QUALITY CHECKS

STRUCTURES:
FOUNDATION :
1.

Availability of identified & protected permanent bench mark.

2.

Elevation of top of foundation pedestals w.r.t. permanent bench mark

(Tolerance : + 30 20 mm).

3.

Disposition of foundation pedestals w.r.t. longitudinal axis of boiler and reference axis.

4.

Spacing between the foundation pedestals. (Tolerance : Between adjacent

pedestals 1 mm / M, 5mm Max., between first and last row of foundation 1mm
/ M, 15mm Max).

5.

Diagonals of the main column foundation pedestals. (Tolerance : 1 mm / M, 10 mm

max., cumulative diagonal difference 1 mm / M, 25 mm max.)

6.

Pitch distance of foundation pedestal bolts on both the axes and its diagonals.
(Tolerance : pitch distance : 3 mm, diagonal difference : 5 mm max.)
STRUCTURES :

1.

Pre-assembly of columns before erection, wherever applicable.

2.

Individual column piece camber and sweep (Tolerance: 1 mm / M; 10 mm max.).

3.

Camber and sweep for assembled columns (Tolerance: 1 mm / M; 18 mm max.).

4.

Total length of column before erection (Tolerance: 15 mm max.).

5.

Orientation of columns. Check for match mark, elevation mark, column No., splice
size etc.

6.

Ensure matching of centre line of base plate with pedestal axes.

7.

Elevation of column at 1 M level with reference to bench mark (Tolerance : 5 mm ).

8.

Alignment of first piece of column with horizontal beams and vertical bracings
(Tolerance: Position w.r.t. reference axis: 5 mm ; elevation : 5 mm).

9.

Completion of boxes with main brace level members (MBL).

10.

Grouting gap below the column base (Min. 20 mm ; max. 70 mm ).

11.

Verification of test certificates and batch certificates of grout material.

12.

Grouting of column bases.

13.

Alignment of columns at every stage of erection.

14.

Camber and sweep of the individual ceiling girder pieces

(Tolerance : 1 mm / M, max. 5 mm).

15.

Alignment of ceiling girders. (Tolerance - Spacing : 5 mm; diagonal : 25 mm max.)

16.

Verticality of columns before and after ceiling girder erection, at every 5M and at
column erection joints. (Tolerance : 1mm / M; Max. 25mm).

17.

Centre line of ceiling girders marked w.r.t. longitudinal axis of boiler transferred from
ground level to top. (Tolerance : 12 mm max.)

18.

Readiness of structure for drum erection.

19.

Verticality of all main columns (wherever possible) immediately after drum lifting and
compare with previous values.

20.

Removal of temporary supports.

ELECTROSTATIC PRECIPITATOR
FOUNDATION :
1.

Location of foundation pedestals of ESP w.r.t. axes of boiler.

2.

Top elevation of foundation pedestals (Tolerance 10mm).

3.

Spacing between foundation pedestals and its diagonals

(Tolerance - Spacing : 10mm; Diagonals : 1mm / M, 10mm Max.).

4.

Bolt pitches and its diagonals of individual pedestals.

STRUCTURE :

1.

Camber and sweep in column pieces before erection.

2.

Orientation, spacing between columns and its diagonals.

3.

Verticality of X81 columns both in X & Y directions (Tolerance : 1mm / M, 10mm

Max).

4.

Ensure that top of columns are in same level.

5.

Location & orientation of sliding supports w.r.t. fixed foot (Tolerance : 5mm).

6.

Top level of support (slide supports and fixed foot) (Tolerance : 5mm).

7.

Horizontality of slide supports.

8.

Ensure availability of lock-nuts in foundation bolts after completion of alignment.

9.

Verification of test certificates of grout material and grouting of column bases.

10.

Diagonals of inlet, outlet and intermediate frames (pre-assembly)(Tolerance : 5mm).

11.

Verticality of all columns of inlet, outlet and intermediate frames in both X & Y
directions (Tolerance : 1mm / M, 10mm Max).

12.

Verticality of inlet, outlet and intermediate frames after erection.

13.

