1033 H000 A11000 019 XXXX XXXX(Construction Manual for Final) Rev 00
148
Up gradation of DR Module 1 Mesaieed, Qatar CONSTRUCTION MANUAL FOR UPGRADATION PROJECT ESSAR ENGINEERING SERVICES LTD. HAZIRA PREPARED BY (EESL) CHECKED & APPROVED BY (EESL) APPROVED BY (QSC) JR/PS/KCP JEGA/VHP DOC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 1
Transcript of 1033 H000 A11000 019 XXXX XXXX(Construction Manual for Final) Rev 00
Up gradation of DR Module 1Mesaieed, Qatar
CONSTRUCTION MANUAL FOR UPGRADATION PROJECT
ESSAR ENGINEERING SERVICES LTD.HAZIRA
PREPARED BY(EESL)
CHECKED & APPROVED BY
(EESL)
APPROVED BY(QSC)
JR/PS/KCP JEGA/VHP
DATE DETAILS OF REVISION REV NO
DOC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10Page 1
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14.09.10 Issued for Client Approval 00
CONTENTS
1. GENERAL................................................................................................................................... 61
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1.1. BACKGROUND........................................................................................................................... 61
1.2. PROJECT SCHEDULE...............................................................................................................62
1.3. GENERAL INSTRUCTION..........................................................................................................62
2. TOP GAS SCRUBBER,TGS VENTURI AND TGS DUCT...........................................................64
2.1. SCOPE OF WORK......................................................................................................................64
2.2. REFRENCE DRAWINGS & DOCUMENTS................................................................................65
2.3. SHUT DOWN ACTIVITIES..........................................................................................................66
2.3.1. DEMOLITION ACTIVITIES.........................................................................................................66
2.3.2. CONSTRUCTION ACTIVITIES...................................................................................................69
3. COOLING ZONE SCRUBBER,CZS VENTURY AND EXTERNAL CZS MIST ELIMINATOR.....71
3.1. SCOPE OF WORK......................................................................................................................71
3.2. REFRENCE DRAWINGS & DOCUMENTS................................................................................72
3.3. PRE-SHUTDOWN ACTIVITIES..................................................................................................74
3.3.1. CZS EXTERNAL MIST ELIMINATOR ERECTION.....................................................................74
3.4. SHUT DOWN ACTIVITIES..........................................................................................................74
3.4.1. DEMOLITION ACTIVITIES.........................................................................................................74
3.4.2. CONSTRUCTION ACTIVITIES...................................................................................................76
4. DIRECT RECYCLE PROCESS GAS MIST ELIMINATOR..........................................................77
4.1. SCOPE OF WORK......................................................................................................................77
4.2. REFRENCE DRAWINGS & DOCUMENTS................................................................................78
4.3. PRE-SHUTDOWN ACTIVITIES..................................................................................................80
4.3.1. DEMOLITION ACTIVITIES.........................................................................................................80
4.3.2. CONSTRUCTION ACTIVITIES...................................................................................................80
4.4. SHUT DOWN ACTIVITIES..........................................................................................................80
4.4.1. DEMOLITION ACTIVITIES.........................................................................................................80
4.4.2. CONSTRUCTION ACTIVITIES...................................................................................................80
5. COLD VENT BUBBLER..............................................................................................................81
5.1. SCOPE OF WORK......................................................................................................................81
5.2. REFRENCE DRAWINGS & DOCUMENTS................................................................................82
5.3. PRE-SHUTDOWN ACTIVITIES..................................................................................................83
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5.3.1. COLD VENT BUBBLER & ITS SUPPORT STRUCTURE INSTALLATION................................83
5.4. SHUT DOWN ACTIVITIES..........................................................................................................83
5.4.1. CONSTRUCTION ACTIVITIES...................................................................................................83
6. FURNACE LOWER SEAL LEG...................................................................................................84
6.1. SCOPE OF WORK......................................................................................................................84
6.2. REFRENCE DRAWINGS & DOCUMENTS................................................................................85
6.3. PRE-SHUTDOWN ACTIVITIES..................................................................................................86
6.4. SHUT DOWN ACTIVITIES..........................................................................................................86
6.4.1. DEMOLITION ACTIVITIES.........................................................................................................86
6.4.2. CONSTRUCTION ACTIVITIES...................................................................................................86
7. HEAT RECOVERY,FLUE GAS STACK......................................................................................87
7.1. SCOPE OF WORK......................................................................................................................87
7.2. REFRENCE DRAWINGS & DOCUMENTS................................................................................88
7.3. PRE-SHUTDOWN ACTIVITIES..................................................................................................90
7.3.1. DEMOLITION OF EXISTING H2S REMOVAL FACILITY............................................................90
7.3.2. CIVIL........................................................................................................................................... 91
7.3.3. FLUE GAS STACK ERECTION..................................................................................................91
7.3.4. STRUCTURE.............................................................................................................................. 91
7.3.5. PIPING AND DUCTING..............................................................................................................93
7.3.6. REFRACTORY............................................................................................................................ 94
7.4. SHUT DOWN ACTIVITIES..........................................................................................................96
7.4.1. DEMOLITION OF EXISTING POWER STACK AND POWER STACK FAN...............................96
7.4.2. CIVIL........................................................................................................................................... 96
7.4.3. STRUCTURE.............................................................................................................................. 97
7.4.4. PIPING AND DUCTING..............................................................................................................98
7.4.5. REFRACTORY............................................................................................................................ 98
7.4.6. EQUIPMENT............................................................................................................................... 99
8. REFORMER.............................................................................................................................. 100
8.1. SCOPE OF WORK....................................................................................................................100
8.2. REFRENCE DRAWINGS & DOCUMENTS..............................................................................101
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8.3. SHUT DOWN ACTIVITIES........................................................................................................102
8.3.1. DEMOLITION ACTIVITIES.......................................................................................................102
8.3.2. CONSTRUCTION ACTIVITIES.................................................................................................107
9. SEAL GAS COOLER................................................................................................................117
9.1. SCOPE OF WORK....................................................................................................................117
9.2. REFRENCE DRAWINGS & DOCUMENTS..............................................................................117
9.3. SHUTDOWN ACTIVITIES.........................................................................................................119
9.3.1. DEMOLITION ACTIVITIES.......................................................................................................119
9.3.2. CONSTRUCTION ACTIVITIES.................................................................................................119
10. FLUE GAS FAN & TRANSITION PIECE...................................................................................119
10.1. SCOPE OF WORK....................................................................................................................119
10.2. PRE-SHUTDOWN ACTIVITIES................................................................................................120
10.2.1. PRE-SHURDOWN DEMOLITION ACTIVITIES.........................................................................120
10.2.2. PRE-SHUTDOWN DEMOLITION REFERENCE DOCUMENTS..............................................121
10.2.3. PRE-SHUTDOWN DEMOLITION SCOPE................................................................................121
10.2.4. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES..................................................................122
10.2.5. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES.......................................125
10.2.6. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS........................................125
10.2.7. PRE-SHUTDOWN CONSTRUCTION SCOPE.........................................................................126
10.3. SHUT DOWN ACTIVITIES........................................................................................................127
10.3.1. SHUTDOWN DEMOLITION ACTIVITIES.................................................................................127
10.3.2. SHUTDOWN CONSTRUCTION ACTIVITIES...........................................................................127
10.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES...........................................................127
11. MAIN AIR BLOWER..................................................................................................................128
11.1. SCOPE OF WORK....................................................................................................................128
11.2. PRE-SHUTDOWN ACTIVITIES................................................................................................129
11.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES.........................................................................129
11.2.2. PRE-SHUTDOWN DEMOLITION REFERENCE DOCUMENTS..............................................129
11.2.3. PRE-SHUTDOWN DEMOLITION SCOPE................................................................................130
11.2.4. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES..................................................................130
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11.2.6. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS........................................134
11.2.7. PRE-SHUTDOWN CONSTRUCTION SCOPE.........................................................................134
11.3. SHUT DOWN ACTIVITIES........................................................................................................135
11.3.1. SHUTDOWN DEMOLITION ACTIVITIES.................................................................................135
11.3.2. SHUTDOWN CONSTRUCTION ACTIVITIES...........................................................................135
11.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES...........................................................136
12. AUXILIARY AIR BLOWER........................................................................................................136
12.1. SCOPE OF WORK....................................................................................................................136
12.2. PRE-SHUTDOWN ACTIVITIES................................................................................................137
12.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES.........................................................................137
12.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES..................................................................137
12.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES.......................................139
12.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS........................................140
12.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE.........................................................................141
12.3. SHUT DOWN ACTIVITIES........................................................................................................141
12.3.1. SHUTDOWN-DEMOLITION ACTIVITIES.................................................................................141
12.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS.......................................................142
12.3.3. SHUTDOWN-DEMOLITION SCOPE........................................................................................143
12.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES...........................................................................144
12.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS................................................145
12.3.6. SHUTDOWN-CONSTRUCTION SCOPE..................................................................................146
12.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES...........................................................147
13. BSG COMPRESSOR UNIT.......................................................................................................147
13.1. SCOPE OF WORK....................................................................................................................147
13.2. PRE-SHUTDOWN ACTIVITIES................................................................................................148
13.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES.........................................................................148
13.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES..................................................................148
13.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES.......................................151
13.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS........................................151
13.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE.........................................................................152
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13.3. SHUT DOWN ACTIVITIES........................................................................................................153
13.3.1. SHUTDOWN-DEMOLITION ACTIVITIES.................................................................................153
13.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS.......................................................153
13.3.3. SHUTDOWN-DEMOLITION SCOPE........................................................................................154
13.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES...........................................................................155
13.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS................................................156
13.3.6. SHUTDOWN-CONSTRUCTION SCOPE..................................................................................157
13.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES...........................................................158
14. FIRST STAGE PROCESS GAS COMPRESSOR.....................................................................158
14.1. SCOPE OF WORK....................................................................................................................158
14.2. PRE-SHUTDOWN ACTIVITIES................................................................................................159
14.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES.........................................................................159
14.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES..................................................................159
14.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES.......................................161
14.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS........................................161
14.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE.........................................................................162
14.3. SHUT DOWN ACTIVITIES........................................................................................................163
14.3.1. SHUTDOWN-DEMOLITION ACTIVITIES.................................................................................163
14.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS.......................................................163
14.3.3. SHUTDOWN-DEMOLITION SCOPE........................................................................................164
14.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES...........................................................................165
14.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS................................................167
14.3.6. SHUTDOWN-CONSTRUCTION SCOPE..................................................................................168
14.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES...........................................................168
15. SECOND STAGE COMPRESSOR...........................................................................................169
15.1. SCOPE OF WORK....................................................................................................................169
15.2. PRE-SHUTDOWN ACTIVITIES................................................................................................170
15.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES.........................................................................170
15.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES..................................................................170
15.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES.......................................172
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15.2.4. ERECTION REFERENCE DOCUMENTS.................................................................................172
15.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE.........................................................................173
15.3. SHUT DOWN ACTIVITIES........................................................................................................174
15.3.1. SHUTDOWN DEMOLITION ACTIVITIES.................................................................................174
15.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS.......................................................175
15.3.3. SHUTDOWN-DEMOLITION SCOPE........................................................................................175
15.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES...........................................................................176
15.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS................................................178
15.3.6. SHUTDOWN-CONSTRUCTION SCOPE..................................................................................179
15.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES...........................................................180
16. FURNACE HYDRAULIC ROOM & HYDRAULIC UNIT.............................................................180
16.1. SCOPE OF WORK....................................................................................................................180
16.2. PRE-SHUTDOWN ACTIVITIES................................................................................................182
16.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES.........................................................................182
16.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES..................................................................182
16.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES.......................................184
16.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS........................................185
16.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE.........................................................................186
16.3. SHUT DOWN ACTIVITIES........................................................................................................186
16.3.1. SHUTDOWN-DEMOLITION ACTIVITIES.................................................................................186
16.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS.......................................................187
16.3.3. SHUTDOWN-DEMOLITION SCOPE........................................................................................188
16.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES...........................................................................188
16.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS................................................189
16.3.6. SHUTDOWN-CONSTRUCTION SCOPE..................................................................................190
16.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES...........................................................190
17. EXISTING DILUTION AIR BLOWER DEMOLITION.................................................................191
17.1. SCOPE OF WORK....................................................................................................................191
17.2. PRE-SHUTDOWN ACTIVITIES................................................................................................191
17.3. SHUT DOWN ACTIVITIES........................................................................................................192
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17.3.1. EQUIPMENT DEMOLITION......................................................................................................192
17.3.2. STRUCTURE DEMOLITION.....................................................................................................192
17.3.3. PIPING DEMOLITION...............................................................................................................193
17.4. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS.......................................................193
17.5. SHUTDOWN-DEMOLITION SCOPE........................................................................................194
18. EXISTING AUXILIARY AIR BLOWER DEMOLITION...............................................................194
18.1. SCOPE OF WORK....................................................................................................................195
18.2. PRE-SHUTDOWN ACTIVITIES................................................................................................195
18.3. SHUT DOWN ACTIVITIES........................................................................................................195
18.3.1. EQUIPMENT DEMOLITION......................................................................................................195
18.3.2. STRUCTURE DEMOLITION.....................................................................................................196
18.3.3. PIPING DEMOLITION...............................................................................................................196
18.4. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS.......................................................197
18.5. SHUTDOWN-DEMOLITION SCOPE........................................................................................198
DEFINITIONS & ABBREVIATIONS
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PATEL, 09/14/10,
Cooling gas compressor gear box job missing
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DEFINITIONS
Owner-shall mean M/s Qatar Steel Company that owns the DR-1 Module up
gradation project
Purchaser-shall mean an entity that owns the Procurement support contract
of the project tendered by Owner
Engineering Consultant-shall mean an entity that owns the Engineering
contract of the project.
