STANDARD ERECTION

MANUAL
(Pressure Parts)

Prepared by

Power Sector – Technical Services (HQ)

Noida

Corporate Quality Assurance

Bharat Heavy Electricals Limited,
New Delhi

1
2
 INDEX

SL. No. TOPIC Instruction No.

1.1 Introduction I - 01 - 0201G

1.2 Pressure Parts Erection Sequence

1.3 Pressure Parts Components

2 Boiler Drum B1 - 0I - 0202T

3 Erection of Headers B1 - 01 - 0203T

4 Erection of water walls, headers B1 - 01 - 0205T

6 Down comer erection B1 - 01 - 0206T

7  Erection of steam cooled walls B1 - 01 - 0207T

and SH / RH/ EVAP. / ECO.
COILS
 FBHE Header and Coil Erection

8 Buckstay erection B1 – 01 - 0208T

9 Air And Gas Tightness Test (Boiler) B1 - 01 – 0212T

10 Annexures

10.1 Manpower, Requirement. B1 – 01 - 0213T

10.2 Bar Chart B1 – 01 - 0213L

10.3 Erection Record of Formats B1 – 01 - 213 G

10.4 Reference Documents B1 – 01 - 214G

3
 BOILER PRESSURE PARTS

Introduction

The general arrangement of pressure parts of a conventional

design boiler of 250 MW unit is shown in Fig.1: combustor
area and Fig. 2 (back – Pass. The locations of Pressure part
components and assembled are also indicated in the figures.

At job site, the main function of erection group is to receive

the components, store them, protect them from damage,
preserve them during storage to sustain the original
condition and assemble them which the permissible
limit/tolerance specified in the Pub 2022 to achieve pre-
determined performance during operation.

Around 5600 MT of pressure parts components per unit are

dispatched loose to the job site by road and rail. Hence, it
becomes all the more important for the job site erection
group to take utmost care right from the receipt stage to
completion of erection, so that commissioning activities can
proceed without any difficulties.

The major components in pressure parts to be erected are

boiler drum, headers, water – walls and stream cooled walls,
super – heater and reheater coils, buck – stays.

Recommended hydraulic test procedure, welding & NDE

also covered in this section.

4
3…… Pressure Parts Erection Sequence

3.1 Boiler Drum Erection:

Before starting Pressure erection study FQP on pressure part

carefully and understand acceptance criteria. FQP on pressure
parts is hyper linked with text here. Minimum structure to be
erected is referred in FQP on structure which is hyper linked.
Approx. 3850 MT structural weight is to be erected before drum
lifting as enclosed in table.

3.1.1 Preparatory works:

Like in conventional boilers, drum is dragged and placed at ground

just below its permanent position in between combustor and back
pass. Boiler Drum is inspected on ground prior to erection on
receipt. It should be shifted under boiler structure carefully. Obtain
statutory clearance as applicable.

 There is approximately 3850 MT to be erected prior to boiler

drum erection. Following members should be erected and
welding completed.

 These structure arrangements are identified as –

 First pass – accommodating furnace. Middle Walls FBHEs, air /

flue ducts etc.

 Second pass- accommodating boiler drum, steam cooled SH,

SH III, SH IB, RH II. Economizer etc.

 Third pass- accommodating FBHE Air pre-heater (tubular type)

and quad sector regenerative air pre- heater with inter
connecting duct – work.

Total number of column 38 nos.

Height of the column maximum 63.750M

Number of column tiers 05 nos.

Bracings vertical and horizontal, trusses etc.

1.1.2 To carry out Dimension checks as per FQP. To be

recorded
1.1.3 Final dimensions of combustor and
second passes

5
 1.1.4 Final dimensions of third pass (APH) To be
recorded

 Temporary Cat Head lifting structure is locally fabricated (after

vetting of engineering for the design) and erected.

 If decided for Stand jack system, the lifting equipment is placed

and approach plat form is made at ceiling girder level.

 Similar of conventional boilers, all arrangements for strand jack

equipment emergency power, sheaving etc are carried out.

 Mark and punch position of washer plates over the drum

suspension welded beam and cross check the same with
respect to boiler and drum axis. Take the diagonal of washer
plate center to center, if required adjust It. Mark and punch the
center and angle over washer plate. Assemble rocker over
washer plate wrt O Movement as given in the drawing. Erect all
washer plate along with rocker over welded beam where drum
is to be suspended. Check axis measurement once again and
fill up long sheet.

 The axis mark on suspension rod with drum should be ensured.

Mark and punch.

3.1.2 Strand jack method is used for drum lifting.

Wire rope of 20 meter length for lashing multi sheave pulley block
at cat head and 40 meter rope for lashing multi sheave pulley clock
with drum is used.

o The co-ordinates of drum lifting structure is checked from

boiler axis. LPI/ DPT checks are carried out for welding of
structure. The main hoisting pulley blocks are attached to
drum is safe manner with minimum 8 to 10 turns on each
side.

 The axis of top and bottom pulley blocks should be in one line.
The wire ropes clamps should be checked for correct size
capacity, quantity, tightness and positioning.

 The anchor end of the wire ropes at pulley blocks at winch point
and drum point should be checked for safety. Avoid over lapping
of wire ropes.

3.1.3 Total operation from start of lift to release of load of electrical winch
usually takes 06 to 07 hours.

6
  Crane or electrical winches can lift the drum.

 ESP – erection can be preceded as a parallel activity. Refer

section 05 for details.

 Pressure parts erection is undertaken in following sequence.

 Similar to conventional boilers, furnace and second pass were

erected from top to bottom.

3.2 Furnace:

Following sequence is followed.

3.2.1 Roof pre- assembled and lifted to position

3.2.2 Building up front, rear, right and left side water wall

3.2.3 Upper panels

3.2.4 Inter panels + upper panels buck – stay

3.2.5 Pent leg panels

3.2.6 Pent leg buck stays

3.2.7 Down comer, riser, inter connecting links / pipes etc as and
when availability of fronts and materials.

3.3 Second pass

Following sequence is followed

3.3.1 Roof pre- assembled and lifted to position with hanger tubes

3.3.2 SCW SH upper panels

3.3.3 Final SH III

3.3.4 SCW SH lower panels

3.3.5 RH II coils

3.3.6 Evaporator

3.3.7 Economizer

3.3.8 Buck – stays / support matching to next stage of erection

7
 3.3.9 All inter connection links / pipe, headers + loose tubes failing
outside the second pass panels, gas ducts as per available
of materials.

3.3.10 Complete FBHE Casing

3.3.11 Then refractory work on FBHE Casing should be completed.

Refractory Dry out can be done at latter stage.

3.3.12 Erect FBHEs coils

3.4 All balance pressure parts are erected as parallel activity,

comprising of the system from economizer inlet feed line isolation /
NRV to main steam line isolation valve at boiler end consisting of all
links, drains, vents, expanders, filling line, sampling line, chemical
dozing lines, fine fittings etc, with all supports.

3.5 Since combustion is pressurized, all attachments panel to panel are

to be seal welded totally from outside and inside after back
gouging. LPI test is done for ensuring quality seal welding.
Approximate 12 kms of seal welded is done totally. Inside seal
welding app 6 kms, which are not covered by refractory of
combustor are flush ground to avoid erosion/ turbulence of hot flue
gas / ash during operation. Second pass is having negative
pressure, therefore it is seal welded typical to conventional boilers.

4. Insulation: refer section 07 for details

Mineral wool insulation pins outside the first / second pass walls, all
refractory holding down / anchoring parts inside combustor. FBHEs.
Seal pots and all attachments are fully welded.

After a through inspection of all completion of work and protocols

completed, total system is tested with compressed air and leaks
noticed are attended.

5. Erection Works completion for Hydraulic Test of Boiler

Major pressure parts works for hydraulic tests are:

 Pressure parts 5600 MT*

 HP joints – physical 35000 Nos.*

 Refractory iron components 16 MT*

 Sea welding of furnace, FBHE and second pass 20 Kms*

8
Note: * indicative quantity for exact quantity refer drawings as applicable.

 Platforms

Hydraulic test procedure is followed as enclosed in section 14.

