VIETNAM OIL AND GAS GROUP

Long Phu 1 Thermal Power Plant Project, Vietnam

CONSORTIUM: OJSC POWER MACHINES (PM) -
PETROVIETNAM TECHNICAL SERVICES CORPORATION (PTSC)

BOILER ERECTION MANUAL

OF PP-600
Type Pp-1900-25,8-568/568 BOILER
LP1-TKZ-10X-M-M1A-MAN-8405

UNID 208405

TKZ Number: 300117125

The present document contains the

information on PJSC Krasny Kotelshchik,
which is proprietary and confidential. The
document cannot be used or copied, and the
information contained herein cannot be
disclosed either partially or fully, except in the
case when there is exact written consent by
PJSC Krasny Kotelshchik.

DOCUMENT STATUS:
CONTRACTOR: PM
CATEGORY

PM LP1PP
SUBCONTRACTOR: TKZ
RevNo PREPARED BY REVIEWED BY APPROVED BY REVISED BY APPROVED BY
DATE
. NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE

A 01.02.16 Nosak 01.02.16 Zhukov 01.02.16 Putivtsev 01.02.16

B 28.03.16 Nosak 28.03.16 Zhukov 28.03.16 Putivtsev 28.03.16
15.08.16 Nosak 15.08.16 Zhukov 15.08.16 Putivtsev 15.08.16
 LP1 PM-PTSC
Long Phu 1 Thermal Power Plant Project
Document No.
LP1-TKZ-10X-M- Boiler Erection Manual Page 2 of 27
M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016
REVISION SHEET

No. Revision Revision Content Revision Date

1 A First Presentation 01-Feb-2016

2 Response to comments LP1PP CaRs 405 (R1) 28-Mar-2016

1. LP1PPs comments have been considered CaRs 405 (R2).

2. In item 1.3, 1.8, 6.1.1, 8.3.1 the following has been
corrected this Boiler Erection Manual
3. In item 1.12 the flowing has been added - LP1-TKZ-
10XX-M-M1A-MAN-8104.
4. In item 5.1.2 the following has been corrected in
DBR for the steam Boiler - LP1-TKZ-10HXX-M-M1A-
3 C DEG-8201. 15-August-2016
5. In item 5.2.15 the following has been added
nozzles,.
6. In items 7.1, 8.1.8 the following has been corrected
this Boiler Erection Manual .
7. In item 7.2.4, in Table 4, in line 1 and in line 5 the
deviations and allowed deviations have been corrected

10

11

12

13

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Long Phu 1 Thermal Power Plant Project
Document No.
LP1-TKZ-10X-M- Boiler Erection Manual Page 3 of 27
M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016

TABLE OF CONTENTS
Page.
1 General Instructions 4
2. References Used 5
3. Codes and Standards 5
4. Industrial Safety Precautions 5
5. Boiler Unit Design 6
5.1 General 6
5.2 Furnace Chamber 6
5.3 Superheater 8
5.3.1 Gastight Enclosing Heating Surfaces 8
5.3.2 Platen Superheater 9
5.3.3 High Pressure Convection Superheater 9
5.3.4 Low Pressure Convection Superheater 9
5.4 Steam Coil Air Preheaters 10
5.5 Water Economizer 10
5.6 Burner Devices 11
5.7 Boiler Supporting Steel Structure 12
5.8 Air Preheater 12
5.9 Boiler Thermal Protection Enclosure 12
5.10 Cleaning of Heating Surfaces 13
6 Managerial and Engineering Support 13
6.1 Technical Documentation 13
6.2 Boiler Unit Delivery 15
6.3 Readiness of Foundations for Erection Works 15
7. Enlargement Assembly as Preparation for Erection 16
7.1 Preparation for Supporting Steel Structure Erection 16
7.2 Preparation for Heating Surface and Piping Erection 17
8 Boiler Unit Erection 18
8.1 Boiler Supporting Steel Structure Erection 18
8.2 General Requirements for Making the Welding Joints and High-Strength-
Bolt Joints while erecting the Supporting Steel Structure 19
8.3 Erection of Boiler Heating Surface Enlarged Assemblies 21
8.4 Boiler Safety Devices Erection 22
8.5 Field Adjustment of Heating Surface Hanger Spring 22
8.6 Insulation and Setting Installation Works 24
9 Delivery and Acceptance of Mounted Equipment 24
9.1 Boiler Gas Leak Test 24
9.2 Boiler Hydraulic Testing 25
9.3 Preoperational Chemical Cleaning 26
9.4 Boiler Steam-Pressure Test 26
9.5 Boiler Full-Scale Test 27

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Document No.
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016

1 GENERAL INSTRUCTIONS

1.1 The present Manual is an integral part of the design documentation; it contains the
information related to the design, erection, pre-start procedures of the gastight Once-Through
Steam Boiler of TPP-600 type Pp-1900-25,8-568/568.
1.2 The Manual is intended to be used by supervision staff of PJSC Krasny Kotelshchik
(hereinafter the Supplier) and by erecting, maintenance and operating personnel of the EPC
Contractor OJSC Power Machines (hereinafter the Customer).
1.3 The Manual can not be used instead of the Erection Works Project. The Erection Works
Project shall be developed by a specialized design organization in accordance with Boiler
manufacturers drawings, this Boiler Erection Manual requirements and with the Site specific
conditions. The Erection Works Project shall determine the erection strategy and sequence, and
the TPP demand for lifting devices (cranes), special tools and materials.
1.4 Pp-1900-25,8-568/568 Boiler equipment, in accordance with the Supply Technical
Specification, shall be shipped to the Customer in individual assemblies and members with
regard to the possibility of erection at Site.
1.5 The Boiler equipment shall be stored and, if necessary, preserved with regard to the
requirements stated in the Manufacturers Manual for the PP-600 Type Pp-1900-25,8-
568/568 Boiler Equipment Stockpiling, Storage, Preservation and Transportation of LP1-
TKZ-10XXX-M-M1A-MAN-8404.
1.6 Repair of the equipment damaged during transportation, handling or at Customers
storehouses shall be carried out by the Customer.
1.7 Sequence of Boiler erection operations and a preceding enlargement assembly shall be
carried out in accordance with the Erection Works Project and Boiler Manufacturers drawings.
1.8 The equipment depreservation (removal of the anticorrosive manufacturers proofing),
revision of components (preparatory works prior to the installation specified by the
manufacturers technical requirements), finishing and adjustment works which occur during the
Boiler assembly and erection as a result of the summing-up of tolerances are to be carried by and
at the expense of the EPC-Contractor (his subcontract erection organizations) according to the

design documentation requirements (this Boiler Erection Manual, certificates and the Boiler set-
making equipment manufactures) and the Suppliers supervisors instructions.
1.9 A List of Changes and Erection Instructions is part of the design documentation under
which additional works are carried out.
1.10 Any deviations from the design which may become necessary in the process of
enlargement assembly and erection are to be agreed with the Suppliers representative (erection
supervisors) or with the Supplier itself.
1.11 Acceptance of the mounted Boiler equipment is to be recorded by the erection
organization using special record books and reports to be signed by representatives of the
Customer, EPC-Contractor, erection organization and the Supplier (erection supervisor).
1.12 Boiler Unit start-up shutdown procedure as well as the issues connected with the its

operation are given in the Operation Manual - LP1-TKZ-10XX-M-M1A-MAN-8104.

