PROCEDURE FOR ASSEMBLY & DOCUMENT NO.

:
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 1 of 19 00

PROCEDURE FOR ASSEMBLY & ERECTION OF AIR PREHEATER

FOR
3X330 MW STEAM POWER GENERATION

DOCUMENT NO: P-T3109-CONS-010

ORIGINATED APPROVED
REVIEWED BY DISTRIBUTION
BY BY
- SDCC : Original
- CNEEC : Copy
Mujiono Subrata Dey Iman Paryaman Agus Subagyo - All Dept. : Copy
Area Manager Cons Manager SMR Site Manager

REV. ISSUED EFFECTIVE

BRIEF OF REVISION
NO DATE DATE

00 May-26-08 May-26-08
01 June 24,2008 June 24,2008
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 2 of 19 00

No. Descriptions Page

1 TITLE 1 of 18

2 TABLE of CONTENT 2 of 18

3 SCOPE 3 of 18

4 OBJECTIVE 3 of 18

5 REFFERENCES 3 of 18

6 DESCRIPTION : 3 of 18

7 GENERAL INSTRUDUCTION 3 of 18

8 ERECTION SEQUENCE 4 of 18

9 ERECTION PROCEDURE 4 of 18 to

16 of 18

10 ROTOR TYER ALIGNMENT 16 Of 18

11 INSULATION 17 OF 18

12 ERECTION EQUIPMENT 18 of 18

13 SAFETY MEASSURER 18 of 18

14 ATTACHMENT :
Rigging plan
Organization Chart
Man Power and Equipment Plan
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 3 of 19 00

1.TITLE

PROCEDURE FOR ASSEMBLY & ERECTION OF AIR PREHEATER FOR 3X330 MW

STEAM POWER GENERATION.

2. SCOPES

This procedure is to describe assembly & erection method of the Air Preheater for 3x330 MW
Coal Fire Steam Power Plant in Indramayu, Indonesia for CHINA NATIONAL ELECTRICAL
EQUIPMENT COORPORATION (CNEEC)-BEIJING ROC.

3. OBJECTIVE

As guidance for engineer or supervisor or related person to providing and following the
erection method of Air Pre heater. The procedure is applicable for boiler unit 1, unit 2 & 3 of
the above steam generating plant.

4. REFERENCES

4.1 P-T3109-SDCC-001, Guidelines for Establishing Project Procedure

4.2 Drawing No. 07Z06244/001001 Rev-D
4.3 Material Receiving., Moving and Storage Proc.
4.4 Approved Inspection Test Procedure
4.5 All erection Drawings and documents of Air Preheater.
4.6 Welding Procedure Specification

5. DESCRIPTION.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 4 of 19 00

5.1 GENERAL INTRODUCTION.

5.1.1The air preheater is manufacturer by HOWDEN HUA ENGINEERING Co LTD. China.

With type Rotary Regenarative
5.1.2 Quantity of the Air Preheater are 2 units per Boiler.
5.1.3 Air Preheaters dimensional space requirement is 12800 mm x 12310 mm for unit.
5.1.4 Location of the air heaters are on the Boiler steel structure at elevation +11970 (top
beam) in axis B1.6 to B4.4 and line K4 to K6.
5.1.5 Main part of the air preheaters consist of :
Bottom Girder.
Heating surface elements and containers.
Rotor.
Rotor housing.
End pillars.
Top Structure.
Bottom Structure.
Sealing Arrangement.
Drive unit.
Rotor top and Bottom bearing.