9
PRESSURE PARTS COMPONENTS

10
11
12
PRESSURE PARTS

13
14
15
16
I. Boiler Supporting Structure – Requirements

1. Boiler supporting required for drum lifting to be erected 1.n all

respects including alignment and full welding and cleared for drum
erection.

Joint inspection protocol for completion for structure prior to drum

erection are to be filled and cleared for drum erection.

(Refer checklist BR(STR) – 200 /210 -92 & Log sheet No FQA –
O1-35-00- L12.

2. Identify one main column (preferably S9 –or S10 – left or right) for
all elevation measurement, to avoid column to column elevation
marking variation.

3. Punch mark the elevation of drum (elevation shown in the Contract

erection drawing) on the identified column for drum alignment.

II. Calibration Requirements

1. All the measuring instruments are to be identified and registered

as per FQA System F- 15 and guidelines for calibration F – 15
/GL – O1.

2. Calibration label (F -15 -02 are to be fixed on the instrument,

with duly filled details like registration no, next calibration due for
calibration etc.

17
III. Special Equipment – Requirement and Inspection

S. No. Description Quantity

1. Electric winch 10 ton capacity (for drum) 2 Nos.
2. Electric winch 3 or 5 ton capacity (for U rod) 2 Nos.

3. Wire Ropes 1400 M length, 25 mm dia. 6 x 37 2 Nos.

construction IWRC and right lay (for Drum)
4. Wire rope 400M length, 19 mm dia. 6 x 37 2 Nos.
construction, IWRC and right lay (for U rod)
5. 10 sheeve 100 ton pulley block 4 Nos.
6. Single sheeve 10 ton pulley block 8 Nos.
7. 3 ton or 5 ton chain pulley block 4 Nos.
8. 3 ton pulling and lifting machine 4 Nos.

Or
9. Wire rope 26 or 28 mm dia. 6 x 37 construction
and IWRC.

a) 40 mm length for lashing 10 sheeve pulley 2 Nos.

with cat band structure

b) 80 M length for lashing 10 sheeve pulley

with drum. 2 Nos.

10. Forged steel bull grips to suit the dia. Of rope 60 Nos.

2. Inspection:

1. Electrical Winch

 Megger the winch motor for IR value. In no case the IR value

should less than 1 mrga Ogm. If necessary IR value can be
improved by providing lamp for heating. (Use SOOV Megger)

 Starter of the motor, having sufficient capacity.

 Check up for proper relay setting.

18
  Calibrate the ammeter and voltmeter for indicating correct rating
(if provided for indication).

 Check the effectiveness of braking system – if necessary, fir

with new brake liners.

 Fill up gear box with correct grade of oil to specified level.

 Fill up with correct grade grease wherever grease nipples are

provided.

 Arrange for AC power supply – 3 phase 415 volt 200 amps.

 Keep spare fuse 1. times the maximum current capacity of the

winch.

 Arrange for alternate AC/ DC source in case of failure of main

AC source.

 Idle run the winch motor for 4 hours and check the following:

a) Effectiveness of brake

b) Phase voltage and current at no load, and at load, if

possible

c) Excessive heating of motor.

d) Any abnormal sound in the gear box or any moving parts.

e) Smooth switching over from AC to DC supply.

2. Pulleys

During pulley servicing check the following:

 No wear out, chips and cracks on flange.

 No groove wear out.

 No bearing wobbling (in case of bush, check the clearance)

 Properly lubricated.

 Free rotation of pulley,

 Correct grove size.

19
  No shaft wear out.

 Trueness of the sheaves with shaft.

 All the clearances are within limits (recommended by the supplier).

 Greasing holes are clean.

 Fill up with recommended grease.

3. Wire Rope

The total length of wire rope is to be inspected and record the damage
details if any like:

 Broken wires, wear and abrasion, reduction in rope dia, rope

stretch, corrosion, crushed strands, jammed strands, flattened
strands, high stranding and unlaying, bird caging kinks, bulges in
rope etc.

 Check whether the lubrication is sufficient.

 Examine the cleanliness of the grooves between the strands,

Deposits of hard grease or dirt which prevent the lubricant from
flowing through the grooves, shall be removed.

 Clean the wire rope with wire brush.

 Apply the lubricant to wire rope using a brush (cadmium

compound.)

 For rejection criteria, refer Notes.

4. Chain Pulley Blocks

 Examine (if required with magnifying glass the links for:

 Elongation of stretch, gouges, chips, cuts and wear at bearing

surfaces.

 Locking Mechanism.

 Load Test for four Hours by loading with number of concrete blocks
to its capacity.

20
5. Pulling and Lifting Machine

Load test for 4 hours (by loading with number of concrete block to its
capacity).

6. Bull Dog Grips

 Only forged steel bull dog grips to be used.

 Check for any damage like cut mark, etc. on the “u” Bolt.

 Check for any damage in threaded portion of I-Bolt.

 Check the saddle inner surface for nay damage.

 Check that the „U‟ Bolt nuts are freely moving on the „u‟ Bolt
threads.

Notes:

1) If the inspection reports are found satisfactory clear the equipment

for use.

2) Criteria for rejection of wire ropes.

The wire rope will be rejected under the following conditions:

a) Broken wires

i) Six or more broken wires in one lay.

ii) Three or more broken wires in one strand in one lay.

iii) More than one broken wire in the valley,.

b) Wear and abrasions

i) If the wear exceeds 1/3 of the diameter of the wire.

c) Reduction in rope diameter

i) 1mm (3/64”) for rope diameter of up to and including 19 mm (3/4”)

ii) 1.5 mm (1/16”) for rope diameter of 22 -28 mm (7/8” to 1”)

iii) 2mm (3/32”) for rope diameters of 32 -38 mm (1/1/4” to 1- ½”)

21
d) Rope Stretch

i) An approximate elongation of 150 mm (6”) per 30 M (100 ft) of

length for 6 strand of rope.

e) Rejection of Rope

The rope may be rejected if the following observed:

i) Corrosion

ii) Crushed, jarruned and flattened strand.

iii) High, standing and unlaying.

iv) Bird caging, kinks and bulges.

IV. Unloading and leading the boiler drum

The wagon should be placed on the railway siding at such a location

where it will be convenient to unload and lead to just underneath the
boiler structure.

Anyone of the following methods may be adopted for unloading from

the wagon:

a) Method I

 The place shall be well consolidated.

 Prepare stage by sleepers on either ends almost to the same

height to that height of the wagon.

 Select rails, which are capable of taking the weight of Drum, and
bolt two of them together.

ii) An approximate elongation of 230 mm (9”) to 254 mm (10”) per

30 M (100 ft) of length for 8 strand of rope.

 Lift on end of drum by crawler crane (75 MT Capacity) or by

suitable jacks, insert the prepared rails bringing the entire width of
wagon and stage.

 Same arrangement should be made at the other end also.

 Two and winches of 5 T capacity with 25 rom rope, should be

properly anchored.

22
  Fasten the winch rope on either end of the drum and skid the drum
of the sleeper stage and release the wagon.

b) Method II

By using two crawler cranes (75 T capacity) the drum is unloaded

The Method, I is preferred out or a or b.

Note:

 Cranes shall be placed on well consolidated ground and utmost care

shall be taken in operating, signaling and correct slinging.

 Now the drum is led towards the boiler either by skidding or by using
two crawler cranes of 75 MT capacity with very careful signaling
operations and brought to location in the correct orientation.

V CAT HEAD STRUCTURE (A FRAME)

Fabricate the CAT Head Structure in fabrication Yard. The dimensions are
to be maintained as shown in the drawing. The design and drawing will be
duly vetted by approved agency or by Unit.

The welding involved in fabrication and erection of cat head structure are
to e subjected to 100% Liquid Penetrate Inspection for its soundness.
(Record the LPI details in Exhibit No. F-11-01 of FQA System Manual).

