pgp erection manual-24!06!09

7/30/2019 PGP Erection Manual-24!06!09

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ERECTION SEQUENCE & MANUAL

FOR

PRODUCER GAS PLANT

BY

INDIA INDUSTRIAL ENTERPRISES

(ENGINEERING DIVISION)

CAMAC COURT - 2F,25B, CAMAC STREET,KOLKATA - 700 016

PH : 66336300-330, TELEFAX : 2287 5680E-mail: [email protected]

HEAD OFFICE : 23, BRABOURNE ROAD, 4Th FLOOR,KOLKATA - 700 001

PH.2242 2440/6067/6068/2459 & FAX 2242-2590

1.0. INTRODUCTION/var/www/apps/conversion/tmp/scratch_2/123929111.doc - 1 -


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1.1. The Extended Shaft Gasifier is installed to produce clean high calorificvalue Producer Gas for firing in various furnaces of Steel Mills, calcinationKilns, rotary kilns of various duties, shaft kilns etc and its benefit is mainlyderived from replacement of Petro-Fuels and reduction of fuel cost.

2.0. BASIC DESIGN PHILOSOPHY AND ADVANTAGES OF EXTENDED COLUMN

GASIFIERS

The object of the New Technology is to produce a clean consistentquality Producer Gas of high Calorific Value from majority of grades of IndianCoal from B to G grade and with faster rate of gasification or more coalthrough-put per unit grate area. With this objective in view, a deep coal bedhas been introduced with extension of shaft over the conventional generatorproper of the single stage design and the product gas has been fully diverted to

the top to come out from the top of the gasifier. The advantages accrued fromsuch modifications are thus:

The Extended Shaft is so precisely calculated that the fuel coal whilemoving downwards get stripped off its Volatile Matter to a great extent and thecoal itself gets converted to Near-Coke state with an acquired advantage ofgreater reactivity for a faster gasification almost similar to coke gasification.The product gas, on the other hand, while moving upwards, counter-current tothe incoming feed coal gets auto enriched with the stripped and distilled volatilematter of coal to a higher calorific value. This novel feature had greatlyimproved the kinetics of gasification, specific mass flow of gas per unit empty

cross section of the gasifier, gas make per MT of coal, calorific value, andconsistency of gas quality and more stream days of operation withoutinterruption.

At the same time, coal bed of Extended Shaft helps to adsorb dustssoots etc of the product gas and no extensive cleaning facilities are requiredfor better and consistent quality of gas.

Faster gasification leads to a higher coal throughput and higher gasmake per MT of coal. Higher hot gas efficiency (88% to 92% as against 65% to70% in single stage gasifier. Better adaptability to almost all grades of coal

from B to G grade which is not possible in a single stage gasifier which can runonly with B grade coal. The Process is continuous and as controllable andmaneuverable as oil firing.

The Process is Eco-friendly; the equipment is operation friendly andconforms to all PCB norms.

3. CONSTRUCTIONAL FEATURES:3.1. Prime parts from Top to Bottom for each gasifier are:/var/www/apps/conversion/tmp/scratch_2/123929111.doc - 2 -


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Sl.No.

Item No installed

i. The overhead coal bunker and feeding system havingcapacity of 30 MT.

1 No

ii. Coal Feeding System comprising of a Sector Gatefollowed by two Bell Cones all the three operated bypneumatic power cylinders and opened and closedsequentially for discharging coal centrally inside thegasifier

1 set.

iii. Refractory lined Extended Shaft 1 No

iv. Bottom shell with cooling jacket or generator of3.2M I.D/ 4.2M O.D

1 No

v. Grate stools with grate Rings, Guide rings etc 1 set.

vi. Ash bowl with adjustable ploughs 1 set.

vii. Bottom seal and skirt (300 mm) 1 set.

viii. Double gas off takes at the top of the Producer 1 set.ix. Pipings and Fittings for steam and air, soft water and

Tar.1 set.

x. Gas vents from Top 1 set.

xi. Washing Chamber with water circulation system, waterPipings and Gas piping and bottom seal

1 No.

xii. Hydraulic Pusher for grate rotation with twin speedsystem, one at very slow speed to keep the coal andash bed moving at a slow speed and the other at aninterval of about 2 hrs to give a jerk and allow the ashto come out to the ash-bowl.

