AIR PREHEATER 3B FQP WISE INSPECTION LIST DATE WISE

Last up date: 03.11.2017 OPGC IB TPS BANHARPALI 2X660MW UNIT # 3 DOC. NO:QPE:BNP:660:BR:22
Format of Log
Sl NO CHARACTERISTICS Type of Check record RFI NO Sheet No Inspection Date Of APH 3B Protocol REMARKS

1 Availabelity of hydrolic test certificate for SCAPE. B Class

(Verifection of test certificate)
2 Compressed air cleaning of tube internaly and externally. C Class
3 Alignment of SCAPH between ducts (for elevation & axia location). C Class
4 Completion of fixing of CAF gaskets in flange joints of SCAPH and C Class
tightening of bolts
5 Completion of piping flanges with gaskets. C Class
6 Ensure no shift in axis of flanges of SCAPH and pipelines. C Class
7 Ensure parallality of flange of SCAPH and pipelines. C Class

SUPPORTING STEEL:
1 Ensure APH Support beams locattion wrt GA drawing of boiler and APH. A Class L-01 1008A 1 23.09.16 Complete
2 Welding of air heater supporting beam. C Class L-00 2 28.12.16 Complete
3 Elevation and level of supporting steel. A Class L-01 1010 3,19 23.09.16 & 11.11.16 Complete

4 Squareness of air heater supporting beam by measuring the diagonals. A Class L-01 1027 4 30.09.16 Complete
5 Level, Elevetion and spacing of expansion arrangement on the bottom plate. A Class L-02 1012A,1152,1236,1251 5,20,27,30,42 24.09.16 & 11.11.16 & Complete
(Tolerance: +/- 2mm Max). 25.11.16 & 29.11.16
6 Blue matching of base plate of expension arrangement with supporting structure. A Class L-00 1009A,1153,1235,1251 6,21,26,29 23.09.16 & 11.11.16 &25.11.16 Complete
&29.11.16

PEDESTAL AND PANEL:

1 Height of each panel C Class L-00
2 Marking of centre line (if not marked by mfd.unit). C Class L-00 NA 8,22 29.09.16 & Complete
12.11.16
3 Pedestal level,elevetion of top of main and side pedestals (allowable tolerance + or - 1.5mm). C Class L-00 NA 9,23 29.09.16 & Complete
12.11.16
4 Verticality of pedestal and panel (Tolerance: 2mm Max). C Class L-00 NA 10,24,28,40 29.09.16 & 12.11.16 & Complete
25.11.16 & 03.12.16
5 Distance between opposite pedestals (Tolerance: +/- 6mm) C Class L-03 NA 11,25 29.09.16
6 Housing panel level A Class L-03 1294 31 09.12.16 Complete
7 Completion of seal welding of all panels except rotor drive panel. C Class L-00
Note: Welding of rotor drive panel to be complete only after final alignment of rotor drive assembly.

CONNECTING PLATE ASSEMBLY - COLD END:

1 Matching of centre line marking with pedestal centre line marking. C Class L-00 NA 15 29.09.16 Complete
2 Centre section level (Tolerance: +/- 1.5mm). B Class L-04 NA 16,32 30.09.16 & 03.12.16 Complete
3 Alignment of foot pad with expension plate and base pad & fillet weld installation of seismic stop. C Class L-00 NA 32 03.12.16 Complete
4 Diagonals distance between split line cornes. (Tolerance:+/- 6mm) B Class L-04 NA 34 03.12.16 Complete
5 Cleat angel welding between hanger plates and center section. B Class L-00 NA 14 13.10.16 Complete
6 NDE on clit angel welding (LPI). B Class L-00 NA 14 13.10.16 Complete
7 Support bearing alignment / level. (Tolerance: +/- 0.42mm per mtr) A Class L-05 1082,1294A,1640 17,35,44 20.10.16 & 09.12.16 & Complete
05.02.17
8 Ensure seal between the housing cover and the bearing house is correctly installed. C Class L-00

1 Post, Trunnion & Spool assembly C Class L-00

Installation of post, trunnion and spool assembly on to support bearing.Verticality 0.4mm permeter C Class L-00 NA 41 09.12.16 Complete

