Erection Manual-Isolux

STD ER - 001
Date : 22.03.2011
Page : 1
ERECTION OF BOILER
ISGEC JOHN THOMPSON
PROJECT : 1 X 180 TPH, Bi DRUM, WATER TUBE, TRAVELING GRATE

BOILER AT M/s. Isolux Columbia
ACTIVITES DURING ERECTION OF BOILER
1.
CHECKING OF FOUNDATIONS
2.
ERECTION OF STRUCTURES
3.
ERECTION OF DRUM
4.
ERECTION OF WATER WALL PANELS
5.
ERECTION OF SUPERHEATER COILS
6.
ERECTION OF FORCED FLOW ELEMENTS
7.
ERECTION OF DOWNCOMER & RISERS
8.
ERECTION OF BOILER PIPING
9.
ERECTION OF DE-SUPERHEATER
10. ERECTION OF STOKER

11. ERECTION OF AIRHEATER
12. APPLICATION OF REFRACTORY, BRICKWORK
13. INSTALLATION OF SAFETY VALVE
14. BOUGHT OUT ITEMS
Prepared by
Approved by
( Construction Engineer )
( Construction Head)
Page 1 of 31
STD ER - 001
Date : 22.03.2011
Page : 2
ISGEC JOHN THOMPSON
1.
Check elevation of the foundation with reference to the zero level and
record the same in the log book. Tolerance limit is + 0/- 25 mm. Ensure
top level is maintained (-10 to -25mm for providing packer plates.)
2.
Check centre to centre distance of the columns with reference to boiler

both axis centre line. Ensure both axis centre line is checked with right
angle. Column centre line distance deviation limit is +\- 5. Record the
same in the log book.
3.
Check the foundation diagonals and individual pockets dimensions.

Ensure deviations are within tolerance limit (+10/- 0 mm). Record the
4.
Check all foundations pocket sizes (length, width, depth.) Record the
5.
Check the top of foundation and ensure roughness. If found any loose
concrete in the top surface of foundation, remove the same.
6.
Ensure foreign materials and loose concretes, water in the pockets are
removed before grouting of the foundation bolts.
7.
Ensure proper concrete mixer is used for foundation bolt grouting (As
recommended by civil drawing).
8.
Check foundation overall dimensions and verticality. If found any loose

plastering work done, same to be removed.
9.
Ensure insert plates locations and check whether insert plate lugs are
welded with reinforcement rod of the foundation. Also check top
elevation is maintained as per drawing.
10. Ensure all foundation bolts are received as per bill of material
list/drawing. Foundation bolts must be stored in fully covered shed.
11.
Ensure threaded portion of the foundation bolts are covered properly

with gunny bag/poly bag. Checks whether rust preventive solution
/grease is applied. If not, apply the same.
Page 2 of 31
STD ER - 001
Date : 22.03.2011
Page : 3
ISGEC JOHN THOMPSON
12.
Ensure proper templates are used for grouting the foundation bolts.
Check all templates holes centre and diagonals.
13.
Ensure before grouting templates are aligned properly. Record the

dimensions in the log book. After aligning the templates, arrest the
same properly.
14.
Ensure foundation bolt projection (above the base plate top) is

maintained as mentioned below:Minimum required projection above the top of base plate of column
= (Washer thk. + Nut thk. + Lock nut thk. + 25 mm)
Page 3 of 31
ERECTION OF STRUCTURE
STD ER - 001
Date : 22.03.2011
Page : 4
ISGEC JOHN THOMPSON
1.
Check and ensure the structures are received with proper identification
mark. If not, mark identification with the help of Hard- punch. Mark the
same with Aluminium Paint for easy identification.
2.
Ensure all supporting materials are stored away from water stagnant
area if possible stores the materials near to the boiler house for easy
leading. While leading use proper pipe rollers.
3.
Before erection of column check the foundation elevation and

foundation bolts centre to centre distance and diagonals with reference
to the column base plate.
4.
Check and ensure the following before erection of column :

i)
ii)
iii)
Dimensions of column, identification mark

Cleats / brackets (orientation and level)
Straightness, twist, base plate square ness,
Tolerance limit:
i.
ii.
iii.
iv.
Length +/-3 mm
Hole pitch +/-3 mm
Straightness 1 mm/mtr. (Max. 10 mm) whichever is less
Twist 1 % section height (Max. 5 mm)
If split up column:
5.
Check and ensure match marks, splice plates locations, site weld
preparations are given as per drawing. If not, clarify from engineering.
6.
Check the elevation of column base plate with help of water level with
reference to zero level. To maintain the elevation as per drawing, if
required, provide packer plates ( 50 mm width x Base Plate length X
Required thick less) at the bottom of Base Plates in two locations (near
to the foundation bolts). Use 1 mm to 10 mm thickness packer plates
for easy alignment. Elevation Tolerance limit +/-3 mm.
Page 4 of 31
ERECTION OF STRUCTURE
STD ER - 001
Date : 22.03.2011
Page : 5
ISGEC JOHN THOMPSON
7.
Check the column vertically with the help of plumb. Use Piano Wire for
checking the column. Tolerance limits 1 mm/mtr. Or max. 10 mm
whichever is less.
8.
Check the column to column distance with reference to the boiler main
axis Tolerance limit +3/- 10 mm.
9.
Check the diagonals of the columns and record the same Tolerance limit
+/- 5 mm.
10. Ensure the tightness of packer plates by hammering test.

