Annexure-IV

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PREFACE

This volume on storage instruction for the various Boiler and Auxiliary components is
our first attempt to bring about a concise booklet for us at site. It is possible that
some addition or deletion may have to be incorporated in this volume after receiving
feedback from various site wherein our erection works are in progress.

INDEX

A. Introduction

B. Material Control Procedure

C. Contractual Obligations

D. General

E. Storage Instructions for :

i) Machined surfaces

ii) Pressure parts

iii) Soot Blowers

iv) Piping

v) Oil Burners

vi) Fans

vii) Electrical and Instrumentation

viii) Structural components

ix) Air and Flue Gas Ducting

x) Refractory and Insulation

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STORAGE AND HANDLING INSTRUCTION

A. Instruction :

Boiler & auxiliary components are normally dispatched by road through trucks
and trailors.

In both the cases adequate material handling facilities have to be made

available at site so that unloading of the components and storing at the proper
place can be arranged. The storage of the components should be done
systematically so that components can be easily taken out (without disrupting
orderly arrangement of the other components stored in the neighborhood) .

Sufficient floor area for storage of various components shall be arranged.

Necessary planning to achieve these shall be done before commencing site
activities. Sufficient open storage space close to the boiler site and also close
to the pre-assembly yard shall be provided with adequate facilities for handling
and movement of the materials. In addition semi-covered and covered sheds
shall also be provided adequately to protect the equipments / components that
need protection from rain and sun.

B. Material Control Procedure :

Efficient handling of material in the field will result in lower erection cost.
Erection in-charge is responsible to the material control procedure. The basic
responsibilities are :

Receipt of material, Proper storage, Preservation and feeding for erection work
without hold up.

C. Contractual Obligation :

In case of turn-key contracts the responsibility of material control procedure is

of erection in-charge . In case of supervisory contracts, the responsibility of
employing suitable personnel for handling and storage of boiler material falls
within the scope of customer. Erection in-charge is responsible to guide the
customer .
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In both the cases erection in-charge shall have adequate space to have
access for inspecting the storage of various components and physically carry
out inspection.

An efficient and successful storage will be possible only with the whole hearted
co-operation from the customer.

D. General

No matter whether in a particular site a contract is on a turn key basis or on a

supervisory basis it should be ensured that the person in charge of store
keeping and material control are fully aware of the procedures for handling and
storages of the equipment / components . Apart from the procedures laid out,
suitable additional instruction may be evolved at site in the following manner :

1. Handling as per instruction

2. Proper storage and identification
3. Periodical inspection for longer period of storage
4. Special instruction for storage of consumables, boiler components,
accessories and equipments to be followed.
5. Procedures to be observed specially in the form of dos & dont.
6. Effective safeguard against pilferage specifically for easily removable
attractive parts.

Preparation of open storage area :

Ground condition, level, drainage facilities, access roads for cranes , trucks etc.
and lighting arrangements to be made.

Preservation :

i) Painting of rusted surfaces

ii) Greasing of machined components
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E. STORAGE INSTRUCTIONS :

1. Machined Surfaces Protection :

All machined parts of the boiler need protection during storage and
erection (Tube ends, nipples should have protection cover attached).
(As soon as end covers are removed for erection the surfaces should
be cleaned by blowing compressed air.) Machined surfaces of rotating
machinery shall be protected by observing storage procedure given by
the manufacturer. Generally all machined parts should be kept in closed
shed only like shafts, couplings, bearing, housing etc.

2. Pressure Parts :

Details of pressure parts

i) Drum
ii) Water walls
iii) Superheaters
iv) Atemperators
v) Economisers

i) Boiler Drums

Drums are usually stored in open store. It is advantageous to store the drum in

as received packing.

