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Erection Manual For Condenser: RIHAND # 3&4 - 500 MW
Erection Manual For Condenser: RIHAND # 3&4 - 500 MW
PREFACE
Feed back and suggestions from the users/task performers are solicited
for further improvements.
CODIFICATION
FOR
INSTRUCTION NUMBER
The following codification system is used for numbering of instructions and the
codification of Log sheets is as per FAQ document.
XX X XX XX XX X
Alpha Numeric Numeric Numeric Numeric Alpha
Type of
Instruction
System Designation
Type of Manual
Product Code
B - Boiler
BA - Boiler Aux.
T - Turbine
TA - Turbine Aux.
G - Generator
GA - Generator Aux.
P - Power Plant Piping
CI - C&I
1. - Erection
2. - Commissioning
3. - Services
1. - 200/210 MW
2. - 120 MW
03. - 110 MW
04. - 60 MW
05. - 30 MW
06. - 100 MW
07. - 235 MW
08. - 500 MW -KWU Design
09. - 210 MW -KWU Design
10. - 120 MW -KWU Design
11. - 60 MW -KWU Design
12. - 70MW -KWU Design
13. - Industrial Units
14. - 210 MW -Tower Type Concrete Pylem
15. - 210MW -Tower Type Steel Structure
16. - 500MW -Tower Type Once Through
17. - 250MW
18. - CCP
01 - General Instuction
02 - Technical Data
03 - Erection Strategy - Condenser
4 - Erection Procedure- Condenser
01 - General Description
02 - Technical Data
03 - Erection Strategy - Condenser
04 - Erection Procedure - Condenser
01 - General Instruction
02 - Technical Data
03 - Erection Strategy - Condenser
04 - Erection Procedure - Condenser
G - General
T - Technical
L - Log Sheet
C - Check List
INDEX
INDEX
5. LIST OF DRAWINGS
GENERAL DESCRIPTION
1.0 INTRODUCTION
2.0 CONSTRUCTION
10
11
TECHNICAL DATA
12
13
14
ERECTION STRATEGY
15
ERECTION STRATEGY
i) Bottem plate.
iv) Front water chambers and Rear water chambers with tube plates.
16
(III) PREASSEMBLIES
a) BOTTOM PLATES
b) SIDE WALLES
Both sidewalls are carrying in four parts. Two joints would be welded
outside the foundation.
d) STIFFNERS
e) DOME WALLS
Each dome wall, both upper and lower is in two parts. These would be
assembled together before erection.
g) CLEANING OF COMPONENTS
18
(VI) ERECTION
This would be carried out as per the normal erection procedure given in
next chapter taking due care of all the normal / quality checks.
(V) TUBING
The tubing of the condenser shall be carried out from the end of the
condenser. The opening in “A” row in front of the condenser is not to
be closed till tubing is complete. Tubes shall be transported on a long bed
trailer so that the overhang is not more than 1.5mm either side. In case a
small crane and space is available the tube boxes shall be unloaded near
“A” row columns. However, in normal cases the boxes shall be unloaded
inside the TG hall by EOT crane and shifted to position manually.
- Steam space
This would be tested by filling the water in the steam spaces to the
required level and the fluorescent powder shall be mixed with it. It would
be inspected by UV Light.
-Water space
19
This would be tested along with the RE joints and the butterfly valves.
This would ensure tightness of the RE joints flanges along with the
condenser. Moreover the time for fixing blanks can be saved.
20
ERECTION PROCEDURE
21
A. BOTTOM PLATE
I. PREPARATORY WORK
3. Lower the sections making up the bottom plate onto the support
plates of the condenser foundation.
4. Assemble and align the sections which have been lowered onto
the foundation.
6. Lift hot well and weld with bottom plate. Align the bottom plate
to the turbine axis in zero elevation.
22
8. When the bottom plate is at zero elevation, shim plates under all
spring elements.
10. Detach the tack welded base plates from the spring elements
and eliminate the weld spots.
