9135MW CAPTIVE POWER PROJECT ERECTION PROCEDURE OF AIR PREHEATER

Content
1 preface 2. Suggested field erection sequences: 3 erector drawing 4 erection step 4.1 step 1 4.4 step 4 4.5 step 5 4.6 step 6 4.7 step 7 4.8 step 8 4.9 step 9 4.10 step 10 5. Seal setting 6. Final erections summary inspection records 7. Final erection summary before operation 8. Recommended lubricant chart

1. Preface
This type ljungstrom air preheater is designed in accordance with the technique of alstom air preheater company. Prior to starting of

erection, this manual and the relevant information must be familiar to the erectors. There are methods for erection, correction, check, and notes on erectors drawings. The field erection sequences, which connect all procedures as a unit, are emphasized in this manual. Particular attention should be paid to the suggested drawings during all phases of erection. All readings are to be recorded on sheets provided in this manual and a copy, which is to be evidence for air preheater performance, is to be furnished to SBW.

2. Suggested field erection sequences

The following sequences are for reference only. During actual field assemble the field erection procedures and the erection drawings included and indexed in this manual should be referred to. Obtain support steel elevations, center lines, and locate expansion arrangements .Level expansion arrangements on a same elevation. 2. Assemble cold end center section to expansion arrangements. 3. Assemble main pedestals and axial sealing plate to the cold end pocket ring. 4. Install the support bearing assembly and support oil circulation unit. 5. Assemble side pedestals to the expansion arrangements and the temporary support . 6. Install the lower pipe brace. 7. Install the Primary section (CE), pipe brace and the temporary support . 8. Install the other Pocket ring and pipe brace (CE). 9. Assemble main pedestals and axial sealing plate to the cold end pocket ring of primary. Assemble the temporary support. 10. Install rotor post and trunnion assembly. 11. Set hot end center section and pocket ring to the main pedestals. 12. Install the guild bearing assembly and guild oil circuit unit. 13. Install the rotor drive panel and temporal brace.
1.

Install the H.E. Primary section and pipe brace. Install the other Pocket ring and pipe brace (HE). Install the other parts of the C.E. Connecting plate assy, such as tension ring, casing, duct corner assy, and formed flange. 17. Install the housing casing assembly. 18. Install the other parts of the Connecting plate assy (HE), such as tension ring, casing, duct corner assy, and formed flange. 19. Install the casing of side pedestal. 20. Install the thermal element. 21. Check the levelness of rotor. 22. Install the pin rack. 23. Install the drive reducer, water washing device, soot blower, fire alarm system, and etc. 24. Install the rotor angle and sealing angle. 25. Install the sealing plate of Rotor (CE). 26. Install the radial, axial, and bypass sealing. 27. Adjust the setting seal gap of the sector plate. 28. Adjust the setting seal gap of the axial sealing plate. 29. Install the static seal assembly. 30. Install the auxiliary equipment such as air seal components, rotor stoppage alarm device. 31. Fill the checking table. 32. Final checks out and debug
14. 15. 16.

Note
1. Reading and studying the notes of the erection drawings before erection. 2. If there is any difference between this manual and the erecting drawings, please use the information of the erecting drawings. 3. Please remove the yellow paint parts and temporal support before operation.

4 erection step

4.1 step #1
Install the expansion arrangements, cold end center section, support bearing ass'y, main pedestal ass'y and axial sealing plate.

4.1.1 Main procedure

a. Establish centerlines and determine elevations of steel at locations of expansion arrangements. b. Refer to the general arrangement drawings, and the centering procedural for orientation with customer steel. c. Using a transit, obtain steel elevations at all support foot locations and note any variations. Add or subtract shims from expansion lock assemblies to achieve the elevations shown on the general drawings. d. Install expansion block assemblies at this time. Weld base pads to customer support steel. Do not weld across ends of the sliding surfaces. e. Install lower end center section to expansion block assemblies. (Notes: 1.The arrangement for the center section should same as the the gad of boiler. 2. Lifting lugs are to be used to lift the center section only. Do not use lifting lugs as anchors to lift other components.) f. Using a precision level, check the levelness of the center section from the highest elevation machined surface on the bearing housing base at four locations (90 degree apart on the air preheater centerlines). Shim center section support ends and center support to obtain a levelness of .4mm/m and elevations as required. g. Install main pedestal and axial seal plate assemblies to lower end center section pocket rings at each end of center section. Ensure that main pedestal and axial seal plate assemblies are perpendicular to lower end center section by measuring diagonals. Align centerline marks as shown. Install temporary bracing as shown and weld main pedestal assemblies to the lower end pocket rings. Do not weld bracing to sector plates or axial seal plates. h. Refer to support bearing assembly drawing and assemble bearing components to allow for installation of rotor post assembly. i. Install the support oil circulation.

