Abstract:
An installation construction method is provided for boiler facilities in which the boiler facilities include a boiler building configured of a steel structure, a boiler main unit to be installed within the boiler building, various types of equipment to be installed to the boiler main unit, and accessory members which are accessory thereto. During construction of the boiler building, the various types of equipment and the accessory members are carried into the boiler building and installed.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates an installation construction method for boiler facilities, and particularly relates to an installation construction method for improving work efficiency and safety in the installation of the various types of equipment disposed within a steel structure building and accessory members accessory thereto. 
     2. Description of the Related Art 
       FIG. 19  is a schematic configuration diagram of a common boiler facility for electric power production. A boiler main unit  1  is disposed within a boiler building  3  configured of a steel structure  2  around and above, and is suspended from top girders traversing the top of the boiler building  3  by sling bolts. 
     Secondary air for combustion to the boiler main unit  1  is guided to a furnace combustion chamber with a burner, via a forced draft fan, an air pre-heater  5 , a wind box  6 , and so on forth. Also, coal fuel transporting air is guided from the air pre-heater  5  to a mill  8  via a primary air duct  7 . 
     Coal to serve as fuel is stored in a bunker  9 , and is supplied to the mill  8  while being measured by a stoker  10 , and is pulverized to a predetermined particle size. The fine powder coal generated at the mille  8  is supplied to the burner disposed within the wind box  6  through a fuel pipe along with the coal fuel transporting air, and is burned in the furnace combustion chamber. 
     The hot combustion gas generated by combustion in the furnace combustion chamber is then subjected to heat exchanges within an internal fluid flowing through a secondary superheater  11 , a tertiary superheater  12 , a reheater  13 , a primary superheater  14 , an economizer  15 , and so on forth, disposed within an air flue of the boiler main unit  1 . The combustion gas subjected to heat exchange passes through an economizer discharge gas duct  16 , a denitration device, the air pre-heater  5 , and an air pre-heater discharge gas duct  17 , and is externally discharged from the boiler building  3 . 
     On the other hand, water feed to the boiler main unit  1  is performed by water passing from a condenser outside of the boiler building  3  through a main water pipe to each of the heat exchangers such as the economizer  15 , where heat exchange creates high-temperature high-pressure steam, which passes through a main steam pipe and is guided to a high-pressure turbine outside of the boiler building  3 . 
     Steam from a medium-pressure turbine is guided to the reheater  13  via a low-temperature reheating steam pipe, and the reheated steam passes through a high-temperature reheating steam pipe and is guided to a low-pressure turbine outside of the boiler building  3 . 
       FIGS. 20 through 29  are schematic configuration diagrams for describing a conventional boiler facilities installation construction method. In these drawings,  FIGS. 21 ,  23 ,  25 ,  27 , and  29 , are views taken along line A-A in  FIGS. 20 ,  22 ,  24 ,  26 , and  28 , respectively. 
     As shown in  FIGS. 20 and 22 , first, a predetermined number of first-level steel columns  21  are erected, and between the first-level steel columns  21  are assembled first floor beams for a floor  22  and second floor beams for a floor  23 . Next, as shown in  FIGS. 22 and 23 , second-level steel columns  24  are erected upon the first-level steel columns  21 , and between the second-level steel columns  24  are assembled third floor beams for a floor  25  and fourth floor beams for a floor  26 . Next, as shown in  FIGS. 24 and 25 , third-level steel columns  27  are erected upon the second-level steel columns  24 , and between the third-level steel columns  27  are assembled fifth floor beams for a floor  28  and sixth floor beams for a floor  29 . Next, as shown in  FIGS. 26 and 27 , fourth-level steel columns  30  are erected upon the third-level steel columns  27 , and between the fourth-level steel columns  30  are assembled seventh floor beams for a floor  31 , eighth floor beams for a floor  32 , and top girders  33 , thereby completing construction of the boiler building  34 . 
     Subsequently, as shown in  FIGS. 28 and 29 , the top girders  33  are used to suspend the boiler main unit  35  from the top of the boiler building  34 . Also, ducts  36 , a bunker  37 , stoker  38 , fuel pipes  39 , soot blower  40 , various types of piping, cable tray  41 , railing, electric panel, and so on forth, are carried into the boiler building  34  from the sides, by crane, temporary monorail, chain hoist, and so on forth, and positioned and welded into plate, thereby completing installation of the boiler facilities. 