Ensure the centre line matching of X81 columns, X01 bearings and X48 columns
before erection of casing assembly (maximum permissible deviation : 5 mm)

Transfer the foundation centre line to base plate centre line.

From the base plate, transfer the centre line to bearing bottom plate.

From the bearing bottom plate, transfer the centre line to X48 column centre.

Ensure the correct orientation of X01 bearings.

CASING :
1.

Straightness and diagonals of wall panel assembly before erection.

2.

Verticality of walls.

3.

Distance between the walls.

4.

Straightness of wall along the gas flow.

5.

Camber and sweep of roof beams in pre-assembly condition before erection.

6.

Length, out of squareness of roof beams before erection.

7.

Locking of bearings.

8.

Level of bottom flange of roof beams (Tolerance : 5mm Max.).

9.

Diagonals of wall panel assembly after erection (Tolerance : 10mm).

10.

Spacing of roof beams.

11.

Marking of gas path centre line (GPCL) on roof beams on top and bottom flange
(Tolerance : 2mm).

12.

Alignment of roof panel w.r.t. GPCL spacing and diagonals.

COLLECTING ELECTRODE SUSPENSION :

1.

Diagonal variation of individual frame between corner hooks

(Tolerance : 7mm Max.).

2.

Individual and cumulative pitch of support angles (Tolerance : 3mm).

3.

Straightness of frame.

4.

Alignment of frame w.r.t. GPCL (Tolerance : 3mm).

5.

Disposition of adjacent suspension frame, cumulative measurement from GPCL to

the middle angle of individual suspension frames (Tolerance : 3mm).

6.

Hooks in angles at rapping side are in one line perpendicular to GPCL.

7.

Distance between centre of emitting system suspension point to first hook with
collecting electrodes frames (Tolerance : 3mm).

8.

Distance between top pads edge and shock bar guides.

9.

Gap between guide ends and casing walls.

10.

Level of suspension frames at bottom of end slots in each field.

EMITTING ELECTRODE SUSPENSION :

1.

Diagonal variation of individual frames between corner holders

(Tolerance : 7mm Max.).

2.

Individual and cumulative pitch between rows (Tolerance : 3mm).

3.

Straightness of support beams, vertical beams and shock beams.

4.

Straightness of vertical stays.

5.

Alignment of support beam with frame part top (Tolerance : 5mm).

6.

Alignment of frame part top w.r.t. GPCL.

7.

Cumulative pitches and diagonals of the holders of frame part top.

8.

Holders are in one line for top, middle and bottom frame part.

9.

Verticality and diagonals of emitting frame work assembly for frame part middle and
bottom (Tolerance Verticality 5mm Max.; Diagonals : 10mm Max.).

10.

Alignment of holders top to bottom in both directions measure at four extreme

corner holders.
COLLECTING SYSTEM :

1.

Straightness of collecting electrodes before erection.

2.

Ensure that each collecting electrode rests on both hooks.

3.

Distance between collecting electrodes to vertical beam (on front & rear).

4.

Gap at bottom of gas distributor screen assembly (Minimum 100 mm to be

maintained).

5.

Clearance between shock bar edge to ridge cap (Min. 40mm).

6.

Clearance between shock bar edge to shock bar guide (Min.40 mm).

7.

Shock pads of all shock bars are in one line.

8.

Clearance between collecting electrodes and hopper (vertical) deflection plate in the
vertical plane (40 mm).

9.

Straightness of shock bars and guides.

EMITTING SYSTEM :

1.

Record sweep / camber for vertical beam, vertical stay and supporting beam.

2.

Distance between top of collecting electrode suspension angle to bottom of frame

part top (Tolerance : 5mm).

3.

Concentricity of suspension rod to screen tube.

4.

Distance between emitting suspension screen tube edge and deflection plate (shield)
(Tolerance : 5mm).

5.

Distance between emitting rapping shaft screen tube edge and deflection plate
(Tolerance : 5mm).

6.

Pin wheel clearance.

7.

Spring back of emitting electrode (Tolerance : Min. 350mm).

8.