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Long Phu 1 Thermal Power Plant Project
Document No.
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016

2 REFERENCES USED

This Document shall be considered together with the following Documents:

- LP1-TKZ-10XXX-M-M1A-MAN-8402 - Anti-corrosion, Preservation coating System for

Boiler Pressure Parts and Auxiliary Equipment;
- LP1-TKZ-10XXX-M-M1A-MAN-8404 - Instruction manual for stockpiling,
preservation, storage and transportation;

- LP1-TKZ-10HXX-M-M1A-MAN-8104 - Operation Manual;

- LP1-TKZ-10XXX-M-M1A-MAN-8405 - Boiler Erection Manual;
- LP1-TKZ-10XXX-M-M1A-MAN-8407 - Boiler Piping Capping Procedure;

- LP1-TKZ-10HXX-M-M1A-DEG -8201 - Design Basis for Steam Boiler Design;

- LP1-KZ-10HXX-M-M1A-DAS-8020 - Design parameters for pressure parts;
- LP1-KZ-10HXX-M-M1A-DGA-0003 - Boiler sectional elevation;
- LP1-KZ-10HSD-M-M1A-DGA-7015 - Assy of SCAPH;
- LP1-KZ-10H-M-8 - DGA-7504 - Oil / Coal Burner / Arrangement;
- LP1-TKZ-10HBB -M-M1A-IDX-7512 - List of refractory drawings;
- LP1-KZ-10 -M-M1A-S-7505 - List of insulation and skin casing of external
parts;
- LP1-KZ-10 -M-M1A-S-7506 - List of refractory materials of the Boiler;
- LP1-TKZ-10 -M-M1A-SPC-7507 - Specification of the Boiler skin casing;
- LP1-KZ-10 -M-M1A-CRT-7503 - Sootblowers selection data and philosophy;
- LP1-TKZ-10XX -M-M1A-DRS-2201 - List of erection drawings;
- LP1-TKZ-11XXX -M-M1A-CAL-9401 - Safety valve sizing and selection.

3 CODES AND STANDARDS

- AISC 348-14 - Specification for Structural Joints Using High-Strength Bolts;

- AISC 303-10 - Code of Standard Practice for Steel Buildings and Bridges;
- AWS D1.1 - Structural Welding Code.

4 INDUSTRIAL SAFETY PRECAUTIONS

4.1 The Customer and its subcontractors carrying out the unloading, warehousing, storage and
handling of the TPP-600 Pp-1900-25,8-568/568 Boiler equipment at the TPP Site, as well as
the enlargement assembly, erection and adjustment, are to ensure safety in carrying out those
works in accordance with the requirements of the normative documents in force.
4.2 The Suppliers supervision personnel shall be under an obligation to observe the
industrial safety precautions as well as to exercise personal caution when carrying out the
works at Site.

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Long Phu 1 Thermal Power Plant Project
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016

5 BOILER UNIT DESIGN

5.1 General

5.1.1 Introduction
The Pulverized-Coal Supercritical Boiler is designed for operation in a 600MW Unit at the
Long Phu-1 TPP, Vietnam.
The Boiler and its main components design complies with the ASME requirements, whose
fulfillment ensures a reliable, durable and safe operation of the equipment.
5.1.2 Boiler Application
The Once Through Boiler is designed for generation of the superheated steam to be used in a
600 MW Steam Power Unit at the flame (chamber) combustion of bituminous coals. The Boiler
scheme is a single-boiler single-turbine combination, with a double-bypass start-up scheme. The
Boiler is of an outdoor layout. The heating surface layout is a double-pass configuration.
On the Boiler, the following requirements are met with regard to the Boiler reliability:
The Boiler design service life will be not less than 30 years.
The annual number of the Boiler operating hours will be not less than 7000 hours.
Under the normal conditions, the Boiler is designed for the operation at the base load, as well
as allows operation at the cyclic load or operation in two shifts, or in the hot reserve condition,
designed for maintain the auxiliary load.
The Boiler is designed for the sliding pressure operation, including both at the start-ups and
shutdowns, and has a possibility of the accelerated load dumping.
The allowable Boiler load change rate, when it is operated in the turndown range:
- in the Boiler load range from minimum to 70% BMCR - 3%/min

- at the loads over 70% BMCR - 6%/min.

The Boiler firing-up guidelines are specified by the Boiler Operation Manual.
The Boiler feeding is carried out with the turbine waste steam condensate, the losses being
replenished with the chemically demineralized water.
The minimum requirements for the Boiler feed water quality under various chemical water
treatment conditions are given in the DBR for the steam Boiler - LP1-TKZ-10HXX-M-M1A-
DEG-8201.
The Boiler Unit has been designed to be operated with a dry slag removal. The main fuel for
boilers is coal. The lighting up fuel is light diesel fuel. The guaranteed coal composition, ash
properties and light diesel fuel composition are specified in the DBR for the steam Boiler - LP1-
TKZ-10HXX-M-M1A-DEG-8201.

5.2 FURNACE CHAMBER.

5.2.1 Furnace chamber is an uptake gas duct with a chamber (flame) firing of the pulverized
fuel. In the furnace upper part provided are 3 stages of the platen superheater, high pressure and
low pressure convection superheaters. Furnace chamber water walls, horizontal and downtake
gas duct tube walls form an all-welded gastight box from the tubes welded with each other.
5.2.2. The furnace chamber is rectangular in its cross-section, tube axis-to-tube axis
dimensions as for the front (rear) and side walls are respectively 16032mm 22214 mm.

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Long Phu 1 Thermal Power Plant Project
Document No.
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016
5.2.3 On the front and rear Boiler furnace walls, 24 low NOx pulverized-coal burners are
arranged in three tiers, facing each other. Under the burners of the 1st tier, 18 lower air blowing
nozzles with nozzle exit area 500450mm are installed. Above the burners of the 3rd tier, 8

upper air blowing nozzles with nozzle exit area 800620mm are installed.
5.2.4 The furnace chamber is formed by gastight all-welded tube panels made from tubes in
a tube-strip-tube design, using calibrated strip.
5.2.5 The furnace front and rear walls are formed by 9 panels each, side walls 6 panels each.
The panel maximum width has been chosen proceeding from the condition of ensuring their
possible railway transportation.
5.2.6 To provide an operational reliability all furnace water walls are divided in the steam-
water path into 3 runs. Furnace heightwise, the furnace water walls are divided into a Lower
Radiant Part (LRP) and an Upper Radiant Part (URP). The front and rear furnace walls (the
extreme assemblies), side furnace walls are made with a split heightwise between el. +28,850m
and +32,650m; +40,600m and +43,200m. The front and rear furnace walls (the middle
assemblies) are made with a split between el. +43,200m and +46,200m.
5.2.7 The furnace bottom ash hopper is double-slope, formed by the inclined (front and rear)
and vertical (on the side walls) water walls changing for LRP water walls. Furnace bottom
hopper slopes are inclined at an angle of 55 to the horizon.
5.2.8 The panels of the inclined front and rear water wall part (bottom ash hopper) have 6
rows of fasteners each, via which they rest on the furnace bottom ash hopper steel structures.
5.2.9 On the lower radiant part of the furnace front and rear waters walls, in four panels, at
el. +22,000m, +27,000m, +32,000m a provision has been made for tube arrangements for the
burner devices.
5.2.10 The furnace chamber rear wall in the URP area forms an aerodynamic projection inside
the furnace and changes for the horizontal gas duct slope tube walls. In the horizontal gas duct, a
provision is made for the arrangement of the platen superheater and the high pressure and low
pressure convection superheaters.
5.2.11 At the top, the furnace is enclosed with ceiling tube walls
5.2.12 Joints of the URP and LRP water walls and of the ceiling wall tubes are sealed with
special welded parts.
5.2.13 Throughout the furnace height as well as on other enclosures of the gas ducts installed
are buckstays.
5.2.14 All furnace water walls have inlet (lower) and outlet (upper) headers.
5.2.15 The furnace water walls have relevant tube arrangement for burners, nozzles,
manholes, peep holes, water wall cleaning devices, instrumentation installation holes, etc. All
tube arrangements are sealed with boxes.
5.2.16 To all furnace water walls welded are pins to fasten an on-tube insulation.
5.2.17 Loads due to the weight of the front and side walls are transferred to the ceiling steel
structure shields through spring hangers hinged with fasteners on those walls.
5.2.18 Boiler steam-cooled hanger tubes:
5.2.19 Steam-cooled hanger tubes-1 are arranged between the axes of the furnace rear water
walls, they are of two-row in-line arrangement.
Steam-cooled hanger tubes-2 the convection shaft front wall tubes change into steam-
cooled hanger tubes-2.

