ON GOING SITE STATUS:

Name of Customer:
Date:
Thermax OC No.:

Sl.
Activites:
No.
A. Civil Foundation: Start Date Completion Date Remarks
1 ESP foundation inspection and its acceptance protocol (axial & diagonal measurements as per drawing).

B. ESP Support Structure:

1 ESP support structure columns erection.
2 Tie beams & bracings erection. Alignment of supportting structures(plumb,axial & diagonal) & acceptance protocol.
3 Welding of tie beams & bracings.
4 Scrap removal.
C. ESP Bearing:

1 Erection of bearing plates as per drawing. Alignment of bearing plates & its acceptance protocol.
2 Temporary locking of bearing plates.
3 Full welding of fixed bearing.
D. Casing:
1 Ground assembly of casing columns A1-B1 with panels.
2 Ground assembly of casing columns C1-D1 with panels.
3 Ground assembly of casing columns E1-F1 with panels.
4 Ground assembly of casing columns A2-B2 with panels.
5 Ground assembly of casing columns C2-D2 with panels.
6 Ground assembly of casing columns E2-F2 with panels.
7 Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
welding defects like blow holes, welding cracks etc.
8 Erection of casing columns A1-B1 with panels.
9 Erection of casing columns A2-B2with panels.
10 Erection of bottom & top girders between col A-B.
11 Erection of casing columns C1-D1 with panels.
12 Erection of casing columns C2-D2 with panels.
 1 ESP foundation inspection and its acceptance protocol (axial & diagonal measurements as per drawing).

B. ESP Support Structure:

13 Erection of bottom & top girders C-D.
14 Erection of casing columns E1-F1 with panels.
15 Erection of casing columns E2-F2 with panels.
16 Erection of bottom & top girders E-F.
17 Erection & welding of casing side panels between col B-C & D-E.
18 Allignment of casing columns & its acceptance protocol..
19 Welding of all top & bottom girders.
20 Outside stitch welding of side casing panels.
21 Welding of splice pl. between casing col & side panel stiffener channel.
22 welding of casing rungs.
23 Installation & seal welding of all casing baffles.
24 Erection & welding of casing access doors & inside platform.
25 Erection & welding of casing hot roof.
26 Erection & welding of casing inner access doors.
27 Removal all temporary supports provided for casing erection / welding purpose, after ESP alignment and before ESP box-
up.Nozzle with Perforated Sheets:
E. Inlet
1 Ground assembly of inlet nozzle as per drawings.
2 Inspection of weld joints. Kerosene leak test of all weld joints.Rectification of all weld joints.
3 Alignment of inlet nozzle inlet flange (plumbness and diagonal).
4 Ground assembly of inlet nozzle G.D. screen . Fixing of GD screens.
5 Welding of pipe stiffener.
6 Fixing of G.D. screen lockings.
7 Welding of lifting lugs for its erection.
8 Erection of inlet nozzle.
9 Allignment & welding of nozzle.
10 Making an opening for inlet nozzle access door.
11 Erection of access door.
12 Welding of access door.
13 Erection of expansion joints.
14 Fixing of inlet nozzle rapping channel.
15 Inlet nozzle rapper rod & boot mountings fixing.
16 Removal all temporary supports provided for erection / welding purpose.
F. Outlet Nozzle with Perforated Sheets:
 1 ESP foundation inspection and its acceptance protocol (axial & diagonal measurements as per drawing).

B. ESP Support Structure:

1 Ground assembly of outlet nozzle as per drawings.
2 Inspection of weld joints. Kerosene leak test of all weld joints.Rectification of all weld joints.
3 Alignment of outlet nozzle outlet flange (plumbness and diagonal).
4 Ground assembly of outlet nozzle G.D. screen . Fixing of GD screens.
5 Welding of pipe stiffener.
6 Fixing of G.D. screen lockings.
7 Welding of lifting lugs for its erection.
8 Erection of outlet nozzle.
9 Allignment & welding of nozzle.
10 Making an opening for outlet nozzle access door.
11 Erection of access door.
12 Welding of access door.
13 Erection of expansion joints.
14 Removal all temporary supports provided for erection / welding purpose.
G. Hopper with its baffle plates and other accessories:
1 Erection & welding of top hopper-1.
2 Erection of bottom hopper -1
3 Welding fo pipe stiffener - hopper-1.
4 Welding of hopper-1 corner flat.
5 Erection & welding of top hopper-2.
6 Erection of bottom hopper -2.
7 Welding fo pipe stiffener - hopper-2.
8 Welding of hopper-2corner flat.
9 Erection & welding of top hopper-3.
10 Erection of bottom hopper -3
11 Welding fo pipe stiffener - hopper-3.
12 Welding of hopper-3 corner flat.
13 Erection & welding of top hopper-4.
14 Erection of bottom hopper -4
15 Welding fo pipe stiffener - hopper-4.
16 Welding of hopper-4 corner flat.
17 Erection & welding of top hopper-5.
18 Erection of bottom hopper -5
19 Welding fo pipe stiffener - hopper-5.
20 Welding of hopper-5 corner flat.
 1 ESP foundation inspection and its acceptance protocol (axial & diagonal measurements as per drawing).

