ealing and anti seizing compound used in turbine as per BHEL s Turbine

manual.
==============================================
==========================
Joint plane of hpt ipt & valve casings, gland boxes & strainer housings,
breech nut mating face.
- Metal to metal joint in high temperature zone
- Use irkosit , Stag B , Magnesite compound of bhel standard.
================================================
================
Joint plane of LP outer casing (without rubber sealing chord).
-Metal to metal joint in low temperature zone
-Useoldite and Loctite 574
================================================
================
Joint plane of bearing pedestals, mop casing, valve servomotor
Metal to metal joint in oil environment
ylomer , Golden Hermetite and Victor Shellac .
================================================
=================
Threaded fastners including, breech nut threads, keys, packers,
Dowel pins u & i - seal rings in high temperature zone.
high temperature ( < 350c) antisiezing . Use molykote p37 and oks 255
================================================
=================
Threaded fastners, keys, packers, dowel pins in low temp. zone, coupling bolts
seal

segments, hp/ip casing palm packers, hp front & rear bearing pedestal packers
(other
than self lubricated lubrite packers . i.e low temperature ( < 350c) antisiezing
use Molykote d 21, Oks 511, Mgs 400
ips on different aspect of Main Turbine Erection.
-When ever JOP is not available, use always thick oil during rotation of shaft
over
bearing.The type of oil may be used as servo cylinder 1000 grade of IOC.
The bearing parting plane bolts are to be tightened to required torque only no
other
method of tightening of these bolts may be used.
-Alignment and coupling of HP-IP and LP rotors are to be completed before
starting the
rolling test of the casing in normal case but this can be done without coupling of
LP rotor
also.

-No inlet and outlet pipes are to be welded with the casing till completion of
rolling test
and installation of final keys and packer of the casing.
After completion of the rolling test the installation of final keys and packers of
the H.P.
and I.P. casing, the same can be cleared for welding of inlet and outlet pipelines.
The
main steam inlet line from main steam strainer to the control valves and then
from
control valves to the H.P. casing need much more care during erection / welding
of the
pipelines. Similarly the Hot Reheat lines between two Hot Reheat strainer to the
control

valves and from control valves to the I.P. casing also need equal care during
erection /
welding of these pipelines.
- Projections of these axes in the corresponding drgs. shall be as under :
X axis = view toward generator
Y axis = view upward generator
Z axis = view to the right
-The breech nut assembly used in between connection of main steam inlet line
and HP
module. A special care is must while making the breech nut assembly first time
at site
during erection stage. Follow the OEM instruction carefully.
ERECTION SEQUENCE (For 500 MW Fixed pedestal type Turbine with spring
loaded
foundation) BHEL MAKE TURBINE

1. Cleaning and checking of Turbine and Generator foundations as per the

transverse and
longitudinal axis including their elevation.
2. Prepare and install LP base plates, HP front pedestal, HP rear pedestal, LP
front pedestal,
LP rear pedestal along with their anchor bolts and anchor plates.
3. Provisionally align and level all the pedestal and LP base plates as per the
transverse and
longitudinal axis including their elevation.
4. Matching of anchor plates of pedestal and LP base plates to ensure their
perfect seating.
5. Finally align and level HP front, HP rear, LP front and LP rear pedestals
along with LP base

plates as per the transverse and longitudinal axis including their elevation
and catenary as
per the design.
6. Prepare and install steel bars for LP casing centralising keys in foundation
slab as per the
required centre line .
7. Weld locating ring of LP front pedestal and steel bars of LP front and LP
rear centralising
keys.
8. Prepare shuttering and grouting of the pedestals and LP base plates
including anchor
plates of HP rear pedestal.
9. Prepare, install, align/ level both the LP girder along with their carrier
plates.
10. Prepare , install and assemble LP front and rear end walls with the LP
girders.
11. Level / align LP outer casing lower half as per the transverse and
longitudinal axis of the
machine.
12. Install permanent packers of LP outer casing including their radial and
ax14. Align LP inner outer
casing lower half and level it. Install LP casing parting plane platform .
13. Prepare and install LP inner outer casing along with gusset plates in
position
14. Align LP inner outer casing lower half and level it. Install LP casing
parting plane platform.
15. Prepare and install LP front and LP rear lower half shaft seals housing and
align it provisionally.

16. Prepare and install LP rotor along with their bellows in position.
17. Align LP rotor radially and axially in position and record free run out of
rotor.
18. Record/ Ensure radial and axial clearances of the LP casing including
rotor float including
fitting of final axial keys of the LP inner casing .
19. Box up LP inner inner casing and heat tighten the parting plane bolts.
20. Box up LP inner outer casing.
21. Prepare and place HP module in position on temporary packers.
22. Transfer the load of HP rotor on bearings from the transport device and
align it radially

and axially.
23. Check free run out of HP rotor on journal and coupling face including its
float.
24. Prepare and place IP module in position on temporary packers. (In case IP
module is sent
to site in disassembled condition.)
25. Loading of IP rear end of the shaft on bearing and removal of transport
device.
26. Provisionally align HP, IP and LP rotor.
27. Couple HP / IP rotor on temporary Bolts and align rotor / casing radially
and axially.
28. Record/ Ensure IP rotor float by shifting HP casing axially.
29. Conduct Horn drop test of HP casing without any radial and axial keys
and pipe lines.
30. Conduct Horn drop test of IP casing without IP inlet upper half pipe lines.

31. Assembly of breech nut of HP casing and Main Steam Stop & Control
valve assembly.
32. Erection of Reheat Stop & Control valve assembly.
33. Weld IP inlet upper half pipe and record Horn drop values without radialaxial keys.
34. Alignment of HP/IP/LP rotors and their coupling on temporary bolts
including its couple
run out.
35. Swing check of HP rotor on its front end with temporary alternate bolt
tightened on
HP/IP coupling.
36. MOP alignment and its doweling.
37. Reaming/honing of HP/IP and LP/IP coupling including fitting of final
coupling bolts.
38. Fixing of axial position of shaft and assembly of thrust bearing including
its colour
matching.
39. Roll check of HP/IP casing and fixing of radial and axial keys of the casing
(Casing final
packers need not to be put at this stage).
40. Assembly of bearings and checking of all clearances including fittings of
side pads of

bearing, yoke keys etc.

41. Turbine Supervisory Instrument works in all the pedestal i.e. assembly
and calibration of thrust
bearing axial shift, LP rotor expansions pick up, Hall generator and
thermocouples of bearing .
42. Preparations of the bearing for oil flushing.

43. Oil flushing of the machine and normalizing the bearing after oil flushing.
44. Preparation and floating of TG deck as per OEM instruction.
45. Decoupling of HP / IP, LP/IP, LP/Gen., Gen./Exciter coupling and
rechecking of
alignment/catenary after floating of TG deck spring.
46. Final tightening of HP/IP, IP/LP , LP/Generator and Generator / Exciter
coupling after
correcting the alignment including their couple run out and swing check of
rotor on HP Front
and exciter rotor.
47. Checking /Correction of LP shaft seal clearance after floating of TG deck
with CW pump
in operation and water in the hot well of condenser up to operating level.
48. Roll check of HP, IP casing in up and down direction only with TG deck in
floating
condition and CW pump in operation including water in hot well up to normal
level.
49. Assembly of final packers of the HP, IP casing after completing the roll
check in up and
down direction.
50. Recording of final Horn drop of HP and IP casing after completing the
welding of HP
inlet, HP exhaust , IP inlet and Cross around piping.
51. Preparation and boxing up of LP casing after competing the full Roll check
of LP casing
and fitting of final casing packers and radial keys.
52. Barring gear.
Continued to Part -XII

P.S If you are looking to earn few legitimate extra money from the comfort of your home then please click
on the link given below

STRUCTURAL ERECTION PROCESS FOR BOILER

In last submission we have discussed about the secondary grouting of columns and equipment.
Structural erection can be divided into three part 1. Main Boiler 2. From boiler outlet flange
to ESP inlet 3. ESP outlet to chimney inlet. 4. Miscellaneous structure interconnection , roof
structures , elevator structures etc. Common processes followed for these structures are given
below.
- Foundation checking elevation , spacing , diagonals etc w.r.t boiler axis.
- Pitch distance mapping on foundation bolts on both axis and their diagonals .
- Sweep , camber checking of column and pre-assembly of column if required.
- Completion of boxes with Main Brace Level ( MBL ).
- HSFG bolt torque tightening and secondary grouting.
- Alignment and welding checking at every stage.
- Availability of WPS , PQR and NDE schedules.
- MPI to be carried out if the structural member thickness is > 32 mm.
- MPI / LPI test on finished weld < 25 mm.
A few protocol sheet is attached herewith for reference.