The suspension rods and other components accompanying the boiler drum are

to be stored in open storage space.

ii) Water walls, superheater, economizer and other pressure parts :

The water wall components are sent to site in panels as well as individual tubes. The handling
should be done carefully to avoid damage to the panels and other pressure parts of the water wall
system.
Straight panels can be stored one over the other with maximum of three to
four panels but care should be taken to stack them properly so that the
panels are stored horizontally.
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Loose tubes and headers are to be stored in such a way that they are not in
contact with stagnant water or buried in ground.

The ends of all the uncovered tubes and stubs are to be closed with plastic end
caps and should be retained in position. Whenever an end cap is found to be
missing or lost, prompt replacement should be ensured.

3. Soot Blowers :

i) General :

After receipt of these components at site they have to be inspected for

correctness of quantity and the boxes have to be repacked once again. The
boxes can be stored in open yard in a leveled area, however, the boxes are to
be covered with tarpaulin during rainy season. Boxes can be stored one over
the other.

ii) Soot Blower Pipeline :

Storage and handling instruction for pressure parts in boilers will also to be
applicable for these pipeline.

4. Piping Group :

The following components in the piping group broadly consist of :

Pipes, tubes , bends, vessels, valves, fittings etc. The storage instruction for
most of the above components are also covered in the pressure parts system
coming in the boiler. Details of the vessels storage are as below : -

1. A thorough visual inspection of the components has to be carried out to

ensure that the components are free from apparent damages.
2. Slinging is never to be done on stubs.
3. Careful handling is essential to avoid repair to nozzle or stubs which
may get bent when the handling of the vessel is rough.
4. Storage of the vessel should be done in such a way that it does not
come in contact with stagnant water.
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5. Oil Burning System :

Equipment coming under oil system and oil burners consisting of :

Pumps, strainers, valves, to be stored under open storage space. Other terms
like motors, oil burners, gauges to be stored in semi covered space.

6. Fans :

The following important components go into the assembly of FD, ID and PA

fans.

i) Bearing and bearing housing

ii) Regulating vane assembly
iii) Impellers
iv) Impeller housing

i) Bearing and bearing housing should be stored in semi-covered

space. Rust formation on bearing or housing should not be allowed.
ii) All other parts can be stored in open storage yard. Tarpaulin to be
used for covering the items.

7. Electrical and Instrumentation :

The equipments coming under electricals and instrumentation comprise

mostly of the following :

i) Panels
ii) Cables, wires, copper tubes
iii) Control valves
iv) Motors, transmitters, Rectifiers, couplings
v) Junction boxes, cable glands, distribution boxes.
vi) Ammeters, volt meters
vii) Special instruments.
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i) Panels

Most of the panels are usually received with water proof packing in well crated
wooded boxes. As soon as the panels are received at site it is desired to open
fully and then inspect the panels. As soon as the inspection is completed, the
packing should be redone and stored in semi covered space.

ii) Cable , Wires, Copper tubes etc.,

As far as possible the cables, wires etc., shall be kept in a semi covered
storage space. The thermocouple compensating cables are to be thoroughly
lined with polythene paper and should be kept inside a box. The copper tubes
are preferably to be obtained in the form of coils and this should be kept inside
polythene packing.

iii) Control valves

Control valves are to be kept in semi covered storage space. They require
handling as per manufacturer instruction.

iv) Motors

It is to be stored under open storage space with polythene cover. Motors shall
be periodically checked for their external appearance and for their resistance
values.

v) Junction boxes

Junction boxes etc., should be kept in semi-covered storage space.

vi) Ammeters, Volt Meters

These are to be kept in covered storage space. The volt meters and
ammeters are to be inside cardboard boxes with sufficient polythene lining.

vii) Special Instruments.

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Apart from these general instruments other special instruments like sample
cooler instruments, water treatment plant instruments may also be available.
All these instruments are to be kept under closed storage space.

Some fragile equipments like air filter regulators, lubricants, filters etc., are not
only to be kept in covered storage space but also should be given suitable
packing so that entry of dust and water is prevented sand also breakages
avoided.