11. Ensure the foundation bolts tightness (use pipe lever for proper
tightness). Provide the lock nun.
12. Before full grouting of columns, check provided packer plates are welded
together. Ensure packer plates are not welded with column bas plate.
13. Tie beams elevation, orientation is to be checked before full welding.
Check the tie beams both sides level.
14. Ensure erected tie beams are full welded before loading any equipment
Ensure erection weld fillet size.
15. Use E7018 electrodes wherever plate thickness exceeds 20 mm and do
the proper pre-heating.
Page 5 of 31
ERECTION OF DRUMS
STD ER - 001
Date : 22.03.2011
Page : 6
ISGEC JOHN THOMPSON
1. Ensure the drum is stored away from water stagnant area. Use wooden
slipper for bottom packing, cover the drum with tarpaulin. If possible,
unload the drum near to the Boiler House area.
2. Check the identification and centre line marks are marked property.
FOR STEAM DRUM
1. Before lifting of drum, check drum orientation and ensure all related
Tie-beams full welding are completed.
a) In case of Top supported Boiler, check drum orientation and ensure
all ceiling girder with cross beams are fully welded.
b) Preparation of U Rod arresting cum lifting frame and fixing the same
on U Rod.
c) Preparation of temporary lifting arrangement for U Rod at both side
on ceiling girder.
2. Check all lifting tools and tackles and wire slings and wire ropes, Pulleys
capacity and soundness.
3. Before lifting the drum mark the elevation level of drum in the main
columns with reference to the zero level.
4. Drum resting tie-beams levels and centerline are to be checked properly
with reference to the boiler main axis. Ensure all are matching with
drawing dimensions.
5. During Drum Lifting welding shall not be carried out in the boiler area.
6. All the wire rope and wire slings shall be of single length.
Page 6 of 31
ERECTION OF DRUMS
STD ER - 001
Date : 22.03.2011
Page : 7
ISGEC JOHN THOMPSON
7.
Ensure the electric power supply in all manners.
8.
After lifting the drum upto + 2.00 mm elevation it should be hold for
30 minutes for ensuring the straightness and elongation and twist of
wire rope.
9.
Lifting of Drum with the help of winch up to correct elevation.
10.
For Top supported Boiler before lifting of the drum, ensure fixing of U
Rod at both side of the Boiler Drum & tie up with lifting cum arresting
frame.
11.
After erection of the drum check elevation of the drum with reference
to the zero level and record the same i.e., +/-2, mm.
12.
Ensure orientation of stubs is as per drawing.
13.
Check and ensure boiler axis centerline are matching with both drums
centerline (plump test is must). If drum centerline is offset as per
drawing, measure the offset dimension on both ends and record the
same.
14.
Check water levels on both axis drum (minimum. 3 sites must be

equal).
15.
Check and ensure supporting arrangements are provided as per

drawing. Care must be taken for sliding arrangement supports.
16.
Sliding faces are to be coated with high temperature resisting

molybdenum or equivalent grease.
MUD DRUM
1.
2.
Before lifting of drum, check drum orientation and ensure all related
tie-beams full welding are completed.
3.
Check all lifting tools and tackles and wire slings and wire ropes,
Pulleys capacity and soundness.
4.
Before lifting the drum mark the elevation level of drum in the main
columns with reference to the zero level.
5. Drum resting tie-beams levels and centerline are to be checked properly

with reference to the boiler main axis. Ensure all are matching with drawing
dimensions.
Page 7 of 31
ERECTION OF DRUMS
STD ER - 001
Date : 22.03.2011
Page : 7
ISGEC JOHN THOMPSON
6.
During Drum Lifting welding shall not be carried out in the boiler area.
7.
All the wire rope and wire slings shall be of single length.
8.
Ensure the electric power supply in all manner.
9.
After lifting the drum upto + 2.00 mm elevation it should be hold for 30
minutes for ensuring the straightness and elongation and twist of wire
rope.
10.
Lifting of Drum with the help of winch up to correct elevation.
11.
After erection of the drum check elevation of the drum with reference to
the zero level and record the same i.e., +/-2, mm.
12.
Ensure orientation of stubs is as per drawing.
13.
Check and ensure boiler axis centerline are matching with both drums
centerline (plump test is must). If drum centerline is offset as per
drawing, measure the offset dimension on both ends and record the
same.
14.
Check water levels on both axis drum (minimum. 3 sites must be equal).
15.
Check the final alignment of both drums by inserting bank tubes of

extreme left, right & middle row for checking the projection of the tubes.
16.
Check & ensure projection of the bank tubes inside both drums are
within the tolerance limit in drawing. main axis. Ensure all are
matching with drawing dimensions.
Page 8 of 31
ERECTION OF WATER WALL