Stretching of emitting electrodes (by stretching tools only).

9.

Insulators cleanliness, glassiness and no cracks.

10.

Clearance between the emitting frame and collecting electrode (Tolerance : 5mm).
COLLECTING RAPPING SYSTEM :

1.

Clearance between shaft axis to gable wall - front / rear (Tolerance : Min.350mm).

2.

Distance between centre line of rapping shaft to centre of shock bar (310 mm).

3.

Shock pad face and shaft axis to be in the same vertical plane (to be in the same line
for effective rapping).

4.

Lateral shift of hammers w.r.t. shock pad centres.

5.

Ensure phase angle of hammers and direction of rotation before welding of sleeves.

6.

Locking of plain bearings and set rings.

7.

Alignment of plain bearing and proper seating of rapping shaft in the bearing with
lock plate.

8.

Ensure water level throughout the length of each shaft assembly (use shims if
required).

9.

Set ring position and completion of welding with pre-heating using recommended
welding electrode.

10.

Ensure circumferential groove on coupling matches with the edge of clutch.

11.

Radial and axial alignment of clutch and coupling.

EMITTING RAPPING SYSTEM :

1.

Distance between shaft centre to vertical beam (Tolerance : 5mm).

2.

Distance between centre line of rapping shaft to hitting point on shock beam
(Tolerance : 5mm).

3.

Phase angle of hammers and direction of rotation.

4.

Alignment of bearing & proper seating of rapping shaft in the bearing with lock plates.

5.

Ensure water level throughout the length of each shaft assembly (use shims if
required).

6.

Set ring position and completion of welding with pre-heating using recommended
welding electrode.
G D SCREEN RAPPING SYSTEM :

1.

Clearance between shaft axis to primary screen edge.

2.

Distance between centre line of rapping shaft to hitting point at rapping bracket.

3.

Lateral shift of hammers w.r.t. hitting point at rapping bracket.

4.

Phase angle of hammers and direction of rotation.

5.

Alignment of bearing and proper seating of rapping shaft in the bearing with lock
plate.

6.

Ensure circumferential groove on the coupling matches with the edge of clutch.

7.

Radial and axial alignment of clutch and coupling.

8.

Set ring position and completion of welding with pre-heating using recommended
welding electrode.
INLET & OUTLET FUNNELS AND HOPPERS :
FUNNELS :

1.

Elevation.

2.

Length and opening dimensions.

HOPPERS :

1.

Elevation.

2.

Spacing w.r.t. reference axes.

3.

Ensure correct orientation of hopper manhole door location w.r.t. gas flow direction
for each row of hoppers.

4.

Ensure welding of matching channel with ridges and casing assembly horizontal
channels.
ELECTRICAL PANELS :

1.

Ensure panels are in one line.

2.

Size of cable gland.

3.

Glanding of cables and tightening of electrical connections.

4.

Earthing of all rapping motors, disconnecting switches, insulator housings, control

panels, H V Rectifiers.

5.

Concentricity of HT bare conductor with duct and connection tightness.

6.

Check for end covers, cooling fans, terminal boxes and oil plugs of rapping motors.

PRESSURE PARTS :
DRUM :
1.

Check for inspecting authoritys stamp on drum and certificate.

2.

Readiness of structure for boiler drum erection.

3.

Ground inspection of drum, its orientation.

4.

Drum suspension U rod dimensions and freeness of nuts. (Tolerance : arm length, arm
to arm distance : 25 mm; twist between limbs : 10 mm max.)

5.

Disposition of drum axis from centre line of furnace (Tolerance : 1 mm/ M, 5 mm max.)

6.

Elevation of drum suspension support beam (Tolerance : 5 mm).

7.

Spacing of washer plate w.r.t. boiler and drum axis. (Tolerance 1 mm/ M, 5 mm max.)

8.

Diagonal difference between washer plate locations (Tolerance : 5 mm max.)

9.

Ensure clearance between drum and structural members during hoisting.

10.

Elevation of drum (Tolerance : 5 mm; cumulative not to exceed 8 mm).

11.

