PRE ASSEMBLY AND ERECTION

OF GIRDERS
 BOILER 04. PRE-ASSEMBLY AND
ERECTION ERECTION OF GIRDERS

A) Preassembly of Ceiling Girder:

- Identify the pieces for the following:
- Work order no.
- PGMA
- DU No.
- Girder designation.

- Position the girder pieces over the pre assembly bed inside the furnace cavity
keeping left, middle and right side pieces following shop punch mark details.
Typical details of girder pieces are given in Annexure I.

- Check and measure the following:

- Camber Length & diagonal
- Sweep
- Twist

- Edge preparation and condition.

- Web height at extended portion and compare with flange to flange inner distance
( For easy insersion 1 mm gap to be ensured on either side. If required grind web
ends to achieve the above).

Major deviation if any, to be informed to manufacturing unit for Corrective action.

Rectify the deviations accordingly.

B) Final Check and finishing.

i) Repeat the dimensional check, carried out prior to welding, after Post Weld Heat
Treatment and compare the two.

ii) Clean and paint the weld region.

iii) Check the holes drilled in the web of ceiling girder (distance from the end and
Centreline distance of each group of holes, which is the Centreline distance of
Welded beams).
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.

v) Ensure pre-assembly bed is made on the leveled and consolidated area to avoid
sinking during placement of girders on the bed.
vi) Ensure the pre –assembly bed members are properly spaced to avoid sagging of
girder pieces when they are placed over it. ( Refer Fig . 22);

vii) Match the pieces as per match marks provided in the pieces. Ensure the
orientation of girder pieces as per drawing (Ref.Fig. 23 A & 23B)

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1.0 Fit Up :

a) While leveling the pieces, the reference lines punched on the web at about 1 to 1.5M
level from bottom flange may be taken as reference.

b) While adjusting the overall length of the girder, check the distance between girder pin
connection bolt hole centers which is marked in the bottom flange and as well as on
the top flange.
c) While adjusting the overall straightness of the girder piece the longitudinal centerline
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 6mm and 6 to 8mm respectively in the field joint areas (Ref. Fig.23B).

e) The parts to be joined by fillet welds shall be brought as close as practicable.

f) Butting parts to be joined by butt welds shall be carefully aligned. An offset exceeding
10% of the thickness of the thinner part, but in no case more than 3.2mm may be
permitted.
g) Members to be welded shall be properly aligned and held in position by bolts, clamps,
wedges and other suitable devices until welding is completed.

h) 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.
i) Ensure after dimensional check-up the girder assembly is properly locked in position
by using stoppers, ‘L’ clamps, wedges, guy ropes and struts or by any suitable device
to avoid distortion during welding and Post Weld Heat Treatment operations. Ensure
proper locking, in such a way that the girder assembly can move longitudinally during
welding and Post Weld Heat Treatment operations to avoid accumulation of thermal
stress.

2.0 Dimensional check-up:

a) Section depth and flange width can be checked as cross reference since these
are already checked up in shop.
Tolerance : Section depth upto 1 M - ± 3mm
Above 1 M upto 2 M - ± 4.5mm
Above 2 M - +7.5mm
- - 4.5mm
Flange width - ± 3mm
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 BOILER 04. PRE-ASSEMBLY AND
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2.0 b) Check the following dimensions prior to clearing the assembly for welding and are
to be recorded in the log sheet.

1. Level of the girder assembly

2. Deviation in straightness on both flanges.
3. Flatness of web on both vertical and horizontal axis.
4. Out-of squareness of the assembly.
5. Flange and web join alignment.
6. Overall length of the assembly and Girder pin bolt hole to
hole distance
7. Flatness of bottom flange in girder pin locations.
8. Longitudinal and cross diagonals of the assembly.
9. Welded beam location distance on either side of the field joint.

3.0 Dimensional tolerance:

1. Individual piece camber and sweep - Max. 5mm
2. Individual piece length - ± 5 mm
3. Level of girder assembly - Max. 5mm
4. Deviation in straightness on total length - Max. 15mm
5. Flatness of Web - Max. 10mm
6. Out-of squareness of assembly - Max. 8mm
7. Overall length of assembly - ± 15mm
(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).
8. Flatness of bottom flange at girder pin connection location . - Max.2mm
9. Longitudinal and cross diagonal of assembly(difference) - Max.15mm
4.0 Pre-heating

a) Pre-heat temperature required for various range of plate

material thickness is as follows:

t : upto 19mm - Nil

t : over 19mm upto 38mm - 65º C
t : over 38mm upto 63mm - 100ºC
t : over 63mm - 150 ºC

b) It is desirable to pre-heat using electric resistance coil heaters. Use of self pre-
heat is not permitted.
c) When electrode of 3mm and below are used the minimum pre-heat temperature
shall be increased by 50º C from the pre-heat temperature mentioned above.
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 BOILER 04. PRE-ASSEMBLY AND
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5.0 Welding
a) Welders shall be qualified as per Welding Manual.