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Long Phu 1 Thermal Power Plant Project
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016

5.3 Steamsuperheater

Boiler TPP-600 Pp-1900-25,8-568/568 superheater as to the heat pickup nature is divided

into the following components:
- heating surface gastight enclosures;
- platen radiant-convection heating surfaces;
- low and high pressure convection superheaters.

5.3.1 Gastight Enclosing Heating Surfaces

5.3.1.1 The ceiling above the furnace and transient gas duct (Boiler ceiling water wall), front
and rear parts of the transient gas duct, convection shaft internal and external side tube walls and
convection shaft front and rear tubes walls are formed by gastight panels and connected in the
Boiler steam-water path.
5.3.1.2 The whole superheater path consists of two independent immiscible flows.
5.3.1.3 The Boiler ceiling water wall consists of 8 panels.
Panel material is low-alloy steel.
5.3.1.4 Each panel has two headers: an inlet header and an outlet header. Each header has two
nozzles for the supply and discharge of steam.
5.3.1.5 Loose assemblies, panels and tubes are welded with each other at Site along the field
joint lines of tubes.
5.3.1.6 In all panels of the ceiling water wall there are tube arrangements the tube penetrations
of the platen, high pressure and low pressure convection superheaters, and steam-cooled hanger
tubes-1, etc.
5.3.1.7 To provide the Boiler unit gas tightness all penetrations of the heating surfaces
(platens, low pressure and high pressure convection superheaters, steam-cooled hanger tubes,
etc.) through the ceiling water wall are sealed with special boxes.
5.3.1.8 The side walls of the transient gas duct consist of 6 panels. Each water wall panel
has an inlet (lower) and an outlet (upper) header. The lower gastight water wall of the transient
gas duct consists of 9 panels.
5.3.1.9 At elevations +56,100m, +59,400m, +62,600m, +65,850m, 69,100m fitted are rows
of panel-to-buckstay fasteners.
5.3.1.10 The front and rear wall of the convection shaft comprises 8 panels. The side walls
10 panels.
5.3.1.11 Each panel is provided with the inlet and outlet headers including nozzles.
5.3.1.12 The convection shaft a provision is made for manhole tube arrangements which are
sealed with sealing boxes.
5.3.1.13 On the front, rear and side walls of the convection shaft at el. +40,585m,
+43,900m, +47,885m, +50,000m, +53,000m,+56,595m, +59,400m, +62,600m, +65,850m there
are rows of panel-to-buckstay frame fasteners..
5.3.1.14 On all panels of the convection shaft tube walls pins are welded for fixing the
insulation.

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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016

5.3.2 Platen Superheater (PSH)

5.3.2.1 Platen superheater (radiant-convection surface) is arranged in an upper part of the

uptake gas duct and comprises three stages: PSH-1 (1 stage), PSH-2 (2 stage), and PSH-3 (3
stage).
5.3.2.2 The platen superheater PSH-1, PSH-2 and PSH-3 consists of 30 vertically arranged
platens. Each platen of PSH-1,2,3 comprises "U"-coils and 2 headers: inlet and outlet.
5.3.2.3 In the heated area the platens of all three stages have fasteners heightwise formed by
their own connecting piping, which provide spacing of coils in the platens.
5.3.2.4 All platens in the Boiler are fixed using hangers by the lugs welded to the inlet and
outlet headers. The hangers react loads due to the weight of platens and transfer the same to the
Boiler ceiling steel structure.
5.3.2.5 Platen penetrations through the ceiling superheater tube arrangements are sealed with
special boxes.
The PSH pitch edgewise has been chosen with regard to preventing the slag formation at the
high gas temperature conditions (initial ash deformation temperature).

5.3.3 High Pressure Convection Superheater

5.3.3.1 The High Pressure Convection Superheater (HP CSH) is arranged in the horizontal
gas duct in the warm gas area.
From the design point of view, the HP CSH banks represent a vertical coil structure passing
through the ceiling water wall and suspended from the ceiling structure. The HP CSH is the
last surface in the medium flow direction in the HP path.
The coil banks have an in-line arrangement with a medium direct flow.
5.3.3.2 The HP CSH comprises 8 assemblies. Each assembly consists of an inlet header, an
outlet header and coil banks.
5.3.3.3 In the heated area the tubes in banks are spaced with rows of special fasteners
comprised of spacer plates fixed with clamps.
5.3.3.4 Tubes of coil banks of the High Pressure Convection Superheaters, in places of their
penetrations through the ceiling superheater are sealed with special seals.
5.3.3.5 Load due to weight of assemblies of the HP CSHs is transferred through headers to
the Boiler ceiling steel structures by means of the non-cooled disk spring hangers.

5.3.4 Low Pressure Convection Superheater

A part of the low pressure steam is supplied to the inlet headers of the first stage, which is
called the control stage, of the Low Pressure Convection Superheater (LP CSH). Afterwards,
the medium flows to the first part of the LP CSH.
The first stage LP CSH represents horizontal coils arranged in the convection shaft
perpendicular to the front. It is suspended by the economizer hanger tubes. The first stage LP
CSH, heightwise, is made as three banks with the maintenance intervals between them.

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Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016
From henceforth, the medium flows to the second part of the first stage LP CSH, where it is
mixed with the bypassing steam. The low pressure steam temperature is controlled by changing
the flow through the control stage using the butterfly gate.
The second part of the first stage LP CSH is also made as a horizontal bank in the
convection shaft, that is arranged at the reversing chamber outlet and rests on the economizer
hanger tubes.
The LP CSH hanger tubes, with a large pitch edgewise the gas duct, pass through the
reversing chamber and pass out through the ceiling water wall.
After the first stage LP CSH, the LP steam flows into the outlet LP convection banks
arranged between the steam-cooled hanger tubes and HP CSH. The LP CSH outlet stage
arrangement in the area of the rather high temperatures is possible owing to the double-bypass
Unit start-up scheme.
The second stage LP CSH banks represent a vertical coil structure passing through the
ceiling water wall and suspended from the ceiling structure. The LP CSH has an in-line design
with the direct medium flow. Spacers provide for the structural rigidity.

5.4 Steam Coil air Preheaters

In the pressurized air blowers a provision is made for the installation of the Stem Coil Air
Preheaters (SCAPH) after each secondary air fan.
At the Boiler loads BMCR 50%BMCR, the steam parameters for the SCAPH shall be
taken from the turbine 5th extraction in accordance with the GE turbine balances.
At the Boiler loads under 50%BMCR and at the start-up conditions the steam for the
SCAPH shall be taken from the turbine 7th extraction in accordance with the GE turbine
balances.
The air temperature after the SCAPH (at the RAPH inlet), with the change in the ambient
temperature, shall be controlled by taking out of service a number of the steam sections in the
SCAPH.
The SCAPH assembly is made according to document LP1-KZ-10HSD-M-M1A-DGA-
7015.

