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ERECTION MANUAL FOR
CONDENSER PROJECT 2 X 500 MW STAGE III
(VINDHYACHAL SUPER THERMAL POWER PROJECT)
CUSTOMER : NTPC
DOC. NO. PW:TSX:VNT: 009:00
Document No. Issue Date Effective Date
PW: TSX:VNT:009:00 06/07/2004 06/07/2004
Prepared By Reviewed by Approved by
S. K. JANGDE Sr. MANAGER (TSX)
S N MAITI Sr. DGM (TSX)
K. J. PRABHU Sr. DGM (TSX)
CONTROL NO.: ISSUED BY: ISSUED TO:
S. K. JANGDE Sr. MANAGER (TSX)
Shri K.K. Bhatia CM, BHEL SITE, VINDHYACHAL
Bharat Heavy Electricals Limited Power Sector Western Region
Shree Mohini Complex, 345, Kingsway, Nagpur- 440 001
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CODIFICATION FOR INSTRUCTION NUMBER
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The following codification system is used for numbering of
instructions and the codification of Log sheets is as per FAQ
document.
1.1 Product Code
B - Boiler
BA - Boiler Aux.
T - Turbine
TA - Turbine Aux.
G - Generator
GA - Generator Aux.
P - Power Plant Piping
CI - C&I
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1.2 Type of Manual
1. - Erection
2. - Commissioning
3. - Services
1.3 Rating of Main Equipment
01. - 200/210 MW
02. - 120 MW
03. - 110 MW
04. - 60 MW
05. - 30 MW
06. - 100 MW
07. - 235 MW
08. - 500 MW -KWU Design
09. - 210 MW -KWU Design
10. - 120 MW -KWU Design
11. - 60 MW -KWU Design
12. - 70MW -KWU Design
13. - Industrial Units
14. - 210 MW -Tower Type Concrete Pylem
15. - 210MW -Tower Type Steel Structure
16. - 500MW -Tower Type Once Through
17. - 250MW
18. - CCP
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1.4 System Designation
01 - General Instruction
02 - Technical Data
03 - Erection Strategy - Condenser
04 - Erection Procedure- Condenser
1.5 System Instruction No.
01 - General Description
02 - Technical Data
03 - Erection Strategy - Condenser
04 - Erection Procedure - Condenser
1.6 System Instruction No.
01 - General Instruction
02 - Technical Data
03 - Erection Strategy - Condenser
04 - Erection Procedure - Condenser
1.7 Type of Instruction
G - General
T - Technical
L - Log Sheet
C - Check List
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INDEX
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INDEX
S. NO. DESCRIPTION INSTN NO.
1. GENERAL DESCRIPTION TA1-08-0101G
2. TECHNICAL DATA TA1-08-0202G
3. ERECTION STRATEGY TA1-08-0303G
4. ERECTION PROCEDURE TA1-08-0404G
5. LIST OF DRAWINGS
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GENERAL DESCRIPTION
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1.0 INTRODUCTION
The condenser is a box type construction with divided water box
design double flow; two pass which facilitates the operation of one
half of the condenser while other half is under maintenance. The
steam space is of rectangular cross-section with integral
air-cooling section from where air and non-condensable gases are
drawn out with the help of air evacuation equipment.
2.0 CONSTRUCTION
2.1 The surface condenser is mounted on spring supports. The
condenser is welded with the exhaust hood of the low-pressure
turbine. The tube plates are welded with the water chambers.
Condensers are provided with domed shape water box. The condenser
tubes are supported within the condenser shell by tube support
plates, which are so spaced that the vibrations of the tubes are
prevented under normal operating conditions. The condenser is
installed in such a way that all condenser tubes are drained
automatically into the condenser water boxes.
2.2 NECK
Condition has been provided with an extension suitably to
connect it to the turbine exhaust opening. Adequate internal
clearance is provided. The rigid construction results in a
sound-condenser combination for trouble free operation.