b) Welding consumables conforming to the design requirements shall be used.

c) Selection of welding consumable shall be out of the “Approved list of welding

consumables” issued by WTC, Trichy.

d) Welding consumables used for this are to be stored properly and issued after
necessary baking. Electrodes issued for job should be kept in holding ovens
and maintain the temperature. The above are to be carried out as per welding
manual.

e) Pre-heating requirements for materials shall be strictly followed as mentioned.

f) The sequence of welding to be followed as indicated in Fig.24A

g) Complete the root plus three runs on inner side as per the sequence shown in
Fig. 24A.

h) Back gouge/chip the weld from outer side and carryout LPI/MPI tests for
ensuring defect free root weld.

i) Complete the outer side weld for three runs as per the sequence indicated in
Fig. No.24A.
j) Complete the flange joint weld, around 60% thickness of the joint on both sides of
flange alternately ( inner and outer) as per the sequence shown in Fig. 24B
k) After completion of 60% of flange welding check the web alignment (adjust with
wedges to achieve web alignment if required.)

l) Check the root gap. If required, ground to get the gap.

m) Preheat to 150º C and adopt the weld sequence for the web root welding plus
two runs as shown in Fig. 24A.

n) Back gouge /chip the second side of the weld to achieve defect free root weld.

o) Carryout LPI/MPI on the weld joint on root side.

p) Complete the two runs of weld on the second side as per the sequence shown
in Fig.24B.

q) Complete the balance flange joint and then the balance web joint as per the
sequence indicated respectively in Fig. 24A & 24B.

Note: The welding sequence of flange and web can be changed depending
on the number of welders engaged.
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 BOILER 04. PRE-ASSEMBLY AND
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r) Complete the fillet welding between flange and web on both sides.
s) Carry out the post heating of weld joint for 1 hour at 250ºC
t) 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.
u) The sizes and length of weld shall not be less or substantially in excess than the
specified in the drawing.

6.0 Post Weld Heat Treatment

For C&C-Mn Steel : ( IS 2062, ASTM A36 BS 4360 Gr 43D, DIN 17100 ST 37.3, JIS
3106 SM 41, 3192)

a) Butt welds in plates over 50mm thick shall be subjected to Post Weld Heat Treatment.
For unequal thickness of plates, the groove depth at the weld shall be considered for
Post Weld Heat Treatment.
b) The fillet welds for fixing attachments like pads etc. made on tension flanges over
50mm thick shall also be post weld-heat treated.

a) Butt welds in plates 50mm and above thick shall be Post Weld Heat Treated. For
unequal thickness of plates, the groove depth at the weld shall be considered for Post
Weld Heat Treatment.
b) The fillet welds for fixing attachments like pads etc. made on tension flanges 50mm
and above thickness shall also be post weld heat treated.

For the fillet welds joining the tension flange to web need not be out post weld heat treated.
All the post weld heat treatment cycle range shall be 600ºC to 650ºC. The above cycle shall
be controlled within a tolerance of ± 10ºC. The recommended temperature for Post Weld
Heat Treatment must be selected as the mid point of the recommended range.

Soaking time for Post Weld Heat Treatment shall be 1 hr. /25mm thick upto 50mm and 2 hr
+15 minutes for each additional 25mm thickness over 50mm.
The heating rate above 400ºC and cooling rate after Post Weld Heat Treatment upto 400ºC
shall be as follows:
Thickness range Rate of Rate of Cooling ( Max)
Heating (Max)
Upto 25mm thick 220ºC /hr 110ºC/hr
Over 25 – 50mm thick 110ºC/hr 110ºC/hr
Over 50 – 75mm thick 75ºC/hr 110ºC/hr
Over 75mm thick 55ºC/hr 65ºC/hr

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 BOILER 04. PRE-ASSEMBLY AND
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Autographic calibrated recorder shall be used to record rate of heating, soaking and rate of
cooling. Fixing and location of thermocouple shall be made as per details in Welding
Manual. (Typical case – Refer to Fig. 25 & 26).