PREASSEMBLY
23
B. CONDENSER SHELL
1. Place the sidewall sections side by side, align and weld together
to from one complete sidewall. After welding together check
the sidewall for warpage and rectify, if necessary.
Assembly Sequence
1. Hook up the prepared water box units to the crane and lower
through the foundation cavity, using hydraulic jacks as required
to secure the units against tilting.
24
3. Align the water box unit in the horizontal plane using water
level. Select two symmetric holes in the lowest outermost row of holes
on the right and left side. Insert guide pins in the selected holes, to be
used as oriented points for alignment.
5. Before the crane hook carrying the water box is lowered and
the load removed, the water box unit must be secured by means of
cables and stiffeners.
7. After tack welding, tack flat guides to the water box units and
bottom plate.
8. Do not weld the water box units to the bottom plate until the
sidewalls have been assembled, as otherwise weld warpage
may occur.
25
10. Align the side walls in lowered position and tack weld them at
several points to the water box units and to the bottom plate.
11. Remove the bracing cables, hosting gear, bracing lugs, etc.
from the sidewalls & dome walls & from the bottom plate.
Locations are measured from the tubes, which will be and are marked on
the outer edges and the centerline of the bottom plate sides. Then move
the landing bars in to position, align and tack weld. Weld using the back
step method from both sides simultaneously.
Erect the vertical landing bars parallel to the landing bars on the bottom
plats. For this purpose, drop perpendiculars to the landing bars already
mounted on the bottom plate, mark the installation locations for the
vertical bars on sidewalls and tack weld the landing bars in position. Do
26
not permanently weld the vertical landings bars until the condenser has
been completely welded together namely after preassembly of the steam
dome. Remove weld residue from the weld zones using a chisel and wire
brush.
1. Mount the flat iron supports for the air cooler shields and weld
onto the tube support plate sections with the aid of a template at the
time of attaching the landing bars onto the bottom plate. It is important
to place wooden beams under the tube support plate sections to prevent
deformation.
27
1. Hook up each tube support plate sections upto crane. Lower into the
condenser shell and insert into the landing bars on the bottom plate and
sidewall, beginning at the front and the rear water boxes. During this
procedure, it is important that connection holes for the circulating water
pipe, countersunk by the manufacturer, face the tubing side.
3. Move sufficient tube support plate sections into the condenser shell and
fix them in position relative to each other by means of spacers to enable
the internals to be set down in the spaces provided in the tube support
plate sections. They consist of the following; steam baffle plates, part of
the air extraction line, as well as various bracing assemblies such as flat
irons and tubes necessary for later assembly of all the internals.
28
5. Suitable tie rods should be used to hold the support plates against any
tilting.
6.Secure all tube support plate sections against tilting, since it is not
possible to commence alignment of the tube support plate sections
and assembly of the internals until after the steam dome including the
dome bracing has been preassembled and the condenser shell has
been welded together.
29
1.Insert thin steel wires at four identical points in each tube plate of a
water box and feed the wires through the holes at the corresponding
points in the tube support plate sections. Hold the ends of the wires in
the centers of the tube plate holes using a special device and attach
the weights to keep the wire taut. Then align each tube support plate
sections in such a way that the tensioned steel wire passes through
the center points of the holes for the circulating water tube
30
2. Tack weld the tube support plate sections aligned with the center
point to the slot profiles on the bottom plate and sidewalls. After
tack welding, verify that the holes in the support plates lie in the
vertical and the horizontal planes. Enter the actual measurements on
the measurement data record provided.
The thin steel wire and alignment devices can now be removed, as
they are no longer for further assembly of the condenser shell
internals.
3. Note: The stem baffles and bracing units must not be tacked
to the tube of the water boxes. This operation is not
performed until all the internals have been welded to one
another.
4. Align the various sections of the air extraction line, weld them
together to form one unit and tack weld to the tube support plates.
31
system through the connection holes. Set down the shields on the flat
iron supports, align and tack weld.