2.3 TUBE LAYOUT
The tube layout is of modular type reinforced having properly
sized tube bundles. Steam lanes are designed from thermo-hydraulic
considerations resulting into better heat transfer, effective
deaeration and minimum pressure drop. Air-cooling zone is
suitability located for effective venting.
2.4 WATER BOX
The water boxes of the condenser have been designed for smooth
entry and uniform distribution of cooling water to all
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the tubes. The water boxes are removable type and have been
provided with necessary hinged manholes for easy access to the
interior for inspection. Each water box has been provided with a
vent and drain connection. The circulating water connections of
adequate size have been provided with water boxes. Safety guards
have been provided to protect the operating personnel from failing
during inspection or maintenance.
2.5 HOT WELL
Hot well (of adequate capacity) is divided longitudinally for
detecting contamination of the condenser half. Suitable manholes
are provided in each of the hot well sections for easy access and
inspection. The condensate produced in the condenser & drains
entering through flash vessels collect in the hot well from where
the pass to the condensate pumps.
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TECHNICAL DATA
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STEAM SURFACE CONDENSER
1. Manufacturer - BHEL / HARDWAR
2. No. of passes - Two
3. Tube length between tube plates (mm) - 14630
4. Total no. of tubes - 24398
5. Tube outside diameter and thickness (mm x mm) - OD 31.75 x
0.7112 mm thick. Top 2 rows 0.889 mm thick
6. Tube material - Welded stainless steel ASTMA249, TP 304
7. Water box design pro Kg/cm (g) - 5.0
8. Water test pro Kg/cm2 (g) - 7.5
9. Duration of test (min) - 30
10. Shell design pro Kg/cm2 (abs) - Full vacuum and 1.08
kg/cm2g
11. Shell test pro Kg/cm2 (abs) - Water fill up to LPT blade
tip
12. Duration of test hrs. - 24 (Min)
13. No. of support plates - 2 x 18
14. No. of spring elements - 36
15. Method of supporting the condenser. -Spring mounted
16. Type of condenser neck to LP turbine casing -Welded
joint
17. WEIGHTS (approx)
a) EMPTY WEIGHT
i. Condenser (without spring) with LP heater no.1 - 710,000
kgs.
b) OPERATING WEIGHT
Condenser + LP heater no. 1 - 1260,000 kgs.
c) FLOODEDWEIGHT
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Water filled up to LPT blade tip of last stage with CW side and
LP heater no. 1 - 2100,000 kgs.
d) Weight of cooling water - 448,000 kgs.
e) Weight of spring elements - 32,000 kgs.
Ref: Drg No: 0-160-10-700 43c 80 Rev 02 Condenser assembly.
f) Weight of single heaviest part (front water box) - 30, 000
kgs.
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ERECTION STRATEGY
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ERECTION STRATEGY
The condenser to be assembled and erected for 250MW/ 500 MW
Sites is supplied in various components from the works.
* Loose parts mainly comprise of the following:
i) Bottom plate.
ii) Turbine & Generator side wall plates.
iii) Dome walls.
iv) Front water chambers and Rear water chambers with tube
plates.
v) Tube support plates nos.
vi) Hot well.
vii) Spring elements - nos.
viii) Steam throw devices - nos.
ix) Condenser tubes.
(I) PREPARATION FOR ERECTION
1. Approach to TG hall should be suitable for movement of heavy
equipment to transport the components.
2. The EOT Crane should be available covering the complete
condenser area.
3. Sufficient area should be available for pre-assembling
preferably on the turbine floor
4. Power source of 200 Amps should be available
(II) TOOLS & PLANTS
- All normal small tools should be available.
