MAHAN THERMAL POWER MAHAN THERMAL POWER PLANTPLANT

FLOW CHART AND ERECTION SEQUENCEFLOW CHART AND ERECTION SEQUENCE

TOPICTOPICPOWER PLANT- GENERAL FLOW CHARTPOWER PLANT- GENERAL FLOW CHART

FLOW CHART- INSIDE BOILERFLOW CHART- INSIDE BOILER

BOILER STRUCTURAL ERECTION SEQUENCE - ELEVATION VIEWBOILER STRUCTURAL ERECTION SEQUENCE - ELEVATION VIEW

BOILER CELING GIRDER ERECTION SEQUENCE - PLAN VIEWBOILER CELING GIRDER ERECTION SEQUENCE - PLAN VIEW

BOILER DRUM ERECTION SEQUENCEBOILER DRUM ERECTION SEQUENCE

BOILER PARTS ERECTION SEQUENCEBOILER PARTS ERECTION SEQUENCE

TG AREA- ERECTION SEQUENCE FOR HEATERS/ DEARATOR/ EOTTG AREA- ERECTION SEQUENCE FOR HEATERS/ DEARATOR/ EOT– ELEVATION VIEW.ELEVATION VIEW.– PLAN VIEWPLAN VIEW

COAL MILL LIFTING SEQUENCE.COAL MILL LIFTING SEQUENCE.

GENERATOR STATOR LIFTING SEQUENCEGENERATOR STATOR LIFTING SEQUENCE

CONDENSERCONDENSER

COOLING TOWERCOOLING TOWER

LP H-1LP H-1LP H-2LP H-2LP H-3LP H-3

HP H-1HP H-1HP H-2HP H-2

ECONOMISERECONOMISER

LP HEATER (TEMP- IN 37, OUT 145 LP HEATER (TEMP- IN 37, OUT 145 HP HEATER 1 &2 (TEMP – IN 186 OUT 281 )HP HEATER 1 &2 (TEMP – IN 186 OUT 281 )

DEARATORDEARATOR

DRUMDRUM

PRIMARY SUPERHEATER PRIMARY SUPERHEATER

SUPERHEATER (T-538 P-167)SUPERHEATER (T-538 P-167)

HP TURBINE (HP TURBINE (T- 538 , P- 167)T- 538 , P- 167)

REHEATER (T-538 P-38.16) REHEATER (T-538 P-38.16)

IP TURBINE IP TURBINE (T- 538 P- 34.38(T- 538 P- 34.38) )

LP TURBINE( T-368 P-12 )LP TURBINE( T-368 P-12 )