5.1.6 The weight of major part during installation are :

Bottom girder total weight approximately 15978 kg
Top structure 15740 kg.
Rotor assembly 89623 kg.
Total weight as per assembled is 408541 kg
(Refer to drawing no.07Z06244/0011002)

6. ERECTION SEQUENCE.

6.1 Bottom Girder.

6.2 Bottom Bearing.
6.3 Bottom Structure.
6.4 End pillar.
6.5 Rotor spider.
6.6 Top structure.
6.7 Top bearing.
6.8 Drive unit.
6.9 Rotor housing for air site.
6.10 Air duct connection.
6.11 Rotor sectors.
6.12 Gas side rotor housing.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 5 of 19 00

6.13 Cold and hot element.

6.14 Rotor tyer alignment.
6.15 Insulation.

6.1.1 Lifting Sequence for major Equipments.

Number Equipment Description Weight in kg/piece Qt’y Remark

1 Bottom Girder+ Bottom 24.555 2 set / 2 lift Preassembled
bearing + Bottom Structure
2 End Pillar 4756 2 set / 4 lift
3 Rotor Spider 17670 2 pcs / 2 lift
4 Top Structure 16500 2 pcs / 2 lift
5 Top Bearing
6 Rotor housing 15592 2 set / 4 lift Preassembled
7 Heating Element Container
8 Drive unit 5090 1 set / 2 lift

7. ERECTION PROCEDURE.

7.1 BOTTOM GIRDER.

Before lifting of the bottom girder to the final position, the preparation work should be done
as follows:

Marking center line on the boiler steel structure.

Check and Record the elevation of the steel beam on the boiler steel structure.
Prepare shim plate as necessary.

Preassembly work on the ground to be carried out before lifting to the final position.

Preassembly preparation :
Prepare temporary support on ground with the good level.
Connect girder 1 and 2 trough bottom bearing support stool, measure the level by
instrument (Fly level), tight all bolts when level is oke. Ready for erection.

Erection work of the bottom girder.

When the preassembly work is completed, erection work will be carried out by using Crawler
crane with capacity 150 ton.
The weight of the equipment preassembled is approximately 15978 kg.
(Reference to drawing no.07Z06244/100001 Rev D.)
Lifting lug which supplied by manufacture will be used for lifting the equipment.

Alignment the equipment.

 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 6 of 19 00

The center line and elevation of the bottom girder will be aligned immediately after the
equipment on position.

The tools for adjustment of the equipment are :

Lever block with capacity 3 ton for adjust left and right.
Hydraulic jack for adjustment up and down.
Record the elevation and center line of the equipment with respect to the tolerance of the
installation.
The tolerance of alignment will follow manufacture standard.
Tight all bolts connection between bottom girder to structure beam

Mounted bearing housing on the bearing stool, and prepare shim plate as required.

7.2 BOTTOM STRUCTURE.

After the bottom girder in position and finish aligned, the bottom structure will be erected
individually.

Position 6 jacks on top flange of bottom girder to regulate the height and levelness of the
bottom structure.

Slowly lift the bottom structure to jacks, adjust the center of the bottom structure
according to the diameter of the sector plate, the bottom structure is approximately 8577
kg.
Weld bottom structure support plates to top flange of the bottom girder.
Do not weld these support plates to bottom structure supports at this stage.

7.3 END PILLAR.

Set up end pillar hinge on the top of bottom girder. Measure and record the levelness of
each end pillar hinge mounting face.
Measure and record the relative position of jack plate to end pillar hinge.

Ensure that all end pillars hinges are positioned and secured as required,
The temporary securing plates at both sides are perfect.

Lift the end pillar on one side and axial seal plate assembly on top of hinges.
Adjust the axial seal plate position if necessary to obtain a close fit with the end of the
sector plate. Secure the soleplate with the bolts provided and torque to 600 Nm.

Fit temporary stays to secure the vertical location of the end of pillar assembly
And axial seal plate.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 7 of 19 00

Repeat the steps above for the others side of end pillar.

Check that both end pillars are vertical in both directions and that the dimension between
them is correct refer to drawing.

7.4 ROTOR SPIDER.

Ensure that the bottom bearing cover plate and jacking plate are assembled and fitted
correctly.

Marking top position of rotor spider, then remove the bolt of transportation cradle.

Lift with 2 cranes and using by nylon slings on both of the rotor spider, reverse carefully
the spider with releasing one crane on bottom side, so the rotor spider become vertical
condition according to the final position. Remove sling on bottom side of rotor spider.