Axial disposition of drum centre w.r.t. longitudinal axis of boiler. (Tolerance : 5 mm)

12.

Verticality of U rod. (Tolerance : 10 mm)

12.

Minimum projection of threads above the nuts in the drum suspension rods.

13.

Verify verticality of column after Drum Erection.

14.

Assembly of drum internals.

HEADERS :

1.

Check for Inspecting Authoritys stamp on headers and certificate.

2.

Identification of the headers.

3.

Cleanliness of headers.

4.

Bow in headers (Tolerance: 1mm / M, Max. 8mm for membrane panel headers and
Max. 10mm for other headers).

5.

Header scarffing line (Tolerance: 2mm Max. for membrane panels and 4mm Max. for
others).

6.

Completion of supports.

7.

Alignment of headers and elevation, horizontality and distance from reference axes.
(Tolerance : 3mm).

PANELS :
1.

Identification of panels.

2.

Width, diagonals & location of openings of the panels (Tolerance : Panel width : + 2mm
or 5mm. Diagonal difference (D1 ~ D2) : 10mm Max.).

3.

Cleanliness of the panels (sponge test with compressed air).

4.

Completion of supports.

5.

Completion of panel to panel joints

6.

Verticality of panels (Tolerance : 1mm / M, Max.10mm).

7.

Alignment of water walls (Tolerance : Furnace Width & Depth : +10mm or 15mm;
Diagonal difference 20mm Max.).

8.

Ensure welding completion of baffle wall prior to the erection of SH / Eco coil assemblies.

9.

Ensure that furnace walls are studded and refractory lined upto 1200 mm from Distributor
Plate.
COILS AND TUBES :

1.

Identification of the coils.

2.

Cleanliness of the coils (sponge test with compressed air).

3.

Alignment of coils w.r.t. inlet and outlet headers.

4.

Alignment of baffle wall screen tubes.

5.

Erection completion of bed evaporator tubes

SUPERHEATER COILS:

1.

Identification of super heater coils.

2.

Clearance between end coil assembly and water wall side walls (Tolerance : 10mm).

3.

Individual pitches between coils (Tolerance : 10mm).

4.

Clearance between coil ends and front water wall / upper baffle wall
(Tolerance : 20mm).

5.

Erection completion of bed super heater coils.

ECONOMISER :

1.

Identification of economiser coils.

2.

Clearance between end coil assembly and water wall side walls (Tolerance : 10mm).

3.

Individual pitches between coils (Tolerance : 10mm).

4.

Clearance between coil ends and upper baffle wall / rear water wall
(Tolerance : 20mm).

5.

Alignment and locking of cassette baffles.

DOWNCOMER PIPES (DC PIPES) :

1.

Identification of the DC pipes.

2.

Cleanliness of the pipes.

3.

Orientation of DC pipes.

4.

Alignment of DC pipes (Verticality of DC pipes : 1mm / M, 5mm Max.).

5.

Alignment of supports.

6.

Completion of seismic guides.

RISER TUBES / SH CONNECTING TUBES / CORNER TRANSITION TUBES :

1.

Identification of the tubes.

2.

Cleanliness of the tubes (sponge test with compressed air).

3.

Alignment of tubes.

4.

Completion of supports.
BUCKSTAYS :

1.

Identification of the components.

2.

Completion of buckstay channel, stirrup angle with beams.

3.

Completion of attachment welds such as scalloped plates and lugs.

4.

Alignment of buckstay beams.

5.

Completion of corner joints.

6.

Completion of furnace guides.

GENERAL :

1.

Verticality and loading of suspensions.

2.

Cold compression of all springs and locking of the spring assembly.

3.

Completion of pressure parts attachment welds.

4.

Closing of voids and cut-outs made during erection.

5.

Locking of supports for hydraulic test.

6.

Servicing of valves.

7.

Completion of drain / vent valves.

8.

Ensure welding of metal temperature pads on superheater coils.

HYDRAULIC TEST :

1.

Welding of insulation hooks / studs and attachments to pressure parts completion before
hydraulic test.

2.

Seal welding of all site RT plugs.

3.

