THERMAX LIMITED

BOILER & HEATER GROUP

Document No.: DORL-FGSG-099

DORC Document No : A545-7950-5043-VD-LW1001AND LW1002- 110012

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

MECHANICAL CONTRATOR

EIL JOB NO. : A545

PACKAGE/UNIT NO.: 115-LW-1001 & 1002
PR CODE : A545-111-LW-PR-7940

THERMAX OC NO. : QL1221/1222

SUPPLY: FLUE GAS STEAM GENERATOR PACKAGE

OWNER :- DANGOTE OIL REFINING COMPANY

Project Name:

0 14.06.2019 For Information VP VP VP

Rev. Date Purpose Prepared By Checked By Approved By

27-JUN-2019
VIJAY KUMAR (C572)

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 List of Items and Activity to be done by Mechanical Contractor -
Date : 14.06.2019

Boiler parameters : 2 X 377 TPH FLUE GAS STEAM GENERATOR

Doc no: - DORL-FGSG-099 REV 0
Notes & Basis of the Below BOM :

1. The Submitted SOR is for understanding the Execution Philosophy

2. The quantity mentioned in the SOR are only indicative. The quantity may change during detail engineering stage.
3. Thermax shall not be liable for any back charge due to change in quantum of work with respect to details given above.
4. This SOR covers the activity list that are to be executed at site pertaining to Thermax scope of supply. Quality, Safety, Statutory & erection tools & tackles are not covered in this List.
5. Seal welding of 10% of total welding in the project to be considered at site.
6. Piping of 50NB & below will be supplied loose and shall be routed to suit site.
7. For 50MT & above consignments, actual weight may vary by +/- 10% for Logistics & Erection purpose.
8. Site modification manhours (5 % of total project manhours) to be considered by erection contractor.
9. SOR Quantities with 90- 95% accuracy shall be provided after engineering completion during post order execution.All Final drawings will be submitted to EIL and DORC after 100% Engg completion
10. For the rotating equipments like, RC Pump, Fans , Turbines, Motors, Soot Blowers etc have to be stored indoor and hand rotation test/oiling/greasing &proper protection to be done at interval of every 3 months.

11. For the shelf life items such as Refractory, paints, chemicals, lubricants, etc , the validity of our quated price and delivery is limited to one year from the date of receipt of bulk material at our place. However, if the site
requirement (for site patch up/touch up work) defers beyound one year, the price and delivery schedules will be mutually discussed. Site requirements for procurement of these items need 6 month notice period looking at
manufacturing and Hazardous cargo formalities.

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

Size in Mtr
Sr. Weight
Item Description Condition of supply Qty Unit Length X Width X Work to be done at site. (Approximate)
No. In MT
Height

1 Base frame Main Stools Duly pre fabricated stools 14 Nos Stool Height - 1.5 m 1. Erection of base frame Main Stools - 14 nos, its alignment and welded with insert plate / foundation.

1. Once the main stools are fixed, the boiler block Module needs to be be installed on these stools (Welding requirement for base frame - Approx.
80 running meter @ 16mm thk fillet per boiler).
Fully modularised FGC block (duly painted &
insulated, Hydro Tested and leak tested)
2. Module- I levelling and alignment
comprising of base frame, Super Heater 2A,
2B, 1A, 1B HP Evap 1, 2, 3, MP Evap 1, Eco 1
3. Temporary structural support painted with yellow colour to be cut and removed
& 2, floor & roof panels, LHS & RHS panels
FGC Block - Module 1 for SH & ECO areas, screen tubes and panels,
4. Piping fitment & welding for
(Pressure Parts) backstays, hopper below SH and Eco, Knife 28 mtr length x 9 mtr
2 1 Lot 1450 a. Pre-fabricated Feed water piping
Edge Gate Valves (Motorised Actuator), Non width x 15 mtr height
b. Drain & vent piping
Integral Water, Steam, Drain & Vent Piping.
c. Steam piping (from Steam Drum and import steam inlet to PSH)
(Part - connected to Module 1)
5. Installation of valves in Drain & vent (below 2" socket welded) line; installment of instruments on module-I
6. Insulation for connection points to other modules to be done at site (Interface ducting and piping insulation).
*]Along with this module 1 part loose items
will also be supplied viz down comer pipes &
Note :
blow down valves.
1. Project specificInstallation/Erection procedure is to be referred

