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Coal Bin: --- coal bin is the storage for coal used as fuel for furnace. Shape of bins may
be circular, polygonal, square, or rectangular in plan. Bottom hopper portion is generally
conical-cum-hyperbolic or any other profile shape. Bins are termed as bunkers or silos
according to their shape and plane of rupture of coal. The bins are fabricated and
erected in segments and are made of mild steel plates joined together with full strength
butt weld and provided with stiffeners at regular intervals. Stiffeners are also provided on
external face of the coal bunkers.
The bending of plates and rolled sections to the required shape for fabrication is done by
plate bending machine without resorting to heating, hammering, angle smithy or black
smithy process.
Poking holes (manual or pneumatic ) and striking plate shall be provided to facilitate coal
flow .Poking holes have circular MS pipe and cover cap as detailed in attached drawing
below.
AT Bhilai project we have circular type coal bunker with conical type hoppers and a ring
beam in between that connects the cylindrical shells with hopper below. The ring beam
rests at 29.00 m with the support of main support beams.
The coal bunkers are made up of IS 2062 Grade B MS plates of thickness 12 mm and 8
mm with provision of lining by SS plates of grade SS 304M
Reasons to use strand jack method for erection of silos instead of conventional method
of erection by crane:-
Customer was aggressively asking BHEL to complete the tripper floor suggesting that it is
required for erection of conveyer and tripper, due to this change in sequence of erection
and floor completion, TRIPPER FLOOR was casted .Now it became impossible to get
erected all bunker by conventional method of erection by crane, as we have to feed the
various shells in parts from top.
It was then decided, after protracted discussions within BHEL as well as with our
associate for structural fabrication and erection M/s L&T, to finalize strand jack method
for erection of coal bunkers using the FEEDER FLOOR. M/s L & T then proposed a
suitable erection scheme in line with BHEL set targets and keeping in mind safety
aspects as well as quality aspects.
a) Manpower involved:-
1) Gang of ten labors for 1 man day @ 165/day = 1650
99000 Per silo
Total = Rs 99000 per silo
Grand Total = Rs 12870000.00 for 13 silo
(A)
b) T&P Involved:-
2) Two no hydra (12 T cap) = 177600 for one month
1598400 for nine months
Fit up involves fixing up of shell with the places above maintaining verticality/circularity.
Fit up of ring beam is in two pieces to facilitate erection. Hopper is to be Fit up
completely at feeder floor and then lifted up for assembly to the ring beam.
b) T&P Involved:-
2) Stand jack fixing arrangement for 14 mandays per silo= 4200 per silo
Rs 54600 for nine silos
T&P Involved:-
a) Strand jack Hire Charges per jack = 15000 150000 per silo
1) lifting arrangement at shell for lifting through hooks= 59247.908 per silo
Rs 770222.8 for 13 silos
2) rail arrangement at feeder floor grid 12-13 upto grid 2-3
3) MC 150used for a 14736 mm length of 84 mtr
4) platform extension at 12-13 grid=
MB 600 used for 21834.222 mm length of 17 mtr
5) strand jack support beam arrangement at tripper floor=184310.48
6) Strand jack support beam arrangement dismantling & fixing at new position=
For 5 times in a set of 1612716.5 three jacks
Grand Total = Rs. 2603819.72 (I)
Total Amount = Rs. 32,141,330.72 (A+B+D+E+F+G+H+I+J)
Notes:
Technical reasons for delay in Bunker erection at 2x250 Mw Bhilai Expansion Project
01. Delays in engineering and release of RFC drawings for silos and hopper.
Drawing for coal bunker (RFC) was received at site on 17//07/07.Normal duration for
fabrication and erection of silo & hopper structure work is around 12-14 months from
the date of receipt of RFC drawing including ordering and receipt of required structural
material at site. Earlier fabrication for hopper was supposed to be from SS 409 M vide
email from Fichtner /PEM on 27/09/06(SS 3.15 mm thick SS304 M plate for cylindrical
shell liner ,8 mm thick SS 409 M plate for hopper bottom plate).However it was put on
hold for the propose of re-engineering of hopper portion as there was a crack in hopper
portion at simadri TPS.For the reason sited above it was decided to design hopper using
both MS and SS plates ,this decision of re- engineering which includes aerodynamic flow
study of coal through hopper portion took several months which led to our inability to
initiate any procurement action. We could get BOQ for Hopper only after 19/07/07 with
combination of 8 mm MS plate as base and 4 mm SS plate as liner for hopper portion
.This means a delay of almost 10 months in engineering led to structural steel
procurement delay.
02. Delays in structural material procurement.
After receiving RFC drawing on17/07/07, planning for material procurement showed
special requirement of 12 mm plate (size 1250 mm length and 2500 mm width) to avoid
vertical joints in shell. We had to place separate order for this special size of MS plate of
12 mm thick required for cylindrical portion of silo. Further material from BSP/SAIL also
could not receive in time and in one lot. Whole material was also not received in time.
