Condenser Erection

Station:
NTPC- Rihand
BHEL Ref No:
PW/TSX/RIT/TUR-PR/001/REV00
Plant area:
CONDENSER
Document- Type
ERECTION MANUAL
Revalidated document prepared based on doc, BHEL/PSNR/TSX/VSTPP/TA-08 for internal use.

POWER SECTOR-WESTERN REGION TECHNICAL SERVICES NAGPUR-440 001
1

Issued to Date of Issue
TN VARDARAJAN/ CM/RIHAND

Prepared By Reviewed by Approved by

Issued by
O. D.SHARMA D K SHRIVASTAVA ML SAH B.P.RAO
Sr.Mgr./ TS/PSWR SDGM/TSX/PSWR GM/TSX & SAS/PSWR Head/TSX

ERECTION MANUAL FOR CONDENSER

RIHAND # 3&4 - 500 MW
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PREFACE

The erection manual of condenser for Rihand 3&4- 500 MW project
provides guidelines for erection of Condenser. The procedure may require
some minor alterations at site to meet the local site conditions.

BHEL reserves the right to adopt alternate procedure, if necessasity
arises.

Feed back and suggestions from the users/task performers are solicited
for further improvements.

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CODIFICATION
FOR
INSTRUCTION NUMBER
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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 Instuction No.

System Designation

Rating of Main Equipment

Type of Manual

Product Code

1.1 Product Code

B - Boiler
BA - Boiler Aux.
T - Turbine
TA - Turbine Aux.
G - Generator
GA - Generator Aux.
P - Power Plant Piping
CI - C&I

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1.2 Type of Manual

1. - Erection

2. - Commissioning

3. - Services

1.3 Rating of Main Equipment

01. - 200/210 MW
02. - 120 MW
03. - 110 MW
04. - 60 MW
05. - 30 MW
06. - 100 MW
07. - 235 MW
08. - 500 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
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1.4 System Designation

01 - General Instuction
02 - Technical Data
03 - Erection Strategy - Condenser
04 - Erection Procedure- Condenser

1.5 System Instuction No.

01 - General Description
02 - Technical Data
04 - Erection Procedure - Condenser

1.6 System Instruction No.

01 - General Instruction
02 - Technical Data
04 - Erection Procedure - Condenser

1.7 Type of Instruction

G - General

T - Technical

L - Log Sheet

C - Check List

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INDEX

S. NO. DESCRIPTIONINSTN NO.

1. GENERAL DESCRIPTION TA1-08-0101G

2. TECHNICAL DATA TA1-08-0202G

3. ERECTION STRATEGY TA1-08-0303G

4. ERECTION PROCEDURE TA1-08-0404G

5. LIST OF DRAWINGS

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GENERAL DESCRIPTION
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1.0 INTRODUCTION

The condenser is a box type construction with divided water box
design double flow; two pass which facilitates the operation of one half of
the condenser while other half is under maintenance. The steam space is
of rectangular cross-section with integral air-cooling section from where
air and noncondensable gases are drawn out with the help of air
evacuation equipment.

2.0 CONSTRUCTION

2.1 The surface condenser is mounted on spring supports. The
condenser is welded with the exhaust hood of the low-pressure turbine.
The tube plates are welded with the water chambers. Condensers are
provided with domed shape water box. The condenser tubes are
supported within the condenser shell by tube support plates, which are so
spaced that the vibrations of the tubes are prevented under normal
operating conditions. The condenser is installed in such a way that all
condenser tubes are drained automatically into the condenser water
boxes.
2.2 NECK
Condition has been provided with an extension suitably to connect it to
the turbine exhaust opening. Adequate internal clearance is provided. The
rigid construction results in a sound-condenser combination for trouble
free operation.
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2.3 TUBE LAYOUT
The tube layout is of modular type reinforced having properly sized tube
bundles. Steam lanes are designed from thermo-hydraulic considerations
resulting into better heat transfer, effective deaeration and minimum
pressure drop. Air-cooling zone is suitability located for effective venting.

