JPRS ID: 8457 TRANSLATIONS ON USSR RESOURCES

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• Collection: JPRS
• Document Number (FOIA) /ESDN (CREST): CIA-RDP82-00850R000100050028-5
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• Document Page Count: 39
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JPItS L/8457
14 May 19 79 I
~
T RANS lAT I 0NS ON USS R RESO ~'J RCES
(FOUO ll/79)
, ~
_ U. S. JOINT PUBLICATIONS RESEARCI~ SERVICE
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_ mation was summarized ur exCracted.
Unfamiliar names rendered phoneCically or transliterated are
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JPRS L/8457 .
~4 May ~979
TRANSLATIONS ON USSR R~SOURCES ~
- (FOVO i~/~9)
CONTENTS PAGE.
ELECTRIC POWER AND POiWER EQUIPMEI~r
Engineering Equipment Changes in Flektrostroypodstautsii
Trus~ ~
(M. S. (~rabel.~kovekiy; ENERaETICgESKOYE STROT:TEL'STVO,
~ 79) ~
Znstallation of Zndustrial Fc~uip~ment oP Berezovskaya aRES-1 ~
(M. Ya. Borts; II~'ERQETIC~SKOYE STROITEL~S~.'Y0, Mar 79) 9
_ ~a~ures of P-67 Boiler of an 800 NW Power Block ~f
Berezovskaya (~RES-1
(Yu. D. Sologub, et al.; ENE~taETTCF~SKOYE S~tOITEL'3TV0,
~ 79) 2~
FUEIS AND RELAiED EQvIPNIE[V'~'
Methods for Coping With Oil and Gas Spouters, Well Fires
Told
(FORMIltOVA1vIYA GRAZ~ANSKOY OB~tONY V BOR~BE SO
sTIK~IYriYI~ BEDSTVIYAM[, 1978) 30
- a - ~III - USSR - 37 FOUOJ
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~LECTRIC POWER AND POWER EQUIPMENT
UDC 62]..311.4.002.2:65.027
ENf~INEERINC~ EQUIPMENT CFiANt~EB IN ELEKTROSTROYPODSTANTSTI TRUST
Moecow ENERGETICHESKOYE STROITEL'STVO in Rusaian No 3, Mar 79 pp 20-23
(Article by eng~.neer M.I. Grabel~kovskiy]
(TexC] The Elektroatxoypodstanesii [ElecCrical Substation Conatruction
Adminiatration~ trust, created in 1966, is a large apecialized entarprise
which consCructs 110 - 750 kilovolt substatione in Moscow, Che Moscow
oblase, as we11 ae in eight oblasta in the European part of the USSR
(Bryanak, Orlov, Kurak, Belgorod, Lipetsk, Kalinin, Ivanovo and Tambov).
The volume of construction and inatallation work performed over 10 years
(1967 - 1977) has grown from tl.l up to 22 miliion rubles. A11 of the w~ork
at construction sitee~ (with ~he exception of electrical installation and
communications facilitiea) for 220 KV and higher subatations Was carried
out by the truat usina its own personnel: in 1978, the vol~�~a of construction
and installation work amounted to 2.4 million rubles, and 3.2 million KVA of
tranaformer capacities were placed on line.
The performance of such volumes of work requires the refinement and even
a fundamental change in the existing eystem for material and technic$1
supply.
In the USSR Ministry of Energy, special attention is being devoted to the .
' question of providing construction with prefabricated high quality induatr.ial
material xesources: a large capacity base has been created for the cAnstruc-
tion industry, which is being periodically expanded, and administrations have
also been creaCed for the centralization and distribution ~f material re-
sources (~nergostroykomplektateiya, Energozhilkamplekt, fnergotekhkrnnplekt,
etc.), and progressive structural designs and materials are constantly being
introduced into production; the "Temporary Technical Specifications for the
Comprehensive Supply of Steel Reinforced Concrete Structures to the Enter-
prises of the Main Power Engineering Construct{on Industry Administration"
have been approved, and a number of other measures have been implemented,
Which have specifically improved the matertal and technical supplq system.
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Moreover, at tihe pregent time given the large number of auppliers and ehe
diversiCy of e~ructuYes, ma~erials, equipment and produc~s, ~.t ie an ex-
tremely complicaCed maCCer Co provide for their comprehensive supply, and
someeimes, even impossible. The Tndustirial ProducCion Comprehena3ve Sup-
port Adminis~rarion ~U~TK) was creaCed for Chis purpose in the Crust 3n �
1973.
The tasks, obligations and righ~s of the UPTK, as well as the forma of its ~
interrela~ionships with Che aubdivisions of ~he ~rust w~re defined by the
"Temporary S~a~ute", as well as by a special direcCive for the ~ruet.
The primary task of the UPTK is the improvemenr of the existing material
and equipment supply sys~em.
The following basic factors were taken into account in working out the
organizational structure of the UPTK: apecialization (a territorial criCer-
ion), the volume of work being performed, the numbsr of existing subdivi-
sions and ~heir dislocation, the current and long term plans for the con-
struction of facilities, etc. Taking into account Chat presenCed here, a
combined adminis~ration sysCem for comprehensive equipment package supply,
a centralized and decentralized system, was adopCed.
, A11 forms of steel reinforced concrete, concrete, metal. and other structures
and the baeic ma~erials for facilities being built izl Moscow and in the Moscow
oblast are su~plied in a centralized manner by motor vehicle transportation
- fzom the comprehensive producCion equipment package bases of the UPTK, which
are located in Noginsk, or depending on the remoteness of the facility from
, the base, located in Moacow. Non-metallic, bricks, readimiac concrete and
mortar, as well as separate materials, are trucked in a centralized fashion
�rom che suppliers. .
Only the suppliers provide the remaining facilities with all types of struc-
tures. The cargos arrive at the nearest railroad atations. The production
preparation B~cCions of the trust subdivisions are responaihle for their de-
_ livery directly to the construction s3.tes, moreover, these aectiona provide
the constructio.~ sltes with local constiruction materials, set aside through
the ~nicipal or ~~~last planning organizations. . ,
In accordance with thp products list approved by the trust, allocated sc,er.ce
materials are deli.vered only by the UPTK from its bases.
The following ma~or functions of the UPTK were defined in accordance with
Che reco~nendations ~f the Scientific Research Institute for Construceion
Economics of the USSR Gosstroy:
--The planning of material and equinment and supply in the trust, the
arrxval of complete industrial atructural packages, assemblies, parts, pro-
ducts, and materials at canstruction sites, the comprehensive supply of
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matieri~l and equipmene reaources to induatir~.al en~~rpYisea and o~h~r sub-
div~.siong of tihe rrus~, ~g we~.l gg rhe comprehen~ive ourput of produce~
by induatrial enterpr~.aea and the eranspor~a~ion eh~.pmenCs of atructures,
produc~s and ma~erials;
�--~Th~ oxganization of efficient mangemenC links to plants and guppliers and
supply-marketiing organizationa, decenCralized procurement and purchasing,
providing comprehensive indusCrial production packages, the arrival of com-
plete industrial s~ructural packages, assemblies, produces and maeerials
3,n accordance wiCh Che schedule Eor ~he execution of construction and inaeal-
lation work at each construc~ion e~.~e, centralized Cransportation ehipmenta
of structures~ assemblies, produc~s and ma~erials (where poasible, in con-
Cainers and packages) ~o ~he working area of the conatruction site, providing
induserial enterprises and other aubdivisions of the trust with ma~erials,
tools, equ~pmenC, eCc., and receiving and s~oring ma~erial and equipment re-
sources ar Che bases.
--1'he production of nonst~ndard and non-series-produced structures and pro-
ducts, increasing the construcCion readineas of materials, semimanufactures
and producta;
--Operational accounCing for and monitoring of the industrial supply packages
�or construction sites, the arrival of complete packages of strucCures and
products from plants and induatrial enterpriaes of the UPTK, the realization
of allocations and quotas, the movement of stocks, as well ae the utilizaeion
and sCorage of material and technical resources in all of,the trust subdivi-
sions;
--Operational regulation of the comprehensive industrial supply of construc-
tion sites with structures, products and maCerials, as we11 as the regulation
of transport shipments;
--Technical and economic planning, and the analysis of the production manage-
ment activity of the UPTK and its subdivisions;
-�-The organization and execution of the calculations for the comprehensive
package deliveries;
--Material incentives for the workers of the comprehensive industrial produc-
tion supply system;
--Economic s~netions for the violation of deadlines, volumes, the failure to
observe complete package supply and low quality of deliveries and shipments,
as well as for failure to meet other agreement obligations;
---The implementt~tion of statistical accountability for material and equipment
supply;
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-~-'~h~ plxnning and organ~.zati.on of ine~sures Co boosti Ghe e~ficiency of the
comp~ehensive ~.ndusCria~. produc~~on package supply sygCem~
The performance oE ~he enumerated Eunctions ig asaured by the operaCional
pzoduceion departmenC, ~he depar~menCs of comprehensive equipmenC packaging
and realizaCien, ~he economic pianning departmen~, as we17. as ehe bookkeeping
and flow 13ne producCion sec~ion~
Parricular atCenC~.on was devo~ed to the ~echn~.ca1 economic indicatora �or
the acriviry o~ ~he UPTK. ~rior ~o Che changeover of ehe CrusC and the UPTK
to the new system of planning and economic incen~ives, indicators were used
which did noC reflect ~he easence of the ac~ivitiy of Che comprehensive equip-
ment auppl}r organ~.zation~ Under Chese condi~ions, goods turnover (~arehouse
and CransiC), procurement and warehousing expenses, price markups, the person-
ne1 force and salary funde were a11 taken inCo account.
The indic~tora authorir.ed at the preaent time promote the ~xecution of Che
plan for conseruction and installation work and the t~nely placemenC of
trans~ormer capacities on-1ine, and permie the analysis and evaluation of
the activity of Che entire collective. At the same r_;me, these indicaCors
take into account the nature and specific features of the production manage-
ment activity of the UPTK.
Ttte trust approves the indicatora in the form of plan asaignments in eerms
of the ma~or activity (the volume of complete equipment packages being de-
livered to Che construction sites and the works stages being completed in
the planning period), in terms of labor (the overall annuai salary fund),
anc~ in terms of finances (the assignment for the reduction of the costs for
comprehensive induatrial production equipment package supply).
The basic indicator is the volume of complete equipment package deliveries.
It is directly related to the indicatox "volume of construction and instal-
lation work for the conatrucCion sites and work aCages, being compleCed in
the planning period and sub~ect to turnover to ~he customer" for the mechan- `
ical supply coll:mns and is respons3ble for the ma~or assigmaenC of the trust:
assuring the placement of ttie facilities on-line within the Flan peri~ds.
The outlay indicator for the comprEhensive ind~istrial production equipment
packages is a cost indicator which reflects the expenses of Che UPTK in
moving materials from the supplier to the construction site.
The use of structures with a high degree of plant readiness.and the necessity
o� making the deliveries in the form of complete industrial or supply sets
necessitated refinements in the warehousing and delivery system. Flow line
- (central and auxiliary) complete production package sections for a territory
- were organized for this purpose.
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The ~entr~l b~se o� rhe Elow 11ne producrion aection, which is locaeed in
Nog~.nak c~ose Co the moror vehicle transportae~.on en~erprise of the truat, ~
aon~is~g o� ~he �ollnwing complexes: a warehouse complex with a group for
putCing Cog~~her complete equipmenC se~s, con~ainerization and centralized
ghipmenCs; a produceion complex wi~h a group of ahops �or the fabrica~ion
o� nonsCandard (non-series-produced)~me~al struceures; sanitary engineering
~nd venti].aeion syaCeme af'a11 kinds. Moreover, included in Che complement
of the base are a mechanization section with a group for the operatiion and
rep~ir of machines and mechanisms, as we11 as a cons~ruction aubdivision for
the repair of buildings and atructurea.
An ~uxil~ary Cerritorial comple~e equipment packaging section, which is
1ocaCed in Moscow, provides for the reception and cenCrallzed delivery of
sets of ~teel reinforced concrete and metal sCructu~cea, supplied from the
plants o� the Main Power Engineering Tndus~rial ConsCrucCion AdminisCrar~~n
~nd Che Power ~ng3neering Steel SCructures Association.
