Boiler Erection Tools and Sequence

Corporate Quality – New Delhi
Corporate Quality, New Delhi Module 5

General erection sequence of
Boiler including
Material Handling, Erection
Tools and Plants (T&P)
requirement, their placements

General erection sequence…
• Installation of a 500MW boiler at project site is a long time

consuming process. It is expected to take from 24 to 28
months from start of boiler erection to bring it to operational
stage. It needs a comprehensive plan of deployment of
experienced engineers, deployment of heavy, medium, small
and special lifting tools, deployment of hundreds of skilled,
semi-skilled working hands and working in changing
weathers and environmental conditions.
•The adopted erection sequence at a particular project is the
result of layout study, deployment of lifting equipments
(cranes), lots and lots of common sense.

General erection sequence
• Project lay out and specific plot plan play a vital

role in deciding open storage plot, pre-assembly plot,
corridors of material movement, crane movement &
location along with most general sequence of
erection.

Tools & Plants…
 Following material handling and erection T&P is normally

required:
• At least 2 numbers of 75MT crawler or tyre mounted cranes
for material handling.
• At least 2 flat bed 15MT trailers along with prime movers.
• At least one flat bed 30 to 40MT trailer with suitable prime
mover.
• 2 Numbers of 18MT/14MT, 3 numbers of 10MT mobile
cranes as support cranes.
• At least one 75MT to 100MT crane with long reach boom to
take care of erection of components beyond main boiler
cavity such as ESP, ducting (beyond main boiler cavity), fans
and mills etc.

Tools & Plants…
• At least one 150MT class crawler carne with long

reach boom for structural erection followed by
erection of various boiler components.
• At least one large capacity 250MT to 350MT crane

with long reach boom, capable of placing girders
weighing around 120MT at an elevation of
approximately 85M.
• At least 2 numbers 15MT winches along with four

200MT capacity multi-sheave pulley blocks for
raising the steam drum. Alternatively Strand Jack
arrangement.

Tools & Plants
• At least 10 electrical winches of 3MT to 5MT line pull

capacity.
• Sufficient quantity of other tackles like chain pulley
blocks, rope pullers, slings, welding generators, welding
electrode baking ovens , pre-heating & post heating
equipment and other measuring and monitoring devices
etc.

Boiler Erection Sequence…
• The installation of boiler and auxiliaries, once all required

foundations are made available, can generally be started on
two parallel fronts. One covers the main boiler island and
second is beyond Boiler up to chimney mainly ESP.
• Within main boiler island job starts with installation of
support structure and proceeds tier wise from bottom to
top. As the columns and tie beams of a lower tier are
aligned along with required vertical and horizontal
diagonal bracings (MBL) and next tier is taken up, the
erection of staircase, major platform members is started on
the lower tier.
• The process continues till the structure reaches top of
columns elevation. The middle row columns are deferred
at this stage since erection crane is generally stationed on
boiler centerline within the boiler cavity.

• In this period girders are assembled to one piece (using 3

supplied pieces) at a near by location. The specific heavy
duty crane is placed on boiler centerline in the boiler cavity
and girders are raised starting from front row.
• The crane retreats back after placing front and next row
girders & interconnecting welded beams. Furnace cavity
rear frame of columns/beams/bracings are raised in
sequence, till the crane fully retreats out of boiler cavity.
Standing out of cavity the rear frame of structure on last
row followed by last girder is erected.

• The roof load carrying structure is aligned/bolted and

welded. The boiler top weather protection roof structure,
silencers above roof and passenger cum goods lift support
structure are erected using the crane from outside.
• Utility of major crane beyond this point gets reduced and
further erection in boiler cavity is taken over by winches.
• An in depth study is needed to complete and leave certain
zones of platforms and structural members for smoothness
of further feeding and raising of components. In general
platform job at various levels continue till Hydraulic test
period or little beyond.

• This stage of structural erection generally provides three
parallel fronts in boiler cavity. Furnace cavity, second pass
cavity and front for erection of air pre-heaters open
simultaneously.
• Though there is no restriction to take up erection activities
in any of the above cavities, as an accepted practice, the
drum is raised at this stage. Elaborate arrangements as per
laid down procedures are made using 15MT winches and
multi-sheeve pulley blocks, to raise the drum to location.
The raised drum makes a reference point for pressure part
erection and clears the front for raising the inner structure
in front of front water wall of furnace. This in turn clears
the way for installation of Down comers, CC pumps, CC
pump suction header and discharge lines.