2.4 WATER BOX
The water boxes of the condenser have been designed for smooth entry
and uniform distribution of cooling water to all the tubes. The water boxes
are removable type and have been provided with necessary hinged
manholes for easy access to the interior for inspection. Each water box
has been provided with a vent and drain connection. The circulating water
connections of adequate size have been provided with water boxes.
Safety guards have been provided to protect the operating personnel
from failing during inspection or maintenance.

2.5 HOT WELL

Hot well (of adequate capacity) is divided longitudinally for detecting
contamination of the condenser half. Suitable manholes are provided in
each of the hot well sections for easy access and inspection. The
condensate produced in the condenser & drains entering through flash
vessels collect in the hot well from where the pass to the condensate
pumps.

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TECHNICAL DATA
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STEAM SURFACE CONDENSER

1. Manufacturer - BHEL / HARDWAR

2. No. of passes -Two

3. Tube length between tube plates (mm) -14630

4. Total no. of tubes -24398

5. Tube outside diameter
and thickness (mm x mm) -OD 31.75 X 0.7112
mm thick. Top 2 rows
0.889 mm thick.

6. Tube material -Welded stainless steel
ASTMA249, TP304

7. Water box design pr. Kg/cm (g) -5.0

8. Water test pr. Kg/cm2 (g) -7.5

9. Duration of test (min) -30

10.Shell design pr. Kg/cm2 (abs) -Full vacuum and 1.08
kg/cm2g

11. Shell test pr. Kg/cm2 (abs) -Water fill up to LPT
blade tip

12. Duration of test hrs. -24 (min)

13. No. of support plates -2 x 18

14. No. of spring elements - 36

15. Method of supporting the condenser. -Spring mounted

16. Type of condenser neck to LP turbine casing -Welded joint

17. WEIGHTS (approx)
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a). EMPTY WEIGHT

i. Condenser (without spring) with LP heater no.1 - 710,000kgs.

b). OPERATING WEIGHT

Condenser + LP heater no.1 - 1260,000 kgs.

c). FLOODED WEIGHT

Water filled up to LPT blade tip of last stage - 2100,000 kgs.
with CW side and LP heater no.1

d). Weight of cooling water - 448,000 kgs.

e). Weight of spring elements - 32,000 kgs.

Ref: Drg No: - 0-160-10-700 43c 80 Rev 02 Condenser assembly.

f). Weight of single heaviest part (front water box) - 30,000kgs.

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ERECTION STRATEGY
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ERECTION STRATEGY

The condenser to be assembled and erected at Rihand 2 x 500MW is
supplied in various components from the works.

* Loose parts mainly comprise of the following:

i) Bottem plate.

ii) Turbine & Generator side wall plates.

Iii Dome walls.

iv) Front water chambers and Rear water chambers with tube plates.

v) Tube support plates 2 x 18 nos.

vi) Hot well.

vii) Spring elements - 36 nos.

viii) Steam throw devices - 2 nos.

ix) Condenser tubes.

(I) PREPARATION FOR ERECTION

1. Approach to TG hall should be suitable for movement of heavy
equipment to transport the components.

2. The EOT Crane should be available covering the complete
condenser area.

3. Sufficient area should be available for pre-assembling preferably on
the turbine floor.

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4. Power source of 200 Amps should be available.

(II) TOOLS & PLANTS

-All normal small tools should be available.

-Apart from this the following shall be required during erection: -

1. Welding Generators 4 nos.

2. Chain pulley blocks 5T 4 nos.

3. Slings (40mm) 4 nos.

4. Angle grinders 1 set

5. Tube expander with tools 2 nos.

6. Tube cutting bits 2 sets

7. Trailer with pulling unit Sufficient Qty.

8. Trailer with pulling unit for tubes 1 no.

9. Rolled steel section for pre assy. 1 no.

10. Wooden planks for condenser covering. 1 MT App.

11. GI / Black sheet for condenser covering Sufficient Qty.

12. UV Lamp 1 set

(III) PREASSEMBLIES

a) BOTTOM PLATES

Depending on site conditions, the preassembly of the plate will be
done.If the foundation and approach is ready then it would be directly
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assembled on the foundation. However, if the foundations are not
ready it would be assembled separately outside. The bottom plate is in
four parts and two of them will be pre-assembled outside. On each
half the hot well and the spring supports will be welded/tacked. As the
opening on the foundation is big enough the preassembled bottom
plate can be lowered flat without any risk.

