THERMAL POWER PLANT

FLOW CHART AND ERECTION SEQUENCE

TOPIC
POWER PLANT- GENERAL FLOW CHART

FLOW CHART- INSIDE BOILER

BOILER STRUCTURAL ERECTION SEQUENCE - ELEVATION VIEW BOILER CELING GIRDER ERECTION SEQUENCE - PLAN VIEW

BOILER DRUM ERECTION SEQUENCE

BOILER PARTS ERECTION SEQUENCE TG AREA- ERECTION SEQUENCE FOR HEATERS/ DEARATOR/ EOT
ELEVATION VIEW. PLAN VIEW

COAL MILL LIFTING SEQUENCE. GENERATOR STATOR LIFTING SEQUENCE

ECONOMISER

REHEATER (T-538 P-38.16)

FLOW DIAGRAM - THERMAL PP

HP TURBINE (T- 538 , P- 167) IP TURBINE (T- 538 P- 34.38) LP TURBINE( T-368 P-12 )

SUPERHEATER (T-538 P-167)

PRIMARY SUPERHEATER

T- 44.5, P- .09

COOLING TOWER DRUM

DEARATOR BURNER

CONDENSER

T-35 P-22.5

CEP
LP H-3 HP H-2 HP H-1 LP H-2 LP H-1

FURNACE AREA
HP HEATER 1 &2 (TEMP IN 186 OUT 281 )

LP HEATER (TEMP- IN 37, OUT 145

21 1

23

BOILER FLOW DIAGRAM

22
1. Steam Drum

3
4
DIV PANEL SUPERHEATER PLATEN SUPERHEATER FINAL REHEATERS
FINAL SUPERHEATERS FINAL SUPERHEATERS

2. Downcomer
3. Inlet/Outlet Roof Headers 4. Water Wall Side Header 5. Steam Cooled Water Wall 6. Right water wall 7. Div. Panel Super Heater

25

MEDIUM REHEATERS

14 11
PRIMARY SUPERHEATERS

10 16 12 17

8. Platen Super Heater 9. Medium Re-heaters

H P
2

PRIMARY SUPERHEATERS

10. Final Re-heaters

11. Final Super heaters 12. Primary Super heaters Coils 13. Primary Super heaters in Hdr 14. Primary Super heaters Header 15. Economizer

PRIMARY SUPERHEATERS

13

I P 18 L P
19 20

ECONOMIZER

16. Water wall

ECONOMIZER

17. Water wall 18. Burners 19. Water Wall 20. Lower Water Header 21. Riser Tubes 22. SuperHeater Tubes 23. Pri. SH Tubes 24. Main Steam Tube 25. Cold Reheat tube

15

BOILER STRUCTURAL ERECTION-ELEVATION

85.09

AIR PREHEATER

10.62

10.62

PLAN VIEW OF BOILER GIRDER ERECTION

6.9 6.2 5.5 5.0 4.5 3.8 3.1

CEILING GIRDER 70 MT , EL-87.52 MTS

K
TOWER CRANE 75 MT

CEILING GIRDER 90 MT, EL 87.52 MTS

CEILING GIRDER 105 MT, EL 87.52 MTS

HOLD

ERECTION AS SHOWN IN PREVIOUS SLIDE

CRAWLER CRANE

N
REAR SIDE

DRUM LIFTING PROCEDURE BY STRAND JACKS

STRAND JACKS FIXING ARRANGEMENT

STRAND JACKS

LIFTING SLING

ROLLERS CEILING GIRDER DRUM EL 76.3

DRUM TO BE TAKEN IN HORIZONTAL POSITION TO BE SHIFT TOWARDS ITS VERTICAL AXIS LIFT AGAIN TO GET EXACT ELEVATION

BOILER COLUMNS

CONNECTING BEAMS
DRUM TO BE INCLINED UP TO 370 TO GET ERECTION CLEARENCE BETWEEN THE COLUMNS

370

SPECIFICATIONS: 1. DRUM SIZE: DIA 2.1M & 28M LG

NOTE: 1. 2 NOS STRAND JACK OF 150MT CAP EACH

2.

ROLLERS OF

CAP WILL BE REQD. TO SHIFT THE DRUM.

2.