Slowly lift the rotor spider to the center hole of sector plate and sector false plate. Once
the spider is installed onto the top plate, the bottom spider seal can not be installed, so the
assemblies of bottom spider seal shall be fixed in position before rotor spider assembly.

Care must be taken when lowering the rotor spider to ensure that the recess of the bottom
face of the bottom hub correctly locates wit the spigot on the jacking plate, the bottom of
the spider in close fit to jacking plate.

After checking and adjusting the levelness of rotor spider, install temporary props to hold
the rotor spider plumb until the top steady bearing is installed,
Then removed.

Remove lifting lug from top of rotor spider.

7.5 TOP STRUCTURE.

Before lifting the structure. Four support angle at the top of each end pillar column should
be positioned and leveled within 1mm, After the correct positions of the angle has been
achieved, each angle must be tack welded to the end pillar columns.

Positioning four slings to the lifting lugs provided by manufacture. After erection of the top
structure is completed the lifting lug must be removed.

Ensure that the top sector plate aligns with the top of rotor hub and the holes in the top
false sector plate aligned with support angles at the top of the end pillars.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 8 of 19 00

Locate bolt through top false sector plate and support angle, check dimension between the
bottom and the false sector plate at the four corners adjacent to the end pillar, this should
be to follow drawing dimension. Move support angle as necessary to achieve this.

After ensuring that top structure is correctly installed, tighten all bolts at end pillar.

Weld the top structure to end pillars according to requirement to the drawing.

Weld the tension bars between top structure and end pillars.

Remove temporary stay from end pillars.

7.6 TOP BEARING.

The top hub seal gland housing bearing should be fitted to the top structure before the top
steady bearing is fitted.
Lift the steady assembly bearing by means M36 eye bolt on the main shaft and gently
lowering into position.

Fit the special M36 bolts to connect rotor drive shaft and spider hub and separately tighten
up to 2000 Nm. as indicate on the assembly drawing 136001

Joint all bolts, nuts, upper and lower washer plates between support channel and top
structure on the top steady bearing housing, take care not to fasten tightly for easy
adjustment.

Remove temporary support bar holding bearing housing in position.

Fit shims between top structure and bearing housing support leg such that the zero
graduation mark on the mounting bell lines up with the top cover of the bearing housing.

Screw tightly as requested on the drawing and check all regulation bolts
(300 Nm) and set bolts (500 Nm) of top bearing one by to be necessary torque.

Remove eye bolt at the end of drive shaft, carefully label for future identification and send
to store for safe keeping.

Remove temporary props for rotor spider.

7.7 Drive unit.

 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 9 of 19 00

Check whether the drive orientation, motor power and model, each gear box model, oil
level indicator, breather and oil filter hole is correct.

Degreasing drive unit terminal output box and drive shaft.

Apply mounting paste on drive shaft.
A thin layer of oil shaft to be applied evenly in all direction, remove residual oil with eraser
or non fluffy cloth to make surface not glossy. Don’t apply oil on hub bore.
Remove the spacers between the shrink disc collars that were fitted for protection during
transportation.

Use the lifting lug of final stage gear box as lifting point to lift the complete drive unit.

Lower drive unit gently until it locates on the drive shaft shoulder.

Measure the gap between both collars at various points to ensure equal spacing.

Slide shrink disc into hub (Outside surface of shrink disc can be greased)

Tighten all locking screws gradually and all the way round.

Install the torque brackets ensuring that the faces are coated with anti friction compound.

Weld brackets to top surface frames as shown on assembly drawing.

Install inverter as requested ensuring both drive motor of drive unit being separately
controlled for start-up and operation by two different inverters.

Check and ensure that both electric motors are driving the rotor in the same direction of
rotation and the rotation is in according with the general arrangement drawing 001001.
This last check can’t be performed until the air preheater is fully erected and the inverter is
connected to power supply (refer to APH O&M Manual)

7.8 ROTOR HOUSING for AIR SIDE.

Rotor housing assembled are dispatched to side separately. The rotor housing section
should be suitably grouped for easy of handling into the position. The section should be
welded together at site.