ID,FD,PA FANS FOR BOILER IN THERMAL POWER PLANT PLAN

AND BRIEF DESCRIPTION OF FANS
Till my last dispatch I completed the topics of Boiler structure , Boiler Pressure Parts , Rotary
air preheater as major equipment . I have discussed about the plans and erection sequence of the
same . Now I will discuss about the fans ( ID , FD and PA) .I am receiving number of e-mails
about my dispatches .The questions are mainly about erection sequences ,clarification of the
pictures , suitability of my erection sequence with their project and also about construction
equipment. I
request all the readers to read relevant blogs of my 87 dispatches and he will certainly get the
answer.
If there is any doubt I will be there to help you out.
Erection sequence of FANs differs with the layout of the plant. According to Mill position side
,rear
or front Fan erection sequence differs. These are true for FD ,PA fans only. ID Fan is
independent
of
Boiler erection . An e-mail received from one of the reader about the commencement of civil
work
for
foundations.
First of all we should not consider only fans in that area. There will foundations for Duct support
between Boiler Outlet Flange to ESP , Foundations for Transfer point structures , foundations for
Mill Reject System silos.If foundations require piling then piling and pile cap to be completed
with boiler foundations. If pile cap drawings are not available then pile cap can be done
afterwards.
But then pile cap to be carried out one by one. It has been seen that this type of job leads to delay

due to massive excavation for individual fans.This excavation can only be started when Boiler
supporting structure erection completion ( ceiling Girder erection , rear structure erection and air
heater structure erection completion). There should be alternate route for feeding second Pass
Pressure
Part
material feeding . Civil works for other foundations are to completed with fan foundations .
Minimum two heavy duty crane ( 250 MT) capacities will be placed in boiler rear to carry out
erection work of Boiler and CHP.Individual fan erection time cycle is around three months to
four months. During this time boiler 2nd pass erection ,ducting above air heater , air heaters ,
Eco handling structures , ESP side inlet nozzle , Gates and dampers of ducting will also be
required for erection completion. Therefore this area is very important regarding interfaces are
concern
and
close
co-ordination
and
monitoring
are
required
.
Besides ID ,FD and PA there are two important fans are there one is seal air fan and other is
scanner
fan.
A
brief
description
is
given
below.
FANS FOR POWER PLANT
-Supply air for combustion in the furnace and for evacuation of the flue gases formed from the
combustion.
-Maintain Balanced Draft inside the furnace

-Supply air for cooling of equipments working in hot zones.

-Supply air for sealing of gates, feeders & mills bearings etc.
-Air used for combustion is divided into 2 parts:
1.Primary Air
Portion of total air sent through mills to the furnace. This air dries the pulverized coal and
transport it to the furnace for combustion.
2.Secondary Air
Large portion of total air sent to furnace to supply necessary oxygen for the combustion.
Types of Fans :- 1. Axial Fan with two subgroup as i) Impulse ii) Reaction.
2. Radial fans or Centrifugal fan. ( Single suction or double suction).
FD FANS
Supplies secondary air to the furnace through APH to assist in combustion.
Supply total air flow to the furnace except where an independent atmospheric P.A fan is used.
Provides air for sealing requirement and excess air requirement in the furnace.

Axial fan-reaction type with blade pitch control is use in the Pulverized fired boiler(210/250/500
MW).
PA FANS

Supply high pressure primary air through APH needed to dry & transport coal directly from the
coal mills to the furnace.
Primary air for mills is divided into cold & hot primary air.
Axial fan-double stage-reaction type with blade pitch control is use in the Pulverized fired
boiler(210/250/500 MW).
ID FANS
Suck the gases out of the furnace and throw them into the stack by creating sufficient negative
pressure in the furnace (5-10 mmwc) in the balanced draft units.
Located in between the ESP and Chimney in the flue gas path.
Radial Fans -double suction-backward curved vane with inlet guide vane (IGV)control and VFD
control is use in all boilers
Handles large volume hot dust/ash laden flue gas (temp up to 150 deg C) from furnace and all
leakages occurring in the system till the inlet of the fan.
Overcome the pressure drop inside the furnace, Super heater, Re -heater, Economiser, Gas
ducting & ESP.
Consumes max. power in all boiler auxiliaries as it handles the large volume and heavy pressure
drop of the flue gas.
SCANNER AIR FANS

Scanner Air Fan is belong to Centrifugal Fan category.

Supply cooling air to all the flame scanners at different elevations housed in the furnace for
sensing flame.
A.C scanner fan boost the pressure of cold secondary air from F.D fan discharge duct in normal
operation.

D.C scanner operates only in case of a.c power failure and sucks air directly from the
atmosphere.
SEAL AIR FANS
Seal Air Fan is also belong to Centrifugal Fan category.
Supply seal air at a pressure higher than system or equipment pressure.
Supply seal air to raw coal feeders, mills bearings, gates etc
Seal fan either boost the pressure of cold secondary air from F.D fan discharge duct or takes air
directly from the atmosphere in normal operation.
In my next part i will provide erection sequence of three major fans.

TURBINE GENERATOR PKG ERECTION PART-XII, SPRING ERECTION

AND RELEASE - ABC OF THERMAL POWER PLANT.
Earlier days up to 250 MW most of the foundation was rigid and casted along
with the main column foundation. But now a days all the TG deck foundation
are casted having Spring /viscous dampers in between. This type of
foundation has some added advantage on turbine erection and size of
turbine column. All the foundation above 500MW and above is having such
type of foundation. In BHEL we use GERB spring as our standard spring
supplier wherever I worked.

The spring element in 500MW machines and further higher rating machines
are used with visco dampers. The springs units are not supplied to site with
required pre-tension values through these are supplied with some amount of
pre-tension. The required pre-tension of the spring units are done at site
before its installation in position. A special device for pre-compression of
these springs units is also supplied by spring supplier.

The shuttering of RCC slab of TG deck is furnished before installation of these

spring units. The top surface of individual column where these spring units
are mounted should be within accuracy of +00 mm to -3.00 mm. If necessary
these may be corrected by chipping before installations of the spring units.
The level deviation among various columns is permitted +00 mm to -5.00
mm in total including individual column variation of +00 mm to -3.00 mm.
The bottom shuttering of pedestal must be cut over the column head for
lowering the spring units.

After lowering the spring unit the cover steel plates are placed in position
with shuttering supports.

An air gap of about 5.00 mm to 10.00 mm is left between cover plate and
spring units for

settlement of deck during casting. The visco dampers are also filled up at
site only with visco liquids

supplied by spring supplier. Each spring units are placed over the resistance
pad to avoid movement

of the spring units during operation of the machine. Similarly the resistance

pad is given on top of the steel shim to avoid the shifting of the shim during
operation of the machine. Each spring unit is provided with 10.00 mm of
steel shim for future adjustment.