- Apart from this the following shall be required during
erection: -
1. Welding Generators 4 nos.
2. Chain pulley blocks 5T 4 nos.
3. Slings (40mm) 4 nos.
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4. Angle grinders 1 set
5. Tube expander with tools 2 nos.
6. Tube cutting bits 2 sets
7. Trailer with pulling unit Sufficient Qty.
8. Trailer with pulling unit for tubes 1 no.
9. Rolled steel section for pre -assy. 1 no.
10. Wooden planks for condenser covering. 1 MT App.
11. GI / Black sheet for condenser covering Sufficient Qty.
12. UV Lamp 1 set
(III) PREASSEMBLIES
a) BOTTOM PLATES
Depending on site conditions, the preassembly of the plate will
be done. If the foundation and approach is ready then it would be
directly assembled on the foundation. However, if the foundations
are not ready it would be assembled separately outside. The bottom
plate is in four parts and two of them will be pre-assembled
outside. On each half the hot well and the spring supports will be
welded / tacked. As the opening on the foundation is big enough the
preassembled bottom plate can be lowered flat without any risk.
b) SIDE WALLES
Both sidewalls are carrying in four parts. Two joints would be
welded outside the foundation.
c) WATER CHAMBER / BOXES
The assemblies of these would be checked and lowered in an
assembled condition.
d) STIFFNERS
These would be assembled and welded in twos.
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e) DOME WALLS
Each dome wall, both upper and lower is in two parts. These
would be assembled together before erection.
f) DOME SHIFTING STRUCTURE
The central portion of the structure shall be assembled
outside.
g) CLEANING OF COMPONENTS
The cleaning of components shall be done either by sand blasting
using low-pressure air (2.5 kg) or by alkali and hot water.
(VI) ERECTION
This would be carried out as per the nor-mal erection procedure
given in next chapter taking due care of all the normal / quality
checks.
(V) TUBING
The tubing of the condenser shall be carried out from the end of
the condenser. The opening in "A row in front of the condenser is
not to be closed till tubing is complete. Tubes shall be
transported on a long bed trailer so that the overhang is not more
than 1.5mm either side. In case a small crane and space is
available the tube boxes shall be unloaded near "A" row columns.
However, in normal cases the boxes shall be unloaded inside the TG
hall by EOT crane and shifted to position manually.
(VII) WATER BOX HANDLING DEVICE
This would be erected when the welding of internals is in the
progress. In case this is not available it would be better to have
suitable openings on TG Floor and oil canal from where the slings
can be inserted to handle the water boxes when they are opened for
tube inspection.
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(VIII) HYDRAULIC TEST
- Steam space
This would be tested by filling the water in the steam spaces to
the required level and the fluorescent powder shall be mixed with
it. It would be inspected by UV Light.
-Water space
This would be tested along with the RE joints and the butterfly
valves. This would ensure tightness of the RE joints flanges along
with the condenser. Moreover the time for fixing blanks can be
saved.
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ERECTION PROCEDURE
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A. BOTTOM PLATE
I. PREPARATORY WORK
1. Check the foundation for dimensional accuracy in accordance
with the plate foundation drawings.
2. Set the support plates in mortar and align with the positions
in which the spring elements will be mounted.
II. ASSEMBLY SEQUENCE
1. Tack the base plates to the spring elements.
2. Lower hot well below and place it on the ground.
3. Lower the sections making up the bottom plate onto the
support plates of the condenser foundation.
4. Assemble and align the sections which have been lowered onto
the foundation.
5. Weld bottom plate as per sequence.
6. Lift hot well and weld with bottom plate. Align the bottom
plate to the turbine axis in zero elevation.
7. Raise bottom plate in axial direction and into zero
elevation, taking care that when condenser is finally tilted, its
centerline would match with turbine axis.
8. When the bottom plate is at zero elevation, shim plates under
all spring elements.
9. In order to avoid displacement of the bottom plate during
assembly of the water boxes and condenser shell internals, the
support bolts of all the spring elements must be in their uppermost
positions before the work is commenced.
10. Detach the tack welded base plates from the spring elements
and eliminate the weld spots.
PREASSEMBLY
1. Preassemble tube plates (L & R) and check for any
distortion of main tube plate.
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2. Any deviation in alignment of holes should be similar in both
front and rear assemblies. In case of variation the matter should
be referred to the BHEL/HWR.
3. Assemble the water box covers with the water chambers without
gasket and check whether:
a) All bolts are fitting and
b) Any clearance in the parting plane, rectify if necessary.
4. In case suitable slings for lifting the complete assembly are
available then welding of tile two halves should be done. In case
of any doubt, the assemblies can be lowered in parts.
