You are on page 1of 21

BHARAT HEAVY ELECTRICALS LIMITED

Power Sector Western Region


NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

BASIC STRATEGY :

Basic strategy shall be to go in for cycle time reduction in every area by taking
up erection of all possible fronts Parallelly , system completion at first go itself and
by applying innovative ideas and modern erection practices. To achieve this we shall
have highly experienced and effective execution team posted at site with back up of
strong infrastructural support made available to them .They shall be always aiming for
achieving the project milestones as planned by changing the intermediate course of
direction depending on availability of inputs. The infrastructural support and basic
erection sequences / strategy is explained below.

SUBCONTRACTING STRATEGY:

Subcontractors shall be finalized from the list of vendors duly approved by


NTPC (as applicable as per agreement) for following packages,

1) Main boiler and Rotating equipments


2) ESP and Flue gas duct beyond boiler
3) Power Cycle piping
4) Lining and insulation

INSPECTION & QUALITY

An exclusive Quality group at site ensures all installation checks and stage
protocols with respect to approved quality plans for individual system , involving
Consultant/ Customer representatives. List of Area wise applicable quality plan is
enclosed. (Annexure-1)

In addition to this, to ensure system completion, before execution of a defined


Mile Stone activity during installation, an audit team from PS-WR HQ visits the site
before Construction Manager is permitted to execute the Mile Stone activity.

SAFETY

An exclusive officer shall be deployed at job site to guide, monitor and


control all HSE related activities as per companys HSE instructions. He shall directly
report to Construction Manager. Also our erection agencies shall nominate exclusive
safety supervisor to assist us.

Page 1 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

MATERIAL MANAGEMENT

Unique identification system for components is utilized by all BHEL units. A


strong team of officers and supervisors shall keep intensive track records of
dispatches, receipt, storage and issues of components using modern electronic media.

On receipt, components shall be inspected and verified before storage.


Exclusive Material Receipt cum Inspection Reports shall be prepared along with
Consultant/Customer representative.

Components shall be stored in Open , Semi-closed, closed or Special


environment conditions as applicable. They shall be preserved during storage and
installation stages as per the instruction given in our preservation manual.

A comprehensive tracking system, with appropriate records shall be


maintained for all issues.

DOCUMENTATION AT SITE

A totally computerized documentation system shall be adopted at site to keep


track of total drawings and manuals required to complete installation to ensure proper
monitoring of receipt , issue and revisions .

FACILITY ENGINEERING AT SITE

An exclusive executive shall be deployed to supervise and monitor the


availability of T&Ps being provided by BHEL

TOOLS AND PLANTS

Sufficient numbers of T&P s shall be deployed either by BHEL or by their


erection agencies . Enclosed list of major T&Ps that shall be deployed to execute
Boiler , ESP and piping package . ( Annexure-2)

MANPOWER DEPLOYMENT :

Sufficient number of BHEL staff shall be posted for installation of this


package. Area wise deployment plan of BHEL staff is enclosed. (Annexure-3)

Following shall be tentative manpower ( main category) deployment plan


per unit by erection agencies ;

Page 2 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

Boiler erection agency: Engineer- 7 , supervisors- 15 , Rigger foreman- 2 , Fitters-


27 , Structural welder 30 , HP welder 12 , Gas cutter - 4 , Grinder 10 , SR
technician 4 , Radiographic Technician- 4

ESP erection agency: Engineer- 1 , supervisors- 4 , Rigger foreman- 1 , Fitters- 12 ,


Structural welder 15 , Gas cutter- 2 , Grinder-2

Piping erection agency: Engineer- 3 , supervisors- 6 ,Rigger foreman- 2 , Fitters-


12 , Structural welder 10 , HP welder 10 , Gas cutter - 2 , Grinder- 6 , SR
technician 4 , Radiographic Technician- 4

ERECTION SEQUENCE:

BOILER SUPPORTING STRUCTURE :

Main supporting structure columns ( Nos. S1 to S6 L&R, S7 to S12 L&R ,


S13L&R , shall be erected in following combinations:

Bottom tier - single piece


2nd & 3rd tier combined with Tata 75 MT and Link Belt LS 248H
4th & 5th tier combined
6th & 7th tier combined ---------------- with FMC LS 718 HLA 330 ft boom + Jib

All connected horizontal beams , MBL members , vertical diagonal bracings


as required to maintain verticality of the columns shall be erected before proceeding
to next level. All MBL members between box of four columns shall be judiciously pre
assembled on ground to ensure better workmanship and speedy erection. Erection of
all balance items of such components shall proceed parallelly and shall be completed
prior to ceiling girder lifting.