B. ESP Support Structure:

21 Erection & welding of by-pass chutes
22 SS lining for bottom hopper.
23 Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
welding defects like blow holes, welding cracks etc.
24 Inspection of hopper outlet flange/s for its spirit / water level.
25 Erection & welding of hopper doors.
26 Welding the section for manual hammering.
27 Erection of slide gate valve.
28 Erection of RAV.
29 Welding of hopper rungs.
30 Welding of Pneumatic vibrators.
31 Removal all temporary supports provided for erection / welding purpose.
H. Collecting Plate Assembly with its allied parts:
1 Making of collecting plate straightening jig.
2 Checking of collecting plate straightness. Straight if found bend.
3 Making of lifting frame.
4 Assembly of collecting plates with top & bottom tadpole.
5 Erection of roof bolts & floating channels. Alignment of floating channels.
6 Erection of 1st field collecting plates.
7 Erection of 2nd field collecting plates.
8 Erection of 3rd field collecting plates.
9 Erection of 4th field collecting plates.
10 Erection of 5th field collecting plates.
11 Allignment of collecting plates.
12 Check all collecting plates are free from bows / local deformations.
13 Inspection of collecting plate assemblies for its diagonals and other measurement, as per drawing.
14 Check the tightness of fasteners used for collecting plates assemblies and its welding before collecting plate erection.
15 Check the straightness & plumb of installed collecting plate, in its free hanging condition. All collecting plates should be
straight in the tolerance of +/- 5 mm, either side.
16 Welding of all fasteners (Nut to bolt welding) used for collecting plates / its assemblies after alignment.
17 Fixing of bottom tie bars & keeper bars.
18 Fixing of alignment rake.
19 Fixing of adjustable yoke end.
20 Fixing of spreader bars, anvil plates & raper rod positioner.
21 Welding of boot mounting pipes.
22 Erection of raper rods.
I. Regitrode system with its allied parts
1 Ground assembly of top HV frame.
 1 ESP foundation inspection and its acceptance protocol (axial & diagonal measurements as per drawing).

B. ESP Support Structure:

2 Erection of HV frames.
3 Inspection of top HV frame erection and its alignment (level & positioning w.r.t. adjacent collecting plate rows). Ensure that
the regitrode rows (in gas flow direction) are in the mid-way of the adjacent collecting plate rows.
4 Erection of rigitrodes.
5 Erection of bottom guide frame.
6 Check the straightness of all installed regitrodes, in its free hanging condition. All regitrodes must be straight.
7 Check the gap between collecting plate and regitrode, using GO / NO GO type gauge. All temporary locking / supports of
regitrode frame must be removed before gap checking. While checking the gap, top HV frame should be in free hanging
condition. Record all the deviations of this inspection and attach the records with this checklist.

8 Welding of all fasteners (Nut to bolt welding) used for regitrodes and its allied parts, after gauge checking.
9 Erection of rigitrode raper rod with nut,suspension & sliding base plate,support insulator,insulator flange plate.
10 Erection of tripple spring retainer,clamp coupling,shaft insulators.
11 Load transfer to support insulator.
12 Welding of boot mounting pipes.
13 Removal all temporary supports provided for erection / welding purpose.
J. Collecting Plate,Discharge Electrode & Inlet Gas Distribution Screen Rapping System
1 Alignment (verticality / plumb) of rapper rods.
2 Exposure of rapper plunger outside the rapper coil. The plunger should be projected 38mm (ONLY) outside the coil, for
effective rapping.
3 Alignment of rapper coils. All rapper coils must be in correct vertical position (plumb).
4 Grounding of the rapper rods.
5 Sealing of rapper rods, using hypalon boot and clamps.
K. Mechanical Interlock Systems:
1 Check correct interlocks are fixed on following locations -
a. TR set (Grounding Switch & Live Position Switch).

b. TRCC Panel key.

c. Casing Access Doors keys.
d. Hopper Access Doors keys.
e. Penthouse Access Doors key.
f. Inlet & Outlet Nozzle Access Doors keys.
2 Fixing of mechanical interlock key box.

3 Check Functioning of interlock system with individual keys & transfer blocks.
L. Penthouse section:
1 Erection , alignment & welding of pent house columns.
2 Installation of penthouse panels as per drawing and its inside seal welding.
3 Outside stitch welding.
 1 ESP foundation inspection and its acceptance protocol (axial & diagonal measurements as per drawing).

B. ESP Support Structure:

4 Kerosene leak test of all seal weld joints & rectification.
5 Erection of pent house roof panels.
6 Welding of pent house roof panels.
7 Erection & welding of pent house door.
8 Scrap removal.
M. Purge Air System:
1 Check the location of purge air system & installation of PAB with its accessories as per drawing.
2 Fixing of anti vibration pads and flexible connection(at inlet & outlet of blower) for purge air blower.
N. Monorail Structure with lifting equip.:
1 Erection , alignment & welding of monorail columns.
2 Erection & welding of monorail tie beams.
3 Erection & welding of bracings.
4 Monorail beam installation, alignment and welding as per drawing
5 Welding of stoppers at both free ends of the monorail beam.
6 Installation of lifting equipment (Chain Pulley Block) with trolley.
7 Free travel of the trolley with chain block.
8 Scrap removal.
O. Transformer Rectifier Set with HV Duct:
1 Check the TR set oil BDV value. If BDV value is less than 50 kV, the TR oil re-filtration is to be bone, till BDV value
reaches more than 50 kV. This is to be done before TR set is erected on ESP top.
2 Erection of TR set and its HV ducting as per drawing.Welding of HV duct.
3 Oil level in the TR set.
4 Operation of TR set earthing switch.

5 Locking of TR set base roller.

6 Fixing of bus bar pipe , connecting link & jumper.
P.General:
1 Erection & welding of stair case bracket , landing platform & stair cases.
2 Erection & welding of dust discharge level platform.
3 Fixing & welding of rain gaurds.
4 Erection & welding of hand railings.
5 Air leak test of ESP. Clearence for thermal insulation.
Q. Thermal insulation:
1 Insulation of hoppers.
2 Insulation of casing area.
3 Insulation of inlet & outlet nozzles
4 Insulation of pent house area