1、THE HANDBOOK FOR WATERWALL AND BUCKSTAY ERECTION(1X600 MW THERMAL POWER PLANT, INDIA)CONTENTS1.BASIS FOR PREPARATION錯誤！未定義書簽。2. PREPARATION AND CONDITIONS BEFORE OPERATION42.1Technical Preparation42.2 Operators Allocation42.3 Instrument and Tool52.4 Machinary Equipment52.5 Safety Apparatus52.6 Prece

2、dure Change63. OPERATIONAL METHODS, PRECEDURE AND DETAILS63.1 Methods63.2 Procedure63.3 Details73.3.1 Equipment Examination73.3.3 Header Clean-up and Pipe Ball Passing Test73.3.4 Waterwall Assembly83.3.5 Buckstay and Ironwork Assembly83.3.6 Door Hole Assembly83.3.7 Waterwall and Buckstay Component M

3、ounting83.3.8 Cautions94. CONTROL POINTS SETTING-UP, USUAL QUALITY ISSUES AND PREVENTION94.1 Control points94.2 Quality standards and requirements104.3 Prevention124.4 Requirements on quality record135. SAFETY 135.1 Safety Prevention and Measures135.2 Regarding to the Construction Staff145.3 Require

4、ments on all the Machinery, Tool, Lifting Wires and Devices：141. Basis for PreparationØ Technical Specifications on the Electric Power Construction and Acceptance(boiler part) DL/T504796Ø Quality Inspection and Assessment of Coal-fired Power Plant Construction(boiler part, 1996 edition)

5、16; Specifications on the Quality Acceptance of Structure Steel Engineering and Construction GB502052001Ø Standards on the Quality Inspection and Assessment of Structure Steel Engineering and Construction GB5022195Ø Lifting and Delivery(Water and Hydrogen Power Press)Ø Operational Pro

6、cedure on the Safety of Electric Power Construction(coal-fired power plant part) DL5009.12002Ø Standards on Quality Inspection and Assessment of Coal-fired Power Plant Construction(welding part)Ø Technical Specifications on Safety of Temporary Electricity at Construction SiteØ Relevan

7、t files such as design drawings, bidding documents, contract and so on.For the above standards, the newest will prevail if any published.2. Preparations and Conditions before Operation2.1 Technical PreparationNo.Necessary ConditionsRemarks1For the drawings, the problems discovered in the reviewing p

8、rocess were resolved, and they had been handed down, of which it were kept with records.2Operation instruction preparation and discussion completed, approved, and distributed and recorded within the list.3Commence Report approved4All the necessary procurement or machined parts completes with the sta

9、tistic, approval after reported to material supply department, and already purchasing.5The drawings have been distributed with record.6Relevant papers, such as self-inspection record, construction record, on-site meeting record, inspection forms, etc, were all distributed within list.7The constructi

10、on staff shall move to get familiar with the drawings and requirements on the technique and quality, and make the construction scope, contents and order defined.8Regarding to safety, the technical explanation and signature of its document was completed.2.2 Operators AllocationPostNumberObligationLif

11、ting and Assembling Chief-in-Charge1Being in charge of lifting and assemblyTechnician1drawing, scheme, acceptance and measurementConstruction Supervisor2coordinate with acceptance and measurement, find out structural memberslifting Operators4equipment lifting, combination, downloading and transporti

12、ngcoordinating worker10coordinate with equipment lifting, combination, downloading and delivering.Erection Operators40frame erection, equipment counting, ball passing and site clearance, assembly at ground, erection in high.Scaffolding Operators6scaffolding, steel cat ladder, soft cat ladderWelders1

13、5on-site weldingWarehouse Management Staff1management on the tool or equipment accessing to the warehouseOperators6hoister operationDrivers3on-site transportationProfessional Safety Supervisors2onsite safety and well-management of construction2.3 Operational Instrument and ToolNo.NameTypeAmountRemar

14、ks1steel tape measurer100m1qualified through contrast, and being on shelf time.2steel tape measurer50m1qualified through contrast, and being on shelf time.3chain block10t4qualified through tensile force test4chain block5t4qualified through tensile force test5chain block3t20qualified through tensile

15、force test6chain block2t60qualified through tensile force test7jack10t48shackle5t129shackle3t4010steel ruler1m211steel ruler2m212glass pipe level50m113polishing machine1001014guide rope100m215B.W plier2016plumb line417electric grinder1018hanger rod adjusting tool119Sample Maker220cutter & auxili

16、aries6including meters, belt, oxygen and ethyne cylinders21level bar450mm222jemmyseveral23iron wedgeseveral2.4 Operational Machines and ToolNo.NamesAmountFunctionsRemarks1250t, crawler crane1Lifting of waterwall & components and buckstays230t, gantry crane1working with the truck350t, crawler cra

17、ne1downloading, transportation, and larger parts lifting and assembly450t, truck crane1downloading and transportation525t, low-frame plate truck1transportation610t, plate truck1transportation7air compressor1ball passing and clean-up2.5 Safety Devices and ToolNo.NameTypeAmountRemarks1safety belt202ey