The TG deck springs are released after installation of all Turbine Generator
components including piping and the condenser has to be filled up to
operating level including CW pump in operation for full load condition. The
shims provided for additional compression of the spring units are also
adjusted during this stage, the final alignment of various rotors and turbine
casing are done after release of the spring unit. The Generator hydrogen
cooler & LP heater if any inside the condenser are to be filled up in cooling
water space for their operating condition before release of TG desk spring.
The insulation of various casing / pipe lines including cladding if any are also
to be installed otherwise the equivalent weight is to be incorporated before
release of desk spring. All the pipe lines connected with the Turbine and
Generator should be made available on permanent hangers and supports to
avoid any additional load on the TG deck afterwards. The TG deck should
also be made free all- around to avoid any obstruction in its movement.

During release of TG deck springs and final alignment of rotors the

condenser spring is also to be kept in floating condition considering that

condenser neck welding is already done. Similarly the condenser spring

measurement should be with in + 1.00 mm otherwise the shims may be
adjusted in condenser springs. No adjustment of TG deck springs or
condenser springs are permitted after final alignment of the rotors. During
any subsequent adjustment of TG deck spring the final alignment of all rotors
are to be checked.
There are finer points of spring installation and releasing but we need not to
discuss now. Basics of installation and releasing are given above. There are
few important activity needs to be performed which will be indicated very
briefly.
- Condenser neck welding having spring loaded foundation.
- Assembly of breach nut.
-Turbine Insulation
- Turbine Integral piping and other piping. It is better to identify the scope of
piping between IBR/Non IBR. This demarcation should be available with
construction man. Any deviation from IBR norms will attract problems from
statutory authority. Therefore system wise identification is needed. In general
oil lines ,water lines ,air lines and Gas lines are not under IBR but some of the
steam lines are under the scope of IBR. Interpretation of IBR authority varies
from state to state therefore one should take state IBR authority in
confidence.

For above works it is advised to follow the OEMs practice in vogue. All the
OEM ( original Equipment Manufacturer) detailed it in there erection manual.
One should follow the approved FQP ( field Quality Plan) for measurement
and records of various reading in the log sheets of FQP . This will help in
analysing any future problem.

TURBINE GENERATOR PKG ERECTION PART-IX, ALIGHNMENT OF

HP,IP AND LP TURBINE ,COUPLING ETC.- ABC OF THERMAL POWER
PLANT.
PART- IX
PLACEMENT OF LP ROTOR
Measure journal diameter, spigot diameter and coupling hole sizes.
Ensure centring of temporary bearing support in the LP front pedestal for
placement of LP
rotor.
Place LP rear bearing in position.

Prepare shaft seal compensator along with gaskets (Gasket to be installed in

fully ring shape
only) and position them on LP rotor with the help of supplied supports of
compensator.
Lift LP rotor with the supplied lifting beam in perfectly level condition and
place it in
position. During lowering of rotor ensure radial clearance with the help of
long feeler gauges

in the LP casing.
WELDING OF LP OUTER CASING
The welding of LP outer cover is to be carried out before placement of LP
Rotor in position
to avoid damage to the rotor.
Colour match and remove all high spots of the matching flange of the LP
outer casing.
Ensure good contact between parted diffuser of LP front and LP rear cover.
Colour match and remove all the high spots of the parted diffuser/vertical
face to ensure
good contact with the compensator at a later stage.
Colour match and remove all burrs and high spots from parting plane of LP
outer casing.
Side flange of LP front and rear cover are to be ensured in right angle to
achieve good
contact with their matching flanges.

Place LP front LP rear cover along with parted diffuser and ensure feeler tight
joint after
tightening the parting plane bolts. The joint must be feeler tight just after
normal tightening
of bolts. Do not over tighten parting plane bolts.
Ensure matching of parted diffuser face on both side of LP casing. If
necessary colour
matching may be carried out to achieve a feeler tight joint.
Drill/ream all the parting plane holes as per drawings and install all dowel
pins.
After fixing of LP front and rear cover measure the dimension for positioning
of both the
centre flanges. The dimensions are to be recorded in such a way that there is
no clearance
after fitting of centre flanges in position on both side with the LP front and
rear cover. The
centre flanges are supplied in extra length on both sides from the factory and
final length
are to be maintained at site only.
Drill/ream dowel pin holes in centre flanges and install all dowel pins in
position. Ensure
drilling and reaming of all dowel pin holes to equal depth.
Fit both the centre pieces of the cover in position.
Achieve the fitting clearances for welding as per laid down procedure.
Weld/lock LP upper half flange with respect to lower half casing with the help
of metal
cleats to minimise the distortion during welding of LP cover. The cleats may
be welded at an
interval of about one meter distance.

Carry out the welding as per the following welding procedure.

Follow the welding procedure and sequence of welding as suggested by
manufacturer.
ALIGNMENT AND COUPLING OF LP-IP & HP ROTOR
LP rotor is to be aligned on pedestal seal bore and LP inner outer casing is to
be centralised
in such a way that enough clearances are available to LP rotor, during
alignment. Now this
alignment activity of all the three rotor can be divided as below :
-Preparation of HP rotor for alignment.
-Preparation of IP rotor for alignment.
-Preparation of LP rotor for alignment.
-Alignment of LP-IP & HP rotors.
-Reaming, honing of the coupling holes.
-Balancing of coupling bolts weight.
Alignment preparation of individual rotor ( i.e HP,IP and LP) to be completed
as per OEM s
instruction manual and this is not discussed here. I am going to the next
step.
ALIGNMENT OF HP, IP AND LP ROTORS
-Ensure radial and axial run out of all the three rotors are individually in
order. If necessary
Individual rotor module can be taken out for correction of coupling face run
out. Any
Variation on radial run out of rotor is to be referred to the factory.
-Match coupling faces of two rotor as per the axial face reading of the rotor.
Ensure that the

higher point of the rotor coupling face and lower point of another rotor
coupling face are
matched together. This is to be compared with shop protocol also.
-Preliminary align (radial and axial) all the three rotors and shift them in
spigot along with
the casing to avoid fouling of rotor inside the casing.
-During alignment achieve left and right movement of the rotor with the help
of shims in
spherical / torus piece of the bearing. The up and down movement of the
rotor is to be
achieved with the help of shims in the cylindrical/spherical support of the
bearing . The
adjustment of shims in the bearing should be within the permissible limits
only.
-Ensure during alignment that the catenaries of the shaft are maintained.
-Check/record spigot clearance of HP-IP and LP-IP rotors by actually moving
them in spigot.
Install four nos. supplied bolts along with one/two pins in HP-IP and LP-IP
coupling. Hand
tighten the coupling bolts by keeping a gap of > 1.00 mm in coupling faces
for alignment.
Rotate the rotor system and record the coupling gap at 90 Deg. intervals on
left, right and
top position. Ensure that the coupling, bolts and pins remain free while
recording the gap of
the coupling for the alignment purposes.
-Check swing check value of the HP rotor with alternate bolts in position. The
above value
must be within the prescribed limit only otherwise a correction must be
carried out at site in

consultation with designer.