1 set.

Other auxiliary Installations Common for single ormultiple gasifiers.

xiii. Air Blowers with delivery pressure of about 600 mm WSand fitted with Variable Frequency Drive (VFD)

1+1No.

xv. Poke Hole Air Blowers each having capacity of 500Nm3/hr at a pressure of 500 mm WS to supply gassealing air to the poke holes at the time of poking

1+1No.

xvi. Water Circulation Tank having adequate capacity. 1 No.

xvii. Soft Water Ground Tank having capacity of 10 KL to20KL fitted with float valve in the water inlet line

1 No.

xix. Day Tar storage tank having capacity of 5 MT to 25 MTfitted with steam coil.

1 No.

xx. Process water overhead tank. 1 No.

xxi. Electrical including MCC LCSs Cables, Lighting,earthling etc.

-Lot.

xxii Instrumentation and Control based on PLC andComprising of Central PLC Station, field instrumentsBST Controller, control valves, power cylinders,Solenoid valves etc.

-Lot.

Coal Handling Unit

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There will be 2 (Two) Ground Hoppers with a Grizzly of 250mm. The coal willbe feed to raw coal conveyor (BC-1) through RP Gates and Vibro Feeder. BC-1will feed coal to Primary Crusher which will crush the coal to -100mm. Theentire material after crushing will be delivered to Secondary Crusher which willagain crush the coal to -25mm and the entire material will be delivering toVibrating Screen. In the screen -10mm will be segregated and delivered tofines conveyor (BC-2), +25mm will be delivered to return conveyor (BC-3) orSecondary Crusher and the feed size (10mm to -25mm) will be delivered tofeed conveyor (BC-4). Fines conveyor (BC-2) will deliver the fines to a fineshopper (50MT) with motorized gate. Feed conveyor (BC-4) will deliver the coalto Reversible Shuttle Conveyor (RSBC-1) which will feed all the 8 Bunkers. Coalmeasurement and Dust extraction system (Bag Filter) is to be provided.

The Producer Gas generated in the system will be put into the ETP (with By-pass system). After cleaning to a level of 15mgm/Nm3 (Tar content), the gaswill be boosted to a pressure of 800mmWC by a booster of 25000Nm3/hr.capacity. The boosted gas will be transported to the 2 Lime Kilns. Lime Kiln-1(155 TPD) Burner is to be replaced by Duel Fuel Burner. Kiln-2 (200 TPD) hasgot Duel Fuel Burner already. Gas volume measurement device and calorimeteris to be provided for measuring the C.V of gas.

Ash generated will be transported through an Ash Conveyor (BC-5) and will bedelivered to an elevated Ash Hopper of 60MT capacity.

Tar generated will be delivered to Tar tank (50MT). We can envisage the watersegregation system from tar.

Erection of Producer Gas Plant may be divided by the following parts.

A) Erection of Building Structurei) Column for Main Building with MB500 beams.ii) Bracing & Floor Beam upto 8.9M level.iii) Start stair case in one side upto 8.9M level.iv) Keep one side below 8.9M level clear to fix cooling jacket.

v) Erect column for extended platform (400mm beam) for 14.25 &21M level.vi) Fix all bracing for beam, floor beams & fix chequered plate at 8.9Mlevel keeping 4.3M dia open at the centre.vii) Raise stair case upto 21M level.viii) Fix chequer plate keeping approx 3.1M at 14.25M & 5.1M at 21M

level opening at the centre.