PANELS
STD ER - 001
Date : 22.03.2011
Page : 8
ISGEC JOHN THOMPSON
1.
Check and ensure the materials are received free from transit damage
and with proper ends caps.
2.
Ensure the materials are stored away from water stagnant area.
Materials should always be unloaded and stored near the boiler location
to ease erection activities.
3.
Check and ensure all the materials are received as per packing list and
drawing. If any short supply or damage is noticed the same to be
informed to Head Office immediately.
4.
Ensure the materials like valves & fasteners are stored in a closed shed.
5.
Check and ensure the overall dimensions of panels, headers and loose
tubes are as per drawing and within the tolerance limit.
6.
Check the header supports centre to centre distances and ensure the
same is as per drawing.
7.
Check the orientation of down-comer and riser nozzles in the headers.
8.
While fixing the header supports ensure the slot arrangements are fixed
as per drawing to take care of the expansion.
9.
Ensure the top level of header support are as per drawing Tolerance + 2
mm
10.
Ensure the edge preparation of tubes, nozzles and headers are

completed.
11.
Ensure the square ness of edge preparation.
12.
Ensure the lifting arrangements are made in proper way with necessary
safety precaution.
13.
Ensure the lifting tools capacity and their service condition.
STD ER - 001
Page 9 of 31

PANELS
Date : 22.03.2011
Page : 9
ISGEC JOHN THOMPSON
14.
Ensure necessary temporary supporting arrangements are made to

support the panels if required.
15.
Check the lifting tools, guy ropes and derrick posts after lifting the
material for 1mtr Height from the ground level for any abnormality.
16.
Ensure the panels are being erected as per the sequence.
17.
Ensure the wire ropes are tied in a proper way with the panel in the
lifting hooks thought D shackles wire ropes should never be tied on the
tubes directly which may damage the tubes.
18.
Check and ensure there are no foreign materials inside the panels.
19.
Ensure enough supports have been provided for the panels before
removing the lifting arrangements.
20.
Ensure the orientation of panels & headers.
21.
Check the elevation of each header and ensure the same is as per
drawing and within the tolerance limits. Check the same with reference
to steam and mud down centerlines.
22.
Check the verticality of the panels. Tolerance limit is 1 mm/ mtr with
the max of 10 mm which are is less.
23.
Ensure the slot arrangements of headers & saddle supports are as per
drawing.
24.
Ensure the root gap is being maintained properly while making fit up of
headers and tubes.
25.
Ensure the projection of roof and rest tubes inside the drum are as per
drawing and within the tolerance of + 2mm.
26.
Check and ensure the selection of welding consumables as per welding

schedule.
Page 10 of 31

PANELS
STD ER - 001
Date : 22.03.2011
Page : 10
ISGEC JOHN THOMPSON
27.
Ensure the root run is being done by TIG welding and subsequent run
by SMAW.
28.
After completion of root run, check the root by Dye Penetrant Test (DPT)
of minimum 10% joints. If defects are observed do 100% DPT.
Radiography (RT) should be carried out on completed joint as per IBR
/ASME (wherever applicable).
29.
Ensure heat treatment procedures are being strictly followed as per

drawing/welding schedule/IBR (ASME wherever applicable).
30.
Ensure completeness of buck stay plates and seal boxes welding before
erection of the water wall panels.
31.
Check and ensure the elevation of burner openings if any.
32.
Ensure the fin plates are provided after full welding and radiography of
tubes are completed at site weld locations.
33.
Ensure the tack welds on the tubes and headers are ground smoothly.
34.
Ensure all temporary supports are removed.
35.
Ensure all shoulder bolts are fixed in all saddle supports.
36.
Alignment details to be filled up in inspection erection format.
Page 11 of 31
ERECTION OF SUPER HEATER

COILS
STD ER - 001
Date : 22.03.2011
Page : 11
ISGEC JOHN THOMPSON
1.
and with proper end caps.
2.
Materials should always be unloaded and stored near the boiler location
to ease erection activities.
3.
drawing. If any shot supply or damage is to be informed immediately to
H.Q. Check for the mark no. on each coil for sequence of erection as per
drawing.
4.
Ensure the materials like valves & fasteners and loose items like
supports plates, header and doors are stored in a closed shed.
5.
Ensure the identification marks are marked properly. If not mark the
same for ease identification.
6.
Check the received coils dimensions with respective drawing.
7.
Ensure erection of coils with respect to lugs provided for

maintaining pitch and their elevation.
8.
Ensure all coils are tested with sponge ball test with compressed air.
9.
Check the header supports centre to centre distances and ensure the
same is as per drawing.
10.
Check the header elevation levels and nozzle orientations.
11.
While fixing the header supports ensure the slot arrangements are fixed
12.
Ensure the top level of header supports are as per drawing Tolerance
2mm.
13.
Ensure the edge preparation of tubes, nozzles and headers are

completed and also ensure the squareness of edge preparation.
STD ER - 001
Page 12 of 31

