Deaerator vessel is installed at the top of BFW Section, which handles BFW at about 2.0 Kg/Cm2 at C.

Transcription

1 NATIONAL FERTILIZERS LIMITED (TECHNICAL SCOPE OF WORK) Page 1 of 8 Annexure-1 SD-1103 SUB: 1. Inspection of Trays of ADA Inspection of Trays of ADA Demister inspection of (i) ADA 202, (ii) AFA 201/ADA 201, (iii) AFA 301, (iv) AFA 302, (v) Inter Separator of Air Compressor, (vi) After Separator of Air Compressor, (vii) Knockout Drum of Ref Compressor, (viii) Drain Separator of FA-2 of ASU (ix) Carbon Scrubber ADA 101 (x) ADA Inspection, Cleaning and repair of Steam Superheater ABA Inspection, Repair/Replacement of deaerator internals. 6. Cleaning of Dome Jackets of Gasifier Reactors ADC 101 (A,B & C). A) GENERAL DESCRIPTION ADA203 vessel is handling Methanol and is installed in Rectisol section in Ammonia plant. The height of the vessel is about 34 meters and dia is meter. There are working platforms at different elevations and there is monkey ladder throughout the height of the tower to reach at platforms. It has 5 (five) numbers of manhole covers of size 20 Ø 150# at different elevation. In all 62 number of trays with their down comers are fixed in the vessel with changed orientation for side and central flow alternatively. Each tray is in 6~8 parts with down comer. Tray parts are assembled with each other supported on angle supports and bolted with the vessel. Down comer or each tray is bolted to it. ADA 204 vessel is having total height of approx. 25 meters & diameter of 1.0 meter. There are working platform and monkey ladders for throughout the height of tower for working at different elevation of the vessels. There are 45 Nos. tray with their down comers etc. are installed in the vessel with changed orientation for side & central flow alternatively, each tray split in for pieces with down comers for side flow, tray pieces are assembled with each other through clamps provided on each pieces, supported on angles supports & belted with the vessel. Down comers of each tray is bolted with the vessel. Down comer of each tray is bolted to it. Demisters are installed in the vertical vessels erected in Rectisol, CO Shift Conversion section ASU and Compressor House. During coming shutdown demisters as given in scope of work are to be inspected and repair/replacement is to be carried out as per condition of the demisters. Steam Super Heater having radiant tubes hanging from the hanger supports all around the inner periphery of the super heater shell separated by refractory lining. There are S.S. bracket supports with U-bolt clamps for holding the vertical tubes in position. During operation, some of tubes get dislocated from the position and support brackets and U-bolt clamps get damaged which need repair and replacement. Deaerator vessel is installed at the top of BFW Section, which handles BFW at about 2.0 Kg/Cm2 at C. There are three Gasifier ADC101 A, B &C installed in Ammonia Plant Gasifiers Reactor is a refractory lined vessel. The Gasifier reactor top spherical in shape is a water-jacketed. Inside the reactor dome portion, refractory bricks are installed. Due to flow continuous flow of cooling water and high temperature inside, there gets scaling in the jacketed portion.

