Shutdown Book 2007

SHUTDOWN BOOK

HALDIA REFINERY SHUTDOWN -2007 (From- 13th September To- 16th October)

Issued By Mechanical Maintenance Planning Cell

CONTENTS

1.

SHUTDOWN SCHEDULE

2.

SHUTDOWN SAFETY INSTRUCTIONS

3.

SHUTDOWN CO-ORDINATORS

4.

SHUTDOWN ORGANOGRAM

5.

SAFETY ROTA PLAN

6.

CRITICAL ACTIVITIES

7.

EQUIPMENT TALLY

8.

DETAILED JOB LIST

9.

CRITICAL ERECTION ACTIVITIES

10. LIST OF AGENCIES 11. SPECIAL TOOLS AND TECHNIQUES FOR S/D JOBS 12. OEM SUPPORTS 13. CRITICAL ACTIVITY PLAN 14. SAFETY CHECK LIST

UNIT SHUTDOWN PLAN Units

Days

FLARE

3+10+1

SEPT - OCT 2007

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1

2

3

4

5

6

7

8

9 10 11 12 13 14 15 16 17 18 19 38 39

TPS / PCT 1+12+1 FCCU

3+20+4

HGU

3+14+3

PDA

5+20+5

NMP

5+17+3

CDU-I

2+15+3

CDU-II

2+14+3

CRU

9+16+4

KHDS

3+21+2

VDU-I

2+16+3

VDU-II

2+17+3

DHDS

3+18+2

MSQ

3+24+4

MSQ-87

3+25+2

FEU

2+22+3

SDU

28

HFU

3+21+3

VBU

3+19+3

CDW

3+21+5

#

SHUT DOWN # Shutdown & regeneration

M&I

IDLE

START UP

SAFETY RULES PROCEDURES & INSTRUCTIONS IN SHUTDOWN •

Each and every person moving/ working in shutdown area should wear personal protective equipment like safety helmet, safety shoes etc.

•

Dust Masks (NOSE FILTERS) to be used by person working in confined dusty area i.e. inside furnace, columns, vessels, reactors, etc.

•

Main header valves of fire hydrant are to be kept open during shutdown period. Nozzle valves of fire hydrant are to remain closed during shutdown period.

•

Foam extinguishers are to be provided in shutdown area at a distance of every five meters and at every elevated platform near hot job area etc.

•

While taking radiographs, the radioactive prone area is to be cordoned off.

•

Oxygen masks are to be provided for personnel working in underground vessels with odour and fumes.

•

Safety goggle, face shield, hand gloves must be worn while working in chipping, grinding, cutting, wielding, blinding jobs etc.

•

Without valid fire permit /safety permit as well as clearance certificate no hot jobs should be carried out.

•

A running water hose is to be kept near not job area. If hot jobs are being carried on elevated area, one running water hose is to be kept at ground level also.

•

In case of fire, fire and safety department, CISF and medical section (First Aid) are to be informed immediately on phone.

•

Exhaust fan to be provided at manholes for personnel working inside the columns, vessel and furnaces etc.

•

All materials ( taken out from column/ vessel etc. after cleaning) where presence of pyrophoric iron is expected to be identified by production and instruction to be given to concerned maintenance group accordingly. All those materials to be buried to a designated place only.

•

24-volt hand lamp to be used by person working inside columns, vessels, and furnace etc.

•

Naphtha and petrol should not be used for washing purpose.

•

While carrying out hot jobs, all the OWS old manholes are to be covered by wet gunny bags.

•

Lifting tools & equipment like chain pulley block, wire rope, sling etc should not be allowed to use without valid test certificate.

•

Fully stocked First aid box should be available in the shutdown office.

•

A standby personnel should be always be outside the vessel / column manholes to pull out the working personnel outside in case of emergencies.

•

The personnel working inside a confined space should come out of the space immediately in case of any discomfort in breathing.

Safety Rules for Elevated Locations •

While carrying out shutdown jobs at elevated places, steel scaffolding to be used, which should be securely fastened with solid supports/ structural. Also, scaffolding should not be overloaded with materials

•

People working on elevated and projected structures are to wear safety belts around their chests & fastened to a firm structure, pipe etc.

•

Before using a ladder, it should be ensured that ladder components & joints are firm and in good condition.

•

Ladder should be based on a firm & even base. The pitch of a ladder should be approx. 4 to 1 i.e. for a ladder placed 6m up a vertical wall, the base of the ladder should be 1.5 m away from the base of wall. Also, it should project at least 1 meter above any landing platform. For better stability its top must be lashed in position to prevent slipping.

•

Metal ladder should not be used where there is risk of accidental contact with live electrical equipment.

•

The ladder should be used cautiously, giving proper attention on slippery rings & shoe soles. Also always face the ladder while climbing or descending.

•

Always keep hands free while climbing. Tools & equipments should be carried on belt.

MANDATORY SAFETY PRECAUTIONS DURING SHUTDOWN •

Prior to boxing up of equipment (Columns, Vessels, Reactors, Furnaces, etc) the clearance by concerned department, i.e. Production, Process, Mechanical, Civil, Inspection, Electrical, Instrument is to be given by signing the follow up Chart displayed in the shutdown office. It is to be made Mandatory Practice that no equipment will be boxed up unless its box up clearance is signed by above departmental engineer. • Action: All concerned deptts.

•

At the time of final box up, the representative of Production & Maintenance have to be physically present on the spot to avoid any abnormal happenings. • Action: Production/ Maintenance

•

As per the prevailing practice, all hot jobs clearance/ equipments entry permits are being renewed after every 12 Hrs. It is to be ensured that at each renewal time, the hot job place/equipments are FREE from gases and the same is documented. • Action: Production

•

If any permanent structure i.e. railing/grating/trench covers/drain manholes are removed, the written clearance to be taken from site Engineers and metallic barricading(sufficiently strong) of the area is to be done. The implementation responsibility lies with Production Engineer in operating plant and with Shut down office. • Action: Maintenance/Production.

•

During Shutdown safety Inspector has to be present in the plant, keeping vigilance at work site for unsafe practice. He will be empowered to stop the work if safety instructions are not complied with and details to be recorded in the log book maintained in Shutdown office.

•

                                 

Action: Fire & Safety

•

While awarding the job to the out side agencies, a clause is to be incorporated in SCC, that any loss/ any damage to man/machine by contractor’s fault will be heavily penalized to keep a check on unsafe practices. • Action: Contract Cell/P&C (contract)

•

During shutdown, plenty of safety banners & posters at every 10 mtr. Should be displayed by F&S Deptt. To keep the people reminded about safety consciousness. The display matters will be on both side in two languages i.e. Hindi & English. • Action: Fire & Safety

•

All hot job clearance should be signed by respective Field Engineer before starting of the hot job. On completion of hot job, the work request/clearance are to submitted within 4 HRS to the originator. • Action: Production/ Maintenance

                                                 

Hand tools Safety

           

Lifting tools Safety

Respiratory PPE

                     

Non-Respiratory

                       

           

Safety while working at height        

SHUTDOWN-2007 NAME OF SHUTDOWN COORDINATORS

Department / Section

Name

Designation

Overall Coordinator

Amalendu Kumar

DGM(MN)

Mechanical maintenance

Sudhir Kumar S.Mukherjee B.P.Sarkar A.E Rao D.K.Pradhan D.P.Ghosh S.K.Chattopadhyay A Ghosh S Dasgupta S K Dutta A B Pathak U Kundu A Choudhury T K Sett S Sen Goutam Das D Roy S Mitra A.K.Sarkar T K Kar G C Kundu S K Ganguly

CMNM-I CMNM-II CMNM(Civil) CMNM(EL) SMNMEL-I SMNMEL-II CITM CIPM CTSM CESM CPNM CPNM CPNM CPUM CMTM(I/C) CMTM CFM CPJM CPJM CPJM CM(F&S) CM(A&W)

Civil maintenance Electrical maintenance

Instrumentation maintenance Inspection Process Engineering Services Production

Power & Utility Materials Finance Project Special Project Cell Fire & Safety Welfare & Administration

SHUTDOWN ORGANOGRAMM Unit

Discipline

Mech. Maint

FOB

Location

Day

Furnace + Column

A.Behra, SMLE

Reactor + Hot jobs

A.Jana, MLE

Heat Exchangers + Valve

External-1

Civil Maint

All civil jobs

H Pramanik, DMCL & T Haokip, CLE

Elect. Maint

Over all

K D Kalandar, ELE

All Jobs

S.Ghosal, DMIP

Night

Area In-Charge

B. K. Dutta, SMLE + External-2

MNM(FOB)

Vikas Kumar, CLE and N.K. Ghosh SCLE

SMNMCL MNMEL-I( S N Jha) SPNM (FOB)

Inst. Maint Inspection

Over all Shutdown Manager

Engg. Serv.

External

B R Naik, MLS(ES)

SIPM Anil Kr , ESM

Process Project Production

Mech. Maint

Hot Job

Nirmal Kumar, SMLE

Valve Job + Unit-84

A.K. Dhar, SMLE

Column, Vessel, Heat Exchanger.

External-3 / HR

Furnace

K. Kumar, MLE

Other Units

External-4

Civil Maint

All civil jobs

KL Samanta, EA and KS Rajak, DMCL

Elect. Maint

Over all

Santosh Mishra, SELE / S P Sigh, ELE

S. K. Mondal, MLE+ External-5

Vikas Kumar, CLE and N.K. Ghosh SCLE.

MNM(LOB)

SMNMCL MNMEL-I( S N Jha)

Inst. Maint M.A.Baig, DMIP Inspection

All Jobs

External

SIPM

S.K.Mitra, SIPE

LOB Engg. Serv.

Amit Sahai, MLE(ES)

Process Project Unit-31

Production

M S Jana, PNE

Unit-32 & 36

Lalan Paul

Unit-33

P K Das

& Sh A K Chakraborty

Unit-34 & 35

T Neogi

Unit-37

P K Maiti & Sh G K Pandey

Unit-38

S Santra & Sh A R Mukherjee

Unit-84

V Kumar

SPNM (LOB) S.Roychoudhury, ESM

Valve replacement + HE

P.Biswas, DMNM

General rotary jobs

A.K.Saha, Ex-Emp

HOT Jobs + valve revisioning

R.K.Das, SMLE

Civil Maint

All civil jobs

H Pramanik, DMCL & T Haokip, CLE

Elect. Maint

Over all

G Maity, ELE

Mech. Maint

TPS

D.Yadav, MLE

Vikas Kumar, CLE Ghosh SCLE.

SMNM-II

N.K.

SMNMCL MNMEL-I( S N Jha) SPUM (TPS)

Inst. Maint Inspection

All Jobs

Engg. Serv.

S.K.Mitra, SIPE + External

External

B.R.Naik, MLE(ES)

SIPM Anil Kr, ESM

Process Project P&U

MAB+WGC

S.K. Bandopadhay, DMNM

Catalyst Section+ COB + Reactor

N. D. Shah, SMLE

Column+Vessel+HE+F/C

External-7 / MR

Hot Jobs+ Valves

External-8 / MR

A. Bhengra,SMLE + External-10 Mech. Maint

FCCU / VDU-II / MSQ

Belco Section

External-9

Civil Maint

All civil jobs

SP Mandal, EA and KS Rajak, DMCL

Elect. Maint

Over all

G C Bera, SELE / C R Kapat, ELE

DMNM(FCCU)

External- 11 Praveen Kumar, CLE N.K. Ghosh SCLE.

SMNMCL MNMEL-II( Archisman Roy)

Inst. Maint PNM (DHDS)

D.P.Ghosh,IPM Inspection

All Jobs

External

IPM

J.K.Besra, IPE Engg. Serv.

M.K.Sahu , DMCL(ES)

C.Guin, SESM(EL)

Process Project R-R/COI/MAB-WGC/AMINE/BELCO

M.ELAMARAN/R.K.MITRA

COLUMN/VESSELS/HE/MERICHEM

S.MONDAL/K.DHARA

MSQ

D.P.CHAKRABORTI

VDU-II

SHIFT OFFICERS

SHIFT OFFICERS Production SHIFT OFFICERS

24-F-02

A.K. Kulshrestha, DMNM

Reactors, Hot Jobs, Hydrogen Comp.

S.K. Bandopadhay, DMNM

All jobs of ARURU

N. Aamir, MLE

Civil Maint

All civil jobs

SP Mandal, EA and KS Rajak, DMCL

Elect. Maint

Over all

G C Bera, SELE / C R Kapat, ELE

DHDS + ARU + SRU

External

External

IPM

HGU

S.Ghosal,DMIP+ External

External

SIPM

Mech. Maint

C.C. Dhara, SMLE+ External-12

Praveen Kumar, CLE N.K. Ghosh SCLE.

DMNM(DHDS)

SMNMCL MNMEL-II( Archisman Roy)

Inst. Maint HGU/ DHDS/ ARU/ SRU

Inspection Engg. Serv.

A.Hazra, DMCL(ES)

PNM (DHDS)

N.K.Sidhu, ESM

Process Project

Production

HGU

D.K.METYA/U.K.PRAMANIK

DHDS

P.K.MISHRA/V.YADAV

ARU/SRU

H.C.RANJIT/M.K.MISHRA

Flare Tip+ Vessel

S.K. Dolui, SMLE

Fl Flare line+ li O/S Piping Pi i

C.M. Baitalik, SMLE+ 6

Civil Maint

All civil jobs

KS Rajak, DMCL and D.Das EA

Elect. Maint

Over all

S P Mondal, DMEL / B P Mandal, ELE

All jobs

J.K.Besra, IPE + External

Mech. Maint

External External-

SHIFT OFFICERS

S.HALDER,DMPN

U Khara, SMLE

DMNM(O/S) ( )

Vikas Kumar Ghosh SCLE.

N.K.

SMNMCL MNMEL-I( S N Jha)

Inst. Maint Offsite

Inspection Engg. Serv.

External

A.Sahai,MLE(ES)

IPM S.Roychoudhury, ESM

Process Project O/S Piping

A.K.Sahu/N.C.Barman/B.B.Munuan

Flare line and related all jobs/

M S Chattaraj SPNM/S.K.Das,SPNM

Pump + Fabrication + Machining Jobs

R.Naik, SMLE

Valve jobs

S.Hazra, SMLE

Inspection

Valve jobs

C.R.Das, DMIP

Elec. Maint

Over all

A K Malik, SELE

Production

M.W.Beg Shift Officers M S Chattaraj

Mech. Maint Workshop

SMNM-I External

IPM MNMEL-II( Archisman Roy)

Inst. Maint

B.B.Das, DMNM Garage

All Jobs

D.K. Parua, MLE J.Singh, MLE

SMNM-I

M.W.Beg,SPNM/M.S. Chattaraj,SPNM/S.K.D as,SPNM

Mech. Maint Planning Elec. Maint

FOB + LOB + OFFSITE

B.Mallick, MLE

FCCU + DHDS

S.Sharma, MLE

Materials

M.S.Ghosh, SMLE

Over all

R P Shukla

SMNM-I

MNMEL-II( Archisman Roy)

Inst. Maint

SPC

G Sen , DMTM Store section J.J Thomas , SMTO Materials I Behera, SMTO Purchase section J SIKDAR , MTO

Finance

Concurrance Jobs

Welfare

All Jobs

D. Saha, FM

FM

G.K.Sahu, SO (HR) Manager (HR) B.Gupta, SO (HR)

Offsite

S.K.Bandopadhyay, SMFS

FOB & TPS

B.B.Bharasa, MFS

FCCU & DHDS

Pallab Nath, MSF

LOB

K.Ganesh, SF&SO

Telecom/ AC/ Fire prot.

Over all

R S Vyas, SELE / S P Sahoo, SELE

Elect Testing

Over all

A K Malik, SELE / V Joshi, ELE

Fire & Safety

SMNMEL-II ( D P Ghosh)

MNMEL-II( Archisman Roy)

SAFETY ROTA FOR SHUTDOWN - 2007 AREA

DATE

08:00-12:00 Hrs.

12:00-16:00 Hrs

16:00-20:00 Hrs

FOB

9/23/2007 9/24/2007 9/25/2007 9/26/2007 9/27/2007 9/28/2007 9/29/2007 9/30/2007 10/1/2007 10/2/2007 10/3/2007 10/4/2007 10/5/2007 10/6/2007 10/7/2007 10/8/2007 10/9/2007 10/10/2007

B.K.Barik, PSE A.K.Soreng, DMIS Praveen Kumar, QCO B.K.Barik, PSE P.S.Yadav, O(ER) Santosh Kumar, PSE B.K.Barik, PSE A.K.Soreng, DMIS Santosh Kumar, PSE B.K.Barik, PSE P.S.Yadav, O(ER) Praveen Kumar, QCO B.K.Barik, PSE A.K.Soreng, DMIS Praveen Kumar, QCO B.K.Barik, PSE Santosh Kumar, PSE P.S.Yadav, O(ER)

P.S.Yadav, O(ER) B.K.Barik, PSE A.K.Soreng, DMIS A.K.Soreng, DMIS B.K.Barik, PSE P.S.Yadav, O(ER) Praveen Kumar, QCO B.K.Barik, PSE A.K.Soreng, DMIS Santosh Kumar, PSE B.K.Barik, PSE P.S.Yadav, O(ER) A.K.Soreng, DMIS B.K.Barik, PSE A.K.Soreng, DMIS P.S.Yadav, O(ER) B.K.Barik, PSE Santosh Kumar, PSE

Santosh Kumar, PSE P.S.Yadav, O(ER) B.K.Barik, PSE Santosh Kumar, PSE A.K.Soreng, DMIS B.K.Barik, PSE P.S.Yadav, O(ER) Praveen Kumar, QCO B.K.Barik, PSE A.K.Soreng, DMIS Santosh Kumar, PSE B.K.Barik, PSE P.S.Yadav, O(ER) Santosh Kumar, PSE B.K.Barik, PSE A.K.Soreng, DMIS P.S.Yadav, O(ER) B.K.Barik, PSE

Praveen Kumar, QCO Santosh Kumar, PSE P.S.Yadav, O(ER) Praveen Kumar, QCO Praveen Kumar, QCO A.K.Soreng, DMIS Santosh Kumar, PSE P.S.Yadav, O(ER) Praveen Kumar, QCO Praveen Kumar, QCO A.K.Soreng, DMIS Santosh Kumar, PSE Praveen Kumar, QCO P.S.Yadav, O(ER) Santosh Kumar, PSE Praveen Kumar, QCO A.K.Soreng, DMIS Praveen Kumar, QCO

20:00-08:00 Hrs

LOB

9/23/2007 9/24/2007 9/25/2007 9/26/2007 9/27/2007 9/28/2007 9/29/2007 9/30/2007 10/1/2007 10/2/2007 10/3/2007 10/4/2007 10/5/2007 10/6/2007 10/7/2007 10/8/2007 10/9/2007 10/10/2007 10/11/2007 10/12/2007

S.Saha, SPSE N.Mudugal, O(ER) N.Mudugal, O(ER) S.Saha, SPSE S.Sahit,PSE N.Mudugal, O(ER) S.Saha, SPSE J.Sharma, SISO A.C.Kar, QCO S.Saha, SPSE S Sahit PSE S.Sahit,PSE N.Mudugal, O(ER) S.Saha, SPSE J.Sharma, SISO A.C.Kar, QCO S.Saha, SPSE S.Sahit,PSE A.C.Kar, QCO S.Saha, SPSE J.Sharma, SISO

J.Sharma, SISO S.Saha, SPSE J.Sharma, SISO A.C.Kar, QCO S.Saha, SPSE S.Sahit,PSE N.Mudugal, O(ER) S.Saha, SPSE J.Sharma, SISO A.C.Kar, QCO S Saha SPSE S.Saha, S.Sahit,PSE N.Mudugal, O(ER) S.Saha, SPSE J.Sharma, SISO S.Sahit,PSE S.Saha, SPSE S.Sahit,PSE J.Sharma, SISO S.Saha, SPSE

N.Mudugal, O(ER) J.Sharma, SISO S.Saha, SPSE J.Sharma, SISO A.C.Kar, QCO S.Saha, SPSE S.Sahit,PSE N.Mudugal, O(ER) S.Saha, SPSE J.Sharma, SISO A C Kar QCO A.C.Kar, S.Saha, SPSE S.Sahit,PSE N.Mudugal, O(ER) S.Saha, SPSE J.Sharma, SISO N.Mudugal, O(ER) S.Saha, SPSE S.Sahit,PSE N.Mudugal, O(ER)

A.C.Kar, QCO A.C.Kar, QCO S.Sahit,PSE N.Mudugal, O(ER) J.Sharma, SISO A.C.Kar, QCO A.C.Kar, QCO S.Sahit,PSE N.Mudugal, O(ER) N.Mudugal, O(ER) J Sharma SISO J.Sharma, A.C.Kar, QCO A.C.Kar, QCO S.Sahit,PSE N.Mudugal, O(ER) A.C.Kar, QCO J.Sharma, SISO N.Mudugal, O(ER) A.C.Kar, QCO S.Sahit,PSE

TPS

9/25/2007 9/26/2007 9/27/2007 9/28/2007 9/29/2007 9/30/2007 10/1/2007 10/2/2007 10/3/2007 10/4/2007 10/5/2007 10/6/2007 10/7/2007

H.K.Bora, DMPS B.Midya, QCO Manas Biswas, DMIS H.K.Bora, DMPS S.Mandal, PSE B.Midya, QCO H.K.Bora, DMPS Manas Biswas, DMIS S.Kumar, ACO H.K.Bora, DMPS S.Kumar, ACO B.Midya, QCO H.K.Bora, DMPS

S.Mandal, PSE H.K.Bora, DMPS B.Midya, QCO Manas Biswas, DMIS H.K.Bora, DMPS S.Mandal, PSE S.Kumar, ACO H.K.Bora, DMPS Manas Biswas, DMIS S.Mandal, PSE H.K.Bora, DMPS S.Kumar, ACO Manas Biswas, DMIS

S.Kumar, ACO S.Mandal, PSE H.K.Bora, DMPS S.Kumar, ACO Manas Biswas, DMIS H.K.Bora, DMPS S.Mandal, PSE S.Kumar, ACO H.K.Bora, DMPS Manas Biswas, DMIS S.Mandal, PSE H.K.Bora, DMPS S.Kumar, ACO

Manas Biswas, DMIS E.Gopinathan, IAM S.Mandal, PSE B.Midya, QCO T.Ghosal, IAM Manas Biswas, DMIS B.Midya, QCO S.Mandal, PSE B.Midya, QCO B.Midya, QCO Manas Biswas, DMIS S.Mandal, PSE B.Midya, QCO

SAFETY ROTA FOR SHUTDOWN - 2007 AREA

08:00-12:00 Hrs. S.K.Mitra, SPNE (E&C) T. Sikdar, QCO J.Bag, PSE S.K.Mitra, SPNE (E&C) A.Haldar, PSE T. Sikdar, QCO S.K.Mitra, SPNE (E&C) J.Bag, PSE T. Sikdar, QCO S.K.Mitra, SPNE (E&C) S.Sen, PSE T. Sikdar, QCO S.K.Mitra, SPNE (E&C)

12:00-16:00 Hrs A.Haldar, PSE S.K.Mitra, SPNE (E&C) T. Sikdar, QCO J.Bag, PSE S.K.Mitra, SPNE (E&C) A.Haldar, PSE S.Sen, PSE S.K.Mitra, SPNE (E&C) J.Bag, PSE A.Haldar, PSE S.K.Mitra, SPNE (E&C) S.Sen, PSE J.Bag, PSE

16:00-20:00 Hrs S.Sen, PSE A.Haldar, PSE S.K.Mitra, SPNE (E&C) S.Sen, PSE J.Bag, PSE S.K.Mitra, SPNE (E&C) A.Haldar, PSE S.Sen, PSE S.K.Mitra, SPNE (E&C) J.Bag, PSE A.Haldar, PSE S.K.Mitra, SPNE (E&C) S.Sen, PSE

20:00-08:00 Hrs J.Bag, PSE S.Sen, PSE A.Haldar, PSE T. Sikdar, QCO S.Sen, PSE J.Bag, PSE T. Sikdar, QCO A.Haldar, PSE S.Sen, PSE T. Sikdar, QCO J.Bag, PSE A.Haldar, PSE T. Sikdar, QCO

FCCU / VDU-II / MSQ

9/19/2007 9/20/2007 9/21/2007 9/22/2007 9/23/2007 9/24/2007 9/25/2007 9/26/2007 9/27/2007 9/28/2007 9/29/2007 9/30/2007 10/1/2007 10/2/2007 10/3/2007 10/4/2007 10/5/2007 10/6/2007 10/7/2007 10/8/2007 10/9/2007 10/10/2007

S.Dey, SPSE S.Das, SQCO S.Prabhu, PJE S.Dey, SPSE A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE S.Prabhu, PJE S.Das, SQCO S.Dey, SPSE A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE S.Prabhu, PJE S.Das, SQCO y, SPSE S.Dey, A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE S.Das, SQCO S.Das, SQCO S.Dey, SPSE

S.C. Singh, SO(ER) S.Dey, SPSE S.Das, SQCO S.Prabhu, PJE S.Dey, SPSE A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE S.Prabhu, PJE S.Das, SQCO S.Dey, SPSE A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE S.Prabhu, PJE S.Das,, SQCO S.Dey, SPSE A.P.Barua, DMIS S.Prabhu, PJE S.Dey, SPSE S.C. Singh, SO(ER) S.Das, SQCO

A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE A.P.Barua, DMIS S.Prabhu, PJE S.Dey, SPSE A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE S.Prabhu, PJE S.Das, SQCO S.Dey, SPSE A.P.Barua, DMIS S.C. Singh, SO(ER) S.Dey, SPSE S.Prabhu,, PJE S.Das, SQCO S.Dey, SPSE A.P.Barua, DMIS S.Prabhu, PJE S.Dey, SPSE S.C. Singh, SO(ER)

S.Prabhu, PJE A.P.Barua, DMIS S.C. Singh, SO(ER) S.Das, SQCO S.Das, SQCO S.Prabhu, PJE S.Das, SQCO A.P.Barua, DMIS S.C. Singh, SO(ER) S.C. Singh, SO(ER) S.Prabhu, PJE S.Das, SQCO S.Das, SQCO A.P.Barua, DMIS A.P.Barua, DMIS g , SO(ER) ( ) S.C. Singh, S.Prabhu, PJE S.Das, SQCO S.C. Singh, SO(ER) A.P.Barua, DMIS S.Prabhu, PJE S.Prabhu, PJE

HGU/ DHDS/ ARU/ SRU

9/22/2007 9/23/2007 9/24/2007 9/25/2007 9/26/2007 9/27/2007 9/28/2007 9/29/2007 9/30/2007 10/1/2007 10/2/2007 10/3/2007 10/4/2007 10/5/2007 10/6/2007 10/7/2007 10/8/2007 10/9/2007 10/10/2007

S.Bandopadhyay, SPSE J.Soren, DMQC M.A.Ali, DMCL S.Bandopadhyay, SPSE P.K.Banerjee, SITE J.Soren, DMQC S.Bandopadhyay, SPSE B.Gupta, SO(ER) M.A.Ali, DMCL S.Bandopadhyay, SPSE J.Soren, DMQC M.A.Ali, DMCL S.Bandopadhyay, SPSE P.K.Banerjee, SITE M.A.Ali, DMCL S.Bandopadhyay, SPSE B.Gupta, SO(ER) M.A.Ali, DMCL S.Bandopadhyay, SPSE

P.K.Banerjee, SITE S.Bandopadhyay, SPSE J.Soren, DMQC B.Gupta, SO(ER) S.Bandopadhyay, SPSE P.K.Banerjee, SITE J.Soren, DMQC S.Bandopadhyay, SPSE B.Gupta, SO(ER) P.K.Banerjee, SITE S.Bandopadhyay, SPSE J.Soren, DMQC B.Gupta, SO(ER) S.Bandopadhyay, SPSE P.K.Banerjee, SITE J.Soren, DMQC S.Bandopadhyay, SPSE B.Gupta, SO(ER) P.K.Banerjee, SITE

B.Gupta, SO(ER) P.K.Banerjee, SITE S.Bandopadhyay, SPSE M.A.Ali, DMCL B.Gupta, SO(ER) S.Bandopadhyay, SPSE P.K.Banerjee, SITE J.Soren, DMQC S.Bandopadhyay, SPSE B.Gupta, SO(ER) P.K.Banerjee, SITE S.Bandopadhyay, SPSE J.Soren, DMQC B.Gupta, SO(ER) S.Bandopadhyay, SPSE P.K.Banerjee, SITE J.Soren, DMQC S.Bandopadhyay, SPSE B.Gupta, SO(ER)

M.A.Ali, DMCL B.Gupta, SO(ER) P.K.Banerjee, SITE J.Soren, DMQC M.A.Ali, DMCL B.Gupta, SO(ER) M.A.Ali, DMCL P.K.Banerjee, SITE J.Soren, DMQC M.A.Ali, DMCL B.Gupta, SO(ER) P.K.Banerjee, SITE M.A.Ali, DMCL J.Soren, DMQC B.Gupta, SO(ER) M.A.Ali, DMCL P.K.Banerjee, SITE J.Soren, DMQC M.A.Ali, DMCL

O/S

DATE 9/25/2007 9/26/2007 9/27/2007 9/28/2007 9/29/2007 9/30/2007 10/1/2007 10/2/2007 10/3/2007 10/4/2007 10/5/2007 10/6/2007 10/7/2007

CRITICAL ACTIVITY JOBS Area

HGU / DHDS

GT / HRSG

Critical

Description

Catalyst tube replacement

Reqd. Time (Days) 14

Total Engg. (Days) 14

1st 2nd

Heat Exchangers of HGU

13

14

3rd

Air fin coolers of DHDS

16

18

1st

CI-BI of GT

7

7

2nd

Maintenance of HRSG

7

7

1st

CO-Stack

20

20

2nd

Regenerator

20

20

3rd

Exchanger - 59 Nos.

19

20

1st

Flare line

10

10

2nd

Offsite piping

10

10

3rd

Flare tip

09

10

1st

11-F-01

14.5

15

2nd

11-C-01

14

15

3rd

16-F-01

13

14

1st

Steam Valve

16

19

2nd

CW Valve

14.33

19

3rd

PCT

14

19

1st

Pre heat Exchanger - VBU

19

19

2nd

32-F-01

19.8

20

3rd

Heat Exchanger - PDA

17

20

FCCU

Offsite

FOB

TPS

LOB

EQUIPMENT TALLY FOR S/D 2007 Eqpt Type

Furnace

Column

Vessel

Reactor/ Regenerator

Area

Nos.

HGU FCCU PDA NMP CDU-I CDU-II VDU-I HRSG FCCU PDA NMP ARU CDU-I CRU CIDW VBU O/S TPS HGU FCCU PDA ARU NMP FCCU HGU MSQ CRU

2 4 1 2 1 1 1 1 8 10 11 1 1 1 1 1 7 19 19 23 11 12 18 3 5 1 1

Total

13

34

109

10

Heat Exchanger

Air Cooler

Safety Valve

Rotary

Piping

TPS HGU FCCU PDA NMP ARU DHDS FOB LOB HGU DHDS FCCU PDA NMP O/S TPS HGU FCCU PDA ARU NMP HRSG HGU GT TPS FCCU

8 41 59 32 39 8 39 40 38 3 8 15 6 2 26 25 16 44 73 16 42 8 K1A/B, K2A/B, P11 CIBI CW Pumps MAB, WGC, Bottom pumps

LOB, FOB

Under ground and above ground Cooling Water circuit -

304

34

250

JOB LIST FOB FINAL LIST

1.0

FURNACE

1.1.0

Blinding / De-blinding, De-coking of Furnace, opening of Man-way, dropping of Burner Blocks, erection of volumetric Scaffolding inside the furnace, opening of Convection Manholes, opening of end-panels in Convection section, external manual cleaning of radiation tubes, Inspection of Furnace, refractory / ceramic pad repair as per recommendations, replacement of guides & hangers, checking of thermocouples, cutting of tubes , fitting of new tubes, welding of new joints, pre-SR X-ray, stress relieving of joints, post SR X-ray, hydraulic pressure testing of coils, refractory repair of floor, revisioning of Burners, revisioning of Air-registers, revisioning of Soot-blowers, peeps holes, damper plates and boxing up of the furnace after completion of all activities in the Furnace

1.1.1 11- F - 01 a) Replacement of 4 tubes (Half Length) in 11-F-01. b) Replacement of tube hangers and locking bars.

1.1.2 16-F-01 a) Replacement of 3 tubes (Half Length) in 16-F-01

2.0

COLUMNS (11-C-01 & 21-C-01)

2.1.0

Blinding / De-blinding, opening of manholes, air circulation inside the Column, gas test & man-entry, opening of tray manways, erection of scaffolding inside the column (wherever required), unloading of stractured packings from packed beds, manual cleaning of Column internals, Inspection, repair / replacement as per inspection recommendations, fixing back columns internals (if required), box-up of tray man ways and final box-up of column manholes after completion of all maintenance activities in the columns.

3.0

REACTORS

3.1.0

Blinding/ De-blinding, opening of manholes, air circulation inside the Reactor, gas test & man entry, opening of internals, erection of scaffolding inside the Reactor (wherever required), manual cleaning of internals, inspection, repair/replacement as per inspection recommendations, refractory jobs as per requirement, fixing back of internals, and final box-up of manholes after completion of all maintenance activities in the Reactor.

