boiler drum erection of unit-2

7/28/2019 Boiler Drum Erection of Unit-2

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BOILER DRUM ERECTION

OF UNIT-25X270 MW TPP, NASIK

DATE: 27-July-2011


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Boiler Structure Ready


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Drum Erection Procedure

Structure Readiness for drum lifting

Joint Inspection & Quality Protocols Signing

All Safety Checks Carried Out

Rotation of Boiler Drum on Saddles

Load Test

Planning Activity

Start of Drum Lift

U-Bolt in Vertical Position

Boiler Drum in Horizontal Position

Final Position

U-Bolt Tightening

Alignment


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BOILER DRUM

Contractor: BHEL.

Location : Sinnar, Nasik.

Project : 5 X 270MW Thermal Power Plant.

Total Tons : 133 MT

Erection Time : 5 hr 30 min


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OVERALL VIEW OF BOILER DRUM


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UNLOADING OF BOILER DRUM


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BOILER DRUM

SALIENT FUTURE:

WEIGHT:- 137 MT

LENGTH:- 16.5 M

THICKNESS : 170mm & 135mm

DESIGN PRESSURE:-182.5Kg/sq.cm

DESIGN TEMPERATURE:- 357C

HYDRO TEST PRESSURE:-273.75Kg/sq.cm

MOC: HIGH CARBON STEEL (SA299)

DRUM CONNECTIONS DETAILS:

SUPERHEATER OUTLET TUBES:22 NOS

RISER TUBES:285 NOS

DOWNCOMER TUBES:6 NOS FEED NOZZLE: 2 NOS

PRESSURE TAPPING: 6 NOS

NITROGEN FILLING:2NOS

AIRVENT:2NOS


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DRUM SUSPENSION ARRANGEMENT

8


9/28

STABLE STRUCTURAL ARRANGEMENT OF

BOILER FOR DRUM ERECTION


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U BOLT AND ITS INSERTION


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EQUIPMENTS TO BE USED IN DRUM

LIFTING

POWER PACK :3NOS (1 STAND BY)

STRAND JACK: 2NOS

SWL:185 TONNE

WORKING PRESSURE:292 BAR

STROKE:500mm WEIGHT:1437Kgs

STRANDS:12 X 2=24 NOS DIAMETER:18mm

WINCH MACHINE:2 NOS

CAPACITY:5 TONNE EACH. CLEVIS :2NOS

CAT HEAD STRUCTURE:2 NOS

CHAIN PULLEY BLOCK:2 NOS

STRAND GUIDE:2 NOS

DERRECK:2NOS(For chain pulley block suspension )


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POWER PACK


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POWER PACK SPECIFICATION

Power source : 1*30kW+1*4kW Electric motor

Electrical supply requirement : 400V AC,50Hz 3 Phase + Earth

Number of strand jack main cylinder outlet : 1

Flow per main cylinder outlet : 40 ltr per Min

Main cylinder circuit working pressure : 300 bar

Flow to mini jack circuit : 8 Ltr per Min

Mini jack circuit working pressure : 100 bar max

Tank volume : 400l/300 Ltr fill

Oil grade : ISO46

Oil cooling : Air blast 19kW cooling at T=20 C

Main cylinder extend connection : 1 Screw fitting (VVS)

Main cylinder retract connection : 3/4 Screw fitting (VVS)

Top anchor open port size : 3/8 flat face QRC Top anchor close port size : 3/8 flat face QRC

Base anchor open port size : Flat face QRC

Base anchor close port size : Flat face QRC

Control system : Local / DL-M (Remote consol)

Built : Crash frame mounted.


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STRAND JACK


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STRAND JACK SPECIFICATIONS

Maximum working pressure/load : 185 ton at 292 bar.

Extend / Retract area ratio : 1:1.69

Number of 18mm Dyform strands : 12

Load factor against strand MBL(380kN/strand) : 2.5

Jack stroke : 500mm

Anchor mini jack system : Double acting.

Main cylinder extend port size : 1 screw fitting (VVS)

Main cylinder retract port size : Screw fitting (VVS)

Top anchor open port size : 3/8 Flat face QRC

Top anchor close port size : 3/8 Flat face QRC Base anchor open port size : Flat face QRC

Base anchor close port size : Flat face QRC


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CAT HEAD STRUCTURE


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LIFTING ARRAGEMENT


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FIXING OF STRANDS & STRAND

ARRANGEMENT


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ALIGNMENT INSPECTION


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INSPECTION AT DRUM SUSPENSION


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Job Safety & Risk Assessment Analysis

Both the winches and all the lifting equipments used for U boltlifting were properly load tested.

Third party & Manufacturer test certificates for Strand jacks,Strands & other equipments were checked & found OK.

Job safety analysis (JSA) & Risk assessment (RA) werecarried out.

Special Safety Induction Programme (Tool box talk) wasconducted to all the executives & workers involved in Drumlifting activities before the Drum lifting

Special florescent jackets were provided for Executives &workers.


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Nasik Power Project Drum Lifting

Plan


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DRUM AT VARIOUS ELEVATION

DRUM AT 15 mtrDRUM AT 60.106 mtr

(Position)


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U-ROD FIXING AT POSITION


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WORKSHIP CEREMONY BEFOR DRUM

LIFTING


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SOME MOVEMENTS


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TEAM NASIK

THANKING YOU ALL

boiler drum erection of unit-2

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