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manual.
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Joint plane of hpt ipt & valve casings, gland boxes & strainer housings,
breech nut mating face.
- Metal to metal joint in high temperature zone
- Use irkosit , Stag B , Magnesite compound of bhel standard.
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================
Joint plane of LP outer casing (without rubber sealing chord).
-Metal to metal joint in low temperature zone
-Useoldite and Loctite 574
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================
Joint plane of bearing pedestals, mop casing, valve servomotor
Metal to metal joint in oil environment
ylomer , Golden Hermetite and Victor Shellac .
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=================
Threaded fastners including, breech nut threads, keys, packers,
Dowel pins u & i - seal rings in high temperature zone.
high temperature ( < 350c) antisiezing . Use molykote p37 and oks 255
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=================
Threaded fastners, keys, packers, dowel pins in low temp. zone, coupling bolts
seal
segments, hp/ip casing palm packers, hp front & rear bearing pedestal packers
(other
than self lubricated lubrite packers . i.e low temperature ( < 350c) antisiezing
use Molykote d 21, Oks 511, Mgs 400
ips on different aspect of Main Turbine Erection.
-When ever JOP is not available, use always thick oil during rotation of shaft
over
bearing.The type of oil may be used as servo cylinder 1000 grade of IOC.
The bearing parting plane bolts are to be tightened to required torque only no
other
method of tightening of these bolts may be used.
-Alignment and coupling of HP-IP and LP rotors are to be completed before
starting the
rolling test of the casing in normal case but this can be done without coupling of
LP rotor
also.
-No inlet and outlet pipes are to be welded with the casing till completion of
rolling test
and installation of final keys and packer of the casing.
After completion of the rolling test the installation of final keys and packers of
the H.P.
and I.P. casing, the same can be cleared for welding of inlet and outlet pipelines.
The
main steam inlet line from main steam strainer to the control valves and then
from
control valves to the H.P. casing need much more care during erection / welding
of the
pipelines. Similarly the Hot Reheat lines between two Hot Reheat strainer to the
control
valves and from control valves to the I.P. casing also need equal care during
erection /
welding of these pipelines.
- Projections of these axes in the corresponding drgs. shall be as under :
X axis = view toward generator
Y axis = view upward generator
Z axis = view to the right
-The breech nut assembly used in between connection of main steam inlet line
and HP
module. A special care is must while making the breech nut assembly first time
at site
during erection stage. Follow the OEM instruction carefully.
ERECTION SEQUENCE (For 500 MW Fixed pedestal type Turbine with spring
loaded
foundation) BHEL MAKE TURBINE
plates as per the transverse and longitudinal axis including their elevation
and catenary as
per the design.
6. Prepare and install steel bars for LP casing centralising keys in foundation
slab as per the
required centre line .
7. Weld locating ring of LP front pedestal and steel bars of LP front and LP
rear centralising
keys.
8. Prepare shuttering and grouting of the pedestals and LP base plates
including anchor
plates of HP rear pedestal.
9. Prepare, install, align/ level both the LP girder along with their carrier
plates.
10. Prepare , install and assemble LP front and rear end walls with the LP
girders.
11. Level / align LP outer casing lower half as per the transverse and
longitudinal axis of the
machine.
12. Install permanent packers of LP outer casing including their radial and
ax14. Align LP inner outer
casing lower half and level it. Install LP casing parting plane platform .
13. Prepare and install LP inner outer casing along with gusset plates in
position
14. Align LP inner outer casing lower half and level it. Install LP casing
parting plane platform.
15. Prepare and install LP front and LP rear lower half shaft seals housing and
align it provisionally.
16. Prepare and install LP rotor along with their bellows in position.
17. Align LP rotor radially and axially in position and record free run out of
rotor.
18. Record/ Ensure radial and axial clearances of the LP casing including
rotor float including
fitting of final axial keys of the LP inner casing .
19. Box up LP inner inner casing and heat tighten the parting plane bolts.
20. Box up LP inner outer casing.
21. Prepare and place HP module in position on temporary packers.
22. Transfer the load of HP rotor on bearings from the transport device and
align it radially
and axially.
23. Check free run out of HP rotor on journal and coupling face including its
float.
24. Prepare and place IP module in position on temporary packers. (In case IP
module is sent
to site in disassembled condition.)
