Heater Erection Procedure.pdf

5/19/2018 Heater Erection Procedure.pdf

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CONSTRUCTION EXECUTION &

ERECTION PLAN


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PROJECT CONSTRUCTION EXECUTION PLAN INDEX

1.0

Purpose

2.0 Description of Project

3.0 Pre-Erection Procedures

4.0 Erection Procedures

1.0

PURPOSE

1.1 The purpose of this Erection Plan is to establish the construction philosophy and

plan of execution such that all work will be completed in accordance with the

requirements of the Quality System program for the project. These guidelinessuggest a general installation erection procedure, organization, construction

schedule, execution strategy, project controls, Construction Quality Program,

Safety, Health and Environment Program, transportation and liftingrequirements, temporary facilities and responsibility for construction

completion.

2.0

DESCRIPTION OF PROJECT

2.1 The Hot Water Heaters, are to be fabricated in ...................

2.2 The heaters are a vertical cylindrical type consisting of a vertical radiant section,horizontal process convection section, transition section and a stack. The

process coil in the radiant section and the process convection coil are in a (4)

pass arrangement.

2.3 The heater is provided with (4) natural draft burners.

2.4 The radiant coil is supported from the top of the coil bundle with tube hangers.

The process convection tubes are supported at each end by the tube sheets.

2.5 The heater is provided with castable refractory (or equal) on radiant floor,

convection walls, radiant walls, stack and arch .


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3.0

PRE-ERECTION PROCEDURES

3.1 This procedure covers the construction and erection of pre-fabricated panels &

modules for Hot Water Heater,

3.2

On receipt of all material and components, care shall be taken to ensure thatthose items listed in the shipping documentation are in fact those which were

received and that all deficiencies and defects are reported immediately to Born

Inc. for verification and immediate action.

3.3 Before arrival of the equipment on site, sufficient area around the heater

foundations must be cleared and leveled for the temporary storage of pre-fabricated components prior to erection and for the positioning and movement

of lifting equipment.

3.4 These are suggested erection procedures, but it is ultimately the responsibility of

the client to ensure the heater package and equipment has been assembledcorrectly.

3.5 Site preparation is the responsibility of and performed by the client.

3.6 Lifting equipment to be used during erection of the heater must have theappropriate certification. It is recommended to erect scaffolding at all stages of

the erection and to modify scaffolding as required as erection takes place.

3.7 Locate the 8 lb/ft3(128 kg/m

3) ceramic fiber blanket insulation. Use this

material to make batons to be placed between the major components of the

heater. Refer to drawing D-3072-1A for examples of batonlocations/installations. Not all locations are shown. Avoid ceramic fiber

blanket between steel members of joints so as to maintain metal-to-metal

contact.

3.8 All weights and dimensions of the heater components can be located onshipping drawing, .

4.0

ERECTION PROCEDURES

4.1 The site must be prepared, leveled, surveyed and compacted with foundationsready for assembly and erection. The client is to provide sufficient laydown

area and some warehousing for storage of all components.

4.2 The client should check that the height and orientation of the piers are correct

and that bench marks if any, are clearly marked by the client for this purpose.

The tops of the foundation should be prepared for installation of the heater.


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4.3 Prior to erection of the heater, the foundation should be previously poured and

properly cured with all anchor bolts set per drawing Loading Diagram andAnchor Bolt Layout.

4.4 The radiant shell is fabricated in (6) sections with refractory installed. The

radiant tubes which are fabricated in (4) sections. Each panel and bundle

section should be erected based on individual identification.

4.5 It is the clients responsibility to ensure sufficient metal shims using the largest

size possible have been installed and leveled on the top of the foundations forrequired elevation. Shims should be sized to ensure maximum area coverage.

Grout thickness should not exceed 1. (Normal thickness of grout is 1 inch).

4.6 The convection section will be fabricated and shipped complete with all

refractory, coils and header boxes fitted. They will have flanged inlet & outlet

connections.

4.7

For weights and dimensions see shipping data drawing . Do notremove any internal shipping braces (painted yellow) until the heater has beensatisfactorily erected and secured or until instructed to do so.

4.8 Component mark numbers, elevations, orientations and bolting requirements are

given on drawing.

4.9 Lifting lugs are provided which are of an appropriate type and suitable for

attachment. Refer to drawing for lifting point spacing and weights. Company

does not recommend using alternate lift points for erection of any section of

the heater other than specified by Born Inc.

4.10 Place base plates on top of the piers. Install nuts to anchor bolts

and hand tighten to temporarily secure.

4.11 Prepare the bottom of each column of heatersand the base plates . The base plate welds are shown on drawing .

4.12 With the primary crane securely attached to the top lifting points of radiant

panel and a secondary crane securely attached to the tailing lugs, remove thebanding fastening the panel to the shipping saddles.

4.13 Place the radiant panel on top of the base plates on the piers. Check to ensurethe orientation and base plate alignment is in accordance with drawing . Once

the panel is properly aligned, tack weld the columns to the base plates. See

drawing .....column and base plate orientation.


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4.14 Before removing the primary crane, tie the panel off in each direction to ensure

stability while erecting other panels.

