CONFIDENTIAL

Kudgi Super Thermal Power (800MW x 3 Units)

Boiler Erection Sequence
 2

This erection sequence is intended to guide the installation procedure for Boiler proper and
other part so that works can be performed in accordance with the contract and applicable code,
and the management methods for them can be established.
The erection company must use this as a guide that the method and sequence of erection of
boiler and other part explained in this document.
Therefore this erection sequence must be modified by the erector corresponding
to the site conditions before applying this to the site erection

Only information :
Description in “Boiler Erection Sequence” is information for
erection of whole Boiler parts and details are described
in erection manual or work procedure of each part.
 3
Contents of Boiler Erection Sequence

1 BOILER LAYOUT

STEEL STRUCTURE
2
PART

3 FURNACE PART

4 BACKPASS PART

5 EQUIPMENT

6 PIPING
 3
1. BOILER LAYOUT

⊙ Lara Boiler Package ( 800MW * 2 Units)

- Steel Structure : 28,210 Ton
- Pressure Part : 15,164 Ton
- Non Pressure Part : 27,445 Ton
- Gas Air-heater : 3,526 Ton
- BOP : 3,337 Ton
- Insulation : 8,896 Ton
- Elevator etc
- Power Cable 210,000 m
- Control Cable 265,900 m
- Ground Cable 10,000 m

⊙ Kudgi Boiler Package ( 800MW * 3 Units)

- Steel Structure : 42,300 Ton
- Pressure Part : 22,746 Ton
- Non Pressure Part : 42,500 Ton
- Gas Air-heater : 5,040 Ton
- BOP : 4,374 Ton
- Insulation : 13,225 Ton
- Elevator 등
- Power Cable 315,000 m
- Control Cable 330,400 m
- Ground Cable 12,000 m
 5
Contents of Boiler Erection Sequence

1 BOILER LAYOUT

STEEL STRUCTURE
2
PART

3 FURNACE PART

4 BACKPASS PART

5 EQUIPMENT

6 PIPING
 6
2. STEEL STRUCTURE PART_Quantity of Boiler Steel Structure (per Unit)
COLUMN BEAM & MISC STEEL GRATING $ BOLTS
DESCRIPTION WEIGHT UNIT WEIGHT PIECES WEIGHT UNIT WEIGHT PIECES WEIGHT
(TON) (TON/ EA) (EA) (TON) (TON/ EA) (EA) (TON)
Tie r 1 450 14.063 32 947 0.986 960 110
Tie r 2 280 8.750 32 548 0.571 960 69
Tie r 3 451 14.083 32 971 0.971 1,000 110
Boile r Zone Tie r 4 374 11.698 32 806 0.823 980 92
Tie r 5 317 9.902 32 683 0.656 1,040 78
Tie r 6 430 13.438 32 996 0.958 1,040 105
Sub- Tota l 2,302 11.989 192 4,950 0.828 5,980 564
Tie r 1 160 4.717 34 267 0.685 390 39
Tie r 2 116 3.412 34 173 0.407 425 28
AP Zone
Tie r 3 85 3.400 25 180 0.480 375 21
Sub- Tota l 361 3.886 93 620 0.521 1,190 88
Tie r 1 185 6.609 28 296 1.184 250 45
Tie r 2 98 3.494 28 189 0.591 320 24
Mill Zone Tie r 3 173 6.190 28 231 0.722 320 42
Tie r 4 144 5.142 28 192 0.738 260 35
Sub- Tota l 600 5.359 112 908 0.790 1,150 146
 7
2. STEEL STRUCTURE PART_Steel Erection (Phase 1)

 Foundations ready.

 Individual columns or pre-

assembled column lines can be
erected.

 Platforms, gratings and

handrails can be pre-assembled
to larger elements.

 Erection by Crowler, Mobile or

Tower crane.
 8
2. STEEL STRUCTURE PART_Steel Erection (Phase 2)

 Second tier can start after first

tier is fixed and preferably
gratings are erected.

 Stairs, gratings and stair erected

simultaneously with main
columns.

 Erection by Crowler, Mobile or

Tower crane.
 9
2. STEEL STRUCTURE PART_Steel Erection (Phase 3)

 Third tier can start after second

tier is fixed.