4.1.3 The

approximate weights of the components covered in this section are: a. The assembly of cold end center section, support bearing, and sector plates 15 t b. One main pedestal and axial sealing plate ass'y 1t

4.2 step #2
Install the expansion arrangements, side pedestal assembly, pipe brace assembly.

4.2.1 Main procedure

a. Refer to the general arrangement drawings, and the housing assembly for orientation with customer steel. b. Install the expansion of side pedestal. Add or subtract shims from expansion lock assemblies to achieve the elevations. Install expansion block assemblies at this time. Weld base pads to customer support steel. Do not weld across ends of the sliding surfaces. c. Install the side pedestal assemblies to the expansion block assemblies On the support steel verifying that they are perpendicular to the support steel. Level side pedestals and add temporary bracing to the lower end center section or support steel. d. Install pipe braces and gussets.

4.3 step #3
Install the cold end primary center section assembly, pocket ring assembly, pipe braces, and pedestal panel assembly.

4.3.1 Main procedure

a. Refer to the general arrangement drawings, and the centering procedural for place each parts. b. Install the cold end primary center section ass'y, and add the temporary bracing. c. Refer to the drawing of cold end center section ass'y and pocket ring ass'y for install the pocket ring. Install them at the same elevation 3mm. Use bolted arrangements at ring splits and welding. d. Assemble 45 pipe braces. Do not final weld 45pipe brace to

stationary spool at this time. e. Install the primary center section ass'y t other pocket ring and welding. Add the temporary bracing as required. 4.3.3 The approximate weights of the components covered in this sections are: a. The assembly of primary center section, sector plates2 t

4.4 step #4
Install the rotor, hot end center section ass'y, guide bearing ass'y, air seal ass'y

4.4.1 Main procedure

a. Refer to the general arrangement drawings, and the centering procedural for place each parts. b. Set a temporary plate to assemble the rotor on the ground: 1 Set a temporary plate to assemble the rotor on the ground. The static loading of the plate should not less than 60t. And the flatness should not less than 5mm. 2 Clean the split of two half of the rotor. 3 Lift the two half rotor to the plate according the shop assembly mark. Refer the upper and lower surface to shim the rotor. 4. After tight the split of the two half rotor, welding the rotor. c. Refer the drawing of guide bearing ass'y and support bearing ass'y, install erecting the trunnion of guide and support bearing to the rotor post. d. Install the rotor assembly parts to the support bearing, and should not damage any parts. e. Apply protective covering (tarpaulin or plastic sheet) tightly around the post and over the bearing assembly to prevent entrance of dust, dirt, until the bearing assembly can be completed. When welding on any component of the rotor structure, the rotor post must be earth grounded to prevent damage to the bearings. f. Position rotor, trunnion and spool assembly so that they are level and hold in vertical position. Apply temporary bracing. Do not apply bracing to the sector plates. g. Lift upper end center section using the lifting lugs provided. Remove temporary bracing on center section. Set center section over the

guide (attached to the upper end of the rotor post). Lower the center section it on the upper flanges of the main pedestal and axial seal plate verifying that the pre marked centerlines are aligned. Weld pocket ring to main pedestal and axial seal plate assembly as shown. h. Refer to the guide bearing assembly drawing for installation and erection procedures of the guide bearing. i. Check level of rotor using a level on either of the rotor post headers in 2 places 90apart. The levelness of the post and trunnion assembly is 0.4mm/m. bearing housing to realign if alignment exceeds acceptable limit. j. Refer to the erection notes of guide bearing assembly drawing for lock the guide bearing housing with the lock brake. k. Remove temporary shiping protector, and grind if necessary. Adjust the spool ensure the axiality with the rotor is less than 1.5mm. l. Install the air seal ass'y. m. Install the guide oil circulation. 4.4.3 The approximate weights of the components covered in this section are: a. The assembly of hot end center section, and sector plates 8 t b. The assembly of support bearing: 1.5t

4.5 step #5
Install the hot end primary center section ass'y, pocket ring ass'y, pipe braces, and driver panel.

