Format No.

:
Checklist for Roof Skin Casing
APIL-NCR-NPP-CHKL-001
(For Super Critical Boilers)
REV.00

Contract / Project Name

Contract / Project No.
Boiler Type
Drawing Nos.

Skin Casing

Skin casing is a metallic membrane used to seal void in between pressure parts to prevent
the hot gas from escaping the boiler. The skin casing is installed or welded always during
boiler erection.

All welds to pressure parts require inspection during hydro. The installation or welding of the
skin casing directly on the pressure parts generally is forbidden from welding inspection point
of view. Welded directly on the pressure parts prior to hydro, will make it impossible to
inspect the inner part of the weld.

To bypass the welding restrictions, a metallic membrane is welded first on the pressure parts
attachments namely “SKIN CASING ATTACHMENTS” to facilitate inspection during hydro .

The following list is skin casing drawings for super critical boilers.

1. Roof Skin Casing, 2. Furnace Rear Arch Skin Casing, 3. Furnace Bottom Skin Casing, 4.
Backpass Skin Casing.

Skin Casing Attachments

Skin casing attachments are metallic components welded on pressure parts members to
facilitate the welding of the skin casing.

The skin casing attachments are welded partially in the shop and partially during boiler
erection.

The process for shop installation is named “OPTIMIZED”, the process of field installation is
named “NON-OPTIMIZED”.

Therefore, the attachments installed in the shop are named “SHOP WELDED
ATTACHMENTS”(SWA), the attachments installed during erection are named “FIELD
WELDED ATTACHMENTS” (FWA).

The explanation of skin casing attachments of an optimized and non-optimized boiler.

An fully optimized boiler includes as many as possible skin casing attachments welded in the
shop such as panels, header bars and hard to access during erection attachments, with the
remainder skin casing attachments shipped loose for welding during field erection.

A non-optimized boiler includes only the essential skin casing attachments welded in the
shop such as header bars and hard to access during erection, with remainder skin casing
attachments shipped for welding during field erection.

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 Format No. :
Checklist for Roof Skin Casing
APIL-NCR-NPP-CHKL-001
(For Super Critical Boilers)
REV.00

Status
SL.
Checkpoints (Tick if Remarks
No.
Confirmed)
Print the latest checklist for Roof Skin Casing from the
1
master checklist
Read the Engineering specification furnished by APW
2
before starting the drawing.

Input Requirements
Check the following inputs are uploaded by APW in
3
supplier net.
A Engineering specification for skin casing
Contract No-1E0001
B General Arrangements
to 1E0019
C Furnace opening locations Contract No -1E0030
Contract No -1E0100
D Pressure Parts arrangements
to 1E0139
E Pressure Parts Conn. & Exp. Movement diagram Total 5 to 6 drawings
Contract No -1E0500
F PPA – Panel Arrangements
to 1E0502
Contract No
G Pressure Parts Supports
-1E03501 to
Contract No -1E3590
H Element Supports & Seals
to 1E3592
I Expansion bellow details for roof skin casing

J Roof skin casing related Pr. Parts 3D model drawings.

K High crown plate details

If any of the above input is incomplete please inform to

4
APW immediately

General
The rook skin casing temperature is higher during
5 operation due to heat conduction through the refractory
between the roof tubes.
Ensure the boiler is optimized unit or Non-optimized unit
6
with “Engineering Specification”

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 Format No. :
Checklist for Roof Skin Casing
APIL-NCR-NPP-CHKL-001
(For Super Critical Boilers)
REV.00

The lead drawing sheet to show the sectional side

elevation view of the boiler, show only the pressure
parts with circuit numbers related to shop welded
attachments and skin casing.
From the roof skin casing lead drawing sheet, sections
7 and details are taken for the following drawings.
a) Furnace Roof Skin Casing
b) Furnace Rear Skin Casing
c) Furnace Bottom Skin Casing
d) Backpass Skin Casing

Ensure the roof skin casing lead drawing sheet includes

as following.
a) Sectional Side Elevation of the boiler
b) BOM (Piece Mark List)
c) General Notes
d) Erector Notes
8
e) Material Specification
f) Reference Drawing List
g) Standard Drawing List
h) Legend
i) Casing Stiffener Welding Chart

Expect lead drawing sheet, all other drawing sheets to

9 include a note stating, “ FOR NOTES & REFERENCE
DWG’S SEE DWG.XXXX-XXXXX.

