Tender For O/H <(>&<)> Rep. Of W.H.Boilers In Acid Plant -OVERHAULING OF WASTE HEAT BOILER # 1(WB-201) AND WASTE HEAT BOILER # 2 (WB-202), STEAM DRUM (SD-201) AND ITS MOUNTINGS AND ACCESSORIES. GENERAL TECHNICAL SPECIFICATIONS: FLOWRATE / STEAM GENERATED: 8,700 KG/H, OPERATING PRESSURE: 13 KG/CM2 G, DESIGN PRESSURE: 15 KG/CM2 G, TEST PRESSURE: 22.5 KG/CM2 G, HEATING SURFACE AREA: WHE#1: 108 SQ.M, WHE#2: 43SQ.M. SCOPE OF WORK: A) WASTE HEAT BOILER # 1: CUT MANHOLE COVERS OF INLET AND OUTLET VESTIBULES SIZES 1000MM AND 500MM RESPECTIVELY. DISMANTLE AND OPEN BOILER MANHOLE COVER SIZE NB 450MM. DISMANTLE AND TAKE OUT INSPECTION HOLE COVERS. CLEAN 285 NOS. OF BOILER TUBES SIZE OD 44.5MM X 4.0MM WT X 3488MM LENGTH FROM INSIDE BY ROUND BRUSH. CLEAN OUTSIDE SURFACE OF TUBES FROM SHELL END THROUGH MANHOLE AND INSPECTION HOLES. OFFER CLEAN TUBES TO SITE IN-CHARGES AND IBR AUTHORITY. DISMANTLE AND TAKE OUT TWO SETS OF DRAIN ISOLATION VALVES NB 40 AND BLOW DOWN VALVES NB 40, OVERHAUL THEM, TEST THEIR WORKABILITY, OFFER FOR INSPECTION TO THE SITE IN-CHARGE AND THE IBR AUTHORITY AND THEN FIT BACK. DISMANTLE AND TAKE OUT STEAM PURGING AND GAS CONDENSATE DRAIN VALVES NB 50, OVERHAUL THEM, TEST THEIR WORKABILITY AND FIT BACK. FIT MANHOLE AND INSPECTION HOLE COVERS. CLEAN VESTIBULE OF INLET & OUTLET OF THE BOILER, REPAIR / REPLACE DRAIN NOZZLES. OVERHAUL DRAIN VALVES AND TEST THEIR WORKABILITY. WELD WELDING LUGS AS PER INSTRUCTION OF SITE IN-CHARGE TO FACILITATE FIXING OF FERRULES. WELD BACK VESTIBULE MANHOLE COVERS AFTER GETTING CLEARANCE FROM THE SITE IN-CHARGE. B) WASTE HEAT BOILER # 2: CUT MANHOLE COVERS OF INLET AND OUTLET VESTIBULES SIZES 1000MM AND 500MM RESPECTIVELY. DISMANTLE AND OPEN BOILER MANHOLE COVER SIZE NB 450MM. DISMANTLE AND TAKE OUT COVERS OF INSPECTION HOLES. CLEAN 285 NOS. OF BOILER TUBES SIZE OD 44.5MM X 4.0MM WT X 1388MM LENGTH FROM INSIDE WITH HELP OF BRUSH. CLEAN OUTSIDE OF TUBES FROM SHELL END THROUGH MANHOLE AND INSPECTION HOLES. OFFER CLEAN TUBES TO SITE IN-CHARGES AND IBR AUTHORITY. DISMANTLE AND TAKE OUT TWO SETS OF DRAIN ISOLATION VALVES NB 40 AND BLOW DOWN VALVES NB 40, OVERHAUL THEM, TEST THEIR WORKABILITY, OFFER FOR INSPECTION TO THE SITE IN-CHARGE AND THE IBR AUTHORITY AND THEN FIT BACK. FIT MANHOLE AND INSPECTION HOLE COVERS. CLEAN INLET AND OUTLET VESTIBULES, REPAIR DRAIN NOZZLES, OVERHAUL DRAIN VALVES AND FIT BACK. WELD BACK VESTIBULE MANHOLE COVERS AFTER GETTING CLEARANCE FROM