WEIGHT: 246 MT

DRUM LIFTING PROCEDURE BY STRAND JACKS (SIDE VIEW)

DRUM EL 76.3

BRING BACK TO HORIZONTAL POSITION

LIFTING TO THE POSITION

4 MTR SHIFTING TOWARDS ITS EXACT VERTICAL AXIS

TO BE INCLINED UP TO 370

J ROW COLUMN

I ROW COLUMN

H ROW COLUMN

BOILER DRUM LIFTING

ELEVATION WEIGHT DIMENSION METHOD OF LIFTING
PROCEDURE: GROUND PREPARATORY WORK AT +0.0 ELEVATION. SHIFTING OF BOILDER DRUM TO SITE AND PLACED BETWEEN THE I & J ROW OF BOILER COLUMNS. GROUND INSPECTION OF BOILDER DRUM. PLACEMENT OF CAT-HEAD BEAM ON CELING GIRDER. WALKWAYS AND PLATFORMS ARE MADE BETWEEN TWO CAT BEAMS. POWER PACK TO PLACED BETWEEN TWO CAT BEAMS. 2 NOS. 200T CAP JACKS ARE RAISED AND FIXED TO THE TOP OF CAT HEAD BEAMS. STRAND GUIDE IS FIXED NEAR THE JACK.

: 76.3 MTS : 246 MT : 28 MTS (LONG) X 2.2 MTS WIDE : STRAND JACK.

STRAND IS INSERTED IN JACK ANCHORS FROM BOTTOM TILL THE FREE END COMES OUT OF TOP ANCHOR AND IS PLACED ON STRAND GUIDE.

BOILER DRUM LIFTINGcontd

INSERTION OF CORRESPONDING STRAND IN FIXED ANCHOR ON DRUM. U-RODS ARE LEFT HANGING ON DRUM AT AN APPROPRIATE LOCATION BEFORE LIFTING. BOILDER DRUM WILL BE FIRST LIFT TO INCLINED UP TO 37 DEGREE TO GET CLEARANCE BETWEEN THE COLUMNS, BECAUSE LENGTH OF THE DRUM IS LARGER THAN THE DISTANCE BETWEEN 2 COLUMS. DRUM (IN INCLINED POSITION) WILL BE THEN LIFT SLOWLY TILL REACH UP TO +71.0 MTR. ELEVATION. AT +71.0 MTR. ELEVATION IT WILL BRING BACK TO HORIZONTAL POSITION. STRAND JACKS WITH POWER PACK ARRANGEMENT WILL THEN SHIFT 4 MTR TOWARDS H ROW ON SAME ELEVATION TILL REACH TO ITS VERTICAL CENTER LINE. AFTER 4 MTR SHIFTING, IT WILL BE FURTHER LIFTED UP TO + 76.3 MTR TO REACH ITS FINAL POSITION.

U-BOLTS WILL BE FIXED AT TOP BY SEPARATE ARRANGEMENT.

AFTER ALIGNMENT OF DRUM AND TIGHTENED OF U-BOLTS, STAND JACKS ARE TO BE RELEASED AND DISMANTLED ALL TEMPORARY ARRANGEMENTS.

Boiler Erection Sequence

21 1 23 22
1. Steam Drum

3
4
DIV PANEL SUPERHEATER PLATEN SUPERHEATER FINAL REHEATERS
FINAL SUPERHEATERS FINAL SUPERHEATERS

2. Downcomer
3. Inlet/Outlet Roof Headers 4. Water Wall Side Header 5. Steam Cooled Water Wall 6. Right water wall 7. Div. Panel Super Heater

25

MEDIUM REHEATERS

14 11
PRIMARY SUPERHEATERS

10 16 12 17

8. Platen nel Super Heater 9. Medium Re-heaters

H P
2

PRIMARY SUPERHEATERS

10. Final Re-heaters

11. Final Super heaters 12. Primary Super heaters Coils 13. Primary Super heaters in Hdr 14. Primary Super heaters Header 15. Economizer

PRIMARY SUPERHEATERS

13

I P 18 L P
19 20

ECONOMIZER

16. Water wall

ECONOMIZER

17. Water wall 18. Burners 19. Water Wall 20. Lower Water Header 21. Riser Tubes 22. SuperHeater Tubes 23. Pri. SH Tubes 24. Main Steam Tube 25. Cold Reheat tube

15

VIEW OF PREHEATER / DEARATOR / EOT ERECTION

1. ERECTION OF HP HEATER 2. ERECTION OF DEAREATORS 3. ERECTION OF EOT 4. ERECTION OF LAST TG ROOF GIRDER
DEARETOR STORAGE TANK