Readiness of total system for hydraulic test.

4.

Completion of air test of the system. (Max. Test Pressure : 2 Kg. / Cm2 g)

5.

Rectification of leak joints and details.

6.

Clearance of milestone activity.

7.

Completion of hydraulic test.

DISTR IBUTOR PLATE (DP) AND COAL PIPING (CP):

1.

Elevation and location of lug plates for supporting Distributor Plate (DP) assembly
(Tolerance 3 mm).

2.

Soundness of welding of lug plates with W.W. Tubes (Random LPI 10 %).

3.

Trial assembly of DP frame for compartments at ground level.

4.

Assembly of DP compartments and seal welding.

5.

Soundness of welding of scalloped bar with W.W. Tube and DP (Random LPI 10 %).

6.

Elevation and routing of coal feed air line from header to DP connection
(Tolerance 5 mm).

7.

Coal pipe from bunker to fuel feed inlet.

8.

Completion of pipe line supports.

9.

Soundness of welded joints in the pipe line to avoid fuel / air leaks.

10.

Wind box connection to DP and soundness of weld joints.

11.

Provision of bed ash drain line & over flow line.

(Tolerance on elevation & location: 3mm).

12.

Provision of choking points in fuel feed line.

DUCTS, DAMPERS, GATES & EXPANSION JOINTS :

DUCTS :
1

Dimensions / diagonal of assembled duct (difference between diagonals not to exceed 2

mm / M ; Max. 5mm).

Distance of duct from the reference axis (Tolerance : 5 mm).

Elevation of duct w.r.t. bench mark (Tolerance : 5 mm).

End out of squareness of ducts (Tolerance : 2 mm / M ; Max. : 5 mm).

Out of roundness of circular ducts (Tolerance : 2 mm / M ; Max. : 5 mm).

Flatness of contact faces (Tolerance : 3 mm).

Centre line of bolt holes of matching faces of rectangular / circular flanges (applicable for
site drilled flanges) (Tolerance : 1.5 mm).

Minimum clearance between duct and adjacent member for insulation and thermal
expansion.

Cold pulling of ducts wherever indicated.

10

Freeness of slide bearing supports.

11

Contact of sliding supports.

12

Location and orientation of guides.

13

Orientation of flow measuring devices.

14

Location and cold set position of spring hangers.

15

Opening dimensions of duct w.r.t. damper dimensions

(Tolerance : width / height : 5 mm ).

16

Ensure cover plates for gas side expansion joints.

17

Welding completion for supports, suspensions, guides, internal stays, studs and tapping
points.

18

Removal of temporary stays and temporary supports of the duct.

19

Ensure releasing of hangers and cold value setting after insulation.

20

Cleanliness of ducts from foreign materials.

DAMPERS :

Internal dimensions and diagonals.

Links and seals for damages.

Verticality on both planes (Tolerance 1 mm / M ; Max. 5 mm)

Twist / out of squareness (Tolerance 1 mm / M ; Max. 5 mm)

Clearance between blade tip to tip and between frame and blade tip.

Free operation and full closure of dampers.

Orientation of dampers.

Match marks for multi-piece dampers.

Alignment of actuators.

10

Ensure the correct position of drive side shaft collar with the flap pulled towards drive
side.
GATES :

Orientation of gates.

Match marks for split up gates.

Seal damages.

Verticality on both planes (Tolerance ; 1 mm / M ; Max. 10 mm )

Twist / out of squareness (Tolerance Max.10 mm ).

Alignment of actuators.

Ensure chain sag is equal to chain thickness.

EXPANSION JOINTS :

Dimensions and diagonals after fit up

(Tolerance : 1.5 mm / M Max. 5 mm).

Height of expansion joints.

Matching of expansion bellow flange with duct flange connector.

Ensure cold pulled dimensions of expansion joints.

Ensure removal of flats, transport clamps between the bellows of the expansion joint.

Ensure cover plates direction of flow and welding completion of cover plate.
AIR & GAS TIGHTNESS TEST :
Air and gas tightness test for complete assembly of ducts, dampers, gates and expansion
joints.
INSULATION :

Completion of insulation for ducts, hot air / gas dampers, gates and expansion joints.