THE SITE IN-CHARGE. C) STEAM DRUM: DISMANTLE AND OPEN END COVERS. CLEAN DRUM FROM INSIDE. DISMANTLE AND TAKE OUT I) SIGHT GLASS ASSEMBLY # 2 SET, II) COLUM GAUGE # 2SET, III) GLOBE VALVES NB 15 TO 150 # 24 NOS., IV) SAFETY VALVE SIZE 50 X 80 # 2 NOS. AND V) BLOW DOWN VALVE NB 25 -1 NO. OVERHAUL THE ABOVE ITEMS, TEST THEIR WORKABILITY, AND OFFER FOR INSPECTION TO THE SITE IN-CHARGE AND IBR AUTHORITY. FIT THEM BACK IN POSITION. FIT NEW ITEMS IN PLACE OF DEFECTIVE ONES. FIT BACK END COVERS. HYDRAULIC TESTING: FILL WATER IN BOILER # 1, BOILER # 2 AND STEAM DRUM. CONNECT TESTING PUMP AND RAISE WATER PRESSURE UP TO 22.5 KG/CM2 G. CHECK LEAKAGES, IF ANY AND RECTIFY. SHOW THE HYDRAULIC TEST TO THE IBR AUTHORITY. DRAIN THE SYSTEM COMPLETELY. SET BLOW PRESSURE OF SAFETY VALVE #1AT 14 KG/CM2 G AND SAFETY VALVE # 2 AT 15 KG/SQ.CM G. TEST THEM AGAIN DURING BOILER OPERATION. RESTORE SITE AND RENDER NECESSARY HELPS DURING COMMISSIONING OF THE BOILER, OVERHAULING OF ECONOMISER-1 (EC-201) AND ITS MOUNTINGS AND ACCESSORIES. THE ECONOMIZER IS DIVIDED INTO TWO ZONE A) ECONOMIZER TOP BANK AND B) ECONOMIZER BOTTOM BANK. GENERAL TECHNICAL SPECIFICATIONS ON WATER (TUBE) SIDE:- FLUID FLOW RATE A/B : 8900 / 8900 KG/H, SURFACE AREA A/B: 88 / 103 SQ.M, OPERATING PRESSURE A/B: 14 / 14.5 KG/CM2 G, DESIGN PRESSURE A/B: 16 / 16 KG/CM2 G, TEST PRESSURE A/B: 24 / 24 KG/CM2 G, SCOPE OF WORK: DISMANTLE AND OPEN TOP AND BOTTOM MANHOLE COVERS. PREPARE SAFE SCAFFOLDING PLATFORMS FOR WORKING AT TOP BANK. REMOVE SULPHUR DEOSITS AND OTHER FOREIGN MATERIALS FRM GILLS, RINGS, CASINGS FITTED ON TUBES, BENDS. REMOVE DEOSTS FROM GAS CHAMBER. REPAIR / REPLACE DRAIN NOZZLES. OFFER FOR INSPECTION TO SITE IN-CHARGE AND IBR AUTHORITY. DISMANTLE AND TAKE OUT GATE VALVES, GLOBE VALVES, BALL VALVES, SAFETY VALVE AND NON RETURN VALVES, QUANTITY 16 NOS SIZES NB 25 TO 80. OVERHAUL AND TEST THEIR WORKABILITY. OFFER FOR INSPECTION TO THE SITE IN-CHARGE AND IBR AUTHORITY. REPLACE DEFECTIVE ITEMS. FIT ALL THE ITEMS IN POSITION. TEST TOP AND BOTTOM BANK HYDRAULICALLY UP TO PRESSURE 24 KG/CM2 G. RECTIFY THE DEFECTS. OFFER FOR INSPECTION TO THE SITE INCHARGE AND IBR AUTHORITY FOR WET TEST. SET THE SAFETY VALVE BLOW OFF PRESSURE AT 15 KG/CM2.G. RE SET THE SAME DURING THE SYSTEM IS IN OPERATION. CHECK THE ECONOMIZER SHELL SIDE BODY. REPAIR THE BODY, IF IT IS CORRODED OR HAVING LEAKAGES(APPROX. AREA OF REPAIRING: 5 SQ.MTR).BOX UP MANHOLE COVER. RESTORE SITE, etc.