2 Page 2 of 8 The other details/drawings of the equipments and actual working conditions can be seen at site on any working day. (B) SCOPE OF WORK B (i) INSPECTION OF TRAYS OF ADA Opening of manholes covers of 20 Ø 150#, 5 in Nos. 2. Dismantling of all the trays in parts along with down comers and taking these out of the vessel, using all safety appliances like safety belts and helmets. 3. Lowering of dismantled tray parts and down comers to ground level with the help of rope pulley etc. 4. Cleaning of the sealing, foreign material from the surface of tower with wire brush to the entire satisfaction of site Engineer In charge. 5. Cleaning of all the trays, down comers etc. with wire brush. 6. Fixing of missing valves max. 100 in numbers in SS trays. 7. Refixing of trays, and down comers one by one from bottom to top. Each tray is to be got inspected from Engineer In Charge to his satisfaction. 8. Any rectifications, if required & any defect are to be attended immediately by the contractor without causing any delay. 9. Shifting of all the scrap to the scrap yard. 10. Any other unforeseen job related to the job as per site requirement. B (ii) INSPECTION OF TRAYS OF ADA Opening of all manhole covers of 20 Ø 150# for inspection & removal of trays from vessel using all safety appliances like safety belts & helmets. 2. Dismantling of all SS trays along with down comers in different pieces & taking them of the vessels. 3. Lowering of all the trays & down comers to ground level with the help of rope pulleys etc. 4. Cleaning of all the trays and down comer with the help of wire brush. 5. Cleaning of the vessel for corroded foreign material with wire brush to the entire satisfaction of the site Engineer/ In charge. 6. To re-fix the trays down comers in position, any missing valves in trays have to be fixed. Refixing of trays & down comers are to be started from bottom of vessel. Each tray after fixing is to be got inspection by Engineer- in-charge. 7. Boxing up of all the manholes with new gaskets & making them leak proof. 8. Any other unforeseen job related to the job as per site requirement B (iii) INSPECTION, REPAIR/ REPLACEMENT OF DEMISTERS OF AMMONIA PLANT. B (iii) (A) ADA-202 Demister 1. Making scaffolding arrangements to make the safe working area, wherever required after taking all safety precautions 2. Opening of bottom 2 Nos. manholes size 20 Ø 3. Opening of flange 6 bottom methanol outlet and 8 bottom methanol inlet flanges putting blinds and boxing up the same. 4. Opening & removal of bottom 2 demister after making proper approach. 5. Refixing the new/ old demisters in position after cleaning and inspection to the satisfaction of Engineer in charge. 6. Removal of all slip plates fixed earlier and boxing of all flanges after cleaning the flange faces and using new gaskets to make these leak proof. 7. Removal of all scaffolding material and scrap material from in side the vessel. 8. Boxing the manholes after cleaning faces and using new gaskets to make it leak proof.

3 Page 3 of 8 B (iii) (B) AFA 201 Demister 2. Opening of 20 Ø, 300 # manholes (1 no) at different heights. 3. Opening of 36" Dia. Demister cover. 4. Opening of 10 Ø, 150 lbs flanges (1 no), 6 Ø, 150 lbs (2 no) & 8 Ø, 150 lbs (2No.) at different heights and boxing up after fixing slip plates in all the flanges. 5. Dismantling & removal of Demister, which is in segments, after making proper, approach in side the vessel. 6. Re fixing of old/ new demister in position as per the instruction and up to the satisfaction of Engineer In charge. 7. Removal of all scaffolding material and scrap material from in side the vessel. 8. Removal of all the slip plates fixing already and boxing up the flanges after lapping 9. Boxing up of manhole after cleaning the seat faces to make it leak proof. B (iii) (C) AFA-301 Demister 2. Opening of manhole of size 20 x 600#. 3. Opening of 16 x 600# flanges RTJ 2 Nos. & boxing up the same after fixing the slip plates and new gaskets in the same. 4. Dismantling & removal of Demister, which is in segments, after making proper, approach in side the vessel. 5. Re fixing of old/ new demister in position as per the instruction of Engineer In charge. 6. Removal of all scaffolding material and scrap material from in side the vessel. 7. Removal of all the slip plates fixing already and boxing up the flanges after lapping 8. Boxing up of manhole after cleaning the seat faces to make it leak proof. B (iii) (D) AFA 302 Demister. 2. Opening of manhole of size 20 * 600#. - 1 No. 3. Opening of flanges size 14 * 600# - 4 Nos. at different height and boxing up after fixing slip plates in all flanges. 4. Dismantling & removal of Demister, which is in segments, after making proper approach in side the vessel. 5. Re fixing of old/ new demister in position as per the instruction of Engineer In charge. 6. Removal of all scaffolding material and scrap material from in side the vessel. 7. Removal of all the slip plates fixing already and boxing up the flanges after lapping 8. Boxing up of manhole after cleaning the seat faces to make it leak proof. B (iii) (E) Inter-Separator Demister for Air Compressor 2. Opening of manhole flanges of size 24 Ø, 150# of the vessels. 3. Dismantling & removal of Demister, after making proper, approach in side the vessel. 4. Re fixing of old/ new demister in position as per the instruction of Engineer In charge. 5. Removal of all scaffolding material and scrap material from in side the vessel. 6. Boxing up of manhole after cleaning the seat faces to make it leak proof.

