Pre Fabrication, Erection and Hooking Up of inlet,outlet,bypass and additional heating ducts of new W3 heat exchanger in SAP,FACT-CD.

Pre Fabrication, Erection and Hooking Up of inlet,outlet,bypass and additional heating ducts of new W3 heat exchanger in SAP,FACT-CD.

Prefabrication of inlet, outlet, bypass and additional heating ducts of new W3 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 SS 304 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 sizes i.e,1800 mm,1000 mm and 700 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 5 Nos 90° mitred elbows, 1800 mm Dia and 3 Nos 90° mitered elbows,1000 mm Dia . Additionally fabricate two Adapter Ring( 2224x1800x400 & 2144x1800x300) for connecting inlet and outlet of the vessel with ducts which shall be welded with both shell & ducts. All requisite bellows and valves shall be supplied. Full welding the duct pieces, complete / required lengths and join as per instruction and generally as per drawing (DRG No. 32460-03-KP-00001) to facilitate erection at site. Any other fabrication as per the drawing shall be done by the contractor as per the instructions of the site engineer. 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 structural shall be neatly stacked in area earmarked. Approx. total length of duct excluding mitres is 38.5 m for 1800mm duct 12.5 m for 1000 mm duct and 3 m for 700 mm duct.including mitres. . 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 inlet, outlet, bypass and additional heating ducts of old W3 : Arrange necessary tools and tackles required for the work. Make required site arrangements. Cut and remove existing: 1. 1800 mm inlet duct from 2nd bed outlet of convertor with bellow , at the tie point/hook up joint as per relevant drawing and site instructions to facilitate erection of new inlet duct 2. 1800 mm outlet duct to third bed inlet of convertor with bellow and outlet valve at the tie point/hook up joint as per relevant drawing and site instructions to facilitate erection of new outlet duct 3. 1000 mm bypass duct with valve 4. 700 mm additional heating duct to hot air duct header with valve, at the tie point/hook up joint as per relevant drawing and site instructions to facilitate erection of new duct. Necessary temporary supports shall be provided. Unwanted associated structural shall also be dismantled as per instructions. FACT cranes shall be made available for dismantling of ducts and structural. Dismantled duct shall be transported to the earmarked area/scrapyard as per instruction. Scope of collection, loading/unloading and transportation of dismantled ducts/structural/any scrap arising out of fabrication and erection of subject work shall be under contractor’s scope.

Erection of inlet, outlet, bypass and additional heating ducts of new W3 heat exchanger Arrange necessary tools and tackles required for the work. Make required site arrangements. Transport the fabricated duct pieces and mitres to worksite. Erect: 1. 1800 mm inlet duct with adaptor ring from 2nd bed outlet of convertor with bellow , and hook up to the tie point as per drawing- DRG No. 32460-03-KP-00001 and site instructions 2. 1800 mm outlet duct with adaptor ring to third bed inlet of convertor with bellow and outlet valve and hook up to the tie point as per drawing- DRG No. 32460-03-KP-00001 and site instructions 3. 1000 mm bypass duct with valve as per drawing DRG No. 32460-03-KP-00001 and site instructions and hook up to the tie point 4. 700 mm additional heating duct to hot air duct header with valve, at the tie point/hook up joint as per drawing- DRG No. 32460-03-KP-00001 and site instructions and hook up to the tie point. Please note that the valve and mitre bend of the existing duct shall be reused and hooked up with new fabricated SS duct between 1800mm outlet duct & hot air valve . Final hook up shall be done during ATA 2022 tentatively during April 2022. Necessary temporary supports shall be provided. The tie point/hook up joint area shall be beveled 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. 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 instructions after fabricating the end dummies. After erection, all ducts shall be leak-proof and leaks if any shall be repaired by contractor at his own cost & risk.

Fabricate and Erect Structural Support for 1800 mm Gas Ducts of W3: Collection of required materials from FACT -CD stores / plant area and transport to the work site.New duck foot shoe support (PS 102) shall be fabricated for W3 outlet and saddle supports PS 101 and PS 104 shall be fabricated for inlet and bypass ducts of W3 as per drawing - DRG no: 32460-03-KP-00001.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.

M A ALI

M A Shamsudeen

K G SIVANANDAN

HASSAN MM

MBM ENGG WORKS

DEEPAK ENGINEERING WORKS