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Main NG line Blind

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N2 Blinds ( Auto purge and Rapid Purge ) (N2 to Bottom seal )

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Packing Removal and scrubber cleaning

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Packing Cleaning and Segregation

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Filling (After Mechanical, venturi cone replacement)

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Packing Removal and scrubber cleaning

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Packing Cleaning and Segregation

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Filling (After Mechanical jobs and painting)

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Inspection

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Cleaning Carbon Deposit

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Repair

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Day
Reforming cut OFF and Furnace emptying to be initiated.
Furnace purging to remove CO and explosives.
Furnace cooling by natural draft.
Reformer purging / cooling (after Furnace emptying ).
Manhole Opening and boxup/Blind insertion and removal
Blinds insertion

TGS Packing removal ,cleaning and filling back .

CGS Packing removal ,cleaning and filling back .

Bustle and RG Header inpection & Repair

Bustle port/planum area cleaning.

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Furnace refractory inpection

Furnace Filling
Furnace wall clusters breaking.
Inspection
Repair
Reformer Box , recuperator and combustion header inspection .
Inspection
Repair

Reformer Bay inspection & gravel spreading job if needed .

Catalyst Dumping, screening & Reloading

Seal gas aftercooler packing removal and filling.

10
11

Inert gas cooler refractory inspection and repair.


Combustion offtake and manifold refractory inspection and repair.

12

Feed gas refractory inspection and repair.

13

Module Heatup/Start up

Module - 1 Annual Shutdown Bar chart -2015 For Mechanical department


Sl

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1.28 conveyor discharge chute inspection / repairing

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1.28 A conveyor discharge chute inspection / repairing

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Top slide gate bottom pipe & top pipe replacement / bottom Slide gate
inspection / repairing if required

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Octopus leg pipes replacement

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Furnace inside refractory retaining skirt inspection / repairing

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Upper burden feeder all pins & bushes inspection / replacement

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UBF, MBF & LBF Burden feeder tooth inspection / repairing

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Job Description

Upper burden feeder gland packing inspection / adding as required

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Middle burden feeder gland packing inspection / adding as required

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10

Lower burden feeder gland packing inspection / adding as required

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Servicing / replacing all knife gate valves in TGS / CGS

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Sand blasting / Epoxy painting in Cooling gas scrubber inside/ Out side party

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Sand blasting / Epoxy painting in top gas scrubber inside/ Out side party

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Top gas scrubber cone replacement (below swirl line)

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Top gas scrubber - conus drain line connecting to clarifier replacement

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Upper / Lower slide gate - repack gland in indication rod stuffing box

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Furnace discharge vibrofeeder inspection / repairing

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Charge bin bottom gate inspection / rectification if passing

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Charge bin inside liner plate inspection /repairing

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P.G Compressor both stage lobe inspection, internal cleaning, compressor


replacement if required

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P.G Compressor suction strainer & both stage silencer inspection /


repairing,cleaning & box-up

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Cooling gas compressors - suction strainers inspection & both stage silencer
manhole opening & box-up after inspection

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Cooling gas compressor 2C. 31 SILO side) replacement

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Seal Gas cooler dome opening / box up & demister pad inspection /
replacement

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Reformer combustion air header joints inspection / repairing if required

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Reformer bottom floor inspection / repairing if required

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Open reformer doors for internal inspection & box up after completion of job

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Existing OFF-Gas line to be modified in two sub branches

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Cooling gas scrubber U seal pipe removing / inspection / wrapping with


bitumate tape & fixing back

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Hot air fan main drive gear coupling inspection

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FDC duct spool replacement

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Hot air fan - clutch coupling inspection

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Furnace thermo well inspection & replacement if required

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Module # 01 Man holes opening & box up


Cooling gas compressor 4.31 motor replacement.

36

TGF line near mist eliminator and below chemical injection point tee portion
spool to be cut for inspection of custic accumulation & inspection weld back.

37

PNG vernier valve replacement with globe valve hot work.

M-2,3,5

M-2,3,5

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Instrumentation
1

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Replacement of PNG vernier valve FV1A32 with globe control valve


(same as Mod2).
Inspection & cleaning of following thermo wells, thermocouples
& its cables. Replacement if required.

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Reformer box all roof temperatures.

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Reformed gas header TW/ TE 1A25-1, 2, 3 & 4.