It may be noted that all columns for Rihand shall be trial assembled in full
length at Trichy hence pre assembly and joint matching at site shall not be required .

Once the structure as mentioned above are erected and verticality of columns
are ensured Ceiling girder erection shall start . Ceiling Girder Erection shall be done
in following sequence:

With 1st rigged position of FMC - Girder '0' , Girder-A , Girder-'B'


With 2nd rigged position of FMC -Girder-'C' , Girder-'D'
With 3rd rigged position of FMC - Girder-'E'

Page 3 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

Ceiling girders will be supplied in three pieces and shall be pre assembled on
ground before lifting. Enclosed Annexure-4 may be referred showing proposed
assembly locations. It may be noted that casting of foundation pedestal of FD
fan-B to be hold till ceiling girder C&D is shifted to boiler cavity after pre
assembly. Also it may be noted that the bottom most vertical diagonal bracing
between column S10 R&S11R will not be erected for this purpose. Designer
clearance towards this is already obtained.

For erection of structure as mentioned above the basic sequence of erection


will be from front to rear i.e. from Row-D to L keeping the crane inside boiler cavity.
Entry of cranes are envisaged from right side of boiler through rear of boiler i.e. from
between boiler rear and mill bay col. i.e between Row-L&M.
For movement of crane inside boiler cavity it will be necessary to hold erection of
middle /air pre heater columns namely Columns Nos. S15L&R , S16L&R, S17,
S18, S19L&R, S20L&R, S21, S24R, S25R, S29R,FH-11R,FH-12R, Mill bay M &
N row columns . Also it should be ensured that the foundation pedestals of
columns S15L&R , S16L&R, S17, S18, S19L&R, S20L&R, S21, Mill bay M
row cols 2nos at center. do not project above ground. Enclosed annexure may be
referred for better understanding. Annexure-5

Columns nos. S15L&R , S16L&R and its connecting bracings will be erected
as soon as FMC moves out to clear the area after Ceiling girder A&B is erected ,
but necessarily have to be erected before Ceiling girder C erection.

Columns nos. S17 , S18 and its connecting bracings will be erected as soon
as FMC moves out to clear the area after Ceiling girder C & D is erected , but
necessarily have to be erected before Ceiling girder E erection.

Columns Nos S14L&R and its connecting bracings shall be erected


immediately after boiler drum is erected.

Erection of balance columns Nos. S19L&R , S20L&R , S21, S22L&R ,


S24L&R , S25L&R , S26L&R , S27L&R , S28L&R , S29L&R and its connecting
bracings shall be erected independently after ceiling girder erection is completed and
FMC crane is moved out.

BOILER DRUM UNLOADING AND ERECTION:

In case of unit-3 the boiler drum will be received by rail near to boiler LHS i.e.
co-ordinate approx 2075N,2250E. Boiler drum will be unloaded with the help of two
cranes namely LS248H 180MT and Manitowoc 250MT by the boiler erection agency.
The drum then shall be dragged onto temporary rails to boiler cavity.

Page 4 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


In case of unit-4 the boiler drum will be unloaded at the same location and the
drum shall be dragged on to temporary rails to unit-4 . the location of temporary rail is
shown in enclosed annexure.(Annexure-6)

Boiler drum will be lifted in single stage with help of two nos 15MT electric
winches and pulleys suspended from temporary structure ( will be either fabricated at
site or will be diverted from other site ) at top. Winches will be placed in front of ESP
and will be anchored with the help of concrete counterweights of FMC crane placed
in pit. After the drum is aligned the lifting arrangement will be removed and pressure
part erection will follow.

PRESSURE PART ERECTION AND HYDRAULIC TEST :

Being top suspended type of boiler , general sequence of erection of


pressure part will be from top to bottom and from outside to in side . Actual
sequence of erection will be decided at site depending on the sequence of material
receipt at site. However our aim shall be to go for maximum possible pre assembly
of pressure part components on ground or optimization at works , so that to reduce
numbers of lifts and to achieve better quality which will effectively reduce erection
cycle time.

