CFB BOILER ERECTION PROCEDURES

FIELD CONSTRUCTION OF A CFB BOILER

One of the first activities of the field-construction phase is the verification of the accuracy of all concrete foundations for
the boiler. All column-to-column dimensions, anchor-bolt locations, and concrete elevations are measured and Verified
against the drawings.
STRUCTURAL STEEL ERECTION
Since a boiler structure height is typicaly 160 feet high, crane(s) are needed for erection. Main crane(s) with boom
heights of 200 feet and lifting capacities of 200 tons or more are common.
Because of the large quantity of boiler steel (approximately 3500 tons) boiler components, and other plant equipment and
materials, it is usually impossible or uneconomical to store all the boiler items within reach of the main crane. A
multi-acre storage yard and adequate warehouse storage are necessary for the material; such additional equipment as
lighter capacity cranes, cherry pickers (small, rubber-tired mobile cranes), and flatbed trucks are required for moving the
material to and from the storage areas.
The structural steel is designed to be erected by the tier method, shown below.

Tier method of steel erection

The large sizes of some of the boiler components, such as the ductwork, cyclones, silos, and sootblowers, may require
that these components be installed as the building structure is erected. For this reason, close coordination between the
material suppliers and the constructor is essential. It is desirable in many instances for the boiler erector also to erect the
boiler support steel. This facilitates the planning of erection sequences, and firm dates for finishing elevations can be
planned with a minimum of coordination problems or schedule disruptions.
The steel erection begins with the main boiler columns, beams and braces usually starting on the turbine and
steam-drum sides of the unit. Then the main girders are erected. They support the main boiler sections and the steam
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drum from the top of the unit. There are many girders located within the main boiler support steel. Similar sized girders
are used for supporting the fuel silos and the airheater.
MAIN-GIRDER ERECTION
Main-girder erection is one of many rigging problems of the structural-steel erection process. The most accepted method
of lifting the heavier girders is as follows: Once the girder is raised above the column tops, bring the girder parallel to the
front of the boiler. The girder can then be connected to the upper ends of the columns. Once the girder is in place,
intermediate steel can be installed to tie all of the upper steel together. Coordinated radio communication, highly
experienced operating engineers and rigging supervisors, and first-class equipment are imperative for successful girder
erection.


CYCLONES
The recycle cyclones can be partially ground-assembled and then set in-place once the second tier of boiler structural
steel has been erected and bolted. The lower cone sections are ground assembled with the cones inverted, then set into
the structural support ring. This is followed by ground assembly of cyclone barrels and top.
The refractory lining system for the recycle cyclones will be installed after the cyclones have been erected, assembled
and fully welded.

Furnace Gas
Outlet Duct

Cyclone Gas Outlet

Duct to Backpass

Furnace Rear
Wall Tubes
Seal Pot

Solids Return
To Furnace

CYCLONE
CONE

FUEL, LIMESTONE AND BED MEDIUM SILOS

The bed medium silo can be ground assembled and then set in place after the first tier of boiler structural steel has been
erected.
The fuel and limestone silos can be partially ground-assembled and then set in place after the second tier of boiler
structural steel has been erected and bolted.
STEAM-DRUM INSTALLATION
The steam drum can be raised into position at the top of the boiler once the main girder steel, vertical and horizontal
bracing, have been erected and completely bolted. The drum is hung just below the main girder steel by means of huge
U-bolts that encircle the drum. Steam drum is approximately 6 feet in outside diameter, over 60 feet long, and weighs
approximately 230 tons.

RAISING A DRUM
The drum is raised parallel to the ground. Based on the lifting lugs welded on the drum in the shop, the location of the
support steel for the load blocks can be determined before construction is started. A set of "cat heads" (a temporary
support for the upper portion of the block-and-tackle arrangement which is used to raise the load) rests on top of the
support steel, through which the upper load block is pinned.
*The block can rotate according to the angle of the drum.
The steam drum is usually brought inside the furnace cavity, and off-loaded. The line-pull two-drum hoist that is used for
lifting is usually located on the ground with the two load lines following a column line up to the top blocks hanging in the
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cat heads. Because of the inner dimensions of the structural steel and the location of the cat heads, an outhaul may be
used to keep the drum from drifting into the steel work. Proper location of all rigging is important because of the height of
the boiler and the lifting distance.