7.0 Non –Destructive Examination ( N.D.E.)

Ceiling girder assembled keeping web
vertical. Cut edges
a) Flame cut welding edges for thickness over 38mm – 100% MPI
b) Random MPI for all edges of thickness above 20mm

Weld build up areas in flanges and web – 100% MPI/LPI.

Flange butt joint
100% MPI for thickness 25mm and above.
100% RT for thickness 32mm and above.
Web butt joint
a) 100% LPI for back gouged/chipped area before second side welding.
b) SPOT RT – 10% The defective areas shall be further repaired and re-
radiographed. Fillet welds
a) Fillet weld between ( tension) bottom flange and web – 100 % MPI
b) When both flange and web are above 25mm – 100% MPI
c) Other fillet welds – random MPI.
8.0 Final check –up and finishing:
After Post Weld Heat Treatment, surface to be cleaned properly and painted with
two coats of red oxide primer.
Cement washed surfaces are to be cleaned properly in the HSFG bolt area
including cleat angles.
Dimensional check-up of girder shall be carried out and to be recorded in the log sheets.
‘No stray arc’ shall be done on heat treated members.
B. Erection of Ceiling Girders
The dimension of ceiling girder after full assembly shall be checked and recorded.
The erection activity is detailed in 5 parts.
A) Preparation of structure for girders lifting.
B) Preparation of heavy duty crane 250 MT capacity ( FMC crane LS – 718 –42 )
for girders lifting.
C) Preparation of girder to be lifted.
D) Tools and tackles.
E) Erection of girder.
(A) Preparation of structure for Girder lifting
1. All the main columns except middle columns shall be erected, welded and bolt
tightened.
2. All main horizontal members, diagonal bracing shall be erected in that particular
span where the girder is lifted.
3. Verticality of columns shall be checked and logged.
4. One side of staircase shall be completed upto 75 metres so as to facilitate easy
movement of persons during erection.
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 BOILER 04. PRE-ASSEMBLY AND
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5. Temporary platform shall be made around the column top so as to facilitate column
bolting with the ceiling girder.
6. Connected welded beams shall be kept ready for erection immediately after girder
erection.
7. Guy ropes with pulling machines shall be tied to the columns and anchored at both
sides of columns so as to have adjustment at the top during erection.

(B) Preparation of Heavy duty crane ( FMC crane) for girder lifting
After completion of preassembly of girders all the four ceiling girders are erected
with the help of FMC crane/ Heavy duty crane with ringer attachment.
The FMC crane LS 718 HL 250 T cap. /heavy duty crane shall be assembled with
310 ft boom with ringer attachment. The crane shall be assembled near Electrostatic
Precipitator area and moved inside the furnace cavity.
Heavy duty crane with ring horse attachment involves following assembles.
a) Crawler and cabin
b) Ringer attachement
c) Mast assembly
d) Boom assembly
e) Arrangement of jacks
f) Reeving of boom wire rope.
g) Loading of counter weights.
h) Fixing of jib.
After complete assembly, the crane shall be moved to the furnace cavity.
Girders shall be erected from the predetermined positions in furnace cavity as per
Fig.27 welded beams on front side, Girder – B & Girder – C shall be lifted from
position – I. The girder ‘D’ & ‘E’ shall be lifted from position – II.

(C) Preparation of the girder to be lifted

1. Preassembled ceiling girder shall be shifted from preassembly bed to the nearest
columns.
2. The girder shall be assembled with pin connection assemblies at both ends.
3. The girder shall be kept over the wooden sleepers.
4. The girder shall be kept at angle of 20 degree to the horizontal plane as the length
of the girders is more compared to the span of the column.
5. Temporary Platform shall be made around girder for easy movement at top. The
typical arrangement is shown in Fig. 28.

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 BOILER 04. PRE-ASSEMBLY AND
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(D) Tools and tackles readiness

1. 80mm wire rope 16 M long – 2no’s shall be tied to the girder at the center as
shown in Fig. 29.
2. Two Nos. D-Shackles shall be tied to each one of top portion of slings.
3. Two Nos arrestor channels shall be provided to keep both the slings at a
distance.
4. The details of slinging is shown in Fig.29
5. Small tools like spanners, pulling machine etc. shall be kept ready.
6. The list of Tools and Tackles for ceiling girder lifting is given in Annexure – II.

(E) Erection plan for girder

1. Erection check list shall be completed before erection of ceiling girder. Typical
check list is shown in Annexure – III.
2. Heavy duty crane shall be positioned at a predetermined distance in the
furnace cavity.
3. It is preferable to start girder erection early morning so as to avoid heavy wind.
4. The girder shall be lifted slowly at an inclined direction with respect to
horizontal plane.