Following pre assemblies / optimization at works , are envisaged :

1) All headers above roof will be assembled in single piece


2) All possible assemblies to handleable sizes in lines and links above roof
3) All crown plates with end bars for coil suspension above roof
4) Furnace radiant roof Front - in seven assemblies ( each block of
suspension arrangement ) , Inlet header shall be lifted separately in single
piece and joining with tubes shall be done in position. Rear in two
assemblies ( each block with piece of out let header )
5) Back pass furnace roof with all hanger tubes above it along with inlet header
in single assy.
6) Back pass front wall hanger tubes with suspension end bars.
7) Back pass front wall upper with lower panels
8) Back pass side wall upper panels to inter panels
9) Back pass rear wall upper panels to inter panels
10) Back pass rear lower walls with two headers(complete assy)
11) Extended water wall upper panel with lower(individual)
12) Furnace rear wall upper panels with hanger tubes and arch tubes( individual
panel)
13) Burner panels with lower inter panels ( individual panels)
14) Furnace side Lower inter walls with lower walls ( individual panels)
15) Furnace front and rear lower panels with floor panels( individual panels)
16) LTSH upper coils to lower coils. ( individual coils)
17) Economiser upper with intermediate coils( individual coils)
18) Sh. Divisional panels front assy to rear assy( individual panels)
19) Furnace bottom Z panels with floor panels and loose tubes

Page 5 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


20) All buckstays with stirrups and keybuckstays
21) Superheater and Reaheater spray control stations

However a judicious relook into above assemblies will be essential after


detailed engineering of pressure part is completed.

Material feeding for first pass will mostly be done from RHS of boiler
between columns S8&9 on temporary rail. For back pass material shall be fed from
rear side. Also modern erection practices like use of omega lugs , anti deformation
frame for handling of Eco , Superheater and Rheater coils , special lifting tackle for
coil lifting will be inducted for safe and quicker erection of pressure part.

Hydraulic test of boiler will be done in three parts. Drainable part includes
the circulation system and drainable portion of the superheater. During this the link
connecting the non drainable portion of superheater shall be dummied. This will
facilitate early clearance for insulation of water walls and back pass walls required for
light up. Nondraianable part , which includes the non drainable portion of the
superheater system also , will be done just prior to boiler light up so that preservation
and rusting of superheater system can be avoided. Reheater hydraulic test shall be
done along with reheat system piping before steam blowing operation.

AIR AND FLUE GAS DUCTING ERECTION:

Air and flue gas ducting erection shall be taken up parallelly with boiler
pressure part so as to reduce the gap between boiler hydrotest and light up. Almost all
duct (excepting duct like below back pass U-headers etc. ) shall be pre assembled on
ground and shall be kerosene tested to reduce ,number of lifts and work in position
which will in turn reduce erection cycle time.
The assembled duct will mostly be fed with help of crane from sides of boilers.
However the inter connecting hot secondary air duct will be assembled below boiler ,
for straight lift.

AIR PREHEATER ERECTION :

Airpreheater erection shall be taken up immediately after the structure is


getting ready after ceiling girders lifting. Most of components will be lifted with crane
( Monitowoc-250MT and FMC 350 MT one on either side) depending on
accessibility which will help in reducing erection cycle time.

FANS ERECTION :

This being independent parallel activity it will be taken up as early as possible


depending on availability of foundations. There is fixed sequence of erection of fans
as specified in erection manual , the same shall be followed strictly.

Page 6 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

MILLS ERECTION :

Shall be taken up after availability of foundations . There is fixed sequence


of erection of mills as specified in erection manual , the same shall be followed
strictly. Major components like mill base , air compartment , separator body , mill
top / classifier assy, MDV assy will be placed with crane KH500 . NTPC to
coordinate with mill bay structure erection agency regarding hold in structural
bracings etc. for crane approach.

ESP ERECTION :

This is altogether an independent island . ESP erection shall be started as soon


as column foundations and material is available . It has an almost fixed sequence of
erection. . In ESP also we shall go for all possible pre assembly like casing walls ,
hopper walls etc. Collecting electrode will be inserted from top.

POWER CYCLE PIPING ERECTION :

This will be treated as a highly specialized work ,specially in case of P-91


( High Crome alloy steel ) . The erection can start from any side terminal point ,
however normal sequence shall be from boiler end to turbine building as the boiler
side terminal point will be ready earlier. Utmost care shall be taken by highly
experienced engineers / supervisors w.r.t. welding , preheat / post heat treatment of
welds , NDT , free floating of lines before connecting to equipments.

SPECIAL ERECTION PRACTICES :

Following special erection practices will be followed,

1. Permanent flooring of boiler cavity prior to BES : NTPC to provide


permanent flooring in boiler cavity (leaving the area for foundations under
hold) , around boilers and below ESP before start of erection . This will
create a very convenient work atmosphere which will help us in maintaining
good house keeping also it will avoid unnecessary rehandling of material /
temporary installations to facilitate flooring at later stage.
It may be noted that the flooring should have load bearing capacity of 2.5
Kg/Cm2

2. Usage of passenger cum goods erection elevator: BHEL shall provide one
no. of passenger cum goods elevator in each boiler ( at location as shown in
Annexure-7 enclosed ) which will be installed by our erection agency. This

Page 7 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


will transport people and gas cylinders to higher location which will help in
effective supervision and higher productivity.