Assemble hinges side pillars in positions as indicated in the drawings and secure to
supporting steel work using bolts.

Recheck the elevations and the levels of end pillars in different point by using the surveyor
level.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 10 of 19 00

Add temporary ties to each side pillars after leveling to stabilize them during erection of
housing sections.
Rise of air side housing section, local to the end pillars into position and secure to
appropriate end pillars using bolts. Locate on hinged site pillars and bolted section
together. Butt seal weld adjacent top and bottom landing plates together.

Assembly the top and bottom tri-sector plates. Leveling should be completed after these
are assembled.

Measure and record the concentricity of three axial seal plate.

At this stage the top side pillars plate should be tack weld to the bottom landing plate of
rotor housing.

7.9 DUCT CONNECTION.

TRANSITION DUCT.
Transition ducts comprise of primary air and secondary air duct. Secondary ducts sections
are separately dispatched to site. The duct are presented to the respective top and bottom
housing landing plates and tri sector structure, correctly positioned and welded to place as
indicated on drawing.

For the convenience of the site erection, duct section can be preassembled. Each split
sections can be welded together

BOTTOM DUCT SECTION.

With the bottom duct sections the location is important to ensure that regular shape is
maintained all round in relationship to the bottom rotor tyre for circumferential sealing.

Select two ducts sections and position these below the housing.
Sling and lift the secondary duct sections into position utilizing 22 mm holes in the bottom
landing plate and flange of duct folded and bend edge, Making duct flange close to bottom
housing landing plate and tri sector structure for tack weld.

With the section of duct tack welded in position, carry out an alignment check.

Fully weld the duct section to landing plate and wing plate before releasing the sling.
Remove all positioning bracket.

Repeat the above method for primary air duct.

 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 11 of 19 00

Select bottom tabular duct stiffener, support plates and seal plates etc. as indicate on the
drawing no.116002.
Grind seal plates to suit stiffener profile and fit over the stiffeners.

Arrange the tabular stiffener through the hole in the duct wing plates on the center and
tack weld support plates, seal plates and external stiffener in position.

Select the bottom flange tabular duct stiffener and install as indicate in the drawing no.
116003.

Check the erection position of the duct assembly.

Fully weld the duct section to the housing landing plate and duct wing plate.

TOP AIR DUCT SECTION.

Lift the secondary air duct onto the housing top landing plate. Utilizing 22 mm holes on the
top of landing plate and flange of duct folded and bended edge, locate into position and
tack.

With the section of duct tack welded in position, carry out an alignment check.

Lift the primary air duct onto the housing top landing plate. Utilizing 22 mm holes on the
top of landing plate and flange of duct folded and bended edge, locate into position and
tack.

Select the top tabular duct stiffener and install as indicate in the drawing no. 116001.
Select the top flange tabular duct stiffener and install as indicate in the drawing no.
116003.

Carry out an alignment check for duct.

Measure and record the distance between duct flange surface and housing landing plate.

7.10 ROTOR SECTOR/ROTOR SECTION.

Refer to rotor site assembly instruction no.001007, 001008.

Before commencing site assembly of rotor, particular care should be exercised to ensure
identification is carefully followed.
Ensure that there are safe temporary platforms to local assembly point.

Rotate rotor by hand turning device, to the required position i.e position suitable for lifting
rotor sector (180/0/1) into position related to temporary erection plat form.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 12 of 19 00

Raise the first rotor sector (180/0/1) into position by means of the lifting lugs provided by
winch or crane.

Level of at correct height relative to rotor spider and secure to rotor spider with butt angles
and bolts. Before rotor turning, the lifting lugs on the division plate must be removed.

Rotate rotor through 1800.

Lift the second rotor sector (180/0/5) level off and secure to rotor spider with fitted bolts
and butt angles. Before rotor turning, the lifting lugs on the division plate must be
removed.