3.1.1 3.1.2

21-R-01: Skimming of catalyst: 1900 KG. From top 22-R-02: Skimming of catalyst: 2500 KG. From top ( Only top layer of the catalyst bed will be unloaded for skimming operation through the top flange of the reactor)

4.0

MODIFICATION JOBS

4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 4.1.12 4.1.13

5

Provision of back flushing facility in 11-E-29. Provision of back flushing facility in 12-E-04. Modification in discharge & warm up line of 16-P-07 A/B/C. Replacement of cooling water battery limit valve at FOB (Gr-10) Provision of bypass facility in naptha caustic and water wash mixing of valve of CDU-I Routing of PF(11-C-101) & MF(11-C-01) naptha to slop header in CDU-I Provision of back flushing facility in CDU-I trim coolers Modification of LPG processing facility in CDU-I Routing of 90-140 cut Naphtha ex CDU-I to Hy FCC gasoline feed surge drum of Naphtha Hydro Treatment Unit (U-21) Modification in discharge and warm up line of RCO pumps (16P07A/B/C of CDU-II) Provision of isolation valve in the SKCR return line ex 16-E-33 (splitter reboiler) of CDU-II Provision of back flushing facility in CDU-II trim coolers Modification of LPG processing facility in CDU-II

PROJECT JOB

5.1.0 VR Burning in CDU-II

6.0

VALVE REVISIONING

6.1.1

Revisioning of valves at U-11

a) 11P 9B (HSD)-suction 10” dia gate valves- 2 nos. , discharge 10” dia gate valves –2 nos . b) 11P10 (HSD) suction 12” gate valve –1 no, discharge 10” gate valve –1 no . c) 11E11 :Shell side:( LPG+Naphtha) inlet 10” gate valve- 1 no, Shell side outlet 14” gate valve –1 no Tube side (HSD): inlet/outlet : 8” dia –2 nos. d) 11E 11 A: Shell side:( LPG+Naphtha) inlet 10” gate valve- 1 no, Shell side outlet 14” gate valve 1no Tube side (HSD): inlet/outlet : 10” dia –2 nos. e) 11E 09 A/B/C/D: Shell side:( HSD) inlet 8” gate valve- 2 no. Shell side outlet 8” gate valve –2 no . f) 11P03B (LPG+ Naphtha) : discharge valve 4” –1 no gate valve. g) 11C104 : PSV isolation valves –4 nos. gate valve - Feed line C/V isolation valve – 3 nos ( 2 gate, 1 globe) - Reflux C/V isolation valve. – 3 nos ( 2 gate, 1 globe) - O/H vapour line valve –1 no gate valve - O/H vapour line for pressurisation- 1no.

6.1.2

Revisioning of valves at U-16 a)16 E 14 C/D s/s inlet and outlet valves. b)16E10A/B shell side ( RCO ) O/L B/V a) Crude inlet block valve to 16E12 B to be replaced ( defective).

7.0

STRUCTURAL JOBS

GR-10 (CDU-I) Description Sl.No. 1 11B01/B101 platform structural supports are badly corroded. Some gratings of platform are to be changed. 2 11E22A/B gratings are to be changed. 3 15E02 platform support beams have corroded badly. East side railing of the same has badly corroded. All are required to be changed. 4 15B06 platform’s gratings are to be replaced at 6-7 locations. 5 11E23 A/B platform side railings & 5-6 nos of gratings are to be replaced. 6 13B01 bottom platform checkers plate is to be changed. 7 Approach platform for post desalter pump disch PSV isolation valve & post pf pump disch PSV isolation valve are to be made. GR-20 (NHDT, CRU & KHDS) Description Sl.No. 1 CRU common stack SOX/NOX analyzer probe is not approachable. Platform is to be made. 2 23F01 Monkey ladder near oxygen analyzer is corroded. To be replaced. 3 H2 bullet lower platform checkers plates are corroded. To be replaced 4 Alternate escape ladder is to be provided for 23F01 platform. 5 OBSG damper platform gratings and side railings are to be replaced. 6 23F01 approach stair’s steps are bent, to be replaced. 7 Approach platform to be made near battery limit isolation valve of flare headers in u21/22. U-16 (CDU-II) Description Sl.No. 1 16C05 (de-ethaniser) monkey ladders with guards, platform railings, bracket and channels are to be replaced. 2 16C09 (de-propaniser) top monkey ladder along with its guard is to be replaced. Monkey ladder to be provided to approach PSV platform. Railing of topmost platform is to be replaced. 3 16C04(stabilizer) top monkey ladder and its guard, railing of top platform is corroded badly, some channels between ladder and column shell are also badly corroded and needs to be replaced. 4

Platform railing guards in 16-C-01 are completely damaged, particularly 2 nd, 3 rd, 4 th and 5 th platform from the top. Platform supporting channels are badly damaged in 3 rd platform from the top. Monkey ladder at the top of the column is also badly damaged. Brackets between ladder and column are badly damaged and thinned down. All rare to be attended.

5

16C07(PF) top two monkey ladders & its guard is badly corroded. Side railings of top two platforms are badly corroded. 16C01 & 16C07 PSV platform’s gap are to be provided with gratings & side railings. Service water valve and steam valve on the pipe rack above 16P16A/B are not approachable 16F01/11F01/22F201 COT thermocouples are not approachable. Plat forms are to be extended. Gap near 16E43 is to be filled up with new grating 16F01 approach stair’s to be replaced completely as it is badly corroded and unsafe.

6 7 8 9 10

RE-ORIENTATION REQUIREMENT w.r.t. SAFETY (SSCM) Description Sl.No. 1 Near 11P06A/B Inst. JB is restricting to approach welding DB,to be relocated. 2 11P07B suc./disch. Valves are very nearer in which hands are touching on the hot lines during operation, to be re-oriented. 3 23K102 MES inlet b/v to be rotated 4 23K02(corbline comp) inst panel is to be relocated.

SHUTDOWN JOB LIST PROPANE DEASPHALTING UNIT Final List 1.0

FURNACE (32-F-01) Blinding / deblinding, decoking, opening of manway, erection of scaffolding inside the furnace, opening of convection manholes, external cleaning of tubes, refractory repair as per recommendation, checking of thermocouples, refractory repair of floor, revisioning of burners, soot blowers, air-registers, explosion doors, damper plates, peep holes, hydraulic testing of radiation, & convection coils and boxing up of furnace after completion of all activities.

1.1

REPAIR / REPLACEMENT JOBS IN 32-F-01

1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.1.16 1.1.17

Thorough external cleaning of all radiation tubes. Complete replacement of convection studded tubes Replacement of 8 Nos. modified new burners. Checking / repair / replacement of thermocouple points. Repair of damaged entire furnace shell and arch zone refractory / complete replacement of entire refractory with ceramic fibre lining. Furnace bulged floors to be repaired. External patch repair of furnace casing plate in the roof, vertical & arch zone (80 SqM) Complete replacement of stack with internal castable lining. Revisioning of stack damper All hanger supports to be checked and rectified, if required. All FO burners are to be cleaned and damaged burner tips are to be replaced Hydraulic testing of convection and radiation coils Relocation of two Nos. of peep holes as per drawing issued by ES. Painting of entire furnace along with structural. Revisioning/Replacement of air registers Dechoking/Replacement of flue gas sampling point Revisionin/Replacement of explosion doors(2Nos.) and peephole covers(6Nos.)

2.0

COLUMN

1.1.6 1.1.7

Opening of manholes, tray manways, erection of scaffolding wherever required, cleaning of internals of column including both surface of trays & other fittings inside the column, offering for inspection, repair / replacement as per inspection recommendation and fixing back of tray manways and final boxing up of column after completion of all activities in the following columns :2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

C-01A C-01B C-01C C-110 C-108 C-02 - Repair/replacement of demister & frame, weld build up of M/H neck C-04 - Repair/replacement of demister & frame C-05 C-06 C-07 - Replacement of column.

Page 1 of 1

NOTE : - Removal of insulation and necessary scaffolding to be provided for all nozzles to facilitate inspection.

3.0

VESSEL Blinding / deblinding of connected lines, opening of manholes, removal of internals, cleaning, inspection, repair / replacement jobs as per recommendation, refixing of internals & final boxing up after completion of all activities of the following vessels : ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾

External painting to be done Gratings replacement Checking of magnetic float Weld build up of vessel 2.5 SqM External painting to be done Gratings replacement Checking and repair of magnetic float Weld build up of vessel 2.5 SqM

Suction K.O Drum of K-01/K1R

¾ ¾

Repair / replacement of demister pad Checking and repair of internal float and level switch

Flare K.O Drum

¾

B-07

Flushing Oil Drum

¾ ¾

3.8

B-08

Defoamer Drum

¾ ¾

3.9

B-11

Debutaniser

Cover plate & 2” dia nozzle to be replaced. Hydro test of steam coil External painting of vessel Partial replacement & hydro-testing of steam coil Level Gauge to be replaced Partial replacement of bot. shell & dome External Painting of vessel Maintenance of vessel. Partial replacement of steam coil.

3.10

B-111

3.11

B-201

3.12

B-202

3.13

B-203

Tempered Water Drum MHP Condensate K.O Drum M.P Condensate K.O Drum LP condensate Vessel

3.1

32B-01

Propane Bullet

3.2

32B-02

Propane Bullet

3.3

3.6

32B-03 individual compressor K.O pots B-06

3.7

¾ ¾ ¾

External Painting of vessel

¾

External Painting of Vessel

¾ ¾ ¾ ¾

Repair of damaged level tapping External Painting of vessel External Painting of vessel Demister pad may come replacement.

for

32-B-10, 11, 112, 201, 202 & 203 to be hydrotested. 4.0

HEAT EXCHANGER Check-III activities i.e. opening of the covers, pulling out the tube bundle from the shell, cleaning insertion, testing & boxing up, repair jobs including weld build up and rectification of channel box & floating head covers, anode fixing, are to be performed to the following including blinding / deblinding. Two nos. of tube bundle for 32-E-06 to be kept ready for replacement. 4.1 4.2 4.3 4.4

32E112A/B 32E06A/A1 32E06B/B1 32E06C/C1

Page 2 of 2

4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22

32E06D/D1 32E06E/E1 32E06H/H1 32E06I/I1 32E10A 32E10B 32E10C 32E122 32E05A 32E05B 32E114A/B 32E114C/D 32E117 32E121A/B 32E115 32E107 32E08 32E116 A to F Air coolers

PAINTING JOBS IN EXCHANGERS Water contact surfaces of all components of coolers & condensers (i.e. floating head, channel box, channel cover tube sheet) to be painted as detailed below. Surface preparation – Grit/sand blasting conforming to Sa2. ½, Paint application – Self priming epoxy (minimum DFT 100 Micron). Followed by two coats of chlorinated rubber paint (minimum DFT 90 Micron)

5.0

SAFETY VALVES All PSV's are to be revisioned & tested at Workshop.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

32-PSV-01K 32-PSV-02K 32-PSV-03K 32-PSV-04K 32-PSV-05K 32-PSV-06K 32-PSV-21K 32-PSV-22K 32-PSV-23K 32-PSV-24K 32-PSV-01 32-PSV-02 32-PSV-03 32-PSV-04 32-PSV-05 32-PSV-06 32-PSV-07 32-PSV-08

32-C-1-A 32-C-1-A 32-C-1B 32-C-1B 32-C-1-C 32-C-10 32-C-3 32-C-4

Page 3 of 3

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

32-PSV-09 32-PSV-10 32-PSV-11 32-PSV-12 32-PSV-3213 32-PSV-14 32-PSV-15 32-PSV-16 32-PSV-17 32-PSV-20 32-PSV-21 32-PSV-26 32-PSV-27 32PSV-28 32-PSV-29 32-PSV-30 32-PSV-31 32PSV-32 32-PSV-33 32-PSV-34 32-PSV-35 32-PSV-36 32-PSV-201 32-PSV-202 32-PSV-203 32-PSV-204 32-PSV-206 32-PSV-207 32-PSV-208 32-PSV-209 32-PSV-210 32-PSV-303 32-PSV-304 32-PSV-401 32-PSV-404A 32-PSV-404B 32-PSV-405A 32-PSV-405B 32-PSV-01 32-TSV-303 32-TSV-402A 32-TSV-402B 32-TSV-402C 32-TSV-402D 32-TSV-402E 32-TSV-403 32-PSV-37 32-PSV-38 32-PSV-39 32-PSV-40 32-PSV-103A 32-PSV-106

32-B-1 32-B-1 32-B-2 32-B-2 32-C-2 32-C-5 32-C-6 32-C-7 32-B-3 32-B-3 32-B-9 32-E-9 32-E-10-A 32-E-10B 32-E-10-C 32-E-10-A 32-E-10-A 32-E-10-C 32-E-3-A 32-E-3B 32-E-4 32-E-5 32-E-103 32-C-103 32-C-104 32-E-104 32-E-106 32-E-107 32-B-103 32-E-105 32-E-108 Asphal + PVMP 32-C-05 32-K-101 32-B-01 32-B-01 32-B-02 32-B-02 100-P-32-D-051 80-P-32 32-E-106A 32-E-106B 32-E-106C 32-E-106D 32-E-106E 32-E-107 32-K-01 32-K-01 32-K-01R 32-K-01R 32-C-101 32-E-101 Page 4 of 4

71 32-PSV-103B 72 32-PSV-104 73 32-PSV-105

32-E-101 32-E-110 32-E-110

6.0

VALVE JOBS

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

Replacement of 20mm FO valve in Burner No. 1 . Revisioning/Replacement of NRV’s on discharge of K-01 and K-01R for heavy passing Revisioning/Replacement of discharge valves on K-01/K-01R Revisioning of discharge valves of P-110C/D/E Revisioning of NRV’s on discharge of P-110C/D/E Revisioning of P-103A/B suction valves(2Nos.) Revisioning of C-05 to P-103A/B suction valve Replacement of C-02 LCV bypass valve Replacement of common discharge valve of K-1/1R at the inlet of E-06. Replacement of P-102A suction valve. Revisioning of 18 Nos. ( dia 6” )of CW supply and return valves of E-06 Revisioning of Battery limit isolation valves

7.0

REPAIR / REPLACEMENT OF PIPING

7.1 7.2

Insulation of transfer line to be removed for complete inspection. Replacement of approx 4000 metre of corroded/ leaky tracer lines covering SR feed circuit, Asphalt circuit, DAO circuit and anti-foam injection lines, etc. E-107 inlet line leaky portion to be replaced. Replacement of P-104/104R, P-05A/B/C bearing cooling water lines. Repair of clamped portion of CW return line ex E-6A/A1. All CW oultlet vents /sampling point to be replaced as per inspection recommendation 6 valve wheels to be provided in the CW lines of E-06G/G1, E-06F/F1, E-06 E/E1 and E-06 C/C1. Fire Water sprinkler leak in Bullet area to be attended. E-106C/C1 S/S vent line is to be dechoked. Replacement of steam traps as required. Dechoking of 2” suction /discharge header to/from P-05A/B/C ex –Extractors-Approx 150M length( Pressure:40kg/cm2, Temp:75 C) Revival of hot Gas Oil flushing facility for all E-06 condensers-job involves dechoking of approx 100M of ¾” lines, provision of isolation valves with blinding facility-approx 10Nos. Capital maintenance of P-03/3R (asphalt service), for low pressure /low flow problem, malfunctioning of chicken lubricator, perennial gland leakage problem, both from steam side and process side. Capital maintenance of K-01 and K-01R to attend chronic problem of seal leak (due to shaft bending), low L.O pressure, outage of hand L.O pump, mal-operation of compressor loading valve facility, malfunctioning of chicken lubricator,etc. Revival of supply and return line filter/strainer facility in Seal Oil system of all P110A/B/C/D/E/F pumps. All governor Oil and seal oil tanks are to be cleaned, level indication and temperature indication are to be rectified. Positive isolation of VB, VM, CB and CM and all utility lines in U-32 Expansion areaThis involves cutting and providing flanges for blinding( approx 15Nos.) Revival of 32-B01/B02 drain facility through close circuit system vent to flare for safe operation. This involves Inspection of KOP in the circuit and de-choking, replacement of the line as per inspection recommendation.

7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12

7.13

7.14

7.15

7.16 7.17

Page 5 of 5

7.18 7.19 7.20 7.21 7.22 7.23

De-choking of ¾” evacuation line of all condensers of 32 E6 ( about 150 Meters) De choking / inspection of 10 /12” propane vapour line ex 32C2/C4 to E6 condensers for suspected chokage. Dechoking of shell side inlet line to E-06 E/E1, D/D1 and C/C1. Trap monitoring facility in C-110 steam sate lines is to be made functional. Deblinding of P-05A suction line ex C-01 Following piping replacement jobs as anticipated by Inspection to be done.

a) Partial replacement of FO/FG/Atomising steam /purging steam lines may come for. b) Major replacement of steam tracers. Approx 4000 Mt steam tracer line may come for complete replacement. Please note that along with tracers, insulation repair jobs will also be involved. Also provision shall be kept for new steam tracer headers as per requirement. c) The condensate steam piping shall come for replacement. Provision shall be kept for approx 300 Mt of dia 2” CS piping replacement. d) The leaky and externally corroded PSV discharge line of 32 B 01 & B-02 shall be completely replaced. The isolation valves in the line shall be revisioned. Matl- dia 8” Sch. 40 CS piping , approx length – 25 Mt. e) The O/H lines of extractor 32 C 01 A/B/C, 32 C110 & columns 32 C 108/C02/04/05/06 may come for partial replacement. f) The PSV inlet nozzles and steam vent nozzles above extractors/columns may come for replacement. g) The leaky dia 3” inlet line of 32 E 107 need replacement. Approx. length – 25 Mt. h) The dia 40 mm SS 316 / CS propane piping near 32 B 01 / 02 may come for partial replacement. Approx length – 50 Mt. i) The pipes on overhead pipe-rack between U-32 & U-35 corridor (N-S) shall be exposed by removing insulation, especially at support locations. Partial replacement of some of the lines are anticipated. Scaffolding will be required as well. j) The CW lines are in bad shape in most locations. The dia 8” CW line near 32 E 06 series is leaking. These CW lines will come for extensive repair. Positive isolation to be ensured for any repair jobs. k) It has been witnessed that repair of CW /FW lines are quite difficult as the isolation valves are not holding in most of the areas. To overcome this perennial problem, it is recommended that a phased revisioning of isolation valves to be planned. Apart from above, sufficient provision shall be kept for replacement of pipes as detected during shutdown inspection and approx. 200 mt each of dia 2”, 3” & 4” as well as 100 Mt of dia 6” pipes shall be kept for above purposes. Small bore piping around furnace Æ ½” – 300m, ¾” – 300m & 1” – 100m.

8.0

CIVIL MAINTENANCE

8.1 Water side (floating side, channel box, channel cover, tube sheet) of unpainted condensers & coolers to be painted using the following paint system : a) Surface preparation - Sand blasting to SA2½ b) Primer Inorganic Zinc Silicate by spray application (DFT 60 – 70μm single coat c) Mist coat HB epoxy by brush application (DFT 35 - 40μm in one coat) d) Finish paint HB epoxy by brush application (DFT - 150μm in two coats) Total min. DFT : 250μm 8.2

100% removals & re-insulation of hot insulation lines of all process & utility lines for requirement of line inspection, tracing steam replacement.etc.

Page 6 of 6

8.3 8.4 etc. 8.5 8.6

Painting of all bare lines, vessels & columns. Repair / replacement of all damaged hot insulation of columns, exchangers, pipes

9.0

INSTRUMENT JOBS

9.1

Rectification / checking of following thermocouples of 32F01 :a) TI02 (convection skin outlet) b) TI14 (flue gas ex. stack 1) c) TI15 (flue gas ex. stack 3) d) TI201 (box temperature, bottom right) e) TI202 (box temperature, top left) f) TI-29 COT indication goes out in rain and this problem is to be solved. g) TI-301 (Pass-2 Radiation o/l) h) TI-302(Pass-1Radiation o/l) i) TI-303(Pass-4 Radiation o/l) j) TI-304 (Pass –3 Radiation o/l) k) TI-27(Pass –1 Convection I/l) l) TI-28(Pass-2 Convection o/l) m) TI-305(Pass-3 Convection o/l) n) TI-306(Pass-4 Convection O/l) o) TI-39 (Flue gas Convection Inlet) p) TI-40(Flue gas Convection i/l) q) TI-41 (Flue gas conv i/l) r) TI-311(Flue gas conv i/l) s) TI-312(Flue gas con o/l) t) TI-48 (Flue gas conv o/l) Rectification of FI-26(cooling water to unit )flow indication VM and VB B/L flow indications. All. faulty draft gauges are to be rectified along with replacement of its chocked / corroded draft lines. Asphalt target flow meter to be recalibrated / rectified. All furnace pass flow indications to be checked.(FI-301,302,306 and 307) Following control valves are to be revisioned :a) 32LV01(C-1 BTM) b) LV-04(C-1B BTM) c) LV-07(C-1C BTM) d) FV-04K(C-110 BTM O/L) e) FC02K f) PC01K g) PC h) DPC

9.2 9.3 9.4 9.5 9.6 9.7

9.8 9.9 9.10 9.11 9.12 9.13 9.14

Repair/replacement of damaged refractory in F-01, including stack Painting of stack and all structure of furnaces.

Calibration of FI-50( FO inlet) and FI-51(outlet flow) in F-01 Calibration of AI-01 Oxygen analyser in 32F-01. C-110 bottom LC01Kand FC04K cascade to be changed to LC only (as in other extractors.) Provision of Pressure gauges on P-03/3R(Asphalt service), P-107A/B/C (antifoam service) with suitable facility for dampener, to take care of pulsating flow. Relocation of C-02 field level transmitter indication at ground level for easier monitoring. Provision of F-01 COT indication in field, for safety of operation Zero check/Rectification of tachometers and provision of local rpm indication for P110C/D/E/F

Page 7 of 7

9.15 9.16 9.17 9.18 9.19

Provision of suitable level gauge glass in place of existing PVC tube in B-07 tank and providing level indication facility at field and also at DCS, with software alarm facility Calibration of all internal float level trolls Calibration / stroke checking of all control valves Checking of all skin thermocouples Total interlock checking for the unit

10.0

ELECTRICAL JOBS

10.1

Hand lamps, floodlights & temporary electrical connections to be provided inside furnace, column, vessels & other locations as per requirement. Revisioning of motors & micro-switches of soot blower of 32F01. Maintenance of following Motors.

10.2 10.3

S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Tag No.

Type of Maint

32PM 104 32PM 104R 32PM 110C1 32PM 110C2 32PM 110D1 32PM 110D2 32PM 110E1 32PM 110E2 32PM 110A1 32PM 110A2 32PM 110B1 32PM 110B2 32PM 110A 32PM 110B 32PM 103 32PM 103R 32EM 116A1 32EM 116A2 32EM116B1 32E116B2 32EM116C1 31EM116C2 32EM116D1 32EM116D2 32EM116E1 32EM116E2 32EM116F1 32EM116F2 32P-110C3 32P-110D3 32P-110E3 32PM102A

"A" Schedule "A" Schedule "B" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule

Page 8 of 8

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

32PM102B 32PM102C 32PM110A1 32PM110A2 32PM110B1 32PM110B2 32PM102S1 32PM102S2 32KM-01 32KM-01R 36PM01 36PM02 36PM03 36PM04 32PM05A 32PM05B 32PM05C 32PM07A 32PM07B 32PM07C

"A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "B” Schedule "B” Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule "A" Schedule

NOTE: For B-schedule maintenance, mechanical maintenance, will decouple and shift motors to garage. 10.5

10.6

Checking of Lighting system including circuit checking, replacing fused lamps, cleaning of light fitting glass, checking and sealing of JB, s and if required replacing the defective light fittings etc. Dressing and removal of unused cables.

11.0

PROCESS MODIFICATION JOBS

11.1

Facility for online mixing of heavy extract and asphalt ex U-32 to produce bitumen bypassing U-36. Existing control valve in Cooling water make up line to 32-C-07 has to be converted to flow control valve . To provide shutdown valve(solenoid operated) based on High furnace box pressure, Low fuel Oil supply pressure, etc for safety of operation. Stack damper to be made pneumatic operated from DCS panel. Relocation of anti-foam injection point in asphalt circuit I) at downstream of C-110 bottom line connection ii) At upstream of C-02 LCV, instead of present connection at downstream.. Provision of depressurising ROV at B-03 outlet(3”) to flare, along with downstream isolation facility. ROV is required to be operated from DCS, for safety of operations. The ROV presently redundant on B-103 line can be utilised for this purpose. Relocation of the common discharge valve of K-01/1R at E-6 inlet to safe location. Dismantling and removal of redundant propane condenser E-02 and asphalt cooler E-109 and associated piping, for decongestion of pump-house area, for safe movement Revival of P-110F and connect it to DAO mix service ex-C-01A/B/C/110 to C-108, for running Unit at rated capacity. Relocation of existing PDA furnace 32-F-01 box & coil purging of steam line isolation valves to safe distance 15 M Replacement of inter stage KOD of 32-K-01 for providing auto draining facility Piping connections for installation of new propane compressor 32-K-101R

11.2 11.3 11.4 11.5

11.6

11.7 11.8

11.9 11.10 11.11 11.12

Page 9 of 9

11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20

Provision of minimum circulation line in DAO run down pumps Modification of cooling water lines in U-32 Provision of C2-C2 circulation facility in 32-P-103A/B Provision of back flushing facility for 32-E-117A Process scheme for providing double isolation valves and flanged ends at high pressure drain and vent points in U-32 Provision of ROVs at the suction lines of 32P110 A/B/C/D/E Dismantling of redundant lines & equipments in U-32 (PDA)(in addition to PS244) Dismantling of redundant lines & equipments in U-32 (PDA)

12.0

AF JOBS

12.1 12.2 12.3 12.4

Implementation of VR burning facility. Replacement of propane compressor 32-K-01 Replacement of 40 Nos. convection studded tubes in 32-F-01 Replacement of 8 Nos. modified new burners in 32-F-01 --------------- xx -------------

Page 10 of 10

JOB LIST NMP Extraction Unit FINAL LIST

1.0

FURNACE

1.1.0

Blinding / De-blinding, De-coking of Furnace, opening of Man-way, dropping of Burner Blocks, erection of volumetric Scaffolding inside the furnace, opening of Convection Manholes, opening of end-panels in Convection section, washing of convection tubes, external manual cleaning of radiation tubes, Inspection of Furnace, refractory / ceramic pad repair as per recommendations, checking of thermocouples, hydraulic pressure testing of coils, refractory repair of floor, revisioning of Burners, revisioning of Air-registers, revisioning of Soot-blowers, peeps holes, damper plates and boxing up of the furnace after completion of all activities in the Furnace

Furnace 38 F 01 & 38 F 02 • • • • • • • • • • • • • •

The furnaces shall be offered for inspection after decoking and cleaning of convection zone. Proper cleaning (washing or mopping) of coils to be done by DM water (service water & fire water is not suited as the tubes are of SS 304 L metallurgy. Inspection of Decoking pot & connected piping to be done. As both the raffinate & extract furnace have SS 304L tubes in the radiation zone, passivation will be required before opening. Inspection of convection coils after cleaning . Convection zone of 38 F 01 is made of SS 304 L material & hence passivation will again be required. Inspection of APH of 38 F 01 to be done after cleaning by washing on outside & blowing air inside the tubes. The thermocouple points are to be checked & repaired/replaced as per the need. The spigot /spigot sleeves shall be cleaned off any deposition. The burners shall be dropped to check the integrity of burner components etc. Refractory repairs of Floor, burner throats etc to be done. The FG / FO / Atomizing steam lines / purging steam lines connected to the furnaces shall be exposed by removing insulation. These piping may come for partial replacement. The Air duct connecting F01 & F02 shall be opened, cleaned and offered for inspection. Provision of scaffolding & lighting inside the furnace for inspection and repair jobs After completion of all hot jobs, product coils of both the furnaces shall be hydrotested. Inspection of transfer lines after removal of insulation and passivation.

2.0

COLUMNS

2.1.0

Blinding / De-blinding, opening of manholes, air circulation inside the Column, gas test & man-entry, opening of internals (wherever required), insulation removal around nozzles for thickness survey, erection of scaffolding inside the Column (wherever required), manual cleaning of Column internals, Inspection, repair / replacement (if required), re-fitting of Column internals, final box-up of the Column after completion of all activities .

2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8

38-C-01 38-C-02 38-C-03 380-C-04 38-C-05 38-C-06 38-C-07 38-C-08

2.1.9 38-C-09 2.1.10 38-C-10 2.1.11 38-C-11

3.0

VESSEL

3.1.0

Blinding / De-blinding, opening of manholes, air circulation inside the vessel, gas test & man-entry, opening of internals (wherever required), erection of scaffolding inside the vessel (wherever required), manual cleaning of vessel internals, Inspection, repair / replacement (if required), re-fitting of vessel internals, final box-up of the vessel after completion of all activities in the vessels. 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.15 3.1.16 3.1.17 3.1.18

38-V-01 38-V-02 38-V-03 38-V-04 38-V-05 38-V-06 38-V-07 38-V-08 38-V-09 38-V-10 38-V-11 38-V-12 38-V-14 38-V-15 38-V-16 38-V-18 38-V-20 38-V-21

(Replacement of Demister) (Insulation removal around nozzles)

(Replacement of Demister)

(Replacement of Demister)

Hydrotesting of 38-V-08, 09,10, 11, 12, 15 & 18 to be done.

4.0

HEAT EXCHANGERS

4.1.0

Check-III Activities Blinding / De-blinding, opening of covers, pulling out of tube bundles, hydro-blast cleaning of tube bundles, Inspection, repair / replacement (if required), insertion of tube bundles, shell test, tube test and final box-up of the equipment after completion of all activities of the heat-exchangers. a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p)

38-E-01 A/B/C 38-E-02 A/B 38-E-03 A/B RETUBING OF 38-E-03A 38-E-04 38-E-05 A/B/C/D 38-E-06 38-E-07 A/B/C 38-E-08 38-E-09 A/B 38-E-11 38-E-12 38-E-13 38-E-14 38-E-15 AIR FIN COOLER 38-E-16 38-E-17 Replacement of tube bundle

q) r) s) t) u) v) w) x)

38-E-18 AIR FIN COOLER 38-E-19 A/B 38-E-20 38-E-21 A/B 38-E-22 A/B 38-E-23 A/B/C 38-E-24 38-E-25 Replacement of tube bundle TOTAL : 40 Nos.

4.2.0

Check-II Activities Blinding / De-blinding, opening of covers, hydro-blast cleaning of tube bundles, Inspection, repair / replacement (if required), shell test, tube test and final box-up of the equipment after completion of all activities of the heat-exchangers. a)

38-E-10 Dismantling of entire equipment from location by means of crane, lowering to ground level, carrying out of maintenance activities, testing, etc at ground level and erection back in position by means of crane

4.3.0

Waterside of coolers/ condensers to be painted with self priming epoxy & followed by two coats of chlorinated rubber paint after sand blast cleaning. 38-E-02 A/B, 38-E-03 A/B , 38—06 , 38-E-11, 38-E-12, 38-E-13 , 38-E-17 , 38-E-21 A/B, 38-E-22 A/B , 38-E-24 , & 38-E-25.

4.4.0

Anticipated Tube Bundle Replacement: 38-E-02A/B 38-E-03A/B 38-E-06 38-E-11 38-E-12 38-E-13 38-E-17 38-E-21 A/B 38-E-22A/B 38-E-24 38-E-25

5.0

PRESSURE SAFETY VALVES

5.1.0

Blinding / De-blinding, lowering to ground, transportation to workshop, dismantling of PSVs/ TSVs, repair / replacement / revisioning, testing of PSVs /TSVs as per details contained in data sheet, erection of the PSVs back in position. PSV Æ 25 Nos. TSV Æ 17 Nos.

TAG NO. 38-PSV-1903 38-PSV-1904 38-PSV-1901 38-PSV-1902 38-PSV-1103A 38-PSV-1105A 38-PSV-1201A 38-PSV-1201B 38-PSV-1202 38-PSV-1301A 38-PSV-1301B 38-PSV-1302A 38-PSV-1302B 38-PSV-1303 38-PSV-1601A 38-PSV-1601B 38-PSV-1602 38-PSV-1801 38-PSV-1802A 38-PSV-1802B 38-PSV-1803A 38-PSV-1803B 38-PSV-2001 38-PSV-2002A 38-PSV-2002B 38-TSV-1101 38-TSV-1102 38-TSV-1103 38-TSV-1104 38-TSV-1105 38-TSV-1302A 38-TSV-1302B 38-TSV-1602 38-TSV-1501 38-TSV-1601 38-TSV-1603 38-TSV-1106A 38-TSV-1106B 38-TSV-1201 38-TSV-1301 38-TSV-1901 38-TSV-1902

6.0

LOCATION 38-P-14A/B 38-P-14A/B 38-P-15A/B 38-P-15A/B 38-C-01 38-C-02 38-C-02 38-C-02 38-V-06 38-C-07 38-C-07 38-C-06 38-C-06 38-V-15 38-V-09 38-V-09 38-V-01 38-V-12 38-V-05 38-V-05 38-V-04 38-V-04 38-V-16 6”-SH-38-1704-B2A 6”-SH-38-1704-B2A 6”-WCR-38-1102-A3A 6”-WCR-38-1101-A3A 38-C-01 8”-WCR-38-1103-A3A 38-C-02 ¾”-P-38-1367-A1A-IT ¾”-P-38-1370-A1A-IT 38-E-06 38-E-11 38-E-12 38-E-13 6”-TWR-38-1106-B2A 6”-TWR-38-1106-B2A 38-E-17 38-E-20 38-E-22 38-E-21

VALVE JOBS The following valve replacement / repair jobs shall be carried out a) b) c)

Revisioning of all AUDCO FG and Pilot Gas valves in F-01 and F-02 – 18 nos Replacement of P-08A/B needle valve on steam quench to seal line Replacement of P-08A seal cooler S/S outlet line needle valve

d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s)

7.0

Replacement of P-08A suction drain valve Replacement of P-08A casing drain needle valve Replacement of P-05B casing drain needle valve Replacement of P-18A steam quench to seal line needle valve Replacement of P-07B suction drain to CBD valve Repair/Replacement of P-02A steam quench line to seal valve 1” gland Replacement of P-02A suction drain valve P-09A steam quench line to seal 1” valve gland repair/replacement Replacement of P-09A steam quench line to seal needle valve Repair/replacement of P-09B 1” NRV bypass valve Replacement of P-04B casing drain needle valve Replacement of damaged root valve of PG on DM water make up line to E-25 Replacement of damaged PG drain valve on P-09A Replacement of steam trap b/p b/v drain dia 1” u/s of MHP steam to PC 2003 at B/L Replacement of C-09 stripping steam drain, as it is passing on fully closed condition Replacement of all CW sample point drains dia ¾” and dia 1” ~ 20 nos.