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Furnace bottom seal leg (RTD) TW/ TE 1H04.

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Flue gas headers to recuperator TW/ TE1C08-1 & 2.

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Furnace thermo well inspection & replacement if required.


Thermocouple inspection & replacement if required.

Replacement of Cold process wtr to TGS control valve (TV1E02)PG sec.

Replacement of Cold process wtr to TGS control valve (TV1E09)TG sec.

4
5
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Flue gas fan discharge header TW/ TE1C18.

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Combustion air header to Main burner TW/TE1C12.

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Feed gas preheater TW/TE 1A84-2A, TW /TE1A84-2B, TW/ TE1A84-6A,


TW/TE1A84-6B; TW/TE1A84-3A , B; TW/TE1A84-7A,B.
Combustion air preheater TW/TE1A84-8A, TW/TE1A84-8B, TW/TE1A849A, TW/TE1A84-9B; TW/TE1B40-1A; TW/TE1B40-2B

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NG preheater TW1A84-4A, TW1A84-4B, TW1A84-5A & TW1A84-5B.

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Feed gas preheater thermowells TW1A84-2A, TW1A84-2B, TW1A84-6A,


TW1A84-6B; TW1A84-3A , B; TW1A84-7A,B.

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Inspection & Maintenance of following valves (In-house)

PV1 C07 Flue gas fan IGV (actuator only).

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PV1B09 Auxilliary air fan IGV (actuator only).

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PV1B70 Cold flare (System pressure) control valve.

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SOV1B26.1 & 26.3 Auxiliary burner NG block valve 1 & 3.

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SOV1A86-1 PNG block valve 1.

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SOV1A18-1 Main burner NG block valve 1.

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FV1A20 CG bleed flow control valve.

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h
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FV1E60 CG scrubber water flow control valve.

FV1E16 Hot process wtr to TGS control valve (PG sec.)

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FV1E13 TGS CPW swirl water flow control valve.

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FV1E14 TGS throat water flow control valve.

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FV1E17 CGS CPW swirl water flow control valve

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FV1E19 CGS throat water flow control valve.

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PRV 1B27 NG to Aux burners after block valves.

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o
7

reformer bull horns SOV1C07.1 & 07.2 (pneumatic actuators only).

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Maintenance of following control valves by external party.


Main burner NG control valve FV1B06-1.

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FV 1B11-1 Aux burner NG flow control (Main).

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FV 1 B 11.2 Auxiliary Burner Natural Gas flow (vernier).

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PV1B08 Top fuel pressure control vlv

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PV1B19.1 PG flow control valve (main)

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PV1B19.2 PG flow control valve -(Vernier).

FV1A72 NG flow to cooling gas.

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PV1B02-2 main air fan vent valve.

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N2 purge tank Pressure Safety Valve overhaulling & calibration.

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Calibration of following control valves.

TV1C02.1 & 02.2 dilution air to flue gas mixer.

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TV1C18.1 & 18.2 atmospher air to flue gas header

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TV1B22 Auxilliary burner air control

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DCS FCS battery & filter replacement.

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TW1E02 Cold process wtr to TGS PG section

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Inspection / cleaning of Top fuel gas flow annubar (FT1B06-2).

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Inspection / cleaning of Mass spec sample tapping points & primary

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After burner (Inlet of SG cooler) thermowell / thermocouple removal,

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10 Inspection & cleaning of following thermo wells, RTDs


a

10 Modification for ON line N2 purging system.

11 coolers of BG, FG, RG, PG, Ref fl1 & 2, HRC1 & 2.

12 inspection & installation after completion of refractory jobs.

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Furnace lower leg (above bottom slide gate) TE1H04 thermo well

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Removal of any additional instruments , connections etc as per

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17 Arresting air leak at INST air header union joint near flue gas fan.
Weighing system

10

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Inspection / replacement of cold flare seal tank level switches.

13 LSL1B67.

14 Replacement of UBF water tank level switches. LSL1M13 & LSLL1M13.


15 getting eroded frequently. To modify similar to Mod2.

16 requirement of other departments (except above planned jobs).