A typical arrangement of cat head structure is shown in Fig: 3

Note:

According to contract drawing, dimensions are to be fixed to suit the site

condition.

VI Lifting Arrangement

The total layout of drum lifting arrangement is to be decided at site

depending on the site condition.

a. Winch location.

b. Winch anchorage

c. Guide Pulley location.

d. Guide Pulley fixing arrangement.

 Suggested Layout arrangement is given below.

23
a) Winch Location (For all winches)

The winch should be placed from the first guide pulley in such a way
that the fleet angle of 1 to 1 – ¼ degree is maintained, a shown in Fig:
4A

Erect the cat head structure as per the drawing dimensions, using
tower crane (if available) or derrick.

 The first guide pulley should be in line with the winch drum centre.
This will aid smooth booking of ropes over the winch drum.

b) Winch anchorage

1. Drum Lifting Winches

 Dig a hole in ground of size – “Length # 5 feet, Width # 3 feet

and depth # 8 feet.”

 Fabricate a frame as shown in figure 4 B

Note:

 The design / method of anchoring are to be finalizes with Civil

Engineering Section / approved agency.

 The fabricated frame to be positioned in the hole due in such a way

that minimum 2 feet of the 18MB 400 is above ground level.

 Fill up the hole with boulders up to 6 feet height from the bottom,
leaving 4 feet of the 18 MB 400 at top as detailed below:

 First one layer of boulders,

 Fill up the gaps better the holders with sand.

 Pour water to consolidate / compaction.

 The same sequence is to b repeated to fill up to 6 feet.

24
25
26
27
  Fill up the balance 2 feet depth with concrete mixture and cure it
properly.

 The projecting portion of ISMB 400 above ground level

(approximately 2 feet) can be used as anchoring points for the
drum lifting winch.

 This arrangement is to be made ready for both the drum lifting

winches at the location decided by site.

Note:

In case any other anchoring method is decided along with customer, it

may also be acceptable, after checking with Civil Engineering Section.

 The winch frame to be directly welded with anchoring arrangement

through connecting members, as show in Fig: 4C.

c) “U” Rod lifting Winch

These winches to be anchored with main column of the boiler

(between S 12 and S 13 as shown in Fig: 4D.

Note: Winch can be anchored with arrangement using wire rope.

d) Guide pulley location for drum

 One set of guide pulley is to be fixed over ISMB 600 Beam C or

Beam D near the bottom Flange on left or right size near Column S
18.

 This guide pulley should be located in such a way that it is in line,

with the pulley from winch the wire rope comes out of the block 1”
pulley, as shown in Fig: 4E

 Another set of pulley is to be fixed over the bottom of main column

S11 R or S 11L (left and, right side) to suit the site condition. Take
the wire rope directly from this guide pulley to the winch.

28
 Note:

 If required one more set of guide pulley may be fixed in S 13 left

and right columns.

 However it is always preferable to use less number of guide

pulleys to minimize the frictional load on the total arrangement.

 A typical sketch for drum lifting arrangement is shown in Fig: 5

e) Guide pulley fixing arrangement

Fabricate fixing plate as shown in Fig 6A.

29
30
31
32
33
 D - hole to be drilled to suit shackle dia:

M- minimum available length from hole to the end of plate should be 1

-1/2 times the dia, of hole.

f) Fixing plate welding

 Only qualified welders are to be engaged.

 Use E 7018 electrode

 Pre heat to minimum 150Oc

 Ensure baking of electrode to recommended temperature

(Welding Manual Vol.I).

 Ensure usage of holding oven to maintain electrode temperature

above 100Oc.

 100% LPI on fixing plate welding.

g) Fixing arrangement at ceiling beam and column

 The fixing plate welding is to be carried out as show in Fig -6B.

 While fixing over the column the fixing plate should be in line
with web.

 Similar procedure to be followed for fixing the plate with main

column.

The guide pulleys to be fixed to the fixing plate using forged steel „D‟
shackles of correct grade and capacity as recommended by standards.

In case any other fixing arrangement is decided at site, the procedure

should be approved by site I/C before implementation.

VIII. RECEIVING ARRANGEMENT

Caution:

 No welding is permitted on boiler aside after bringing the drum

lifting wire rope inside boiler area, to avoid any possible damage to
rope due to sparking.

 Over the leveled ground spread thin sheets or tarpaulin to protect

the wire rope touching the ground, (Mainly to avoid sand
accumulation in the wire rope groove).

34
  Place the two 10 sheave pulleys at a convenient distance of say 5
to 7 meters for reeving.

The reeving shall be done as shown in Fig: 7A

Note:

Any change in the reeving arrangement, if decided at site, shall be

informed to Head – Quarters Facility Engineering group and got approved
before carrying out the changed method at site).

35
36
37
38
VIII. a) Fixing pulley block with cat head

 As shown in Fig 7B using 28 mm wire rope the top pulley shall be

fixed with cat head arrangement.

 Minimum 10 layers are to be lashed.

 Correct size bull dog grip („U‟ clamp) to be used.

 When the rope is clamped by „U‟ clamps (Bull dog grip) „u‟ end
should be on the dead end of the rope and there should be six „u‟
clamps at the interval of 6 inches for proper clamping.

 After fixing the top pulley block with cat head arrangement, the
drum lifting wire rope shall be loosened and the bottom pulley to be
brought down for fixing with drum.

b) Fixing pulley block with drum

The lashing of pulley with drum shall be done as shown in Fig : 7C.

Note:

1. Lashing generally will need adjustment because all the layers will
nor get equal loading causing tilt in pulley block. It should be
adjusted till pulley blocks are vertical when they are loaded.

2. Top and bottom pulleys are to be in one line, in such a way that the
rope fall is perpendicular to both pulley shaft and drum axis.

c) Guide pulley location for „U‟ Rod:

 Since the „U‟ Rod has to pass through the drum supporting beam,
washer Plate rocker & nut, it is necessary to lift the „U‟ Rod up to
the drum Supporting beam level through one lifting arrangement
and then transfer the load to another lifting arrangement provided at
the top.

 A three sheeve pulley of 10 T capacity is to be first fixed at the top,

below the drum supporting beam. This pulley should be fixed so
that it is at the centre of „U‟ Rod‟s arm distance. Refer: Fig 7D.

d) Fixing of bottom pulley with „u‟ Rod

 The bottom pulley to be fixed with „u‟ Rod as shown in Fig: 7E

39
Note:

Retainer arrangement is given for keeping the arm distance as per

drawing for easy insertion of the „u‟ Rod at the top. This is to be
removed after inserting the „u‟ Rod in the washer plate, rocker and nut
and after tightening the nut for minimum 10 threads.

 The location of guide pulley to be fixed at site according to site

condition.

40
41
Note:

While fixing the location of guide pulley care to be taken that the “u” Rod
lifting wire rope is not interfering with drum lifting wire rope.

e) Arrangement for transferring the “U” Rod at Top:

 The lifting arrangement to be made at top as shown ion Fig 7F and

the chain block pulley as shown, for transferring the load.

 After insertion in washer and rocker tighten with nut so that the
required length of threads are above the nut.

IX Checks on drum and “u” Rod

 Position the drum in the rear of combustor area pass (in rear area
of S11 L, S18, S11 R columns) and in front of back in front of back
in front of column S12L & S12R

 The orientation of drum should be adjusted so as to keep the down

– comer stubs at the bottom, safety valve stub at the top and water
riser stubs facing the furnace.

Note: It is essential to rotate and adjust the drum so as to keep down

comer at the ground level it self to the correct orientation to
avoid any major adjustment at the higher elevation.

 Check the availability of all stubs / attachments, as per drawing.

 Close all the stub openings if end caps are missing.

 Check for the marking of drum axis and „U‟ Rod location on the
drum. (According to shop match mark).

 Check the distance between the „u‟ Rod stopper plates.

 Check the following dimension of „u‟ Rod with respect to drawing

dimension, after removing the spacer rod. Keep the U Rod on
horizontal plane Refer Fig: 7G

 Arm to arm distance

 Threaded length

 Out of plane of arm

 Free movement of nut.