4 Page 4 of 8 B (iii) (F) After Separator Demister for Air Compressor 2. Opening of manhole flange of size 20 Ø, 150# of the vessel. 3. Dismantling & removal of Demister, after making proper, approach in side the vessel. 4. Repair of center beam and side supports welded with vessel for holding of the demister. 5. Re fixing of old/ new demister in position as per the instruction of Engineer In charge. 6. Removal of all scaffolding material and scrap material from in side the vessel. 7. Boxing up of manhole after cleaning the seat faces to make it leak proof. B (iii) (G) Suction K.O.Drum Demister for Ammonia Refrigeration Compressor 2. Opening & boxing up of manholes of size 24 Ø 300# of vessel. 3. Opening of flange18 Ø, 300# each and boxing up with slip plate and new gasket after cleaning the flange seat. 4. Dismantling & removal of Demister, after making proper, approach in side the vessel. 5. Re fixing of old/ new demister in position as per the instruction and up to the satisfaction of Engineer In charge. 6. Removal of all scaffolding material and scrap material from in side the vessel. 7. Removal of all the slip plates fixing already and boxing up the flanges after lapping 8. Boxing up of manhole after cleaning the seat faces to make it leak proof. B (iii) (H) Drain Separator FA-2 Demister of ASU 1. Making scaffolding arrangements in side and out side the vessel. To make the safe. 2. Opening of 2 Nos. manholes of size 20 dia. 150 rating. 3. Dismantling and removal of Demister, after making proper approach in side the vessel. 4. Replacement of lower supporting frame and upper supporting frame of the demister. 5. All job of replacement of upper and lower demister frame (SS) shall be done by the contractor including fabrication of new supporting frames of the demister. 6. Refixing of the demister after making proper approach in side the vessel. 7. Refixing of the demister in position as per the instruction and upto the satisfaction of Engineer in charge. 8. Removal of all scaffolding material and scrap material from in side of the vessel. 9. Boxing up of manholes after cleaning from in side of the vessel. B (iii) (I) ADA 101 Demister. 2. Opening of 20 Ø, 600 # manholes (3 no) at different heights. 3. Opening of 12 Ø, 600 lbs flanges (2 no), & 2 Ø, 600 lbs (3 no) at different heights and boxing up after fixing slip plates in all the flanges. 4. Dismantling & removal of Demister, which is in segments, after making proper, approach in side the vessel. 5. Repair of Demister holder by replacement of corroded plates. 6. Re fixing of old/ new demister in position as per the instruction and up to the satisfaction of Engineer In charge 7. Removal of all scaffolding material and scrap material from in side the vessel. 8. Removal of all the slip plates fixing already and boxing up the flanges after lapping 9. Boxing up of manhole after cleaning the seat faces to make it leak proof.

