PT.

Nusareka Prima Engineering

Construction & Maintenance Service for Industrial and Power Plant.

BOILER ERECTION/INSTALLATION

Address : Ruko Golden Madrid II Blok I No 25, Jln. Letnan Sutopo, BSD - Tangerang Selatan 15323
Phone : +62-21 53164920, Fax : +62-21 53164921, Email : project.admin@nusareka.com, Website :
www.nusareka.com

FIELD CONSTRUCTION OF BOILER

One of the first activities of the field

construction phase is the verification of the
accuracy of all concrete foundations for the
boiler. All column to column dimensions,
anchor bolt locations, and concrete
elevations are measured and Verified
against the drawings.

Address : Ruko Golden Madrid II Blok I No 25, Jln. Letnan Sutopo, BSD - Tangerang Selatan 15323
Phone : +62-21 53164920, Fax : +62-21 53164921, Email : project.admin@nusareka.com, Website :
www.nusareka.com

STRUCTURAL STEEL ERECTION

The steel erection
begins with the main
boiler columns, beams
and braces usually
starting on the turbine
and steam drum sides
of the unit. Then the
main girders are
erected. They support
the main boiler sections
and the steam drum
from the top of the
unit. There are many
girders located within
the main boiler support
steel. Similar sized
girders are used for
supporting the fuel silos
and the airheater.

MAIN-GIRDER ERECTION

Main girder erection is one of many rigging problems of the structural steel erection process.
The most accepted method of lifting the heavier girders is as follows: Once the girder is raised
above the column tops, bring the girder parallel to the front of the boiler. The girder can then
be connected to the upper ends of the columns. Once the girder is in place, intermediate
steel can be installed to tie all of the upper steel together. Coordinated radio communication,
highly experienced operating engineers and rigging supervisors, and first-class equipment are
imperative for successful girder erection.

STEAM-DRUM INSTALLATION

The steam drum can be raised into position at the top of the boiler once the main girder steel, vertical and horizontal bracing, have been
erected and completely bolted. The drum is hung just below the main girder steel by means of huge U bolts that encircle the drum

Ensure the direction of steam drum is correct since loading on the port
Prepare all rigging tools to be used.
Ensure that ground condition stability is enough to support transporter to
transfer the steam drum to lifting area.
The drum is hung from the main structure by two U type strap hangers. To
easier lifting operation and facilities the erection of hangers, the U road
hangers shall be assembled at ground level or the drum in order to be lifted
simultaneously.
The hanger threads are clean, to check nuts onto rods and Joints of U
roads- attention of the threads

Before steam drum lifting, drum should be hanging 1 meter from ground
floor and check by measuring tools the position of drum, hold for one hour to
see there are decline or not of the stem drum, this is to ensure that the lifting
tools is good condition
Lift up the steam drum around three(3) meters height then and tie in with wire
sling.
Stop the crane no 2 and lift up the crane no 1 to decline steam drum position
until 30 degree, until steam drum free from any obstruction.
After steam drum lifted to the final elevation, lock jack 1 and lift up jack 2 to
straight steam drum in horizontal position

The drum lift and positioned at the elevation appropriate and the operations of
hydraulic jack shall be locked.
The drum are moved towards to front boiler direction by slide steam drum in
temporary rail until final position.

STEAM DRUM INSTALLATION

After the drum is set in position, the below
mentioned alignment is carried out to confirm
the centre of drum along X and Y axis. The
levelness measuring and checking of steam
drum can be carried out by selecting 2 points
on each of the left and right end.
The elevation reference point of steam drum
on the steel columns marked.

Tighten the nuts of hangers in order to reach

perfect contact of all parts
Simultaneously release the hydraulic jack
system and dismantle the lifting equipment.
On completion of positioning the drum, the
confirmation of the tension on the U road is
necessary. The tension on the each strap
must be equal to the down load

PRESSURE PARTS SUPPORT STEEL ERECTION

While the steam drum is being erected, the pressure parts support steel can be installed. This
steel, located at the top of the unit, supports the weight of the boiler. Unlike conventional
structures that are built from the ground up, most modern boilers are built from the top down,
with the furnace suspended by constant load springs (locked) and the backpass suspended by
rigid hanger rods all from the main girders. This permits the furnace to expand upward and the
backpass to expand downward during the start up of the plant. The correct setting of the
pressure parts support steel is very important because every part of the boiler is located with
respect to this steel. It controls all elevations and is continually used as a reference to align the
different components as they are erected.

HANGER RODS

HANGER RODS
INSTALLATION

DOWNCOMER PIPE INSTALLATION

The downcomers from the steam drum to the lower water wall and
FBHE evaporator inlet headers are raised into place after the
above-mentioned work is completed. Each downcomer requires about 3
sections. Rigging must be located underneath the steam drum itself,
because the downcomers are welded directly to the drum nozzles. Clips
are welded on the ends so that threaded rods can be inserted to raise or
lower the downcomer a few inches for proper positioning for welding.
As soon as the downcomers are in place, welders can begin the fit up
and welding procedures that will ultimately join the downcomers to the
drum. Large, welded joints must be ground smooth for stress relieving
and radiography.