 Stairs, gratings and stair erected

simultaneously with main
columns.

 Erection by Crowler, Mobile or

Tower crane.
 10
2. STEEL STRUCTURE PART_Steel Erection (Phase 4)

 Fourth tier can start after

second tier is fixed.

 Stairs, gratings and stair erected

simultaneously with main
columns.

 Erection by Crowler, Mobile or

Tower crane.
 11
2. STEEL STRUCTURE PART_Steel Erection (Phase 5)

 Last step of the steel construction

work.

 Boiler hanger rods installed to main

beams on the ground and lifted
with the beams.

 The nuts of the hanger rods must

be locked after lifting.

 Erection by Crowler, Mobile or

Tower crane.
 12
Contents of Boiler Erection Sequence

1 BOILER LAYOUT

STEEL STRUCTURE
2
PART

3 FURNACE PART

4 BACKPASS PART

5 EQUIPMENT

6 PIPING
 13
3. FURNACE PART_Erection Sequence Overview

Erection Sequence of Furnace Part

Hanger
HangerRods
Rods Links
Links Furnace
Furnace Upper
UpperHeader
Header Separators
Separators

Furn
FurnVertical
Vertical Water
WaterWall
Wall
Reheater
ReheaterHeader
Header Buckstay
Buckstay Furnace
Furnace Roof
RoofPanel
Panel
PNL
PNL

Furnace
Furnace Reheater
ReheaterTube
Tube Division
DivisionSH
SHCoils
Coils Final
Final SH
SHCoils
Coils Arch
ArchPanel
Panel

Furn
FurnINT
INTHDR
HDR&& Burner
Burnerblock
block Spiral
Spiral Panel
Panel Hopper
HopperPanel
Panel
Transition
TransitionPNL
PNL

Ring
RingHeader
Header
 14
3. FURNACE PART_Hanger Rods Erection

 Before lifting hanger rod, insert the end of wire

into connecting plate, sleeve, nut, clevis, in order and
fall it to ground level through the hole of girder.
Tightly bind the wire to eyebolt, and then lift it.

 After lifting, pre-set the hanger rod by tightening the nut,

disjoint eyebolt, and move it to next work place

 Erection by winch
 15
3. FURNACE PART_Links Erection

 The erector shall give attention to the install direction of

Link spool from its related construction drawings

 Link pipe shall be fit-up after all headers fixed perfectly.

 Erection by winch
 16
3. FURNACE PART_Upper Header Erection

 In other to facilitate adjustment and holding in position,

if necessary, temporary supports shall be assembled.
It is forbidden to make weld and arc strike on the
headers as well as on hanger rods.

 After header lifting, header shall be adjusted and fixed

by provisional clamps or by the header supports.

 Erection by winch
 17
3. FURNACE PART_Separators Erection
 18
3. FURNACE PART_Reheater Header Lifting
 19
3. FURNACE PART_Buckstay Erection
 20
3. FURNACE PART_Vertical Water wall Panel erection

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
water wall. i.e.
- assembly of wall panels (header + wall panel)
- assembly of accessorize on water wall panels.
- install of buckstay, leveling device, etc.

 The upper end of the panel shall be directly lifted by means of the
device used for lifting, up to its final position.

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 21
3. FURNACE PART_Roof Panel

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
roof panel
- assembly of accessorize on roof panels.

 The upper end of the panel shall be directly lifted by means of the
device used for lifting, up to its final position.

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 22
3. FURNACE PART_Final Reheater Tube Lifting
 23
3. FURNACE PART_DIVISION SH Coils Erection
 24
3. FURNACE PART_Final SH Coils
 25
3. FURNACE PART_Arch Panel Lifting
 26
3. FURNACE PART_Intermediate HDR & Transition Panel

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
water wall. i.e.
- assembly of wall panels (header + wall panel)
- assembly of accessorize on water wall panels.
- install of buckstay, leveling device, etc.

 The upper end of the panel shall be directly lifted by means of the
device used for lifting, up to its final position.

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 27
3. FURNACE PART_Burner Block Lifting
 28
3. FURNACE PART_Spiral Panel Erection

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
spiral water wall. i.e.
- assembly of accessorize on spiral water wall panels.
- install of buckstay, leveling device, etc.

