Welcome to Power Plant Erection

Presentation on Erection of Steam Generators

Erection of Steam Generators

TONNAGE SCHEDULE OF SG
10000

6000 6500

1500 4000
Structures Ducting Pressure Parts Fuel Oil system& piping
Erection of Steam Generators

4500
Rotary Machines & Mills ESP
2

1.0 Sequence of erection

Erection

columns

of Main and Auxiliary of MBLs (Main Brace Level) of Ceiling Girders

Erection Erection Boiler

Drum Lifting
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Erection of Pent House Headers and Roof Erection of Water Wall tubes and Ring Header Erection of Super heater coils, Reheater coils, Economizer coils and Eco inlet header Erection of Back Pass Roof, steam cooled walls and back pass lower headers

Erection of Steam Generators

 Erection

of Eco link, MS Pipe and RH inlet & outlet pipes. test of Boiler and Trial of FD fan and Trial of SAPH of Secondary Air path
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Hydro

Installation Installation Completion

Completion of Flue Gas path with Flap Damper Installation and Trial of coal mills Boiler Light Up with LDO/ HFO/Coal Alkali Boil Out, Acid Cleaning Steam Blowing
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 Synchronization Trial PG

of unit

operation

Test Over to O&M Group

Handing

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2.0 Documents Required

Erection Drawings
Category 1 Drawing: Approved by NTPC Category 2 Drawing: Subject to comments Category 3 Drawing: Not Approved Category 2 Drawing: Taken for information (Only conceptual drawing) Contd
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2.0 Documents Required

WPS FQP (Field Quality Plan) Welding Schedule Contract Documents (e.g. LOA, LOI, NOA Scope of work, General &Special condition of contract etc.)

Erection of Steam Generators

3.0 T&P Requirement

FMC-LS-718 Crane : 1 No.: 350 MT capacity with ringer FMC-LS-248 Crane : 1 No.: 150 MT capacity KH-700 Crane : 1 No.: 150 MT capacity KF-500Crane: 1 No.: 100 MT capacity TFC-280 Crane: 6 No.: 75 MT capacity TFC-75 Crane: 1 No.: 25 MT capacity Winches : 15 No. (of capacity 2MT,5MT, 10MT, 20MT) Winches : 2 No. (of capacity 30MT) Chain Pulley Blocks, Hook chooks & Wire rope slings as and when required.
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4.0 Erection Strategy

Preassembly

: The main tool to reduce the project cycle time Sequence : The foresightedness of the Executer

Erection

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5.0 System of Nomenclature of contractor (e.g. BHEL)

PG MA DU

(Product Group) (Main Assembly) No. (Dispatch Unit number)

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12

6.0 Project Cycle Time

36

months for Coal firing & Synchronization months for Completion of Trial operation & PG Test.

42

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SL NO

MILESTONE 1Establishment Of Site Office

MONTHS (FROM NOA) 6 8 11 15 26 30 31 32 33 34 35 36 36

REMARKS

1.1Mobilization Of Installation Staff At Site 2Commencement of Boiler Erection 3Boiler Drum Lifting 4 Boiler Hydraulic Test (Drainable) 5Readiness of SG C&I for Boiler Light up 6Readiness of ESP 7Boiler Light Up & Alkali Boil out Acid cleaning completion 9Steam Blowing completion. 10Safety valve Floating 11Steam to TG Set 12Coal Firing
Erection of Steam Generators

Approx. Tonnage 17% Approx. Tonnage 61%

Approx. Tonnage 81%

Approx. Tonnage 95%

14

QTY (MT) 1000 1500 2000 2500 500 0

MONTH 0

OC NOT'02 DEV'02 JAC'02 FEN'03 MA B'0 R AP 'O33 MAR'03 JUY'03 JU N'0 L AUY'033 SEG'03 OCP'03 NOT'03 DEV'03 JAC'03 FEN'04 MA B'0 R AP 'O44 MAR'04 JUY'04 JU N'0 L AUY'044 SEG'04 OCP'04 NOT'04 DEV'04 JAC'04 FEN'05 MA B'0 R AP 'O55 MAR'05 JUY'05 JU N'0 L AUY'055 SEG'05 P'0 5

B L R # 3 M O N T H Erection 4 M O N Generators# 3 C U M M .L R # 4 C U M M . B Y R # of Steam T HBL LYR LL B 5000 10000 QTY (MT) 15000 20000 25000
15

M O N T H L Y E R E C T IO N D E T A IL S O F B O IL E R
30000

H P E Q U IV A L E N T J O IN T C O M P L E T IO N D E T A IL S
7000 6000 5000 JOINTS (NO.) 4000 3000 2000 1000 0
JU LY AU '03 G'0 SE 3 P'0 OC 3 T '0 NO 3 V'0 DE 3 C'0 JA 3 N' 0 FE 4 B MA '04 R'O AP 4 R'0 MA 4 Y'0 JU 4 N JU '04 LY AU '04 G'0 SE 4 P'0 OC 4 T NO '04 V DE '04 C'0 JA 4 N' 0 FE 5 B MA '05 R'O 5

