CFB BOILER ERECTION/INSTALLATION

PT. Nusareka Prima Engineering

Construction, Industrial Power Plant Services & Maintenance, Project Management Supply
Ruko Golden Madrid II Blok I No 25, Jln. Letnan Sutopo, BSD Tangerang Selatan 15323
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.

PT. Nusareka Prima Engineering

Construction, Industrial Power Plant Services & Maintenance, Project Management Supply
Ruko Golden Madrid II Blok I No 25, Jln. Letnan Sutopo, BSD Tangerang Selatan 15323
 STRUCTURAL STEEL ERECTION

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 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.
PT. Nusareka Prima Engineering
Construction, Industrial Power Plant Services & Maintenance, Project Management Supply
Ruko Golden Madrid II Blok I No 25, Jln. Letnan Sutopo, BSD Tangerang Selatan 15323
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.
 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

Ensure the direction of steam drum is

correct since loading on the port Wire strand
Hydraulic
jack
Install the temporary jack support on the
top of boiler structure. hoses
Upper
Install 2(two) hydraulic jack/strand jack and anchorage
it is accessories such us frame to support Lower
anchorage
jack, skid roller etc.
Prepare all rigging tools to be used.
TOP OF
Ensure that ground condition stability is GIRDER
enough to support transporter to transfer
the steam drum to lifting area.
The drum is hung from the main structure
by two U type strap hangers.To easier
lifting operation and facilities the erection Hanger or
U Rod
of hangers, the U road hangers shall be
assembled at ground level or the drum in
Hanger
order to be lifted simultaneously. Steam Drum Rod

The hanger threads are clean, to check

nuts onto rods and Joints of U roads-
attention of the threads
 STEAM-DRUM INSTALLATION

Before steam drum lifting, drum should be hanging 1

meter from ground floor and check by measuring tools
the position of drum, hold for one hour to see there are
decline or not of the stem drum, this is to ensure that
the lifting tools is good condition

Lift up the steam drum around three(3) meters

height then and tie in with wire sling.
Lock hydraulic jack no 2 and lift up jack no 1 to
decline steam drum position until 30 degree, until
steam drum free from any obstruction.

After steam drum lifted to the final elevation, lock

jack 1 and lift up jack 2 to straight steam drum in
horizontal position

The drum lift and positioned at the elevation

appropriate and the operations of hydraulic jack
shall be locked.

The drum are moved towards to front boiler

direction by slide steam drum in temporary rail until
final position.
 STEAM DRUM INSTALLATION
After the drum is set in position, the below
mentioned alignment is carried out to confirm
the centre of drum along X and Y axis. The
levelness measuring and checking of steam
drum can be carried out by selecting 2 points
on each of the left and right end.
The elevation reference point of steam drum
on the steel columns marked.

Tighten the nuts of hangers in order to

reach perfect contact of all parts
Simultaneously release the hydraulic jack
system and dismantle the lifting equipment.
On completion of positioning the drum, the
confirmation of the tension on the U road
is necessary. The tension on the each strap
must be equal to the down load
PRESSURE PARTS SUPPORT STEELE RECTION

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.

SUSPENSION ROD
DOWNCOMER PIPE INSTALLATION

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. Each downcomer
DOWNCOMER PIPE
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.
 TOP HEADERS INSTALLATION
The capacity, number of sleeve pulleys,
lifting wire rope diameter and guide
pulley location etc. is to be decided at
site based on the weight of the header
and position of the lifting winch.
While lifting the header a tag line must be
used to control the load(movement of
header)
Lift the header and place it at match the
header axis with the centre line marked
and connect the hanger rod with the
header lugs using the pins
Note: provided the correct size of
cotter pin
Check the elevation of the header,
orientation, horizontally and distance
from reference axis before arresting the
header.
WALL PANEL 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 waterwalls 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 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.
WALL PANEL ERECTION
COMBUSTOR ROOF PANEL ASSEMBLIES

1. COMBUSTOR UPPER RIGHT SIDEWALL

LEFT SIDEWALL RIGHT
SIDEWALL COMBUSTOR REAR WALL ASSEMBLIES
ASSEMBLY
2. COMBUSTOR UPPER LEFT SIDEWALL
ASSEMBLY
3. COMBUSTOR UPPER REAR WALL ASSEMBLY
1
4. COMBUSTOR UPPER FRONT WALL
2 ASSEMBLY(4)
3
4 5. COMBUSTOR INTERMEDIATE REAR WALL
5
6
ASSEMBLY
7 6. COMBUSTOR LOWER RIGHT SIDEWALL
Combustor Water Walls 8
9 ASSEMBLY
10
11 7. COMBUSTOR LOWER LEFT SIDEWALL
12
13
ASSEMBLY
14 8. COMBUSTOR LOWER FRONT WALL
15
16 ASSEMBLY(3)
17
18
9. COMBUSTOR LOWER REAR WALL
19 ASSEMBLY(3)
10. COMBUSTOR LOWER RING HEADER
ASSEMBLY