1. Erection & alignment of Module-II on civil pedestals.

2. Alignment of Module- II with respect to Module-I
3. Module-II foundation bolt tightening.
This comprises of Main Boiler Structure duly
4. Removal of temporary transportation beam which is painted with yellow paint
painted -Front side, Pipe Rack (Terminal
5. Erection of loose staircases from ground with foundation bolts to connections of Module -II assembled staircase, loose cantilever structural
Point Structure) ; Soot Blower -LRSB, Steam
items and piping between module I and module II
Drum - HP, Steam Drum - MP, Down comers,
6. Erection of Support structure and Spring hangers for risers.
Non Integral Water, Steam, Drain & Vent
7. Fit up and welding of pre-fabricated Risers & Down comers : Approximate welding quantum: -
Piping; Pipes supports ; Integral Process /
a. 6" dia x 122 joints = 732 inch dia
Motorised Valves ; Piping Spring Hangers
b. 4" dia x 168 joints = 672 inch dia
along with insulation of piping, Seal Air
c. 3" dia x 16 joints = 48 inch dia
Ducting, Power Distribution Box (for Soot
d. 8" dia x 6 joints = 48 inch dia
Blowers), Electrical Items, Soot Blower PLC
FGC Block - Module 2 e.10" dia x 2 joints = 20 inch dia
Panel, Instrument Cable Tray, Cables, JBs & 44 mtr length x 11
(Pressure Parts & f. 16" dia x 2 joints = 32 inch dia
3 Accessories, Transmitters, Analysers, 1 Lot 900 mtr width x 23 mtr
Structure) g.18" dia x 2 joints = 36 inch dia
Gauges, Control/On-Off Valves, Temp height
Elements,
8. Piping Assembly between Grid A to C and 1 to 8 , below EL+1500 (piping between PSH to SSH and SSH to BL). Welding quantum will be given
later after detailing of piping.
*]Along with this module 2 part loose items
will also be supplied viz
9. Alignment and erection of all soot blowers on Module II with Knife Edge Gate valves on Module-I
a.Downcomer spool Piece
b. Pre-fabricated Piping
10. Seal Air piping connections at both ends. One end to Soot Blowers with hose pipes and other end to be welded with Seal air Header
c. Staircase (2 nos) from Ground to 1st
Elevation
11. Erection of silencer support structure, silencers (10 nos) and connecting piping.
d. Other loose items shall be informed later
after completion of detail engineering.
12. Insulation for riser & downcomers and connection points (Interface ducting and piping insulation)

1. Erection of package skid on Foundation with foundation bolts

2. Erection, welding, bolting of outlet duct, dampers & expansion bellows

4 Seal Air Fan with Motor Duly assembled fan and motor 1 No. - -
3. Erection and welding of outlet duct support structure

4. Erection of instruments, JBs, cable trays & caballing within Skid and connection to Tie-in points.

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

2. Erection, welding, bolting of inlet & outlet RC Pump piping with its supports
5 RC Pump with Motor Duly assembled pump and motor 1 No. - -
3. Erection of cooling water piping with its supports

