Lanco 2x660

1
 Capacity :2x660 MW (For Phase-I)
 Primary Fuel :Coal
 Transmission System :400 KV Line to PGCIL
 Requirement of Water (Cum/Hr) :4000 Cum/Hr
 Project Location :Khurunti, Dist-Dhenkanal
2
 Main Boiler
 Rotary Air Heater
 Coal Bunker
 Fuel Oil/ Firing System
 Coal Pulverizer
 F.D Fan
 I.D. Fan
 P.A. Fan
 Seal Air Fan
 Coal Feeder
 Electrostatic Precipitator
3
Manufacturer Dongfang Electric Company, China
Boiler with supercritical parameter, once through,
Type Water Tube, coal fired, balanced draft, Single reheat &
outdoor arrangement
Boiler Maximum 2090 tph
Continuous Rating
Steam Pressure at SH
25.5 MPa
Outlet
Steam Temp. at SH Outlet 571 deg. Celsius
Steam Flow at RH Outlet 1803.2 tph
Steam Pressure at RH Inlet 4.65 MPa
Steam Pressure at RH
4.43 MPa
Outlet
Steam Temp. at RH Inlet 323 Deg Celsius
Steam Temp. at RH Outlet 569 Deg Celsius
Feed Water Temp. entering
282 Deg Celsius
Economizer
Feed Water Pressure
29.66 MPa
entering Economizer
4
Water Wall 4872 m2
Platen SH 2327 m2
Final SH 3013 m2
Final RH 3160 m2
Vertical Primary RH 2110 m2
Horizontal Primary RH 20429 m2
Vertical Primary SH 1226 m2
Horizontal Primary SH 7931 m2
Economizer 17896 m2
Heat Recovery Area Tubes 1841 m2
5
1. Height of the Boiler (Top of Ceiling Girder): 90 m
2. Furnace Dimension(L x W): 22162.4 X 15456.8 mm
3. Convection Pass Dimension: 22160.2X16459.2 mm
4. No. of Field HP Joints: 39059 Nos.
5. Max. Expansion of Furnace: 411 mm
6
1. Total weight of Boiler structure - 7000
MT.
2. Total No. of tiers - 6 Tiers
3. Top of ceiling girder (K-4) elevation - 90620
mm
4. Maximum weight of ceiling girder - (106 +
93 = 199 ) MT
7
Sl
Activity Description Start Finish Day
no
1 1st. Tier column. Beam, Bracing and platform erection.
2nd Tier column. Beam, Bracing and platform

2
erection.
3 3rd Tier column. Beam, Bracing and platform erection.
4th. Tier column. Beam, Bracing and platform

4
erection.
5 5th Tier column. Beam, Bracing and platform erection.
6 6th Tier column. Beam, Bracing and platform erection.
7 Ceiling girder Erection
8
8 Structure 1st Tier Start Finish Day
9 Erection of structure 1st tier column , beam
10 C2 & Connecting Beam
11 C11 & Vertical Bracing
12 c-4 & connecting beam.
13 C-3,C13 & connectin Beam
14 C-17
15 C-25 to C-26 & vertical Bracing
16 C-19 & vertical Bracing
17 C-28 & C-29 Vertical Bracing
18 Erection of Platform and stair case

Elev-82000 main connecting member, stair case including landing platform, grating &
19
handrail.
20
handrail.
21
handrail.
22
handrail.
23 1st tier alignment & bolt tightening
24 Alignment, Bolt tightening, & inspection Left side
25 Alignment, Bolt tightening, & inspection Rightside
26 Alignment, Bolt tightening, & inspection Frontside
9
27 Structure 2nd Tier Start Finish Day
28 C-1,C-2,C-6,C-7 & connecting beam
29 C-10, C-11, Vertical Bracing
30 C-4,C-5, C-8,C-9 & Connecting beam.
31 C-3,C-13, C-14 & connecting beam
32 C-16, C-17,C-21
33 C-25 , C-26 & vertical bracing
34 C-19,C-20,C-24 & vertical bracing
35 C -28,C-29, vertical bracing
36 2nd Tier Erection of platform & stair case
37
handrail.
38
handrail.
39
handrail.
40 2nd tier alignment & bolt tightening
42 Alignment, Bolt tightening, & inspection Right side
43 Alignment, Bolt tightening, & inspection Front side
10
44 Structure 3rd Tier Start Finish Day
45 Erection of 3rd tier column & beams
50 C-16, C-17,C-21
54 3rd Tier Erection of platform & stair case