CONNECTING PLATE ASSEMBLY - HOT END:

1 Matching of centre line marking with pedestal center line marking. C Class L-00
2 Centre section level. B Class L-04 NA 33 03.12.16 Complete
3 Alignment of upper and lowel connecting plate (Diagonal variation: 3mm Max). B Class L-04 NA 33 03.12.16 Complete
4 Welding of connecting plate after rotor post assembly. C Class
5 Alignment of rotor post between splits. B Class L-06 NA 47 05.02.17 Complete beyond the lemit
6 Guide bearing housing distance between bearing housing flange and housing sleeve flange. A Class L-07 1293, 1638, 2667 38,45 09.12.16 & 05.02.17 Complete beyond the lemit
& 15.06.17
7 Guide bearing housing level before and after module loading A Class L-07 1293, 1638, 2667 38,45 09.12.16 & 05.02.17 Complete beyond the lemit
& 15.06.17
8 Contact between trunion shaft and adopter sleeve of guide bearing.On completion of taper fit check ensure that the cap A Class L-08 96 07.09.17 Complete REQ. 2ND INSPECTION
bolts are torque tightened over cap plate and stoper plates are welded to the cap bolts as per the drawing.

9 Tightening and locking of cap bolt A Class L-08

10 Removal of all temporary braces C Class L-00
 ROTOR MODULES:
1 Ensure that the rotor post pins are inserted peoperly and welded with rotor post. C Class L-00
2 Ensure that the bottom of modules is seated properly in the lower ring. C Class L-00
3 Sequential erection of rotor shall segments and completion of welding between the segments & B Class L-00 NA 53 14.02.17 Complete
rotor post and instoll modules.
4 Bolting of modules with shims together and record the chord dimensions. B Class L-09 NA 48 05.02.17 Complete
5 Recheck the alignment of support and guide bearing A Class L-05/L-07
6 Rotor level A Class L-10 1639 46 05.02.17 & 15.06.17 Complete
7 Manually rotate the rotor and check: L-00
a) Maximum radiel run out tolerance from a fixed point in rotor housing at pin rack location B Class L-00 NA 56,57 14.02.17 Complete
b) Rotor shell axial fluctuation at cold end and hot end when rotated over a fixed point. B Class L-00 NA 58,59 06.03.17 Complete
8 Rotor angel alignment B Class L-11 NA 74,75 10.05.17 Complete
9 Record housing pedestal elevetion after rotor level B Class L-03 NA 49 11.02.17 Complete
10 Elevation of pin rack as rotor assembly drawing. C Class L-00 NA 50 09.02.17 Complete
11 Circularity of pin rack (radial and axial run out) B Class L-12 NA 62 04.05.17 Complete
12 Pitch of the pin at the erection joint. B Class L-12 NA 63 04.05.17 Complete
13 Marking of high point of pin rack (axial and radial) by welding A Class L-12 2235,2255A 64,73 04.05.17 & 06.05.17 Complete

DRIVE UNIT:
1 Distance between point of bottom pin rack bar to bottom of pinion. A Class L-13 2369 77 20.05.17 Complete
2 Clearance between pin and penion (root gap). A Class L-13 2369 78 20.05.17 Complete
3 Axil position of pinion w.r.t. pin rack. A Class L-13 2369 79 20.05.17 Complete
4 Alignment of drive motor with gear box. A Class L-00
5 Ensure line contact between pinion and pin rack pins. B Class L-00 NA 80 20.05.17 Complete
6 Ensure torque tightening of taper lock bus/ QD bus bolts. B Class L-00
7 Axial wobble of pinion at the root periphery. ( 0.8 mm Max ) A Class L-00 2369 81 20.05.17 Complete
6 T-bar for run out (radial and axial) B Class L-14 NA 82 01.06.17
7 Marking of high point of T-bar (axial and radial) by welding. B Class L-14 01.06.17
8 Clearance between T-bar and pin rack bar. B Class L-15
9 a) Sector plate setting at cold and hot ends. A Class L-16 98 08.09.17 Beyond the lemit
b) Sector plate level (cold and hot ends). B Class L-17 NA 99 08.09.17 Complete