B) At 2.3M level & below 8.9M leveli) Place the Bottom seal.

ii) Place of roller base & keep 50mm gap by suitable packing forgrouting to make 2.3M level & make water level.

iii) Put Skid.iv) Put Ash Bowl lower plate (16mm Thick) top of Skid then tight the bolts.

v) Now the Ash Bowl Cone to be bolted with the lower plate and thenwelding to be done to fix the same.

vi) Pushing teeth to be placed & bolted.vii) Ash bowl (put 5 mm dia asbestos rope between pushing teeth and



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ash bowl).viii) Fix bottom seal with bottom of Ash Bowl.ix) Ash Bowl. Bottom seal will have 300mm water column in thebottom tank placed approx 200mm above ground level.x) Grate stool put asbestos rope of 25mm dia between Ash Bowl andgrate stool.xi) Grate rings to be fixed.xii) Fix cooling jacket and along with bottom skirt over a beamsupport of 350mm from the bottom of the ash bowl. Ensure top of theboiler and 8.9M level is in one plane. Put asbestos rope of 25mmbetween bottom skirt and cooling jacket flange.

C) 8.9M level and below 14.25M leveli) Fix the top shell flange on top of boiler flange. The centre of line of top

shell should be in line with the centre line of jacket boiler.ii) Fixing of mixing chamber in portion.

D) 14.25M level & below 21M leveli) Fix Bell Cone assembly (2 nos) of coal feeding system in line on top

flange of the Top shell. Use 12mm dia asbestos rope between top shell& coal feeding system.

ii) Erect coal bunker (ensure canopy in the coal bunker) and align suitablyto make one centre line through top shell, jacket boiler and centre ofthe bottom seal and then fix it on octagonal support at 21M level.

iii) Fix sector gate.iv) Fix LTC pipe, gas box and pipes connecting to mixing chamber. Put

12mm asbestos rope in LTC piping flange joints.v) Fix chimney pipe on top of Top Shell.vi) Fix Poke valve assembly both at 14.25 & 8.9M level.vii) Erect emergency Water Tank at 14.25M level.

E) Fix Purling & Sheeting.

F) Erection of Coal Crushing System that consist of :i) Vibrating Screen & Crusher both primary & Secondary.ii) Feed conveyor BC-1.iii) Conveyor BC-2.iv) Transfer Tower.v) Conveyor BC-3.vi) Product Conveyor.vii) Reversible Belt Conveyor at 21M level.viii) Erect Ash Hopper with supporting structure.ix) Erect Ash Conveyor.

G) Erection of Equipments-i) Water Circulating Tank.ii) Soft Water Plant.iii) Soft Water Tanks (2 nos).iv) All Tar Tanks.v) ETP.

vi) Saturator.



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vii) Heat Exchangers.viii) Tar Pits.ix) Booster, Poke & Main Air Blower.

H) Erection of Pipe line that consist ofi) Emergency water tank piping to mixing chamber and then to

recirculating water tank.ii) Soft water pipe with tank.iii) All connection of tar tanks.iv) ETP, Heat exchanger, Booster, Blower, BST line.v) Steam piping.vi) Gas header & steam header + flare stack.vii) Hyd. Piping & fixing of hyd cylinders.

I) Erection of yard pipingi) Erection of gas header, u-seals & gas line with associated drip pots seal

pots etc.ii) Erection of gas train line in lime kiln.

J) Erection of all valves in the tanks & equipments, steam line, cooling jackets.

K) Electrical and instrument connections, cable trays, motor connection PLC etcearth pit, lighting arrestors, lightning etc.

Detailed Erection procedure

1. Erection of Bottom Seal

Place all parts of fabricated bottom seal in between six supportingcolumn of roller base before erection of roller base & alignment to be done withAsh bowl, after erection of Ash Bowl.

Place the fabricated Roller Base with the help of Crane or chain pulley oncivil foundation where its anchor bolts are fixed, Check the level of its topflange with a water level, if any deviation observed provide packing plates inbetween its bottom flange & civil foundation. After ensuring the level is okaytight the nuts of the anchor bolts. (Level of the top flange should be24605mm).Then grout the bottom of the roller base. This should be donewithin one day.