 The upper end of the panel shall be directly lifted by means of the
device used for lifting, up to its final position.

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 29
3. FURNACE PART_Hopper Panel

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
hopper wall. i.e.
- assembly of accessorize on hopper water wall panels.
- install of buckstay, leveling device, etc.

 The upper end of the panel shall be directly lifted by means of the
device used for lifting, up to its final position.

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 30
3. FURNACE PART_Ring Header Lifting

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
Ring header. i.e.
- assembly of accessorize Ring header.
 31
Contents of Boiler Erection Sequence

1 BOILER LAYOUT

STEEL STRUCTURE
2
PART

3 FURNACE PART

4 BACKPASS PART

5 EQUIPMENT

6 PIPING
 32
4. BACKPASS PART_Erection Sequence Overview

Erection Sequence of Backpass Part

Hanger
HangerRods
Rods Links
Links Backpass
Backpass Headers
Headers Buckstay
Buckstay

BP
BPRoof
RoofPNL
PNLwith
withECO
ECO BP
BPScreen
ScreenHeader
Headerwith
with
Backpass
Backpass Rear
RearSide
Side PNL
PNL LTRH
LTRHCoils
Coils
Hanger Tubes
Hanger Tubes Screen Tubes
Screen Tubes

BP
BPRing
RingHeader
Header ECO
ECO Outlet
OutletHeader
Header Economiser
EconomiserBundles
Bundles Economiser
EconomiserInlet
InletHeader
Header

Boiler
BoilerPressure
Pressure Parts
Parts Boiler
BoilerPressure
Pressure Part
Part
Economiser
EconomiserCasing
Casing Hydro Test Boundary
Hydro Test Boundary Hydro Test
Hydro Test
 33
4. BACKPASS PART_Hanger Rods Erection

 Before lifting hanger rod, insert the end of wire

into connecting plate, sleeve, nut, clevis, in order and
fall it to ground level through the hole of girder.
Tightly bind the wire to eyebolt, and then lift it.

 After lifting, pre-set the hanger rod by tightening the nut,

disjoint eyebolt, and move it to next work place

 Erection by winch
 34
4. BACKPASS PART_Links Lifting

 The erector shall give attention to the install direction of

Link spool from its related construction drawings

 Link pipe shall be fit-up after all headers fixed perfectly.

 Erection by winch
 35
4. BACKPASS PART_Headers

 In other to facilitate adjustment and holding in position,

if necessary, temporary supports shall be assembled.
It is forbidden to make weld and arc strike on the
headers as well as on hanger rods.

 After header lifting, header shall be adjusted and fixed

by provisional clamps or by the header supports.

 Erection by winch
 36
4. BACKPASS PART_Buckstay Lifting
 37
4. BACKPASS PART_Rear Side Panels
 38
4. BACKPASS PART_Rear Side Panels

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
water wall. i.e.
- assembly of wall panels (header + wall panel)
- assembly of accessorize on water wall panels.
- install of buckstay, leveling device, etc.

 The upper end of the panel shall be directly lifted by means of the
device used for lifting, up to its final position.

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 39
4. BACKPASS PART_ Roof Panels with Eco Hanger Tubes

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
panel

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 40
4. BACKPASS PART_Screen Header with Screen Tubes Lifting

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
screen tubes

 The Lower end of the panel shall be lifted by means of several

provisional lifting devices (winch, traveling, crane, etc..) in order
to limit the panel deflection less then Or equal to 1/20 of its length.
 41
4. BACKPASS PART_LTRH Coils Lifting
 42
4. BACKPASS PART_Ring Header Lifting

 It is possible for the erection company to carry out the maximum

amount of preassembly work compatible with the erection of the
Ring header. i.e.
- assembly of accessorize Ring header.
 43
4. BACKPASS PART_ECONOMISER Outlet Header Lifting

 Economizer header shall be installed, and hung by hanger rod.

 Economizer hanger tubes shall be welded after lifting bundle,

and connection tubes shall be welded after roof casing installation.
 44
4. BACKPASS PART_ECONOMISER Bundles Lifting

 Economizer tube bundles shall be install from left side or right side
in sequence by using the installed trolley.