25. Loading of IP rear end of the shaft on bearing and removal of transport
device.
26. Provisionally align HP, IP and LP rotor.
27. Couple HP / IP rotor on temporary Bolts and align rotor / casing radially
and axially.
28. Record/ Ensure IP rotor float by shifting HP casing axially.
29. Conduct Horn drop test of HP casing without any radial and axial keys
and pipe lines.
30. Conduct Horn drop test of IP casing without IP inlet upper half pipe lines.
31. Assembly of breech nut of HP casing and Main Steam Stop & Control
valve assembly.
32. Erection of Reheat Stop & Control valve assembly.
33. Weld IP inlet upper half pipe and record Horn drop values without radialaxial keys.
34. Alignment of HP/IP/LP rotors and their coupling on temporary bolts
including its couple
run out.
35. Swing check of HP rotor on its front end with temporary alternate bolt
tightened on
HP/IP coupling.
36. MOP alignment and its doweling.
37. Reaming/honing of HP/IP and LP/IP coupling including fitting of final
coupling bolts.
38. Fixing of axial position of shaft and assembly of thrust bearing including
its colour
matching.
39. Roll check of HP/IP casing and fixing of radial and axial keys of the casing
(Casing final
packers need not to be put at this stage).
40. Assembly of bearings and checking of all clearances including fittings of
side pads of
43. Oil flushing of the machine and normalizing the bearing after oil flushing.
44. Preparation and floating of TG deck as per OEM instruction.
45. Decoupling of HP / IP, LP/IP, LP/Gen., Gen./Exciter coupling and
rechecking of
alignment/catenary after floating of TG deck spring.
46. Final tightening of HP/IP, IP/LP , LP/Generator and Generator / Exciter
coupling after
correcting the alignment including their couple run out and swing check of
rotor on HP Front
and exciter rotor.
47. Checking /Correction of LP shaft seal clearance after floating of TG deck
with CW pump
in operation and water in the hot well of condenser up to operating level.
48. Roll check of HP, IP casing in up and down direction only with TG deck in
floating
condition and CW pump in operation including water in hot well up to normal
level.
49. Assembly of final packers of the HP, IP casing after completing the roll
check in up and
down direction.
50. Recording of final Horn drop of HP and IP casing after completing the
welding of HP
inlet, HP exhaust , IP inlet and Cross around piping.
51. Preparation and boxing up of LP casing after competing the full Roll check
of LP casing
and fitting of final casing packers and radial keys.
52. Barring gear.
Continued to Part -XII
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due to massive excavation for individual fans.This excavation can only be started when Boiler
supporting structure erection completion ( ceiling Girder erection , rear structure erection and air
heater structure erection completion). There should be alternate route for feeding second Pass
Pressure
Part
material feeding . Civil works for other foundations are to completed with fan foundations .
Minimum two heavy duty crane ( 250 MT) capacities will be placed in boiler rear to carry out
erection work of Boiler and CHP.Individual fan erection time cycle is around three months to
four months. During this time boiler 2nd pass erection ,ducting above air heater , air heaters ,
Eco handling structures , ESP side inlet nozzle , Gates and dampers of ducting will also be
required for erection completion. Therefore this area is very important regarding interfaces are
concern
and
close
co-ordination
and
monitoring
are
required
.
Besides ID ,FD and PA there are two important fans are there one is seal air fan and other is
scanner
fan.
A
brief
description
is
given
below.
FANS FOR POWER PLANT
-Supply air for combustion in the furnace and for evacuation of the flue gases formed from the
combustion.
-Maintain Balanced Draft inside the furnace
Axial fan-reaction type with blade pitch control is use in the Pulverized fired boiler(210/250/500
MW).
PA FANS
Supply high pressure primary air through APH needed to dry & transport coal directly from the
coal mills to the furnace.
Primary air for mills is divided into cold & hot primary air.
Axial fan-double stage-reaction type with blade pitch control is use in the Pulverized fired
boiler(210/250/500 MW).
ID FANS
Suck the gases out of the furnace and throw them into the stack by creating sufficient negative
pressure in the furnace (5-10 mmwc) in the balanced draft units.
Located in between the ESP and Chimney in the flue gas path.