FLOW DIAGRAM - THERMAL PPFLOW DIAGRAM - THERMAL PP

T-35 P-22.5T-35 P-22.5

T- 44.5, P- .09 T- 44.5, P- .09

FURNACE AREAFURNACE AREA

BURNERBURNER

CEPCEP

HP

1133

1.1. Steam DrumSteam Drum

22

66 77 88 99

10101111

1515

1414

1212

1616

1717

18

1919

2020

2121 22222323

2525

IP

LP

BOILER FLOW DIAGRAMBOILER FLOW DIAGRAM

2. Downcomer2. Downcomer3. Inlet/Outlet Roof 3. Inlet/Outlet Roof

HeadersHeaders

4. Water Wall Side 4. Water Wall Side HeaderHeader

55. Steam Cooled Water Steam Cooled Water WallWall

6. Right water wallRight water wall

7. Div. Panel Super 7. Div. Panel Super HeaterHeater

44

DIV

PA

NE

L S

UP

ER

HE

AT

ER

DIV

PA

NE

L S

UP

ER

HE

AT

ER

PL

AT

EN

SU

PE

RH

EA

TE

RP

LA

TE

N S

UP

ER

HE

AT

ER

8. Platen Super Heater8. Platen Super Heater

ME

DIU

M R

EH

EA

TE

RS

ME

DIU

M R

EH

EA

TE

RS

9. Medium Re-heaters9. Medium Re-heaters

FIN

AL

RE

HE

AT

ER

SF

INA

L R

EH

EA

TE

RS

10. Final Re-heaters10. Final Re-heaters

11. Final Super heaters11. Final Super heaters

FIN

AL

SU

PE

RH

EA

TE

RS

FIN

AL

SU

PE

RH

EA

TE

RS

FIN

AL

SU

PE

RH

EA

TE

RS

FIN

AL

SU

PE

RH

EA

TE

RS

12. Primary Super 12. Primary Super heaters Coilsheaters Coils

1313 13. Primary Super 13. Primary Super heaters in Hdrheaters in Hdr

PRIMARY SUPERHEATERSPRIMARY SUPERHEATERS

PRIMARY SUPERHEATERSPRIMARY SUPERHEATERS

PRIMARY SUPERHEATERSPRIMARY SUPERHEATERS

14. Primary Super 14. Primary Super heaters Headerheaters Header

15. Economizer15. EconomizerECONOMIZERECONOMIZER

ECONOMIZERECONOMIZER

16. Water wall16. Water wall

17. Water wall17. Water wall

18. Burners18. Burners

19. Water Wall19. Water Wall

20. Lower Water Header20. Lower Water Header

21. Riser Tubes21. Riser Tubes

22. SuperHeater Tubes22. SuperHeater Tubes

23. Pri. SH Tubes23. Pri. SH Tubes

24. Main Steam Tube24. Main Steam Tube

25. Cold Reheat tube25. Cold Reheat tube

55

10.

62

10.

62

85.0

9

AIR PREHEATER

BOILER STRUCTURAL BOILER STRUCTURAL ERECTION-ELEVATIONERECTION-ELEVATION

NN MM LL KK HHJJ

PLAN VIEW OF BOILER GIRDER ERECTIONPLAN VIEW OF BOILER GIRDER ERECTION

CEILING GIRDER 70 MT , EL-87.52 MTSCEILING GIRDER 70 MT , EL-87.52 MTS

CEILING GIRDER 105 MT, EL 87.52 MTSCEILING GIRDER 105 MT, EL 87.52 MTS

CEILING GIRDER 70 MT, EL 87.525 MTS

CEILING GIRDER 70 MT, EL 87.525 MTS

CEILING GIRDER 105 MT, EL 87.52 MTS

CEILING GIRDER 105 MT, EL 87.52 MTS

TOWER CRANE TOWER CRANE 75 MT75 MT

NN

MM

LL

KK

JJ

6.96.9

HOLDHOLD

ERECTION AS SHOWN IN ERECTION AS SHOWN IN PREVIOUS SLIDEPREVIOUS SLIDE

CEILING GIRDER 90 MT, EL 87.52 MTSCEILING GIRDER 90 MT, EL 87.52 MTS

CRAWLER CRANECRAWLER CRANE

HH

REAR SIDEREAR SIDE

6.26.2 5.55.5 5.05.0 4.54.5 3.83.8 3.13.1

STRAND JACKS

DRUM EL 76.3

CEILING GIRDER

ROLLERS

STRAND JACKS FIXING ARRANGEMENT

BOILER COLUMNS

CONNECTING BEAMS

370

SPECIFICATIONS:

1. DRUM SIZE: DIA 2.1M & 28M LG

2. WEIGHT: 246 MT

NOTE:

1. 2 NOS STRAND JACK OF 150MT CAP EACH

2. ROLLERS OF CAP WILL BE REQD. TO SHIFT THE DRUM.

LIFTING SLING

DRUM TO BE INCLINED UP TO 370 TO GET ERECTION CLEARENCE BETWEEN THE COLUMNS

DRUM TO BE TAKEN IN HORIZONTAL POSITION

TO BE SHIFT TOWARDS ITS VERTICAL AXIS

LIFT AGAIN TO GET EXACT ELEVATION

DRUM LIFTING PROCEDURE BY STRAND JACKSDRUM LIFTING PROCEDURE BY STRAND JACKS

‘‘I’ ROW COLUMNI’ ROW COLUMN‘‘J’ ROW J’ ROW COLUMNCOLUMN

‘‘H’ ROW H’ ROW COLUMNCOLUMN

DRUM EL 76.3DRUM EL 76.3

TO BE INCLINED UP TO BE INCLINED UP TO 37TO 3700

BRING BACK TO BRING BACK TO HORIZONTAL POSITIONHORIZONTAL POSITION

4 MTR SHIFTING TOWARDS 4 MTR SHIFTING TOWARDS ITS EXACT VERTICAL AXISITS EXACT VERTICAL AXIS

LIFTING TO THE POSITIONLIFTING TO THE POSITION

DRUM LIFTING PROCEDURE BY STRAND JACKS (SIDE VIEW)DRUM LIFTING PROCEDURE BY STRAND JACKS (SIDE VIEW)