42
  Arm length (straight length from the drum center to top of
thread.

 Inner radius of U-Rod

To find the expected thread length to be protruding above the nut (=P)

 Calculate the following.

 TOS elevation of drum suspension beam # A meters.

 Thickness of washer plate # B Meters

43
44
  Height of rocker

 Height of nut.

A +B + C+ D = X metres (measured value)

 Drum elevation given in the drawing = Y metres

 Calculated distance from (X- Y) meters

Top of nut to drum level = say Z meters

 Length of arm measured = L meters

 Hence threaded portion above nut = (L-Z) = P meters

 This calculation will help to find out approximately how much

threaded portion is above the nut after maintaining the drum
level as per drawing. Also, the alignment of the drum will be
easier with minimum adjustment. This can be cross referred
with drawing for minimum projection envisaged by designs.

X) Trial Lifting of Drum:

Lift the: drum to 1 to 2 meters height above the ground level and hold it for
10 minutes. During the above operation check the following points for
correctness.

 Main hoist pulley blocks anchorage both at cat head structure and
drum.

 Anchorage of icle pulleys in the system.

 Anchorage of winches.

 Free movement of all pulleys while lifting.

 No vibration of boiler structure and the structure.

 No interference of wire rope.

Free path up to drum level for drum lifting (if any temporary members were
welded for erection purpose they are to be removed between S11L, S18,
S11R combustor side and S12L to S12 R left and right side Back Pass
area)

45
The drum may be lifted in tilted condition to clear the fouling.

 Winch current during lifting.

 Coupling for the motor with gear box.

 Soundness of “Winch – Break” (one at a time by transferring the loas

on it to required).

 Readjust it, if required.

Then lower the drum to its location and recheck the above points once
gain.

 After ensuring all the requirements, the total system is ready for drum
lifting.

 Similar trial lifting operation is to be carried out for „U‟ Rod also.

IX) Reference axis and angle marking

 Punch mark the reference line on the washer plate (to match the
centre line of the rocker) to the specified angle shown in drawing for
rocker alignment.

 Typical marking detail is shown in Fig 8A

 Punch mark the boiler axis on the top flange of ceiling girder C3
and middle row of WBs over Columns S 17, S 18, S19 Also check
the perpendicularity of the boiler axis with respect to drum
longitudinal axis as shown in Fig: BC

Note:

All RBs are to be positioned with respect to “boiler longitudinal axis”

and drum axis / Combustor and Back Pass.

 Position the square washer plate over the drum suspension beam
and arrest it with cleat angle on four sides (the cleat angles are to
be tack welded with structural members only) and check the
correctness of position with respect to drawing, as shown in the Fig:
8D.

Allowance tolerance from drawing dimension:

 A and B from center line of: # 3 + /-3 mm

Beam D, Beam B and Ceiling Girder C # Maximum + /- 10 mm

46
47
48
  Position the rocker over the washer plate and align it with punched
line on the washer plate.

 Position the nut over the rocker.

XII Drum Lifting operation

 Start the drum lifting operation, preferably morning i=under good

natural light (for visibility).

 Allow the drum to travel at least 2 meters up and then start

lifting the „U‟ Rod.

 The drum should be maintained at same titled condition from

horizontal throughout the lifting operation a sin initial position,
adequate enough to clear the fouling from structural members.

 The gap between drum bottom and „U‟ Rod should be

maintained throughout the lifting operation.

 During drum lifting operation, recheck all given for trial lifting to
ensure that arrangement is in normal condition,

 Stop the drum lifting winches, when the drum reaches 0.5 metre
above the drum elevation shown in the drawing. Make the drum
in horizontal condition now.

 Stop the „U‟ lifting winch when the gap between drum and „u‟
Rod is around 0.5 meter.

 Take the „u‟ Rod load on the other lifting arrangement provided
at the top.

 Release the sign attached to the „u‟ Rod and pulley block,

 Lift the „u‟ Rod using chain block.

 Insert the „u‟ Rod is the washer and rocker. (Keep the nut
slightly above).

 Tighten the nut so that the calculated value of threaded portion

above the but is maintained.

 Allow the nut to sir properly over the rocker.

 Then slowly lower the drum and allow it to sit over the „u‟ Rod.

49
  Release the load on winch.

 Keep the total lifting arrangement till the completion of drum

alignment.

XIII Alignment of drum (Refer: Fig 9)

 Align the drum for horizontality. Tolerance allowed is – 5 mm

from one corner to the other cornet (centre line marked on the
drum).

 Align the drum for its elevation – Tolerance ± 5 mm.

50
51
52
  Check for the alignment of drum centre with reference to boiler
axis – Tolerance ± 5 mm.

Note:

 With the drum load on „U‟ Rod the nut should not be tightened
or loosened to adjust drum level.

 Any adjustment by nut should be done only after lifting the drum
slightly up and „U‟ Rod in free condition.

 Check the vertically of each limb (arm) of „U‟ Rod (using plumb
bob). Tolerance 10 mm.

 Check the contact between „u‟ Rod and drum (30o contact on
either side from bottom most point). In case of any variation,
report to designs at manufacturing unit for clarification.

 Record all the regarding in FQA log sheet number FQA01-Q4-

00-L-O1.

 The vertically of column (wherever possible) is to be checked

and recorded) after drum lifting by the structural erection group.

XIV DRUM INTERNALS

Following procedure is to be followed, if the drum internals are dispatched

separately or drum internals are removed and are to be fitted back:

53
54
BOILER DRUM

1. The concerned contract assembly drawing of drum internal is to be

studied before start of the internal assembly. A typical cross sectional
view of drum internal is shown in Fig: IOA.

2. While dismantling drum internals at site, match marks are to be made

so that same sub assembly component 1S fitted in the same place
during reassembly.

3. Seal welding is to be done only as per arrangement of drum internal

drawing.

4. All bolted connections are to be used with double washers. One

washer is to be put at the back of nut and the other at the front of bolt
and ensure that the washers cover the holes / slots fully.

5. Inspect all vent and drain holes in the internals, to make certain they
are open.

6. Ensure that the weld joint of feed pipe are leak proof.

7. The drier sections are not to be welded together nor to the drier
supporting structure. But the supporting structures to be seal welded to
the drier base angle as per arrangement shown in Fig : 10D.

8. Ends (entry and exit) of secondary separators must be opened for

steam passage. Refer Fig. 10B.

9. Ensure that all parts of separating chamber are fitted without any gap.
The welds at the joints should be complete and leak proof.

10. Check whether the primary separator is clamped to its supports rigidly
with its axis vertical so that it does not tilt or fall during operation.

Refer Fig: 10 B. A tolerance of ± 5.0 mrn is allowed in the vertically of

turbo separator.

11. Check, whether the passage are through in individual screen drier
boxes and ensure that these are free from foreign material. Refer Fig:
10C.

12. Check whether the screen drier boxes are fixed with each other such
that the gap does not exceed 1 mm.

13. Ensure that drum is free of all foreign particles, especially tools and
electrode bits which may remain inside after the erection of internals.

55
14. Before closing the manhole door, see that manhole door gasket is in
perfect condition.

15. Check whether the down – comer cover assembly has been installed
over the down – comer cover openings to avoid vortex formation
during operation.

16. Check for the orientation of holes in blow down pipe. These holes are
to be in the direction opposite to Chemical – Dosing- pipe.

17. The holes in the chemical doing pipe should be facing towards the
Feed Distribution pipes.

56
57
ERECTION OF HEADERS

58
 ERECTION OF HEADERS

1. Checks on Supporting Structure Prior to Erection:

Check the dimensional correctness of the pressure parts supporting

structures (RBs) with respect to reference axis shown in the
structural drawing.

Note:

For erection of supporting structure, the drawings given in structural

group are to be followed. For the header location with respect to
reference axis the pressure parts drawings are to be followed.
There will be a difference in dimension of the centre line of supports
at the top and centre line of header with respect to reference axis.
This difference is preset to accommodate thermal expansion a
shown in the Fig. 1

Δ - Presetting for that particular suspension depends on „O‟

D - Distance from origin of expansion

X - Distance of the pressure part component that is

suspended from reference structure.