Radial Fans -double suction-backward curved vane with inlet guide vane (IGV)control and VFD
control is use in all boilers
Handles large volume hot dust/ash laden flue gas (temp up to 150 deg C) from furnace and all
leakages occurring in the system till the inlet of the fan.
Overcome the pressure drop inside the furnace, Super heater, Re -heater, Economiser, Gas
ducting & ESP.
Consumes max. power in all boiler auxiliaries as it handles the large volume and heavy pressure
drop of the flue gas.
SCANNER AIR FANS
D.C scanner operates only in case of a.c power failure and sucks air directly from the
atmosphere.
SEAL AIR FANS
Seal Air Fan is also belong to Centrifugal Fan category.
Supply seal air at a pressure higher than system or equipment pressure.
Supply seal air to raw coal feeders, mills bearings, gates etc
Seal fan either boost the pressure of cold secondary air from F.D fan discharge duct or takes air
directly from the atmosphere in normal operation.
In my next part i will provide erection sequence of three major fans.
The spring element in 500MW machines and further higher rating machines
are used with visco dampers. The springs units are not supplied to site with
required pre-tension values through these are supplied with some amount of
pre-tension. The required pre-tension of the spring units are done at site
before its installation in position. A special device for pre-compression of
these springs units is also supplied by spring supplier.
After lowering the spring unit the cover steel plates are placed in position
with shuttering supports.
An air gap of about 5.00 mm to 10.00 mm is left between cover plate and
spring units for
settlement of deck during casting. The visco dampers are also filled up at
site only with visco liquids
supplied by spring supplier. Each spring units are placed over the resistance
pad to avoid movement
of the spring units during operation of the machine. Similarly the resistance
pad is given on top of the steel shim to avoid the shifting of the shim during
operation of the machine. Each spring unit is provided with 10.00 mm of
steel shim for future adjustment.
The TG deck springs are released after installation of all Turbine Generator
components including piping and the condenser has to be filled up to
operating level including CW pump in operation for full load condition. The
shims provided for additional compression of the spring units are also
adjusted during this stage, the final alignment of various rotors and turbine
casing are done after release of the spring unit. The Generator hydrogen
cooler & LP heater if any inside the condenser are to be filled up in cooling
water space for their operating condition before release of TG desk spring.
The insulation of various casing / pipe lines including cladding if any are also
to be installed otherwise the equivalent weight is to be incorporated before
release of desk spring. All the pipe lines connected with the Turbine and
Generator should be made available on permanent hangers and supports to
avoid any additional load on the TG deck afterwards. The TG deck should
also be made free all- around to avoid any obstruction in its movement.
For above works it is advised to follow the OEMs practice in vogue. All the
OEM ( original Equipment Manufacturer) detailed it in there erection manual.
One should follow the approved FQP ( field Quality Plan) for measurement
and records of various reading in the log sheets of FQP . This will help in
analysing any future problem.
in the LP casing.
WELDING OF LP OUTER CASING
The welding of LP outer cover is to be carried out before placement of LP
Rotor in position
to avoid damage to the rotor.
Colour match and remove all high spots of the matching flange of the LP
outer casing.
Ensure good contact between parted diffuser of LP front and LP rear cover.
Colour match and remove all the high spots of the parted diffuser/vertical
face to ensure
good contact with the compensator at a later stage.
Colour match and remove all burrs and high spots from parting plane of LP
outer casing.
Side flange of LP front and rear cover are to be ensured in right angle to
achieve good
contact with their matching flanges.
Place LP front LP rear cover along with parted diffuser and ensure feeler tight
joint after
tightening the parting plane bolts. The joint must be feeler tight just after
normal tightening
of bolts. Do not over tighten parting plane bolts.
Ensure matching of parted diffuser face on both side of LP casing. If
necessary colour
matching may be carried out to achieve a feeler tight joint.
Drill/ream all the parting plane holes as per drawings and install all dowel
pins.
After fixing of LP front and rear cover measure the dimension for positioning
of both the
centre flanges. The dimensions are to be recorded in such a way that there is
no clearance
after fitting of centre flanges in position on both side with the LP front and
rear cover. The
centre flanges are supplied in extra length on both sides from the factory and
final length
are to be maintained at site only.