63

39.0

DEAREATOR

33.85

EOT

26.0

TG DECK

13.7

6.7

B
PREHEATER

PLAN VIEW OF PREHEATER / DEARATOR / EOT ERECTION

1/03

1/02

1/01

HOLD

54 DEGREE

CRAWLER CRANE
HP HEATER DECK EL13.7 DEARATO R DECK EL-26

DEARATOR TANK

eot

EOT

TG DECK EL-13.7

HOLD

FEEDWATER TANK AND DEARATOR LIFTING

FEED WATER TANK WEIGHT : 110 MT. ELEVATION : 26 MTS LIFTING METHOD : TOWER CRANE AND CRAWLER CRANE
PROCEDURE : FOUNDATION / SUPPORTING BEAM TO BE CHECKED AS PER DRAWING PRIOR TO INSTALLATION OF FEED WATER TANK. ALL CENTRE LINE AND ELEVATION TO BE CHECKED PROPERLY BEFORE LIFTING. LOAD BEARING CAPACITY OF THE SOIL TO BE CHECK BEFORE PLACING OF THE CRANE. FEED WATER TANK TO BE LIFTED WITH THE HELP OF 500 MT CRANE AS PER SKETCH, CRANE CAPACITY AS PER SKETCH IS 125 MT.

B ROW COLUMN TO BE HELD ABOVE +26 METER ELEVATION TO FACILITATE FOR CRANE SWINGING FROM B ROW SIDE. C ROW COLUMN NUMBER 1 & 2 TO BE HOLD FOR CRANE POSITION, SO THAT CRANE BOOM CAN REACH UP TO REQUIRED DISTANCE.
FEED WATER TANK TO BE PLACED DIRECTLY ON FOUDATION / SUPPORTING BEAMS.

FEEDWATER TANK AND DEARATOR LIFTING

ALL NOZZLES ORIENTATION TO BE CHECKED DURING LIFTING. AFTER ALIGNMENT OF FEED WATER TANK TEMPORARY SUPPORTS MAY BE PROVIDED TO HOLD THE DEAERATOR TANK ABOVE FEED WATER TANK. AFTER ALIGNMENT OF DEAERATOR, LOAD TO BE GIVEN ON PERMANENT SUPPORTS AND INTERCONNECTING PIPING BETWEEN DEAERATOR AND FEED WATER TANK TO BE COMPLETED. ALL INTERNALS OF DEAERATOR TANK TO BE FIXED AFTER COMPLETION OF ALIGNMENT. ALL EXPANSION PROVISION IS TO BE CHECKED CAREFULLY TO AVOID PROBLEM DURING COMMISSIONING.

HP HEATERS
WEIGHT : 120 MT DIMENSION : 12 MTR LG x 2.3 MTR DIA ELEVATION : +13.7 MTR METHOD OF LIFTING: TOWER CRANE AND CRAWLER CRANE
PROCEDURE:

FOUNDATION CHECKING AND GROUND PREPARATION AT +0.0 ELEVATION.

SETTING OF PACKER PLATES. HOLD CONNECTING BEAM BETWEEN B AND C AXIS OF COLUMN 1 & 2 AT +27 METER & 39 METER ELEVATION. 500 MT CRAWLER CRANE TO BE USED TO LIFT HP HEATERS UPTO 13.7 MTS ELEVATION THROUGH B C BAY. AFTER LIFTING HP HEATER TO BE DRAGGED UPTO FOUNDATION BY USING ROLLER. AFTER INSTALLATION ALIGNMENT TO BE DONE AS PER DRAWING.

COAL MILL LIFTING PROCEDURE

Mill assly & alignment in progress

Roller removed

Hydraulic Jack placed

Pulling arrangement by chain block

Crane & roller placed

D1

D2

Mill 6

D3

Mill 5

D4

Mill 4

D5

Mill 3

D6

Mill 2

D7

Mill 1 Lowered on foundation by hydraulic jack

D8 Mill Foundation D9

Temporay beam arrangement

Rolling towards foundation

Note: Same procedure will be followed for rest of the mills. Weight of each Mill : 300 MT Dimension of the Mill: Dia 5 Mtr x 10 Mtr height

COAL MILL LIFTING PROCEDURE

Mill assly & alignment in progress Mill 6 D1 D Row D2 D3 Mill 5 D4 Mill 4 D5 Mill 3 D6 Mill 2 D7 Mill 1