FUEL FIRING SYSTEM

PUMP MOTOR ASSEMBLY :
1

Foundation of oil pumping units.

Alignment of shaft and shaft gap (for site assembly only).

Parallelness of both coupling halves.

Alignment of base plate.

PIPILINES AND OTHER FITTINGS :

Slope for the entire pipeline layout.

Expansion loops in the oil lines.

Matching of connection pipelines.

Completion of welding and all NDE checks.

Completion of supports for the lines and removal of temporary supports.

Hydraulic test for the lines.

INSTRUMENTS, VALVES & OTHER FITTINGS :

Ensure the following are erected / installed only after completion of hydraulic test and
steam blowing for oil lines.
- Orifices
- Flow meter
- Trip valves and 3 way valves (oil system)

Flow direction of control valves, traps, non-return valves and trip valves for oil lines.

Length of pipe from burner valves to oil gun.

The HEA ignitor flexible cable hanging / or U form without twist and strain.

HEA flexible spark rod length A dimension.

STEAM TRACING :

Steam tracing of heavy fuel oil piping scheme.

Tracer / J.B. location in a place free from falling water.

Circuit length.

OIL COMPARTMENT :
1

Check the following after keeping the nozzle tips in 0 degree position.
a) Oil burner length and position.
b) HEA ignitor tip location.
c) Scanner viewing head position.

Profile of SV burner assembly.

Configuration / orientation of throat assembly.

Limit switch gun engagement.

Ensure oil and air entry connection.

Primary and secondary vane damper position.

Ensure the following :

a) HEA ignitor guide pipe (hose) installed with no sharp bends.
b) Insertion and retraction of the spark rod at various positions of tilt.
c) HEA ignitor guide pipe end butts in the sleeve provided in the nozzle tip.
d) HEA exciter is provided with canopy.
e) HEA ignitor cooling air / oil gun cooling air is connected properly.
OIL GUN ASSEMBLY :

K or KF dimensions for all oil guns.

Engagement of locating pin on the burner panel while bolting.

Tightening of cap-nut with spray plate upto the required torque value.

Disposition of diffuser shroud with respect to the wind box nozzle outlet plane after
mounting.

RADIAL FAN :
FOUNDATION :
1.

Disposition with respect to reference axes.

2.

Elevation.

3.

Spacing between the pockets.

FAN :

1.

Alignment of base plates and bearing pedestals (Horizontality of bearing pedestals within
0.04 mm / M with respect to the fan centre line).

2.

Grouting of base plates and bearing pedestals.

3.

Cube testing for compressive strength.

4.

Pre-assembly of spiral casing and ensure completion of seal welding for gas tightness
and welding of distance bolts with casing.

5.

Ensure dimensional compliance.

6.

Alignment of spiral casing with respect to fan centre line.

7.

Ensure verticality of spiral casing.

8.

Elevation and horizontality at the parting plane of bottom half of spiral casing at four
corners.

9.

Dimensions of shaft ends and couplings.

10.

Ensure proper seating of the locating groove in the shaft flange with the impeller.

11.

Torque tightening of bolts for shaft, conical cover plate, flange and impeller.

12.

Gap between impeller & shaft flange and impeller mating face (0.05 mm feeler should
not go).

13.

Sealing of flange of conical cover plate and impeller.

14.

Correct elevation of bearing pedestal.

15.

Ensure 80% colour matching between bearing housing and the bearing pedestals.

16.

Horizontality of bearing housing to 0.04 mm / M.

17.

The shaft at fixed end bearing should be levelled to within 0.04 mm / M.

18.

Clearance between impeller ring and sealing ring :

Overlap (axial distance).

 Radial
19.

Fixing of labyrinth seals at expansion and non-expansion end of shaft.

20.

Clearances in slide supports.

21.

Adjustment of duct supports of suction and discharge ducts to avoid loading / pulling of
fan.

22.

Alignment of coupling with motor & fan and ensure tightness of bolts fixing coupling with
shaft.