Schenck weigh scale calibration

10

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Schenck Feeder control panel cleaning & cable dressing

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Inspection and maintenance of low voltage panel MCC - 1(all low


voltage motor in mod 1 will stop)
Inspection and maintenance of medium voltage motor incomer panel
MCCA1
inspection and maintenance of medium voltage motor incomer panel
MCCA2

10

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30

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ELECTRICAL
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Preventive maintenance of Process Gas compressor motors 1c2.01 and


1c2.02 and Isolation handle lever to be replaced.

Flue gas fan motor preventive maintenace.

10

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23

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Seal gas compressor 1c4.03 preventive maintenance and oil


replacement.
cooling gas compressor inspection and maitenance, if need oil
replacement.

Main air fan motor inspection and maintenance.

10

11

12

13

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15

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22

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Mod 1 furnace and reformer area light repairing.

10

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Providing of industrial power socket at every platform.

10

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30

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19

20

Cooling gas compressor 1C2.31 motor replacement.

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

Hot Air Fan coupling, Guide Vane, Actuator link, inspection and
rectification of broken turn buckle
Reforemer Tie Rod Compressed Spring replaced and measurement
taken

Reforemer Tier Rod Faulty Spring to Be replaced.

Seal Gas compressore filter cleaning ,oil cooler, PRV, exhaust fan
inspection and cleaning, oil replacement
Dilution air fan guide vane bearing, coupling inspection and
rectification of faulty bearing and both bearing inspection
Auxiliary Air Fan guide vane bearing coupling inspection and rergreasing and both bearing inspection

8
8

Main Air fan guide vane studs, bearing inspection and replacement
PG Compressor 2nd Stage oil filter, gear box filter, oil cooler inspection
and rectification
PG Compressor 1st Stage oil filter, gear box filter, oil cooler inspection
and rectification, lubrication line oil leakage to arresting
Cooling gas compressor seal flushing line to be inspectiona and oil
cooler cleaning
Furnace Power Pack Unit oil replacement,tank to be cleaning and
hydraulic line oil leak to be arresting
Z-Coneyor gear box coupling, back stop, bearing fitted roller ( Curve
Roller) and all pulley's bearing inspection and greasing.
Top Gas Scrubber inside inspection and thickness measurement to be
taken

14 CG Scrubber inside inspection and thickness measurement to be taken


15 1.28 A tail end pulley bearing inspection and re-greasing

11

12

15

17

18

16

14
5

13

14
5

12

15

16

7
9

10

16 Furnace charge hopper thickness measurement


17 Furnace lower part of furnace thickness measurement
18

Regarding Scafolding ?
Regarding Scafolding ?

21

22
22

23

Furnace All Burden feeder grease line inspection and rectification. IIr. With

Production
19 Furnace All burden feeder teeth to be inspection. IIr. With Production
Furnace Crismas Tree thisckness, and welding crack to be inspection. IIr.
20
With Production
Furnace Wind box Duct plate and welding joint to be inspect. IIr. With
21
Production

Work With Production Crew


Work With Production Crew
Work With Production Crew
Work With Production Crew

22 Furnace Inside Feed leg to be inspection.IIr. With Production


23 OF 3.01 Diverter Chute Bearing inspection and Re-Greasing
24 Schanke Feeder Gear Box oil to be replacement

Work With Production Crew

13

14

15

14

15

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Mod-2 S/D jobs Bar Chart for production deparment


Reforming cut OFF and Furnace emptying to be initiated.

1
1

2
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3
3

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8
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30

Furnace purging to remove CO and explosives.

10

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Furnace cooling by natural draft.

10

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23

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Reformer purging / cooling (after Furnace emptying ).

10

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23

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Manhole Opening and boxup/Blind insertion and removal

10

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Main NG line Blind

10

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N2 Blinds ( Auto purge and Rapid Purge ) (N2 to Bottom seal )

10

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Packing Removal and scrubber cleaning

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Packing Cleaning and Segregation

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Filling (After Mechanical, throat cone replacement)

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Packing Removal and scrubber cleaning

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Packing Cleaning and Segregation

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Filling (After Mechanical jobs and painting)

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Inspection

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Cleaning Carbon Deposit

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Repair

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Bustle port/planum area cleaning.

10

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Furnace refractory inpection


Furnace Filling

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Furnace wall clusters breaking.

10

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Inspection

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Repair

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Inspection

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30

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.
.
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6

Day

Blinds insertion

TGS Packing removal ,cleaning and filling back .

CGS Packing removal ,cleaning and filling back .