Steam drum


PRESSURE-PARTS SUPPORT-STEEL ERECTION
While the steam drum is being erected, the pressure-parts support steel can be installed. This steel, located at the top of
the unit, supports the weight of the boiler. Unlike conventional structures that are built from the ground up, most modern
boilers are built from the top down, with the furnace suspended by constant load springs (locked) and the backpass
suspended by rigid hanger rods all from the main girders. This permits the furnace to expand upward and the backpass to
expand downward during the start-up of the plant. The correct setting of the pressure-parts support steel is very important
because every part of the boiler is located with respect to this steel. It controls all elevations and is continually used as a
reference to align the different components as they are erected.

INSTALLATION OF UPPER RISERS AND CONNECTING LINKS

The upper risers and economizer links are hung just below the pressure-parts support steel.
By the time these components are raised, the crane used to erect the boiler steel has usually been moved and may not
reach the areas where these components will be located. Therefore, most are raised from the ground inside the furnace
cavity using block and tackle (a set of pulleys in a frame). The components are then hung on their respective hanger
rods, which support the different boiler components, or are lashed temporarily to the pressure-parts support steel. The
sequencing of component installation requires extra care on units where there are multiple riser tubes to the steam drum
from the side-wall headers. These pipe sections are flexible and may contain several compound bends. Temporary cable
lashings may be required to support risers and links prior to welding.
At this point in the installation of the boiler, no pressure part final welding has been started. All work has involved the
placement of equipment.
The downcomers from the steam drum to the lower water-wall and FBHE evaporator inlet headers are raised into place
after the above-mentioned work is completed. Usually arriving on the jobsite in 60 ft sections, downcomers are about 16
inch in diameter and weigh as much as 7 tons per section. Each downcomer requires about 3 sections. Rigging must be
located underneath the steam drum itself, because the downcomers are welded directly to the drum nozzles. Clips are
welded on the ends so that threaded rods can be inserted to raise or lower the downcomer a few inches for proper
positioning for welding.
As soon as the downcomers are in place, welders can begin the fit-up and welding procedures that will ultimately join the
downcomers to the drum. Large, welded joints must be ground smooth for stress relieving and radiography.
FLUID BED HEAT EXCHANGERS (FBHE's)
FBHE's are esentially a refractory lined box containing boiler heat transfer surface located beneath the recycle cyclone
and configured as either superheat, reheat or evaporative surface.
Each FBHE is composed of platework and lined with refractory (both for insulation and erosion resistance). The FBHE's
can be erected as soon as the first tier of boiler structural steel is erected.
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The refractory lining system of the sidewalls and floor of the FBHE should be installed after the platework has been
erected and fully welded but before the tube bundles are installed. The roof should be lined at grade in an inverted
position so that the refractory (castable) may be poured onto the roof panels.

Solids from Cyclone

Seal Pot

Ash Control Valve

Fluidizing
Air Nozzle

Furnace

Heat Exchanger Surface Superheat, Reheat, or

Evaporator

Fluid Bed
Heat Exchanger

Solids from Seal Pot

Toggle
Expansion
Joint

FBHE Heat
Transfer Surface

Solids Return
to Furnace

FLUID BED ASH COOLERS (FBACs)

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FBACs which are used to cool the bottom ash before it is discharged to the bottom ash conveyor.
The FBAC is composed of platework and lined with refractory (both for insulation and erosion resistance). Erection of the
FBAC should take place after vertical erection access to the front of the boiler is no longer required.
The refractory lining system of the sidewalls and floor of the FBAC should be installed after the platework has been
erected and fully welded but before the tube bundles are installed. The roof should be lined at grade in an inverted
position so that the refractory castable may be poured onto the roof panels.
Typical Cooling Surface
(Feed Water or Cooling Water)