COILS
Date : 22.03.2011
Page : 12
ISGEC JOHN THOMPSON
14. Ensure the lifting arrangements are made in proper way with necessary
safety precautions.
15. Ensure the lifting tools capacity and their service condition.
16. Ensure necessary temporary supporting arrangements are made to
support the coil if required.
17. Check the lifting tools guy ropes and derrick posts soundness. After
lifting the material for 1 meter height from ground level once again
examine all lifting arrangements.
18. Ensure the wire ropes are tied in a proper way with the lifting hooks
through D shackles, wire ropes should never be tied on the tubes
directly which may damage the tubes.
19. Ensure the coils are being erected as per sequence.
20. Ensure the orientation of coils & headers nozzles.
21. Ensure enough supports have been provided for the coils before
22. Check the elevation of each header and ensure the same is as per
drawing and within tolerance limits. Check the same with reference to
steam drum centerlines.
23. Check the verticality of the coils before welding of coils with
header.
24. Ensure the slot arrangement of headers and saddles supports are as per
drawing.
25. Ensure the root gap is being maintained property (2.5 mm gap max in
tubes, 2.5 to 4 mm in pipes).
26. Ensure the projection of coils inside the steam drum (wherever
applicable) is maintained as per drawing + 2mm.
Page 13 of 31

COILS
STD ER - 001
Date : 22.03.2011
Page : 13
ISGEC JOHN THOMPSON
27.

schedule.
28.
by SMAW.
29.
After completion of root run, check the root by Dye Penetrate Test
(DPT) of minimum 10% joints. If defects are observed to 100% DPT.
Radiography (RT) should be carried out on completed joint as per IBR.
30.

31.
Ensure the tack welds on the coils and headers are grounded
smoothly.
32.
Ensure all shoulder bolts are fixed in header saddle supports.
33.
Ensure all temporary supports are removed after providing permanent

supports.
34.
Ensure gap between Superheater coil to side water wall and rear
waterwall tubes are maintained as per drawing.
35.
Alignment details are to be filled up in inspection erection format.
Page 14 of 31
ERECTION OF FORCED FLOW

ELEMENTS
STD ER - 001
Date : 22.03.2011
Page : 14
ISGEC JOHN THOMPSON
1.
Check and ensure the forced flow elements are received free from transit
damage and with proper end caps with identification marks.
2.
3.
Ensure the materials like valves & fasteners and loose items are stored
in a closed shed.
4.
Check and ensure the overall dimensions of the forced flow elements.
5.
Check and ensure the pen to support beams is erected as per drawing.
6.
Check and ensure all F.F elements are tested with sponge ball with the
help of compressed air.
7.
Check and ensure soot blower support lug coils are placed properly as
per drawing.
8.
Check and ensure in/outlet header supports are fixed as per drawing
dimensions.
9.
Check and ensure header stubs orientation is as per drawing.
10.
While fixing the header supports ensure the slot arrangement is fixed as
per drawing to take care of the expansion.
11.
safety precautions.
12.
Ensure the lifting tools capacity and their service condition.
13.
Ensure necessary temporary supports arrangements are made to

support the coils if required.
14.
Ensure the coils are being erected as per the sequence.
15.
Ensure the wire ropes are tied in a proper way with the coils in the
lifting hooks through D shackles wire ropes should never be tied on the
tubes directly which may damage the tubes.
16.
Check and ensure there are no foreign materials inside the Headers.
Page 15 of 31
ERECTION OF FORCED FLOW

ELEMENTS
STD ER - 001
Date : 22.03.2011
Page : 15
ISGEC JOHN THOMPSON
17.
Ensure enough supports have been provided for the coils before
18.
Check the inlet/outlet header levels and ensure the same is as per
drawing.
19.
Check the same with reference to steam drum centre lines.
20.
Ensure the slot arrangements of Header & Saddle supports are as per
drawing.
21.
Ensure the root gap is being maintained properly while making fit up to
headers and tubes.
22.
Ensure alignment of all coils maintaining pitch distance between coils

and uniform gap with respect to casing before final welding.
23.

schedule.
24.
by SMAW.
25.
After completion of root run, check the root by Dye Penetrant Test (DPT)
of minimum 10% joints. If defects are observed do 100% DPT.
26.
Ensure the tack welds on the tubes and headers are grounded
smoothly.
27.
Ensure all temporary supports are removed after providing all

permanent supports.
28.
Ensure shoulder bolts are fixed in headers saddle supports.
29.
Ensure fixed support/sliding supports are provided as per drawing.
30.
Ensure installation & welding of baffles plates(wherever applicable) as

per drawing for protection of the coil bends.
31.
Alignment details to be filled up in inspection erection format.
STD ER - 001
Page 16 of 31
ERECTION OF DOWN COMER