     With the conventional boiler facility installation construction method, the series of work from manufacturing the steel beams to installation on-site to construct the boiler building has been performed by a steel fabrication manufacturer. The ducts, bunker, stoker, fuel pipes, soot blower, various types of piping, cable tray, railing, electric panel, and so on forth, to be installed in the boiler building have been carried in and installed following completion of the boiler building. 
     Boiler facility installation construction methods are described in, for example, Japanese Unexamined Patent Application Publication No. 07-091603, Japanese Unexamined Patent Application Publication No. 08-114302, Japanese Unexamined Patent Application Publication No. 08-261405, Japanese Unexamined Patent Application Publication No. 11-211003, Japanese Unexamined Patent Application Publication No. 2002-098304, and Japanese Unexamined Patent Application Publication No. 2002-213707. 
     With such conventional boiler facility installation construction methods, ducts, bunker, stoker, fuel pipes, soot blower, various types of piping, cable tray, railing, various types of electric equipment such as electric panels, and so on forth, and accessory members accessory thereto, were carried in and installed following completion of the boiler building. 
     Accordingly, ducts, piping, and the like, were carried into the boiler building from the side thereof as duct panels, piping pieces, and so on forth, in relatively small sizes, to facilitate carrying into the assembled boiler building, by crane, temporary monorail, chain hoist, and so forth. 
     This means that the work of carrying in and installing various types of equipment and accessories is concentrated in the period following completion of the boiler building, leading to problems in that all work regarding ducts, piping, and so forth, is high-place work, meaning deterioration in work capability, and in that work within a limited space means work is restricted, requiring a longer construction schedule, and further that the amount of high-risk work at high places is great, leading to higher construction costs, and increased risk of workplace accidents. 
     Also, with arrangements wherein multiple members are combined to form a unit, and these are hoisted above the installation location using a crane and the lower for installation, already-assembled beams and columns and the like tend to interfere with carrying in and installing the units. 
     SUMMARY OF THE INVENTION 
     The present invention has been made to solve the aforementioned shortcomings of conventional methods, and accordingly, it is an object of the present invention thereof to provide an installation construction method for boiler facilities with high work efficiency. 
     According to an aspect of the present invention, with an installation construction method for boiler facilities in which the boiler facilities include a boiler building configured of a steel structure, a boiler main unit to be installed within the boiler building, various types of equipment to be installed to the boiler main unit, and accessory members which are accessory thereto; during construction of the boiler building, the various types of equipment and the accessory members are carried into the boiler building and installed. 
     Floor units, having at least floor beams and a floor, assembled beforehand within a hoisting limit load of a crane, may be carried in and installed in parallel with construction of the boiler building. 
     Tie-ins for tying in to tie-in portions of the boiler building may be provided to the floor units. 
     A duct block, having at least a duct casing panel, internal support, and a damper, assembled beforehand within a hoisting limit load of a crane, may be carried in and installed in parallel with construction of the boiler building. 
     Thermal insulation and cladding sheets may be installed to the duct block beforehand. 
     A fuel pipe block, having at least a fuel pipe and a supporting device thereof, assembled beforehand within a hoisting limit load of a crane, may be carried in and installed in parallel with construction of the boiler building. 
     Piping, fabricated so as to be within a length to allow for transportation from factory to the site, is carried in and installed in parallel with construction of the boiler building. 
     A piping skid, integrally linking at least piping and a valve, may be carried in and installed in parallel with construction of the boiler building. 
     A bunker block, in which component parts of a bunker are assembled in a ring-like form beforehand within a hoisting limit load of a crane, may be carried in and installed in parallel with construction of the boiler building. 
     A floor unit integral article, configured by the floor unit and at least one of the various types of equipment and accessory members accessory thereto being assembled beforehand within a hoisting limit load of a crane, may be carried in and installed in parallel with construction of the boiler building. 
     The boiler building may be constructed in the shape of a box with one side opened when viewed from above so that one side of the boiler building forms an opening, with the boiler main unit being placed inside the boiler building through the opening and installed therein. 
     With the present invention, as described above, the various types of equipment and accessory members to be installed within the boiler building are carried in and installed while building the boiler building, so the columns and beams of the boiler building pose little obstruction, and accordingly the various types of equipment and accessory members can be easily carried in an installed. Also, construction of the boiler building and carrying in and installation of the various types of equipment and accessory members are performed in parallel, thereby improving work efficiency. 