Bustle and RG Header inpection & Repair

Reformer Box , recuperator and combustion header inspection .


Repair

Reformer Bay inspection & gravel spreading job if needed .

10

11

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23

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Catalyst Dumping, screening & Reloading

10

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23

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Seal gas aftercooler packing removal and filling.

10

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23

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10 Inert gas cooler refractory inspection and repair.

10

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11 Combustion offtake and manifold refractory inspection and repair.

10

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12 Feed gas refractory inspection and repair.

10

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13 Leak Test

10

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14 Module Heatup/Start up

10

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Module - 2 Annual Shutdown Bar chart -2014 for Mechanical department


Job Description

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27

OF.1.28, Z conveyor head pulley replacement

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29
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28
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1.28, Z conveyor curve roller inspection / repairing

10

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OF.1.28, Z conveyor Gear Box replacement

10

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1.28 conveyor discharge chute inspection / repairing

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1.28 A conveyor belt replacement.

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1.28 A conveyor discharge chute inspection / repairing

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Top slide gate bottom pipe & top pipe replacement / bottom Slide gate
inspection / repairing if required

10

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23

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Octopus leg pipes/ proportional hopper replacement

10

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Furnace inside refractory retaining skirt inspection / repairing

10

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Sl.

10 UBF, MBF & LBF Burden feeder tooth inspection / repairing

10

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13

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30

20 FDC fan suction duct repairing near furnace.

10

11

12

13

14

15

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18

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21

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23

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30

21 FDC dry cyclone - replacement of worn out portion

10

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13

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21

22

23

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25

26

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30

22 Charge bin inside liner plate inspection /repairing

10

11

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13

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23 Charge bin bottom gate inspection / rectification if passing

10

11

12

13

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23

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30

Sand blasting / Epoxy painting in Cooling gas scrubber inside/ Out side
24
party

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11 Upper burden feeder all pins & bushes inspection / replacement


12 Upper burden feeder gland packing inspection / adding as required
13 Top Gas Scrubber throat cone/ Nozzle pipe replacement.
14 Middle burden feeder gland packing inspection / adding as required
15 Lower burden feeder gland packing inspection / adding as required
16

Remove broken bolts from lower burden feeder - locking plates/ Out
side party

17 Upper / Lower slide gate - repack gland in indication rod stuffing box
18 Furnace discharge vibrofeeder inspection / repairing
19 Furnace discharge conveyor belt (3.01)with structure replacement

25 Sand blasting / Epoxy painting in top gas scrubber inside/ Out side party

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

27

P.G Compressor 1st stage lobe inspection, internal cleaning,


compressor replacement if required

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

28

P.G Compressor suction strainer & both stage silencer inspection /


repairing,cleaning & box-up

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

29 P.G Compressor 1st stage gear box internal inspection.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Cooling gas compressors - suction strainers inspection & both stage


30
silencer manhole opening & box-up for inspection

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31 Cooling gas compressor 2C. 32 SILO side) replacement

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

32 Cooling gas compressor both stage gear box inspection.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

33 Cooling gas scrubber throte nozzle and bellow inspection.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

34 Oxygen injection vessel header port and nozzle inspection.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

CGS U seal pipe removing /inspection /wrapping with bitumate tape &
35
fixing

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

36 Seal gas compressor relocation.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

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14

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23

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26

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28

29

30

10

11

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23

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30

10

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30

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30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

42 Reformer bottom floor inspection / repairing if required

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

43 Hot air fan main drive gear coupling inspection

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

44 Hot air fan - clutch coupling inspection

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

45 Main air fan bearing inspection / replacement

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

46 Existing OFF-Gas line to be modified in two sub branches

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

47 Furnace thermo well inspection & replacement if required

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

48

10

11

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13

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15

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18

19

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21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

26 P.G 2nd stage comprssor replacement.

37 Seal Gas cooler dome opening / box up & demister pad inspection.
38

Open reformer doors for internal inspection & box up after completion
of job

39 reformer combustion air off take line inspection / repairing if any


40

Combustion air 2nd stage elliptical bellow inspection / rectification if


any

41 Reformer combustion air header joints inspection / repairing if required

Module # 02 Man holes opening & box up

49 Reformer bend tube replacement. / Out side party


50

NG station near recuparator main isolation valve upstream drain point


crack nipple to be replaced.