SEALS:
1 Recheck the rotor level after module erection and before seal seatting B Class L-00 NA 85 15.06.17 Complete
2 Recheck the alignment of support and guide bearing A Class L-05/L-07 2667 83,84 15.06.17 Complete
3 Completion of rotor post seals C Class L-00
4 Radiel run out of bypass seal angle at hot and cold end during initial setting C Class L-00 NA 86 15.06.17 Complete
5 Axial seal plate (alignment) circularity B Class L-18 NA 95 07.09.17 Beyond the lemit
6 Fixcing and setting of seals to clearance as per seal clearance chart A Class L-00
a) Radial seal L-19
b) Bypass seal L-20
c) Axial seal L-21 NA 94 07.09.17 Beyond the lemit
d) Sealing tabs L-00
7 Completion of: C Class L-00
a) Oil circulation unit L-00
b) Water washing system L-00
c) Rotor stoppage alarm L-00
d) Fire sensing device L-00
e) Oil carry over probe L-00
f) Cleaning device L-00
g) Observation port and light. L-00

WELDING AND NDE

1 Welder's performance qualification A Class L-00
2 Adoption of correct procedure, approved electrodes and methodes. A Class L-00
3 NDE on welding A Class L-00 NA 65,66,67,68,69,7 05.10.16,08.12.16,12.06.17,
0,71,72,87,88,89, 26.07.17,29.07.17
90,91
 GENERAL:
1 Completion of seal welding of housing to avoid leakages. C Class L-00
2 Air leak test on casing of APH, adjoining of ducts and expension joints. A Class L-00
3 Completion of seal tabs to avoid air leakages to gas side. B Class L-00
4 Completion of insulation with specified thickness. C Class L-00
5 Air preheater is free from duct loading (Adjusment of supports of ducts). B Class L-00
6 Cold run test of APH A Class L-00
L-00
1 Ascertain the completion of alignment of internal clerance. B Class L-00
2 Complete cleanlines (debris, welding materials, scaffolding etc. inside air and gas path at cold and B Class L-00
hot ends to be removed fully).
3 Freeness of air heater from external load such as ducts, expension below and platforms. B Class L-00
4 Free expension of pedestal without any interfereness. B Class L-00
5 Connection of all instruments on airheater. C Class L-00
6 Continuity of all circuits C Class L-00
7 Motor connection. C Class L-00
8 Thermal overload relay setting C Class L-00
9 Pipie load is not transmitted to swivel joint of cleanning device and support of soot blowing pipe line. B Class L-00
10 Coolers of support & guide bearing for no leaks by hydraulic test and no physical damage. B Class L-00
11 Acid pickling of lube oil lines. C Class L-00
12 Lubrication of motor and reducer. C Class L-00
13 Correct grade and level of oil in the fluid coupling and reducer unit. C Class L-00
14 Corrct position of pinion air seal carbon rings. C Class L-00
15 Correct grade & level of oil in the support and guide bearing, after flushing operation. C Class L-00
16 Ensure no oil leakages in the following : B Class L-00
a) Drain plugs. L-00
b) Thermocouple connections and thermostats. L-00
c) Dip stick. L-00
d) Other piping and plugs. L-00
17 Etablish oil flow to the bearings. B Class L-00
18 Pressure guage & thermostats are calibrated and connections are made. B Class L-00
19 Completion of lube oil system trail run and line flushing for support and guide bearing assembly. B Class L-00
20 Ensure completion of seal air supply lines to reducer and guide bearing areas, cooling water supply C Class L-00
to coolers and oil detection unit.
21 Ensure proper functioning of the following: C Class L-00
a) Fire sensing device. L-00
b) Rotor stoppage alarm. L-00
c) Oil circulation unit. L-00
d) Warer washing system. L-00
e) Ceanning device. L-00
f) Oil carry over probe L-00
g) Observation port. L-00
h) Fire fighting system. L-00
i) ALSc, whereaver applicable. L-00
22 Ensure proper functioning of local indication, interlocks & protections. B Class L-00
23 Verifection of work completion. A Class L-22
24 Trial run of air preheater. A Class L-23
 AIR PREHEATER 3A FQP WISE INSPECTION LIST DATE WISE
Last up date: 15.11.2017 OPGC IB TPS BANHARPALI 2X660MW UNIT # 3 DOC. NO:QPE:BNP:660:BR:22