Ensure the skin casing drawing whether shop welded

10 attachments are shown correctly and should be in
phantom line.

The skin casing material is 12 Gage (1/8”) thick and

material specification is CORTEN A-606 Type 4 (H.R.
10
Corten-A) Unless material specification specified in
“Engineering Specification” furnished by APW.

11 Ensure the skin casing to be 1/8” continuous seal weld

Ensure the maximum length of the skin casing sheet to
12
be approximately 10’-0”.

Ensure the skin casing lap joint and skin casing crimp
sizes as per APW standard and refer reference
13
drawings. (Remember if any changes to the existing
configuration may require a new set of dies.)

14 Ensure the seal box formed by bent sheet.

Ensure the piece mark nos. with prefix as per following
a) Prefix with “RS” – Roof skin weld (items welded
after hydro.)
15 b) Prefix with “FWA/RS” – Field welded
attachment / Roof skin (attachments welded
c) before hydro.)

16 Furnish the piece mark nos. with “RS” from 1 to 299

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 Format No. :
Checklist for Roof Skin Casing
APIL-NCR-NPP-CHKL-001
(For Super Critical Boilers)
REV.00

Furnish the piece mark nos. with “FWA/RS” from 300

17
and over.

The skin casing retaining pipes are 1” NPS and material

specification is SA-355 Gr. P12 HF. Unless material
18
specification specified in “Engineering Specification”
furnished by APW.

Ensure the skin casing retaining pipes to be spaced

19
approximately 2’-6” apart.
Ensure the right and left side panels end of fin should be
20
12” from roof tubes centerline.
In BOM mention the quantity nos. with R (right side) or
21
L (left side) if necessary
In detail drawings mention the item nos. with R (right
22
side) or L (left side) if necessary
Locating the skin casing attachments, the drawing to
22
bear the notes “HOT SIDE” or “COLD SIDE”

Ensure the header attachments material size is ¼” thick

x 1” wide and material specification is SA-387 class 1 or
23
class 2. Unless material specification specified in
“Engineering Specification” furnished by APW.

Ensure the header attachment bar 1/8” continuous seal

24 weld at cold side and 1/8” x 1” long every 12” stitch weld
at hot side.
Ensure the skin-casing rod to be 3/16” continuous seal
25
weld at cold side.
Ensure the tapping / piping openings are provided in the
26 skin casing as per general arrangement refer reference
contract.

Scalloped Bar
The scalloped bar thick is ¼” and material specification
is SA-387 class 1 or class 2. Unless material
27
specification specified in “Engineering Specification”
furnished by APW.

Ensure the scalloped bar to be 1/8” continuous seal

28 weld at cold side. (Applicable for skin casing and SWA
drawings)

Ensure the scalloped bar to be 1/8” continuous seal

weld at outside respective to the skin casing
29
arrangement and opposite side 1/8” every 3 spaces
weld on fin only. (Applicable for SWA drawings)

Ensure the scalloped bar Radius = Tube Radius + 1/16”

30
as per APW standard.

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 Format No. :
Checklist for Roof Skin Casing
APIL-NCR-NPP-CHKL-001
(For Super Critical Boilers)
REV.00

Ensure the gap between fin to scalloped bar is 1/8” as

31
per APW standard.
Ensure the gap between scalloped bar to scalloped bar
32 is 1/4” as per APW standard. (Applicable for SWA
drawings)

Ensure the scalloped bar at front panel should be

33 placed 1” below from the fin end. (Applicable for SWA
drawings)

Ensure the scalloped bar at rear panel right & left side
34 should be placed 2” below from the tube bent line.
(Applicable for skin casing drawings)

Ensure the scalloped bar thick 3/16” at right and left

35 side panel above the roof tubes and placed as per
reference contract. (Applicable for skin casing drawings)

Ensure the scalloped bar between S-22 header to roof

36 tubes should be placed parallel to the intersecting
centerlines. (Applicable for SWA drawings)

Seal Band
The seal bands thick is 3/16” and material specification
37 is SA-387 class 1 or class 2. Unless specified in
“Engineering Specification” furnished by APW.