55
handrail.
56
handrail.
57
handrail.
58 3rd tier alignment & bolt tightening
60 Alignment, Bolt tightening, & inspection Right side
61 Alignment, Bolt tightening, & inspection Front side
11
62 Structure 4th Tier Start Finish Day
63 Erection 4th Tier column Beam
68 C-16, C-17,C-21
72 4thTier Erection of platform & stair case

Elev-52100main connecting member, stair case including landing platform, grating &
73
handrail.
74
handrail.
80
handrail.
76 4th tier alignment & bolt tightening
12
80 Structure 5th Tier Start Finish Day
86 C-16, C-17,C-21
91
handrail.
92
handrail.
13
97 Structure 6th tier Start Finish Day
103 C-16, C-17,C-21
Elev-62300main connecting member, stair case including landing platform, grating &
108
handrail.
109
handrail.
14
114 Girder Erection Start Finish Day
115 K1 Girder
116 K2 Girder
117 K1-K2 W -beam & R-beam
118 K3 Girder
119 K2-K3 W-beam & R-beam
120 K4 Girder
121 K3-K4 W-beam & R-beam
122 C-27 Column & connecting beam erection 1st tier to 6th tier
123 K5 Girder
124 K4-K5 W-Beam & R-Beam
125 Girder Alignment
15
16
C-1 C-6 C-10 C-16 C-25 G-1
C-17 C- C-26 G-2

21
C-2 C-7 C-11 G-3
C-
22
C- C- C- G-4
C-3 12 15 18 C-27
C-
23
C-4 C-8 C-13 G-5
C-19 C- C-28 G-6

24
G-7
C-5 C-9 C-14 C-20 C-29
K1 K2 K3 K4 K5 K6
17
1st Tier erection
1. Foundation take over as per drawing with protocols.
-Inspection of permanent Bench mark.

-Inspection of foundation bolt co-ordinates and elevation.
-Inspection of foundation elevation.
-Inspection of diagonal and spacing between the foundation.
-Foundation center marking.
2 .Inspection of column according to identification No., match mark, column No,