Crane avaibility for Bunker/silo erection work has also been on shared basis with
mechanical agencies which has on some occasions resulted in slowing down of progress
.Initally,it was planned to erect silos by heavy lift crane only and after erection of silos
,floor beams for Tripper floor were planned to erect and do the slab casting of tripper
floor subsequently however ,on great insistence/pressure from customer to give front
for erection of coal handling equipments/conveyer on tripper floor ,erection of bunker
was planned by strand jack method.
ERECTION SEQUENCE:-
Erection scheme proposed and implemented by M/S L&T is as follows:
It was proposed to set up four nos. strand jack at tripper floor controlled by one power
pack (used to operate strand jacks). Such three sets of four nos. jack will be used for
erection of three silos as parallel activities. One single jack has capacity to take load
equals to 105 MT, if seven wires are used to hold the material of heavy lift. Lifting lugs
and anchor plates were design for holding shell by wire coming out from strand jack. All
four jacks was set up on built up beam meant of double I-section union i.e. base of jack
rest on it. Four nos. holes at different angles from center point of bunker were made at
tripper floor to pass on strand of jack through it, to hold anchor plate of top shell portion.
Shell shall be feeded at feeder floor by use of crane and kept at built up trolley specially
designed to take load more than the load of member to carry it to specified position.
Then strands are fixed with anchor and lifting lug and it is lifted to height in accordance
to accommodate second shell/hopper piece/Ring beam. After that union of two was
completed as per FQP and again lifted to accommodate third pieces. Same will be
followed for every silo. After completion of erection of six shell and Ring beam in two
pieces.Erection of 8 nos 29.00 mtr beam and subsequently erection of 8 nos. stub
column is executed and as per drawing along with it bracings. Locking of stub column by
stitch welding with 29.00 mtr beam and its bracing is completed and after that jack can
be release. Means load can be transferred through 29.00 mtr beam assembly to
secondary beam of frame and then to VB and HB and columns and ground through base
plate. Then we can use this set of jack for erection of other silos.
CONTROL POINTS:--
1. Proper fit up to maintain gap for welding using long cleats ,to maintain circularity.
2. Proper Edge preparation.
3. Maintaining plumb for control of center position to match with feeder coal pipe.
5. Ensure proper supply to welding generators/rectifiers.
6. Safety controlles like safety belt, life line rope, goggles for welder. Strong supports,
strong, Wire ropes, slings used, pulley fixed, electric winch load capacity test and its due
dates.
7. Night works with proper illumination with flood lights. Adequate safety for working at
heights should be maintained at all times. Daily safety talk should be provided to
workers.
8. Ensure proper fabrication backup to support erection team.
9. Proper housekeeping which minimizes risk of hazards. (At 17 mtr feeder floor)
10. Proper planning for next day job and realization of job at the end of the day, keeping
in view the last target date of its completion. Constant and continuous follow ups
required and optimum utilization of all T&P‘s with proper mobilization of expertise
manpower. As in this project silo supporting bracing gang got expertise in erection and
their productivity becomes higher.
11. If any change in sequence of erection is required as per site requirement, we should
keep in mind the effect of such changes for all future projects.
12. Keeping record of all dismantling and re-erection of the same such that it becomes
easy to process the item claim against it in contractor’s bill.
13. Constant watch on DPR (Daily Progress report) of the project.
PROBLEMS ENCOUNTERD:--
1. Mismatch of PCD bolt dia hole made to connect with coal pipe of feeder.
2. Due to change in erection sequence 29.00 mtr main beam flange was required to be
cut at eight positions to avoid fouling of strand jack erection hooks. It was corrected after
erection completion.
3. Clashes between two agencies working at feeder floor.
4. Sometimes non-availability of construction power.
5. Slow down of work progress during rainy season, specially welding and painting.
7. Labour strikes.
A circular inside support system is prepared (three nos.) for easy and safe working while
doing finishing, welding, grinding of joints etc inside the shell. Support system is
generated from the scraps and its makes the working inside shell so easy. It is kept in
hanging position by using slings supported from tripper floor (as shown above in
photograph). It can be easily positioned at required place. After completion of all jobs
from inside, it is dismantled and removed from inside.
Hopper portion and its erection:-
Final inspection protocol
Final inspection joint protocol was prepared with our customer for clearance of bunker
from inside .Erection in charge (civil) from BHEL and customer and commissioning in
charge will physical witnessed the completion of job and certify that, now bunker is ready
for coal feeding. Protocol includes opening closing from top, chute completion,
cleanliness from inside and removal of all temporary supports from inside of bunker.
While checking if some of the punch point given by our customer, then it has to be
attended immediately and again requisition is given to customer for re-inspection of the
same.
After completion of final inspection, no works inside the bunker is permitted.
Gantry crane in fabrication yard M/S L&T:-
This crane is used for shifting u/p fabricated material within the fabrication yard.
Outside stiffening of shell:-
Stiffeners are welded outside the shell surface, generally using 12mm plates to
strengthen shell.
Silo supporting bracings: -
COAL BUNKER
Chute deflector plate
Fixation details of SS plate at MS plate
DETAILS OF SILO SUPPORTING BRACINGS AT
29.00 mtr Elevation