3. Usage of waste disposal chute: BHEL shall provide and erection agency
will install one no. waste disposal chute in each boiler running vertically with
branch in each floor ( at location as shown in Annexure-7enclosed )

4. Construction Power distribution system : BHEL shall ensure that erection


agencies follows a standard construction power distribution system as
explained below,

a) Agency for Main Boiler package:


They will lay individual construction power cable from main Sub Station to
DBs for individual welding generators booth at 5 locations as follows .
These DBs will be provided with ELCBs and the cables will be run
underground before reaching boiler island and within the boiler island the
cable will be run on cable trays (vertical run will be along column no.
S12L&R )

o On ground floor between column box S11L-12L-6L-5L will have


provision for 10 welding m/cs - 200 Amps from SS- 9 for U-3 from
SS 10 for U-4
o On boiler floor at 18M elevation between column box S11R-12R-6R-
5R- will have provision for 10 welding m/cs 200 amps from SS 8
for U-3 from SS 13 for U-4

o On boiler floor at 31M elevation between column box S11R-12R-6R-


5R- will have provision for 10 welding m/cs 200 amps from SS-9
for U-3 from SS 10 for U-4

o On boiler floor at 62 M elevation between column box S9L-10L-4L-


3L- will have provision for 10 welding m/cs 200amps from SS-8
for U-3 from SS 13 for U-4

o In preassy yard for 10 m/cs 200 amps from SS-6

Tentative quantity of Cable 240sq.mm, three core, Al. cable 2000 M and
cable tray 8 500M , DB(200amps) 5 per boiler will be required.

All such DBs will cater the need of power supply for Post Weld Heat
Treatment also.

Above locations of DB and booth installation and routing of Power cable for
above are indicative , exact location shall be decided at site in consultation
with NTPC .

Page 8 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


Other than welding booth they will provide a power distribution board every
after two floors with at least ten points , with standard industrial socket
arrangement for miscellaneous use of hand tools and hand lamps. These
boards will be connected with nearest DB of welding booth

b) Agency for ESP and ducting:

They shall lay construction power cable from main Sub station to DB for
welding booth as follows

At ground floor on LHS of ESP 10 welding m/cs 200 amps from


SS-9 for U-3 from SS 10 for U-4

At ground floor on RHS of ESP 10 welding m/cs 200 amps from


SS-8 for U-3 from SS 13 for U-4

DBs will be provided with ELCBs. the cables will be run underground before
reaching ESP island and within the ESP island the cable will be run on cable
trays.

Tentative quantity of Cable 240sq.mm,three core ,Al. cable 600 M and cable
tray 8 150M No. of DB (200 apms )-2 per ESP will be required.

Above locations of DB and booth installation and routing of Power cable for
above are indicative , exact location shall be decided at site in consultation
with NTPC .

Other than welding booth they shall provide a power distribution board at
least ten points one casing manhole door platform and one in pent house of
each pass,with standard industrial socket arrangement for miscellaneous use of
hand tools and hand lamps. These boards will be connected with nearest DB of
welding booth.

c) Piping erection agency : They shall lay construction power cable from main
Sub station(No. to DB for welding booth as follows

At 4.5 M in B- C bay near column 48- 10 welding m/cs - 200 amps


+ 1 induction heating m/c 200 amps from SS-7 for both units.

On boiler floor At 31 M near col. S7L will have provision for 10


welding m/cs 200 amps . Induction Heating m/c will later be shifted
from 62M along with power cable to 31M from SS-7 in U-3 and from
SS-11 in unit-4

On boiler floor at 62 M elevation between column box S9L-10L-4L-


3L- will have provision for 10 welding m/cs - 200 amps - from SS-11

Page 9 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


in both units + 1 induction heating m/cs 200amps from SS-7 in both
units.

The cables will be run underground before reaching boiler island and within
the boiler island and in power house the cable will be run on cable trays .
Vertical run in boiler will along cable-S7L

It may be noted that Sub Station (SS) -7 shall be provided with back up DG
set power supply to avert power failure to Induction Heating M/c.

Tentative quantity of Cable 200sq.mm three core al. cable 2000 M and cable
tray 8 500M , DB (200apms)- 5 per boiler will be required.