PIPING JOBS As this is the first major M&I, no typical trend in deterioration / replacement is known. Also, no typical experience exists for NMP induced corrosion. However, as NMP turns acidic in presence of water, the following piping need to be inspected at great detail. Necessary arrangements like scaffolding, insulation removal etc. shall be made to facilitate the same. The piping are :

7.1

7.14

Overhead lines connecting 38-C-10 to 38-V-04 , 38-C-01 to 38-V-07 , 38-C-03 to 38-V-09 , 38-C-04 to 38-V-05 , 38-C-08 to 38-V-09 , 38-C-09 to 38-V-05 , inlet line of 38-C-11(common PSV discharge header). Process lines: Both the transfer lines, 38-T-01/02 to 38-C-10 bottom , 38-V-05 bottom to 38-C-10,38V-09 to 38-C-10 , inlet & outlet lines of 38-V-08 , connected piping of the ejector systems. The bottom outlet lines of 38-C-11 & recirculating quench water line of 38-C-11 , barometric legs to hot welletc. All pump suction & discharge piping upto pipe racks. Condensate water circuit & cooling water circuit. LPD & HPV jobs: Stagewise inspection & subsequent root welding of all the LPD & HPV of all the critical lines. Inspection of leaky clamped lines to be done. Insulation of transfer line from F-01 to C-07 and F-02 to C-03 to be removed for complete inspection. Sample cooler lines of C-06 and C-10 to be dechoked and made operable All seal coolers in pumps P-8A/B, P-05A/B and P-18A/B to be taken out and cleaned and boxed up Provision to be made for relocation of C-07 LCV to C-08 at technological platform for easier operation and safe maintenance Relocation of E-10 on technological platform for easy/safe maintenance Replacement of all choked vent /sampling points from CW outlet of all coolers: E-11/E-12/E-13/E24/E-21A/B, E-22A/B Replacement of P-04A casing drain line elbow portion for leak.

8.0

TAG JOBS

7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13

8.1 8.2 8.3 8.4 8.5 8.6 8.7 •

FO & FG lines from battery limit to furnace to be flushed with steam / inert gas Dechoking/Replacement of flue gas sample point lines in F-01/F-02 E-05A S/S outlet first isolation valve gland and bonnet flange leak to be rectified E-05C to E-05D S/S and T/S interconnecting flange gasket leak to be rectified E-05A T/S outlet first isolation valve gland leak and d/s flange gasket leak to be rectified E-05A S/S inlet valve gland leak to be rectified Dechoking/thoroughness check of following lines: F-01 to C-07 transfer line

• • • 8.7

8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20 8.21 8.22

F-02 to C-03 transfer line C-07 to C-08 C-03 to C-04 Replacement of choked and corroded cooling water outlet vents point by 1” drain line with isolation valve in coolers: E-02A/B, E-03A/B, E11, E12, E13, E24, E-21A/B and E-22A/Bapprox dia 1”-20m & 12Nos. 1” valve MHP steam PV 2003 d/s b/v u/s flange leak VM steam header b/v spectacle blind flange behind V-16 in Tech platform-1 E-22A/B ejector condensers VM steam line b/v gland leak to be replaced 4 nos Foll leaks in P-08B to be attended- discharge b/v u/s and d/s flanges, NRV u/s and d/s flanges, NRV spindle leak, min circ b/v gland P-05B suction b/v flange leak to be attended F-01 pass flow-2 FCV u/s b/v to be attended P-06A discharge b/b u/s flange and its NRV u/s and d/s flange leak to be attended. P-06 discharge b/v u/s flange leak to be attended Foll leaks in P-03A to be attended- both flanges of NRV d/s spool piece and its discharge b/v gland P-03B discharge b/v gland leak to be attended P-18B min circ b/v gland leak and discharge b/v u/s and d/s flanges leak , equalising valve gland leak to be attended P-18A min circ b/v u/s flange and gland leak, NRV top cover flange and spindle leak to be attended P-09A/B discharge b/v d/s flanges and gland leaks to be attended P-11A/B discharge b/v u/s and d/s flanges (4Nos.) to eb attended P-11B NRV flanges and discharge B/v bonnet leak and gland leak to be attended

8.23

HP steam to E-14 c/v (FV-1502) u/s drain first isolation valve d/s flange gasket leak to be rectified

8.24

Rectification of gland leak from 1”VM steam valve to J-01A/B and J-02A/B (Total: 4Nos.)

8.25

Tracing Steam on IFO/FG/PG lines to F-01 and F-02 to be provided to prevent frequent burner chokage (approx length: ~ 250m)-- Fuel Oil congealing problem

8.26

6” VM Steam second isolation valve at B/L u/s flange gasket replacement

8.27

HP steam root isolation valve of PT-2013 at B/L and damaged vent valve to be replaced

8.28

HP steam at B/L TI-2001 point flange leak to be rectified by replacing gasket

8.29

MHP Steam c/v at B/L (PV-2003) first isolation valve u/s bonnet flange leak to be attended

8.30

Gasket replacement on 2” VM Steam to F-01 for atomising (Total : 2Nos.)

8.31

Repair / replacement of T-02A defective 2” drain valve

8.32

1” pressure equalising line from V-15 to E-16 gasket leak to be attended

8.33

MHP Steam to E-16 c/v (FV-1802) u/s flange gasket leak to be rectified

8.34

V-12 LCV (LV-1804) u/s valve u/s flange gasket leak to be rectified

8.35

HP Steam to E-10 (FC-1304) orifice root valve gland leak to be attended

8.36

Replacement of V-15 LG standpipe drain valve

8.37

E-09B S/S O/L flange gasket leak to be rectified

8.38

C-07 LG 2” isolation valves gland leak and bonnet flange leak to be rectified.

8.39

Rectification of seal leak in P-02

8.40

Revisioning of soot blowers of F-01

8.41

Repair/replacement of damaged checker plates/gratings (~ 100sq metres) on technological platform

8.42

Provision of 4” funnel with 2” header(~200 m length) for routing condensate from steam traps of copper tubes from LG’s, etc, of all columns and vessels.

8.43

Condensate collection system from steam traps near F-01 pass flow c/v’s to be suitably modified to avoid spillage

8.44

Dechoking of funnels and proper steam tracing on sampling points of all beds in C-02

8.45

Approx 25Nos. of defective small bore steam traps and around 30Nos of defective condensate/steam ¾” valves are to be replaced.

8.46

4000m to steam tracer lines replacement

8.47

S.O coolers of P-08A/B, P-18A/B and P-05A/b to be cleaned

8.48

C-10 bottom sampling point revisioning

8.49

Safe sampling point provision for raffinate and extract sampling like VBTar sampling point in U-37-safety point

8.50

Provision for sampling point drain tray like in U-84

9.0

MODIFICATION JOBS

9.1

Rerouting C-07 LCV to technological platform for easier operation and maintenance – safety point

9.2

Modification of structurals to facilitatemaintenence of E-10

9.3

Revisioning / modifying existing Pilot Gas facility suitably along with provision of PRCV (selfactuating), Pressure gauge, with fool-proof system in F-01/F-02, for safe operation of furnace.

9.4

Provision of K.O pot and strainers on FG/PG line to F-01/F-02 to arrest frequent carryover of liquid, etc. affecting burner operation.

9.5

Provision for routing V-09 liquid to C-02 bottom at P-10A/B suction and/or P-15A/B suction.-pending job.(related to solvent loss)

9.6

Provision of suitable strainer at Column outlet for arresting broken tray valves at C-09 and C-04, in line with existing provision in C-07.

9.7

Replacement of connecting flue gas duct between F-02 to F-01 by larger diameter pipe, to avoid box –presssurisation problem.

9.8

Provison for isolation valve on V-14 to V-04 transfer line suitably, for safe transfer of slop ex V-14-.For ease of operation and better slop management.

9.9

Addl fire fighting facility in column nos. 38-C-02, C-03/04, C-05/06/07, C-08/09 & C-10 in Unit-38

9.10

Provision of bypass line for the NMP run down cooler 38-E-06

9.11

Enlargement of duct of 38-F-02

10.0

INSTRUMENTATION JOBS a) Rectification of TI-1303 (C-06 inlet temperature), TI-1441 (F-02 stack temperature) and TI-1604 (C-03 inlet temperature) b) Revisioning of c/v LV-2002 (V-16 LCV) & TCV-1202 c) Checking of DP’s of all beds of C-02: DP-1202/1203/1204/1205/1206/1027 d) Oxygen Analysers AI-1801 and AI-1441 to be attended and rectified e) All draft gauges of F-01 and F-02 to be checked and calibrated f) PI-1701, PI-1754, PX-1442 and PI-1441 to be checked and rectified g) All skin thermocouples in F-01 and F-02 to be checked and repaired h) Replacement of defective c/v LV-2002 (V-16 LCV) i) (E-16 steam ) c/v FV 1802 to be attended for heavy passing j) All sight glasses on CW line to seal coolers in P-05A/B and P-08A/B and P-18A/B to be taken out and put back after cleaning. k) Repair of all self actuating PCV’s on Inert Gas blanketing line to T-01A/B and T-02A/B l) Rectification of FI-2101A (CW flow at B/L) m) Revisioning of following control valves: • PV-1301 (C-06 Pr Control) • PV-1302 (C-07 Pr Control) • PV-1605A/B (V-01 Pr control) • PV-1210A/B (V-06 Pr Control) • TV-1202 (Solvent to C-02 Temp Control) n) Checking and Calibration of following: • FI-1753/1752 (FD01A/B suction flow) • FX-1754 (Combustion Air Flow) • FI-1713/1709 (F-01 IFO inlet/Outlet flow) • FI-1409/1406 (F-02 IFO inlet /Outlet Flow) 0) Following to be attended for frequent malfunctioning in rain: • F-02 Pass Flows • V-01 Level • V-06 Level

ALL LOOPS ON AUTO TO BE ENSURED

Steam tracing to be checked. Civil maint. to do asbestos roping and celicote on the impulse piping. 1. HP steam at B/L TI-2001 point flange leak to be rectified by replacing gasket. 2. MHP Steam to E-16 c/v (FV-1802) u/s flange gasket leak to be rectified 3. 38FC1101 high side drain valve damage. To be replaced & 38FC1304 Root valve gland leakage to be rectify. 4. FIN fan cooler vibration switches indication to be provided on DCS. 5. Unit interlock to be checked and to be taken in line. TS to provide modified trip setting to take interlock in line because the current trip setting is appox. Equal to the process value. 6. 38FI1601 steam tracing to be extended to ground level. Near E14 first floor platform. 7. 38FT1507, 38FT1503 & 38FT1904 orifice flange leaking. Mech. Maint to replace the flange Gasket. 8. 38FI1204 root valve to be replace.

11.0

ELECTRICAL JOBS

a) Hand lamps, floodlights & temporary electrical connections to be provided inside furnace, column, vessels & other locations as per requirement. b) Revisioning of motors & micro-switches of soot blower of 38F01. c) Preventive maintenance of FD-01A and FD-01B d) Maintenance of all Motors. e) Rectification of VVVF Drive of E-15B f)

12.0

Checking of Lighting system including circuit checking, replacing fused lamps/emergency lamps, cleaning of light fitting glass, checking and sealing of JB’ s and if required, replacing the defective light fittings etc.

CIVIL JOBS a) • • b) c) d) e) f) g)

INSULATION Removal of approx 300M insulation, for rectification of steam leak and re-insulate./replace all damaged insulation Repair / replacement of all damaged hot insulation of columns, exchangers, pipes etc. Painting of all bare lines, vessels & columns, as per colour code. Painting of coolers / condensers. Painting of stack and structure of furnaces. All other jobs as per job list. Area development in Furnace and ground floor of technological platform, near V-07, with proper slope to avoid water-logging. Concreting of base/area around samplig point in B/L after installation of sample draini tray like in U-84

JOB LIST for FCCU ______________________________________________

_______Final List

1.0

FURNACE

1.1.0

Blinding / De-blinding, opening of Man-way, dropping of Burner Blocks, Erection of volumetric Scaffolding inside the furnace, opening of Convection Manholes, opening of end-panels in Convection section, water washing of APH module, external manual cleaning of radiation / convection tubes, Inspection of Furnace, refractory / ceramic pad repair as per recommendations, checking of thermocouples, cutting of tubes (if required), fitting of new tubes, welding of new joints, pre-SR X-ray, stress relieving of joints, post-SR X-ray, hydraulic pressure testing of coils using DM water, refractory repair of floor, revisioning of Burners, revisioning of Air-registers, revisioning of Soot-blowers, peeps holes, damper plates and boxing up of the furnace after completion of all activities in the Furnace

1.1.1

18-F-10

i)

Scaffolding with metallic jallies should be erected in such away that all the top return bends, middle of tubes are accessible. Through cleaning of all the return bends, tubes should be ensured for visual inspection and thickness survey along with OD gauging.

ii)

Repair/replacement of thermocouples as per Inspection recommendation followed by DP test.

iii)

Replacement of diffuser plate of burner assembly with 6 mm thickness , SS 310 plate.

iv)

Minor Ceramic fiber lining repair / replacements is anticipated. Moreover, refractory repair at floor & burner mouth is also anticipated.

v)

Internal insulation of hot air chamber of burner assy shall be renewed after painting.

vi)

All the spigot supports to be inspected after thorough cleaning & removal of its external cover.

vii)

Internal inspection of stack .

viii)

External painting of heater & stack with heat resistant Al paint .

ix)

Maintenance of soot blowers. To be dismantled from 18-F-10 and installed to 18-E-02.

1.1.2

18-F-03 (CO-Incinerator)

i)

The CO-Incinerator should be opened for internal inspection after thorough catalyst cleaning. Refractory repair is anticipated in the flue gas distribution chamber, conical portion of the main shell. Local refractory repair is anticipated at the burner mouth locations

ii)

The damaged internal refractory lining of outlet duct of CO-Incinerator shall be repaired using phosphate bonded refractory material (76 mm of H-W Greenlite 45-L + 76 mm of H-W LO ABRADE CASTABLE with 3 wt% of SS 304 fibres.

iii)

Damaged external painting shall be painted with one coat of Inorganic Zinc silicate coating (65-75 microns DFT / coat) after sand blasting followed by two coats of finish paints ( 20 microns DFT / Coat) of heat resistant silicone Aluminium paint suitable upto 500 C. Approx area – 5 M2.

iv)

Provision of valve in Flame Scanner install pipe.

1.1.3

CO-Stack & Ducts

i)

Refractory repair is anticipated mainly upto 50 meter height, inlet duct, bypass duct, and its blind end. Complete renewal of refractory is anticipated mainly upto CO bypass duct height including inlet duct. Moreover localised refractory damages are also anticipated at 70 – 80 meter height. External patch repairs to be done wherever required using SS-316L , 5-6 mm thick). Refractory material including lugs (Tata cast 15 Li (S), Lugs – SS-316L and dimension as per drawing) for 2007 shutdown to be used for above mentioned jobs.

ii)

Replacement of stack drain line with dia 6” sch-40S , SS-316L pipe.

iii)

Repair / replacement of stack access door as per original drawing using SS-316L material and refractory lining by tata cast 15 Li (s) with ss-316L lugs.

1.1.4

DFAHs ( 18-F-01/ 02)

i)

Both the Air heaters including connected hot air line shall be offered for internal inspection. Damaged external painting shall be painted with one coat of Inorganic Zinc silicate coating (65-75 microns DFT / coat) after sand blasting followed by two coats of finish paints ( 20 microns DFT / Coat) of heat resistant silicone Aluminium paint suitable upto 500 C. Approx area – 2 M2.

2.0

COLUMN

2.1.1

Blinding / De-blinding, opening of manholes, air circulation inside the column, gas test & manentry, opening of tray manways, erection of scaffolding inside the column (wherever required), unloading of structured packings from packed beds, manual cleaning of column internals, Inspection, repair / replacement as per inspection recommendations, fixing back of columns internals, box-up of tray manways and final box-up of column manholes after completion of all maintenance activities in the Columns.

i) ii) iii) iv) v) vi) vii) viii)

18-C-10 18-C-12 18-C-13 18-C-14 18-C-15 18-C-16 18-C-18 18-C-19

Tray nos. 26,27,28&29 including downcomers to be replaced

TOTAL : 08 NOS. •

Inspection approach for thickness survey of all the nozzle locations. Scaffolding erection for unapproachable nozzles from outside. Insulation to be removed from all the nozzle locations for thickness survey

•

Mechanical buffing (from inside) of weld joint between top dome and shell in 18-C-10, 18-C-13, 18-C-14, 18-C-15, 18-C-16 & 18-C-18 to facilitate wet fluorescent magnetic particle inspection (WFMPI) for suspected wet H2S cracking / H2 blistering.

•

External insulation to be removed from top dome and shell locations corresponding to operating temperature 50 – 120 C & 120 – 150 C to find out CUI. In case of deterioration, complete insulation renewal may come. The shell surface shall be painted with High temperature AL paint after proper manual cleaning.

3.0

REACTOR Blinding / De-blinding, opening of manholes, air circulation inside the Reactor, gas test & manentry, opening of internals, erection of scaffolding inside the Reactor (wherever required), manual cleaning of internals, Inspection, repair / replacement as per inspection recommendations, refractory jobs as per requirement, fixing back of internals, and final box-up of manholes after completion of all maintenance activities in the Reactor , External painting with high temperature Al paint.

3.1.1 i) ii)

4.0

18-R-01 19-R-04

REGENERATORS Blinding / De-blinding, opening of manholes, air circulation inside the Regenerators, gas test & man-entry, opening of internals, erection of scaffolding inside the Regenerators (wherever required), manual cleaning of internals, Inspection, repair / replacement as per inspection recommendations, refractory jobs as per requirement, fixing back of internals, and final box-up of manholes after completion of all maintenance activities in the Regenerators. 4.1.1

18-RG-01

4.1.2

18-RG-02

i)

Internal inspection of Catalyst lift line shall be offered after cutting the man-way at the top of catalyst distributor. Moving “Julla” to be provided for Internal inspection of Lift Line, for possible refractory / HEX mesh damage. Local repair is anticipated in abrasive resistant refractory lining (Resco AA-22S, 19 mm thick). Moreover, external surface of catalyst lift line shall also be inspected.

ii)

Internal inspection of shell refractory lining condition after provision of scaffolding from bottom upto the top. Metallic jallies are to be provided at different levels of scaffolding. Localized refractory lining repair is anticipated at the bottom conical portion of RG-02. Resco cast 9Li (125 mm thick) is required for such repair and approx area is 5 M2.

iii)

Inspection of all the cyclones (both external and internal) including their dip legs . Possible refractory repair in the Ducts connecting Primary Cyclone to Secondary Cyclone and Secondary Cyclone to Plenum chamber of RG-02. Refractory material (Resco 17E , 100 mm thick) may be ensured for approx 2 M2 area

iv)

Inspection of Air rings of both the Regenerators. Possible abrasive resistant refractory lining repair (Resco AA-22A, 25 mm thick) at outer and inner air ring of RG-01 and Air ring of RG-02. Approx quantity of anticipated repair – 5 M2 . Refractory material and Hex mesh (SS-304) shall be kept ready.

v)

Repair / replacement of Torch oil nozzles (SS 304H) in both the Regenerator. Replacement for 4 nos of nozzles as per M/s SWEC DRAWING.

vi)

Repair of bulged / damaged liner of bottom manhole of Regenerator-II using SS-304 (6 mm thick) material.

vii)

Repair of top support weld joint of catalyst lift line. Modification of top support weld joint of catalyst lift line as per SWEC approved drawing.

viii)

Inspection of the bathtub distributor after catalyst cleaning. Minor refractory lining (Resco AA22A, Resco cat 9Li) repair is anticipated , approx area – 1 M2.

5.0

RISER

5.1.0

WYE section and WYE Stabilization Ring:

i)

Riser bottom cover shall be opened for inspection of WYE stabilization steam ring.

ii)

Material for stabilization steam ring shall be ensured as per SWEC drawing no 18-A1-411-014 (Main ring: Mat- SS-304H, Dia – 3” SCH XXS pipe 170 Rad,, Drain Nozzle: Strictly as per SWEC drawing) for anticipated replacement / any eventuality.

iii)

External abrasive resistant refractory lining (Resco AA-22S, 25 mm thick) of the subject steam ring shall be renewed.

iv)

All the welding joints of WYE-Segment should be offered for DP test. Buffing of welding of WYEsegment also to be carried out to facilitate Ultrasonic Flaw Detection.

v)

Dechoking of one HCO nozzle of riser to be done

vi)

Dismantling and inspection of HCO, Feed and slurry nozzles.

5.1.1

Internal / External riser:

i)

Provision shall be made for thorough internal assessment of VC lining condition as well as abrasive resistant refractory lining with a movable trolley and proper lighting.

ii)

Repairs are anticipated in protective sleeves of feed nozzles / HCO nozzles / slurry back wash nozzle. with Stelliting electrode (Stellite 1 & 6).

iii)

Replacement of VB naphtha nozzle of Riser as recommended earlier vide Inspection report H/INSP/18.0 dated June 6, 2005.

iv)

VC lining repair may come in riser pipe and accordingly Resco 17 E to be kept ready for any (for approx 8 M2 areas having thickness of 100 mm).

v)

Abrasive resistant refractory Resco AA-22S to be kept ready for repair in internal riser for (approx 4-5 M2 areas having thickness of 25 mm.)

5.1.2

Termination device (LDD):

i)

Thorough inspection of ROT thermo well connections and this will necessitates cutting of cover plate of both the horizontal gas tubes. Material for ROT CAP to be kept ready.

ii)

Pre-Stripping steam ring including its drain nozzle (OD 60.3 mm, 8.74 mm thick, R200 (cold), SA 106 GR B) of both the Dipleg of LDD may come for replacement. Material for steam ring and its drain nozzle to be kept ready.

iii)

External abrasive resistant refractory lining (Resco AA-22S) of Pre-Stripping steam rings are also to be renewed. Local repair of abrasive resistant refractory lining (Resco AA-22S) of DIP Legs of LDD and vertical gas tubes of LDD are also anticipated.

5.1.3

Cyclones:

i) ii)

Arrangement should be made for internal inspection of cyclones using Rope ladder. Cleaning of External surface of Dip leg of both the cyclones for thorough visual inspection and thickness survey. Inspection of Trickle valves to be done for suspected erosion of seating / sealing surface. Inspection of all the support locations to be done after thorough cleaning (coke deposits also likely). Necessary scaffolding is to be prepared for inspection, wherever needed, to facilitate inspection.

iii) iv)

5.1.4

Stripper:

i)

Inspection of baffles of stripper section after cleaning and necessary approach.

ii)

Fluffing steam ring (CS, OD 88.9 mm, 7.62 mm thick, 6.5 mm & 5.9 mm drilled holes as per BHPV drawing no PPPV-2120-01-A-000-Rev A1 SHT 6 of 7) located at the bottom of stripper may come for repair / replacement.

iii)

Anticipated repair / replacement nozzle of main Stripping steam ring as per BHPV drawing no: PPPV-2120-01–A-000 – Rev A2 and as per details given below : Main nozzle: SA 105, Length – 115 mm, Nozzle ID – 19.5, RO ID – 12.5 mm, Quantity - 10 nos Drain nozzle: SA 105, Nozzle ID – 22 mm, RO ID – 6 mm, Length – 155 mm, Quantity - 3 nos

iv)

Refractory lining (Resco 9Li, 100 mm thick) damage is anticipated at the Fluffing steam ring location and the same shall be repaired, if required, with “Tapered plug” design as per SWEC earlier recommendation using Resco cast 9Li refractory.

6.0

VESSEL

6.1.0

Blinding / De-blinding, opening of manholes, air circulation inside the vessel, gas test & manentry, opening of internals (wherever required), removal of external insulation of nozzle location and inspection pockets provision at shell area especially at top and bottom for insulated vessels, erection of scaffolding inside the vessel (wherever required), manual cleaning of vessel internals, Inspection, repair / replacement (if required), re-fitting of vessel internals, hydrotesting as per Factory Act, external painting , final box-up of the vessel after completion of all activities in the vessels.

i) ii)

17-B-01 - SS –316 seal weld of outlet duct flange 18-B-03 - Damaged manhole liner is to be replaced in 18-B-03 (Withdrawal well) with SS-304, 5-6 mm thick plate, having expansion slot as per SWEC guidelines. Dechoking and repair of air ring 18-B-11 - Anticipated replacement of Demister pad 18-B-12 18-B-13 18-B-14 18-B-15 18-B-17 18-B-18 18-B-19 18-B-20 18-B-21 18-B-22 18-B-27 - Coalescer pad replacement in 18-B-27 18-B-28 18-B-29 18-B-33 19-B-01 19-B-02 19-B-03 - Anticipated replacement of Demister pad 19-B-06 19-B-20 - Anticipated replacement of Demister pad 17-B-04, 17-T-03/ 05/ 06/ 07&10 at BELCO to be cleaned

iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) xix) xx) xxi) xxii) xxiii) •

Mechanical buffing of weld joints to top dome from inside in 18-B-11, 18-B-12, 18-B-13, 18-B-14, 18-B-19, 18-B-20 & 18-B-21 to facilitate wet fluorescent magnetic particle inspection (WFMPI) for suspected wet H2S cracking / H2 blistering.

•

Removal of external insulation of nozzle location and inspection pockets provision at shell area especially at top and bottom for insulated vessels. In case of CUI, complete removal of insulation and painting to be done followed by re-insulation.

•

Internal cleaning to be carried out before offering for internal inspection and thickness survey.

•

Opening and cleaning of Demister pad assembly in 18-B-11, 18-B-12, 18-B-13 18-B-19, 18-B-20, 18-B-21, 18-B-22, 19-B-03 & 19-B-20.

•

External painting of vessels is to be done as per IOCL painting manual. External insulation job is to be done as per inspection recommendation during shutdown

•

18-B-21 & 19-R-04 vent outlet flame arrestors at CO incinerator to be fitted back and its connected piping to be dechoked

6.1.1

Orifice Chambers

i)

All the manholes of both the orifice chambers should be opened for internal inspection.

ii)

Injection of pump-able thermal ceramic fiber through the existing 4 nos external threadolets at each and every grid level of both the orifice chambers. Fiber lining details is as per BHPV drawings nos. PPPV – 2120 11 – A-002 (Rev 3) & PPPV – 2120 12 – A-002(Rev 2).

iii)

Man way opening through grid levels to be made by cutting welded segments of grids at its central location & this is to be done for all the grid level of both the orifice chamber.

iv)

Repair of damaged refractory lining should be carried out as per specifications given in BHPV drawings nos. PPPV – 2120 11 – A-002 (Rev 3) & PPPV – 2120 12 – A-002(Rev 2).

v) vi)

Anticipated replacements of grid nozzles. Two nos internal Retainer plate (CS & SS – 304H, 18 MM thick each) may come for replacement. Dimension of plates are as per M/S BHPV drawings PP-2120 12 –A-000 Rev 4. This may please be made available.

vii)

Two nos internal Retainer plate (CS & SS – 304H, 18 MM thick each) may come for replacement. Dimension of plates are as per M/S BHPV drawings PP-2120 12 –A-000 Rev 4 .

6.1.2

Bellows of Flue Gas Line

i)

Dia 96 inch bellow installed at the outlet of CO-Incinerator (Tag No- VA-359-1) should be replaced with upgraded metallurgy (Inconel – 625 LCF) .100% radiography of weld joints shall be carried out in addition to normal inspection procedures like fit up check, DP check.

ii)

Inspection of all the other bellows installed in flue gas lines to be done after removal of external protection covers . The 54” bellow in flue gas line ex RG-01 (Tag No VA-357-R1), which was replaced in May / June –2003 with the then available SS-304 metallurgy may require replacement with upgraded metallurgy (Inconel-625 LCF). Final decision shall be taken based on the shutdown observation.

iii)

Inspection of Bellows installed at the spent catalyst line as well as at the catalyst lift line to be done after removal of external protection cover plates.

iv)

Misaligned bellow between CO-Boiler outlet duct and inlet of Quench tower is to be rectified as per ES opinion. This was not done in the last shutdown. Drawing to be supplied by ES deptt.

v)

Other bellows ( 54” & 42”) in R/R section and bellows at the inlet of 17-P01 A/B/C to be offered for inspection.

7.0

HEAT EXCHANGERS

7.1.1

Check-III Activities

Blinding / De-blinding, opening of covers, pulling out of tube bundles, hydro-blast cleaning of tube bundles, Inspection, repair / replacement (if required), painting of all water side channel / channel cover / partition plates with high build epoxy paint after proper surface preparation (SA 2½ ), replacement of sacrificial anodes as per inspection recommendations, insertion of tube bundles, shell test, tube test and final box-up of the equipment after completion of all activities of the heat-exchangers.

i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) xix) xx) xxi) xxii) xxiii) xxiv) xxv) xxvi) xxvii) xxviii) xxix) xxx) xxxi)

18-E-10A/B 18-E-11 18-E-12 18-E-13 A/B 18-E-14 18-E-15 18-E-16 A/B 18-E-18 A/B 18-E-19 A/B 18-E-21 A/B 18-E-23 18-E-24 18-E- 25 A/B 18-E-26 18-E-27 18-E-28 18-E-29 18-E-30 18-E-31 18-E-32 A/B 18-E-33 A/B 18-E-34 A/B 18-E-35 18-E-36 A/B/C/D 18-E-37 18-E-38 A/B 18-E-40 A/B/C/D/E/F 18-E-41 18-E-42 A/B 19-E-01 19-E-02

7.1.2

Check-II Activities

Blinding / De-blinding, opening of covers, hydro-blast cleaning of tube side, Inspection, repair / replacement (if required), painting of all water side channel / channel cover / partition plates with high build epoxy paint after proper surface preparation (SA 2½ ), replacement of sacrificial anodes as per inspection recommendations, shell test, tube test and final box-up of the equipment after completion of all activities of the heatexchangers. 1. 2. 3. 4.

Surface condensers Ejector condensers gland steam condensers lube oil coolers

7.1.3

Cleaning & Maintenance activities of the following air coolers – The following air fin coolers are to be offered for inspection as below.

•

18-EA-10, 18-EA-11-A/B/C/D, 18-EA-12, 18-EA-13-A/B/C/D, 18-EA-15-A/B/C/D & 18-EA-16.

•

Cleaning of tube bundles by hydro jetting. Fan blade removal and scaffolding erection upto tube height.

•

Anticipated replacement of 18-EA-13 A/B. Material availability as per our inspection recommendation vides H/INSP/18.0 dated June 6, 2005 may be ensured.

•

As recommended earlier vide H/Insp/18.0 dated 14/08/2006, material availability for 18-EA-11 C/D (Two nos) may be ensured for anticipated replacement.

•

As recommended earlier vide H/Insp/18.0 dated 29/12/2006, material availability for re-tubing of 18-EA-10 A/B (Two nos) may be ensured for anticipated replacement

•

Tube ID measurement from both header ends. Therefore degree of cleaning shall be extremely good.

•

Visual inspection of internal condition of tubes is to be carried out before and after hydro jetting.

•

Tube testing is to be carried out at respective test pressures. Individual ttube test arrangement may be ensured for identification of leaky tube, if any. Approach from bottom and proper illumination is required during hydro test.

7.1.4

Cleaning & Maintenance activities of 18-E-02 Although the flue gas cooler (18-E-02) will be due for IBR inspection in April-2007 As a routine practice, IBR authority will witness dry inspection as well as hydro testing at 37.5 kg/cm2 (g) pressure. The following components are under the preview of IBR inspection.

i)

Opening, cleaning & internal inspection of both the drums .

ii)

Through cleaning of bottom bends of economizer coils to be carried out before IBR inspection.

iii)

Cleaning and inspection of downcomer / bank tubes/super heater coils /screen tubes/headers. Casing plate to be cut for thorough inspection of Screen tubes, at top header location. 3 nos of screen tubes, which were patch repaired earlier, shall be replaced in the shutdown. Material specifications: (OD – 50.8 mm, 3.25 mm thick, SA 210 GR A1 HFS, IBR material and length and shape as per drawing no HJ G317 0291 of M/s Thermax).

iv)

Replacement of steam drum safety valves(2 Nos.). Super heater safety valve shall be overhauled & tested at W/S.

v)

Replacement of 29 nos of bank tubes, which were patch repaired earlier on account of localized thinning caused by improper soot blowing.

vi)

Leaky drain line of CO-Boiler is to be replaced using ASTM A 106 GR B, SCH-160 pipe.

vii)

Anticipated replacement of one no. super heater coil (coil no 16, counting from top), which was plugged during May / June 2003 shutdown .

viii)

Replacement of manhole cover of Screen tube zone,if reqd, shall be as per Thermax’s existing drawing.

ix)

Replacement of gasket sealing at the rectangular joint between flue gas cooler and connecting duct (Ex CO-Incinerator).

x)

All the jobs shall be carried out by ibr approved agency and compliance with all the ibr rules and requirements including material identification, repair procedure approval, stage wise inspection/approval and final hydro test clearance.

xi)

Hydro testing of flue gas cooler is to be carried out at 37.5 Kg/Cm2 g pressure using DM water .

8.0

PRESSURE SAFETY VALVES

Blinding / De-blinding, lowering to ground, transportation to workshop, dismantling of PSVs, repair / replacement / revisioning, testing of PSV as per details contained in PSV data sheet, erection of the PSVs back in position. Revisioning and testing of the following safety valves to be carried out. PSV/TSV Nos.