BOILER DRUM LIFTINGBOILER DRUM LIFTING

ELEVATION ELEVATION : 76.3 MTS: 76.3 MTSWEIGHTWEIGHT : 246 MT: 246 MTDIMENSIONDIMENSION : 28 MTS (LONG) X 2.2 MTS WIDE: 28 MTS (LONG) X 2.2 MTS WIDEMETHOD OF LIFTINGMETHOD OF LIFTING : STRAND JACK.: STRAND JACK.

PROCEDURE:PROCEDURE:

GROUND PREPARATORY WORK AT +0.0 ELEVATION.GROUND PREPARATORY WORK AT +0.0 ELEVATION.

SHIFTING OF BOILDER DRUM TO SITE AND PLACED BETWEEN THE I & J ROW OF BOILER COLUMNS.SHIFTING OF BOILDER DRUM TO SITE AND PLACED BETWEEN THE I & J ROW OF BOILER COLUMNS.

GROUND INSPECTION OF BOILDER DRUM.GROUND INSPECTION OF BOILDER DRUM.

PLACEMENT OF CAT-HEAD BEAM ON CELING GIRDER.PLACEMENT OF CAT-HEAD BEAM ON CELING GIRDER.

WALKWAYS AND PLATFORMS ARE MADE BETWEEN TWO CAT BEAMS.WALKWAYS AND PLATFORMS ARE MADE BETWEEN TWO CAT BEAMS.

POWER PACK TO PLACED 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.2 NOS. 200T CAP JACKS ARE RAISED AND FIXED TO THE TOP OF CAT HEAD BEAMS.

STRAND GUIDE IS FIXED NEAR THE JACK.STRAND 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 IS INSERTED IN JACK ANCHORS FROM BOTTOM TILL THE FREE END COMES OUT OF TOP ANCHOR AND IS PLACED ON STRAND GUIDE.STRAND GUIDE.

BOILER DRUM LIFTING…contdBOILER DRUM LIFTING…contd

INSERTION OF CORRESPONDING STRAND IN FIXED ANCHOR ON DRUM.INSERTION OF CORRESPONDING STRAND IN FIXED ANCHOR ON DRUM.

U-RODS ARE LEFT HANGING ON DRUM AT AN APPROPRIATE LOCATION BEFORE LIFTING.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 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 THE COLUMNS, BECAUSE LENGTH OF THE DRUM IS LARGER THAN THE DISTANCE BETWEEN 2 COLUMS.COLUMS.

DRUM (IN INCLINED POSITION) WILL BE THEN LIFT SLOWLY TILL REACH UP TO +71.0 MTR. ELEVATION.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.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 STRAND JACKS WITH POWER PACK ARRANGEMENT WILL THEN SHIFT 4 MTR TOWARDS H ROW ON SAME ELEVATION TILL REACH TO IT’S VERTICAL CENTER LINE.SAME ELEVATION TILL REACH TO IT’S VERTICAL CENTER LINE.

AFTER 4 MTR SHIFTING, IT WILL BE FURTHER LIFTED UP TO + 76.3 MTR TO REACH ITS FINAL AFTER 4 MTR SHIFTING, IT WILL BE FURTHER LIFTED UP TO + 76.3 MTR TO REACH ITS FINAL POSITION.POSITION.

U-BOLTS WILL BE FIXED AT TOP BY SEPARATE ARRANGEMENT.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 AFTER ALIGNMENT OF DRUM AND TIGHTENED OF U-BOLTS, STAND JACKS ARE TO BE RELEASED AND DISMANTLED ALL TEMPORARY ARRANGEMENTS.AND DISMANTLED ALL TEMPORARY ARRANGEMENTS.