Drill/ream dowel pin holes in centre flanges and install all dowel pins in
position. Ensure
drilling and reaming of all dowel pin holes to equal depth.
Fit both the centre pieces of the cover in position.
Achieve the fitting clearances for welding as per laid down procedure.
Weld/lock LP upper half flange with respect to lower half casing with the help
of metal
cleats to minimise the distortion during welding of LP cover. The cleats may
be welded at an
interval of about one meter distance.
higher point of the rotor coupling face and lower point of another rotor
coupling face are
matched together. This is to be compared with shop protocol also.
-Preliminary align (radial and axial) all the three rotors and shift them in
spigot along with
the casing to avoid fouling of rotor inside the casing.
-During alignment achieve left and right movement of the rotor with the help
of shims in
spherical / torus piece of the bearing. The up and down movement of the
rotor is to be
achieved with the help of shims in the cylindrical/spherical support of the
bearing . The
adjustment of shims in the bearing should be within the permissible limits
only.
-Ensure during alignment that the catenaries of the shaft are maintained.
-Check/record spigot clearance of HP-IP and LP-IP rotors by actually moving
them in spigot.
Install four nos. supplied bolts along with one/two pins in HP-IP and LP-IP
coupling. Hand
tighten the coupling bolts by keeping a gap of > 1.00 mm in coupling faces
for alignment.
Rotate the rotor system and record the coupling gap at 90 Deg. intervals on
left, right and
top position. Ensure that the coupling, bolts and pins remain free while
recording the gap of
the coupling for the alignment purposes.
-Check swing check value of the HP rotor with alternate bolts in position. The
above value
must be within the prescribed limit only otherwise a correction must be
carried out at site in
accuracy and an accurate balance which can take a load of about 20 kg. may
be used. During
balancing of coupling bolts following points are to be taken care.
Final balancing of the coupling bolts are to be done along with the coupling
nut of individual
bolt.
If all the coupling bolt hole sizes are same before/after reaming and honing
then all the
bolts can be kept of equal weight.
If necessary adjust the weight of the bolts by machining the metal from the
bolt head.
COLOUR MATCHING OF THRUST BEARING
After completion of reaming/honing and preliminary tightening of the
coupling bolts, the
colour matching of the thrust bearing pad have to be carried out with respect
to the thrust
collar of the HP Rotor. During colour matching a good contact on all the pads
of front and
rear side are to be ensured with respect to rotor collar by moving the rotor in
+/- direction
during its hand rotation.
Air pre heater erection sequence and plan is given above. Also this process can be
utilised for
monitoring purpose. Electrical ,C&I are left out as the same will be discussed
separately. Air
heater erection from start to erection finish is about 4 to 6 months job. Material flow
for the
job should be as per sequence mentioned earlier. Around 30 to 40 persons are
required to
execute the job in that time frame with adequate T&P and IMTE.
Air preheater erection can be started just after erection of last ceiling girder and can
be continued
along with Pressure Part erection. However approach for pressure part should be
kept open.
For Boiler where Air heaters are installed in second pass approach from rear and
both sides
should be available. Two other issues may crop up i) Construction of fan foundations
( PA & FD)
ii) Erection of ducts just above Air heater. It is noticed that approach area at the
rear gets
congested early because of multi- discipline starting of erection work like ESP , SG ,
coal
gallery , Ash handling work , duct support , electrical tray work etc. Therefore it
needs good
planning and idea about the priorities for all the above work otherwise conflict
bound to happen
and derails the time schedule.
The picture above shows the overall construction feature of Ljunstorm air pre
heater'
Names of the main parts of the LJUNGSTROM APH are:1) Expansion block (08)
Picture shows the location of Air preheater in a boiler ( having mills on the
side) . PAPH stands
for Primary Air Preheater ( Left and Right) and SAPH stands for Secondary Air
Preheater (Left
and right)
Picture above shows Air Preheaters are in advanced stage of erection including
interconnecting duct.
Above picture show the secondary Grouting of Turbine pedestal . Form work is seen in the
picture .
Already grouting has been completed.
