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    Welcome: Awarness Program On Boiler Supporting Stuctures

    Uploaded by

    Raja T
    The document discusses quality checks for column fabrication and erection in boiler structures. It describes the different types of columns and outlines the multi-stage quality check process for plate marking, welding, fitting, trial assembly and erection. Key steps include checking dimensions, alignments, orientations and punch markings at each stage to ensure columns meet design requirements and specifications.

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    © All Rights Reserved
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    Welcome: Awarness Program On Boiler Supporting Stuctures

    Uploaded by

    Raja T
    39 views34 pages
    The document discusses quality checks for column fabrication and erection in boiler structures. It describes the different types of columns and outlines the multi-stage quality check process for plate marking, welding, fitting, trial assembly and erection. Key steps include checking dimensions, alignments, orientations and punch markings at each stage to ensure columns meet design requirements and specifications.

    Original Description:

    Column

    Original Title

    COLUMN

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    The document discusses quality checks for column fabrication and erection in boiler structures. It describes the different types of columns and outlines the multi-stage quality check process for plate marking, welding, fitting, trial assembly and erection. Key steps include checking dimensions, alignments, orientations and punch markings at each stage to ensure columns meet design requirements and specifications.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    39 views34 pages

    Welcome: Awarness Program On Boiler Supporting Stuctures

    Uploaded by

    Raja T
    The document discusses quality checks for column fabrication and erection in boiler structures. It describes the different types of columns and outlines the multi-stage quality check process for plate marking, welding, fitting, trial assembly and erection. Key steps include checking dimensions, alignments, orientations and punch markings at each stage to ensure columns meet design requirements and specifications.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 34

    WELCOME

    AWARNESS PROGRAM ON

    .
    BOILER SUPPORTING STUCTURES
    COLUMN

    COLUMN IS MAIN STRUCTURE IN BOILER,WHICH


    SUPPORT ALL CEILING GIRDERS DRUM, HANGERS,
    HEADERS AND WATERWALLS. SUPER HEATER ETC.
    COLUMN ARE DESIGNED SUCH A WAY THAT TO TAKE
    CARE OF FLOOR LOAD, WIND LOAD AND SEISMIC
    LOADS. ALL BOILER COLUMNS ARE
    INTERCONNECTED WITH BRACINGS
    COLUMN LAY OUT
    COLUMN

    COLUMNS ARE CLASSIFIED AS

    1.MAIN COLUMN

    2.SECONDARY COLUMN

    3.LIFT AND POST

    4.ESP COLUMN
    COLUMN

    PLATE FORMED PLUS TYPE

    PLATE FORMED BOX TYPE

    CHANNEL-BOX TYPE

    ROLLED SECTION PLUS TYPE


    CEILING GIRDER PIN CONNECTION DETAIL
    COLUMN

    PROCESS FOR PLUS TYPE

    1.RAW MATERIAL CLEARANCE

    2. IDENTIFICATION : IDENTIFY WO,DU BY


    PAINTING FOR ALL PLATES AND PUNCH
    SPECN&MELT

    3. PLATE MARKING FOR FLANGE WITH


    CUTTING
    & HAZ GRINDING ALLOWANCE
    COLUMN

    PLATE MARKING FOR I SECTION WEB

    CHECK FLANGE PLATE THICKNESS

    WEB WIDTH = (SECTION DEPTH – Flange


    thick(actual thick X2)+(EXTRA for cutting &shrinkage
    allowance)

    NOTE: NOT TO MARK THE WEB WIDTH TO


    DRAWING SIZE
    COLUMN
    Example:Column 600 x300x63

    Flange T(act 61.5)

    Section
    Web width depth
    +3mm

    Web width=600- 123 (61.5 x2)=477+3mm shrinkage + 8mm


    cutting allowance
    Total web width on plate for marking = 488mm
    COLUMN
    MARKING FOR I SECTION:
    2MM FOR CUTTING AND 3+3MM FOR CUT EDGES GRINDING ON
    EACH SIDE 8MM MAX FOR CUTTING ALLOWANCE
    488
    8 480
    4
    4
    COLUMN

    PLATE MARKING FOR T SECTION


    (Forming I section and cutting as T section)

    CHECK FLANGE PLATE THICKNESS AND


    WEB THICKNESS

    WEB WIDTH = SECTION DEPTH - FL(T)X2 -


    web thickness of I section + 11MM cutting &
    grinding allowance
    COLUMN
    Example:600x300x63

    Flange T
    Web width
    Web T of I section Section
    depth

    Web width=600-123 (flg 61.5 x2)- web t(61.5)=415+8mm web


    cutting allowance+ 8mm plate cutting &+3mm shrinkage allowance
    Total web width on plate for marking = 434mm
    COLUMN
    MARKING FOR T SECTION:
    2MM FOR CUTTING AND 3+3MM FOR CUT EDGES GRINDING ON
    EACH SIDE CUTTING ALLOWANCE
    8 MM MAX.
    434
    426
    4
    4