LOCATION

18-PSV-1001 18-PSV-1002 18-PSV-1003 18-PSV-1004 18 PSV 0102A 18 PSV 0102B 18 PSV 1103 18 PSV 1104 18 PSV 1105 18 PSV 1201A 18 PSV 1201B 18-PSV-3601 18 PSV 3701 18 PSV 3702 18 PSV 3703 18 PSV 3801 18 PSV 3901 18 PSV 3902 18 PSV 4001 18 PSV 4002 18 PSV 4101 18 PSV 4201 18 PSV 4202 18 PSV 4301 18 PSV 4302 18 PSV 4401 18 PSV 4402 18 PSV 4501 18 PSV 4502 18 PSV 4601 18 PSV 4701 18 PSV 4702 18 PSV 4703 18 PSV 4801 18 PSV 5101 18 PSV 5102 18 PSV 5103 18 PSV 5104 18 PSV 5301 18 PSV 5302 18 PSV 6501 18 PSV 6601 18 PSV 6602 18 PSV 6603

18-E-02(DRUM) 18-E-02(DRUM) 18-E-02(super heated steam ) 18-B-51 (FLASH TANK) Air Blower Disch Air Blower Disch 18-B-06 (2”CT-18-1118-A14A) 18-B-07 (2”-CT-18-1119-A14A) 18-B-08(2”-CT-18-1120-A14A) 18-B-01(8”-WDM-18-1201-A1K) 18-B-01(8”-WDM-18-1202-A1K) 2”-P-18-3603-B4F-IT O/H LINE OF 18-R-01 O/H LINE OF 18-R-01 O/H LINE OF 18-R-01 18-B-11 18B12(4”P-18-3905-A16A) 18B13(3”P-18-3915-A16A) 2ND STAGE DISCH OF 18-K-10 2ND STAGE DISCH OF 18-K-10 18B14(4”P-18-4110-B16A) 18-C-13 (6”-P-18-4215-B16A) 18-C-13 (6”-P-18-4216-B16A) 18B15(4”P-18-4315-B16A) 18B15(4”P-18-4314-B16A) 18C15(3”P-18-4410-B16A) 18C15(3”P-18-4409-B16A) 18-C-16(8”-P-18-4511-B16A) 18-C-16(8”-P-18-4510-B16A) 18B17(4”P-18-4619-B16A) 18C17(12”P-18-4708-A1A) 18C17(12”P-18-4709-A1A) Naphtha splitter re-boiler 18-B-18 18E18A(SV-18-5101/2-B2A) 18E18B(SV-18-5102/2-B2A) 18E18B(SV-18-5103-B2A) 18E18B(SV-18-5104-B2A) 18-E-20 18-E-20 18B32(4”P-18-6501-A5A) 18B24(3”SL-18-6602/3-A2A) 18B24(3”SL-18-6602/3-A2A) LPG

PSV/TSV Nos. 18 PSV 6604 18 PSV 7201 18 PSV 7202 18 PSV 7301 18 PSV 7302 18-PSV-8601 18-PSV-8602 18 PSV 8701 18 PSV 9101 18 PSV 9301 18 PSV 9302 18 PSV 9701 18 PSV 9901 18 PSV 9902 18 PSV 9903 18 PSV 9904 18 TSV 3201 18 TSV 3202 18 TSV 3203 18 TSV 3204 18 TSV 3205 18 TSV 3206 18 TSV 3207 18 TSV 3208 18 TSV 3209 18 TSV 3210 18 TSV 3801 18 TSV 3901 18 TSV 4101 18 TSV 4301 18 TSV 4401 18 TSV 4901 18 TSV 4902 18 TSV 4903 18 TSV 4904 18 TSV 5001 18 TSV 5002 18 TSV 5003 18 TSV 5004 18 TSV 5005 18 TSV 9901 18 TSV 9902

LOCATION LPG MHP BFW MHP BFW LP STEAM LP STEAM 17-P09A 17-P09B MERCAP /H2/VAP 18-B-23(3”P-18-9109-A19A) 18-B-21(rich amine flash drum 18-B-21(rich amine flash drum) 18-B25(SL-18-9702-A3A-IH) AMINE REGENEATOR AMINE REGENERATOR MP STEAM TO REBOILER MP STEAM TO REBOILER 8”P-18-3106-B1A 8”P-18-3201-B1A 8”P-18-3202-B1A 8”P-18-3203-B1A 8”P-18-3233-B9A

8”P-18-3252-B1A 8”P-18-3236-B9A

¾”P-18-9918-A6K

9.0

VALVES SCSV/ RCSV / DDSVs shall be opened for inspection & maintenance. Partial replacement of orifice plate, guides, disc may come after inspection. , hex-mesh, resco aa-22s and spares etc to be kept ready. Checking and repair / replacement of hand wheel gear system.

Inspection of plug valve and possible replacement / repair of plug. Checking and repair / replacement of hand wheel gear system Replacement of about 20 Nos. 3” & 2” valves in Amine circuit.

10.0

PIPING JOBS Scaffolding erection and, or insulation removal to be carried out for the following piping circuits for inspection purpose. HPV and LPD locations are also to be offered for thorough inspection (after insulation removal for insulated line). All the bends / reducers are to be exposed for inspection purpose. Moreover, representative samples of main pipes are also to expose for inspection (Min. 10% of main pipe). Replacement recommendations, if any, shall be communicated after the subject inspection. Moreover, Inspection pockets shall be provided in insulated lines.

a) b) c) d) e) f) g) h) i) j) k) l) m) n) o)

SLURRY CIRCUIT HEATER TRANSFER CIRCUIT 18 C 10 OVERHEAD LINE UPTO MAIN FRACTIONATOR OVERHEAD RECEIVER CIRCUIT HCO CIRCUIT (RECYCLE) DEBUTANIZER COLUMN FEED CIRCUIT ABSORBER OVERHEAD VAPOUR CIRCUIT DEBUTANIZER OVERHEAD CIRCUIT HCO PUMP AROUND CIRCUIT OVERHEAD RECYCLE VAPOUR CIRCUIT STRIPPER FEED AND ABSORBER FEED CIRCUIT SPONGE ABSORBER FEED VAPOUR & OFFGAS FROM SPONGE ABSORBER CIRCUIT LPG PRODUCT & DEBUTANIZER REFLUX CIRCUIT FCCU FEED CIRCUIT NAPTHA SPLITTER REFLUX & LCN PRODUCT CIRCUIT OVERHEAD NAPTHA SPLITTER CIRCUIT

NOTE : All HPV & LPD of hydrocarbon lines shall be inspected and weld reinforcement will be done with provision of additional valves wherever required.

REFRACTORY LINED PIPELINES The following pipelines shall be offered for internal inspection / cleaning and refractory repairs, if any. - Flue gas lines Ex 18-RG-01 & 18-RG-02 - Flue gas lines Ex 18-B-04 & 18-B-05 - Reactor overhead line – coke removal job. - Spent catalyst stand pipe - Regenerated catalyst stand pipe

Replacement of distorted hanger rods of constant spring supports installed on flue gas line Ex 18RG-02 - 4 nos.

11.0

CIVIL JOBS

1)

Complete insulation renewal at Super heater headers, Screen tube headers and at the membrane panel casing locations.

2)

Water side (channel head / channel box / partition plates etc.) components of coolers /condensers to be painted with high build epoxy paint after proper surface preparation (Sa 2 ½)

3)

All other jobs as per list.

12.0

MODIFICATION JOBS

1) 2) 3) 4) 5) 6) 7) 8) 9)

Tray replacement / revamp jobs in 18-C-13 and 18-C-16 Dechoking of dia 3” piping about 100 M in BELCO circuit Provision of caustic line in T-109B and caustic supply to MSQ Provision of control valve and flow water in the bypass and inlet of pall filter respectively Process scheme for segregation of wild naptha and MSQ naptha injection to FCCU reactor riser Provision of inter-connection between 18P42A/B and 18P52A/B from discharge Provision of jump over connection in MSQ lean/rich Amine to FCCU Amine section Replacement of RFCCU stack Platform at dosing tank in MAB (only drawing required)

13.0

ROTARY EQUIPMENT

1) 2) 3) 4) 5) 6) 7)

Capital overhauling of wet gas compressor & turbine Capital overhauling of MAB compressor & turbine Overhauling of trip oil system of MAB and checking of thermocouple Overhauling of governing oil system of WGC and checking of thermocouple Overhauling of LO & CW pumps of both MAB & WGC Overhauling of bottom pumps PALL filter replacement of 18-P-60 depending on material availability.

14.0

MISCELLANEOUS JOBS

1)

Replacement of filter cartridges for Lean amine & Rich amine

15.0

AF JOBS

1)

Water trim cooler at debutaniser overhead circuit of RFCCU

2)

Modification in Belco Filtering Module

16.0

TAG JOBS

GASKET REPLACEMENT JOB Sl

Job description

Action by M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

18FIC4701 F.O gasket leak. 18E27 LCO I/L and O/L exchanger body nozzle gasket leak. 18TV4201 D/S B/V gasket leak. 18P14A discharge B/V gasket leak. 18P13A/B suction/discharge B/V gasket leaks. 1818TC3406 D/S B/V gasket leak. 18FC3403 U/S and Bypass B/V gasket leak. 18P16B discharge B/V gasket leak. 18FC3202 D/S NRV gasket leak. 18C10 Level tapping body valve gland and gasket leak. 18F10 Hot feed and F10 bypass B/V at manifold gasket leaks. 18FIC 3301 and 18 FiC3303 F.O flange gasket leaks. 18FC3303 CV flange gasket leak.

14. 15. 16.

18FC3303 D/S B/V gasket leak. 18FC3301 U/S B/V gasket leak. Lean and Rich amine charcoal filter manifold B/V gland and gasket leaks.(List earlier given to M/M) 18P37 Min circulation CV U/S B/V gland and gasket leak. 18E18A/B slurry I/L B/V gasket leaks. 18E21 DW water O/L flange gasket leak.(short bolting). 18E15 BFW O/L flange gasket leak. 18E40 Slurry I/L and O/L and B/V gland and gasket and exchanger Nozzle gasket leaks. 18E16B channel head gaskets leak. 18E18A BFW I/L D/S B/V bonnet leak. 18E19B slurry I/L flange and.channel head gasket leaks. PALL filter receiver PSVs isolation and bypass B/V gasket leaks.Vessel and PALL B/L slurry I/L and O/L B/V gasket leaks. 18P60A discharge flange gasket leaks. 18P37A/B suction and discharge B/V gasket leaks. 18P37A/B warm up line break flange Gasket leaks. 18P37B suction and discharge nozzle gasket leak 18P16B discharge Nozzle gasket leak. 18P15B discharge Nozzle gasket leak 18P15B discharge B/V gasket leak. 18P14A/B discharge nozzle gasket leak and 18P14B suction Nozzle gasket leak. 18FIC3505 F.O gasket leak. VR To FCCU 18FV2222 U/S B/V gland leak.

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M

FLANGE JOINTS JOBS Sl 1 2 3 4 5 6

Job description 18E29 floating head cover leak –gasket replacement 18E27 tube side I/L and O/L nozzle gasket replacement. 18TV4201 C/V U/S B/V U/S flange gasket replacement. 18TV4201 C/V D/S B/V U/S flange and bonnet gasket replacement. 18FV4201(E27) C/V bypass B/V U/S flange, U/S B/V U/S and D/S flange, and CV U/S flange gasket replacement( 4 nos) 18FI4201 orifice flange gasket to be replaced.

Tag No. 157 162 163 164 165 166 168

Action by M/M M/M M/M M/M M/M M/M

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

18FV2222 bonnet gasket to be replaced. 18P13B discharge B/V D/S flange gasket top be replaced. 18P12B suction B/V U/S flange gasket to be replaced. 18P14A suction line nozzle flange gasket to be replaced. 18P14B suction and discharge nozzle gasket to be replaced. 18P13B discharge B/V U/S flange gasket replacement 18P13B suction B/V U/S flange gasket replacement 18P13A discharge B/V U/S and D/S gasket replacement. 18P13A suction B/V U/S flange gasket replacement. 18P13A/B discharge line orifice flange gasket replacement. 18P15B flushing oil line B/V D/S flange leak . 18P15B suction and discharge nozzle flange gasket to be replaced. Slurry quench CV U/S and D/S B/V gasket to be replaced. Slurry quench CV bypass valve bonnet gasket to be replaced. 18P16B discharge B/V U/S flange and NRV top flange gasket to be replaced. 18P16B discharge line orifice flange gasket to be replaced. 18P37A W/U line B/V flange to be replaced. 18P37A discharge valve and NRV top flange gaskets to be replaced. 18P37A suction line B/V flange gaskets to be replaced. 18P37B warm up line B/V gaskets to be replaced. 18P37B discharge B/V U/S gasket to be replaced. 18PP37B NRV top flange gasket to be replaced. 18P37B suction B/V both gaskets to be replaced. 18P37B suction nozzle flange gasket to be replaced. 18P37B discharge nozzle flange gasket to be replaced. 18P37 FLO line 3 Nos of gaskets to be replaced. HCO to riser line near P16A NRV D/S gasket to be replaced. HCO to riser C/V bypass B/V both gaskets to be replaced. HCO PA C/V bypass B/V U/S flange and B/V bonnet gasket to be replaced. HCO PA C/V U/S flange gasket to be replaced. 18FV3501 CV bypass B/V both gaskets to be replaced. 18SOV3401 D/S B/V D/S flange gasket to be replaced. Slurry C/V D/S B/V U/S & D/S flange gasket to be replaced. DCO to 18P37 B/V D/S flange gasket to be replaced. HCO to PALL filter B/V U/S and D/S flange gaskets to be replaced. MHP main header near 18P02 condensate leg end flange gasket to be replaced. Feed nozzle gasket to be replaced. 18C10 level troll nozzle flange gasket to be replaced. Feed Dispersion steam Cv-18FV0505 –U/S and D/S gasket to be replaced. Fed to riser SDV-18SDV0506- flange gaskets to be replaced.

171 217 218 220 212 221 222 223 224 227 228 229 234 235 236

I/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M

237 244 245 246 248 249 250 252 253 254 255 258 259 263

M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M

265 269 283 284 286 287 295

I/M M/M M/M M/M M/M M/M M/M

301 304 305

M/M M/M I/M

306

I/M

Tag No. 137 138 141 142 143 144 145

Action by M/M M/M M/M M/M M/M M/M M/M

VALVE-GLAND JOBS Sl 1 2 3 4 5 6 7

Job description 19B06 product B/V gland packing replacement (S/D) 19B06 caustic line C/V D/S B/V gland packing (S/D) 19B20 caustic manifold 2 nos of B/V gland packing. 19B06 caustic line B/V gland packing. 19B06 caustic line 2nd B/V gland packing. 19B06 product line B/V gland packing. 19B06 product O/L B/V gland packing.

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

18P29B discharge B/V gland packing 18P12B suction B/V gland packing. 18P13A Discharge B/V gland packing to be done. 18P13A seal quenching line B/V gland to be tightened. Slurry quench C/V bypass B/V gland packing to be redone. 18P37A W/U line B/V gland packing to be changed. 18P37B vent line B/V gland packing to be changed. HCO to riser C/V U/S and D/S B/V and bypass B/V gland packing to b replaced. 18P16A/B suction and Discharge B/V gland packing to be redone. HCO PA C/V bypass B/V gland packing to be redone. HCO PA C/V gland packing to be replaced. 18FV3501 gland packing to be replaced. MP steam B/L B/V gland leak to be attended. LP steam B/L B/V gland leak to be attended. Tracing steam to Feed line B/B gland leak to be attended. 18P13A W/U line B/V gland leak to be attended. 18PC1002 U/S B/V gland leak to be attended. Steam to 18P02 C/V and CV D/S B/V gland leak to be arrested.

197 207 223 225 235 244 253 260

M/M M/M M/M M/M M/M M/M M/M M/M

262 263 264 268 270 271 275 276 296 298

M/M M/M I/M I/M M/M M/M M/M M/M M/M I&M/M

MISCELLANEOUS JOBS Sl 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Job description 19LC5401 U/S and D/S bleeder lines to be end capped. Service airline drain bleeder wheel to be fixed and line end blinded. Process air line PG drain line valve wheel providing Catalyst pot U/S vent bleeder to be end blinded. 19R04 caustic drain line to be end blinded. 19B06 ½” caustic line CV U/S&D/S drain bleeder to be end blinded. 19B06 caustic line B/V to be replaced.(S/D job) 19B20-ex P03 manifold B/V to be replaced.(S/D) 19B20 vent line to CBD drain lined end blinding. DM water line U-bend drain bleeder end blinding. DM line U-bend drain bleeder end blinding. 18P53A suction line B/V D/S end blinding. 18P53A discharge NRV D/S bleeder end blinding. 18P53B suction line B/V D/S end blinding 18P53B discharge NRV D/S bleeder end blinding. PCV D/S drain bleeder end blinding. Anti-oxidant tank level HP tapping drain end blinding. 19B20 caustic mixture drain bleeder wheel fixing and end blinding.(S/D) 18E42B CW line drain bleeder end blinding. 18E29-18FV3402 C/V U/S drain bleeder end blinding. 18LV4702 C/V D/S drain bleeder end blinding. 18E30 shell side I/L line B/V U/S drain bleeder end blinding. Near 18C14 fire header B/V D/S adaptor to be fixed. 18E27-C13 reboiler line to pump out line inter connection spool drain line end blinding. 18FV4201 C/V U/S drain bleeder end blinding. Fuel gas ex C-18 near 18P19B B/V D/S drain bleeder to be end blinded. 18P19B warm up line B/V wheel missing. VR to FCCU C/V bypass B/V replacement 18P19A discharge line drain bleeder B/V wheel missing. 18P30A seal pot CW supply B/V wheel missing. 18P31B PG drain line cap to be provided. 18P30A PG drain line end cap to be provided 18P27B lube oil cup to be fixed properly

Tag No. 128 129 130 131 132 135 136 139 140 146 147 148 149 150 151 152 153 154 155 156 158 159 160 161

Action by I/M M/M M/M M/M M/M I/M M/M M/M M/M M/M M/M M/M M/M M/M M/M M/M I/M M/M M/M I/M I/M M/M M/M M/M

167 169 170 171 172 173 174 175 176

M/M M/M M/M M M/M M/M I/M I/M I/M

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92

18P27A lube oil cup marking to be done 18P28B seal pot drain line B/V wheel to be provided. 18P28A seal pot LG H/P tapping B/V to be replaced. 18P25B lube oil cup marking to be done 18P26B vent line B/V wheel to be replaced. 18P24B seal pot TSV O/L piece to be fixed. 18P24A seal pot TSV O/L piece to be fixed. 18P10B seal pot TSV O/L spool to be fixed. 18P10A seal pot TSV O/L spool to be fixed. 18P11A PG drain line to be end capped. 18P10A lube oil cup marking to be done. 18P11A seal pot TSV O/L line spool to be fixed. 18P18B PG drain line B/B stem broken-to be replaced. 18P18A vent line B/V wheel missing. 18P18A lube oil cup marking to be done 18P11B seal pot O/L B/V wheel missing 18P11A seal pot O/L line B/V wheel missing. 18P29B PG 2nd B/V wheel missing and drain end cap Missing-to be provided. 18P29B seal pot view glass long bolting. 18P29B TSV O/L line providing. 18P29A warm-up line wheel missing. 18P29A CW lines B/V wheel missing-2 nos-to provide. 18P29A seal pot union joint leak 18P50B PG drain line to be end capped. 18P50B CW line B/V wheel missing. 18FV4302 C/V D/S bleeder to be end blinded. 18P12B open cable to be removed. 18P50A lube oil cup marking 18P12 suction line PG drain to be end capped. 18P12A PG drain line B/V to be replaced. 18P12A PG to be replaced. 18P14B CW supply line leak to be arrested. 18P14B warm up line B/V wheel to be provided. 18P14B vent line to be end blinded. 18P14A vent line to be end blinded. 18P14B seal quenching steam B/V gland leak. 18P13B seal quenching steam line B/V wheel to be provided. 18P14A NRV D/S drain bleeder B/V wheel and end blind to be provided. 18LV4401 D/S bleeder to be end blinded. 18P15B warm up valve to be replaced. 18P15A seal flushing line threaded joint leak to be attended. 18P15B seal flushing line threaded joint leak to be attended. 18P15A discharge NRV D/S drain bleeder to be end blinded. 18P16B vent line B/V wheel to be fixed. 18P16A discharge line Plug leak to be attended. 18P16A PG tapping B/V and tracing steam B/V wheels to be fixed. 18P16A PG diaphragm leak to be attended. 18P37A FLO line B/V wheel to be fixed. 18P37A discharge line PG drain cap to be fixed. 18P37B body discharge line plug leak to be arrested. 18P37B PG union leak to be arrested. Sour water B/L B/V U/S bleeder to be end blinded. Preheated feed to HCO line drain bleeder to be end blinded. HCO to riser C/V drain bleeders to be end blinded. HCO PA C/V D/S drain bleeder to be end blinded. 18FV3401 drain bleeders to be end blinded. LCN sample line at B/L B/V to be replaced. Condensate B/V passing near 18P30A-to be replaced. Passing steam trap near 18P25A to be replaced.

177 178 179 180 181 182 183 184 185 187 186 188 189 190 191 192 193 194

M/M M/M I/M M/M M/M M/M M/M M/M M/M I/M M/M M/M M/M M/M M/M M/M M/M I/M

195 196 198 199 200 201 202 204 205 203 206 208 209 210 211 213 214 215 216 219 226 230 231 232 233 238 239 240 241 242 243 247 251 256 257 261 266 267 272 273 274

I/M M/M M/M M/M M/M I/M M/M I/M E/M M/M I/M M/M I/M M/M M/M M/M M/M M/M M/M M/M I/M M/M M/M M/M M/M M/M M/M M/M I/M M/M I/M M/M I/M M/M M/M I/M I/M I/M M/M M/M M/M

93 94 95 96 97 98 99 100 101

18C12 stripping steam condensate trap is passing to be replaced. Slurry PA C/V drain bleeders to be end blinded. 18SOV3401-steam to 18P17 drain bleeder hose to be removed and end blinded. 18P21 PG drain bleeder to be capped. Electrical plug points cover to be provided. Service water point near 18B13 B/V to be replaced. 18P02B min circulation line drain point to be end blinded. Steam to 18P02 vent bleeder to be capped. CRWS man holes de-choking

278 281 282

M/M I/M M/M

288 292 293 297 299 300

I/M E/M M/M M/M M/M C/M

Shutdown Job List HGU _____________________________________________________________Final list 1.0

FURNACE (24-F-01/02)

1.1.

Blinding / De-blinding, opening of Man-way, dropping of Burner Blocks, Erection of volumetric Scaffolding inside the furnace, opening of Convection Manholes, Inspection of Furnace, refractory / ceramic pad repair as per recommendations, checking of thermocouples, refractory repair of floor, revisioning of Burners, revisioning of Air-registers, peeps holes, damper plates and boxing up of the furnace after completion of all activities in the Furnaces Reformer furnace (24-F-01) 1.1.1 Internal and external Passivation of tubes before opening. 1.1.2 Internal inspection of the heater coil to be carried out after provision of scaffolding from burner floor up to radiation top. Metallic jallies to be provided at one level of scaffolding. Radiation coil and convection tubes are to be properly cleaned to suit inspection requirements, before offering the heater for inspection. 1.1.3 Convection tubes also to be cleaned and offered for inspection. 1.1.4 Visual inspection and thickness survey along with OD gauging to be done. 1.1.5 Defective Skin thermo couple (TI 1225) of naphtha Super heater (24-F-01) furnace to be replaced with new thermo couple. Filler rod ER-347 to be used for welding purpose followed by DP testing. The other thermo couple should be offered for Visual inspection & DP testing and repair / replacement recommendation , if any, will be issued only after inspection. 1.1.6 The burner block is to be cleaned and necessary alignment also to be carried out. Diffuser plates of burner assembly may come for replacement. Material availability (SS-310, 6 mm thick plate, 1 sq. mt.) is to be ensured for anticipated replacement. 1.1.7 Minor refractory repair at floor level and at burner mouth is anticipated. 1.1.8 Local repair/ replacement of ceramic fiber lining in radiation zone is also anticipated. Material availability (ceramic fiber lining resistance upto temperature 1260°C, quantity - 2 sq. mt. having thickness 150 mm) for the same to be ensured. 1.1.9 Bellows in the flue gas line should be offered for inspection after casing removal and suitable cleaning. 1.1.10 Stack manhole should be offered for internal inspection. There could be some patch repair of refractory.

1.1.11 Hydro testing of the entire convection and radiation coils using DM water. 1.1.12 External painting of heater and stack with heat resistant aluminium paint after proper manual surface cleaning.

2.0

Reformer furnace (24-F-02) including convection section 2.1.1 DP testing of the welds at furnace top (external). Insulation removal and necessary cleaning before offering for inspection. Necessary Insulation material as per HTAS specification to be ensured. Inlet header to pigtail tubes - 60 nos ( 1 inch tube size) Pigtail to catalyst tubes – 60 nos (1 inch tube size) 2.1.2 Automatic ultrasonic scanning (AUS) of reformer catalyst tubes shall be carried out during shutdown. The following standard prerequisites for AUS should be arranged well in advance to facilitate completion of AUS within the stipulated time period. 2.1.3 Thorough cleaning of external surface of all tubes using DM water soaked cloth to arrange before commencement of AUS for better signal processing 2.1.4 Continuous DM water supply at the furnace top, to be utilized as acoustic couplant during Crawler movement. Two nos of 200-liter capacity drums each fitted with ¼ inch drain nozzle to be provided at the furnace top for continuous DM water supply, to the tube external surface. 2.1.5 Two nos. water collector at the tube bottom and continuous removal of water from furnace to be ensured. 2.1.6 Supply of compressed air at 6 to 8 kg/cm2 pressure for movement of AUS Probe crawler assembly to arrange. 2.1.7 Scaffolding from floor level upto radiation top is to be erected for thorough inspection of catalyst tubes (visual, OD gauging, thickness gauging, radiography) and assessment of refractory condition. Metallic jallies to be provided at different level of scaffolding for smooth and safe inspection. The following NDT requirement may be arranged to facilitate the inspection. 2.1.9 Radiogrpahy – 60 nos weld joints of catalyst tube (OD – 136 mm) after unloading the entire catalyst . 2.1.10 DP testing – 30 nos of weld joints of catalyst tubes (OD – 136 mm) 2.1.11 Total 35 nos of Catalyst tubes may come for replacement. All the material including refractory and insulation for catalyst tube replacement job is to be ensured as per Inspection report on HGU shutdown vide H/INSP/24.0 dated September 16, 2006. During replacement, TIG welding shall be carried out. 100 % radiography (10 segment for each tube) to be carried out.

2.1.12 Refractory lining of inlet tube sheet of waste heat exchanger 24-E17 shall be removed for thorough inspection of ferrules. Replacement of 264 Nos. ferrules. After inspection and ferrule

replacement, the refractory lining is to be renewed as per specification given in Inspection report vide H/INSP/24.0 dated September 11, 2006 (Anchor – SS-310, Height – 50 mm, dia- 6 mm, 33 nos + refractory Firecrete 95 or equivalent 75 mm thick. Heat curing / dry out of refractory lining shall be as per approved procedure. Reputed vendor, who has don similar job, may be engaged. 2.1.13 The balance Calcium silicate insulation of feed inlet line (dia-8”) shall be renewed at the next shutdown. Moisture barrier shall also be provided. 2.1.14 Hot spot in burner blocks A2/7 & B2/7 to be suitably attended. 2.1.15 All the manholes of Cold Collector to be opened for thorough internal assessment of refractory condition. Thermo well, installed at cold collector shall be removed from position for ease for movement inside cold collector. Availability of refractory material as per HTAS specification (Working layer – 75 mm thick Firecrete 95 or equivalent, Insulating layer – 175 mm thick Firelite 2300 VLI or equivalent) may be ensured for anticipated local repairs in working layer (approximate 3 sqr. mtr area) and for manholes. 2.1.16 After casing/panels removal, all the bends of 24-E-11, 24-E-12 & 24-E-13 should be offered for visual inspection / thickness survey. 2.1.17 Damage is anticipated in Expansion joint provided in WHR Module – B (L&T drawing nos. 44341RW1D2131 & 44341RW12135), just above APH 24-E-15A. The same joint should be offered for inspection from both sides. Ceramic fiber blanket (resistance upto 1260 C) will be used for repair. 2.1.18 Cleaning and revisioning of 40 Nos. burners, 25 nos. off gas valves & 25 Nos. air-registers. Replacement of aprox. 25 nos. Naptha Valves. 2.1.19 Internal tube cleaning by acetone for all new 35 Nos. of tubes.

3.0

Column (24-C-01)

3.1

Providing entire external scaffolding with platform, removal of insulation as per inspection, ultrasonic thickness scanning.

4.0

Air Fin Coolers

4.1

Blinding/ de-blinding, opening of covers, Cleaning of tube bundles by hydro-testing, Scaffolding at unapproachable nozzle locations, Tube ID measurement from both header ends, Visual inspection of internal condition of tubes before and after hydro jetting, Tube testing at respective test pressure for the following Air Fin Coolers. 4.1.1. 24-AC-01 4.1.2. 24-AC-02 4.1.3. 24-AC-03 (Total – 3 Nos.)

5.0

Heat Exchangers (Check-III)

5.1

Blinding/ de-blinding, opening of the covers, pulling out of the tube bundle from the shell (wherever required), cleaning of shell, hydroblasting of tube bundle, repairing job, if any, Inspection, testing and boxing up are to be performed for the following exchangers / coolers / condensers including blinding/deblinding job. Water wide (Channel head / Channel box / partition plates etc.) components of coolers / condensers should be painted with high built epoxy paint after proper surface preparation (SA 2 ½). SL.NO . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

EQPT.NO. 24-E-01 24-E-02 24-E-03 24-E-04 24-E-05 24-E-06 24-E-07 24-E-18 24-E-19 24-E-20 24-E-22 24-E-23 24-E-34 24-E-35 24-E-36 24-E-38 G/C of 03A/B G/C of 04A/B I/C of I/C of

18 19 20

JOB TO BE DONE

A/B/C/D/E/F A/B A/B/C/D

Passivation before opening

A/B A/B A/B A/B

A/B

24-K24-K24-K-03A/B 24-K-04A/B

Total no. – 38

6.0

Vessel 6.1 Blinding / deblinding of connected lines, opening of manholes, scaffolding, if required, removal of internals, cleaning, inspection, repair / replacement as per recommendation, re-fixing of internals and final box up after completion of all activities of the following vessels. SL. NO. 1 2 3 4 5 6

EQPT.NO. 24-V-01 24-V-02 24-V-03 24-V-04 24-V-06 24-V-07

JOB TO BE DONE Cleaning and maintenance Cleaning, Hydro-testing as per factory act. Cleaning and maintenance Cleaning and maintenance Cleaning, Hydro-testing as per factory act. Cleaning, Hydro-testing as per factory act.

7 24-V-08 8 24-V-10 9 24-V-11 10 24-V-14 11 24-V-15 12 24-V-22 13 24-V-29 14 24-V-30 to 36 Total – 18 Nos.

Packing removal, weld joint repair Cleaning and maintenance Cleaning and maintenance Cleaning and maintenance Cleaning and maintenance Cleaning and maintenance Cleaning, Hydro-testing as per factory act. Scaffolding and external inspection

All CS vessels are to be externally painted as per insp. recommendation

7.0

REACTORS: Blinding / deblinding, reversal of elbow, opening of manholes/handholes/vent etc., scaffolding inside Reactor, removal, sieving / refilling of catalyst, chlorine guard and sulphur guard, thorough cleaning of internal surface along with internals, offer for inspection, repair / replacement as per recommendation, fixing back of all internals, regeneration of catalyst and final boxing up of reactor after completion of all activities in the following Reactors. 7.1.1 24-R-01 – Passivation, buffing of weld joints (10m X 16” wide) for insitu metallography & DP testing. catalyst replacement. 7.1.2 24-R-02 – DP testing (2m ), catalyst replacement. 7.1.3 24-R-03A/B - catalyst replacement. 7.1.4 24-R-104 - DP testing (3m) & catalyst replacement. NOTE : DP testing of all ring joint groove whatever will be opened. DP testing & hydrotesting of all thermowell of all reactors.

8.0

IBR Inspection 1

SL.NO.

EQPT.NO 24-V-05

2

24-E-17

3

24-E-14

4

24-E-13

JOB TO BE DONE Opening & cleaning including internals followed by visual inspection, thickness survey, offer for IBR inspection. Opening of both manholes, cleaning of tube bundle, visual inspection, offer of IBR inspection. All end panels and manholes to be opened, Cleaning, offer for IBR Inspection. All end panels and manholes to be opened, Cleaning, offer for IBR Inspection.

Hydrotesting of waste heat boiler (24-V-05, 24-E-17, 24-E-13 and E-14) are to be carried out at 78.0 Kg. / Cm2

9.0

24-

Safety Valves Blinding / deblinding, lowering to ground, transportation to workshop, dismantling of PSVs /TSVs, Repair / Replacment / Revisioning, Testing, and erection of the following PSVs/TSVs in position.

Sl.No.

Safety Valve No.

1 2 3

24-PSV-1558 24-PSV-1654 24-PSV-1952

Set Pressure Kg/cm2 42.0 42.84 89.75

4

24-PSV-1952

89.8

5

24-PSV-1953

89.8

6

24-PSV-1961

89.8

7 8 9 10 11

24-PSV-3101 24-PSV-3302 24-PSV-3304 24-PSV-3305 24-PSV-5152

95.0 35.5 35.5 35.5 89.8

12.

24-PSV-5153

89.8

13.

24-PSV-5154

89.8

14. 15. 16.