Boiler Erection Sequence
• Within furnace cavity, the sequence of erection to be
followed is from top to bottom and from outer edges of
furnace to inner side. The similar sequence is adopted for
second pass also. However, all air-heaters being bottom
supported, the job is concentrated on completing the
housing and releasing it for duct connections above and
below of heaters.
• The size and weight of components that can be dispatched
by manufacturing units to site is governed by restrictions
of railway and roads. But to reduce numbers of lifts and to
reduce erection cycle time further to avail advantage of
work at ground level number of pre-assemblies are
desired before erection. Some of them are technically
essential and others facilitate the faster and neater erection.
Pre-assembly is adopted in almost all areas. A few are
listed below:-

Boiler Erection Sequence –
Pre assemblies…
STRUCTURE :
• Assembly of two pieces of auxiliary column. (Optional,
preferred)
• Assembly of girders supplied in pieces. (Essential)
• Partial assembly of MBL frames coming between any four
columns at various elevations. (Optional, Preferred)
• Assembly of platform zones in crane handleable sizes.
(Optional, Preferred)
• Some external frames beyond boiler to chimney, along
with related columns/beams and bracings. (Optional)

Pre assemblies…
PRESSURE PART… :
• Assembly of any two lengths of Down comer pipes.
• Assembly of upper super heater links to winch/crane
handleable sizes and completing some large alloy steel
joints on ground. (Optional, Preferred)
• Assembly of certain lengths of riser tubes to winch/crane
handleable sizes. (Optional, Preferred)
• Assembly of end-bars and crown plate suspension frames
for Platen SH, Re-heater front and rear coils and SH vertical
spaced rear coils (Essential)
• Assembly of radiant roof front panels, its inlet header and
suspension members, on ground in furnace cavity, to form
full width roof. (Optional, Preferred)
Pre assemblies…
PRESSURE PART….
• Assembly of rear radiant roof tube bundles to formed
panels. (Optional)
• Assembly of smaller length water wall panels to
corresponding middle length panel. (Optional, Preferred)
• Assembly of burner panels with short corner panels and
then with burner blocks to raise them with burner blocks.
• Assembly of rear arch neck panels with corresponding
lower part of hanger tubes. (Optional, Preferred)
• Assembly of divisional panel in case received as two sub-
assemblies. (Essential)

Pre assemblies…
PRESSURE PART :
• Assembly of second pass front steam cooled hanger tubes
with respective suspension plates as sub-assemblies.
(Essential)
• Assembly of complete rear roof panels, junction header
and upper (above roof) hanger tubes. (Optional, Preferred)
• Assembly of relatively short steam cooled side or front
wall panels with corresponding panels to handleable sizes.
• Assembly of LTSH inlet header, rear SCW lower header
and panels between the two headers. (Optional, Preferred)
• Assembly of any two bank individual coil of LTSH or
economizer. (Optional)

Pre assemblies…
DUCTING :
• An in depth study of air and flue gas duct path is
absolutely essential. Duct paths from point to point are
divided in to smaller lengths, having flanges at both ends.
Later during design and fabrication stages four walls of
this flange-to-flange duct is sub-divided in to walls.
• Supplied wall pieces, length of duct from one flanged joint
to another, over all size, weight of total assembly, its
location, suspension or support configuration and
approaches for either raising it with winches or placing it
with external crane, decide and guide the assemblies to be
done on ground.
• In general 60 to 70 percent of duct lengths can be pre-
assembled in yard before raising them to location.

Pre assemblies
ESP:
• Depending on reach and capacity of erection crane almost
all housing walls of ESP are assembled as sub-assemblies.
• Lower sections of ash hoppers are assembled from
respective walls.
• Inlet and outlet funnels are assembled.