& RISERS
Date : 22.03.2011
Page : 16
ISGEC JOHN THOMPSON
1.
2.
Check and ensure the identification marks are done as per the drawing.
3.
Ensure the materials are stored away from water stagnant area. Use
proper wooden packing support.
4.
Check and ensure the overall dimensions of downcomer are as per

drawing.
5.
Check the supports type, and locations.
6.
Check the orientation of downcomer with mud drum and water wall
bottom headers.
7.
While fixing the sliding supports ensure the supports are fixed as per
drawing to take care of the expansion.
8.
Ensure the edge preparation of downcomer and drum side stub are
done properly as per drawing.
Ensure the squareness of edge
preparation.
9.
Wherever different thickness pipes butt joints are coming ensure proper
ID matching by tapering the higher thickness pipe to 1:4 ratio.
10. Ensure there are no foreign materials inside the pipes.

11. Ensure lifting tools capacity and their service condition.
12. Ensure the downcomer and risers are erected as per the sequence.
13. Ensure the supports locations are as per drawing.
14. Check the elevations and other dimensions are as per drawing. Check
the same with reference to steam and mud drum centre lines.
15. Ensure the root gap is being maintained properly while making fit up of
the down-comer and risers. Recommended root gap is (2.5 to 3 mm)
land 1mm min.
Page 17 of 31
ERECTION OF DOWN COMER

& RISERS
STD ER - 001
Date : 22.03.2011
Page : 17
ISGEC JOHN THOMPSON
16. Ensure the root run is being done by TIG welding and subsequent run
by SMAW.
17. Check and ensure the selection of welding consumables as per welding
schedule.
18. After completion of root run, check the root by Dye Penetrant Test (DPT)
of minimum 10% joints.
If defects are observed do 100% DPT.
19. Ensure heat treatment procedures are being strictly followed as per
Page 18 of 31
STD ER - 001
Date : 22.03.2011
Page : 18
ISGEC JOHN THOMPSON
1.
2.
3.
Ensure that all pipes are segregated size wise and grade wise and are
stored separately for easy identification.
4.
drawing. If any shot supply or damage is to be informed immediately to
H.Q.
5.
Check and ensure the overall dimensions of piping and identification

mark as per drawing.
6.
Ensure that there is no foreign material inside the pipes/tubes. Check

with compressed air.
7.
Ensure that edge preparation of tube/ pipes are done as per the
drawing. Check the sequence of edge preparation.
8.
Check the orientation of stubs, support type and location of supports.
9.
While fixing the support ensure the sliding supports are fixed as per
drawing to take care of expansion.
10. Ensure the elevations and stub orientations are as per drawing.
11. Ensure necessary slopes are maintained in all drain lines.
12. Ensure necessary valves/ fittings are fixed as per drawing. Check all
lines verticality and levels.
13. Check the elevations of pipelines and orientations and support
types/locations and record the same in inspection erection format.
Page 19 of 31
STD ER - 001
Date : 22.03.2011
Page : 19
ISGEC JOHN THOMPSON
the pipelines.
schedule.
by SMAW.
19. Ensure that the tack welds on the pipes / tubes are ground smoothly.
20. Ensure all temporary supports are removed.
21. Ensure all lines are flushing out / dried after completion of hydro test
and make protocol for all lines.
22. Ensure main steam flow nozzle be erected after completion of steam
blowing activity.
Page 20 of 31
ERECTION OF DE-SUPER
HEATER
STD ER - 001
Date : 22.03.2011
Page : 20
ISGEC JOHN THOMPSON
1.
Ensure the material is stored away from water stagnant area. Use
proper wooden sleeper packing.
2.
Check and ensure the material is received free from transit damage and
proper identification mark.
3.
Ensure materials are received as per drawing.
4.
Check and ensure the overall dimensions of De-Superheater are as per