HP

1133

1.1. Steam DrumSteam Drum

22

66 77 88 99

10101111

1515

1414

1212

1616

1717

18

1919

2020

2121 22222323

2525

IP

LP

Boiler Erection Sequence

2. Downcomer2. Downcomer3. Inlet/Outlet Roof 3. Inlet/Outlet Roof

HeadersHeaders

4. Water Wall Side 4. Water Wall Side HeaderHeader

55. Steam Cooled Water Steam Cooled Water WallWall

6. Right water wallRight water wall

7. Div. Panel Super 7. Div. Panel Super HeaterHeater

44

DIV

PA

NE

L S

UP

ER

HE

AT

ER

DIV

PA

NE

L S

UP

ER

HE

AT

ER

PL

AT

EN

SU

PE

RH

EA

TE

RP

LA

TE

N S

UP

ER

HE

AT

ER

8. Platen nel Super 8. Platen nel Super HeaterHeaterM

ED

IUM

RE

HE

AT

ER

SM

ED

IUM

RE

HE

AT

ER

S

9. Medium Re-heaters9. Medium Re-heaters

FIN

AL

RE

HE

AT

ER

SF

INA

L R

EH

EA

TE

RS

10. Final Re-heaters10. Final Re-heaters

11. Final Super heaters11. Final Super heaters

FIN

AL

SU

PE

RH

EA

TE

RS

FIN

AL

SU

PE

RH

EA

TE

RS

FIN

AL

SU

PE

RH

EA

TE

RS

FIN

AL

SU

PE

RH

EA

TE

RS

12. Primary Super 12. Primary Super heaters Coilsheaters Coils

1313 13. Primary Super 13. Primary Super heaters in Hdrheaters in Hdr

PRIMARY SUPERHEATERSPRIMARY SUPERHEATERS

PRIMARY SUPERHEATERSPRIMARY SUPERHEATERS

PRIMARY SUPERHEATERSPRIMARY SUPERHEATERS

14. Primary Super 14. Primary Super heaters Headerheaters Header

15. Economizer15. EconomizerECONOMIZERECONOMIZER

ECONOMIZERECONOMIZER

16. Water wall16. Water wall

17. Water wall17. Water wall

18. Burners18. Burners

19. Water Wall19. Water Wall

20. Lower Water Header20. Lower Water Header

21. Riser Tubes21. Riser Tubes

22. SuperHeater Tubes22. SuperHeater Tubes

23. Pri. SH Tubes23. Pri. SH Tubes

24. Main Steam Tube24. Main Steam Tube

25. Cold Reheat tube25. Cold Reheat tube

55

AA BB CC DD

6.76.7

26.026.0

13.713.7

39.039.0

33.8533.85

6363

2. ERECTION OF DEAREATORS2. ERECTION OF DEAREATORS

1. ERECTION OF HP HEATER1. ERECTION OF HP HEATER

3. ERECTION OF EOT3. ERECTION OF EOT

4. ERECTION OF LAST TG ROOF GIRDER4. ERECTION OF LAST TG ROOF GIRDER

VIEW OF PREHEATER / DEARATOR / EOT ERECTIONVIEW OF PREHEATER / DEARATOR / EOT ERECTION

EOT EOT

PREHEATERPREHEATER

DEARETOR STORAGE

TANK

TG DECKTG DECK

DEAREATORDEAREATOR

eot

54 DEGREE54 DEGREE

AA

DD

CC

BB

11 22 33 44 55 66 77 881/011/011/021/021/031/03

HOLDHOLD

HOLDHOLD

TG DECK TG DECK

EL-EL-13.713.7

HP HP

HEATERHEATER DECK EL-DECK EL-13.713.7

DEARATODEARATORR DECK DECK EL-26EL-26

HP HEATER

HP HEATER

DEARATOR TANKDEARATOR TANK

EO

T

CRAWLER CRANECRAWLER CRANE

PLAN VIEW OF PREHEATER / DEARATOR / EOT ERECTIONPLAN VIEW OF PREHEATER / DEARATOR / EOT ERECTION

FEEDWATER TANK AND DEARATOR LIFTINGFEEDWATER TANK AND DEARATOR LIFTING

FEED WATER TANK WEIGHT : 110 MT.FEED WATER TANK WEIGHT : 110 MT.ELEVATION : 26 MTSELEVATION : 26 MTSLIFTING METHOD : TOWER CRANE AND CRAWLER CRANELIFTING METHOD : TOWER CRANE AND CRAWLER CRANE

PROCEDURE :PROCEDURE :

FOUNDATION / SUPPORTING BEAM TO BE CHECKED AS PER DRAWING PRIOR TO INSTALLATION OF FEED WATER FOUNDATION / SUPPORTING BEAM TO BE CHECKED AS PER DRAWING PRIOR TO INSTALLATION OF FEED WATER TANK.TANK.