First Pass…
ERECTION SEQUENCE IN MAIN FURNACE CAVITY
Experience indicates that following is the most
preferred sequence of erection in furnace cavity:
• Upper most SH links, which have been pre-assembled to
suitable lengths are raised and left suspended on temporary
slings, near to their final location.
• Re-heater inlet and outlet headers are raised to their
approximate level and location and are left hanging on
their temporary suspensions.
• Platen SH inlet and outlet headers are raised to their
approximate level and location and are left hanging on
their temporary suspensions.
• Re-heater rear and front coil crown plate suspension
assemblies are raised and left on their permanent hanger
rods.

First Pass…
• Platen SH coil crown plate suspension assemblies are
raised and are left on their permanent hanger rods.
• Radiant roof outlet header is raised to its location.
• Permanent suspension hangers for Screen tube header,
Hanger tube header, both side wall outlet headers and front
wall outlet headers are raised.
• All of above 5 headers are raised and suspended on
respective hangers.

First Pass…
• Assembly of radiant roof front panels, its inlet header and
suspension items is made on ground and raised to location.
The assembly is suspended on permanent suspensions.
Using the gap between platen SH coil suspension and rear
edge of front radiant roof panels, raise division panel inlet
and outlet headers. Suspend them on respective permanent
hangers.
• The above gap is also used to raise as many riser tubes as
possible. The shorter length riser tubes can be stacked on
nearby platform for feeding at later date.
• All the items raised till this stage are aligned for their
correct elevation and location and are temporarily arrested.

First Pass…
• Raise upper buck stay beams for both side walls and front
water wall to their approximate respective level and
location. Arrest them temporarily to near by structure.
• Raise both side extended water wall panels and leave them
suspended to upper header.
• Raise items related to rear arch buck stays and stack them
on the platform below rear arch horizontal pass.
• Raise bundles of screen and hanger tubes also and stack
them on above platform.
• Raise both side water wall upper panels and leave them
suspended to upper header.
• Raise upper front water wall panels and leave them
suspended to outlet header.

First Pass…
• Make arrangements to start joint welding between upper
panels and headers on side and front wall.
• Raise re-heater rear coils and leave them resting in crown
plate suspension.
• Raise re-heater front coils and leave them resting in crown
plate suspension.
• Raise platen SH coils and leave them resting in crown
plate suspension.
• Take up installation of screen tubes, upper hanger tubes
with header, rear arch panels etc. in the horizontal pass.
• Take up installation of loose tubes forming rear of radiant
roof.

First Pass…
• Lots of HP joint fronts are available at this stage like re-
heater rear coils to header, re-heater front coils to header,
radiant roof joints, screen tubes, hanger tubes, rear arch
panels etc. in addition to water wall joints.
• Raise division panels and install few inlet and outlet tubes
to take load of panel.
• Once upper water wall panels are welded to upper headers
and panel to panel fins are stitch welded to give shape to
upper furnace, raise middle level buck stay beams,
arresting them to near by structure, followed by raising of
upper inter water wall panels. Leave them suspended to
respective upper panels.

First Pass…
• Once re-heater and platen coils are welded to respective
headers, raise rear wall neck panels
• Complete the joints between upper and upper inter water
wall panels. Stitch weld longitudinal fin ends of panels and
give shape to furnace in upper inter level.
• Start installation of, already raised and temporarily arrested
to near by structure, buck stay beams on upper water wall
panels. It is started from upper most level and proceeds
down ward.
• When furnace shape to upper-inter level is formed, raise
burner blocks, four numbers-one in each corner, and
suspend them temporarily. Each is around 40MT.

First Pass…
• Raise lower inter level buck stay beams and secure them to
near by structure.
• Raise lower inter water wall panels of all the four walls
and leave them suspended to corresponding upper inter
panels.
• Raise burner panels in each corner also.
• Make arrangement for placing furnace bottom headers.
Temporary brackets from near by structure are to be
installed for resting them.
• Raise both side water wall bottom headers. Raise front and
rear bottom headers. Each is around 40MT.
• Complete water wall tube joints on all four walls between
lower inter and upper inter panels. Weld upper joints of
burner panels.

First Pass…
• Align and re-check furnace dimensions and secure them
using temporary arrestors.
• Side water wall full height is normally having only 3 levels
of panels. Thus side walls shall reach bottom headers.
• Front and rear water wall is supplied in 4 levels. Raise
lower most hopper panels and floor panels and temporarily
secure them.
• Weld bottom four headers to form ring header.
Simultaneously take up balance rows of panel joints.