Sl NO CHARACTERISTICS Type of Check Format of RFI NO Log Inspection Date Of APH 3A Protocol REMARKS
record Sheet No
1 Availabelity of hydrolic test certificate for SCAPE. B Class
(Verifection of test certificate)
2 Compressed air cleaning of tube internaly and externally. C Class
3 Alignment of SCAPH between ducts (for elevation & axia location). C Class
4 Completion of fixing of CAF gaskets in flange joints of SCAPH and C Class
tightening of bolts

5 Completion of piping flanges with gaskets. C Class

6 Ensure no shift in axis of flanges of SCAPH and pipelines. C Class
7 Ensure parallality of flange of SCAPH and pipelines. C Class

SUPPORTING STEEL:
1 Ensure APH Support beams locattion wrt GA drawing of boiler and APH. A Class L-01 3420 3 19.09.17 Complete
2 Welding of air heater supporting beam. C Class L-00 1 15.09.17 Complete
3 Elevation and level of supporting steel. A Class L-01 3454A,3779A,3799, 42 21.09.17,10.10.17,18.10.17, Complete
3869 21.10.17,25.10.17
4 Squareness of air heater supporting beam by measuring the diagonals. A Class L-01 3472 7 23.09.17 Complete
5 Level, Elevetion and spacing of expansion arrangement on the bottom plate. A Class L-02 3454,3779A,3799, 42 21.09.17,18.10.17,21.10.17, Complete
(Tolerance: +/- 2mm Max). 3869 25.10.17
6 Blue matching of base plate of expension arrangement with supporting structure. A Class L-00 3453,3779,3798A, 6,19,26,37 21.09.17,18.10.17,21.10.17, Complete
3780 25.10.17

PEDESTAL AND PANEL:

1 Height of each panel C Class L-00 47
2 Marking of centre line (if not marked by mfd.unit). C Class L-00 NA 12,31 09.10.17,23.10.17
3 Pedestal level,elevetion of top of main and side pedestals (allowable tolerance + or - 1.5mm). C Class L-00 NA 8,32 28.09.17,19.10.17,23.10.17,
26.10.17
4 Verticality of pedestal and panel (Tolerance: 2mm Max). C Class L-00 NA 9,29,30,38 26.09.17,19.10.17,23.10.17

5 Distance between opposite pedestals (Tolerance: +/- 6mm) C Class L-03 NA 10 26.09.17
6 Housing panel level A Class L-03 3945 41 31.10.17 Complete
7 Completion of seal welding of all panels except rotor drive panel. C Class L-00
Note: Welding of rotor drive panel to be complete only after final alignment of rotor drive assembly.

CONNECTING PLATE ASSEMBLY - COLD END:

1 Matching of centre line marking with pedestal centre line marking. C Class L-00 NA 14 09.10.17
2 Centre section level (Tolerance: +/- 1.5mm). B Class L-04 NA 13,20 09.10.17,17.10.17 Complete
3 Alignment of foot pad with expension plate and base pad & fillet weld installation of seismic stop. C Class L-00
4 Diagonals distance between split line cornes. (Tolerance:+/- 6mm) B Class L-04 NA 16 17.10.17 Complete
5 Cleat angel welding between hanger plates and center section. B Class L-00 NA 11 09.10.17
6 NDE on clit angel welding (LPI). B Class L-00 NA 11 09.10.17
7 Support bearing alignment / level. (Tolerance: +/- 0.42mm per mtr) A Class L-05 3869, 4159 15, 48 25.10.17, 14.11.17 Complete Req. 2nd Inspection

8 Ensure seal between the housing cover and the bearing house is correctly installed. C Class L-00

1 Post, Trunnion & Spool assembly C Class L-00

Installation of post, trunnion and spool assembly on to support bearing.Verticality 0.4mm permeter C Class L-00 NA 18 16.10.17