24-PSV-5256 24-PSV-5451 24-PSV-5452

7.0 23.1 23.1

Remarks / Recommendations `O` Ring to be replaced. `O` Ring to be replaced. Spring & Disc to be replaced. Spring, Nozzle & Disc to replaced. Spring, Nozzle & Disc to replaced. Spring, Nozzle & Disc to replaced. `O` Ring to be replaced. `O` Ring to be replaced. `O` Ring to be replaced. `O` Ring to be replaced. Spring, Nozzle & Disc to replaced. Spring, Nozzle & Disc to replaced. Spring, Nozzle & Disc to replaced. `O` Ring to be replaced. `O` Ring to be replaced. `O` Ring to be replaced.

be be be

be be be

Total. – 16 Nos

10.0 Valve jobs 1. 24FC1301 bypass valves to be replaced.

11.0 Repair/Replacement in process pipings 11.1 24-K-03A/B, 24-K-04 A/B, 24-K-07 connected H2 lines. Suction discharge lines of 24K-03A/B and 24-K04A/B may come for replacement. 11.2 Overhead circuit of H2S stripper (24-C-01) including reflux line. 11.3 Process gas line from 24-V-07 to PSA inlet 11.4 Process gas lines from Cold collector to 24-E-19 A/B 11.5 Process gas line from 24-V-06 to 24-V-07 11.6 H2 lines from HGU to DHDS 11.7 Dia 3” & 4” Fuel Naphtha line from V-10 to 24-F-02 11.8 Dia 2”, Condensate line from reformer furnace to 24-v-26 vessel 11.9 All HPV & LPD shall be thoroughly inspected and necessary seal welding to be done with additional valve wherever required. 11.10 Process condensate line (dia 1.5”) replacement with Alloy 625 metallurgy 11.11 Emergency hydrogen line from hydrogen bullet to U-24 about 10M, sch.80 to be replaced with 4 nos. bleeder. NOTE : Provision of scaffolding to be ensured.

12.0 Civil Maintenance 12.1

Water wide (Channel head / Channel box / partition plates etc.) components of coolers / condensers should be painted with high built epoxy paint after proper surface preparation (SA 2 ½).

12.2

Removal / Renewal of insulation for damaged lines / equipments as per recommendation.

12.3

Painting of equipment & other jobs as per job list.

12.4

Repair / replacement of reformer furnace roof.

13.0 Instrumentation jobs 13.1

24PC2402 passing problem to be rectified.

13.2 All BFW desuperheating control valves washing problem to be rectified. 13.3

24TI2002 to be rectified.

14.0 Electrical Maintenance 14.1

Hand lamps, flood light and temporary electrical connections are to be provided inside Furnaces, Reactors / Vessels and at other locations as per requirement.

14.2

All HT & LT motors annual maintenance.

15.0 Modification jobs 15.1

Provision of two new safety valves in 24-E-17 outlet line.

16.0 Rotary jobs 16.1 16.2 16.3

Capital maintenance of FD Fan (24-K-01 A/B) Capital Maintenance of ID fan (24-K-02A/B) Overhauling of CBD pump (24-P-11)

JOB LIST ARU ________________________________________

1.0

_____________Final List

COLUMN – 26-C-01 Blinding / De-blinding, opening of manholes, air circulation inside the column, gas test & manentry, opening of tray manways and internals (wherever required), erection of scaffolding inside the column (wherever required), manual cleaning of internals, Inspection, repair / replacement as per inspection recommendations, fixing back of internals, box-up of tray manways and final boxup of equipment after completion of all maintenance activities. All the nozzles shall be exposed by removing insulation and necessary scaffolding arrangement shall be made to facilitate thickness survey of nozzles, wherever necessary. The bottom dome is without insulation. Same shall be provided after fixing lugs etc.

2.0

VESSEL Blinding / De-blinding, opening of manholes, air circulation inside the vessel, gas test & manentry, opening of internals (wherever required), erection of scaffolding inside the vessel (wherever required), manual cleaning of vessel internals, Inspection, repair / replacement (if required), refitting of vessel internals, final box-up of the vessel after completion of all activities in the vessels. i) ii) iii) iv) v) vi) vii)

26-V-01 26-V-02 26-V-04 26-V-06 26-V-07 26-V-08 26-T-01

All the nozzles shall be exposed by removing insulation and necessary scaffolding arrangement shall be made to facilitate thickness survey of nozzles, wherever necessary.

3.0

FILTER Blinding / De-blinding, opening of manholes, air circulation inside the vessel, gas test & manentry, opening of internals (wherever required), erection of scaffolding inside the vessel (wherever required), manual cleaning of vessel internals, Inspection, repair / replacement (if required), refitting of vessel internals, final box-up of the vessel after completion of all activities in the vessels.

1. 2. 3.

26-FS-01 26-FS-02A/B 26-FS-03A/B

External painting of all filters using HB Bituminous paint system.

4.0

HEAT EXCHANGERS

Blinding / De-blinding, opening of covers, pulling out of tube bundles wherever required, hydro-blast cleaning of tube bundles, Inspection, repair / replacement (if required), painting of all water side channel / channel cover / partition plates with high build epoxy paint after proper surface preparation (SA 2½ ), replacement of sacrificial anodes as per inspection recommendations, insertion of tube bundles, shell test, tube test and final boxup of the equipment after completion of all activities of the heat-exchangers. Exchangers Coolers Air Coolers

5.0

- 26-E-02A/B & 26-E-03A/B - 26-E-01 & 26-E-04 (Replacement, if material is available) - 26-AC-05 & 26-AC-06

PRESSURE SAFETY VALVES Blinding / De-blinding, lowering to ground, transportation to workshop, dismantling of PSVs, repair / replacement / revisioning, testing of PSV as per details contained in PSV data sheet, erection of the PSVs back in position. Revisioning and testing of the following safety valves to be carried out. Sl. No. 1 2 3 4 5 6 7 8 9 10 11

6.0

TAG JOBS • • • • •

7.0

PSV/TSV Nos. 26-PSV-6605 26-PSV-6509A/B 26-PSV-6510A/B 26-PSV-6603A/B 26-PSV-6706 26-PSV-6306A/B 26-PSV-6403 26-PSV-6508 26-PSV-6207 26-PSV-6305 26-PSV-6307A/B

Critical tap off points to be cleaned and offered for inspection. Insulation removal & renewal jobs. Inspection pockets to be provided in the critical piping, column and vessels. Overall painting of equipment / structural to be planned Some rectification of few structural may come for.

PIPING JOBS Anticipated replacement as per following

1) 2) 3) 4)

Dia 2” – Sch.80 Dia 3” – Sch.40 Dia 4” – Sch.40 Dia 6” – Sch.40

- CS- CS- CS- CS-

80M 50M 40M 25M

------------------------------------X------------------------------------X----------------------------------X-----------------------------------

THERMAL POWER STATION Final list 1.0

TANK : BLINDING / DEBLINDING OF CONNECTED LINES, OPENING OF MANHOLES, REMOVAL OF INTERNALS, CLEANING, INSPECTION, REPAIR / REPLACEMENT JOBS AS PER RECOMMENDATION, REFIXING OF INTERNALS & FINAL BOXING UP AFTER COMPLETION OF ALL ACTIVITIES OF THE FOLLOWING TANKS :

2.0

Sl. No 1.1

Tank no

Description

51-T-02

FO Tank

1.2

51-T-02 A

FO Tank

1.3 1.4

51-T-03 51-T-07 A

LDO Tank Cond. Tank

1.5

51-T-08

Cond. Tank

1.6 1.7 1.8

51-T-01 A 51-T-02 B 51-T-03 C

DM water tank DM water tank DM water tank

Anticipated job Partial replacement of roof (6mm thk. Plate) & steam coil(Dia 2 inch A106 Gr. B sch-40-20 mts) Possible replacement of roof & bottom plate (50 m2) & steam coil(Dia 2 inch A106 Gr. B sch-40-20 mts) Partial replacement of roof (6mm thk. Plate) Partial replacement of bottom plate (8 mm)IS-2062 B ,30 M2 Complete bottom plate replacement(8 mm)IS-2062 B ,35 M2 Cleaning and inspection only

Cleaning and inspection only Cleaning and inspection only

VESSEL : BLINDING / DEBLINDING OF CONNECTED LINES, OPENING OF MANHOLES, REMOVAL OF INTERNALS, CLEANING, INSPECTION, REPAIR / REPLACEMENT JOBS AS PER RECOMMENDATION, REFIXING OF INTERNALS & FINAL BOXING UP AFTER COMPLETION OF ALL ACTIVITIES OF THE FOLLOWING VESSELS : Sl. No 2.1

Vessel no

Description

Anticipated job

51-B-02

Deaerator

2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11

51-B-102 55-B-11 A 57-B-01 57-B-02 55-B-12 A 55-B-12 B 51-B-06 55-B-10 A 55-B-10 B 51-B-08

Deaerator Acid measuring vessel Service air vessel Instrument air vessel Alkali measuring vessel Alkali measuring vessel Fuel Gas Drum Degasser sump Degasser sump Flash Drum

To be offered for internal inspection; Thorough NDT like LPT, WFMPT, UTG shall be done -do-

CLEANING & INSPECTION -do-do-do-do-do-do-do-do-

3.0

HEAT EXCHANGERS

3.1

Check-III Activities Blinding / De-blinding, opening of covers, pulling out of tube bundles, hydro-blast cleaning of tube bundles, Inspection, repair / replacement (if required), painting of all water side channel / channel cover / partition plates with high build epoxy paint after proper surface preparation (SA 2½ ), replacement of sacrificial anodes as per inspection recommendations, insertion of tube bundles, shell test, tube test and final box-up of the equipment after completion of all activities of the heat-exchangers. Sl. No 3.1.1 3.1.2

3.1.3 3.1.4 3.1.5 3.1.6 3.1.7

3.1.8 4.0

HX. no 57-E-01 57-E-02 57-E-02 51-E-02 51-E-03 51-E-03 51-E-05 57-E-05

Description

A B A B A B

57-K-01 A intercooler Air Cooler Air Cooler Vaporiser Oily cond/ DM water Oily cond/ DM water FO heater FO heater

SAFETY VALVES: Following PSV s / TSV s are to be sent to workshop for overhauling and testing: Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

PSV No. 1614 / 1 1614 / 2 51 SV 19AX 51 SV 19BX 51-TSV-03 51-TSV-04 51-PSV-44 A 51-PSV-44 B 51-PSV-44 C 51-PSV-29 64-PSV-12 51-PSV-23 A 51-PSV-23 B 51-PSV-24 A 51-PSV-24 B 57-TSV-01 57-TSV-02 57-TSV-03 57-TSV-04 57-TSV-05 57-TSV-06 57-TSV-07 57-PSV-02X 57-PSV-06X 57-PSV-08X

Location 51-B-102 51-B-102 51-B-02 51-B-02 51-T-03 51-T-04 PRDS PRDS PRDS 51-P-04 64-P-03E 51-PT-05 A 51-PT-05 A 51-PT-05 B 51-PT-05 B Compressor house area : 57 K01 A/B, K02 , K03,K04, E02 , E01, CW Lines

K 02 Disch K 01 A/B Disch K 03 Disch

5.0

REPAIR/ REPLACEMENT JOBS IN PIPING : Partial replacement of the following piping circuits during the shut-down : Sl. No 5.1

5.2

5.3

Circuit description. FO lines near Tank Farm area & on rack near boilers

Insulation removal Y/N Y

LDO lines near Tank Farm area & on rack near boilers

Y

FG lines near Tank Farm area

Y

5.4

LP Condensate lines on rack

Y

5.5

MP Condensate lines on rack

Y

5.6

HP Condensate lines on rack

Y

5.7

Y

5.10

LP Condensate lines to Deaerators thru surface condensers Condensate inlet line to Deaerator-1 from units Condensate inlet line to Deaerator-2 from units Oily Condensate circuit

5.11

De-oily condensate circuit

Y

5.12

CW Risers in PCT-09 nos.

N

5.13

CW circuits in compressor and cooler area

N

5.14

N

5.15

PHE make up water line near TPS and PCT Acid dosing lines near CT

5.16

Dewatering lines near CT

N

5.17

Motor cooling lines near CT

N

5.18

Hypo dosing lines in CT

N

5.19

VH steam header and entire circuit VM steam header and entire circuit

Y

5.8 5.9

5.20

Y Y Y

N

Y

Material Requirement Dia 6 inch 106 GR B Sch-40 approx. length-20 mts Dia 3 inch 106 GR B Sch-40 approx. length-30 mts Dia 4 inch 106 GR B Sch-40 approx. length-20 mts Dia 2 inch 106 GR B Sch-80 approx. length-30 mts Dia 6 inch 106 GR B Sch-40 approx. length-10 mts Dia 3 inch 106 GR B Sch-40 approx. length-20 mts Dia 3 inch 106 GR B Sch-40 approx. length-20 mts Dia 3 inch 106 GR B Sch-40 approx. length-20 mts Dia 3 inch 106 GR B Sch-40 approx. length-20 mts Dia 3 inch 106 GR B Sch-40 approx. length-20 mts

pipe; pipe; pipe; pipe; pipe; pipe; pipe; pipe; pipe; pipe;

Dia 4 inch 106 GR B Sch-40 pipe; approx. length-20 mts Dia 4 inch 106 GR B Sch-40 pipe; approx. length-20 mts Dia 4 inch 106 GR B Sch-40 pipe; approx. length-20 mts Dia 4 inch 106 GR B Sch-40 pipe; approx. length-25 mts Replacement of Dia 24 inch CS welded pipe. Dia 6 inch A106 GR B Sch-40 pipe; approx. length-20 mts Dia 4 inch A 106 GR B Sch-40 pipe; approx. length-30 mts Dia 3 inch A 106 GR B Sch-40 pipe; approx. length-25 mts Dia 12 inch API 5L GR B Sch-20 pipe; approx. length-100 mts Dia 4 inch 106 GR B Sch-40 pipe; approx. length-20 mts Dia 2 inch 106 GR B Sch-40 pipe; approx. length-20 mts Dia 1.5 inch 106 GR B Sch-80 pipe; approx. length-20 mts Dia 2 inch 106 GR B Sch-80 pipe; approx. length-20 mts RLA shall be done. Quantity shall be finalized during s/d.

5.21 5.22 5.23

VB steam header and entire circuit Boiler Feed water circuit

Y

Y

Quantity shall be finalized during s/d. Quantity shall be finalized during s/d. Shall be DP tested

Y

Shall be DP tested

Y

Shall be DP tested

Y

Shall be DP tested

N

Y

5.27

Small bore tapping in VH circuits- 20 nos. Small bore tappings in VM circuits-20 nos. Small bore tappings in VB circuits-20 nos. Small bore tappings in BFW and CW header circuits-20 nos. Instrument air line

5.28

Service air line

5.29

Fire water line

N

5.30

Service water line

N

5.31

VB steam line near PCT

Y

5.32

VM steam line near PCT

Y

5.33

VH, VM ,VB and BFW flow impulse lines VH, VM ,VB and BFW equaliser lines U/G CW lines

Y

Dia 2 inch A 106 GR B Sch-80 pipe; approx. length-20 mts Dia 2 inch A 106 GR B Sch-80 pipe; approx. length-20 mts Dia 6 inch A 106 GR B Sch-40 pipe; approx. length-20 mts Dia 4 inch A 106 GR B Sch-40 pipe; approx. length-20 mts Dia 2 inch A 106 GR B Sch-80 pipe; approx. length-20 mts Dia 16 inch API 5L GR B Sch-30 pipe; approx. length-20 mts Dia 10 inch A 106 GR B Sch-30 pipe; approx. length-20 mts For VH, P11 metallurgy is required

T

For VH, P11 metallurgy is required

5.24 5.25 5.26

5.34 5.35 •

Excavation

Replacement of approximately 5 tons of structural for piping & other jobs.

VALVE JOBS : THE FOLLOWING VALVES AT DIFFERENT AREAS OF TPS ARE TO BE REPLACED.

Sl. Unit No 1 Boiler : 1/2/3 VS STM Block Valve (Boiler G/floor) 2 Boiler : 1/2/3 Equaliser of VH STM Block Valves Boiler G/floor 3 Boiler : 1/2/3 VH STM Boot Drain Valves Boiler G/floor

Size (Apx)

Type

End type

Qty

10” #900

Gate

Welded

3 Nos.

¾” #1500

Gate

Welded

6 Nos.

¾” #1500

Gate

Welded

6 Nos.

4

5 6

7

8

9

10

11 12

13 14

15

Boiler : 2 Automising STM root valve (Burner floor) LPG Flair STM Tracing Valve Boiler : 3 FO-in battery limit valve (Burner floor) Boiler : 1/2/3 BFW Off-take valve TG : 1,2&3 Aux. STM root valve (Turbine G/floor) TG : 3 VH Steam valve (Turbine G/floor) TG : 2 Condenser in/outlet valves (Turbine G/floor) VH stm equliser valve Cooling Tower TPS CW Pump “03J” Disch valve PCT : All CW Pump NRV Other steam valves - Without MOV Butterfly valve in CWP I/O Line

2” #900

Gate

Flanged (Weld Prfd)

1 No.

2” #300

Gate

1 No.

2” #150

Gate

Flanged (Weld Prfd) Flanged

6” #900

Gate

Flanged (Weld Prfd)

3 Nos.

2” #900

Gate

Welded

6 Nos.

10” #900

Gate

Welded

1 No.

12” #150

Gate

¾” #1500

Gate

Welded

40 Nos.

14” #150

Gate

Flanged

1 No.

24” #150

Gate

Flanged

7 Nos.

12” #900 10” #900 3” #900 2” #900 24” #150 30” #150

Gate Gate Gate Gate

Welded Welded Welded Welded Flanged Flanged

1 No. 8 nos. 11 Nos. 6 Nos. 7 Nos. 7 Nos.

1 No.

2 Nos.

7.0

CIVIL MAINTENANCE :

7.1

De-silting and repairing of Process, TPS & DHDS cooling towers.

7.2

Repair of under water wooden structures in PCT & TPSCT sump.

7.3

Water side components of cooler & condensers are to be painted with appropriate paint system.

7.4

External painting of static equipment & piping where ever damaged for non existing are to be done .

7.5

Removal of insulation from the lines as mentioned in Sl. No.5.0 & re-insulation after Inspection & Maint job .

7.6

Insulation pockets are to be provided at critical locations as per recommendations of Reliability Task Force.

7.7

Following lines are to be painted as per recommendation:

Sl. no 1

Equipment FO and LDO Tanks

External/ Internal Both

Painting Specification Roof inside: Self priming epoxy + Epoxy Zinc phosphate + HB epoxy External: Self priming epoxy + Epoxy Aluminum Internal : Self priming epoxy + Epoxy Zinc phosphate + HB epoxy

2

Condensate Tanks- 51-T-07 A/B and 51-T-08

Both

3

DM water tanks –03 nos.

Both

External : Acrylic aliphatic PU Internal : Self priming epoxy + Epoxy Zinc phosphate + HB epoxy

4 5

Acid and caustic tanks Raw water tank

External Both

External : Acrylic aliphatic PU External : Acrylic aliphatic PU Internal : Self priming epoxy + Epoxy Zinc phosphate + HB epoxy

6 7 8

Un-insulated vessels Insulated vessels Condensate lines

External External External

9

Water side of coolers and condensers

Internal

10

Un-insulated lines near CT area

External

11

External

12

Un-insulated lines near DM plant Equipment near DM plant

13

Sand filters in DM plant

Internal

14

CT Risers

External

15

CT headers to and from TPS

External

External

External : Acrylic aliphatic PU External : Acrylic aliphatic PU Polysiloxane paint- 2 coats External: Self priming epoxy + Epoxy Aluminum Roof inside: IOZ silicate + Epoxy Zinc phosphate + HB epoxy As per Advanced paint system already finalized As per Advanced paint system already finalized As per Advanced paint system already finalized IOZ silicate + Epoxy Zinc phosphate + HB epoxy Advanced paint system already finalized Advanced paint system already finalized

Structurals are to be painted with SA 21/2 + IOZ silicate + Epoxy zinc phosphate + CT epoxy paint system.

8.0

ELECTRICAL MAINTENANCE JOBS : TPS LT SWITCHGEAR SHUTDOWN JOBS Shutdown of TR-11,12 & PC-11,12 Disconnection of all power & control cables of PC-11 & 12 Dismantling & removal of PC-11 & 12 panels incl. Busduct Installation of PC-11 (upto B/C 11/12) Installation of PC-12 (upto B/C 12/13) Installation & commissioning of PC-11 Tr. Busduct Installation & commissioning of PC-12 Tr. Busduct Testing & commissioning of PC-11 Testing & commissioning of PC-12 Commissioning of MCC-111, 112, 113, 114, ASS-11 Commissioning of 64PM2D, 64KM01K, MCC-122, 123, ASS-12 Arrangement for Jumpering of MCC-131, 132, & N-pit MCC Shutdown of PC-13 Disconnection of all power & control cables of PC-13 Dismantling & removal of PC-13 panels incl. busduct Installation of PC-13 Installation & commissioning of PC-13 Tr. Busduct Testing & commissioning of PC-13 Commissioning of 64PM2C, 64KM01L, 64KM01M, 51PM107, MCC-132, N-pit MCC

Other Major Electrical Jobs During TPS SD Hook-up of 2nd UPS supply to existing UPS system Testing of Auto-changeover & Bus differential scheme of HT switchgear Dismantling , shifting & re-installation of ECS panels at TPS Load testing of all battery banks at TPS DHDS SS Bus differential scheme commissioning

9.0 10.0

INSTRUMENT MAINTENANCE JOBS : TAG JOBS a. During check-III maintenance of Heat exchangers, deteriorated Stud / Nuts and all the Gaskets are to be replaced with new ones. b. Insulation of critical tap-off points at HP lines to be removed for inspection activities like visual and DP testing. c.

Old/deteriorated insulation is to be replaced with fresh ones; locations shall be shown at site.

d. Sacrificial anodes of the coolers and condensers are to be replaced with fresh onesapprox. no-100 nos. e. f. 11.0

Repalcement of CS and Brass plugs: approx- 200 nos Provision of suction strainer in CW pump of PCT

PROCESS MODIFICATION JOBS: a b

Installation of welded valve in BFW Line of TPS for boiler No. 1, 2 & 3 Enlargement of suction piping of 64P01L

Gas Turbine & HRSG Shutdown Job List Final List

Mechanical Jobs CIBI jobs of Gas Turbine 1. Recording data and shutdown of the unit. 2. Removing gas and atomizing pigtail piping. 3. Removing liquid fuel lines. 4. Removing fuel nozzles. 5. Removing spark plugs and flame detectors 6. Removing combustion can covers 7. Removing combustion liners, cross fire tubes & retainers 8. Cleaning of all parts 9. Disassemble and inspection of fuel nozzles 10. Inspection of liners, cross fire tubes & retainers 11. Inspection of combustion chambers 12. Assembling of fuel nozzles 13. Installation of combustion can covers 14. Installation of spark plugs and flame detectors 15. Installation of fuel nozzles 16. Installation of liquid fuel lines 17. Installation of gas and atomizing pigtail piping 18. Removal of Borescope plugs 19. Cranking and checking for air leaks 20. FSNL and loading of machine 21. Blinding / de-blinding of various Atomizing air lines (6 nos) for the purpose of GT compressor water wash.

Other related jobs of Gas Turbine 1. Mist Eliminator: Filter cleaning & fan maintenance. 2. Rectification of supports for Naphtha fuel line after PCV. 3. Overhauling / replacement of Flow Divider. 4. Replacement of all the “swagelok” fittings on the fuel lines. 5. Replacement of on base Fuel HP filer. 6. Plugging the space around Exhaust gas pipe of Diesel Engine. 7. Replacement of APU airline isolating valve at compressor end 8. Cleaning of GT inlet air filter cartridges. 9. Cleaning of GT Y strainer just before Fuel stop valve. 10. Cleaning of Lube Oil Cooler-1 & 2. 11. Cleaning / replacement of various Oil filters- L.O , Hyd Oil, Trip Oil etc. 12. Rectification of G.O Forwarding Pump No. 2 discharge NRV passing problem. 13. Cleaning of View Glass after 3-way valve from inside. 14. Cleaning / tuning of GT Off base PRVs (AOP, EOP & Return line) 15. Repair of Duct Expansion bellows in between GT & HRSG. 16. Cleaning & inspection of Heat exchanger of GT atomizing air. 17. Generator Cooler is to be opened, cleaned and inspected. 18. Replacement of passing Main Fuel Stop Valve is passing. 19. Rectification of L.O leakage from union joint of suction line to Ratchet pump. 20. Leakages from union joints around HP filter. Replacement of leaky tube to be done. 21. Lube oil leakages from load-gear body fixing bolts are to be arrested. 22. Replacement of glass view port on the HSD recirculation line 23. Replacement of condensate drain of Atomizing Air line of GT including earlier removes piece. 24. Replacement of off base pump lube oil outlet line.

Miscellaneous jobs of HRSG

1. Cleaning of Suction Strainers of BFW Pumps, DM Transfer pumps, DM Circulation pumps. 2. Rectification of Steam leakage in the flange of Steam Trap of VM line near Naphtha CBD Tank. 3. HRSG all 4 nos. FG Firing Burners to be cleaned by removing out side. 4. Safety valve testing before bringing down the HRSG in presence of Inspection & Maint (workshop) 5. Opening of HRSG Man-holes for speedier cooling, after HRSG is brought down. 6. Scaffolding for Visual inspection & cleaning of Economizer, Evaporator & Super heater modules. 7. Maintenance of steam drum for visual inspection & cleaning. 8. Hydraulic pressure testing of HRSG. 9. Dry inspection & hydraulic pressure test of HRSG (to be witnessed by IBR) 10. Isolation valves repairing/replacement of HRSG Drum physical level indicators. 11. Rectification of HRSG VM Steam drain traps and trap bypass line valve (area

near Tank dyke & Control room).

12. Cleaning of FG scrubbers’ suction strainers. 13. Repair / replacement of Huge expansion bellows between HRSG & HRSG stack.

14. Repair / Replacement of Perforated casing bellows 15. Elimination

of

water

accumulation

problems

over

the

structural

beams/channels by providing adequate sized holes. 16. Cleaning & Inspection of HRSG IBD vessel. 17. Following steam leakage jobs need to be attended:-

½” VM line at battery limit valve drain Æ 1 No.

-

½” VM line near Naphtha CBD tank Æ 9 Nos.

-

½” VM line near GT-2 new stack area Æ 4 Nos.

-

12” VM line near Naphtha CBD tank Æ 1 No.

-

½” VB line near BFP area Æ 4 Nos.

-

1” VM line at boiler drum floor Æ 4 Nos.

Dia 1” drain line of superheater-II inlet header (12” dia) shall be replaced With SA335 P22 , sch-80 material Instrument Maintenance: 1. All Servo valve (IGV & Fuel control) filters are to be replaced. 2. Testing & Calibration of SO2 & dissolved O2 analyzers, pH & conductivity analyzers of HRSG SWAS panel. 3. Any hook up job of DCS/PLC between existing and incoming panels. 4. Frequent failure of HRSG burners while lighting up to be rectified. 5. Defective pr. & Temp. Gauges to repaired/replaced. (Final list will be given a week before s/dn). 6. All exhaust TC’s junction boxes are to be opened for checking TB condition and Tightness. Electrical Maintenance: 1. CO2 system thorough checking. Repeated N2 leakage. 2. “B”-schedule maint. Of onbase AOP, AHOP, EOP, Offbase AOP, Offbase EOP & Mist Eliminator and Vent fans motors. Has to be done or else we can’t do this when GT is running. 3. Repair of Diverter damper Seal air Fan Damper MOV (Auma make). 4. Generator control panel field & excitation ammeter to be checked as sometimes it gives erratic reading during running. 5. Temporary lighting for various jobs in GT & HRSG areas.

6. Load testing of Battery Banks of UPS, 220V/125V /110V DC systems. 7. Cleaning / M&I of HT sections/PCCs/MCCs. 8. All HRSG MOV’s and DD, GD MOV’s are to be checked thoroughly. Civil maintenance: 1. Cleaning of GT generator cooler compartment, exciter base area, GT compartment & accessory compartment. 2. Cleaning of GT enclosure Doors and roof. 3. Cleaning of HRSG drum floor area after IBR job over. 4. General cleaning for spilt lube oil & other waste generated during shutdown activities. 5. Repair of Ceramic Fiber insulation in HRSG area as per instructions from Inspection dept., as and when required. 6. Repair, cleaning and repainting of drum internals as per Inspection recommendation after opening of HRSG drum. 7. Replacement of damaged calcium silicate insulations of VM, VB steam headers.

Project : 1. Commissioning of New panels of GT 2, its hook ups with existing GT panels, UPS additional LT bus bar fitting/connection. 2. Any hook up job of DCS/PLC between existing and incoming panels. 3. Hook up of HT/LT panels and T/Rs if any. 4. Necessary hook up jobs for GT-2 & GT-3 may be carried out during the CIBI Shutdown period.

Process Modification : . 1. Modification of CW I/L & O/L of oil cooler in GT

--------------------- X --------------------------- X ------------------------------- X ------------------

M/PL/61

OFFSITE Final list 1.0

VESSEL BLINDING / DEBLINDING OF CONNECTED LINES, OPENING OF MANHOLES, REMOVAL OF INTERNALS, CLEANING, INSPECTION, REPAIR / REPLACEMENT JOBS AS PER RECOMMENDATION, REFIXING OF INTERNALS & FINAL BOXING UP AFTER COMPLETION OF ALL ACTIVITIES OF THE FOLLOWING VESSELS :SL. NO. 1.1

TANK/ VESSEL NO. 61B01

DESCRIPTION FLARE KNOCK OUT POT

1.2 1.3 1.4 1.5 1.6 1.7

61B02 79V01 79V02 79V03 46B01 46B02

H2S KNOCK OUT POT WATER SEAL DRUM KNOCK OUT DRUM KNOCK OUT DRUM L.P.COND.VESSEL H.P.COND. VESSEL

JOBS MAINTENANCE & INSPECTION SAND BLASTING & GUINNITING MAINTENANCE & INSPECTION MAINTENANCE & INSPECTION MAINTENANCE & INSPECTION MAINTENANCE & INSPECTION MAINTENANCE & INSPECTION MAINTENANCE & INSPECTION

TOTAL : 07 NOS. 2.0

A)

FLARE SYSTEM

i.

REPLACEMENT OF HYDROCARBON FLARE TIP (INCOLOY-800H METALLURGY) ALONG WITH RETENTION RING AND FLAME STABILISER.

ii.

PARTIAL REPLACEMENT OF ACID FLARE TIP ALONG WITH RETENTION RING AND FLAME STABILISER WITH INCONEL-625 METALLURGY.

iii.

REPLACEMENT OF ALL THE PILOT BURNER ASSEMBLIES OF BOTH THE FLARES (4 NOS. IN HYDROCARBON FLARE & 3 NOS. IN H2S FLARE) WITH NEW ONES.( METALLURGY-SS 304).

iv.

EXTERNAL STEAM PIPE OF HYDROCARBON FLARE MAY COME FOR REPLACEMENT (APPROX LENGTH – 1000 MM). MATERIAL: SS 316 PIPE. SIZE- Φ1” SCH-40.

v.

REPLACEMENT OF DAMAGED WIND SHIELD OF BOTH THE FLARES WITH NEW ONE. (METALLURGY-INCOLLOY 800H)

vi.

REPLACEMENT OF CENTRAL STEAM PIPE ALONG WITH TIP, IF REQD .

vii.

SUPPORT FLATS ALONG WITH CENTRALLY LOCATED SUPPORT PIPE MAY COME FOR COMPLETE REPLACEMENT.

viii.

SUPPORTS OF STEAM / PILOT GAS /AIRLINES MAY COME FOR REPLACEMENT.

Page 1 of 1

M/PL/61

B)

MAIN FLARE LINE 1.

REPLACEMENT OF LP FLARE LINE : DIA.22” = 280 M & DIA.28” = 180 M.

2.

REPLACEMENT OF HP FLARE LINE : DIA.18” = 280 M & DIA.24” = 180 M.

3.

REPLACEMENT OF DRAIN LINES = 7 NOS. = 70 M.

Flare lines along St.8

C)

D)

1.

REPLACEMENT OF LP FLARE LINE: DIA.18” = 200 M

2.

REPLACEMENT OF HP FLARE LINE : DIA.12” = 200 M

3.

REPLACEMENT OF ACID FLARE LINE : DIA.6” = 200 M

FLARE LINE SUPPORTING COLUMN THE STRUCTURALS OF BOTH HP & LP FLARE LINE SUPPORTING COLUMN TO BE REPAIRED / REPLCED AS PER INSPECTION RECOMMENDATION

3.0

OFFSITE PIPING JOB OF STRIKETHROUGH LINES SHALL NOT BE DONE DURING SHUTDOWN PERIOD. ALL THOSE LINES SHALL BE ATTENDED EITHER AS PRESHUTDOWN OR POST-SHUTDOWN ACTIVITY DEPENDING ON MATERIAL AVAILABILITY.

3.1

REPAIR / REPLACEMENT OF LPG LINES 3.1.1 3.1.2 3.1.3 3.1.4

3.2

- U-11 R/D - Circulation line of Bullets - U-16 R/D - Propane to U-32

REPAIR / REPLACEMENT OF H2 LINES 3.2.1 3.2.2 3.2.3

3.3

Dia.1 ½” = 20 M Dia2” = 60 M Dia.3” = 80 M Dia.4” = 120 M

Dia2” = 60 M Dia.3” = 84 M Dia.4” = 36 M

- CR to U-24/U-25 to U-24/R/D to Bullets - U-22 to U-35 - U-24 to Fuel Gas Header/U-24 to U-84

REPAIR / REPLACEMENT OF NAPTHA LINES 3.3.1 3.3.2 3.3.3

Dia2” = 24 M - Wild Napththa in E-3 T/F Dia.3” = 200 M - U-16 to R/D to Tkl-203/204 / DSN to DHDS/Rd.D Dia.4” = 60 M - Tk-203/204 /Ex.E-1P/H to Tk-406/to Tk- 463/464

Page 2 of 2

M/PL/61

3.3.4 3.3.5 3.3.6

3.4

Dia.4” = 100 M Dia.6” = 60 M Dia.8” = 30 M Dia.12” = 160 M Dia.14” = 30 M Dia.18” = 30 M

- Ex. Tk-401-405 to F-3 P/H - Ex.F-2 P/H to Tk-451/453 / MS circulation to Tk-403 - Small Header - Ex. Tk-405 to F-3 P/H / Export Gr. MS to Mktg. - MS line to jetty - MS big header.