5 Page 5 of 8 B (iii) (J) ADA 402 Bottom Demister 1. Opening of 20 Ø, 300 # manholes (3 no) from bottom section of ADA Making scaffolding for opening flanges in bottom section for 2.5 methanol inlet, 12 methanol inlet, 12 methanol outlet, 2 gas outlet & 4 drain flanges. 3. Opening of flanges in bottom section for 2.5 methanol inlet, 12 methanol inlet, 12 methanol outlet, 2 gas outlet & 4 drain flanges and providing slip plates in them. 4. Vessel entry after making proper approach in side the vessel and removal of bottom demister. 5. Replacement or cleaning of demister after inspection by Engineer In Charge and then boxing up the same. 6. Removal of slip plates from flanges in bottom section for 2.5 methanol inlet, 12 methanol inlet, 12 methanol outlet, 2 gas outlet & 4 drain flanges and boxing up the same. 7. Boxing up of manhole after cleaning the seat faces and studs/bolts to make it leak proof 8. Removing scaffolding. B (iv) INSPECTION, CLEANING & REPAIR OF STEAM SUPERHEATER ABA Opening of top and bottom manholes 2 Nos. Size 20 each. 2. Slip plating 16, 150# flange of tail gas and 1 flange of LPG lines for entry. 3. Making proper ( metallic) scaffolding inside SSH from bottom to top up to the height of 11mtr using full body safety belts, helmets, etc. 4. Positioning the dislocated tubes from hanger supports at the top. 5. Replacement of damaged SS brackets about 20 Nos. and U-clamps about 80 Nos. supporting the tubes inside the SSH. at different heights to maintain the required gap between the radiant tube. The tubes gap shall be maintained after pushing the tilted tubes into their original positions. 6. Cleaning of all the 56 tube guides at bottom and removal of debris from the pockets by opening bottom tube guide caps. 7. Welding of broken bottom guide tube pieces of size 1-1/4 dia, Length 240 mm about 10 Nos. with chromotherm-1 electrode. 8. Wrapping of Aluminum foil around the bottom guide tube. 9. Removal of all the scaffolding and the scrap from inside the SSH. 10. Cleaning of all the 8 No. burners by opening and boxing up of the following: - a) Opening and boxing up of 6 tail gas spool piece flanges 16 Nos. b) Opening and boxing up of 12 air line spool piece flanges 16 Nos. c) Opening and boxing up of 6 burner gun side flanges 8 Nos. d) Opening and boxing up of ½ steam line flanges 8Nos. e) Opening and boxing up of ½ oil line flanges 8Nos. 11. Removal of slip plates from the flanges. 12. Boxing up of top and bottom manholes. 13. Any unforeseen related is to be carried out without any financial implication. B (v) INSPECTION, REPAIR/REPLACEMENT OF DEAERATOR INTERNALS 1. Opening of manholes 3 Nos. of Dearator size 20 dia x 150# 2. Removal of all the trays (160 Nos.) 3. Repair/Replacement of damaged trays. 4. Welding of all the supports and clits, found broken. 5. Replacement of damaged spray valves. 6. Repair of spray valves by lapping etc. max. 20 Nos. 7. Replacement of damaged portion of inner cell distributor, cylindrical type made from 2 to 3 mm thick sheet of SS 304. The job involves the cutting of damaged SS sheet

6 Page 6 of 8 by cutting wheel and welding of new SS sheet of 2mm thick by TIG welding to repair the area of approx.10 sq.mtr. 8. Refixing of all the tray sand spray valves in position 9. Boxing of the manhole of Dearator and Storage Tank with new gasket. 10. Any unforeseen related job is to be carried out without any financial implication. B (vi) CLEANING of DOME JACKETS of GASIFIER REACTORS ADC 101 (A,B & C) 1. Cutting of obstructing grating and supports around the Dome portion of Gasifier. 2. Making proper scaffolding using PPE, like safety helmet, safety belts etc. 3. Opening of connecting flanges of cooling water & dome jacket hand holes. 4. Cutting of Dome jacket of gasifiers A, B & C with electric grinder and cutting of sub reactor tunnel jacket of Gasifier A, B & C with Gas-Cutting. The gap between spherical head /dome of Gasifier reactor and dome jacket is about 10mm. 5. Removal of dome jackets from position. 6. Removal of hard scaling by buffing etc. 7. Welding of new spacer rods/distance piece. 8. After proper cleaning and grinding of edges, the jackets are to be welded. 9. After complete welding of dome jacket, boxing of all the connecting flanges. 10. Any leakage during testing is to be attended by the party immediately. 11. Removal of scaffolding and welding of gratings and supports already cut. 12. Any unforeseen related job is to be carried out without any financial implication. (C) SCOPE OF SUPPLY BY NFL. 1) Electricity, service air, Water will be supplied free of cost by NFL. 2) All spare parts shall be supplied by NFL free of cost. However, these are to be collected from NFL main store by the contractor. 3) Crane facility when required shall be provided free of cost. (D) SCOPE OF SUPPLY BY CONTRACTOR 1. All the consumables like gas cylinders, suitable welding electrodes (D&H/Advani/Essab make), grinding wheel etc. and welding set, cutting set grinders will be arranged by the contractor. 2. All the tools and tackle lifting tools, spanners will be arranged by the contractor. All the steel Scaffolding material and safety appliances like safety belts(full body), helmets, grinding goggles etc. are to be arranged by the contractor. 3. Contractor will make proper scaffolding in side and out side the vessel, wherever required, for safe working of the workmen, after taking all safety precautions. (E) SPECIAL TERMS AND CONDITIONS % Security shall be deducted against defect liability period of six months and Income Tax shall be deducted from the bill being statutory deduction under Income Tax Act. EMD shall be adjusted against security deposit. 2. In case of award of work, contractor will submit in duplicate as under along with bill: Copy of proof of PF deposit Copy of proof of deposit of ESIC Copy of wage register Pre stamped receipt-cum- no claim certificate Wage certificate as per GTCC clause no. 17(XXVII) Clearance from NFL s industrial department cell regarding fulfillment of statutory requirements

