Pre Fabrication, Erection and Hooking Up of 1800 mm Gas Ducts Between W2 and W5 HE and 900mm W2 bypass duct in SA Plant, FACT-CD.

Pre Fabrication, Erection and Hooking Up of 1800 mm Gas Ducts Between W2 and W5 HE and 900mm W2 bypass duct in SA Plant, FACT-CD.

Prefabrication of 1800 mm Gas duct and Mitre Elbows between W5 Heat exchanger and W2 Heat Exchanger : Collect and transport required materials,tools and tackles for the work. Make necessary site arrangements for the work. Mark and cut 8mm thick BQ plate to correct size and grind the inside / outside plate edges properly with suitable bevel / single Vee, where the welding is to be done.The plates shall be rolled / shaped to the required duct size ,1800 mm. Joining / setting the rolled duct pieces properly after correcting the ovality if any, tack / stitch welding to form the required length as per available drawings. Mark,cut, set and fabricate 1 Nos 90 degree mitred elbows, 1800 mm Dia . Existing bellows shall be taken from old line during dismantling and reused. Full welding the duct pieces , complete / required lengths and join as per instruction and generally as per available drawing to facilitate erection at site. After root weld, all joints shall be DP Tested as per instructions and defects if any shall be repaired as per instructions of Engineer-in - Charge. Necessary erection hook with pad plate, as per standards shall be welded on each piece to facilitate the erection at high altitude site. The ducts and mitre elbows shall be welded with required fillet. All welding joints shall be ground properly. After complete fabrication, clear the site, unused plates and structurals shall be neatly stacked in area earmarked,scrap shall be collected in area earmarked. Approx total length of duct excluding mitres is 18 m. Quantity indicated in the drawing/schedule is approximate. Contactor shall take exact length/measurements at site. Weight taken will be weight of final finished duct and mitres.

Prefabrication of 900 mm W2 bypass duct and Mitre Elbows :Collect and transport required materials,tools and tackles for the work. Make necessary site arrangements for the work. Mark and cut 8mm thick BQ plate to correct size and grind the inside / outside plate edges properly with suitable bevel / single Vee, where the welding is to be done.The plates shall be rolled / shaped to the required duct size ,900 mm. Joining / setting the rolled duct pieces properly after correcting the ovality if any,tack / stitch welding to form the required length as per available drawings. Mark,cut, set and fabricate 1 No 90 degree mitred elbows, 900 mm Dia . Also weld 900 mm Flange to be bolted to bypass valve flange. Existing bellows shall be taken from old line during dismantling and reused. Full welding the duct pieces , complete / required lengths and join as per instruction and generally as per available drawing to facilitate erection at site. After root weld, all joints shall be DP Tested as per instructions and defects if any shall be repaired as per instructions of Engineer-in - Charge. Necessary erection hook with pad plate, as per standards shall be welded on each piece to facilitate the erection at highaltitude site. The ducts and mitre elbows shall be welded with required fillet. All welding joints shall be ground properly. After complete fabrication, clear the site, unused plates and structurals shall be neatly stacked in area earmarked,scrap shall be collected in area earmarked. Approx total length of duct excluding mitres is 12m. Quantity indicated in the drawing/schedule is approximate. Contactor shall take exact length/measurements at site. Any additional mitre elbows/ducts required to be fabricated shall also be under contractor's scope as per site instructions.Weight taken will be weigh of final finished duct and mitres.

Dismantle Existing 900mm W2 bypass duct,Scrap Collection and Transportation to Scrapyard: Arrange necessary tools and tackles required for the work. Make required site arrangements. Cut and remove existing 900 W2 bypass duct at the tie point/hook up joint as per relevant drawing and site instructions to facilitate erection of new ducts.Necessary temporary supports shall be provided for supporting the other end of duct and also to avoid strain in duct while erection of new ducts. Bellows , if any shall be clamped properly before dismantling the same.Unwanted assosiated structurals / any structural which are to be dismantled for smooth operation of the work shall also be dismantled as per instructions. FACT cranes shall be made available for dismantling of ducts and structurals. Dismantled duct shall be transported to the earmarked area/scrapyard as per instruction. Scope of collection,loading/unloading and transporation of dismantled ducts/structurals/any scrap arising out of fabrication and erection of subject work shall be under contractors scope.