2. ERECTION OF ROLLER BASE

Place the fabricated Roller Base with the help of Crane or chain pulley oncivil foundation where its anchor bolts are fixed, Check the level of its topflange with a water level, if any deviation observed provide packing plates inbetween its bottom flange & civil foundation. After ensuring the level is okaytight the nuts of the anchor bolts. (Level of the top flange should be24605mm).Then grout the bottom of the roller base. This should be donewithin one day.

3. Erection of support Roller Assly

Place the 6 support rollers on roller base, match the base hole of the



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Bearing housing with the hole at Roller base, lower dia of the roller should betowards the center of producer. Fix it with roller base by bolts. Level of allrollers to be checked with water level & center height of the two bearing blockof a roller should be within 0.5mm. After ensuring its alignments are okaytight the nuts & tightly fix it with roller base. Maintain top of all 6 rollers in thesame level & within 2mm.

4. Erection of Ash Bowl

Place the bottom plate of the ash bowl on a temporary support of falsejoists (may be wooden) at Roller Base leaving a uniform gap of 350mm onroller base and put the inner conical part of ash bowl on base plate. Check theheight of top flange of conical part from base plate with straight bar &tape atleast 4 places if the difference of the heights are within 5mm weld the conicalpart with base plate. Erect the side conical plates (three parts) of ash bowl (AshPan) after erection of grate stool, grate ring & bottom skirt. Maintain the levelof toothed portion within 2 mm.

5. Erection of Skid for Ash Bowl

Place the skid below the base plate of Ash bowl with the help of chainPulley & Temporary fix with base plate of ash bowl by fixing bolts. Check thelevel of its bottom with respect to ash bowl base plate at 6-8 places & distanceof the circumference of taper plates from center of Ash Bowl at least 4 places.If the deviations are within 2 mm finally tight the nuts of its fixing bolts tothe ash bowl.

6. Erection of Grate Stool

Place the stool on the inner cone of ash bowl. Match the holes of itsbottom flange with the holes at the top flange of inner cone of ash bowl &temporarily fix its fixing bolts. Check the center of the stool from inner shell ofcooling Jacket. Finally fix it with inner cone of ash bowl.

7. Erection of Grate Ring

Grate rings will be dispatched after checking its assembly with gratestool; match mark will be given at grate stool & rings, place the bottom tworings in four parts on grate stool as per match mark & bolt with its matching

parts. After checking the center distance from inner shell of cooling jacket & itslevel tight the bolts to make a single ring by assembling the four parts. Thereafter top five rings are to be assembled. Then check the center of the assemblyfrom inner shell of cooling jacket, if it is 75-80mm offset finally fix it with gratestool by tie bolt.

8. Erection, Assembly, Fitment of Cooling Jacket:

Place temporary support at least 6 places on base plate of ash bowl to maintain1074mm height from the top of the base of ash bowl. Leveling of the supportsis to be done by water level. Place lower part of inner shell on the support.

Check its center with respect to center of roller base & ash bowl, center of theabove shall be same, top part of inner shell are to be placed on lower part./var/www/apps/conversion/tmp/scratch_2/123929111.doc - 7 -


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Proper alignment with lower part are to be done (such as match of O/D,straightness, gap for welding penetration as per fabrication drg. to bemaintain). Matching of O/D & straightness are to be checked by straight bar,scale or piano wire. After proper alignment welding to be done. DP test are tobe done in each run of welding.

9. Erection, Assembly, Fitment of Top Shell

Top Shell to be erected in three or four parts depending on the conditionof site. The lower ( 4200) part of the shell are to be placed on temporarybeam at 8.9 mm floor, or its Bottom flange are to be placed at the matchingflange of cooling jacket, 25 mm thick flange of the shell are to be fit with it insix parts, straightness of the flanges to be checked by straight bar, top of the25 mm thk flange is to be matched with the floor level at 8.9 Mtr. & centershall match with the center of cooling jacket. Lower part of 3.0 m dia parts ofthe shell are to be placed on 25 mm flange & align as per fabrication drg.Middle part of the shell is to be placed on lower part by crane or chain pulley.