-Ensure free movement of rotor on their bearing. Do not rotate the rotor if it
is tight during
its rotation.
-Ensue that the coupling holes are properly aligned to avoid unnecessary
enlargement of
holes.
-Ensure HP-IP-LP rotor radial run out after tightening with alternate clearance
bolts. Release
the couplings for reaming / honing of couplings.
REAMING / HONING OF COUPLING
Ensure that there is no disturbance on coupling during reaming/honing
operation.
First ream/hone two opposite holes of the coupling and install two pins/bolts
with sliding fit
and then take up all other holes.
Enlarge coupling holes to the minimum possible diameter and try to make all
the holes to
same dia.
Ensure that the finished holes are straight and there is no banana shape.
This can be
ensured by checking hole with a straight ground finish pin having 0.02/0.03
mm clearance.
Reaming ,Honing of coupling holes is an expert job for machinist and not the
job of erectors
. Therefore it will be better to engage professional service to do this job.
BALANCING OF COUPLING BOLTS
After fitting the coupling bolts in all the holes these are to be balanced within
+/-5 gms

accuracy and an accurate balance which can take a load of about 20 kg. may
be used. During
balancing of coupling bolts following points are to be taken care.
Final balancing of the coupling bolts are to be done along with the coupling
nut of individual
bolt.
If all the coupling bolt hole sizes are same before/after reaming and honing
then all the
bolts can be kept of equal weight.
If necessary adjust the weight of the bolts by machining the metal from the
bolt head.
COLOUR MATCHING OF THRUST BEARING
After completion of reaming/honing and preliminary tightening of the
coupling bolts, the
colour matching of the thrust bearing pad have to be carried out with respect
to the thrust
collar of the HP Rotor. During colour matching a good contact on all the pads
of front and
rear side are to be ensured with respect to rotor collar by moving the rotor in
+/- direction
during its hand rotation.

ERECTION PLAN AND SEQUENCE FOR AIR PREHEATER PART-V

Air Pre-heater erection Part - V continues

Air pre heater erection sequence and plan is given above. Also this process can be
utilised for
monitoring purpose. Electrical ,C&I are left out as the same will be discussed
separately. Air
heater erection from start to erection finish is about 4 to 6 months job. Material flow
for the
job should be as per sequence mentioned earlier. Around 30 to 40 persons are
required to
execute the job in that time frame with adequate T&P and IMTE.

ERECTION OF AIR PREHEATER FOR SUPER CRITICAL BOILER PARTIV

Air pre heater erection continues part-iv.

ERECTION OF AIR PREHEATER PART-III OF SUPER CRITICAL

THERMAL PLANT
Air Pre Heater erection continues:-

AIR PREHEATER ( LUNJSTORM) FOR BOILER ERECTION PLAN PART-2

Air preheater erection can be started just after erection of last ceiling girder and can
be continued
along with Pressure Part erection. However approach for pressure part should be
kept open.
For Boiler where Air heaters are installed in second pass approach from rear and
both sides
should be available. Two other issues may crop up i) Construction of fan foundations

( PA & FD)
ii) Erection of ducts just above Air heater. It is noticed that approach area at the
rear gets
congested early because of multi- discipline starting of erection work like ESP , SG ,
coal
gallery , Ash handling work , duct support , electrical tray work etc. Therefore it
needs good
planning and idea about the priorities for all the above work otherwise conflict
bound to happen
and derails the time schedule.

AIR PRE HEATER FOR BOILER IN THERMAL POWER PLANT

We have completed our discussion on Steam Generator structural and
Pressure part erection
work. Small tips were also provided to construction worker which i think will
be useful during
actual erection work. After completing the structural and pressure parts it is
time now to discuss
about other main equipment like AIR PRE HEATER.
An Air Pre heater (APH) is a general term to describe any device designed
to heat air, before
another process (for example, combustion in a boiler) with the primary
objective of
increasing the thermal efficiency of the process. They may be used alone or
to replace a
recuperative heat system or to replace a steam coil.
Air pre heaters are mainly two types (i) Tubular Airheater (ii) Ljunstorm
rotary air pre heater

bisector or trisector. Tubular air heater is now becoming an obsolete

equipment only can be
seen in old and small capacity power house. However use of Ljunstorm air
heater is common
to any size of unit. There are advantages and dis advantages for both type of
air pre heater in
use. We will confine our discussion only on Ljunstorm air preheater erection.

The picture above shows the overall construction feature of Ljunstorm air pre
heater'

Names of the main parts of the LJUNGSTROM APH are:1) Expansion block (08)

2) Cold centre section (01)

3) Main pedestal (02)
4) Side pedestal (02)
5) Guide bearing Assy (01)
6) Support bearing Assy (01)
7) Rotor post (01)
8) Cold pocket ring (08)
9) Hot pocket ring (08)
10) Hot centre section (01)
11) Cold end tension rings (08)
12) Hot end tension rings (08)
13) Drive pedestal (01)
14) Rotor drive unit
15) Guide bearing oil circulation unit
16) Support bearing oil circulation unit
17) Rotor stoppage alarm sensor
18) Soot blowing system
19) Leakage control system
20) Shop assy modules (09)
21) Semi modules (09)
22) Gratings (72)
23) Baskets(heating elements)
24) Duct corner Assy (08)
25) Seismic stoppers (08)
26) Rolled panels/Casings (16)
27) Field insulation
28) Thermocouple for temperature Measurement.

Picture shows the location of Air preheater in a boiler ( having mills on the
side) . PAPH stands
for Primary Air Preheater ( Left and Right) and SAPH stands for Secondary Air
Preheater (Left
and right)

Picture above shows Air Preheaters are in advanced stage of erection including
interconnecting duct.

SECONDARY GROUTING OF COLUMNS STRUCTURE AND EQUIPMENT

FOUNDATIONS FOR THERMAL POWER PLANT
We have covered the topic of Bolting in structures and one more important activity to be done to
all columns , equipment foundations ( static /rotating) is secondary Grouting . The process of
doing the same is given below.
-The surface of the foundation shall be dressed up to required level before placement of column.
- Top 25 mm /loose concrete should be chipped of and cleaned.
- If necessary grove is to be made on the foundation for placing packer plate.
- The grouting cement shall have high strength having minimum compressive strength.

- The value is 50 to 60 N/mm2 at 28 days.

- The grout shall be chloride free, cement based ,non-metallic , free flowing Grout.
- The Grout shall have good flow ability even at very low water/ grout powder ratio.
- The Grout shall have characteristics of controlled expansion to be able to occupy
its original volume to fill the voids and to compensate for shrinkage.
- Grout shall be of pre-mix variety so that only water needs to be added before use.
- After the base has been prepared, its alignment and level has been checked and approved
and before actually placing the grout, a low dam shall be set around the base at a distance
that will permit pouring and manipulation of the grout. The height of such dam shall be
at least 25mm above the bottom of the base. Suitable size and number of chains shall
be introduced under the base before placing the grout, so that such chains can be moved
back & forth to push the grout into every part of the space under the base.
- The top surface pocket of the bolts etc was cleaned with water .
- The surface was then cleaned with compressed air to remove any presence of water in the
pocket.
- The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides to make the grout move in a solid mass under the base
and out in the opposite side. Pouring shall be continued until the entire space below
the base is thoroughly filled and the grout stands at least 25 mm higher all around than
the bottom of the base. Enough care should be taken to avoid any air or water pockets
beneath the bases.
- There are few suppliers in INDIA who are supplying ready mix concrete in 25 kgs bag.
- The suppliers are FOSROC ( CONBEXTRA GP 1 OR GP 2) , ACC ( SIKKA )

PIDILITE ( PAGEL CEMENT).

- It is all time better for grouting critical area manufacturer's representative should be
present at site during grouting and taking sample for cube test.
- The columns is to be loaded before grouting so that there is no deviation from initial data.

Above picture show the secondary Grouting of Turbine pedestal . Form work is seen in the
picture .
Already grouting has been completed.

Concrete pouring through mechanical mixture machine under progress.

CONSTRUCTION TIPS ON PRESSURE PARTS ERECTION FOR A

THERMAL POWER PLANT.