First Pass…
• Continue to install buck stay beams on water walls,
moving towards furnace bottom.
• The furnace takes full shape at this stage.
• Mount burner blocks on corner panels and check/correct
over all furnace dimensions and burner firing angles.
• Take up full penetration panel to panel fin welding and
install hopper bottom water seal plates.
• The installation of down comers below drum, CC pump
suction header, CC pump suction spools, CC pump
discharge valves, discharge lines to front of ring header, in
this sequence, is taken up parallel with furnace.
• Install CC pumps.

First Pass…
Following finishing jobs are taken up as and when the
front is available.
• Installation of riser tubes.
• Installation of re-heater cross over tubes.
• Installation of division panel inlet and outlet tubes.
• Installation of corner transition tubes.
• Installation of super heater links including DESH.
• Installation of rear arch buck stays.
• Installation of buck stays corner connections, leveler
guides and furnace guides.
• Installation of furnace bottom hopper supports.
• Installation of ring header supports.
• Installation of drum to radiant roof SH saturated steam
link pipes.
First Pass
• Welding of re-heater front & rear coils and platen SH coils
to crown plate suspensions.
• Installation of steam cooled spacers.
• Installation of down comer guides.
• Installation of CC pumps coolers.
• Installation of drain lines, vent lines, Safety valves on drum,
the fittings around drum etc.
• Installation of seal boxes for various openings on water
walls.
• Installation of wall blowers and furnace temperature probe.
• Installation of metal temperature measuring pads on coils.
• Other finishing jobs to make the boiler ready for hydraulic
test.

Erection Sequence of
Second Pass:Pressure parts…
Experience indicates that following is the most
preferred sequence of erection in the second pass:
• Raise and temporarily suspend LTSH outlet header at
approximate drawing location.
• Raise sub-assemblies of SH rear spaced vertical crown
plate suspension and leave them on permanent hanger
rods.
• Consider assembling rear roof panels, junction header and
above roof steam cooled hanger tubes, on ground, as a full
width assembly and raise it. Alternately junction header
and roof panels can be raised separately to form the roof.
Hanger tubes, above roof, can be installed in position.

• Raise and suspend both side SCW top headers.
• Make sub-assemblies and raise front steam cooled wall
upper hanger tubes along with their permanent suspension.
• Raise buck stay beams for entire second pass walls and
secure them to near by structure at various elevations and
locations.
• Raise steam cooled side wall upper panels and leave them
suspended to upper headers.
• Raise rear upper SCW panels and leave them suspended on
junction header.
• Make arrangements and weld panel to header joints for
side and rear upper panels.

• Align upper panels and stitch weld fin ends of panels. Give
approximate shape to second pass walls.
• Raise middle level of side SCW panels and leave them
suspended to upper panels.
• Raise middle level of rear SCW panels and leave them
suspended on upper panels.
• Raise middle level of front SCW panels and weld upper
joints with already erected hanger tube assemblies.
• Complete joints between upper and middle level wall
panels and extend the shape of second pass downward.
• Start installing buck stay beams on upper panels, starting
from upper most level.

• Raise lower level of side SCW panels and leave them
suspended on middle panels.
• Raise the assembly of full width lower rear SCW panels,
LTSH inlet header and rear SCW lower header. Leave it
suspended to middle rear panels.
• Raise lower front SCW panels and leave them suspended
to middle panels.
• Raise front SCW lower header and leave it suspended to
lower panels
• Raise bottom SCW headers of both side walls (4 headers)
and leave them suspended to lower side panels.
• Align complete second pass walls and take up tube joints
between panels, tube joints between panels and lower
headers and header to header joints on bottom headers.

• Continue to install buck stay beams on walls, moving
downward.
• Second pass wall well has taken shape at this stage. Now
the inner cavity is to be filled with LTSH and economizer
coils.
• Raise super heater rear vertical spaced coils and leave them
resting in crown plate suspensions.
• Align upper side wall headers and weld them to radiant
roof outlet header.
• Align LTSH outlet header and take up tube joints between
header and rear spaced vertical coils.