b) SIDE WALLES

Both sidewalls are carrying in four parts. Two joints would be welded
outside the foundation.

c) WATER CHAMBER / BOXES

The assemblies of these would be checked and lowered in an assembled
condition.

d) STIFFNERS

These would be assembled and welded in twos.

e) DOME WALLS

Each dome wall, both upper and lower is in two parts. These would be
assembled together before erection.

f) DOME SHIFTING STRUCTURE

The central portion of the structure shall be assembled outside.

g) CLEANING OF COMPONENTS

The cleaning of components shall be done either by sand blasting using
low-pressure air (2.5 kg) or by alkali and hot water.
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(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.

(VII) WATER BOX HANDLING DEVICE

This would be erected when the welding of internals is in the progress. In
case this is not available it would be better to have suitable openings on
TG Floor and oil canal from where the slings can be inserted to handle
the water boxes when they are opened for tube inspection.

(VIII) HYDRAULIC TEST

- 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

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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.

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ERECTION PROCEDURE
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A. BOTTOM PLATE

I. PREPARATORY WORK

1. Check the foundation for dimensional accuracy in accordance with
the plate foundation drawings.
2. Set the support plates in mortar and align with the positions in
which the spring elements will be mounted.

II. ASSEMBLY SEQUENCE

1. Tack the base plates to the spring elements.

2. Lower hot well below and place it on the ground.

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.

5. Weld bottom plate as per sequence.

6. Lift hot well and weld with bottom plate. Align the bottom plate
to the turbine axis in zero elevation.

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7. Raise bottom plate in axial direction and into zero elevation,
taking care that when condenser is finally tilted, its centerline
would match with turbine axis.

8. When the bottom plate is at zero elevation, shim plates under all
spring elements.

9. In order to avoid displacement of the bottom plate during
assembly of the water boxes and condenser shell internals, the
support bolts of all the spring elements must be in their
uppermost positions before the work is commenced.

10. Detach the tack welded base plates from the spring elements
and eliminate the weld spots.

PREASSEMBLY

1. Preassemble tube plates (L & R) and check for any distoration
of main tube plate.

2. Any deviation in alignment of holes should be similar in both
front and rear assemblies. In case of variation the matter
should be referred to the BHEL /HWR.

3. Assemble the water box covers with the water chambers
without gasket and check whether:
a) All bolts are fitting and
b) Any clearance in the parting plane, rectify if necessary.
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4. In case suitable slings for lifting the complete assembly are
available then welding of the two halves should be done. In
case of any doubt, the assemblies can be lowered in parts.

B. CONDENSER SHELL

General preparatory work

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.

2. Welding of two or more pieces together outside the foundation
may be carried out.

3. Prepare the water boxes for installation by passing shackles and
wire cable through the lifting lugs.

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.

2. As soon as the lowered water box unit is standing upright on the
bottom plate, match the center to the transverse axis.

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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.

4. Drop a plumb bob to the bottom plate at each other edge
and move the water box unit into the vertical position. When the water
box unit has been aligned in the horizontal and vertical planes, tack weld
to the bottom plate.

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.

6. Repeat the assembly procedure described above for the second
water box unit of the condenser.

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.

9. Hook up the sidewalls by means of shackles and cables passed
through the lifting lugs, move over the foundation cavity and
lowered onto the prepared location.

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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.

12. Weld the complete shell.

CONDENSER SHELL INTERNALS

1. Preparation of the shell
Remove any accessories inside the shell & sweep the whole interior
clean. When preparatory work has been concluded, commence
installation of landing bars.

2. Installation of the landing bars
Mark the installation locations for the landing bars on the bottom plate
according to the drawings.

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
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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.

Preparing for installation of the tube support sections

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
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wooden beams under the tube support plate sections to prevent
deformation.
2. Installation of the tube support plate sections may then be taken up. Use
the lifting device to transport the tube support plate sections.

Installation of the tube support plate sections and internals.

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.