Colour Coding of filler wire

Specification

Brand Name

RT Mo (ER 80s-D2)

TGSM

Colour Code
Green

RT 1 Cr Mo (ER 80s B2)

TGS 1CM

Silver grey/white

RT2 Cr 1 Mo (ER90s B3)

TGS 2CM

Brown /Red

RT 9 Cr 1 Mo V

TGS9Cb

RT 347 (ER 347)

TGS -347

Blue

Low and extra low Hydrogen Electrodes

As per IIW (Indian Institute of welding) classification of Hydrogen
Content classify electrodes is given below.
High : greater than 15 ml /100gm
Medium: 10-15 ml /100gm
Low: 5-10 ml /100 gm
Extra low: less than 5 ml /100 gm
Baking, Storage and Handling
The electrodes have tendency to pick up moisture when exposed
to atmosphere and the amount depends on the time, relative humidity
and also the type of coating on the electrode. The recommendation
of baking electrodes are given below.
AWS Classification

Baking temperature & Time Holding temp

E-7018

250-300 & 2 hrs

100 deg C

E-7018 -1

250-300 & 2 hrs

100 deg C

E-7018- A1

250-300 & 2 hrs

100 deg C

E -8018 B2

250-300 & 2 hrs

100 deg C

E-9018- B3

250-300 & 2 hrs

100 deg C

E-8018- B2L

250-300 & 2 hrs

100 deg C

E-9018 B3L

250-300 & 2 hrs

100 deg C

E309 & E347

250-300 & 1 hr

100 deg C

** - After issue the electrode from site store to welder the temperature
Portable oven should be around 65 to 70 deg C during actual use by welder.
This is not applicable to E309, E347 and E 6013.
Selection of electrodes for non pressure parts work
Material P1 + P1
A. For butt welds, up to 6mm inclusive: E6013
> 6mm

: E7018

B. For fillet welds up to 8mm inclusive

> 8mm

: E6013
: E7018

Carbon Steel + P1

: E6013 or E7018

Carbon steel + Carbon Steel

: E8018 B2

Note: E6013 can be used for all non load carrying welds of all thickness
of IS2062 plates 20mm thickness and 8mm fillets. For structural material
like Ceiling Girders thickness of material is > 63 mm needs preheating (120

Degree C) and stress relieving (600-700 degree C) depends on material.

Common Knowledge required by construction supervisors engaged in boiler
work
Weight Calculation for tubes:W = (D-1.1425t) x 1.1425t x 0.024466 Kg/M
W= Weight of the tube in kg/M
D = Specified outside diameter in mm
t = Specific thickness
Weight Calculation For pipes:W = (D-t) t x 0.02466 kg/M
W- Weight of pipes in Kg/M
D- Specified outside diameter
t - Specified thickness
Weight Calculation for ID controlled pipes/tubes
W = (Dot) t x 0.02466 kg/M
W- Weight of pipes in Kg/M
D- Specified outside diameter
t - Specified thickness
Temperature Measurement
For measuring the stress relieving temperature we generally use
Thermocouples. The thermoelectric voltage in a thermocouple depends
on the temperature difference between two junctions and is used and
is used for the purpose of temperature measurement when one of the
temperature is known. At project site we use Chromel Alumel thermocouple
popularly known as K type.

Colour Code of thermocouple is yellow (+) and Red (-) over all Brown.
(Polarity +/- should be known otherwise it will give erroneous reading)
Thermocouple extension wire Yellow (+) and Red (-) overall yellow.
(Thermocouple can only be connected by thermocouple extension wire not
by any other wire)
There are other types of thermocouple but in India K type is only used at
the project site. The temperature milivolt curve is linear. The increase is
4.13 mv per 100 degree C. (approximately)
Radiography Source
In India for industrial radiography we use two type of source i.e Cobalt -60
and Iridium -192. Out of that use of Cobalt -60 is extremely unpopular
because it requires stringent safety precautions to be followed and it
affects the progress of work. Instead of cobalt -60 now a days all are
using ultrasonic machine to detect the fault. Ultrasonic machine requires
Test block (made of same material to be tested) to be made as per the
Specification of IIW.
Iridium -192 is having half life of 74.4 days. All our pipes and tubes are
Radio graphed by this source except pipe /structural thickness of > 60 mm.
In those cases only UT is performed. The Iridium source should be more
than 30 Curie strength. It will require less exposure time and time can be
saved. Exposure time is inversely proportional to the strength. In 500MW
/660 MW boiler around 10,000 to 12000 shots are taken.
For surface defects of welds two very simple tests are carried out (i) Magnetic

particle test (ii) Dye Penetration test.

STRUCTURAL ERECTION CONTINUED FOR THERMAL POWER PLANT
We will be discussing about the bolting structures in Steam Generation .
Most of the structures erected for Boiler is either welded or bolted . Some of the company
used both as per their design. For all the bolted structure HSFG bolts are used . HSFG
stands for High strength Friction Grip bolts . The specification and use of such bolts are
explained in IS 3757 - 1985 and IS 4000 - 1992. However we will give only the information
required at site .
-The most commonly used ordinary bolts are 4.8 grade
- The most commonly used High strength is 8.8 Precision bolts.
- High strength bolts used in INDIA is 8.8S and 10.9 and 10.9S..
- The grade and manufactured name are embossed on the head of the bolt.
- Generally we use M16 , M20 and M24 of various length.
- As a thumb rule after tightening of the bolt at least 10mm length protruded outside nut.
- These bolts are used for column to column connection , bracing connection , gusset plate etc.
- The bolts are hand tighten at first. Then these bolts are tightened by electric or pneumatic
torque wrench . The value can be obtained for IS codes mentioned above.
- Finally calibrated manual torque wrench is being used to check the tightening in citu
by sampling method.
- There is also other method where HSFG bolts quantities are very less. The same is called
half turn method . The same has been explained in the IS Code.
- Colour coding is used to identify bolts to be torque tightened , already torquing done
and after torquing checking is also completed. This will give us status of torquing at a

glance.
- HSFG bolts are much costlier than ordinary 4.8 and 8.8 precision bolts.
- Bolt once torque tightened can not be used for the same purposes.

Above picture shows the erection of bracing in steam generation. Wherever HSFG bolts are used
are shown in the picture. Column bolting also can be seen in the picture.

CONSTRUCTION PLAN FOR PRESSURE PARTS- SCHEDULE FOR

11MONTHS PART -IIn
Continued from last dispatch about erection plan for pressure Part of
super critical boilers

6th month erection schedule

Furnace Rear wall Interim Header
Furnace Rear wall Intermediate Header
Furnace lower buck stays
Upper furnace key buck stays
Lower Furnace key buck stays
Low Temperature Re Heater inlet header
Low Temperature Re Heater coils lower

7th month erection schedule

Furnace Lower Spiral Rear wall panels
Furnace guides
Economiser outlet header ( after pre-assembly)
Economiser outlet terminal tubes (after pre-assembly)
Economiser miscellaneous items supports, suspension etc
8th month erection schedule
Circulation system for feed water
Furnace loose tubes for connecting furnace corners , burner panel etc
Pressure Parts attachment items
Economiser coil upper assembly ( after pre- assembly
Economiser intermediate plain tube ( after pre-assembly)
Recirculation pump and its piping etc (coming under Trim piping group)

9th month erection schedule

Furnace front ,rear and side (L & R) header lower after pre-assembly
Furnace bottom support after pre-assembly
Expansion movement attachment, seal boxes arrangement etc
Super heater & Re heater spacer tubes
Economiser inlet header ( after pre-assembly)
Economiser coil assembly lower ,Economiser Feed pipe and link etc
Economiser outlet link etc
10th and 11th month schedule
LRSB ( long retractable soot blower) mounting on furnace
wall de slagger mounting on furnace
Temperature probe
Root valves for vent and drains
Boiler Recirculation Pump and piping
Starting of trim piping line ( soot Blower piping)
Attachment work like door ,peep hole etc ,Supports of economiser line etc
Mixing vessel , CBD and IBD tank , piping , vent piping etc.
Schedule mentioned above is tentative and hold good for matching supply . This can be
varied as per requirement of site as per availability of material. We have not mentioned
the pre- fabrication of crown plates. This is a major activities and can be started with
ceiling girder pre-assembly if material (alloy steel ) plates are available. The prefabrication involves welding , pre-heating and post heating also. For pressure parts

erection we require 10 to 12 electrical winches ( 2 nos 10 T , 4 to 6 nos 5T ,rest

can be 3T) with 10000 mtrs wire rope 12 mm 19mm will be required . The winches
are to be positioned side of the main column. The level of winches should be 1 M
above the ground level so that winches remain unaffected due to accumulated water
below. Large number of max puller ,chain pulley blocks will be required ( more than
100 numbers).
Welding of pressure parts start from zero dates of pressure parts at pre-assembly bed.
We are not going to discuss about welding here as this is specialised subject but
information required for construction will be shared.