Vendor/Manufacturer – shall mean an entity that owns the Hoist supplier of
the project fixed by purchaser/owner.
ABBREVIATIONS
EESL - Essar Engineering Services Ltd
QSC - Qatar Steel Company
1. BACKGROUND
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Qatar Steel is one among the top steel producers in the Middle East. The
Integrated Steel Plant consists of the following:
DR Plant.
Electric Arc Furnace.
Continuous Casting Machine.
Rolling Mill.
DR Plant has 2 Modules which capacities as below
Module 1 – 0.4 Million tons per year capacity DRI producing 0.8 Millions
Module 2 – 1.5 Million tons per year DRI
This Project is aimed at upgrading Module 1 from 0.8 Million tons per year to 1
Million tons per year production capacity
More about Company details and process description can be found on website
www.qatarsteel.com
2. PROJECT SCHEDULE
Engineering Completed by October 2010.
Procurement activities complete and items on site by 1st August 2011(2
months float).
(This is applicable only for long lead items, other items shall reach site
earlier).
Pre shutdown activities in August & September 2011.
Shutdown starts from 1st October and completes by January 3rd week.
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Start-up & commissioning during 4th week of January 2012.
3. GENERAL INSTRUCTION
Match Marking Activities before shutdown and dismantling
Below listed activity should be completed prior to shut down.
o Scaffolding and approach to be provided near piping and ducting tie
in point or as required.
o Provide temporary support to all piping and ducting and structures to
be dismantle in order to avoid any movement after cutting.
o Items to be removed should be matched marked properly.
o Match marking of all structures and piping as require.
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4. TOP GAS SCRUBBER,TGS VENTURI
4.1. SCOPE OF WORK
4.1.1. The work involves the following activities for the demolition of existing
TGS and installation of new TGS for plant up gradation
Prefabrication and supply
Demolition
Construction
Tie in activities
Start up & Commissioning
4.1.2. The Main activities are consisting of but not limited to the following:
Pre shut down fabrication of Top Gas scrubber, TGS supporting
structures, top gas duct spools etc.
During shutdown, assembly & erection as per the scope specified
herein.
Demolition of existing Top Gas Scrubber.
Demolition of existing TGS structure and civil work.
Installation of new TGS and existing ventury
Tie-in with existing ducts and pipes with new TGS
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4.2. REFRENCE DRAWINGS & DOCUMENTSSr.N
oArea Drawing / Document Numbers
A. Demolition
P&ID1033-H000-A11000-0019-1904-
0004
Equipment1033-H000-A11350-0019-1910-
0009
B. Pre-Shutdown Work
Fabrication of Top Gas Scrubber
1033-H000-A11350-0019-1911-0031 to
1033-H000-A11350-0019-1911-0046
C. Shut Down Work
Erection/Assembly of New Top Gas Scrubber
1033-H000-A11350-0019-1911-0031 to
1033-H000-A11350-0019-1911-0046
4.3. SHUT DOWN ACTIVITIES
4.3.1. DEMOLITION ACTIVITIES
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Remove the packing from existing top gas scrubber and
preserve it for reuse in cooling zone scrubber prior to start
dismantling.
Items (Mechanical, Ducting, Piping, Electrical,
Instrumentation etc.) to be removed must match marked and
secure properly.
4.3.1.1. TOP GAS SCRUBBER VENTURI AND SUPPORT STRUCTURE Fix Bellow Position by providing the appropriate stoppers
then cut bellow from its bottom flange. Dismantle the
water connection line for Swirl and throat spray nozzles.
Remove the necessary instrumentation and electrical
cables. Provide lifting lug on venturi and remove it and
keep it for reuse. Extra care need to be taken for bellow
as it will be reuse.
Remove Spring support and preserved it for reuse.
Venturi’s existing supporting structure above
EL+52061(GL+21881) will be reused as per drawing
1033-H000-A11350-0019-1910-0009. Before dismantling
the structure all the pipe supports, cable and cable trays
supports on the structure to be removed. Engage the
crane and hold the structure cut the columns as shown in
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drawing (structure drawing reference) remove the
structure and preserve it for reuse.
4.3.1.2. TOP GAS SCRUBBER Process Gas, Top Gas Fuel and Process gas recycle
existing duct to be cut and support as specified in the
construction manual no.: 1033-H000-A11360-0015-1500-
0000. All the supply line to be dismantles. Return water
line to be cut as specified in the construction manual no.:
1033-H000-A11360-0015-1500-0000. Remove the U-loop
ducting and keep it safe for reuse. Drain line of TGS to be
removed.
Check lifting lug provision on existing TGS provide if not
available engage the crane and hold the TGS and
dismantle it from existing support structure and keep it on
ground.
4.3.2. CONSTRUCTION ACTIVITIES
4.3.2.1. TOP GAS SCRUBBER & VENTURI TGS Erection weight = 59000 Kg.
Place top gas scrubber on support structure as shown in
1033-H000-A11350-0019-1911-0031. Existing preserved
venturi supporting structure to be erected on new
structure. Place the venturi along with bellow and weld
the bellow bottom flange with TGS Inlet nozzle flange.
Install TGS spray nozzles.
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PATEL, 14/09/10,
Water supply
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Fill up the packing inside New Top gas Scrubber and box-
up the manholes after completion of all hot works.
4.3.2.2. REFRACTORY Do the necessary refractory work inside the Top gas duct
(scaffolding may require) as per 1003-H000-A11350-
0019-1911-7001.
5. COOLING ZONE SCRUBBER,CZS VENTURY AND EXTERNAL CZS MIST ELIMINATOR
5.1. SCOPE OF WORK
5.1.1. The work involves the following activities for the demolition,
modification and installation of CZS, CZS ventury and External
CZS Mist Eliminator for plant up gradation
Prefabrication and supply
Demolition
Construction
Tie in activities
Start up & Commissioning assistance
5.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication, assembly
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PATEL, 09/14/10,
Manhole to be boxed up after cleaning and inspection of top gas scrubber, Pressure leak test to be carried out during start up for flanges of piping connected to top gas scrubber and PG mist eliminator
PATEL, 09/14/10,
Spray nozzle to be erected after flushing the water header. Spray pattern to be confirm before closing man way.
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Erection as per the scope specified herein.
Demolition of existing Internal CZS Roof and CZS internal Mist
Eliminator.
Modification of existing Cooling Zone Scrubber
Demolition of existing CZS Ventury and Replace it by new CZS
Ventury.
Installation of CZS Roof and water distribution headers
Installation of New External CZS Mist Eliminator on its civil
foundation
Ducting work between CZS and mist eliminator and to CZ
compressor
CZS U seal pipe modification work
Other miscellaneous activities as explained in the scope of work.
5.2. REFRENCE DRAWINGS & DOCUMENTSSr.N
oArea
Drawing / Document Numbers
A. Demolition
P&ID1033-H000-A11000-0019-
1904-0024Equipment 1033-H000-A11350-0019-
1911-00011033-H000-A11350-0019-
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 18 of 106
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1911-0016B. Pre-Shutdown Work
Fabrication of Cooling Zone Scrubber Top roof , External Mist Eliminator & Venturi
1033-H000-A11350-0019-1911-0001
to1033-H000-A11350-0019-
1911-00081033-H000-A11350-0019-
1911-00181033-H000-A11350-0019-
1911-00191033-H000-A11350-0019-
1911-00201033-H000-A11350-0019-
1911-0021To
1033-H000-A11350-0019-1911-0025
Erection of CZS External Mist Eliminator
1033-H000-A11350-0019-1911-0021
C. Shut Down WorkCooling Zone Scrubber
1033-H000-A11350-0019-1911-0001
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 19 of 106
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Modification & Venturi Erection
to1033-H000-A11350-0019-
1911-00081033-H000-A11350-0019-
1911-0016
5.3. PRE-SHUTDOWN ACTIVITIES
5.3.1. CZS EXTERNAL MIST ELIMINATOR ERECTION Erection Weight = 9273 Kg.
CZS mist eliminator to be fixed on civil foundation as shown
in drawing 1033-H000-A11350-0019-1911-0021. Water
supply and drain line to be erected and cabling for electrical
and instrumentation accessories to be done as required.
Install and fix the demister pad on support inside the vessel
and Install spray nozzle for flushing and spray to be check
then Box-up the manhole.
5.4. SHUT DOWN ACTIVITIES
5.4.1. DEMOLITION ACTIVITIES Items (Mechanical, Ducting, Piping, Electrical,
Instrumentation etc.) to be removed must match marked and
secure properly.