35000 30000 25000 15000 10000 5000 0 JOINTS (NO.) 20000

MONTH U # 3 M O N T H U Y# 4ErectionNof Steam#Generators M U L A T I V E4 C U M M U L A 16I V E L M O T H UY 3 C U M L U # T

MONTHLY MT 1000 900 800 700 600 500 400 300 200 100 0

M O N T H L Y T O N N A G E D E T A IL S O F E S P

MONTH

OC NOT'02 DEV'02 JAC'02 FEN'02 MA B'0 R AP 'O32 MAR'03 JUY'03 JU N'0 L AUY'033 SEG'03 OCP'03 NO T'03 DEV'03 JAC'03 FEN'04 MA B'0 R AP 'O44 MAR'04 JUY'04 JU N'0 L AUY'044 SEG'04 OCP'04 NO T'04 DEV'04 JAC'04 FEN'05 MA B'0 R AP 'O55 MAR'05 JUY'05 JU N'0 L AUY'055 SEG'05 P'0 5

E S P # 3 M O N T EErection of Steam N T E S Y # 3 C U M EMS. P # 4 C U M M . H S Y # 4 M O Generators LP HLP 17 1000 CUMMULATIVE MT 2000 3000 4000 5000 6000

7000

7.0 Budget
7.0 (A) Contract Value for Korba, Stage- III (1X500 MW) under LOI No. 4669 Description Prices (Rs) 10 20 30 Ex Works Price for main equipment 8,49,50,00,000 Ex Works Price for mandatory spares Type Test Charge TOTAL 36,50,00,000 3,25,00,000 8,89,25,00,000

Total in words: Rupees Eight Billion Eight Hundred Ninety Two Million Five Hundred Thousand Only.

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7.0 (B) Contract Value for Korba, Stage- III (1X500 MW) under LOI No. 4670
Sl No 10 Description Unloading, receipt, handling, storage, complete installation, supervision, pre commissioning, commissioning, completion of facilities, conducting guarantee tests Local transportation including port clearance & port charges and inland insurance charges for main equipment Local transportation including port clearance & port charges and inland insurance charges for mandatory spares TOTAL Prices (Rs) 86,00,00,000

20

19,35,00,000

30

1,40,00,000

1,06,75,00,000

Total in words: Rupees One Billion Sixty Seven Million Five Hundred Thousand Only.
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8.0 Scope of Work Under SG Package

Furnace

Risers

,Water Wall Headers, Tubes,

Drum Super

with internals and fittings

heaters, Re heaters & Economizer with its auxiliaries

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 Water

circulation pumps with drives and coolers type attemperators with valves and accessories valves and fittings for boiler & aux. blowing system
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Spray

Complete

Soot

Thermal insulation for the boiler and piping FD fans with silencers (2 no. per unit) Motors for the above ID fans (2 no. per unit) Motors for the above

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Regenerative air pre heaters 4 No. per unit (2 no. PAPH &2 no. SAPH) Steam coil air pre heaters4 No. per unit Coal preparation system which includes raw coal chutes, bunker shut off gates and raw coal feeders. Coal pulverisers with motors (10 no. per unit) Bowl & Roller type XRP1003
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 Seal Coal PF

air fans (2 No. per unit) burners

piping and ceramic bends ducting

Complete Dampers

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 Fuel

oil system

Galleries,

stairways, walkways, roofing, handrails, platforms, gratings etc. precipitators

Electrostatic Cranes

and hoists
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9.0 Constructional Details Of Boiler

Design

Wt. of each unit (Boiler + ESP):32000 MT Approx. of ceiling girders : 6

No

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 Elevation

of T.O.S. of main columns

84.945 m
Type Type No.

of Main columns: Star section of aux columns: Box section

of HP joints: 27000 approx.

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 No No No No

of Coal elevations of Oil elevations

: 8 to 10 : 4 to 5

of front & rear WW tubes : 269 of left & right side WW tubes: 212

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No of blocks in Eco system No of rows of Eco system coils No. of tubes in one coil of Eco No of blocks in LTSH system

: 2 to 3 : 184 :6 :2

No of rows of LTSH system coils : 124 No. of tubes in one coil of LTSH
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:6
29

 No

of rows of RH system of tubes in one coil

: 74 : 12 : 25

No. No

of rows of Platen coils

No.

