Catalyst Replacement In Reactors And Reformers In Plant-214 During Short Shutdown, 2023 At Cpcl-Manali , Catalyst Replacementin Reactors , Plant-214 Reactors Catalystreplacement The Rate Quoted For Unit Cum Includes The Following Jobs I. Shutting Down & Start Up Assistance To Manufacturing Ii. Manway / Top Cover / Top Elbow Piece / Reactor Manway / Dump Nozzle Opening / Box Up. Iii. Passivation Of Removed Internal Parts, Top Elbow Piece Of Reactors Iv. Materials Collection And Return ( Collection & Transportation Of Necessary Catalyst, Gaskets, Stud Bolts And Other Free Issue Materials From Cpcl Warehouse And Return Back The Unused Catalyst To Warehouse ) V. Empty Drum / Fresh Catalyst Drum / Jumbo Bags Collection / Shifting / Transportation From Cpcl Warehouse To Site And Discarding The Spent Catalyst To The Place As Identified By Eic & Return Back Empty Drums To Stores. Vi. Unloading Of The Catalyst Under Inert Atmosphere And The Catalyst To Be Stored In Drums Purged With Nitrogen. Vii. Weighment Using Digital Weighing Machine And Labelling Of The Unloaded Catalyst Viii. Complete Internal Scaffolding Erection And Dismantling Including Scaffolding Material Supply Ix. Provision Of Lighting Inside / Outside Reactor At Platform Levels. X. Removal And Refixing Of All The Reactor Internals Like Feed Diffuser, Distributor, Trays, Screen, Etc. To Complete The Job In All Respects. Xi. Thorough Internal Surface Cleaning Of Reactor Including Internals Xii. Cold Repair Of The Reactor Internals Xiii. Loading Of The Catalyst Under Atmospheric Condition By Sock Loading Method. Xiv. Videography Recording For 214-R-01, 214-R-02A / B, 214-R-03 & 214-R-04 Xv. Necessary Torque Tool Tightening Kit For Box-Up Of The Reactor Xvi. Shifting Of The Used Catalyst After Weighment To The Designated Place As Identified By Eic Xvii. Manpower Assistance For Coordinating With Cpcl Inspection For Carrying Out The Ndt. Xviii. Area Cleaning & Start Up Coverage. Xix. Necessary Cranes, Compressor, Forklift And Tractor Trailer Along With Valid Operator For The Carrying Catalyst Replacement. Necessary Diesel Is In Contractor Scope. , Unloading Of The Catalyst Under Inert Atmosphere And Loading Of The Catalyst Under Atmosphericcondition In The214-R-01 Hydro Treating Catalyst , Unloading Of The Catalyst Under Inert Atmosphere And Loading Of The Catalyst Under Atmosphericcondition In The Chloride Guard214-R-02 ( A / B ) , Unloading Of The Catalyst Under Inert Atmosphere And Loading Of The Catalyst Under Atmosphericcondition In The Zno Guard214-R-02 ( A / B ) , Unloading Of The Catalyst Under Inert Atmosphere And Loading Of The Catalyst Under Atmosphericcondition In The Pre-Reformer214-R-03 , Unloading Of The Catalyst Under Inert Atmosphere And Loading Of The Catalyst Under Atmosphericcondition In The Reformer Mt Shiftreactor 214-R-04 , The Rate Quoted For Unit Tube Includes The Following Jobs I. Shutting Down & Start Up Assistance To Manufacturing. Ii. Locking And Unlocking Of The Spring Supports For Catalyst Replacement. Iii. Opening Of The Top Flange Of The Reformer Tube. Iv. Unloading Of The Catalyst Using The Vacuum Extraction. V. Weighment Using Digital Weighing Machine And Labelling Of The Unloaded Catalyst., The Catalyst To Be Stored In Drums Purged With Nitrogen. Vi. Shifting Of The Used Catalyst After Weighment To The Designated Place Vii. Materials Collection And Return ( Collection & Transportation Of Necessary Catalyst, Gaskets, Stud Bolts And Other Free Issue Materials From Cpcl Warehouse And Return Back The Unused Catalyst To Warehouse ) Viii. Empty Drum / Fresh Catalyst Drum / Jumbo Bags Collection / Shifting / Transportation From Cpcl Warehouse To Site And Discarding The Spent Catalyst To The Place As Identified By Eic & Return Back Empty Drums To Stores. Ix. Thorough Cleaning Of The Reformer Tube With Chemical Solution. X. Dp Measurement Of The Tube ( Before Catalyst Loading ) Xi. Weighment Using Digital Weighing Machineof The New Catalyst To Be Loaded. Xii. Unidense Loading Of Reformer Catalyst Under Normal Atmosphere As Per Attached Procedure ( Total No. Of Tubes-78 Nos, Total Volume Of Catalyst 9.4 Cum ) Xiii. Dp Measurement Of The Tube ( After Catalyst Loading ) Xiv. Boxing Up Top Flange Of The Reformer Tube. Xv. Videography Recording Xvi. Area Cleaning & Start Up Coverage. Xvii. Necessary Torque Tool Tightening Kit For Box-Up Of The Reactor. Xviii. Manpower Assistance For Coordinating With Cpcl Inspection For Carrying Out The Ndt Xix. Necessary Cranes, Air Compressor, Forklift And Tractor Trailer Along With Valid Operator For The Carrying Catalyst Replacement. Necessary Diesel Is In Contractor Scope , Unloading, Cleaning