• Raise hanger tubes, above LTSH upper bank coils,
crossing the roof, and weld each tube to corresponding
above roof hanger tube.
• Before taking up erection of LTSH upper bank coils, the
soundness of hanger tube suspension for all four rows is to
be established. These hanger tubes take up the load of all
LTSH and Economizer coils.
• Raise 2 or 3 LTSH upper coils on any one ( left or right )
side and leave them suspended to corresponding row of
hanger tubes.
• Weld the joints between coils and hanger tubes, so that
these first few coils are solidly hanging on their respective
hanger tubes. Use the width provided by these 3 coils as
platform for welding hanger tubes joints of still to be
raised coils.

• Raise next LTSH upper coil and leave it suspended on
hanger tubes after welding at least two hanger tube joints.
• Repeat the cycle till all upper coils are raised and each is
left hanging on two hanger tubes.
• Start welding balance hanger tube joints from one end and
repeating the cycle of upper coils raise all lower LTSH
coils also.
• Continue to weld joints between LTSH upper and lower
hanger tubes and raise four intermediate headers.
• Align arrest and complete welding of all four headers
upper joints to hanger tubes. These shall take the load of
all economizer coils.
• Raise and arrest economizer outlet header.

• Repeat the process adopted for LTSH upper coils and raise
economizer upper bank coils.
• Repeat the cycle and raise economizer middle bank coil
and economizer lower bank coils.
• Raise economizer inlet header and temporarily suspend it
to eco. Lower coils.
• Initial concentration, from LTSH upper coils to economizer
lower bank, is kept on erection of coils without completing
coil joints. The minimum required joints to take load are
welded along with erection.

Reaching the economizer bottom level, presents
number of parallel fronts for high pressure joints, such
as
• LTSH upper to bottom of rear vertical spaced coils.
• LTSH upper coils to LTSH bottom coils.
• LTSH bottom coils to LTSH inlet header on rear wall.
• Economizer upper bank to economizer outlet header.
• Eco. Middle bank coils to Eco. Upper bank coils.
• Eco. Lower bank coils to Eco. Middle bank coils.
• Eco. Lower bank coils to Eco. Inlet header.
• Installation and joints of lower most hanger tubes from
Eco. Lower bank to front SCW lower header.

Following jobs are taken up at appropriate stages, as
and when a front is available.
• Cassette baffles of individual coil (LTSH or Eco.) are
installed during coil erection.
• Vibration snubbers are installed when bank of coils are
fully aligned.
• Leveller guides, furnace guides and buck stay corner
connections are taken up when beams are fixed on
walls.
• Seal boxes of instrument openings, of manholes and
LRSBs on walls.

Second Pass:Pressure parts
• Installation of LRSBs.
• Economizer outlet links to drum.
• Economizer feed pipe and valves on this line.
• Fin welding on voids on walls and skin casing.
• Drain and vent lines.
• Other finishing jobs to integrate the system with
furnace and make it ready for hydraulic test.

Air Preheaters Erection
Sequence…
There are four APH per boiler in 500MW boiler. Two are
Primary APH and two are Secondary APH. Each is bi-
sector APH. The primary APH being on left and right of
rear boiler cavity can have better utility of crane. An in
depth study of crane capacity and approach to Secondary
APH zone, from top, is needed to use external crane.

Sequence…
Following is the most preferred and adopted sequence
of erection for individual APH:
• Ensure the soundness and correct dimensions including
levels of APH support frame on structure.
• Place sliding supports and two pedestals in position and
secure them temporarily.
• Raise lower central section and fix it to pedestals.
• Raise support bearing in lower central section.

Sequence…
• There is always a good possibility of assembling support
bearing with lower central section and raising them
together.
• Raise the rotor post, fix it with support bearing and secure
it temporarily in fairly vertical position.
• Raise upper central section and fix it to pedestals. The top
of rotor post shall be passing through it.
• Raise guide bearing and place it in upper central section.
The top of rotor post is to be inserted in the bearing.

Sequence
• Align the complete set of already raised items.
• Raise housing walls, secure them and give shape to outer
periphery of housing.
• Raise sectors of heating elements, following proper
sequence and fix them to rotor post. Complete the rotor.
• Install rack on rotor, install drive unit, complete housing
and release it for duct connections.
• Align all placed items and set the axial and radial seals.
• Install other balance items like ports, soot blowers etc. and
bring the pre-heater to mechanical completion stage.