COMBUSTOR FRONT WALL

FURNACE LOWER HEADER ASSEMBLY

COILS ERECTION
INSTALLATION OF EVAPORATOR PANEL
The evaporator panel will be erection after
upper wall panel finish installation and welding.
The Evaporator panel will be erection by electric
winch, erection only six (6) element and then
erection Vertical super-heater panel will be
proceeded until finish, then continue installation
Evaporator Panel until finish erection.
COILS ERECTION
FINISH SUPERHEATER INSTALLATION
Assembly the Finish super-heater element
on ground floor. Assembly with hangers
tube. Set on two element (see attached).
The element will be erected from below,
lifting by winch, lift one by one until the
lower the roof lifting by chain block, One
element positioned seal weld the tube
end of the super heater element to the
level above, final joint at hanger tube on top
roof.
Some fitters will be fitted-up tube element
to header of side wall and lower header of
finish super-heater
 COILS ERECTION
Hanger Tubes
ECONOMIZER INSTALLATION
The economizer, located just above the air Flue Gas from Cyclone
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. Superheater
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 Steam Cooled
from the around with a tugger rigged in the Wall Tubes
area of the outlet headers. Banks of
economizer elements can be pre assembled
Reheater
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 Economizer
and minimize space requirements, fitting the
last few elements sometimes presents a
rigging problem. It is difficult to pass hoisting Fly Ash Hopper
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.
COILS ERECTION
Lift up the frame and element at the same time using two
Winch winch, until the position is approximately 85, and then lift up
the element vertically to the erection position while other winch
is lift down the frame back to the early position and prepared to
another element lifting

Element Frame

5
 BACKPASS ERECTION
BACKPASS ROOF PANELS & E-8 HDR.

1. BACKPASS ROOF AND ECONOMIZER

LEFT SIDEWALL RIGHT SIDEWALL OUTLET HEADER ASSEMBLY
BACKPASS REAR WALL ASSEMBLIES 2. BACKPASS UPPER RIGHT SIDEWALL
ASSEMBLY
3. BACKPASS UPPER LEFT SIDE WALL
ASSEMBLY
4. BACKPASS UPPER FRONTWALL
ASSEMBLY
5. BACKPASS UPPER REARWALL
ASSEMBLIES(3)
6. BACKPASS LOWER RIGHT SIDEWALL
ASSEMBLY
7. BACKPASS LOWER LEFT SIDEWALL
ASSEMBLY
8. BACKPASS LOWER FRONTWALL
ASSEMBLIES(3)
9. BACKPASS LOWER REARWALL
ASSEMBLIES(3)

BACKPASS FRONT WALL ASSEMBLIES

BOTTOM HEADER ERECTION

All the lower headers will be erected using sling with variety of
capacity depend on each weight of the headers. After the headers
hanged to their position the fit up checked by QC and then
continued to welding job.
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.
 CYCLONES ERECTION
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.
CYCLONES ERECTION
 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
CYCLONE CONE
erected as soon as the first tier of boiler structural steel is erected.

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 FBHE
Furnace Air Nozzle

Heat Exchanger Surface - Fluid Bed

Superheat, Reheat, or Heat Exchanger
Evaporator
 FLUID BED ASH COOLERS (FBACs)
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 Cooling Surface or

(Feed Water or Cooling Water) Air Compartment

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

FBACs
Ash Discharge
400F / 200C
(Typical)

Fluidizing Air
From Blower

Refractory- Lined Box

12 in./ 300 mm thick
Gravel Screw
Oversized Ash
Cooler
Discharge
SEAL POTS INSTALLATION
Seat Pots, one- for each cyclone. Each seal pot FUEL SILO HOPPERS
directs hot solids to both the lower furnace and
to its attendant FBHE.
Each seal pot is composed of platework and SEAL POTS
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.
 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 Combustor buckstays

Backpass buckstays

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.
BUCKSTAY ERECTION
The buck stay which has storage on the boiler steel structure can be Fitted up start from bottom panels to the
top for the safety as well as accessibility. These are some more importants notes :
Setting work should be performed after aligning panels. Panels located in the place where buckstays are to be
installed should be seal welded.
Fix Buckstays by inserting the guide pins to tie bar lugs which are welded to the panels.

Erection sequence of buckstay installation :

1. Set the position of buckstay which tie bar assembled on the furnace / boiler wall then tie bar are positioned
between two raws of guide bar. Temporary insert undersized pins through the guide bars to hold the bulk stay
assembly in place. Then check the buck stay level based on furnace wall to confirm . After that install the
guide pin supplied from the manufacture across the furnace wall and make sure not to bend any of the
supplied pin .

2. Weld tie bar at the corner of the buck stay assembly and check the furnace cavity for square and Rt angle .

3. Next fit up the corner connection plate and the tack weld them into
position . Clamp the stand off bar to the web of I Beam (buck stay
beam ) and verify the pereset dimention to be occurate.
Then stand off bars can be welded to the web . Finish corner
connection plate welding above and below and then attach the
linkage bar with the pin provided (according to drawing ) . Inserting
pins shall not using hammer.

Support : Attach the clips to the lugs provided on the convention pass rear wall for this purpose with the support
rod attached to the angle on the back side of the econimizer support bar with a lock washer and nuts . Weld the
angle to the econimizer support bar and tack weld the nut to the support rod after nut tightened .
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 HOPPERS

FUEL SILO

FUEL FEEDERS
 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 system Primary air system

 DUCTWORK ERECTION
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

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.
 WELDING OF ERECTED COMPONENTS
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
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.
PT Nusareka Prima Engineering

SEKIAN DAN TERIMAKASIH

PT. Nusareka Prima Engineering

Construction, Industrial Power Plant Services & Maintenance, Project Management Supply
Ruko Golden Madrid II Blok I No 25, Jln. Letnan Sutopo, BSD Tangerang Selatan 15323