And Loading Of The Catalyst In Reformer Tube ( Unit Of Measurement Ea =Per Tube ) , Mobilisation And Demobilisation Charges For Equipments, Heavy Equipments Like Crane, Forklift , Air Compressor& Tractor Trailer Andtools & Tackles For Plant -214 Reactors& Reformer Catalyst Replacement , Part- B Soq , Blinding And De-Blinding , , , , , , The Job Includes Collection & Transportation Of Required Quantity Of Materials Like Blinds, Gaskets, Fasteners, Etc., From Owners Storage Point, Loosening & Tightening Of Studs ( Cold / Gas Cutting If Required ) , Wedge Opening, Cleaning Of Flanges, Insertions Andremoval Of Blind & Gaskets, Providing New Gaskets After Removal Of Blinds, Overhauling Of Fasteners Using Oil, Replacing The Defective Studs / Nuts To Ensure Zero Leak Of Joints Including Hot Bolting., , , , , , The Job Also Includes Supplying Of All Types Of Tools & Tackles, Lifting Arrangements Like Chain Pulley Blocks, Machineries, All Consumables And Labour To Complete The Job In All Respects, Transportation Of Unused Materials To Owners Storage Point And Dumping The Generated Scrap Material To Designated Area As Per Eic Instructions. , , , , , , , Blinding And Deblinding For 150# & 300# Ratings: , Blinding & Deblinding - Size Upto1-1 / 2 Inch Dia. , Blinding & Deblinding - Size 2 Inch Dia. To 5 Inch Dia. , Blinding & Deblinding - Size 6 Inch Dia. To 10 Inch Dia. , Blinding & Deblinding - Size 12 Inch Dia. To 16 Inch Dia. , Blinding & Deblinding - Size 18Inch Dia. To 24Inch Dia. , Blinding And Deblinding For 600# & 900# Ratings: , Blinding & Deblinding - Size Upto1-1 / 2 Inch Dia. , Blinding & Deblinding - Size 2 Inch Dia. To 5 Inch Dia. , Blinding & Deblinding - Size 6 Inch Dia. To 10 Inch Dia. , Blinding & Deblinding - Size 12 Inch Dia. To 16 Inch Dia. , Blinding And Deblinding For 1500# & 2500# Rating Without Torque Wrench , Blinding & Deblinding - Size Upto1-1 / 2 Inch Dia. , Blinding & Deblinding - Size 2 Inch Dia. To 5 Inch Dia. , Blinding & Deblinding - Size 6 Inch Dia. To 10 Inch Dia. , Blinding & Deblinding - Size 12 Inch Dia. To 16 Inch Dia. , Supply, Erection & Dismantling Of Steel Scaffolding- For External Purpose - Insulation Removal, Thickness Gauging, Ndtjobs The Job Includes Transportaiton Of Scaffolding Materials In Contractors Scope Of Supply , Erection Of Scaffolding At Site Covering The Areas Specified Including Providing Vertical Posts Of Pipes At Inter Distance Of 1.5M And Horizontal Numbers At A Inter Distance Of 0.5 To 0.75 Meter, Providing Rods At Corners To Give Sufficient Strength To The Structure, Placing The Wooden / Steel Planks / Frp Gratings On Top For Making Sufficient Area. Dismantling Scaffolding After Completion Of Job And Returning The Scaffolding Material To Specified Place Including All Tools, Tackles, Consumables, Labours And Contractors Supervision As Directed By The Engineer-In-Charge Note : I ) For Measurement In Sqm : 2 ( Length + Width ) X Height Area Covered By The Scaffolding Is To Be Taken Ii ) Scaffolding Measurement To Be Done By Breaking The Height Into Parts As Per Height Slab Mentioned Below And Adopting Respective Rates Against Mentioned Height Slabs. , Supply, Scaffolding Erection & Dismantling ( External ) , Up To 6M Height , Above 6 M Up To 10 M Height , Above 10 M Up To 20 M Height , Above 20 M Up To 30 M Height , Intermediate Platform , Buffing Of Weld Joints Job Involves Buffing And Cleaning Of Total Weld Area Of The Reactor / Vessel / Column Etc, Using Power Brush, Thejob Has To Be Completed In All Respect To The Entire Satisfaction Of The Engineer-In-Charge ( Each Length Of Buffing Will Be Up To Width Of 150 Mm ) Necessaty Buffing Tools / Machineries And Consumables Are In Contractors Scope , Power Tool Cleaning / Buffing To Sspc - Sp-2 / St3 Standards - 150 Mm Width Of Weld Seams / Haz , Note: ( 1 ) For Weld Seam Buffing The Width Of Buffing Shall Be 150Mm ( I.E ) 75Mm On Both Sides Of The Weld Seam. , Dye Penetration Test For Weld Jointscarryout Dp Test Of The Critical Weld Joints, New / Old Rtjgakets / Rtj Gasket Seating Surface Areas As Per Cpcl Inspection Adviceperformance Of Dye Penetration Test Including Supply Of All Necessary Materials, Penetrant, Developer Etc, Along With All Equipments, Labour For Carrying Out The Work As Per Specification And Direction Of Engineer-In-Charge At All Elevations. Test Has To Be Carried Out In All Metallurgy The Test Has To Carry Out On All Schedule , Dp Test Of Weld Joints ( Unit Of Measurement Ea = Inch Length ) , Note: ( 1 ) For Weld Seamthe Width Of Dpt Shall Be 150Mm ( I.E ) 75Mm On Both Sides Of The Weld Seam. ( 2 ) For The Gasket Seating Surface, Width Of The Dpt Shall Be 150 Mm.
