BOILER DRUM ERECTION OF UNIT-2 5X270 MW TPP, NASIK

DATE: 27-July-2011

Boiler Structure Ready

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

BOILER DRUM

Contractor: BHEL. Location : Sinnar, Nasik.

Project : 5 X 270MW Thermal Power Plant.

Total Tons : 133 MT Erection Time : 5 hr 30 min

OVERALL VIEW OF BOILER DRUM

UNLOADING OF BOILER DRUM

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

DRUM SUSPENSION ARRANGEMENT

8

STABLE STRUCTURAL ARRANGEMENT OF BOILER FOR DRUM ERECTION

U BOLT AND ITS INSERTION

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 )

POWER PACK

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.

STRAND JACK

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

CAT HEAD STRUCTURE

LIFTING ARRAGEMENT

FIXING OF STRANDS & STRAND ARRANGEMENT

ALIGNMENT INSPECTION

INSPECTION AT DRUM SUSPENSION

Job Safety & Risk Assessment Analysis

Both the winches and all the lifting equipments used for U bolt lifting 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) were carried out.
Special Safety Induction Programme (Tool box talk) was conducted to all the executives & workers involved in Drum lifting activities before the Drum lifting Special florescent jackets were provided for Executives & workers.

Nasik Power Project Drum Lifting Plan

DRUM AT VARIOUS ELEVATION

DRUM AT 60.106 mtr (Position)

DRUM AT 15 mtr

U-ROD FIXING AT POSITION

WORKSHIP CEREMONY BEFOR DRUM LIFTING

SOME MOVEMENTS

TEAM NASIK

THANKING YOU ALL

TEAM NASIK