TGF line near mist eliminator and below chemical injection point tee
51 portion spool to be cut for inspection of custic accumulation &
inspection weld back.

10

11

12

10

11

12

10

11

10

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Instrumentation Jobs (Mod 2)


1

Furnace thermo well inspection & replacement if required.


Thermocouple inspection & replacement if required.

Replacement of Cold process wtr to TGS control valve (TV2E02)PG sec.

Replacement of Cold process wtr to TGS control valve (FV2E09)TG sec.

Inspection & Maintenance of following valves (In-house)

PV2 C07 Flue gas fan IGV (actuator to be replaced with new) .

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

PV2B09 Auxilliary air fan IGV (actuator only).

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

PV2B70 Cold flare (System pressure) control valve.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

SOV2B26.1 & 26.3 Auxiliary burner NG block valve 1 & 3.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

SOV2A86-1 PNG block valve 1.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

SOV2A18-1 Main burner NG block valve 1.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2A20 CG bleed flow control valve.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2E16 Hot process wtr to TGS control valve (PG sec.)

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2E13 TGS CPW swirl water flow control valve.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2E14 TGS throat water flow control valve.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2E17 CGS CPW swirl water flow control valve

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2E19 CGS throat water flow control valve.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Replacement of main burner NG control valve FV2B06-1.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Replacement of PRV 2B27 NG to Aux burners after block valves.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Maintenance of reformer bull horns SOV2C07.1 & 07.2 actuators.

Inspection & pressure testing of AV2A33 Bustle NG valve .

Inspection & cleaning of following thermo wells, thermocouples


& its cables. Replacement if required.

Reformer box all roof temperatures.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Reformed gas header TW/ TE 2A25-1, 2, 3 & 4.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Bustle gas header TW/ TE 2A34-1/2.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Top gas header TW/ TE 2A35.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Cooling gas take off TW/ TE 2A73 -1,2 & 3.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Furnace bottom seal leg (RTD) TW/ TE 2H04.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Flue gas headers to recuperator TW/ TE2C08-1 & 2.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Flue gas fan discharge header TW/ TE2C18.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Feed gas preheater TW/TE 2A84-2A, TW /TE2A84-2B, TW/ TE2A84-6A,


TW/TE2A84-6B; TW/TE2A84-3A , B; TW/TE2A84-7A,B.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Combustion air preheater TW/TE2A84-8A, TW/TE2A84-8B, TW/TE2A849A, TW/TE2A84-9B; TW/TE2B40-1A; TW/TE2B40-2B

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

NG preheater TW2A84-4A, TW2A84-4B, TW2A84-5A & TW2A84-5B.

10

11

12

13

14

15

16

17

18

19

20

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23

24

25

26

27

28

29

30

10

11

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30

1
1

2
2

3
3

4
4

5
5

6
6

7
7

8
8

9
9

10
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11

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30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Flue gas headers to recuperator after dilution TW/ TE2C02-1 & 2.

10 Inspection & cleaning of Top fuel flow annubar FT2B06.2.


Inspection / cleaning of Mass spec sample tapping points & primary
11
coolers of BG, FG, RG, PG.
12
13

After burner (Inlet of SG cooler) thermocouple inspection & installation


after refractory job is over.
calibration of following control valves.

TV2C02.1 & 02.2 dilution air to flue gas mixer.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

TV2C18.1 & 18.2 atmosper air to flue gas header

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

TV2B22 Auxilliary burner air control

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

TV 2A34 Reformed gas temp control valve

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

14

Maintenance & calibration of following control valves by


external party

Cold

PV2B08 Top fuel pressure control vlv

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

PV2B19.1 PG flow control valve (main)

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

PV2B19.2 PG flow control valve -(Vernier).

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2A72 NG flow to cooling gas.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV 2B11-1 Aux burner NG flow control (Main).

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV 2B11.2 Auxiliary Burner Natural Gas flow (vernier).

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

PV2B02-2 main air fan vent valve.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

FV2B07 - Main air fan flow control.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

15 Inspection of cold flare seal tank level switches. LSL2B67.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Inspection of UBF water tank level switches. LSL2M13 &


16
LSLL2M13.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

N2 purge tank Pressure Safety Valve overhaulling & calibration.

17

Removal of any additional instruments , connections etc as per


requirement of other departments (except above planned jobs).