drawing.
5.
Check the nozzles orientation inside the De-Superheater and ensure

water flow should be indirection of steam flow.
6.
While fixing the sliding supports ensure the slot arrangements are fixed
7.
Ensure the edge preparation of site joints are done properly. Check
squareness of the same.
8.
safety precautions.
9.
Ensure lifting tools capacity and service condition.
10. Check and ensure there is no foreign materials inside De-super heater.
11. Ensure the orientation of stubs.
12. Ensure necessary supports have been provided for the De-Superheater
before removing the arrangements.
13. Check the elevation of De-Superheater.
14. Check the verticality if it is vertical type or check the water level if its
horizontal type.
the butt joints (2.5 to 4 mm gap).
Page 21 of 31
ERECTION OF DE-SUPER
HEATER
STD ER - 001
Date : 22.03.2011
Page : 21
ISGEC JOHN THOMPSON
by SMAW.
Radiography (RT) should be carried out on completed joint as per
IBR/ASME (wherever applicable).
schedule.
Page 22 of 31
ERECTION OF STOKER
STD ER - 001
Date : 22.03.2011
Page : 22
ISGEC JOHN THOMPSON
1.
Check and ensure all stoker materials are received with proper
identification mark. If not, mark identification with the help of Hardpunch. Mark the same with Aluminium Paint for easy identification.
2.
Ensure all materials are stored away from water stagnant areas if
possible store the materials near to the boiler house for easy leading.
While leading use proper pipe rollers.
3.
Check & ensure the following before starting the erection of stoker
a) Furnace diagonal
b) Elevation of bottom headers
c) Center line of furnace
= 5mm
= 2mm
= as per drawing
4.
Ensure erection of stoker base frame with cross beam as per drawing
and elevation & diagonal of base frame within tolerance limit of 2mm
& 5mm respectively.
5.
Ensure rear shaft idler dimensions are as per drawing.
6.
Check & ensure the following at the time of erection of stoker front
and rear shaft :
a) Elevation of front shaft
b) Elevation of rear shaft
c) Diagonal distance
= 2mm
= + 2mm
= 2mm
Ensure elevation of rear shaft is higher than front shaft of stoker.

7.
Check & ensure skid bar top level is lower than top level rear shaft
idler by min. of 20mm within tolerance limit of +2mm.
8.
Check orientation of chain; direction of rotation is as per drawing.
9.
Ensure elevation of skid bar is within the tolerance limit of +2mm &
higher than refractory seal trays.
10. Ensure completeness of tack welding for washers and bush for all
grate bars.
Page 23 of 31
ERECTION OF STOKER
STD ER - 001
Date : 22.03.2011
Page : 23
ISGEC JOHN THOMPSON
11. Ensure clearance of chain and grate bars with base frame /RCC floor
(wherever applicable) is as per drawing and there is no fouling with
other parts of stoker.
12. Ensure installation of all guide vanes are as per drawing.
13. Ensure proper matching of C.I. rear seal plate with C.I. protection
block before erection.
14. Ensure proper matching of rear seal plate with C.I. bearer bar before
erection.
15. Ensure proper arrangement & welding of all corners sealings, front &
rear sealings with expansion provision as per drawing.
16. Check alignment of stoker front shafts with hydraulic/mechanical
drive & maintain the gap as per drawing.
Page 24 of 31
ERECTION OF AIR HEATER
STD ER - 001
Date : 22.03.2011
Page : 24
ISGEC JOHN THOMPSON
1.
Check and ensure received Air Heater tubes, Expansion bellow and
Tube Sheets are having proper stencilling and identification marks.
2.
Ensure availability of Copper sheet and asbestos tape as per

requirement.
3.
Ensure Air Heater tubes are stored away from water stagnant area with
proper wooden sleeper packing covered preferably with tarpaulin.
4.
Ensure all Air Heater tubes are segregated material wise (i.e. Carbon
Steel & Corten Steel) and separated as per the Batch nos.
5.
Before lifting of Air Heater Tube Sheet, check Tube Sheet mark no. &
orientation and ensure all related structure and Tie beams are fully
welded as per drawing. Also the elevation levels of Tube sheets are to be
marked on the main columns with reference to the zero level.
6.
Check the capacity and soundness of all lifting tools and tackles
including wire slings and wire ropes.
7.
After erection of Air Heater Tube Sheets check elevation of the Tube
Sheets is maintained in limits of +/- 3mm of water level, Tube holes are
in same vertical axis( Plumb Test is must) and is as per drawing.
8.
Before starting erection of Tubes, clean both ends of tubes

(inside/outside) by using emery sheet/buffing wheel Minimum required
length (25mm + Air Heater Tube Sheet thk)
9.
While cleaning apply emery sheet/buffing wheel circumference wise on

the tube and do not do the longitudinal wise cleaning as longitudinal
scratch are not allowable for tube expansion.
10. Check Air Heater Tube Sheet alignment and holes cleaning, arresting of
Tube Sheets by using temporary arrestor before starting Air Heater tube
erection.
11. First of all, erect Air Heater Stay Tubes and carry out its expansion
(Refer point no. 14), bell-mouthing and welding (Wherever applicable) as
per Drawing so as to maintain distance between tube sheets and avoid
sagging of Tube Sheets.
Page 25 of 31
ERECTION OF AIR HEATER
STD ER - 001
Date : 22.03.2011
Page : 25
ISGEC JOHN THOMPSON
12.
After erection of Stay Tubes, start erection of balance tubes. Before

starting tack rolling ensure tubes projection is maintained as per
drawing.
13.
Tube projection of Air Heaters tubes and Stay tubes should be as

per the drawings.
14.
Ensure Air Heater tubes are expanded and bell-mouthed as per

expansion schedule.
15.
Check 100% of the tubes with go and no go gauges. After completion

of full expansion of the tubes, also ensure the final ID of the tube.
Minimum required tube thinning 4% (go gauge)