5.5 Water Economizer

The Water Economizer (WE) is the last heating surface in the gas flow direction and the
first heating surface in the medium flow direction, and is arranged in the convection shaft. The
WE headers are arranged in the gas duct and are insulated.
From the design point of view, the WE represents a horizontal bank from the plain tubes.
The WE coil banks with the horizontal tubes are arranged in parallel to the convection shaft
side walls (perpendicular to the Boiler front). The WE is made as 3 parts heightwise, with the
maintenance intervals between them.
The WE is suspended by the hanger tubes incorporated into the path after the WE. This
design ensures the absence of the non-cooled fasteners and simplifies the surface arrangement
in the convection shaft.

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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016
Note: the range of the used materials specified in items 3.2, 3.3.1, 3.3.2, 3.3.3, 3.3.4, 3.5, for
the Boiler pressure parts it is specified in the document LP1-KZ-10HXX-M-M1A-DAS-
8020.

5.6 Burner Devices

5.6.1 The Burners are pulverized-coal type.

For reducing the NO emissions to 450mg/Nm the following arrangements have been
implemented:
- Burners with the reduced NO emissions have been employed;
- two-stage combustion due to supply of the part of air through the lower blowing air
nozzle;
- the selective catalytic NOx reduction system (SCR) is installed in the gas path, after the air
preheater.
The Lower Blowing Air System (LBA) reduces the NO emissions and prevents from the
emergence of the local reduction zones at water walls due to air supply along the water walls.
For reducing the temperature level in the Burner area, a provision is made for the
recirculation air supply through the Burners with the possibility to redistribute them among the
Burner tiers.
On the front and rear Boiler furnace walls, installed are 24 pieces of the low NOx
pulverized-coal Burners ensuring the low NOx generation, opposite, in three tiers at elevations
22,000m, +27,000m, +32,000m. Under the 1st tier Burners installed are the LBA air nozzles.
The Burners of the vortex (turbulent) type with the axial swirler in the pulverized-coal/air
mixture and hot air.
From the design point of view, the Burner is made with a common duct supplying a mixture
of the hot air and recirculation gases, with an individual pulverized coal and central air supply.
The hot air common duct is divided into two channels: peripheral and internal.
In the Burner peripheral, internal and central air channels installed are axial swirlers.
In the Burner central air channel arranged are tubes with high-energy arc igniters, a start-up
liquid-fuel steam-mechanical atomizer, a flame scanner and an inspection hole for the visual
observation.
The tube for the pulverized-coal burner flame scanner installation is installed in the Burner
peripheral channel.
The Burner installation is as per LP1-KZ-10H-M-8- DGA-7504.
5.6.2. Atomizers
For burning the liquid fuel in the Boiler load working range, the Burner is equipped with a
steam/mechanical Atomizer, which is arranged in the tube installed in the Burner central part.
The Atomizer has separate channels for supply of the liquid fuel and steam for atomization.
The liquid fuel is supplied to the central Atomizer barrel channel, and in succession, flows
through the distributor functioning, at the same time, as a coarse filter, through the swirler and
nozzle, from which the fuel flows as a film falling into small drops. The steam channel coaxes
the fuel channel and has a swirler from which steam, leaving as swirling flow near the fuel
nozzle, participates in the liquid fuel atomization process.
The Atomizer is connected to the steam/fuel pipelines by means of the shoe ensuring a tight
connection and possibility of the quick Atomizer installation and removal.

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The maximum Atomizer capacity control range due to the fuel pressure change before it is
10:1. The working control range is 4:1. The maximum capacity is ensured at the fuel pressure
at the nominal load 35 kgf/cm.
The Atomizer fuel channel shall be purged with steam prior to the fuel supply and after the
cut off. The steam flow for atomization shall not exceed 5% of the liquid fuel flow rate at the
nominal load.
CAUTION!
) Load transfer due to weight of pulverized coal ducts and air ducts on the burners shall be
PROHIBITED.
) Atomizer operation with no steam supply to the Atomizer shall be PROHIBITED.

5.7 Boiler Supporting Steel Structures

5.7.1 The Boiler supporting steel structure is intended to react loads due to weight of all
heating surfaces, insulation, maintenance platforms as well as of air and gas ducts and other
Boiler components.
The Boiler supporting steel structure is the main bearing structure of the Boiler and
represents a spacial metal multi-post grid comprising columns joined with horizontal structural
braces (system of collar beams, beams, stiffening trusses) which form an integral bearing
structure.
The Boiler supporting steel structure is manufactured according to the following Design
Documentation:
- LP1-KZ-10-M-M1A-IDX-5050 1st tier;
- LP1-KZ-10-M-M1A-IDX-5051 2nd tier;
- LP1-KZ-10-M-M1A-IDX-5052 3rd tier;
- LP1-KZ-10-M-M1A-IDX-5053 4th tier;
- LP1-KZ-10-M-M1A-IDX-5054 5th tier;
- LP1-KZ-10-M-M1A-IDX-5055 6th tier.

5.8 Air Preheater

The Boiler Unit has two tri-sector regenerative air preheaters designed for heating the
primary and secondary air supplied for combustion in the Boiler furnace.

5.9 Boiler Thermal Protection Enclosure

The Boiler Thermal Insulation Enclosure is made of the fibrous insulants mineral wool
blankets according to Documents LP1-TKZ-10HBB-M-M1A-IDX-7512, LP1-KZ-10-
M-M1A-S-7505 and LP1-KZ-10-M-M1A-S-7506.
The insulation thickness has been chosen basing on the condition that the temperature on its
external surface will not exceed 65 at the ambient temperature 38, at a distance of 1,5
meter from the external insulation, during the Boiler operation.
The insulation materials shall be laid on the heating surfaces and steel structure casing
sheets with an appropriate field joint factor, at that, the insulation density in the working
condition will be not less than 96kg/m. The insulation is fixed by 10mm pins, washers and

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nuts to be installed at site. In places of installation of burners, manholes, inspection holes,
access holes, tube passage through the water walls, etc. a provision is made for sealing boxes
filled with refractory and heat-insulating concrete. The burner arches made from the studded
tubes are covered with a refractory mixture heightwise the stud.
Over the insulation, a protective casing is installed according to LP1-KZ-10-M-M1A-
S-7507, which is fixed between the buckstays, and protects the insulation from the
mechanical damages, watering, exposure to environment, and forms up an aesthetic Boiler
appearance, and allows the Boiler hydrocleaning.
Insulation of the Boiler pipelines, gas/air ducts and auxiliary components is also made using
the mineral fiber-based insulation materials.

5.10 Cleaning of Heating Surfaces

For cleaning the Boiler heating surfaces used are sootblowers according to LP1-KZ-
10-M-M1A-CRT-7503.

6 MANAGERIAL AND ENGINEERING SUPPORT

6.1 Technical Documentation

6.1.1 To carry out the site assembly-preassembly and erection works of the Boiler, the
availability of the following technical documentation as well as the compliance with
requirements of the same is required:
- erection documentation of PJSC Krasny Kotelshchik in the scope of the List of Erection
Drawings - LP1-TKZ-10XX-M-M1A-DRS-2201, List of Refractory Drawings - LP1-TKZ-
10HBB-M-M1A-IDX-7512, Specifications for the Insulation and Skin Casing of the Boiler
External Parts - LP1-TKZ-10-M-M1A-SPC-7505, Refractory Material Specifications -
LP1-TKZ-10-M-M1A-SPC-7506, Boiler Skin Casing Specifications - LP1-TKZ-10-
M-M1A-SPC-7507, List of Changes and Erection Instructions;
- Stockpiling, Storage, Preservation and Transportation Manual - LP1-TKZ-10XXX-M-
M1A-MAN-8404;
- this Boiler Erection Manual;
- Erection Works Project (EWP);
- Certificates for complementary parts.
6.1.2 During the equipment examination, erection and commissioning works it is necessary
to draw up reports, fill in log-books and make the required records in the erection works log in
due time.
The following data shall be entered into the erection works log:
- main stages of the site assembly- preassembly and erection works with the dates of their
commencement and completion being indicated;
- data on verification inspection of the site assembly of the and erection works;
- instructions of the Suppliers supervision personnel based on the requirements of the
technical documentation and normative documents;

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- Suppliers supervision personnel permit for carrying out the prestart-up procedures.
6.1.3 In the process of the site assembly-preassembly and erection works the erection
organization shall draw up the reports and data forms and submit them to the Customer and the
Supplier's supervision personnel for signature.
The rough list of the technical documentation drawn up by the erection organization and the
Customer with involving the Supplier's supervision personnel is given in Table 1.