B. CONDENSER SHELL
General preparatory work
1. Place the sidewall sections side by side, align and weld
together to from one complete sidewall. After welding together
check the sidewall for warpage and rectify, if necessary.
2. Welding of two or more pieces together outside the foundation
may be carried out.
3. Prepare the water boxes for installation by passing shackles
and wire cable through the lifting lugs.
Assembly Sequence
1. Hook up the prepared water box units to the crane and lower
through the foundation cavity, using hydraulic jacks as required to
secure the units against tilting.
2. As soon as the lowered water box unit is standing upright on
the bottom plate, match the center to the transverse axis.
3. Align the water box unit in the horizontal plane using water
level. Select two symmetric holes in the lowest outermost row of
holes on the right and left side. Insert guide pins in
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the selected holes, to be used as oriented points for
alignment.
4. Drop plumb bob the bottom plate at each other edge and move
the water box unit into the vertical position. When the water box
unit has been aligned in the horizontal and vertical planes, tack
weld to the bottom plate.
5. Before the crane hook carrying the water box is lowered and
the load removed, the water box unit must be secured by means of
cables and stiffeners.
6. Repeat the assembly procedure described above for the second
water box unit of the condenser.
7. After tack welding, tack flat guides to the water box units
and bottom plate.
8. Do not weld the water box units to the bottom plate until the
sidewalls have been assembled, as otherwise weld warpage may
occur.
9. Hook up the sidewalls by means of shackles and cables passed
through the lifting lugs, move over the foundation cavity and
lowered onto the prepared location.
10. Align the side walls in lowered position and tack weld them
at several points to the water box units and to the bottom
plate.
11. Remove the bracing cables, hosting gear, bracing lugs, etc.
from the sidewalls & dome walls & from the bottom
plate.
12. Weld the complete shell.
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CONDENSER SHELL INTERNALS
1. Preparation of the shell
Remove any accessories inside the shell & sweep the whole
interior clean. When preparatory work has been concluded, commence
installation of landing bars.
2. Installation of the landing bars
Mark the installation locations for the landing bars on the
bottom plate according to the drawings.
Locations are measured from the tubes, which will be and are
marked on the outer edges and the centerline of the bottom plate
sides. Then move the landing bars in to position, align and tack
weld. Weld using the back step method from both sides
simultaneously.
Erect the vertical landing bars parallel to the landing bars on
the bottom plats. For this purpose, drop perpendiculars to the
landing bars already mounted on the bottom plate, mark the
installation locations for the vertical bars on sidewalls and tack
weld the landing bars in position. Do not permanently weld the
vertical landings bars until the condenser has been completely
welded together namely after preassembly of the steam dome. Remove
weld residue from the weld zones using a chisel and wire brush.
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Preparing for installation of the tube support sections
1. Mount the flat iron supports for the air cooler shields and
weld onto the tube support plate sections with the aid of a
template at the time of attaching the landing bars onto the bottom
plate. It is important to place wooden beams under the tube support
plate sections to prevent deformation.
2. Installation of the tube support plate sections may then be
taken up. Use the lifting device to transport the tube support
plate sections.
Installation of the tube support plate sections and
internals.
1. Hook up each tube support plate sections upto crane. Lower
into the condenser shell and insert into the landing bars on the
bottom plate and sidewall, beginning at the front and the rear
water boxes. During this procedure, it is important that connection
holes for the circulating water pipe, countersunk by the
manufacturer, face the tubing side.
2. Fix each tube support plate sections at least 4 / 6 points
using adjustable spacers.
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3. Move sufficient tube support plate sections into the
condenser shell and fix them in position relative to each other by
means of spacers to enable the internals to be set down in the
spaces provided in the tube support plate sections. They consist of
the following; steam baffle plates, part of the air extraction
line, as well as various bracing assemblies such as flat irons and
tubes necessary for later assembly of all the internals.
Fig.: Lifting device for the tube support plate sections
4. Insert stiffening rods inside the tube support plates.
5. Suitable tie rods should be used to hold the support plates
against any tilting.