Maximum permissible tube thinning - 8%
(9% No go gauge)
GO, NO-GO GAUGE sizes calculation is as follows:
GO GAUGE SIZE
Avg. tube I/D + (Avg. hole-Avg. tube O/D) + thinning min. x 2 x Avg.
tube thickness
NO-GO GAUGE SIZE
Avg. tube I/D + (Avg. hole-Avg. tube O/D) + thinning max. x 2 x Avg.
tube thickness
16.
Ensure whether proper lubricant is used during tube expansion (use

grease or oil).
17.
Clean all the tubes after completion of expansion/belling process.
18.
After completion of above, proceed for removal of temporary supports

and start for the erection of Expansion Bellow and ensure proper
sealing of bellow is as per mentioned in the drawing.
Page 26 of 31
APPLICATION OF
REFRACTORY, BRICK WORK
STD ER - 001
Date : 22.03.2011
Page : 26
ISGEC JOHN THOMPSON
1.
CASTABLES are manufactured out of graded refractory materials which

have been blended with suitable binders. They belong to a family of
materials generally called Monolithics.
2.
It is essential to store castable Refractories in a dry place since moisture

can reduce their ultimate strength, even cause hardening, thus, it is
recommended that they be stored indoor in moisture free location. If
they must be stored outside they should be covered by tarpauline of
heavy gauge polythene sheet upto the base. The stack should not be
more than 5ft. high and on a raised platform.
3.
Castable Refractories set hydraulically a few hours after casting to give

a strong structure, at high temperatures this hydraulic bond weakens
and is replaced by a ceramic bond.
4.
Castable Refractories are supplied in various grades corresponding to

the range of operating temperatures in service, and it is, therefore,
important that only the right grade be used.
5.
Before starting the installation of refractory, the materials and

equipments needed at the site should be checked and got ready. As for
mixing equipment, paddle type mixers and suitable for installations.
However, a small concrete mixer may be suitable for small installations.
6.
Depending on the dimensions and position of the refractory lining, it

must be provided with special anchors and supports to hold and secure
the lining to the outer wall or steel structure. These anchors have to be
wrapped with tape or coated with bituminous or waxy coat to take care
of the differential expansion of the metal and the lining.
7.
Castables should be poured to full lining thickness in one continuous

operation. If it is not possible then before laying further, the first layer
must be screeded a little to ensure proper bond between the two layers.
Fill in slightly excess quantity on the top layer and trowel the expose
surface properly. It is recommended that a large area should be
subdivided into smaller, more manageable sections.
Page 27 of 31
APPLICATION OF
STD ER - 001
Date : 22.03.2011
Page : 27
ISGEC JOHN THOMPSON
8.
The back-up wall or lining against which the fresh casting is poured
should be smooth and free from wide gaps or cracks. This surface, if not
waterproof, must be covered with plastic film or coated with paint, oil or
a bituminous compound.
9.
Empty the entire contents of one or more bags of Castable Refractory

into a clean, dry mixer. Rotate the mixer for about1/2 minute to
uniformly blend the ingredients which may have segregated during
shipment/transportation.
10. Water for mixing must be portable at a optimum temperature range 15

Degree to 24 Degree C. Both the amount of water and mixing time have
to be carefully controlled. The nominal amount of water require, and the
exact quantity to be actually used, varies with the water temperature,
ambient temperature and the space to be filled. Too little water will
result in poor workability and produce laminations and too much water
will adversely affect the physical properties of the material. To determine
right consistency, a compact ball of the mix may be formed, tossed up
about a foot high and allow to fall back in the hand. If the ball does not
disintegrate of falling and if the mix does not bleed through the fingers,
the right consistency is generally achieved. The total mixing time for
general purpose dense castables should range from 5 to 10 minutes,
depending upon the type of mixer being used.
11. Pouring should commence as soon as mixing is completed. The total
time interval from the addition of water until the material is poured
should not exceed 20/25 minutes. Pour the castable refractory into
place, ram/poke/paddle or vibrate the material immediately to remove
entrapped air. (In large sections, provision of expansion joint may be
made).
12. Curing begins after preliminary casting has been done. The initial
setting time of castable is four hours approx. The exact time depends on
environmental and atmospheric conditions. Once a shape has been
cast, it should not be disturbed until it has set hard. After the lapse of
about 6/8 hours, we gunny bags should be placed on the castable. In
dry conditions or if furnaces are near about it would be admissible to
periodically sprinkle water for at least 24 hours - to obtain best results
curing should be done for 72 hours. If casting is being done in very cold
weather ensure that the concrete does not freeze during the period of
curing.
Page 28 of 31
APPLICATION OF
STD ER - 001
Date : 22.03.2011
Page : 28
ISGEC JOHN THOMPSON
13. Ensure expansion provisions are provided as per drawing.