 During economizer tube bundles install, economizer hanger tube

shall be carried out weld at the same time.
 45
4. BACKPASS PART_ECONOMISER Inlet Header Lifting

 After economizer bundle installation, economizer inlet header

shall be lifted at lower part of economizer tube bundle.
 46
4. BACKPASS PART_ECONOMISER Casing Lifting
 47
4. BACKPASS PART_Boiler Pressure Parts Hydro test boundary

Hydro test boundary

Hydro test
- The hydrostatic Test is a way of checking leaks which has to give
pressure up to the setting point to inspect of leaks about the shop and
the site welding
Lime silo
point after the boiler erection according to the Code
and regulation
Fly ash Hydro test boundary
conveyor
s - High Pressure Part
(Feed water Pipe + Boiler Pressure Part + Main steam Pipe)
- Intermediate Pressure Part
(Cold Reheater Pipe+ Reheater + Hot Reheater Pipe)

Hydro test
Fuel
presser
conveyors

Bottom - High Pressure Part : Design Pressure X 1.5 )

ash silo
- Intermediate Pressure Part : Design Pressure X 1.5
Fly ash Bottom ash
silo conveyors
Hydro test water requirement
- Hydro test water : flash water or demi - water
- Water temperature : > 20℃
 48
4. BACKPASS PART_Hydro test Process Flow

CHECK BEFORE H/T

AIR LEAK TEST

INJECT NH3, HYDRAZINE

1ST FILLING

YES
FLUSHING INSPECTION

PRESSURIZING
REPAIR

NO
INSPECTION DRAIN

YES

DE-PRESSURIZING

DRAIN

FINISH
 49
4. BACKPASS PART_Boiler Pressure Parts Hydro test

Filling pump & Test Presser

Filling Pump Station Presser gage

 50
Contents of Boiler Erection Sequence

1 BOILER LAYOUT

STEEL STRUCTURE
2
PART

3 FURNACE PART

4 BACKPASS PART

5 EQUIPMENT

6 PIPING
 51
5. EQUIPMENT_Air Preheater System

Air Heater System

The purpose of the Air Preheater is to recover the

heat from the boiler flue gas which increases the
thermal efficiency of the boiler by reducing the
useful heat lost in the flue gas. As a consequence,
cold air supplied to the boiler and pulverizers by fans
becomes 300 – 350 ℃ after heat absorption from the
flue gas in the Air Prehehater and the flue gases are
also sent to the stack at a lower temperature,
allowing simplified design of the ducting and the
stack. It also allows control over the temperature of
gases leaving the stack
 52
5. EQUIPMENT_Erection Sequence Overview of Air Preheater

Air Preheater Erection Sequence

Support
SupportErection
Erection Cold
ColdCenter
CenterSection
Section Main
MainPedestal
PedestalAss'y
Ass'y Support
SupportBearing
BearingAss'y
Ass'y

Rotor
RotorPost
PostAss'y
Ass'y Hot
HotCenter
CenterSection
Section Guide
Guide Bearing
BearingAss'y
Ass'y Side
Side Pedestal
PedestalAss'y
Ass'y

Cold
ColdPri.
Pri. Center
CenterSection,
Section, Primary
Primary Pedestal
PedestalAss'y,
Ass'y, Cold
ColdEnd
EndConnecting
Connecting
Hot
HotPri.
Pri. Center
CenterSection
Section
Cold
Cold EndPocket
End PocketRing
Ring Rotor
Rotor Drive Pedestal
Drive Pedestal Plates
Plates &&Duct
DuctCorners
Corners

Rotor
RotorHousing
Housing&& Hot
HotEnd
EndConnecting
Connecting Rotor
RotorModules
Modules Basket
BasketElements
Elements
Basket
BasketRemoval
Removal Door
Door Plates
Plates & DuctCorners
& Duct Corners

Pin
PinRack
RackAss'y
Ass'y &&
Expansion
ExpansionBlocks
Blocks A/H
A/HLifting
Lifting Seal
Seal Plates
Plates
Rotor
Rotor Drive Unit
Drive Unit