Dia2” = 30 M Dia.3” = 84 M Dia.6” = 60 M Dia.10” = 90 M Dia.12” = 60 M Dia.14” = 120 M Dia.20” = 300 M

-

SKO to BEU Hydroo treated Keo line, Rd.D / St. 8 U-11 R/D to SR Kero U-11 R/D to Tk-418 / Ex.U-23 to Tk-417/418 Ex. Tk-206 to U-23 Ex.Tk-434 / Ex. Tk-435 to Tk-434 SKO to jetty

Dia.6” = 120 M - Circ. line of Tk-418 I/L to Tk-418 / Ex.U-11 to Tk-424 Dia.8” = 60 M - HSD to Barge Dia.14” = 60 M - HSD under culvert

REPAIR / REPLACEMENT OF SLOP LINES 3.9.1 3.9.2

3.10

- R/D Ex.U-23 to Tk-458/459 / RTF Circulation to PM

REPAIR / REPLACEMENT OF HSD lines 3.8.1 3.8.2 3.8.3

3.9

Dia.6” = 120 M

REPAIR / REPLACEMENT OF SKO lines 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 3.7.7

3.8

- Ex.U-11 to Tk-411/414 / U-11 to Tk-441 - Ex.F-2 P/H to Tk-460 / Ex.F-3 P/H to TTL - Ex. Tk-441 - AFT Header

REPAIR / REPLACEMENT OF MS lines 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6

3.7

Dia.4” = 60 M Dia.6” = 60 M Dia.12” = 18 M Dia.14”= 40 M

REPAIR / REPLACEMENT OF RTF lines 3.5.1

3.6

- SRN to Mktg.

REPAIR / REPLACEMENT OF ATF lines 3.4.1 3.4.2 3.4.3 3.4.4

3.5

Dia.12”= 120 M Dia.16” = 30 M Dia.20” = 30 M

Dia.3” = 2000 M Dia.6” = 120 M

- Slop processing to U-37 - Light slop / Slop Header

REPAIR / REPLACEMENT OF OFF GAS LINES 3.10.1 Dia.2” = 36 M 3.10.2 Dia.3” = 60 M 3.10.3 Dia.4” = 60 M

- Ex.U-35 to FOB - Ex. U-35 / 39 to FOB - Ex. U-35 / 39 to FOB

Page 3 of 3

M/PL/61

3.11

REPAIR / REPLACEMENT OF SOUR GAS LINES 3.11.1 Dia.6” = 60 M

3.12

- Ex.U-37 to U-23

REPAIR / REPLACEMENT OF SERVICE WATER LINES 3.12.1 Dia2” = 400 M 3.12.2 Dia.3” = 1500 M 3.12.3 Dia.6” = 300 M

REPAIR / REPLACEMENT OF FUEL GAS LINES 3.13.1 3.13.2 3.13.3 3.13.4 3.14

Dia2” = 80 M Dia.4” = 30 M Dia.6” = 40 M Dia.8” = 60 M

REPAIR / REPLACEMENT OF AMMONIA LINES

3.14.1 Dia.3” = 24 M 3.14.2 Dia.4” = 30 M 3.15

Dia3” = 60 M Dia.6” = 160 M Dia.8” = 12 M Dia.10”=150 M Dia.14”=24 M

- Treated MTO line - Treated MTO line - MTO to Tanker

REPAIR / REPLACEMENT OF VB Gasolene lines

3.17.1 Dia.2” =80 M 3.17.2 Dia.3” = 36 M 3.18

- To Tk-303/304 - Ex. E-1 to TTL/Circulation line to Tk-427 -

REPAIR / REPLACEMENT OF MTO lines

3.16.1 Dia3” = 36 M 3.16.2 Dia.6” = 30 M 3.16.3 Dia.14” = 24 M 3.17

-

REPAIR / REPLACEMENT OF JBO LINES

3.15.1 3.15.2 3.15.3 3.15.4 3.15.5 3.16

- FC/Pilot gas to Flare - Sweet fuel Gas to FOB - Ex. Gr.20 / FG to LOB - FG Ex. FOB / FG to FOB

- Ex. U-13 - Ex. Tk-201/202

REPAIR / REPLACEMENT OF Amine lines 3.18.1 Dia.2” = 120 M 3.18.2 Dia.3” = 60 M

3.19

- Rich Amine ex. U-35 / Lean Amine to U-35 - Ex. DHDS

REPAIR / REPLACEMENT OF IFO lines

3.19.1 Dia.1 ½” = 60 M 3.19.2 Dia.2” = 120 M 3.19.3 Dia.3” = 200 M

- Supply line to CDU-1/Gr.-20 - Return line from CDU-1 / Gr.-20 - Supplyu line to CDU-2 /Return line from CDU-2

Page 4 of 4

M/PL/61

3.20

REPAIR / REPLACEMENT OF INSTRUMENT & SERVICE AIR LINES

3.20.1 3.20.2 3.20.3 3.20.4 3.21

REPAIR / REPLACEMENT OF COOLING WATER LINES

3.21.1 3.21.2 3.21.3 3.21.4 3.21.5 3.22

Dia.1 ½” = 60 M Dia.2” = 240 M Dia.3” = 300 M Dia.8” = 30 M (Plant air)

Dia.3” = 800 M Dia.4” = 1200 M Dia.6” = 200 M Dia.18” = 200 M Dia.24” = 80 M

REPAIR / REPLACEMENT OF SOUR WATER LINES 3.22.1 Dia.3” = 100 M 3.22.2 Dia.4” = 100 M

3.23

REPAIR / REPLACEMENT OF N2 LINES 3.23.1 Dia.3” = 120 M 3.23.2 Dia.4” = 30 M 3.23.3 Dia.6” = 30 M

3.24

REPAIR / REPLACEMENT OF SLACK WAX LINES 3.24.1 Dia.3” = 120 M 3.24.2 Dia.4” = 60 M

3.25

REPAIR / REPLACEMENT OF STEAM LINES 3.25.1 Dia.2” = 15 M 3.25.2 Dia 3” = 15 M

3.26

REPAIR / REPLACEMENT OF LPD / HPV & INSTRUMENT POINTS 3.26.1 3.26.2 3.26.3 3.26.4 3.26.5 3.26.6 3.26.7

Dia 2” Dia.2” Dia.3” Dia.6” Dia.10” Dia.32” Dia.32”

-

Cond. Return ex.U-25Utility line opp.C/TInstrument air linePlant Air line FCCU Feed lineCW inlet TO FOBCW outlet ex. FOB-

Near U-25 culvert Opp. TPS C/T Behind SRU-2 Behind SRU-2 Near FOB corner Near TPS Near TPS

Page 5 of 5

M/PL/61

Repair / replacement of 36 Circuits shall be done during shutdown period (3.1.2 3.1.3 , 3.2.1 , 3.2.2 , 3.2.3 , 3.3.1 , 3.3.2 , 3.3.3 , 3.4.1 , 3.4.2 , 3.5.1 , 3.7.2 ,.3.7.3 3.8.1 , 3.10.1 , 3.10.2 , 3.10.3 , 3.11.1 , 3.13.1 , 3.13.2 , 3.13.3 , 3.13.4 , 3.18.1 3.18.2 , 3.19.1 , 3.19.2 , 3.19.3 , 3.20.1 , 3.20.2 , 3.20.3 , 3.20.4 , 3.21.4 , 3.21.5 3.23.1, 3.25.1 , 3.25.2)

, , , ,

All support location shall be provided with extra reinforcement pad over the pipe whever required. Hydrotesting shall have to be done for all LPG, HYDROGEN and OFFGAS lines. Hydrotesting of other lines should be done depending on availability of time. Radiography shall be done as follows:10% with hydrotest. 50% without hydrotest.

4.0 PRESSURE SAFETY VALVE(PSV/TSV) FOLLOWING PSV’S / TSV’S ARE TO BE SENT TO WORKSHOP FOR REVISIONING & TESTING :SL. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TAG NO. 61T463 (2 NOS.) 61T464 (2 NOS.) 46B01 46B02 (2 NOS.) 61V101A (2 NOS.) 61V101B (2 NOS.) 69B03A1 (2 NOS.) 69B03A2 (2 NOS.) 69B03B1 (2 NOS.) 69B03B2 (2 NOS.) 48B01 (2 NOS.) 48E01A 48E01B 48E01C 48E02A 48E02B

LOCATION TANK NO. 463 TANK NO. 464 CONDENSATE STATION CONDENSATE STATION ALONG ROAD-G ALONG ROAD-G LPG BOTTLING PLANT LPG BOTTLING PLANT LPG BOTTLING PLANT LPG BOTTLING PLANT BITUMEN COOLING STATION BITUMEN COOLING STATION BITUMEN COOLING STATION BITUMEN COOLING STATION BITUMEN COOLING STATION BITUMEN COOLING STATION

TOTAL : 26 NOS.

5.0 CIVIL MAINTENANCE 5.1 Removal and re-insulation all pipelines for maintenance 5.2 Rectification of foundations as required. 5.3 Sand blasting & painting of lines including flare line supports as per inspection recommendation. 5.4 Area cleaning .

Page 6 of 6

M/PL/61

6.0 ELECTRICAL MAINTENANCE 6.1 Providing power connection for welding / grinding / sand blasting machines etc. 6.2 Providing light for all locations wherever required. 6.3 Arranging 4 Nos. walky-talky sets for flare tip job. 7.0 INSTRUMENT MAINTENANCE RE-ORIENTATION OF ORIFICE FLANGE OF ETP FLOW METERS. TAG NOS. AND SERVICE AS BELOW. a) b) c) d) e)

Tag No:65FT403 Service: TO TREATED WATER POND Tag No:65FT303 Service: DISCH. HDR. TO RVR HOOGHLY Tag No:65FT304 Service: TO PDA SCRUBBER Tag No:65 FE02 Service: DAF RECYCLE PUMP TO SATURATION VESSEL Ph sensor 1/2" tapping point is to be relocated at reachable place. The new punctured point has to be pipe side wise as it is presently from pipe bottom. f) DO (Dissolved Oxygen) sensor 1/2" tapping point has to be increased in size i.e 3/4" line. REPLACEMENT OF PASSING ISOLATION VALVES OF GAUGE GLASSES (UPPER G/G) OF LPG BULLET NO. 102 & 103.

8.0 PROCESS MODIFICATION 8.1 Repl of existing impellers & couplings of DHDS feed pumps 61-P-101A/B with higher size impellers 8.2 Repl of existing impeller of HGU feed pump 61-P-102A with higher dia impeller 8.3 Flare line replacement 8.4 Modification in supports of MP steam line in Track-B pipe rack in Offsite

9.0 PROJECT JOB 9.1 VR Burning facility - Offsite jobs 9.2 Modernisation of 1st Gantry - Additional jobs including facelifting 10.0

TAG JOBS

Page 7 of 7

Annexure-I

JOB LIST FOR COOLING WATER CIRCUIT Final List

1.0

COOLING WATER CIRCUIT AT FOB

1.1.1

Following Cooling Water Lines (Above ground) shall be replaced (Annex-III) Sl. No. Size Schedule Approximate Length 1 3 INCH 80 5 MTRS 2 10 INCH 30 40 MTRS 3 18 INCH 30 50 MTRS 4 20 INCH 30 25 MTRS

1.1.2

Following Cooling Water Lines (Under ground) shall be replaced (Annex-III) Sl. No. Size Schedule Approximate Length 1 8 INCH 30 10 MTRS 2 12 INCH 30 20 MTRS

2.0

COOLING WATER CIRCUIT AT LOB

2.1.1

Following above ground Cooling Water Lines shall be replaced as per details in Annex-I. Sl. No. Size Schedule/Thickness Approximate Length 1 2” 80 150 2 3” 40 100 3 4” 40 125 4 6” 40 360 5 8” 40 300 6 12” 8 mm 150 7 16” 10 mm 100 8 20” 12 mm 080 9 24” 12 mm 090 10 28” 12 mm 030

2.1.2

Following under ground Cooling Water Lines shall be replaced as per Annex-II. Sl. No. Size Schedule Approximate Length 1 8 INCH 40 48 MTRS 2 10 INCH 40 12 MTRS 3 12 NCH 40 44 MTRS 4 12 INCH 30 14 MTRS 5 16 INCH 30 36 MTRS 6 18 INCH 30 24 MTRS 7 20 INCH 20 04 MTRS 8 24 INCH 20 56 MTRS 9 28 INCH 20 24 MTRS

Annexure-I

3.0

COOLING TOWER RISER PIPES AT TPS

3.1.1

Approximate length of Cooling Tower riser pipes to be replaced—270 MTRS (Size-24 INCH).

DETAILS OF COOLING WATER PIPES TO BE REPLACED

UNIT - 31 : Sl no 1 2 3 4 5 6 7 8 9 10 11 12 13

Particulars φ 4” CW line connected at i/l of 31-E-127 φ 2 hot well gas oil lines connected to 31-P-111/111R φ 3” hot well gas oil lines connected to 31-P-111/111R φ 3” sour water lines connected to 31-P-102/102R φ 6” non condensable line from 31-E-130 to 31-B-07 φ2” Drain line of 31-B-07 φ 6” barometric leg from 31-E-128Ato 31-B-02 8”/12” T portion of CW inlet line to 31-E-128A φ2” line of 31-E-116C φ 12” CW header o/h at pump house near 31-P-114A/B/C φ 8/12” CW line & header o/h at pump house near 31-E114A φ 12” CW line & header o/h at pump house near 31-E-114A φ 4” fire water monitor line at top floor

Size & sch φ4’ sch 40 φ 2” sch 80 φ 3” sch 40 φ 3” sch 40 φ 6” sch 40 φ 2” sch 80 φ 6” sch 40 φ 8 & 12” sch 30 φ 2” sch 80 φ 12” sch 30 φ 8” & 12” sch 30

Length 3 mtrs total 15 mtrs 3 mtrs 3 mtrs 10 mtrs 40 mtrs 40 mtrs 1.5 Mtrs 4 mtrs 30 mtrs 40 mtrs

φ 12” sch 30 φ 4” sch 40

10 mtrs 15 mtrs

UNIT - 32 Sl no

Line location

1

φ24” inlet header at n/e corner of the main platform φ24” outlet header at n/e corner of the main platform φ8” inlet line (last 2 mtrs including the bottom bends up to the inlet nozzles of 32-E-06 condenser pairs) φ8” outlet line (first 6 mtrs including the bottom bends from the outlet nozzles of 32-E-06A/A1, C/C1, D/D1, F/F1, I/I1 condenser pairs) φ8” inlet /outlet circuits connected to condenser 34-E-06B/B1 φ3” line going to pumps 32-P-110C/D/E up to isolation valve (balance already recommended) φ12” line connected to main header at north of U32 (rose portion) φ2” line to 32-K-01 φ3” inlet header to 32-K-01 φ2” o/l header to 32-K-01 φ2” header portion to 32-P-04/5 φ8” ETP treated water to 32-C-107 φ6” ETP treated water to 32-C-107

2 3

4

5 6 7 8 9 10 11 12 13

Approx length 40 mtrs.

Specification

Matl

φ24” / thk 12 mm

API 5L / EFSW

43 mtrs.

φ24” /thk 12 mm

API 5L / EFSW

18 mtrs.

φ8” sch.40

A-106 Gr. B

30 mtrs.

φ8” sch.40

A-106 Gr. B

24 mtrs

φ6” sch 40

A-106 Gr. B

6 mtrs

φ3” sch 40

A-106 Gr. B

6mtrs

φ12 ” sch 30

API 5L / EFSW

6mtrs 15 mtrs 15mtrs 6 mtrs 90 mtrs 16 mtrs

φ2” sch 80 φ3” sch 80 φ2” sch 80 φ2” sch 80 φ8” sch 40 φ6” sch 40

A-106 Gr. B A-106 Gr. B A-106 Gr. B A-106 Gr. B A-106 Gr. B A-106 Gr. B

Annexure-I

UNIT -33 1) Cooling water Inlet/Outlet of 33-J-01. Material – A 106 Gr. B, Size - Φ4”, Sch-40. Length- Approx.-10 M. 2) Cooling water Inlet to 33-B-08. Material – A 106 Gr. B, Size - Φ2”, Sch-80. Length- Approx.-6 M. 3) Cooling water Inlet/Outlet of 33-E-06B. Material – A 106 Gr. B, Size - Φ8”, Sch-40. Length- Approx.-10 M. 4) Cooling water Inlet/Outlet of 33-E-13D. Material – A 106 Gr. B, Size - Φ6”, Sch-40. Length- Approx.-12 M. 5) Cooling water main header (inlet). Material – API 5L Gr. B, Size - Φ14”, Sch-40. Length- Approx.-40 M. 6) Cooling water main header (outlet). Material – API 5L Gr. B, Size - Φ14”, Sch-40. Length- Approx.-40 M.

UNIT-34 Sl no 1

φ28” inlet header at n/w corner of the main platform

2

φ28” outlet header at n/w corner of the main platform

3

φ24” inlet sub header below 1st platform

4

φ20” outlet header at n/w corner of the main platform

5 6 7 8 9

φ6” outlet circuits connected to condenser 34-E-15D φ8” line to outlet sub header from u/g φ6” line from inlet sub header to u/g φ6” inlet line to 34-E-2/I φ12” inlet line to 34-E-16

Appro x length 18 mtrs. 12 mtrs. 30 mtrs. 30 mtrs. 16 mtrs 16 mtrs 14 mtrs 18 mtrs 10 mtrs

10

φ12” inlet line to 34-E-17D

10 mtrs

11

φ16” 2nd inlet sub header connected to coolers 37-E15A/B/C φ12” reduced inlet header (down stream portion of main header) at two locations φ8” reduced inlet header ( down stream portion of main header)

6 mtrs

12 13

Line location

35 mtrs 12 mtrs

Specificati on

Matl

φ28” / thk 12 mm φ28” /thk 12 mm φ24” /thk 12 mm φ20” /thk 12 mm φ6” sch 40 φ8” sch 40 φ6” sch 40 φ6” sch 40 φ12” / thk 8 mm φ12” / thk 8 mm φ16” / thk 10 mm φ12” / thk 8 mm φ12” sch 30

API 5L / EFSW API 5L / EFSW API 5L / EFSW API 5L / EFSW A-106 Gr. B A-106 Gr. B A-106 Gr. B A-106 Gr. B API 5L / EFSW API 5L / EFSW API 5L / EFSW API 5L / EFSW A-106 Gr. B

Annexure-I

14 16

φ20” reduced outlet header (up stream portion of main header) φ6” inlet line of 34-E-10C at 2 locations

10 mtrs 20mtrs

φ20” / thk 12 mm φ6” sch 40

API 5L / EFSW A-106 Gr. B

UNIT : 35

Material Material Material Material

– – – –

A A A A

106 106 106 106

Gr. Gr. Gr. Gr.

B, B, B, B,

Size Size Size Size

-

Φ8”, Φ6”, Φ3”, Φ2”,

Sch-40. Sch-40. Sch-40. Sch-40.

LengthLengthLengthLength-

Approx.-40 M. Approx.-180 M. Approx.-40 M. Approx.-40 M.

UNIT –37 : Sl no 1

Line location

Specificati on φ3” sch 40

2 3 4

φ3” Header with 1” stubs at circuits connected to pumps 03/3R/10/10R φ4” inlet outlet circuits connected to condenser 37-E-06 φ4” inlet drain connected to condenser 37-E-02B φ16” inlet header connected to cooler 37-E-02B

Approx length 8 mtrs. 56 mtrs 14 mtrs 4 mtrs

5

φ8” inlet outlet circuits connected to coolers 37-E-03/7

18 mtrs

φ4” sch 40 φ4” sch 40 φ16” sch 20 φ8” sch 30

5 6

φ2” inlet outlet circuits connected to coolers 37-E-03/7 φ12” inlet circuits connected to coolers 37-E-08A/B

3 mtrs 10 mtrs

7

φ6” line connected to coolers 37-E-08A/B inlet circuits

4 mtrs

φ2” sch 80 φ12” sch 30 φ12” sch 40

Matl A-106 Gr. B A-106 Gr. B A-106 Gr. B A-106 Gr. B / API 5L A-106 Gr. B / API 5L A-106 Gr. B A-106 Gr. B / API 5l A-106 Gr. B / API 5l

JOBS TO BE IMPLEMENTED DURING FORTHCOMING SHUTDOWN DATE: 03/08/07 Sl. No.

Scheme No.

Name of the Scheme

Area : CDU-I (U-11) PROCESS MODIFICATION SCHEMES 1 41 Replacement of cooling water battery limit valve at FOB (Gr-10) 2 232 Provision of bypass facility in naptha caustic and water wash mixing of valve of CDU-I 3 233 Routing of PF(11-C-101) & MF(11-C-01) naptha to slop header in CDU-I 4 234A Provision of back flushing facility in CDU-I trim coolers 5 236A Modification of LPG processing facility in CDU-I 6 237 Routing of 90-140 cut Naphtha ex CDU-I to Hy FCC gasoline feed surge drum of Naphtha Hydro Treatment Unit (U-21) Area : CDU-II (U-16) AF JOBS 7 RH0136 VR Burning in CDU-II PROCESS MODIFICATION SCHEMES 8 140 Modification in discharge and warm up line of RCO pumps (16P07A/B/C of CDU-II) 9 231 Provision of isolation valve in the SKCR return line ex 16-E-33 (splitter reboiler) of CDU-II 10 234B Provision of back flushing facility in CDU-II trim coolers 11 236B Modification of LPG processing facility in CDU-II Area : FCCU (U-17/18/19) AF JOBS 12 RH0142 Water trim cooler at debutaniser overhead circuit of RFCCU 13 RH0272 Modification in Belco Filtering Module PROCESS MODIFICATION SCHEMES 14 51 Catalyst lift line support modification RFCCU 15 177 Provision of caustic line in T-109B and caustic supply to MSQ 16 185 Provision of control valve and flow water in the bypass and inlet of pall filter respectively 17 199 Process scheme for segregation of wild naptha and MSQ naptha injection to FCCU reactor riser

Execution By

Agency

Maintenance

Under lining up

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Available

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Agency available

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Project

Agency available

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Under lining up

Maintenance

By Maint. Plg.

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Agency available

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Sl. No. 18 19 20 21

Scheme Name of the Scheme No. 200 Provision of inter-connection between 18P42A/B and 18P52A/B from discharge 229 Provision of jump over connection in MSQ lean/rich Amine to FCCU Amine section Replacement of RFCCU stack Platform at dosing tank in MAB (only drawing required)

Area : CRU (U-22) PROCESS MODIFICATION SCHEMES 22 33 Continuation of 6" fire water header at FOB along Road-'C4' Area : KHDS (U-23) PROCESS MODIFICATION SCHEMES 23 15 Use of 23B05 of KHDS unit at FOB as knock out pot of sour water ex-VisBreaker Unit 24 Modification of supports of reboiler vapour return line ex 23E01 to 23C01 due to vibration problem 25 Water washing facility in 23-E-03A/B Area : DHDS (U-25) PROCESS MODIFICATION SCHEMES 26 Spill back arrangement in recycle gas compressor 27 227 Routing of underground fire water header through covered trench laid in between DHDS & Hydrogen unit 28 Modification in inlet pass line & its supports to 25-F-01 ex 25-E-02D in DHDS Unit due to vibration problem 29 Modification in supports of inlet pass line to 25-F-01 ex 25-E-02B in DHDS Unit due to vibration problem (only supports) 30 Modification in supports of effluent piping ex reactor 25-R-02 to feed exchanger train inlet in DHDS Unit due to vibration problem (only supports) 31 245 Process scheme for inter-connection between 85-P-107discharge and hot condensate line from TPS at DHDS B/L Area : SRU-II (U-28) PROCESS MODIFICATION SCHEMES 32 26 Separate service water header for SRU-II yard Sprinkler

Execution By

Agency

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Maintenance

Agency available

Maintenance

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Maintenance

Agency available

Scheme Name of the Scheme Execution By No. Area : VDU-I (U-31) PROCESS MODIFICATION SCHEMES 33 131 Repl of gate valves in the motive steam line Maintenance to ejector by globe valves in VDU-I 34 60 VDU-I Furnace (31F01) air preheater hot - do air duct modifcation Sl. No.

Area: PDA (U-32) AF JOBS 35 RH0136 VR Burning in LOB Project 36 RH0186 Repl of existing burners of 32-F-01 with low - do NOx burners PROCESS MODIFICATION SCHEMES 37 18 Provision of solonide operated shutdown Maintenance valve in 32-F-01 38 20 Rerouting of anti-foam chemical injection - do line in U-32 39 21 Provision of depressurising ROV at 32-B- do 03 outlet line to flare 40 29 Flow control valve in the cooling water - do supply line to 32-C-07 41 3 Relocation of existing PDA furnace 32-F-01 - do box & coil purging of steam line isolation valves to safe distance 15 M 42 126 Replacement of inter stage KOD of 32-K-01 - do for providing auto draining facility 43 127 Piping connections for installation of new - do propane compressor 32-K-101R 44 139 Provision of minimum circulation line in - do DAO run down pumps 46 225 Modification of cooling water lines in U-32 - do 47

230

48

235

49

239A

50

247

51

248

52

244

Provision of C2-C2 circulation facility in 32P-103A/B Provision of back flushing facility for 32-E117A Process scheme for providing double isolation valves and flanged ends at high pressure drain and vent points in U-32 Provision of ROVs at the suction lines of 32P110 A/B/C/D/E Dismantling of redundant lines & equipments in U-32 (PDA)(in addition to PS244) Dismantling of redundant lines & equipments in U-32 (PDA)

Agency

Agency available - do -

Agency lined up LOA expected by 16/08/07

Agency available - do - do - do - do -

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Scheme Name of the Scheme No. Area : FEU (U-33) PROCESS MODIFICATION SCHEMES 53 238 Process scheme for provision of fuel oil shutdown valve in 33F01 and 33F02 54 Modification in suction headers & its supports of 33-P-7/7R/11/11R due to vibration problem 55 Modification in supports of discharge lines of 33-P-7/7R/11/11R due to vibration problem Sl. No.

Area : HFU (U-35) PROCESS MODIFICATION SCHEMES 56 225 Modification of cooling water lines in U-35 57

239B

58

240

Process scheme for providing double isolation valve and flanged end at high pressure drain and vent points in U-35 Process scheme for NRV in make up gas line in U-35

Area : BBU (U-36) PROCESS MODIFICATION SCHEMES 59 249 Dismantling of redundant lines & equipments in U-36 (BBU) Area : VBU (U-37) AF JOBS 60 RH0186 Repl of existing burners of 37-F-01 with low NOx burners 61 RH0193 Installation of new Preheat exchangers 37E-01 E/F in VBU PROCESS MODIFICATION SCHEMES 62 216 Revival of slop transfer facility from 37B01 using 37P11 63 Modification in supports of suction & discharge lines of 37-P-4/4R/13/13R due to vibration problem

Execution By

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Maintenance

Agency available

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Agency available

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Maintenace

Separate agency is being lined up

Project

LOA expected by 16/08/07

Project

LOA expected by 06/08/07.

Maintenance

Agency available

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Area : NMPEU (U-38) PROCESS MODIFICATION SCHEMES 64 122 Addl fire fighting facility in column nos. 38- Maintenance C-02, C-03/04, C-05/06/07, C-08/09 & C-10 in Unit-38 65 228 Provision of bypass line for the NMP run - do down cooler 38-E-06 66 Enlargement of duct of 38-F-02 - do Area : VDU-II (U-82) AF JOBS 67 RH0136 Balance jobs for VR burning facility in VDUII

Project

Agency available

- do New agency being lined up

Agency available

Scheme Name of the Scheme No. Area : SRU-III (U-83) PROCESS MODIFICATION SCHEMES 68 123 Provision stop valve in SRU-III super heater header 69 241 Recovery of condensate from SRU-III Sl. No.

Area : CDWU (U-84) PROCESS MODIFICATION SCHEMES 70 207 Additional isolation valve in the suction of recycle compressor 84K02A/B in CDW Unit

Area : MSQIU (U-85/86/87) PROCESS MODIFICATION SCHEMES 71 220 Rerouting of DIH bottom stream to HGU naptha pool in MSQ unit 72 214 Modification of existing Pygass filter circuit for SHU feed at prime G+ unit Area : TPS AF JOBS 73 RH0135 VR Burning in TPS PROCESS MODIFICATION SCHEMES 74 58 Installation of welded valve in BFW Line of TPS for boiler No. 1, 2 & 3 75 Enlargement of suction piping of 64P01L

Execution By

Agency

Maintenance Agency being lined up by Maint. Plg. - do Agency available

Maintenance

Agency available

Maintenance

Agency available

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Project

Agency lined up

Maintenance

Estimate clubbed with Maintenance job. Agency available

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Area: GT PROCESS MODIFICATION SCHEMES 76 Modification of CW I/L & O/L of oil cooler in Maintenance GT Area : OFF-SITE AF JOBS 77 RH0136 VR Burning facility - Offsite jobs

78

RH0161 Modernisation of 1st Gantry - Additional jobs including facelifting

79 RH0218 Hook-up for Flare Gas Recovery System PROCESS MODIFICATION SCHEMES 80 175 Repl of existing impellers & couplings of DHDS feed pumps 61-P-101A/B with higher size impellers 81 Repl of existing impeller of HGU feed pump 61-P-102A with higher dia impeller 82 Flare line replacement

83

Modification in supports of MP steam line in Track-B pipe rack in Offsite

P&U (Electrical) / Maint. (Mech) Project

Maint.

Agency for motor repl job available; coupling repl to be done by Workshop Estimate shall be prepared after approval of additional jobs Agency available

Maintenance

To be done by Workshop

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Civil: Agencies lined up; Mech: Agency by Maint. Plg.

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Scheme Name of the Scheme Execution By No. Area : REPLACEMENT ITEMS 84 Monel Chimney tray for top portion of main Maintenance CDU column 11-C-01 Sl. No.

