boiler drum erection of unit-2
TRANSCRIPT
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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
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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