Rotate rotor until rotor sector (180/0/3) is in correct location for lifting.

Lift the third rotor sector (180/0/3) into position, level of and secure with fitted bolt to
temporary butt straps and than remove the lifting lugs.

Rotate rotor through 1800.

Lift the fourth rotor sector (180/0/7) into position, level of and secure with fitted bolt to
temporary butt straps and than remove the lifting lugs.

Rotate rotor until rotor sector (180/0/2) is in correct location for lifting.

Lift the fifth rotor sector (180/0/2) into position, level of and secure with fitted bolt to
temporary butt straps and than remove the lifting lugs.

Rotate rotor through 1800.

Lift the sixth rotor sector (180/0/6) into position, level of and secure with fitted bolt to
temporary butt straps and than remove the lifting lugs.
Repeat above steps until all 37.50 rotor segments are installed.

Fit temporary ties ref.191/100 between the assembled rotor sectors, adjust and equalize
spacing between sectors.
Check circularity of rotor, top and bottom, local to radial division plates.
Maximum radial out of tolerance at true should be checked from appoint on the end pillar
is 3 mm.

Check rotor fluctuation when rotated over a fixed point tolerance is 3mm.
It may be necessary to fit shims between the bolted connections at the spider to achieve
this tolerance. the shims will require to be cut from shim material supplied.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 13 of 19 00

Turn rotor until the gap between erected sector 180/0/3 and 180/0/4, is in position in
relation to temporary access platform.

Fit and tack weld 7.50 rotor sections in sequence.

After fitting and tack welding each 7.50 rotor sections, fit the cold element closing plate
inside 7.50 rotor section and remove the temporary ties.

Measure and record circularity and levelness.

Fully weld rotor assembly in according with drawing. do not weld until the above has been
checked by engineer or manufacture representative.

Ensure all top and bottom tyre bars are fitted to the rotor periphery.
Fit and tack weld the cold end element grids in all rotor sections.

Remove and trims the top and bottom tyre bars at site according site erection requirement.

Check rotor after welding to ensure tolerance remains within that defined under check
point.

7.11 GAS SIDE ROTOR HOUSING.

After all rotor sectors has been erected, the gas side rotor housing to be carried out.

Gas side rotor housing to be supported with 2 sets hinged side pillars and attached to end
pillars.

Assemble hinged side pillars in position as indicated on drawings and secure to supporting
steelwork using bolts. Shim hinge pillars as required to align top bracket plate with landing
plate extension on end pillars.

Using surveyor level gauge for check level of side pillars to reference points.

Add temporary ties to each side pillars after leveling to stabilizing them during erection of
housing sections.

Lift the gas side rotor housing adjacent to end pillars into position and bolt to end pillars,
which would supported to side pillar. Once it was located, each part of rotor housing shall
be bolted together and adjacent plate to be butt welded.

At this stage the top end pillar blanking plates should be tack welded to the rotor housing.

Crawler crane 150 ton will be use for lifting/erection of this rotor housing.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 14 of 19 00

Ducts connection to be carried out as air ducts erection steps.

FINAL CHECK AND WELDING.

Check levels of rotor housing relative to rotor by selecting 22 point on the top and bottom
landing plate and checking against the rotor.
Adjust shimming under side pillars when necessary.

Check Circularity of the cold end duct/landing plates to the circularity of the rotor by
dropping the straight edge from the duct onto the rotor tyre (outer circumferential seal
carrier) to the rotor tyre bars.

Fully weld hinged side pillar top brackets to the rotor landing plate. Refer to drawing.
Fully weld top duct to rotor housing and to duct wing plate on centre section.
The vertical bolted flange connection joining the two sections of duct is also seal welded
inside. Refer to drawing.
Weld the duct tabular stiffeners as indicate in the drawing.

Fully weld rotor housing joints between housing sections and at the end pillars.
All temporary adjuster brackets and all temporary stiffeners to be removed and associated
welds to be removed and smooth.

7.12 COLD and HOT ELEMENT.

After rotor sector and rotor housing has been erected, the elements to be loaded to the
containers.