Auxiliary
Auxiliary EQUIPMENT
EQUIPMENT Final
Final Check
Check
 53
5. EQUIPMENT_Air Preheater_Centering of Foundation & Support Frame
5. EQUIPMENT_Air Preheater_Lower (Cold) Side Center Section & Setting 54
of Support Bearing
 55
5. EQUIPMENT_Air Preheater_Main Pedestals & Rotor Post
5. EQUIPMENT_Air Preheater_Upper (Hot) Side Center Section & Guide 56
Bearing
 57
5. EQUIPMENT_Air Preheater_Side Pedestals (Gas Side only)
 58
5. EQUIPMENT_Air Preheater_Assembly of Rotor
 59
5. EQUIPMENT_Air Preheater_Side Pedestals (Air Side only)
 60
5. EQUIPMENT_Air Preheater_Pocket Rings
 61
5. EQUIPMENT_Air Preheater_Rotor Housing Panels
 62
5. EQUIPMENT_Air Preheater_Lower (Cold) Side Connecting Duct
 63
5. EQUIPMENT_Air Preheater_Upper (Hot) Side Connecting Duct
 64
5. EQUIPMENT_Air Preheater_Pin Rack Segments
 65
5. EQUIPMENT_Air Preheater_Installation of Elements
 66
5. EQUIPMENT_Air Preheater_Hot Sector Drive Unit
 67
5. EQUIPMENT_Pulverizer

 Pulverizer is one of major devices in coal fired boiler. In order to achieve proper combustion, coal
may be grinded, dried and classified.
 Raw coal will be fed by Coal Feeder into bowl, which is rotating in the pulverizer, and equally
distributed to Grinding Ring by its centrifugal force, then grinded by Grinding Roll.
 Pulverized coal will be mixed and classified with hot air for proper combustion, then transferred to
the Furnace.
 68
5. EQUIPMENT_Pulverizer

Pulverizer Detail Mill Coal Pipe to Burner

Coal Center Feed Pipe
Separator Top

Journal Opening Cover

Separator Body
Grinding Roller

Journal Loading System

(Hydraulic/Spring)
Air Flow Ports
(Vane Wheel)

Primary Mixing Air Inlet

Mill Foundation Planetary Gearbox

 69
5. EQUIPMENT_Pulverizer Erection Sequence Overview

Pulverizer Erection Sequence

Mill
Mill Base
Base Foundation
Foundation Foundation
FoundationFrame
Frame && Mill
Mill Stand
Stand Mill
Mill Stand
Stand(Ring
(RingDuct,
Duct,
(Concrete)
(Concrete) Gearbox
Gearbox Base Plate
Base Plate (Pedestal
(Pedestal &&Bridges)
Bridges) Gas
Gas Duct &Grouting)
Duct & Grouting)

Classifier
Classifier(Grit
(GritFunnel
Funnel &&
Gear
GearBox
Box &&Motor
Motor Table
TableAssembly
Assembly Mill
Mill Body
BodyAssembly
Assembly Lower
LowerHousing)
Housing)

Rocker
RockerArm
Arm&&Spring
Spring
Classifier
ClassifierAssembly
Assembly Grinding
GrindingRoller
Roller Final
FinalAssembly
Assembly
Assembly
Assembly
 70
5. EQUIPMENT_Pulverizer Erection Sequence
Mill Base Foundation (Concrete) Foundation Frame & Gearbox Base Plate

Mill Stand (Pedestal & Bridges)

 71
5. EQUIPMENT_Pulverizer Erection Sequence

Mill Stand (Ring Duct, Gas Duct & Grouting) Gear Box & Motor
 72
5. EQUIPMENT_Pulverizer Erection Sequence

Table Assembly
 73
5. EQUIPMENT_Pulverizer Erection Sequence

Mill Body Assembly

 74
5. EQUIPMENT_Pulverizer Erection Sequence
Classifier (Grit Funnel & Lower Housing)
 75
5. EQUIPMENT_Pulverizer Erection Sequence
Classifier Assembly
 76
5. EQUIPMENT_Pulverizer Erection Sequence
Rocker Arm & Spring Assembly Grinding Roller
 77
5. EQUIPMENT_Pulverizer Erection Sequence

Final Assembly
 78
5. EQUIPMENT_Fan Erection

 PA Fan
Supply primary air to the Boiler

 FD Fan
Supply secondary air to the
Boiler

 ID Fan
Discharging combustion gas
passed EP to stack.
 79
5. EQUIPMENT_Installation Sequence Overview of Fan