CONNECTING PLATE ASSEMBLY - HOT END:

1 Matching of centre line marking with pedestal center line marking. C Class L-00 NA 45 16.10.17
2 Centre section level. B Class L-04 NA 21 17.10.17 Complete
3 Alignment of upper and lowel connecting plate (Diagonal variation: 3mm Max). B Class L-04 NA 22 17.10.17
4 Welding of connecting plate after rotor post assembly. C Class L-00
5 Alignment of rotor post between splits. B Class L-06 NA 23, 53 17.10.17, 15.11.17 Complete
6 Guide bearing housing distance between bearing housing flange and housing sleeve flange. A Class L-07 3868, 4150 34, 49 25.10.17, 14.11.17 Complete Req. 2nd Inspection
7 Guide bearing housing level before and after module loading A Class L-07 3868, 4150 34, 49 25.10.17, 14.11.17 Complete Req. 2nd Inspection
8 Contact between trunion shaft and adopter sleeve of guide bearing.On completion of taper fit check ensure that the cap bolts A Class L-08
are torque tightened over cap plate and stoper plates are welded to the cap bolts as per the drawing.
9 Tightening and locking of cap bolt A Class L-08
10 Removal of all temporary braces C Class L-00

ROTOR MODULES:
1 Ensure that the rotor post pins are inserted peoperly and welded with rotor post. C Class L-00
2 Ensure that the bottom of modules is seated properly in the lower ring. C Class L-00 NA 43 29.10.17
3 Sequential erection of rotor shall segments and completion of welding between the segments & B Class L-00 N/A 44 30.10.17
rotor post and instoll modules.
4 Bolting of modules with shims together and record the chord dimensions. B Class L-09
5 Recheck the alignment of support and guide bearing A Class L-05/L-07
6 Rotor level A Class L-10 4151 50 14.11.17
7 Manually rotate the rotor and check:
a) Maximum radiel run out tolerance from a fixed point in rotor housing at pin rack location B Class L-00 N/A 51 & 52
b) Rotor shell axial fluctuation at cold end and hot end when rotated over a fixed point. B Class L-00
8 Rotor angel alignment B Class L-11
9 Record housing pedestal elevetion after rotor level B Class L-03
10 Elevation of pin rack as rotor assembly drawing. C Class L-00 N/A 54 15.11.17
11 Circularity of pin rack (radial and axial run out) B Class L-12
12 Pitch of the pin at the erection joint. B Class L-12
13 Marking of high point of pin rack (axial and radial) by welding A Class L-12

DRIVE UNIT:
1 Distance between point of bottom pin rack bar to bottom of pinion. A Class L-13
2 Clearance between pin and penion (root gap). A Class L-13
3 Axil position of pinion w.r.t. pin rack. A Class L-13
4 Alignment of drive motor with gear box. A Class L-00
5 Ensure line contact between pinion and pin rack pins. B Class L-00
6 Ensure torque tightening of taper lock bus/ QD bus bolts. B Class L-00
7 Axial wobble of pinion at the root periphery. ( 0.8 mm Max ) A Class L-00
6 T-bar for run out (radial and axial) B Class L-14
7 Marking of high point of T-bar (axial and radial) by welding. B Class L-14
8 Clearance between T-bar and pin rack bar. B Class L-15
9 a) Sector plate setting at cold and hot ends. A Class L-16
b) Sector plate level (cold and hot ends). B Class L-17

SEALS:
1 Recheck the rotor level after module erection and before seal seatting B Class L-00
2 Recheck the alignment of support and guide bearing A Class L-05/L-07
3 Completion of rotor post seals C Class L-00
4 Radiel run out of bypass seal angle at hot and cold end during initial setting C Class L-00
5 Axial seal plate (alignment) circularity B Class L-18
6 Fixcing and setting of seals to clearance as per seal clearance chart A Class L-00
a) Radial seal L-19
b) Bypass seal L-20
c) Axial seal L-21
d) Sealing tabs
7 Completion of: C Class L-00
a) Oil circulation unit L-00
b) Water washing system L-00
c) Rotor stoppage alarm L-00
d) Fire sensing device L-00
e) Oil carry over probe L-00
f) Cleaning device L-00
g) Observation port and light. L-00