Thus, the flow line production section is a multipurpose, highly mechanized
mana~ement unit, which performs the following funcCions Co ref ine rhe material
and equipmenr aupply sysCem for construction and the entire conatrucCion pro-
duction indus~ry as a whole:
--The concentraCion and ac~ive main~enance o~ the scarce materials being
allocated with their subsequent synchronized delivery to particularly im-
portant construcc~Ian sites, �igured on a per site, stage or construction
stnrr basis;
--The receiving, accumulation and combining into complete industrial sets
of various structures, and their centralized delivery to construction
- sites;
--The Fabrication of nonstandard (small series production) metal structures ~
with a weight of up to 50 kg, and their cenCralized delivery in containers
to construction sites; .
--The fabrication of components for sanitation engineering and ventilation
systems, noise suppression systems and their centralized delivery in compleCe
sets together with the equipment to the construction sites;
' --The organization of centralized shipments, using special rolling stock,
the container and pallet fleet, and the execution of loading and unloading
operations;
--The control of residues of material resources, and assuring their preserv-
ation.
An important role in the UPTK is assigned to the system oE cenCralized ship-
ments of sCructures and materials from the production packaging basis to the
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coneCrucCton aiCea, ae we11 as from Che aupp~.ying planCs whiah are located
in Moscow. The plan for centralized ehipmenCe is worked ouC for the plan-
ning year and approved by ~he ~rust. The monChly plans, which are coordi-
nared wi~h ~he consumere and the mo~or vehicle ~ranspor~a~~.on enCerprise
o� ~he CrusC, a~e approved byr CRe operaCional produc~ion deparCmenr of the
UPTK on Che Dae~.s oE ~he annual plan.
The ~ntiroducCion of ehe cen~ra].ized delivery systiem has permiteed a signif~
icant improvement in the utilization of motor vehicle transportation, as '
we11 as providing ~or a uniform ~echnological flow of material resourcea,
the implementaCion of special3zaCion oF moCor vehicles, and improving the
system o� accoun~ing for, moni~oring and the mu~ual reaponsib3lity of ~he
subdivisions which carry ou~ the cona~ruc~ion.
B1111ng calculations between the UPTK, suppliers and subdivisions of the
truat are alao of no small importance. In thia regard, a decision was made
to introduce a ei~gle payer (the UPTK) for ehe complete seta of etructures
and basic materials being supplied, eamething which simpli�ied the account-
ing syaCem. Moreover, this has permi~~ed having an oper~tionally ~imely
influence on the system of deliveries, and controlling their flow.
However, it is necessary Co assure the permanent raolvency of the UPTK to
further re�ine the sysCem of technical and ma~er~al supply.
In Che opinion of the author, the most practical approaches to the solution
of this problem are as follows:
--Transfer the current account of the UPTK a portion of the totals
set aside by the buyers in the form of a~lvance payments to the subdiviaions
for the stages of the work being performed, with the subsequenC liquidation
of these totals by the suppliers of the materials and structures;
--The introduction of a sysCem of plan payments, i.e., transfer Co the
current account of the UPTK by the subdivisions of the trust the current
accounting aums for the volume of the plan period deliveries;
--The systematic utilization of bank loans through on-call accounts and
loans for the plan stock of materials.
The difficulties related to assuring the completenesa of the supplied struc-
tures are explained by the fact that there is no chief supplier with which
the UPTK could have accounts. At the present time, Che UPTK pays to the
account of each plant when it delivers a part of a complete set. Such a
sysCem does not exerC a substantial influence on accelerating the delivery
of the entire complete set. In this regard, it is expedient to introduce
a statute concerning the system of supply for the electrical power network
facilities with industrial complete sets.
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'Che cr~atiott of Che UPTK, and o~ tihe flow ~.ine sectiona in its compl.emenC,
perm~.e~ concentraCing ~he alloca~ed funda eomerhing which in turn makes ie
possible to rou~e ma~erials ,~o ~he f~ci13~3esbeing brough~-3n, includ~ng
sever~;ly scarce ma~erials, ~n accordance wi~h ~he quota charra an'd depart-
mentis puCting ~he packages ~ogether. Th~.s facC is of substantial signifi-
_ cance, since Che �unds and quotas are, as a rule, allocared in August-Sep-
rember of ~h~ year preceding the planning year, while the plan and Che eech-
nical documen~at~on are officially drawn up and finally authorized in Sep-
Cember-December.
Thus, the UPTK permits comb~.ning Che efforts of the collectivea of the ataff
of the trust, the cona~ruction subdivisions, and the motor vehicle tranaport-
grion enterprise, and directing them to curtail Che construction timeframes,
ro bring the facilieies in~'on time, �iniah the sCages of the work, deliver
the facili~3ea wi~h a high 1eve1 of qual3ty, as we11 as Cransform the sub-
station facility inCo a construction site during ~he process of the high
speed, ~low line assembly of the individual blocks, assemblies and components.
The UPTK a1~.o~rs for the concen~raCion and centralized disCribution of material
resources of an improved �acCory readiness, as well as assuring the delivery
o~ a11 Cypes o~ structu~es, materials and equipmen~ Co the conatruction site
in compleCe industrial seta.
The UPTK organization has made it possible ~o free the collectives of the
production subdivisions of the derermina~ion of the need for funds, register-
ing, legalizing, apecify*inr and concluding agreements in accordance with the
allocated funds, selling, shipping, receiving and warehousing stocks at Che
bases of the subdivisions, payments to various suppiiers for the received
structures and materials, as we11 as ~he fabrication aC the construction site "
of various structures, products, systems, etc. The subdivisions which are
loca~ed in ~Re zone of immediate ac~ivity of the UPTK can dispense ~rl.th
their own Warehouse msnagemenCs and signiP~cantly reduce expend~tures for
this outlay~item.
To furrher ref ine the industrial production system for supplying complete
packages, in the opinion of the suthor, is expedient to implement the follow-
in~ measures:
--Change the time periods for the presentation of Che technical documentation
by the planning organizations, linking them to the timeframes for assigning
quotas and placing orders for structures and materials;
--Refine the technical documentation, taking into account the breakdown of
the entire complex of construction and installation work into complete in-
dustrial sets, linked to the payment atages;
--Change the ratio of the quotas allocaCed b~tween the biennia in the direc-
tion of an tncrease in Che first biennium;
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--~Organize a sing~.e organizaCion for putCing compleCe conatrucCion packages
toge~her, wh~ch ~s inves~ed wi~h CRE func~ione of planning, dis~ribution and
supply of sCee~. re:tnEorced concre~e and metal struc~ures, and ~oiner~s pro-
duc~s, ~aking inCo accoun~ ~he comple~e industir3al set, within the sysCem o�
the USSR Minis~ry~ oP Energy*;
~,Witihin ~he USSR Miniatr}r of Energy, approve a ata~utiP on a syatem for
supplying complete indusCrial se~s, including the drawing up of structural
and organizational ~orms, the definition of managemenC functiona for suppli-
ers oE compleCe se~s, es~abl~sh,~ng ~he interrelationships between industrial,
compleCe package assembly and elec~rical pnwer network organizarions, as we11
as refining ~he procedure for mu~ual billing calculat3ons based on central-
ized and s~reng~hened billing calcula~~ons for a complete del3vered ind~.t~tri-
al se~;
-~Work out a syatem of accounts between th.e UPTK and Che production subdivis-
ions of the trust, where this system assures the solvency of the UPTK;
--Work out a single standardized normative and technological doctunentation
(UNTD) for putting together complete packages;
--Work ouC pro~ect plans for standard produc~ion and complete package
assembly bast.s of ~he UPTK of ~he electrical power network trusts and allo-
caCe funds for their construction in a centralized manner;
--Convert Che UPTK to a cost accounting subdivision, which parCicipates in
generating the plan and above-~lan income for the trust;
--Work out and approve a s3ngle statute in the USSR Ministry of Energy on
providing bonus awards to UPTK workers from the economic incentive fund, as _
well as for the placement of facilities on-line;
--Incorpoxate the UPTK inCo the list of organizations which parCicipate in
the socialist competition between the organizations of the USSR Ministiry of
Energy.
~ ~
COPYRIGHT: Izdatel'stvo "Energiya', "Energeticheskoye stroitel~stvo", 1979
8'l25
CS0:1822 -
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ELECTRIC POWER AND POWER EQUI,PMENT
' ~ UDC 62~..3~.1.22.002.~51
INB~ALT~ATZON OF INDUSTR7AL EQUIPME~VT OF BEREZCVSKAYA GRES-1
. Moscow ENERGETICHESKOYE STRQITEL~STVO in Russian No 3, Mar 79 pp 27-31 �
, [ArCicle by engineer M.Ya. Borts]
[Text] The'Berezovskaya GRES=1 with an overall capacity o� 6,400 MW (eight
power units of 800 MW each) which ia the largest in the USSR,.ia the chief
electrical power staiion of the southern group of the Kaneko-Achinsk fuel
and power engineering complex (KATEK).
The unit length of one power block is 72 m. A repair opening with a width
o� 12 m is providt+d af ~er each power uni~ w3~h an even number. The over- .
a11 length of a main.housing of the Berezovsk,aya GRES is 696 m, Che diameter
through the A-J section is 242 m, and the bottam mark of Che roof trusses of
the boiler compartmen~ is.117.5 m. The framework of the main housing is
~.eecuted in metal.. Two smokestacks (one for each four po~rer blocks) with
a height of 360 m each will be erected at the electric power station.
The following main equipmenC is included in the complement of a pewer b lock:
--A P-6; ~i0 boiler plant (pilot model) with a sCeam generating capacity o~
2,650 tihr (25.5 MPa; 545/545� C), in a T-configuration, single stage, with
- a square boiler of a gas tight design; ~ ~ .
--A single shaft, f ive cylinder condensation K-800-240-3 LMZ steam turbine
_ with a eapaci~y of.80U MW (steam pressure of 24 MPa, temperature 540� C);
~ --A TW-800-2 generator (the "Elektro~ila~~ All-Union Association) with a
~ capacity of 800 MW in a c.losed-loop design (a provision is made for edoling
the rotor~with hydrogen and the stator with hydrogen and water). ~
~ In considering the engineering pro~ect plan for the GRES, the Scientific and
Engineering.Council of the USSR Ministry of Energy adopted the following
basic conditions for its cons~ruction: ~
9
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~ox o~F~cini, us~ or~.Y
--'Ch~ gt~rt of Ch~ ~i~~e power biock a~ould be accompli~hed 37 monthg follow-
ing th~ ~eart of the conetrunCion o~ the main housing;
~
--Th~ ~pacing in placing eh~ biock~ en-iin~ a~e eaken a~ ~ix montha;
~-'~he pace ~f cone~ruc~ion for the und~rground poreio~t o�.the main housing '
~tiouid ~mount tio two secCiens ef Che cross-s~c~iona7~ diameter per monCh;
thp ground secCion of ~he main housing eh~uld go ae a r~C~ of 1.3 epceion~
nf th~ crdge-~ectSonal diame~~r pet~ monrh; ~
--Thp ingtal].gtion o~ rhQ first power block ehould be accompliahed from eh~
sid~ of the stationary end fece.
Th~ baeia principlee for the orggnization of the equipment inetnllation of
the ~er~zoskaya GRES-1 were developed taking inCo account the advanc~d ~x-
p~rience ia Che inetailation of the equipment of the 800 MW rapacity power `
blocks at Che UglegorBkeya and Zaporozhsksya GRES'g as applied to tih~ sp~ci-
fic conditione �or the eonstrucrion o� the Berezovakaya GRES-1, determir,ed
by the Scientific end Engineering Council n� th~ USSR Mini$try o� Energy.
In thi~ eaee, Che presence of a construction flow for no leae than three
CIt~S~s ~rith a capacity of 8 x 800 MW wag taken into a~count~ where theac
gCaCione comprise the southern group of the KATBK CRES~s.
