STANDARD CHECK LISTS

MECHANICAL

VOLUME V
Section A : I.C. Engines
Section B : Driers
Section C : Soot blowers
Section D : Electrostatic Precipitator
Section E : Ash handling Plant
Section F : Miscellaneous

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.

STANDARD CHECK LISTS

MECHANICAL
VOLUME V
CONTENTS
NO.

TITLE
COMMISSIONING/TESTING ESSENTIAL PREREQUISITES
SECTION A

1)

Driers without Regeneration

SECTION-B

1)

Long Retractable Soot blowers

2)

Wall Deslaggers
SECTION-C

1)

Emitting Electrode Rapping Mechanism

2)

Collecting Electrode Rapping Mechanism

SECTION-D

1)

Clinker Grinder

2)

Scraper Conveyer
SECTION-E

1)

Lubricator-Compressed air line

2)

Windbox Assembly

SCL.REF.NO

LIST OF MANUALS
STANDARD CHECK LISTS
MECHACAL
VOLUME I

VOLUME II

VOLUME III

VOLUME IV

VOLUME V

Section A

Valves

Section B

Pipe Work System

Section A

Tanks & Pr. Vessel

Section B

Pumps

Section C

Filter & Strainer

Section D

Hoat Exchanger

Section A

Fans & Compressors

Section B

Dampers

Section C

Duct Work

Section D

Cranes and Lift

Section E

Power Transmission

Section A

Fuel handling equipment

Section B

C.M. Plant

Section A

I.C. Engines

Section B

Driers

Section C

Soot blowers

Section D

Electrostatic precipitator

Section E

Ash handling Plant

Section F

Miscellaneous

MECHANICAL
STATION

PLANT ITEM :

STANDARD CHECK LIST

SHEET 1 OF 1

COMMISSIONING/TESTING ESSENTIAL PREREQUTSITES

PLANT NOMENCLATURE: _________________________________________________

UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

Access to the plant item is adequate

2.

Illumination in the plant area is adequate.

3.

Any other requisite safety provision is adequate for the

immediate commissioning activity.

4.

Plant item is in a clear condition.

5.

All necessary locks and keys for padlocks, interlocks etc.

are available.

6.

Hot surfaces lagged or screened or screened sufficiently

to provide protection for personnel.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: MS 1/1

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 2 OF 2

DRIERS WITHOUT REGENERATION

NO.

ACTIVITY

7.

Safety valves in position?

8.

Sight glass in position?

9.

Sight glass flanges and joints are tight.

10.

Check for the proper tightness of the flange bolts and

joints at the inlot and outlot pipe segments.

11.

Supports of proper strength have been provided.

12.

Provision for refilling of adsorbant in drier ssatisfactory.

13.

Precalibrated pressure gauges installed at inlot and out

lot?

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 15/1

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 1 OF 1

DRIERS WITHOUT REGENERATION

PLANT NOMENCLATURE: _________________________________________________

UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

General conditions satisfy the site standing instructions as

listed in the Plant Item Commissioning Essential Prerequisites (SCL MS 1/ 1).

2.

The name plate legend agrees with the approved NTPC

Plant nomenclature is clearly visible, securely fixed
durable and correlates with remote labels.

3.

The installation is complete and correct in accordance with

approved drawings and specifications.

4.

Access to the plant satisfactory.

5.

Permanent lighting available.

6.

Adequate clearance towall / stool work around drier?

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 15/1

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 1 OF 1

LONG RETRACTABLE SOOT BLOWERS

PLANT NOMENCLATURE: _________________________________________________

UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

General conditions satisfy the site stranding Instructions

listed in the Plant Item Commissioning Essential Prerequisites (SCL MS 1/1).

2.

The nameplate legend agrees with the approved NTPC

Plant Nomenclature and is clearly visible, securely fixed,
durable and correlates with remote labels.

3.

The installation is complete and correct in accordance with

the latest drawings.

4.

Access for adjustments, maintenance and repairs is

satisfactory.

5.

Check the blower number with reference to the location

drawing to ensure the installation of correct blower in
correct location.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 16/1

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 2 OF 2

PLANT ITEM :

NO.

ACTIVITY

6.

The rotary and traverse powerpacks are flushed and then

filled and then filled with the recommended lubricant.

7.

Check that the lubrication of travelling parts is carried out

(servegem HTXX)

8.

Check that there is no rusting on chains and sprocket and

the lubrication is carried out.

9.

Check for the accessibility of the hand crank for manual

operation.

10.

Check for proper tensioning of chains.

11.