DOWNCOMER PIPE

DOWNCOMER PIPE LIFTING

CONNECT DOWNCOMER PIPE SPOOL

TOP HEADERS INSTALLATION

The capacity, number of sleeve pulleys, lifting wire

rope diameter and guide pulley location etc. is to
be decided at site based on the weight of the
header and position of the lifting winch.
While lifting the header a tag line must be used to
control the load(movement of header)
Lift the header and place it at match the header
axis with the centre line marked and connect the
hanger rod with the header lugs using the pins
Note: provided the correct size of cotter pin
Check the elevation of the header, orientation,
horizontally and distance from reference axis
before arresting the header.

PREPARATION HEADERS
INSTALLATION

HEADER IMAGES HAVE BEEN INSTALLED

WATER WALL & BACKPASS PANEL ERECTION

Once the sootblowers and buckstays have been laid on the

grating temporarily, the waterwalls which form the sides of the
furnace can be erected. The waterwalls are sections of tubes
that are fin welded together into a gas tight panel. They
conduct a mixture of steam and water upward as heat is
applied from the furnace side. The walls extend from the base
of the boiler up to the steam drum level.
Typically waterwall panels are brought into the furnace on a
flatbed truck or its equivalent. Because they are so Iong and
flexible, the biggest problem with these panels is upending
them. Two lines are needed. The crane in the hole lifts the top
line; a cherry picker, the other. Sometimes, a special lifting
device distributes the weight so the panel will not buckle. This
requires that several slots be cut in the welded web between
the tubes. A bar welded to a small T beam is inserted and
pinned on the back. This device assists in keeping the panel
straight along its width during upending process. When the
panel is vertical, it is lifted up to its final position.

WALL WATER AND BACKPASS PANEL ERECTION

WATER WALL PANEL ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

COMBUSTOR
COMBUSTOR
COMBUSTOR
COMBUSTOR
COMBUSTOR
COMBUSTOR
COMBUSTOR
COMBUSTOR
COMBUSTOR
COMBUSTOR

UPPER RIGHT SIDEWALL ASSEMBLY

UPPER LEFT SIDEWALL ASSEMBLY
UPPER REAR WALL ASSEMBLY
UPPER FRONT WALL ASSEMBLY(4)
INTERMEDIATE REAR WALL ASSEMBLY
LOWER RIGHT SIDEWALL ASSEMBLY
LOWER LEFT SIDEWALL ASSEMBLY
LOWER FRONT WALL ASSEMBLY(3)
LOWER REAR WALL ASSEMBLY(3)
LOWER RING HEADER ASSEMBLY

BACKPASS WALL PANEL ASSEMBLY

1.
2.
3.
4.
5.
6.
7.
8.
9.

BACKPASS ROOF AND ECONOMIZER OUTLET HEADER

ASSEMBLY
BACKPASS UPPER RIGHT SIDEWALL ASSEMBLY
BACKPASS UPPER LEFT SIDE WALL ASSEMBLY
BACKPASS UPPER FRONTWALL ASSEMBLY
BACKPASS UPPER REARWALL ASSEMBLIES(3)
BACKPASS LOWER RIGHT SIDEWALL ASSEMBLY
BACKPASS LOWER LEFT SIDEWALL ASSEMBLY
BACKPASS LOWER FRONTWALL ASSEMBLIES(3)
BACKPASS LOWER REARWALL ASSEMBLIES(3)

COILS ERECTION
FINISH SUPERHEATER INSTALLATION

Assembly the Finish super-heater element on ground

floor. Assembly with hangers tube.

The element will be erected from below, lifting by

crane, lift one by one until the lower the roof lifting
by chain block, One element positioned seal weld
the tube end of the super heater element to the
level above, final joint at hanger tube on top roof.

Some fitters will be fitted-up tube element to header

of side wall and lower header of finish super-heater

Preparation to lift the

superheater

Setting position of the

superheater

Connection pin tube of the

superheater to the header

COILS ERECTION
ECONOMIZER INSTALLATION

The economizer, located just above the air preheater, can be erected.
This is a heat recovery device designed to transfer heat from the exiting
flue gases to the incoming, boiler feedwater. The economizer consists
of an interconnected horizontal bare tube array. The upper ends of
each economizer assembly connect to the outlet header, which is
already in place above the roof tubes.