4. Erection of instruments, JBs, cable trays & caballing within Skid and connection to Tie-in points.

27-JUN-2019
VIJAY KUMAR (C572)
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Sr.
Item Description
No.
6 RC Pump with Turbine
7 HP & MP Dosing Skids
8 Sample Cooler (Skid)
9 Main Foundation Bolts
10 Auxiliary Foundation Bolts Loose - Duly fabricated.
11 Insert Plate
LH Side Boiler Structure on
Grid D- D1 to D7
12 Loose - Duly fabricated.
& Support Structure for
Auxiliaries (Silencer)
13 Seal Air Ducting
Outlet Duct from Box to
Scrubber flange (35
14 mtr)with its support
structure and metallic
expansion joints
Refractory lined Outlet Box
15 with duct supports
(structure)
Refractory lined Inlet Box
16 with duct supports
(structure)
17 Risers - SA 106 Gr. B
18 Attemperator I & II
Steam Dryer / Moisture
19
Separator
Integral Piping
1. AS
20
2. CS
3. SS
27-JUN-2019
VIJAY KUMAR (C572)
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BILL OF QUANTITIES FOR 1 NO. OF FLUE GAS STEAM GENERATOR
Size in Mtr
Weight
Condition of supply Qty Unit Length X Width X Work to be done at site. (Approximate)
In MT
Height
1. Erection of package skid on Foundation with foundation bolts
2. Erection, welding, bolting of inlet & outlet RC Pump piping with its supports
3. Erection, welding, bolting of inlet & outlet turbine piping with its supports
Duly assembled pump and turbine 1 No. - -
4. Erection of cooling water piping with its supports
5. Erection of instruments, JBs, cable trays & caballing within Skid and connection to Tie-in points.
6. Piping insulation and cladding
1. Erection of package skid on Foundation with foundation bolts
Duly assembled Skids 2 Nos. - - 2. Erection of DM water piping and dosing piping with its supports
3. Connection to Tie-in Points
1. Erection and alignment of Skid
Duly assembled Skids 1 No. - -
2. Connecting sample piping & cooling water piping
Loose - Duly fabricated. 1 Lot - - 1. To be used at given locations.
1 Lot - - 1. To be used at given locations.
Loose - Duly fabricated. 1 Lot - - 1. To be used at given locations.
1 Lot 40 - 1. Erection, its alignment and bolting. Torque tightening to be done as per drawing requirement.
Loose - Duly fabricated.
1. Loose Pipes with Insulation
1 Lot - - 1. Erection & alignment and welding of pre fabricated duct spools from Seal air fan outlet duct till seal air piping on Module-II
2. Isolation Damper
3. Duct Supports and Anchor Bolts
1. Duct supports (bottom supported duct) to be erected on civil pedestals with foundation bolts.
2. Erection of pre-fabricated Outlet ducting with duct supports from outlet box to Expansion joint.
Duly fabricated
1. Duct in 2 Pieces 3. Erection of Expansion Joint with Scrubber flange.
1 Lot 75 -
2. Expansion Joints
3. Support structure & Duct Saddles 4. Insulation of interface duct pieces (Welding quantum - Approx. 50 running meter @ 10-12 mm thk fillet per boiler)
Note :
1. Civil pedestals for outlet duct supports to be casted after Erection of Module-I
1. Duct supports (bottom supported duct) to be erected on civil pedestals with foundation bolts.
2. Prior to installation, inspection & rectification (if required-refer note-2) of refrractory lined outlet box at site is to be done , followed by its
alignment, fit up and welding to boiler outlet flange. (Approx. 50 running meter @ 10-12 mm thk fillet per boiler)
3. After welding completion, the same is to be inspected for anchor pitching. If required, any additional anchor welding is to be done. Then
refractory patch up application is to be done in transition area where refractory application is not possible at shop. This is to be carried out as per
approved application procedure.
Duly fabricated. 1 Lot 40 -
Note :
1.Civil pedestals for outlet duct supports (DS3; DS4 & DS5) to be casted after Erection of Module-I by DORC
2.After receipt at site, Refractory lined out box is to be inspected for any cracks, bulging /edge loosening and same to be rectified at site in line
with approved rectification procedure before Installation.
1. Duct supports (bottom supported duct) to be erected on civil pedestals with foundation bolts.
2. Prior to installation, inspection & rectification (if required-refer note-2) of refrractory lined outlet box at site is to be done , followed by its
alignment, fit up and welding to boiler inlet flange. (Approx. 50 running meter @ 10-12 mm thk fillet per boiler)
3. After welding completion, the same is to be inspected for anchor pitching. If required, any additional anchor welding is to be done. Then
Duly fabricated 1 Lot 60 -
refractory patch up application is to be done in transition area where refractory application is not possible at shop. This is to be carried out as per
approved application procedure.
Note:
1. Civil pedestals for Inlet duct supports (DS1 & DS2) to be casted after Erection of Module-I
2.After receipt at site, Refractory lined out box is to be inspected for any cracks, bulging /edge loosening and same to be rectified at site in line
with approved rectification procedure before Installation.
1. Refer Sr. No. 7 from Module-II
Pre fabricated 1 Lot 28 -
1. Fit up & welding of Attemperator I & II piping with piping supports.
Pre fabricated 2 No - -
1. Erection and alignment of Steam Dryer / Moisture Separator
Pre fabricated 1 No. - -
2. Connecting piping & its insulation
1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI,
Hardness testing as per ITP, to be done at site.
Pre fabricated spools, ready to erect. 1 set - -
2. Hydro test to be conducted once the piping circuit/ loops are completed.
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 BILL OF QUANTITIES FOR 1 NO. OF FLUE GAS STEAM GENERATOR
Size in Mtr
Sr. Weight
Item Description Condition of supply Qty Unit Length X Width X Work to be done at site. (Approximate)
No. In MT
Height

Non Integral Piping 1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI,
1. AS Hardness testing as per ITP, to be done at site.
21 Pre fabricated spools, ready to erect. 1 set - -
2. CS
3. SS 2. Hydro test to be conducted once the piping circuit/ loops are completed.

