Heat Recovery Steam Generation

In HRSG shop various manual machining process were witnessed. The various process are

y y y y y

Panel Bend Removal Panel Bending Branch Profile Marking Header Length Marking Head Hole Marking

Panel Bending:
y The machine used in CVL Unit-V is PW 2500 machine. y The panel on both sides are cleaned to ensure it is free from welding spatter and weld tacks. y The panel is checked whether it is free from lateral bend and bow bends. y The bend joints are placed such that it does not fall on the butt joints. y Air,light and ball tests are conducted before the panel bending. y Equal diagonals are ensured at the bend area for marking the arc length and centre point of bend.

Branch Profile Marking:

y The pipe and branch configuration is marked on a layout. y The branch profile circle is divided into 16 equal parts. y To mark the Branch length the 16 divided points are extended to the main pipe.

y A rectangle is plotted with branch out-side circumference(OSC) in X-axis and branch diameter in Y-axis. y The branch height (h) measured from 0 axis.

y The measured branch height(h) is plotted on the rectangle and on the points are connected for the curve formation. y The profile is cut as marked on 1mm or 1.6mm sheet. y The template is used to mark the length and profile of the brand pipe.

Header Length Marking:

y The header pipe is identified based on the attested material, movement sheet, melt number and size. y The pipe is fixed on the V-block fixtures. y The Bow is placed within the QPCP limits. y Based on the shrinkage allowance, number of holes, pitch the length of the header is calculated. y The reference punch is punched 50 mm away from one end. y The extra length is marked from the reference punch as per cutting plan. y For gas cutting the extra length is scribed and wrapping a steel tape on the circumference. y Before parting the transfer of material identification and colour coding for every pipe is done. y The drawing number, pipe size and part number are punched.

Head Hole Marking:

y The header holes are marked using the process. The orientation, location, diameter and number of holes are marked from the drawing. y The marking axis is kept on top where the holes are to be marked. y The centre point of the holes and the pitch of holes are checked and the punched. y The centre point is marked and scribed for better visibility. y O punch of the centre is done using the paint marking. y The number of holes and the diameter are mentioned and special arrows.