Ducting Erection Sequence…
• The erection of ducting in a 500MW boiler, probably, leads
to one of the most complicated sequences of erection.
Primarily there are three different circuits of ducting.
Secondary air ducting starts from FD fans and goes to
burner blocks via APHs. Primary air ducting starts from PA
fans and goes to mills via AHPs. A parallel path of cold air
ducting, bypassing the APHs also goes to mills for
tempering. The flue gas ducting starts from economizer
zone goes up to chimney via all the four AHPs, four
parallel ESPs and set of ID fans.
• For erection planning entire layout of ducting is first
subdivided in to two zones.

The flue gas ducting from boiler outlet flange to
chimney. The sequence of erection is decided on
following considerations:
• The layout is simple.
• The entire length of duct is bottom supported and rests
on structure provided for this purpose.
• The width wise spread of parallel paths is the main
consideration.
• Erection sequence heavily depends on reach and
capacity of crane, available approaches and
volume/weight of the pre-assembled duct pieces.
• Since boiler to mill bay (mills on rear), mill bay to ESP
and ESP to chimney are independent areas job can be
taken up any where in parallel.

The secondary, primary and flue gas ducting within
boiler cavity. The sequence of erection is decided based
on following considerations:
• The layout is complicated.
• The wind box on left and right wall is to be installed in
position only, raising the items wall by wall. This area
can only be touched when burner blocks and water wall
panels of this zone are fairly aligned.
• The length of secondary air duct from hot air bus duct
to wind box, on left and right of boiler, can even be pre-
assembled and raised to approximate location during
structural erection period. Later date raising is too
difficult.

• The hot secondary air bus duct, which runs the full width
of boiler and is located below economizer hopper duct, is
to be raised after eco. Hopper duct only. Sections of bus
duct can be assembled on ground and can be raised by
winches only.
• Economizer hopper duct, of flue gas path, cannot be
assembled on ground due to its huge size and weight. This
section is to be raised wall by wall and shape is formed in
position. However, the bottom ash collecting hoppers of
this section can be pre-assembled before raising.

• Considerable length of economizer bypass duct and flue
gas duct from economizer hopper to all four APH can
be pre-assembled on ground. A long reach crane can
place them in position, starting from APH top portion.
• Horizontal run of secondary and primary air ducts, from
respective fans to APH can be pre-assembled but have
to be raised by winches only.

• The vertical runs of above ducts, reaching to the bottom
of APHs are generally raised wall-by-wall using
winches.
• The vertical runs of flue gas ducting from bottom of
APHs also calls for erection adopting wall-by-wall
method.
• A good possibility exists of pre-assembling the
horizontal runs of flue gas ducting from APHs to boiler
outlet flange. The long reach crane can be used for
raising them.

• The placement of gates, expansion pieces and dampers
must be taken up at appropriate time along with duct
lengths. Later erection of these items is too difficult.
• To the extent possible, the raised lengths of ducts shall
be supported or suspended on respective permanent
supports. The alignment and bolting to next piece should
closely follow the erection. Expansion joints are locked
for their design length during erection. These lock are
removed, after entire length of a specific section of duct
is aligned, welded and is on its permanent supports.

Ducting Erection Sequence
• Numbers of sections of large flue gas ducts are
provided with inner structural frames for stiffening.
These are generally taken up after the duct length is
fairly aligned.
• Manholes and instrument tapping on duct walls should
be completed before it is released for insulation.
• When mills are on sides of boiler, entire hot primary air
duct, going to mills, and cold air tempering ducts needs
an in depth study to finalise sequence of erection.
Entire duct is raised using winches.

Fans Erection Sequence…
General:
• Broadly classified into Axial and Radial Fans.
• In Axial Fans the medium enters impeller in

axial/longitudinal direction and leaves in longitudinal
direction.
• In radial fan the medium leaves in lateral direction.

Material Supplies:
• Fan components & forced lube oil units are being supplied
from BAP, Ranipet.
• The drive motors (HT Motors) of higher rating are
generally supplied by HEP, Bhopal.
• The suction side silencer supporting structures, flow meter
ducting in case of axial fans (if applicable) are being
supplied by HPBP, Tiruchy.
• For Variable Frequency Drive (VFD) motor, the flexible
(PMS) couplings with rubber blocks are supplied by EDN,
Bangalore.