Brand Name
RT Mo (ER 80s-D2)
TGSM
Colour Code
Green
TGS 1CM
Silver grey/white
TGS 2CM
Brown /Red
RT 9 Cr 1 Mo V
TGS9Cb
TGS -347
Blue
E-7018
100 deg C
E-7018 -1
100 deg C
E-7018- A1
100 deg C
E -8018 B2
100 deg C
E-9018- B3
100 deg C
E-8018- B2L
100 deg C
E-9018 B3L
100 deg C
250-300 & 1 hr
100 deg C
** - After issue the electrode from site store to welder the temperature
Portable oven should be around 65 to 70 deg C during actual use by welder.
This is not applicable to E309, E347 and E 6013.
Selection of electrodes for non pressure parts work
Material P1 + P1
A. For butt welds, up to 6mm inclusive: E6013
> 6mm
: E7018
: E6013
: E7018
Carbon Steel + P1
: E6013 or E7018
: E8018 B2
Note: E6013 can be used for all non load carrying welds of all thickness
of IS2062 plates 20mm thickness and 8mm fillets. For structural material
like Ceiling Girders thickness of material is > 63 mm needs preheating (120
Colour Code of thermocouple is yellow (+) and Red (-) over all Brown.
(Polarity +/- should be known otherwise it will give erroneous reading)
Thermocouple extension wire Yellow (+) and Red (-) overall yellow.
(Thermocouple can only be connected by thermocouple extension wire not
by any other wire)
There are other types of thermocouple but in India K type is only used at
the project site. The temperature milivolt curve is linear. The increase is
4.13 mv per 100 degree C. (approximately)
Radiography Source
In India for industrial radiography we use two type of source i.e Cobalt -60
and Iridium -192. Out of that use of Cobalt -60 is extremely unpopular
because it requires stringent safety precautions to be followed and it
affects the progress of work. Instead of cobalt -60 now a days all are
using ultrasonic machine to detect the fault. Ultrasonic machine requires
Test block (made of same material to be tested) to be made as per the
Specification of IIW.
Iridium -192 is having half life of 74.4 days. All our pipes and tubes are
Radio graphed by this source except pipe /structural thickness of > 60 mm.
In those cases only UT is performed. The Iridium source should be more
than 30 Curie strength. It will require less exposure time and time can be
saved. Exposure time is inversely proportional to the strength. In 500MW
/660 MW boiler around 10,000 to 12000 shots are taken.
For surface defects of welds two very simple tests are carried out (i) Magnetic
glance.
- HSFG bolts are much costlier than ordinary 4.8 and 8.8 precision bolts.
- Bolt once torque tightened can not be used for the same purposes.
Above picture shows the erection of bracing in steam generation. Wherever HSFG bolts are used
are shown in the picture. Column bolting also can be seen in the picture.
The above picture shows a heavy duty crane is standing on platform . Platforms are made to size
by
20 mm steel plates and ISMC 100/ISMC 150 channel. These platforms made such a way that
crawler
of the crane can stand on it. Platforms can be easily removed from one place to another while
the
crane is on move. In some place 12" square and 10' -12' long wooden logs are used instead of
steel
platform. However arranging wooden logs is very difficult now a days therefore every body
tries to
make steel platforms. The soil need to be compacted by running roller if required boulder
pitching
has to be carried out. Laying of platform should be done such a way that there should not be any
load on the foundation columns located inside the cavity. This can be understood if some one can
looked into the boiler plan given on earlier submission. Any heavy duty crane of 600 MT or 1200
MT
needs to stand firmly on platform within a limit of undulation . Crane manufacturer set half a
degree
is the max limit. A crane sizing ( capacity) depends on lifting of ceiling girder ( heaviest one ) to
required height. In our 660 MW we choose 600 MT Manitowac crane with luffing jib at 67 M
and
jib can lift the heaviest girder. This was done to keep in mind the erection of welded beams ,
rolled
beams and roof structure including the silencers. Our erection method i.e erecting boiler structure
from the cavity does not suit the heavy lift crane with super lift arrangement as crane will not
have
radius to move. Above picture shows the crane platform from other angle.
we will discuss secondary grouting of columns and HSFG bolting at the end.
We will now discuss about the ceiling Girder fabrication and erection.
The limits set out for ceiling Girder pre-fabrication is given below.
- Root gap at the erection joint of the ceiling Girder. Flange 4 mm to 6 mm , web 6
to 10 mm.