Other than welding booth they shall provide a power distribution board at
least ten points at least in five suitable locations , with standard industrial
socket arrangement for miscellaneous use of hand tools and hand lamps. These
boards will be connected with nearest DB of welding booth.

Above locations of DB and booth installation and routing of Power cable for
above are indicative , exact location shall be decided at site in consultation
with NTPC .

Location of substation and tentative routing of construction power cables is


shown in Annexure-8

d. Winch locations : selected number of winch will be positioned as follows by


our erection agencies,

Boier Area:

a. 2 nos of 5MT winches on ground floor near S5L and near S5R
b. 1no of 3 MT winch on boiler floor at 50M near column S4R
c. 2 nos of 2MT winches on boiler floor at 75 M near column S4R and
S4L

ESP area:

No winch is envisaged for ESP erection

Piping area:

a) One 3MT winch on LHS near column no. S7L


b) One 3MT winch on LHS near column no. S7R

Page 10 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


Operation of all these winches shall be controlled by Walkie Talkies from remote.
Locations of the winches are indicative. Actual location can be decided at site.

e. Gas cutting sets : Our erection agencies shall use a set of one DA cylinder
and three oxygen cylinders mounted on trolley to be operated on ground floor.
Also for transportation of such gas cylinders they shall use hand trolley.

f. Small Workshop : Our erection agencies shall install small workshop


containing drill m/c and bench grinder

g. Erection Techniques : Following erection fixtures will be used for pressure


part erection . this will ensure safe and faster erection of pressure part coils /
panels,

i. Omega lugs : An attachment made of tubes and flat will be


welded to pressure part tubes will be used to hang and align
pressure part headers to panel , panels to panels , panels to
headers , hanger tube to coils , coils to coils etc. A sketch is
enclosed showing the arrangement. (Annexure-9) BHEL trichy
shall supply the lugs along with a load table . PSWR shall
arrange for bolts. Location at wich the lugs to be welded shall
be decided by engineers at site and shall be welded accordingly
prior to lifting of components. This will help in quick erection
of pressure part components and will facilitate easy alignment.

ii. Lifting Tool for pressure part Coils : This is a hinged type
clamp which develops grip due to self weight of the component
being lifted.. This will be fabricated at site by our erection
agency. This will be used to lift pressure part vertical coils of
superheaters and reheaters. A sketch is enclosed. (Annexure-
10)

iii. Anti deformation frame for coils: The anti deformation frame
will be fabricated ( considering actual size of coil ) at site and
used for handling longer and heavy pressure part coils like
Platen superheater , reheater front , superheater division panel ,
assembled LTSH / ECO coils , to avoid permanent distortion
while lifting.. A sketch is enclosed . (Annexure-11)

iv. Floating Pulley system for LTSH and economizer coil


erection: An arrangement of a ropeway and a floating pulley
will be used for erection of LTSH and Economiser coils . This
will reduce erection cycle time to great extent otherwise we
would have lost lot of time in changing lifting arrangement
after every few coils. A sketch is enclosed.(Annexure-12)
v. Erection method of Superheater hanger tubes: a very simple
method of lifting sh. Hanger tube will be used which will
facilitate faster erection . A sketch is enclosed. (Annexure-13)

Page 11 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

h. Temporary Rail for material feeding: A temporary rail line will be laid
between boiler column no. S8-S9 through and through both boilers ( pl. see
enclosed Annexure-6 showing location and arrangement). Boiler pressure part

materials like water wall panels and sh./rh. Coils will be transported on to this
rail with help of dip trolley. The rail will be laid on sleepers at 1m spacing. For
transportation / dragging of boiler drum over the same rail continuous sleepers
will be laid for two lengths of drum and rolled on. Requirement of material
for this purpose will be as follows,

Rail - 350 RMS


Sleeper 400 nos. ( 200 for normal material feeding + 200 will be used for
drum dragging)
Rail coupler / fish plate with fastner suitable for 350 RMS rail
Rail fixing clips suitable for 350 RMS rail

The portion of rail between two boilers will be made removable type ( in panel
form ), so that the same can be temporarily removed to give access to other
agencys T&P movement.

i. Temporary Urinal System : A header of 4PVC pipe shall be run on column


S7R with urinal pan connected to 10 floors minimum on boiler and with
suitable underground pit arrangement.

MATERIAL FEEDING AND CRANE PARKING DURING BOILER


ERECTION (major portion):

i) For main boiler supporting structure erection upto drum lifting :

Crane movement / Parking : within boiler cavity .