Check whether stop pin is present on the cam bracket.

12.

Check the position of valve opening cam.

13.

Check the terminal box is properly covered to prevent any

ingress of water.

14.

Check the proper slope consideration is given, as per

drawing, for horizontal and vertical expansion of the boiler
when the unit is working (valves to be supplied by the
erection staff).

15.

Check the refractory filling in the seal box is done.

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 16/1

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 2 OF 2

PLANT ITEM : WALL DE SLAGGERS

NO.

ACTIVITY

6.

Check the perpendicularity of wall sleeve and swivel type

(90 deg + 30 ) (Certificate from erection personnel to be
obtained)

7.

Check the accessibility for hand crank and the switch box
assembly.

8.

Check that the soot blower piping adjacent to the blower is

supported on boiler steel and is not likely to foul with
structural steel when the boiler expansion will take place.

9.

The rotary and traverse gear boxes are thoroughly flushed

and filled with the recommended lubricant.

10.

Check that the lubrication of the linkages is properly

carried out.

11.

Check that the stop nuts are in place on the guide rods.

12.

Check that the drain holes in the motor frames point

downwards and are open.

13.

The SBV head valve is serviced for proper opening and

closing.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 16/2

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 3 OF 3

PLANT ITEM : WALL DE-SLAGGERS

NO.

ACTIVITY

14.

Check that the blower, before starting or at the end of its

operation is in the correct parking position.

15.

Check that a minimum clearance of 1mm is maintained

between the drive serew and SBV head valve stem. (to
ensure tight valve seating).

16.

Check the refractory filling in the seal box is done.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 16/2

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 1 OF 2

ELECTROSTATIC PRECIPITATOR (MECHANICAL)

EMITTING ELECTRODE RAPPING MECHANISM

PLANT NOMENCLATURE: _________________________________________________

UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

General conditions satisfy the site Standing Instructions as

listed in the Plant Item Commissioning Testing Essential
Pre-requisites (SCL/msi/1).

2.

The name plate legend agrees with the approved NTPC

Plant Nomenclature, is clearly visible, securely fixed, is
durable and correlated with any remote labels.

3.

Installation is correct and complete as per the latest

approved drawings.

4.

Ensure that there is no foreign material inside the ESP and

check the cleanliness of hoppers and walls.

5.

Check the disposition of inner arms on rapping shaft set at

proper phase angle.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 17/1

MECHANICAL

STATION

: STANDARD CHECK LIST

SHEET 2 OF 2

PLANT ITEM : ELECTROSTATIC PRECIPITATOR (MECHANICAL)

EMITTING ELECTRODE RAPPING MECHANISM

NO.

ACTIVITY

6.

Check the distance between centre line of rapping shaft to

the centre line of shock beam.

7.

Check the direction of serow provided for emitting rapping

drive.

8.

Check the working clearance of 5mm at the back of the

serow.

9.

Check the radial and axial alignment of clutch and

coupling.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: MS 17/1

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 1 OF 2

PLANT ITEM : ELECTROSTATIC PRECIPITATOR (MECHANICAL)

COLLECTING ELECTRODE RAPPING MECHANISH
PLANT NOMENCLATURE: _________________________________________________
UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

General conditions satisfy the site Standing Instructions as

listed in the Plant Item Commissioning Testing Essential
Pre-requisites (SCL MS 1/1)

2.

The name plate legend agroes with the approved NTPC

Plant Nomenclature, is clearly visible, securely fixed, is
durable and correlates with any remote labels.

3.

Installation is correct and complete as per the latest

approved drawings.

4.

Ensure that there is no foreign material inside the ESP and

check the cleanliness of hoppers and walls.

5.

Check the disposition and tightness of inner arms on

rapping shaft set at proper phase angle.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 17/2

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 2 OF 2

PLANT ITEM :

NO.

ACTIVITY

6.

Check the support bracket provided in the middle of two

hammers.

7.

Check the distance between centre line of rapping shaft to

centre line of shock bar.

8.

Ensure that the shock pad face and shaft axis are in the
same vertical plane.

9.

Check the lateral shift to hammers with reference to shock

pad centre.

10.

Check the proper sealing of the rapping shaft in the

bearing.

11.

Check the set rings position and their welding.

12.

Check the clearance between collecting electrode and gas

screen.

13.

Check the radial & axial alignment of clutch & coupling.

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 17/2

MECHANICAL

DATE

STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 1 OF 3

CLINKER GRINDER

PLANT NOMENCLATURE: _________________________________________________

UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

General conditions satisfy the site standing Instructions as

listed in the Plant Item Commissioning Essential PreRequisties (SCL MS1/1).

