Miscellaneous Instrumentation Works in Ammonia Plant

Cleaning and checking of sensor pH : Work includes removal of sensor from line, cleaning of sensor as per standard procedure, checking of pH sensor as per procedure using standard buffer solutions after connecting with transmitter. All materials for the job will be provided by FACT free of cost.

Dismantling (removing stud bolts of the process flanges, bonnet flange, actuator bolts and other fasteners as required) disassembling, surface clearing, cleaning, preparation, replacing the soft parts and metal parts as instructed by the service personnel of OEM, overhauling, servicing & fixing back of Low Pressure Control Valves of Size - 12" to 14"- Ratings 150/300/600#.Weight- 970-1710kg including control valve body, bonnet & actuator. The work shall also include to and fro transportation of the control valves to Instrumentation calibration room/ repair bay if required. The control valves shall be fixed back in position leak proof as per standard practices / procedures. The work shall be strictly following instructions of OEM’s service technician and FACT’s engineer in charge. All spares, soft parts, fasteners, gaskets shall be supplied by FACT as free issue.

Dismantling (removing stud bolts of the process flanges, bonnet flange, actuator bolts and other fasteners as required) disassembling, surface clearing, cleaning, preparation, replacing the soft parts and metal parts as instructed by the service personnel of OEM, overhauling, servicing & fixing back of Low Pressure Control Valves of Size - 4" to 6"- Ratings 150/300/600, Weight-250-450kg including control valve body, bonnet & actuator. The work shall also include to and fro transportation of the control valves to Instrumentation calibration room/ repair bay if required. The control valves shall be fixed back in position leak proof as per standard practices / procedures. The work shall be strictly following instructions of OEM’s service technician and FACT’s engineer in charge. All spares, soft parts, fasteners, gaskets shall be supplied by FACT as free issue.

Dismantling (removing stud bolts of the process flanges, bonnet flange, actuator bolts and other fasteners as required) disassembling, surface clearing, cleaning, preparation, replacing the soft parts and metal parts as instructed by the service personnel of OEM, overhauling, servicing & fixing back of Low Pressure Control Valves of Size - 2" to 4"- Ratings 150/300/600#.Weight-50 -150kg including control valve body, bonnet & actuator. The work shall also include to and fro transportation of the control valves to Instrumentation calibration room/ repair bay if required. The control valves shall be fixed back in position leak proof as per standard practices / procedures. The work shall be strictly following instructions of OEM’s service technician and FACT’s engineer in charge. All spares, soft parts, fasteners, gaskets shall be supplied by FACT as free issue.

Dismantling (removing stud bolts of the process flanges, bonnet flange, actuator bolts and other fasteners as required) disassembling, surface clearing, cleaning, preparation, replacing the soft parts and metal parts as instructed by the service personnel of OEM, overhauling, servicing & fixing back of High Pressure Control Valves of Size - 1" to 2"- Ratings 900/1500/2500#, Weight-100-150kg including control valve body, bonnet & actuator. The work shall also include to and fro transportation of the control valve.

Fabrication and mounting of Instrument stanchions. Work includes fabrication of instrument stanchion (size 50 NB, SCH80 MS pipe,length 130cm) with base plate of size 225mm X225mm X 6mm.and fixing the stanchion on the floor at site using anchor bolts. Note: All the materials will be issued by FACT except welding and cutting machine.

Fabrication and laying of transmitter impulse lines. Work includes Fabrication of transmitter impulse lines using SS pipe (Size 15NB SCH40/80) and fittings. Laying of these impulse lines from instrument 1st isolation valve to flow/pressure transmitter and connecting both ends using proper SS pipe fittings .All the welded joints of Impulse lines to be pressure tested to ensure leak proof.The fabricated impulse lines to be fixed by using proper clamps, nuts and bolts.All the materials will be supplied by FACT with free of cost.

Installation of DP /Pressure transmitters on instrument stanchions/ supports. Work includes Installation of DP /Pressure Transmitters on stanchions/supports with proper "U" clamps,nuts& bolts. Fixing 2 valve/3 valve manifolds on transmitter body with proper gaskets and bolts&nuts. Note: All the materials will be issued by FACT at free of cost.

Fabrication and laying of transmitter impulse lines. Work includes Fabrication of transmitter impulse lines using SS tubes (Size 12mm ODX1.5mm thick) and fittings. Laying of these impulse lines from instrument 1st isolation valve to flow/pressure transmitter and connecting both ends using proper tube fittings . If required, impulse lines to be fixed by using proper clamps, nuts and bolts. Note: All the materials will be issued by FACT at free of cost.

Laying of 6 mm/8mm SS pneumatic tubing from air headers to the air filter regulators or I/P Converters of control valves located at the plant site. Work includes laying of SS pneumatic tubing of sizes 6mm/8mm OD with standard SS fittings from air headder to control valve accesseries. One end shall be connected at air header tapping and the other end shall be connected at the air filter regulator/ I/P end. Sharp bends shalll be avoided and proper support shall be given using clamps for the pneumatic tubing. All the materials will be issued by FACT.