6. Secure all tube support plate sections against tilting, since
it is not possible to commence alignment of the tube support plate
sections and assembly of the internals until after the
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001
steam dome including the dome bracing has been preassembled and
the condenser shell has been welded together.
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Alignment and welding of the condenser shell internals
1. Insert thin steel wires at four identical points in each tube
plate of a water box and feed the wires through the holes at the
corresponding points in the tube support plate sections. Hold the
ends of the wires in the centers of the tube plate holes using a
special device and attach the weights to keep the wire taut. Then
align each tube support plate sections in such a way that the
tensioned steel wire passes through the center points of the holes
for the circulating .water tube
Fig.: Positioning the alignment wire
2. Tack weld the tube support plate sections aligned with the
center point to the slot profiles on the bottom plate and
sidewalls. After tack welding, verify that the holes in the
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001
support plates lie in the vertical and the horizontal planes.
Enter the actual measurements on the measurement data record
provided.
The thin steel wire and alignment devices can now be removed, as
they are no longer for further assembly of the condenser shell
internals.
Move the internals temporarily housed in the spaces in the tube
support plate sections into their correct positions, align and tack
weld. Assembly the center joining plate and the bracing assemblies
such as flat irons and tubes.
3. Note: The stem baffles and bracing units must not be tacked
to the tube of the water boxes. This operation is not performed
until all the internals have been welded to one another.
4. Align the various sections of the air extraction line, weld
them together to form one unit and tack weld to the tube support
plates.
5. During alignment, ensure that air extraction openings are
directed towards the bottom plate and that therefore the connection
holes for the connecting piping systems are necessarily in the
correct positions. Pass out and fit the pipe work to the connecting
piping system through the connection holes. Set down the shields on
the flat iron supports, align and tack weld.
6. After assembly of all the steam space internals Which, to
allow for welding warpage, may only be tack welded, commence
welding of all the condenser shell internals, the welding sequence
being of up most importance.
7. First weld the steam baffle plates, central joining plate,
feed water heating plate form, condensate drain sheets for the
cooler tube nests, bracing assemblies such as flat irons and tubes.
Then weld the tube support plates to the landing bar strips on the
bottom plate.
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001
8. Then weld the vertical landing bar strips to the sidewalls
and tube support plates. During this procedure, welders should as
far as possible work simultaneously. When the condenser shell
internals have been completely welded together, tack and weld steam
baffle plates, the bracing assemblies and the air extraction line
and the connecting piping system at the front and rear tube plates.
When all the welding work has been concluded, remove all weld
residue from the weld seams and weld zones in the entire condenser
shell.
9. Note:
a) To prevent welding warpage, all welds must be performed
simultaneously from both sides using the back step method. Vertical
joints must be welded from top to bottom, i.e. from the upper edge
of the tube support plate to the bottom plate.
b) Welding with main tube plate should be done after all
internal welding has been completed.
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29POWER SECTOR WESTERN REGION TECHNICAL SERVICES NAGPUR-440
001
Assembly of LPH in condenser
General:
Prior to the erection of LP heater and platform, the pipes for
the extraction system and throw device have to be erected/ placed
in the steam space.
Erection of the LP heater platform
Erection of the feed water heater platform start with mounting
on the U-profile steel support in the area of the central butt-
strapping of the tube-supporting sheet.
This involves firstly mating and bracing the support for LP
heater platform with the cut-to-size sheets and the ends of the
associated U-profiles. The I-profile girders for the feed water
heater platform are mounted on top these. The support brackets for
the LP heater platform support are then mounted on the dome walls
on the water box side.
The elevations for the feed water heater platform support must
be assured.
Then the feed water heater platform and the dome bracing are
installed, aligned and welded as a unit.
Installation of the Feed water Heater through the Turbine
Foundation/Condenser Steam Dome Cavity
The LP heater held in the lifting tackle is inserted the turbine
foundation/condenser steam dome cavity and tilled to the required
angle. Insert the feed water heater through the turbine foundation
into the condenser by lowering crane hook and by gradually
straightening out the lifting bracket towards the horizontal
plane.
