Dorl-fgsg-099_rev-0

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THERMAX LIMITED BOILER & HEATER GROUP

Document No.: DORL-FGSG-099 DORC Document No : A545-7950-5043-VD-LW1001AND LW1002- 110012

DOCUMENT TITLE : LIST OF ITEMS AND ACTIVITY TO BE DONE AT SITE BY MECHANICAL CONTRATOR

EIL JOB NO. : A545 PACKAGE/UNIT NO.: 115-LW-1001 & 1002 PR CODE : A545-111-LW-PR-7940 THERMAX OC NO. : QL1221/1222 SUPPLY: FLUE GAS STEAM GENERATOR PACKAGE

OWNER :- DANGOTE OIL REFINING COMPANY  

Project Name:

0

14.06.2019

For Information

VP

VP

VP

Rev.

Date

Purpose

Prepared By

Checked By

Approved By

27-JUN-2019 VIJAY KUMAR (C572)

List of Items and Activity to be done by Mechanical Contractor Date : 14.06.2019 Boiler parameters : 2 X 377 TPH FLUE GAS STEAM GENERATOR Doc no: - DORL-FGSG-099 REV 0 Notes & Basis of the Below BOM : 1. The Submitted SOR is for understanding the Execution Philosophy 2. The quantity mentioned in the SOR are only indicative. The quantity may change during detail engineering stage. 3. Thermax shall not be liable for any back charge due to change in quantum of work with respect to details given above. 4. This SOR covers the activity list that are to be executed at site pertaining to Thermax scope of supply. Quality, Safety, Statutory & erection tools & tackles are not covered in this List. 5. Seal welding of 10% of total welding in the project to be considered at site. 6. Piping of 50NB & below will be supplied loose and shall be routed to suit site. 7. For 50MT & above consignments, actual weight may vary by +/- 10% for Logistics & Erection purpose. 8. Site modification manhours (5 % of total project manhours) to be considered by erection contractor. 9. SOR Quantities with 90- 95% accuracy shall be provided after engineering completion during post order execution.All Final drawings will be submitted to EIL and DORC after 100% Engg completion 10. For the rotating equipments like, RC Pump, Fans , Turbines, Motors, Soot Blowers etc have to be stored indoor and hand rotation test/oiling/greasing &proper protection to be done at interval of every 3 months. 11. For the shelf life items such as Refractory, paints, chemicals, lubricants, etc , the validity of our quated price and delivery is limited to one year from the date of receipt of bulk material at our place. However, if the site requirement (for site patch up/touch up work) defers beyound one year, the price and delivery schedules will be mutually discussed. Site requirements for procurement of these items need 6 month notice period looking at manufacturing and Hazardous cargo formalities. BILL OF QUANTITIES FOR 1 NO. OF FLUE GAS STEAM GENERATOR Sr. No.

1

Item Description

Base frame Main Stools

2

FGC Block - Module 1 (Pressure Parts)

Condition of supply

Duly pre fabricated stools

Fully modularised FGC block (duly painted & insulated, Hydro Tested and leak tested) comprising of base frame, Super Heater 2A, 2B, 1A, 1B HP Evap 1, 2, 3, MP Evap 1, Eco 1 & 2, floor & roof panels, LHS & RHS panels for SH & ECO areas, screen tubes and panels, backstays, hopper below SH and Eco, Knife Edge Gate Valves (Motorised Actuator), Non Integral Water, Steam, Drain & Vent Piping. (Part - connected to Module 1)

Qty Unit

14

Weight In MT

Nos

Stool Height - 1.5 m

3

FGC Block - Module 2 (Pressure Parts & Structure)

Work to be done at site. (Approximate)

1. Erection of base frame Main Stools - 14 nos, its alignment and welded with insert plate / foundation.

1. Once the main stools are fixed, the boiler block Module needs to be be installed on these stools (Welding requirement for base frame - Approx. 80 running meter @ 16mm thk fillet per boiler). 2. Module- I levelling and alignment 3. Temporary structural support painted with yellow colour to be cut and removed

1 Lot

1450

*]Along with this module 1 part loose items will also be supplied viz down comer pipes & blow down valves.