Table 1

Type of Check Data Form of Technical

Documents
1 2
Commencement of the site assembly-preassembly works Certificate
Acceptance of the Boiler foundations Certificate, Data Form
Commencement of erection Certificate
Acceptance of the erected Boiler supporting steel Certificate, Data Form
structure
Boiler steel structure columns grouting Certificate
Acceptance of the Boiler platforms and stairs Certificate
Ball-rolling control of the Boiler heating surface tubes Certificate
and piping
Inspection of headers for foreign matters and closure of
the headers with ends Certificate
Positive Material Identification of the Boiler parts
manufactured of alloy steels Certificate, Report
Acceptance inspection of the water wall heating surfaces
with headers Certificate, Data Form
Acceptance inspection of the superheaters with
connecting tubes (HP and LP paths) Certificate, Data Form
Acceptance inspection of the water economizer with Certificate, Data Form
headers
Acceptance inspection of the Boiler suspension system Certificate
elements
Acceptance inspection of the Boiler drainage and Certificate
ventilation systems
Acceptance inspection of the burner devices with
atomizers and igniters Certificate
Welding works and heat treatment Certificates, Data Forms
Adjustment of the Boiler heating surface hanger springs Certificate, Data Form
Acceptance inspection of I&C equipment Certificate
Acceptance inspection of the Boiler for clearance from
foreign matters and debris Certificate
Boiler hydraulic test Certificate
Boiler gas tightness test Certificate

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Boiler insulation Certificate
Boiler refractory Certificate
Acceptance inspection of the RAPH Certificate, Data Forms
Boiler preoperational chemical cleaning Certificate
Boiler steam tightness testing by regulating safety valves. Certificate
Boiler Unit complex trial operation Certificate

6.2 Boiler Unit Delivery

6.2.1 The Boiler Unit heating surfaces are supplied to the Customer as transportable delivery
assemblies and sub-assemblies according to the overall dimensions, basing on the conditions of
the transportation and erection technological effectiveness.
6.2.2 If necessary, adjustment of the Boiler mating parts, components and assemblies
fabricated within the tolerances specified in the drawings shall be carried out at Site by the
erection organization and at its own expense.
Those works shall comprise the following:
- installation of mounting gaskets envisaged in the design when mating the adjacent
assemblies and components;
- installation and removal of mounting and transportation arrangements including welded
ones envisaged in the design;
- repair of the equipment damages caused by transportation through no fault of the
Manufacturer;
- adjustment of deviations resulting from the summation of the fabrication and erection
tolerances.

6.3 Readiness of Foundations for Erection Works

6.3.1 After construction of the Boiler Unit foundation the construction organization is to
present the same together with an as-built drawing, for acceptance to the technical supervision
body of the Customer, to the mounting organization and the Supplier's supervision engineer, for
the erection of the Boiler supporting steel structures.
6.3.2 For the purpose of the foundation inspection and presenting the same for acceptance the
construction organization shall remove the constructional concrete form, clean the foundation
from material debris, apply longitudinal and transverse axes of the Boiler to the foundation with
indelible paint of bright color and with a centre-pop.
6.3.3 During the acceptance inspection of the foundation the construction and mounting
organizations, a representative of the Customer's technical supervision body and the
Customer's supervision personnel shall together check the following:
- compliance of the location, geometrical dimensions and elevations of the foundation with
the design;
-absence of surface defects (cracks, blowholes, exposed reinforcement bars);
- availability of reference points to check the subsidence and deformation of the foundation
and of a log- book with initial values of reference check points

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6.3.4 The foundation can be accepted provided that the actual dimensions comply with the
design ones. The measurements shall be made from the boiler longitudinal and transverse axes
using stretched strings.
6.3.5 The foundation graded elevations shall be 100 mm lower than the design elevations of
the column base underside, for making possible a quality column grouting.
6.3.6 Deviations of the foundation dimensions from the design ones shall not exceed the
values specified in the below Table 2.

Table 2
Type of Deviations Allowed Deviations

Distance between the foundation axes and columns axes of the 0,8 inch ( 20 mm)
boiler house
Elevations of the bearing surface - 1,2 inch (- 30 mm)
Basic dimensions in plan 1,2 inch (30 mm)
Deviation of the anchor bolt embedded in concrete from the
0,06 inch (1,5 mm)
vertical throughout the height of projecting part
Anchor bolt axis-to-axis dimensions 0,2 inch ( 5 mm)
Difference of diagonals between the foundation axes 1 inch (25 mm)
Dimensional deviations between the axes of the adjoining anchor
0,24 inch (6 mm)
bolt groups
Deviation of the projecting anchor bolt height 0,5 inch (13 mm)

7 SITE ASSEMBLY OF BOILER EQUIPMENT SHOP-ASSEMBLED MODULES

AS PREPARATION FOR ERECTION

7.1 Preparation of the Supporting Steel Structure for Erection

Site assembly of the shop-assembled modules, fit-up and welding works shall be carried out
according to the design documentation, this Boiler Erection Manual, Erection Works Project
(erection process write-up, guidelines for the field high-strength bolt joints, etc.), according to
AISC 303-10 Code of Standard Practice for Steel Buildings and Bridges and AISC 348-14
Specification for Structural Joints Using High-Strength Bolts.
Prior to installing the supporting steel structure members the following shall be done:
7.1.1 To check marking and geometry of the delivery assemblies (components) for
compliance with the design erection documentation.
7.1.2 Prior to welding the supporting steel structure members, the surfaces with full
penetration welds and the adjoining metal areas, minimum 20 mm wide, shall be cleaned to the
fine metal.
7.1.3 Preparation and installation of high-strength bolts, nuts and washers shall meet the
requirements of the design documentation and recommendations of the Erection Works Project
according to AISC 348-14 Specification for Structural Joints Using High-Strength Bolts.
7.1.4 The corrosion protection system damaged in the course of the Boiler supporting steel
structure assembly shall be restored according to the design documentation.

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7.1.5 Tolerances for the erection component assembly from the shop produced supporting
steel structure members are given in Table 3.