Crane : FMC LS 248H 180MT from 1st to 3rd month , FMC LS 718 with ringer
and 330 boom and jib thereafter.

Tentative Duration : from 1st to 5th month from BES of each unit.

Material feeding :

Unit-3-

From Storage yard / pre assembly area by road though Unit-4 ( either between
mill bay-M row and boiler rear or between mill bay N row and ESP)

Unit-4

From Storage yard / pre assembly area on road

Page 12 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


ii) Pressure part erection :

Crane : All erection will be done with help of winches . For unloading 0f
material 75 MT crane will be located on RHS of each boiler.

Tentative Duration : from 6th to 18th month from BES of each unit

Material feeding :

Unit-3-

From Storage yard / pre assembly area by road though Unit-4 ( either between
mill bay-M row and boiler rear ) then on rail to boiler cavity in case of first pass
and through boiler rear in case of second pass. After drum lifting of unit- 4 is over
the materials can be fed on temporary rail through boiler-4

Unit-4

From Storage yard / pre assembly area on road then on rail to boiler cavity in
case of first pass and through boiler rear in case of second pass.

iii) For balance component like roof structure , silencer , duct , air
preheaters, fans (FD and PA ) erection:

Unit-3 LHS

Crane: Manitowoc 250MT ( 6th to 10th month ) , LS 248H (10th to 18th month)

Tentative Duration : from 6th to 18th month from BES of unit-3

Material feeding :

From Storage yard / pre assembly area by road though Unit-4 ( between mill
bay-M row and boiler rear or between mill bay N row and ESP)

Unit-3 RHS

Crane: FMC LS718 350MT ( 6th to 12th month ) , Manitowoc 250MT ( 12 th to


18th month )

Tentative Duration : from 6th to 18th month from BES of unit-3

Material feeding :

From Storage yard / pre assembly area by road though Unit-4 ( between mill
bay-M row and boiler rear or between mill bay N row and ESP)

Unit-4 LHS

Page 13 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

Crane: Manitowoc 250MT ( 6th to 18th month from BES of Unit-4 )

Material feeding :

From Storage yard / pre assembly area on road though Unit-4 ( between mill
bay-M row and boiler rear or between mill bay N row and ESP)

Unit-4 RHS

Crane: FMC LS 718 350 MT ( 6th to 18th month BES of Unit-4 )

Material feeding :

From Storage yard / pre assembly area by road.

iv) Mill erection :

unit-3
Crane : KH-500
Tentative Duration: 14th to 20th month from BES of unit-3

Material feeding :
From Storage yard / pre assembly area on road though Unit-4 ( between mill bay-
M row and boiler rear or between mill bay N row and ESP)

Unit-4
Crane : KH-500
Tentative Duration: 14th to 20th month from BES of unit-4

Material feeding :
From Storage yard / pre assembly area on road

v) ESP erection:

Crane movement / Parking: all around ESP island

Crane: 75MT , KH500

Tentative Duration: 1st to 18th month from ESP erection start of each unit

Material feeding :

Unit-3
From Storage yard / pre assembly area on road though Unit-4 ( between mill bay
N row and ESP & between ESP and ID fan)

Page 14 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

Unit-4
From Storage yard / pre assembly area on road

Enclosed Annexure-14 shows the routes through which material shall be fed.

HOLDS ON CIVIL FOUNDATIONS / OTHER CONSTRUCTION :

a) Civil Foundations : S15L&R , S16L&R, S17, S18, S19L&R, S20L&R,


S21, Mill bay M row columns 2nos at center and FD fan B (RHS) in each
boiler

This is required for erection crane movement / parking inside boiler cavity and
for ceiling girder pre assembly as explained in erection sequence.

Hold lift Hold shall be lifted as soon as crane is moved out after ceiling
girders erection i.e. 5th month from boiler erection start.

Agency to act : NTPC

b) Other Construction:

i) Mill bay M & N row structure in each unit

This will be required for FMC entry / exit and parking during boiler
structure erection in each unit.

Hold Lift : Hold shall be lifted as soon as crane is moved out after ceiling
girders erection i.e. around 5th month from boiler erection start.

Agency to act : NTPC

ii) Inter Connecting Duct / platform between boiler and mill bay in
each unit :

This is required for moving out erection crane parked on LHS of boiler for
erection of roof structure / fans / APH

Hold Lift: the hold is planned to be lifted in 12 th to 14 th month from BES.

Agency to act: BHEL

Page 15 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

iii) Duct support structure between mill bay and ESP in each unit:

This will be required to facilitate crane movement for Mill heavier


components and ESP erection .