Then move the feed water heater into the prescribed horizontal
position parallel to the feed water heater platform.
As soon as the horizontal assembly position is achieved, adjust
the feed water heater to the prescribed vertical elevation.
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Mount support jacks on the I-profile girders supporting the feed
water heater platform and at the feet of the feed water heater to
support the feed water heater when it is set down from the lifting
bracket.
Adjust all the support to the prescribed pressure and tack the
load off the lifting bracket.
Then take the actual dimension for the LP heater support,
fabricate the parts required and insert under the heater. Tack the
load off the support jacks as the permanent supports are
inserted.
After completion of alignment of the feed water heater along the
longitudinal and transverse axis, the upper halves of the dome wall
can be installed, aligned and welded to the feed water heater as
per the drawing.
Note: The two upper halves of the dome wall on the water box
side are not to be installed and assembled until the installation
of the feed water heater through the turbine foundation/ condenser
cavity has been completed.
STEAM DOME AND BRACING
General
The assembly of steam dome is commenced when the condenser shell
has been adequately tack welded. Prepare the support points at the
upper edges of the condenser shell for assembly of the steam dome.
Tilt the condenser shell as per drawings. Ensure that centerlines
are not disturbed.
Preassembly of the steam dome walls
1. Preassemble the dome walls, divided into section for
shipment, according to the plant drawings. During this procedure
the sections making up a dome wall are assembled on the -turbine
floor with their ribs facing upwards, aligned, adequately tack
welded and then welded to form one integral unit.
2. After completion of welding, clean the welding zone and
examine the dome wall unit for warpage. If necessary, realign the
dome wall unit to match the mounting dimension to the other
component.
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001
3. Prior to installing the dome wall unit, coat inaccessible
weld locations with anti-corrosive paint.
4. After this has been affected, measures out the dome wall
units and Mark the center points by punching.
Installation and Assembly of the dome walls
1. There is no specific sequence for the assembly of the dome
walls. Depending on on-site condition assembly may commence either
with the dome walls on the turbine and generator sides or those on
the water box sides. The dome wall units are hooked up using
suitable cable passed through their transport lungs, moved over the
foundation cavity and lowered into position on the upper edges of
the condenser shell.
2. The sloping edged metal fixtures mentioned above facilitate
insertion when assembling the dome wall on the turbine or generator
side.
3. The dome wall remains suspended from the crane unit it has
been secured against tilting and slipping by suitable clamping.
4. Then the opposite dome wall is installed, when the two
opposite dome walls have been installed and secured, they are to be
aligned with the longitudinal or transverse axis. For this purpose,
drop perpendiculars from the steel wires on the longitudinal and
transverse axes onto the upper edge of the dome walls.
5. When the two opposite dome walls have been aligned, secure
them by tack welding to the steam shell.
6. Insert and install the adjacent dome walls as per drawing, as
dome walls are identical and must be moved into the correct
position.
Assembly of Dome Bracing
1. Commence assembly of the dome bracing parallel to welding
work and after completion of the shell internals.
2. Lower the dome bracing, supplied in required lengths, into
the steam dome by crane, align in position and track weld.
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3. When all the sections of bracing have been preassembled and
track welded, welding of the dome bracing to form one integral unit
to be carried out. However the connection with the LP cylinder
should be done only neck welding.
Assembly of Steam throw nozzles
After the dome walls have been tacked in position,, the steam
throw off nozzles are lowered and rough aligned.
The final alignment is dome along with the LP Bypass down stream
piping.
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WELD CONNECTION BETWEEN CONDENSER AND LOW PRESSURE TURBINE
Welding the condenser to the low pressure turbine
1. After the condenser has been brought to operating weight by
filling water in the hot well or by the springs as indicated in
condenser erection drag and the spring supports have been adjusted
to compensate for welding contraction, prepare for welding the
condenser to the low pressure turbine.
2. Then fit the intermediate, corner and web plates as per gaps
available and prepare the weld edges.