ALL CENTRE LINE AND ELEVATION TO BE CHECKED PROPERLY BEFORE LIFTING.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.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 FEED WATER TANK TO BE LIFTED WITH THE HELP OF 500 MT CRANE AS PER SKETCH, CRANE CAPACITY AS PER SKETCH IS 125 MT.SKETCH IS 125 MT.

““B” ROW COLUMN TO BE HELD ABOVE +26 METER ELEVATION TO FACILITATE FOR CRANE SWINGING FROM B 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 ROW SIDE. “C” ROW COLUMN NUMBER 1 & 2 TO BE HOLD FOR CRANE POSITION, SO THAT CRANE BOOM CAN REACH UP TO REQUIRED DISTANCE.REACH UP TO REQUIRED DISTANCE.

FEED WATER TANK TO BE PLACED DIRECTLY ON FOUDATION / SUPPORTING BEAMS.FEED WATER TANK TO BE PLACED DIRECTLY ON FOUDATION / SUPPORTING BEAMS.

FEEDWATER TANK AND DEARATOR LIFTINGFEEDWATER TANK AND DEARATOR LIFTING

ALL NOZZLES ORIENTATION TO BE CHECKED DURING LIFTING.ALL NOZZLES ORIENTATION TO BE CHECKED DURING LIFTING.

AFTER ALIGNMENT OF FEED WATER TANK TEMPORARY SUPPORTS MAY BE PROVIDED AFTER ALIGNMENT OF FEED WATER TANK TEMPORARY SUPPORTS MAY BE PROVIDED TO HOLD THE DEAERATOR TANK ABOVE FEED WATER TANK.TO HOLD THE DEAERATOR TANK ABOVE FEED WATER TANK.

AFTER ALIGNMENT OF DEAERATOR, LOAD TO BE GIVEN ON PERMANENT SUPPORTS AFTER ALIGNMENT OF DEAERATOR, LOAD TO BE GIVEN ON PERMANENT SUPPORTS AND INTERCONNECTING PIPING BETWEEN DEAERATOR AND FEED WATER TANK TO BE AND INTERCONNECTING PIPING BETWEEN DEAERATOR AND FEED WATER TANK TO BE COMPLETED.COMPLETED.

ALL INTERNALS OF DEAERATOR TANK TO BE FIXED AFTER COMPLETION OF ALL INTERNALS OF DEAERATOR TANK TO BE FIXED AFTER COMPLETION OF ALIGNMENT.ALIGNMENT.

ALL EXPANSION PROVISION IS TO BE CHECKED CAREFULLY TO AVOID PROBLEM ALL EXPANSION PROVISION IS TO BE CHECKED CAREFULLY TO AVOID PROBLEM DURING COMMISSIONING.DURING COMMISSIONING.

HP HEATERS HP HEATERS

WEIGHTWEIGHT : 120 MT: 120 MT

DIMENSIONDIMENSION : 12 MTR LG x 2.3 MTR DIA: 12 MTR LG x 2.3 MTR DIA

ELEVATION : +13.7 MTRELEVATION : +13.7 MTR

METHOD OF LIFTING: TOWER CRANE AND CRAWLER CRANEMETHOD OF LIFTING: TOWER CRANE AND CRAWLER CRANE

PROCEDURE:PROCEDURE:

FOUNDATION CHECKING AND GROUND PREPARATION AT +0.0 ELEVATION.FOUNDATION CHECKING AND GROUND PREPARATION AT +0.0 ELEVATION.

SETTING OF PACKER PLATES.SETTING OF PACKER PLATES.

HOLD CONNECTING BEAM BETWEEN B AND C AXIS OF COLUMN 1 & 2 AT +27 METER & 39 METER HOLD CONNECTING BEAM BETWEEN B AND C AXIS OF COLUMN 1 & 2 AT +27 METER & 39 METER ELEVATION.ELEVATION.