- Camber and sweep of individual ceiling girder 1 mm/ M , max. 15 mm
- Assembled ceiling girders for sweep and camber 1 mm / M max 15 mm.
- Position of Bottom bolt hole with reference to centre of the ceiling girder + /- 3
mm
- Spacing between adjacent ceiling girder +/- 5 mm ( taken during Girder alignment)
- Diagonal difference between to adjacent girders is 25 mm Max .
-ceiling girders centre line variation w.r.t. Boiler axis 12 mm Max.
1 mm/ M or + /- 5mm
( Reference axis is the line which is centre line some times calls as Boiler axis. It is transferred
from
the Bench Mark having marked latitude , longitude and elevation. This point is transferred
column
number 13 and 17 . )
Spacing between two foundations ( adjacent)
1 mm / M or + /- 5 mm
1 mm / M or +/- 10 mm
+ / - 3 mm
+ / - 5 mm
(All foundations are having template made OF steel plates with holes pitched as per drawings .
Bolts are placed there and bottom channel has been locked . The bolts cannot be moved during
casting of foundations . This checks has to be carried out before casting of columns.)
The above picture shows that Boiler column erection has started . Formation of Box between
Main
column and Auxiliary Column is under progress. Some of the manufacturer columns are joined
by
HSFG Bolts . In this picture main column is bolted but auxiliary columns are welded and also
bolted.
The above picture shows boiler erection ( structural) is under progress. Loose columns are tied
with
Guy rope . End of the Guy rope is either terminated to max puller or a hand winch . Both the
cases
the equipment is securely anchored.
Most of the foreign manufacturer supplies material tier wise so that this type of erection is not
done . This type of erection is having safety issues and can be termed as unsafe . But due to
non sequential material such erection was carried out.
6780 MT
3600 MT
3. Structure which is holding ducts of boiler , BOF to ESP and ESP to chimney 2340 MT
4. Misc. inter connecting structures ,platforms ,handling ,elevator etc
1200 MT
The above tonnages are approximate tonnage of a 660 MW boiler . Quantity of smaller unit will
be less than what it is indicated. However the tolerances followed will be the same. Some of the
common tolerances followed not only for Boiler but also civil structure is given below.
he surface1. Individual column piece sweep and camber
1 mm / M max
up to 10 mm
( Individual columns are placed on the pre-assembly bed to check the sweep and camber. Preassembly
bed need to be prepared carefully so there is no undulation on top of the surface. Beds are
prepared
by using concrete blocks and beams . Dimension check ,cleat angle welding , Marker fixing ,
Bolt
Hole cleaning etc are done at Pre - assembly bed.)
2. Camber and Sweep for assembled column
mm
3. Total length of column
1 mm / M max up to 10
+ / - 15 mm
+ / - 5 mm
+ / - 5 mm.
( Measurement of the total length was done at manufacturing time . However during erection
same
check is being carried out after erecting the piece of column and dropping plumb from the top to
the
reference point at regular interval ( thrice up to the 7 th tier ). Final check has been done after
6th tier
column erection and before seventh tier erection. Seventh tier measurement done at ground. )
Grouting Gap below the column base
minimum 20 mm to 70 mm max.
+ 30 mm to - 20 mm.
( All the pedestal need to be cleaned from loose concreting on the surface. At least 10 mm /15
mm
to be chipped of to position the packer plate below the column base plate . If the pedestal is more
on positive side then we have to chip more and doing it manually as it is being done in India will
be
taking extra time. It is all time better to have pedestal elevation on negative side.) .
Typical floor plan ( foundation detail ) of Steam Generator is given above. Column no 7 to 17 L
&R(
except 17 all other columns having two numbers i.e . one in right side and other is on left side)
are the
main columns and column number one to six ( L& R) auxiliary column. Distance between 7R
and 7L
will give an idea of space availability in Boiler cavity. This area inside the boiler is very
important for
erection of steam Generators. Inside the Boiler Cavities there are column no (14 ,15 and 16 ) L
&R .
These columns are shorter columns in height and need to be erected afterwards i.e. only after
erecting
the ceiling Girders. However these column foundations need to be protected until and unless we
start
erection on these columns../
7. Balance of Plant ( Beside above major packages other packages like water system etc)
We will discuss it all one by one starting with steam generator. However our discussion will be
confined to erection and basic design input required. Definition of steam Generator can be
obtained from any standard book or from Internet.