4.15 Prepare and position CFNB batons for the joint between the radiant panels.Avoid ceramic fiber blanket between steel members of joints so as to maintain

metal-to-metal contact.

4.16

Repeat installation of the radiant panels in either direction from the first panel.

Each panel shall be secured and bolted together with the specified field bolts.With the large number of holes that must align, it is recommended to get all of

the panels and floor sections in place before installing and tightening all of the

connecting bolts.

4.17 Prepare and position CFNB batons for the joint between the radiant panels andthe floor sections. Avoid ceramic fiber blanket between steel members of joints

so as to maintain metal-to-metal contact.

4.18 Install the floor sections the bolts

indicated on drawing . The floor sections can be lifted up and lowered intoplace from the top of the radiant section. Care should be taken so that shop

installed castable refractory is not damaged during installation. Temporary

supports should be provided for the floor sections toward the middle of theheater.

4.19 Install radiant tube supports using provided hardware as shownon drawing.

4.20 Hand pack space around supports with provided castable refractory.

4.21 Make sure the radiant section is level and plumb and corresponds to the proper

elevations and orientations. Tighten all anchor bolts. Install and tighten any

connecting bolts between panels and floor sections. Weld the columns to thebase plates as shown on drawing . Please note that the main columns are back

to back channels and care should be taken when welding the 1stchannel not to

interfere with the placement of the 2nd

channel in the back to back pair.

4.22 Install grout under heater column base plates. Grout should be poured tomaximum of 1 thick. See drawing for anchor bolt and grout details.

4.23 Install observation doors (4 places) as shown on drawing .

4.24 Prior to installing the radiant bundles remove flange stubs as indicated

4.25 Using drawings the radiant bundles can now beinstalled. Lift the section from horizontal to vertical. With a separate crane

attached to the shipping steel, cut the shipping steel to remove it from thebundle. It is critical that the bundle is not damaged in this process.


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4.26 With the bundle section now free of shipping steel, lower the section into the

radiant section so that it rests on the tube supports. Repeat this process foreach bundle section. Use drawing to confirm orientation and location of each

bundle section. Connect each bundle section to the adjacent bundle sections as

shown .

4.27

Using drawings reattach the pipe flange stubs tothe radiant coils and test as required.

4.28 Installation of the tube skin thermocouples can be done once the bundles are in

place. One thermocouple is required per pass, four are required in the radiant

section.

4.29 Once all work previously described has been completed, hoist the arch centerinto place on top of the radiant section. Confirm the correct orientation per

drawing . Secure the arch to the radiant section with the required field bolts.

Note: locations requiring A-325 bolts as indicated on dwgshall be confirmed.

4.30

Remove arch doors from arch sides. Hoistthe arch sides into place on top of the radiant section. Confirm the correct

orientation per drawing . Secure the sections to the arch and to the radiantsection with the required field bolts.

4.31 Hoist the arch doors into place on top ofthe arch sides. Confirm the correct orientation per drawing . Secure the

sections to the arch and to the radiant section with the required field bolts.

4.32 Prepare and position CFNB batons for the joint between the arch andconvection section. Avoid ceramic fiber blanket between steel members of

joints so as to maintain metal-to-metal contact.

4.33 Prepare the lower convection box to be hoisted into place on topof the arch. Use a lifting frame or spreader beams to ensure the lift direction is

always vertical at each lift lug. Lift the convection section using the four lift

lugs provided. Please note: the lifting lugs on the header boxes are for headerbox removal only, not for erection. Correct orientation should be verified per

drawing .

4.34 Secure the convection box to the center arch using the field bolts provided.

4.35 Prepare and position CFNB batons for the joint between the convection and

transition sections. Avoid ceramic fiber blanket between steel members ofjoints so as to maintain metal-to-metal contact.

4.36 Install the transition and secure it to the convection section withfield bolts provided. Check that orientation is per drawing .

4.37 Prepare and position CFNB batons for the joint between the transition and stacksections. Avoid ceramic fiber blanket between steel members of joints so as to

maintain metal-to-metal contact.


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4.38 Prepare the stack . The stack is to be lifted using one crane on topand one crane on the bottom for tailing. Install the stack section to transitionwith field bolts provided. Confirm the correct orientation per drawing . Note:

locations requiring A-325 bolts as indicated on dwgshall be confirmed.

4.39

Fit-up flanged crossoversas shown on drawing . See notes on drawing for bolts and gaskets.

These crossovers connect the convection outlets to the radiant inlets.

4.40 Install seal boots to the openings around the process piping. See drawingfor location. Wrap the large end of seal boot around the flange on opening

in the heater wall. Compress the hook & loop seam in the seal boot starting

at the large end and continuing to the small end. Install the provided

stainless steel clamps to both ends to complete the installation.

4.41 Locate and install the required natural draft burners. Please refer to burner

manufacturers operating and installation instructions. See drawing fororientation.

4.42 Install ladders, platforms and handrails per dwgand referenced drawings.

4.43 Upon completion of each section the heater should be trimmed and fully sealed.All doors shall be verified to be installed and sealed.

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Heater Erection Procedure.pdf