7 Page 7 of 8 Execution of agreement on Non-judicial Stamp paper after award of work but not later than start of work as per prescribed NFL format. 3. Any problem arises should be brought to the notice of Engineer-In-charge immediately. 4. The rates should be quoted in words and figures. The offer shall remain valid for 120 days from date of opening of tenders for the acceptance/placement of work order/loi. 5. Quoted rates shall remain valid upto one year from the date of award of contract for execution of the job at any time within that period 6. The quantity may vary and payment shall be made on actual basis. 7. Manager (Mech.) Ammonia shall be the engineer-in-charge for this job. 8. Contractor will submit annexure A (duly filled and signed) along with quotation, in absence of which, the quotation is liable to be rejected. 9. All tools & tackles such as chain blocks, lifting cranes, slings, D - shackles, safety belts etc. to be used for execution of job should be tested one and test shall be witness by the competent person as per Punjab Factory Act Contractor will submit the test certificate of these tools and tackles on Form - 8 as per above act to NFL. This is a statutory requirement and in absence of same, the payment may be held up. 10. The contractor will mention following details on the envelop of the Quotation/offer. (a) Name of work. (b) Reference No. (c) Date of Opening. (d) EMD Details. 11. Each work given in this NIT may be awarded separately on L-1 basis. 12. Other terms & conditions are as per GTCC attached. (F) TIME OF COMPLETION. 1) The each individual job under the scope of work mentioned in this technical scope of work must be completed as per time schedule given below: Job No. Job Description Time for Completion 1. Inspection of Trays of ADA Days 2. Inspection of Trays of ADA Days 3. Inspection, Repair/ Replacement of all the Demisters of 7 Days Ammonia Plant as per B (iii) (A to J) 4. Inspection, Cleaning and repair of Steam Superheater ABA Days 5. Inspection, Repair/Replacement of deaerator internals. 6 Days 6. Cleaning of Dome Jackets of Gasifier Reactors ADC 101 (A, B & C). 6 Days 2) Party may carry out the job on round the clock basis to complete the job within schedule time. However, in case of delay 1% per day subject to maximum of 10% of the total contract value will be leviable. 3) In case more than one job is awarded to any contractor, separate manpower shall be deputed for individual job to carry out the all the jobs in parallel. 4) Job is likely to be taken in the month of March-2011 and exact date will be informed to the party one-week in advance so as to reach at site with manpower and material one day in advance for taking up the job.

8 HOW TO QUOTE : Job Description No. 1 Lumpsum Rate for Inspection of Trays of ADA 203 under the scope of work B(i) 2 Lumpsum Rate for Inspection of Trays of ADA 204 under the scope of work B(ii) 3 Lumpsum Rate for Inspection, Repair/ Replacement of Demisters of Ammonia Plant under the scope of work B(iii) (A to J). 4 Lumpsum Rate for Inspection, Cleaning and repair of Steam Superheater ABA 701 under the scope of work B(iv) 5 Lumpsum Rate for Inspection, Repair/ Replacement of deaerator internals under the scope of work B(v) 6 Lumpsum Rate for Cleaning of Dome Jackets of Gasifier Reactors ADC 101 (A, B & C) under the scope of work B(vi) Page 8 of 8 Quoted Rate Note: 1. Each of the above jobs will be awarded separately on lowest offer basis. 2. Service Tax should be specified by the contractor separately against each job, wherever nothing is given it will be assumed that the quoted rate is inclusive of service tax and wherever service tax is given as extra then the Service Tax as applicable will be paid extra after submission of documentary evidence of having deposited the same with concerned authorities. Service Tax shall be reimbursed only if the proof of deposit of the same is submitted within the next month following the quarter in which payment of the bill has been made. 3. The quoted rate shall be inclusive of all other taxes. Date SIGNATURE OF TENDERER