5.4.1.1. COOLING GAS VENTURI INLET PIPE
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 20 of 106
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Check the lifting lug provision on exiting cooling gas inlet
duct to CZS Venturi, provide if not available. Provide
support to existing cooling gas off take. Position the crane
and hold the cooling gas inlet duct. Remove the existing
spray nozzle inserted up to existing CZS venturi throat.
Cut & Remove the cooling gas duct at CZS venturi and
cooling gas off take end and keep it on ground for reuse.
5.4.1.2. COOLING ZONE SCRUBBER VENTURI Dismantle the CZS Venturi Swirl and throat spray nozzle
water connections. Cut the CZS inlet pipe by keeping
outer projection margin 253mm and remove the venturi as
shown in drawing 1033-H000-A11350-0019-1911-0016.
5.4.1.3. COOLING ZONE SCRUBBER Remove the packing from existing cooling zone scrubber
prior to start dismantling.
Cooling gas Inlet and outlet duct to be supported and
dismantle. Dismantle all the water supply line. Provide the
temporary supports inside CZS to inlet pipe as shown in
drawing 1033-H000-A11350-0019-1911-0016 now
remove welding between inlet pipe and top roof and
welding between internal mist eliminator vanes and top
roof. Remove top cover along with stiffeners, spray
nozzles, outlet nozzle and quick opening manway.
Remove the welding between the internal mist eliminator
vanes and CZS shell plate and inlet pipe and remove
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 21 of 106
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internal mist eliminator Refer drawing 1033-H000-
A11350-0019-1911-0016.
5.4.2. CONSTRUCTION ACTIVITIES
5.4.2.1. COOLING ZONE SCRUBBER MODIFICATION AND MIST ELIMINATOR DUCTING Erection Weight for CZS Modifications = 5397 Kg.
Install Bottom and top grating. Install new top cover of
Cooling zone scrubber stiffeners, outlet and spray nozzles
can be pre install before erection. Weld existing inlet pipe
with new top roof. Remove Temporary supports provided
to inlet pipe. Provide the new flange to inlet duct with
maintaining the outer projection 250mm as shown in
drawing 1033-H000-A11350-0019-1911-0016.
Install water header with spray nozzles.
5.4.2.2. COOLING ZONE SCRUBBER VENTURI Erection weight for Venturi = 4087 Kg.
Place the new venturi and weld it with CZS modified inlet
pipe. Install water supply, return and drain line for CZS
and its venturi. Remove the bored blind flange from top of
cooling gas inlet duct and provide new blind as shown in
drawing 1033-H000-A11350-0019-1911-0016 and place it
and weld with cooling gas off take and cooling gas
venturi. Does the necessary refractory work inside the
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 22 of 106
PATEL, 14/09/10,
Spray nozzle to be erected after flushing the water header. Spray pattern to be confirm before closing man way.
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cooling gas duct (scaffolding may require) refer 1033-
H000-A11350-0019-1911-7002.
Fix the spray nozzles inside the scrubber and spray to be
check. Fill the packing inside CZS and box up the
manholes.
6. DIRECT RECYCLE PROCESS GAS MIST ELIMINATOR
6.1. SCOPE OF WORK
6.1.1. The work involves the following activities for demolition of existing
RG cooler and the installation of new direct recycle process gas
mist eliminator for plant up gradation
Prefabrication and supply
Demolition
Construction
Tie in activities
Start up & Commissioning
6.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication
Assembly &erection as per the scope specified herein.
Demolition of existing RG cooler
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 23 of 106
PATEL, 14/09/10,
It is a part of scrubber and already written
PATEL, 14/09/10,
Manhole to be boxed up after cleaning and inspection of CZ scrubber, CZMEPressure leak test to be carried out during start up for flanges of piping connected to CZME and scrubber.
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Installation of new direct recycle process gas mist eliminator
6.2. REFRENCE DRAWINGS & DOCUMENTSSr.N
oArea
Drawing / Document Numbers
A. Demolition
P&ID1033-H000-A11000-0019-
1904-0012RG Cooler Dismantling
SIM3-541 (QSC Drawing)
B. Pre-Shutdown WorkDismantling of RG Cooler
SIM3-541 (QSC Drawing)
Fabrication of Mist Eliminator
1033-H000-A11350-0019-1911-0051
1033-H000-A11350-0019-1911-0052
1033-H000-A11350-0019-1911-0053
1033-H000-A11350-0019-1911-0054
Erection of DR PG Mist Eliminator
1033-H000-A11350-0019-1910-0008
C. Shut Down Work
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 24 of 106
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6.3. PRE-SHUTDOWN ACTIVITIES
6.3.1. DEMOLITION ACTIVITIES Existing RG cooler ducting, piping, electrical and
instrumentation cable to be removed if available. Unfasten the
RG cooler from the structure by removing all fasteners then
dismantle the RG cooler and keep it on ground.
6.3.2. CONSTRUCTION ACTIVITIES Erection Weight = 2248 Kg.
Install New Support Structure Require to install the mist
eliminator at floor level EL+46792(GL+16612). Install mist
eliminator on new support structure as per drawing 1033-
H000-A11350-0019-1911-0051.
7. COLD VENT BUBBLER
7.1. SCOPE OF WORK
7.1.1. The work involves the following activities for the installation of new
cold vent bubbler for plant up gradation
Prefabrication and supply
Demolition
Construction
Tie in activities
Start up & Commissioning
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 25 of 106
PATEL, 14/09/10,
Manhole to be boxed up after cleaning and inspection of direct recycle mist eliminatorPressure leak test to be carried out during start up for flanges of piping connected to direct recycle ME
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7.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication
Assembly & erection as per the scope specified herein.
Installation of new cold vent bubbler
7.2. REFRENCE DRAWINGS & DOCUMENTSSr.N
oArea
Drawing / Document Numbers
A. DemolitionP&ID 1033-H000-A11000-0019-1904-0004
B. Pre-Shutdown WorkFabrication of Cold Vent Bubbler & Erection of Cold Vent Bubbler
1033-H000-A11350-0019-1911-0062
1033-H000-A11350-0019-1911-0063
1033-H000-A11350-0019-1911-0069
7.3. PRE-SHUTDOWN ACTIVITIES
7.3.1. COLD VENT BUBBLER & ITS SUPPORT STRUCTURE INSTALLATION
Erection Weight = 1274 Kg.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 26 of 106
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New Support Structure Require to install the cold vent bubbler at
floor level EL+55220(GL+25040). Erect the Cold vent bubbler on
support structure as per drawing 1033-H000-A11350-0019-1911-
0062.
8. FURNACE LOWER SEAL LEG
8.1. SCOPE OF WORK
8.1.1. The work involves the following activities for the installation of new
lower seal leg for plant up gradation
Prefabrication and supply
Demolition
Construction
Tie in activities
Start up & Commissioning
8.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication, assembly &erection as per the scope
specified herein.
Installation of new lower seal leg
8.2. REFRENCE DRAWINGS & DOCUMENTSSr.N Area Drawing / Document
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 27 of 106
PATEL, 09/14/10,
Manhole to be boxed up after cleaning and inspection of clod vent bubblerPressure leak test to be carried out during start up for flanges of piping connected to bubbler
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o NumbersA. Demolition
P&ID 1033-H000-A11000-0019-1904-0002
Equipment1033-H000-A11350-0019-1910-0017
1033-H000-A11350-0019-1911-0061
SIFU-049 (QSC Drawing)
B. Pre-Shutdown Work
Fabrication of Lower Seal leg
1033-H000-A11350-0019-1911-0061
1033-H000-A11350-0019-1911-0064
1033-H000-A11350-0019-1911-0070
C. Shut Down Work
Erection of Lower Seal Leg
1033-H000-A11350-0019-1911-0061
1033-H000-A11350-0019-1911-0064
SIFU-049 (QSC Drawing)
8.3. PRE-SHUTDOWN ACTIVITIES There are no activities in the pre-shutdown.
8.4. SHUT DOWN ACTIVITIES
8.4.1. DEMOLITION ACTIVITIES Provide temporary support to existing lower seal leg if
required at EL+37034(GL+6854) and Remove the wiper bar
assembly by de-bolting from the bottom flange of lower slide
gate preserve the Nuts, bolts and gasket for reuse.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 28 of 106
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8.4.2. CONSTRUCTION ACTIVITIES Erection weight = 1273 Kg.
Provide support structure at EL+35180(GL+5000). Provide
gusset plate and base plate to existing lower seal leg (refer
drawing SIFU-049) and position the spring as per drawing
1033-H000-A11350-0019-1911-0061.
Fasten the top part of bottom spool of lower seal leg with
bottom flange of lower slide gate refer drawing 1033-H000-
A11350-0019-1911-0064. Lower part of bottom spool of
lower seal leg to be erected along with furnace discharge
vibro-feeder.
9. HEAT RECOVERY,FLUE GAS STACK
9.1. SCOPE OF WORK
9.1.1. The work involves the following activities for Dismantling of the
existing power stack fan, stack & H2S removal system and
construction of new heat recovery system, flue gas fan & stack for
the DR-1 plant up gradation.
Prefabrication and supply
Demolition
Construction
Tie in activities
Start up & Commissioning
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 29 of 106
PATEL, 14/09/10,
Pressure leak test to be carried out during start up for flanges of lower slide gate
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9.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication
Pre assembly & erection as per the scope specified herein.
Demolition of existing power stack fan, stack and H2S
removal system
Installation of new heat recovery system, flue gas stack and
refractory work.
9.2. REFRENCE DRAWINGS & DOCUMENTSSr.N
oArea
Drawing / Document Numbers
A. Demolition
P&ID1033-H000-A11000-0019-1904-
0008,0009,0010,0020
EquipmentPower stack and power stack fan
S1C2-014 (Demolition Mark-up)
H2S removal facility DH2S-810 (Demolition Mark-up)
B. Pre-Shutdown WorkFabrication of equipment
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 30 of 106
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Cold combustion air pre-heater B04-1(A&B) B04-2(A&B)
1033-H000-A11370-0019-
1911-0001 to 0003.
Feed gas pre-heater first stage (HE-A61-1&2)
1033-H000-A11370-0019-
1911-0021 to 0029.
Feed gas pre-heater second stage (HE-A65-1,2)
1033-H000-A11370-0019-
1911-0031 to 0039.
Natural gas pre-heater (HE-B62-1/2)
1033-H000-A11370-0019-
1911-0041 to 0045.
Flue gas fan 1033-H000-A11390-0019-1917-0001
Flue gas stack1033-H000-A11390-0019-1911-0001
to 0010
Flue gas fan to flue gas stack transition piece
1033-H000-A11390-0019-1911-0011
C. Shut Down WorkErection of the Equipment
Hot combustion air pre-heater B05-1(A&B) B05-2(A&B)
1033-H000-A11370-0019-1911-0011
To 0013.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 31 of 106
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9.3. PRE-SHUTDOWN ACTIVITIES
9.3.1. DEMOLITION OF EXISTING H2S REMOVAL FACILITY. Reference Drawing DH2S-810 (Demolition Mark-up)
The existing H2S removal facility with connecting
equipments, ducts, pipes to be demolish and area to be
made free for the new heat recovery system, flue gas fan
and stack at ground level at GL +300 (EL +30480). After
dismantling of all equipments, ducts, pipes to be removed
and to be shifted to designated area. Area to be demolished
is marked in the QSC drg no.DH2S-810.