Agency By Maint. Planning

85

Tube bundles: a) 11-E-08A b) 11-E-14 c) 11-E-16 d) 11-E-17 e) 16-E-16 f) 16-E-36 g) 22-E-01A h) 22-E-01B i) 22-E-02 j) 25-E-09 k) 34-E-15D l) 34-K-01A intercooler m) 35-E-02 (duplex SS) n) 37-E-02a o) 38-E-03 A/B p) 38-E-17 q) 38-E-25 r) 57-K-01A Intercooler

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86

Heat Exchanger Assembly a) 34-E-3.7A

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Vessel a) 61-B-02

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ADDITIONAL JOB LIST

FUEL OIL BLOCK

CDU-I 11-F-01 : Cleaning of convection zone with soda ash solution Water washing of APH EXCHANGER: Maintenance of following exchangers 11-E-5A/B/C/D, 7A/B/C/D, 9A/B/C/D, 10A/B/C/D/E/F/G/H, 43

CDU-II 16-F-01 : Cleaning of convection zone with soda ash solution Water washing of APH EXCHANGER : Maintenance of following exchangers 16-E-8A/B/C/D, 10A/B/C/D, 11A/B, 12A/B, 13A/B/C/D, 14C/D,

LUBE OIL BLOCK

VDU-I EXCHANGER: Maintenance of following exchangers 31-E-02A/B/C, 7,14A/B, 127,128 MISCELLANEOUS JOBS :

1. 31F01 Stack , APH & FD/ID ducts repair Opening of ~4 nos. APH manholes for visual checking and making arrangement for APH washing ( Suspected APH leak – Tubular elements to replace ) Replacement of 3 nos damaged metallic bellows on combustion air duct and ~6 nos polymer bellows on flue gas duct Revisioning of ~6nos damper hand jacks on APH and 2nos. dampers on ID fan suction Duct Sampling point to be de-choked & Replacement of F-01 flue gas sampling point with 2nos. dia 1” valves 2. Repair of FD-101/102 casing drain lines and associated 4 nos. globe valves 3. 31-F01 Pilot gas line flushing/dechoking. Dropping of all Pilot Gas burners and checking nozzle thoroughness, etc., Droping / revisioning of 3 nos of burner assembly

4. Revisioning / Easing of air registers of all burners 5. Provision of condensate trap & restricted orifice for all the pumps seal flusing line 6. Re-routing of CW drain lines from ID fan bearing housing and repair of dia 3” drain header. Dia 4” funnel leading to dia 4”header to be fabricated at both inboard and outboard CW drains to prevent water-logging in Unit. 7. Relocation & modification for safe sampling of IO, HO & SR streams ( As per process scheme) 8. Replacement of damaged CW / Service water line near P/House & Furnace area. 9. Repair of 2” overhead leaky SO line to VB tar near U-31 GO filters 10. Re-routing / arranging steam / Condensate lines ( Small bore) in P/H area 11. Repair/replacement of 2 nos of leaky tracing steam/condensate lines of dia ¾” and 1½” respectively. Leaky condensate ( About 10 nos) lines are to be repaired / replaced as per inspection recommendations. Damaged steam traps are to be replaced ( About 15 nos) 12. To provide net ( Jali) on OWS funnel (10 Nos)

TAG JOBS : 1. Revisioning of FD-101/102 inlet guide vanes 2. Rectification of high Lube Oil consumption of FD-101 inboard bearing 3. Re-visioning of 12 nos 1” Gas line Audco valves 4. Repair / replacement of 31-P113 damaged 10” by pass valve ( Wheel damaged) 5. Replacement of leaky gaskets on SR, LO & PA lines ( 8 nos)

FEU EXCHANGER: Maintenance of following exchangers 33-E-4, 5A/B, 6, 11C/D, 14 MISCELLANEOUS JOBS : Repair of 2” cond. Line leak (Near Extract sampling point on pipe .) Rectification of 33 E 13 B : Tube side I/L block valve gland leaks Rectification of 33E5: Shell side inlet B/V gland leak to attend. Tag Jobs : • • • • • • •

Rectification of tracing steam header East side of 33 E-8 long bolts /short bolt/ Missing bolts ( Approx 50 nos) 2 nos extended ¾” tracing steam lines from P-105 to be removed apx 20M. Redundant ¾” tracing steam line near C103 /104 to remove for ease of movement ¾” tracing condensate line –( hanging ) 10 M. near C5/C6 to be relocated. B04- steam heating coil leak to rectify. 33 E-2 (West side ) inlet line to check for leakage

10” PSV line ex 33-C2 to B-10 to be de-choked & thoroughness to ensure

SDU EXCHANGER: Maintenance of following exchangers 34-E-15A/B/C/D

HFU EXCHANGER: Maintenance of following exchangers 35-E-2, 102, 6, 7

VBU EXCHANGER: Maintenance of following exchangers 37-E-1A/B/C/D, 2A/B, 3

37-C01 : Blinding / Deblinding jobs Opening of 4 man holes. Cleaning of column bottom trays 05 Nos. Removal of coke from column bottom. Dropping of BPC, cleaning and fixing back Biox-up of column. MISCELLANEOUS JOBS : 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19

6” Sour gas battery limit valve – needs hot job for matching flange 3 Nos 6” B/L Gate valves on Fuel Gas line revisioning / replacement 6” Audco valve on FG line CW return Battery limit valve to provide Isolation valve on 3” CW return line of 37E03 37-P-4 : Suction B/V passing - to rectify Rectification of 2” FG burner line from Audco valve to Individual burners Repair of 37- E01 and E08 S/S blow down line to 6” blowdown main header before NRV. BPCV –01 droping for cleaning Dechoking / inspection of 6” vertical transfer line from BPCV (Approx 20 M) after opening flanges. 2” Slop line de-choking from P9/9R to Column bott. De-choking of corrosion injection line upto C1 & C4 and providing break flanges for ease of online maint. ¾” leaky tracing steam line at B/limit pipe rack Battery limit FO & FG damaged PG manifold to rectify Tracing steam line leak near 37P114A inside Trench Utility air line tap off for flue gas sampling redundant lines removal Steam leak from tracing steam line of Slop header west side of F1 37E1D:Tube side I/l bleeder valve damaged wheel missing ( Repair) About 750 nos of short and long bolts to be rectified. Point wise check list prepared

CIDW EXCHANGER: Maintenance of following exchangers 84-E-15, 16, 17, LO and SO coolers of 84-K-01A/B AND 84-K-02A/B

84-C01 Blinding /de-blinding for preparation of man entry: (dia. 8”- 2 nos, dia 4”-1 no. , dia 3”- 2 nos and dia 2”- 2nos) Opening of m/hole 24” (3-1/2”-800mm- 16 nos studs). required bolt tensioner for opening. projected stud length- 80mm, across face- 134mm. (torque 21476 nm) Opening of top cover (dia 760mm) and removal of top dome. (m80x85mm- 24 nos studs). required bolt tensioner for opening. projected stud length- 58mm, across face – 114mm. (torque 15700 nm) Opening of hand hole dia 14” Removal & repl. of demister pad. 3 Removal, cleaning & box up of 1” pall ring packing (about 1.7 m )

Cleaning of column shell. Opening, checking & box of feed distributor Box up of the column man hole/hand hole and top coevr after inspection. 1.0 Steam leak jobs 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Dia 2” Condensate line flange leak near P 02 A Steam leak above P-20A/B Dia 1” F 01 Convection Box purging steam line. (Inside the Explosion door box casing) Condensate header end blind flange at pipe rack near compressor house. Dia 1” Condensate line pinhole leak near B/L, on O/H pipe rack Pin Hole leak at pipe rack inside compressor house. C 05 ejector platform near by steam leak (tracing) Steam traps to be revision/ replaced (Approx 100 Nos) rd Tracing steam leak from R 02 3 platform. Steam leak from 2” header near u-84 flare KOD Condensate line leak near CBD vessel-on manifold

2.0 Sl No 1 2 3 4 5 6.

Passing Valves Revisioning / Replacement jobs Description/ Location P 02A/B suction valve P15 A/B min flow C/v bypass line valves P 02 A/B seal oil filters isolation valves P 14 B discharge bleeder drain valve damaged P15 A/B U/S, D/S & By-pass B/V of 2” Min circl. C/V 84-P2A/B seal oil filters isolation valves

Size/ Rating 6”/150 lb 2”/1500lb

Nos 2 2

½”/2500lb

12

1”/1500lb

1

2”/1500lb

6 nos

½”/2500lb

16 nos

3.0 Equipment related jobs 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

M 01 to be opened and cleaned. Cartridges to be replaced if required. M 02 to be opened and cleaned. Cartridges to be replaced if required P 02 A/B seal oil coolers/ lube oil coolers to be cleaned. EA 03/M3 bearing replacement. All Fin fan coolers’ fans to check 84- K 01A/B, K 02 A/B lubricator cleaning and lines dechoking. 84-P19 A/B discharge line to CBD to be provided with NRV. 84-K 01 A/B, K 02 A/B jacket water circuit view glasses to be cleaned. 84-P 02 B seal leak, consuming more lube oil 84-P 02 A/B seal oil filters to be provided. P-02A/B view glasses on CW line to be cleaned G-01A/B –new cartridges to be installed K-01A/B -Jacket water coolers and Lube Oil coolers to be opened and cleaned- 4 Nos. K-02A/B- Jacket water coolers and Lube Oil coolers to be opened and cleaned- 4 Nos.

4.0 Miscellaneous Jobs 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

5.0

G 01 A/B drain Spectacle blinds position to be shifted to Upstream of the B/V. B 31 vent to flare line to be dechoked. B 04 level troll diaphragm flanges (3 Nos) leaking. Suction isolation valves to be provided in K 02 A/B Separate C/W lines to be provided for Seal oil coolers in P 02 A/B. P14 A/B lube oil coolers to be cleaned, Seal oil cooler C/W lines to be dechoked. P 15 A/B lube oil coolers to be cleaned P 03 A/B seal oil cooler C/W lines to be dechoked. P 18 A/B seal oil cooler C/W lines to be dechoked P3 A suction strainer flange leak P-15A taking high amps- to be attended Cleaning of all pilot gas/FG burners in F-01/02/03-Total:10X2=20 Nos. All pump / Compressor bearing & seal oil coolers CW supply & return lines are to be made 2” / 1” with break flanges for online cleaning after isolation. 14. De-choking of CBD vent line to flare

Process Modification Jobs

1. Tapping to be taken from C/V upstream for 84 T 01 top up ( operational requirement) 2. ¾” Steam purging ring isolation valves to be provided at safe location at ground at 84 F01/02/03, 39 E01 & 39 reactor top flange, 37 – E01A/B/C/D & Soaker drums, U-31 exchanger area. ( Safety point) 6.0 Instrument Maintenance 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

CBD level switches and level indicator to be attended. Seal nitrogen Pressure transmitter with DCS indication to be provided for K 02 A like in K 02 B P15 A/B discharge C/Vs FV2402, FV2403 is heavily passing to be attended. FV2401 is heavily passing to be attended. B 04 level troll diaphragm flanges are leaking. P 01 A/B discharge line FT1201 diaphragm flanges leaking. All hydrocarbon, H2S, H2 has detectors to be calibrated and one display page to be provided in DCS. B 32 PG and TG glasses to be cleaned. C/W flow indication causes frequent problems, to be attended. C/W line PGs and TGs to be marked. R 03 bottom bed delta pressure indication erratic. EA 06 louvers frequently cause problem, not operating smoothly. Emergency depressurization C/Vs instrument air vessels do not hold for 10 minutes.

13. P-02A/B , P-01A/B discharge flow, wax flow into Unit-impulse lines from orifice to transmitter to be steam traced with Copper tube, with proper draining facility/steam traps 14. Rectification of 84-PDI2110 (84-C01 ) 6.0 1. 2. 3. 4. 5.

Civil Maintenance DWO and HD lines to HSD header to be painted. Flooring at certain places in TPM viewpoint. Painting, stenciling as per TPM viewpoint. Cleaning of pump bases, Compressors external parts and site area. Insulation of R-03 is damaged-to be attended

8.0 Electrical Maintenance 1. 2. 3. 4. 5.

P 02 A motor to be provided. Aviation warning lights of furnace to be rectified F 01/ F 02/F 03 igniters to be rectified. All fused lamps to be replaced. Lighting arrangement to be done for checking P 14 B gearbox lube oil in night shift.

DHDS BLOCK

FCCU Maintenance of following exchangers 18-E-14, 39A/B Cleaning of 18-C-01 column inlet line horizontal portion after opening M/H. Revisioning of two valves provided in the suction line of 18-P-17A/B.

VDU-II 82-F-01 Blinding and deblinding jobs Dropping of all burners and cleaning Erection of scaffolding at three locations for random checking of furnace tubes and thermocouples. Welding of thermocouples as required. APH water washing with soda ash solution. Repair of ID fan casing as required. Blinding and deblinding jobs of 82-C-01 (dia 4”- 04 Nos.) Repair of leak in 82-C-01 vapour line.

SRU-III Maintenance of following exchangers 83-E-01, 02/03, 04/05, 06/07, 14 & 15

MISCELLANEOUS JOBS OF DHDS BLOCK:

1.Revisioning of IGVs and dampers of ID/FD in HGU. 2.Hydrogen line ex bullet to DHDS battery limit 10 nos of block valves gland replacement/block valve replacement (if available). 3.Replacement of 6" nitrogen line main header as per inspection recommendation(appro.5mt). 4.29C51(new SWS stripper) overhead leaky line(already clamped) replacement/repair as per inspection recommendation. 5.25C02 overhead line-corrosion inhibitor injection point(leaked recently) permanent rectification as per inspection recommendation. 6.Steam leak rectification in SRU-II/III/VDU-II/MSQ. 7.DHDS unit underground CBD line rectification of leaky portion. 8.Replacement of damaged air bellows(approx 25nos,refer M/s Hamworthy recommendation) in HGU. 9.Dechocking of 25P02A/B suction line.

CRITICAL ERECTION JOBS DURING SHUTDOWN

FOB Replacement of 11-E-22 Exchanger LOB Replacement of 31-F-01 Stack Replacement of 32-F-01 Stack Replacement of 34-E-3.7 TPS Replacement of Riser pipes of PCT

FCCU Replacement of CO-Stack Replacement of CO-Duct bellow Replacement of forged cone of regenerator lift line Replacement of 18-EA-11 air cooler Replacement of 18-EA-16 air cooler HGU Replacement of catalyst tubes of 24-F-02 ARU Replacement of 26-AC-06 air cooler OFFSITE Replacement of HC & acid Flare tip Replacement of Flare line

SL

AREA

JOB DESCRIPTION

AGENCY

FCCU 1

REVISIONING OF MAB & WGC

SWAMINA

MISC S/D MAINT.JOB IN FCCU

CITY CONSTRUCTION

FCCU 2 FCCU 3 FCCU 4

CHK-III & CHK-II MAINT OF HEAT EXCHANGER/AIR FIN COOLERS

R M WORKS

HIRING OF EXPERT FOR MAINT.OF SLIDE VALVES AT FCCU

Z&J

HIRING OF EXPERT FOR MAINT.OF MAB & WGC

BHEL

FCCU 5 FCCU 6

REPLACEMENT OF 96" DIA FCCU BELLOW

ZENITH

BLINDING / DEBLINDING OF VAPOUR LINE

BAPAN ENTERPRISES

FCCU 7 FCCU

DE-CHOKING OF AERATION POINTS OF 18-R-01 BY DRILLING

8

THE TECHNIC

FCCU 9

FIELD SERVICE FOR DRY GAS SEAL 18-K-10

10

HGU ARU

MISC.S/D MAIMT.JOB IN HGU & ARU

11

HGU ARU

MISC MAINT OF COLUMN/VESSEL/FURNACE/REACTOR

12

HGU ARU DHDS DHDS

CHK-III & CHK-II MAINT OF HEAT EXCHANGER/AIR FIN COOLERS

13

OVERHAULING OF

BURGMANN

ROYAL CONSTRUCTION CO

25-K-01A/B

HGU 14

REPLACEMENT OF CAT.TUBE & MISC.S/D JOB OF 24-F-02

AMAR 3ENGG

HGU 15

MISC.HOT JOB AT DHDS FOR HGU

16

SHU 87)

17

HGU MSQ FOB

18

(USKIMING OF CATALYST OF 87-R-01 DURING S/D-2007

CONTRACT RESOURCES

TO & FRO TRANSPORATION OF DRUMS & WOODEN PLATFORMS

KALPANA ENTERPRISE

MISC.MAINT.JOBS OF FURNACE & COLUMN AT FOB DURING S/D-2007

CITY CONSTRUCTION

MAINT OF 21-C-01

BAPAN ENTERPRISES

FOB 19 FOB 20

MAINT OF 21-R-01 / 22-R-02

PATRA CONSTRUCTION

FOB 21

MAINT.OF HEAT EXCHANGER OF CDU-I /II & SRU-III FOB

22

MISC HOT JOB AT GR-10 FOB

23

MISC HOT JOB AT GR-16 FOB

24

MISC PIPING JOB AT GR-20 LOB

25

MAINT.OF HEAT EXCHANGEROF U-32

EXPO GAS CONTAINERS

REP / MAINT OF COLUMNS IN UNIT-32 & UNIT-38

EXPO GAS CONTAINERS

LOB 26 LOB 27

REP / MAINT OF VESSELS & TANKS IN UNIT-32 & UNIT-38

CHABILAL PARUA

LOB 28

REP / MAINT OF FURNACE STACK OF 32-F-01

A R ENGINEERS

LOB 29

REPLC.OF 31-F-01 STACK & DUCT

A R ENGINEERS

PDA & NMP RELATED JOBS+TPS HEAT EXCH

BHARAT ENGG

LOB 30 LOB 31

MAINT.OF HEAT EXCH OF LOB

U-31 / 33 / 34 / 35 / 37 / 84

COMPLETE RE-TUBING OF HEAT EXCHANGER 38-E11/12/13/24 AT LOB

32 LOB 33

MISC HOT JOB FOR LOB LOB

34

MAINT.OF 37-C-01 LOB

35

36

MAINT.OF 84-C-01 FOB TPS

LOB

CONTRACT RESOURCES

REPLC.OF A/G , U/G C/W LINE & RISER PIPE OF PROCESS COOLING TOWER DURING S/D-2007

TPS 37

MISC.MAINT.JOB AT TPS DURING S/D-2007 TPS

38

MAINT OF VESSEL IN TPS O/S

39

REPLACEMENT OF FLARE LINES

BHARAT ENGG

O/S 40

REP / REPLC OF SMALL BORE PIPE AT O/S AREA O/S

41

REP / REPLC OF PIPING

(6" TO 24") AT O/S AREA

O/S 42

MAINT.OF VESSEL AT O/S AREA

M N MANNA

GT 43

BORESCOPIC INSPECTION OF FRAME-5

BGGT

REPAIR OF SPARE OF FRAME-5 OF GT

BGGT

GT 44 GT 45

REMOVAL,CLEANING & FIXING BACK OF AIR FILTER OF GT

BAPAN ENTERPRISES

TROUBLE SHOOTING & STARTING ASSISTANCE FOR GT

BGGT

GT 46 VDU-II 47

REP / MAINT OF 82-F-01 GEN

48

OUTSOURCING MANPOWER TO SUPERVISE S/D JOBS DURING SEPT-OCT ' 07 AT H/R

GEN 49

HYDROBLAST CLEANING OF EXCHANGER

USHA HYDROBLAST

GEN 50 51

VALVE REVISIONING GEN

AMRUTHA

MAIMT & INSPECTION OF VARIOUS WASTE HEAT BOILERS,HRSG & OTHER IBR PIPING & ALLIED JOBS

GEN 52 53

HIRING OF CRANE GEN

HYDROBLAST CLEANING OF EXCHANGER U-11 / 16 / 31 / 33 / 34 / 35 / 37 / 83 & 84

INDUSTRIAL HANDLING

SPECIAL TOOLS AND TECHNIQUES TO BE ADOPTED DURING SHUTDOWN

High pressure hydrotest pump (400 Kg/Cm2) Tyre mounted 150 MT crane with telescopic boom 350 MT crane with lattice boom & luffing jib. Diamond cutting tool machine Hydraulic bolt tensioner. Hydraulic Torque wrench High Pressure (20,000 PSI) hydroblast cleaning machine Plasma Cutting Machine High source strength radiography Internal Rotary inspection System (IRIS) Ultrasonic Attenuation Testing Direct Current Voltage Gradient (DCVG) testing Current Attenuation Testing (CAT)

OEM SUPPORTS TO BE AVAILED DURING SHUTDOWN

BHEL – 18-K-01/ & 10 (MAB & WGC) Z&J – FCCU Slide valves GE Energy – 25-K-1A/B (Nuovo pignone) BURGMANN – DGS of WGC BGGT – CI-BI of GT HAMWORTHY – 24-F-02 Burners HALDOR TOPSOE – HGU Reformer HONEYWELL – DCS ABB – PLC of TPS

ERECTION CHECKLIST Dated :Sub:-

Sl No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Points

Observations Available Not available

Eqpt. Erection plan available. Does deployed crane has been load tested and has valid test certificate. Does crane has adequate boom length as specified in erection plan Does crane has Overload cut off facility and same has been tested. Certificate available. Does crane has load chart with respect to boom length and angle. Does crane has spark arrester fitted. Are all path way hard surfaced and required plates are placed for crane positioning and levelling Checked all safety interlocking system Does crane hook has locking arrangement and it is ok. Is Crane movement area cordoned off Are all lifting tools/tackles like slings, D-shackles etc have min. required load carrying capacity Are tools/tackles like slings, D-shackles etc load tested and having valid test certificate. Do Erection spreader beam size as per erection plan Are all lifting lugs of specified sizes and thickness Are the riggers involve in the jobs having past experience? Do Crane operator involve in the jobs experienced and has valid certificate/License for crane operation? Are all the lifting/ dismantling loads calculated Working at height permit obtained. Are all persons wearing relevant PPE Valid work permit obtained

Signature of EIC

Signature of supervisor

ID

Task Name

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

MAINT OF 11C01 Shutting down of column with KM Opening of manholes Provision of exhaust fans Air circulation and gas test External scaffolding Opening of tray manways Cleaning of column shell and tra Inspection of column Repair of column internals as pe Final inspection by Process/ Pro Refixing of tray manways Removal of scaffolding Box-up of manholes Deblinding Start up activities

Project: 11C01 Date: Thu 9/6/07

Duration 19 days 124 hrs 16 hrs 16 hrs 24 hrs 48 hrs 24 hrs 48 hrs 48 hrs 36 hrs 16 hrs 24 hrs 36 hrs 24 hrs 16 hrs 72 hrs

Start Fri 9/21/07 Fri 9/21/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Wed 9/26/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Thu 10/4/07 Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07

Finish Wed 10/10/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Wed 10/10/07

Sep 16, '07 Sep 23, '07 Sep 30, '07 Oct 7, '07 T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

MAINT OF 11F01 Shutting down of furnace Gas Test & Man entry Provision of Scaffolding inside Furnace Preliminary Inspection of Furnace & Mark Cleaning of Radiation & Convection Tube Detailed Inspection of furnace Cutting & removal of Radiation Tubes (4 Insertion of tubes, Edge Preparation & Fi Welding of new joints (08 Nos.) Radiography of welded joints Stress Releiving of New Joints (08 joints) Post SR Hardness Checking of Weld join Post SR Radiography of Welded joints Spring hanger replacement Ceramic Fibre Repair at Conv. Section Hydraulic Pressure Testing of Furnace Co Removal of scaffolding Floor Repair / Burner Throat Repair Final Inspection Repair / replacement of Skin thermocoup Revisioning of Damper Plates / Explosion revisioning of Burner Blocks Boxing up of Burner Blocks Final Box up of Manway Start up activities

Project: 11f01 Date: Thu 9/6/07

19.5 days 48 hrs 4 hrs 36 hrs 8 hrs 48 hrs 16 hrs 24 hrs 24 hrs 72 hrs 24 hrs 36 hrs 8 hrs 36 hrs 48 hrs 48 hrs 24 hrs 24 hrs 24 hrs 4 hrs 48 hrs 120 hrs 120 hrs 16 hrs 8 hrs 72 hrs

Fri 9/21/07 Fri 9/21/07 Sun 9/23/07 Sun 9/23/07 Tue 9/25/07 Tue 9/25/07 Thu 9/27/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Tue 9/25/07 Tue 9/25/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 9/23/07 Sun 9/23/07 Fri 9/21/07 Sat 10/6/07 Sun 10/7/07 Sun 10/7/07

Wed 10/10/07 Sun 9/23/07 Sun 9/23/07 Tue 9/25/07 Tue 9/25/07 Thu 9/27/07 Fri 9/28/07 Wed 9/26/07 Wed 9/26/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 9/27/07 Thu 9/27/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Tue 9/25/07 Fri 9/28/07 Wed 9/26/07 Sun 10/7/07 Sun 10/7/07 Wed 10/10/07

F

S

Sep 23, '07 S M T W T

F

S

Sep 30, '07 S M T W T

S

Oct 7, '07 S M T W T F 0%

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

MAINT OF 16-F-01 18.33 days Shutting down of furnace 48 hrs Gas Test & Man entry 4 hrs Provision of Scaffolding inside F 36 hrs Preliminary Inspection of Furnac 8 hrs Cleaning of Radiation & Convec 48 hrs Detailed Inspection of furnace 16 hrs Cutting & removal of Radiation T 16 hrs Insertion of tubes, Edge Prepara 24 hrs Welding of new joints (08 Nos.) 56 hrs Radiography of welded joints 24 hrs Stress Releiving of New Joints ( 36 hrs Post SR Hardness Checking of W 8 hrs Post SR Radiography of Welded 24 hrs Spring hanger replacement 48 hrs Ceramic Fibre Repair at Conv. 48 hrs Hydraulic Pressure Testing of Fu 24 hrs Removal of scaffolding 24 hrs Floor Repair / Burner Throat Re 24 hrs Final Inspection 4 hrs Repair / replacement of Skin the 48 hrs Revisioning of Damper Plates / 120 hrs revisioning of Burner Blocks 120 hrs Boxing up of Burner Blocks 16 hrs Final Box up of Manway 8 hrs Start up activities 72 hrs

Project: 16F01 Date: Thu 9/6/07

Fri 9/21/07 Fri 9/21/07 Sun 9/23/07 Sun 9/23/07 Tue 9/25/07 Tue 9/25/07 Thu 9/27/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 9/25/07 Tue 9/25/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 9/23/07 Sun 9/23/07 Sun 9/23/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07

Tue 10/9/07 Sun 9/23/07 Sun 9/23/07 Tue 9/25/07 Tue 9/25/07 Thu 9/27/07 Fri 9/28/07 Wed 9/26/07 Wed 9/26/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Thu 9/27/07 Thu 9/27/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Tue 9/25/07 Fri 9/28/07 Fri 9/28/07 Sat 10/6/07 Sat 10/6/07 Tue 10/9/07

F

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Sep 23, '07 S M T W

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Sep 30, '07 S M T W

F

S

Oct 7, '07 S M T

W T 0%

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F

ID

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

MAINT OF 32-F-01 Shutting down of furnace Gas Test & Man entry Provision of Scaffolding inside F Preliminary Inspection of Furnac Cleaning of Radiation & Convec Detailed Inspection of furnace External Scaffolding Dismantling of stack Dismantling of refractory Erection of stack Marking of damaged casing plat Cutting of damaged casing plate Erection of plates Welding of new casing plates Surface cleaning Lug welding Painting of casing plate Re lining with new ceramic fibre Hydraulic Pressure Testing of Fu Removal of internal scaffolding Floor Repair / Burner Throat Re Final Inspection Repair / replacement of Skin the Revisioning of Damper Plates / Repair/Replc. of Explosion door revisioning of Burner Blocks Boxing up of Burner Blocks Final Box up of Manway Start up activities

Project: 32F01 Date: Thu 9/6/07

Duration 29 days 120 hrs 4 hrs 24 hrs 8 hrs 48 hrs 16 hrs 24 hrs 72 hrs 96 hrs 72 hrs 24 hrs 48 hrs 48 hrs 96 hrs 96 hrs 48 hrs 120 hrs 96 hrs 24 hrs 16 hrs 24 hrs 8 hrs 48 hrs 120 hrs 48 hrs 120 hrs 16 hrs 8 hrs 120 hrs

Start Thu 9/13/07 Thu 9/13/07 Tue 9/18/07 Tue 9/18/07 Wed 9/19/07 Sun 9/23/07 Tue 9/25/07 Tue 9/18/07 Wed 9/19/07 Wed 9/19/07 Sat 9/22/07 Sun 9/23/07 Mon 9/24/07 Wed 9/26/07 Fri 9/28/07 Sun 9/23/07 Tue 9/25/07 Thu 9/27/07 Sun 9/30/07 Thu 9/27/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 9/23/07 Sun 9/23/07 Sun 9/23/07 Sun 9/23/07 Sat 10/6/07 Sun 10/7/07 Sun 10/7/07

Finish

7 Sep 16, '07 Sep 23, '07 Sep 30, '07 Oct 7, '07 Oct 1 W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M 0% Fri 10/12/07 Tue 9/18/07 0% Tue 9/18/07 0% Wed 9/19/07 0% Wed 9/19/07 0% Tue 9/25/07 0% Wed 9/26/07 0% Wed 9/19/07 0% Sat 9/22/07 0% Sun 9/23/07 0% Tue 9/25/07 0% Mon 9/24/07 0% Wed 9/26/07 0% Fri 9/28/07 0% Tue 10/2/07 0% Thu 9/27/07 0% Thu 9/27/07 0% Tue 10/2/07 0% Thu 10/4/07 0% Fri 9/28/07 0% Fri 10/5/07 0% Sat 10/6/07 0% Sat 10/6/07 0% Tue 9/25/07 0% Fri 9/28/07 0% Tue 9/25/07 0% Fri 9/28/07 0% Sun 10/7/07 0% Sun 10/7/07 0% Fri 10/12/07 0%

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M A IN T O F H E A T E X C H A N G E R S & A I R F IN C O O L E R S A T P D A D U R IN G S /D 0 7 1 30 O p e n in g 2

7 030

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1 1 1 6 30

4 5 6 7 8

Days

9

4 8

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19

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31 35

8

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6 3

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10 4 8

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M A IN T . O F H E A T E X C H A N G E R S & A IR F IN C O O L E R S A T N M P D U R IN G S /D 0 7 1

O p e n in g

7 30

3

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D ays

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2

7 30 11

16

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7 30

8

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H y d ro b la s t in g 11

16

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7

9

B u n d . P u l l in g 7 30

11

7 33

In s p e c t i o n

38

21

26

31

11

7 21

26

31

34

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7 16

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B o x -U p

ID

Task Name

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

FCCU DHUTDOWN JOBS SEPT' 2007 REGENERATOR JOBS SHUTTING DOWN ACTIVITY GAS TEST & MAN ENTRY REMOVAL OF REMAINING CATA ERECTION OF SCAFFOLDING OPENING OF CYCLONE MANWA PROVISION OF ROPE LADDER IN GENERAL CLEANING OF REGEN GENERAL INSPECTION OF REGE MECH. HOT JOB & REFRACTORY REPAIR / REPLACEMENT OF NO SUPPORTING OF LIFT PIPE USIN REMOVAL OF TIE RODS AT THE CUTTING OF MANWAY OPENING MAKING CAGE ARRANGEMENT INSPECTION OF LIFT LINE MARKING OF LENGTH OF LIFT P CHIPPING OF REFRACTORY AT HOLDING OF CATALYST DISTRIB CUTTING OF 3 NOS. POCKETS A REMOVAL OF 4 NOS. CLEATS AN CUTTING OF LIFT PIPE (J-1) BY G CUTTING OF LIFT PIPE (J-2) BY G LOWERING DOWN & REMOVAL O CUTTING OF LIFT PIPE (J-4) BY G CUTTING OF LIFT PIPE (J-3) BY G LOWERING DOWN & REMOVAL O LIFTING OF RISER CATALYST DI REPAIR OF HEXMESH AND RESC EDGE PREPARATION AND DP O ERECTION AND FIT-UP OF J3

Project: FCCU Date: Thu 9/6/07

Duration 632 hrs 632 hrs 68 hrs 4 hrs 16 hrs 24 hrs 48 hrs 8 hrs 72 hrs 120 hrs 72 hrs 48 hrs 24 hrs 24 hrs 16 hrs 8 hrs 8 hrs 8 hrs 24 hrs 16 hrs 16 hrs 16 hrs 8 hrs 8 hrs 8 hrs 16 hrs 16 hrs 8 hrs 16 hrs 24 hrs 16 hrs 16 hrs

Start

Finish

Sun 9/16/07 Sun 9/16/07 Sun 9/16/07 Wed 9/19/07 Wed 9/19/07 Wed 9/19/07 Wed 9/19/07 Sun 9/23/07 Thu 9/20/07 Sun 9/23/07 Fri 9/28/07 Fri 9/28/07 Thu 9/20/07 Fri 9/21/07 Fri 9/21/07 Sat 9/22/07 Sat 9/22/07 Fri 9/21/07 Sat 9/22/07 Fri 9/21/07 Fri 9/21/07 Sat 9/22/07 Sun 9/23/07 Sun 9/23/07 Sun 9/23/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07

Fri 10/12/07 Fri 10/12/07 Wed 9/19/07 Wed 9/19/07 Thu 9/20/07 Thu 9/20/07 Fri 9/21/07 Mon 9/24/07 Sun 9/23/07 Fri 9/28/07 Mon 10/1/07 Sun 9/30/07 Fri 9/21/07 Sat 9/22/07 Sat 9/22/07 Sat 9/22/07 Sun 9/23/07 Sat 9/22/07 Sun 9/23/07 Sat 9/22/07 Sat 9/22/07 Sun 9/23/07 Sun 9/23/07 Sun 9/23/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Wed 9/26/07 Wed 9/26/07

Sep 16, '07 Sep 23, '07 Sep 30, '07 Oct 7, '07 Oct 1 S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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Task Name

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

Project: FCCU Date: Thu 9/6/07

Duration

WELDING OF J3 WITH STAGE W LOWERING OF BOTH THE PIECE ERECTION AND FIT-UP OF J4 WELDING OF J3 & J4 WITH STAG LIFTING OF RISER PIPE ALIGNMENT AND FIT UP OF J2, J WELDING OF J2, J5 & VERTICAL RADIOGRAPHY INSIDE REGENE RESCO LINING & CURING OF BA REMOVAL OF CAGE FROM LIFT WELDING OF MANWAY OPENING FILLING OF CEREMIC BLANKET APPLICATION OF REFRACTORY WELDING OF 4 NOS. CLEAT ON CLOSING OF 3 NOS. POCKET & N FITTING OF LIFT LINE TURN BUC REMOVAL OF LIFTING LUGS IN R FITTING OF ALL CONNECTING P WELDING OF ALL CONNECTING REVISIONING OF PLUG VALVE O FINAL CHECKING OF PLUG VALV REMOVAL OF SCAFFOLDING FR FINAL CLEANING FINAL INSPECTION BY PS, PN, IN BOX UP OF REGENERATOR & CY DEBLINDING START UP ACTIVITY REACTOR JOBS SHUTTING DOWN ACTIVITY GAS TEST & MAN ENTRY OPENING OF CYCLONE MANWA OPENING / CUTTING OF RISER M

16 hrs 8 hrs 32 hrs 32 hrs 8 hrs 16 hrs 24 hrs 16 hrs 24 hrs 8 hrs 16 hrs 24 hrs 16 hrs 16 hrs 16 hrs 16 hrs 16 hrs 16 hrs 16 hrs 72 hrs 8 hrs 16 hrs 8 hrs 8 hrs 24 hrs 24 hrs 96 hrs 632 hrs 68 hrs 4 hrs 48 hrs 48 hrs

Start

Finish

Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Wed 10/3/07 Wed 10/3/07 Wed 10/3/07 Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Thu 10/4/07 Thu 9/20/07 Fri 10/5/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Sun 10/7/07 Sun 10/7/07 Mon 10/8/07 Sun 9/16/07 Sun 9/16/07 Wed 9/19/07 Wed 9/19/07 Wed 9/19/07

Thu 9/27/07 Thu 9/27/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Thu 10/4/07 Thu 10/4/07 Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Fri 10/5/07 Sun 9/23/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07 Fri 10/12/07 Fri 10/12/07 Wed 9/19/07 Wed 9/19/07 Fri 9/21/07 Fri 9/21/07

Sep 16, '07 Sep 23, '07 Sep 30, '07 Oct 7, '07 Oct 1 S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID

Task Name

65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96

Project: FCCU Date: Thu 9/6/07

Duration

PROVISION OF INSPECTION CAG PROVISION OF ROPE LADDERS REMOVAL OF REMAINING CATA ERECTION OF SCAFFOLDING IN GENERAL CLEANING OF REACT GENERAL INSPECTION OF REAC MECH. HOT JOB & REFRACTORY REPAIR / REPLACEMENT OF NO INSPECTION OF RISER & CYCLO REPAIR JOBS IN RISER & CYCLO DECHOKING OF HCO NOZZLES REPLACEMENT OF VB NAPHTHA REPAIR OF LDD TUBES, IF REQU MECHANICAL & REFRACTORY J FINAL INSPECTION OF RISER & REMOVAL OF CAGE FROM RISE REMOVAL OF SCAFFOLDING FR FINAL CLEANING FINAL INSPECTION BY PS, PN, IN WELDING OF RISER MANHOLES BOX UP OF REACTOR AND CYC DEBLINDING START UP ACTIVITY ORIFICE CHAMBER JOBS SHUTTING DOWN ACTIVITY GAS TEST & MAN ENTRY REMOVAL OF REMAINING CATA CUTTING OF GRID MANWAYS PROVISION OF ROPE LADDER F GENERAL CLEANING OF ORIFIC INSPECTION OF ORIFICE CHAMB MECH. HOT JOB & REFRACTORY

8 hrs 8 hrs 16 hrs 72 hrs 48 hrs 24 hrs 168 hrs 120 hrs 48 hrs 96 hrs 120 hrs 48 hrs 48 hrs 96 hrs 8 hrs 24 hrs 16 hrs 8 hrs 8 hrs 24 hrs 24 hrs 24 hrs 96 hrs 632 hrs 68 hrs 4 hrs 8 hrs 120 hrs 8 hrs 16 hrs 16 hrs 72 hrs