Installation of Junction Boxes of size 350x420x150mm (approx) on newly fabricated MS Supports with GRP type CANOPY. The work shall include the fabrication of MS supports with necessary holes drilled for mounting the JBs & CANOPY and fixing it to the available structures by welding/using fastners (SS 304 bolt, nut and washers)/ anchor bolts). The Junction box & Canopy shall be mounted to the newly fabricated MS supports by using SS304 nut, bolt and washers of size M6 X 40. All the materials except SS304 Bolts, nuts & washers will be issued by FACT, free of cost (Required SS Bolts, nuts & washer to be supplied by the contractor). The canopy size (WxDxH) is approximately 550x450x325mm.

Removal & Refixing of Leveltrol head assembly (size 40NB, 600#): Work includes removal of cable with gland, head assembly and displacer from Chamber. Cleaning of the removed parts as per instruction of Engineer-in-Charge. Refixing of removed items viz cable with gland, head assembly and displacer with proper gaskets as per procedure. All materials for the job will be provided by FACT free of cost.

Calibration of Transmitter Leveltrol (size 40NB, 600#): Work includes isolating by closing the isolation valve, removal of top plug, cleaning of displacer chamber with water, Fixing of transparent tube to drain, perfoming wet calibration as per standard procedure (5 point, upscale & downscale) using water. After completion of calibration, fixing back of process connection to transmitter and hookingup of transmitter to the process. Record the results before & after calibration and submit to Engineer-in-Charge. All materials for the job will be provided by FACT free of cost.

Calibration of Level Switch: Work includes isolating by closing the isolation valve, removal of top cover, cleaning of float chamber with water, Fixing of transparent tube to drain, perfoming level switch calibration as per standard procedure using water and hooking up of transmitter to the process. All materials for the job will be provided by FACT free of cost.

Remove & Refixing of terminal blocks in field junction boxes. Work includes disconnecting the wires from terminal blocks, replacing the corroded terminal blocks of maximum 36 Nos and 35 mm DIN rails, fixing of new terminal blocks & DIN rail and terminating the existing cables with proper crimping lugs & ferrules. Terminal blocks shall be provided with cable identification markers. After termination, wires shall be dressed using cable ties and tying buttons. All the material required for the work will be supplied by FACT as free issue.

Glanding of the signal and power cables of size 12/20 pair / 12 Triad: The work includes glanding of the signal and power cables of size 12/20 pair / 12 Triad on junction boxes / field instruments using double compression / single compression glands of proper size. 1.25 inch and 1.5 inch. Standard stripping tools shall be used for peeling of cables so as to ensure quality in work. All the material required for the work will be supplied by FACT as free issue.

Glanding of the signal and power cables of size 1 pair / 1 Triad: Work includes glanding of the signal and power cables of size 1 pair / 1 Triad on junction boxes/field instruments using double compression / single compression glands of proper size. Standard stripping tools shall be used for peeling off cables so as to ensure quality in work. All the material required for the work will be supplied by FACT as free issue.

Removal of armoured cables of size 1 pair/ 1 triad: Work includes removal of unused armoured cables of size 1 pair / 1 triad from different plant areas and transportation of the same to scrap yard or a place identified by the Engineer in charge.

Removal of armoured cables of size 12 / 20 pair, 12 triad: Work includes removal of unused armoured cables of size 12 / 20 pair, 12 triad from different plant areas and transportation of the same to scrap yard or a place identified by the Engineer in charge.

Dressing of Multicore & Branchcore cables: Work includes dressing of existing cables of sizes 20, 12 & 1pair/ 12 & 1 triad in a group of 10 -15 number of cables on unit length of tray on new/existing cable trays of various sizes. The work include arranging and dressing of the cables in ladder type/slotted MS/ aluminium cable racks/trays by using SS wire (1 sq mm dia. min) / aluminium flat strips (20x5mm) at intervals of minimum 50 cm on horizontal runs and 30 cm on vertical runs. The aluminium clamps shall be provided on the trays using M6 X40 SS Fasteners. All materials required for the work will be supplied by FACT as free issue.

Fixing of FRP/ GRP canopies for Field JBs: Work involves fixing of FRP/ GRP canopies of size 550X 450X 325mm (W X D X H) approx for existing junction boxes. The canopies shall be fixed using mounting brackets/ U clamps, nuts and washers (SS 304 material) on 2" pipe/ pedestal/angles. All materials required for the work will be supplied by FACT as free issue.

Fixing of FRP/ GRP canopies for Field Instruments: Work includes fixing of FRP/ GRP canopies of size 360 X 445 X 370mm (W X D X H) approx for existing field instruments. The canopies shall be fixed using mounting brackets/ U clamps, nuts and washers (SS 304 material) on 2" pipe/ pedestal/angles. All materials required for the work will be supplied by FACT as free issue.

Laying of 6 mm/8mm SS pneumatic tube: Work includes laying of 6 mm/8mm SS pneumatic tubing between air headers, air filter regulators, I/P Converters etc of control valves located at the plant site. The tubing will involve providing standard SS fittings from air header to control valve accessories as required. Ends shall be connected at air header tappings, air filter regulator or I/P Converter. Sharp bends shall be avoided and proper support shall be given using clamps for the pneumatic tubing. All materials required for the work will be supplied by FACT as free issue.