9.3.2. CIVIL Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
Before shut down piling, foundation, activities can be
completed for total heat recovery unit except axis A’, A and
for Axis B, works for north side train (between grid 1 and 2)
can complete as per civil construction manual.
9.3.3. FLUE GAS STACK ERECTION Flue gas stacks shall be erected with refractory, reference
drawing 1033-H000-A11390-0019-1911-0001 to 0010
before proceeding with heat recovery erection activities.
Flue gas stack refractory to be done as per the drawing
1033-H000-A11390-0019-1911-7001, 7002 before erection.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 32 of 106
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9.3.4. STRUCTURE Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
9.3.5. EQUIPMENT
9.3.5.1. PREHEATERS Cold combustion air pre-heater B04-1(A&B) B04-2(A&B)
to be erect and assemble as per the reference drawing
1033-H000-A11370-0019-1911-0001 to 0003.
Feed gas pre-heater first stage (HE-A61-1&2) to be erect
as per the reference drawing 1033-H000-A11370-0019-
1911-0021 to 0024.
Feed gas pre-heater second stage (HE-A65-1, 2) to be
erect as per the reference drawing 1033-H000-A11370-
0019-1911-0031 to 0034.
Natural gas pre-heater (HE-B62-1/2) to be erect as per
the reference drawing 1033-H000-A11370-0019-1911-
0041 to 0043.
After installation of feed gas heaters refractory dummy
shall be installed.
9.3.6. REFRACTORY
9.3.6.1. HEAT RECOVERY CASING After erection and alignment of heat recovery casing
refractory to be done as per the drawing 1033-H000-
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 33 of 106
PATEL, 14/09/10,
Top cover to be installed after placing bundles
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A11370-0019-1911-7001 to 7003 from flue gas stacks
side to column axis B.
9.3.6.2. HOT AIR DUCTS External insulation to be provided for duct from air
Preheater to hot combustion air Preheater as per
reference drawing no 1033-H000-A11370-0015-1516-
0022,0023 and external insulation specification no 1033-
H000-A11000-0019-1915-0035.
9.3.6.3. FEED GAS DUCTS External insulation to be provided for the feed gas duct
from the feed gas mixer to first stage feed gas Preheater
inlet as per reference drawing no 1033-H000-A11370-
0015-1516-0022,0023 and external insulation
specification no 1033-H000-A11000-0019-1915-0035.
External insulation to be provided for the feed gas duct
from the feed gas Preheater outlet to Second stage
Preheater inlet as per reference drawing no 1033-H000-
A11370-0015-1516-0022,0023 and external insulation
specification no 1033-H000-A11000-0019-1915-0035.
9.3.6.4. NATURAL GAS LINE External insulation to be provided for natural gas
Preheater outlet to feed gas mixture as per reference
drawing no 1033-H000-A11370-0015-1516-0022,0023
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 34 of 106
PATEL, 14/09/10,
First stage
PATEL, 14/09/10,
Cold combustion air
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and external insulation specification no 1033-H000-
A11000-0019-1915-0035.
9.3.6.5. CASING COVER Refractory of casing cover of feed gas first and second
stage preheater,natural gas Preheater to be done before
erection .Refer drawing no. 1033-H000-A11370-0019-
1911-7001 to 7003
9.3.6.6. DUMMY The refractory work for dummy shall be carried out
separately and to be placed inside casing after feed gas
pre-heaters installation. Refer drawing no. 1033-H000-
A11370-0019-1911-7001 & 7002.
9.4. SHUT DOWN ACTIVITIES
9.4.1. DEMOLITION OF EXISTING POWER STACK AND POWER STACK FAN Reference Drawing S1C2-014 (Demolition Mark-up)
The existing power stack (K-C10) and power stack fan with
connecting equipments, ducts, pipes to be demolish and
area to be made free for the new heat recovery system at
ground level at GL +300 (EL +30480). After dismantling of
all equipments, ducts, pipes to be removed and to be
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 35 of 106
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shifted to designated area. Area to be demolished is
marked in the QSC drg no.S1C2-014. The existing cable
trench to be keep as it is and work in this area to be carry
out with very carefully
9.4.2. EQUIPMENT CONSTRUCTION
9.4.2.1. PREHEATERS Hot combustion air pre-heater B05-1(A&B) B05-2(A&B) to
be erect and assemble as per the reference drawing
1033-H000-A11370-0019-1911-0011 to 0013.
9.4.3. REFRACTORY
9.4.3.1. HEAT RECOVERY CASING After erection and alignment of balance heat recovery
casing and transition piece from flue gas duct to heat
recovery casing refractory to be done as per the drawing
1033-H000-A11370-0019-1911-7001.
9.4.3.2. HOT AIR DUCTS After the erection of the hot air duct from hot combustion
air Preheater to main air header and main air manifold
refractory to be done as per the drawing 1033-H000-
A11370-0019-1911-7004.
9.4.3.3. FEED GAS DUCTS After the erection of the feed gas duct from feed gas
second stage Preheater outlet to feed gas manifold and
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 36 of 106
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feed gas manifold refractory to be done as per the
drawing 1033-H000-A11370-0019-1911-7025.
10. REFORMER
10.1. SCOPE OF WORK
10.1.1. The work involves the following activities for the dismantling of the
existing heat recovery system and construction of 3 bay
extensions for the DR-1 plant up gradation.
Prefabrication and supply
Demolition
Construction
Tie in activities
Start up & Commissioning
10.1.2. The Main activities are consisting of but not limited to the following
Pre shut down fabrication, assembly &erection as per the
scope specified herein.
Dismantling of the existing heat recovery system
Installation of Reformer tube assembly, Burners and its
accessories and refractory work for reformer 3 bay
extension
10.2. REFRENCE DRAWINGS & DOCUMENTSSr.N
oArea
Drawing / Document Numbers
A. Demolition
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 37 of 106
PATEL, 14/09/10,
Manhole to be boxed up after cleaning and inspection of all ductPressure leak test to be carried out during start up for flanges of process gas, feed gas natural gas and main air system
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P&ID1033-H000-A11000-0019-
1904-0011,14 to 17
Equipment
B. Pre-Shutdown Work
Fabrication of reformer equipment assembly and erection
1033-H000-A11360-0019-1911-
0003,0004,0006,0008,0009,0011, 0012,0015 to 0020
C. Shut Down Work
Installation of Equipment and refractory work
1033-H000-A11360-0019-1911-
0003,0004,0006,0008,0009,0011, 0012,0015 to 0020,7000,7001 to 7018,7023 to 7030
10.3. SHUT DOWN ACTIVITIES
10.3.1. DEMOLITION ACTIVITIES
10.3.1.1. HEAT RECOVERY SYSTEM
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 38 of 106
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After dismantling of all ducts and pipes from Heat
recovery area, heat recovery bundles to be removed and
to be shifted to designated area.
The existing heat recovery system casing and structures
which is at the ground level to be completely dismantled.
10.3.1.2. REFRACTORY Reformer doors to be opened and refractory at both
end walls to be removed.
The reformer end wall refractory to be removed
completely as shown the drawing no.1033-A11360-
0019
The existing reformer side wall refractory to be
removed from the nearest expansion joint at the 11th
bay as shown in the drawing no.1033-H000-A11360-
0019
The reformer floor refractory to be completely removed
for all the existing 11 bays and to be replaced with new
refractory and extended till the 14th bay as shown in
the drawing no.1033-H000-A11360-0019
The existing reformer roof refractory to be extended
from the 11th bay till the 14th bay of the reformer. Care
should be taken the existing roof refractory should not
be disturbed.
10.3.2. CONSTRUCTION ACTIVITIES
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 39 of 106
PATEL, 14/09/10,
Repeating the same point
PATEL, 14/09/10,
Why both end wall?
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10.3.2.1. EQUIPMENT
10.3.2.1.1. BURNER The burner to be installed at the reformer bottom floor
as per the drawing no.1033-H000-A11360-0019-1910-
0003. The burners to be installed before the floor
refractory are carried out. The alignment of the burners
is to be properly checked. The burners to be protected
while carrying out the floor refractory.
10.3.2.1.2. REFORMER TUBE ASSEMBLY Install 10” reformer tube (1033-H000-A11360-0019-
1917-0001) to the flanged nozzle in the reformer roof
plate with the rope gasket and high temp red RTV
silicon (Refer Drg No.1033-H000-A11360-0019-191-
0015)
Install reformer tube top canister (1033-H000-A11360-
0019-1911-0011) on top of the reformer tube. The
verticality of the top canister and the reformer tube to
be maintained. The top canister to be installed in
concentric with the reformer tube. The ceramic blanket
to be filled inside the reformer tube as per the drawing
no1033-H000-A11360-0019-1911-7017.
Install reformer tube dogleg filled with insulation
castable & ceramic blanket (1033-H000-A11360-
0019-1911-7026) on top of reformer tube. The flatness
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 40 of 106
PATEL, 14/09/10,
Filled word to be replaced with proper word
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of the dogleg to be maintained. The bottom of dogleg
to be welded air tight with the top of the reformer tube.
The joint of the dogleg connecting with the reformer
gas duct to be welded at site (1033-H000-A11360-
0019-1911-0015).
Install bellows (1033-H000-A11360-0019-1911-0006)
by bolting it to the flanged nozzle in reformer floor plate
with rope gasket and high temp red RTV silicon as
shown in drawing 1033-H000-A11360-0019-1911-
0015.
Install split ring flange (1033-H000-A11360-0019-1911-
00) in the groove near bottom of the reformer tube with
rope gasket and high temp red RTV silicon. Make sure
those split ring flanges are aligned properly with the
bellows.
Install catalyst support tube (1033-H000-A11360-0019-
1911-0008) with vacuum formed special shapes
through bottom of the reformer tube, aligning the slots
in catalyst support plate with lugs on I.D of the reformer
tube and rotating after insertion so that catalyst support
plate is seated on top of the lugs.
With gasket and ceramic fibre blanket (1033-H000-
A11360-0019-1911-7017) bolt feed gas inlet flange to
split ring flange with and high temp red RTV silicon
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 41 of 106
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between flange (refer drawing no.1033-H000-A11360-
0019-1911-0015)
Remove bellows shipping bars and bolt bellows to split
ring flange and gas inlet flange installation length of the
bellow to be maintained as shown in drawing (1033-
H000-A11360-0019-1911-0015)
Thread tube support rod into spring adjustment
bracket. Place tube spring over the spring adjustment
bracket attach to reformer casing floor beams.
Form rope gasket seals by installing two concentric
rings and hold in place with the high temp red RTV
silicon. The ends of each rope should overlap a
minimum of 40 mm with no gap between to typical
installation refer drawing no.1033-H000-A11360-0019-
1911-0015
Feed gas flexible hose to be wrapped with the mineral
wool 50mm thick. Covered with Denel fabric and
flexible mastic.
Do not install insulation around flange connection of
flex hose.
10.3.2.1.3. INSTALLATION OF CATALYST INSIDE REFORMER TUBE
The 10” reformer tube to be filled with the catalyst of
two types:
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 42 of 106
PATEL, 09/14/10,
Exiting 11 bay catalyst to be dump, catalyst to be clean and fill uniformly old and new active catalyst.
