BOILER

ERECTION

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January 19, 2

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Steam generator
A steam generator is a device used to boil water to create steam. It
may refer to:
Boiler, a closed vessel in which water is heated under pressure
Steam generator (nuclear power), a heat exchanger in a
pressurized water reactor equipped nuclear power plant
Steam generator (railroad), a device used in trains to provide heat to
passenger cars.

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Major boiler components

Economiser
Section of boiler in which feed water is first introduced
into the boiler and flue gas is used to raise the
temperature of water
Steam drum
Steam drum seperates steam from steam water mixture
and keeps seperated steam dry.
Superheaters
Bundles of boiler tubing located in the flow path of the hot
flue gases. Heat is transferred from flue gases to the
steam in superheater tubes.
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Major boiler components

Reheater
Bundles of boiler tubes exposed to combustion
gases in the same manner as super heater
Spray attemperators
Are spray nozzles in the boiler tubes between
two superheaters and two reheaters. The spray
nozzles supply a fine mist of pure water into flow
path of steam to prevent damage from
overheating.
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Boiler systems
Pulverised fuel system Bunkers, mills and coal
piping
Draught system- Ducts, dampers and fans
Oil firing system
Boiler fittings
Dust extraction plant

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ISSUES IN BOILER ERECTION

RESPONSIBILITIES

SAFETY

STATUATORY
REGULATIONS

BOILER ERECTION SEQUENCE

Column erection
Pressure part erection
Miscellaneous

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COLUMN ERECTION
The boiler presently in use are hanging type.
The column are broken up during manufacture into
several pieces and transported to site
Where it is pre assembled in two or three pieces
and erected.
Utmost care is taken in the pre-assembly stage to
maintain the matching of the of the column end
faces and to achieve vertically well within the
tolerance limit
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COLUMN ERECTION
Verticality is single most important factor and is
given top priority
The maximum column verticality is 20mm.
Once the column erection is over up to the full
height cross beams are placed securely over the
column which supports the main boiler

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COLUMN ERECTION
In order to carry out this job special erection tool
like cranes with extra long boom to carry heavy
loads at that height are used.
After cross beam erection, entire structure is
adequately braced to achieve sufficient strength.

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PRESSURE PART

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3. Advantage and Weakness of Construction Method

Description
\Type

Advantage

Modulization / Concurrence
Construction Methods

Typical Construction Method

Earlier completion through Modulization

/Concurrence Construction

Many years of experience and Know-How

To utilize standard data /Data base

Competitive time for completion

Reduction design M/H

Curtailment of S/S materials
Reduction manufacturing/installation cost

Lay down Area need for pre-assy at site

Increasing Equipment / Construction Labor
Cost

Weakness Increasing Module temporary material and

S/S materials (about 50% )

Long time for completion

High risk of safety accident due to lots of
works
at the high elevation

Long duration for S/S design

and Complicated design

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2. Comparison of Construction Methods

Modulization / Concurrence
Construction Methods

Concurrent construction of S/S and Boiler

S/S Modulization on the ground
Core Frame, Subsidiary S/S and Boiler
installation at the same time

Typical Construction Method

Boiler installation after completion of S/S

installation
Separate installation of S/S 1Tier ~ 5 Tier
with Bottom-Up method

Lifting after Moduliztion on the ground, Erection Unit Lifting and installation
Using special Lifting device :
Hydraulic jack - to be able to lift Module
[2,500Tons]
Site assembly of Boiler equipment
- Ground assembly : 70%,
- Assembly after installation : 30%

Using ordinary construction lifting device

Site assembly of Boiler equipment
- Ground assembly : 20%,
- Assembly after installation : 80%

Planning and scheduling for concurrent

construction sequence Planning

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Compare to Main Erection Process

Modulization / ConcurrenceConstruction Methods

660MW x 2 Units
Main Proper 5,643tons
Boiler weight
S/S
9,191tons
Duration
(S/S at site~Firing)

HxW
xD 2
January
19,

15.5 Momth
76m x 41m x 41m

Typical Construction Method

560MW x 2 Units
Main Proper 5,103tons
Boiler weight
S/S
5,200tons
1990.07.16~1992.08.14
Duration
(S/S at site~Firing)
(25 M)
HxWxD
76m x 37m x 42m

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 Lifting S/S after pre-Assy Core Frame

on the ground
Pre-assembling Pressure Parts

After Starting
S/S

Separately lifting STL/STR

Pressure Parts unfurnished

?
?
Core
Frame
Module
Work Stand

1Tier

Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
January
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After installation of S/S Core Frame to install