500 MT CRAWLER CRANE TO BE USED TO LIFT HP HEATERS UPTO 13.7 MTS ELEVATION THROUGH 500 MT CRAWLER CRANE TO BE USED TO LIFT HP HEATERS UPTO 13.7 MTS ELEVATION THROUGH ‘B’ ‘C’ BAY.‘B’ ‘C’ BAY.

AFTER LIFTING HP HEATER TO BE DRAGGED UPTO FOUNDATION BY USING ROLLER.AFTER LIFTING HP HEATER TO BE DRAGGED UPTO FOUNDATION BY USING ROLLER.

AFTER INSTALLATION ALIGNMENT TO BE DONE AS PER DRAWING.AFTER INSTALLATION ALIGNMENT TO BE DONE AS PER DRAWING.

D2 D3 D4 D5 D6 D7 D8

D9

D1Crane & roller placed

Mill assly & alignment in progress

Rolling towards foundation

Pulling arrangement by chain block

Roller removed

Hydraulic Jack placed

Lowered on foundation by hydraulic jack

Mill 2Mill 3Mill 4Mill 5Mill 6 Mill 1

Temporay beam arrangement

Mill Foundation

COAL MILL LIFTING PROCEDURECOAL MILL LIFTING PROCEDURE

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

D2D3

D4 D5 D6 D7 D8

View A

Mill assly & alignment in progress

Rolling towards foundation

Mill 2Mill 3Mill 4Mill 5Mill 6 Mill 1

Temporay beam arrangement

Mill Foundation

A

D Row

Jack placed & roller removed

Lowered by Jacks

FrameRollers

Temporay beam arrangement

C Row

D1

COAL MILL LIFTING PROCEDURECOAL MILL LIFTING PROCEDURE

COAL MILL ERECTIONCOAL MILL ERECTION

WEIGHTWEIGHT : 300 MT: 300 MT

DIMENSIONDIMENSION : DIA 5 MTR x 10 MTR HEIGHT: DIA 5 MTR x 10 MTR HEIGHT

PROCEDURE:PROCEDURE:

PREPARATION OF BED FROM STRUCTURAL MATERIAL BETWEEN COLUMN C & D ROW THROUGH OUT THE COAL 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’).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.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 ERECTION OF MILL BASE PLATE, GEAR BOX, CASING ONE BY ONE WITH THE HELP OF CRANE AND ALIGNMENT THE SAME ACCORDINGLY.THE SAME ACCORDINGLY.AFTER COMPLETE ALIGNMENT, PULL THE FRAME BY CHAIN PULLEY BLOCK, WHICH IS PLACED ON OPPOSITE END AFTER COMPLETE ALIGNMENT, PULL THE FRAME BY CHAIN PULLEY BLOCK, WHICH IS PLACED ON OPPOSITE END I.E. WITH C9 & D9.I.E. WITH C9 & D9.

AFTER BRING IT TO THE FOUNDATION POSITION, 4 NOS. HYDRAULIC JACK OF 100 MT CAP WILL BE PLACED, TAKE 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.LOAD ON THE SAME AND RELEASE THE FRAME WITH ROLLERS.

SLOWLY LOWERING THE MILL ON FOUNDATION BY JACKS.SLOWLY LOWERING THE MILL ON FOUNDATION BY JACKS.

FINAL ALIGNMENT CHECKINGFINAL ALIGNMENT CHECKINGLSAME PROCEDURE WILL BE FOLLOWED FOR REST OF THE MILLS.LSAME PROCEDURE WILL BE FOLLOWED FOR REST OF THE MILLS.

AFTER COMPLETION OF ALL SIX MILLS ERECTION, TEMPORARY STRUCTURAL ARRANGEMENT WILL BE REMOVED.AFTER COMPLETION OF ALL SIX MILLS ERECTION, TEMPORARY STRUCTURAL ARRANGEMENT WILL BE REMOVED.