18

Relocation of recuperator thermocouples TE2C17.9 & TE2C17.10 as it is


showing less reading.(As per Mod1).

19 Replacement of power supply units in DCS PDB. (PS01 showing alarm)


20

Rerouting of 24 Vdc power distribution for Field CO meters through


separate power supply PS6.

SGC instruments removal & reinstallation. Relocation of air header near


21 SG aftercooler.

Weighing system
1

Relocation of weigh scale frame, loadcell installation, alignment &


calibration of Furnace discharge weigh scale (WIC2H15).

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Schenck weigh feeder PM & Calibration

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Schenck weigh feeder control panel cleaning & cable dressing

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Inspection and maintenance of low voltage panel MCC - 2


(all low
17 voltage motor in mod 2 will stopped)
Inspection and maintenance of medium voltage motor incomer panel
18 MCCB1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Inspection and maintenance of medium voltage motor incomer panel


19 MCCB2

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

20 Flue gas fan motor preventive maintenance.


Seal gas compressor 1c4.03 preventive maintenance and oil
21 replacement.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

22 2F1.36Mod 2 vibro feeder inspection and maintenance.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

23 Mod 2 furnace and reformer area lights repairing and cleaning.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

7
7

8
8

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

5
6

7
17

18

PM & calibration of 0F1.53, 0F1.54, 0F1.55 & 0F1.56 weigh feeder

PM & calibration of 0F3.22 weigh scale

ELECTRICAL

CBM

Hot Air Fan coupling, Guide Vane, Actuator link, inspection modification
and rectification of broken turn buckle and Oil replaced

Reforemer Tie Rod Compressed Spring replaced and measurement


taken

Reforemer Tier Rod Faulty Spring to Be replaced.

Seal Gas compressore filter cleaning ,oil cooler, PRV, exhaust fan
inspection and cleaning , oil replacement

Dilution air fan guide vane bearing, coupling inspection and


rectification of faulty bearing and both fan bearing inspection and regreasing

Auxiliary Air Fan guide vane bearing coupling inspection and regreasing and both fan bearing inspection and re-greasing

9
9

Main Air fan guide vane studs, bearing inspection and replacement

PG Compressor 2nd Stage oil filter, gear box filter, oil cooler inspection
and rectification

PG Compressor 1st Stage oil filter, gear box filter, oil cooler inspection
and rectification, lubrication line oil leakage to arresting

10

Cooling gas compressor seal flushing line to be inspectiona and oil


cooler cleaning

11

Furnace Power Pack Unit oil replacement,tank to be cleaning and


hydraulic line oil leak to be arresting

12

Z-Conveyor gear box coupling, back stop, bearing fitted roller ( Curve
Roller) and all pulley's bearings inspection and greasing to be carried

13

Top Gas Scrubber inside inspection and thickness measurement to be


taken

10

11

12
19

20
20

13

14

15
15

12

13

21

16

17

14

7
18

14 1.28 A conveyor tail end pulley bearing inspection and re-greasing

19

20

15 CG Scrubber inside inspection and thickness measurement to be taken


16 Furnace charge hopper thickness measurement
17 Furnace lower part of furnace thickness measurement
18
19
20
21

Furnace All Burden feeder grease line inspection and rectification. IIr.

With Production

Work With Production Crew

Furnace All burden feeder teeth to be inspection. IIr. With

Production

Work With Production Crew

Furnace Crismas Tree thisckness, and welding crack to be inspection.

IIr. With Production

Work With Production Crew

Furnace Wind box Duct plate and welding joint to be inspect. IIr. With

Production

22 OF 3.01 Diverter Chute Bearing inspection and Re-Greasing,

Regarding Scafolding ?
Regarding Scafolding ?

Seal Gas Compressor Nitrogen line will be installed in DE side in both


Module
Reforemer Tube replacement will in house
CGS and TGS Grating o be inspection and change if required
Scafolding pf Charge Hopper will take care of Production Crew
Hot Air Fan Bearing to be inspection

Work With Production Crew

17

18

19

Common S/D jobs Bar Chart for production deparment


Day

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.

10

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17

18

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21

22

23

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29

30

Clarifier/Hot well/Cold well Emptying and Clean up


Cooling tower Emptying, cleaning and Fillup fresh RO
Clarifier/Hot well/Cold well Filling

10
11
12
13
14
15
16
Clarifier Filling will be done from 24th day.