Table 3
Type of Deviations Allowed Deviations
Total length of columns, beams, collar beams and posts:
For members under 30 ft (9 m) long 0,08 inch (2 mm)
For members over 30 ft (9 m) long) 0,12 inch (3 mm)
Out-of-squareness of ends of some parts of columns and 0,06 inch (1,5 mm)
shoes in relation to the longitudinal axis
Elevations of column bearing brackets 0,2 inch ( 5 mm)
Deflection of columns, beams, collar beams and posts: /750, but not greater than
0,5 inch (13 mm)
Deflection in the wall plane or the supporting steel structure 0,2 inch ( 5 mm)
frame plane
Dimensions between column and post axes 0,4 inch ( 10 mm)
Dimensions between beams and collar beams 0,2 inch ( 5 mm)
Difference between diagonals in framed structure walls 0,6 inch (15 mm)
Elevation of brackets and platforms 0,4 inch ( 10 mm)

7.2 Preparation of Boiler Heating Surfaces and Internal Piping for Installation

7.2.1 Scope of works on the heating surface and internal piping preparation for installation
covers the site assembly of the shop-assembled modules according to the Supplier's drawings and
the Erection Works Project erection process write-up.
7.2.2 To check the tubes/pipes for the absence of foreign matters the ball running test of the
whole tubular/piping system must be carried out. The ball diameter shall be within 0.5 to 0.7 of
the inside diameter of the tube/pipe to be tested.
7.2.3 Fit-up, welding and welds quality control of the Boiler parts including the Positive
Material Identification of the assemblies and parts made of alloy steel shall be carried out in
compliance with the requirements of the design documentation and Erection Works Project.
7.2.4 The allowed dimensional deviations in the gastight heating surfaces assembled into the
erection assemblies shall not exceed the tolerances given in Table 4.

Table 4
Type of Deviations Allowed Deviations
Panel width : at width to 10 m 5 mm

at width over 10 m 10 mm
Nonparallelism of the extreme tubes 5 mm
The tube misalignment at the panel ends in respect to the not greater than 5 mm
longitudinal central plane of tubes
Panel length: when length is under 8 m not greater than 8 mm
when length is over 8 m not greater than 12 mm
Panel diagonal difference: not greater than 10 mm

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8 BOILER UNIT ERECTION

8.1 Boiler Supporting Steel Structure Erection

8.1.1 The Boiler supporting steel structure (including platforms and stairs) erection shall be
carried out according to the drawings - LP1-KZ-10-M-M1A-DSW-5008, LP1-TKZ-
10HBA-M-M1A-DSW-5013, LP1-TKZ-10HBA-M-M1A-DSW-5015, LP1-TKZ-10HBA-M-
M1A-DSW-5017, LP1-TKZ-10HBA-M-M1A-DSW-5019, LP1-TKZ-10HBA-M-M1A-DSW-
5021, LP1-TKZ-10HBD-M-M1A-DGA-5003, the Boiler Erection Manual LP1-TKZ-
10XXX-M-M1A-MAN-8405, Erection Works Project erection process write-up according to
AISC 303-10 Code of Standard Practice for Steel Buildings and Bridges and AISC 348-14
Specification for Structural Joints Using High-Strength Bolts. AISC 303-10.
8.1.2 It shall be imperative that the application of loading on the Boiler foundation due to the
supporting steel structure assemblies shall be allowed only on condition that the foundation log-
book and the foundation acceptance certificate issued by the acceptance committee are
available. The acceptance certificate shall be signed by representatives of the construction
organization, the Customer's technical supervision body and the Boiler Suppliers supervision
personnel.
The columns shall be fastened to the foundation via the column shoes using anchor bolts.
The ancho bolt washers shall be welded to the shoes.
8.1.3 The column grouting shall be made by the construction organization under the
Customer's technical supervision body and the Boiler Suppliers supervision personnel, after
the first tier of the supporting steel structure has been installed and aligned.
8.1.4 Further works on the supporting steel structure are allowed provided that the grouting
strength has increased to at least 70%.
8.1.5 After the erection of the columns and all major components of the supporting steel
structure, the supporting steel structure final alignment shall be carried out. When carrying out
the alignment of the erected supporting steel structure, all basic dimensions to be entered into
the erection log-book shall be checked.
8.1.6 Deviations from the Boiler supporting steel structure design dimensions shall not
exceed the values specified in the below Table 5.

Table 5
Type of Deviations Allowed Deviations
Deviation of the column shoe bearing surface elevation 0,2 inch
( 5 mm)
The main column shoe centering displacement in relation to the 0,2 inch
foundation laying out axes. ( 5 mm)
Misalignment of the column axis from the vertical in the upper cross
section at height:
under 30 m. /1000, but Not
greater than 0,6
inch ( 15 mm)
over 30 m. /1500, but Not

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greater than 1 inch
( 25 mm)

Deviation of the upper elevations of truss, collar beam and girder 0,4 inch
bearing assemblies (10 mm)
Difference between diagonals of the furnace and convection shaft Not greater
steel structure in plan, at the bottom and at the top than 0,6 inch
(15 mm)
Horizontal deviation of girders, collar beams, trusses and shields 0,2 inch
( 5 mm)
Deviation of distances between beams, trusses and collar beams 0,2 inch
( 5 mm)
Difference in bearing areas length (with their length being >50 Not greater than
mm) of girders, trusses, collar beams and flooring plates 0,4 inch
( 10 mm)

8.1.7 After the supporting steel structure has been aligned, the final installation of the high-
strength bolt connections, welding and fastening of all structural components, platforms and
stairs of the supporting steel structure shall be carried out.
8.1.8 Norms and requirements applicable to the installation of the high-strength bolts during
the supporting steel structure erection shall comply with the design documentation, this Boiler

Erection Manual, and EWP erection process write-up (with regard to the AISC 348-14
requirements).

8.2 General Requirements for Welding Joints and High-Strength Bolt Joints to be
Complied with during the Supporting Steel Structure Erection

8.2.1 Joints shall be made and accepted under the supervision of the person responsible for
carrying out such type of joints under the order of the organization performing those works.
Joints are allowed to be made by the personnel who has undergone an adequate training and
has a certificate allowing performance of the above works.
8.2.2 The bolted assembly process incorporates the following procedures:
8.2.2.1 Preparation of faying surfaces of elements and parts:
Prior to install high-strength bolts it is necessary to check the faying surface machining quality
according to the design documentation requirements. The machined surfaces shall be protected
from dirt, oil and paint. The bolt assembly and tension shall be performed in the shortest
possible time, but not later than 3 days after the faying surface preparation.
8.2.2.2 Preparation of bolts, nuts and washers prior to the installation shall be as per AISC
348-14:
8.2.2.3. Bolted joint assembly:
The bolt joint assembly process shall provide:
- inspection of structures and their checking for compliance with the design documentation
requirements;
- hole alignment and fixing, in the design position, the metalware and mounting plug
fasteners;

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- bolt installation in plug-free holes;
- tensioning the installed bolts for the design force;
- unplugging, bolt installation in plug-free holes and tensioning the installed bolts for the
design force.
Overlapping element thickness difference shall be determined prior to installing the joint
plates, using a ruler and probe; it shall not exceed 0,5 mm.
At the plane difference between 0,5 mm to 3 mm, in order to ensure a smooth joint plate
bending, the extending part edge should be removed with an emery stone at a distance not less
than 30 mm from the part edge. At the plane difference for more than 3 mm, joint plates should
be used. The joint plate application shall be agreed with the design organization.
The hole misalignment in some parts of the assembly shall not exceed the difference of the
hole and bolt nominal diameters.
Joints should be assembled using plugs and bolts of the diameter and strength class
specified in the design. Using, as assembly bolts, the bolts of other diameter and strength
classes is prohibited.
Each bolt shall be installed in a connection with two round washers (one shall be installed
for the bolt head and the other one for the nut). Using more than one washer on each
assembly side is not allowed. Bolts are tensioned for the design force;
8.2.2.4 Bolt tensioning for the design force:
8.2.2.4.1 Bolts shall be tensioned for the design force after checking the geometry of the
assembled structures and completion of welding works in the bolted-welding joints.
8.2.2.4.2 The design documentation of the Boiler supporting steel structure specifies the
following types of the high-strength bolt joints:
- joints with the controlled tension of SC type (shear-critical joint)
- joints with the controlled tension of type (a pretensioned bolt joint with the flanged
column joints);
- joints without controlled tension of ST type (securely tightened joint with shear load and
tension load).
8.2.2.4.3 The bolt tension with the controlled tension shall be carried out, using a nut
wrench and torque wrench, by the torque in the following order:
- Pretensioning of bolts up to 80-90% of the design value using the calibrated wrenches.
- Tensioning for the design load using a torque wrench.
Tightening shall be smooth and shockless. Torque wrenches shall be numbered and
calibrated. The Torque wrench shall be calibrated at least once a shift prior to start works,
provided there are no mechanical damages, as well as after each replacement of the instrument
or wrench repair.
8.2.2.4.4 Bolt tensioning without controlled tension:
- in the bolted joints without the controlled tensioning, bolts with diameter under 16 mm
shall be tightened as far as they will go, using mounting wrenches with a handle of 250mm
long, bolts with diameter 20 mm, 22 mm with a handle of 350 mm long, bolts with diameter
24mm 400mm;
8.2.2.5 Quality control, acceptance and hermetic sealing of the bolted assemblies.
8.2.2.5.1 The bolted assembly quality shall be checked by carrying out the quality
verification functional control. When accepting the works, the following shall be controlled: a
faying surface preparation quality, tensioned assembly density, bolt tensioning value.