~he busir etatutea governing the adopted organizaCion for the equipment in-
stallation of the Berezoskaya GRES conaiet in the following:
--'The construction and installation nf the equipment should be caxri~d out
using the high epeed sloa line method in accordance with a single directive
netw~rk schedule, ~rhich is obligatory for the pxecu~ion of the construction
of the G1t~S by aLl participanrs, including the suppiy~ng piant for thermal
mechanical equipment; the financing and technical material support of the
construction ehould be coordinated aith the indicated directive sch~dule;
--The planning of the performance of the construction Work to erect the
CitE~ ehould be corapletely subordinated to the requirmnents for the ineCal-
laeinn technology of,the equipment, aince this etage is the f tna~ one in
the process of erecting the CRES and determines the timeframes and rate at
Which the capacities are brought on-line;
--Thc performance of the conatructian and installation work will be realized
separately wi.th respect to time and site, something Which is a basic condi-
eion to nssure the requisite pace in bringing the capacities on-line, and
~urtailing the duration and labor intensity of the installation work; the
installation work ahould be accomplished only in an enclosed and heated
building;
--Ti~e assembly and compleCion of the consolidated equipment blocks should be
realized at the ihetmal installation base, ahich is included in the
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FOR O~FtCtAL USE ONLY
compi~m~ne o~ ~h~ r~~ton~l eomp~eheneiv~ production baee (RPit~) �or the
eon~cruction of eh~ eouthern group og KATEK aRE3~e; in thi~ caee, e pro- ~
vi~ion i~ made �or the aseembLy of the block 3n a closed houeing, equipped
vieh ~p~~ial induetr~ai rigging ~rhich a~eure~ a high level of ~r:rk mechan-
izueion;
--It lg pl~nr~ed tt?gt the dRE9 equipment inetaila~ion work be carried out
u~in~ longitudinal specialized flo~+e `riCh the inrroduction o# the appropri-
~C~ org~ni~aeianai erructure for ehe ehermal inetallaCion compiex. _
Th~ con~truction pace of Che main houaing and ite read3ness in the final
Anelysis detiermine the ratea at whi~h the cap8cities are brought on-~in~
and ehe duration of GRES consCruction ae whale. The organiz~~ion of the
ei�ecCion ot the main housing haa a eubeeantiai infiuenc~ on the durati,on of
th~ instaliation of the Chermai mechanical equipment, a~ well ae th~
l~bor inteneity and quality ~?f the arork.
Th~ acheme adopeed in the arection of a GP.ES wiCh 200 and 300 MW power blocks
wh~re the consCruction of the main houeing leade the course of the inerallg-
Cion of the equipment by a minimum of one element of a po~rn~r block o?as pri~
marily determined by the neceesity of organizing rhe inetailation area for
the execution of the pre-installation opereCiona (th~ siinging of the biocks
of th~ boiler being inetalled, bringing ~hem into a verticai pe8ieion, and
the inetailation in the design position). In this cese~ a provision Waa made
for the possibility of brin3ing the bridge cranes out into the indicated area
beyond the lisnits of the uniC of the boiler being installed and installing a
temporary face beyond the limits of the installatic+n area. This scheme cor-
r~eponded tQ the traditional inetallation Ceahnology for boilers by building
up from the bottom upaard and provided for the site separation of the con-
etruction and installation aork flaa~ vi.thin the confines or one main hous-
ing. Th~ traneportation scheme ahich aae irorked out raking into account the
adopted pace for bringing the cepacities on-line (one ~o tWO poWer blocka
per year) provided~for supplying the construction atructure and equipmeat
Without mutual interference.
When organizing the high speed f1oW line insta~lation of equipment at eame
GR~S~e vith a spacing in bringieg three aad more poWer blocke on-line annu-
� ally with a capacity of 300 MW Qach (the first etages of the Ladpzhieekaya~
2aporozhakaya and Uglegorekaya GRES's) required a greater separation of the
construction and installation wrk floas not only in tencs of the vork site,
but glso in time, someehing at?ich was achieved by alternating the Work in
the erection of the main houeing and the installation of the thermel mechan- �
ical equipment. In thie case, Lhe duration of the installation of the main
housing and the installgtion of the equipment Was curtailed.
In the case of the floa line installation of high ~,roductivity boilers,
Which are suspended from the structures of the main housing, one can
11
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~
~
~
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FOR 0~'I~iCTAL tl3E ~NLY
.
~~.mule~neoualy inet~ll nc more Chan two boiler~, whila when the first boiLer
i~ in ~he finiahing etage (the 3nseAlla~ion of a~eaehmeaC~, ~he welding of
the bypaes eyeeem, alignmene, ete.)~ th~ heavy block~ ~r~ be~ng in~tiall~d ~n
~he geednd boilar. ~
The duration of tihe high speed flow line in~tallation of ~ boiler when
bringing two power blocke p~r year on-line ghould not excaed 12 monehe.
Th~ possi.bility of achieving such a dura~ion o~ ineCaliation work for a
power black ie coefirmed by c~lculations, the basi~ for which we~e the ac-
tu~l dat~i on the duration of the instaliation of the equipment of gas-O~el
oil poWe~.� units wirh a capaci~y of 800 MW at ehe 2aporozhekaya GRES.
the numb~ar of critical conditions which aseure the att8inment of the design
timefram~a !or the installarion of th~ powar units and placieg them on-line
within ~he seC deadlinee, boCh the otiganization of the tr~ple shift work in
accordance ~rith a aliding schedule aed the absee~e of superpoeition of the
congtruction and instailation operation~ ehouid be cieed.
Since the volume of the main building nti eh~ Berezoveksya GRES (for eight
poWer blocks of 800 MW each) precludas thg practicability of compieting
i~~ cons~ruction prior to tha atart of ~qLipment e~formancenofCthe construc-
timum soluCion vhich provides f~r nonuverlapping p
tion and inatallation operaeionE ie the separaeion of the main building i.nto
a minimum of two sectione. The layour of the main cargo crene, ueh8eggreubQ
installation of the construction arrucrures of the main building,
atantial influence on the organization of the supply of the equipmenC for
3nstallation. The narroW feed front in the ca8e of large volumes of the '
equipment being inetalled, the etructural deaign solution and the overall
dimenaions of the support gantrys of the ne~t SKR-2200 and SKR-3500 rail-
mounted jib cranes ~rith a base of 15 m pla~:e apecific requirements on the
grrangement of these cranes.
With the separete performance of the construction end installation vcrk aith-
in the confines of the main building, or in an independent part of it, the
constru~.tion crnnes ehould be brought out of the instailation area at the
atart oE ~he equipment installation. por this reason, the choice of their
locatio~i during the period of erection of the main buiiding or ite inde-
pendent portion should not be linked to the organization of the feed of
equipment being installed into the main building. When the consttuction and
in~tallation operations are combined ~rithin the confines of ~he main build-
- ing, it is necessary to pa.ace the conetruction cranea outside the boiler
room, i.e.~ in the ~pans of che maia building, vhich are etresaed to a lesser
~ctent in terms of the load fioa. The installation of the construction cranes
in the boiler room leads to an increase in the g!~ep of the flov line.
The production pr~gram for the thermal installation base Was determined from
design figuree for the placement of tao poWer units ~rith a capacity of 800 MW
~
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FOit OFFICiAL tJ3~ ~NLY
9
. _ ~~QQ
, Od90
3 ~ +tos~oc 3
I
~
. ,
,
~
. , ,
~ ,
, ~ �
,
~
' 8 I 3 I ~ ? .
~ 00
. ~ ~ I I
I ~ 1~~ ~ ~
, ~ I
' ~
S ~ ~ ~ ~
~ ~ ' 1 1 ~
~ ' ~
~ ~ ~ ~
~r y , ~
~p ~ ~ ~ ~
fl ~ ~ j ~ ~
; s ' a ,
9
6~ ~000 ?000 'It000 3J000 ltI00 l1I00
' _ ~A) ~8 ~C~ ~D~ ~E~
~F~
Schematic of the comprehensive mechanization of the equipment installa-
tion in the main building of the Berezovskaqa GRES-1. ~
Key: l. IQ~t-125 bridge crane with a load capacitq of 125/20 t
(3 unita);
2. Jib crane aith a load capacity of 10 t(~4 units);
3. KPP-10 revolving suspension crane with a load capacity
of 10 t (10 units);
4. IQ~t-100B bridge crane aith a load capacity of 100 +
+ 100/10 t (3 unite);
5. Bridge crane ~rith a load capacity of SO/10 t(4 units);
6. BK-1000 toaer crane ~?ith a loed capacity of 50 t
(2 unita);
~ ~
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~o~ o~~ic~~ v9~ oN~.Y
. vs.~
~
~ ,
~ .
6 ~
. .
. ~
~M
~I ~ � ti ' f� r
~ ~ 1~~~ r ~
� ~
I '
. ~ I ` ~
d~ ~ i
,
i W~ ~
~ -f=-+1: ~
~ ~ 1 ~
( ~ ~L~
;
~i~~ ~oo O
cH~ c=~ ~Jy .
(Key to figure from preceding page aad above~s
7. Bridge craae ~?ith a load capaciry.of 30/S t(8 units); ~
� 8. Bridge crane aith a load capacity of 20/S t(2 unite);
9. Jib cra~e irith a load capacitq of 5 t(4 units);
10. Gantrq crane ~rith a laad capacitq of 3.2 t(2 units~.
. ~ ~
each on-line annuallq (in accordance vith the adopted atep of the floir.line
inetallation of th~ power units ~it the CRBS~s of the tUTBK southern gtoup).
The base consists o~ three r~ain sectiona. The first eection is set aside for
the atoraga aad package assea~bly of thermal inatallarion package aquipment.
The equipueat ie stored 3n cloeed varehouees, uuder canopies and ta open areaa,
equipped virh gaatry crsnes. The biocks of it?stallaCion equi~eet are put
14
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,
FOR OFFiCIAL USE ONLY
rog~the~ ~n compl.QCe packa~~e ~rom the ~lements included ~n ehe d~.ffer~nt
a~~emblies in Che eame eaction 3n epe~~siiy ea~ ae~,de areae. The ec~uipmene
ia consolidaCed ~nto ~ne~allaCion bio~ke in the se~ond secCion, in ehe ciosed
produc~~,on bui.lding. Follorr~ng aesembiy, 30~ of Che blo~ke are dal~3ver~d
for lining and ineu~~eion.
~n view of tha po~~ib1Q diacrepancy in the ~e~embly and 3nsfiali~tion cycle~
o~ the blocke, a porCion of ehe f inished block~ are diepa~ched direcCiy for
in~tallat~,on, ahile ehe remaining poreion ~s forwarded to the third eaction -
the fin3ah~ad block Warehouee.
Th~ annual produc~ion program of the thermal iner~ilation baea for Che assem-
bly of equipmant biocks for tao pot~?ar uni.ts wl.eh a capaciey og 800 MW Qech
emounCs to 75,890 t~,aas.The ehroughput of equipment blocks from one square
meter of the produc~ion building amounta to 4.3 ~ma per year, xhich is ten t~nee
~reaeer rhan for ~he cese of b,ock aeeetebly in an open er~e.
~h~ overall e~a�fing at th~ ehermai insrallarion base aae ~et 8t 1,120 per,~ona,
includ in~ 1,038 Woxkers.
TBkin~ into aceount th~ gp~cialization of the inetellation operations and th~
epecif ic ],eyout of ehe equipment, the entire compimc of Chermal inetailatian
~+ork for the case o! the high epeed f1oW lfne inetallation of the equipment
nE the Here~ovekaya GRES-1 can b~ broken dos~m into eight independee~ epec3al-
ized floas:
--The complete packaging and ase~mbiy of the equipmeet (the thenoal installa-
tion baee in the complement of the RPKB);
^-The inatallation of the botler room equipment;
--The installation of the equipment of the dust handling ayatem and tubuler
air preheater equipment;
--The installation of the electrical precipitator equipment and the KVO (ex-
~asion unknoanj of th~ ext~rior installetion;
--The installation of the BDO and BOU (expansicn unknotm~ equipme~t;
--Thp inatal~ation of the equipment of exterior facilities;
--Mechanization and organisation of operations (this flov is organized for
the purpoge of exciudir~g any kind of guxiliary and repair services froa~
the primary production floas).
The thenoal inatallation complex manages all installation operations. The
structure of the complex provides for the coordination of operatione performed
15
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FOR OFFICIAL U9E ONI~Y
by independane ~low~ (e~eh of which ra~.e~ eh~ form o� a co~t accoune~.n~
specializ~d insCa].1aCion e~ct~.on), Ch~ auperv~s~.on oE the ehern~l ~.na~g1-
1aCion work and it~ qualiey control, as well as the resolueion of quaetions
of compl~~e equ~pment packa~es, external li,nke, ~conomi,~ ~nd f~.ng~cial ~~r-
imat~on qu~sCions. The Chermal inetalia~~on complex per~orms none of the
work with ita own pereonnel i,n the erec~ioa o~ ehe GRES.