14. While a shape made out of castable is being cured precaution is to be
taken that it does not become dry before the final set, whereas before
the cast shape is fired it must be ensured that it is completely dry. The
shape, even partially dry, would develop cracks on firing. The same
precaution is to be taken while casting large sections of the
furnace/boiler. In case of large monolithic sections, these should be first
dried by slow firing. After these have been completely dried, these can
be gradually subjected to the required temperature.
15. Following checks are recommended for using refractory, bricks and
tiles.
a) Refer to the Drawing and take out the correct type of refractory
/tiles /bricks from the store.
b) Size of bricks/tiles to be checked in line with the Drawing.
c) Recommended Castable to be used for joining bricks/tiles as per
the Drawings.
d) Do minor chipping if required with proper tools.
e) After application necessary curing to be done.
Page 29 of 31
INSTALLATION OF SAFETY
VALVE
STD ER - 001
Date : 22.03.2011
Page : 29
ISGEC JOHN THOMPSON
1.
2.
3.
Ensure for cleaning of the connections before installation of the safety

valve
4.
Ensure Safety valve must be mounted in vertical position, directly on

the pressure vessel.
5.
Ensure discharge piping should not impose any loading on the safety
valve.
6.
In case of welded inlet valve - Ensure the root run is being done by TIG
welding and subsequent run by SMAW.
7.
After completion of root run, check the root by Dye Penetrant Test
(DPT). If defect is observed, ground smoothly & rectify it. Radiography
(RT) should be carried out on completed joint as per IBR
8.
Check and ensure the selection of welding consumables and its quality.
Record the same in inspection erection format.
9.

drawing.
Page 30 of 31
BOUGHT OUT EQUIPMENTS
STD ER - 001
Date : 22.03.2011
Page : 30
ISGEC JOHN THOMPSON
NOTE: FOR ALL BOUGHT OUT EQUIPMENTS, PLEASE

REFER TO INSTALLATION MANUALS OF
RESPECTIVE MANUFACTURERS.
Page 31 of 31

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STD ER - 001

PROJECT : 1 X 180 TPH, Bi DRUM, WATER TUBE, TRAVELING GRATE

ERECTION OF WATER WALL PANELS

ERECTION OF SUPERHEATER COILS

ERECTION OF FORCED FLOW ELEMENTS

ERECTION OF DOWNCOMER & RISERS

ERECTION OF BOILER PIPING

10. ERECTION OF STOKER

ISGEC JOHN THOMPSON

Check centre to centre distance of the columns with reference to boiler

Check the foundation diagonals and individual pockets dimensions.

Check foundation overall dimensions and verticality. If found any loose

Ensure threaded portion of the foundation bolts are covered properly

ISGEC JOHN THOMPSON

Ensure before grouting templates are aligned properly. Record the

Ensure foundation bolt projection (above the base plate top) is

ISGEC JOHN THOMPSON

Before erection of column check the foundation elevation and

Check and ensure the following before erection of column :

Dimensions of column, identification mark

ISGEC JOHN THOMPSON

10. Ensure the tightness of packer plates by hammering test.

ISGEC JOHN THOMPSON

ISGEC JOHN THOMPSON

Ensure the electric power supply in all manners.

Lifting of Drum with the help of winch up to correct elevation.

Ensure orientation of stubs is as per drawing.

Check water levels on both axis drum (minimum. 3 sites must be

Check and ensure supporting arrangements are provided as per

Sliding faces are to be coated with high temperature resisting

5. Drum resting tie-beams levels and centerline are to be checked properly

ISGEC JOHN THOMPSON

Ensure the electric power supply in all manner.

Lifting of Drum with the help of winch up to correct elevation.

Ensure orientation of stubs is as per drawing.

Check the final alignment of both drums by inserting bank tubes of

ERECTION OF WATER WALL

ISGEC JOHN THOMPSON

Check the orientation of down-comer and riser nozzles in the headers.

Ensure the edge preparation of tubes, nozzles and headers are

Ensure the square ness of edge preparation.

Ensure the lifting tools capacity and their service condition.

ERECTION OF WATER WALL

ISGEC JOHN THOMPSON

Ensure necessary temporary supporting arrangements are made to

Ensure the panels are being erected as per the sequence.

Ensure the orientation of panels & headers.

Check and ensure the selection of welding consumables as per welding

ERECTION OF WATER WALL

ISGEC JOHN THOMPSON

Ensure heat treatment procedures are being strictly followed as per

Check and ensure the elevation of burner openings if any.

Ensure all temporary supports are removed.

Ensure all shoulder bolts are fixed in all saddle supports.

Alignment details to be filled up in inspection erection format.

ERECTION OF SUPER HEATER

ISGEC JOHN THOMPSON

Check the received coils dimensions with respective drawing.

Ensure erection of coils with respect to lugs provided for

Check the header elevation levels and nozzle orientations.

Ensure the edge preparation of tubes, nozzles and headers are

ERECTION OF SUPER HEATER

ISGEC JOHN THOMPSON