Cooling Surface or
Air Compartment

Rotary
Valve
Ash Inlet From
Furnace
1560 - 1650 F
850 - 900 C

Ash Discharge
400F / 200C
(Typical)
Fluidizing Air
From Blower
Refractory- Lined Box
12 in./ 300 mm thick
Oversized Ash
Discharge

Gravel Screw
Cooler

Water Cooled
Valve Shaft

Hydraulic
Actuator
Assembly

Plug

Valve Seat

Refractory Lined
Valve Body


SEAL POTS
Seat Pots, one- for each cyclone. Each seal pot directs hot solids to both the lower furnace and to its attendant FBHE.
Each seal pot is composed of platework and lined with refractory (both for insulation and erosion resistance). The seal
pots can be erected as the second tier of boiler structural steel is erected.
The refractory lining system of the Seal Pots should be installed after the platework has been erected and fully welded.
After the stainless steel refractory anchors have been installed, the back up lining System should be cast on all down
hand surfaces and gunned on walls and overhead surfaces. The service lining must be formed and cast.

FUEL
SILO
HOPPERS

SEAL POTS

ASH RETURN SYSTEMS

These systems are comprised of round platework and lined with refractory (both for insulation and erosion resistance).
These systems connect the bottom of the cyclones to the seal pots, the seal pots to the lower furnace and the FBHE's to
the lower furnace.
The systems can be positioned in their approximate locations at the time the seal pots and FBAC's are being erected.
The lining of the Ash Return Systems should be installed in-situ after the platework has been erected and fully welded.
After the stainless steel refractory anchors have been installed, the back up lining system should be cast on all down
hand surfaces and gunned on walls and overhead surfaces. The service lining must be formed and cast.


BUCKSTAY ERECTION
The buckstays are structural shapes that restrain movement of the waterwalls caused by fluctuation in furnace pressure.
Buckstays should be temporarily set, prior to furnace and backpass wall erection, on the boiler steel elevation closest to
the buckstay's final location. After the furnace and backpass panels are aligned, buckstays can be installed.

Backpass
buckstays
Combustor
buckstays

SOOTBLOWER ERECTION
Cranes can be used to raise the retractable backpass sootblowers and set them on the grating nearest
their correct elevations. The type of fuel to be burned determines the number, type, and location of the
blowers. Mounted horizontally, they have a round tube or lance that is rotated, extended and retracted by
a driving motor(s).
These are long retractable blowers, 'Which can be inserted up to a distance of either full boiler width, or one half the
width of the boiler, depending upon available space and owner preference. These blowers are located in the backpass of
the boiler and extend between the sections of the superheater, reheater and economizer to clean the convection
heat-absorbing surfaces during steam generator operation. Retractable blowers are also used to clean the airheaters.

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WATERWALL ERECTION
Once the sootblowers and buckstays have been laid on the grating temporarily, the waterwalls which form the sides of the
furnace can be erected. The water-walls are sections of tubes that are fin welded together into a gas-tight panel. They
conduct a mixture of steam and water upward as heat is applied from the furnace side. The walls extend from the base of
the boiler up to the steam-drum level.
Typically about 10 feet wide and 65 feet Iong, waterwall panels are brought into the furnace on a flatbed truck or its
equivalent. Because they are so Iong and flexible, the biggest problem with these panels is upending them. Two lines are
needed. The crane in the hole lifts the top line; a cherry picker, the other. Sometimes, a special lifting device distributes
the weight so the panel will not buckle. This requires that several slots be cut in the welded web between the tubes. A bar
welded to a small T-beam is inserted and pinned on the back. This device assists in keeping the panel straight along its
width during upending process. When the panel is vertical, it is lifted up to its final position.
Combustor Water Walls
COMBUSTOR ROOF PANEL ASSEMBLIES