The neceseiey for the ~nCroduction of Buch a echeme for ~he cont~ol and ~
management of operaeione in the conetruct~.on of ~uch pro~ects ~s the
9~~cezovekaya GRE3-1 is expla3ned by the coneiderably ~ncreaged annu~], volume
of installaeion otork being performed by the high apeed glow line method.
The we#.ght of the the~nel mechanicgl aquipment of ona power block witih ~ -
capacity of 800 MW of the Berezovekaya GRES-1, including the center girders
aed metal technologicai eupport et~ucturee amount~ eo 52,700 tons (accord-
ing ro prel~sninary daea), and tek~ng thprma~. ~neulation, ~ncluded 3n the i.n-
etallation blocke, into accounr, about 60,OOJ tong. Thus, working from th~
rate at which the capacitiea of the Ber.ezovskaya GR~9-1 are b~ought on-line,
Che weight of the equipmeeC being inatalled in the main building in one year
amounte to 120,000 tone. It 3e intereseing to note for comparison that the
weight of the therma2 mechanical equipment (~rith the inaulation inciuded in
the blocka) being inatalled over the course of a yegr in the main buiidings
of the 2aporozhokaya and Uglegorekaya GRBB~a With gas-fuei oii poaer blocks
of 800 MFi, amounted to about 30,000 tons, i.e., four tlmea lese than at the
Berezovskaya CRES-1.
In contrast to existing layouts~ ie the boiler room of the Bere~ovskaya
GRE3-1, along ~rith the main apen having a~+idth of 33 m a provieion is made
for tao additional one9 aith aridths of ~2 m each, uged for houeing the .
steam heat exchanger (in the,upper part of the boiler room), the station pip-
ing, the milis-bla?ers (at rhe zero level mark), t:~e fuei feed channels, as
aell as for the organization of boiler repair. Such a structural deaign of
the boiler room, given the considerable height and ~ight of the boiler, as-
sures a mic~imal epan of the center girdera for euspending the bdiler and the
placement of the rigid diak in the supplemental spans outside the boiier.
The scheme for the complex mechanization of the equipment inetalletion at the
Berezovakaya GRES-1 (aee the figure) aed the aelection of the main load lift-
ing mechenism vere determined taking the following factors into account: the
apecific features of the equipment layout in the main building, the overall
~ight of the equipment being inetalled an~nually, the weighta and overall
dimengions of the assembliea and installation blocks of the equipment (in-
cluding the inaulation), the production technology for the installation t+ork,
and the technica~ characteri~tic~ of the series produced and special load
lifting mechanisms. The unusual overall dimensiona and Weight of the boiler,
as aell as the structural configuration of the triple span cross-aection of
the boiler room required desiges af nev load lifting mechanisms for the
equipment inatallations the t~t-100B bYidge crane of the boiler room vith a
load capacity o! 100 + 100/10 t.and a lifting height of 109 m= and the
16
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J
KPP-1,0 roea~ing suepenAion crane art~h a~.oad capaci~y of 10 ~ and a 13fC
haight o! ~rom 50 Co 110 m.
'Stte ioad li�~ing cranea for rhe inaeallaC~.on of tha equipment w~~e distribue~d
as �oliowg.
~hr~~ in~tiall,ation and repair bridge cranes ~rtth a capac3ty of 125/20 t each
wer~ pl~e~d in the turbine ro~m, one of which ie ~n aegembly and d:t.sasaembly
ergne instailed ar eh~ tempor8ry end fac~. ~he in~tallati.an of tihe generator
gtgCoY with a areigh~ of 322 t is executed by theae cranes uaing a system of
crose-pieces.
(iantry cran~~ with a load capac3ty of 3.2 C are uaed gs the auxiliary cranes
for inetallerion and repair work on the turbine and feed eete.
The ingtallation of repair end inatallation suspenaion ~ib cranea w3Ch a load
~apacity of up to 10 t and a 1lfting height of up Co 36 m wae provided in
the deaerator-hopper and hopper roome at each of the markers.
Specia~ su~pane3on, ro~ating, ine~a11a~3on and repair KPP-10 cranee with a
' load c:apacity of 10 t and a lifting height of 110 and 50 m respectively
are insralle8 in epans C-D aad E-F at rhe 115.70 and 102.15 m markera and
in apan C-D aC the 54.00 m marker. The cranes are inCended for the inetal-
lation of equipment (primarily piping)~ arrenged in the rows indicated, ag
aell Aa inaide ehe columne of rows D and E and pareially aithin epae D-E~
as aell as for Che repair of the boiler room equ3praenC. A provieion is made
for the installation of installing cranes with a load capacity of SO t and
a lifting heighr of up to 52 m ae the 54.00 m mark on the C-D and ~-P lines
for the installation of the mill-blower assemblies and other equipment, vhere
these cranes are arranged along ehe line of inatailation ahead of ehe suspen-
sion, rotating cranea at ehe same marker.
Threp lQ~t-100B apecial bridge cranee (vith tao self-propelled carriages) are
installed 3n the main span D-E of the boiler room, where theae cranes are
used to instaii rhe P-67 boiler and the center girder.s.
Experience with the installation of 8uspenaion, large capacity boilers using
apecial bridge cranes of a high load capacity (up to 100 t) hae confirmed the
effectiveness of the utilizgtion of these cranes. Thus, at Che 2aporozhskaya
and Uglegorskaya GRES~~, the rate of installation of the heavy components of
the TCMP-204 boiler reached 3,000 t per month using tao bridge cranes under
very constrained conditians for the Work area of the bridge cranes (the length
df ~n element is 48 m in all). One boiler department for severa~ boi~ers,
When organizing flo~r line Ynstallation, will assure a broader Working front
for the bridge creaes. Along irith this, the fact that the height of the boiler
will be significantly increaepd in thia case ehouid be taken into account.
17
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'rh~ ~.n~t~llat~,on ~nd rep~~.r oE the equipmenti in Che rnom for Che a~.r pre-
heater~ in epae G-T 3e accompl~,ehed using bridge cranes witih ~ load c~pacity
of 30/5 ~ and a Zif~ing heighC up ~0 40 m. Tha pracipitating E~.l~ers and
gas-air pipes ouCside the bounds og the ma3n building are inaeal,led by meane
of ~wo BK~100d powar cranee. ,
A provis3on ie made for moving the BK-1000 power cr~n~s~ regerdles~ nf the
~Cate of ~he atructural pare and the equ~.pm~nt insrallation, where one of
Chese r.ranes ie ins~alled in a corr3dor 17 m wide between the 7'VP [expan-
eion unknoan] room and ~he pra~3pi~ation f1lCere, while the aecond is in-
atalled betwpen ~he precipitation fileers and ehe smokee~ack.
The installation of f1.ue gae extrectors, poeitioned below the precipitation
fil~exa, is accomplished using bridga cYanes with a load capacity of 30/5 t.
~aking th~ height of Che boiler and the building of the boiler department
i.nto account~ as wall as the volwnes of inatiailation work performed at Che .
marker levele of the boiler room, coneiderable attention muet be given Co
Che vertical ~raneporta~ion of instaliation per~onnel. For this puYpoae,
. beeideg the operationai cargo elevators wiCh a cargo c~paciCy of 3.2 t and
the pa~genger elevatore with a capacity of 1 t, ~ provieion is made for Ch~
inseallaCion o� GNE2N0-1000 (manufactured in the Poliah People's Republic)
inatallation pereonnel elevatore with a load capacity og 1 t(the aeight of
12 pasaengera).
A proviaion ie made for 10 lifts and elevatore for t~ao paired boilere.
GNEZNO-1000 inatallation elevatora are inetalled in rhe place of operational
lifts vhere these are absent at the starr of the inetallation work.
The project design labor intensity for the inatallation of the equipment of
Che Berezovskaya GRES-1 Was determined on the basis of preliminary data on
the xeight oP the equipment and the average specific labor~intensity (per
1 t of equipment) of the inatallation vork, figured from the data on the
actually achieved apecific labor intensity of the equipment installation for
the 800 MW gae-fuel oil power blocke (Nos. S and 6) of the Uglegorekaya and ~
Zaporozhskaya GRLS~s. Theee GRES's can be considered analogous for the fol-
loaing reasona:
--Because of the high level of engineering oxganization for the performance
of the installation work, the labor intenaiCy of ehe equipment inetallation
of the ~ag-fuel oil 800 MFi poaer blocka of the Uglegorskaya and Zeporozhskaya
Cit~S's is at the optimel level;
---The gaa-fuel ojil 800 Mtii poWer block equipment is similar in terms of its ~
~ structural desi~n to the equipment of the Berezovoakaya GRES-i.
Because of the organization of the asaembly ~f the blocks in the production
building of the theriml installation base, the apecific labor irtensity of
18
FOR OFFICIAL USE ONLY
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APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100054428-5
~
FOEt 0~'~ICiAL US~ ONLY
Ch~ e~~embly, in accord~nc~ wiCh the c~lCUla~ions~wh~,ch were carr~.ed out, w~a
reduced by 1.Sw-2 C3fle~ as compaxed Co ~he yabor ~.n~ensi~y of ~he aesembly
gr tih~ Ug1.~gorelc~ya ~nd Z~~ore~h~kayg GRES~s.
Th~ ~verage number c+f inetaila~ion workere ax the con~truction eite of ehe
B~rezovskaya GRE3~1, ahere ehe etiep epacing ~.n br~,nging Che eap~ci~~ea of ewo
pow~r blocke of 800 MW each on-line annually, amoun~a ~0 3,330 pereons, in-
cludin~ 1,038 pergone for a4sembiy and 2,292 persons for inerallation.
Cnnnlug~ong
1. The following are necessary for the realizaCion of the principles eet forCh ~
above for the organization of Che install~tion of the technologicai equipment
Che Berezovekaya GR~S-1, with a f~,ow line step of two powex bloctce pex
yeax;
~-�~xh~ ex~cCian of the thermal insCallaCion base in the complement of the it~'Kri
(with ~ cloaed assembly building), the capacity o� which will assure the cnn-
sol,idated assembly of two power blocke of 800 MW per year;
~--Th~ organization of the separate execution of the construction and instal-
lAtion operationa within the confines of the main building, and the separa-
Cion of Lha main building into ts~ro sections for this purpoee;
--Providing for the comprehenaive supply of equipment, and in thie case, the
t~me requiYed for the delivery of a complete equipment ~et for one power
block should not exceed the flo~ line etep for placing the capacities on-line;
--The organization of equipment installaCion "right off the Wheels" aith the
predominant use of railroad tranaport for supplying large biocks of equipment
~'or installation.
2. The equipment inatallation technology developed on the basis of the prin-
ciplea indicated above s+ill permit:
~ -Curtailing the tiaie required for the ingtallation of a atandard pulverized
coal power block ~rith a capacity of 800 MW from 14 montha (according to normg)
down to 12 months;
--Reduce the specific labor intensity of the installation Work (per 1 t of
equipment) by approximately 25X as compared to that actually attained in the
installation of the equipment of the gas-fuel oil 800 Mii power blocks at the
Uglegorskaya and Zaporozhskaya GRES's (the specific design figure for the
labor inteneity of the equipment installation at the Berezovskaya GRES^1 is
9.9 man-days/c, and the actual epecific labor intensity of the installae{.on
oE power blocke Nos. S and 6 at the Uglegorskaya and Zaporozhekeqa GRES's
was 12.5 man-days/t); in thie case~ ~ust by virtue of aesembiing the equipment
, 19
FOR OPFICIAL USE ONLY
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100050028-5

APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100054428-5
FOit OFFZCIAL US~ ANLY'
blocka aC ~he ~h~rmal inetial],a~ion base, ehe eoeal ~orce of ins~a~,laeion
workere over Che antira period of ~he cons~ruc~ion of ~h~ eou~harn gxoup of
KA~~K GR~S~e wi11 6e raduned by 480 ntgn. ~
COPYRIGlt'xs Izdatal's~vo ~'Energiya'~, "Energeticheskoye etroitel~etv~o", 1979
. 8225
CS0:1822
20
FOR OPFICIAL USS ONLY
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APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100054428-5
FOR OFFICIAL U9E ONLY
~LECTRIC POWER AIdD pnWER EQUIPMENT
UDC 621.181.002.72
FEATUR~Eu OF P-67 SOZLER OF AN 800 MW POWEEt ELOCK OF BIItE~OVSKAYA QRES-J.