Straightness of the shell to be checked with lower part by straight bar. Top partof the shell is to be erected by same procedure as middle part. Final weldingsare to be done after erection of top parts. Top (16 mm thick) blank is to beplaced on top part of the shell by crane, top face of the blank is to be matchedwith the floor level at 14.25m & welding are to be done with top shell.Accessory for coal feeding systems, LTC pipes, chimney etc to be fixed later atthe time of erection of the above. The cleats for Refractory Insulation have tobe welded on the inner side of Top Shell after erection.

10. Erection of Coal Bunker

Prior to erecting Coal Bunker ensure fixing capacities (one canopy in coalbunker). The bunker will temporally rest on joist at 21M level flow. Afterensuring the alignment Bunker is to be fixed with 21M level floor Beam. As perfabrication drawing liner for the Bunker is to be placed in portion with the helpof Chain Pulley block and the chain welding to be done.

11. Erection of Mixing Chamber:

Mixing chamber is to be placed at extended platform of 8.9m level. Levelof its bottom or top is to be checked by water level. Ensuring the level is okaywelding it with platform as per fabrication drawing.

12. Erection of LTC Pipe:

750 dia & 600 dia LTC pipes are to placed on mixing chamber with thehelp of crane or chain pulley & Vertically to be checked by plumb wire. Ensuringits verticality permanently fix it with Bolts & Nuts with mixing chamber. Dia 450pipes are to be placed on its position at top shell same procedures are to befollowed. Box at dia 750 pipe is to be fabricated at position. Intermediateconnecting pipes of box & top shell are to be erected as per drawing.

13. Erection of Coal feeding system:

Coal feeding system is to be placed on its position at top shell taking/var/www/apps/conversion/tmp/scratch_2/123929111.doc - 8 -


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attachment for lever & Pneumatic cylinder at chimneys side with the help ofchain pulley Temporarily fix it with top shell by fixing bolts. Check its verticalitywith plum wire. Ensuring its proper verticality tight the nuts of its fixing bolts.Fit its lever after erection of shell with bell cone. Cylinder attachments are to befix after ensuring its proper position with cylinder. Counter weights are to beerected at last & adjusted it distance from center as required moving theweight at slot hole given at lever.

14. Erection of Sector Gate :

Place sector gate on its position at the bottom of coal Bunker takingprecaution that pneumatic cylinder attachment are on proper side shown at GAdrawing. Fix it with Coal Bunker by bolts & Nuts.

15. Erection of Emergency Over Head Tank :

Place the tank at a suitable Position at mixing chamber side on 14.25 M

platform by crane or chain pulley & level it properly by water level & fix it withplatform.

16. Erection of Water Circulation Tank:

Place the tank at its civil foundation ensuring that slope of the base platetowards the tar settling tank. Level its base with the help of water level. Checkthe level of its base from ground by tape. All nozzles to be fitted after erectionof tank, & at time of erection of pipe line.

17. Erection of Soft Water tank(Ground):

Place the tank on its civil foundation with the help of crane. Level itsbase by water level grout its foundation bolts.

18. Erection of Soft Water tank (Over head) :

Place soft water over head tank on 21M floor levels, extension platformon its position by Crane. Check the level of its base by water level & verticalityby plumb wire. Ensuring level & verticality weld its base with platform.

19. Erection of Drive arrangement for Ash Bowl:

Place the structural Frame for drive arrangement at its position in-between roller base & main building column. Level its top with water level,temporarily fix the Hydraulic cylinder-mounting bracket & align the bracket. Fitthe cylinder attachments with piston rod, sufficiently tight it. Place the cylinderon mounting bracket. After adjusting the stroke of the cylinder, weld cylindermounting bracket & finally weld the structure with roller base & main buildingcolumn.

