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VERTICAL BENSON (VOTSG)

BENI SUEF│ BURULLUS│NEW CAPITAL - PROJECTS

EGYPT
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NEM INSTALLATION SEQUENCE

THE PROVIDED SEQUENSE AND PRE-ASSEMBLY STAGES IN THIS

PRESENTATION ARE NOT MANDATORY, BUT A RECOMMENDATION FROM
THE MANUFACTURER AND FOR REFERENCE ONLY.

ALL INFORMATION PROVIDED IN THESE SLIDES IS PRELIMINARY AND

SUBJECT TO FINAL ENGINEERING.
 INSTALLATION MAIN STEEL

The boiler main steel columns 2 till 9 are

delivered to site with the side wall casing
attached

8x Pre-assembled main steel columns

with casing panels per boiler

3
 ARRIVAL AT SITE OF PANELIZED
MAIN STEEL

4
 PANELIZED MAIN STEEL
INSTALLATION

5
 PANELIZED MAIN STEEL
INSTALLATION

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 PANELIZED MAIN STEEL
INSTALLATION

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 INSTALLATION MAIN STEEL

Install the boiler top girders for main

steel columns 2 till 9

8x top girders

Note :
Bolted connections for the main steel
No welding required

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 TOP GIRDER INSTALLATION

9
 INSTALLATION MAIN STEEL

Temporarily store the loose casing panels

by suspending these from the top girders

6 x loose casing panels

10
 INSTALLATION MAIN STEEL

Install the boiler main steel

columns for row 1 and 10

Install the horizontal bracings

11
 INSTALLATION OF THE
INTERMEDIATE CASING

Install the (temporarily suspended)

intermediate panels for the boiler
left and right side walls

12
 INSTALLATION UPPER SIDE
CASING PANELS

Install the upper side wall casing

panels

14 panels in total

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 WELD DETAIL FOR SIDEWALL
CASING

14
 COMPLETION OF MAIN STEEL
STRUCTURE

Complete the main steel

structure by installing the
remaining bracing and stiffener
connections

Note :
Except for the:
-front and rear top space (gray area)
-rear side lower section (gray area)

15
 INSTALLATION FRONT AND REAR
WALL CASING

Install the casing

panels for the front
and rear wall

16
 INSTALLATION FRONT WALL
CASING
The front wall
consists of 5 panels

Panels can be bolted

together for quick
installation

Final welding can be

done in a later stage

17
 INSTALLATION REAR WALL CASING

Rear wall constist of

6 panels

Panels can be bolted

together for quick
installation
Welding can be done
later

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 INSTALLATION REMAINING SIDE
WALL PANELS

Install the remaining 4

sidewall panels at
goalpost row 1 and 10,
connecting the sidewalls
with the front and rear
walls

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 BOILER REMAINING TOP CASING

Install the 4 top panels

front and rear side

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 TYPICAL INSULATION DETAILS
BOILER CASING
Apply internal insulation and liner sheeting to the boiler
casing

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 INSULATION INTERMEDIATE
CASING

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 INSTALLATION TOP PLATFORMS

During casing and

insulation works install
the:

 Remaining bracings
top side main steel
 Top platform

Note :
This ensures proper access
to the top of the boiler
during module loading

23
 GROUTING OF MAIN STEEL

Main steel needs to be

grouted prior to module
installation

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PREPARATIONS FOR MODULE

LOADING
 TYPICAL MODULE LIFT DURING
TRANSPORT

During transportation
the modules are lifted
using a lifting frame
connected to the module
tube plates

26
 MODULE PREPARATION ON SITE

The module is
placed on a low
truck or SPMT for
transportation to
the boiler

Module tarpaulins
removed

Headers secured
to prevent sagging

27
 STRAND JACK SYSTEM ARRIVAL ON
SITE

A hydraulic strand
jack system is used
to lift the modules
into position

28
 STRAND JACK PLACEMENT ON TOP
GIRDERS

Module strand jack

system consists of :

- 8x module strand
jacks (150T)
- 2x header strand
jacks (20T)

Module connection beams:

- 8x

Module header connectors:

- 2x

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 STRAND JACK PREPARATION

Strand jack system

placed on boiler top
girders

30
 STRAND JACKS ON TOP GIRDERS

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MODULE LOADING
 DRIVING FIRST MODULE INTO
POSITION

Drive the module into lifting position and remove the temporary
steel

Temporarily store the field installed baffles and sealing plates on

top of the module prior to lifting (done for logistical advantage)

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 MODULE LIFTING

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 MODULE LIFTING SEQUENCE

The boiler modules

are lifted per string

First the center module

strings are lifted:

 String Nr. 2 and 3

1 2 3 4 After that the outer

module strings are
lifted:

 String Nr. 1 and 4

35
 MODULE LIFTING SEQUENCE

36
 MODULE LIFTING SEQUENCE

37
 MODULE HEADER ALIGNMENT AND
WELDING

Align the modules and

the headers

Example of a Install the headers

header suspensions where
suspension applicable

Remove the
temporary header
lifting provisions

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 MODULE HEADER ALIGNMENT AND
WELDING