Moecow ENERGETTCtiE3IG0YE 3TROITEL~STVO in Ruseian No 3, Mar 79 pp 31-34
(Ar~icle by engineere Yu.D. Sologub, I.G. Olevaoneand P.Ye. Sheryshev]
[~extJ ~he coals of the Berezovskiy deposit oF the Kanako-Achingk noa1.
basin will be used ae Che main fuel for the first electrical power stations
of rhe Kansko-Achinsk fuel end pow~er engineering compiex (KATEK), as weii.
fox the head Berezovskaya GRES-1. Berezovakiy coals are distinguiehed by a
low ash conCen~ (4-12X), moderaCe moisture content (33X), an ineignif.icant
aulfur content (0.3X) and the predominance of calcium oxide i~n ths ash
(40-60X). The calcium oxide content in the aeh of these coala increases
with a reduction in the aeh content, Che aeh temperature in the liquid eCate
increasea at Che eame time (1,270-1,630� C), and consequently, the slag form-
ing capability of the fuel increases aignificantly.
As is well known, Berezovskiy coals were not mined prior to 1975, and indus-
trial�experience in burning them is tacking, something which causes certain
diff;tculties in designing boilera intended for operating with this fuel.
At the preaent time, the Podol'sk Machine Conetruction Plant imeni
Ordzhonikitze (Zi0), in con~unction with the organizations of the USSR Min-
istry of Energy (VTI [the All-Union Red Banner of Labor Heat Engineering
Institi~te ~meni F.E. Dzerzhinakiy], the Special Deaign Office of the VTT,
the Thermal Electrical Power Engineering Planning Adminietration and the
Power Engineering Installation Pianning Administration) are developing the
manufacturing piant for the Pp-2G50-255 (P-67) boiler for the S00 MW block
of ehe Berezovekaya GRES-1.
The P-67 boiler ia a single housing, suspension type, straight-through gas
tight boiler with a T-layout of the heating surfaces. The technical data
on the boiler are given below:
Steam productivity 2,65U t/hr
Steam presaure:
of the live steam 25.5 I~a
superheated reheat steam 3.7 I~a
21
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_ I
FOk OFFICIAL US~ ONLY
~ TemperaCure: ,
of the superheated eteam 545/545 C
of Che feed wa~~r 275� C
o� the exhauat gages 160� C
The furnace chamber of the boiler has dimensiona in the p1.an view between _
the cen~ers of Che Wa~er wa11s of 23,080 x 23,080'mm. Installed ir? Che
furnace in four~Ciers are 32 ~angenCially oriented straight-through burnera
(Giere of ~wo burnerc each on each wa11).
The heighC of ~he furnace chamber from the center of the cold hopper funnel
to the boC~om of ~he shield surfaces 3s 60 m. The marker o� the centers of
the crown pipes of ~he boiler was Caken at 90.1 m.
The cnnfiguration for the ateam-water channel of the boiler provides for
two nonmi.xing and independenCly conCro11ab1e flows of working medium, which
flow Co the left and to the right relaeive to Che axis of symmetry, perpen-
d3.cular to the frr~nt of the boiler.
An economizer manufactured from pipes,with dimensions of 42 x 6.5 [?mm?]
(20 sCeel) is pasitioned in the path of the steam-water medium, where the
economizer has longitudinal ribbing wiCh stripa welded on having dimensions
' of80 x 4 mm.. The economizer is :~upplied in 64 blocks. Thereafter,.Che ,
mediura is fed to the ahields of ~he furnace ch~rmber, which are broken down
over the heigh~~in~o lower and upper radiation sections (NRCh and VRCh).
The frorit and back shields are vertical shields and extend out beyond the
- limiCs of the crown shield. The side shields form an aerodynamic pro~ection
of the furnace and the slopePi shield of the connecting gas duct. The st~am
exhaust pipea of this shield, having dimensions of 89 x 14 mm, pass through
the gas duct and participaCe in tak3ng Up the weight loads from the pipes
~ and shields of the convective shaft. .
Each wall of the furnace is broken down over its width into 10 panels. The
NRCh panel incorporates four delivery blocks in its height. Following their
monitored asaembly, they are welded in the welding area at the 18.3, 31.3
and 47.1 m markers. At the 62.2 m marker, the NRCh panels are ~oined to ,
the VRCh panels by a special connection (Figure la). The panels, whic.h ure
made of finned pipes with dimensions of 32 x 6 x 48 mm (12Kh1MF steel) have
a width of .2,256 mm. The overall number of delivery blocks is 164 for the
NRCh and 116 for the VRCh. .
Following the VRCh, the medium successively passes through the so-called
festoon of the side walls of the furnace and the crown shield. The festoon
consists of pipe with dimensiona of 42 x 11 mm and strips of 24 x 6 mm
welded be~ween them.
22
FOR OFFICIAL USE ONLY
~
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FOR OFFZCIAL USE ONLY
xhe stxips of fegCoon pipes,
6~ i,' 16 which are run wiCh a spacing oE
B ~ ~ 576 mm �rota ~he aerodqnamic
B pra~ec~ion ~o Che crown shield,
~ in con~unceion wirh the front
p-A ~ g~g ~ o '
.ae~nonu M 1IIIIIIII' and rear w~11s of Che VRCh, take
I ~l!
~OIIlNpNUA ~ I~' ~ up th~ 1oad f rom the weight of
~ ~i
' ~ 1 I� 1 1 ---a ~ I I' I I I I~' i tihe f urnace and the cold hopper `
, 1 funnel~ The panels of the crown
, ~ , ~,~~II
~ ( AT' 'j,v IIIIIIIIII shie1d, which are fabricated from
ae tia~ 4s ~ f inned p3pes with dimensions of
, a~ ~a~ ~b~6~ e~e 4~s~ 32 x 6 x 48 mm (12Kh1MF steel) ,
Fi~ure 1. The assembly for ~oining the are supplied in the amounC of
eRields of ~he upper and lower 27,6 pieces. During asaembly,
radiative secLions (a), and an they are welded together a~ 10
installa~ion block of the ahroud points.
type ateam auperheater (b). Then the medium passea through
Key: 1. Details of rhe seal. the shields of the convective
shafts and the separating gas
intake baff~.ea posiCioned para-
llel to them. The baffles which are heated on both sides are made similar
to Che furnace shie]da from finned pipes with dimens3ons of 32 x 6 x 48 mm.
The shielda cf tfie side wall of the convective shaft are subdivided into
10 panels over their width, while Che shields of the front and rear wa11s,
as w~11 as the wa11s of the gas intake, are broken down into four panels.
Each panel ~s is supplied in two blocks comprising the height. The
blocks are welded during the assembly. The welded ~oint on all panels is ~
positioned at the 76.7 m marker. The overall number of supplied blocks
o� shields for the wa11s and gas 3ntake is 144 pieces.
Further, steam-steam heat exchangers (PPTO) follow in the primary steam
channel, where these are intended fot regulating the superheated reheat
temperaCure by means of bypassing at the secondary steam side and which con-
sisC of 160 standard sections from ZiO. A spray type desuperheater with a
built-in gate valve is connected to the pipe following the PPTO. Kindling
separators are positioned parallel to them. Thereafter there run three
stages of the sliielded steam superheater and the ouClet convective packets.
The shrouds of stage II (Figure lb) made�of finned pipe wiCh dimensions of
32 x 6 x 48 mm (12Kh1MF steel), the shrauds of stage III made of piges with
dimensions of 32 x 5 mm (12Kh18N12T steel) and Lhe shrouds of stage I made ~
of pipes of the same size (12Kh1MF steel) are placed in the line of gas flow
in the horizontal gas duct. The overall number of shrouds is 228 pieces.
The outlet convective superheater consists of two sections. The first sec-
tion is made of pipes with dimensions c,f 38 x 7 mm (12Kh1MF steel), while
23
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_
Ftltt OF~tCLAi, USE ONLY
th~ ~~~nnd i~ madp of ptp~~ wi~h diin~n~ion~ ~6 x 6.~ nua ~i2Kh16N12T
~e~~i). Th~ ee~gm ~up~rhe~t~r i~ ~Uppli@d in 32 block~.
- Th~ g~cnndary Aup~rheaC~r incorp~rae~~ two se~~~~. On~ ~egg~, vhich i~
placed in ~he conveceive ehaft, i~ mad~ of pip~s wi.th dimen~~on~ oE 5~ x G mm
, (1`lKhiMF steei) gnd i~ ~uppiied ~n 9G biock~. The s~cond ~eage i~ eh@ ~hroud
p~rpion which i~ pig~~d in eh~ ha~i~ane~i du~e, m~t~uf~~~ur~d from pip~~
Wi~h dim~ngions of 57 x 4 mm (12Kh18N12T ete~l).
Th~ ~truc~urai d~~ign ef
~ ehe boi~er prcvide~ for
, ~ ~he fre~ euspension of ~11
e ~ of the h~atin~ ~urf~e~~
' ~ _ and the bypaee eyetem from
~ the roof c~v~r~
1
. ~ ~~~p ,I~~I , .
~ ~ I~,j~j,i,,~ , Th~ ~u~peneion syae~m af
. i~ I th~ convectiv~ ahaft,
( I~ ~f ~il~ I Whieh i~ manufactur~d from
Nl~~d~;fllil pipe~ ~ith dimensione of
~ 42 x 11 n~ (12Khll~4t ete~1),
is ~uppZ3~d in 32 blocks
~ I \ and 640 individual pipe
/ , elements.
i ~ To take up the internel
~ ' pressures in the furnace
I~' I and ehe convective ahaft
~ (during thumping and rar~-
; faction), stiffening bea:as
~ ! j ~ are installed around their
~ ( � perim~ter.
~
. .
- . ~ ~ ' ~ j ' The etiffening beams,
I Which are located in the
region of the VRCh, are
~ I i ' suspended from the roof
''iiai '~r"ooe.;;~ i~eoo naae "r.aoe ~ cover of the building on
~s~a~ e~~~ r~D~ (E~A ~F~ e~~)~,~ ~~cold" hangers end fasten-
Figure 2. Transverge section through the boiler. ed to the shieids with _
hinges. 'Y'he stiffening ~
beams, placed in the
region of tha NRCh~ are
guspended on one side with "hot" hangers, and on the other, vith the shields.
The stiffening beams of the front, rear and side walls of the furnace and
convective shaft are ~relded. The heighr of a beam ts 1,000 mm, ahile the
width of the boom is 400 mm.
24
FOR OFFICIAL U5E QNLY
~
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_ _
FOR OFF~CtAt, U9~ ONLY
`Cli~ ~.ubui~r ~~r pr~h@~e~r i~ compo~ed af i~r~~ biock a~~c~on~ af e~n~id~r-
~bi~ h~i~he (6.6 m), Wh~.ch are ~n~tall@d in ewo t~~r~ With eh@ upper ei~r
r~~ei~~ on eh~ 1~r one.
Th~ eh~rmai. in~ulation of eh~ bot.l~r con~isC~ of ehr~~ i~y~r~ ~f 1~.me~Eon~-
~iiiceoug pQnela with ~ ehickn~s~ af y mm ~~eh ~nd aa oue~r m~e~l ~o~~ing
1.~ n~n rhick. To in~ulae~ ~h~ p~~c@~ of p~~~a~~ af ch~mb~r~ gnd coii~
rhra~gh th~ pan~l~, fire re~i~Can~ 8nd ~h~irmal ineuia~~d eoncr~t~~ ar~ em~
pioy~d for ehQ h~ating eurface~.
~ight mi11s-bloW~r~ of rh~ MV ~ype ~~h ov~r~11 dimen~ion~ of 3,3~A x 80a x
x 4~0 mm ar~ prov~,ded to pulverize eh~ fue1. ~li~ nomin~l productivity o�
~ach mill vh~n puiv~ri~ing B~rezov~kiy coal ie 70 r/hr, and th~ ventila~ion
capaciry ie 200,000 m~/hr at a tl~ad of 125 t~e Hg.
Th~ fu~i i~ f~d from th~ r~w coal bunker~ to ehe fQedere, and then in~o th~
pip~-dri~r, and th~n ~ion~ With th~ drying ~gent into th~ m311~-bida~r~.