of tubes in one coil of Platen : 16

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 No

of rows of Divisional SH system coils :6 No. of coils in one row of Div. SH :8 No of tubes in one coil of Div. SH :9
No

of LRSB No of Wall blowers

: 34 : 88

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 FD

fan : 2 No, AXIAL AP1-26/16, Blade pitch control, 980 rpm, 1300 kw motor PA fan : 2 No, AXIAL AP2-20/12, Blade pitch control, 1480 rpm, 2950 kw motor. ID fan :2 No, NDZV 47 SIDOR, Inlet damper + VFD control, 580 rpm 4050 kw motor
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10.0 Constructional Details of ESP

ESP No No

efficiency: 99.914 %

of ESP passes: 4 pass per unit of fields : 8 fields/pass

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 Total

no. of collecting electrodes per boiler : 11712 Nominal length of collecting el : 13 m Nominal length of collecting el :750 mm Type of emitting el: Spiral with hooks Size of emitting electrode: 2.7 mm dia. Total no of emitting electrodes per boiler : 1,03,680
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 Rappers

for collecting electrodes

No. of rappers: one drop hammer per row Rapper size: 4.9 kg Frequency of rap: varying from 20 raps per hour at inlet field to 1 rap per hour at the exit field.

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 Rappers

for emitting electrodes

No. of rappers : Approx. one drop hammer for two rows of electrodes. Rapper size : 3.0 kgs Frequency of rapping: 10 raps per hour No. of hoppers per unit: 32

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11.0 Insulation Details

Mineral Wool Pourable Refractory Castable Refractory

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12.0 Stress Relieving of Ceiling Girders

Heating up to 620 degree: Web- @ 65 deg/hr Flange - @75 deg/hr Soaking: At 620 degrees for a time period of Web - 96 Min. Flange - 135 Min Cooling: @ 65 deg/hr for both flange & web up to 300 degrees and then left for natural cooling.
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13.0 Boiler Mountings

Location Safety Valves Drum SH outlet RH SV ERV Inlet Outlet(1) Outlet(2) Soot Blower Water Drum level indicator DWLG EWLI No 2 4 2 5 4 4 4 1 2 4 ----------------------Set Pr.(Kg/cm2) 207.0,209.0 211.1,211.1,213.2,213.2 188.5,188.5 185.5,185.5,186.6,186.6,186.6 52.4,52.4,54.0,54.0 49.4,49.4,50.9,50.9 48.4,48.4,48.9,48.9 40

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14.0 Materials used in Pressure Parts

Material
SA 335 P91 SA 213 T91 SA 213 TP 347H SA 213 T22 SA 213 T11 SA210Gr C

Area of Application
(MS line) (Re heater stage-II, SH Platen & Divisional) (Platen& Div. SH, RH, SC spacers) (Platen& Div. SH, RH tubes) (Radiant Roof, LTSH ) (WW panels, UCT, LCT,WW hanger tubes, WW screen tubes, WW bottom Hdr nipples, BP SC wall tubes, BP hanger tubes) (Suction manifold & Disch. Line of CC pump, WW O/L Hdrs, Saturation tubes (DESH link LTSH to Div. I/L header & Div. O/L header to platen ) (DC pipes, Lower ring Hdrs) (Collector plate, Crown plate)
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SA106Gr C SA335 P 12 SA515Gr70 SA387Gr12CL2

15.0 Major steps taken to reduce cycle time

Pre

assembly:

If we reduce the no of lifts, the cycle time of any activity reduces itself. Therefore, two auxiliary columns of boiler are welded at ground and then they were erected in single lift. For example
Aux MBL Bracing

column + Aux Column + Gusset Plate

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 During mill erection, union head and journal may be preassembled in yard, transported to site and then erected. This has reduced the number of lifts from 60 to 30. Coal pipes may be welded at ground where ever it was possible.

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 Foresightedness:

If MBL members are not available in sequence then ? Planning for Space for movement of crane for erecting ceiling girders
Middle columns & Rear equipments

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 Planning for loose soils

CAT HAED structures developed at ground. Drum dragging saddles (2 no.) fabrication To use the psychological slack time

After Drum Lifting: Erection of Silencers & BP Roof P/A etc After Hydro Test
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 use of sliding pulley arrangement to erect the Economizer coils and LTSH coils, which reduces the change over time from one coil to another. Use of same resource for maximum time e g
Scaffoldings Sky climbers cranes
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 Supply of electricity supply from two sources Installation of welding equipments at different locations Arrangement for alternate resources in critical areas like welding of P91 Material

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17.0 QUALITY ASSURANCE

* A- class check : critical * B- class check: major * C- class check: minor

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How to ensure quality ?

Use of good quality manpower and material like argon gas, welding consumables etc Deployment of qualified, experienced and sincere supervisors Higher frequency of inspection

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18.0 DEVIATIONS AND THEIR DISPOSITIONING STRATEGIES:

MDR SAR NCR
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19.0 SAFETY ASSURANCE

PEP talk Demonstrations Use of PPEs Reward Warning & Penalty

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Thank You
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