LEFT SIDEWALL

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

RIGHT
SIDEWALL

COMBUSTOR REAR WALL ASSEMBLIES

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

BACKPASS ROOF AND ECONOMIZER OUTLET HEADER ASSEMBLY

COMBUSTOR UPPER RIGHT SIDEWALL ASSEMBLY
BACKPASS UPPER RIGHT SIDEWALL ASSEMBLY
COMBUSTOR UPPER LEFT SIDEWALL ASSEMBLY
BACKPASS UPPER LEFT SIDEWALL ASSEMBLY
COMBUSTOR UPPER REAR WALL ASSEMBLY
BACKPASS UPPER FRONT WALL ASSEMBLY
COMBUSTOR UPPER FRONT WALL ASSEMBLIES (4)
BACKPASS UPPER REAR WALL ASSEMBLIES (3)
COMBUSTOR INTERMEDIATE REAR WALL ASSEMBLY
COMBUSTOR LOWER RIGHT SIDEWALL ASSEMBLY
BACKPASS LOWER RIGHT SIDEWALL ASSEMBLY
COMBUSTOR LOWER LEFT SIDEWALL ASSEMBLY
BACKPASS LOWER LEFT SIDEWALL ASEMBLY
COMBUSTOR LOWER FRONT WALL ASSEMBLIES (3)
BACKPASS LOWER FRONT WALL ASSEMBLIES (3)
COMBUSTOR LOWER REAR WALL ASSEMBLIES (3)
BACKPASS LOWER REAR WALL ASSEMBLIES (3)
COMBUSTOR LOWER RING HEADER ASSEMBLY

COMBUSTOR FRONT WALL

FURNACE LOWER HEADER ASSEMBLY

BackPass Water Walls

BACKPASS ROOF PANELS & E-8 HDR.

LEFT SIDEWALL

RIGHT SIDEWALL
BACKPASS REAR WALL ASSEMBLIES

BACKPASS FRONT WALL ASSEMBLIES

ECONOMIZER ERECTION
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The economizer, located just above the air preheater, can be erected. This is a heat recovery device designed to transfer
heat from the exiting flue gases to the incoming, boiler feedwater. The economizer consists of an interconnected
horizontal bare tube array. The upper ends of each economizer assembly connect to the outlet header, which is already in
place above the roof tubes.
Economizer assemblies are raised into place from the around with a tugger rigged in the area of the outlet headers.
Banks of economizer elements can be pre-assembled in groups. Pins and rods usually support the assemblies directly to
lugs welded to the bottom of the intermediate headers. Because the economizer tubes are often fabricated in a staggered
pitch to increase heat transfer and minimize space requirements, fitting the last few elements sometimes presents a
rigging problem. It is difficult to pass hoisting falls through the staggered tubes. This often means that the already
installed elements must be spread apart and the side walls must be moved out.

Hanger Tubes
Flue Gas from Cyclone

Superheater
Steam Cooled
Wall Tubes

Reheater

Economizer
Fly Ash Hopper

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ECONOMIZER
HOPPER


START-UP BURNER ERECTION
After the lower waterwall panels are in place, start-up burners can be attached to their respective seal boxes on both side
waterwalls.

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FUEL AND LIMESTONE FEED SYSTEMS ERECTION
The fuel and limestone feeders should be placed at elevation during structural steel erection, if possible.
Early placement of this equipment minimizes handling and rigging.

FUEL SILO

FUEL
FEEDERS

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DUCTWORK ERECTION
Ductwork erection can be completely integrated with boiler erection to avoid problems in fitting ductwork sections into the
structural steel framework.
The boiler ductwork consists of two main systems; the air-supply system, which includes the primary and secondary air
and the flue-gas system, which includes the backpass ash hopper and ductwork to the air preheater, precipitators,
induced-draft fans, and stack.
The primary and secondary hot-air ductwork from the airheaters to the furnace contains some of the biggest pieces of
equipment on the boiler. Because of the sizes involved, ductwork is generally assembled on the ground with sections
installed simultaneously with the structural steel. Hanger rods and expansion joints in the ductwork allow for thermal
expansion. Hangers and ductwork supports should be installed prior to erecting ductwork.