Th~ f~pd~rs 8r~ poeition~d ae ~he c~ii~.n~ fiaor~ at th~ 22.0 m mgrk. A
provigion is made for the us~ of the ~moke ga~ee at a~~mper8ture of 680� C
for dryin~ th~ fu~1, where the gase~ are ~ak~n off at th~ inpue to th~ ro-
tating chamber of the convective ehaft and fed via the ahieid channpi of the
gas int~ka, poeieioned in eh~ cenrer of rhe conv~ctive ahaft. Th~ temperature
, of th~ eir mixtur~ is regulated by ehe addition of gesee at a temperature of
360� C f~om th~ recircula~rfo~t rh~nn~l.
Th~ r~circulation gaseg are taken off from the gas ductg folloaing the Water
econo~iz~r at g temp6ratur~ of 360' C, paee through the eeh cleaner and ere
trgnsported by ~our flue gae extractors into the upper part of the furnace
rhamber and the bumer. A provieion ia made for the inatailation of three
UOD-43 flue gag e~ctraceora and rvo VDN-36x2 forced bioaers to assure the
requisit~ steam producCiviry and reliable operAtion of the boiler.
The boiler plant is housed in a building ~+ith a cell Width of 72 m and
n depeh of 51 m. Bunker levels ~ith apans of 12 m each (B-C and F-G) are
built on tc~ the three epan boiler building (spans C-D, D-B and E-F are 12,
33 and 12 m respectively). The frame of the buiiding is executed in metAi.
The boiler it~elf is houspd in gpan D-E. The boiler is suspended from eight
center girdera (the girder heighe is 6 m, the length is 33 m, and the a~ight
i~ 85 t), which rest on the girders of roas D and E beloW the cenCer
gird~rg.
'The millg-blowers are positioned two each on each side of the furnace chamber
of the boiler in spans C-D, D-E and E-F~. The heat exchangera are ingtalled
~t the 106.4 m mark in apans C-D and D-F.
A gperi~l feature of the gtructural design of the EramQWOrk of the boiler
building ig the colocation of the boiler and building frames. The building
~
r~5
FOR OFFICIAL USE ~DNLY
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FAR OFFIGtAL U9~ ONLY
f ram~ eak~~ up ~1,1 kind~ of hori~onegi ~nd v~re~,~~1 ~,a~.d~ baeh �rom ~h@
bu~tldin~ and from th~ bo~1@r. The co~umn~ of ro~ fl and E ar@ a~ c~o~~
a~ pos~ibi@ co Che boiler. Span D-8~ ~n ~+fti.ch the bo3ler ieeeif i~ p~ac~d,
W~~ eak~n equal eo 33 m. Th3e e~ructur~~ de~ige of ehe framer+c~rk and buiid-
, ing ~ayou~ permie ~urtailing ~he conaum~tion of inetai ~n the er~c~ion of
th~ bo~ier room.
Th~ epaeiai etrueeurei confi~urgtion of ~h@ bai~~~ bui~din~, formed from
eh~ no~uems of rot+s C-D ~nd ~-F, ~nd which a~~ pos3e~oned aboue th~ p~r~-
m~ter of th~ boiier c~ils eh@ 54.0 end 1~2.A m m~rker~ of ~h@ horieonrai
pian~ ~~ruese8 makee ie poes~b~~ pr3~or eo th~ ~tart of eh~ bo3~er in~eaii~-
~ion to co~nplet~ly fieieh rhe coneCruction of ehQ butiding aithou~ in9rai=
lin~ the c~aneer ~iYd~re of the roof cov~r. The ine~allation of theee giYdere
ig ac`ompl;Lehed in conjunct~on trirh ehe in~ealiation of the boiler biocka,
somaehing irhich eignif~cantly ~impiifie~ t~~ inatel~aCion of ~he larg~ bo~ler
biock~ in ~:he poeition ceiied foc ~n the pian.
Th~ folioai.ng ioad iifeing m8chaniea~~ are pi~ced in the boiier rooms
--Thr~~ bridge cran~e vith ~ load capacity of 100-10 t each in ~he U-E
~pan at rhe 110.0 m marker for the installaeion of the boiler, the auxii-
iary boiier equipment, the metal strrrcrures of the roof, and ehe cent~r
_ ~irder~ af the raaf cov~ring Wfth an av~r~11 a~ight of ~bout 15,0~0 t;
--Two fully rotating, suspension cranes each in th~ upper sacrion o~ gpans
C-D aed E�1~ at the 114.0 m marker having a ioad capacity of 10 t each for
the inetaliation of the heat exchaegers and ~he piping witi~in the confinea
oE the boiler with an overall aeighr of about 450 t=
--Tvo fu11y rotating, guspeneion cranes each in epane C-D and E-F aith a
load capacity of 10 t under ehe horizontal truss at the 101.0 m marker
for the installation of station piping, as well as piping Within the con-
fines of ehe boiler With an overall mass of about 2,200 t;
--On~ bridge crene each in apans C-D and E-F at the 54.0 m marker aith a
idad capacity of SO/10 t for the installation of the auxiliary boiler
equipment (dust-gae-air pipes, milis~hlos~?ers, etc.) With an overall aeight
of 5,000 t;
--Two bridge cranee With a load capacity of 30/S t each (in the ~pan D-H)
for the inetallation of the structures of the tubular air preheater and the
auxiliary boiler equipment in chis grea ~+ith an overall Weight of about
3,000 t.
The appropriate openings Will be left in the ends of the building to move
the bridge and fully rotating cranes from one cell to the other, ahile
overhang brackets.are in9talled in the last end face for the capability of
disasse~a~ling the cranes.
26
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'Phr@~ in~e~~i~cion ap~ning~ are provid~d in ~he b~s~~r room for ~upplying
~quipm~~es ~n~ ~rieh a h@igh~ oP 16 m aad a aidch of 23 m beCr~teen row~ D-~
on eh~ axie of eh~ Purnac~, ehe ~~cvnd wiCh a h~ighe of 14 m and a wideh ~f
9 m b~~ween rc?r~ C-D and E�F, ~nd rhe ehird wteh a h~ight of 13 m~~d ~
width of i2 m~,n th~. ~nd waii of ehe air preh~ae~r b~~id~n~,
tn wnrking out th~ in~ea~~~e~on e~chnoio$y fa~ eh~ baii~r~, ~p~~ific
~erueeural dee~gn ~e~enre~, th~ layou~ of th~ bo~~~r buiiding and ~he pre-
e~nc~ o~ eWO br~,dge sranee 3n ie hav3n~ ~ c~pac~ey of i00 t~~~h were t~k~n
ineo ~ecounC.
Ie i~ provided ehae th~ assembly of ~h~ in~t~llat~on block~ be e~rried out
th~ R~~iona~ Compr~hQnsiv~ Production Saee (RPKB).
~nstalla~ion 91ock~ ~~~Q~ Toea~. W~i~ht,
of Pi~e~~ eon~
Ldw~r r~diative g~c~ion ehielde 8 gp6
Upp~r radiative e~~tion shields ~ 394
C~nneetin~ gas duct ehielas 8 gt,~
Convectiv~ ahaft ehields 12 934
Shi~ids of ceiling ever ~he furnace S 35
The cold hopper funnel y ggg
Ga~ intake ehaft ehield 2 2g6
Shroud~d st~am superheat+~rs 24 1,577
Steam guperheaters and the econrnaizer
of the convective shaft 32 2~780
- 1ie~t exchengers 20 208
Tata1 124 8,497
A schemstic shoain~ the breakdrnm of the boiler heating eurfaceg into
ingrallation blocka ia shoan in Figure 2, and th~ number and aeight of th~
block~ ure indicated in the tab~~.
* The questions of organizing the installation of the main technological
equipment of the Berezovskaya GRES-1 are treated in more detail in the
erticle o~ M.Ya. Borts, which is published in this same iss~ue.
27
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FOR ~~PiCiAL t~9~ ONLY
'fh~ edra! ~3ghe oE eh~ m~e~i pa~e~ ag eh~ b~i~@~ amoune~ to ~bout
18,000 e.
Th~ eoEa~ numb~r of ~1d~d ~oint~ ~e 43,70A, and ~h~ lengeh o� eh~ ~id~d
en~me along ~he lin~ 04 ~h~ p3~~~ ~~id ~h~ 4~ 1~,000 m.
A1~ of eh@ bloctcg of furnae~ And eonv~ee~v~ ~ha~t ~hi@id~ (Figur@ ~r@
btiought oue in a v~rti~~l poe~.eion in the FurnQC@ apace by oae b~ridgp
er~n~ u~ing a tiit~.eg ~redle (eha raiiroad f~a~care are dei~v~red by e
di~e~i ahuneer). fin eh~e ca~~, th~ heek of ehe e~cond crane w~th th~
, Er~~ly hanging ~l~n~s i~ connected to ehe upper p~tt of eh~ bio~k, ~ua-
pend~d on the 6racket pro~~ceion of the ~~lting cradl~. Th~ ~econd cran~
retaovea the biock Erom eh~ eilting eradie and ~n~eaii8 it in ~h~ planned
position~ Then, by uaing the firse crane and th~ rai~road lia~car, th~
ti~ting eradle 3e Aet 3n ehe eranapore pa~~c~on.
T~~ biockg of th~ ~hroud ~tea~ euperh~ater
~ ~;~I;;,~ Figure 1b) ar~ dellv~red to th~ a~~em-
n i sse t~iy gon~ and brough~ into a vertica~ pogi-
~~~.:~i:?~: ers. The e3lrin of ehe8~
illl~~~i, tion in conra~n ~
I blocke ie accompliehed by t~+o cranee.
a~, The in8taliation o~ the biocka in ~h~e piann~d
poeition is performed by meana of the inven-
' ??j�t 'x~ torY cro8s memb~r-rriangles, iestallation
, baams and other attachmente.
~ ;
~a~.� in accordance al,eh ~he adopted ~echeology,
the conetruceion and installation work in
Figure 3. M inetallation the boiYer bui~ding shout.d be completed ~th-
block of che in the iimits of the boiler ce11 prior to the
convective shaft etart of boiler installation, ~rith the excep-
haating surf.aces. tion of the instailation of the metal sttuc-
eureg of the ceiling cover, ahich is performed
eimultaneousiy i+ith the inetallation of the
boiler biocks.
Thp production sequenre for the installation of the blocks iss
1) The metal etructures up to ~he 43.0 m mark, the pulverised coal~burners~
the dust-gas-air ducts, ~he shot bunkers, exhaust gae and gas inlet cases
up to the 56.9 m mark;
2) The BT-1 center girders above the convective shafts (KSh), the piping of
the suspenBion syet~m of the seiffening beams of the outer side aalis of the
KSh, and the stiflening beams of the outer shields of the KSh side walls;
28
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~ FOR OFPtGiAL t~9~ BNLY
Th~ i~T-2 c~ne~~r ~ird~rg, eh~ ~~e~l g~ruc~u~~~ a~ Ch~ r~of aov~r in eh~
r~gi~n of eh~ K9h~e, ehe blo~ke of ChQ it8h eid~ gh~~id~, aed of �rh~ frcn~
and r~ar aaila ef ehe K3h~a, ~he block~ of ehe h~~e~ng ~urfan~e and erorm
~ pipee oE ehe Ksh~~, eh~ blecke of the eide ehieid ~rt~h fe8toon~, and ehe
bieck~ ~f eh+~ ~eifP@~tit~ b~~~ of ~h@ i~e@~~~ ~~d~ a~ii af eh~ ~9t~~~;
4) ~h~ m~t~~ eeruceuree of eh~ rru~~ ae the 70.A m mark under eh@ hor~-
~on~ai gae duceA, ~h~ pip~a po~~,eioe~d beer~reen the furnaae and ~he K9h,
~h~ ~u~perteion pip@~ of rh~ 8e~,f~~n~n~ b~am~ o~ ehe ineernai K9h ~re11, eh@
bloek~ o~ aeSf#en~n~ b~am~ ~nd ahieid~ of eh~ NRCh of th@ furnae~, ~he
biocke of the VRCh 8hield~ of ~hQ ~id@ w~11~ of the furnace and ~he block~
of th~ hn~rth of ~h~ horiaon~al gag d~ce;
The ~~-3 cenCar girder~, Ehe fr~nt end rear b~ocka of ghi~ida of ehe
horigoneai gae duc~, and ~he biocka of rhe ehroude of th~ ee~ge iT e~condar~r
~~~~m ~up~rh~gt~r;
Th~ BP-4 center girder~ th~ block~ of the etg~e I ghroud ~rea~ pr~heat~re
t+ieh ~e~CoonB, eh~ blockg of the VRCh and NRCh shieidg of the eide w~~l of
th@ furnace, ehe blocke of the ehiaid w3th ehe aerodynamic pro~eceion, the
blocks of etiffenin~ beams for the fron~ and re8r aai18 of ehe furnac~, the
biockg of rhe VRCh of the front and rear wa11g of the fUrnace, ehe bioclcs
of the stageg II and ~TI ~hrouded prehegter, and the biock8 for the cold
funn~i hopper and cro~rn pipes.