3. Tack these parts to the condenser dome with welds with a tack
length of three times the plate thickness at intervals of 25 times
the plate thickness.
4. When all the aforementioned parts have been welded to the
condenser dome, tack weld to the low-pressure turbine.
5. Weld the joint using the back step method form tack to tack
(see diagram). When the base layer has been completed, make the
following filler weld layers, each in a single pass, and reversing
direction for each layer (see diagram).
6. After welding, clean the weld zone using suitable tools. When
the condenser has been completely welded to the low-pressure
turbine. Relieve the spring supports of the load applied to
facilitate welding and measure in relieved condition.
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7. The spring supports must return to within +/- 1 mm of
their
settings. If the deviations exceed this tolerance range, spacers
must be used to return the pretension of the spring supports to
their original settings.
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8. Then immobilize the supports again.
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36POWER SECTOR WESTERN REGION TECHNICAL SERVICES NAGPUR-440
001
INSTALLATION OF THE CONDENSER TUBING
General
The circulating water tubes, cut to length and provided with
guide heads delivered in crates to the site.
Erection of an assembly platform
Before erecting the assembly platform, remove the water box
covers and set down on wooden beams in a suitable location.
The assembly platform must be erected in such a way that it is
safe to walk on and presents no danger of falling off. In addition,
it must be stable enough to withstand the weight of the crates
containing the circulating water tubes.
Preparation of the holes for the circulating water tubes
The holes in the tube plates must be clean to the base metal.
Clean all holes using round steel brushes or reamers. Use of
chemicals /solvents is not desirable. If the hinge assembly has
been installed then one condenser box can be opened at a time.
Installation of tubing
The tubings are inserted manually, Insert the tube from the
bottom end and pull through towards the top end until the same
length of tubing protrudes from the front and rear tube plates.
Remove the guide heads from the circulating water tubes. In case
the insertion is difficult then the tube should be taken out and
the support plates rectified by reaming.
Tube expander
Use electronically controlled tube end expanders to roll the cw
tubes into tube plates. When the desired pressure is reached, the
expander switches to reverse speed.
The following points must be observed when expanding tube
ends:
The tube plate holes and the tube ends must be clean to the bare
metal and free from axial draglines.
Before expanding in the tube ends, moisten the roller with at
least two drops of glycerin or vegetable oil. Moistening is
necessary to
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001
ensure that expander rollers rotate smoothly and with minimum
wear.
The complete tube end expander unit consisting of the monitor
and the tube expander be kept together as one unit. If one part is
replaced the setting must be re-adjusted to give the correct
expansion as required for tight connection.
The locking device on the roller head must be set to block the
rollers to a depth of 80% of main tube plate thickness before
reaching the steam compartment side of the tube plate. If the tubes
are expanded beyond the steam compartment side of the tube plate,
they will be damaged.
Finishing work on the tube plates and cw tubes
1. Remove any burrs at the tube inlet edges.
2. After expanding into the opposite tube plate, mill off the
protruding tube ends to the stipulated dimension and deburr the
inner edges.
Fig. Condenser Tube Ends
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Preparing the water box covers and tube plates
Clean the joints of the water box covers and tube plates.
Note: When cementing the gasket, the joints must be free of
grease, clean and dry.
Assemble the rubber cord and spacer gaskets.
Assembly of the water box covers
The water box covers are attached to the lifting equipment using
appropriate cables, swiveled into the assembly position and moved
in front of the respective water box.
The hexagonal bolts and nuts necessary for the assembly of the
water boxes must be coated with a lubricant / graphite and
subsequently tightened.
The initial phase of this procedure is to tighten four bolts
marked x in figure. Afterwards all the bolts in the fig. are
consecutively tightened starting from the middle with x1, x2, x3,
x4, x5, x6.
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Caution: It is imperative that the bolts be tightened in two
stages
HYDRAULIC TEST OF WATER BOXES
The condensers are subjected to a hydraulic pressure test on the
cw side. For this purpose, the cw inlet and outlet pipes must be
blanked using suitable hydro test flanges and the manholes using
the original covers. The water box covers must be mounted ready for
operation and a protective coating must have been applied to the
water boxes.