23.

Alignment of motor & fan after successful trial run and dowell all the areas as specified in
the drawing.

24.

Completion of silencer assembly.

AIR PREHEATER :
1

Supporting beam spacing w.r.t. boiler axis and air pre heater axis.
(Tolerance : 1 mm / M ; Max. 5 mm).

Elevation of the supporting beam. (Tolerance : 3 mm).

Straightness of the supporting beam. (Tolerance : 1 mm / M ; Max. 5 mm).

Squareness of the supporting beam. (Tolerance : Max. 10 mm).

Positioning of air heater blocks coincides with supporting beam axes.

Diverting plates are to be welded prior to assembling blocks at site.

Matching of the blocks and seal welding.

Protection to tube and tube nest to avoid entrapment of foreign material.

Alignment of air heater blocks :

a)

Verticality (Tolerance : 5 mm Max).

b) Horizontality (Tolerance : 5 mm Max).

c) Diagonal difference between top and bottom corner face to face

(Tolerance : 10 mm Max).
10

Welding completion of expansion pieces.

11

Welding of duct wall to air pre heater duct opening.

12

Completion of gas and air duct connection to air heater blocks.

13

Completion of duct supports.

14

Ensure duct loads, thermal expansion loads etc. are not transmitted to air pre heater
blocks.

15

Completion of seal plates of expansion pieces.

16

Ensure seal plates are welded with tube plate assembly after fixing the duct.

17

Ensure seal welding all around between bolt & nut and bolt, nut and split plate.

18

Completion of guide vanes and splitter vanes at the inlet and outlet of air ducts for
uniform distribution of the air across the air pre heater and to avoid flow stratification.

19

Completion of tapping points.

20

Completion of insulation of air heater blocks.

21

Completion of castable refractories at gas inlet of each block to a height of 150 mm.

PIPING :
1

Check for the following :

a) Dimensions
b) Edge preparation, Weld end diameter, out of squareness and ovality.

Location and disposition of terminal points (Tolerance : 5mm).

Identification of the components and check for statutory agency clearance.

Completion of the supporting structure for pipelines.

Completion of supports (Tolerance : Elevation 5mm).

Elevation, disposition and slope of the pipelines (Tolerance : 5mm).

Verticality of pipelines.

Ensure sufficient gap around the pipelines with structure / wall to accommodate the
insulation thickness and expansion provision during operation.

Ensure erection of boiler feed re-circulation NRVs after chemical cleaning of pipelines.

10

Welders performance qualification records.

11

Adoption of correct procedure, approved electrodes and methods.

12

Cleanliness of piping.

13

Fit-up of joints, orientation and alignment of piping.

Note : Applicable for main piping, drains, vents, impulse and sampling lines.

14

Identification of weld joints and maintenance of records indicating number of joints, heat
treatment carried out and NDE results.

15

Acceptance or rejection / repair details.

16

Completion of pre-heating, welding and post heating.

17

Completion of NDE.
Note : MPI / LPI on completed welds shall be carried out.

18

Completion of PWHT.

19

Locking of the supports.

20

Completion of all drains, vents, impulse and sampling lines.

21

Removal of temporary supports and completion of permanent supports.

22

Provision of hydrostatic test plug for safety valves.

23

Ensure usage of calibrated pressure gauges for hydraulic test.

24

Completion of hydraulic test of pipelines.

25

Completion of insulation and check for thickness.

LINING & INSULATION

SKIN CASING / INSULATION FIXING :
1

Ensure the waterwall, superheat and roof tubes regions, all tubes are in one plane before
application of castable refractories.

Ensure the availability of the asbestos packings and for proper closing and opening operation
for manholes, pee holes and elliptical doors before fixing.

Ensure the replacement of coir ropes by asbestos packing ropes in al the door assemblies
while erection.

Ensure the liner plates of manhole, peephole, observation doors and elliptical doors are filled
with castable refractories and proper curing of the same.

Ensure studs in seal boxes are intact.

Ensure proper expansion provisions for castable refractories and pourable insulations.