2.

The name plate legend agrees with the approved NTPC

Plant Nomenclature is cloarly visible, securely fixed,
durable and correlates with remote labels.

3.

Installation is complete and correct in accordance with

approved drawings and specification.

4.

Adequate access for adjustment, maintenance and repairs

is provided.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 18/1

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

NO.

SHEET 2 OF 3

CLINKER GRINDER

ACTIVITY

6.

Verify that sliding wheel is provided.

7.

Check that fluid coupling is provided.

8.

Verify that Reduction Gearbox is provided.

9.

Check that sprocket and chains are installed correctly.

10.

Verify that sealing water connections to roller bearings are

made.

11.

Check that pressure gauges and pressure switches are

mounted properly on the sealing water line.

12.

Check the fluid coupling as per SCL

13.

Check reduction gearbox as per SCL

14.

Check that clinker grinder roller bearings, sprocket and

chain lubrication is complete.

15.

Check that motor trial run has been taken satisfactorily.

16.

Verify that start permissive and protection of clinker grinder

checked is satisfactory.

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 15/1

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 3 OF 3

PLANT ITEM : CLINKER GRINDER

NO.

ACTIVITY

17.

Verify that S.C.C. is taken. Record the ref. no. and

effective date.

18.

Simulate the operation of emergency push button.

19.

Short the clinker grinder trial run, continue run for 4 Hrs
and observe:-

WITNESSED
NTPC

BHEL

19.1 Motor Bearing Vibration.

19.2 No over heating of clinker grinder roller bearings.
19.3 Interlock with seal water pressure and clinker grinder
working satisfactorily.
19.4 Reverse rotation of clinker grinder.
20.

Check smooth operation of inlot chute flap gate.

REMARKS :
SCL REF: M 18/1

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 1 OF 3

SCRAPER CONVEYOR

PLANT NOMENCLATURE: _________________________________________________

UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

General conditions satisfy the Site Standing Instruction as

listed in the PLANT ITEM COMMISSIONING ESSENTAL
PRE REQUISITES (SCL MSI/1).

2.

The name plate legend agrees with the approved NTPC

Plant nomenclature is clearly visible, securely fixed,
durable and correlates with remote labels.

3.

Installation is complete and correct in accordance with

approved drawings and specification.

4.

Adequate access for adjustment, maintenance and repairs

is provided.

5.

Verify that all construction Dobris is removed from the

scraper conveyer through.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 18/2

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 2 OF 3

SCRAPER CONVEYOR

NO.

ACTIVITY

6.

Check that LP water connection to scraper conveyer

trough is made correctly.

7.

Check that HP water connection to scraper bar cleaning is

made and nozzle is installed correctly.

8.

Check the reduction gearbox as per SCL

9.

Verify that drive chin sprocket bearings are greased and

chains have been lubricated properly.

10.

Check that scraper conveyer pulleys are rotating smoothly

and freely.

11.

Check that conveyer bars coated with lubricant.

12.

Check that motor trial run has been taken satisfactorily.

13.

Verify that protection and interlocks of scraper conveyor

checked out satisfactorily.

14.

Verify that S.C.C. is taken. Record the ref.no. and effective

date.

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 18/2

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 3 OF 3

PLANT ITEM : SCRAPER CONVEYOR

NO.

ACTIVITY

15.

Verify that the operation of emergency push button has

been checked.

16.

Start the scraper conveyor trial run and continue the trial
run for 6 hrs. and observe.

WITNESSED
NTPC

BHEL

16.1 Smooth functioning of scraper conveyer.

16.2 Smooth functioning of tension adjusting device.
16.3 Smooth functioning of nozzles for cleaning of scraper
bars.

REMARKS :
SCL REF: M 18/2

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 1 OF 2

PLANT ITEM : LUBRICATOR COMPRESSED AIR LINE

PLANT NOMENCLATURE: _________________________________________________
UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
WITNESSED

NO.

ACTIVITY

1.

General conditions satisfy the site standing instruction as

listed in the Plant Item Commissioning Essential Pre
requisites (SCL MSI/1).

2.

The name plate legend agrees with the approved NTPC

Plant nomenclature and is clearly visible, securely fixed,
durable and correlates with remote labels.

3.

The installation is complete and correct in accordance with

the latest drawings and specification.

4.

Check that quick opening cap arrangement for oil filling is

provided.

5.

Check that air line connected at inlet and outlet

lubrication are tested and blown.

