Design and analysis of fixture for easy lug plate fit up at bend portion of first pass and second pass gang bend water wall panels phase I

With the technological evolution of “high-pressure steam generators” from sub-critical to the super-critical stage, the “Water-wall Panels” is transformed from “straight panels” to “terminal bend panels” and “gang bend panels”. The lug plates are fitted at the bend portion of the terminal and gang bend panels as per the design. The traditional method of lug plate fit up has an awkward impact on the working method, productivity, quality, and re-work. This paper aims to discuss the design and analysis of the fixture to avoid the manual lug plate fit up. With the proposed design of the fixture, the lug plate fit up can be done easily at the bend portion of tubes of gang bend and terminal bend “Water-wall Panels”. Proposed design not only solves the problems being faced while giving the easy fit up but also brings in marked improvements in workplace-safety, productivity, working environment coupled with a considerable reduction in manpower and operational risks.