Ensure the scalloped bars are cut at the top with opening for pouring of castable refractories
and then weld scalloped bars.

Ensure the openings on the top of scalloped bars in seal boxes are closed with patch plate
after curing of the castable refractories.

Ensure the provision of correct size openings in the refractories provided in the seal boxes.

10

Ensure the erection of gas distribution baffles in the second pass simultaneously along with
the pressure parts.

11

Ensure availability of gap between wall baffles and tubular elements.

12

Ensure the slotted holes connections given for expansion shall not be welded (applicable for
enclosures).

13

Ensure no tampering / hammering of the skin casing after fixing in position so as to avoid any
damage / crack in already cast areas with pourable / castable refractories.

14

Ensure proper / correct reinforcement provided for application of castable refractories

wherever required.

15

Ensure the gap between the two adjacent fins is not more than 4 mm before the application of
castable refractories.

16

Ensure the compliance of proper heat treatment procedures wherever required.

17

Ensure completion of welding of all the items under fixing components and skin casing with
pressure parts before hydraulic test. Subsequently establish the quality of weld by hydraulic
test.
REFRACTORY & INSULATION MATERIALS :

Ensure the completion of following before taking up insulation work.

For Pressure Parts

i)

All supports, attachments, instruments, inserts and cables are provided.

ii)

Completion of air leak test.

iii)

Completion of hydraulic test

iv)

Completion of radiography, repair and heat treatment of weld joints.

v)

Surfaces are cleaned and painted.

vi)

Hooks / studs welding on pressure parts using correct length of hooks / studs.

vii)

Ensure weld quality and size.

Ensure that the life of refractory materials is within the expiry date.

Ensure the implementation of recommended procedure for application, curing of castable

refractory and pourable insulation is followed.

Fixing of top retainers after insulation.

Ensure the coating of bituminous paint for tube surfaces and any other metal surfaces which
are embedded in or in contact with castable refractories / pourable insulation.
Ensure all aluminium sheets and M.S. Ribbed sheets are coated with two coats of black
bituminous paint or inner side.

6
7

Ensure the following during erection :

a) Placing of correct thickness of material in respective areas.
b) Proper binding with GI wire through retainers.
c) Proper sewing of wire mesh facing with adjacent one for each layer of mattress and no
caving in between mattress.

Ensure proper iron parts and casing supports are fixed at required pitches and in straight
rows for sheeting works.

Ensure beadings are provided in all sheet edges.

10

Ensure the outer casings are not in direct contact with any hot surface (like stiffeners, lifting
hooks etc.).

11

Ensure fixing of neoprene strips or aluminium paint coating wherever aluminium sheets are
envisaged over the retainers.

12

Ensure the provision of outer casing sheets immediately after erection of insulation to avoid
rain water entry.

13

Ensure segmental sheeting assembly for bends, elbows etc. following the same profile of

piping and ducts.

14

Ensure overlapping of sheeting edges are facing down against water flow direction for water
proof arrangements for vertical portion.

15

Ensure sheets and seams are overlapping on sides for effective water proofing in horizontal
portion.

16

Application of sealing compound on overlapping areas of outer casing sheets.

17

Ensure proper pitch on either directions and maintaining of tightness for self tapping screws.
OUTER CASING / FIXING COMPONENTS :

Ensure all the fixing components are welded on pressure parts (water wall) issued under
PGMA 31-010 and 37-010 for fixing outer casing.

Clearance for boiler expansion between outer casing and structural members, floor etc.

Ensure all MS ribbed sheets are coated with two coats of black bituminous paint on inner
side, after application of red oxide primer.
Ensure the use of proper drill bit for making holes to fix self tapping screws.

4
5

Ensure all the openings around access doors, observation doors, instrument tappings etc. are
properly finished / terminated with plain sheets and fixed adequately with self tapping screws.

Ensure outer sheet casings are provided immediately after the insulations are fixed (this will
prevent rain water entry).

Ensure the gap between wall and ribbed casing is not more than as given in the drawing.

Ensure all fixing components are erected on buckstay beams before fixing the outer casing.

Ensure completeness of erection of lining & insulation.