Mechanical
1
2
3
4
5
6
7
8
9
10

Mechanical structures inspection / repairing in clarifier tank


inside
Sand blasting & Epoxy painting inside clarifier wall &
structures
Replacement of gear boxes in clarifier - rotary
HOT PROCESS & COLD PROCESS PUMPS - suc / disch / NRV
removing / cleaning and fixing back
1.12 Oxide conveyor belt replacement.
Replacement of product screen 3.16
Dust collection lines modification inside the product screen
area
Clarifier underflow lines replacement.
Raw water pump (4.14) suction valve replacement
Provision of additional suction point in hot well & cold well
Instrumentation

1
2
3
4
5
6

10

11

12

13

14

15

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21

22

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25

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30

Adding IO cards for New Cooling Tower.


Cleaning of marshalling panels of Water complex DCS
Cleaning of marshalling panels of Material handling DCS

10

11

12

13

14

15

16

17

18

19

20

21

22

23

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25

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10

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13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Gas Chromatograph sampling system maintenance, GC


calibration.
Maintenance & Calibration of Valves & Instruments
Main & Expander control Panel cleaning

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

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10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Oil Cooler Fan inspection and cleaning of fines

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

NGL Pump Inspection

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Hydrocyclone ON- off valves maintenance


New Thermowell for cold clean water header.
Inspection & cleaning of thermowells in MCW, Hot process,
cold process, clean water, Cooling water systems.

NGPT
1
2
3
4
5
6
7

Regeneration Cooler A Fan inspection and cleaning of fines


Regeneration Cooler B Fan inspection and cleaning of fines

.
.

Ethanol Pump inspection and oil change

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Common S/D jobs Bar Chart for ELECTRICAL deparment


Inspection and maintenance of switch gear High voltage and
medium voltage incomer and outgoing panels.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Inspection and cleaning of SWGR High voltage Transformers


301, 302 and 303 primary and secondary side with bus ducts.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

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30

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30

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30

10

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30

10

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30

10

11

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30

10

11

12

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30

10

11

12

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30

10

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10

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30

10

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30

10

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10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

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30

Inspection and cleaning of MCC-4 Transformer's 201, 202,


and 203 primary and secondary side with bus ducts

.
.
.
.
.
.
.
.
.
.

Inspection and maintenance of MCC-4 main PCC & MCC41,MCC4-2 ,MCC4-3,MCC4-4,MCC4-5 and MCC 4-6 panel.

.
.
.
.
.
.
.

Inspection and Operation of both module capacitor bank


tripping circuit and addition of auto closing circuit.

Inspection and maintenance of MCC-3 Transformer 204.


Inspection and maintenance of MCC-3 main PCC.
Inspection and maintenance of NGPT Transformer with low
voltage panel.
inspection for Auto mode of 5KV switchgear tripping to be
check.
Replacement of SWGR battery bank battery and relocation
inside the swgr.
Inspection and maintenance of SWGR battery charger.
Inspection and cleaning of High voltage cable gallery from
Power plant to DRI product silo.
Mod-1 & Mod-2 furnace cable dressing from top to bottom
Inspection and Maintenance of SWGR RTCC & Relay Panels.

Charging of Transformer T303.


Oil filteration of all low voltage transformers Tr-201-202-203204-205.
Inspection and Maintenance of OF 1.22 oxide feed conveyor
motor.
Inspection and Maintenance of OF 1.12 oxide conveyor .
Inspection and Maintenance of OF 1.13 oxide belt conveyor.
Inspection and Maintenance oF BC00 conveyor motor

.
.
.
.
.
.
.
.
.

Inspection and Maintenance of OP 4.29 Screw classifier


motor.
Inspection and Maintenance of OP4.21,22 Clarifier rake Arm
motor.
Inspection and Maintenance of OP4.23 Clarifier rake lift
motor.
Energy meter to be provide at water complex cold process
motor MCC 4-6.

Seal gas compressor motor power cable arrangement and rete


Stacker top side cables inspection and arrangement.
Inspection of cold process pumps, main incomer power cable
joints.
Installation of new power meter at main incomer cum
outgoing feeder Tr301
Installation of new power meter at main incomer cum
outgoing feeder Tr302

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

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28

29

30

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