This comprises of Main Boiler Structure duly painted -Front side, Pipe Rack (Terminal Point Structure) ; Soot Blower -LRSB, Steam Drum - HP, Steam Drum - MP, Down comers, Non Integral Water, Steam, Drain & Vent Piping; Pipes supports ; Integral Process / Motorised Valves ; Piping Spring Hangers along with insulation of piping, Seal Air Ducting, Power Distribution Box (for Soot Blowers), Electrical Items, Soot Blower PLC Panel, Instrument Cable Tray, Cables, JBs & Accessories, Transmitters, Analysers, Gauges, Control/On-Off Valves, Temp Elements,

Size in Mtr Length X Width X Height

4. Piping fitment & welding for 28 mtr length x 9 mtr a. Pre-fabricated Feed water piping width x 15 mtr height b. Drain & vent piping c. Steam piping (from Steam Drum and import steam inlet to PSH) 5. Installation of valves in Drain & vent (below 2" socket welded) line; installment of instruments on module-I 6. Insulation for connection points to other modules to be done at site (Interface ducting and piping insulation). Note : 1. Project specificInstallation/Erection procedure is to be referred

1 Lot

900

1. Erection & alignment of Module-II on civil pedestals. 2. Alignment of Module- II with respect to Module-I 3. Module-II foundation bolt tightening. 4. Removal of temporary transportation beam which is painted with yellow paint 5. Erection of loose staircases from ground with foundation bolts to connections of Module -II assembled staircase, loose cantilever structural items and piping between module I and module II 6. Erection of Support structure and Spring hangers for risers. 7. Fit up and welding of pre-fabricated Risers & Down comers : Approximate welding quantum: a. 6" dia x 122 joints = 732 inch dia b. 4" dia x 168 joints = 672 inch dia c. 3" dia x 16 joints = 48 inch dia d. 8" dia x 6 joints = 48 inch dia e.10" dia x 2 joints = 20 inch dia 44 mtr length x 11 f. 16" dia x 2 joints = 32 inch dia mtr width x 23 mtr g.18" dia x 2 joints = 36 inch dia height 8. Piping Assembly between Grid A to C and 1 to 8 , below EL+1500 (piping between PSH to SSH and SSH to BL). Welding quantum will be given later after detailing of piping.

*]Along with this module 2 part loose items will also be supplied viz a.Downcomer spool Piece b. Pre-fabricated Piping c. Staircase (2 nos) from Ground to 1st Elevation d. Other loose items shall be informed later after completion of detail engineering.

9. Alignment and erection of all soot blowers on Module II with Knife Edge Gate valves on Module-I 10. Seal Air piping connections at both ends. One end to Soot Blowers with hose pipes and other end to be welded with Seal air Header 11. Erection of silencer support structure, silencers (10 nos) and connecting piping. 12. Insulation for riser & downcomers and connection points (Interface ducting and piping insulation)

1. Erection of package skid on Foundation with foundation bolts 2. Erection, welding, bolting of outlet duct, dampers & expansion bellows 4

Seal Air Fan with Motor

Duly assembled fan and motor

1 No.

-

3. Erection and welding of outlet duct support structure 4. Erection of instruments, JBs, cable trays & caballing within Skid and connection to Tie-in points.

1. Erection of package skid on Foundation, with foundation bolts 2. Erection, welding, bolting of inlet & outlet RC Pump piping with its supports 5

RC Pump with Motor

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Duly assembled pump and motor

1 No.

-

-

3. Erection of cooling water piping with its supports 4. Erection of instruments, JBs, cable trays & caballing within Skid and connection to Tie-in points.

27-JUN-2019 VIJAY KUMAR (C572) Page 1 of 3

BILL OF QUANTITIES FOR 1 NO. OF FLUE GAS STEAM GENERATOR Sr. No.

Item Description

Condition of supply

Qty Unit

Weight In MT

Size in Mtr Length X Width X Height

Work to be done at site. (Approximate)

1. Erection of package skid on Foundation with foundation bolts 2. Erection, welding, bolting of inlet & outlet RC Pump piping with its supports 3. Erection, welding, bolting of inlet & outlet turbine piping with its supports 6

RC Pump with Turbine

Duly assembled pump and turbine

1 No.

-

4. Erection of cooling water piping with its supports 5. Erection of instruments, JBs, cable trays & caballing within Skid and connection to Tie-in points. 6. Piping insulation and cladding

1. Erection of package skid on Foundation with foundation bolts 7

HP & MP Dosing Skids

Duly assembled Skids

2 Nos.

-

-

2. Erection of DM water piping and dosing piping with its supports 3. Connection to Tie-in Points 1. Erection and alignment of Skid

8

Sample Cooler (Skid)

Duly assembled Skids

1 No.

-

2. Connecting sample piping & cooling water piping

Loose - Duly fabricated.

1 Lot

-

-

1. To be used at given locations.

10 Auxiliary Foundation Bolts Loose - Duly fabricated.

1 Lot

-

-

1. To be used at given locations.

Loose - Duly fabricated.