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Bottom of reformer tube –Low Active R8 up to 1.2 m
Top of Reformer tube – High Active R7GG 6.8 m
The catalyst to be filled after completion of upper
reformer tube assembly and lower tube assembly from
top dogleg flange opening and before the fixing of the
flexible hose.
10.3.2.2. REFRACTORY
10.3.2.2.1. REFORMER BOX After the erection of reformer columns with top and
bottom grids along with end wall, side wall, roof and
floor , the roof refractory to be done as per the drawing
1033-H000-A11360-0019-1911
The end wall refractory to be done as per the drawing
no.1033-H000-A11360-0019-1911-
The side wall refractory to be carried out from the 14th
bay to the 12th bay.
The floor refractory to be carried out from the 14th bay
to 12th bay. The floor refractory to be carried out after
the installation of reformer burner is scaffoldings to be
provided for last four bays for carrying out the erection
jobs. completed
10.3.2.2.2. HOT AIR DUCT After the erection of the hot air ducts it is to be filled
inside with refractory from 12th bay to 14th bay as
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 43 of 106
PATEL, 14/09/10,
Filled word to be replaced with proper word
PATEL, 14/09/10,
Statement is mismatching
PATEL, 14/09/10,
Floor refrectory for all bays
PATEL, 14/09/10,
Pressure drop check after catalyst filling to be mention
PATEL, 14/09/10,
Including old and new catalyst
PATEL, 14/09/10,
Including old and new catalyst
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shown in the drawing no.1033-H000-A11360-0019-
1911-.External insulation to be provided for the risers
at the extended bays as shown in the drawing 1033-
H000-A11360-0019-
10.3.2.2.3. FEED GAS DUCT External insulation to be provided for the fabricated
feed gas duct from the 1st bay to 14th bay and the
feed gas risers to be insulated as shown in the drawing
no.1033-H000-A11360-0019-1911
10.3.2.2.4. REFORMED GAS DUCT After the erection of the reformed gas duct it is to be
filled with the inside refractory from 12th bay to 14th
bay as shown in the drawing no.1033-H000-A11360-
0019-1911
11. SEAL GAS COOLER
11.1. SCOPE OF WORK
11.1.1. The work involves the following activities for demolition of existing
seal gas water distribution trays, replacing packing materials, and
modifying cooling water distribution spray system.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 44 of 106
PATEL, 09/14/10,
Manhole to be boxed up after cleaning and inspection of all ductPressure leak test to be carried out during start up for flanges of process gas, feed gas, refromed gas,natural gas and main air system
PATEL, 14/09/10,
Filled word to be replaced with proper word
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Prefabrication and supply of spray nozzles
Demolition
Construction
Tie in activities
Start up & Commissioning
11.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication
Assembly &erection as per the scope specified herein.
Demolition of existing water spray trays
Installation of water spray pipes and spray nozzles
11.2. REFRENCE DRAWINGS & DOCUMENTSSr.N
oArea
Drawing / Document Numbers
A. DemolitionP&ID 1033-H000-A11000-0019-1904-0012
Seal gas Cooler Dismantling
SIM3-541 (QSC Drawing)
B. Shutdown WorkDismantling of SG Cooler
SIM3-541 (QSC Drawing)
Modifying Seal gas Cooler
1033-H000-A11350-0019-1911-0051
1033-H000-A11350-0019-1911-0052
1033-H000-A11350-0019-1911-0053
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 45 of 106
PATEL, 14/09/10,
0027
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1033-H000-A11350-0019-1911-0054
11.3. SHUTDOWN ACTIVITIES
11.3.1. DEMOLITION ACTIVITIES The Existing SG cooler water inlet piping and distribution
trays to be removed as per drawing 1033-H000-A11350-
0019-1911-0051 to 0054.
11.3.2. CONSTRUCTION ACTIVITIES Erection Weight = 2248 Kg.
Install new water spray pipes, headers and spray nozzle as
per drawing 1033-H000-A11350-0019-1911-0051 to 0054.
Rerouting the spray water inlet header and patching the
existing water inlet pipe opening with a blind plate as per
drawing 1033-H000-A11350-0019-1911-0051 to 0054.
12. FLUE GAS FAN & TRANSITION PIECE
12.1. SCOPE OF WORK
12.1.1. The work involves the following activities for Dismantling of the
existing H2S removal system and construction of flue gas fan for
the DR-1 plant up gradation.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 46 of 106
PATEL, 14/09/10,
Manhole to be boxed up after cleaning and inspection.Pressure leak test to be carried out during start up.
PATEL, 14/09/10,
Packing to be removed before any mechanical work. New packing to be filled after all mechanical work completed. Nozzel to be fixed after flushing the water pipe.
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CONSTRUCTION MANUAL FOR
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Prefabrication, assembly and Supply
Demolition
Construction
Tie in activities
Start up & Commissioning
12.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication, assembly & erection as per the scope
specified herein.
Demolition of existing H2S removal system Equipments, structures,
piping’s.
Installation of new Flue fan and transition Piece refractory work.
12.2. PRE-SHUTDOWN ACTIVITIES
12.2.1. PRE-SHURDOWN DEMOLITION ACTIVITIES
Demolition activities to be carried as per the reference drawing
& instruction as per the site Engineer.
The existing H2S removal facility with connecting equipments,
ducts, pipes to be demolish and area to be made free for the
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 47 of 106
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flue gas fan at ground level at GL +300 (EL +30480). After
dismantling of all equipments, ducts, pipes to be removed and
to be shifted to designated area. Area to be demolished is
marked in the drawing.
During the demolition activities take care of the running
existing connecting lines, equipments.
Safety procedure to be follow as per the QSC procedure & Site
engineer requirement.
And the Heavy & rotary equipments dismantling to be done as
per the equipment manufacturer manual & the site engineer
requirement
12.2.2. PRE-SHUTDOWN DEMOLITION REFERENCE DOCUMENTS
General Drawings & Documents:
The H2S removal facilities for QATAR - G701-LD003
12.2.3. PRE-SHUTDOWN DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments QSC12.2.4. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 48 of 106
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12.2.4.1. EQUIPMENT ERECTION
Flue gas fan to be erection to be carried as per the reference
drawing and Erection specification enclosed with document.
The Transition piece between the fan outlet to flue gas stack to
be done as per the reference drawings before the transition
piece erection the refractory to done as per the refractory
requirement in this document.
The alignments of the Rotary and static equipments to be
carried as per the erection specification if the manufacturer
manual not available.
The Manufacturer manual shall be referring the rotary
equipment erection procedures.
12.2.4.2. REFRACTORY ERECTION
The Transition refractory between the fan outlet to flue
gas stack to be done as per the reference drawings
before the transition piece erection.
The Manufacturer manual shall be referring the refractory
erection procedures.
The general refractory erection procedure to be follow for
the erection of refractory as per the Enclosed documents
along with this document.
12.2.5. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 49 of 106
PATEL, 09/14/10,
Something wromg
PATEL, 09/14/10,
I think no refractory pl check
PATEL, 09/14/10,
I think no refractory pl check
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All Pressure test and cleaning of piping of lubrication system
and utility system up to hook up point shall be carried as per
the Enclosed erection specification.
Lubrication System test and cleaning shall be carried as per
the enclosed erection specification.
After that the Lubrication system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
12.2.6. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Vendor Drawings & Manual -
P & ID drawings:
P & ID for the Flue gas & stack-
1033-H000-A11000-1909-0009/10 and 0019
General Drawings & Documents:
General arrangement of flue gas fan & stack
- 1033-H000-A11000-1904-0020
12.2.7. PRE-SHUTDOWN CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 50 of 106
PATEL, 09/14/10,
Check number
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01. Equipments 20000(App)
12.3. SHUT DOWN ACTIVITIES
12.3.1. SHUTDOWN DEMOLITION ACTIVITIES
The demolition works not there during shutdown.
12.3.2. SHUTDOWN CONSTRUCTION ACTIVITIES
12.3.2.1. CIVIL ERECTION
The civil foundation works not there during shutdown.
12.3.2.2. STRUCTURE ERECTION
The structural works not there during shutdown.
12.3.2.3. PIPING ERECTION
12.3.2.3.1. Utility piping
The hook up of the utility piping with existing utility
facilities as per the reference drawing.
The erection procedures will be as per the enclosed
erection specification
12.3.2.4. REFRACTORY ERECTION
The Refractory works not there during shutdown.
12.3.2.5. EQUIPMENT ERECTION
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 51 of 106
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The Equipment Erection works not there during
shutdown.
12.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of lubrication system
and utility system with hook up point shall be carried as per the
Enclosed erection specification.
After that the Flue gas fan system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
Note: Before starting the Flue gas fan the Heat recovery
system all activities should be completed and hook up with
reformer should be completed.
13. MAIN AIR BLOWER
13.1. SCOPE OF WORK
13.1.1. The work involves the following activities for construction of Main
Air Blower for the DR-1 plant up gradation.
Prefabrication, assembly and Supply
Construction
Tie in activities
Start up & Commissioning
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 52 of 106
PATEL, 09/14/10,
Guide vane checking before fan start up. Inspection in casing nothing is left out. Inspection also to be carried out from inside recuperator that nothing is lying on guide vane and any loose material which sucked in
PATEL, 09/14/10,
Motor direction to be checked and then couple
PATEL, 09/14/10,
Already mention earlier
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13.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down fabrication, assembly & erection as per the scope
specified herein.
Installation of new Main Air Blower including civil, structure, piping
and refractory work.
13.2. PRE-SHUTDOWN ACTIVITIES
13.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES
Demolition activities are not there in the Main Air Blower
because it’s totally new blower and the separate location.
13.2.2. PRE-SHUTDOWN DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
------------------Nil----------------
General Drawings & Documents:
------------------Nil----------------
13.2.3. PRE-SHUTDOWN DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments ---Nil--- ---Nil---
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 53 of 106
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13.2.4. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES
13.2.4.1. CIVIL FOUNDATIONS
Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
13.2.4.2. EQUIPMENT ERECTION
Main Air Blower to be erection to be carried as per the
reference drawing and Erection specification enclosed with
document.
The Transition piece between the Blower outlets to 550
pipe racks to be done as per the reference drawings.
The alignments of the Rotary and static equipments to be
carried as per the erection specification if the manufacturer
manual not available.
The Manufacturer manual shall be referring the rotary
equipment erection procedures.
13.2.4.3. STRUCTURE ERECTION
Structural Steel Erections shall be carried as per the
construction manual no.:1033-H000-A11000-0008-0811-
0006.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 54 of 106
PATEL, 09/14/10,
Erection of lube oil system
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13.2.4.4. PIPING & DUCT ERECTION
13.2.4.4.1. Lubrication system piping
The new pipe from Blower lubrication system to Blower
bearing block inlet to be erected with control instruments
and accessories as shown in the drawings
The new pipe from Blower bearing block outlet to Blower
lubrication system be erected with control instruments
and accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
13.2.4.4.2. Utility piping
The new pipe from Blower lubrication system cooler to
plant utility system facility to be erected with control
instruments and accessories as shown in the drawings
The new pipe from blower lubrication system cooler to
plant utility system facility to be erected with control
instruments and accessories as shown in the drawings
All other utility gas pipe lines from blower lubrication
system, blower unit to plant utility system facility to be
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 55 of 106
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erected with control instruments and accessories as
shown in the drawings
The erection procedures will be as per the enclosed
erection specification
13.2.4.4.3. Blower Outlet Duct
The new fabricated duct from Blower outlet to plant pipe
rack 550 facility to be erected with control instruments
and accessories as shown in the drawings
The venting provision from Blower outlet to blower
silencer room open area facility to be erected with control
instruments and accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
13.2.5. COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of lubrication system
and utility system up to hook up point shall be carried as per
the Enclosed erection specification.