X+ Δ - Distance of the suspension point on the structure from

the reference structure.

For the dimensions and the amount of presetting refer the contract
drawing.

For the dimensions and the amount of presetting refer the contract
drawing.

2. Check the following on headers:

a) Orientation of the headers.

b) Axis marking at the ends in the II & IV quadrants.

c) Left / Right marking for the headers parallel to drum axis.

d) Front / Rear marking for the headers perpendicular to drum axis,

e) Flexible hose test * for long stubs of the header to ensure free
passage.

59
f) Sponge test * for open header stubs.

* - Refer FQA log sheet No. FQA –O1-05-00-L-02 and Instruction

No. BI- OI – 0204T/3 of 8 for the procedure.

g) The bow in both the planes, scarfing line and sub stub verticality.
(Refer log sheet No. FQA –OI – 05-00-L-03.) Clean the weld edge
preparation and apply weldable primer and fix all end caps.

3. Erection of header supports.

Position the baring plate over the support channels as per the
structure drawing dimension and tack weld as shown in the Fig:2.

Insert the hanger rods / tie rods through bearing plate and tighten
with nut.

60
61
62
 Note:

Proper care is to be taken while lashing the ropes over the WBs.

 The capacity, number of sheeve 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.

 Header lugs must be used for lifting as shown in the Fig: 5.

 While lifting the header, use a tag line to control the load
(movement of header)

 Lift the header and place it over the temporary support and
match the header axis with the centre line marked over the
temporary support.

 Connect the hanger rod with the header lug using the pin.

 Provide the correct size cotter pin.

 Check the elevation of the header, orientation, horizontality and

distance from reference axis before arresting the header.

 Arrest the header as shown in the Fig 6:

 Other headers like bottom header which are connected with

water – wall and like SHH 5 & 6 which are connected with
steam cooled wall are to be positioned aligned and welded with
water wall / SCW etc respectively.

63
64
Note:

1. The end caps should be removed only during final fit up.

2. All temporary supports should be removed only prior to

hydraulic test. The temporary supports should be erected in
such a way that it should not be a hindrance to any
permanent suspension / components.

3. Other important aspects of header suspension and header

alignment are shown in Fig : 7A to 7E.

65
66
67
68
69
70
Procedure for sponge test

 A sponge piece of width & breath 1 ½ or 2 times dia of tube ID and

length minimum 6:” (150 mm) to be pushed in the tube by compressing
the sponge.

 Pass compressed air in the tube where the sponge is inserted.

 Due to the air pressure sponge will be pushed ID the tube towards the
other end.

 During the sponge movement in the tubes, the accumulated dust if any
or the VCO pellet powder etc, will be cleaned. If there is any choking,
the sponge will get stuck up.

 This procedure is applicable for all loose tubes, coils, panels etc. (FQA
log sheet No. FQA – OI – OS- 00-LO2)

 After cleaning the tube, close the end openings with end caps.

 Identify the cleaned tubes with paint marking (say X or Y etc.). This
marking will help in erecting clean only cleaned tubes.

71
 PRESSURE PARTS
(Water Wall / SH Steam cooled wall)

72
I. Water Wall

Proceed for erection form top to bottom refer chapter on erection

sequence Carry out preassembly on ground depending upon site
conditions.

 Complete the erection including permanent supports and alignment of

all headers as under.

o Combustor upper and lower WW headers. (Front, left, right and

rear side), front and rear roof headers, transition inlet Headers front
and rear, transition inlet Headers left and rear, Evaporator and let
header (middle wall outlet header). Evaporator inlet headers
(middle wall inlet header) etc.

 Carry out sponge tests of all water wall panels, riser tubes, pipes and
headers close the openings with end caps after test.

Note

End caps are to be removed just before final fir – up.

Check the following

 Width of panel

 Length of panel

 Permanent Bow, if any

 Any damage like sling mark, deep out, tool mark etc. to be rectified
before lifting.

 Location of opening as per drawing.

 Edge preparation

 Preassemble the following with panel seal box as shown in Fig : 1.

 Man hole doors, Peep hole doors, instrument Openings, Blower

openings etc.

 The surface of all tubes that are completely embedded in castable

refractory should be painted with two coats of bituminous paints.

 Preassemble the roof panel at ground as per site conditions and Lift
combustor roof panels (front and rear) as per site convenience.

73
Scalloped Bar Welding Detail

1. Cut the scalloped bar (only top scalloped bar of seal box) as shown in
(Fig: IX).

2. Weld item B bottom scalloped bar and seal box with pressure parts
before the hydraulic test (refer the Fig: 1Y)

3. Item A ahs to be welded to item B after pouring castable refractory

inside the seal box (refer Fig 1Z).

4. The, lifting arrangement is to be suitably decided at site based on the

location of winch.

5. Water wall / SCW panels are to be handled with care to avoid

permanent bow and damage.

6. The suggested panel handling method 1 is shown in Fig- 3 (for both

lifting and alignment).

7. Lift all the top water wall panels and align the panels within permissible
tolerance by adjusting panel to panel welding gap (Refer Fig: 4A to Fig
.4C)

74
75
 Complete the welding after alignment.

Notes: Refer Figure : 4C

1. In field align panel edge bars, not tube centres in wall assembly.

2. While assembling the panels, ensure that this pitch tolerance is not
cumulated. The tolerance on width & depth is to be maintained as
per specified Tolerance (+ 10, -15).

 After erecting all top water wall panels, erect the buck – stays
coming in that panel and align (this will help us to maintain
vertically of the water wall panels and furnace dimension within
permissible limit)

 Erect all other panels and complete the welding following the
above procedure.

Note:

Care should be taken while erecting the bottom panel.

Additional temporary supports are to be provided with main

structural members to position them.

Pre assembly of Bottom header (Refer Fig 5A)

 Check the following during preferably.

 First, level the individual header on temporary supports with water

level.

76
77
78
79
80
 Mark the centre points on four sides.

 Measure A1, A2, A3 and A4. Tolerance ± 3mm from centre point.

 Measure B1, B2, B3 and B4 – Tolerance ± 5 mm from centre point.

 Measure D1 & D2 – Tolerance D1- D2 = 15 mm max.

 Then clear it for welding.

 Carry out post weld heat treatment.

 Carry out NDE checks.

 Select locations for fixing top pulley.

 Erect temporary supports for placing the bottom header after lifting, as
shown in Fig: 5B.

 Lift the bottom headers and place it on the temporary support.

(Minimum two supports are required fro each side).

 Align the bottom headers front, left, rear, right side with boiler and
combustor axis.

Check the following

 Elevation of bottom header (each side at ends with water level).

 Matching the centre points with respective axis.

 Arrest the bottom header over temporary support to avoid any possible
movement.

 Align the bend tube (left / right side) with water wall panel and header
stubs.

81
82
83
 Align the straight tube (first and rear) with water wall and header stub.

 Complete the welding and remove the temporary spacer block

provided over coils.

 Complete the erection of all upper and lower buck stay beams. Erect
and align all furnace guides. Maintain gaps as per drawing.

 Complete erection of all bottom header supports.

 Erect and align all riser tubes on temporary supports.

 Provide spacer blocks of necessary to avoid fouling.

 Complete the welding and remove temporary spacer blocks.

 Complete the erection of all permanent supports.

 Complete the erection, alignment and welding of all panels with

openings such as combustor gas outlet opening, FBHE return leg
opening, seal pot return leg opening, FBHE return leg opening, ash
cooler opening.

Note:

Fix the panels with burnet opening in their respective position as per
drawing, and check the alignment. Apply anti seizing compound on the
studs. Complete the alignment of burner blocks and record the alignment
and elevation with respect to combustor axis.

II. SH STEAM COOLED WALL

1. Erect all rear roof supports in back pass.

2. Check the alignment of front, left, rear and right side top headers of
second pass (SH side wall inlet headers) and ensure that all
permanent support are provided.

