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    Power Plant Presentation

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    Ashwani Dogra
    The document provides details on the erection sequence and lifting procedures for various components of a thermal power plant, including: - Boiler erection, beginning with lifting the boiler drum using strand jacks and proceeding through other boiler parts - Lifting the feedwater tank and deaerator using a tower crane and crawler crane - Erecting heaters like the HP heaters using a tower crane and crawler crane - Lifting coal mills weighing 300MT each using temporary structural supports, rollers, hydraulic jacks and chain blocks - Lifting the generator stator weighing 300MT using strand jacks, temporary structures and hillman rollers.

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    Power Plant Presentation

    Uploaded by

    Ashwani Dogra
    277 views24 pages
    The document provides details on the erection sequence and lifting procedures for various components of a thermal power plant, including: - Boiler erection, beginning with lifting the boiler drum using strand jacks and proceeding through other boiler parts - Lifting the feedwater tank and deaerator using a tower crane and crawler crane - Erecting heaters like the HP heaters using a tower crane and crawler crane - Lifting coal mills weighing 300MT each using temporary structural supports, rollers, hydraulic jacks and chain blocks - Lifting the generator stator weighing 300MT using strand jacks, temporary structures and hillman rollers.

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    The document provides details on the erection sequence and lifting procedures for various components of a thermal power plant, including: - Boiler erection, beginning with lifting the boiler drum using strand jacks and proceeding through other boiler parts - Lifting the feedwater tank and deaerator using a tower crane and crawler crane - Erecting heaters like the HP heaters using a tower crane and crawler crane - Lifting coal mills weighing 300MT each using temporary structural supports, rollers, hydraulic jacks and chain blocks - Lifting the generator stator weighing 300MT using strand jacks, temporary structures and hillman rollers.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    277 views24 pages

    Power Plant Presentation

    Uploaded by

    Ashwani Dogra
    The document provides details on the erection sequence and lifting procedures for various components of a thermal power plant, including: - Boiler erection, beginning with lifting the boiler drum using strand jacks and proceeding through other boiler parts - Lifting the feedwater tank and deaerator using a tower crane and crawler crane - Erecting heaters like the HP heaters using a tower crane and crawler crane - Lifting coal mills weighing 300MT each using temporary structural supports, rollers, hydraulic jacks and chain blocks - Lifting the generator stator weighing 300MT using strand jacks, temporary structures and hillman rollers.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 24

    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.

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