STRUCTURAL ERECTION OF STEAM GENERATOR PART-IV.

Structural erection of steam Generator /boiler can be divided into few parts according to the
importance .
a. Preparation of soil inside the cavity for heavy duty crane movement in spite of columns
located
inside the cavity.
b. Secondary grouting of the columns by ready mix concrete.
c. Procedure of torque tightening of HSFG bolts .
d. Most important item is fabrication and erection of Ceiling Girders . This is heaviest structural
items
to be lifted at site.
e. Structural items like beam ,bracing , welded beams ,rolled beams , angles ,channel , fabricated
piece
etc are erected as per drawing as routine erection but a planning needs to be done before hand so
that
clear passage to be kept at ground level so that crane can move inside and also passage to be
made
for pressure parts material movement. It may require a few bracing to be kept on hold for
erection.

The above picture shows a heavy duty crane is standing on platform . Platforms are made to size
by
20 mm steel plates and ISMC 100/ISMC 150 channel. These platforms made such a way that
crawler

of the crane can stand on it. Platforms can be easily removed from one place to another while
the
crane is on move. In some place 12" square and 10' -12' long wooden logs are used instead of
steel
platform. However arranging wooden logs is very difficult now a days therefore every body
tries to
make steel platforms. The soil need to be compacted by running roller if required boulder
pitching
has to be carried out. Laying of platform should be done such a way that there should not be any
load on the foundation columns located inside the cavity. This can be understood if some one can
looked into the boiler plan given on earlier submission. Any heavy duty crane of 600 MT or 1200
MT
needs to stand firmly on platform within a limit of undulation . Crane manufacturer set half a
degree
is the max limit. A crane sizing ( capacity) depends on lifting of ceiling girder ( heaviest one ) to
required height. In our 660 MW we choose 600 MT Manitowac crane with luffing jib at 67 M
and
jib can lift the heaviest girder. This was done to keep in mind the erection of welded beams ,
rolled
beams and roof structure including the silencers. Our erection method i.e erecting boiler structure
from the cavity does not suit the heavy lift crane with super lift arrangement as crane will not
have

radius to move. Above picture shows the crane platform from other angle.

we will discuss secondary grouting of columns and HSFG bolting at the end.
We will now discuss about the ceiling Girder fabrication and erection.
The limits set out for ceiling Girder pre-fabrication is given below.
- Root gap at the erection joint of the ceiling Girder. Flange 4 mm to 6 mm , web 6
to 10 mm.
- Camber and sweep of individual ceiling girder 1 mm/ M , max. 15 mm
- Assembled ceiling girders for sweep and camber 1 mm / M max 15 mm.
- Position of Bottom bolt hole with reference to centre of the ceiling girder + /- 3
mm
- Spacing between adjacent ceiling girder +/- 5 mm ( taken during Girder alignment)
- Diagonal difference between to adjacent girders is 25 mm Max .
-ceiling girders centre line variation w.r.t. Boiler axis 12 mm Max.

STRUCTURAL ERECTION WORK PART -III OF STEAM GENERATOR/

BOILER.
Spacing between reference axis and pedestal

1 mm/ M or + /- 5mm

( Reference axis is the line which is centre line some times calls as Boiler axis. It is transferred
from
the Bench Mark having marked latitude , longitude and elevation. This point is transferred
column
number 13 and 17 . )
Spacing between two foundations ( adjacent)

1 mm / M or + /- 5 mm

Spacing between first row and last row foundation 1 mm / M or +/- 15 mm

Diagonals between foundations

1 mm / M or +/- 10 mm

( this is most important measurement )

Pitch difference between two foundation bolts

+ / - 3 mm

Diagonal difference between foundation bolts

+ / - 5 mm

(All foundations are having template made OF steel plates with holes pitched as per drawings .
Bolts are placed there and bottom channel has been locked . The bolts cannot be moved during
casting of foundations . This checks has to be carried out before casting of columns.)

The above picture shows that Boiler column erection has started . Formation of Box between
Main
column and Auxiliary Column is under progress. Some of the manufacturer columns are joined
by
HSFG Bolts . In this picture main column is bolted but auxiliary columns are welded and also
bolted.

The above picture shows boiler erection ( structural) is under progress. Loose columns are tied
with
Guy rope . End of the Guy rope is either terminated to max puller or a hand winch . Both the
cases
the equipment is securely anchored.

Most of the foreign manufacturer supplies material tier wise so that this type of erection is not
done . This type of erection is having safety issues and can be termed as unsafe . But due to
non sequential material such erection was carried out.

250 MT crawler crane assembly is going on.

STRUCTURAL ERECTION PART -II OF STEAM GENERATION

We will now discussing the erection of Steam Generator structures . Our discussion will be
mainly on super critical boiler which is now being introduced in India. The unit capacity is 660
MW onwards. Capacity less than 660 MW units are all sub critical and available in plenty in
India.
Structures for Sub critical and super critical do not have major difference in construction.
Structure can be divided in to following parts .
1. Structure which is holding the furnace

6780 MT

2. Structure which is holding platforms ,Air heaters and auxiliaries

3600 MT

3. Structure which is holding ducts of boiler , BOF to ESP and ESP to chimney 2340 MT
4. Misc. inter connecting structures ,platforms ,handling ,elevator etc

1200 MT

The above tonnages are approximate tonnage of a 660 MW boiler . Quantity of smaller unit will
be less than what it is indicated. However the tolerances followed will be the same. Some of the
common tolerances followed not only for Boiler but also civil structure is given below.
he surface1. Individual column piece sweep and camber
1 mm / M max
up to 10 mm
( Individual columns are placed on the pre-assembly bed to check the sweep and camber. Preassembly
bed need to be prepared carefully so there is no undulation on top of the surface. Beds are
prepared
by using concrete blocks and beams . Dimension check ,cleat angle welding , Marker fixing ,
Bolt
Hole cleaning etc are done at Pre - assembly bed.)
2. Camber and Sweep for assembled column
mm
3. Total length of column

1 mm / M max up to 10
+ / - 15 mm

4. Top elevation of column with reference point

+ / - 5 mm

5. Position with reference axis

+ / - 5 mm.

( Measurement of the total length was done at manufacturing time . However during erection
same
check is being carried out after erecting the piece of column and dropping plumb from the top to
the
reference point at regular interval ( thrice up to the 7 th tier ). Final check has been done after
6th tier
column erection and before seventh tier erection. Seventh tier measurement done at ground. )
Grouting Gap below the column base

minimum 20 mm to 70 mm max.

( Ideal gap is 35 mm to 45 mm ) for easy free flow secondary grouting)

Elevation of Top of pedestal

+ 30 mm to - 20 mm.

( All the pedestal need to be cleaned from loose concreting on the surface. At least 10 mm /15
mm

to be chipped of to position the packer plate below the column base plate . If the pedestal is more
on positive side then we have to chip more and doing it manually as it is being done in India will
be
taking extra time. It is all time better to have pedestal elevation on negative side.) .