Fan Installation Sequence

Positioning
Positioningofofsole
sole
Foundation
Foundationfor
forfan
fan Travel
Travel rail
rail Lower
Lowerpart
partof
ofinlet
inletbox
box
plates
plates

Diffuser
Diffuserplaced
placedon
on
Inlet
InletBox
Box Diffuser
Diffuserparts
parts Bearing
Bearingassembly
assembly
foundation
foundation

Installed
Installedblades
blades Blades
Blades assembly
assembly Motor
Motorin
inposition
position Internal
Internal hub
hubassembly
assembly

Hydro
HydroOil
Oil Unit
Unit&&Oil
Oil Pipe
Pipe Sealing
Sealingair
airunit
unit Vibration
Vibrationcontrol
control
 80
5. EQUIPMENT_Fan Single-stage axial flow fan

Impeller
Diffuser casing Inlet box
Coupling
Single stage fan – general overview
Blades Main motor
Main bearing
assembly

Travel rail Control drive Hub Lubrication cabinet

Coupling guard
Hydraulic
cabinet Seal air

80
 81
5. EQUIPMENT_Fan Two-stage axial flow fan

Intermediate Inlet box

piece
Impeller
Diffuser casing Blades
Main motor
Couplings

Control drive Hub Shaft Coupling

Hydraulic Main bearing guard
cabinet Travel rail assembly Travel rail Lubrication
cabinet
 82
5. EQUIPMENT_Foundation for fan
 83
5. EQUIPMENT_Positioning of sole plates
 84
5. EQUIPMENT_Travel rail
 85
5. EQUIPMENT_Lower part of inlet box
 86
5. EQUIPMENT_Fan Inlet box
 87
5. EQUIPMENT_Fan Diffuser parts
 88
5. EQUIPMENT_Fan Diffuser placed on foundation
 89
5. EQUIPMENT_Fan Bearing assembly
Finalized sleeve bearing assembly Sleeve bearing to be lifted in

Sleeve bearing to be lifted in Placement of MBA arrangement

 90
5. EQUIPMENT_Fan Installed blades
5. EQUIPMENT_Fan Blades assembly 91

Blade shaft Mounting of blade

Blades
 92
5. EQUIPMENT_Fan Motor in position
 93
5. EQUIPMENT_Fan Internal hub assembly

Balancing blocks for hub Hydraulic cylinder

Hydraulic cylinder, mounted

5. EQUIPMENT_Fan Hydro Oil Unit & Oil Pipe 94

Lubricating pipes in inner tube Hydraulic pipe arrangement Hydraulic hoses

Actuator Oil pipes, flow and return lines Hydraulic and lubricating cabinets
 95
5. EQUIPMENT_Fan Sealing air unit
 96
5. EQUIPMENT_Fan Vibration control

Stall probes Stall probes

Vibration control monitor

 97
5. EQUIPMENT_Duct Erection
A duct is a path which carries air in boiler for combustion and flue gas
up to the Stack for emission.

 Primary Air Duct

- It’s a duct which carries primary air supplied by PA
Fan into pulverizers.
- Pulverized coal will be dried with primary air not
more than the self–ignition temperature and then
be transferred into Burners.

1) Cold Primary Air Duct.

2) Hot Primary Air Duct :

 Secondary air duct :

It’s a duct which carries secondary air supplied by FD Fan
into Furnace for complete combustion.

 Gas duct :
It’s a duct which carries hot gas up to the Stack via Air Pre-
heater and ID Fan.
 98
5. EQUIPMENT_Installation Sequence Overview of Duct

Duct Installation Sequence

Welding
Welding&&Installing
Installing Secondary
Secondary overfire
overfire air
air
Preparation
Preparation Onsite
Onsite Material
Material Lifting
LiftingLug
Lug duct Lifting
duct Lifting

Duct
Ductto
towindbox
windbox Windbox
Windbox connection
connection Common
Commonair
airSuction
Suction Hot
Hotair
airduct
ductto
tomills
mills
connection
connection

Economizer
Economizerhopper
hoppergas
gas
Cold
Coldair
airduct
duct Gas
Gas duct
ductto
toSCR
SCR SCR
SCRHopper
Hoppergas
gas duct
duct
duct
duct

A.H
A.Hgas
gas outlet
outletduct
duct Gas
Gas duct
ductto
toE.P
E.P Gas
Gas duct
ductto
toI/D
I/D
 99
5. EQUIPMENT_Duct Erection

 Larger ducting sections inside of

the building can be prelifted to
the floors.