Size of steam Generator will be different for different size of unit e.g 60 MW ,120 MW , 210
MW , 250 MW , 300 MW, 500 MW ,600 MW , 660 MW and 800 MW. Mostly these sizes units
are available in India . The sizes will be different for same unit if fuels are different in
composition. However construction features will be same for all the units.
- Steam generators comprises of following components .
- Structure ( columns , bracing ,beams , angles ,platforms , Ceiling Girders , welded beams
,rolled beams , HSFG nuts and bolts , Gusset Plates etc.
- Pressure Parts ( water wall panel , economiser , super heater Panels , HP piping , Re heater ,
Suspension , headers , Link tubes , Tie rod etc.
- Ducting - Air and flue gas Pass through it. Plates, beams , pipes etc are required to manufacture
the ducts.
- Rotating Machinery - FD ,ID ,PA , SEAL AIR FANS , MILLS and other small rotating
equipment.
- Insulation - Glass wool or rock wool , refractories etc.
SOME OF THE ERECTION TOLERANCE FOR STRUCTURAL WORK IN A POWER
HOUSE
(TYPICAL)
-Foundation for columns ( Top elevation)
- 20 mm / + 10 mm.
1mm/metre max. up to + 5
1mm/metre max. up to + 15
+ 3 mm
+ / - 5 mm
+ 25 to + 70 mm (max)
1mm/metre max. up to + 10 mm
+ / - 15 mm
max 15 mm.
- Out of vertical
1mm/metre max. up to 25 M
+ 5 mm
5 mm
5 mm
5 mm
5 mm
5 mm
+ /- 7 mm
+ / - 10 mm
+ / - 10 mm
+ /- 15 mm
column
Beams
Crane girder
0.1 mm
Frame Joints
2.0 mm
1.5 mm
1.5 mm
0.1 mm
1.5 mm
1.5 mm
0.1 mm
1.5 mm
0.1 mm
0.1 mm
1.5 mm
0.1 mm
Beam brackets
2.0 mm
none
20 degree C
66 degree C
110 degree C
- Pre -heating can be done by LPG heating , electric resistance heating or by electric induction
heating.
- Temperature can be checked by thermal chalk or putting Thermocouple ( generally Nickelcromium-Nickel ) . The relation between temperature and voltage is 4.12 mv /100 deg c rise
(approximately).
- Sequence of welding to be followed as per WPS and drawings .However a few basics may be
noted.
- The direction of welding should be away from restraint point and should be towards open end.
- Butt weld in flange plates and/or web plates shall be completed before the flanges and webs are
welded together.
- Generally The beam and column stiffeners shall preferably be welded to the webs before the
web and flanges are assembled.
- All welders including tack welders to be tested as per IS codes and identity card to be issued for
verification time to time during actual job.
- Carry out Non Destructive examination RT / UT /LPI as per requirement.
A general view of fabrication yard where plates are getting cut into pieces for
further fabrication.
A general view of electrode drying oven . The electrodes are dried here and
transported to holding oven.
13000 MT.
29000 MT.
- For a project 2x660 MW super critical unit structural steel required is 30000 MT.
Fabrication for the above tonnage is also done at site.
STRUCTURAL STEEL.
Some of the standard sections of structural steel are given below for ready reference.
Angles : Designation
Beam
Size ( lxbxt)
weight in kg/M
ISA 50x50x6
ISA 50x50x5
ISA 65x65x5
ISA 65x65x6
ISA 65x65x8
ISA 75x75x8
ISA 100x100x10
ISA 130x130x10
ISA 130x130x12
50x50x6
50x50x5
65x65x5
65x65x6
65x65x8
75x75x8
100x100x10
130x130x10
130x130x12
ISMB 100
ISMB 125
ISMB 150
ISMB 175
ISMB 200
ISMB 250
ISMB 300
ISMB 400
ISMB 500
ISMB 600
8.9
13.3
15.0
19.6
24.2
37.3
46.0
61.5
86.9
123.0
75 X40
100X50
125X65
150X75
200X75
7.14
9.56
13.10
16.80
22.30
Channel ISMC 75
ISMC 100
ISMC 125
ISMC 150
ISMC 200
4.9
4.1
4.9
5.8
7.7
8.9
14.9
19.7
23.4
( these are few section mentioned above generally being used in thermal power structural
fabrication.)