Dismantle Existing 1800mm Gas Duct,Scrap Collection and Transportation to Scrapyard: Arrange necessary tools and tackles required for the work. Make required site arrangements. Cut and remove existing 1800 mm duct from W5 to W2 at the tie point/hook up joint as per relevant drawing and site instructions to facilitate erection of new ducts.Necessary temporary supports shall be provided for supporting the other end of duct and also to avoid strain in duct while erection of new ducts. Bellows , if any shall be clamped properly before dismantling the same. Unwanted assosiated structurals / any structural which are to be dismantled for smooth operation of the work shall also be dismantled as per instructions. FACT cranes shall be made available for dismantling of ducts and structurals. Dismantled duct shall be transported to the earmarked area/scrapyard as per instruction. Scope of collection,loading/unloading and transporation of dismantled ducts/structurals/any scrap arising out of fabrication and erection of subject work shall be under contractors scope.

Erection of Newly Fabricated 1800mm Gas Ducts and Mitres: Arrange necessary tools and tackles required for the work. Make required site arrangements.Transport the fabricated duct pieces and mitres to worksite.Erect 1800mm gas inlet duct between W5 & W2 with existing bellows along with mitre elbows as per relevant drawings and site conditionsand hook up to the tie point. All existing bellows shall be reused and after full welding of duct clamps provided during dismantling shall be removed. Necessary temporary supports shall be provided. The tie point/hook up joint area shall be bevelled before welding. After erection and setting of the duct pieces and mitre elbows, full weld all the fit up joints.All welding joints shall be free from any strain and ovality. Any modifications at site shall be done as per instructions from engineer in charge. Any structural dismantled for smooth erection of the duct shall be fixed back by the contractor after erection. After erection and full welding clear the site and transport the scrap to area earmarked. Blinding of open end of ducts shall be carried out where ever necessary as per instuctions after fabricating the end dummies. After erection, all ducts shall be leakproof and leaks if any shall be repaired by contractor at his own cost & risk.

Erection of 900 mm W2 bypass duct and Mitre Elbows: Arrange necessary tools and tackles required for the work. Make required site arrangements.Transport the fabricated duct pieces and mitres to worksite.Erect 900 mm W2 bypass duct along with mitre elbows as per relevant drawings and site conditionsand hook up to the tie point. All existing bellows shall be reused and after full welding of duct clamps provided during dismantling shall be removed. Necessary temporary supports shall be provided. The tie point/hook up joint area shall be bevelled before welding. After erection and setting of the duct pieces and mitre elbows, full weld all the fit up joints.All welding joints shall be free from any strain and ovality. Any modifications at site shall be done as per instructions from engineer in charge. Any structural dismantled for smooth erection of the duct shall be fixed back by the contractor after erection.After erection and full welding clear the site and transport the scrap to area earmarked. Blinding of open end of ducts shall be carried out where ever necessary as per instuctions after fabricating the end dummies. After erection, all ducts shall be leakproof and leaks if any shall be repaired by contractor at his own cost & risk.

Fabricate and Erect Structural Support for 1800 mm & 900 NB Gas Duct: Collection of required materials from FACT -CD stores / plant area and transport to the work site. New duct shoe supports shall be fabricated for 1800NB duct & 900NB ducts as per the requirement. All joints/bellows shall be properly supported to maintain requisite elevation/slope to avoid any residual stress thereof as per the instruction of the officer - in -charge to meet site requirement. All welding joints shall be suitably bevelled and full welded. Existing supports/temporary supports if required shall be strengthned as per site instructions. Site shall be cleared after work, unused structurals shall be transorted and neatly stacked in area earmarked, scrap shall be collected in area earmarked.Supply and application of primer / finish paints over fabricated/erected structures,supports,air ducts etc. as per manufactures std / specifications, and instructions from the engineer- in- charge. The external surfaces of pre-fabricated structures /duct sections shall be cleaned by mechanical means such as mechanical wire brushes. All consumables, painting accessories, scaffolding at all heights, manpower etc are to be arranged by the contractor at his own cost. The painting shall consist of 2 coats of zinc chromate yellow primer of approved make and quality and 2 coats of synthetic enamel paint of approved make and quality, colour of the enamel paint shall be as per standards for air ducts, structurals etc. Clean the site after completing the work.

Replacemnt of 900NB W5 Bypass Valve: Arranging necessary scaffolding dismantling and transporting the valve to earmarked area as per the instruction from Engineer in charge. Temporary supports shall be provided for the ducts before dismantling the valve. Labour assistance for overhauling the valve at workshop, repair/replacement of mating flanges of valves ( if required as per instruction)shall be under contractors scope. Transport the serviced valves from workshop and fixing on line with gasket and leak testing. Also repair/provide necessary structural support for valves if reqd as per instruction of Engineer in charge. After erection and full welding clear the site and transport the scrap to area earmarked.

M A ALI

M A Shamsudeen

K G SIVANANDAN

HASSAN MM

MADONNA INDUSTRIES

AYYAPPANKUTTY M M

TRINITY ENGINEERING SERVICES