     Moreover, a great part of the various types of equipment and accessory members to be installed within the boiler building can be assembled near the ground rather than at high places, and can be directly assembled by crane as with the steel structure, so work safety can be improved, and costs can be reduced due to standardization of work amount during the construction schedule and improved work efficiency. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic configuration diagram for describing the boiler facilities installation construction method according to an embodiment of the invention; 
         FIG. 2  is a view taken along line A-A in  FIG. 1 ; 
         FIG. 3  is a schematic configuration diagram for describing the boiler facilities installation construction method according to an embodiment of the invention; 
         FIG. 4  is a view taken along line A-A in  FIG. 3 ; 
         FIG. 5  is a schematic configuration diagram for describing the boiler facilities installation construction method according to an embodiment of the invention; 
         FIG. 6  is a view taken along line A-A in  FIG. 5 ; 
         FIG. 7  is a schematic configuration diagram for describing the boiler facilities installation construction method according to an embodiment of the invention; 
         FIG. 8  is a view taken along line A-A in  FIG. 7 ; 
         FIG. 9  is a schematic configuration diagram for describing the boiler facilities installation construction method according to an embodiment of the invention; 
         FIG. 10  is a view taken along line A-A in  FIG. 9 ; 
         FIG. 11  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 12  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 13  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 14  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 15  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 16  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 17  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 18  is a perspective view illustrating the state of installing the boiler facilities according to the embodiment; 
         FIG. 19  is a schematic configuration diagram of the boiler facilities; 
         FIG. 20  is a schematic configuration diagram for describing a conventional boiler facilities installation construction method; 
         FIG. 21  is a view taken along line A-A in  FIG. 20 ; 
         FIG. 22  is a schematic configuration diagram for describing a conventional boiler facilities installation construction method; 
         FIG. 23  is a view taken along line A-A in  FIG. 22 ; 
         FIG. 24  is a schematic configuration diagram for describing a conventional boiler facilities installation construction method; 
         FIG. 25  is a view taken along line A-A in  FIG. 24 ; 
         FIG. 26  is a schematic configuration diagram for describing a conventional boiler facilities installation construction method; 
         FIG. 27  is a view taken along line A-A in  FIG. 26 ; 
         FIG. 28  is a schematic configuration diagram for describing a conventional boiler facilities installation construction method; and 
         FIG. 29  is a view taken along line A-A in  FIG. 28 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Next, an embodiment of the present invention will be described, with reference to the drawings.  FIGS. 1 through 10  are schematic configuration diagrams for describing the boiler facilities installation construction method according to the present embodiment. In these drawings,  FIGS. 2 ,  4 ,  6 ,  8 , and  10 , are views taken along line A-A in  FIGS. 1 ,  3 ,  5 ,  7 , and  9 , respectively. Also,  FIGS. 11 through 18  are perspective views illustrating the state at the time of installing the boiler facilities. 
     First, as shown in  FIGS. 1 and 2 , a predetermined number of first-level steel columns  21  are assembled, and in conjunction therewith, a first floor unit  45  is disposed between the first-level steel columns  21 .  FIG. 11  illustrates the state of assembling the first-level steel columns  21  by a crane  46 . 
     The steel structure is made up of columns and beams, which are fastened at the joints thereof with, for example, L-shaped fasteners and bolts. The columns are vertically divided in to multiple sections, and are assembled on-site for use. Floors are laid on steel beams, and are configured of floor beams, grating, checker plate, or the like, each fixed by welding. 
     A floor unit has at least floor beams and a floor, and has been assembled beforehand, taking the hoisting limit load of the crane into consideration. Tie-ins are provided to the floor unit to facilitating tying in with the steel beams and columns. The tie-ins are used to dispose the floor units between the steel columns on each level. 
     A duct block  47 , fuel block  48 , cable tray  49 , mill, and so forth, are carried in above the first floor unit  45 , and installed. The duct block  47 , fuel block  48 , and cable tray  49  may be carried in separately from or together with the first floor unit  45 . For example, an arrangement wherein the floor unit  45  and the duct block  47  are integrally formed and carried in, or wherein the floor unit  45  and the fuel block  48  are integrally formed and carried in, would have greater work efficiency. 