length, camber sweep, deflection, check visually for any damages/surface defects etc.
3. Erection of 22 No's column with connection beam vertical bracing and horizontal
bracing. Other 7 no's columns with held for crane movement for erection of K-1, K-2, K-3
Ceiling Girder and will be erecting after erection of K-1, K-2 , K-3 and K-4 Ceiling girders.
4. Erection of Platform with grating, handrail and Stair case.
5. Alignment and bolt tightening .
6. Grouting of column with foundation.
7. Clearance for erecting 2nd tier With protocol.
8. Major resources utilized- 80 MT and 150 MT Cranes.
18
1. Inspection of column according to identification No., match mark,
column
No., length, camber sweep, deflection, check visually for any
damages/surface defects etc.
2. Erection of 22 Nos column with connection beam vertical bracing
and
horizontal bracing other 7 nos columns are with held for crane
movement
for erection of K-1, K-2, K-3 and K-4 Ceiling Girders and will be
erecting after erection
of K-1, K-2, K-3 and K-4 Ceiling girders.
5. Clearance for erecting 5rd tier With protocol.
6. Major resources utilized - 150 MT and 250 MT Crane.
19
1. Inspection of column according to identification No., match mark,
column No., length,
camber sweep, deflection, check visually for any damages/surface
defects etc.
2. Erection of 22 Nos columns with connection beam vertical bracing
and horizontal
bracing other 7 nos columns is with held for crane movement for
erection of K-1,K-2, K-3 and
K-4 Ceiling Girder and will be erecting after erection of K-1,K-2,K-3 and
K-4 Ceiling girder.
5. Clearance for erecting 6th tier With protocol.
6. Major resources utilized are 80 MT, 250 MT & 500 MT Crane.
20
1. Inspection of column according to identification No.,
match mark, column No., length, camber sweep, deflection,
check visually for any damages/surface defects etc.
2. Erection of 22 nos. columns with connection beam
vertical bracing and horizontal bracing other 7 nos. columns
is with held for crane movement for erection of K-1, K-2,K-3,
and K-4 Ceiling Girder, will be erecting after erection of K-1,
K-2,K-3 and K-4 Ceiling girder.
5. Clearance for erecting Ceiling Girder With protocol.
6. Major resources utilized are 250 MT,500 MT and 80 MT
Tower Cranes.
21
1. Inspection of Ceiling Girder according to identification No.,
match mark, column No., length, camber sweep, deflection, check
visually for any damages/surface defects etc.
2. Erection of 4 Nos Girder(K-1,K-2,K-3 and K-4) with connection
W-beam. Other Girder K-5 will be erected after erection of K-5
row balance Structure.
3. Balance structure erection of K-5 row.
4.Erection of k-5 ceiling girder and connecting beams.
7. Marking of boiler axis and elevation transfer for reference of
pressure parts erection.
8. Clearance for pressure parts erection with protocol.
9. Major Resources utilized for erection 250 MT, 500 MT and 80
MT Tower Crane.
22
23
24
25
26
27
TG TG
C-D Bay
F F
2nd Pass Coil
CONCRETE ROAD
Stacking area
Bed-1(16mx7m)
TC
TC
R Furnace L R Furnace L
14mx6.5m
Bed-3
55 m
25 m
R R
Road between Boiler & ESP
T.C-Tower
Crane ESP ESP Bed-2
7mx10m
28
1. Hanger rod assembly with hanger beam in sequence wise.
2.Front upper water wall with O/L header.
3. Right side upper water wall with O/L header.
4. Left side upper water wall with O/L header.
5. Furnace extended side wall panel with header.
6. Water wall screen header with screen tube.
7. Furnace open pass outlet header with hanger tube pre assembly.
8. Water wall rear arch panel pre assembly.
9. Rear intermediate water wall panel pre assembly.
10.Roof super heater panel (front ) pre assembly.
11.Spiral water wall assembly.
12.Spiral water wall reducer section(Hopper area) assembly including
bottom support.
29
30
FIRST PASS ERECTION METHODOLOGY (1/3)
S.NO. Description of activity Lifting methodology
1 Buckstay erection. Lifting by 80 T tower crane and temporary locking
Hanger rod and hanger beam erection for
2 water wall system Lifting by 80 T tower crane (top loading)
Sub assembly will be shifted by tower crane and turned straight
Front water wall with header erection. with tandem operation with 80 MT crane and final positioning by
3 80 MT tower crane (top loading)
Hanger rod with hanger beam erection for

Lifting by 80 T tower crane ( top loading)
Steam separator and Storage tank.
4
Erection & alignment of separator and
5 storage tank. Lifting by 80 T tower crane. (Top loading)
Right side upper water wall panel with Sub assembly will be shifted by tower crane and turned straight
upper header. with tandem operation with 80 MT crane and final positioning by
Left side upper water wall with upper Sub assembly will be shifted by tower crane and turned straight
header. with tandem operation with 80 MT crane and final positioning by
Right side furnace extended side wall Sub assembly will be shifted by tower crane and turned straight
with header. with tandem operation with 80 MT crane and final positioning by
Left side furnace extended side wall with Sub assembly will be shifted by tower crane and turned straight
header. with tandem operation with 80 MT crane and final positioning by
Furnace intermediate transition headers.

10 Lifting by 80 T tower crane ( top loading)
31
FIRST PASS ERECTION METHODOLOGY (2/3)
11 Screen header with screen tube. Lifting by 80 T tower crane ( top loading)
12 Final RH header. Lifting by 80 T tower crane ( top loading)
Final RH coil erection

Furnace open pass outlet header with
14 hanger tube. Lifting by 80 T tower crane ( top loading)
15 Final SH header erection. Lifting by80T tower crane ( top loading)
Final SH coil erection .

Rear arch panel erection. Lifting by 80T tower crane/winch machine ( bottom loading)
17
Rear intermediate water wall panel
18 erection. Lifting by 80 MT winch machine ( bottom loading)
19 Roof inlet header. Lifting by 80 T tower crane ( top loading)
Secondary SH header (div. header)
20 erection. Lifting by 80 T tower crane ( top loading)
1st pass roof assembly (front) erection.