Hold lift: the hold is planned to be lifted progressively from 18 th month from
BES

Agency to act: BHEL

iv) Duct support structure between ESP and ID fan: this is required to
facilitate crane movement for ESP erection and ID fan heavier component
erection .

Hold Lift: Hold is planned to be lifted progressively from 14 th month from Boiler
erection start.

Agency to act: BHEL

v) Mill bay N row bracings :

This will be required to facilitate crane approach for erecting mill heavier
components. The particular bracing items need to be hold will be decided at
site in consultation with NTPC.

Hold Lift : hold is planned to be lifted progressively from 14th month of BES

Agency to act : NTPC

ADDITIONAL INPUTS (Not Envisaged Originally ) TO BE TIED UP :

By NTPC :

a) Hold on foundations / structure as mentioned above


b) Finished flooring in / around boiler island and below ESP
c) Finished flooring / consolidated area for laying temporary rail

By BHEL :
a) Temporary rail / sleepers etc.
b) Bolt for omega lugs
c) Temporary structure for drum lifting
d) DESH Link temporary Dummy plates for non drainable HT

Page 16 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2


e) DG set 500KVA for Induction Heating m/c

By erection agencies:

a) Construction Power Distribution board


b) Construction power cables
c) Cable trays for above
d) Portable Cutting Gas cylinder skid
e) Cutting gas cylinder transportation trolley
f) Small workshop
g) Walkie talkies for winch control
h) Urinal arrangement on boiler

TENTATIVE ERECTION PLAN : With all above we shall complete


erection of boiler package as per the plan enclosed . ( Annexure-15)

Page 17 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

ANNEXURE - I
MASTER LIST OF QUALITY DOCUMENTS

UNIT DOC. NO.


SL.NO DOC. TITLE
CUST. DOC. NO.
1. FQP FOR BOILER & AUX. (STORAGE &
1230-001-QVG-G-1001
PRESERVATION)
2. FQP FOR STG. & AUX. (STORAGE &
1230-001-QVG-G-1031
PRESERVATION)
3.
BOILER STRUCTURE 1230-001-QVG-G-1002
4.
PRESSURE PARTS 1230-001-QVG-G-1003
5.
SOOT BLOWERS & FINE FITTINGS 1230-001-QVG-G-1004
6.
VALVES (BOILER HPBP, TG &AUX) 1230-001-QVG-G-1005
7.
FUEL FIRING SYSTEM 1230-001-QVG-G-1006
8. C&I OF STATION & BOILER & AUX. ST
1230-001-QVG-G-1046
AND TG
9.
COAL PULVERIZER 1230-001-QVG-G-1007
10.
AIR PRE HEATER AND SCAPH 1230-001-QVG-G-1008
11.
BOILER FANS (ID, FD & PA FANS) 1230-001-QVG-G-1009
12.
IGNITOR, SCANNER & SEAL AIR FAN 1230-001-QVG-G-1010
13.
SGWC PUMP 1230-001-QVG-G-1011
14.
ELECTROSTATIC PRECIPITATOR 1230-001-QVG-G-1012
15.
DUCTS, DAMPERS, GATES 7 EXP. JOINTS 1230-001-QVG-G-1013
16.
LINNING AND INSULATION 1230-001-QVG-G-1014
17.
PULVERISER FUEL PIPING 1230-001-QVG-G-1015
18.
GRAVIMETRIC FEEDER 1230-001-QVG-G-1016
19.
POWER CYCLE PIPING 1230-001-QVG-G-1017
20. STEAM TURBINE AND AUX. INCL.
1230-001-QVG-G-1032
HEATERS, CEP & DEAREATOR
21.
GENERATOR & AUX. 1230-001-QVG-G-1033
22. LP PIPING 1230-001-QVG-G-1081

Page 18 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

23. BOILER FEED PUMP (MOTOR & TUR.


1230-001-QVG-G-1034
DRIVE)
24.
DRIVE TURBINE FOR BFP 1230-001-QVG-G-1035
25.
BUSDUCT 21 KV 1230-001-QVG-G-1058
26.
MV BUS DUCT 1230-001-QVG-G-1059
27. TRANSFORMERS (GENERATOR, STATION,
1230-001-QVG-G-1060
UAT, POWER)
28.
SWITCHYARD 1230-001-QVG-G-1061
29.
HT MOTORS 1230-001-QVG-G-1062
30.
EFFULUENT TREATMENT SYSTEM 1230-001-QVG-G-1082
31.
COMPRESSED AIR SYSTEM 1230-001-QVG-G-1083
32.
VACUUM CLEANING SYSTEM 1230-001-QVG-G-1084
33.
CONDENSATE POLISHING UNIT 1230-001-QVG-G-1085
34.
CRANES EOT & MISC 1230-001-QVG-G-1086
35.
FIRE PROTECTION SYSTEM 1230-001-QVG-G-1087
36.
FUEL OIL SYSTEM 1230-001-QVG-G-1088