Economizer assemblies are raised into place from the around with a
tugger rigged in the area of the outlet headers. Banks of economizer
elements can be pre assembled in groups. Pins and rods usually
support the assemblies directly to lugs welded to the bottom of the
intermediate headers. Because the economizer tubes are often
fabricated in a staggered pitch to increase heat transfer and minimize
space requirements, fitting the last few elements sometimes presents a
rigging problem. It is difficult to pass hoisting falls through the
staggered tubes. This often means that the already installed elements
must be spread apart and the side walls must be moved out.

BOTTOM HEADER ERECTION

All the lower headers will be erected using

sling with variety of capacity depend on each
weight of the headers. After the headers
hanged to their position the fit up checked
by QC and then continued to welding job.
Typically, the lower waterwall headers are
the last lifts made and are installed after
most of the pressure part welding has been
completed. The headers extend the full
width and depth of the furnace. Once
headers are in position, they are welded to
the side, front and rear waterwall panels.

BOTTOM HEADERS

BUCKSTAY ERECTION

The buckstays are structural

shapes that restrain
movement of the waterwalls
caused by fluctuation in
furnace pressure. Buckstays
should be temporarily set,
prior to furnace and
backpass wall erection, on
the boiler steel elevation
closest to the buckstay's final
location. After the furnace
and backpass panels are
aligned, buckstays can be
installed.

Backpass buckstays
Combustor buckstays

BUCKSTAY ERECTION
The buck stay which has storage on the boiler steel structure can be Fitted up start from bottom panels to
the top for the safety as well as accessibility. These are some more importants notes :
Setting work should be performed after aligning panels. Panels located in the place where buckstays are to be
installed should be seal welded.
Fix Buckstays by inserting the guide pins to tie bar lugs which are welded to the panels.
Erection sequence of buckstay installation :
1. Set the position of buckstays which tie bar assembled on the furnace / boiler wall then tie bar are
positioned between two raws of guide bar. Temporary insert undersized pins through the guide bars to hold
the bulk stay assembly in place. Then check the buck stay level based on
furnace wall to confirm .
After that install the guide pin supplied from the manufacture across the furnace wall and make sure not to
bend any of the supplied pin .
2. Weld tie bar at the corner of the buck stay assembly and check the furnace cavity for square and angle
3. Next fit up the corner connection plate and the tack weld them into
position . Clamp the stand off bar to the web of I Beam (buck stay
beam ) and verify the preset dimension to be accurate.
Then stand off bars can be welded to the web . Finish corner
connection plate welding above and below and then attach the
linkage bar with the pin provided (according to drawing ) . Inserting
pins shall not using hammer.
Support : Attach the clips to the lugs provided on the convention pass rear wall for this purpose with the
support rod attached to the angle on the back side of the economizer support bar with a lock washer and nuts
. Weld the angle to the economizer support bar and tack weld the nut to the support rod after nut tightened .

FUEL AND LIMESTONE FEED SYSTEMS ERECTION

The fuel and limestone feeders should be placed at elevation during
structural steel erection, if possible.
Early placement of this equipment minimizes handling and rigging.
FUEL SILO HOPPERS

FUEL SILO

FUEL FEEDERS

DUCTWORK ERECTION

Ductwork erection can be completely integrated with boiler erection to avoid problems in fitting
ductwork sections into the structural steel framework.
The boiler ductwork consists of two main systems; the air supply system, which includes the primary
and secondary air and the flue gas system, which includes the backpass ash hopper and ductwork to
the air preheater, precipitators, induced draft fans, and stack.
The primary and secondary hot air ductwork from the airheaters to the furnace contains some of
the biggest pieces of equipment on the boiler. Because of the sizes involved, ductwork is generally
assembled on the ground with sections installed simultaneously with the structural steel. Hanger
rods and expansion joints in the ductwork allow for thermal expansion. Hangers and ductwork
supports should be installed prior to erecting ductwork.

Primary air system

Secondary air system

DUCTWORK ERECTION
The gas system ductwork extends from the bottom of the economizer to the
exit side of the tubular airheaters. It also includes the ductwork from the
airheater to the precipitator, to the induced draft fans, and to the stack. Most
of this ductwork is installed after the airheater is in place.

Economizer outlet

Air Heater

Gas Duct System

To Baghouse

WELDING OF ERECTED COMPONENTS

As the boiler erection has proceeded, the different components have been raised and hung by
hanger rods, springs or temporary rigging. After a group of components is installed, the fit up and
welding must be performed. Except for the structural steel, which is most commonly bolted together,
almost everything else on the boiler is welded.

PT. Nusareka Prima Engineering

Construction & Maintenance Service for Industrial and Power Plant.

THANK YOU FOR YOUR

ATTENTION

Address : Ruko Golden Madrid II Blok I No 25, Jln. Letnan Sutopo, BSD - Tangerang Selatan 15323
Phone : +62-21 53164920, Fax : +62-21 53164921, Email : project.admin@nusareka.com, Website :
www.nusareka.com