Secondary air
Primary air system
system
The gas-system ductwork extends from the bottom of the economizer to the exit side of the tubular airheaters. It also
includes the ductwork from the airheater to the precipitator, to the induced-draft fans, and to the stack. Most of this
ductwork is installed after the airheater is in place.
Economizer
outlet

Air Heater

To
Baghouse

Gas Duct System

15

Dampers to isolate equipment or regulate airflow or gas flow to and from the boiler are installed with the ductwork.

LOWER WATERWALL HEADER ERECTION

Typically, the lower waterwall headers are the last lifts made and are installed after most of the pressure part welding has
been completed. The headers extend the full width and depth of the furnace. Once headers are in position, they are
welded to the side, front and rear waterwall panels.

WELDING OF ERECTED COMPONENTS

As the boiler erection has proceeded, the different components have been raised and hung by hanger rods, springs or
temporary rigging. After a group of components is installed, the fit-up and welding must be performed. Except for the
structural steel, which is most commonly bolted together, almost everything else on the boiler is welded.
Several different welding processes are used in the field. One such process is gas tungsten arc welding (GTAW) in which
a bare filler rod is fed into the molten weld. The tungsten electrode, which is not consumed, provides heat to the
workpiece. An externally supplied shielding, gas excludes the atmosphere from the weld puddle. Argon is usually the
shielding gas, although other gases or combinations of gases may be used. Historically, this relatively slow process is
used to put in the root (first) pass in pressure-part butt welds.
The most extensively used process is shielded metal arc welding (SMAW), more commonly referred to as the "stick
electrode" process. In this process, the flux-covered electrode is consumed in the weld. The flux coating produces the
shielding gas which is externally supplied in the GTAW process; it also promotes electrical conductivity across the arc
column, adds slag forming materials that help prevent rapid oxidation of the weld metal and, in many cases, adds
alloying materials to the weld. This process follows the GTAW root pass and completes the pressure-part butt weld. It is
also used to weld ductwork, waterwall seams, and other plate and pipe components.
The third process frequently used during the field construction of boiler components is the gas metal arc welding
(GMAW) process. In this process, a machine feeds bare of flux-cored (flux-filled tubular) wire from a spool into the weld.
The wire is the consumed electrode as in SMAW. The shielding gas may be externally supplied (as with GTAW) or may
be supplied by the flux (as with SMAW) if flux-cored wire is used. This process is also used for ductwork, water-wall
seams, and other plate welding.
Machine welding is being performed in the field. In field machine welding, the equipment performs the welding operation
under the constant observation and control of a welding operator. Machines which make pressure-part welds are called
orbital-welding machines. They usually employ the GTAW process, although the GMAW process is in the early stage of
development for use in the field. The main advantage of orbital welding is the higher quality of the deposited weld. The
improved quality results from the repeatability of the machine and the decreased fatigue of the operators over manual
welders.
Field welds are radiographically examined as required by code, contract, and self-imposed quality control standard
requirements. For this analysis radiographic film is placed on one side of a weld and a radioactive source is temporarily
placed on the other side. (Sometimes the source is placed inside a pipe weld for a panoramic shot and other times the
source is placed on the outside of a tube or pipe weld for a double-wall shot.) When the film is developed, discontinuities
may be disclosed requiring interpretation by a qualified radiographer. Any discontinuity which is interpreted as a defect
must be ground out and re-welded
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Depending on the material specification of the component and the diameter and thickness of the weld, post-weld heat
treating may be required to reduce the residual stresses induced by the welding. This stress-relieving process involves
the placement of electric elements or coils, or gas burners around the weld area of the component. A band around the
weld joint is brought up to a predetermined temperature, at a controlled rate, and is held there for a time period that is a
function of the weld thickness. Thermocouples attached at the outside of the heat band, or temperature indicating
crayons, are used to monitor the temperature. The component is then lowered to ambient temperature at a controlled
rate.
ADDITIONAL CONSTRUCTION WORK
When the lower headers have been set in place, the lower waterwall panels are brought in and raised into place, the
downtake system is installed. Additional work that can proceed simultaneously in other sections of the boiler is attaching
the buckstays to the waterwalls, bolting the sootblowers to the backpass walls, connecting the piping for the sootblowers,
and welding safety valves to the steam drum and outlet leads to the turbine. At this stage, a "punch list" of work that must
be completed before the hydrostatic test should be compiled, so that all responsible contractors can be aware of
unfinished items.
ERECTION OF STEAM GENERATOR AUXILIARY EQUIPMENT
Other equipment that is worked on during boiler erection are precipitators, fans and the stack. The precipitator is located
downstream of the steam generator proper and removes the solid particulate from the flue gases It rests on a
structural-steel frame which is also tied into the main support members for the precipitator. The hoppers are erected first
and lowered into the steel from above with a crane. The hoppers are usually sub-assembled on the ground and erected
as one piece. The main supports, sides and internal bracing are put up next along with the inlet and outlet ductwork. The
collecting and discharge electrodes, or other types of internals, are then erected. The inner roof, weather-roof, and
electrical components finish the main sections. Work on alignment, wiring and checkout is required before the unit is
complete.
On this unit, there are two primary air and secondary air fans that move combustion air through the tubular airheaters
and into the furnace through the watercooled grate and overfire air nozzles. Additionally, there are two fluidizing air
blowers that move combustion air through the tubular air heaters and into the seal pots, FBHE's, and FBACs through
fluidizing air nozzles and two induced-draft fans that pull the hot gases from the boiler and direct them to the stack.