Lubrication System test and cleaning shall be carried as per
the enclosed erection specification.
After that the Lubrication system shall be started and
performance shall be checked as per the manufacturer
Manual and specification.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 56 of 106
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13.2.6. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Vendor Drawings & Manual –
General Drawings & Documents:
Main Air blower assignment drawings
- 1033-H000-A11180-0019-1910-0001
P & ID Drawing:
P & ID drawing for Main Air Blower
- 1033-H000-A11000-0019-1904-0019
13.2.7. PRE-SHUTDOWN CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 17000(App)
13.3. SHUT DOWN ACTIVITIES
13.3.1. SHUTDOWN DEMOLITION ACTIVITIES
The demolition works not there during shutdown.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 57 of 106
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13.3.2. SHUTDOWN CONSTRUCTION ACTIVITIES
13.3.2.1. CIVIL ERECTION
The civil foundation works not there during shutdown.
13.3.2.2. STRUCTURE ERECTION
The structural works not there during shutdown.
13.3.2.3. PIPING ERECTION
13.3.2.3.1. Utility piping
The hook up of the utility piping with existing utility
facilities as per the reference drawing.
The erection procedures will be as per the enclosed
erection specification
13.3.2.4. EQUIPMENT ERECTION
The Equipment Erection works not there during shutdown.
13.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of lubrication system
and utility system with hook up point shall be carried as per the
Enclosed erection specification.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 58 of 106
PATEL, 09/14/10,
Motor direction rotation to be checked before coupling Inlet Guide vane to be stroke checked
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After that the Main Air Blower system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
Note: Before starting the Main Air Blower the Downstream
system all activities should be completed and hook up with
reformer should be completed.
14. AUXILIARY AIR BLOWER
14.1. SCOPE OF WORK
14.1.1. The work involves the following activities demolition of existing
main air blower, its duct and construction of New Aux Air Blower,
its duct for the DR-1 plant up gradation.
Demolition of the Existing main air Blower & its duct
Prefabrication, assembly and Supply
Construction
Tie in activities
Start up & Commissioning
14.1.2. The Main activities are consisting of but not limited to the
following:
Demolition of the Existing main air blower & its Duct.
Pre shut down fabrication, assembly & erection as per the scope
specified herein.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 59 of 106
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Installation of new Main Air Blower including civil, structure, piping
and refractory work.
14.2. PRE-SHUTDOWN ACTIVITIES
14.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES
There are no demolition activities in pre-shutdown activities.
14.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES
14.2.2.1. CIVIL FOUNDATIONS
Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
14.2.2.2. EQUIPMENT ERECTION
The new auxiliary air blower to be shift at site
The preassembly required with silencer and blower shall
be carried.
14.2.2.3. STRUCTURE ERECTION
Structure Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
14.2.2.4. PIPING & DUCT ERECTION
14.2.2.4.1. Utility piping
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All other utility gas pipe lines from blower unit to plant
utility system facility to be erected with control
instruments and accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
14.2.2.4.2. Blower Outlet Duct
The new fabricated duct from Blower outlet to reformer
auxiliary air header and the bypass line from pipe rack
550 and dilution line shall be erected with control
instruments and accessories as shown in the drawings
The venting provision from Blower outlet to open area
facility to be erected with control instruments and
accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
14.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of utility system up to hook
up point shall be carried as per the Enclosed erection specification.
The outlet duct and bypass line for the main air duct and the
dilution air duct shall be clean and test shall be carried as per the
reference drawings.
Venting line clean and test shall be carried.
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All controls in the duct except the auxiliary TV-B22 shall be check
and clear for the further process.
14.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
------------------Nil---------------------
General Drawings & Documents:
----------------Nil--------------------
14.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments ---Nil---
14.3. SHUT DOWN ACTIVITIES
14.3.1. SHUTDOWN-DEMOLITION ACTIVITIES
Demolition activities to be carried as per the reference drawing &
instruction as per the site Engineer.
The existing main air blower removal with connecting equipments,
ducts, pipes to be demolish and area to be made free for the
Aux.air blower at level of GL +1753 (EL
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+32233),GL+970(EL+31450). After dismantling of all equipments,
ducts, pipes to be removed and to be shifted to designated area.
Area to be demolished is marked in the drawing.
During the demolition activities take care of the running existing
connecting lines, equipments.
Safety procedure to be follow as per the QSC procedure & Site
engineer requirement.
And the Heavy & rotary equipments dismantling to be done as per
the equipment manufacturer manual & the site engineer
requirement
14.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Existing Main Air blower - 76-0030
General Drawings & Documents:
------------------Nil----------------
14.3.3. SHUTDOWN-DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 12000(QSC)
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14.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES
14.3.4.1. CIVIL ERECTION
Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
14.3.4.2. STRUCTURE ERECTION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
14.3.4.3. PIPING ERECTION
14.3.4.3.1. Utility piping
The hook up of the utility piping with existing utility
facilities as per the reference drawing.
The erection procedures will be as per the enclosed
erection specification
14.3.4.4. EQUIPMENT ERECTION
New auxiliary air blower to be erection to be carried as per
the reference drawing and Erection specification enclosed
with document.
The Transition piece between the blower outlets to auxiliary
air shall be done as per the reference drawings before the
transition piece erection all alignments of equipments, duct
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to done as per the requirement in erection specification
document.
The alignments of the Rotary and static equipments to be
carried as per the erection specification if the manufacturer
manual not available.
The Manufacturer manual shall be referring the rotary
equipment erection procedures.
14.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Vendor Drawings & Manual -
General Drawings & Documents:
General Arrangement drawings for the Auxiliary Air Blower -
1033-H000-A11180-0019-1910-0002
P & ID Drawings:
P & ID drawing for the Auxiliary Burner System -
1033-H000-A11000-0019-1904-0021
14.3.6. SHUTDOWN-CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 8000(App)
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14.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of utility system and the
outlet duct with hook up point shall be carried as per the
Enclosed erection specification.
After that the Auxiliary Air Blower system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
Note: Before starting the Auxiliary Air Blower the Downstream
system all activities should be completed and hook up with
reformer, heat recovery system should be completed.
15. BSG COMPRESSOR UNIT
15.1. SCOPE OF WORK
15.1.1. The work involves the following activities demolition of existing
desiccant dryer, its piping and construction of New BSG
Compressor, its duct, piping for the DR-1 plant up gradation.
Demolition of the Existing desiccant dryer & its piping
Prefabrication, assembly and Supply
Construction
Tie in activities
Start up & Commissioning
15.1.2. The Main activities are consisting of but not limited to the
following:
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 66 of 106
PATEL, 09/14/10,
Motor direction rotation to be checked before coupling. Inlet Guide vane to be stroke checked
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Demolition of the Existing desiccant dryer & its piping.
Pre shut down fabrication, assembly & erection as per the scope
specified herein.
Installation of new BSG Compressor including civil, structure,
piping and refractory work.
15.2. PRE-SHUTDOWN ACTIVITIES
15.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES
There are no demolition activities in pre-shutdown activities.
15.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES
15.2.2.1. CIVIL FOUNDATIONS
Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
15.2.2.2. EQUIPMENT ERECTION
The new BSG Compressor to be shift at site
The preassembly required with separator, cooler shall be
carried.
15.2.2.3. STRUCTURE ERECTION
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Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
15.2.2.4. PIPING ERECTION
15.2.2.4.1. Utility piping
All other utility gas pipe lines from compressor unit to plant
utility system facility to be erected with control instruments
and accessories as shown in the drawings
All water pipe lines from compressor unit,seperater,cooler
to plant utility system facility to be erected with control
instruments and accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
15.2.2.4.2. Compressor Inlet & Outlet Duct
The new pipe from seal gas cooler outlet to new BSG
compressor line shall be erected with control instruments
and accessories as shown in the drawings
The BSG Compressor to water separator pipe and
separator to cooler pipe line shall be erect with control
instruments and accessories as show in the drawings.
BSG cooler to plant facilities pipe line shall be erect with
control instruments and accessories as show in the
drawings.
SPEC.NO: 1033-H000-A11000-0019-XXXX-XXXX Rev00 DATE: 14.09.10 Page 68 of 106
PATEL, 09/14/10,
piping
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The venting provision from compressor outlet to open area
facility to be erected with control instruments and
accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
15.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of utility system up to hook
up point shall be carried as per the Enclosed erection specification.
The inlet, outlet line for the BSG compressor shall be clean and
test shall be carried as per the reference drawings.
Venting line clean and test shall be carried.
All controls in the duct shall be check and clear for the further
process.
15.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
-------------Nil--------------
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General Drawings & Documents:
------------Nil------------
15.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments ----Nil----
15.3. SHUT DOWN ACTIVITIES
15.3.1. SHUTDOWN-DEMOLITION ACTIVITIES
Demolition activities to be carried as per the reference drawing &
instruction as per the site Engineer.
The existing desiccant dryer removal with connecting equipments,
ducts, pipes to be demolish and area to be made free for the new
BSG compressor at level of GL +300 (EL +30480). After
dismantling of all equipments, pipes to be removed and to be
shifted to designated area. Area to be demolished is marked in the
drawing.
During the demolition activities take care of the running existing
connecting lines, equipments.
Safety procedure to be follow as per the QSC procedure & Site
engineer requirement.
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And the Heavy & rotary equipments dismantling to be done as per
the equipment manufacturer manual & the site engineer
requirement
15.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
-----------------Nil-----------------
General Drawings & Documents:
Equipment Arrangement Plan Blower Area-
3134-G3-03
15.3.3. SHUTDOWN-DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 5000(QSC)
15.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES
15.3.4.1. CIVIL ERECTION
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Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
15.3.4.2. STRUCTURE ERECTION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
15.3.4.3. PIPING ERECTION
15.3.4.3.1. Utility piping
The hook up of the utility piping with existing utility
facilities as per the reference drawing.
The inlet, outlet pipe line from the BSG compressor to
plant facilities shall be hook up as per the enclosed
erection specification.
The erection procedures will be as per the enclosed
erection specification
15.3.4.4. EQUIPMENT ERECTION
New BSG compressor unit to be erection to be carried as
per the reference drawing and Erection specification
enclosed with document.
The connecting piece between the compressor inlet, outlets
to pipe line shall be done as per the reference drawings
before the connecting piece erection all alignments of
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equipments, pipe to done as per the requirement in
erection specification document.
The alignments of the Rotary and static equipments to be
carried as per the erection specification if the manufacturer
manual not available.
The Manufacturer manual shall be referring the rotary
equipment erection procedures.