8. Structural Components

The components in the structural group broadly consist of the following :

Columns, Beams, Bracings, Bolts, Nuts, Stair Case and platforms, Floor grills,
Foundation Bolts etc.

a) Columns :
Columns are usually stored in open space. Other components shall not be kept
over the columns boxes.

b) Beams, Platforms etc.,

Beams, platforms, ladders, floor grills etc., are usually stored in the open
space.

c) Bolts, nuts etc.,

Structural components like foundation bolts, bolts and nuts are to be stored in
doors.

9. Air and Flue Gas Ducting

The components in the above flue duct broadly consists of the following :

Expansion piece, dampers, gaskets, asbestos, ropes, sheets etc.

i) Ducts
Air ducts, flue ducts etc., are dispatched as panels to be assembled at site and
some other are sent as assembled ducts.
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These are stored in the open space.

ii) Expansion Pieces & Dampers

Expansion pieces are usually sent fully fabricated and are stored in open
space.

iii) Gaskets, Asbestos Sheets etc.,

All these components are to be stored in closed storage space.

10. Refractory and Insulation Materials

Refractory materials and insulation comprise mostly of the following :

i) Refractory bricks
ii) Insulating bricks
iii) Calcium silicate
iv) Mineral wool mattresses
v) Aluminum sheet
vi) Castable Refractory

As far as handling is concerned, it is important to note that in all the cases

weather proof packing done it supplies should remain intact after handling. In
case of formed bricks and calcium silicate blocks rough handling might lead to
damages. Rough handling of aluminum sheet might result in scratches and
cuttings. Stacking of the bricks one over the other should be restricted to the
minimum to avoid damages. The same applies to stacking mineral wood
mattresses, castable refractories etc.

i) Refractory bricks

The refractory bricks corresponding to IS8, IS6 specification are of

silimnite quality . Careful handling is required to avoid breakages, as these
materials are quite fragile.
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In general open storage of the refractory brick is permissible without providing

any elaborate covered storages provided the bricks are kept under cover of
tarpaulins and also above the ground level with the help of wooden planks.
The bricks can be stacked to a height equal to times to their base width.

ii) Insulating bricks

They should be always stored in covered shed. Insulating bricks are porous in
nature and hence they should not be exposed to retain water or damp
moisture. Stacking height should be carefully decided to avoid damages.

iii) Calcium silicate

Calcium silicate should always be stored in covered space. Normally they are
received by packing in card board boxes. Stacking shall be restricted to the
strength of card board boxes.

iv) Mineral wool mattresses

It is absolutely essential that covered space shall be provided for storing the
mineral wool mattresses or mineral wool in loose form. The material shall not
be stored over damp floor but wooden planks with suitable thickness should be
provided over the floor before stacking of the mattresses is carried out .

In the case of mattresses, it is essential that the storing is such that the
shape of the mattress will not be affected. Towards this end, the storage height
in a single stack shall be restricted to 2 mattresses.

In case of bags containing loose mineral wool the height of the storage
shall be restricted so that the bags in lower layer will not get damaged by
tearing off.
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v) Aluminum Sheets :

Handling of Aluminum products shall be kept to minimum. Aluminum parts

shall be lifted ad placed (not dropped) when handled. Crating is suggested for
handling aluminum parts to avoid possible damages from slings, hooks, wire etc.,

During fabrication or erection the quantity of Aluminum removed from the

storage area should not exceed that required for one working day.

All aluminum parts should be protected from weld spatters, painting or other
activities which would be detrimental to the appearance of the completed unit .

vi) Castable Refractories

These are usually received in polythene lined gunny bags.

Castables are hydraulic setting . To protect them in storage before they are used,
primary precautions against easy ingress of water or moisture from air are required .
Normally, castables are not to be stored for longer periods and in humid
atmosphere .

a. Keep dry in storage

b. Store in a building or shed whose walls / floor are waterproof and built of
concrete / masonry.

c. The roof should be of reinforced concrete

d. The windows should be kept tightly shut.
e. The floor should be 15cm thick with concrete slab laid on a dry coarse of
soiling.