18、e protector203guard rope2004safety rope(with isolating layer)5005check circuit breaker86safety net6m×6m307fire extinguisher52.6 Procedure TransitionIt can be started when the steel structure erection of boiler building was qualified by overall inspection, as well as the field and paths for equi

19、pment transportation and downloading carried out with clean-up, planning and compaction to be ready.3. Erection Methods, Procedures and Details3.1 MethodsWaterwall erection schedule proceeds in divisions, coordinated with partial combination. That is the buckstays will be lifted to their correspondi

20、ng elevations in prior to carrying on waterwall hoisting; major parts of buckstays and waterwall will be hanged up from the bottom of furnace and other waterwall will be filled in from the top of furnace according to the size of frame space of top plate. Waterwall is erected from top to bottom. When

21、 one layer was finished, its supposed to go on butt joint and centering at soon and erect buckstays, and then comes to the next layer.3.2 ProceduresEquipment counting & examinationTech. preparation & explanationPersonals, and machinery & tool preparationRecordsHeader clean-up, and ball p

22、assing test on pipesWaterwall & buckstay assembly acceptanceUpper waterwall & buckstay erection acceptanceLower waterwall & buckstay erection acceptanceOverall acceptanceFurnace wall auxillary and enclosing part installationRecordsRecordsRecordsRecords3.3 Contents Equipment Examinationl

23、Check the amount, type, quality and material to make sure whether they meet with the requirement or not. If any, it must be resolved immediately.l Due to being different types of components, it is necessary to check out the code, shipment number to make a arrangement. When the box is opened, it ough

24、t to be verified and kept with records, as per shipment list and drawing.l Equipment in the same box should be concentrated at the same place and numbered, other smaller components can be stored in warehouse.l All the components on the same equipment need be counted at once, such as, tube panel, hea

25、ders, fire peep hole, door holes, hanger rods, buckstay, steel member auxiliaries, etc.l All the alloy devices will be carried out with spectro analysis, with marks and records as qualified through inspection, and stored dividently.l Defects found in the examination of components: flattening, collis

26、ion, crack, pin hole, etc; quality and size of welding joint doesnt meet with the requirements; pipe hole and hand hole amount and quality doesnt comply with the regulations; disqualified pipe shape, bending and length, and unflat pipe opening; the bending of headers and buckstays, etc, surpass the

27、allowable limitation; unflat panel with excessive bulks or grooves; need be corrected.l Correcting methods: additional welding of joint, polishing of pipe opening, replacing of pipes, hot bending, and so on. Header Clean-up and Ball Passing Test on Pipesl There must be ball passing in prior to the c

28、ombination of waterwall tubes and headers, for which 12 minutes blowing through compressed air need be conducted to clean up internal ash deposit and redundant. And watch whether falling items exists or not, as a result of hole drilling.l Steel balls(for types, refer to the following) and compressed

29、 air with a pressure force of 46kg/cm2, will be adopted. And ball passing ought to be undergone in the sequence that ball laid after tube blowing.Passing Ball Diameters(mm)bending radiusoutside pipe diameterD16032D160D132R3.5D10.85D00.80D00.70D02.5D1R3.5D10.85D00.80D00.70D01.8D1R2.5D10.75D00.75D00.7

30、0D01.4D1R1.8D10.70D00.70D00.70D0R1.4D10.65D00.65D00.65D0Note: DOinside diameter of pipe(as for inlet pipe, D1 is actual measured data)/D1outside pipe diameter/Rbending radiusl Ball handing-down would be documented and managed. Those tubes already past with balls should be marked and sealed, as well

31、as headers sealed with steel sheet after header clean-up confirmed qualified after survey from QC personals and consultants.l Relevant documents need be signed after ball passing is over, without loss of anyone.l It can be considered to use a steel brush and rebar to remove the rust, meditation rema

32、inant, glass rins,etc, inside the header under no effectiveness by compressed air clean-up. For those tubes failed in ball passing, it was surposed to find out the locations and replace the tubes or short ones. Waterwall Assemblyl To reduce the man-hour as working in high, components must be appropr

33、iately selected on the considerations of crane, dimension and lifting, etc.l From the panel to the fire-orient combination frame, check the positions and directions of manhole doors, peep hole doors, anti-explosion doors, instrument doors and blower doors at each section, and view whether there is a

34、ny unapt dimension, wrong laying on left or right, and inverted panel.l Adjust the dimension of component to make its length, width and diagonal line meet with the requirements. In order to prevent a reduced width due to panel welding, a tolerance can be preserved as well as limit steel welded on bo

35、th sides of the component.l Use the diagonal line to center the header and panel, and fix them with channel steel.l To keep the butt joint welding convenient, a 300mm would be cut inside the pin at two sides of the tube opening. For some short tube and coordinate short tube, they can not be proceede

36、d with butt joint under hot expansion, and the dispositioned openings will be aligned by using a l It should be interval and jumping welding, of which removing from one side to neighboring other side is prohibited.l When panel butt joint welding completes, its time to carry forward with the seam cov