Jack placed & roller removed D8

Rolling towards foundation

C Row Temporay beam arrangement

Lowered by Jacks

Mill Foundation

Rollers

Frame

Temporay beam arrangement

View A

COAL MILL ERECTION

WEIGHT DIMENSION PROCEDURE:
PREPARATION OF BED FROM STRUCTURAL MATERIAL BETWEEN COLUMN C & D ROW THROUGH OUT THE COAL MILL AREA TO OUTSIDE OF C1 & D1 COLUMN., (AS SHOWN IN VIEW A). PLACEMENT OF FRAME AND ROLLER ON TOP OF THE TEMPORARY STRUCTURAL ARRANGEMENT. ERECTION OF MILL BASE PLATE, GEAR BOX, CASING ONE BY ONE WITH THE HELP OF CRANE AND ALIGNMENT THE SAME ACCORDINGLY. AFTER COMPLETE ALIGNMENT, PULL THE FRAME BY CHAIN PULLEY BLOCK, WHICH IS PLACED ON OPPOSITE END I.E. WITH C9 & D9. AFTER BRING IT TO THE FOUNDATION POSITION, 4 NOS. HYDRAULIC JACK OF 100 MT CAP WILL BE PLACED, TAKE LOAD ON THE SAME AND RELEASE THE FRAME WITH ROLLERS. SLOWLY LOWERING THE MILL ON FOUNDATION BY JACKS. FINAL ALIGNMENT CHECKING LSAME PROCEDURE WILL BE FOLLOWED FOR REST OF THE MILLS. AFTER COMPLETION OF ALL SIX MILLS ERECTION, TEMPORARY STRUCTURAL ARRANGEMENT WILL BE REMOVED.

: 300 MT : DIA 5 MTR x 10 MTR HEIGHT

11

After unloading Stator to be rotate by using rotator

150-200T Cap Strand Jacks

10

Temporary structure

Stator to be shifted to site by Nicolus

Hillman rollers

8
Original location of stator

4
B A

Schematic diagram of Generator stator lifting procedure (sh-2)

2 B A

150-200T Cap Strand Jack

Temporary structure

EL +13.7

Schematic diagram of Generator stator lifting procedure (sh-1)

GENERATOR STATOR LIFTING

WEIGHT DIMENSION ELEVATION PROCEDURE: GROUND PREPARATION UP TO LOAD BEARING CAPACITY +25.0 MT/MTR2 (TO BE CONFIRMED) AT +0.0 ELEVATION. : 300 MT : 10.5 MTR LG x 4.3 MTR DIA : +13.7 MTR

SHIFTING OF STATOR AT SITE AND PLACED INSIDE POWER HOUSE BUILDING NEAR TG DECK THROUGH A ROW AS SHOWN IN THE SKETCH.
GENERATOR STATOR TO BE UNLOADED ON A ROTATOR TO ROTATE THE STATOR UP TO 90 DEGREE, ROTATOR SHOULD HAVE THE CAPACITY TO TAKE LOAD OF 300 MT. ERECTION OF TEMPORARY STRUCTURE FOR PUTTING UP GANTRY & 4 NOS. STRAND JACKS ON TOP.

PLACEMENT OF 2 NOS. HORIZONTAL BEAM ALONG WITH CHANNEL AT + 13.7 MTR ELEVATION THROUGHOUT TEMPORARY STRUCTURAL ARRANGEMENT TO GENERATOR FOUNDATION.

GENERATOR STATOR LIFTING

PLACEMENT OF GANTRY ALONG WITH WHEELS ON TEMPORARY ARRANGEMENT OF H-BEAM AND CHANNEL.
PLACEMENT OF CAT-HEAD BEAM ON TOP OF GANTRY. WALKWAYS AND PLATFORMS ARE MADE BETWEEN TWO CAT BEAMS. POWER PACK IS RAISED AND PLACED BETWEEN TWO CAT BEAMS. 4 NOS. 150T/200MT CAP STRAND JACKS ARE TO BE FIXED TO THE TOP OF CAT HEAD BEAMS. LSTRAND GUIDE IS FIXED NEAR THE JACK. STRAND IS INSERTED IN JACK ANCHORS FROM BOTTOM TILL THE FREE END COMES OUT OF TOP ANCHOR AND IS PLACED ON STRAND GUIDE. INSERTION OF CORRESPONDING STRAND IN FIXED ANCHOR ON STATOR. STATOR WILL BE LIFTED TO > +18.0 MTR ELEVATION. GANTRY WITH STATOR LOADED WILL BE TRAVELED TOWARDS GENERATOR FOUNDATION ON THE TEMPORARY ARRANGEMENT OF BEAM & CHANNELS BY MOTOR OPERATED ROLLERS. ON GENERATOR FOUNDATION, IT WILL BE LOWERED AT REQUIRED ELEVATION AND STRAND JACK LOAD WILL BE RELEASED.

GANTRY WILL BE TAKING BACK TO INITIAL POSITION.