Coneluaions
l. Placing the building coiumns of ro~+e C aed D cloae ~o the boiler
mak~~ it poeeibie to ehorten th~ gpan of ehe boiler room dawn to 33 m, and
r~ducp the ~ight and geometric dimensions of the center girders, eomethtng
whi~h significantly simplifies their installation in the plan position vith
one crane.
2. C~mbining the boiler and boiler room building framea petmiee the manimum
a~~~hanization of th~ inatallation op~ration. The placement of th~ insta118-
tion frames in tfie epana of th~ boiler room makes it possibie to orgenise
th~ inatallation operations in independent flo~+s.
3. Bringing the blocks into a vertical poaition, and placing them in th~
plan po$ition are accompli~hpd by meane of special inventory accessories,
something whl.ch significantly reduces th~ metal coneumption in th~ inatal-
iation of th~ bo~iler.
COPYRIGHT: Izdatel~s[Vo "Energiya", "~nergeticheskoye stroitel~stvo", I979
g225
CS0:1822
~ ~
FOR OFFICIAI. USE ONLY
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FOR Oi~ICIAL U98 ONLY
~U~L~ ANfl R~I.ATFD EQUIPM~NT
~
Ma~TlIOb:~ ~OR COP~NB WITN O~L AND aA9 ~PAUTER~, HELL P~RES TOL~
Mogeow Ft~RM2ROVANtYA QRAZNDAN3KOY OBORONY V BOR'~~ 9A ST~K~ltYNYMt ~EDST-
vt~rnrt~ ~n Russ~ar~ ~97~ ~,39-~43
[Seetfon d of ~h~p~~r 9 of the book, ~~Formirovaniya ara:hdanakoy Obororyr v
~ar~b~ g~ st~khiy~ B~d~~viyemi~~ ~Civi1 Defenee Forma~ions in ~he Fight
Ag~ingt Na~ur~1 Di~~g~et~~jt ~~Peouliariti~8 of Ov~eraoming ~~ergenai~s Q~
Oi1 ~nd (ias Pielde"j
[T~xtj L~rge oil and ~as fi~1d indus~ry enterpri~e~ include Ne118 ~ha~
~r~ b~fng drilled or opera~ed and th~ neeessary eqaipment. B@eause of tihe
pr~sen~~ e~ almost every produe~ion f~cili~y of easily iflfl~mmable ~nd
combustible liquids, oil and ga8 fields are ex~rgordinariiy d~ngerous Ni~h
r~speet to fire.
~m~cgeneies at Ne11s arise moet frequently during ~he oonoluding pha8e of
d~illing, ~?s g consequena~ of a violation of tihe operating regul~tione or
the ~ffects of reservoir presaure. As a result of theae faetors~ the
drilling tool mqy b~ ~~~c~ed (or the operating equipmen~ m~y be broken
off) Nith an intenae gnshing of of1 or gas. ~mergen~ies that combine
fir~s, explosions and the forming of Iateral burning craters are of an
especi~lly dangeroua nature.
Cnn~i~tering thc serioug danger of such cmergencies~ definite o~~izatiion-
a1, engineering and ~echnica~ mesaures for dealin~ Nith ~hem mus~ be
called fnr in advance. 3ervices for preventing the oecurrenee of and for
~l~minating gae end oil apouters gnd ~upp~rt e~nt~rs for extingufshing
fires are ereated~ special cunching for personnel is organized, and so on.
Fm~rgCncies at oi1 and gas fields are eliminated by the 3oint efforts of
the 1oca1 ageney's gervice for the prevention and elimination cf gas and
oil spou~ers, the oilfield'a civil defense units, and the oblast's (or
rqyon'~) firefigh~ing ~erviC~. tn the case of large Fires~ the forces and
regourc~s of neighborin~ oblasts and other services are used. In order to
dcvclop preparatory measures and to ~rork on the elimination of spout~rs~ g
gLaff is created that ordinarily includes engineers and technicians of
thc oi1 or gas field, representatives of the services for preventing at~d
eliminating oil and gas spouters~ Gosgortekhnadzor [State Committee for
30
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t~OR OFF~C~AI, U98 ONLY
~h~ 9upervia~on of fndus~ri~~ 9~f~~y and for Mining tn~p~e~~on] org~ns~
~h~ ob1a~~'s oivil def~n~e ~~aff, ~nd flr~fightifl~ ~nd e~h~~ ~ervia~g ~nd
~~a or~afli~~~~ofl~ ~h~t ~r~ involved in ~limin~~in~ ~u~h~r~. Th~ ohi~f af
~h~ s~~ff i8 named from ~he field'~ adminis~ration and i8 ~he ~r~p~rvi~or
of oper~~ione. Respon~ible lin~ pergonnel, yho ~r~ deputiee of ~he ahief
af ~he s~~ff, directily eup~twis~ th~ ~etion~ af p~r~onn~1.
~ Wh~n a~pou~er oeeu~g, th~ cl~ief of driiling �he dri~l~n~ for~manl i~ r~-
qufred ~o quiekly report th~ ev~~t t~ th~ fi~ld~~ ~~n~g~m~n~ ~nd ea~11 thC
~ubunit~ of ~he Bervie~ for ~he pr~ven~ion ~nd elimina~ion of ~ae and oil
~pou~er8, ~h~ firefigh~in~ ~~rvie~, aad medio~i fire~ ~id.
~n ~he d~nger.~con~, prior t~ arriv~i of h~ip, work e~~g~~ and ~n ~v~cu-
~tion of p~r8onn~i ig org~nized. Wi~h a vi~a to preventiing i~~nition of
~he guaher, in~ernal oombu~tion engin~a ~r~ g~opp~d, poaer and light~ng
iines are sNitehed off, open flame goure~$ ~re ex~inguished, and ~rari8-
port movamen~ ia e~opp~d in ~he ad~aeen~ grounds. We~~ing doan of ~h~
fiowing ~~ream and of the m~~a1 a~ruo~ur~ ~ha~ comes in oon~aa~ ai~h .it ig
or~~nized~ for Nhiah purpo8e all produa~ion units ~nd fire-ex~ingui~hing
r~soureeg are u~~d. Wher~ n~eeg~ary, measur~g ~r~ ~~k~n ~o pr~v~nti ~he
of1 from 8preading. If tihere is danger tha~ gas wi11 invade n~ighboring
facfli~i~8, ~heir opera~ion~ aleo aease. ~
TMe ~hfef of ~he ataff, on arriving a~ ~h~ scene of ~he fir~~ organizes a
r~c~onn~igs~nce for da~~ tha~ wi11 ea~ablisht the aireums~anc~g arid causcs
of ~he oil gusher, the oondition of the rreil bore and the bloNOat preven~-
er, the gusher~g parameters, and so on; the extent of spread of the gas~
taking into aeaount the prevailing Ninds and placea phere gas oould aocu-
mulate; directions of the oi1's apill~ng, identifica~ion of the faoilitiieg
that are threatened in this CA9~~ ~d the me~sures for restrioting thc
oil's overfloN (leveeg, oil traps and so on); and the availabili~y and
~tatus of the Na~er supply.
The amount of urgent emergency Nork is specified. The places and periodi-
city for sampling air for toxicity and risk of explosion are determined.
Warning signals are defined in order to prevent access by ou~siders to
the d~ng~r zone, and ~raffic-control points manned round-the-elock by
the f~cility's Norkers are established. The danger zone ig surrounded by
signs that Narn and that restrict mov~a~ent.
Communitiies and economic f~cilitieg that can be ~eopardized by the pr~s-
ence of gas are identified. On obtainiag such information, the appropri-
~?te civil defenae ~hiefs specify a plan of action, organize CD gtiaffs in
round-the-clock Watches~ and establish end maintain continuous communiea-
tions Nith the emergency-elimination st~ff.
eased upon an evaluation of the situatian that exists~ an effective plun
of operations for eliminating the emergency is developed. Thi~ pl~?n r~-
flects: a~ethods for eliminating the spouter; the sequence for performing
the operations~ the volume of the operations~ ar~d the disposition of for-
ces and resources; requirements for equipmen~~ tools and attachments~
. 31
FOR OFFICIai. IJSE 0~'LY
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FOR OFF~CIAL U9~ ONLY
~~~ardin~ ~o ~he m~~hod eho~~n far ~l~min~~ing ~h~ ~m~r~~ney; ~ad mea~ur~s
P~r pravid~n~ s~f~~y for th~ ~p~r~tion~.
Wh~r~ ~h~r~ i~ ~n ~m~rg~ney wi~h tha aimul~~n~ou~ oeeurr~no~ of fi~ra~
Pir~t of ~11 ~h~ danger o~ spre~ding ~h~ fire i~ ~limin~~~d ~nd ~h~ p~d~~e-
ti~n of n~ighboring ~~ru~tures is organized. On ob~ain~.ng ~he r~qu~.rad
inform~~~on from ~h~ ohief of driliing, ~he oommand~r of ~h~ f~r~f~gh~ing
9l1bUfl~~ ~99U@~ ~n in~tit?ue~ion ~o dep~oy ~h~ firef~gh~~ng forces and
~quipm~t~~.
ACt~r thi~ ~h~ fir~figh~in~ ~up~rvi~or, ~joiatly Nith ~h~ chi~f of ~h~
~t~ff~ m~lt~ a r~conn~i~sane~, durin~ Nhieh ~h~y de~erminet ~h~ re~i~bi1~ -
ty di th~ pro~~o~ion of n~ighborin~ e~ruc~ur~a; ~he poa0ibili~y of evaou~t-
in~ v~iu~ble equ~pment from th~ dan~~r zone; ~he ~~atiua of the Ne1~ head
and th~ ~quipm~nt ingti~lled ~hereon; tihe na~ure of ~he floN; and ~he eoure~
~ ~f th~ N~~er aupply ~nd ~he availabili~y of w~~er reeerves.
A~ ~xp~rieno~ ifldi~at~g, mueh ~ime i~ ti~ken up Hi~h prepara~ory Nork Nhen
~xtin~uighing gusherg. Thi~ ineiudea elearing the eo~ne of ~he fire,
~gt~bli~hing wa~er re~~rvg~, deploying ~he ex~inguishin~ equipmen~, and
ed~ching the personnel.
iVhen el~aring ~he fir~ a~ene, peraonnel and equipm~n~ op~r~t~, ~ rul~,
under ~he oover of a Na~er cur~~in beeauge of ~he inten~e r~di~nt h~~t. Si-
multrineou~~y wi~h cl~aring the Ke11 head, Mork pr~ceede on organiza~ion of
the roada and sites for inatialling fir~fighting equipment and making
lev~e~ at the se~n~ of tihe emergeney.
Wat~r re~erves are eatablished, based upon an analysis of n~eds for ex-
tiinguishing the fire and cooling the zone efter the fire is out. Ma~er at
the fi~ldg is ugually inadequate for this purpose. Therefare~ astificial
N~~~r impoundments are bui1~ and wa~er pipe ia laid ~o them~ pumping unitg
are get up~ and go on. Places for Nater impoundments are chosen no aloser
than ~00 meters from the fire aite and on the side of it opposite the di-
rco~inn of the prevailing xinds. Sites for installing autometi~c fire-
fighting pumps about the impoundroents are stipulated.