21 Lifting by 80 T tower crane/winch machine ( bottom loading)
22 SH roof tube erection. Lifting by 80 T tower crane ( top loading)
23 Secondary s/h coils(div. panel). Lifting by 10 MT winch machine ( bottom loading)
Spiral water wall assembly erection.

24 Lifting by 2 set of 10 MT winch machine ( bottom loading)
32
FIRST PASS ERECTION METHODOLOGY(3/3)
25 Bottom distributor header with Supports. Lifting by 10 MT winch machine ( bottom loading)
Final SH outlet pipe erection up to stop

valve.
27 1st and 2nd stage attemperator. Lifting by 80 T tower crane ( top loading)
28 All top connecting links. Lifting by 80 T tower crane ( top loading)
Backstays positioning and attachments

29 Shifted with the help of chain blocks
with water wall.
30 All Peep holes and man hole doors. Lifting by 80 T tower crane ( boiler LHS/RHS side)
31 All drains and vents piping. Lifting by 80 T tower crane ( boiler LHS/RHS side)
32 Air Leak Test. (pressure parts circuit) With the help of Air compressor (6 -7 kg/cm2)
33 Hydro test (Drainable). With hydraulic reciprocating pups. (600 kg/cm2)
33
SECOND PASS ERECTION METHODOLOGY (1/2)
1 Buckstay erection. Lifting by 80 T tower crane, and temporary locking
Hanger and hanger beam erection for second
Lifting by 80 T tower crane (top loading)
2 pass in sequence.
Back pass front wall with top and bottom Sub assembly will be shifted by tower crane and turned straight
header erection. with tandem operation with 80 MT crane and final positioning by
Back pass left wall with top and bottom Sub assembly will be shifted by tower crane and turned straight
Back pass right wall with top and bottom Sub assembly will be shifted by tower crane and turned straight
Back pass rear wall with top header.( two Sub assembly will be shifted by tower crane and turned straight
parts) with tandem operation with 80 MT crane and final positioning by
Roof outlet header with roof tubes erection &
7 alignment. Lifting by 80 T tower crane ( top loading)
low temperature re-heater outlet header
Low temperature re-heater vertical coil
LTRH horizontal coil erection. Set down by 80 MT tower crane from boiler right, the electric hoist
10 replace hook and transporting for positioning
11 LTRH inlet header erection. Lifting by 80 T tower crane ( top loading) 34
SECOND PASS ERECTION METHODOLOGY (2/2)
Connecting pass baffle wall header with wall
12
erection.. Lifting by 80 T tower crane ( top loading)
13 LTSH outlet header erection. Lifting by 80 T tower crane ( top loading)
14 LTSH vertical coil erection. Lifting by 80 T tower crane ( top loading)
15 LTSH horizontal coil erection. Set down by 80 MT tower crane from boiler right, the electric hoist
replace hook and transporting for positioning
16 LTSH inlet header erection. Lifting by 80 T tower crane ( top loading)
17 Eco outlet header erection & alignment.
18 Eco horizontal coil erection. Set down by 80 MT tower crane from boiler right, the electric hoist
replace hook and transporting for positioning
19 Eco inlet header erection & alignment.
20 Primary r/h inlet pipe erection & alignment.
Lifting by 80 T tower crane ( boiler side loading)
21 Eco inlet pipe erection & alignment.
Buckstay positioning and attachement with
22
wall. Shifted with the help of chain blocks
23 All peep holes and man hole doors.
All drains and vents piping. With air test and

