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The company takes due pride in mentioning a few of the innovative erection techniques adopted recently at its on-going Supercritical Technology Projects:
Ever since its launch, PCPIL has laid full emphasis on, and introduced many innovative techniques for erection of intricate and critical equipment not only to save time and effort but to achieve better quality with due safety of material, T & P and manpower. The company in its endeavors has earned laurels & appreciation from various customers especially in the field of Thermal Power Generation like BHEL, NTPC & SEB’s for maintaining required pace of erection with quality and required safety standards.
660 MW Super Critical Boiler-PPGCL Bara (Allahabad)
FURNACE“S” SHAPE WATER WALLS PANELS
Working with the same strategy to reduce the erection time and ensure better quality, the evolved innovative technique of assembling the parts at ground, was further adopted for spiral tube WW panels of boiler furnace. All the 18 nos. panels, in “S” Shape 5 nos. long horizontal buck stays and 70 nos. vertical buck stays were assembled in boiler cavity and the total assembly weighing 119 MT successfully lifted to position taking just 10 days as against the normal time of 21 days.
FURNACE WATER WALLS
As the conventional way of working did not suit the stipulated time frame alloted to complete the project, as per the tight schedule, our executives pooled the ideas and evolved some innovative techniques in which the boiler tube panels were assembled at ground including fixing of attachments and then lifted to position after exercising all quality checks. Each assembly of size 14566 x 18352 eighing 88 MT was given additional support and lifted to location in such a safe manner that the OEM representative, who was initially hesitant & reluctant to approve the new technique, applauded and recommended the same method to be used for the erection of the remaining panels.
FURNACE SPIRAL WATER WALLS
Super Critical technology, introduced now in India in a big way, involves erection of spiral water wall tube panels in boiler, which is an intricate and time consuming job. Again, to reduce the erection time and achieve the required quality, pre-assembly of Spiral Panels have been done at ground level and after fixing the attachments lifted as a single piece.
REAR ARCH BOILER TUBE PANEL
The erection of Rear Arch Panels of 660 MW Super critical Thermal Power Project, a herculean and time consuming job, has been done in a highly innovative method. All the 12 similar panels were assembled and weighing 68 MT and hoisted to 65 Mtrs elevatoin with required position with all safety precautions.
BOILER BACK PASS LOWER HEADERS
The innovative technique adopted in pre-assembling of 4 nos. back pass lower headers 20988 x 14996 MM at ground and erected as a single piece weighing 54 MT has been highly appreciate. The high accuracy, quality & safety maintained during assembly & erection is the demand of the power industry for expeditious completion of the projects.
ASSEMBLY AND ERECTION OF DUCT
To reduce the erection time and ensure better quality standard, innovative techniques for pre-assembly and erection of air and gas ducts have been evolved & practiced. Complete wind box duct of size 16503 x 13545 x 1100 MM and weight 34 MT has been assembled and erected in single piece from the boiler cavity on both left and right side of the boiler.
GAS DUCT AT ESP OUTLET
In another such innovative erection methodology, the gas duct at ESP outlet has been assembled with guillotine gates and assembly in Y configuration erected as single piece thus reducing the erection time ensuring the standard of quality and safety.
Time is of the essence to fulfil the demand of the power industry. A high pace of progress with quality has to be maintained for which one has to look for and evolve improvised techniques. Moving on these lines and adopting innovative ideas, a record erection of 3241 MT and welding of 6441 no’s joints of boiler high pressure tubes of unit # 1 at Bara has been achieved in a single month
ASSEMBLY OF ECONOMISER HOPPER
The pre-assembly of economiser hopper including their internal supports below the second pass of furnace of 660 MW Boiler was done at Bara and the assembly weighing 98 ton lifted in a single piece.