Checklist for installation

Pre –installation:

1. Availability of material at site.

2. Availability of all drawings.
3. Inspection of material received at site for any damage or wrongly dispatched.
4. Availability of contractor manpower.
5. Availability of crane at site.
6. Availability of rooms for labors/engineers.
7. Handover of civil foundation to ISOTEX.
8. Completion of all foundation tentative date.
9. GL Level marking on foundation.
10. Inspection for foundation rigidness.
11. Inspection for Leveling of foundation.
12. Centre to centre distance of foundation.
13. Measurement of foundation sizes as per drawing.
14. Inspection for pocket size and there distance.
15. Availability of all necessary nut bolts before erection activities.
16. Availability of grouting bolts.
17. Compaction of site crane parking area.
18. Clearance of crane route.
19. Site preparation also includes fixing position of the site office, go downs, guards, labor
shed, access and existing roads for trucks and carts etc.
20. Ensure the capacity of fuel feeders /fans etc.
21. Check availability of all valves and NRVs.
22. Check availability of all necessary instruments with fittings.
23. Check valves and NRVs in open condition for their proper working, if found in faulty
condition then replace them with new one.
24. Check for furnace nozzles according to design.
25. Availability of cables as per cable schedule and of sufficient length.
26. Check thickness of ducting according to heater design.
27. All structural material must should available at site.
CHECKLIST FOR ERECTION WORK:

1. Check loading capacity of cranes.

2. Check lifting capacity of sling & D-shackles.
3. Parking of crane w.r.t load chart.
4. Parking of crane footing properly with proper supports.
5. Parking of crane with proper leveling.
6. Handling of equipments with proper centre of slings.
7. Shifting of material near site as per location in proper way.
8. Arrangement of centre line marking with each foundation.
9. Check erection of equipment according to centre line.
10. Check water leveling of equipment.
11. Check proper nut bolting /grouting of equipments.
12. Check orientation of equipments as per drawing.
13. Check diagonal of equipments w.r.t each other.
14. Check diagonal of ducting flanges
15. Check position and number of holes of flanges.
16. Check proper fitment of asbestos rope in flanges.
17. Check that nut bolting of all equipment and flanges should be properly tightend.
18. Check proper grouting of rotating fans and extra space required for rotating parts.
19. Check for minimum working space required during erection work.
20. Check for verticality of equipments.
21. Check for proper connecting of ducts with complete number of bolts with proper size of
nut bolts.
22. Ensure that piping sizes of pipe line should be as per design.
23. Ensure that pipe line and nut bolting should be of proper specification.
24. Check proper connection of piping with heaters.
25. Ensure for proper heater drain provision with globe valve arrangement.
26. Ensure the fitment of gasket in flanges should be of proper size.
27. Check that pump must be stress free and viberation
28. Check that there should be no load on rotating parts.
29. Check proper piping of pumps and it should be stress free.
30. Check that supporting of pump and fans should be proper.
31. Check that approach for dampers operations of equipments should be proper.
32. Check proper fitment of impellers with casing.
33. Check bracing of equipments as per load of equipments.
34. Check load bearing capacity of platform.
35. Check height of expansion tank structure according to heater design. Should be
minimum 3 mtrs from the top point of TFH line or HE-1.
36. Check capacity of expansion and drain tank. Should be minimum 30 % of total Volume.
37. Check that no leakage should be there in expansion and drain tank.
38. Check proper sizing of chimney.
39. Check angle and length of ID fan to chimney duct. Not less than 45 deg and not more
than 7 mtrs. Chimney connection should be 50 mm more than ID fan inlet duct.
40. Check for shortest distance of cabling route.
41. Check draught measurement provision in all ducts. Pressure must be measures after
every equipments before commissioning.
42. Check fitment of degassing vessel at appropriate height. it should be at same height of
TFH top line or at 1500 mm below expansion tank.
43. Provision of temperature sensing arrangement should be in proper way.
44. Ensure that all manual dampers operation should be in their proper working condition
and must be mark for ON/OFF condition.
45. Check for unwanted dampers in any flue gas duct.
46. Check gap between power and feedback cable. (should be 100 mm min.).
47. Check for any overlapping of cables in cable tray. ( Avoid overlapping of cables).
48. Check cable tray size.
49. Check insulation material density and thickness.
50. Check angle of HE2 Piping. (Avoid any sharp bend or T joints, prefer shoe bends).
51. Check all instrument tapping for proper welding and thermo-well.
52. Air vent position of valves in pipe line of heater and WHRU should be proper.
53. Check for provision of valve for all necessary instrument and safety valves.
54. Provision for manometer arrangement.
55. All piping work should be as per P& ID.
56. Check earthing of all motors, electric panel and ESP.
 Commissioning :-

1. Check refractory lining work should be as per drawing.

2. Check shut off Pressure of all pumps, fans and plenum chamber.
3. Check lubrication and greasing in all gear boxes, diesel engine and thermic pumps.
4. Check rotation of fan, pumps and all feeders.
5. Check NO load trial of all motors.
6. Check proper alignment of Thermic pumps and motors.
7. Check oil level in expansion tank. Should be minimum 2” at cold condition.
8. During cold circulation check pressure at gauge if there is fluctuation then air is present
at line ,this will be removed by cold circulation though de-aerator unit.
9. During cold circulation check current consuming by pump , control amperes by cracking
the discharge line valve.
10. Start slow firing for curing of furnace refectory and warm thremic fluid
11. First 24 hour temp should be about 90 degree, after 48 hours 150 degree and hot bolting should
be done of entire pipeline flange joints, and also clean the strainer .After 72 hours increase the
temp up to requirement.
12. Also check expansion tank level because that oil expend 7% every 100 degree increase in
temperature.
13. After slow firing of 72 hrs. stop wood feeding and allow the furnace to cool at normal
condition
14. After that clean the furnace nozzles and palnium chamber. Then prepare bed. Bed
material specification should be as per fuel used.
15.
16. Refer SOP for further operation.