Typical floor plan ( foundation detail ) of Steam Generator is given above. Column no 7 to 17 L
&R(
except 17 all other columns having two numbers i.e . one in right side and other is on left side)
are the
main columns and column number one to six ( L& R) auxiliary column. Distance between 7R
and 7L
will give an idea of space availability in Boiler cavity. This area inside the boiler is very
important for
erection of steam Generators. Inside the Boiler Cavities there are column no (14 ,15 and 16 ) L
&R .
These columns are shorter columns in height and need to be erected afterwards i.e. only after
erecting
the ceiling Girders. However these column foundations need to be protected until and unless we
start
erection on these columns../

STEAM GENERATOR ERECTION PART- I

We have covered important civil works in thermal Power Station. We have discussed major
works in civil and structural work . How they have been carried out , the requirement of tools
and tackles for the job, Limits and tolerances to be kept for the job. Last 50 episodes will give a
total picture of civil and structural work to the newcomers.
Now we will start discussing major equipment of thermal power plant. Power Plant can be
divided into a few major groups .
1. Steam Generator or popularly known as Boiler and its auxiliaries.
2. Turbine Generator and auxiliaries .
3. Coal Handling Plant
4. Ash Handling Plant.
5. Switch yard
6. Plant electrical and C&I system.

7. Balance of Plant ( Beside above major packages other packages like water system etc)
We will discuss it all one by one starting with steam generator. However our discussion will be
confined to erection and basic design input required. Definition of steam Generator can be
obtained from any standard book or from Internet.
Size of steam Generator will be different for different size of unit e.g 60 MW ,120 MW , 210
MW , 250 MW , 300 MW, 500 MW ,600 MW , 660 MW and 800 MW. Mostly these sizes units
are available in India . The sizes will be different for same unit if fuels are different in
composition. However construction features will be same for all the units.
- Steam generators comprises of following components .
- Structure ( columns , bracing ,beams , angles ,platforms , Ceiling Girders , welded beams
,rolled beams , HSFG nuts and bolts , Gusset Plates etc.
- Pressure Parts ( water wall panel , economiser , super heater Panels , HP piping , Re heater ,
Suspension , headers , Link tubes , Tie rod etc.
- Ducting - Air and flue gas Pass through it. Plates, beams , pipes etc are required to manufacture
the ducts.
- Rotating Machinery - FD ,ID ,PA , SEAL AIR FANS , MILLS and other small rotating
equipment.
- Insulation - Glass wool or rock wool , refractories etc.
SOME OF THE ERECTION TOLERANCE FOR STRUCTURAL WORK IN A POWER
HOUSE
(TYPICAL)
-Foundation for columns ( Top elevation)

- 20 mm / + 10 mm.

-Dimension between two adjacent foundations for columns

mm

1mm/metre max. up to + 5

-Adjacent pedestal diagonal difference

mm

1mm/metre max. up to + 15

- Foundation Bolt pitch difference

+ 3 mm

- Foundation bolt diagonal difference

+ / - 5 mm

- Grouting Gap for secondary Grout

- Individual Column sweep and Camber
-Total length after pre-assembly

+ 25 to + 70 mm (max)
1mm/metre max. up to + 10 mm
+ / - 15 mm

- Sweep and camber for total length

max 15 mm.

- Out of vertical

1mm/metre max. up to 25 M

- Elevation Tolerance at reference level

+ 5 mm

- Level difference of supporting joints

5 mm

- Deviation difference between purlins

5 mm

- Crane Girder centre to center spacing

5 mm

- Crane girder top level

5 mm

- platform level difference

5 mm

- HSFG bolt tightening

( as per size of the bolt with torque wrench )

- when truss span < 25 metre

+ /- 7 mm

- truu span is > 25 metre

+ / - 10 mm

- Beam span is < 25 metre

+ / - 10 mm

-Beam span is > 25 metre

+ /- 15 mm

SOME OF THE FABRICATION TOLERANCES

Name of Deviation

column

Beams

Crane girder

Base plate and column

0.1 mm

Frame Joints

2.0 mm

Web and flange

1.5 mm

1.5 mm

0.1 mm

Web & stiffeners

1.5 mm

1.5 mm

0.1 mm

Flange & stiffeners Intermediate

stiffeners & Bearing stiffeners:

1.5 mm

Cap plate & column

0.1 mm

Crane girder seat

0.1 mm

1.5 mm

0.1 mm

Beam brackets

2.0 mm

PORTABLE HOLDING OVENS FOR WELDER 'S USE AT WORK SITE.

A TYPICAL SKETCH OF COLUMN FOUNDATION SHOWING MEASUREMENT PTS.

STRUCTURAL WORK CONTINUED WITH WELDING

- Suitable electrodes are to be used for the structural steel.
- Generally low Hydrogen electrodes are used for plates more than 20 mm thickness.
- All low hydrogen electrodes shall be baked and stored before use as per manufacturer
recommendations.The electrodes shall be re baked at 250 C - 300 degree C for one hour and later
on cooled in the same oven to 100 degree C. It shall be transferred to an holding oven maintained
at 60 degree C -70 degree C. The electrodes shall be drawn from this oven for use.
- Minimum pre-heating and inter pass temperature for welding is given below.
- Thickness of thicker part at the point of welding
SAW

Welding with low hydrogen electrode or

Up to and equal to 20 mm thickness

none

Over 20 mm and Up to and equal to 40 mm

20 degree C

Over 40 mm and Up to and equal to 63 mm

66 degree C

Over and Above 63 mm

110 degree C

- Pre -heating can be done by LPG heating , electric resistance heating or by electric induction
heating.
- Temperature can be checked by thermal chalk or putting Thermocouple ( generally Nickelcromium-Nickel ) . The relation between temperature and voltage is 4.12 mv /100 deg c rise
(approximately).
- Sequence of welding to be followed as per WPS and drawings .However a few basics may be
noted.
- The direction of welding should be away from restraint point and should be towards open end.
- Butt weld in flange plates and/or web plates shall be completed before the flanges and webs are
welded together.
- Generally The beam and column stiffeners shall preferably be welded to the webs before the
web and flanges are assembled.
- All welders including tack welders to be tested as per IS codes and identity card to be issued for
verification time to time during actual job.
- Carry out Non Destructive examination RT / UT /LPI as per requirement.

A general view of fabrication yard where plates are getting cut into pieces for
further fabrication.

A general view of electrode drying oven . The electrodes are dried here and
transported to holding oven.

STRUCTURAL WORK IN A THERMAL POWER STATION

Structural work comprises of Power House structure , Gallery , Miscellaneous building structures
, pipe and cable rack structures etc. It has two parts one is Fabrication and other part is erection.
In India structural work ( civil) are executed at site unlike Boiler and other equipment . The
approximate tonnage involved in structural work is given below .
- For a project 2x210 MW unit the structural steel required is

13000 MT.

- For a project 2x500 MW unit the structural steel required is

29000 MT.

- For a project 2x660 MW super critical unit structural steel required is 30000 MT.
Fabrication for the above tonnage is also done at site.
STRUCTURAL STEEL.