Ensure the seal band to be 1/8” continuous seal weld

The seal band dimensions and position as per APW
38
standard and refer reference contract.
Ensure the seal band located on the right and left side
39 panels are running throughout from furnace front panel
to backpass rear panel without terminate.
Ensure the S-22 header location, whether seal bands
40
are released other than shop welded attachments.
Ensure the U seal band at right and left side panels are
41 running throughout from furnace front panel to backpass
rear panel without terminate.
The U seal band dimensions and position as per APW
42
standard and refer reference contract.

Metallic Expansion Bellows

Bellow expansions joints may be used for linear motion,
43
angular motion or a combination of both

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 Format No. :
Checklist for Roof Skin Casing
APIL-NCR-NPP-CHKL-001
(For Super Critical Boilers)
REV.00

Two types of metallic bellows for expansion joints listed

below.
a) Full size (8.5” high) made from 12 gage sheet
b) Half size (4.25” high) made from 16 gage sheet

44 The full size expansions bellow is preferred over the half

size expansion bellow because it is easy to weld. The
half size expansions bellow is preferred for its size and
made with round corners. Even though get it
confirmation from APW for type of expansion bellow and
quantity.
The expansion allowed is ½” per convolute and
45
expansion bellow can also compress ½” per convolute.
Ensure the expansion bellow at roof tubes to be placed
46
after clearing the corner tubes.
Ensure the expansion bellow at roof tubes to be placed
47 12” outside from the front panel centerline as per APW
standard.

Closed end expansion bellow (single bellow in between

48 the skin casing sheet.) is provided for an equal
flexibility.
Ensure the expansion bellow flange height is less than
49
the matting flange height for easy field welding.
Ensure the expansion bellows are marked original
50
dimension + preset dimension.
51 Ensure expansion bellow length not more than 12’-0”.
Ensure the expansion bellows are named as RS-EJ1 &
52
RS-EJ2 etc…

When modifying any of the existing configurations, try to

keep radius, height and pitch the same and remember
53
any changes to the configuration may required a new
set of dies.

54 Shop Welded Attachments (SWA) Drawing List.

A Furnace Upper Front (Scalloped Bar) 00206-F-4U-NPPC-1

Furnace Upper Front & Corner FW Panel (Scalloped 00206-F-4U & F-
B
Bar) 4UC-NPPC-2
00206-F-19U & S-07-
C Furnace & BP Ext. Side Wall (Seal Band)
NPPC-1
D Furnace Roof Outlet Header (Fin and Scalloped Bar) 00206-S-05-NPPC-1
00206-S-12U-NPPC-
E Backpass Side Wall (Seal Band)
1

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 Format No. :
Checklist for Roof Skin Casing
APIL-NCR-NPP-CHKL-001
(For Super Critical Boilers)
REV.00

55 APW Standard Drawing List.

A Half Size Bellows Configuration. (16 GA.) C-991-199

B Full Size Bellows Configuration. (12 GA.) C-991-523

C Round Corner Expansion Joint (Full Size 12 GA.) E-991-263

D Round Corner Expansion Joint (Half Size 16 GA.) E-991-264

E Bellows Expansion Joint (12 GA. Single Bellow) B-991-388

F Expansions Joint for High Crown Area. B-991-389

G Roof Skin Casing Construction E-991-238

56 APW Reference Drawing List.

00206 – 1D2285 /
A Expansion Joint – Roof Skin Casing
00506 – 1E2285
00206/00506 –
B Roof Skin Casing Arrangement / Erection
1E2265 to 1E2275

Checked by Approved by
Signature with date : Signature with date :

Name : Name :