15.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Vendor Drawings & Manual -
P & ID Drawings:
P & ID for BSG Compressor-
1033-H000-A11000-0019-1904-0029
General Drawings & Documents:
General Plan of Blower House-
1033-H000-A11260-0019-1909-0001
15.3.6. SHUTDOWN-CONSTRUCTION SCOPE
Sr.N Description Weight(Kg) Others
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o
01. Equipments 10000(App)
15.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of utility system and the
inlet, outlet pipe with hook up point shall be carried as per the
Enclosed erection specification.
After that the BSG compressor system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
Note: Before starting the BSG compressor unit the Upstream,
Downstream system all activities should be completed and hook
up with seal gas cooler, furnace system should be completed.
16. FIRST STAGE PROCESS GAS COMPRESSOR
16.1. SCOPE OF WORK
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16.1.1. The work involves the following activities demolition of existing
first stage compressor gearboxes, motors, gearbox lubrication
system & its piping, silencers & its duct and construction of New
Compressor gearboxes, motors, gearbox lubrication system & its
piping, silencers & its duct for the DR-1 plant up gradation.
Demolition of the Existing first stage compressor gearboxes,
motors, gearbox lubrication system & its piping, silencers & its duct
Prefabrication, assembly and Supply
Construction
Tie in activities
Start up & Commissioning
16.1.2. The Main activities are consisting of but not limited to the
following:
Demolition of the Existing first stage compressor gearboxes,
motors, gearbox lubrication system & its piping, silencers & its
duct.
Pre shut down fabrication, assembly & erection as per the scope
specified herein.
Installation of new Compressor gearboxes, motors, gearbox
lubrication system & its piping, silencers & its duct including civil,
structure, piping work.
16.2. PRE-SHUTDOWN ACTIVITIES
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16.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES
There are no demolition activities in pre-shutdown activities.
16.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES
16.2.2.1. CIVIL FOUNDATIONS
Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
16.2.2.2. EQUIPMENT ERECTION
The new PG Compressor gearboxes,motor,gearbox
lubrication system to be shift at site
The preassembly required for gearbox input/output
couplings motor half coupling shall be carried.
16.2.2.3. STRUCTURE ERECTION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
16.2.2.4. PIPING ERECTION
16.2.2.4.1. Utility piping
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All other utility gas pipe lines from compressor unit to plant
utility system facility to be erected with control instruments
and accessories as shown in the drawings
All water pipe lines from compressor unit,silencer,cooler to
plant utility system facility to be erected with control
instruments and accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
16.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of utility system up to hook
up point shall be carried as per the Enclosed erection specification.
All controls in the duct shall be check and clear for the further
process.
16.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
-------------------Nil---------------
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General Drawings & Documents:
-------------------Nil---------------
16.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments ----Nil----
16.3. SHUT DOWN ACTIVITIES
16.3.1. SHUTDOWN-DEMOLITION ACTIVITIES
Demolition activities to be carried as per the reference drawing &
instruction as per the site Engineer.
The existing gearbox, gearbox lubrication system & its piping,
silencer removal with connecting equipments, ducts, pipes to be
demolish and area to be made free for the new gearboxes,
gearbox lube oil system & its piping, silencer & its piping at its
corresponding level. After dismantling of all equipments, pipes to
be removed and to be shifted to designated area. Area to be
demolished is marked in the drawing.
During the demolition activities take care of the running existing
connecting lines, equipments.
Safety procedure to be follow as per the QSC procedure & Site
engineer requirement.
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And the Heavy & rotary equipments dismantling to be done as per
the equipment manufacturer manual & the site engineer
requirement
16.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Dimensional Drawing of Existing Gearbox-
1905507.
Existing Motor Drawing-
3AFB 5236832
Existing Silencer Drawing-
DR-V1468-1
General Drawings & Documents:
Equipment Arrangement Area Section I – I
3134-G3-05
Equipment Arrangement Area Section 2 – 2
3134-G3-06
16.3.3. SHUTDOWN-DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 30000
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16.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES
16.3.4.1. CIVIL ERECTION
Civil foundations shall be carried as per the civil construction
manual no.:1033-H000-A11000-0008-0811-0005.
16.3.4.2. STRUCTURE ERECTION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
16.3.4.3. PIPING ERECTION
16.3.4.3.1. Lubrication system piping
The new pipe from compressor gearbox lubrication
system to cooler inlet to be erected with control
instruments and accessories as shown in the drawings
The new pipe from cooler outlet to compressor gearbox
lubrication system be erected with control instruments
and accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
16.3.4.3.2. Utility piping
The hook up of the utility piping with existing utility
facilities as per the reference drawing.
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The inlet, outlet pipe line from the compressor unit to
plant facilities shall be hook up as per the enclosed
erection specification.
The erection procedures will be as per the enclosed
erection specification
16.3.4.4. EQUIPMENT ERECTION
New compressor gearboxes, silencer, gearbox lubrication
system to be erection to be carried as per the reference
drawing and Erection specification enclosed with document.
The connecting piece between the compressor inlet, outlets
to pipe line shall be done as per the reference drawings
before the connecting piece erection all alignments of
equipments, pipe to done as per the requirement in erection
specification document.
The alignments of the Rotary and static equipments to be
carried as per the erection specification if the manufacturer
manual not available.
The Manufacturer manual shall be referring the rotary
equipment erection procedures.
16.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Vendor Drawings & Manual for Gearbox -
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Vendor Drawings & Manual for Motor -
Silencer Drawings-
General Drawings & Documents:
GA Drawing for Process gas Compressor -
1033-H000-A11260-0019-1917-0001
P & ID Drawing:
P & ID Drawing for 1st stage (K-A48A)-
1033-H000-A11000-0019-1904-0005
P & ID Drawing for 1st stage (K-A48B)-
1033-H000-A11000-0019-1904-0006
16.3.6. SHUTDOWN-CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 40000(App)
16.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES
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All Pressure test and cleaning of piping of utility system and the
inlet, outlet pipe with hook up point shall be carried as per the
Enclosed erection specification.
After that the compressor system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
Note: Before starting the compressor unit the Upstream,
Downstream system all activities should be completed and hook
up with process gas system and furnace should be completed.
17. SECOND STAGE COMPRESSOR
17.1. SCOPE OF WORK
17.1.1. The work involves the following activities demolition of existing
second stage compressor, compressor lubrication system & its
piping, gearbox, motor, gearbox lubrication system & its piping,
silencer & its duct and construction of new compressor,
compressor lubrication system & its piping,gearbox,motor,gearbox
lubrication system & its piping, silencers & its duct for the DR-1
plant up gradation.
Demolition of the Existing second stage compressor, compressor
lubrication system & its piping, gearbox, motor, gearbox lubrication
system & its piping, silencer & its duct.
Prefabrication, assembly and Supply
Construction
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Tie in activities
Start up & Commissioning
17.1.2. The Main activities are consisting of but not limited to the
following:
Demolition of the Existing second stage compressor, compressor
lubrication system & its piping, gearbox, motor, gearbox lubrication
system & its piping, silencer & its duct.
Pre shut down fabrication, assembly & erection as per the scope
specified herein.
construction of new compressor, compressor lubrication system &
its piping, gearbox, motor, gearbox lubrication system & its piping,
silencers & its duct including civil, structure, piping work.
17.2. PRE-SHUTDOWN ACTIVITIES
17.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES
There are no demolition activities in pre-shutdown activities.
17.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES
17.2.2.1. CIVIL FOUNDATIONS
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Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
17.2.2.2. EQUIPMENT ERECTION
The new compressor, compressor lubrication system parts
gearbox, motor, gearbox lubrication system, silencer to be
shift at site.
The preassembly required for compressor coupling,
gearbox input/output couplings motor half coupling shall be
carried.
17.2.2.3. STRUCTURE ERECTION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
17.2.2.4. PIPING ERECTION
17.2.2.4.1. Utility piping
All other utility gas pipe lines from compressor unit to
plant utility system facility to be erected with control
instruments and accessories as shown in the drawings
All water pipe lines from compressor unit,silencer,cooler
to plant utility system facility to be erected with control
instruments and accessories as shown in the drawings
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The erection procedures will be as per the enclosed
erection specification
17.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of utility system up to hook
up point shall be carried as per the Enclosed erection specification.
All controls in the duct shall be check and clear for the further
process.
17.2.4. PRE-SHUTDOWN ERECTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
----------Nil--------------
General Drawings & Documents:
-----------Nil--------------
17.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments ----Nil----
17.3. SHUT DOWN ACTIVITIES
17.3.1. SHUTDOWN DEMOLITION ACTIVITIES
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Demolition activities to be carried as per the reference drawing &
instruction as per the site Engineer.
The existing compressor, compressor lubrication system & its
piping, gearbox, gearbox lubrication system & its piping, silencer
removal with connecting equipments, ducts, pipes to be demolish
and area to be made free for the new compressor, gearbox,
gearbox lube oil system & its piping, silencer & its piping at its
corresponding level. After dismantling of all equipments, pipes to
be removed and to be shifted to designated area. Area to be
demolished is marked in the drawing.
During the demolition activities take care of the running existing
connecting lines, equipments.
Safety procedure to be follow as per the QSC procedure & Site
engineer requirement.
And the Heavy & rotary equipments dismantling to be done as per
the equipment manufacturer manual & the site engineer
requirement
17.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Dimensional Drawing of Existing Gearbox-
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1905507.
Existing Motor Drawing-
3AFB 5236832
Existing Silencer Drawing-
SIBL-910
General Drawing for 3649 RGS-VJ Unit-
84867013
General Drawings & Documents:
Equipment Arrangement Area Section I – I
3134-G3-05
Equipment Arrangement Area Section 2 – 2
3134-G3-06
17.3.3. SHUTDOWN-DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 50000
17.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES
17.3.4.1. CIVIL ERECTION
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Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
17.3.4.2. STRUCTURE ERECTION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
17.3.4.3. PIPING ERECTION
17.3.4.3.1. Lubrication system piping
The new pipe from compressor lubrication unit to
compressor inlet, compressor gearbox lubrication
system to cooler inlet to be erected with control
instruments and accessories as shown in the drawings
The new pipe from compressor outlet to compressor
lubrication system, cooler outlet to compressor gearbox
lubrication system be erected with control instruments
and accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
17.3.4.3.2. Utility piping
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The hook up of the utility piping with existing utility
facilities as per the reference drawing.
The inlet, outlet pipe line from the compressor unit to
plant facilities shall be hook up as per the enclosed
erection specification.
The erection procedures will be as per the enclosed
erection specification
17.3.4.4. EQUIPMENT ERECTION
New compressor, compressor lubrication system,
compressor gearbox, silencer, gearbox lubrication system
to be erection to be carried as per the reference drawing
and Erection specification enclosed with document.
The connecting piece between the compressor inlet,
outlets to pipe line shall be done as per the reference
drawings before the connecting piece erection all
alignments of equipments, pipe to done as per the
requirement in erection specification document.
The alignments of the Rotary and static equipments to be
carried as per the erection specification if the manufacturer
manual not available.
The Manufacturer manual shall be referring the rotary
equipment erection procedures.