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 MODULE HEADER ALIGNMENT AND
WELDING

Weld all module

header connections

40
 BOILER INTERNAL PIPING

Install all boiler

internal piping, till
first circumferential
weld outside the
casing

41
 INTERNAL BAFFLING AND SEALING
PLATES

Install all HRSG internal:

 Side wall gas baffles

 Side wall sealing plates
 Sealing plates between modules
 Tube plate shoulders

Note:
All baffling and sealing plates were stored on top of the
module during lifting for easy handling

42
 INTERNAL BAFFLING AND SEALING
PLATES

Tube plate shoulder

(brown)

Side wall sealing plate

(light blue)

Sealing plate between

modules (purple)

Side wall gas baffle

43
 INTERNAL BAFFLING AND SEALING
PLATES

Install all HRSG internal:

 Hot box gas baffles

 Hot box sealing angles

44
 STAIR CASE

Install the HRSG staircase

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DRUMS AND HP SEPARATOR INSTALLATION

 DRUMS AND HP SEPERATOR
BOTTLE

Install the LP LP Drum

drum IP Drum

Install the IP
drum
HP separator
bottle
Install the HP
separator bottle

47
 DRUMS AND HP SEPERATOR
BOTTLE

IP and LP steam drum HP separator bottle

48
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EXTERNAL PIPING INSTALLATION

 REMAINING SECONDARY STEEL

Install the remaining

secondary steel, like
platforms, ladders and
supporting, except for the
blow down tank platform

50
 EXTERNAL PIPING

Start installation of the

boiler external piping

Note:
Piping installation is
executed in parallel with
the secondary steel
installation

51
 EXTERNAL PIPING

Installation of the boiler external piping

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INLET DUCT AND BOILER REMAINING CASING

 BOILER REMAINING CASING –
FRONT AND REAR SIDE

Remaining casing
front :
 2 panels

Remaining casing
rear :
 4 panels

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 BOILER BOTTOM INLET DUCT

Install the inlet duct

bottom panels :

 7 panels

inlet duct bottom side

55
 INSTALLATION OF THE INLET DUCT
BOTTOM PANELS

Install the inlet duct

bottom panels

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BLOW DOWN SYSTEM AND BLOW OFF PIPING

 BLOW DOWN TANK

Install the blow down tank including platform

underneath the inlet duct

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 BLOW OFF PIPING

Install the blow off piping and steam silencers

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OUTLET DUCT AND TRANSITION DUCT INSTALLATION

 PRE-ASSEMBLY OF THE OUTLET
DUCT

Pre-assemble the
vertical panels of the
outlet duct - right and
left side

Total nr. of panels 14x

61
 PRE-ASSEMBLY OF THE OUTLET
DUCT

• Pre-assemble
the outlet duct -
front and rear
side

• Total nr. of loose panels 8x

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 PRE-ASSEMBLY OF THE OUTLET
DUCT

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 PRE-ASSEMBLY OF THE
TRANSITION DUCT

The transition duct consists out of 4x 90° shells, which

are pre-assembled into one piece at ground level

The duct is rectangular on the bottom and round on the

top

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 OUTLET & TRANSITION DUCT
ASSEMBLY

Install the pre-assembled transition duct onto the pre-

assembled outlet duct

Complete all external insulation and secondary steel for

the assembly at ground level

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 FLUE GAS SILENCERS

Install the flue gas silencers on top of the main

steel girders

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 OUTLET DUCT

Install the pre-assembled

outlet duct (including
transition duct) onto the
HRSG main steel
structure

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 LIFTING OF THE OUTLET DUCT

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 STACK DAMPER

The stack damper is

delivered to site in two
pieces

Pre-assemble the stack

damper on the ground

After pre-assembly it
can be lifted on top of
the transition duct

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STACK INSTALLATION
 TYPICAL DELIVERY OF STACK
SHELLS TO SITE

The stack sections

come delivered to
site in transport
frames

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 PRE-ASSEMBLY OF THE STACK

The stack sections

are delivered in 90
degree shells

8 stack shells per

boiler stack

Pre-assemble the stack

into one or two liftable
parts

Complete all external

insulation and
secondary steel for the
assembly at ground
level

72
 INSTALLATION STACK

After pre-assembly
completion the stack
parts can be lifted
into position

73
 LIFTING OF STACK PART

Stack elevation
reached 60m

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INLET DUCT FRONT WALL

 THE INLET DUCT – FRONT WALL

Install the Inlet duct front wall

panels

 7 panels

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 FABRIC EXPANSION BELLOW

Install the fabric

expansion bellow
between the inlet
duct and the by-pass
stack

77
 PIPING PENETRATION BELLOWS

Install the fabric

expansion bellows for
all piping penetrations

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 CONSTRUCTION COMPLETED

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