall be grouted after the
completion of erection and alignment of first piece tier of all main and auxiliary
column (bottom piece) with connected beams and vertical bearings.
Grounting Material
Desirable to use, with the cement mortar, stone chips 6 mm and down
graded. This mixture of cement mortar and stone chips is referred to
commonly as „Cement concrete grout‟.
The grout space below base plate shall be generally not less than 20 m or not
more than 70 mm. Refer foundation drawing.
Accordingly cement concrete grout is used for Boiler column Base Foundation
Grouting.
2. The composition of the grout mix shall such that it ensures n ultimate
strength equivalent to one grade higher than the grade of concrete
adopted for foundation. E.g. If concrete foundation is MISO, Grout mix
shall be M200.
3. The proportion of grout shall have minimum water required for giving
consistency and, fluidity and to have minimum shrinkage. The extent of
shrinkage will depend on the water content in the grout and keeping water
minimum will control shrinkage.
82
Additives
Apart from reducing water content, the shrinkage of grout could be controlled
by using expansive additives. Aluminum power has been used for a long time
as an additive to reduce shrinkage of grout. The theory relating to the use of
aluminum powder is that it reacts with the alkaline constituents of cement and
generates hydrogen gas, resulting in expansion of the mortar and thereby it
enables the grout to fit snugly in the space which confines it. The proportion of
aluminum powder additive usually recommended is – 1 teaspoonful (about 5
gm) for each 50kg of cement.
Cement concrete mix 1: 1: 1 (i.e.) one part of fresh Portland cement 1 part of
well graded sand and 1 part of hand broken blue granite stone gelly passing
through 6 mm can also be used for General Grouting. The Portland cement to
be used shall conform to IS: 269 or equivalent.
1 Part Cement
Fluid Mix Under 25 0.44
1 part sand
83
Special Grouts:
a) SHRINKOMP
Shrinkomp N Shrinkomp H
Conbextra GP 1
(20) (20)
b. Ferrogrout
The mix proportion for the grout shall be one of the following alternatives.
Or
Add 50 kg of ordinary Portland cement with 100 ibs of Ferrogrout, 100 Ibs of
clean dry sand 150 Ibs of stone chips 6 to 10mm size (clean and graded)
using about 22.5 litres of water. In this proportion mix enough grout for the
space to be grouted.
a) More fluidity
b) Non- Shrinkage
84
c) Quick Setting
d) High strength
Procedure
The space between the machine base and the top of foundation should be
thoroughly cleaned with compressed air and moistened with water before
applying grout. Oil or grease should be treated with a caustic solution and
thoroughly flushed or removed by chipping to a sufficient depth. The machine
base or sole plate should be cleaned of rust, mill scale, paint or oil.
Water particles entrapped in the grout space shall be removed before grouting
is started.
Use proper form work on all sides of the base plate to prevent escape of the
grout.
Form work around the base plated shall be form to prevent any leakage of
grout material.
Mixing of the grout shall be one in a mechanical mixer for about 3 minutes to
obtain a fluid of uniform consistency. It is desirable to mix the dry constituents
thoroughly before adding water. The quantity of water may be varied slightly.
At the discretion of Engineer – in- charge to suit each application. Mixing shall
be done as close as possible to the area of application. Mixing shall be done
as close as possible to the area of application.
Place the grout uniformly and compact by thorough manual Roding except
where insertion of needle vibrator is possible. The entire process of mixing,
placing and compactness shall be done in a fast and continuous manner and
grout shall be a single cast.
Care shall be taken to see that grouting material is evenly spread under the
base plate and the top rough concrete and uniform consistency is maintained.
Curing should be done for a minimum period of 7 days. The exposed faces of
grout may be covered with wet sack during the curing period.
During this period it would not be advisable to load the foundation through
substantial loads from columns.
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ANNEXURE – 5
1. Clean the HSFG bolting area. At the time of surface in contract should
be free from paint or any other foreign material like oil, dust, burrs and
other defects which would interfere with the development of friction
between them.
2. Ensure that the alignment of members is such that the bolts for the
holes freely – forcing the bolts into the holes by means of hammering
which will damage the threads, should be avoided at all costs.
3. Fix all the ASFG bolts nuts (of specified length and grade) with correct
washers.
5. The nuts shall be so placed in the joint that its identification mark is
clearly visible after tightening.
7. Snug tighten all the bolts sequentially from fixed end to free end and
inner to outer.
b) During tightening, the bolt head or nut should be held by hand spanner
of spud wrench to prevent it from turning.
Snug tight
Snug tight is tightening of bolt with correct size hand spanner by the single
person, without nay leverage and additional force. This may develop a tension
of approximately 5000 to 10000 ibs. It is good practice to take second run
over the bolts with correct size hand spanner (by the same person without
leverage) in the same sequence as above, to check the snug tight position.
8) Make permanent location mark on each nut and the protruding end of
the bolt as shown in Fig .1, to record their relative position. This mark
may be made with paint or by using a cold chisel.
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This can be verified by the marking done on the bolt top and nut.
10) Mark on one face of the nut to indicate the completion of tightening as
shown in Fig: 2.
Note: Recheck for ensuring full tightening, which can be done by using
calibrated torque wrench and bolt tension calibrator – min. 10% of bolts or 2
Nos. in each joint which ever is more.
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Fig. 41
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ANNEXURE - 6
APPLICABLE PGMA WITH SUGGESTED ERECTION SEQUENCE
Stage Description Applicable PGMA
I. Foundation
S1 to S22 Foundation Materials 35 -010
II. Columns, Horizontal Beams, Bracings First Tier (three sub- stages
Erection (each sub0stage not exceeding 3 meters preferably at erection
joints)
1st set of pieces
1. S1 – S2 – S7 – S8 – Left side columns
and Connected beams
9. Stairs landing and hand railing and platforms (35-390, 35- 820
(right side) 35-850)
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vi) Airheater and Second Pass Structure
35-120
35-130
35- 520
35-530
35-250
35-230
Foundation Materials
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APPLICABLE PGMA WITH SUGGESTED ERECTION SEQUENCE
39-300
lv. Platforms floor grills and guard plate
39-810
hand rails
39-850
39-301
vi. Platform for Fan Hood for Motor
39-302
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APPLICABLE PGMA WITH SUGGESTED ERECTION SEQUENCE
36-240 36-390
Materials:
92
Fig. 42
93
Fig. 43
94
FQA LOG SHEETS LIST
95
REFERENCE DOCUMENTS
Tightening procedure of
2 Pub. 2302 BHEL (T)
HSFG Bolts
96