Dcplayment of ~he ex~inguishing eq~ipm~nt stert~, as a rule~ Nith th~ ar-
rang~ment of firefightiing vehielc~~ at the Nater sourceg and lqying of hoar
lines to the scene of the fire. in order to reduce the length of hose
" 1ine~ ~nd to use pumpa at fu11 capacity from ~he impoundments, metal pipc-
lines usually are leid to thc scene of the firc. hthen there ar~ not
cnnugh fir~figh~ing vehicleg at the Nater irapoundments~ special pumping
units are established.
C~~ching of ~he personnel coaimences after the n~cessary reserves of Kater
and equipm~nt have been established and eppropriate measures that relate
to extin~uishing ~nd ~hutting off th~ guaher h~v~ b~~n t~t~n. Th~ m~in
~urpose of the coaching is to perfect the ~hosen method of extinguishing
the fire and to achieve coordination in the actions of the personnel of
thc fotmations under high-temperature situations. The supervisor of fire
~
FOfi Ol~'FICIai. L'5E 0~'LY
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APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100054428-5
FOR OFF~C~AL U9~ ~NLY
~xtin~ui~hin~, ~ain~ly with ~h~ ~ppropri~t~ r~pr~~~n~~~iv~~ of ~h~ ail-
fi~ld~ dr~~ni~~ ~nd eandu~t ~he ~o~ehing~
M~~hod~ fo~r ~xtin~ul.ghing th~ fir~ d~p~nd upo~ ~h~ n~t~r~ of th~ oi1 ~u~h-
~r~ it~ in~engi~y, th~ lo~al ~itua~ion, and tihe ~vailabiii~y of fire-~x-
tin~ui~hing r~~our~ee. Th~s~ m~tihod~ inolud~: ~hu~ting off ~he ma~~er
Qontrol killin~ th~ ~r~ll= di~pa~~n~ o~ oil ~nd from ~he w~il=
u~in~ di~p~r8~d a~~~r spr~+~; de~on~~~ng ~xp~o~iv~~; ~nd u~in~ ~urbo~~~
in~~~ll~tione.
~huttin~ off the m~~t~r eontrai ~~te i~ ~he ~imp1~~~ m~~hod of extingu~~h-
in~ th~ fire. ~'his i~ ug~d in ~he initial ~t~~e of ~h~ fir~ wh~n th~
r+~ll-M~~d ~quipment i~ pr~~~n~. A group of fir~men ~quipped wi~h eom-
prega~d-~~,r app~~atus ~nd ~hieiding elothing ~dvan~~ on ~he weil und~r
prot~etive water sprqye and eloae ~he ma8~er oon~rol gat~. Combus~ion
~e~see as a re~uit of eiiminating ~he f1oN.
Killing th~ w~ll i~ u~~d Nh~n equipmen~ ree~ain~ a~ the Ne11 head that
wi11 ~n~b1e ~h~ ki~ling uni~g to be BNitched on. The e~senog of ~hfs
m~thod ~ongie~g in ~h~ faot ~ha~ r+hen wat~r or c1~ mud is in,~ec~ed into
th~ We11 ~hrough ~he dri11 pipe or ~he tubing, a pregsur~ ig created
ther~in that ~xceeds the reservoir preggure~ as a regult of Nhich tih~
flowing eeageg and the flame ie in~errup~ed (snuffed ou~1. ~v~n if the
in,~~ct~d liquid is completi~ly e~eeted by the gush~r's ~~ream and doe~ not
~ucc~~d in ex~inguiahing the f~ame, the temperature of the burning gugher
fg reduced, enabling the use of othor methods for extinguiahing it. _
Th~ withdraNal of oi1 and gas from a Ke11 ia executed~ as a rule, by ar-
rangemen~s for draining. Bulldozers make a ring levee around the N~11 ~o
tha~ th~ burning oil Ni11 not spread. Simultaneously~ pipes Nith ~yrdraul-
ic valves on ~he ends are laid under th~ levee at a slope from the Nell.
The~ the l~vee is gradually ~onstiricted abou~ the whole perimeter. in se
doing, the oil descends along the pipes ~o a safe place. When the burning
area is redueed~ drainnge is cons~ructed. For this purpose metal and
rubble are trro~+n up behind the levee and perforated pipe is laid for the
removal df gas and oil. When a drainage lqyer of the required height is
formed above the pipes, the fire zone is covered Nith steel sheets and
clay is piled on. Burning gas Khich seeps through thc drainage lqyer is
extinguished by dispersed Nater spra~ys. Moreover, the oi1 and gas ean be
r~mnved through alant-drilled Ne11s, through a cap Nftih NithdraKal pipe
that ig slipped onto the He11 head, and so on.
Di~p~raed Mater sprays extinguish gushera that have diffused flarea, ae
Nel1 as burning craterq thgt are sma11. The essence of thig method is
this: after an earthen levee has been ereated around the Me11 and it is
heatied~ all the dispersed water spr~ys simultanedusly are moved gradually
ft~m ~h~ base of the levee ~o i~s summit. ?h~ steam tha~ is fo~ed dur~?
ing evaporation of the Nater enters the fire zone and stops the combus-
tion. The advantage of this method is the caaparatively small Nater
consump~ion.
33
FOft O~FICI~. L'5E 01'LY
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,
~OR O~FICIAL U3~ ~NLY
Camp~~~ ~tr~~m~ of w~t~r, a rul~, ~xti~~ui~h ~u~her~ c~C ~m~1i or mod~r-
~t~ inten~i~y whu~~ ~tr~~m~ a~~ ~ntir~ly v~rtic~l in dir~etiion~ Th~ ~x-
~in~ui~hing e~f gu~her witih ~omp~o~ ~i;r~~m~ i~ b~~~d upon tih~ ue~
d~ th~ ~tr~~m's dyn~mic fore~t iti ~~pi~r~~o~~ ~h~ ~a~ gush~r ~nd 9@~~3'~t@~
~i~o1~?~~g) the burning f1~r~. Th~ forma~ion of ati~am, whfeh r~dao~~ th~
~emp~ratur~ ~nd the a~ygen oon~~n~ in ~h~ oombu~tion ~~n~, ~l~a h~lpg ~o
pwt aut th~ fir~.
Turb~~jr~t inr~t~~l~~ian~ ~P~ wid~iy ug~d +.c~ ~xtinguigh ga~ and g~g-and-oii
gu~hrr~. Th~ fira ig ~xtin~uieh~d by mean8 of a fire-qu~nohing stir~~re
th~t ~ongi~~e of ~ mix~ur~ of ~h~ ~urbo,~p~ ~ngin~~e ~xhaug~ g~s~~ and
~pr~y~d w~t~r. Th~ esgeno~ af thie m~~h~d i~ ~he fao~ th~~ ~h~ f~re-
qu~nehing s~ream from th~ ins~~ll~tion i~ plao~d und~r the base of tih~
burning ~ugher in ord~r ~o ~ep~ra~e ~he gualier~s cnmbue~ion ~on~ from th~
we11-h~ad equipmen~.
AftCr th~ fire ie extingui~h~d, a~~eond and no l~s~ eanplioa~~d ta~k i~
r~sulv~d--that of a~pping th~ gu~h~r, for wh~ch purpos~ th~ m~thod~a d~-
~~rib~d above for eloging th~ m~s~~r oontrol gat~~ killing tih~ w~11, and
rCmnvi~g oi~ ~nd gag ar~ ug~d, ~nd ulsa underground naci~ar explo~iong
~r~ uged.
Uper~tinng dir~atly at ~he we11 he~d for ~lfminating ~~usher ~r~ per-
~drm~d by personnel nf ape~ial ~ubuni~a with the par~ieipaLinn of tihe
fir~figh~fng 8~rvia~. The per~onnel of c~ther service:~ ~nd foneations for
pr~p~retory operatiions in tihe dang~r zone ar~ inv~lved only af~er tih~y are
giv~n special inatiruc~ions and provided with proteatiive ~quipment and s~e-
aial clothing.
Oper~tions at rhe Ne11 head and on ad,jac~~t grourid ara p~rformed under
the ob~ervation of firefighters, who provide xa~er proteetion to the
wdrker~ and eon~inuou~ feed of N~~~r fnto the gu~hing atream ttnd to the
gurrounding metal structure.
The extinguishing of gusher firea involves gerious danger for people.
Thertfore~ in solving organizationul ~nd pr~ctical quegtions far eliminat-
ing em~rgenaies, measureg are d~fined that Kill provide for people's
~nfcty ~nd alsa protect firefighting and other equipment. in additidn to
thc gcner~l safety m~asures~ personnel are given an "acalimatization" fdr
N~rk in a high-temparature environmcnt. For this purpoae, the time that
people gpend continuously in the zone of thp fire's heat effecte i~ in-
cr~aged gradually, and contiinuity in ex~inguishing the fire i~ aehieved
by wnrking the p~rsonnel in t~ro oc three shifts.
~rinr to the start of oper~tions at the head of a apouting well and in
th~ xnne ud~acent th~reto, the surroundir~g air is analyxed for the pres-
cnCC of g~a~s that are potentially explosive or toxic. On this basis,
mcana for protection are determined, and routes for people to appro~ch
thc Ncll and to leave the dangtr zone are established.
34
FOR OFFLCIai. L'5~ 0~'LY
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100050028-5

APPROVED FOR RELEASE: 2007/02/49: CIA-RDP82-44850R000100054428-5
I
FAR OFFIC~AI, U3E ~NLY
A11 op~r~~ion~ in rh~ xon~ wh~r~ g~8 ia pr~~~n~ ~re p~rforro~d by p~r~onn~1
dre~~~d in individuai means of protieo~ion (tih~ s~~ff ~~~abli~h~s ~h~ tiyp~~
~f proti~o~ive means) and oniy wi~h ~up~rnum~r~ri~~. The ~tlp@PflW1~3'~~'~,~~
ehou]~d kncw tihe in~~ial eymp~oma oF ~oxio e~feo~g, know how ~o ex~end
fira~ aid~ and n18o know th~ rou~es for evaoua~in~ vfo~ims~
buring op~ra~ion in ~~one wh~re th~r~ is ~ riek o~ a g~8 explo~ion~ only
= sparkfree tools ehould be uaed, and ~h~ workers' ghoes should not have
me~a1 r~inforoemen~s or a~~~1 na~la.
In ~~tabliehing work pbriode ~r?d resti periodg for personnel ~n an environ-
m~n~ wh~re ~here is gas~ consifleratiion ie ~iven ~o tihe de~r~e ~o which ga~
ig pr~aenb, ~he na~ure nf tihe work and climatio oonditiiona. ~es~ tiime
ahouid be no lesa than ~he ~ength of ~ime apent working in tihe pro~eotiive
~quipmenti. ~t ia redueed only when neoeseary to resaue people~ The peri-
od for eon~~nuoua work a~ a apouter ahould no~ exeeed ib minu~ea.
~eople who work in a high-tiempera~ure ~rea ehould be dresaed in apeeial
~lo~hing. Moreover~ tihe workers' clotihing must be gpr~yed contiinuou~ly.
Weter oannon are alloaatied for thia purpoae.
Me~a1 or wooden ahields padded wi~h asbestos fiber are uaed to proteot
people from atones and roek tihrown by the gusher. Moreover, tiemporary
~wningg are eonatirueted and, for protieetiion againsti radiant he~ti, shields
are provided. Special earmuffa are used tio pro~ec~ the hearing organa
from the noise made by the stiream of gas. '
The us~ of iIV's [exploaives] muat be guided by the appropriate instruo-
tions. Work on preparing th~ charge, placin~ it in the case, installing
the electrical detonators, ~?nd suapendin~ it should be carried out only by
exploaives apeoialist~.
In order to extend urgent medical assiatance to the in~jured, a medical
post is organized close tio the place where the fire is being extinguish~d.
With the Coming of darkness, during fog or anowstorms, and also during
~hunderstonos~ a11 operations at the gusher head and in areas where gas is
pre~ent cease~ except for Work connected Nith rescuing people.
Safcty measur~s during the preparation for and conducti of operationg for
extinguishing and capping gushers are act by special instructions, the
contents of Nhieh should be knoKn to all peraonnel. The chief of tihe
st~ff names one of his asaistants ~o be responsible for inauring operat-
ing safety and for observing safety meagure~.
COPYttIGHT: Stroyizdat, 1978, s izmeneniyami.
11409
C50: 1822 END
35
FOR OFFICI~u. L'SE OI~'LY
APPROVED FOR RELEASE: 2007/02/09: CIA-RDP82-00850R000100050028-5