5. Manila rope tied at the both ends shall be controlled to avoid sway during
erection.

6. After reaching top of column, the girder shall be made parallel to column and
kept over the columns.

7. Erection crew is to be arranged at top of temporary platform around columns

on both sides.

8. Girder pin connections shall be bolted to the column top.

9. Immediately after girder erection , 2 Nos. welded beams shall be erected so

as to connect the girder with other ceiling structure.

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ANNEXURE – I

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 BOILER 04. PRE-ASSEMBLY AND
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ANNEXURE - I

DIMENSIONS AND WEIGHT DETAILS OF CEILING GIRDERS (TYP.)

Sl CEILING LENGTH WIDTH THICKNESS THICKNESS THICKNESS DEPTH WEIGHT

No GIRDER IN MM IN MM OF MIDDLE OF END OF WEB MM IN MM MT
DESIG. FLANGE MM FLANCE MM

B 25710 1000 63 50 MID : 25 3788 50

01.
END : 32

C 25710 1300 50 40 MID : 25 3780 54

02
END : 36

D 25700 1400 56 50 MID : 25 3788 60

03
END : 36

E 29510 1500 100 75 MID : 32 3800 103

04.
END : 50

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ANNEXURE – II

TOOLS AND TACKLES USED FOR CEILING GIRDER LIFTING

1. HEAVY DUTY CRANE – 250 T CAPACITY ( FMC CRANE) - 1 No

WITH RINGER ATTACHMENT

2. 80MM DIA WIRE ROPE SLINGS ( 16 METER LONG) - 2 Nos

3. ‘D’ SHACKLES – 100 MT. CAP - 4 Nos

4. PULLING MACHINE – 6 T CAP - 4 Nos

5. MANILA ROPE – 200 METERS - 2 Nos

6. SMALL TOOLS LIKE SPANNERS & WINCHES - 2 SETS

7. 3/4" GUY ROPE ( EACH 150 METERS) - 2 NOS

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 BOILER 04. PRE-ASSEMBLY AND
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ANNEXURE : III
SHEET : 01/04
CEILING GIRDER ERECTION
CHECKS FOR LIFTING

CONTRACTOR NO. : __________________________

CEILING GIRDER NO. : __________________________

REFERENCE DRG.NO. : __________________________

SL.No. PARTICULARS CHECKS SIGNATURE REMARKS

1. Inspection of lifting tackles

(wire ropes, slings, shackles,
clamps. Etc.)
2. Position of crane on ringer
3. Check for proper slinging
4. Positioning of frame, pipe sleeves
timber, etc.
5. Trial lift
6. Trial to be taken for crane boom
clearance
7. Guide ropes at either end
8. Arrangement of guys, maxpullers,
etc.(for columns)

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 BOILER 04. PRE-ASSEMBLY AND
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Annexure : III
Sheet : 02/04
9. Persons to be recognized for
Lifting directions.
10. Communication arrangement
11. Manpower availability

12. Check items of attached annexure

Remarks CONTRACTOR

Remarks BHEL/ERN.

Remarks BHEL/QAE

CUSTOMER

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ANNEXURE : III
SHEET : 03/04
SL PARTICULARS CHECKS SIGNATURE REMARKS
NO
1. Girder supporting columns.
2. Verticality of columns
(All required).
3. Level of top of columns.
4. Marking of column top bolt holes center
5. Distance between two column centers at
top
6. Tightening of column bolts
7. All the necessary horizontal beams and
bracings to be aligned, welded & bolted
8. Main brace level structure at 9M, 21M,
31.2M, 43M, 56M & 68M on left, right and
front to be completed.
9. Cleaning of all mating surfaces like
column top, ceiling girder bottom, pin
connection surfaces.
10. Bolts to be tried thru holes for no
obstruction.
11. Lubrication of pin surfaces.

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 BOILER 04. PRE-ASSEMBLY AND
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Annexure : III
Sheet : 04/04
12. Bolting of pin connection on top of column & checking
of gaps prior to ceiling girder erection
13. Inspection of locking plate for pin connection.
14. Inspection of welding of bolt hole lugs to pin
connection
15. Pre-assembly clearance of ceiling Girder
( Dimensional & welding, NDT and stress relieving)
16. Fixing (Clamping) of temporary rails on top of the
flange of ceiling Girder for safety use. Welding of
temporary ladders on sides of girder.
17. Clamping of temporary angles on bottom flange of
ceiling girders for facilitating the scaffolding making
after erection.
18. Cross beams required to-connect should be kept
ready.
19. Arrangements for lifting and fixing of cross beams.

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