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8.2.2.5.2 An element and part faying surface preparation shall be checked by visual testing
prior to joint assembly. Defective surfaces or parts thereof shall be repaired.
8.2.2.5.3 The tensioned assembly density shall be checked by a probe of 0,3 mm thick. At
that, the probe shall penetrate clearances between the connecting parts.
The clearance between the faying flat surfaces of the column flanges in the bolt locations is
not allowed. The probe of 0,1 mm thick shall not penetrate the 40 mm radius area from the bolt
axis. Notwithstanding the tensioning method, a visual testing of the joint shall be performed
with appropriate data being entered the log.
A stamp shall be applied to the finished joint. After the joint acceptance, all joint surfaces,
including those along the joint strap outline, shall have the primer applied according to the
design.
8.2.3 General requirements for the welded field joints.
The field welded joints of the supporting steel structure members shall be made according to
the design documentation, Erection Works Project and requirements of AWS D1.1.

8.3 Erection of the Boiler Heating Surface Enlarged Assemblies

8.3.1 Erection of the Boiler heating surfaces and technological order of the shop-assembled
module installation shall be carried out according to the manufacturing drawings, this Boiler

Erection Manual instructions and the Erection Works Project erection process write-up.
8.3.2 Deviation from the basic design dimensions during the heating surface erection shall
not exceed the values given in Table 6.

Table 6
Type of Deviations Allowed Deviations
Horizontal deviation of headers 3 mm
Deviation of header elevations 5 mm
Protrusion of tubes beyond the common area 5 mm
Deviation of distances between platens at the 30 mm
bottom
Deviation of distances between headers 10 mm
Deviation of the distance between the header
axis and the supporting steel structure main 5 mm
column axes

8.3.3 Prior to capping the open ends of headers, the headers shall be thoroughly checked for
cleanliness; foreign matters, rust, and other contaminants should be removed from the headers.
Capping of the ends shall be carried out only in the presence of the Customer's representative
and recorded in a special log or report.

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8.4 Boiler Safety Devices Erection

8.4.1 Boiler Safety Devices shall be installed in accordance with the requirements of the
drawings, Manufacturer 's Manual and the Document - LP1-TKZ-11XXX-M-M1A-CAL-9401.
8.4.2 Location of the Safety Devices shall meet the requirements of the technical
specification for the Safety Device supply:
- routing of connecting pulse tubes should be designed in such a way that their length is the
least possible;
- place of the Safety Device installation should be provided with a shelter to protect the Safety
Devices against weathering, direct sunlight and to reduce the wind force significantly;
8.4.3 Thermal expansion of the steam collecting chamber with the safety valves installed
thereon is not to be obstructed in any way and not to be hindered with the valve mounting
groups.

8.5 Field Adjustment of Heating Surface Hanger Spring

8.5.1 Adjustment of the hanger springs of the wall enclosures, evaporative water walls and
superheaters of the gastight Boiler Units is a critical and labor-intensive field operation which
determines the Boiler furnace and gas duct gas tightness. Preparation for the adjustment
operations shall be carried out in full with great care.
8.5.2 The spring adjustment and all preparation works shall be carried out according to the
shop scheme of the spring tension for this Boiler, wherein the design loads on each hanger
separately are given tonnage-wise. The design loads shall be the input data for carrying out the
field adjustment of springs.
8.5.3 The spring tension adjustment procedure consists in establishing an adjustment factor
"K" and in a further fine adjustment of springs as to the factor "K".
8.5.4 The adjustment procedure comprises the following operations:
- measurement of the actual spring tension of each hanger on the erected Boiler using a
hydraulic unit;
- spring tension to the required value as to the adjustment factor "K";
- FINE ADJUSTMENT after the Boiler has been warmed up and has reached the required
load.
8.5.5 ATTENTION! Adjustment of springs shall be carried out only with the participation of
the Supplier's supervision engineer.
8.5.6 The adjustment procedure is as follows:
- all hangers shall be numbered according to their positions in the assembly drawings and the
shop scheme of the spring tension. Hanger No. shall be legibly applied on the hanger.
- a table shall be compiled according to the data form given in Table 7.

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Long Phu 1 Thermal Power Plant Project
Document No.
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016
Table 7
Hanger Maximum Hanger Measured Load Adjustment Load Spring Design
Number Design Load, on Each Hanger, on Each Hanger, Solid Height,
2 3 4 mm
1 2 3 4 5

- fill in the first and second columns of the Table;

The second column shall be filled in with regard to the design loads as per the shop scheme
- actual loads on each hanger shall be measured using a hydraulic unit and measurement
results shall be entered in column 3 of the Table. (Attention! 1 kf/cm2 of the pressure gauge
indication at the oil station corresponds to 238.6 kg of load);
- total loads in columns 2 and 3 of the Table (P2 and P3) shall be determined;
- adjustment factor "K" shall be calculated as follows;

3
= -------
2
- adjustment load for each hanger shall be determined by the formula: 4= 2;
- the obtained results P4 shall be entered in column 4 of the Table.
- total adjustment load shall be determined in column 4 of the Table.
If the adjustment has been carried out correctly, the total load values in columns 3 and 4 shall be
equal.
- If load P4 on this hanger is greater than the measured load P3, the load on that spring
should be incremented by increasing the pressure in the hydraulic unit up to the required value,
and a new position of the spring shall be fixed by tightening the hanger nut up.
- If load P4 is less than load P3, the load on the spring should be reduced. For that purpose
the hydraulic unit shall be used to create the load higher than the one existing on the hanger.
The nut shall be unscrewed, the load shall be reduced to the required value using the hydraulic
unit and a new position f the spring shall be fixed.
- After the Boiler Unit has reached the nominal load, the spring tension shall be fine
adjusted, if the actual loads on the springs are much different from the adjustment ones.
- a hanger spring field adjustment log-book shall be drawn up.

8.6 Insulation and Setting Installation Works

8.6.1 The scope of insulating and setting works on the erected Boiler shall cover the
following:
- installation of thermal insulation on the gas-tight heating surfaces;
- packing of the Boiler assemblies insulation jointing edges;
- installation of setting in places of platen and superheater tubes and other Boiler component
penetrations through the ceiling water wall;
- application of a refractory mixture on studded surfaces.

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Document No.
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016
8.6.2 Preparation and application of the refractory mixture on the studded surface shall be
carried out in compliance with the Boiler Manufacturer's Manual to be sent to the Customer
along with the insulation drawings.
8.6.3 Insulation of the Boiler (penthouse ("warm" box), burner, air pre-heater, piping, etc.)
external parts.