NTPC

BHEL

DATE

of

REMARKS :
SCL REF: M 20/1

MECHANICAL
STATION

: STANDARD CHECK LIST

PLANT ITEM :

SHEET 2 OF 2

LUBRICATOR COMPRESSED AIR LINE

NO.

ACTIVITY

6.

Confirm the integrity of the joints at inlet and outlet of

lubricator.

7.

Check the oil level in the lubricator.

8.

Adjust the drip rate to 1 drop/minute by adjustor

mechanism.

9.

Check that the drip rate is clearly visible through

transparent polycarbonate bowl and sight tube.

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 20/1

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 1 OF 3

PLANT ITEM : WINDBOX ASSEMBLY

PLANT NOMENCLATURE: _________________________________________________
UNIT____________________________ SYSTEM _________________________________
MANUFACTURER ___________________ SRL. NO. __________________________
LOCATION: _______________________________________________________________
NO.

ACTIVITY

1.

General conditions satisfy the site standing Instructions as

listed in the Plant Item Commissioning Essential Prerequisites (SCL MS 1/1).

2.

The installation is complete and correct in accordance with

the latest drawings.

3.

Access for adjustments, maintenance and repairs is

satisfactory.

4.

The correct wind box assembly is installed in correct

furnace corner.

5.

Burner tilt position indicator with pointer is provided in each

corner.

6.

There is no obstruction to the movement of wind box

dampers when opening and closing and the dampers are
free in operation.

WITNESSED
NTPC

BHEL

DATE

REMARKS :
SCL REF: M 20/1

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 2 OF 3

PLANT ITEM : WINDBOX ASSEMBLY

NO.

ACTIVITY

7.

The wind box dampers remain 5 deg open in closed

condition.

8.

Ensure that the tilting mechanism is properly erected.

9.

Inspect tilt linkages to ensure components are in good

condition and there is no interforance with other
components, building steel, platforms etc.

10.

Stipulated clearance from wind box assembly to structural

steel is provided to take care of thermal expansion of the
boiler.

11.

Check Burner nozzle tips have stipulated clearance from

waterwalls.

12.

Check burner tilt mechanism for smooth operation.

13.

Set the burner tilt at zero degrees as indicated in the

position indicator and check all the nozzles are herizental.

14.

Set the burner tilt at + 30 deg as indicated on position

indicator. Measure actual angle of nozzle tilt at all
elevations and check that they are within (30 + 1 ) deg

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 20/2

DATE

MECHANICAL
STATION

: STANDARD CHECK LIST

SHEET 2 OF 2

PLANT ITEM : WINDBOX ASSEMBLY

NO.

ACTIVITY

15.

Set the burner tilt at-30 deg as indicated on position

indicator. Measure actual angle of nozzle tilt at elevations
and check that they are within (-30+ 1 ) deg.

16.

Obtain the Certificate from erection personnel stating that

the assemblies are installed to give a correct firing angle
and stating the actual firing angle.

17.

Check all the dampers as per dampers standard check list.

WITNESSED
NTPC

BHEL

REMARKS :
SCL REF: M 20/2

DATE

LOG SHEET FOR CLINKER GRINDER

DATE :
APPENDIX NO:

SIMHADRI 2 X 500 MW

TIME
Hrs.

CHRRENT
Amps.

VOLTAGE
Volts.

MOTOR BODY
TEMPERATURE
C deg

MOTOR BEARING
TEMP.
NDE
C deg

DE
C deg

CLINKER GRINDER NO: A/B

UNIT NO :

GEARBOX HOUSING
VIBRATION
H

V
Mm

REMARKS

A
Sec

STARTING TIME:
STARTING CURRENT :

SIGNATURE :
OPERATOR :
COMMISSIONING IN CHARGE (NTPC) :
COMMISSIONING IN CHARGE ( CONTRACTOR) :

LOG SHEET FOR CLINKER GRINDER

DATE :
APPENDIX NO:

SIMHADRI 2 X 500 MW

TIME
Hrs.

CHRRENT
Amps.

VOLTAGE
Volts.

MOTOR BODY
TEMPERATURE
C deg

CLINKER GRINDER NO: A/B

UNIT NO :

MOTOR BEARING
TEMP.
NDE
C deg

DE
C deg

GEARBOX HOUSING
VIBRATION
H

V
Mm

REMARKS

A
Sec

STARTING TIME:
STARTING CURRENT :

SIGNATURE :
OPERATOR :
COMMISSIONING IN CHARGE (NTPC) :
COMMISSIONING IN CHARGE ( CONTRACTOR) :