17.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS
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Equipment drawings & Documents:
Vendor Drawing & Manual for Compressor-
Vendor Drawing & Manual for gearbox-
Vendor Drawing & Manual for Motor-
Silencer Drawings-
P & ID Drawing:
P & ID Drawing for the 2nd stage (K-A51)-
1033-H000-A11000-0019-1904-0007
General Drawings & Documents:
General Arrangement drawing of PGC 2nd Stage-
17.3.6. SHUTDOWN-CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 60000(App)
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17.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of piping of utility system and the
inlet, outlet pipe with hook up point shall be carried as per the
Enclosed erection specification.
After that the compressor system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
Note: Before starting the compressor unit the Upstream,
Downstream system all activities should be completed and hook
up with process gas system and furnace should be completed.
18. FURNACE HYDRAULIC ROOM & HYDRAULIC UNIT
18.1. SCOPE OF WORK
18.1.1. The work involves the following activities demolition of existing
hydraulic unit and tubing from the hydraulic unit to individual
cylinder and individual cylinder to hydraulic unit, accumulator unit
and construction of new hydraulic unit, valve stands, hydraulic
room, hydraulic room hoist, tubing from hydraulic unit to valve
stands, tubing from valve stands to individual cylinders & its return
lines tubing to valve stands, return lines from valve stands to
hydraulic unit, all supports for the tubing’s for the DR-1 plant up
gradation.
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Demolition of the Existing hydraulic unit and tubing from the
hydraulic unit to individual cylinder and individual cylinder to
hydraulic unit, accumulator unit.
Prefabrication, assembly and Supply
Construction
Tie in activities
Start up & Commissioning
18.1.2. The Main activities are consisting of but not limited to the
following:
Demolition of the Existing hydraulic unit and tubing from the
hydraulic unit to individual cylinder and individual cylinder to
hydraulic unit, accumulator unit.
Pre shut down fabrication, assembly & erection as per the scope
specified herein.
Construction of new hydraulic unit, valve stands, hydraulic room,
hydraulic room hoist, tubing from hydraulic unit to valve stands,
tubing from valve stands to individual cylinders & its return lines
tubing to valve stands, return lines from valve stands to hydraulic
unit, all supports for the tubing’s including civil, structure, piping
work.
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18.2. PRE-SHUTDOWN ACTIVITIES
18.2.1. PRE-SHUTDOWN DEMOLITION ACTIVITIES
There are no demolition activities in pre-shutdown activities.
18.2.2. PRE-SHUTDOWN CONSTRUCTION ACTIVITIES
18.2.2.1. CIVIL FOUNDATIONS
Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
18.2.2.2. EQUIPMENT ERECTION
The new hydraulic unit, valve stands, Hoist erection shall
be carried after the completion of the civil & structure
activities.
The alignments of the Rotary and static equipments to be
carried as per the erection specification if the manufacturer
manual not available.
The Manufacturer manual shall be referring the rotary
equipment erection procedures.
18.2.2.3. STRUCTURE ERECTION
Structure Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
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18.2.2.4. PIPING & TUBING ERECTION
18.2.2.4.1. Hydraulic Tubing’s
Once the hydraulic unit erection was completed the
tubing from the hydraulic unit to valve stands and valve
stands to individual cylinders hook up point at different
elevation shall be carried as per the drawings &
specifications.
The all tubing supports shall be carried as per the
drawings & specifications.
All tubing’s shall be carried with all instruments &
accessories (Hoses, clamps).
During the tubing erection all running equipments and
running lines shall be protect from the damage.
18.2.2.4.2. Utility piping
All water pipe lines from hydraulic unit, to plant utility
system facility to be erected with control instruments and
accessories as shown in the drawings
The erection procedures will be as per the enclosed
erection specification
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18.2.3. PRE-SHUTDOWN COMMISSIONING AND STARTUP ACTIVITIES
The testing of the hydraulic room hoist shall be carried as per the
enclosed specification and manufacturer manuals.
All Pressure test and cleaning of hydraulic tubing’s, cooling water
piping up to hook up point shall be carried as per the Enclosed
erection specification.
The hydraulic unit cleaning shall be carried as per the
specifications.
During the hydraulic tube cleaning the NASS value must attain 5
for the tubing surface.
The Hydraulic unit performance test shall be carried as per the
manufacturer manual once the tubing testing completed.
All controls in the system shall be check and clear for the further
process.
18.2.4. PRE-SHUTDOWN CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Vendor Drawings for the Hydraulic System-
Vendor Drawings for the Hoist
General Drawings & Documents:
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General Arrangement Drawing of Furnace hydraulic system-
P & ID Drawing:
P& ID Drawing of Cluster Breaker hydraulic unit-
1033-H000-A11000-0019-1904-0003
18.2.5. PRE-SHUTDOWN CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 13000(App)
18.3. SHUT DOWN ACTIVITIES
18.3.1. SHUTDOWN-DEMOLITION ACTIVITIES
Demolition activities to be carried as per the reference drawing &
instruction as per the site Engineer.
The existing hydraulic unit and tubing from the hydraulic unit to
individual cylinder and individual cylinder to hydraulic unit,
accumulator unit to be demolish area to be made free. After
dismantling of all equipments, pipes to be removed and to be
shifted to designated area. Area to be demolished is marked in the
drawing.
During the demolition activities take care of the running existing
connecting lines, equipments.
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Safety procedure shall be follow as per the QSC requirements &
Site engineer requirement.
And the Heavy & rotary equipments dismantling to be done as per
the equipment manufacturer manual & the site engineer
requirement
18.3.2. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Hydraulic Unit schematic Drawing-
3134-F1-215
Lower & wiper bar cluster breaker-
SIFU-402
Middle, Upper cluster breaker & Slide Gates-
SIFU-401
General Drawings & Documents:
------------------Nil----------------
18.3.3. SHUTDOWN-DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments QSC
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18.3.4. SHUTDOWN-CONSTRUCTION ACTIVITIES
18.3.4.1. CIVIL ERECTION
Civil foundations shall be carried as per the civil
construction manual no.:1033-H000-A11000-0008-0811-
0005.
18.3.4.2. STRUCTURE ERECTION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
18.3.4.3. PIPING ERECTION
18.3.4.3.1. Hydraulic Tubing’s
Only the tubing’s which are not completed during the
running time shall be carried at different elevation as per
the drawings & specifications.
The tubing’s Hydraulic cylinder ends shall be connected
with the hydraulic cylinders.
18.3.4.3.2. Utility piping
The hook up of the utility piping with existing utility
facilities as per the reference drawing.
The erection procedures will be as per the enclosed
erection specification
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18.3.4.4. EQUIPMENT ERECTION
The equipment erection works not there during shutdown.
18.3.5. SHUTDOWN-CONSTRUCTION REFERENCE DOCUMENTS
Equipment drawings & Documents:
-----------Nil-----------
General Drawings & Documents:
-----------Nil---------
18.3.6. SHUTDOWN-CONSTRUCTION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments ----Nil----
18.4. FINAL COMMISSIONING AND STARTUP ACTIVITIES
All Pressure test and cleaning of tubing’s, utility piping with hook
up point shall be carried as per the enclosed erection
specification if required.
After that the total hydraulic system shall be started and
performance shall be checked as per the manufacturer Manual
and specification.
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Note: Before starting the hydraulic unit the cluster breakers,
slide gates activities should be check with furnace system.
19. EXISTING DILUTION AIR BLOWER DEMOLITION
19.1. SCOPE OF WORK
19.1.1. The work involves the following activities demolition of Existing
dilution air blower & its piping for the DR-1 plant up gradation.
Preparation for demolition
Demolition
Shifting the equipments to safe place.
19.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down preparations for the demolition of existing dilution
air blower & its piping as per the scope specified herein.
19.2. PRE-SHUTDOWN ACTIVITIES
The required tools & tackles shall be prepared for the demolition.
Shifting of the required materials to site.
Preparation of Approaches for the demolition works.
19.3. SHUT DOWN ACTIVITIES
19.3.1. EQUIPMENT DEMOLITION
The existing dilution air blower Motor electrical connection
shall be demolished as per the standard procedures.
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And the electrical cables, control cables from the existing
plant facilities to the equipment shall demolished as per the
standard procedure.
And then the electrical motor, blower shall be demolished
from the existing foundations.
During the demolition activities take care of the running
existing connecting lines, equipments.
Safety procedure shall be follow as per the QSC
requirements & Site engineer requirement.
All instruments shall be demolished.
19.3.2. STRUCTURE DEMOLITION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
19.3.3. PIPING DEMOLITION
The all utility pipe lines from the plant facilities to dilution air
blower shall be demolished or modified as per the hook up
drawings and reference drawings.
The outlet pipes from the dilution air blower to the flue gas
mixer shall be demolished as per the standard procedure.
The all valves and fittings shall be demolished as per the site
engineer instructions and reference drawings.
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All control cables for the piping instruments shall be
demolished or modified as per the reference drawings.
19.4. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Assembly drawing for Dilution Air fan-
76-0114-C
General Drawings & Documents:
------------------Nil----------------
19.5. SHUTDOWN-DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 6000(QSC)
20. EXISTING AUXILIARY AIR BLOWER DEMOLITION
20.1. SCOPE OF WORK
20.1.1. The work involves the following activities demolition of Existing
Auxiliary air blower & its piping for the DR-1 plant up gradation.
Preparation for demolition
Demolition
Shifting the equipments to safe place.
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20.1.2. The Main activities are consisting of but not limited to the
following:
Pre shut down preparations for the demolition of existing Auxiliary
air blower & its piping as per the scope specified herein.
20.2. PRE-SHUTDOWN ACTIVITIES
The required tools & tackles shall be prepared for the demolition.
Shifting of the required materials to site.
Preparation of Approaches for the demolition works.
20.3. SHUT DOWN ACTIVITIES
20.3.1. EQUIPMENT DEMOLITION
The existing Auxiliary air blower Motor electrical connection
shall be demolished as per the standard procedures.
And the electrical cables, control cables from the existing
plant facilities to the equipment shall demolished as per the
standard procedure.
And then the electrical motor, blower shall be demolished
from the existing foundations.
During the demolition activities take care of the running
existing connecting lines, equipments.
Safety procedure shall be follow as per the QSC
requirements & Site engineer requirement.
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All instruments shall be demolished.
20.3.2. STRUCTURE DEMOLITION
Structural Erection shall be carried as per the construction
manual no.:1033-H000-A11000-0008-0811-0006.
20.3.3. PIPING DEMOLITION
The all utility pipe lines from the plant facilities to Auxiliary air
blower shall be demolished or modified as per the hook up
drawings and reference drawings.
The outlet pipes from the Auxiliary air blower to the flue gas
mixer shall be demolished as per the standard procedure.
The all valves and fittings shall be demolished as per the site
engineer instructions and reference drawings.
All control cables for the piping instruments shall be
demolished or modified as per the reference drawings.
20.4. SHUTDOWN-DEMOLITION REFERENCE DOCUMENTS
Equipment drawings & Documents:
Assembly Drawing of Auxiliary Air fan-
76-0113
General Drawings & Documents:
------------------Nil----------------
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20.5. SHUTDOWN-DEMOLITION SCOPE
Sr.N
oDescription Weight(Kg)
Others
01. Equipments 5000(QSC)
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