1 Lot

-

-

1. To be used at given locations.

LH Side Boiler Structure on Grid D- D1 to D7 12 Loose - Duly fabricated. & Support Structure for Auxiliaries (Silencer)

1 Lot

40

-

1. Erection, its alignment and bolting. Torque tightening to be done as per drawing requirement.

1 Lot

-

-

1. Erection & alignment and welding of pre fabricated duct spools from Seal air fan outlet duct till seal air piping on Module-II

9

11

13

Main Foundation Bolts

Insert Plate

Seal Air Ducting

Loose - Duly fabricated. 1. Loose Pipes with Insulation 2. Isolation Damper 3. Duct Supports and Anchor Bolts

1. Duct supports (bottom supported duct) to be erected on civil pedestals with foundation bolts. Outlet Duct from Box to Scrubber flange (35 14 mtr)with its support structure and metallic expansion joints

2. Erection of pre-fabricated Outlet ducting with duct supports from outlet box to Expansion joint. Duly fabricated 1. Duct in 2 Pieces 2. Expansion Joints 3. Support structure & Duct Saddles

1 Lot

75

-

3. Erection of Expansion Joint with Scrubber flange. 4. Insulation of interface duct pieces (Welding quantum - Approx. 50 running meter @ 10-12 mm thk fillet per boiler) Note : 1. Civil pedestals for outlet duct supports to be casted after Erection of Module-I

1. Duct supports (bottom supported duct) to be erected on civil pedestals with foundation bolts. 2. Prior to installation, inspection & rectification (if required-refer note-2) of refrractory lined outlet box at site is to be done , followed by its alignment, fit up and welding to boiler outlet flange. (Approx. 50 running meter @ 10-12 mm thk fillet per boiler)

15

Refractory lined Outlet Box with duct supports Duly fabricated. (structure)

3. After welding completion, the same is to be inspected for anchor pitching. If required, any additional anchor welding is to be done. Then refractory patch up application is to be done in transition area where refractory application is not possible at shop. This is to be carried out as per approved application procedure. 1 Lot

40

Note : 1.Civil pedestals for outlet duct supports (DS3; DS4 & DS5) to be casted after Erection of Module-I by DORC 2.After receipt at site, Refractory lined out box is to be inspected for any cracks, bulging /edge loosening and same to be rectified at site in line with approved rectification procedure before Installation.

1. Duct supports (bottom supported duct) to be erected on civil pedestals with foundation bolts. 2. Prior to installation, inspection & rectification (if required-refer note-2) of refrractory lined outlet box at site is to be done , followed by its alignment, fit up and welding to boiler inlet flange. (Approx. 50 running meter @ 10-12 mm thk fillet per boiler) Refractory lined Inlet Box 16 with duct supports (structure)

Duly fabricated

1 Lot

60

-

Risers - SA 106 Gr. B

Pre fabricated

1 Lot

28

-

Pre fabricated

2 No

-

-

Pre fabricated

1 No.

-

-

17

18 Attemperator I & II 19

Steam Dryer / Moisture Separator

Integral Piping 1. AS 20 2. CS 3. SS

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3. After welding completion, the same is to be inspected for anchor pitching. If required, any additional anchor welding is to be done. Then refractory patch up application is to be done in transition area where refractory application is not possible at shop. This is to be carried out as per approved application procedure. Note: 1. Civil pedestals for Inlet duct supports (DS1 & DS2) to be casted after Erection of Module-I 2.After receipt at site, Refractory lined out box is to be inspected for any cracks, bulging /edge loosening and same to be rectified at site in line with approved rectification procedure before Installation.

1. Refer Sr. No. 7 from Module-II 1. Fit up & welding of Attemperator I & II piping with piping supports. 1. Erection and alignment of Steam Dryer / Moisture Separator

Pre fabricated spools, ready to erect.

1 set

-

-

2. Connecting piping & its insulation 1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI, Hardness testing as per ITP, to be done at site. 2. Hydro test to be conducted once the piping circuit/ loops are completed.

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BILL OF QUANTITIES FOR 1 NO. OF FLUE GAS STEAM GENERATOR Sr. No.

21

Item Description

Non Integral Piping 1. AS 2. CS 3. SS

Condition of supply

Pre fabricated spools, ready to erect.

Fabricated Supports for Integral, Non Integral, Water, Steam, Drain & Vent Piping

1 set

Weight In MT

-

Size in Mtr Length X Width X Height

-

Work to be done at site. (Approximate)

1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI, Hardness testing as per ITP, to be done at site. 2. Hydro test to be conducted once the piping circuit/ loops are completed.

Non Integral Water , Steam, Drain & Vent Piping 22 1. AS Pre fabricated spools, ready to erect. 2. CS 3. SS

23

Qty Unit

Pre fabricated spools, ready to erect.