6. After assembly of all the steam space internals which, to allow for
welding warpage, may only be tack welded, commence welding of all
the condenser shell internals, the welding sequence being of up most
importance.
7 First weld the steam baffle plates, central joining plate, feed water
heating plate form, condensate drain sheets for the cooler tube nests,
bracing assemblies such as flat irons and tubes. Then weld the tube
support plates to the landing bar strips on the bottom plate.
8. Then weld the vertical landing bar strips to the sidewalls and tube
support plates. During this procedure, welders should as far as
possible work simultaneously. When the condenser shell internals
have been completely welded together, tack and weld steam baffle
plates, the bracing assemblies and the air extraction line and the
connecting piping system at the front and rear tube plates. When all
the welding work has been concluded, remove all weld residue from
the weld seams and weld zones in the entire condenser shell.
9. Note:
a) To prevent welding warpage, all welds must be performed
simultaneously from both sides using the back step method.
Vertical joints must be welded from top to bottom, i.e. from
the upper edge of the tube support plate to the bottom plate.
32
General:
Prior to the erection of LP heater and platform, the pipes for the
extraction system and throw device have to be erected/ placed in the
steam space.
Erection of the feed water heater platform start with mounting on the U-
profile steel support in the area of the central butt- strapping of the
tube-supporting sheet.
This involves firstly mating and bracing the support for LP heater
platform with the cut-to-size sheets and the ends of the associated U-
profiles. The I-profile girders for the feed water heater platform are
mounted on top these. The support brackets for the LP heater platform
support are then mounted on the dome walls on the water box side.
The elevations for the feed water heater platform support must
be assured.
Then the feed water heater platform and the dome bracing are installed,
aligned and welded as a unit.
33
Then move the feed water heater into the prescribed horizontal position
parallel to the feed water heater platform.
Mount support jacks on the I-profile girders supporting the feed water
heater platform and at the feet of the feed water heater to support the
feed water heater when it is set down from the lifting bracket.
Adjust all the support to the prescribed pressure and tack the load off
the lifting bracket.
Then take the actual dimension for the LP heater support, fabricate the
parts required and insert under the heater. Tack the load off the support
jacks as the permanent supports are inserted.
34
Note: The two upper halves of the dome wall on the water box
side are not to be installed and assembled until the installation of
the feed water heater through the turbine foundation/ condenser
cavity has been completed.
General
35
2. After completion of welding, clean the welding zone and examine the
dome wall unit for warpage. If necessary, realign the dome wall unit
to match the mounting dimension to the other component.
3. Prior to installing the dome wall unit, coat inaccessible weld locations
with anti-corrosive paint.
4. After this has been affected, measures out the dome wall units and
Mark the center points by punching.
36
3. The dome wall remains suspended from the crane unit it has been
secured against tilting and slipping by suitable clamping.
4. Then the opposite dome wall is installed. When the two opposite dome
walls have been installed and secured, they are to be aligned with the
longitudinal or transverse axis. For this purpose, drop perpendiculars
from the steel wires on the longitudinal and transverse axes onto the
upper edge of the dome walls.
5. When the two opposite dome walls have been aligned, secure them by
tack welding to the steam shell.
5. Insert and install the adjacent dome walls as per drawing, as dome
walls are identical and must be moved into the correct position.
2. Lower the dome bracing, supplied in required lengths, into the steam
dome by crane, align in position and track weld.
3. When all the sections of bracing have been preassembled and track
welded, welding of the dome bracing to form one integral unit to be
carried out. However the connection with the LP cylinder should be
done only neck welding.
37
After the dome walls have been tacked in position, the steam throw off
nozzles are lowered and rough aligned.
The final alignment is dome along with the LP Bypass down stream
piping.
2. Then fit the intermediate, corner and web plates as per gaps available
and prepare the weld edges.
3. Tack these parts to the condenser dome with welds with a tack length
of three times the plate thickness at intervals of 25 times the plate
thickness.
38
5. Weld the joint using the back step method form tack to tack (see
diagram). When the base layer has been completed, make the
following filler weld layers, each in a single pass, and reversing
direction for each layer (see diagram).