Fan Foundation:
The quality of sound foundation, the disposition of
bolt hole pockets, packer & anchor plate contact
surfaces, elevation/levels are required to be
ascertained. They play a vital role in minimizing fan
vibrations. Orientation of fan & lube oil unit
foundation, fan axis and their disposition w.r.t boiler
lay-out are also required to be verified from project
drawings for their correctness.

AXIAL FANS INSTALLATION:
• To start with, centre line marking over fan foundation wrt

fan axis and foundation bolts dispositions have to be done
legibly, which shall be referred in course of work.
• The area around primary packers, sole plates/ base plates

of equipments over foundation have to be rough chipped.
Contact surfaces between fan impeller housing to base
plates, drive motor foot to sole plates, foundation bolt
anchor plates to foundation, drive motor packers to
foundation are required to be blue matched.

• After positioning of primary packers, major components
such as fan impeller housing lower half, diffuser and
suction chamber are placed and leveled w.r.t fan axis. A
minimum of 2 to 3 mm thick shims are added in between
impeller housing and base plate.
• Bearing housing with impeller is placed over impeller

housing and the shaft level is required to be checked with
master level in case of FD Fan. In case of PA Fan, the level
is checked on drive side impeller machined flange with
right angle master level. Now the required axial gaps for
diffuser, suction housing are to be maintained from
impeller/ impeller housing.

In case of spring loaded foundation, all fan
major components and drive motor placement
are to be done in their approximate positions,
the maximum loading over fan deck is to be
established and then the fan shaft level is
required to be rechecked and corrected after
release of springs.

• The dimensions of fan and motor shaft ends, drive
coupling bores needs verification.
• The drive couplings are heated in oil bath/ induction coil

and mounted on respective shafts. After keeping fan regi-
flex coupling distance piece in position, the drive motor is
positioned over sole plates. Provide at least 2 to 3mm thick
shims between motor foot and sole plates.

• Fan Lube oil unit, their pipe routings & joints welding,
acid cleaning of piping, cooler hydro test and lube oil lines
oil flushing activities can be done in parallel which are
required to be commissioned well before checking fan
blade clearances. Only with running lube oil system, the
blades can be opened or closed through the hydraulic
servomotor of impeller.
• Similarly, the electrical/ pneumatic actuator unit for blade

pitch control needs to be placed and leveled. The
connecting link components between this actuator and
impeller servomotor oil distributor head need to be
assembled, aligned and finally actuator base frame has to
be grouted.

• Installation of fan suction side silencer parts, their ducting,
suction hood can be done in parallel for which the
necessary supporting structures should have been installed
earlier.
• Fan blades are supplied as sets/ series after balancing at

works and hence mix-up of blades from one series to
another is not permitted. The fan blades are fixed as per
their serial no. marked on impeller. Fan blade tip
clearances with impeller housing are checked with longest
blade as per procedure. It is done in both open/ close
condition of blades. In order to open/ close the blades the
lube oil system has to be run.

• Before final box-up of impeller top housing, all
instruments including vibration pick-up units are required
to be mounted. Other clearances such as seal plate
clearances, fan foot expansion clearances are also required
to be set.
• After carrying out drive coupling alignments, grouting of

motor sole plates and fan parts base plates are carried out
with non-shrink grout cement. Parallely, all expansion
joints from suction side to delivery side of fan parts works
can be carried out.
• After de-coupled motor trial, and also coupled fan trial the
coupling alignment need to be checked and re-established.

RADIAL FANS INSTALLATION
• Radial fans come in different construction like simply

supported, over hang type, single suction, double suction
etc. Further they are classified with styles like Inlet Guide
Vane controlled Howden type, Inlet damper controlled
Sidor type and Herakles etc.
• In simply supported design, the bearing housings are on

either ends of fan shaft, the expansion bearing on non-
drive end. In overhang design, both bearing housings are
on same bearing pedestal on drive motor side, the impeller
being over hung on shaft end over non-drive side.

