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Replace condenser components on boiler 13
Installation of the condenser and flye gas transfer for boiler 13
Installation of the condenser and flye gas transfer for boiler 13
1
Step 1 of 36
<p>Continuing on from previous project tasks with all systems locked out.</p>

Continuing on from previous project tasks with all systems locked out.

2
Step 2 of 36
<p>Complete this task with the CO2 manifold removed.</p>

Complete this task with the CO2 manifold removed.

3
Step 3 of 36
<p>Cross brace and improve the strength of the gantry.</p>

Cross brace and improve the strength of the gantry.

4
Step 4 of 36
<p>Prepare for the removal by moving the cable tray at the staging area for condenser removal and install. (CT electric required)</p>

Prepare for the removal by moving the cable tray at the staging area for condenser removal and install. (CT electric required)

5
Step 5 of 36
<p>Close off the condenser cooling water pipes at the newly installed butterfly valves and remove the pipe elbows that connect to the condenser</p>

Close off the condenser cooling water pipes at the newly installed butterfly valves and remove the pipe elbows that connect to the condenser

6
Step 6 of 36
<p>Utilize the crane service to attach to boiler 13 vertical stack and hold firm.</p>

Utilize the crane service to attach to boiler 13 vertical stack and hold firm.

7
Step 7 of 36
<p>Remove the required iron from the roof using all necessary safety and fall prevention equipment.</p>

Remove the required iron from the roof using all necessary safety and fall prevention equipment.

8
Step 8 of 36
<p>Remove the stack bracing at the underside of the shed roof.</p>

Remove the stack bracing at the underside of the shed roof.

9
Step 9 of 36
<p>Disconnect the CO2 butterfly valve from boiler 13 vertical stack.</p>

Disconnect the CO2 butterfly valve from boiler 13 vertical stack.

10
Step 10 of 36
<p>Unscrew all screws that attach the stack to the condenser hood.</p>

Unscrew all screws that attach the stack to the condenser hood.

11
Step 11 of 36
<p>Carefully raise the stack until the base of the stack is above the gantry horizontal beams.</p>

Carefully raise the stack until the base of the stack is above the gantry horizontal beams.

12
Step 12 of 36
<p>Place steel cross members under the stack and carefully lower the stack to rest on the cross members using the crane service.</p>

Place steel cross members under the stack and carefully lower the stack to rest on the cross members using the crane service.

13
Step 13 of 36
<p>Remove condenser hood using the gantry rollers and endless chain system.</p>

Remove condenser hood using the gantry rollers and endless chain system.

14
Step 14 of 36
<p>Disconnect the northern condenser and use the gantry rollers system to raise the condenser to the required height and then slew the condenser to the lowering area. Lower to the ground and remove.</p>

Disconnect the northern condenser and use the gantry rollers system to raise the condenser to the required height and then slew the condenser to the lowering area. Lower to the ground and remove.

15
Step 15 of 36
<p>Disconnect the south condenser and raise with the gantry roller system.</p>

Disconnect the south condenser and raise with the gantry roller system.

16
Step 16 of 36
<p>Remove the condenser feed pipe from the buffer cold pipe only if the boiler room draining step completely drains the boiler room. (test thoroughly prior to removal)</p>

Remove the condenser feed pipe from the buffer cold pipe only if the boiler room draining step completely drains the boiler room. (test thoroughly prior to removal)

17
Step 17 of 36
<p>If the removal of the condenser feed pipe from buffer is unsuccessful, utilize a 5th gantry roller system to perform a &quot;pass under&quot; technique to navigate the condenser around the buffer to condenser feed pipe.</p>

If the removal of the condenser feed pipe from buffer is unsuccessful, utilize a 5th gantry roller system to perform a "pass under" technique to navigate the condenser around the buffer to condenser feed pipe.

18
Step 18 of 36
<p>Lower the condenser to ground at the landing zone and remove from the area.</p>

Lower the condenser to ground at the landing zone and remove from the area.

19
Step 19 of 36
<p>Secure the northern flue gas transfer with the gantry roller system and tension slightly.</p>

Secure the northern flue gas transfer with the gantry roller system and tension slightly.

20
Step 20 of 36
<p>Cut off the north flue gas transfer from the boiler using the plasma cutter or oxy acetylene if needed.</p>

Cut off the north flue gas transfer from the boiler using the plasma cutter or oxy acetylene if needed.

21
Step 21 of 36
<p>Utilize the gantry roller system to slew the flue gas transfer to the lowering area. Lower the transfer to ground and remove from the area.</p>

Utilize the gantry roller system to slew the flue gas transfer to the lowering area. Lower the transfer to ground and remove from the area.

22
Step 22 of 36
<p>Perform the same procedure for the removal of the southern flue gas transfer.</p>

Perform the same procedure for the removal of the southern flue gas transfer.

23
Step 23 of 36
<p>Utilize the &quot;pass under&quot; technique if required to remove the southern flue gas transfer.</p>

Utilize the "pass under" technique if required to remove the southern flue gas transfer.

24
Step 24 of 36
<p>Connect the new southern flue gas transfer to the gantry roller system and raise to the required height. Move the transfer to position with the gantry roller system. Follow any necessary steps to locate the transfer.</p>

Connect the new southern flue gas transfer to the gantry roller system and raise to the required height. Move the transfer to position with the gantry roller system. Follow any necessary steps to locate the transfer.

25
Step 25 of 36
<p>Once the transfer is in place, fully weld the transfer to the boiler.</p>

Once the transfer is in place, fully weld the transfer to the boiler.

26
Step 26 of 36
<p>Repeat this process to install the northern flue gas transfer.</p>

Repeat this process to install the northern flue gas transfer.

27
Step 27 of 36
<p>Position the southern condenser at the lift staging area. Connect condenser to the gantry roller system and move the condenser to position using the &quot;pass under&quot; technique if required.</p>

Position the southern condenser at the lift staging area. Connect condenser to the gantry roller system and move the condenser to position using the "pass under" technique if required.

28
Step 28 of 36
<p>Repeat this process to install the northern condenser.</p>

Repeat this process to install the northern condenser.

29
Step 29 of 36
<p>Use the gantry roller system to install the twin condenser hood.</p>

Use the gantry roller system to install the twin condenser hood.

30
Step 30 of 36
<p>Utilize the crane service to lift the vertical stack and remove the cross bracing.</p>

Utilize the crane service to lift the vertical stack and remove the cross bracing.

31
Step 31 of 36
<p>Lower stack into hood and fix down with teks. Seal the join.</p>

Lower stack into hood and fix down with teks. Seal the join.

32
Step 32 of 36
<p>Bolt in the horizontal transfer to the CO2 butterfly valve.</p>

Bolt in the horizontal transfer to the CO2 butterfly valve.

33
Step 33 of 36
<p>Secure the vertical stack top bracing.</p>

Secure the vertical stack top bracing.

34
Step 34 of 36
<p>Re-install the removed roof iron.</p>

Re-install the removed roof iron.

35
Step 35 of 36
<p>Release crane service from the stack.</p>

Release crane service from the stack.

36
Step 36 of 36
<p>Install condenser feed pipes that were removed for the job along with the cable tray and any other obstacles that were removed that need to be re-installed.</p>

Install condenser feed pipes that were removed for the job along with the cable tray and any other obstacles that were removed that need to be re-installed.