20. Erection of Column for Main Building:

Place 1st column up to 11.825M level on its civil foundation with the helpof crane hold it suitably by wire rope and Turn-buckle. Then place 2 nd Column

on its foundation by same method temporarily fixing the tie beam from



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column1 to column 2. Then proceed similarly upto 18 columns, fix bracings andTie Beams for all. Level of all column should be within 5 mm & level of lowerface base plate should be 2M 5 mm. Check the verticality of the column, byplumb wire. Check distance from one column to other & diagonal distance fromone to other. Ensuring the level & verticality of the column, place the washerplate for anchor bolts & weld the washer plates. Finally tight the nuts of theanchor bolts by wrench.

21. Erection of Column for main building above 11.825 M level:

Place the columns fabricated by MB 400 on the top plate of columnsfabricated by MB 500, temporarily fix it with erection bolts check the distancefrom one column to other & its diagonal distance ensuring the distances are within limit. Tight its erection bolts & welds it with the top plate of MB 500 Column.

22 Erection of floor beam level 8.9 M, 21M & 26 M:

Place floor beam form column to column on its fixing points, given incolumns. Temporarily fix it by erection bolts. Level the top of the beam. Thenplace the short floor beam from one long beam to other beam on item positiongiven in fabrication drawing. Fix it temporarily by erection bolts Level the top ofthe beam by water level. Then tight the nuts of erection bolt & finally weld it asper drawing.

23. Erection of Bracings:

Place the fabricated bracings on it position given at columns & floorbeams. Fix it with erection bolts. Check the straightness of the bracings fromone end to other end by piano wire weld it as per fabrication drawing.

24. Erection of Column for Extended platform:

Erect the MB 200 beams in one side (Axis B) for extended platform withthe building Columns. Check the level of its two ends. Level the top by waterlevel. Permanently weld the beams with main building column & with itssupports. Place the columns for extended platform on its position on MB 200beams. Temporarily bolts it with the beam. Check the distance of the columnsfrom main building columns at least 3 places for a column. Check the distancebetween two extended platforms column. Check diagonal distance from mainbuilding column to extended platform columns. Finally tight the nuts of the

erection bolts & weld it with supporting beams.

25. Erection of floor beam for extended Platform:

Follow same procedure as erection of floor beam for 8.9 m,14.25m,21m.

26. Erection of Portal frame:

Place fabricated portal frame at the top of the column on its position.Check the distance from one frame to another & check the level of the top of

the frames. Top level of all frame should be same. Top level of the frame may



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checked by piano wire weld the frame with columns.

27. Erection of Parlins:

Place the fabricated parlins on its position at portal frame. Temporarily

fix it with erection bolts. Check the level of its top (straightness of the top) bypiano wire. Tight the nuts of the bolts.

28. Erection of structure of Yard Pipe line:

Place the structure (Column) for Yard pipeline on respective foundation.Check the level of its base plate by water level & straightness by plumb wire.Tight the nut of its foundation bolts, structure from one column to anothershall be erected after erection of pipe line

29. Erection of Poke hole plug assly (Equpt. No. IIE/ME/08/00):

Place 8 Nos. poke hole plug assly at the 25 mm the flanges plate of topshell at 8.9 m platform & 3 Nos top flange of Top shell at 14.25 M platform.This is to be fitted as per drawing. Lever from poke hole plug to the valves areto be fabricated & fitted as per site condition.

30. Erection of Air Pipes with valves:

Air pipes are to be fabricated at site, & other air pipes & valves will besend in standard length & pieces respectively, all pipes are to be cut & erect asper drawing.

31. Erection of water circulation Pipes with valves:

All pipes & valves will be sent in standard length & pieces respectively,pipes are to be cut & erected as per drawing & site condition.

32. Erection of soft water piping with fitting & valves:

All pipes, valves & fittings of soft water piping will be sending as perStandard length & pieces. Pipes are to be cut as per drawing & site condition &erect as per the drawing.

33. Erection of Yard Pipes with Flanges:

Yard Pipe will be fabricated at site except150 NB pipes which will besend in standard length. All pipes are to be fabricated as per drawing & erect asper drawing & site conditions.