• The procedure for inlet damper controlled Sidor type ID
Fan installation is being explained below which is widely
used.
• To start with, centre line marking over fan foundation w.r.t

fan axis and foundation bolts dispositions have to be done
legibly which shall be referred in course of work.
• The foundation area around fan foot primary packers,

motor sole plates, fan control frames have to be rough
chipped. Contact surfaces between fan bearing housings to
bearing pedestal, drive motor foots to sole plates,
foundation bolt anchor plates to foundation, drive motor
packers to foundation are required to be blue matched.

• The bearing journal portions of fan shaft shall be
checked for any transit damage, pit marks etc before
taking up for installation. Dimensions of fan and drive
motor shaft ends, coupling bores are to be verified.
The pre-assembly of fan shaft with impeller, cone
plates can be done at ground level independently.
Similarly, the bearings are checked against any transit
damage and their bore dimensions verified.

• The bearing pedestals are placed in position and
leveled. The centre control frames are placed on their
respective areas. The fan foot primary packers are
placed and leveled in their respective position. The
bottom half of the fan housings are placed on these
primary packers and assembled on position using
temporary steel supports. Once the bottom half is
completed it is checked with water level on all corners
and if required shims are added below primary
packers.

• The fan shaft with impeller assembly is placed well above
bearing pedestals with suitably fabricated steel frame
supports from centre control frame areas. The rest of the
top fan housings are assembled, aligned and then joints
welded as per drawings. Balance items like side control
frames, end control frames are brought into their respective
positions.
• Fan inlet dampers are preferably ground inspected after

removing shipping/transshipment locks for their free
open/close and placed over suction flanges. Inlet damper
control electrical/ pneumatic actuator is placed over site
fabricated base frame. The universal shaft connecting both
inlet dampers are installed and the connecting links to
actuator is set and adjusted for blades full open/ close.
Later the actuator base frame gets grouted.

• The bottom halves of the bearing housing, bearing liners
are brought into their exact position. A minimum of 2 to
3mm thick shims are placed between bearing housings and
bearing pedestals and the DE side bearing housing is
maintained at required elevation with help of water level.
• The bearing housings are leveled with master level and the
fan shaft is lowered on the bearing liners. The NDE side
bearing pedestal is raised to maintain shaft level at DE
side. The bearing clearances are measured and bearing
housings are then boxed-up.

In-case of spring loaded foundation, all fan
parts, voith coupling if applicable, drive motor
are placed in their approximate position, the
maximum loading over fan deck is to be
established and then the fan shaft, bearing
housing levels are to be rechecked again and
corrected after release of springs.

• Couplings over fan and drive motor shafts are mounted
using oil bath / induction coil heating. The drive motor,
voith hydraulic coupling unit (if applicable) are placed
over their sole plates and positioned.
• The forced lube oil unit placement, lube oil cooler hydro
test, lube oil pipes joints welding, acid cleaning of piping
followed by oil flushing of pipelines are done in parallel
after establishing bearing housings placement.
• Similarly impeller seal clearances, fan expansion foot

clearances, control frame clearances can also be carried out
in parallel.

• In case of journal bearings on drive motor, the bearing
clearances of DE & NDE are to be checked, motor
placement to be positioned w.r.t magnetic centre of drive
motor shaft.
• Coupling alignments is then carried out and in case of

voith hydraulic coupling, required coupling off set needs to
be added. Once coupling alignments are done, grouting of
base plates of motor, voith coupling, fan foots, control
frames are carried out with non-shrink cement.
• Coupling alignments are to be re-checked and established

after de-coupled motor trial run, coupled fan trial. Later the
fan bearings are dowelled on to bearing pedestals.


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Corporate Quality, New Delhi Module 5

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Corporate Quality, New Delhi Module 5

Corporate Quality, New Delhi Module 5

Corporate Quality, New Delhi Module 5

Corporate Quality, New Delhi Module 5

Corporate Quality, New Delhi Module 5

Corporate Quality, New Delhi Module 5

Corporate Quality, New Delhi Module 5

Corporate Quality, New Delhi Module 5

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Corporate Quality, New Delhi Module 5

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Corporate Quality, New Delhi Module 5

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Corporate Quality, New Delhi Module 5

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• In Axial Fans the medium enters impeller in