24 Lifting by 80 T tower crane ( boiler side loading)
hydro test arrangement.
25 Air leak test.(pressure parts circuit) With the help of Air compressor (6 -7 kg/cm2)
26 Hydro test (Drainable). With hydraulic reciprocating pups. (600 kg/cm2
35
36
37
There are two APH per boiler in
660MW boiler. One is Primary APH and
2nd one is Secondary APH. Each is Tri-
sector APH. Both are Rotary Type.
38
•Following is the most preferred and adopted sequence
of erection for individual APH:
Ensure the soundness and correct dimensions including
levels of APH support frame on structure.
•Place sliding supports and two pedestals in position and
secure them temporarily.
Raise lower central section and fix it to pedestals.
•Raise support bearing in lower central section.
There is always a good possibility of assembling support
bearing with lower central section and raising them together.
•Raise the rotor post, fix it with support bearing and secure it
temporarily in fairly vertical position.
Raise upper central section and fix it to pedestals. The top of
rotor post shall be passing through it.
39
•Raise guide bearing and place it in upper central section.
The top of rotor post is to be inserted in the bearing
Align the complete set of already raised items.
•Raise housing walls, secure them and give shape to
outer periphery of housing.
Raise sectors of heating elements, following proper
sequence and fix them to rotor post. Complete the rotor.
•Install rack on rotor, install drive unit, complete housing
and release it for duct connections.
Align all placed items and set the axial and radial seals.
•Install other balance items like ports, soot blowers etc.
and bring the pre-heater to mechanical completion stage.
40
 No of ID fans-2
 No of FD fans-2
 No of PA fans-2
 No of Seal Air Fan-2
41
42

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1

 Capacity :2x660 MW (For Phase-I)

 Primary Fuel :Coal

 Transmission System :400 KV Line to PGCIL

 Requirement of Water (Cum/Hr) :4000 Cum/Hr

 Project Location :Khurunti, Dist-Dhenkanal

2. Furnace Dimension(L x W): 22162.4 X 15456.8 mm

3. Convection Pass Dimension: 22160.2X16459.2 mm

4. No. of Field HP Joints: 39059 Nos.

5. Max. Expansion of Furnace: 411 mm

1 1st. Tier column. Beam, Bracing and platform erection.

2nd Tier column. Beam, Bracing and platform

3 3rd Tier column. Beam, Bracing and platform erection.

4th. Tier column. Beam, Bracing and platform

5 5th Tier column. Beam, Bracing and platform erection.

6 6th Tier column. Beam, Bracing and platform erection.

7 Ceiling girder Erection

10 C2 & Connecting Beam

11 C11 & Vertical Bracing

12 c-4 & connecting beam.

13 C-3,C13 & connectin Beam

15 C-25 to C-26 & vertical Bracing

16 C-19 & vertical Bracing

17 C-28 & C-29 Vertical Bracing

18 Erection of Platform and stair case

24 Alignment, Bolt tightening, & inspection Left side

25 Alignment, Bolt tightening, & inspection Rightside

26 Alignment, Bolt tightening, & inspection Frontside

29 C-10, C-11, Vertical Bracing

30 C-4,C-5, C-8,C-9 & Connecting beam.

31 C-3,C-13, C-14 & connecting beam

33 C-25 , C-26 & vertical bracing

34 C-19,C-20,C-24 & vertical bracing

35 C -28,C-29, vertical bracing

36 2nd Tier Erection of platform & stair case

40 2nd tier alignment & bolt tightening

41 Alignment, Bolt tightening, & inspection Left side

42 Alignment, Bolt tightening, & inspection Right side

43 Alignment, Bolt tightening, & inspection Front side

46 C-1,C-2,C-6,C-7 & connecting beam

47 C-10, C-11, Vertical Bracing

48 C-4,C-5, C-8,C-9 & Connecting beam.

49 C-3,C-13, C-14 & connecting beam

51 C-25 , C-26 & vertical bracing

52 C-19,C-20,C-24 & vertical bracing

53 C -28,C-29, vertical bracing

54 3rd Tier Erection of platform & stair case

59 Alignment, Bolt tightening, & inspection Left side

60 Alignment, Bolt tightening, & inspection Right side

61 Alignment, Bolt tightening, & inspection Front side

64 C-1,C-2,C-6,C-7 & connecting beam

65 C-10, C-11, Vertical Bracing

66 C-4,C-5, C-8,C-9 & Connecting beam.

67 C-3,C-13, C-14 & connecting beam

69 C-25 , C-26 & vertical bracing

70 C-19,C-20,C-24 & vertical bracing

71 C -28,C-29, vertical bracing

72 4thTier Erection of platform & stair case

77 Alignment, Bolt tightening, & inspection Left side

78 Alignment, Bolt tightening, & inspection Rightside

79 Alignment, Bolt tightening, & inspection Frontside

82 C-1,C-2,C-6,C-7 & connecting beam

83 C-10, C-11, Vertical Bracing