The hydro-test can also be done by closing the butterfly valves
in the inlet and outlet of condensers. This apart from also
ensuring the
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001
tightness of B. F. valves and expansion joints, reduce the time
cycle as the temporary test flanges need not be erected.
After the hydro test, drain the cw.
Hydro fill test on steam side
After the tubing has been completed, including the trimming of
the tubes the hydro fill test is to be conducted on the steam
space.
1. Lock the spring supports in position.
2. Gradually fill the steam space with water. A water tube
arrangement is to be installed so that the level of water can be
monitored.
3. During filling, constantly check the tubes for any leakage.
In case any leakage is observed, that particular tube should be
further expanded.
4. In case any tube is not getting sealed, it may be
plugged.
Caution: This should be done as a last resort.
5. Fill the water upto last stage blade tip of LP Turbine and
leave for 24 hours. Check thoroughly for any leakage.
6. Add a fluorescent dye (Sodium floursceine) 2-3 ppm (approx. 2
Kg) to the filled water in the condenser. Stir the complete water
and dye with compressed air.
7. Leave the water for another 24/36 hours.
8. Finally inspect the tubes by ultra - violet light with the
help of U-V lamp.
9. When no fluorescence is observed it can be inferred that
there is no leakage.
10. During this test, other connected areas (falling under
vacuum during operation) can be inspected for any leakages.
11. Release the condenser springs, after all water has been
drained from both the steam space / cw side. The springs are
finally set as per drawings.
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001
NOTE: Water should never be filled on both steam and CW side at
the same time.
SPECIAL PRECAUTIONS TO BE TAKEN DURING ERECTION:
1. The joining plates between the water chambers should be
welded and checked before lowering of condenser intervals.
2. The corners of the neck joint with LP turbine should be
checked to ensure completeness.
3. The welding of the stiffeners with the main tube plate should
be done only after welding of all support plates with the shell and
stiffness has been completed.
4. Welding sequence should be reversed for every layers of
welding.
5. During preassembly of bottom plates / sidewalls & dome
walls it is advisable to put a packer below the joint so that
during welding the plates straighten out.
6. Not more than four welders should be deployed during the
welding of the internals. Adequate supervision should be exercised
to ensure proper welding sequence.
7. It is desirable that after 5010of the welding of internals
has been completed the alignment of the tube plates is rechecked.
Subsequent welding sequence should be decided based on the
observation made.
8. During tubing in case the tube is not going freely the holes
of the tubes support plates may be reamed suitably.
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LIST OF DRAWINGS
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S Description Drawing No. 1. CONDENSER ASSLY (GA)
0-160-10-70043C80
2. CONDENSER GENERALASSLY. (3 - SHEETS)
0-160-10-70043 ER
3. INSTALLATIONOF LEVEL INSTRUMENTSON CONDENSER
2-160-00-70001 C80
4. HANDLING ARRANGEMENT FOR FRONT WATER BOX
0-160-0070023C80
5. HANDLING ARRANGEMENT FOR REAR WATER BOX
1-160-00-70060C80
6. BOTIOM PLATE 0-160-11-70010 ER
7. LOWER DOME WALL (TUR END) 0-160-12-70025 ER
8. LOWER DOME WALL (GEN. END) 0-160-13-70030 ER
9. SIDE WALL (TUR. END) 1-160-14-70005 ER
10. LOWER DOME WALL (FWB SIDE) 0-160-15-70032 ER
11. LOWER DOME WALL (RWB SIDE) 0-160-16-70036 ER
12. SIDE WALL (GEN. END) 1-160-17-70005 ER
13. DOME INTERNAL STIFFENING 0-160-27-70027 ER
14. SHELL INTERNAL DETAILS 0-160-28-70031 ER
15. AIR EXTRACTION PIPING 1-160-71-70027 ER
16. LP HEATER SUPPORT ARRGT. 0-160-38-70081 ER
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17. HOT WELL 0-160-28-70028 ER
18. CONDENSER SUPPORTS 1-160-71-70027 ER