Non Integral Water ,

1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI,
Steam, Drain & Vent Piping
Hardness testing as per ITP, to be done at site.
22 1. AS Pre fabricated spools, ready to erect. 1 set - -
2. CS
2. Hydro test to be conducted once the piping circuit/ loops are completed.
3. SS

Fabricated Supports for

Integral, Non Integral,
23 Pre fabricated spools, ready to erect. 1 set - - 1.Pre fabricated supports - Secondary & Primary to be welded to the structure and piping.
Water, Steam, Drain &
Vent Piping
1. Piping spools will be supplied at site and fit up and welding, NDT as per ITP, Pre heating (If applicable), post heating ( (If applicable), PT, PMI,
Hardness testing as per ITP, to be done at site.
Steam Blowing
24 Pre fabricated spools, ready to erect. 1 set - -
Arrangement
2. This needs to be cut and removed after completion of steam blowing.

25 Silencers Pre fabricated, ready to erect. 1 set - - 1. To be erected on the structural supports.
Power Distribution Box -
26 For Dosing Motors & Duly finished item. 1 set - - 1. To be fixed as per requirement.
MOVs
27 Electrical Items Duly finished item - Loose 1 set - - 1. To be fixed/ installed as per requirement.
28 Rotary Valve Duly finished item. 7 Nos. - - 1. To be fixed/ installed as per requirement.

29 Metallic Expansion Joints Duly finished item. 3 Nos. - - 1. To be fixed/ installed as per requirement.

Instrument Cable Tray,

30 Duly finished item - Loose 1 set - - 1. To be fixed/ installed as per requirement.
Cables, JBs, Accessories

Transmitters, Analysers,
31 Gauges, Control/On-Off Duly finished item - Loose 1 set - - 1. To be fixed/ installed as per requirement.
Valves, Temp Elements

Seismic Stop & Expansion

32 Duly finished item - Loose 1 set - - 1. To be fixed/ installed as per requirement.
Pointers

33 Insulation for Boiler LRB & Cladding sheets (Rolls) 1 set - - 1. To be fixed/ installed as per requirement.
LRB/ piping sections & Cladding sheets
34 Insulation for Piping 1 set - - 1. To be fixed/ installed as per requirement.
(Rolls)

1. The structure viz Purlins, Louvers, Truss, Sag rods, Gutters & Drain pipes needs to be erected at site and bolting and torque tightening to be
Canopy Structure & its done.
35 Pre fabricated structure & canopy sheets. 1 set - -
sheeting's.
1. Canopy Sheets to be fixed on the structure and clamps to be tightened.

36 Monorail & its structure Pre fabricated structure & trolley. 1 set - - 1. The structure to be erected , bolted and trolley to be fixed.

Chemicals / Lubricants
37 (Hazardous Cargo with Ready to use. 1 set - - 1. These lubricants/ chemicals are to be used during pre commissioning & commissioning stage of boiler.
Shelf Life)

38 Paint for site touch up Ready to use. 1 set - - 1. To be applied at the welding areas as per QAP/ ITP.

Spring Hangers for Piping

39 Ready to use / erect. 1 set - - 1. To be erected & fixed with piping at one side and with the structure at the other side.
(RC Pump Piping)

Spring Hangers for

40 Ready to use/ erect. 1 set - - 1. To be erected & fixed with piping at one side and with the structure at the other side.
Pressure Parts (Risers)
41 Safety Valve Ready to use/ erect. 1 set - - 1. To be erected on the flanges or to be welded if it is of welded construction.
42 Level Gauge Ready to use/ erect. 1 set - - 1. To be erected on the flanges or to be welded if it is of welded construction.
43 Relief Valve Ready to use/ erect. 1 set - - 1. To be erected on the flanges or to be welded if it is of welded construction.
44 Sacrificing Valve Ready to use/ erect. 1 set - - 1. To be erected, fit up and welded to the steam blowing piping.
45 Integral Process Valve Ready to use/ erect. 1 set - - 1. To be erected on the flanges or to be welded if it is of welded construction.

46 Non Integral Process Valve Ready to use/ erect. 1 set - - 1. To be erected on the flanges or to be welded if it is of welded construction.

47 Integral Motorised Valve Ready to use/ erect. 1 set - - 1. To be erected on the flanges or to be welded if it is of welded construction.
Non Integral Motorised
48 Ready to use/ erect. 1 set - - 1. To be erected on the flanges or to be welded if it is of welded construction.
Valve
1. Hydro testing of pressure part circuit and external piping. Once the hydro test is done, piping insulation can be done. For doing this work, filling
49 Hydro testing - - - - -
pump, hydro test pump, testing gauge and graphs to be used.
50 Leak test - - - - - 1. Leak test of gas side. Once the leak test is done, the insulation work can be done on the gas side.

27-JUN-2019
VIJAY KUMAR (C572)
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 VENDOR TO ADHERE THE CONTRACT/ PR REQUIREMENTS.

27-JUN-2019
VIJAY KUMAR (C572)

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