1 set

-

-

1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI, Hardness testing as per ITP, to be done at site. 2. Hydro test to be conducted once the piping circuit/ loops are completed.

1 set

-

-

1.Pre fabricated supports - Secondary & Primary to be welded to the structure and piping. 1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI, Hardness testing as per ITP, to be done at site.

Steam Blowing Arrangement

Pre fabricated spools, ready to erect.

Silencers

Pre fabricated, ready to erect.

1 set

-

-

1. To be erected on the structural supports.

Power Distribution Box 26 For Dosing Motors & MOVs

Duly finished item.

1 set

-

-

1. To be fixed as per requirement.

Electrical Items 28 Rotary Valve

Duly finished item - Loose Duly finished item.

1 set 7 Nos.

-

-

1. To be fixed/ installed as per requirement. 1. To be fixed/ installed as per requirement.

24

25

27

1 set

-

2. This needs to be cut and removed after completion of steam blowing.

29

Metallic Expansion Joints

Duly finished item.

3 Nos.

-

-

1. To be fixed/ installed as per requirement.

30

Instrument Cable Tray, Cables, JBs, Accessories

Duly finished item - Loose

1 set

-

-

1. To be fixed/ installed as per requirement.

31

Transmitters, Analysers, Gauges, Control/On-Off Valves, Temp Elements

Duly finished item - Loose

1 set

-

-

1. To be fixed/ installed as per requirement.

32

Seismic Stop & Expansion Pointers

Duly finished item - Loose

1 set

-

-

1. To be fixed/ installed as per requirement.

33

Insulation for Boiler

LRB & Cladding sheets (Rolls)

1 set

-

-

1. To be fixed/ installed as per requirement.

LRB/ piping sections & Cladding sheets (Rolls)

1 set

-

-

1. To be fixed/ installed as per requirement.

34 Insulation for Piping

35

Canopy Structure & its sheeting's.

Pre fabricated structure & canopy sheets.

1 set

-

-

1. The structure viz Purlins, Louvers, Truss, Sag rods, Gutters & Drain pipes needs to be erected at site and bolting and torque tightening to be done. 1. Canopy Sheets to be fixed on the structure and clamps to be tightened.

36 Monorail & its structure

37

Chemicals / Lubricants (Hazardous Cargo with Shelf Life)

38 Paint for site touch up

Pre fabricated structure & trolley.

1 set

-

-

1. The structure to be erected , bolted and trolley to be fixed.

Ready to use.

1 set

-

-

1. These lubricants/ chemicals are to be used during pre commissioning & commissioning stage of boiler.

Ready to use.

1 set

-

-

1. To be applied at the welding areas as per QAP/ ITP.

39

Spring Hangers for Piping (RC Pump Piping)

Ready to use / erect.

1 set

-

-

1. To be erected & fixed with piping at one side and with the structure at the other side.

40

Spring Hangers for Pressure Parts (Risers)

Ready to use/ erect.

1 set

-

-

1. To be erected & fixed with piping at one side and with the structure at the other side.

41

Safety Valve

44 Sacrificing Valve

Ready to use/ erect. Ready to use/ erect. Ready to use/ erect. Ready to use/ erect.

1 1 1 1

set set set set

-

-

1. To be erected on the flanges or to be welded if it is of welded construction. 1. To be erected on the flanges or to be welded if it is of welded construction. 1. To be erected on the flanges or to be welded if it is of welded construction. 1. To be erected, fit up and welded to the steam blowing piping.

45

Ready to use/ erect.

1 set

-

-

1. To be erected on the flanges or to be welded if it is of welded construction.

46 Non Integral Process Valve Ready to use/ erect.

1 set

-

-

1. To be erected on the flanges or to be welded if it is of welded construction.

42 Level Gauge 43

Relief Valve Integral Process Valve

47

Integral Motorised Valve

Ready to use/ erect.

1 set

-

-

1. To be erected on the flanges or to be welded if it is of welded construction.

48

Non Integral Motorised Valve

Ready to use/ erect.

1 set

-

-

1. To be erected on the flanges or to be welded if it is of welded construction.

49 Hydro testing

-

-

-

-

-

50 Leak test

-

-

-

-

-

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1. Hydro testing of pressure part circuit and external piping. Once the hydro test is done, piping insulation can be done. For doing this work, filling pump, hydro test pump, testing gauge and graphs to be used. 1. Leak test of gas side. Once the leak test is done, the insulation work can be done on the gas side.

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VENDOR TO ADHERE THE CONTRACT/ PR

27-JUN-2019 VIJAY KUMAR (C572)

REQUIREMENTS.