2. Fix each tube support plate sections at least 4 / 6 points using
adjustable spacers.

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.

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4. Insert stiffening rods inside the tube support plates.

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.

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Alignment and welding of the condenser shell internals

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

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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.

Move the internals temporarily housed in the spaces in the tube
support plate sections into their correct positions, align and tack
weld. Assembly the center joining plate and the bracing assemblies
such as flat irons and tubes.

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.

5. During alignment, ensure that air extraction openings are directed
towards the bottom plate and that therefore the connection holes for
the connecting piping systems are necessarily in the correct
positions. Pass out and fit the pipe work to the connecting piping
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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.

b) Welding with main tube plate should be done after all
internal welding has been completed.
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Assembly of LPH in condenser

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 LP heater platform

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.
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Installation of the Feed water Heater through the Turbine
Foundation/Condenser Steam Dome Cavity

The LP heater held in the lifting tackle is inserted the turbine
foundation/condenser steam dome cavity and tilled to the required
angle. Insert the feed water heater through the turbine foundation into
the condenser by lowering crane hook and by gradually straightening out
the lifting bracket towards the horizontal plane.

Then move the feed water heater into the prescribed horizontal position
parallel to the feed water heater platform.

As soon as the horizontal assembly position is achieved, adjust the feed
water heater to the prescribed vertical elevation.

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.

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After completion of alignment of the feed water heater along the
longitudinal and transverse axis, the upper halves of the dome walls can
be installed, aligned and welded to the feed water heater as per the
drawing.

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.

STEAM DOME AND BRACING

General

The assembly of steam dome is commenced when the condenser shell
has been adequately tack welded. Prepare the support points at the
upper edges of the condenser shell for assembly of the steam dome. Tilt
the condenser shell as per drawings. Ensure that centerlines are not
disturbed.

Preassembly of the steam dome walls

1. Preassemble the dome walls, divided into section for shipment,
according to the plant drawings. During this procedure the sections
making up a dome wall are assembled on the turbine floor with their
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ribs facing upwards, aligned, adequately tack welded and then
welded to form one integral unit.

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.

Installation and Assembly of the dome walls

1. There is no specific sequence for the assembly of the dome walls.
Depending on on-site condition assembly may commence either with
the dome walls on the turbine and generator sides or those on the
water box sides. The dome wall units are hooked up using suitable
cable passed through their transport lungs, moved over the
foundation cavity and lowered into position on the upper edges of the
condenser shell.

2. The sloping edged metal fixtures mentioned above facilitate insertion
when assembling the dome wall on the turbine or generator side.

Station:
NTPC- Rihand
BHEL Ref No:
Plant area:
CONDENSER
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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.

Assembly of Dome Bracing

1. Commence assembly of the dome bracing parallel to welding work
and after completion of the shell internals.

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.

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Plant area:
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Assembly of Steam throw nozzles

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.

WELD CONNECTION BETWEEN CONDENSER AND LOW PRESSURE
TURBINE

Welding the condenser to the low pressure turbine

1. After the condenser has been brought to operating weight by filling
water in the hot well or by the springs as indicated in condenser
erection drag and the spring supports have been adjusted to
compensate for welding contraction, prepare for welding the
condenser to the low pressure turbine.

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.

4. When all the aforementioned parts have been welded to the
condenser dome, tack weld to the low-pressure turbine.
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NTPC- Rihand
BHEL Ref No:
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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.

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NTPC- Rihand
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Plant area:
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7. The spring supports must return to within +/- 1 mm of their settings.
If the deviations exceed this tolerance range, spacers must be used
to return the pretension of the spring supports to their original
settings.

Station:
NTPC- Rihand
BHEL Ref No:
Plant area:
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8. Then immobilize the spring supports again.

INSTALLATION OF THE CONDENSER TUBING

General

The circulating water tubes, cut to length and provided with guide heads
delivered in crates to the site.

Erection of an assembly platform

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.

Preparation of the holes for 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
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NTPC- Rihand
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not desirable. If the hinge assembly has been installed then one condenser
box can be opened at a time.

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 following points must be observed when expanding tube ends:

The tube plate holes and the tube ends must be clean to the
bare metal and free from axial draglines.