Some of the standard sections of structural steel are given below for ready reference.
Angles : Designation

Beam

Size ( lxbxt)

weight in kg/M

ISA 50x50x6
ISA 50x50x5
ISA 65x65x5
ISA 65x65x6
ISA 65x65x8
ISA 75x75x8
ISA 100x100x10
ISA 130x130x10
ISA 130x130x12

50x50x6
50x50x5
65x65x5
65x65x6
65x65x8
75x75x8
100x100x10
130x130x10
130x130x12

ISMB 100
ISMB 125
ISMB 150
ISMB 175
ISMB 200
ISMB 250
ISMB 300
ISMB 400
ISMB 500
ISMB 600

100 X50 ( HXB)

125 X 70
150 X 75
175 X 85
200 X100
250 X125
300 X140
400 X 140
500 X 180
600 X 210

8.9
13.3
15.0
19.6
24.2
37.3
46.0
61.5
86.9
123.0

75 X40
100X50
125X65
150X75
200X75

7.14
9.56
13.10
16.80
22.30

Channel ISMC 75
ISMC 100
ISMC 125
ISMC 150
ISMC 200

4.9
4.1
4.9
5.8
7.7
8.9
14.9
19.7
23.4

( these are few section mentioned above generally being used in thermal power structural
fabrication.)
Besides standard machine cut plates are also used such as 6mm, 8mm , 10mm,12mm, 16mm ,
20mm, 28mm ,32mm ,40mm, 50mm up to 63mm. ETC.
- Fabrication to be done as per fabrication drawing developed from the structural drawing. There
are companies available in India who makes the fabrication drawings / detailed drawing. The
fabrication drawing includes every detail requires for fabrication.
- Welding of structural items are done by electric arc process as referred in the drawing. For
resolving any disputes these documents may please be referred. 1. Drawing . 2. Welding

Procedure defined (WPS) .3. Welding Manual . 4. NDE manual .5. Relevant IS codes like 817 ,
7215, 12843 ,1852 , 2062 , 9595, 3502, 1239, 3589 etc 6. ASME sec IX 7.
- Submerged arc welding shall be used for welding longitudinal fillet welds.
- Longitudinal / transverse butt joints for fabrication of columns, framing beams and crane
girders and
all other built-up members.
- Efforts should be made to position the job such a way so that down hand welding is possible.
-Only qualified welders are to be employed for welding procedures and positions.

Fillet weld members should be close enough so that gap is 0mm. In no case the gap
should be more than 3mm. For example if the fillet gap is found to be 2 mm then
fillet size of the joint should be increased by 2 mm.

PUG MACHINE

CIVIL WORK FINAL SUBMISSION FOR THERMAL POWER PLANT

Foundation of steam Generator under progress. This is last lift of the foundation
where all the foundation bolts are placed temporarily. Engineers are checking the
same with the help of Total Stations so that bolts can be locked with the template
before pouring of concrete.

Series of foundations are shown here . This includes raft ,pile cap and final lift of
foundations including placement of foundation bolts. Concrete blocks shown in the
pictures are for pile load testing. Some of the unbroken piles are also seen here.

This is a picture of TG bay inside power house on early day of construction On the above all
main power TG Deck supporting structures for Turbine and Generator auxiliaries will come to
existence.

Completed foundation at TG Bay is shown. Preparation of removing shuttering is

under progress. Pocket cleaning and final dressing under progress before offering to
mechanical sub vendor for final checking and erection of equipment.

During last write up we have mentioned about different testing and sampling to be done as per
Field Quality Plan. Frequency of sampling and testing of some of the major ingredients are
given below.

Frequency of sampling and testing

Grain Size Analysis

One in every 2000cu.m /type/source

IS 2720

Shrinkage Limit & Free Swell index

One in every 5000cu.m /type/source

IS 2720

Organic matter, Calcium Carbonate, PH etc

One in every 5000cu.m /type/source

IS 2720

Standard Proctor test , Moisture content of fill

One in every 2000cu.m /type/source

Dry density and Permeability Test

Random Test

IS 2720

Coarse Aggregate
Particle Size and Shape ,Moisture Content
Specific gravity , density, voids, absorption

Flakiness and petrographic examinations

others ,soundness ,Reaction with alkali etc

One in every 100cu.m /type/source IS2836

Once in 12 weeks /source

IS2836

Once in 12 weeks /source

IS2836

Random.

( Acceptance criteria will be governed by IS383.)

Fine Aggregate /Sand

Particle Size and Shape

One in every 100cu.m /type/source

IS2836

Specific gravity , density, voids, absorption ,

Soundness and petrographic Examination,
Mortar making Properties , Reaction with
Alkali,.
Once in 12 weeks /source

IS2836

Bulkage , Moisture Content (Routine test)

IS 2836

Every day

Cement
Setting Time , Comprehensive strength , Fineness One sample from each Batch

IS 4031

Water
Harmful substances, pH value, initial
setting time, compressive strength.

Once in a month/source

IS 456

Concrete
Slump and compaction Factor
Crushing Strength

One Sample/2hr / mixing plant

IS 456

IS 1199 & IS456

IS 516

Water Cement Ratio , Cement content

Random

IS 1199

Thus we have completed our discussion on civil job of thermal Power station. If posted
all
queries will be answered . However please refrain from advertising product on blog. From
next writing we will discuss about the structural work of the power station.

TYPICAL FIELD QUALITY PLAN FOR CIVIL WORK AT THERMAL

POWER STATIONS.
Now we will discuss the common Field Quality Plan for Civil work .
- Classification of checks like A,B,C and D depends on the importance of the activity . Most
important activity which need vendor signature , consultant signature and customer signature is
termed as A. B is slightly less important therefore may be or may not be require the presence of
customer. Like that it goes up to D or more. All this classification of checks should be discussed
and finalised before the start of work.
- Type of checks can be classified as R = record verification , V = Visual , M = measurement , P
= Physical , T =Test

Following are few items subjects to field quality checks . These are samples only. There are
many more items will be under FQP's purview.
ii)

i)
Bricks
Earth Work

iii)

Cement

iv)

Fine Aggregate (Sand)

v)

Course Aggregate

vi)

Reinforcing Steel

vii)

Water

viii)

Form Work (Shuttering)

ix)

Concreting

There are number of items which comes under FQP in civil work.
Area of Work : Civil works

Sub System of Civil works : Bricks ; Activities : Construction

s.no.

1.0

Description

toc

instrument class

Ref. doc frequency format

Ensure that the bricks are

free from cracks, war page
and of uniform colour.

1.1

IS codes

1:10000

protocol

Check for the dimension,

Check for bond / closers
thickness of joints in masonry,
Line, level and plumb,

1.2

M Tape ,spirit level

IS codes

1: 10000

Protocol

IS codes

1:10000

Protocol

M Laboratory

IS codes

Note 1

Protocol

M Laboratory

IS codes

Note 1

Protocol

Note 1

Protocol

Compressive strength &

water absorption

laboratory

Earth work ( excavation , filling ,compaction etc)

2.0

Standard Proctor Test

2.1 Relative Density Index

2.2 Dry Density by Core Cutter
Method / Sand Displacement
Method

M Laboratory

IS codes

2.3 Moisture Content of Fill

before Compaction

M Laboratory

IS codes

Note 1

Protocol

2.4 Dry density by Proctor

Needle Penetration

M Laboratory

IS codes

Note 1

Protocol

Cement
3.0 a) Consistency of cement

M Laboratory

Initial and final setting time

(vicat needle)

Compressive strength

(testing m/c)

IS codes

Note 2

Protocol

3days & 7 days

4.0 Sand ( Types of Test carried out on sand before acceptance )
a) Silt & Clay content

M Laboratory

IS codes

Note 3

Protocol

b) Sieve analysis (Particle size and shape)

c) Bulking of sand
d) Specific gravity, density, voids & absorption
e) Moisture content
f) Deleterious materials
g) Petrographic examination
h) Soundness
i) Reaction with Alkali :
Mortar making properties
5.0 Coarse Aggregate (Types of test carried out on coarse aggregate before acceptance.
a) Sieve Analysis (Particle Size and Shape)
b) Moisture content
c) Specific gravity
d) Crushing Strength
e) Bulk density
f) Absorption value, Abrasion value & Impact Value
g) Voids
h) Soundness
i)

Reaction with Alkali

j)

Petrographic examination

k) Deleterious materials
l)

Temperature Cycle test

m) Flakiness
The above tests are carried out site Laboratory as per IS codes mentioned in the FQP ,measured and
protocol ed .
For actual work tests mentioned in the FQP to be followed strictly. FQP mentioned above is only for
example

SOME OF THE LABORATORY EQUIPMENT SHOWN ABOVE.