    Web cutting CL
    after I formation
    COLUMN

    I & T fit up

    CL
    COLUMN

    STAGE 1
    QUALITY CHECK
    1. SECTION DEPTH
    2. SQUARENESS OF FLANGE AND WEB
    3. CENTER LINE AND WEB ALIGNMENT
    COLUMN
    Center line marking after welding: mark center of web
    thickness and transfer on flange
    CL

    Web
    shift
    COLUMN
    WELDING OF I &T SECTION(SAW)

    REVIEW OF WPS AND ENSURE CLEANING


    ENSURE PRE HEATING OF BASE MATERIAL
    ENSURE FLUX BAKING
    ATTACH RUN ON/OFF PIECES
    RECORD ELECTRODE&FLUX BRAND&BATCH NO
    ENSURE WELD SIZE AND SHAPE
    COLUMN
    REMOVE FLANGE WARPAGE
    Hot correction, Hydraulic press
    COLUMN

    STAGE 2
    QUALITY CHECK
    1 FLANGE WARPAGE : 1/100 OF THE FLANGE WIDTH
    or 6MM WHICHEVER IS GREATER
    2.TWIST 0.05H/FOR EVERY 5M LENGTH MAX10MM
    3. SWEEP AND CHAMBER
    4.WELD VISUAL
    5. MPI ON WELD
    COLUMN
    Plus fit up:Check section depth with box type gauge on
    both sides (ensure +3mm in section depth for shrinkage
    allowance,)
    COLUMN

    STAGE 3
    QUALITY CHECK
    1. SECTION DEPTH
    2.WEB SHIFT OR ALIGNMENT
    COLUMN

    WELDING OF PLUS

    ATTACH RUN ON/OFF PIECES

    ENSURE PRE HEAT (if required)AND FLUX BAKING

    RECORD BATCH NO FOR FLUX AND WIRE

    FOLLOW WELD SEQUENCE TO AVOID BOW


    &DISTORTION
    COLUMN

    STAGE 3
    QUALITY CHECKS
    1. SWEEP AND CHAMBER:10MM MAX
    2. SECTION DEPTH : +/- 3MM UP TO 1M
    3. TOTAL LENGTH : +/- 3MM
    4. WELD VISUAL
    5. END EP FOR REST PLATE
    6. MPI ON WELDMENT &EP AREA
    COLUMN

    REST PLATE FIT UP

    WATER LEVEL OF COLUMN AND FIT UP OF


    RESTPLATE AND WELDING

    ENSURE PLUM OUT AT END, MATCH DRILLING


    WITH COVER PLATE ON FLANGE WITH PROPER
    ALIGNMENT

    PUNCH ALL IDENTIFICATION MARKS


    wo,du,column no,piece no,
    COLUMN
    STAGE 4
    QUALITY CHECK
    1.SECTION DEPTH AT REST PLATE ON BOTH
    AXIS
    2 CHECK 100% HOLE DIAMETER
    3.COUNT NO OF HOLES
    4.ALIGNMENT OF COVER PLATE
    5.MISMATCH OF HOLES WITH PIN GAUGE
    6.MPI ON REST PLATE WELDMENT
    7.FLATENESS OF REST PLATE:0.2MM
    COLUMN

    TRIAL ASSEMBLY (TA)

    1.FULL TRIAL ASSEMBLY

    2.PARTIAL TRIAL ASSEMBLY

    ASSEMBLY SEQUENCE

    1.TOP TO BOTTOM

    2.BOTTOM TO TOP
    COLUMN
    QUALITY CHECKS
    1 CENTER LINE ALIGNMENT
    WATER LEVELING OF ADJACENT PIECES: WITHIN 2MM
    OUT OF STRAIGHTNESS : 18MM MAX.(FULL TA)
    :10MM MAX (PARTIAL TA 3PIECES)

    2. OUT OF VERTICALITY
    AT BASE : 4MM MAX.

    AT CAP(TOP) :2MM MAX.


    COLUMN
    3.MATCH MARK PUNCHNING AT EJ
    4. PIN GAUGE CHECK FOR ALL HOLES AT EJ A1 Top side
    A1

    A1
    A1
    A4
    A2
    A4 A4

    A4

    Bottom side
    A3
    COLUMN
    MAIN COLUMN
    5.ORIENTATION OF CAP(TOP) PLATE
    6. FLATENESS OF CAP :0.2MM, LOCALLY 0.5MM

    Parallel to long axis to


    boiler
    COLUMN
    7. SQUARENESS OF CAP ASSY

    Ref.mark from top

    A 1/A4

    A 2/A3

    Check &record dimn A1,A4,A2&A3


    COLUMN
    8.CHECK BOTTOM ORIENTATION wrt to BOILER AXIS
    9.PIN GAUGE CHECK FOR BOLT HOLES

    Parallel to long axis to


    boiler
    COLUMN
    10. ORIENTATION OF SHEAR LUG AND BRACING GUSSET PLATE

    BRACING PLATE
    SHEAR
    LUG
    COLUMN
    11. ZERO LEVEL 5M
    AND OLV PUNCH
    12.Every 5M level mark
    Punch

    0’ M LEVEL at 3 Axis
    OLV PUNCH

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