9 ACCEPTANCE INSPECTION OF THE INSTALLED EQUIPMENT

9.1 Boiler Gas-Leak Test

9.1.1 For the boilers with gas-tight panels it is practical that the tightness of the panel welded
joints be checked through a kerosene test at the assembly site upon completion of the welding
works connected with the site assembly of shop-assembled modules.
9.1.2 Tightness of corner joints of the furnace and transient gas duct, as well as of joints
between the panels on the erected Boiler shall be visually inspected, and electric welds shall be
tested with chalk and kerosene.
9.1.3 Prior to the pressure test of the erected Boiler the most significant places of non-
tightness should be revealed using light sources and removed, with the electrical safety code
provisions being observed. Strong sources of light shall be switched on in the furnace and gas
ducts and the external appearance of welds and penetrations of tubes, suspensions, etc. shall be
examined.
9.1.4 The pressure test shall be carried out using a forced-draft fan with the peep/inspection
holes, manholes and other openings being closed at a pressure not over 100-:-150 mm WG.
Leakages shall be checked by sound, by deflection of a flame or flag caused by the leaking air
head pressure, as well as soap bubbles on a weld soaped surface.
9.1.5 The revealed leakages shall be marked by a chalk and removed.

9.2 Boiler Hydraulic Test

9.2.1 Prior to the inspection testing and commissioning, the erected Boiler shall be subjected
to a technical examination and preliminary working pressure testing.
9.2.2 During the technical examination an external and internal inspection of the Boiler shall
be carried out to determine the extent of completion of the erection works as per the project, as
well as the quality of welding of the heating surfaces and pipelines.
9.2.3 Prior to commence hydraulic testing the following technical documents
shall be prepared:
- Certificate of the element-by-element acceptance inspection of the Boiler main assemblies
according to their designation in the List of assembly drawings;
- Certificate of ball rolling control of the heating surface tubes and coils;
- scope of welding acceptance documents (data forms, certificates, test reports,
nondestructive examination final reports, etc.);
-reports of the Positive Material Identification of the Boiler elements made of alloy steels;

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Document No.
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M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016
- erection data forms for the Boiler main assemblies according to their designation in the List
of assembly drawings.
9.2.4 After the preliminary working pressure hydraulic testing has been carried out and all
comments have been incorporated, the Boiler shall be subjected to the inspection testing at the
test pressure which shall be conducted in the presence of a Boiler Inspectorate Inspector.
9.2.5 The filling water temperature shall minimum +20C and shall not exceed +50C. for
the hydraulic test the clarified water shall be used.
9.2.6 Boiler pressure shall be monitored with two pressure gauges, one of which shall be a
test pressure gage.
9.2.7 The test pressure value at the hydraulic test for the high pressure circuit is 43,15 MPa
(440 kgf/cm), at the maximum allowable working pressure - 28,44 MPa (290 kgf/cm).
The test pressure value at the hydraulic test for the low pressure circuit is 9,8 MPa (100
kgf/cm), at the maximum allowable working pressure - 6,01 MPa (61,3 kgf/cm).
Holding time at the test pressure shall be at least 30 minutes. Afterwards, the pressure shall
be reduced to the working pressure and a thorough inspection of the Boiler elements, welds and
weld adjacent areas shall be carried out.
9.2.8 The hydraulic testing results shall be deemed satisfactory provided that there are no:
- signs of rupture;
- leakages, sweating on welded joints and base metal;
- residual deformations.
9.2.9 Defects revealed during the manufacture, erection or hydraulic test shall be repaired;
the repair works shall be followed by testing.
9.2.10 Repaired areas of welded joints shall be subject to the nondestructive testing (UT, RT)
whenever the material or design makes possible to use the specified testing method.
9.2.11 After the chemical cleaning the hydraulic test shall be conducted using a preservative
solution or desalinated water

9.3 Preoperational Boiler Chemical Cleaning

The preoperational chemical cleaning shall be carried out in accordance with the individual
scheme, procedure and plan developed by a specialized organization and agreed upon with the
Boiler Manufacturer, and approved by the Customer.

9.4 Boiler Steam-Pressure Test

9.4.1 The steam-pressure test scope of works covers the following

operations:
- steam-pressure testing of all heating surfaces, headers, piping and valves;
- check of thermal expansions of some Boiler components envisaged by the design;
- in-service inspection of valves, remote devices, instrumentation and auxiliary
equipment;
- blow-down of the steam piping;
- setting of pulse-safety valves;
- Boiler preparation for the full-scale test.

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9.4.2 The following operations shall be completed prior to start the steam-pressure test:
- the erection and the element-by-element acceptance inspection of the Boiler equipment;
- all technical documentation has been executed;
- Boiler leak test;
- trial run of all auxiliary devices;
- check of clearances for thermal expansions;
- Boiler hydraulic testing;
- Boiler chemical cleaning and reestablishment of the operating circuit;
- completion of the external piping setting and insulating works in full;
- implementation of all required safety practices, sanitary regulations and fire-prevention
measures;
- completion in full and provision of serviceability of the Boiler Unit lighting system.
9.4.3 Blow-down of the steam piping with auxiliary steam shall be carried out at the Boiler
pressure of 4,0 Ma (40 kgf/cm) with a reduction in the end of the blow-down down to
22,5MPa (20-25 kgf/cm) .
Duration of each blow-down stage shall be at least 10-25 minutes.
9.4.4 After the pulse lines have been blown down and welded to the pulse valves, at pressure
4,0 MPa (40 kgf/cm) a piston block travel smoothness of the pulse-safety valves shall be
adjusted, and during operation of the pulse-safety valves the flange connections shall be
warmed up.
- thermal expansions of the tube system and headers shall be monitored with the results being
recorded in an appropriate table. Until the failure has been eliminated, no further increase in the
pressure and temperature shall be carried out;
- a thorough visual inspection and listening-in of the Boiler shall be carried out with an aim
to detect leakages and unsound spots;
- readings of the control instrumentation and operation of remote-controlled valves and
dampers shall be checked;
- burners shall be checked and adjusted, if necessary;
- attemperators and superheater shall be checked for performance;
- check for the valve tightness, of continuous blow-down stations, as well as of the steam and
water sampling points;
- condition of the setting, tube wall thermal insulation and piping insulation shall be visually
tested.
9.4.5 Upon completion of the steam leak test, safety valves shall be adjusted according to
Document LP1-TKZ-11XXX-M-M1A-CAL-9401 Safety Valve Sizing & Selection.
9.4.6 Adjustment of the safety valves shall be carried out according to the Manufacturers
technical requirements specified in the product certificate.
9.4.7 Upon completion of the steam-pressure test and adjustment of the safety valves, a
certificate shall be executed for these procedures with a table of the Boiler element thermal
expansions and a list of comments, if any, attached thereto.
9.4.8 A thorough inspection of the shutdown and cooled Boiler shall be performed, and
revealed defects shall be eliminated.

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TKZ Number: 300117125 26
 LP1 PM-PTSC
Long Phu 1 Thermal Power Plant Project
Document No.
LP1-TKZ-10X-M- Boiler Erection Manual Page 27 of 27
M1A-MAN-8405 PP-600
Rev.: C Type Pp-1900-25,8-568/568 Boiler Date:
15-August-2016

9.5 Boiler Full-Scale Test

9.5.1 After the defects revealed during the pressure test have been eliminated, the Boiler
shall be lighted-up to conduct the full-scale test as required by the Contract.
9.5.2 After the full-scale test of the Boiler has been completed and all defects revealed during
the same have been eliminated, the Boiler shall be put into operation.

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