     Forming blocks such as the duct block  47  or the fuel block  48 , and integration thereof with the floor unit  45 , are performed nearby the installation site, or in a plant. 
     Rectangular ducts are formed of casing in a box shape, with supports provided inside the ducts and thermal insulation and cladding sheets on the outside, and dampers and expansion joints provided along the way. Round ducts are formed of casing in a cylindrical shape, with thermal insulation and cladding sheets on the outside, and expansion joints provided along the way. 
     The duct block  47  has at least duct casing panels, internal supports, and dampers, and is configured beforehand in a block form so as to be within the hoisting limit load of the crane. 
     Fuel pipes are configured of straight piping, bent piping, joints for connection thereof, and supports for supporting these with the steel structure. The fuel block  48  has at least fuel pipes and supporting devices (supporting members) thereof, and is configured beforehand in a block form so as to be within the hoisting limit load of the crane. 
     A second floor unit  50  is assembled above the first floor unit  45 , with a duct block  47  and stoker  51  being carried in an attached.  FIG. 12  illustrates the duct block  47  and stoker  51  being installed using multiple cranes  46 . 
     Next, as shown in  FIGS. 3 and 4 , second-level steel columns  24  are erected, with a third floor unit  52  and fourth floor unit  53  being disposed between the second-level steel columns  24 , and also a bunker cone block  57 , piping  55 , soot blower  56 , and so forth, being carried in and installed. 
     The bunker block  54  (the bunker cone block  57  and later-described bunker cylinder block  60 ) has been assembled beforehand in a ring-like form, taking the hoisting limit load of the crane into consideration. 
     The piping  55  is in a long shape, fabricated so as to be within a length that would allow for transportation between the factory and the site. 
       FIG. 13  illustrates the state of installing the bunker cone block  57  using multiple cranes  46 . The boiler building  34  is in the shape of a box with one side opened when viewed from above until the boiler main unit  34  is strung within, so cranes  46  can enter the inside of the boiler building  34  being built as shown in the drawing, and can carry in equipment such as the bunker cone block  57  and so forth. 
     Next, as shown in  FIGS. 5 and 6 , third-level steel columns  27  are erected, with a fifth floor unit  58  being disposed between the third-level steel columns  27 , and also piping  55 , soot blower  56 , and so forth, being carried in and installed. 
     A sixth floor unit  59  is assembled above the fifth floor unit  58 , with a piping skid and bunker cylinder block  60  and the like being carried in and installed. The piping skid is configured of integrally linking at least piping and valves. 
       FIG. 14  illustrates the bunker cylinder block  60  being installed using multiple cranes  46 . At another place, a fifth floor unit  58  is being installed using a crane  46 . 
     Next, as shown in  FIGS. 7 and 8 , fourth-level steel columns  30  are erected, and following piping  55  and the like being carried in and installed, a seventh floor unit  61  and eighth floor unit  62  are disposed between the fourth-level steel columns  30 , and also top girders  33  and the like are carried in and installed. 
       FIG. 15  illustrates a state of using a crane  46  to install the floor beams of the eighth floor unit  62 , while installing piping  55  with another crane  46 .  FIG. 16  illustrates a state of using a crane  46  to install the top girders  33 , and  FIG. 17  illustrates a state of installing ceiling beams  63  near the top girders  33 . Thus, construction of almost all of the boiler building  34  is completed, and also, carrying in and installation of almost all of the equipment to the boiler building  34  is completed. 
     As shown in  FIGS. 9 and 10 , the boiler main unit  35  is inserted from a rear opening portion  64  of the boiler building  34  (see  FIG. 10 ), the boiler main unit  35  is jacked up to a predetermined height using jacks, and is suspended from the top girders  33  by sling bolts. Other equipment and accessories and the like which could not be carried in parallel to construction of the boiler building  34  can be carried in and installed following completion of the construction of the boiler building  34 . 
       FIG. 18  illustrates a state of installing the air pre-heater discharge gas duct  17 , air pre-heater  5 , economizer discharge gas duct  16 , and so forth, following installing the boiler main unit  35  (not shown). Thus, installation of the boiler facilities is completed. 
     While the mill  8  and bunker  9  and the like are exemplarily described as being installed to the front of the boiler building  34  in the above embodiment, these may be disposed to the sides of the boiler building  34 .