Weld bottom false sector plate to and pillar landing plate.

Slacken bolts on bottom false sector plate support bracket and angle brackets at
centralizers to fit the bolts on the angles plate of the channel steel of bottom structure and
H section steel.

7.12.1 Hot end element loading.

See element drawing for identification of element pack. Remove element access door and
install lifting beam and tackle into duct as required.

Using the hand turning crank, align the rotor with a sector on the center line.

After intermediate end pact loaded, we can start to load hot end pack intermediate and hot
end packs should be loaded using the sling provided.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 15 of 19 00

Attach the tackles of the sling to diagonally opposite lifting holes on the end of an
intermediate tier pack and with the lifting gear. Rise the pack up through the door into top
duct. Lower the pack carefully down inside the rotary heater transition duct and man
handle the pack into position on the rotor. It is strictly forbidden to handle without care.

Repeat procedure above for adjacent pack. And remaining element pack installing pack
pair in a diametrical opposed pattern.

In a similar manner repeat the procedure above for second innermost ring pack.

7.12.2 Cold end element loading.

The cold end element packs will be side withdrawn. For this type cold end element must
fitted after intermediate and hot end element loading completed.

Remove the side withdrawn manhole on the rotor housing.

Hand turn the rotor with the crank provided till one of the rotor section facing this side
withdrawn manhole.

Remove the side withdrawn manhole, install the cold end element landing platform
between the rotor housing and the rotor.
Using the sling provided, attach the special hooks of the sling to diagonally located lifting
pins on the end of a cold end pack and the lifting gear, place the pack on the loading
platform. Ensure these heating elements were lifting stably.
By using the special tools, put the cold end heating element pack along supporting grids
into inner most position of rotor container.

Load adjacent sectors by repeating steps above.

Remove the landing platform and rotate the rotor, by hand turning crank, to be
diametrically opposite sector.
Repeat the procedure above for the remaining element pack installation, the pack in pairs
in diametrically opposed pattern.
Repeat the procedure above for the remaining element pack installation, the pack in pairs
in diametrically opposed pattern.

After all cold end element loaded, replace the side withdrawn, manhole rotor tyre
circumferential division plate and rotor housing.

When the all elements have been loaded into the rotor check for rotor tilt at the periphery
by hand turning the rotor.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 16 of 19 00

The rotor should be jacked and shimmed, such that the dimension between the mean
radial division plate of the rotor housing should be approximately
120 mm.
Tighten the connecting bolts and washers of bottom bearing 1100 N.m

Tighten the bolts on bottom false sector plate support bracket and also at angle bracket for
centralizer.

Remove the retain plate on the end pillar and side hinged pillar.
Fit one of top and bottom radial seals to the trailing edge of the mean radial
division plate, such that seal edge protrudes 40 mm from edge of radial plate.

The top and bottom sector plate should now be adjusted to the settings as indicated in the
drawing (104002) from the edge of the seals.

The sector plate should be level to within 1mm at all adjusted point.

Fit the top and bottom sector plate seals as shown in the drawing and bottom sector plate
seals to sector plates.
Measure and record the dimension between the top and bottom sector plate and the mean
rotor radial as indicate in the drawing.

Weld the bottom false sector plate support to the brackets on the top flange of the bottom
girder at angle bracket for centralizer as shown in the drawing.
Fully weld all stiffeners of gas duct and its flange as shown in the drawing 116001,116002
and 116003.

As required in the drawing 136001, adjust the relative position between mounting bell and
top bearing house top cover.

8. ROTOR TYER ALIGNMENT.

Refer to site assembly drawing No.001002, 001003.
Site assembly of rotor No.001007, 001008.

8.1 Check top tyer bar vertical setting. The top surface of the bar should be set clear of the
top Sector seal plate as indicated on the coal seal setting chart.

Set up one section of rotor tyer bar at the nominated clearance from the top sector seal
plate (Using the plat bar gauge to ensure that the tyer clearance is maintained all across
the surface of the sector plate) and tighten up the securing nuts.