Laying of 12mm SS pneumatic tube: Work includes Laying of 12mm SS pneumatic tubing between air headers, air filter regulators, I/P converters etc of of control valves located at the plant site. The tubing will involve providing standard SS fittings from air header to control valve accessories as required. Ends shall be connected at air header tappings, air filter regulator or I/P Converter. Sharp bends shall be avoided and proper support shall be given using clamps for the pneumatic tubing. All materials required for the work will be supplied by FACT as free issue.

Removal & Refixing of Control Valves (Size 50NB, 300#): Work includes dismantling of control valves (End connection flange size up to 50 NB, rating up to 300#, having weight range 50 to 75 Kg, total end connection flange bolts 16 nos) from plant site, transporting them to FACT-UD workshop and/or loading to truck, bringing back to site and/or unloading from truck, leak proof fixing back in position at site with proper gaskets, bolts & nuts. All materials required for the work will be supplied by FACT as free issue.

Removal, Servicing and refixing of Level Gauge(size 50NB, 150#): Work includes the removal of Level glass (two flanges and four bolts/flange) of size 50NB, 150# from line, dismantling, cleaning, assembling with new glass/float and refixing. All materials required for the work will be supplied by FACT as free issue.

Removal, Servicing and refixing of Level Gauge(size 50NB, 300# ): Work includes the removal of Level glass (two flanges and four bolts/flange) of size 50NB, 300# from line, dismantling, cleaning, assembling with new glass/float and refixing. All materials required for the work will be supplied by FACT as free issue.

Removal, Servicing and refixing of Level Gauge(size 50NB, 600#). Work includes the removal of Level glass (two flanges and four bolts/flange) of size 50NB, 600# from line, dismantling, cleaning, assembling with new glass/float and refixing. All materials required for the work will be supplied by FACT as free issue.

Fabrication and Fixing of Instrument stanchions: Work includes fabrication of instrument stanchion ( size 50 NB, SCH80 MS pipe, length 130cm) with base plate of size 225mm X225mm X 6mm and fixing the stanchion on the floor at site using anchor bolts. All materials required for the work will be supplied by FACT as free issue.

Supply of unskilled workers for attending instrumentation miscellaneous works such as cleaning of local panels, control valves etc and instrument installations in general, transportation of materials ets. on 8 hour shift basis, as directed by Engineer in Charge.

Supply of unskilled workers for attending instrumentation miscellaneous works such as cleaning of local panels, control valves etc and instrument installations in general, transportation of materials ets. on 4 hour shift basis, as directed by Engineer in Charge.

Supply of skilled Instrument craftsmen for attending instrumentation revamping works, tagging works, cable glanding, calibration assistance, aux. control room related up keeping, instr. repair assistance etc on 8 hour Shift basis, as directed by Engineer-in- charge. They shall have a) ITI/ITC Instrumentation NCVT certificate with experience in similar jobs and Apprenticeship in FACT/ Refinery/ Fertiliser/ Petrochemical plants. or b) ITI/ Diploma holders with Six months experience in FACT/ Ammonia Plant/ Refineries/ Fertiliser/ Petrochemical plants in instrument maintenance activities in a running plant.

Supply of skilled Instrument craftsmen for attending instrumentation revamping works, tagging works, cable glanding, calibration assistance, aux. control room related up keeping, instr. repair assistance etc on 4 hour Shift basis, as directed by Engineer-in-charge. They shall have a) ITI/ITC Instrumentation NCVT certificate with experience in similar jobs and Apprenticeship in FACT/ Refinery/ Fertiliser/ Petrochemical plants. or b) ITI/ Diploma holders with Six months experience in FACT/ Ammonia Plant/ Refineries/ Fertiliser/ Petrochemical plants in instrument maintenance activities in a running plant.

Supply of skilled PLC Programmer for the checking and programming of the standard PLCs on 8 hour Shift basis.

Control Panel Fabrication and erection: The job involves fabrication , supply and erection of control panel with material (SS304)16 gauge in thickness .

Supply of skilled labour for the checking and maintenance of the surviellance cameras on hourly basis.

Fabrication and supply of control valve diaphragm: The work includes the fabrication of an actuator diaphragm of diameter ranges from 4 inch to 12 inch with material nylon reinforced nitrile rubber for various applications .

Laying of OFC Cables: Work includes laying of OFC cable for surviellance camera and Online CEEMS analysers from control room to the field. Sharp bends shall be avoided and proper support shall be given. The work include arranging and dressing of the cables by using cable tie. All materials required for the work will be supplied by FACT as free issue.

Activity includes fabrication and supply of Flanged Spool pipes of length 310 mm, 2" pipe of Schedule 40, material SS316L. Two SS316L flanges shall be welded as per the drawing attached. One ½" nipple with ½" NPTF thread at one end is to be welded for liquid draining. All material used for the fabrication shall be SS316L. All materials required for the work shall be the scope of contractor.