Start

Finish

Fri 9/21/07 Fri 9/21/07 Wed 9/19/07 Thu 9/20/07 Sun 9/23/07 Tue 9/25/07 Wed 9/26/07 Wed 9/26/07 Fri 9/21/07 Sun 9/23/07 Wed 9/26/07 Wed 9/26/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Thu 10/4/07 Sun 10/7/07 Mon 10/8/07 Sun 9/16/07 Sun 9/16/07 Wed 9/19/07 Wed 9/19/07 Wed 9/19/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07

Sep 16, '07 Sep 23, '07 Sep 30, '07 Oct 7, '07 Oct 1 S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M Fri 9/21/07 0% Fri 9/21/07 0% Thu 9/20/07 0% Sun 9/23/07 0% Tue 9/25/07 0% Wed 9/26/07 0% Wed 10/3/07 0% Mon 10/1/07 0% Sun 9/23/07 0% Thu 9/27/07 0% Mon 10/1/07 0% Fri 9/28/07 0% Fri 9/28/07 0% Sun 9/30/07 0% Thu 9/27/07 0% Fri 9/28/07 0% Wed 10/3/07 0% Thu 10/4/07 0% Thu 10/4/07 0% Fri 10/5/07 0% Fri 10/5/07 0% Mon 10/8/07 0% Fri 10/12/07 0% 0% Fri 10/12/07 Wed 9/19/07 0% Wed 9/19/07 0% Wed 9/19/07 0% Mon 9/24/07 0% Tue 9/25/07 0% Tue 9/25/07 0% Wed 9/26/07 0% Sat 9/29/07 0%

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ID

Task Name

97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122

Project: FCCU Date: Thu 9/6/07

Duration

FINAL INSPECTION OF ORIFICE WELDING OF GRID MANWAYS BOX UP OF ORIFICE CHAMBER M DEBLINDING START UP ACTIVITY CO-BOILER JOBS SHUTTING DOWN ACTIVITY GAS TEST & MAN ENTRY REMOVAL OF REMAINING CATA ERECTION OF INTERNAL SCAFF OPENING AND CLEANING OF ST CLEANING OF CO-BOILER TUBE DRY INSPECTION OF COB REPLACEMENT OF 03 NOS. SCR REPLACEMENT OF 29 NOS. BAN REPLACEMENT OF 01 NO SUPER REPLACEMENT OF LEAKEY DRA REPLACEMENT OF M/H COVER BOX-UP OF STEAM DRUMS INTERNAL HYDROTESTION HYDROTESTING BY IBR REMOVAL OF SCAFFOLDING FINAL INSPECTION OF COB BY P BOX UP OF COB MANHOLES DEBLINDING START UP ACTIVITY

16 hrs 96 hrs 24 hrs 24 hrs 96 hrs 632 hrs 68 hrs 4 hrs 48 hrs 24 hrs 72 hrs 72 hrs 16 hrs 48 hrs 120 hrs 48 hrs 24 hrs 24 hrs 16 hrs 24 hrs 24 hrs 12 hrs 8 hrs 16 hrs 24 hrs 96 hrs

Start

Finish

Sat 9/29/07 Sun 9/30/07 Thu 10/4/07 Sun 10/7/07 Mon 10/8/07 Sun 9/16/07 Sun 9/16/07 Wed 9/19/07 Wed 9/19/07 Thu 9/20/07 Wed 9/19/07 Fri 9/21/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Sun 10/7/07 Mon 10/8/07

Sep 16, '07 Sep 23, '07 Sep 30, '07 Oct 7, '07 Oct 1 S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M Sun 9/30/07 0% Thu 10/4/07 0% Fri 10/5/07 0% Mon 10/8/07 0% Fri 10/12/07 0% 0% Fri 10/12/07 Wed 9/19/07 0% Wed 9/19/07 0% Fri 9/21/07 0% Fri 9/21/07 0% Sat 9/22/07 0% Mon 9/24/07 0% Tue 9/25/07 0% Thu 9/27/07 0% Sun 9/30/07 0% Thu 9/27/07 0% Wed 9/26/07 0% Wed 9/26/07 0% Sun 9/30/07 0% Mon 10/1/07 0% Tue 10/2/07 0% Wed 10/3/07 0% Wed 10/3/07 0% Thu 10/4/07 0% Mon 10/8/07 0% Fri 10/12/07 0%

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M A IN T . O F A IR F IN C O O L E R S A T F C C U D U R IN G S / D 0 7 1

O p e n i n g o f c o ve r s

2

3 10

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7

H y d ro b la s t C le a n in g 3 1 10

In d i vi d u a l T u b e T e s t in g 3 10

3

5

7

5

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9

11

13

5

3 10

7

7

C o ve r B o x u p

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3 1

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ID

Task Name

Duration

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ep 17

Fri Sep 21 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

CATALYST TUBE REPLACEMENT JOB SHUTTING DOWN/ STEAMING/ BLINDI GAS TEST AND MANENTRY ERECTION OF SCAFFOLDING OPENING COLD COLT M/H OPENING OF CATALYST TUBE - 60 No UNLOADING OF CATALYST - 60 Nos. REMOVAL OF ROOF CORROGATED S LOCKING OF PIG TAIL TUBE SPRINGS REMOVAL OF PIG TAIL INSULATION LOCKING CAT TUBE SPRING DISMANTLING AND REMOVAL OF SPR DISMANTLING AND REMOVAL OF SPR CUTTING OF CATALYST TUBE - 35 JO CUTTING OF FURNACE ROOF & BOTT REMOVAL OF REFRACTORY MATERIA CUTTING OF PIG TAIL BY GRINDING LIFTING OF PIPE FROM TOP EDGE PREPARATOION AND DP TEST ERECTION OF NEW PIPE ALIGNMENT AND FIT UP OF CATALYS RADIOGRAPHY OF JOINTS WELDING OF JOINTS -35 Nos. RADIOGRAPHY OF JOINTS FIXING OF FURNACE ROOF & BOTTOM FIXING OF REFRACTORY MATERIAL A FIXING OF SPRING SUPPORT BEAM FIXING OF SPRING EDGE PREPARATOION AND DP TEST ALIGNMENT AND FIT UP OF PIG TAIL T WELDING OF PIG TAIL TUBES DP & RADIOGRAPHY OF PIG TAIL JOIN

Project: HGU Date: Thu 9/6/07

20 days 72 hrs 4 hrs 24 hrs 16 hrs 24 hrs 72 hrs 24 hrs 16 hrs 8 hrs 16 hrs 8 hrs 8 hrs 48 hrs 48 hrs 48 hrs 24 hrs 48 hrs 48 hrs 96 hrs 96 hrs 96 hrs 120 hrs 72 hrs 24 hrs 48 hrs 48 hrs 48 hrs 48 hrs 96 hrs 48 hrs 16 hrs

Fri 9/21/07 Fri 9/21/07 Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Mon 9/24/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Tue 10/2/07 Wed 10/3/07 Tue 10/2/07 Wed 10/3/07 Thu 9/27/07 Fri 9/28/07 Sun 9/30/07 Tue 10/2/07

12

Thu 10/11/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Fri 9/28/07 Tue 9/25/07 Tue 9/25/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Thu 9/27/07 Thu 9/27/07 Thu 9/27/07 Tue 9/25/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Fri 10/5/07 Sat 10/6/07 Wed 10/3/07 Fri 10/5/07 Thu 10/4/07 Fri 10/5/07 Sat 9/29/07 Tue 10/2/07 Tue 10/2/07 Wed 10/3/07

Tue Sep 25 3

6 0% 0%

0% 0% 0% 0% 0% 0% 0% 0% 0%

0%

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ep 17

Fri Sep 21 3

33 34 35 36 37 38 39 40 41 42 43 44 45

Project: HGU Date: Thu 9/6/07

PROVIDING INSULATION ON PIG TAIL UNLOCKING OF PIG TAIL TUBES LOADING OF CATALYST INSPECTION OF FURNACE & TUBES REVISIONING OF BURNERS / DAMPER REVISIONING OF VALVES BOX-UP OF CATALYST TUBES BOX-UP OF COLD COLLECTOR REMOVAL OF SCAFFOLDING FURNACE FLOOR REPAIR BOX-UP OF FURNACE DEBLINDING ACTIVITIES START UP ACTIVITIES.

24 hrs 24 hrs 48 hrs 72 hrs 96 hrs 96 hrs 48 hrs 48 hrs 12 hrs 12 hrs 8 hrs 8 hrs 72 hrs

Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Fri 10/5/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07

12

Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 10/7/07 Sun 10/7/07 Sun 10/7/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07 Thu 10/11/07

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9

6

Tue Sep 25 3

ue Sep 25 3

Sat Sep 29 9

12

Wed Oct 3 3

6

Sun Oct 7 9

12

6

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

Project: HGU Date: Thu 9/6/07

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Thu Oct 11 3 0%

Mon O 12

9

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Sat Sep 29 9

12

6

Wed Oct 3 3 0%

12

Sun Oct 7 9

6

Thu Oct 11 3

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

Project: HGU Date: Thu 9/6/07

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Mon O 12

9

M A IN T O F H .E . & A IR F IN C O O L E R S A T H G U D U R IN G S /D 0 7 1 30

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6 7

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29

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1 2 3 4 5 6 7 8 9 10

DHDS AIR FIN COOLERS BLIBDING OPENING OF PLUGS - 3264 Nos. HYDROBLAST CLEANING DRYING OF TUBES INSPECTION BY IRIS TECHNIQUE BOXUP OF PLUGS HYDROTESTING OF BUNDLES DEBLING

Project: AIR COOLERS OF DHDS Date: Thu 9/6/07

16 days 24 hrs 192 hrs 192 hrs 192 hrs 192 hrs 192 hrs 192 hrs 24 hrs

Fri 9/14/07 Fri 9/14/07 Sat 9/15/07 Sun 9/16/07 Mon 9/17/07 Tue 9/18/07 Wed 9/19/07 Fri 9/21/07 Sat 9/29/07

Sun 9/30/07 Sat 9/15/07 Sun 9/23/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Sat 9/29/07 Sun 9/30/07

F

S

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Sep 30, '07 S M T 0%

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Sep 23, '07 S M T

M A IN T . O F H .E . & A IR F IN C O O L E R S A T A R U D U R IN G S /D 0 7 1

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M A IN T . O F H E A T E X C H A N G E R S A T F C C U D U R IN G S /D 0 7

1 40 O p e n in g

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1 3 1 7 30 1 8 4 9 7030

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1 1 1 4 1 11 9 7 7

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11 13 15 17 19

53 56

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48

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11 18 14 14

33

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59

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ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Task Name

Duration

VALVE REPLACEMENT JOBS STEAM VALVE - 600 Inch Dia BLINDING OF CIRCUITS FOR HOT J CUTTING OF JOINTS-600 IN.DIA REMOVAL OF OLD VALVES EDGE PREPARATION OF OLD PIPE DP TESTING OF OLD PIPE ERECTION OF NEW VALVES WELDING OF JOINTS-600 IN.DIA NDT OF JOINTS SR OF JOINTS-600 IN.DIA RADIOGRAPHY OF JOINTS HYDROTESTING OF LINES DEBLINDING OF CIRCUITS CW VALVE - 700 Inch Dia BLINDING OF CIRCUITS FOR HOT J CUTTING OF JOINTS-700 IN.DIA REMOVAL OF OLD VALVES EDGE PREPARATION OF OLD PIPE DP TESTING OF OLD PIPE ERECTION OF NEW VALVES WELDING OF JOINTS-700 IN.DIA NDT OF JOINTS HYDROTESTING OF LINES DEBLINDING OF CIRCUITS

Project: TPS Date: Thu 9/6/07

12.33 days 12 days 16 hrs 48 hrs 48 hrs 36 hrs 36 hrs 72 hrs 96 hrs 96 hrs 96 hrs 96 hrs 24 hrs 16 hrs 12.33 days 16 hrs 72 hrs 72 hrs 36 hrs 36 hrs 72 hrs 120 hrs 120 hrs 24 hrs 16 hrs

Start

Finish

Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Thu 10/4/07 Fri 10/5/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Fri 10/5/07 Sat 10/6/07

Sat 10/6/07 Sat 10/6/07 Tue 9/25/07 Thu 9/27/07 Thu 9/27/07 Thu 9/27/07 Thu 9/27/07 Sun 9/30/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Tue 9/25/07 Fri 9/28/07 Fri 9/28/07 Thu 9/27/07 Fri 9/28/07 Mon 10/1/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07

Sep 23, '07 S M T

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H E A T E X C H A N G E R M A IN T . A T T P S D U R IN G S /D 0 7 1

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SHUTDOWN ACTIVITIES IN COOLING TOWER

ACTIVITY

D DURATION Day-1 Day-2 Day-3 HRS. 8 16 24 8 16 24 8 16 24 8

SHUTTING DOWN AND PUMPING OUT WATER

24

SLUDGE CLEANING OF BASIN

144

DISMANTLING OF UNDERWATER WOODEN STRUCTURES

240

FABRICATION AND ERECTION OF WOODEN STRUCTURES

240

CHECKING OF STRUCTURES

24

PARTITIONING OF CELLS STEEL REINFORCEMENT GROUTING

168

SHUTTERING

168

CONCRETING

168

CURING AND HANDING OVER

72

Day-4 Day-5 Day-6 Day-7 Day-8 Day-9 Day-10 Day-11 Day-12 Day-13 Day-14 16 24 8 16 24 8 16 24 8 16 24 8 16 24 8 16 24 8 16 24 8 16 24 8 16 24 8 16 24 8 16 24

ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Task Name

Duration

CI-BI OF FRAME V GT Remove gas & atomising pigtail p Remove liquid fuel lines Remove fuel nozzels Remove spark plugs & flame dete Remove combustion can covers Remove combustion liners , X fire Clean all parts Disassemble & Inspect Fuel nozz Inspect liners Inspect retainers Inspect Cross fire tubes Inspect Combustion Chambers Assemble fuel nozzels Install liners, X fire tubes & retain Install Combustion can covers Install spark plugs & flame detect Install fuel nozzels Install liquid fuel lines Install all gas & atomising piping Remove boroscope Plugs & Inspe Crank & check for air leaks FSNL & load the machine

Project: CI BI OF GT Date: Thu 9/6/07

8 days 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 48 hrs 48 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 24 hrs 48 hrs 24 hrs 24 hrs

Start Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Wed 9/26/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sat 9/29/07 Mon 10/1/07 Sat 9/29/07

Finish

Sep 23, '07 S M

Tue 10/2/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Thu 9/27/07 Thu 9/27/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Sun 9/30/07

T

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Sep 30, '07 S M

W

T

ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Task Name

Duration

HRSG JOBS 7.17 days Opening of manhole of HR 16 hrs Opening of manhole of ste 16 hrs Removal of drum internals 24 hrs Cleaning of vessel 24 hrs Boxup of drum internals 24 hrs Box up of steam drum mna 16 hrs Erection of scaffolding 36 hrs Cleaning of tubes 24 hrs Internal Inspection 16 hrs Dry Inspection by IBR 24 hrs Internal Hydraulic Testing 16 hrs Hydraulic Testing by IBR 24 hrs Box up of HRSG 16 hrs

Project: HRSG Date: Thu 9/6/07

Start Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07

Finish

Sep 23, '07 S M

T

W

T

F

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Sep 30, '07 S M

T 0%

Mon 10/1/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID

Task Name

1

FLARE JOBS

Duration

Start

Finish

2688 hrs

Mon 6/18/07

Jun 17, '07 Jun 24, '07 Jul 1, '07 Jul 8, '07 Jul 15, '07 Jul 22, '07 Jul 29, '07 Aug 5, '07 Aug 12, '07 Aug 19, '07 Aug 26, '07 Sep 2, '07 Sep 9, '07 Sep 16, '07 Sep 23, '07 Sep 30, '07 Oct 7, '07 SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S SMTWT F S 0% Mon 10/8/07

2

FLARE LINE REPLACEMENT

2688 hrs

Mon 6/18/07

Mon 10/8/07

3

Flare line Pre-Shutdown

1992 hrs

Mon 6/18/07

Sun 9/9/07

4

Pilling for supports alo

1464 hrs

Mon 6/18/07

Sat 8/18/07

5

Foundation for suppo

1392 hrs

Tue 7/3/07

Thu 8/30/07

6

Structural fabrication

720 hrs

Wed 8/1/07

Fri 8/31/07

7

Sand blasting & Paint

720 hrs

Wed 8/8/07

Fri 9/7/07

8

Erection and alignme

480 hrs

Mon 8/20/07

Sun 9/9/07

9

Flare line Pre-Shutdown

1104 hrs

Mon 8/6/07

Fri 9/21/07

10

Pre-Fabrication of all

720 hrs

Mon 8/6/07

Wed 9/5/07

11

Sand blasting & Paint

720 hrs

Fri 8/10/07

Sun 9/9/07

12

Transportation of pipe

480 hrs

Wed 8/22/07

Tue 9/11/07

13

Erection of pipe on st

72 hrs

Sun 9/9/07

Wed 9/12/07

14

Joint fit up and Weldi

168 hrs

Wed 9/12/07

Wed 9/19/07

15

NDT of all Joints as p

120 hrs

Sun 9/16/07

Fri 9/21/07

16

Flare line Shutdown Job

336 hrs

Mon 9/24/07

Mon 10/8/07

17

Blinding / Deblinding

72 hrs

Mon 9/24/07

Thu 9/27/07

18

Cutting of all old lines

72 hrs

Thu 9/27/07

Sun 9/30/07

19

Dismantling of pipes

72 hrs

Fri 9/28/07

Mon 10/1/07

20

Welding of hook up jo

48 hrs

Mon 10/1/07

Wed 10/3/07

21

Cutting of damaged s

48 hrs

Sat 9/29/07

Mon 10/1/07

22

Repair of support loca

48 hrs

Sun 9/30/07

Tue 10/2/07

23

Bevelling of old lines

48 hrs

Fri 9/28/07

Sun 9/30/07

24

Erection of pipes alon

48 hrs

Mon 10/1/07

Wed 10/3/07

25

Joint fit-up and weldin

72 hrs

Tue 10/2/07

Fri 10/5/07

26

Radiography of balan

48 hrs

Thu 10/4/07

Sat 10/6/07

27

Blinding / Deblinding

48 hrs

Fri 10/5/07

Sun 10/7/07

28

Start-up activities

24 hrs

Sun 10/7/07

Mon 10/8/07

29

Flare tip replacement job

336 hrs

Mon 9/24/07

Mon 10/8/07 Thu 9/27/07

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

30

Shutting down / Blinding/ D

72 hrs

Mon 9/24/07

31

Revisioning of Devit and m

16 hrs

Thu 9/27/07

Fri 9/28/07

32

Lifting of scaffolding mater

24 hrs

Fri 9/28/07

Sat 9/29/07

33

Erection of scaffoldign out

16 hrs

Fri 9/28/07

Sat 9/29/07

34

Dismantling of Acid flare ti

8 hrs

Thu 9/27/07

Thu 9/27/07

35

Dismantling of Hydrocarbo

16 hrs

Thu 9/27/07

Fri 9/28/07

0%

36

Cutting of Acid flare tip

8 hrs

Thu 9/27/07

Fri 9/28/07

0%

37

Lowering of Acid flare tip

8 hrs

Sat 9/29/07

Sun 9/30/07

38

Grinding & edge preparati

8 hrs

Fri 9/28/07

Fri 9/28/07

39

Erection of Acid flare tip to

8 hrs

Sun 9/30/07

Sun 9/30/07

40

Fit up & welding of Acid fla

8 hrs

Sun 9/30/07

Sun 9/30/07

41

Lowering of Hydrocarbon f

16 hrs

Sun 9/30/07

Mon 10/1/07

42

Erection of Hydrocarbon fl

16 hrs

Mon 10/1/07

Tue 10/2/07

43

Alignment & boxup of Hyd

16 hrs

Tue 10/2/07

Tue 10/2/07

44

Erection of scaffolding insi

16 hrs

Tue 10/2/07

Wed 10/3/07

45

Lifting of other accessories

16 hrs

Tue 10/2/07

Wed 10/3/07

46

Revisioning of Burners & F

24 hrs

Fri 9/28/07

Sat 9/29/07

47

Fitting and welding of all a

16 hrs

Wed 10/3/07

Wed 10/3/07

48

Box-up of all connected lin

16 hrs

Wed 10/3/07

Thu 10/4/07

49

Dismantlingl of scaffolding

16 hrs

Thu 10/4/07

Fri 10/5/07

50

Lowering down of all scaff

16 hrs

Fri 10/5/07

Fri 10/5/07

51

Start-up activities

24 hrs

Sun 10/7/07

Mon 10/8/07

Project: FLARE LINE -2 Date: Thu 9/6/07

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ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Task Name

Duration

OFFSITE PIPING 3.1.3: LPG LINES(3", 80M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.3.1:NAPTHA LINES(2",24 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.3.2:NAPTHA LINE(3",200 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes

Project: OFFSITE PIPING Date: Thu 9/6/07

13.83 days 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 16 hrs 24 hrs 72 hrs 16 hrs 24 hrs 16 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 12 hrs 8 hrs 8 hrs 24 hrs 12 hrs 12 hrs 12 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs 48 hrs

Start

Finish

Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07

Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Sat 9/29/07

Sep 23, '07 S M T

W

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Sep 30, '07 S M T

T

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Oct 7, '07 S M T 0% 0%

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

Task Name

Duration

Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.3.3:NAPTHA LINES(4",60 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.13.1:FUEL GAS LINES(2",80M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water

Project: OFFSITE PIPING Date: Thu 9/6/07

32 hrs 48 hrs 96 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 48 hrs 12 hrs 24 hrs 16 hrs

Start

Finish

Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07

Sat 9/29/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07

Sep 23, '07 S M T

W

T

F

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Sep 30, '07 S M T 0% 0%

T

F

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Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96

Task Name

Duration

Deblinding Start Up activities 3.13.2:FUEL GAS LINES(4",30m) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.13.3:FUEL GAS LINES(6",40 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.13.4:FUEL GAS LINES(8",60M) Blinding / Deblinding Steam & Water Washing Final Blinding

Project: OFFSITE PIPING Date: Thu 9/6/07

12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 12 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 48 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs

Start

Finish

Wed 10/3/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07

Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T

T 0%

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Oct 7, '07 S M T 0% 0%

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ID 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128

Task Name

Duration

Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.2.1:H2 LINES(2",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.2.2: H2 LINES(3",84M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest

Project: OFFSITE PIPING Date: Thu 9/6/07

48 hrs 24 hrs 48 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 48 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs

Start

Finish

Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07

Sat 9/29/07 Sat 9/29/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07

Sep 23, '07 S M T

W

T

F

Sep 30, '07 S S M T 0% 0% 0%

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Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160

Task Name

Duration

Draining of water Deblinding Start Up activities 3.2.3:H2 LINES(4",36 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.4.1:ATF LINES(4",60 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.10.1:OFFGAS LINES(2",36M) Blinding / Deblinding Steam & Water Washing

Project: OFFSITE PIPING Date: Thu 9/6/07

16 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 12 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 48 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs

Start

Finish

Mon 10/1/07 Tue 10/2/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07

Tue 10/2/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T W 0% 0%

F

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Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192

Task Name

Duration

Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.10.2:OFFGAS LINES(3",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.10.3:OFFGAS LINES(4",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT

Project: OFFSITE PIPING Date: Thu 9/6/07

8 hrs 12 hrs 8 hrs 8 hrs 24 hrs 12 hrs 12 hrs 12 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 48 hrs 24 hrs

Start

Finish

Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Mon 10/1/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07

Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07 Wed 10/3/07

Sep 23, '07 S M T

W

T

Sep 30, '07 F S S M T W 0% 0% 0% 0% 0% 0% 0% 0% 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224

Task Name

Duration

Hydrotest Draining of water Deblinding Start Up activities 3.11.1:SOURGAS LINES(6",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.18.1:AMINE LINES(2",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.18.2:AMINE LINES(3",60M) Blinding / Deblinding

Project: OFFSITE PIPING Date: Thu 9/6/07

24 hrs 24 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 24 hrs 24 hrs 24 hrs 72 hrs 16 hrs 24 hrs 24 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 36 hrs 24 hrs 48 hrs 72 hrs 16 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs

Start

Finish

Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07

Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07

Sep 23, '07 S M T

W

T

F

Sep 30, '07 S M T

S

T

F 0%

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256

Task Name

Duration

Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.19.1:IFO LINES(11/2",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.19.2: IFO LINES(2",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe

Project: OFFSITE PIPING Date: Thu 9/6/07

24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 40 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 32 hrs 24 hrs 40 hrs 72 hrs

Start

Finish

Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07

Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07

Sep 23, '07 S M T

W

T

Sep 30, '07 F S S M T W 0% 0% 0% 0% 0% 0% 0% 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288

Task Name

Duration

NDT Hydrotest Draining of water Deblinding Start Up activities 3.19.3: IFO LINES(3",200M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.5.1:RTF LINES(6",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.7.2:SKO LINES(3",84M)

Project: OFFSITE PIPING Date: Thu 9/6/07

12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 48 hrs 48 hrs 48 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 11.83 days 36 hrs 24 hrs 12 hrs 48 hrs 48 hrs 48 hrs 88 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 11.83 days

Start

Finish

Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Wed 9/26/07

Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T

T 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320

Task Name

Duration

Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.7.3:SKO LINES(6",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.8.1:HSD LINES(6",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe

Project: OFFSITE PIPING Date: Thu 9/6/07

36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 11.83 days 36 hrs 24 hrs 12 hrs 24 hrs 24 hrs 24 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 11.83 days 36 hrs 24 hrs 12 hrs 48 hrs 48 hrs 48 hrs

Start

Finish

Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Sun 10/7/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07

Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Mon 10/8/07 Mon 10/8/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07

Sep 23, '07 S M T

W

T

Sep 30, '07 F S S M T W 0% 0% 0% 0% 0% 0% 0% 0% 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 321 322 323 324 325 326

Task Name

Duration

Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities

Project: OFFSITE PIPING Date: Thu 9/6/07

88 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs

Start

Finish

Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T

Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07

T 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0%

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Activity Bar Chart of Refractory Application during Shutdown at P.G.Boiler at IOCL - HALDIA Sr.No.

Activity

A 1 2

R.G.Boiler Dismantling & debris cleaning Surface cleaning & anchor welding

3

End Tube Sheet Casting

4 5 6 7 8

First layer casting using form work Second layer casting Form work removal & natural curing Dry out up to 250 deg C Final Inspection & Boxing up

No. of Days 1

2

3

4

5

6

7

8

9

10

11

12

13

14

ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Task Name

Duration

OFFSITE PIPING 3.1.3: LPG LINES(3", 80M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.3.1:NAPTHA LINES(2",24 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.3.2:NAPTHA LINE(3",200 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes

Project: OFFSITE PIPING Date: Thu 9/6/07

13.83 days 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 16 hrs 24 hrs 72 hrs 16 hrs 24 hrs 16 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 12 hrs 8 hrs 8 hrs 24 hrs 12 hrs 12 hrs 12 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs 48 hrs

Start

Finish

Mon 9/24/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07

Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Sat 9/29/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T

T

F

S

Oct 7, '07 S M T 0% 0%

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

Task Name

Duration

Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.3.3:NAPTHA LINES(4",60 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.13.1:FUEL GAS LINES(2",80M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water

Project: OFFSITE PIPING Date: Thu 9/6/07

32 hrs 48 hrs 96 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 48 hrs 12 hrs 24 hrs 16 hrs

Start

Finish

Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07

Sat 9/29/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T 0% 0%

T

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96

Task Name

Duration

Deblinding Start Up activities 3.13.2:FUEL GAS LINES(4",30m) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.13.3:FUEL GAS LINES(6",40 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.13.4:FUEL GAS LINES(8",60M) Blinding / Deblinding Steam & Water Washing Final Blinding

Project: OFFSITE PIPING Date: Thu 9/6/07

12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 12 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 48 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 12 hrs

Start

Finish

Wed 10/3/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07

Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T

T 0%

F

S

Oct 7, '07 S M T 0% 0%

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128

Task Name

Duration

Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.2.1:H2 LINES(2",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.2.2: H2 LINES(3",84M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest

Project: OFFSITE PIPING Date: Thu 9/6/07

48 hrs 24 hrs 48 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 48 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs

Start

Finish

Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07

Sat 9/29/07 Sat 9/29/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07

Sep 23, '07 S M T

W

T

F

Sep 30, '07 S S M T 0% 0% 0%

T

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160

Task Name

Duration

Draining of water Deblinding Start Up activities 3.2.3:H2 LINES(4",36 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.4.1:ATF LINES(4",60 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.10.1:OFFGAS LINES(2",36M) Blinding / Deblinding Steam & Water Washing

Project: OFFSITE PIPING Date: Thu 9/6/07

16 hrs 12 hrs 24 hrs 13.83 days 36 hrs 24 hrs 8 hrs 24 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 12 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 48 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs

Start

Finish

Mon 10/1/07 Tue 10/2/07 Sun 10/7/07 Mon 9/24/07 Mon 9/24/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07

Tue 10/2/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T W 0% 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192

Task Name

Duration

Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.10.2:OFFGAS LINES(3",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.10.3:OFFGAS LINES(4",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT

Project: OFFSITE PIPING Date: Thu 9/6/07

8 hrs 12 hrs 8 hrs 8 hrs 24 hrs 12 hrs 12 hrs 12 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 24 hrs 12 hrs 24 hrs 48 hrs 24 hrs

Start

Finish

Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Mon 10/1/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07

Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Tue 10/2/07 Wed 10/3/07

Sep 23, '07 S M T

W

T

Sep 30, '07 F S S M T W 0% 0% 0% 0% 0% 0% 0% 0% 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224

Task Name

Duration

Hydrotest Draining of water Deblinding Start Up activities 3.11.1:SOURGAS LINES(6",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.18.1:AMINE LINES(2",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.18.2:AMINE LINES(3",60M) Blinding / Deblinding

Project: OFFSITE PIPING Date: Thu 9/6/07

24 hrs 24 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 24 hrs 24 hrs 24 hrs 72 hrs 16 hrs 24 hrs 24 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 36 hrs 24 hrs 48 hrs 72 hrs 16 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs

Start

Finish

Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07

Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07

Sep 23, '07 S M T

W

T

F

Sep 30, '07 S M T

S

T

F 0%

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256

Task Name

Duration

Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.19.1:IFO LINES(11/2",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.19.2: IFO LINES(2",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe

Project: OFFSITE PIPING Date: Thu 9/6/07

24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 40 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 8 hrs 32 hrs 24 hrs 40 hrs 72 hrs

Start

Finish

Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07

Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Wed 10/3/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07

Sep 23, '07 S M T

W

T

Sep 30, '07 F S S M T W 0% 0% 0% 0% 0% 0% 0% 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288

Task Name

Duration

NDT Hydrotest Draining of water Deblinding Start Up activities 3.19.3: IFO LINES(3",200M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.5.1:RTF LINES(6",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.7.2:SKO LINES(3",84M)

Project: OFFSITE PIPING Date: Thu 9/6/07

12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 12.83 days 36 hrs 24 hrs 12 hrs 48 hrs 48 hrs 48 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 11.83 days 36 hrs 24 hrs 12 hrs 48 hrs 48 hrs 48 hrs 88 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 11.83 days

Start

Finish

Wed 10/3/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sun 10/7/07 Tue 9/25/07 Tue 9/25/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Wed 9/26/07

Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sat 10/6/07 Mon 10/8/07 Mon 10/8/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07 Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T

T 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320

Task Name

Duration

Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.7.3:SKO LINES(6",60M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities 3.8.1:HSD LINES(6",120 M) Blinding / Deblinding Steam & Water Washing Final Blinding Cold Cutting of pipes Dismantling of old pipe Erection of new pipe

Project: OFFSITE PIPING Date: Thu 9/6/07

36 hrs 24 hrs 8 hrs 16 hrs 8 hrs 16 hrs 24 hrs 12 hrs 24 hrs 16 hrs 12 hrs 24 hrs 11.83 days 36 hrs 24 hrs 12 hrs 24 hrs 24 hrs 24 hrs 72 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs 11.83 days 36 hrs 24 hrs 12 hrs 48 hrs 48 hrs 48 hrs

Start

Finish

Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Sun 10/7/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Wed 9/26/07 Wed 9/26/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07

Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Tue 10/2/07 Wed 10/3/07 Thu 10/4/07 Thu 10/4/07 Mon 10/8/07 Mon 10/8/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Sun 9/30/07 Sun 9/30/07 Mon 10/1/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07 Mon 10/8/07 Thu 9/27/07 Fri 9/28/07 Sat 9/29/07 Mon 10/1/07 Mon 10/1/07 Tue 10/2/07

Sep 23, '07 S M T

W

T

Sep 30, '07 F S S M T W 0% 0% 0% 0% 0% 0% 0% 0% 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

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ID 321 322 323 324 325 326

Task Name

Duration

Welding of new pipe NDT Hydrotest Draining of water Deblinding Start Up activities

Project: OFFSITE PIPING Date: Thu 9/6/07

88 hrs 24 hrs 24 hrs 24 hrs 12 hrs 24 hrs

Start

Finish

Sun 9/30/07 Wed 10/3/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07

Sep 23, '07 S M T

W

T

F

S

Sep 30, '07 S M T

Thu 10/4/07 Thu 10/4/07 Fri 10/5/07 Sat 10/6/07 Sun 10/7/07 Mon 10/8/07

T 0%

F

S

Oct 7, '07 S M T

0% 0% 0% 0% 0%

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Activity Bar Chart of Refractory Application during Shutdown at P.G.Boiler at IOCL - HALDIA Sr.No.

Activity

A 1 2

R.G.Boiler Dismantling & debris cleaning Surface cleaning & anchor welding

3

End Tube Sheet Casting

4 5 6 7 8

First layer casting using form work Second layer casting Form work removal & natural curing Dry out up to 250 deg C Final Inspection & Boxing up

No. of Days 1

2

3

4

5

6

7

8

9

10

11

12

13

14