LANCO AMARKANTAK POWER PRIVATE LIMITED

1200 MW THERMAL POWER PLANT

KORBA, CHATTISGARH

AIR AND GAS TIGHTNESS TEST

INDEX:-

1) OBJECTIVE

2) PROPOSAL

3) PRE-COMMISSIONING CHECKS

4) PROCEDURE OF THE LEAKAGE TEST

5) COMPLETION CRITERIA

INSPECTION DATE NAME SIGN.

INSPECTED BY
CLEARED BY
 LANCO AMARKANTAK POWER PRIVATE LIMITED
1200 MW THERMAL POWER PLANT
KORBA, CHATTISGARH

AIR AND GAS TIGHTNESS TEST

A) OBJECTIVE

The air & gas tightness test is carried out in Boiler furnace, air and Gas ducts, in
order to find out
The leaks, incomplete weld joints, left out portion of the weld, flange joint leaks, etc
and to arrange
for repair/ rectification.

The air tightness test is only a Test to find out the tightness of the Boiler furnace, air
and gas ducts
With the respect to the outside environment and is not performed to assess the
strength to withstand
the operating pressure.

B) PROPOSAL

The test will be carried out by furnace leak detection method in the following Stages.

1. Furnace penthouse & rear arch.

2. Scanner air line.

3. PA fan discharge & Coal pipes.

4. Scanner air fan discharge ducts.

5. ID/ FD air fan duct.

C) SERVICES REQUIRED

1. Soap water.
2. Bucket & Mug.
3. Cotton waste.
4. Marker.
5. Lighting arrangement.(Hand Lamps).
6. Man power for conducting the Test.

INSPECTION DATE NAME SIGN.

INSPECTED BY
CLEARED BY
 LANCO AMARKANTAK POWER PRIVATE LIMITED
1200 MW THERMAL POWER PLANT
KORBA, CHATTISGARH

AIR AND GAS TIGHTNESS TEST

D) PRECOMMISSIONING CHECKS

REFERENCE
STATUS
S.NO. ACTIVITY DOC/ACCEPTANC
ok/not ok
E CRITERIA
Ensure completion of erection of Boiler first Refer filled up log
pass/horizontal/rear passes, sheet of the
1.
IDF/FDF/PAF/APH and all ducting of air & erection Quality
flue gases system. plan.
Check the clearance is obtained from ducting
2. system, Fans, AH and main Boiler erection
group.
3. Check the following in the ducts( ID
suction /discharge, ESP inlet /outlet/ inter-
connection, AH O/L to ESP I/L,FD discharge,
AH I/L & O/L, WIND BOX, PA DISCHARGE,, Cold
air bus tampering air, mill I/L.
A) Completion of all supports/sliding
points.
B) Completion of all instruments point.
C) Completion of all bracing.
D) No visible leakage point.
E) Removal of the expansion bellows
locking.
F) Completion of erection &
commissioning of the damper.
G) Tightness of the flange joint.
H) Completion of the flange joint.
4 Check AH for any visible leakage point.
Check ID/FD/PA/Seal air fans for any visible
5
leakage points in the casing.
6 Check wind box for any visible leakage points.
Check the ESP casing, shaft/support
insulator covers Hoppers etc for any visible
7
leakage points.

INSPECTION DATE NAME SIGN.

INSPECTED BY
CLEARED BY
 LANCO AMARKANTAK POWER PRIVATE LIMITED
1200 MW THERMAL POWER PLANT
KORBA, CHATTISGARH

ACTIVITY REF. DOC./

AIR AND GAS TIGHTNESS TEST STATUS
S.No. ACCEPTANCE
Ok/not ok
CRITERIA
8 Check the main Boiler in the following area.
a) Seal trough- Seal plate to trough
proper clearance and proper water level
in seal trough & completion of the
welding.
b) Completion of seal welding in the boiler
bottom arch panel to the panel joint.
c) Completion of the seal welding in the
rear arch (dog house) panel to panel
joint.
d) Completion of the all instrumentation
point.
e) Completion of the burner blocks
connection with the furnace opening &
wind box.
f) Completion of the scallop plate joint
between wind box and furnace left and
right water wall.
g) Completion of all installation of all oil
guns/ igniters/ scanners.
h) Completion of furnace roof sealing skin
casing i.e. between roof panel to side
wall, super heater entry point through
roof, roof entry points at upper drum.
i) Completion of all refractory job in the
roof, rear arch, burner block top
bottom area.
j) Completion of the sealing in rear arch
tubes entry points to the lower drum.
k) Installation of all soot blowers with
proper sealing at gland & entry point.
l) Proper tightness of the manhole and
peephole at various location.
m) Completion of the 2nd pass Eco inlet &
AH I/L duct with proper sealing.
9. Checking seal air ducting, seal air filter
cleaning duct, scanner air duct for any visible
leakage point.

INSPECTION DATE NAME SIGN.

INSPECTED BY
CLEARED BY
 LANCO AMARKANTAK POWER PRIVATE LIMITED
1200 MW THERMAL POWER PLANT
KORBA, CHATTISGARH

\ AIR AND GAS TIGHTNESS TEST

E) PROCEDURE OF THE LEAKAGE TEST

REF.
S.No.
DOCUMENT /
ACTIVITY STATUS
ACCEPTANCE
CRITERIA
1 Repeat the tests
Run ID/FD Fans & pressurize furnace to +25 till all leakages
to +50 mmWc. Check air leakages points in are attended
various ducting, ID/FD Fans. ESP. Spread
soap solution on the pent house roof & check
the leakages and rear arch leakages to be
checked physically.
2 Run PA Fan & pressurized PA & Milling Repeat the tests
System ( keeping burner I/L gate closed) till all leakages
and check the air leakages in the duct, are attended &
casing, mill body, Pf piping & Seal air fan Test is declared
suction duct ( physical leakage detection) over when all
the leakages are
attended.
3 Run the seal air fan and check for the air Repeat the tests
leakages in the seal air discharge & seal air till all leakages
filter cleaning air duct .( Physical leak are attended &
detection.) Test is declared
over when all
the leakages are
attended.
4 Run the scanner air fan & check for air Repeat the tests
leakages in scanner air duct( physical leak till all leakages
detection) are attended &
Test is declared
over when all
the leakages are
attended.

F. COMPLETION CRITERIA

Air and gas tightness for any stage declared complete when identified all the leakages
point attended satisfactorily.

Insulation work for any stage could be taken up after completion of the
Air & Gas tightness Test.

INSPECTION DATE NAME SIGN.

INSPECTED BY
CLEARED BY