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Ash from Furnace
1560-1650F
850-900C

Ash to Bottom Ash

Handling System
400F/200C
(Typical)

18

HYDROSTATIC TESTING AND INSULATION

During hydrostatic testing, with the metal temperature at 70 degrees F or above, water is pumped into the complete water
and steam circuits of the boiler and raised to the pressure of 1 1/2 times the maximum allowable working pressure
(MAWP). The pressure is held for a specified period of time and then lowered to the MAWP and held there for another
period. The entire boiler, including piping, valves, wall panels, and drums, is then inspected for leaks. If any leaks are
found, the pressure is dropped, the water is drained out, and the leak is repaired. The entire process is then repeated until
no more leaks are apparent.
The erector engages the services of a steam-boiler inspection agent who is responsible for verifying the inspection and
assuring the integrity of the boiler to the owner. The owner usually has its own insurance representative on the job at the
same time to look over the records and ensure that proper inspection and tests are per-formed.
Once the hydrostatic test is complete, the insulation and lagging installation can proceed. Insulation blankets or blocks
are installed on all piping, waterwalls, drums and ductwork. Metal lagging is installed over the insulation for protection of
equipment and personnel.

REFRACTORIES INSTALLATION

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The recycle cyclones, ducts to/from cyclones, seal pots, FBHE's, FBACs and the ash return duct systems will be lined
with refractory. The purpose of the refractory lining is two-fold. First, it is used as an insulating medium and second, as an
erosion resistant liner. The various refractory lining materials are installed by casting, ramming, pneumatic gunning, and
by brick laying technique. Erector should insure that all craftsmen employed in this work are skilled in their respective
crafts.

ERECTION-COMMISSIONING INTERFACE
With most of the major work done on the boiler; refractory dryout, boilout and cleaning can be done. Chemicals are
circulated through the boiler for prescribed lengths of time and then drained from the boiler. These procedures remove
internal scale from water-bearing systems and assure free water passage in all tubes, headers and drums. Installation of
boiler-drum Internals may now be completed and access openings closed.
7

The contractual responsibility for the erection phase is usually complete at this point; however, support crafts for assisting
test and start-up engineers may be necessary to take care of items that require modification and/or replacement during
commissioning.

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