3. Make ground pre-assembly of all seal boxes of openings in back pass

such as LRSB, HRSB and Instrument Openings, manholes PG Test
openings as applicable.

4. Erect all the SH steam cooled wall (erection method to be followed as

explained for water – wall.) Check the elev. Of all openings.

5. Complete the erection of all buck-stays. Check the verticality of all SC

walls

84
6. Align the SH-3 outlet header and complete the welding with SC wall..
SH-3 inlet header and complete the welding with SC wall.

7. Check the width and depth of back pass.

 Check the end gaps/ clearance available, which are to be maintained

as per drawing.

85
86
 Check the alignment of EVAP inlet / outlet header, RH – 2 Inlet, Outlet
Headers, Economizer. Inlet and Outlet Headers with SCW wall and
complete welding.

08. During Erection, Adequate Gap Should be maintained between Re-

Heater – 2 & Evaporator Coils and between evaporator outlet header &
superheated – 3 outlet header as shown in the drawing.

09. Complete the welding of link pipes with headers.

87
PRESSURE PARTS
(Down Comers)

88
 Check the drum down – comer stubs (six nos.) centre lien with
respect to reference axis.

 Check the drum down comer stub to stun distance

Note: These checks can be done before drum erection also.

 Check the respective inlet header stub (for down comer connection)
distance from reference axis.

 Check the individual piece length and orientation of supply pipe stubs
(86 nos.).

 Lifting arrangement is to be decided at site.

 Use the erection lugs and associated rod, washer and nuts for
erection and alignment. (Refer Fig : 1)

 Erect all top pieces and align with the drum stub.

 Check the distance of down – comer pipe from reference axis.

 Check the vertically.

 Check the down – comer pipe to pipe distance.

 Check the weld fir up.

 Clean the joint for welding after achieving all dimensions within
permissible limit.

 Further pipes are to be erected as explained above.

 Complete the erection of all permanent supports and seismic guides.

 After completion of one joint, the erection attachments to be removed

and used for subsequent level.

89
90
 PRESSURE PARTS
(Down Comers, Coils, Buck Stay)

91
 Further pipes are to be erected as explained above.

 Complete the erection of all permanent supports and seismic guides.

 After completion of one joint, the erection attachments to be removed

and used for subsequent level.

92
 ERECTION OF COILS

I. Pre erection checks

1. Check the width and length of the coils, such as Economizer,

Evaporator, SH – 3, RH coils. Ensure flexible connections
availability and welding as per drawing.

 Sponge test is to be carried out for the SH, RH, EVAP, Economizer coil
assy., and hanger tubes.

 Check for damages like sling marks, deep cut and dent etc.

 Check the weld end connections such as edge preparation and ID and
compare with header stub weld end connections.

 Clean the edge preparation and apply weldable primer.

 Check for any permanent bow (if bow is observed, inform

manufacturing unit for corrective action before taking it up for erection).

 Remove the end caps and carry out sponge test and then fix all th end
caps, The end caps are to be removed only at the time of final fir up.

 The suspension arrangement to be pre assembled and positioned as

explained in the first pass roof erection.

 Fabricate and anti- deformation frame as shown in Fig 1A (Temporary

binder if ant is to be removed), and also fabricate a lifting device as
shown in Fig IB. Complete following jobs at ground.

1. Precision shields are to be provided for hanger tubes and sorefn tubes
are the fuef gas in et to back pass.

2. a) half sleeves of fuel length with suitable material shall be provided at

the top most rows of all co ranks to protect against erosion.

B0 half sleeves shall also be provided over the coils exposed to the
operating range of individual soci blower.

3. Evaporator coils which are supplied as two paris are 10 be ground

assembled before lifting to position.

4. The coil penetration location at the steam cooled walls are to be

provided with suitable level tubes.

5. Erection weld of hanger tubes at EL 57.050M should be done at

ground itself.

93
6. Fix the lifting and guide pulleys according to site condition. This
arrangement should be in such a way that it can be shifted at top to
lift each coil.

II. Erection of coils (SH-3, RH-2, EVAP, and Economizer coils)

1. Check alignment of all headers.

2. Erect all the hanger tubes with permanent support and complete
the welding with header.

3. The coils are to be lifted as shown in Fig 2 in the sequence from top
to bottom, SH – 3, Evap, RH, Economizer.

94
95
96
Note:

 Provide baffle plates as per drawing of back pass at front and rear
walls as recommended by manufacturing Unit.

 Weld the bottom terminal tube with the header stubs (Header is
already welded with rear steam cooled wall) through the connecting
tubes.

 Weld the hanger tubes after checking the header alignment.

 Measure the total height of all economizer banks including the support
plate. Ensure that this dimension is as per drawing.

4. Lift the Evap, RH, upper Eco coils 2.2, using the floating pulley system.

5. Weld the SH – 3, Evap, RH, Upper Eco coil terminal tube connection
with the outlet header – stubs.

6. Erect the Eco upper 2.1 and lower bank 1.2 connecting suspension
arrangements.

7. Lift the lower Eco coils and suspend with the supporting plate already
erected, with upper coil.

8. Weld the terminal tube connection between upper and lower coils.

9. Check alignment the Eco inlet header with its supports and align.

10. Complete the welding of inlet header stub with the terminal tubes.

 Eco. 1.1

 Evap. Inlet header.

 RH inlet header

 SH inlet header

2. The baffle plate arresting arrangements is to be completed as per

drawing in above economizer 1.2 in front and rear walls.

 The baffle plate arresting arrangement is to be completed above

Evaporator coil assy, in front wall, and above SH – 3 coil assy, and
above RH coil assy in ear SCW.

3. Complete the erection and welding of Eco outlet header to eco. Link
pipes to drum including permanent support.

97
  Complete welding of Link pipes from Evap. Out let header at
combustor bottom.

 Complete the erection, alignment and welding of Eco outlet header

to eco. Link pipes to drum including permanent support.

 Complete welding of link pipes from Evap. Out let header to drum
along with permanent support.

 Complete line pipes from Middle wall out let header to Evap. Out let
header at combustor bottom.

4. Complete the erection, alignment and welding of DESH links between

FBHE out let header to SHH – 5 (SH inlet) header, including
permanent supports (orientation of Stubs to be checked).

5. Important aspects of coil erection and alignment are shown in the back
pass fig. 1A to Fig 1D.

Preassembly of Buckstay (Refer: Fig 2A)

 Assemble the key channel with stirrups (the number of stirrups and its
locations to be maintained as pee contract drawing).

 Align the buck – stay beam with stirrups (Ensure that the stirrup is in
full contact with the buck – stay beam flange).

 Weld the top and bottom angle with the stirrup. (Ensure the bottom
stirrup angle is in full bearing with the toe of the buck – stay beam
flange).

 Lock the assembly of the ends and in between, to avoid the buck –
stay beam slipping from its location.

 Bolted type design (Refer Fig 2B)

 While preassembly, the stirrup bolt location in the bucks stay slots
should be checked for the relative expansion of ~all with respect to the
buck – stay indicated in the drawing, for cold – Junction. (Refer: Fig
2C).

 The location of the bolt in the slot, during erection, should be such that
the relative movement of the wall with respect to buck-stay is fully
permitted and should fully conform to the contract drawing.

 Lift the buck 0 stay and place it over the temporary support provided
on the main column at the appropriate level (where the buck – stay is
to be fixed with wall panels) as shown in Fig 3.

98
 Mark the centre line of the buck – stay on the wall panels. (Refer Fig:
4).

 Check and ensure the completion of panel to panel welding and

closing of all voids in the buck stay region.

 Weld the bottom side scalloped plates/ pas on wall panels after
leveling them.

 Fix the buck- stay assembly (already preassembled) over the

scalloped plate / pad.

 Ensure that the key channel is in full contact with all tubes of the wall
panels.