B A

Hillman rollers

150-200T Cap Strand Jacks

Schematic diagram of Generator stator lifting procedure (sh-2)

A

3

4

5

6

8

10

7

11

9

B

2

Stator to be shifted to site by Nicolus

After unloading Stator to be rotate by using rotator

Original location of stator

Temporary structure

4 5 6 7 8

EL +13.7

93

150-200T Cap Strand Jack

Schematic diagram of Generator stator lifting procedure (sh-1)

Temporary structure

GENERATOR STATOR LIFTINGGENERATOR STATOR LIFTING

WEIGHTWEIGHT : 300 MT: 300 MT

DIMENSIONDIMENSION : 10.5 MTR LG x 4.3 MTR DIA: 10.5 MTR LG x 4.3 MTR DIA

ELEVATION : +13.7 MTRELEVATION : +13.7 MTR

PROCEDURE:PROCEDURE:

GROUND PREPARATION UP TO LOAD BEARING CAPACITY +25.0 MT/MTR2 (TO BE CONFIRMED) AT +0.0 GROUND PREPARATION UP TO LOAD BEARING CAPACITY +25.0 MT/MTR2 (TO BE CONFIRMED) AT +0.0 ELEVATION.ELEVATION.

SHIFTING OF STATOR AT SITE AND PLACED INSIDE POWER HOUSE BUILDING NEAR TG DECK SHIFTING OF STATOR AT SITE AND PLACED INSIDE POWER HOUSE BUILDING NEAR TG DECK THROUGH A ROW AS SHOWN IN THE SKETCH.THROUGH A ROW AS SHOWN IN THE SKETCH.

GENERATOR STATOR TO BE UNLOADED ON A ROTATOR TO ROTATE THE STATOR UP TO 90 DEGREE, 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.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.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 PLACEMENT OF 2 NOS. HORIZONTAL BEAM ALONG WITH CHANNEL AT + 13.7 MTR ELEVATION THROUGHOUT TEMPORARY STRUCTURAL ARRANGEMENT TO GENERATOR FOUNDATION.THROUGHOUT TEMPORARY STRUCTURAL ARRANGEMENT TO GENERATOR FOUNDATION.

GENERATOR STATOR LIFTINGGENERATOR STATOR LIFTING

PLACEMENT OF GANTRY ALONG WITH WHEELS ON TEMPORARY ARRANGEMENT OF H-BEAM AND CHANNEL.PLACEMENT OF GANTRY ALONG WITH WHEELS ON TEMPORARY ARRANGEMENT OF H-BEAM AND CHANNEL.

PLACEMENT OF CAT-HEAD BEAM ON TOP OF GANTRY.PLACEMENT OF CAT-HEAD BEAM ON TOP OF GANTRY.

WALKWAYS AND PLATFORMS ARE MADE BETWEEN TWO CAT BEAMS.WALKWAYS AND PLATFORMS ARE MADE BETWEEN TWO CAT BEAMS.

POWER PACK IS RAISED AND PLACED 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.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.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 STRAND IS INSERTED IN JACK ANCHORS FROM BOTTOM TILL THE FREE END COMES OUT OF TOP ANCHOR AND IS PLACED ON STRAND GUIDE.ON STRAND GUIDE.

INSERTION OF CORRESPONDING STRAND IN FIXED ANCHOR ON STATOR.INSERTION OF CORRESPONDING STRAND IN FIXED ANCHOR ON STATOR.

STATOR WILL BE LIFTED TO > +18.0 MTR ELEVATION.STATOR WILL BE LIFTED TO > +18.0 MTR ELEVATION.

GANTRY WITH STATOR LOADED WILL BE TRAVELED TOWARDS GENERATOR FOUNDATION ON THE TEMPORARY GANTRY WITH STATOR LOADED WILL BE TRAVELED TOWARDS GENERATOR FOUNDATION ON THE TEMPORARY ARRANGEMENT OF BEAM & CHANNELS BY MOTOR OPERATED ROLLERS.ARRANGEMENT OF BEAM & CHANNELS BY MOTOR OPERATED ROLLERS.

ON GENERATOR FOUNDATION, IT WILL BE LOWERED AT REQUIRED ELEVATION AND STRAND JACK LOAD WILL BE ON GENERATOR FOUNDATION, IT WILL BE LOWERED AT REQUIRED ELEVATION AND STRAND JACK LOAD WILL BE RELEASED.RELEASED.

GANTRY WILL BE TAKING BACK TO INITIAL POSITION.GANTRY WILL BE TAKING BACK TO INITIAL POSITION.