6. After welding, clean the weld zone using suitable tools. When the
condenser has been completely welded to the low-pressure turbine.
Relieve the spring supports of the load applied to facilitate welding
and measure in relieved condition.
39
40
General
The circulating water tubes, cut to length and provided with guide heads
delivered in crates to the site.
Before erecting the assembly platform, remove the water box covers and
set down on wooden beams in a suitable location.
The assembly platform must be erected in such a way that it is safe to walk
on and presents no danger of falling off. In addition, it must be stable
enough to withstand the weight of the crates containing the circulating
water tubes.
The holes in the tube plates must be clean to the base metal. Clean all
holes using round steel brushes or reamers. Use of chemicals/ solvents is
not desirable. If the hinge assembly has been installed then one condenser
box can be opened at a time.
41
Installation of tubing
The tubings are inserted manually, Insert the tube from the bottom end
and pull through towards the top end until the same length of tubing
protrudes from the front and rear tube plates. Remove the guide heads
from the circulating water tubes. In case the insertion is difficult then the
tube should be taken out and the support plates rectified by reaming.
Tube expander
Use electronically controlled tube end expanders to roll the cw tubes into
tube plates. When the desired pressure is reached, the expander switches
to reverse speed.
The tube plate holes and the tube ends must be clean to the
bare metal and free from axial draglines.
42
The locking device on the roller head must be set to block the
rollers to a depth of 80% of main tube plate thickness before
reaching the steam compartment side of the tube plate. If the
tubes are expanded beyond the steam compartment side of the
tube plate, they will be damaged.
2. After expanding into the opposite tube plate, mill off the protruding
tube ends to the stipulated dimension and deburr the inner edges.
43
Clean the joints of the water box covers and tube plates.
44
The water box covers are attached to the lifting equipment using
appropriate cables, swiveled into the assembly position and moved in front
of the respective water box.
The hexagonal bolts and nuts necessary for the assembly of the water
boxes must be coated with a lubricant / graphite and subsequently
tightened.
45
46
water box covers must be mounted ready for operation and a protective
coating must have been applied to the water boxes.
The hydro-test can also be done by closing the butterfly valves in the inlet
and outlet of condensers. This apart from also ensuring the tightness of
B.F. valves and expansion joints, reduce the time cycle as the temporary
test flanges need not be erected.
After the tubing has been completed, including the trimming of the tubes
the hydro fill test is to be conducted on the steam space.
2. Gradually fill the steam space with water. A water tube arrangement
is to be installed so that the level of water can be monitored.
3. During filling, constantly check the tubes for any leakage. In case
any leakage is observed, that particular tube should be further
expanded.
47
5. Fill the water upto last stage blade tip of LP Turbine and leave for 24
hours. Check thoroughly for any leakage.
6. Add a fluorescent dye (Sodium floursceine) 2-3 ppm (approx. 2 Kg)
to the filled water in the condenser. Stir the complete water and dye
with compressed air.
7. Leave the water for another 24/36 hours.
8. Finally inspect the tubes by ultra – violet light with the help of U-V
lamp.
9. When no fluorescence is observed it can be inferred that there is no
leakage.
10.During this test, other connected areas (falling under vacuum during
operation) can be inspected for any leakages.
11.Release the condenser springs, after all water has been drained from
both the steam space / cw side. The springs are finally set as per
drawings.
48
3. The welding of the stiffeners with the main tube plate should be
done only after welding of all support plates with the shell and
stiffness has been completed.
6. Not more than four welders should be deployed during the welding
of the internals. Adequate supervision should be exercised to ensure
proper welding sequence.
7. It is desirable that after 50% of the welding of internals has been
completed the alignment of the tube plates is rechecked. Subsequent
welding sequence should be decided based on the observation made.
8. During tubing in case the tube is not going freely the holes of the
tubes support plates may be reamed suitably.
49
LIST OF DRAWINGS
50
51