4.5.1 Main procedure

a. Refer to the general arrangement drawings, and the centering procedural for place each parts. b. Install the hot end primary center section ass'y, and add the temporary bracing. c. Install rotor drive panel. Align centerline of rotor drive panel with the 45centerline (rotor drive centerline). Weld panel to lower end pocket ring as shown. d. Refer to the drawing of hot end center section ass'y and pocket ring ass'y for install the pocket ring. Install them at the same elevation 3mm. Use bolted arrangements at ring splits and welding.

e. Assemble 45 pipe braces. Do not final weld 45pipe brace to stationary spool at this time. 4.5.3 The approximate weights of the components covered in this section are: a. The assembly of primary center section, sector plates1.5 t

4.6 step #6
Install the duct corner assembly, connecting plate ass'y, round casing and tension ring

4.6.1 Main procedure

a. Refer to the general arrangement drawings, and the centering procedural for place each parts. b. Assemble cold end tension ring using the erection assistance brace to set both the outside radius and the elevation of the tension ring. The tension radius is to be the same as the outside pocket ring radius. Use erection assistance brace as required. c. The rolled connecting plates can be assembled to the tension ring. Use the erection assistance brace to set the proper elevation and weld Be sure to begin at the 45 line (slit in the pocket ring) and work out towards both the main center section and the side pedestal assembly. Make use of lap bar connections at interfaces. d. Assemble duct corners to connecting plates. Set duct opening dimensions and elevation before welding. Assemble connecting plate flange pieces and set duct openings before welding. Note that fit up trimming may be required. e. Refer to the housing ass'y assemble the round casing. Install the basket remove door after lifting the element to model. f. Assemble the hot end tension rings according the procedure and requirement of cold end. g. Assemble the duct corners according the procedure and requirement of cold end.

4.7 step #7

Install the element, pin rack, driver reducer, washing and deluge pipes ass'y, soot blower, and fir alarm device.

4.7.1 Main procedure

a. Refer to hot end basket, cold end basket drawing, assemble the hot end element from the upper duct of APH, and assemble cold end element from the basket remove door. b. Check level of rotor using a level on either of the rotor post headers in 2 places 90 apart. The levelness of the rotor assembly is 0.4mm/m. Bearing housing to realign if alignment exceeds acceptable limit. c. Refer to the drawing of pin rack assembles the pin rack. d. Refer to the drawing of rotor drive ass'y choose the correct rotation of the gear box, and assemble the reducer to rotor drive support panel. e. Refer to the drawing of rotor drive ass'y adjust the gap between the pin and pinion. Check the gap between the pin and pinion from the top point to the pin rack. f. Install upper and lower wash pipe assemblies. Refer to assembly drawings and the general arrangement drawings for complete procedures. g. Refer to assembly drawings and the general arrangement drawings install fire detection system

4.8 step #8
Install the angle of rotor, seal angle, axial seal ass'y, by-pass seal ass'y, and radial seal ass'y.

4.8.1 Main procedure

a. Refer to the drawing of radial seal ass'y and seal install setting assemble the angle of rotor. b. Refer to the dimension of the drawing assemble the seal angle and seal plate and machine them by special tool. c. Refer to the assembly drawing install the radial seal plate. d. Refer to the assembly drawing install the axial seal plate. e. Refer to the assembly drawing install the bypass seal plate

4.9 step #9
Adjust sector plate, seal angle, axial seal plate, by-pass seal plate, and radial seal plate. Install the staic sealing.

4.9.1 Main procedure

a. Refer to the seal install setting assemble the radial seal straight edge ass'y and axial seal straight edge ass'y. b. Refer to the setting gap adjust the seal plate by the straight edge. c. Install the static seal ass'y (CE) and static seal ass'y (HE) when the sector plate and spool final adjusted.

4.10 step #10

Install the auxiliary equipment such as air seal pipe ass'y, rotor stoppage alarm ass'y, platform, observation port ass'y and etc.

4.10.1 Main procedure:

a. Refer to the general arrangement drawing (gad) of APH, Centering procedural and drawing of each ass'y install the auxiliary equipment. b. Install the observation port ass'y near to the plate form. Remove and store the platform of change element

8. Recommended lubricant chart

For guide bearing-15 litre For support bearing- 75 litre

TESTING CARRIED OUT IN AIR PREHEATER

Expansion arrangement levelness Support bearing housing levelness Guide bearing housing levelness Axial seal checking Radial seal checking By pass seal checking

 Pin rack alignment Rotor elevation

SEAL SETTING CHART

Item 1 Description Radial Seal Location Cold End Inboard Cold End Outboard Hot End Inboard Hot End Outboard Hot End Cold End Hot End Cold End Code A B C D G H M N Value 0.0 9.0 5.5 0.0 7.0 3.5 3.5 9.0

2 3

Axial Seal By-Pass Seal