37、erage and sealing. Recheck the outside dimension of component, and flatness and diagonal lines of panel with technical record. And it will be sealed to be ready for acceptance after confirmed qualified by self-inspection.l For the non-assembling component of panel, it will be centered after butt joi

38、nt in high completes, and sealed after acceptance. Buckstay and Ironwork Assemblyl All the rigid beams ought to be sorted out and posted with signs, and their installation elevation and positions must be marked.l Numbering the combination ironwork corresponding to the buckstay, their positions will

39、be sorted out one by one on the ironwork, in prior to erect them from both sides of centerline in consequence and fix & weld the integration on the buckstay.l Buckstay was transversely arranged on the waterwall panel, following the location lines drawn from based upper header centerline to the l

40、ower header. And rectify the positions and spacing dimensions of each buckstay.l Carry on the assembly of ironwork and buckstay on the line drawing at the location direction on both sides of component. If any bulk appears between waterwalls, it will be jacked, coordinated with appropriate heating, u

41、ntil it comes to be flat, and then the steel plate can be welded. Door Hole AssemblyFor all the door hole equipment classification and combination, it will be welded on the panel at the location line which is based on the upper header centerline by marking one by one towards the lower header. Waterw

42、all & Buckstays Component Mounting.1 Components Erection Order：upper components of front waterwallupper components of right waterwallupper components of left waterwallmiddle components of right waterwallmiddle components of left waterwallcomponents of rear waterwall panellower components of fron

43、t waterwalllower components of right waterwalllower components of left waterwallcomponents of rear waterwall hanger tubemiddle components of rear waterwallcomponents of rear waterwall nosecomponents of lower rear water. .2 Upper Vertical Section Waterwall ErectionDividing the front, left and right v

44、ertical panel of waterwall into two parts from top and down, the upper one would be lifted and positioned upon the top of furnace after it was already attached to the upper header, for which it is possibly adjusted according to the dimensions indicated in the drawing when connected to the hanger rod

45、s to make them uniformly loaded, and the centerline elevation and surrounding locations of upper header was within the permissioned scope. The front waterwall buckstay can be lifted separately as a result of excessive dimension after combined with waterwall, and for the left & right waterwalls t

46、hey depend on the crane working condition, As regarding to the rear waterwall hanger tubes and panel, it can be considered to fabricate a temporary platform on the rotary layer at the boiler structural steel to lift the header which will be delivered to the position with plate truck from the furnace

47、 bottom, to combine with tubes which were already at ground and then hoisted manually by means of ropes, and later comes to the fixing setting. As it completed, A 250t or 5t hoister will be deployed to lift the components to carry on the assembly, and the rear furnace components will be overpassed t

48、o be located. Rear waterwall hanger tubes would be divided into top-and-down parts, and after the top part and header components located, the vertical section components will be lifted and assembled upon the top furnace, to erect the lower section hanger tubes. Then, the duct tube panels will be sus

49、pended to carry on butt welding with the fire-hiding angle tube panel after its previous weld completes.3 Lower SpiralTube Ring Waterwall and Buckstay ErectionBefore the waterwall erection initiated, the centering of transition header and its above vertical tube panel is completed, with elevation of

50、 transition and relative positions of furnace wall and furnace frame meeting with the requirements of design and a reliable support between it and the frame. For the lower spiral tube ring waterwall and buckstay, it will be assembled dividently or may be partially done on the ground. The hanged wate

51、rwall panel will be centered according to the boiler centerline and assembly sign marked previously on the buckstay which was already centered. Additionally rectify the spiral rising angle of panel and carry on butt joint welding.According to the requirements of design, the spiral tube panel will be

52、 carried out with ground preassembly of expansion plates with rectified spiral rising angle & geometric dimension of components, which requires to be adjusted as calculation. Draw the bench mark centerline of tube panel and number it with signs which will be used as the basis for erection.When t

53、he surrounding responding buckstay is centered and fixed, and formed a frame with a steady support with the structural steel, the panel will be carried out with butt joint and welding according to the centerline and sign after rectifying the spiral angle. A scaffolding and self-made welding platform

54、 may be erected outside and inside the furnace wall respectively.Waterwall would be erected top-and-down and layer after layer from the spiral direction of panels. When one layer was finished, it was about to carry out with the alignment, butt welding, joint treatment and buckstay installation.Bucks

55、tay will be attached to the tube panel through backing plates and moon plates, ensuring the rated spacing between connecting poles and clamping plates, horizontal accuracy of connecting plates, and expansion clearance. Angle area connection ought to be carried out in consequence of tube panel and bu

56、ckstay centering, keeping components horizontal and connecting plates active. And pins at angle location should be welded outside the furnace in prior to erect components. Buckstay at front furnace would be aligned with upper header, as well as those at rear furnace and front-and-rear drums done wit

57、h underneath header. To the buckstays at the front-and-rear furnace and with connections, the welding must be carried out, spontaneously, one course after another. PrecautionsSpiral pipe ring waterwall is the key bearing component of supercritical or once through boiler, of which its quality of erection of its transition section, combust