 Fix the top scalloped plate / pas on wall panel, and complete, the
welding,

 Weld the scalloped plate / pas with key channel both at top and
bottom,

 Complete the corner link connection (the corner link should be inclined
outwards with respect to wall. This is to accommodate the expansion
of wall. The buck stay does not expand).

 Complete the erection of buck – stay including support hangers and

links. (There shall be no rigid connection between vertical and
horizontal buck – stays).

 Complete the erection of leveler channels with guide. (the leveler

channel shall be rigidly connected at one end and guided at the other
end).

 Complete the erection of furnace guide. Keep 3 mm clearance for the

guides to move down without any obstruction for boiler expansion.

 The important aspects of buck – stay erection details are given in the
Figs: SA to 5W.

99
 ERECTIN OF FBHE COILS

I) Pre erection checks

1. Check the width and length of the coil assy. In FBHE 1, 2, 3 and 4.
Carry out ground assy. Refer Fig 2 for details enclosed.

1 Sponge test is to be carried out for the SH, RH, coil assy., and
support arrangement.

2. Check for damages like sling marks, deep cut and dent etc.

3. Check the weld end connections such as edge preparation and ID

and compare with header stub weld end connections.

4. Clean the edge preparation and apply weldable primer.

5. Check the any permanent bow (if bow is observed, inform

manufacturing unit for corrective action before taking it up for
erection).

6. Remove the end caps and carry out sponge test and then fix all the
end caps. The end caps are to be removed only at the time of final
fit up.

7. The suspension arrangement to be pre assembles and positioned.

8. Fabricate an – deformation frame as shown in Fig 1A.

(Temporary binder if any is to be removed), and also fabricate a

lifting device as shown in Fig 1B. Complete following jobs at ground

9. Fix the lifting and guide pulleys according to site condition. This
arrangement should be in such a way that it can be shifted at top to
lift each coil.

10. Ensure that PBHE enclosure is made before erecting coils and
refractory is completed in approachable areas.

11. Transfer the reference line from boiler axis for PBHE 1, 2, 3, 7 4
axis.

II. Erection of coils (SH – 1.2 a & b , SH 2.1 a & b SH 2.2 a & b, RH
-1 a and 1b)

1) Position inlet and out let headers on permanent supports for

coil assy. SH – 1.2 a & b, SH 2.1 a & b SH 2.2 a & b, RH – 1
a and 1b Check alignment of all headers for respective coil

100
 as above with respect to FBHE axis. Maintain correct
elevation.

 The coils are to be lifted as shown in Fig 2 in the

sequence and lowered in enclosure using the floating
pulley system.

2) Check the orientation of header stubs.

3) Align with respect to coil terminal points.

4) Weld the terminal tube connection w.r.t. header stubs.

5) Make sure that weld accessibility is maintained for easy

welding.

6) Ensure correct location of DESH, Ensure correct position and

alignment for SH and CRH path.

7) Mark Erection weld locations in FBHE area

8) Make connections with link pipes at inlet and outlet of coil

assy, with headers.

9) Maesure the end gaps in coil assy.

10) Carry out welding.

11) Carry out test before refractory completion.

12) Complete the balance refractory.

101
102
103
104
105
  Air and gas tightness test of boiler is conducted, prior to taking up
insulation work, to detect air ingress / leakage points through the
fin, attachment welds, flange joints etc, and attend the same. The
total area covered is boiler combustor – pass, wind box for burners,
FBHEs Duck work from combustor to cyclones, from cyclone to
back pass and entire fluidized ash path up to economizer outlet
damper.

 Prior to start of the test ensure work completion on the following

fronts:

 Completion of welding – area wise.

 Completion of hydraulic test.

 Refractory areas/

 Pour able, cast able insulation works.

 The test is carried out in two stages

I. Visual inspection.

II. Tightness test by pressurization with air.

I) Visual Inspection

Visual inspection of the entire system is carried out first and noted defects,
erection omissions are attended. This work is done by an identified
supervisory audit team and Protocol made accordingly.

 The critical areas checked are for Completion of fin to fin welding.

 Completion of fin to fin welding.

 Proper closing of all doors Access Doors and Inspection doors with
asbestos, rope etc.)

 Closing of all corner openings etc.

 Closing of instrument tappings and LPSB, HRB soot blower

openings etc.

 Closing of openings in burner block, respective wing boxes.

106
ii) Air Tightness Test
The entire system, after executing necessary blanking
arrangements, is pressurized 10 150 mmwc + 25, -0 mmwc (or as
per contract terms) and checked for air leakage points, physically
and later on with soap solution. The boiler is checked is stages (as
mentioned below) and the leakage points, elevation wise, are
noted. Depressurize and attend to all the identified lrake of defects.
Repeat the test, till all the all the points are attended to the
satisfaction of the supervisory audit team, till all the points are
attended to the satisfaction of the supervisory audit team A protocol
is made and boiler is normalized and released for insulation work.
ii) Stages of Air Tightness Test:
 Combustor Area
 FBHE Area
 Cyclone area
 Seal Pot Area
 Speise Valves flanges
 Duct from combustor to Cyclones four nos.
 Duct from Cyclone to back pass
 Duct from Back pass
 Economizer hoppers, duct up to APH Path
 AHP Pass
 Damper at Boiler outlet
iv) INPUT REQUIRED
 Forced draft fan or auxiliary air blower along with associated
starter or ejector with compressed air, for pressurizing the
Boiler, to be made ready.
 Blanking of boiler first pass at the ring header level (Refer Fig:2)
 Tight close all the peepholes, manholes, test / instrument
pockets; economizer outlet damper. Use asbestos rope,
gaskets, putty, sealing tape etc. for the same.
 In case blower / ejector.
Temporary duct work from blower / ejector to the boiler wind box
connecting duct.

107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
 Air and Gas Tightness Test

 Air and gas tightness test of boiler is conducted, prior to taking up

insulation work, to detect air ingress / leakage points through the
fin, attachment welds, flange joints etc. and attend the same. The
total area covered is boiler combustor – pass, wind box for burners,
FBHEs Duct work from combustor to cyclones, from cyclone to
back pass and entire fluidized ash path up to economizer outlet
damper.

 Prior to start of the test ensure work completion on the following

fronts.

 Completion of welding – area wise.

 Completion of hydraulic test.

 Refractory areas/

 Pour able, cast able insulation stages.

I) Visual inspection.

II) Tightness test by pressurization with air at 2000 mmWC in

entire fluidization path using pa Fan. Blank design is to be
approved by manufacturing unit.

I) Visual Inspection

Visual inspection of the entire system is carried out first and noted
defects, erection omissions are attended. This work is done an
identified supervisory audit team and

Protocol made accordingly.

 The critical areas checked are to Completion of fin to fin welding .

 Completion of fin to fin welding.

 Proper closing of all doors Access Doors and Inspection doors with
asbestos, rope etc.)

 Closing of all corner openings etc.

 Closing of instrument tappings and LRSB, HRB soot blower

openings etc.

 Closing of openings in burner block, respective wind boxes.

127
II) AIR – Tightness Test

The entire system, after executing necessary blanking arrangements,

blocking Back pass area, is pressurized to 2000 mmwc and checked
for air leakage points, physically and later on with soap solution. The
boiler is checked in stages (as mentioned below) and the leakage
points, elevation wise, are noted. Depressurize and attend to all the
identified leaks or defects. Repeat the test, till all the points are
attended to the satisfaction of the supervisory audit team. A protocol is
made and boiler is normalized and released for insulation work.

Back pass is checked at design pressure using ID fan suction effect.

III) Stage of Air Tightness Test

 Combustor Area
 FBHE Area
 Cyclone area
 Seal Pot Area
 Speise Valves flanges
 Duct from combustor to Cycolnes four nos.
 Duct from Cyclone to back pass
 Economizer hoppers, duct up to APH Path
 AHP Pass
 Damper at Boiler outlet

IV) INPUT REQUIRED

 Forced draft fan or auxiliary air blower along with associated starter or
ejector with compressed air, for pressurizing the Boiler, to be made
ready.