37.
MILL REJECT HANDLING SYSTEM 1230-001-QVG-G-1089
38.
PASSENGER CUM GOODS ELEVATORS 1230-001-QVG-G-1090
39.
TANK & VESSELS 1230-001-QVG-G-1091
40.
HVAC 1230-001-QVG-G-1092
41.
AUX. TRANSFORMER DRY TYPE 1230-001-QVG-G-1063
42.
AUX. TRANSFORMER OIL FILLED 1230-001-QVG-G-1064
43.
CABLING (HT/LT CONTROL CABLE) 1230-001-QVG-G-1065
44.
DC SYSTEM 220/24 V BATTERY 1230-001-QVG-G-1093
45.
BATTERY CHARGER 1230-001-QVG-G-1094
46. HT SWITCHGEAR 1230-001-QVG-G-1066

Page 19 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

47.
GENERATOR CIRCUIT BREAKER 1230-001-QVG-G-1067
48.
DG SET 1230-001-QVG-G-1095
49.
LT BUSDUCT 1230-001-QVG-G-1068
50.
LT SWITCH GEAR 1230-001-QVG-G-1069
51.
NEUTRAL GROUNDING SYSTEM 1230-001-QVG-G-1070
52.
STATION LIGHTING SYSTEM 1230-001-QVG-G-1096
53.
132 KV CABLE LAYING & JOINTING 1230-001-QVG-G-1071
54.
GAS CONDITIONING UNIT 1230-001-QVG-G-1018
55.
FABRIC EXPANSION JOINT 1230-001-QVG-G-1019
56.
DIVERTER DAMPER 1230-001-QVG-G-1020
57. CONDENSER ONLOAD TUBE CLEANING
1230-001-QVG-G-1036
SYSTEM
58.
TURBINE INSULATION 1230-001-QVG-G-1037
59.
CONDENSATE STORAGE TANK 1230-001-QVG-G-1097

Page 20 of 21
BHARAT HEAVY ELECTRICALS LIMITED
Power Sector Western Region
NAGPUR

ERECTION STRATEGY FOR BOILER NTPC RIHAND STPP STAGE-2

LIST OF CE T&P AND SPECIAL EQUIPMENT

T&P BEING PROVIDED BY BHEL:

Sl. Description of Equipment Qty Range / Accuracy Work Area


No. Capacity
A MM Package
Fire Retardant / PVC 100 10x8M
Tarpaulins
B Erection Package
1. Telco TFC-280 Crane 1 75 T NA Boiler Erecn.
2. Telco TFC-280 Crawler 1 75 T NA ESP-1
Crane
3. Telco 955 ALC Crawler 1 75 T NA Boiler
Crane
4. Telco 955 ALC Crawler 1 75 T NA BOP
Crane
5. Telco 955 ALC Crawler 1 75 T NA ESP-II
Crane
6. Link-Belt LS-718 with 1 325 T NA Boiler
Ringer (FMC)
7. Telco KH-500 Crawler 1 100T NA Mills / Rot.
Crane M/c.
8. Manitowoc M-250 T Truck 1 250 T NA Str. / Roof
Crane top.
9. Passenger Cum Goods Lift 1 1T NA Boiler-I
1T
10. Passenger Cum Goods Lift 1 1T NA Boiler-II
1T
11. E/O Pipe Bending M/c. 2 4 NA Boiler /
Piping.
12. Electric Scraper 2 NA Blr./ PCP/ TG
13. Hydraulic Test Pump 2 600 NA Boiler
Kg./CM2
14. Hydraulic Test Pump 1 450 Kg NA Boiler / PCP
15. Induction Heating 6 125 KW/3 NA Boiler / PCP
Equipment MHZ
16. Fogging M/c. 1 NA ESP
17 E/O Winch with rope 2 15 T NA Boiler Drum
18. Multi Sheave Pulley Block 4 300/200 T NA Boiler Drum
15 sheave.
19 Single Sheave Pulley Block 10 10 T NA Boiler
20. Acid Cleaning Pump with 7 200 TPH NA Boiler
control Panel
14. Huck Bolting M/c. 4 NA ESP

Page 21 of 21