WELDING AND NDE

1 Welder's performance qualification A Class L-00
2 Adoption of correct procedure, approved electrodes and methodes. A Class L-00
3 NDE on welding A Class L-00 39
 GENERAL:
1 Completion of seal welding of housing to avoid leakages. C Class L-00
2 Air leak test on casing of APH, adjoining of ducts and expension joints. A Class L-00
3 Completion of seal tabs to avoid air leakages to gas side. B Class L-00
4 Completion of insulation with specified thickness. C Class L-00
5 Air preheater is free from duct loading (Adjusment of supports of ducts). B Class L-00
6 Cold run test of APH A Class L-00

1 Ascertain the completion of alignment of internal clerance. B Class L-00

2 Complete cleanlines (debris, welding materials, scaffolding etc. inside air and gas path at cold and B Class L-00
hot ends to be removed fully).
3 Freeness of air heater from external load such as ducts, expension below and platforms. B Class L-00
4 Free expension of pedestal without any interfereness. B Class L-00
5 Connection of all instruments on airheater. C Class L-00
6 Continuity of all circuits C Class L-00
7 Motor connection. C Class L-00
8 Thermal overload relay setting C Class L-00
9 Pipie load is not transmitted to swivel joint of cleanning device and support of soot blowing pipe line. B Class L-00
10 Coolers of support & guide bearing for no leaks by hydraulic test and no physical damage. B Class L-00
11 Acid pickling of lube oil lines. C Class L-00
12 Lubrication of motor and reducer. C Class L-00
13 Correct grade and level of oil in the fluid coupling and reducer unit. C Class L-00
14 Corrct position of pinion air seal carbon rings. C Class L-00
15 Correct grade & level of oil in the support and guide bearing, after flushing operation. C Class L-00
16 Ensure no oil leakages in the following : B Class L-00
a) Drain plugs. L-00
b) Thermocouple connections and thermostats. L-00
c) Dip stick. L-00
d) Other piping and plugs. L-00
17 Etablish oil flow to the bearings. B Class L-00
18 Pressure guage & thermostats are calibrated and connections are made. B Class L-00
19 Completion of lube oil system trail run and line flushing for support and guide bearing assembly. B Class L-00
20 Ensure completion of seal air supply lines to reducer and guide bearing areas, cooling water supply C Class L-00
to coolers and oil detection unit.
21 Ensure proper functioning of the following: C Class L-00
a) Fire sensing device. L-00
b) Rotor stoppage alarm. L-00
c) Oil circulation unit. L-00
d) Warer washing system. L-00
e) Ceanning device. L-00
f) Oil carry over probe L-00
g) Observation port. L-00
h) Fire fighting system. L-00
i) ALSc, whereaver applicable. L-00
22 Ensure proper functioning of local indication, interlocks & protections. B Class L-00
23 Verifection of work completion. A Class L-22
24 Trial run of air preheater. A Class L-23
 OPGC IB TPS BANHARPALI 2 X 660 MW
UNIT # 3 BOILER APH ARRANGEMENT II LIST OF WELDING BALABCE

Sl No Characteristics PGMA DU No
1 Pin rack assembly to shell plate side around corners welding 52-012 1,2,3,4,5
2 Hot end center section to Primary center section welding 52-041 18,16
3 Cold end Primary Center section 52-042 4
4 Cold end connecting plate 52-042 6,8,10,12,14,16,18,20,22,24,26,28,29,30
5 Large Air heater - Rotor housing (Middel casing wall) 52-030 4,6,7,8,11,13,15,17,19,21
6 Hot end connecting plate (Corner Casing) 52-041 5,7,9,11,13,14,20,21,22,23,24,25
7 Large Air heater - Rotor housing (Side Pedestal) 52-030 17,7
8 Man hole door 52-220 30
9 T bar welding 52-013-01696 34,35,26
10 Rotar angle welding 52-010-01763 20
11 Spacer bar assembly and inboard spacer assembly 52-013- 15,43
12 Bracings welding 52-042 29,30
13 By Pass angle welding 52-041-02488 1