Pressure Panel and subsidiary-S/S at the same time
Coil Modulization on the ground

2 month after
starting S/S

Completion S/S 2 tier

Panel
Assy

?
?
Sub-S/S
Assy

2Tier

1Tier

Module
Work
Stand

Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
January
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Heavy Girder
Installation

S/S Heavy Girder installation

(Using Crane)
6 month after starting S/S

Heavy Girder
Lifting

In the process of Modulization of

Boiler Furnace & Back Pass on the ground
S/S Heavy Girder installation (Using Crane)
2 month after Starting S/S

Heavy Girder
Installation

Module Assy
on the Ground

Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
January
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After S/S Core Frame / Heavy Girder completion

starting sub-S/S installation and
20% of Pressure parts installation
3 month after starting S/S

After completion of S/S 1~5 tiers

starting pressure parts installation
7.5 month after starting S/S

DRUM
Lifting

4.5 month earlier in comparison with Typical Method

[Drum lifting point]
S/S Core Frame design for Boiler load support
Module work on the ground and concurrence installation
of S/S and Boiler

Winch

Lifting using
Hydraulic Jack

?
?

Drum

Drum

Pressure Parts
Module
assembly on the
ground

Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
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 Back Pass module assembly on the ground

Lifting after Boiler Coil Module work
(Using Hydraulic Jack)
Lifting after Sub-S/S module assembly

After Drum
lifting

Hydraulic Jack

Completion of S/S installation

Separate installation of Boiler Pressure
parts (Using Winch)

Winch

Coil Module
Lifting

?
Back pass Module
assembly on the
ground

Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
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 50 % completion of total S/S installation

Concurrent Lifting Boiler Back Pass and
S/S Support (Using Hydraulic Jack System)
8.5 month after starting S/S

Back Pass
Lifting

Hydraulic Jack

Completion of S/S installation

Separate installation of Boiler Back Pass
(Using Winch)

16.5 month after starting S/S

Winch

Back pass
Module
Lifting

?
Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
January
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60 % completion of total S/S installation

100% completion of Boiler pressure parts
installation
10 month after starting S/S

Hydro Test

Completion of S/S installation

Completion of Boiler pressure parts
installation
19 month after starting S/S

9 month earlier in comparison with Samchunpo

[Hydro test point]
Installation S/S Aux. after Hydro test
Ground Module assembly and S/S & Boiler concurrent construction

?
Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
January
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Completion of S/S installation

Completion of Boiler installation
15.5 month after starting S/S

First Firing

Completion of S/S installation

Completion of Boiler installation
24.5 month after starting S/S

9 month earlier in comparison with Typical Method

[First firing point]
Ground Module assembly and S/S & Boiler
concurrent construction

Modulization/Concurrent
Erection MethodPMI Revision 00
Typical Construction Method
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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

Install Heavy
Girder after
Panel Erection

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

Assemble RH Final &

SH Final Tube Module

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Sequence of Modulization / Concurrent Installation

Install
Jack for
Drum

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Sequence of Modulization / Concurrent Installation

DRUM
LIFTING

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Sequence of Modulization / Concurrent Installation

Install
Downcomer
pipes (6ea)

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

Assemble Back Pass Module

(Hanger rods, roof panel, LTRH)

Prepare the
Assembling of
SH DIV. Module

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Sequence of Modulization / Concurrent Installation

Lift the Subassembled SH

DIV. Module

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Sequence of Modulization / Concurrent Installation

Install the Jack

for SHP & RHP

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

Install the Jack

for Back Pass
Module Lifting

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Sequence of Modulization / Concurrent Installation

Install the Wire

for Back Pass
Module Lifting

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Sequence of Modulization / Concurrent Installation

1st Lifting
of
Back Pass
Module

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

Assemble the
Back Pass
Wall Panel

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Sequence of Modulization / Concurrent Installation

SH tube
bundle
lifting

Lower panel lifting

Assemble Back
Pass LTRH
Arch lifting

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Sequence of Modulization / Concurrent Installation

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Sequence of Modulization / Concurrent Installation

Assemble Eco
Tube, Eco Header

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Sequence of Modulization / Concurrent Installation

Back Pass
Module
Final Lifting

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Sequence of Modulization / Concurrent Installation

Install the
Burner windbox,
Low water panel,
Hopper panel,
Water inlet header,
Suction inlet piping.

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READYNESS OF BOILER

Hydraulic test
Gas tightness test
Air tightness test
Acid cleaning
Boiler light up
Steam blowing
Safety valve floating
Synchronisation
Performance guarantee test
Trial operation

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THANK YOU

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