34. Erection of Hydraulic systems:

Place hydraulic power pack at its foundation. Level it by water level. Fixits foundation bolts & grand the same. After grouting the power pack, Hydraulicpipes are to be cut in size as per drawing & Erection of the pipes & fitting are tobe done as per the Drawing & site condition.

35. Erection of Tar pipes:



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Same procedure to be followed as per drawing.

36. Erection of steam pipes:

Same procedure to be followed & erection to be done as per drawing.

37. Erection of Chimney (Equpt.STD/ME/22/00):

Chimneys are to be erected after erection of all Structure & otherequipments at the plant. Erection of the chimney to be done as per drawing.Precaution to be taken for the verticality of the Chimney.

40. Erection of vibrating screens:

The supporting structure of the screen shall be arranged in such a waythat eccentric shaft of the screen shall be horizontal. As the screen frame is

connected to be base frame by way of helical spring, which was show smallirregularities in from, the supporting structure would not be fixed definitely in itsplace before the machine has been fully assembled & aligned on its working ofthe screen.

41. Erection of belt conveyors:

Place the structural column for conveyors as marked on its civilFoundation & as instructed by the Engineer present at site on behalf of thesupplier of the equipments. Place the supporting structure for rollers on thecolumn, level the top of the supporting structure, top of this structure should

be in same lines. It is to be checked by piano wire, then place walkway on itsposition. Place tail pulley assly with take up device to its place marked onstructure, check the level of tail pulley, it should be perfectly horizontal. Placeimpact throughing idlers & carrying throughing idlers on its position, check thelevel of its top. Top of all center roller of three roller idlers should be in sameline, it is to be checked by piano wire. Throughing angle of idlers should be 20approx. Place head (Drive) drive drum on its position on drive platform, level it.It should be perfectly horizontal. Center height of the drive shaft, output shaftof the gear box should be same level, center height of the input shaft of gearbox & motor shaft should be same level. Then place snub pulley & return idlerone by one. Top of the all return idler should be same line. Place its belt &

make it endless by vulcanizing or belt clamps. Adjust its tension by adjustingtake up device. skirt board & covers are to be erected at last.

42. Erection of Electrical & Instruments Systems:

a) Erection Panels, JBs LPS etc :

The Base frame of the Panels shall be fabricated & boltedto the floor inserts & all JBs & LPB are wall mounted, it is to bemount in another fabricated frame welded with wall inserts. Allpanels are to be leveled properly. It is to be take utmost careduring erection & installation to avoid damage to theequipments.



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b) Erection of Field instruments :

All field instruments are to be erected as per C&I diagramlatest Revision.

c) Erection of Cables & Cable support structure:

All Cables should be run in overhead trays. There will beseparate try for Power, Control & signal cables. Main power cabletrays are to be fabricated from suitable rolled sections at Site.Other will be G.I. perforated tray. All trays are to be erected aspersite condition & as instructed by site Engineer, Cables are to belaid as per cable schedule. Terminations are to be done as pertermination chart. Before termination of cables properidentification tag & ferruling are to be done. All cables shall betested for insulation & continuation before laying. While layingcables, care should be taken to avoid kinks, twist or othermechanical damages cables shall be clamped at regular intervalof 1500 mm along the run for horizontal run & 1000 mm forvertical run. Cable entry openings in the equipments shall bescaled & made vermin proof. Compression type cable glands shallbe used at the gland before entry of cable into panel/equipments.Termination of cables are to be done by suitable Lug.

43. Erection of Sheeting :

Put the asbestos sheet on roof & side of the building as per drawing &fix it by J hook as required. where required Cementing to be done with jute bag.

44. Erection of Light fittings:

Light fitting are to be erected at the suitable place at the plant soThat sufficient intensity of light are available at each equipments.

45. Erection of earthing materials:All equipments shall be properly earths for this purpose earthing pits

shall be made as per our earthing drawing & as instructed by our site Engineer.Continuity of the earthing strip shall be maintained through welding betweenthe strips.


pgp erection manual-24!06!09

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