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STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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PREFACE
This volume on storage instruction for the various Boiler and Auxiliary components is
our first attempt to bring about a concise booklet for us at site. It is possible that
some addition or deletion may have to be incorporated in this volume after receiving
feedback from various site wherein our erection works are in progress.
INDEX
A.
Introduction
B.
C.
Contractual Obligations
D.
General
E.
Machined surfaces
ii)
Pressure parts
iii)
Soot Blowers
iv)
Piping
v)
Oil Burners
vi)
Fans
vii)
viii)
Structural components
ix)
x)
REVISION
STORAGE MANUAL
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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Instruction :
Boiler & auxiliary components are normally dispatched by road through trucks
and trailors.
In both the cases adequate material handling facilities have to be made
available at site so that unloading of the components and storing at the proper
place can be arranged. The storage of the components should be done
systematically so that components can be easily taken out (without disrupting
orderly arrangement of the other components stored in the neighborhood) .
Sufficient floor area for storage of various components shall be arranged.
Necessary planning to achieve these shall be done before commencing site
activities. Sufficient open storage space close to the boiler site and also close
to the pre-assembly yard shall be provided with adequate facilities for handling
and movement of the materials. In addition semi-covered and covered sheds
shall also be provided adequately to protect the equipments / components that
need protection from rain and sun.
B.
C.
Contractual Obligation :
In case of turn-key contracts the responsibility of material control procedure is
of erection in-charge . In case of supervisory contracts, the responsibility of
employing suitable personnel for handling and storage of boiler material falls
within the scope of customer. Erection in-charge is responsible to guide the
customer .
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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In both the cases erection in-charge shall have adequate space to have
access for inspecting the storage of various components and physically carry
out inspection.
An efficient and successful storage will be possible only with the whole hearted
co-operation from the customer.
D.
General
No matter whether in a particular site a contract is on a turn key basis or on a
supervisory basis it should be ensured that the person in charge of store
keeping and material control are fully aware of the procedures for handling and
storages of the equipment / components . Apart from the procedures laid out,
suitable additional instruction may be evolved at site in the following manner :
1.
2.
3.
4.
5.
6.
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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STORAGE INSTRUCTIONS :
1.
2.
Pressure Parts :
Details of pressure parts
i)
ii)
iii)
iv)
v)
Drum
Water walls
Superheaters
Atemperators
Economisers
i)
Boiler Drums
Drums are usually stored in open store. It is advantageous to store the drum in
as received packing.
The suspension rods and other components accompanying the boiler drum are
to be stored in open storage space.
ii)
The water wall components are sent to site in panels as well as individual tubes. The handling
should be done carefully to avoid damage to the panels and other pressure parts of the water wall
system.
Straight panels can be stored one over the other with maximum of three to
four panels but care should be taken to stack them properly so that the
panels are stored horizontally.
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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Loose tubes and headers are to be stored in such a way that they are not in
contact with stagnant water or buried in ground.
The ends of all the uncovered tubes and stubs are to be closed with plastic end
caps and should be retained in position. Whenever an end cap is found to be
missing or lost, prompt replacement should be ensured.
3.
Soot Blowers :
i) General :
After receipt of these components at site they have to be inspected for
correctness of quantity and the boxes have to be repacked once again. The
boxes can be stored in open yard in a leveled area, however, the boxes are to
be covered with tarpaulin during rainy season. Boxes can be stored one over
the other.
ii) Soot Blower Pipeline :
Storage and handling instruction for pressure parts in boilers will also to be
applicable for these pipeline.
4.
Piping Group :
The following components in the piping group broadly consist of :
Pipes, tubes , bends, vessels, valves, fittings etc. The storage instruction for
most of the above components are also covered in the pressure parts system
coming in the boiler. Details of the vessels storage are as below : 1.
2.
3.
4.
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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6.
Fans :
The following important components go into the assembly of FD, ID and PA
fans.
i)
ii)
iii)
iv)
i)
ii)
7.
Panels
Cables, wires, copper tubes
Control valves
Motors, transmitters, Rectifiers, couplings
Junction boxes, cable glands, distribution boxes.
Ammeters, volt meters
Special instruments.
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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Panels
Most of the panels are usually received with water proof packing in well crated
wooded boxes. As soon as the panels are received at site it is desired to open
fully and then inspect the panels. As soon as the inspection is completed, the
packing should be redone and stored in semi covered space.
ii)
As far as possible the cables, wires etc., shall be kept in a semi covered
storage space. The thermocouple compensating cables are to be thoroughly
lined with polythene paper and should be kept inside a box. The copper tubes
are preferably to be obtained in the form of coils and this should be kept inside
polythene packing.
iii)
Control valves
Control valves are to be kept in semi covered storage space. They require
handling as per manufacturer instruction.
iv)
Motors
It is to be stored under open storage space with polythene cover. Motors shall
be periodically checked for their external appearance and for their resistance
values.
v)
Junction boxes
These are to be kept in covered storage space. The volt meters and
ammeters are to be inside cardboard boxes with sufficient polythene lining.
vii)
Special Instruments.
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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Apart from these general instruments other special instruments like sample
cooler instruments, water treatment plant instruments may also be available.
All these instruments are to be kept under closed storage space.
Some fragile equipments like air filter regulators, lubricants, filters etc., are not
only to be kept in covered storage space but also should be given suitable
packing so that entry of dust and water is prevented sand also breakages
avoided.
8.
Structural Components
The components in the structural group broadly consist of the following :
Columns, Beams, Bracings, Bolts, Nuts, Stair Case and platforms, Floor grills,
Foundation Bolts etc.
a)
Columns :
Columns are usually stored in open space. Other components shall not be kept
over the columns boxes.
b)
c)
9.
i)
Ducts
Air ducts, flue ducts etc., are dispatched as panels to be assembled at site and
some other are sent as assembled ducts.
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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iii)
10.
Refractory bricks
Insulating bricks
Calcium silicate
Mineral wool mattresses
Aluminum sheet
Castable Refractory
Refractory bricks
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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Insulating bricks
They should be always stored in covered shed. Insulating bricks are porous in
nature and hence they should not be exposed to retain water or damp
moisture. Stacking height should be carefully decided to avoid damages.
iii)
Calcium silicate
Calcium silicate should always be stored in covered space. Normally they are
received by packing in card board boxes. Stacking shall be restricted to the
strength of card board boxes.
iv)
It is absolutely essential that covered space shall be provided for storing the
mineral wool mattresses or mineral wool in loose form. The material shall not
be stored over damp floor but wooden planks with suitable thickness should be
provided over the floor before stacking of the mattresses is carried out .
In the case of mattresses, it is essential that the storing is such that the
shape of the mattress will not be affected. Towards this end, the storage height
in a single stack shall be restricted to 2 mattresses.
In case of bags containing loose mineral wool the height of the storage
shall be restricted so that the bags in lower layer will not get damaged by
tearing off.
STORAGE MANUAL
REVISION
FOR BOILER AND AUXILARY
COMPONENTS AT SITE
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Aluminum Sheets :
vi)
Castable Refractories
These are usually received in polythene lined gunny bags.
Castables are hydraulic setting . To protect them in storage before they are used,
primary precautions against easy ingress of water or moisture from air are required .
Normally, castables are not to be stored for longer periods and in humid
atmosphere .
a.
b.
c.
The roof should be of reinforced concrete
d.
The windows should be kept tightly shut.
e.
The floor should be 15cm thick with concrete slab laid on a dry coarse of
soiling.