 External ducting can be pre-

assembled in to larger section
on the laydown area and lifted
with a crane to positions.

 Ducting inside of the building is

erected trough walls or the
maintanance lift opening is
used.
 100
5. EQUIPMENT_Duct Erection
 101
5. EQUIPMENT_Duct Erection
Duct Erection Sequence

1. Preparation Work 2. Prefabrication 3. Lifting lug welding

4. Duct to windbox 5. Windbox connection 6. Common air suction
connection lifting air duct lifting duct lifting
 102
5. EQUIPMENT_Duct Erection

Duct Erection Sequence

7. Hot air duct to Mills lifting 8. Econ. Hopper gas duct lifting 9. Gas duct to SCR lifting

10. Gas duct to E.P lifting 11. Fit-up & Welding 12. Duct leak test
5. EQUIPMENT_Sootblowers Arrangement & Erection 103

 Profile
- Facility to removal soot on the boiler heating surface
which was accumulated .
- It should be installed through the furnace panel(Water Wall)
- Type : Long & Short Retracing Soot Blower.

 Function
Short Soot Blower
- It will be installed on water wall and eliminate attached
particles.
- Motor operating , Rotate 360 degree, Mounted Lance Tube.

Long Soot Blower

- It’s works straight and rotate with long spray nozzle from
boiler outside to inside
- And it makes to eliminate every attachment during
The primary superheater area
the operating, finally it has retraction on set position
sootblowers are fully rectable.
of boiler outside.
The economizer and APH area
sootblowers are ¼ rectable.
5. EQUIPMENT_Sootblowers Arrangement & Erection 104

 Shift Blower & Support to the installation area

 Interference by the thermal expansion and any other condition shall

be considered for the boiler running

 Assemble Nozzle Head to Wall Box

 Assemble Front & Rear Suspension

 Adjust Soot Blower level by Eye Bolt & Nut

 Install the Rear Side Eye Bolts enabling it to absorb the thermal ex-
pansion of Front Suspension when the Boiler starts.

 If the Boiler proper or Economizer Casing moves Horizontally due to

thermal expansion, Boiler wall and blower shall move together.

 If the Boiler proper or Economizer Casing is moves Vertically due to

thermal expansion, it have to be installed with slope to become a
Horizontal level when the boiler starts.

 After installation, check whether the exposed Nozzle length is equal

to drawing

 After inspection, Nozzle must be located at its own position.

 105
Contents of Boiler Erection Sequence

1 BOILER LAYOUT

STEEL STRUCTURE
2
PART

3 FURNACE PART

4 BACKPASS PART

5 EQUIPMENT

6 PIPING
 106
6. PIPING_Boiler Top Area Internal HP Piping Erection

 Pipes are hauled to floors using

the maintanance lift opening.

 Pipes on the top floors can be

pre-lifted with a grane.

 HP piping can start after the

main elements of the boiler are tack
welded and the shape of the boiler
is correct. (Normally the furnace
area is first).

 HP pipes are prefabricated

spools.
6. PIPING_Boiler Bottom Area HP Piping Erection 107

 After the furnace and the grid are

fixed to final position can supply
pipes erection start.

 After the separators are fixed to

final position can supply pipes
erection start.
 108
6. PIPING_Small Bore and Auxiliary Piping Layout

Lime silo

Fly ash
conveyor
s

Fuel
conveyors

Bottom
ash silo

Fly ash Bottom ash

silo conveyors
 109
6. PIPING_Boiler Top Area Small Piping

 Small bore, auxiliary piping and

equipment installation can start
Air vent
header after the boiler main components
are erected.
Lime silo

Fly ash
conveyor
s

Fuel
conveyors

Bottom
ash silo

Fly ash Bottom ash

silo conveyors
6. PIPING_Boiler Bottom Area Small Piping 110

 Small bore, auxiliary piping and

equipment installation can start
after the boiler main components
are erected.
Lime silo

Fly ash
conveyor
s

Fuel
conveyors

Bottom
ash silo

Fly ash Bottom ash

silo conveyors