Turn rotor until this section of tyer is in alignment with the axial seal door and record
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 17 of 19 00

Clearances between tyer and housing landing plate at say tree fixed reference points.

Using top landing plate reference point adjust the remaining segment to this height.

Ensure that all nuts are tight and re-check height to fixed reference point.

8.2 Set up one bottom sector of rotor tyer bar clear of the bottom sector seal plate at both
end to the nominated clearance stated in cold setting chart.

Using the plat bar gauge to ensure that the tyer clearance is maintained all across the
surface of the sector plates.

Turn the rotor until this section of rotor tyer is in alignment with an axial seal door, tighten
securing nuts and from inside the bottom duct check the clearance between the tyer and
the bottom landing plate at three fixed reference point.

Using the reference point, set up the remaining 23 point sections bottom tyer bar to the
required clearance to ensure the cold clearance with the bottom sector seal plate.

Measure and record the flatness the hot end rotor tyer not exceeding 3mm, if exceed this
value, it can be trimmed on site.
Determine the highest point of rotor tyer (Point H), measure and record the clearance
between H and the point of top sector plate
Identify the extreme radial position of the top rotor tyer (RT). Using this point as a
reference position, measure and record the concentricity of the top circumferential seal bar
and determine the tolerance between RT and top rotor tyer section, working through the
axial seal access door. Measure the gaps between the top rotor tyer and all three axial seal
plates across the axial sealing access door.
Identify the lowest point (L) of bottom rotor tyer, measure and record the clearance
between this point and difference angle of sector plate.
Identify the extreme position of the cold end rotor tyer (point RB). Using this point as a
reference position, Measure the gaps between the top rotor tyer and all three axial sealing
plates across the axial seal access door.

8.3 Hand turn the rotor by hand crank, recheck the levelness of top and bottom rotor tyer,
ensure nuts locked tighten.
Recheck if the position of top and bottom rotor tyer after final weld are within specified
allowance.

9. INSULATION.
This procedure is reference to the 1. Site assembly drawing No.001002,001003.
2. Insulation drawing No. 174001,174002.
 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 18 of 19 00

Insulation should be applied to the external surfaces the preheater casing as indicate on
the drawings, the reason is to minimize the heat loss and to maintain uniform temperature
for the center section of the casing which the house of the seal plates.

The insulation materials should be applied over the external surfaces of the rotor housing
which include the center section of the rotor housing (False sector plates) end the end
pillars and also over the transition duct.

The thickness of the insulation material depend on the type of the material selected and on
the acceptable maximum surface temperature.

Insulation panels should be securely attached to the casing and overlapped for expansion
at suitable junctions. Removable section are required for all access openings, tapping
points and where access is required for maintenance (Refer to drawing No.174001).

10. ERECTION EQUIPMENT.

Crawler crane capacity 150 ton is required for erection the main equipments.
Mobile crane capacity 40-60 ton is required for preassembly and transportation work.
Air winch capacity 5 ton is suitable for erection of rotor sectors and small equipments.
The rigging and lifting plan will be attached in separate sheets.

11. SAFETY MEASURER.

Temporary platform and hand rail shall be prepare before lifting the equipment. Fully
barricade to be applied when lifting work is on going.

No body can pass under the working area; sign boar should be applied on the ground
under the working area.

Smoking is prohibited in working area.

All the hand tools must be tight-up with the rope to avoid drop down.

Fire proof sheet must be used for welding and cutting preventing fire spatters.

Fire extinguisher should be putted at close of the working area.

All the workers must be wearing the safety gears.

 PROCEDURE FOR ASSEMBLY & DOCUMENT NO. :
ERECTION OF AIR PREHEATER FOR P-T3109-CONS-010
3X330 MW STEAM POWER ISSUED DATE :
GENERATION May 26, 08
UNIT ISSUING: APPROVED BY : SITE MANAGER PAGE REVISION
CONSTRUCTION 19 of 19 00