 Blanking of boiler first pass at the ring header level (Refer Fig: 2)

 Tight close all the peepholes, manholes, test/ instrument pockets;

economizer outlet damper. Use asbestos rope, gaskets, putty, sealing
tape etc. for the same.

 In case of blower / ejector.

Temporary duct work from blower / ejector to the boiler wind box
connecting duct.

128
 Annexure - 1

MANPOWER REQUIREMENT

S. NO. CATEGORY MANDAYS

1 Fitters 3000

2 Riggers / Khalasi 9000

3 Welders 1500

4 Tack – Welders 2400

5 Grinders 1800

6 Gas Cutters 900

7 Electricians 600

8 Helpers 5000

9 Radiographer 300

10 Evaluator – II 300

11 Winch Operator 500

12 Crane Operator/ Assistants 600

13 Strand Jack Lifting Equipment Vendor Man 6

Power (Increase drum is lifted by Strand
Jack Method)

129
130
 S. No. Description Annexure -3
1 Drum alignment Record No.
2 Internal clearance of headers FQA – 01

3 Banana Bow of header & vertically of stub

4 Locations of headers
5 Check for panels
6 Verticality of WW/ SC Wall Panels
7 Combustor alignment
8 Back pass alignment

9 Clearance between coils and Steam

Cooled walls and pitches
 SH – 3 Coils
 Eavp Coils
 RH – 2 Coils
 Economizer coils 1.1, 1.2, 2.1, 2.2
10 Clarence and pitches between Coils and
FBHE Walls
 RH -1
 SH – 1, SH – 2
11 Vertically and loading of Suspension rods
12 Field welding Log

13 Oil Burnet alignment

14 Dimensions Check of oil burners
15 Elevation Check of openings
16 Hanger loading check
17 Hydraulic test Leakage noticed and
rectification

Note: quality to add nos. in line with FQP.

131
 Annexure - 4

Issuing
S. No. Description Reference No.
Authority
1 Boiler Pressure Parts Trichy
Engineering checks for
erection
2 Boiler Pressure Parts Trichy

3 Recommended Hydraulic Trichy

Test Procedure
4 Product check list of Trichy
pressure parts
5 Welding Manual Vol-1 PSSR –
QUALITY
6 Welding Manual Vol-2 PSSR –
QUALITY
7 Field Heat Treatment Trichy
schedule
8 Handling and erection PSSR -
procedure for Boiler Drum QUALITY
– By strand Jack method
9 NDE Manual PSSR –
QUALITY

10 Erection Welding Trichy

Schedule
11 Field Quality Plans PSSR –
QUALITY
12 Heat Treatment Manual PSSR –
QUALITY
13 T & P Deployment Plan PSSR – A standard T &
FEX P List is
attached

132
 Description of T & P / Duration
S. No. QTY
(Tentative : periodically to be reviewed)

1 Carne
1.1 Heavy Duty Crane 325 t Cap. 1
1.1 Crane 150MT cap. 1
1.2 Crane 100 MT cap. 1
1.4 TFC 280 75 MT cap 4
1.5 Telescope Crane 40 MT cap. 1
1.5 Crane 18 MT cap 03
1.6 Hydra 8 MT cap 03
1.7 Portal Gantry Crane 1

2 21. Strand Jack Lifting arrangement 17

2.1 Electrical Winch 3T 8
Electrical Winch 5T cap
31
2.1 Chain Blocks 3t 26
Chain Blocks 5t 7
2.3 Hook Chook 3T 2
Hook Chook 5t 3
2.4 D-Shackle 25 t 5
D- Shackle 20 t 62
D- Shackle 10 t 158
D- Shackle 5t 39
D- Shackle 3t 21
D- Shackle 2t
3
2.5 Pull Lift 3t 3
Pull Lift 5t

133
 122
2.6 Wire Rope Pulley 5t s/s 10
Wire Rope Pulley 20t 3/s 9
Wire Rope Pulley 10t 3/s 10
Wire Rope Pulley 10t 2/s
20
Chain Pulley Blocks 5.3.2 T cap 35
2.8 Slings assorted 1500 M
2.9 Wire Rope ¾ inch a. M
Wire Rope ½ inch 2130 M
Wire Rope 5/8 inch 2130 M
Wire Rope 7/8 inch
6
2.10 Wire Rope sling 1 inch 11
Wire Rope sling 1.5 inch 6
Wire Rope sling ¾ inch 6
Wire rope sling ½ inch
1500 m
2.12 Power Cable 185 sq mm 60 m
Power Cable 70 sq mm 300 m
Power Cable 100 sq mm
16
2.13 Turn Buckles 3 t .4.5 t 1
2
2.14 Hand Winch 3T
2.15 Electrical winch 5T

134
3 3.1 Tractor Trolley 10T cap 1
3.2 Trailer 40T 1
3.3 Trailer 20T 1
3.4 TATA Truck 10T 1
3.5 Truck 24 T 1
3.6 Hippo Trailer 25 T

4 4.1 Electrical Air Compressor 400 cUM 1

(For refractory works)
4.2 Electrical Air Compressor 100 Cum
1
4.3 Air blower CUM
1

5 5.1 Sky Climber. (for six person load) 1

5.2 Pin- Rack Lift (-Do-)

6 Hydraulic Test Pump 2

One for Boiler HT
One for piping MP / LP HT

7 Acid Cleaning Equipment 5 Nos. Pumps. 1 LOT

Power Panel.
Piping, Instruments. Mixing Tank 1 no.
Alternatively
EDTA Chemical Cleaning Equipment

8 8.1 Welding Generator 28

8.2 Welding Transformer 5
8.3 Welding Rectifier 35

135
9 For Drum Lifting Activity 2 Nos.
9.1 Electrical reversible winch 10 T
capacity
9.2 25 mm dia. new lifting rope of about
1200 meters
3 Sets
9.3 100 MT 10 sheave pulleys
4 Nos.
9.4 10 T idle single pulleys
10 Nos.

9 Huck Boiling M/C

10 10.1 Grinding M/C AG7 10

Grinding M/C GQ 4 6
Grinding M/C AG 4 2
Grinding M/C GQ 4 3
10.2 Bench Grinder 8 inch 1

11 11.1 Drilling M/C 3

11.2 Magnetic drilling m/c 1
11.3 FF2 Machine 3

12 12.1 Stationary Baking Oven for 4

electrodes
12.2 Portable Oven for electrodes 18

13 13.1 Hydraulic Jack 20 t 4

13.2 Screw Jack 3T 7

14 Temperature Recorder for stress relieving 4

15 Bench vice 10 inc 01

16 Torque Wrench 110 kgm 4

136
17 1.7.1 Pug Cutting m/c 2
1.7.2 Gas Cutting equipment 12
1.7.3 Cylinders 02, Acetylene with 100
standard fittings.
VIZ. spark arrestor and gages, cylinder
caps, booth for storage of filled and empty
cylinders

18 Dewatering Pump 02

19 19. Equipment for Grouting 4

19.1 Pan Type Mixing m/c needed during
grouting
19.2 Electrical Vibrator 4

19.3 Mortar Mixing m/c 1

19.4 Weighing balance 01

20 Concrete sleepers

21 Scaffolding Pipes 20 meter long 350 Nos.

Scaffolding Pipes 15 meter long 150 Nos.
Scaffolding Pipes assorted 350 Nos.
Scaffolding clamps 2000 Nos.

22 Main Switch Boards 63 amps.32 amps 4

23 Theodolite optical 1 sec. Accuracy 01

24 Brick cutting m/c 01

25 Equipment for dry out a set of blowers,

kerosene tank, oil pump burners, blanket
Ceramic blanket

26 Hand tools 15 sets

27 Illumination for construction lighting 50-Nos.halogen

lamps fittings
lighting posts

137
28 Radiography equipments, Survey meters, 1 set
Pit for camera storage

29 Lathe, Milling M/C, Shaper, Power 1 Nos. each

Hacksaw

30 Power Supply Booth earthing rubber matts, 4 Nos. sets

earthing wire, GI Pipes, pit etc.

138