Station:
NTPC- Rihand
BHEL Ref No:
Plant area:
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Before expanding in the tube ends, moisten the roller with at
least two drops of glycerin or vegetable oil. Moistening is
necessary to ensure that expander rollers rotate smoothly and
with minimum wear.

The complete tube end expander unit consisting of the monitor
and the tube expander be kept together as one unit. If one part
is replaced the setting must be re-adjusted to give the correct
expansion as required for tight connection.

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.

Finishing work on the tube plates and cw tubes

1. Remove any burrs at the tube inlet edges.

2. After expanding into the opposite tube plate, mill off the protruding
tube ends to the stipulated dimension and deburr the inner edges.
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Preparing the water box covers and tube plates

Clean the joints of the water box covers and tube plates.

Note: When cementing the gasket, the joints must be free of
grease, clean and dry.

Assemble the rubber cord and spacer gaskets.

Assembly of the water box covers
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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.

The initial phase of this procedure is to tighten four bolts marked x in
figure. Afterwards all the bolts in the fig. are consecutively tightened
starting from the middle with x1, x2, x3, x4,x5, x6.

Station:
NTPC- Rihand
BHEL Ref No:
Plant area:
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Caution: It is imperative that the bolts be tightened in two stages

HYDRAULIC TEST OF WATER BOXES

The condensers are subjected to a hydraulic pressure test on the cw side.
For this purpose, the cw inlet and outlet pipes must be blanked using
suitable hydro-test flanges and the manholes using the original covers. The
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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 hydro test, drain the cw.

Hydro fill test on steam side

After the tubing has been completed, including the trimming of the tubes
the hydro fill test is to be conducted on the steam space.

1. Lock the spring supports in position.

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.
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4. In case any tube is not getting sealed, it may be plugged.

Caution: This should be done as a last resort.

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.

NOTE: Water should never be filled on both steam and CW side at
the same time.

SPECIAL PRECAUTIONS TO BE TAKEN DURING ERECTION:

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1. The joining plates between the water chambers should be welded
and checked before lowering of condenser intervals.

2. The corners of the neck joint with LP turbine should be checked to
ensure completeness.

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.

4. Welding sequence should be reversed for every layers of welding.

5. During preassembly of bottom plates / sidewalls & dome walls it is
advisable to put a packer below the joint so that during welding the
plates straighten out.

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.

Station:
NTPC- Rihand
BHEL Ref No:
Plant area:
CONDENSER
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LIST OF DRAWINGS
Station:
NTPC- Rihand
BHEL Ref No:
Plant area:
CONDENSER
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S Description Drawing No.
1. CONDENSER ASSLY (GA) 0 160 10 70043 C 80
2. CONDENSER GENERAL ASSLY.
(3 SHEETS)
0 160 10 70043 ER
3. INSTALLATION OF LEVEL
INSTRUMENTS ON CONDENSER
2 160 00 70001 C 80
4. HANDLING ARRANGEMENT FOR
FRONT WATER BOX
0 160 00 70023 C 80
5. HANDLING ARRANGEMENT FOR
REAR WATER BOX
1 160 00 70060 C 80
6. BOTTOM PLATE 0 160 11 70010 ER
7. LOWER DOME WALL (TUR END) 0 160 12 70025 ER
8. LOWER DOME WALL (GEN. END) 0 160 13 70030 ER
9. SIDE WALL (TUR. END) 1 160 14 70005 ER
10. LOWER DOME WALL (FWB SIDE) 0 160 15 70032 ER
11. LOWER DOME WALL (RWB SIDE) 0 160 16 70036 ER
12. SIDE WALL (GEN. END) 1 160 17 70005 ER
13. DOME INTERNAL STIFFENING 0 160 27 70027 ER
14. SHELL INTERNAL DETAILS 0 160 28 70031 ER
15. AIR EXTRACTION PIPING 1 160 71 70027 ER
16. LP HEATER SUPPORT ARRGT. 0 160 38- 70001 ER
17. HOT WELL 0 160 28 70028 ER
18. CONDENSER SUPPORTS 1 160 71 70027 ER

Condenser Erection

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