Besides standard machine cut plates are also used such as 6mm, 8mm , 10mm,12mm, 16mm ,
20mm, 28mm ,32mm ,40mm, 50mm up to 63mm. ETC.
- Fabrication to be done as per fabrication drawing developed from the structural drawing. There
are companies available in India who makes the fabrication drawings / detailed drawing. The
fabrication drawing includes every detail requires for fabrication.
- Welding of structural items are done by electric arc process as referred in the drawing. For
resolving any disputes these documents may please be referred. 1. Drawing . 2. Welding
Procedure defined (WPS) .3. Welding Manual . 4. NDE manual .5. Relevant IS codes like 817 ,
7215, 12843 ,1852 , 2062 , 9595, 3502, 1239, 3589 etc 6. ASME sec IX 7.
- Submerged arc welding shall be used for welding longitudinal fillet welds.
- Longitudinal / transverse butt joints for fabrication of columns, framing beams and crane
girders and
all other built-up members.
- Efforts should be made to position the job such a way so that down hand welding is possible.
-Only qualified welders are to be employed for welding procedures and positions.
Fillet weld members should be close enough so that gap is 0mm. In no case the gap
should be more than 3mm. For example if the fillet gap is found to be 2 mm then
fillet size of the joint should be increased by 2 mm.
PUG MACHINE
Foundation of steam Generator under progress. This is last lift of the foundation
where all the foundation bolts are placed temporarily. Engineers are checking the
same with the help of Total Stations so that bolts can be locked with the template
before pouring of concrete.
Series of foundations are shown here . This includes raft ,pile cap and final lift of
foundations including placement of foundation bolts. Concrete blocks shown in the
pictures are for pile load testing. Some of the unbroken piles are also seen here.
This is a picture of TG bay inside power house on early day of construction On the above all
main power TG Deck supporting structures for Turbine and Generator auxiliaries will come to
existence.
During last write up we have mentioned about different testing and sampling to be done as per
Field Quality Plan. Frequency of sampling and testing of some of the major ingredients are
given below.
IS 2720
IS 2720
IS 2720
Random Test
IS 2720
Coarse Aggregate
Particle Size and Shape ,Moisture Content
Specific gravity , density, voids, absorption
IS2836
IS2836
Random.
IS2836
IS2836
IS 2836
Every day
Cement
Setting Time , Comprehensive strength , Fineness One sample from each Batch
IS 4031
Water
Harmful substances, pH value, initial
setting time, compressive strength.
Once in a month/source
IS 456
Concrete
Slump and compaction Factor
Crushing Strength
Random
IS 1199
Thus we have completed our discussion on civil job of thermal Power station. If posted
all
queries will be answered . However please refrain from advertising product on blog. From
next writing we will discuss about the structural work of the power station.
Following are few items subjects to field quality checks . These are samples only. There are
many more items will be under FQP's purview.
ii)
i)
Bricks
Earth Work
iii)
Cement
iv)
v)
Course Aggregate
vi)
Reinforcing Steel
vii)
Water
viii)
ix)
Concreting
There are number of items which comes under FQP in civil work.
Area of Work : Civil works
s.no.
1.0
Description
toc
instrument class
1.1
IS codes
1:10000
protocol
1.2
IS codes
1: 10000
Protocol
IS codes
1:10000
Protocol
M Laboratory
IS codes
Note 1
Protocol
M Laboratory
IS codes
Note 1
Protocol
Note 1
Protocol
laboratory
M Laboratory
IS codes
M Laboratory
IS codes
Note 1
Protocol
M Laboratory
IS codes
Note 1
Protocol
Cement
3.0 a) Consistency of cement
M Laboratory
(vicat needle)
Compressive strength
(testing m/c)
IS codes
Note 2
Protocol
M Laboratory
IS codes
Note 3
Protocol
j)
Petrographic examination
k) Deleterious materials
l)
m) Flakiness
The above tests are carried out site Laboratory as per IS codes mentioned in the FQP ,measured and
protocol ed .
For actual work tests mentioned in the FQP to be followed strictly. FQP mentioned above is only for
example